Material Failure Research Articles

The effect of structural bending properties versus material bending properties on maize stalk lodging

Stalk lodging (mechanical failure of stalks or stems before harvest) is a major problem in grain production that significantly reduces yield. Efforts to improve stalk lodging are hampered by a limited understanding of the determinants of stalk failure. This study examined the structural bending properties and material bending properties of maize (Zea mays L.) stalks. First, an in-field phenotyping device known as DARLING (Device for Assessing Resistance to Lodging In Grains) was used to determine structural properties of maize stalks. Stalks were then subjected to a rind penetration protocol and morphological measurements were acquired. Finally, small strips of rind tissue were excised from the stalks and micro three-point bending tests were conducted to determine the material properties of the rind tissue. Results showed that the material bending strength of the rind tissue was approximately twice as large as the bending stresses present in the rind tissue when failure occurred during field testing. This indicates that stalks ultimately fail due to some form of buckling (i.e., structural failure) as opposed to material failure. This result is relevant to genetic and breeding studies seeking to address the problem of stalk lodging. In particular, these results suggest that improvements in stalk lodging resistance should focus on the stalk's geometric features, such as the ratio of rind thickness to diameter, rather than solely on enhancing material strength. For the samples in this study, material strength ranged between 64 and 197 MPa whereas material stiffness ranged between 4 and 12 GPa. Rind penetration resistance was found to be a good predictor of material properties but a poor predictor of structural properties.

Erosion and intergranular corrosion induced failure of S31254 stainless steel – Case study on Venturi scrubber in a natural gas purification plant

The flue gases such as SO2, SO3, and CO2 generated during the purification process of sulfur-containing natural gas need to be treated to a certain concentration before they can be discharged into the atmosphere. The flue gas unit of a purification plant in Sichuan adopts the new Cansolv flue gas treatment process. After running for a period of time, the Venturi scrubber experienced severe corrosion failure, resulting in equipment shutdown and significant economic losses. This paper utilizes an actual failed device as a case study to analyze the corrosion environment of the Venturi scrubber. It conducts a comprehensive failure analysis, encompassing material mechanical properties, metallographic analysis, and failure microstructure analysis, aiming to elucidate the reasons behind the Venturi scrubber failure. Systematic analysis shows that the manufacturing materials used in this scrubber meet all design requirements. However, flue gas at temperatures reaching 280 °C enters the scrubber tower at a flow rate exceeding 10 m/s. The dissolution of acidic gases leads to a significant drop in the pH of the cooling water to 1, manifesting evident signs of erosion corrosion and intergranular corrosion on the material surface. These observations suggest that erosion and intergranular corrosion in high-temperature acidic environments are the predominant factors contributing to the corrosion failure of the Venturi scrubber.

A machine-learning-based peridynamic surrogate model for characterizing deformation and failure of materials and structures

A machine-learning-based peridynamic surrogate model for characterizing deformation and failure of materials and structures

Modeling of fatigue behaviors of rock materials subjected to cyclic loads with fractional-order plastic flow rule

Compressive cyclic loads induce a progressive failure in rock materials, and the long-term stability can not be guaranteed by the strength under monotonic load. To this end, the present study aims at establishing an elastoplastic fractional fatigue damage model for predicting the accumulative deformation of rock materials in a unified framework. A fractional-order plastic flow rule is introduced to describe volume transformation of rock sample from compression to expansion, eliminating the need for plastic potential functions. And a hardening function with an equivalent plastic shear strain is adopted. Concerning the fatigue effects, the progressive deterioration of material due to cyclic loads is intricately linked to microstructural degradation, depicted by a convolution law. In the context of creep deformation, loading cycle serves as an equivalent time measure, connecting the plastic deformation with the fatigue damage. In order to verify the accuracy, the proposed model is numerically implemented by a returning mapping procedure simulate the mechanical responses of three types of rocks in both uniaxial and triaxial cyclic tests. Comparative analysis with associated fatigue model is also provided to evaluate the accumulative deformation and damage evolution of concerned rocks.

