反应器分布器分布管断裂分析

对断裂反应器的分布管进行宏观、金相微观组织、化学成分分析、硬度检验、相结构分析和断口分析。结果表明,在分布器的工况条件下,分布管外表面氧化腐蚀,导致表面晶界氧化裂纹萌生;管内介质NH3分解导致内壁渗氮,生成氮化物材质脆化;在震动作用下,由管外壁起裂,导致失效。     

Failure analysis of components in compressor vane

The paper presents a failure analysis of components damaged in compressor vane. In order to investigate the damage mechanism and failure causes of components, macroscopic and microscopic observations, microstructural investigations, chemical analysis and hardness measurement have been performed. The results show that the damaged components are caused by fractured blades of 1st stage rotor. In all 1st stage rotor blades, 1^# blade is fractured firstly, and is troublemaker in this incident. The fracture mechanism of 1^# blade fractured from blade root is due to first order bending vibration fatigue damage. The microstructure, hardness and chemical compositions of 1^# blade fracture, all which coincide with technical requirements. The bad shot peening qualities in the surface near blade fracture have important influence on fatigue failure.     

Fracture analysis of compressor blade of a helicopter engine

This paper presents the failure analysis of the blade of a helicopter engine. From the visual examination of the fractured surface, it was possible to observe beach marks, typical of fatigue failure. The crack was initiated from the corrosion pit located on the attack edge of the blade. A non-linear finite element method was utilized to determine the stress state of the blade under rotation (operational conditions). In this analysis an undamaged blade was considered. Computations for the blade, working in the vibration conditions additionally were performed for analysis of phenomena occurring during the blade resonance. In this analysis first three mode of vibration were considered. Attention of this study is devoted to the mechanisms of damage of the compressor blade which works in the condition favorable for the pitting corrosion.     

活塞模具的断裂分析

为找出导致活塞模具冲头断裂的原因，本文对其作了分析，包括工作情况分析，宏观断口分析，硬度检查、组织分析等，找出原因后，提出了相应的改进措施。     

Failure analysis of generator rotor fan blades

The failure analysis of a generator rotor fan blade was investigated by mechanical analysis and metallurgical examination of fracture surface. Fracture took place at the airfoil root, surface examination showed that the blade had cracked by a high cycle fatigue mechanism. However, there was no evidence of material defect. A series of analytical, finite element and experimental analysis was utilized to determine the steady-state stresses and dynamic characteristic of the blade. Possibly the failure was due to aerodynamical disturbances that resulted in a state of resonant condition of vibration. The simulation of blade with final crack showed the stress intensity factor (SIF) under these condition exceed the critical SIF and final fracture could be occurred under analyzed stresses.     

Failure Analysis of a Cast Mn-Bronze Propeller

The investigation of a failure of a cast manganese bronze propeller, fractured after a short service period (~4–5 months), was conducted. Chemical analysis, visual inspection, optical microscopy, fractographic evaluation, SEM/EDS analysis, and hardness testing were used as the principal analytical tools for the failure investigation. The findings suggest that the failure occurred due to fatigue mechanism under low stress conditions. The non-conformities detected in material chemical composition, as well as the presence of internal and surface flaws could be considered as the main contributors of the premature failure of the propeller.     

Characterization and Failure Analysis of an Automotive Ball Joint

This case study describes the failure analysis of an automotive lower ball joint that fractured under normal driving conditions. Through spectroscopy, the material was determined to be SAE-AISI 5135H steel. The metallographic examination revealed a tempered martensitic structure, and hardness measurements radially across the surface of the cut ball stud suggested that the stud was through hardened. Scanning electron microscopy of the fracture surfaces indicated fatigue as the main failure mechanism. Finite element analysis was used to analyze the performance of the part under a normal loading condition. A detailed fatigue analysis to determine the effect of various loads on the life of the ball joint was completed using three methods: S-N curve approximation using hardness values, S-N approach using Basquin’s equation, and a linear elastic crack-growth model. The cause of failure was determined to be from surface cracks forming in the high stress concentration neck region where the ball and stud are joined. The presence of a small surface flaw in this region was shown to significantly reduce the fatigue life of the ball joint.     

Evaluation of microstructure of A356 aluminum alloy casting prepared under vibratory conditions during the solidification

The objective of this investigation was to evaluate the effect of vibrations (during solidification) on the metallurgical properties of A356 aluminum casting. Mechanical vibrations were applied to A356 aluminum alloy through set up. A356 melt has been subjected to mechanical vibration with the frequency range from 0 to 400 Hz with constant amplitude 5 µm. Grain refinement was obtained through mold vibration. Metallurgical properties were examined through optical microstructure, tensile fracture scanning electron microscope (SEM) and SEM image of test specimens prepared under different conditions of solidification. Results indicate that mold vibration effectively modified the microstructure of A356 casting and it has uniform and smaller grain size with fibrous silicon particle than nonvibrated casting. Grain refinement results increase in mechanical properties with increase in frequency of vibration of mold during the solidification. SEM micrograph of tensile fracture surface was carried out to study the influence of microstructure on fracture mode. SEM image of tensile fractured surface shows transgranular cleavage facets due to fracture of primary silicon particles. Fractures are brittle in nature so observation indicates low ductility and brittle fracture.     

