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Search results for: FAILURE ANALYSIS
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ENGINEERING FAILURE ANALYSIS
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Failure Analysis of footbridge made of composite materials
PublicationFinite element method analysis of a pedestrian footbridge made of sandwich material is presented. The internal structure of the material is modelled as a structural shell assuming the Equivalent Single Layer approach (ESL). Two FEM commercial codes are employed. The response of the structure is studied in order to determine the load level that activates Hashin and Tsai-Wu failure criteria. Some practical aspects of designing footbridges...
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Failure analysis of the exhaust valve face in diesel marine engine
PublicationThe exhaust valve from marine diesel engine which was damaged after 2000 hours of service was investigated. In order to prolong the service time the valve face was cladded with cobalt base alloy using laser technique. After failure microstructural and chemical analyses reviled that cladding process was conducted improperly. The chemical composition of the clad layer was far from the designed one and what more completely inhomogeneous....
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Journal of Failure Analysis and Prevention
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Electronic Device Failure Analysis
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Failure analysis and modernization of high-pressure hydraulic press for drilling tubes testing
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Progressive failure analysis of laminates in the framework of 6-field nonlinear shell theory
PublicationThe paper presents the model of progressive failure analysis of laminates incorporated into the 6-field non-linear shell theory with non-symmetrical strain measures of Cosserat type. Such a theory is specially recommended in the analysis of shells with intersections due to its specific kinematics including the so-called drilling rotation. As a consequence of asymmetry of strain measures, modified laminates failure criteria must...
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Modes of Failure Analysis in Reinforced Concrete Beam Using Laser Scanning and Synchro-Photogrammetry
PublicationThe following paper reveal the limitations and possibilities of terrestrial laser scanning technology adaptation in diagnostics of reinforced concrete beams. In this paper, authors present potential spectrum of TLS use in modes of failure analysis of R-C beams and determines under which conditions the laser technologies might be applied. Research was carried out at the Regional Laboratory of Structural Engineering at Gdansk University...
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Case Studies in Engineering Failure Analysis
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Laminated plates and shells - first ply failure analysis within 6-parameter shell theory
PublicationThis work describes Tsai-Wu and Hashin criteria modifications, dictated by nonlinear 6-parameter shell theory with asymmetric strain measures and drilling rotation. The material law is based on standard orthotropic elastic constants for a non-polar continuum, under plane state of stress. First ply failure loads of cylindrical panel subjected to pressure and flat compressed plate are estimated by means of Finite Element Analysis....
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Failure analysis of a high-speed induction machine driven by a SiC-inverter and operating on a common shaft with a high-speed generator
PublicationDue to ongoing research work, a prototype test rig for testing high-speed motors/generators has been developed. Its design is quite unique as the two high- speed machines share a single shaft with no support bearings between them. A very high maximum operating speed, up to 80,000 rpm, was required. Because of the need to minimise vibration during operation at very high rotational speeds, rolling bearings were used. To eliminate...
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ANALYSIS OF THE PUNCHING FAILURE MECHANISM IN WORKING PLATFORMS
PublicationPaper presents an analysis of the shear failure mechanism which occurs from the punching of a working platform layer in relation to its thickness, grain size arrangement and mechanical properties, taking into consideration the interaction with soft subgrade. The study is based on the observations of performance of natural scale structures (Streefkerk) and the results of model investigations numerically represented with the use...
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Modes of Failure Analysis in Reinforced Concrete Beam Using Laser Scanning and Synchro-Photogrammetry - How to apply optical technologies in the diagnosis of reinforced concrete elements?
PublicationThe following paper reveal the limitations and possibilities of terrestrial laser scanning technology adaptation in diagnostics of reinforced concrete beams. In this paper, authors present potential spectrum of TLS use in modes of failure analysis of R-C beams and determines under which conditions the laser technologies might be applied. Research was carried out at the Regional Laboratory of Structural Engineering at Gdansk University...
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Analysis of ship shaft line coupling bolts failure
PublicationW artykule przedstawiono dane statystyczne dotyczące uszkodzeń linii wałów okrętowych, w tym także pęknięć zmęczeniowych śrub sprzęgieł kołnierzowych wałów. Wyjaśniono także mechanizm powstawania tego typu uszkodzeń i zagrożenia jakie niosą ze sobą. Opisano przypadki takich uszkodzeń oraz badania jakie są prowadzone dla lepszego poznania zjawisk zmęczeniowych w omawianych uszkodzeniach.
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Combined thrust radial bearing of a submarine main shaft – Design and analysis of failure
PublicationThis paper presents an analysis of the combined thrust radial bearing of a submarine propulsion shaft. The lubrication system of the bearing is based on a fixed ring. The efficiency of the lubrication system depends on the shaft speed and temperature, which affects oil viscosity. In turn, the thrust bearing load also depends on the rotational speed of the shaft, because as the speed increases, the drag of the ship increases simultaneously,...