Inelastic Cyclic Tests of Grade 80 (550 MPa) Bars with Mechanical Splices

This study addresses low-cycle fatigue performance of high-strength steel reinforcement bars (HSRB) when used with mechanical couplers due to the growing demand for higher-strength steel reinforcement bars in both seismic and non-seismic applications, driven by the need to reduce bar congestion, lower material quantities, and consider economic and environmental factors. Low-cycle fatigue involves material failure owing to a finite number of load or deformation cycles, generally occurring under substantial strain rates that surpasses the yielding limit. The experimental program assesses the fatigue behavior of HSRB produced using microalloying, quenching, and tempering techniques, coupled with mechanical couplers (eleven different types) from five companies in the United Stated of America. The study highlights significant differences in fatigue endurance based on the type and make of couplers and suggests potential improvements in manufacturing processes to enhance fatigue resistance. It is found that the mechanical couplers sustain a loading protocol of (-1% to 3%) when there is a clear distance of 2 times the diameter of the bar between the coupler and the gripping machine from top to bottom. The coupled bars sustained a minimum of 6 half cycles and a maximum of 38 half cycles.

Problems of selection of corrosion-resistant steels and alloys in oil and gas industry for operating conditions

Corrosion-resistant steels and alloys have a number of unique properties. This allows them to be used in various industries. Despite their name, they are to some extent subject to various types of corrosion and corrosion-mechanical damage. This article discusses cases of corrosion damage of products made of corrosion-resistant steels and alloys in the oil and gas industry. The reasons of material failure can be incorrect exploitation of material, low-quality material of products, and incorrect selection of material for operating conditions. For each group of failure causes the examples from open sources and from the practice of the team of authors of this work are considered. The paper substantiates the importance of preliminary laboratory studies of corrosion-resistant materials and their testing with simulation of environmental factors. It is necessary for reasonable choice under specific operating conditions. It is shown that in practice the reasonable choice of corrosion-resistant materials is not always given due attention, so the seemingly economically favorable solutions may turn out to be incorrect. The main focus is made on the practical side of the issue in order to avoid such problems in the future. The relevance of the work is confirmed by the recent acute problem of substitution of foreign steel grades.

Study on the lower head failure in severe accidents Part II: Thermal-mechanical coupling behavior analysis on CAP1400 reactor lower head

Under severe accident conditions with core meltdown, large amounts of molten material relocate to the lower head at high temperatures. Significant thermal and mechanical loads may lead to failure of the reactor pressure vessel (RPV) lower head, spreading radioactive fission products. Lower head failure time and location are crucial for accident mitigation and consequence assessment. This study developed a thermodynamic failure analysis model for the lower head by investigating material failure mechanisms, coupling this into an Integrated Severe Accident Analysis code (ISAA), and conducting experimental validation and applied research. Part I mainly introduces the thermodynamic analysis module development, validation against OLHF experiments, and preliminary failure criteria analysis. Results indicate the model accurately predicts lower head failure behavior, and Larson-Miller life fraction and Hedl-Dorn parameter criteria accurately assess lower head integrity. Part II presents applied research after validation and preliminary analysis. Using the improved ISAA, melt pool behavior and lower head thermal–mechanical response were analyzed for a CAP1400 small break loss-of-coolant accident (SBLOCA), assuming multiple safety system failures. Results indicate the bottom of the lower head melt pool didn’t form a hard shell due to high heat release rate, only an oxide shell layer around the second layer. Decay heat from melt pool components cannot be dissipated, leading to lower head failure. Further External Reactor Vessel Cooling (ERVC) heat transfer model analysis and research are needed in ISAA. The two developed mechanical analysis models predict material failure at high temperatures, and the timing and location of lower head failure are consistent, at approximately 16,000 s at 25.38°±5.47° on the lower head. The predicted failure mode is similar to Part I validation, indicating both Larson-Miller life fraction and Hedl-Dorn parameter criteria provide consistent lower head integrity judgments.

