Failure analysis of the conical press-fit connections in a locomotive drive system

The nose-suspension drive designs with overhanging pinion are commonly applied in freight electrical locomotives because of simple, space-saving and cost-effective. The failures of conical press-fit connections in a nose-suspension drive system are analyzed in this paper. It was showed by the analysis that the crack on the inner conical surface of motor shaft is initiated by the combination of fretting and corrosion. Sharp oil groove edge and emergency of crack at the mouth of radial oil hole in pinion will accelerate the formation of fretting wear groove, and consequently the initiation of cracks. Coexist of tensile normal stress under the contact surface within the fretting zone will benefit the propagation of the fretting fatigue cracks.     

Failure analysis of carbon steel pipes used for underground condensate pipeline in the power station

In this paper, the cause of failure of an ASTM A53 Grade B carbon steel pipe was investigated. The investigated ASTM A53 Grade B pipe was used for a condensate pipeline and was found to be cracked after six months in service. The failed parts were investigated by means of stereoscopic microscope, optical microscope, scanning electron microscope equipped with energy dispersive X-ray spectroscopy micro-analysis, spark emission spectrometer, tension tester and Vickers hardness tester, in order to identify the failure causes and to suggest preventive solutions. A specially instrumented indentation tester was used for the measurement of residual stress on welding seam. The study shows that failure was mainly due to stress corrosion cracking caused by chloride and tensile residual stress on the welding seam due to insufficient heat input or low compression, etc during welding processing.     

Failure analysis of a martensitic stainless steel (CA-15M) roll manufactured by centrifugal casting. Part I: Material and fractographic characterization

The failure analysis of a martensitic stainless steel (CA-15M) roll manufactured by centrifugal casting and used in cast glass rolling was carried out by means of traditional characterization techniques (optical metallography, SEM, EDX microanalysis, tensile testing and XRD). The roll was in the as-cast condition and its microstructure featured large proportion of δ ferrite (between 20% and 27%) in a martensitic (α′) matrix, with the δ/α′ interfaces presenting an intergranular network of M₂₃C₆ carbides. The crack propagation began in the internal surface of the roll, with δ/α′ intergranular and transgranular cleavage in the “equiaxed region” of the casting, progressing to δ/α′ intergranular ductile fracture in the “columnar” and “chilled regions”. Tensile thermal stresses in the internal surface of the roll associated with microstructural embrittlement (network of interfacial carbide and microporosities) are thought to be the main causes for the premature failure of the roll. Finally, materials selection was performed to replace the CA-15M stainless steel with another class of stainless steel for centrifugal casting.     

Failure analysis of seven masonry churches severely damaged during the 2012 Emilia-Romagna (Italy) earthquake: Non-linear dynamic analyses vs conventional static approaches

This study presents a detailed failure analysis of seven masonry churches, which were severely damaged during the 2012 Emilia-Romagna (Italy) seismic sequence, by means of 3D FE non-linear dynamic simulations. The main aims of the numerical investigations are: (1) to carry out a sufficiently wide sensitivity study on different specific case studies to have an insight into the role played by the geometry – which is always unique for churches – and by the irregularities; (2) to validate or address the limits of applicability of the most widespread conventional static approaches recommended by Italian Code, i.e. kinematic limit and pushover analyses. Non-linear dynamic analyses are carried out assuming that masonry behaves as a non-linear material exhibiting softening and damage, frictional behavior and different strength in tension and compression. The set of case studies investigated in this work shows how conventional static approaches are still capable of roughly identifying the most critical macro-elements that usually activate a failure mechanism, but that the results (e.g. collapse acceleration, behavior factor) are affected by a level of approximation that may considerably depend on in-plan irregularity and hypotheses done on the interlocking between contiguous walls. From the comparative analyses carried out, it is authors’ opinion that it is always beneficial to perform different types of analysis in order to have a comprehensive insight into the portions of the structure that can suffer a partial collapse with high probability. Once the active mechanism is identified, non-linear dynamic analyses, with more sophisticated material models and with refined FE discretizations of the critical regions, may be useful to deepen the knowledge of the behavior of such complex structures under seismic actions.     

On the applicability of the small punch test to the characterization of the 1CrMoV aged steel: Mechanical testing and numerical analysis

The life extension of a component in service is of great importance in many engineering applications and it relies on the possibility of monitoring the material degradation during in-service loading. In this view, non-destructive testing is needed in order to be able to evaluate the material properties while keeping the component in service.The present work focuses on a miniature mechanical test named small punch test, which has been employed on virgin and aged 1CrMoV steel in order to characterise its mechanical behaviour. A thorough experimental analysis has been carried out using classical and miniature mechanical tests and the results have been compared in order to evaluate the feasibility of the small punch test to the characterisation of an aged steel.A numerical framework based on finite element simulations is also presented to support the findings of the experimental tests. Starting from the simulation of a typical load–displacement curve given by the small punch test, the elastic–plastic parameters have been identified and applied in the simulation of the tensile tests.Experimental results and non-uniqueness of the mathematical problem associated to the identification of the material parameters are discussed.     