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Analysis of Failure Mechanism in Joints with Positive Eccentricity in CFS Truss
PublicationThe paper presents studies concerning the load-bearing capacity of truss joints with a positive eccentricity resulting from the arrangement of geometric members and the failure mechanisms observed in the joints. Based on the previously conducted experimental study, a numerical model of the tested fragment of the CFS truss with eccentricity in the joint was created and validated. All structural details of the tested truss and the...
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Reducing the Probability of Failure in Manufacturing Equipment by Quantitative FTA Analysis
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Post-failure fracture surface analysis of notched steel specimens after bending-torsion fatigue
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Computer aided failure modes and effect analysis of safety related controlsystem
PublicationW artykule przedstawiamy problem związany z podniesieniem bezpieczeństwa funkcjonalnego elementów wykonawczych na przykładzie zaworu regulacyjnego. Jest to istotne z punktu widzenia pracy całego układu, ponieważ elementy wykonawcze decydują o wypełnieniu misji związanej z produkcją lub bezpieczeństwem. Stosowanie analizy FMECA na etapie projektowania umożliwia wyznaczenie krytycznych uszkodzeń z całego ich zbioru oraz określenie...
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Failure of cylindrical steel silos composed of corrugated sheets and columns and repair methods using a sensitivity analysis
PublicationW artykule omówiono przypadek awarii metalowego silosu z blachy walcowej i pionowych słupów. Wykonano analizę wyboczeniową MES z uwzględnieniem imperfekcji geometrycznych. Omówiono metody naprawcze i ich optymalizację w oparciu o analizę wrażliwości.
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FEM analysis of composite materials failure in nonlinear six field shell theory
PublicationThe monography deals with the problem of failure initiation in thin laminated composites. Known techniques of laminate structures modelling are briefly characterised. Eventually, shell based approach is chosen for the purpose of the description of the composite structures behaviour, as it predicts their deformation and states of stress effectively in a global sense. The nonlinear six parameter shell theory (6p theory) with asymmetric...
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Fault Tree Analysis and Failure Diagnosis of Marine Diesel Engine Turbocharger System
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FE-analysis of failure behaviour of reinforced concrete columns under eccentric compression
PublicationArtykuł omawia obliczanie słupów żelbetowych poddanych ściskaniu mimośrodowemu z uwzględnieniem lokalizacji odkształceń. Obliczenia wykonano przy zastosowaniu MES i sprężysto-plastycznego prawa konstytutywnego rozszerzonego o długość charakterystyczną mikrostruktury za pomocą teorii nielokalnej.
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Examination of selected failure criteria with asymmetric shear stresses in the collapse analysis of laminated shells
PublicationThe paper is concerned with failure analysis of composite shells performed with the usage of the nonlinear 6‐parameter shell theory with drilling rotation degree of freedom. This special theory embodies naturally unlim-ited translations and rotations and is suitable for analysis of irregular shells for instance with various, partic-ularly orthogonal, intersections. The presence of the drilling rotation is inherently accompanied...
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An advanced tool integrating failure and sensitivity analysis into novel modeling of the stormwater flood volume
PublicationAn innovative tool for modeling the specific flood volume was presented that can be applied to assess the need for stormwater network modernization as well as for advanced flood risk assessment. Field measurements for a catchment area in Kielce, Poland, were used to apply the model and demonstrate its usefulness. This model extends the capability of recently developed statistical and machine learning hydrodynamic models developed...
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Tensile failure study of 3D printed PLA using DIC technique and FEM analysis
PublicationThe paper presents the experimental and numerical study of the failure behaviour of Fused Filament Fabricated (FFF) Polylactic Acid (PLA) samples subjected to tensile load. The examined samples are printed in flat orientation with 0◦, 45◦ and 90◦ raster angles. During the experiments the deformation of the specimens is continuously scanned with the 3D Aramis measuring system utilizing the digital imaging correlation technique,...
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Numerical Analysis of a Steel Frame Building with Soft-storey Failure under Ground Motion Excitation
PublicationThe aim of this paper is to show the results of a numerical analysis focused on the behaviour of multi-storey steel frame building that suffers from a soft-storey failure under ground motion excitation. A numerical model of the structure was created in FEM computer software and was exposed to an impact that would have been generated after a soft-storey failure due to falling of the upper floors. During the analysis, the whole structure...
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Finite element analysis on failure of reinforced concrete corner in sewage tank under opening bending moment
PublicationW artykule omówiono mechanizm uszkodzenia żelbetowego zbiornika ściekowego w narożniku ściany, który uległ uszkodzeniu podczas próby wypełnienia na skutek nadmiernych przemieszczeń poziomych ścian pod wpływem otwierającego momentu zginającego. Aby wyjaśnić przyczyny awarii, przeprowadzono kompleksowe obliczenia metodą elementów skończonych (MES) żelbetowego zbiornika w warunkach odkształcenia płaskiego. Beton zamodelowano za pomocą...