Local strain heterogeneity and damage mechanisms in zirconia particle-reinforced TRIP steel MMCs: in situ tensile testing with digital image processing

In this work, the microstructural deformation and damage mechanisms of TRIP steel metal matrix composites (MMCs) reinforced with Magnesia Partially Stabilized Zirconia (Mg-PSZ) particles are investigated by employing in situ tensile testing within a scanning electron microscope chamber, complemented by digital image correlation and advanced image processing techniques. The study is carried out on samples with varied volume fractions (0%, 10%, and 20%) of zirconia particles and damage mechanisms in different samples under specified loading conditions. Through both qualitative and quantitative assessments of deformation, damage, and clustering, the investigation provides a comprehensive understanding of the distribution and damage initiation. The study findings reveal that, generally, the steel matrix exhibits high toughness, with minimal occurrences of microcracking at high strains that cause significant damage. In samples with increasing particle content, delamination at the matrix–particle interface and cracking of Mg-PSZ particles were found to be critical contributors to material failure and were quantitatively analyzed using computational analyses conducted with MATLAB. The work highlights the initiation and evolution of each damage mechanism in zirconia particle-reinforced TRIP steel MMCs to facilitate scientists and engineers in improving manufacturing and application decisions in industries such as automotive, aerospace, and heavy machinery, which demand materials with exceptional toughness and durability.Graphical

Manufacture and structural performance of modular hybrid FRP–timber thin-walled beams

Developed to fulfil the rising societal demand for sustainable constructions, Modular Hybrid Fibre-reinforced polymer-Timber (MHFT) thin-walled sections are lightweight timber-based composite structures manufactured through a modular assembly method. Motivated by prior research on MHFT columns characterized by efficient load-carrying capacity, this paper conducted a thorough investigation into the manufacture and structural performance of MHFT beams. Experimental, analytical and numerical studies were conducted for beams subjected to four-point bending load, with parametric analyses of four distinct beam types to investigate design parameter influence on flexural performance. The experimental study demonstrated the structural efficacy of MHFT beams, as evidenced by increased moment of inertia and enhanced resistance to edge split failures, as compared to previously studied folded HFT beams. MHFT beams also exhibited a comparable strength-to-weight ratio compared to their structural steel counterparts. Both numerical and analytical methods provided acceptable predictions for flexural strength and material failure modes of MHFT beams, with strength predictions varying by less than 22% compared to experimental averages. The numerical method reliably predicted flexural stiffness and load–displacement responses, with discrepancies within 12%. The parametric analyses further revealed that the thickness of glass fibre-reinforced polymer (GFRP) layers and cross-sectional geometric profile were most strongly influenced beam parameters. Specifically, the use of 3-layer GFRP material resulted in a strength increase of over 17% and a stiffness increase of over 19% compared to 1-layer material, effectively mitigating the occurrence of local buckling and edge split failures.

Strength-induced Peridynamic model for the dynamic failure of porous materials

Predicting the dynamic failure process of porous materials is a challenging task due to their complex structure. To minimize the use of time-consuming peridynamic (PD) models and to avoid surface effect issues in the dynamic failure of complex porous materials, this paper proposes a strength-induced PD model. The paper first presents the dynamic formula and relevant finite element discrete equation of the coupled PD and classical continuum mechanics (PD-CCM) model based on the Morphing method. The Morphing function is implemented to control the material parameters and enable the free transformation of PD and CCM models. Based on the coupled PD-CCM model, the strength-induced PD model is established to adaptively expand the PD subdomain in porous materials by controlling the Morphing function value through the strength state of the structure. This model enables the PD subdomain to appear automatically when the porous materials reach the critical stress state. The proposed model accurately predicts the location of crack initiation and path while minimizing computational costs and improving efficiency. Three two-dimensional numerical examples are used to verify the effectiveness, efficiency, and accuracy of the model. The results of the simulation suggest that the location where the crack initiates in the porous materials is strongly influenced by the amplitude of the dynamic load. Cracking is dependent on the pores and typically occurs through them.