Constitutive analysis to predict high-temperature flow stress in modified 9Cr–1Mo (P91) steel

Constitutive analysis for hot working of modified 9Cr–1Mo (P91) ferritic steel was carried out employing experimental stress–strain data from isothermal hot compression tests, in a wide range of temperatures (1123–1373 K), strains (0.1–0.5) and strain rates (10⁻³–10² s⁻¹). The effects of temperature and strain rate on deformation behaviour were represented by Zener–Hollomon parameter in an exponent-type equation. The influence of strain was incorporated in the constitutive equation by considering the effect of strain on different material constants. Activation energy was found to vary with strain in the range 369–391 kJ mol⁻¹. The developed constitutive equation (considering the compensation of strain) could predict flow stress of modified 9Cr–1Mo steel over the specified hot working domain with very good correlation and generalization.     

热作模具钢的原位统计分布分析

采用原位统计分布分析技术对不同来源的模具钢进行解析,获得了模具钢坯横剖面较大尺度范围内各化学组成的位置分布、状态分布、含量分布的一系列新信息;定量表征了不同来源模具钢的最大偏析度、统计偏析度、统计符合度、统计致密度、统计疏松度、夹杂物种类和含量以及粒度统计分布等参数的差异性,可用于不同来源模具钢质量差异解析的参考.     

Numerical approach to the study of the stressed (0 0 1)NiO/(1 1 1)Ni coatings

This work is devoted to the study of the thermomechanical behaviour of the oxide films formed during the high-temperature oxidation of loaded (1 1 1)Ni single-crystalline nickel samples. The NiO/Ni system is submitted to a high-temperature creep in the oxygen atmosphere. First experiments performed with this system have shown, several deformation modes (diffusional creep, gliding at the interfaces, etc.) in the oxide film and the appearance of periodic cracks perpendicular to the loading direction. The inter-crack distance varies strongly with the load amplitude. In order to clarify these phenomena, we developed two numerical models. Both models take into account the oxide growth phenomenon and consequently the epitaxial strain due to the lattice misfit between the film and the substrate. A simplified 1D model of the oxide layer evolution and a complete 3D finite element model. The results obtained for this model (residual stress and strain and their distribution in the film along the direction perpendicular to the substrate) are used in the 3D model as initial data for the simulation of successive cracks that appear during external loading. For that simulation, we associate remeshing techniques and field mapping. Using the proposed approach, we study, namely, the dissymmetrical coating growth. We analyse also the effect of the crack generation during the loading on the mechanical fields along the metal/oxide interface.     

Progressive fatigue failure behavior of glass/epoxy (±75)2 filament-wound pipes under pure internal pressure

Fatigue failure behaviors of filament-wound composite pipes under pure internal pressure were investigated. The filament-wound pipes are made of E-glass/epoxy and have four layers which have ±75° winding angle. The fatigue tests have been done in accordance with ASTM D-2992, which stipulate 0.42 Hz frequency and R = 0.05 stress ratio. Tests have been performed at different load levels from 30% to 70% of ultimate tangential strength of the pipe, the damage progression such as whitening, leakage and final failure have been observed, and S–N curves of these damages were obtained.     

Failure analysis on collapsed towers of overhead electrical lines in the region Münsterland (Germany) 2005

End of November 2005 strong south-west wind and heavy snowfall were predominant in the region Münsterland, north-western part of Germany. This led to accretion of a considerable quantity of wet snow to overhead electrical lines in form of snow rolls on the conductors. Eighty-two transmission towers failed catastrophically, most of them by buckling, however some by brittle fracture. As a consequence nearly 250,000 people have been cut off from electrical power supply for several days with major media attention.This paper describes the forensic analysis in order to investigate the failure cause. Therefore extensive materials investigations, mechanical testing of original components and specimens thereof, estimations for the real wind and snow loads and their combinations, structural analyses as well as detailed evaluations on the basis of previous investigations, literature and regulations were conducted. It was revealed that some of the examined components were manufactured from Thomas steel which was partially in embrittled condition. The investigated towers fulfilled the design codes valid at the time of erection. However the present line loads of the wet snow rolls on the conductors exceeded by far the ones given in the design codes valid at that time.The load case leading to failure was reconstructed by the derived positions of loads mainly caused by unequal and asymmetric distribution of snow rolls on left and right electrical system. The loads and corresponding stresses acting on the structure before failure were estimated. By comparison with the fracture forces from mechanical testing of original members of the collapsed tower the component that primarily failed was localised. The primary fracture occurred on a diagonal member under tension made of Thomas steel which was weakened by embrittlement. The failure cause was a combination of heavy weather conditions (storm, approx. 0 °C and wet snowfall leading to heavy snow rolls on conductors), asymmetric loading conditions and the usage of Thomas steel which was partially embrittled. Finally, recommendations for avoiding future failures are given.     