Bimodular behaviour and crack closure in compression in a brittle material

A vibrating beam method was used to determine the elastic modulus of graphite rods. The frequency and apparent modulus were determined as a function of compressive end-loading. Following fracture of the rod, the frequency and apparent modulus were decreased. At a compressive end-loading of about 0.83 MPa (120 p.s.i.), crack closure was sufficient for the fractured rod to behave similarly in vibration to the unfractured rod. Thus, the fractured material behaves in a bimodular fashion and crack closure can be achieved to enable unimpeded stress transfer across the fracture surface during vibration.     

Investigation on Fracture Behaviour of Turbine Blades Under Self‐Exciting Modes

Abstract: This paper investigates the failure mechanisms of turbine blades occurring during similar conditions of turbine operation. Optical techniques are utilised to identify critical frequencies that may be the cause of blade fractures. For that purpose, time average, stroboscopic holographic interferometry and holographic moiré are utilised to record vibration patterns. Strain maps are computed from stroboscopic and holographic moiré patterns. Stress distributions are computed under the assumption of linear elasticity. It is found that stress trajectories deduced from holographic measurements match well with the initial trajectories of crack observed for the in‐service broken specimens. This fact allows the excitation modes causing blade fractures to be identified. Finite element analyses carried out on models corrected in view of the experimentally observed vibration modes provide the values of stress causing fracture initiation. The paper discusses the failure mechanisms of the blades on the basis the experimental evidence and finite elements results. The observed failure modes seem to be a form of the principal normal stress fracture criterion. An argument based on damage accumulation explains the observed behaviour. Further evidence on failure mechanisms is gathered from scanning electron microscope images of the fractured specimens.     

飞机操纵系统链条销轴断裂分析

某型飞机操纵系统链条销轴在使用中断裂。采用化学成分分析、外观检查、断口分析和表面质量检验等方法对断裂销轴进行了分析,又对有裂纹的销轴与断裂销轴进行了对比分析。结果表明：销轴表面存在原始缺陷,加上链条链板在长期使用中的磨损使得链板间隙增大,导致销轴承受剪切力的同时又承受弯曲载荷,最终导致销轴发生疲劳断裂。     

Failure analysis of an automobile valve spring

This paper presents the failure analysis of an automobile valve spring which failed in service. The fractured surfaces as well as the surface of the spring material close to the fractured surface were examined in a scanning electron microscope at suitable magnifications. Optical microscopy was performed to evaluate the basic microstructure of the as-received material. Detailed electron microscopic studies have indicated that the failure was due to the presence of non-metallic inclusions near the surface of the spring material.     

Failure Analysis of Reverse Shaft in the Transmission System of All-Terrain Vehicles

This paper presents a failure analysis of a reverse shaft in the transmission system of an all-terrain vehicle (ATV). The reverse shaft with splines fractured into two pieces during operation. Visual examination of the fractured surface clearly showed cracks initiated from the roots of spline teeth. To find out the cause of fracture of the shaft, a finite element analysis was carried out to predict the stress state of the shaft under steady loading and shock loading, respectively. The steady loading was produced under normal operation, while the shock loading could be generated by an abrupt change of operation such as start-up or sudden braking during working. Results of stress analysis reveal that the highest stressed area coincided with the fractured regions of the failed shaft. The maximum stress predicted under shock loading exceeded the yield strength and was believed to be the stimulant for crack initiation and propagation at this weak region. The failure analysis thus showed that the premature fatigue fracture of the shaft was caused by abnormal operation. Finally, some suggestions to enhance service durability of the transmission system of ATV are discussed.     

Failure analysis of impeller made of FV520B martensitic precipitated hardening stainless steel

This paper presents the failure analysis of a centrifugal compressor impeller. The impeller made of FV520B martensitic precipitated hardening stainless steel, fractured after service for 4 months in moist H₂S condition. Efforts were made to analyze the failure impeller in both experiment and FE methods. Sulfide Stress Cracking (SSC) was the primary failure mechanism for this investigated impeller. The martensite structure, the H₂S medium, and the applied stress consisted of the SSC system. This paper exhibits the details of investigation and suggests remedial measures to improve performance of this type impeller under H₂S corrosive environment.     