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Assessment of unusual failure in crankshaft of heavy-duty truck engine
PublicationThe unusual premature failure of a heavy-duty truck engine crankshaft has been the subject of a rigorous study, and this manuscript describes it in detail. The failure was happened to begin with the growth of the crack from the surface defects, in the form of the clusters of non-metallic inclusions, in the lubrication hole zone of the first main journal, which was the stress concentration zone. A series of experiments including...
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Thermal failure of a second rotor stage in heavy duty gas turbine
PublicationThe impulse mode of operation and the supply of various types of fuels causes frequent failures even in the heavy duty gas turbines. The paper presents the ravages of second rotor stage failure in a gas turbine. The excessive thermal elongation rise caused by fuel change was indicated as the main cause. We applied nonlinear numerical analysis, preceded by thermodynamic calculations of the turbine and visual inspection of the effects...
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Fractal analysis of the bending-torsion fatigue fracture of aluminium alloy
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Finite element modelling of a historic church structure in the context of a masonry damage analysis
PublicationThe paper includes a case study of modelling a real historic church using the finite element method (FEM) based on laser scans of its geometry. The main goal of the study was the analysis of the causes of cracking and crushing of masonry walls. An FEM model of the structure has been defined in ABAQUS. A non-linear dynamic explicit analysis with material model including damage plasticity has been performed. A homogenization procedure...
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Experimental and numerical analysis of the modified TB32 crash tests of the cable barrier system
PublicationRoad restraint systems, including safety barriers, are one of the means used to improve road safety. Currently, they can be allowed to general use after passing the specific crash tests. However, it is always important and desirable to evaluate their performance under various realistic conditions, which can happen on the roads. In this study, the behaviour of the cable barrier system in impact conditions different than assumed...
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Analysis of the possibility of creep damage detection in T24 heat resistant steel with the help of magnetic nondestestructive testing methods
PublicationThe paper presents the result of an analysis of applicability of various electromagnetic methods of nondestructive evaluation for creep damage detection in a novel heat resistant steel - T24 grade. Two sample sets, cut out from membrane wall tubes, were investigated – the as-delivered one and another exploited for 36,000 h in a power plant. There are described results of magnetic hysteresis loops B(H), Barkhausen noise (BN) and...
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Application of linear buckling sensitivity analysis to economic design of cylindrical steel silos composed of corrugated sheets and columns
PublicationThe paper deals with global stability of steel cylindrical silos composed of corrugated walls and vertical columns with loads imposed by a bulk solid following Eurocode 1. The optimum silo design with respect to the steel weight was based on a sensitivity analysis method. The changes of silo column profiles at each design step were performed by means of influence lines for the buckling load factor due to the unit column bending...
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A brief note on monotonic and fatigue fracture events investigation of thin-walled tubular austenitic steel specimens via fracture surface topography analysis (FRASTA)
PublicationThe main objective of this short communication is to show the fracture progression in each loading case and complement knowledge about fracture mechanisms underpinning the tensile and fatigue performance of thin-walled tubes. For this purpose, the fracture surface topography analysis (FRASTA) method was used in the thin-walled tubular austenitic stainless-steel specimens. Two cases were analyzed: monotonic tension, and uniaxial...
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Fractographic-fractal dimension correlation with crack initiation and fatigue life for notched aluminium alloys under bending load
PublicationIn this study, fatigue fracture surfaces of aluminium alloy 2017-T4 notched specimens were investigated under cyclic bending to find an alternative failure loading index.. The surface topographies were measured on the entire fracture area with an optical profilometer for different loading conditions. Fatigue crack initiation life Ni and total fatigue life Nf were examined using standard surface topography parameters (such as, root...
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Metal dusting phenomena of 501 AISI furnace tubes in refinery fractional distillation unit
PublicationThe purpose of this investigation was to conduct the failure analysis of 501 AISI furnace tubes places before distillation column in fractional distillation unit. The investigated furnace tubes were planned to work for ten years however after just two years of exploitation <30% of the material left. The observed corrosion process had the intense and complex character. The well-adhered shiny black deposits and deep, round pits were...
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Fatigue fracture surface metrology of thin-walled tubular austenitic steel specimens after asynchronous loadings
PublicationThis paper aims to study the effect of asynchronous axial-torsional strain-controlled loading histories on fracture surface behavior of thin-walled tubular X5CrNi18-10 (304/304L) austenitic steel specimens. Tests under pure axial loading and pure torsional loading are also conducted to better segregate the effect of multiaxiality. The fractures surface topographies were examined through the profiles over the entire surface with...