Investigation of the aluminum oxide/Si(1 0 0) interface formed by chemical vapor deposition

Thin films of aluminum oxide were deposited using trimethylaluminum and oxygen. The deposition rate was found to decrease with increasing temperature. Fourier transform infrared spectroscopy and X-ray photoelectron spectroscopy (XPS) were used to investigate the film/substrate interface. When dry O₂ was used during deposition, the film/substrate interface was free of any silicon dioxide or aluminum silicate phase. On annealing the as-deposited films in Ar, a layer of silicon dioxide film formed at the interface. XPS results indicated that the O/Al ratio in the as-deposited films was higher than that in stoichiometric Al₂O₃. However, the ratio was found to decrease in the annealed samples suggesting that excess oxygen present in the deposited films is responsible for the formation of interfacial silicon dioxide layer. Interfacial phase formation was observed in the as-deposited samples, when small amounts of ozone along with oxygen were used as the oxygen precursor.     

Accurate determination of the voltage of a transmission electron microscope (TEM) by 〈0 1 2〉 CBED-HOLZ analyses using GaAs crystal

Convergent beam electron diffraction (CBED) is a powerful technique to estimate lattice distortion and lattice strain in crystals. The positions of the higher-order Laue-zone (HOLZ) lines in the transmitted disc of CBED patterns are very sensitive to the lattice parameter, and can therefore be used to estimate changes in the lattice parameter. This offers the possibility to calculate lattice misfit and lattice strain. The positions of the HOLZ lines depend not only on the lattice parameter, but also on the operating voltage of the microscope. It is essential to know the actual voltage of the microscope. In the present work, (1 0 0) GaAs crystal has been used as a standard. Cross-sectional TEM specimens were prepared by argon ion beam thinning technique using a liquid nitrogen cold stage. 〈0 1 2〉 on-zone CBED technique has been used to estimate the actual voltage of the transmission electron microscope (Philips EM430T TEM), when the voltage was set at 250 kV. CBED-HOLZ simulation and analyses have been done, using JEMS software, to correlate with the experimental data. The methodologies adopted for estimating the actual voltage of TEM are discussed in this paper. The studies have also been cross-checked using 〈0 1 2〉 and 〈2 3 3〉 zone axes using (1 0 0) silicon standard. The techniques established are found to be suitable for TEMs operating at a setting voltage of about 250 kV. For the TEM studies, a regular double-tilt specimen holder is required in order to be able to get to the desired zone axes. When the experiments were repeated using a cryogenic double-tilt holder, an improvement in the sharpness of HOLZ lines was observed. Wherever possible, the use of the cryogenic double-tilt holder is recommended. Care must, however, be taken to ensure that effects such as lattice parameter changes (due to temperature changes), phase transformations etc can be properly accounted for.     

Observation of metal on Si(0 0 1) by STM/STS and its consideration based on the first principles calculations

Local density of states (LDOS) is obtained by the first principles calculation based on the density functional theory on the Si(0 0 1)2 × 1 surface and on the surface with an Al dimer. At an Al dimer, LDOS has a high intensity in the conduction band region, which cannot be seen on the Si(0 0 1)2 × 1 surface. This tendency is observed in STS measurements as well. The possibility for a microelementary analysis is presented by applying this method to other metal atoms on the Si surface. Furthermore, it is pointed out that STS measurements should be always performed at the same tip-sample separation to obtain reproducible STS spectrums.     

Identification of the pin offset effect on the friction stir welding (FSW) via Taguchi – Grey relational analysis: A Case study for AA 7075 – AA 6013 alloys

The aim of this work is to present a case study relating to the dissimilar friction stir welding (FSW) ability of AA 7075‐T651 and AA 6013‐T6 by applying pin offset technique. An orthogonal array L18 was conducted to perform the overlapped weld seams using three different values of pin offset, welding speed and tool rotational speed along with two different pin profiles determine the impact of welding parameters on the tensile properties of friction stir welded joints. The nugget zone for each of overlapped weld seams exhibited a complex structure and also, the pin offset and profile also were found to have a great impact on the microstructural evolution of the nugget zone. The ultimate tensile strength, elongation at the rapture and bending strength of welded joints were measured in the ranges of 194–215 MPa, 1.79–3.34 % and 203–352 MPa. From the Taguchi based Grey relational analysis, the optimum welding condition was determined for the welded joint performed using a single fluted pin profile with the zero pin offset, tool rotational speed of 630 min^?1 and welding speed of 63 mm/min. Microstructural and macro‐structural observations revealed that welded joints exhibiting lower tensile strength are consistent of various types of defects (e. g. cracks, tunnels and cavities). The fracture location of welded joints was found to be on the heat affected zone and between the heat affected zone and AA 6013‐base metal. The tool and pin wear was not observed during the welding applications     