移动荷载列作用下简支梁振动响应参数研究

推导了移动荷载列作用下简支梁位移响应的精确解,在此基础上引入3个无量纲参数,研究了荷载移动速度、荷载频率及结构阻尼对桥梁响应的影响,分析了简支梁在一定荷载速度下的共振和消振现象发生机理。结果表明:桥梁跨中的最大位移响应并非随着荷载速度的增大而单调地增大,而是表现出一种类似正弦但波幅逐渐变大的方式;当移动荷载列以消振速度通过桥梁时,引起的桥梁余振响应趋近于零;简支梁的共振速度与移动荷载列的间距有直接关系,当共振速度同时又是消振速度时,共振现象被抑制;当简谐荷载移动速度较低时,梁体位移在荷载频率等于梁体第一阶自振频率时达到最大响应,随着荷载移动速度的增大,梁体位移达最大响应不再发生于荷载频率等于梁体第一阶自振频率的情况。     

全断面开挖爆破产生的自由面对振动频率的影响研究

通过对爆破试验中处于不同自由面条件下的炮孔爆破产生的振动信号进行频谱分析,并结合爆破振动数值模拟,研究了地下洞室全断面毫秒延迟爆破过程中产生的自由面对振动频率的影响机理及变化规律。结果表明：爆炸荷载产生的压应力波传播至自由面时发生反射,反射稀疏波与原应力波叠加致使远区荷载压力的上升时间和持续作用时间变短,造成荷载的频率变大,从而导致有自由面条件下其振动频率增大、高频振动能量占总能量的比重增加;爆源与自由面之间的距离越小,爆破振动频率越高;从振动频率的角度来看,较好的自由面条件可以减小爆破振动对结构的破坏。试验监测结果验证了分析结论的可靠性。     

井下移动式破碎机垂直方向随机振动响应的研究简

 为了研究井下移动式破碎机在破碎头受随机载荷作用下垂直方向的振动特性、探究其工作可靠性低的原因,通过假设与简化,根据多体动力学理论,建立了其动力学模型和垂直方向的运动方程,运用虚拟激励法推导了破碎机垂直向振动响应的数学模型．以国产某型井下移动式破碎机为研究对象,分析确定了破碎头冲击岩石时的随机载荷,运用MATLAB语言程序,得到该破碎机在高位时受随机载荷作用下破碎头、支臂与机身在垂直方向的随机振动响应．结果表明：在载荷峰值为375 kN、均值为186 kN、频率为10 Hz的随机激励作用下,该机各部振幅峰值与均值分别为：破碎头：0.0125 m,0.007 25 m;支臂：0.010 m,0.006 57 m;机身：0.006 1 m,0.003 62 m,可见各部振动比较剧烈．破碎头振动和波动最大,支臂次之,机身最小,与实际情况相符．当各部件振幅达最大时,破碎头、支臂与机身的低频与固有频率接近,容易发生共振,这是导致机器振动剧烈,引起零部件、元器件失效,使用寿命下降的主要原因．所得结论为改进移动式破碎机设计、采取合理的减振措施、延长破碎机使用寿命提供参考．     

Fatigue curves of a low carbon steel obtained from vibration experiments with an electrodynamic shaker

This paper presents an original contribution for the establishment of the high-cycle fatigue curves ε–N_f (strain versus cycle number to failure) of low carbon steel under vibratory testing. These curves are obtained thanks to a vibrational fatigue bench composed of an electrodynamic shaker and a closed loop vibration control system. The main advantage of this is the high frequency excitation compared to conventional fatigue systems. Three criteria based on strain gauge measurements are implemented to provide cycle numbers to failure N_f and to plot the fatigue curves. Furthermore, cycle numbers to failure are also assessed from two modal parameters (resonant frequency and loss damping factor) and compared with the results obtained from these three criteria. Some micrographies of fractured samples observed by scanning electron microscope reveal fatigue striations but also intergranular fracture.     

Failure Analysis of Roller Cone Bit Bearing Based on Mechanics and Microstructure

The service life of the roller cone bit mainly depends on the bearing. In order to figure out the cause and mechanism of bearing failure, mechanics and microstructure analysis of failed roller cone bit bearings are carried out. The results show that the bearing failure mainly includes wear (including adhesive wear and abrasive wear), plastic deformation, crack, fracture and burn. The main reasons for these failures are: abrasives and temperature rise caused by the cuttings and the lubrication failure; stress concentration, shock and vibration due to uneven load and fit clearance; and initial cracks or deficiencies because of unqualified surface treatment. In addition, investigation indicates that seal failure can bring degeneration on the bearing surface, which reduces the hardness of the bearing surface and thus accelerates the failure of the bearing.     

Analysis of a diesel generator crankshaft failure

This paper analyses a catastrophic crankshaft failure of a four-stroke 18 V diesel engine of a power plant for electrical generation when running at a nominal speed of 1500 rpm. The rated power of the engine was 1.5 MW, and before failure it had accumulated 20,000 h in service operating mainly at full load. The fracture occurred in the web between the 2nd journal and the 2nd crankpin. The mechanical properties of the crankshaft including tensile properties and surface hardness (HV₁) were evaluated. Fractographic studies show that fatigue is the dominant mechanism of crankshaft failure, where the beach marks can be clearly identified. A thin and very hard zone was discovered in the template surface close to the fracture initiation point, which suggests that this was the origin of the fatigue fracture. A finite element model of the crankshaft has predicted that the most heavily loaded areas match the fractured zone.