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Calculations of notch stress factor of a thin-walled spreader bracket fillet weld with the use of a local stress approach
PublicationPresence of geometric notches in welded joints causes concentration of strains and stresses, therefore reducing fatigue strength of such joints. This article presents an analysis of stress concentrations in a fillet weld of a spreader mounting bracket on a small sailing yacht. The aim of this article is to direct the attention of designers, manufacturers and regulatory bodies to issues of fatigue cracks that form in brackets fastening...
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The fracture behaviour of notched PMMA specimens under simple loading conditions – Tension and torsion experimental tests
PublicationThis paper presents the results of experimental testing of flat PMMA specimens during uniaxial loading conditions. Two separate tests were conducted: tensile and torsion. The specimens were weakened with V-type edge notches with different root radii: 0.5; 2 and 10 mm. The specimens were made in two thickness variants: 5 and 15 mm. Monotonic tensile and torsion tests were carried out while keeping the averaged strain rate constant,...
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A brief note on entire fracture surface topography parameters for 18Ni300 maraging steel produced by LB-PBF after LCF
PublicationThe concept of entire fracture surface investigation is helpful in explaining fatigue phenomena. In this paper, this method has been applied for 18Ni300 maraging steel using a 3D measurement system. Before post-mortem analysis, the specimens produced by laser beam powder bed fusion (LB-PBF) were tested under low-cycle fatigue (LCF) for eight strain amplitudes in the interval 0.3% to 1.0%. The attention was placed on the relationship...
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Effect of multiaxial bending-torsion loading on fracture surface parameters in high-strength steels processed by conventional and additive manufacturing
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Non-destructive testing of industrial structures with the use of multi-camera Digital Image Correlation method
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Safety assessment of a concrete viaduct damaged by vehicle impact and an evaluation of the repair
PublicationDamage to lower parts of viaducts caused by impact from under-passing high vehicles is relatively frequent. One such incident, in which a viaduct was damaged by the impact from a truck with an improperly assembled hydraulic crane, is considered in this work. The analysis is based on a detailed object damage evaluation, 3D laser scanning, and numerical simulations. The aim of the study is to accurately model the vehicle impact into...
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Failures and a concept of corrosion protection system for spiral classifiers at KGHM Polska Miedź S.A. Ore Concentration Plant
PublicationThe Ore Concentration Plant, where the process of flotation is carried out as well as the final production of copper concentrate, plays a key role in the entire production line of KGHM Polska Miedź S.A. Majority of operations related to the run-of-mine preparation to copper flotation enrichment are carried out in a water environment. The maintaining of production process continuity requires to pursue minimisation of many production...
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Case study of masts damage of the sail training vessel POGORIA
PublicationArtykuł przedstawia opis i analizę przyczyn zdarzenia polegającego na utracie masztów w lipcu 2009 przez barkentynę sts ''POGORIA'' w trakcie regat Tall Ships Race 2009. Przedstawiono podstawowe okoliczności stanowiące tło zdarzenia, dokonano anlizy przyczyn w skali globalnej, zaprezentowano analizę szczegółową utraty nośności konstrukcji stalowej, a na tym tle wypunktowano szczegółowe przyczyny leżące u źródeł wypadku. We wnioskach...
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Degradation of ferritic X10CrAlSi18 stainless steel caused by slurry
PublicationThe slurry erosion tests of ferritic X10CrAlSi18 steel were carried out using a slurry pot device. In order to investigate the erosion process, two series of tests were performed: first one with a constant impact velocity of 5 m/s, 7 m/s and 9 m/s and the second one, during which the impact velocity was changed after every exposure. During each test, an influence of test conditions on volume loss, surface hardness and roughness...
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Pitting corrosion and stress-corrosion cracking of buffer tanks in a brewery
PublicationW pracy przedstawiono wyniki ekspertyzy zbiornika magazynowego na ciepłą wodę do produkcji piwa w browarze. Zbiornik uległ przyśpieszonym procesom korozyjnym, które doprowadziły do jego perforacji. Podczas eksploatacji zbiornika wystąpił proces korozji wżerowej oraz pękania korozyjnego. Przyśpieszone procesy korozyjne zbiornika związane były z wysoką zawartością jonów chlorkowych w wodzie oraz statycznymi naprężeniami mechanicznymi....
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The effect of elevated temperature on LCF damage growth in 2024AA – Experiment and modeling
PublicationThis paper presents the results of experimental low-cycle fatigue (LCF) tests conducted on EN-AW 2024 alloy in T3511 temper at 100 ◦C, 200 ◦C and 300 ◦C. The material’s basic fatigue characteristics were determined, such as fatigue life curve and cyclic strain curve. Both the hysteresis loop and nature of fracture surfaces obtained in macro- and microscopic observations (scanning electron microscope, SEM) were accounted for. The...