Structural study by X-ray diffraction and transmission electron microscopy of the misfit compound (SbS1−xSex)1.16(Nb1.036S2)2

In the Sb-Nb-S-Se system, a new misfit layer compound (MSL) has been synthesized and its structure was determined by combining single crystal X-ray diffraction (XRD) and transmission electron microscopy (TEM) techniques. It presents a composite crystal structure formed by (SbS_1−xSe_x) slabs stacking alternately with double NbS₂ layers and both can be treated as separate monoclinic subsystems. The (SbS_1−xSe_x) slabs comprise a distorted, two-atom-thick layer with NaCl-type structure formed by an array of {SbX₅} square pyramids joined by edges (X: S, Se); the NbS₂ layers consist of {NbS₆} trigonal prisms linked through edge-sharing to form sheets, just as in the 2H-NbS₂ structure type. Both sublattices have the same lattice parameters a = 5.7672(19) Å, c = 17.618(6) Å and β = 96.18(3)°, with incommensurability occurring along the b direction: b₁ = 3.3442(13) Å for the NbS₂ subsystem and b₂ = 2.8755(13) Å for the (SbS_1−xSe_x) subsystem. The occurrence of diffuse scattering intensity streaked along c^* indicates that the (SbS_1−xSe_x) subsystem is subjected to extended defects along the stacking direction.     

Post-synthetic treatments on NixMnxCo1 − 2x(OH)2 for the preparation of lithium metal oxides

A series of hydroxides Ni_xMn_xCo_(1−2x)(OH)₂ for x = 0.00–0.50 were prepared. These hydroxides were used as the precursors in the synthesis of electrochemical active lithiated mixed metal oxides, LiNi_xMn_xCo_{(1 − 2x)}O₂. The traditional co-precipitation method was used to synthesize the hydroxides and the effect of different post-synthetic treatments were tested. The solutions after co-precipitation of the hydroxides were heated under hydrothermal or microwave assisted hydrothermal conditions at 180 °C. All samples were analyzed with X-ray diffraction (XRD), scanning electron microscopy (SEM) and electrochemical measurements. We observed that the hydroxides undergo oxidation to an oxyhydroxide phase as the stoichiometry varies during their synthesis and with post-synthetic treatments. As the concentration of Ni and Mn increases in the sample, a mixture of both hydroxide and oxyhydroxide phases is obtained. SEM images demonstrate a sintering effect on the hydroxide particles after post-synthetic treatment, while XRD measurements on these samples show an increase in crystallinity and reduced turbostratic disorder. The oxides synthesized from these precursors demonstrate similar electrochemical performance with one another.     

Structure analysis on the Ba3Mg(Ta1−xNbx)2O9 ceramics: Coexistence of order and disorder

The Ba₃ZnTa₂O₉ (BZT) and Ba₃MgTa₂O₉ (BMT) ceramics, a family of A₃B²⁺B⁵⁺₂O₉ complex perovskites, are extensively utilized in mobile based technologies due to their intrinsic high unloaded quality factor, high dielectric constant and a low (near-zero) resonant frequency temperature coefficient at microwave frequencies. The preparation conditions as well as size and nature of B cations have a profound effect on the final dielectric properties. In this article, we report the effect of Nb⁵⁺ at the Ta⁵⁺ site on the BMT structure prepared at four synthesis temperatures (1300, 1400, 1500 and 1600 °C). The analysis has been carried out using the Rietveld technique on the X-ray powder diffraction data. Results suggest that both the preparation temperatures and Nb⁵⁺ content have significant effect on the ordering of B cations in the Ba₃Mg(Ta_1−xNb_x)₂O₉ solid solution. A disordered (cubic) structure is preferred by the 1300 °C compounds. The weight percentage of the ordered (trigonal) phase escalates, for a given composition, with increasing calcination temperature. A fully ordered trigonal arrangement exists only for x = 0.0 and 0.2 compounds calcined at 1600 °C, and the rest are biphasic (cubic and trigonal). The increase in the cubic fraction upon Nb⁵⁺ augmentation suggests that the solid solution leans more toward the disordered structural arrangement of B²⁺ and B⁵⁺ cations.