Fluctuations and failure in granular materials: theory and numerical simulations

We consider a dense aggregate of elastic, frictional particles isotropically compressed and next uniaxial strained at constant pressure. We show how failure can be predicted if fluctuations in the kinematics of contacting particles are introduced. We focus on the second order work and the possibility that at some stressed states it becomes negative under proper perturbations. Our analysis involves both a theoretical model and numerical simulations based upon the distinct element method (DEM). The theoretical model deals with contacting particles with incremental relative displacements that deviate from the average deformation in order to ensure their equilibrium. Because of this, the macroscopic stiffness tensor of the aggregate, that relates increments in stress with increments in strain, does not have the major symmetry. Consequently, in the hardening regime, we predict stressed states in which the second order work vanishes. The model seems transparent, and it makes clear and illustrative the role played by the fluctuations introduced in the kinematics of contacting particles in relation to the vanishing of second order work in an aggregate of compressed particles. The comparison with numerical simulations data supports the model.Graphical Statistical representation of the aggregate: conditional average.

Evaluation of rapid gas decompression (RGD) resistance of sealing materials for hydrogen-doped pipeline valves

Abstract With the rapid development of hydrogen-doped natural gas pipelines, the evaluation of the applicability of hydrogen to natural gas pipeline systems is bound to gradually involve all aspects of natural gas pipelines. Targeted at the non-metallic sealing materials for valves of hydrogen-doped natural gas pipelines, this paper, according to the ISO 23936-2 standard, carried out the rapid gas decompression (RGD) tests of hydrogenated nitrile butadiene rubber (HNBR), fluorine rubber 246 (FKM246) and fluorine rubber 26 (FKM26), and the damage level of cracking failure for the rubber materials in the course of rapid release of gaseous medium was obtained (DL). The mechanical properties and volumetric dissolution rate of the three rubber materials were tested before and after the high-pressure gas mixture treatment, which explains the reason for the cracking failure of the rubber materials during the RGD test. The study obtained the influence law of high-pressure gas mixture with different hydrogen volume fractions on the RGD resistance of HNBR, FKM246, and FKM26, and selected the material with the optimal RGD resistance as FKM26, which can be used as a reference for the selection of sealing materials for the valves of hydrogen-doped natural gas pipelines in engineering.

Nonintrusive thermal contact conductance estimation in double-layered pipelines: A reciprocity functional method perspective

Thermal contact conductance (TCC) is a critical factor in various engineering applications involving heat transfer between solid surfaces. Accurate knowledge of TCC enables a more precise thermal system analysis, leading to improved efficiency, reduced energy consumption, and prevention of thermal damages. Moreover, TCC estimation can help to identify material discontinuities or failures. A recent tool for TCC estimation is the Reciprocity Functional Method (RFM) coupled with the Classical Integral Transform Technique (CITT). This method allows the solution of inverse boundary value problems without the need of iterative methods or intrusive measurements, making it valuable for nondestructive testing of interfacial flaws between solid materials. Furthermore, it enables the computation of TCCs using analytical expressions, resulting in a computationally fast procedure. The technique involves the solution of two auxiliary problems: one for the temperature discontinuity estimation, and the other for the interfacial heat flux estimation, both at the inaccessible interface between the two contacting materials. In this study, we applied the RFM and the CITT to estimate different types of TCCs, using a three-dimensional double-layer hollow cylinder geometry as a representative model, like double-layer pipelines used in the oil industry. Temperature measurements for solving the inverse problem were considered available on the outer surface of the pipe which, in the case of a real experiment, could be obtained via an infrared camera. The results demonstrated a good estimate for various analyzed test-cases, even when the measurements were contaminated with Gaussian noises.

Critical temperature-dependent shear band formation in CoCrNi alloy under high-temperature dynamic compression

In numerous engineering applications, the occurrence of highly rapid loading conditions, coupled with significant temperature rise, is prevalent. Under these harsh conditions, shear localization is a prominent material failure mechanism, which may result in catastrophic failure. Generally, materials possessing higher strength, limited work hardening rate, and lower thermal conductivity are more prone to mechanical instability. However, in the current study, a cryo-rolled CoCrNi alloy, characterized by much higher strength and limited work hardening, shows remarkable room and high-temperature mechanical performance under impact loading except at one temperature domain∼600 °C where this material displays mechanical instability by exhibiting adiabetic shearband. To shed light and understand this abnormal mechanical response, an in-depth microstructural study revealed that the ASB formation is closely linked to the recrystallization behavior of this alloy that is invariantly related to the stored energy of cold work, test temperature, and strain rate. Uniquely, the amplified nano-twinning activity at high strain rate and critical temperature promoted the fragmentation of grains and facilitated recrystallization, respectively. Once the recrystallization is completed, the alloy regains work hardening ability even at very high test temperatures, reaching 900 °C due to the deformation of the newly recrystallized matrix. The present work is valuable in delineating the alloy's application domain for rigorous impact and crash-worthiness applications, as there exists a dearth of literature on this material for dynamic scenarios.

On the experimental determination and prediction of damage evolution in composites via cyclic testing

This study introduces a novel approach to obtaining and predicting damage evolution laws using quasi-static cyclic testing within the framework of continuum damage mechanics. To achieve this, a comprehensive set of characterization and parameter identification tests was performed. Carbon-epoxy specimens were manufactured using the filament-winding technique, and these laminates were tested using a universal testing machine. Digital image correlation was employed in all experiments to capture strain fields, and an alternative method utilizing the combined loading compression device is presented to obtain mechanical properties. Once the material was characterized, cyclic tests were conducted, including [Formula: see text], [Formula: see text], and [Formula: see text] tensile tests, and shear v-notch tests. These aim to determine damage evolution laws for both conditions, pure and coupled stress states. From these tests, values for damage onset and threshold were obtained and used to define four new parameters. These parameters permit the estimation of degradation relationships for any arbitrary orientation without requiring additional tests. This approach was tested as the proof-of-concept within the positive range of transverse tension and in-plane shear stress domain. The obtained results are promising, justifying its extension to other failure mechanisms. While acknowledging its limitations, this new approach holds potential for implementation in the analysis of progressive failure in fiber-reinforced composite materials, possibly in conjunction with established failure criteria and computational tools, mainly in the finite element method domain.

Redefinition of failure envelope of composite materials considering uncertainty of test data

After conducting three World-Wide Failure Exercises (WWFEs), it has become apparent that existing strength theories or criteria have certain deficiencies, and no single theory can accurately match all experimental results. As a result, there is a growing focus on the uncertainties present in the macrocosm test data of composite materials. The paper introduces the concept of uncertainty into the collection of test data for the classical Tsai-Wu failure criterion and Hashin criterion. The method proposed involves fitting the coefficients of the failure criteria by treating experimental data as random variables, a technique that diverges significantly from the conventional method of using composite allowable values to define these coefficients. It also uses the probability of success as a constraint and defines the fitted error as an optimization objective. Monte Carlo sampling is employed to perform a reliability analysis, and six sigma is used for a reliability-based optimization of the failure criteria. The Multi-Island Genetic Algorithm is utilized to search for the optimal value. The approach presented in this study provides the ability to predict future failures in composite materials by considering the uncertainty of the test data. By incorporating uncertainties into the analysis and design process, a more accurate and reliable assessment of the performance of composite materials can be achieved. Moreover, there seems to be a significant difference in the fitting error between the mean data and the normal distribution data. Additionally, when Hashin criterion is modified, the test data matches the failure envelope more closely and the degree of fit between the experimental data and the failure envelope is higher.

Molecular dynamics simulation of spall behavior of amorphous/crystalline composites under shock loading

The industrial application of metallic glass (MG) is greatly limited due to its poor ductility and susceptibility to catastrophic fracture. The mechanical properties of MG can be effectively improved by adding crystal phases to make amorphous/crystalline composites. Meanwhile, spallation is a typical form of dynamic failure of materials under shock loading. However, the spall behavior of amorphous /crystalline composites has been rarely studied. In this work, the shock induced spallation process of Cu50Zr50/copper (Cu) composite materials was investigated through molecular dynamics (MD) simulations. It is found that stress waves transmit and reflect at interface due to the mismatch of acoustic impedance. Besides, MG is “softer” than the single crystal Cu from the perspective of stress wave propagation. By changing the loading direction, it was found that classical spall is more likely to occur in the Cu phase, while micro-spall is more likely to occur in the MG phase. However, as the loading velocity increases, the spall form in the Cu phase will also transform into micro-spall. The spall strength and strain rate through acoustic approximation and MD simulations were also obtained. Finally, it was observed that the tensile stress superposition region caused by interface reflection waves may form new danger points where spallation may initiate, thereby resulting in complex spall phenomena in composite materials. The conclusions obtained reveal the characteristics of the spall phenomenon in Cu50Zr50/Cu composite materials, which is beneficial to further understanding the spall mechanism and providing guidance for designing amorphous/crystalline composite materials under shock loading.

Systemic Risk Analysis of Safety, Progress, and Investment in the Construction of a Water Transfer Project and the Importance of Common Cause Failure

Safety, progress, and investment risks are correlated during the construction period of large-scale water transfer projects. However, previous studies have only considered individual risk factors, overlooking the potential systemic risk posed to safety, progress, and investment, as well as any underlying common cause failures. Since traditional risk analysis methods are ill-suited to addressing common cause failure, this paper’s objective was to establish a comprehensive evaluation index framework and to identify the basic events of common cause failure. To do that, we developed a risk analysis method that models common cause failure based on a Bayesian network for assessing that systemic risk. The Henan Section of the Yangtze-to-Huaihe River Water Diversion Project in China was then used as a case study. The results show that a variety of common cause failure events, such as epidemic disease, design alteration, lagged approval process, heavy rain in the flood season, renewal material and failing equipment, construction accidents, and external interference, can significantly impact the safety, progress, and investment systemic risk. Design alteration poses the greatest risk, with renewal material and failing equipment exerting the strongest influence among all common cause failure events. It is also possible to elucidate the predominant causal chains; specifically, the contributing influence of each basic failure event to the systemic risk can be clarified by adjusting their respective initial state. The failure of renewal material and failing equipment was found to significantly increase the safety risk. This study effectively simulated the complex causal relationships and uncertainties of pertinent risk factors, thereby enhancing our understanding of the systemic risk associated with safety, progress, and investment in large-scale water transfer projects.

Analysis of the development of friction and wear testing machine based on complex working conditions

Friction is one of the three main factors leading to the failure of metal materials. In order to improve the service life of machinery and reduce unnecessary losses in industrial production, it is necessary to study the friction and wear properties of industrial materials. Simultaneously in order to explore the impact of various environmental conditions on material properties, friction and wear testing machine war born as the times require. This paper mainly introduces the experimental principles and application scenarios of several universal friction and wear testing machines. At the same time, this paper also explores the situation of several special friction and wear testing machines that adapt to complex environments by organizing the industrial needs generated by the rapid development of technology. This paper collects and organizes literature on the current status and development of friction and wear testing machine in recent years. The paper has found that adding or improving special equipment to the special type of friction and wear testing machine on the basis of the universal model can better meet the needs of actual working conditions.

Full-waveform reconstruction of micro-seismic events via topological derivative approach

Micro-seismic events, naturally occurring within geological formations and quasi-brittle engineered systems, provide a powerful window into the evolving processes of material degradation and failure. Accurate characterization of these events is critical for a comprehensive understanding of the underpinning fracturing mechanisms and potential implications. In this work, we present an algorithm for the spatial reconstruction and characterization of micro-seismic events in a three-dimensional bounded elastic body (with known geometry and nominal material properties) via combined source location and moment tensor inversion. Assuming availability of the full-waveform “acoustic emission” traces whose spectral content can be exposed via Fourier transform, the inverse solution is based on (i) a time-harmonic (forward) elastodynamic model and (ii) the concept of topological derivative as a framework for robust event reconstruction. On exploiting an equivalence between the elastic wavefield generated by the creation of a new micro-surface and that stemming from a suitable set of dipoles and double-couples (whose strengths are synthesized via the seismic moment tensor), we formulate the inverse problem as that for the real (in-phase) and imaginary (out-of-phase) components of the moment tensor at trial grid locations. In this way the optimal solution is obtained via a combinatorial search over a prescribed grid, inherently allowing for successive refinements of event reconstruction over the region(s) of interest. The analysis is illustrated by numerical experiments highlighting the key features of the inversion scheme including the reconstruction of multiple (i.e. contemporaneous) events, localization of the “off-grid” micro-seismic events, and the ability to handle noisy data. The results in particular highlight the utility of multi-frequency event reconstruction toward reducing the demand on the number of sensing locations.