Failure mode transition and energy dissipation in naturally occurring composites

The microstructural aspects of compressive inelastic deformation in balsa wood are investigated with emphasis on the failure mode transition and its effects on energy dissipation characteristics. The architectural features as well as the composite character of cell wall ultrastructure are discussed in a framework to understand the complex interrelationship between microstructure and macroscopic behavior in this extremely lightweight cellular biocomposite. Based on this discussion and experimental results, it is concluded that the biomimetic approach may prove to be a viable strategy in designing composite structures with high specific energy absorption capacity.     

A method of identifying latent human errors in work systems

Work system improvements are implemented in various manufacturing processes to prevent problems caused by human errors. However, they are almost always applied to problems which have already occurred. This paper examines a method of identifying latent human errors existing within the work systems beforehand. A procedure for applying failure mode and effect analysis to this identification problem was defined based on over 1000 empirical errors: a work system decomposition criterion and fundamental error modes for listing latent human errors, and then applied to three practical manufacturing processes in order to evaluate its effectiveness.     

Failure analysis of aluminum cable steel reinforced (ACSR) conductor of the transmission line crossing the Paraná River

The failure of the conductor of the 460 kV overhead transmission line located along the crossing of the Paraná River was investigated. As a result of this failure, a blackout took place in the southern states of Brazil in January of 2002, reaching approximately 67 million inhabitants. Investigation of the external aluminium layer of the ACSR conductor near the fracture showed typical static deformation marks and dynamic fretting wear tangential marks, both associated with the presence of Al₂O₃ debris. Additionally, encrusted silicon particles were observed on the external surface of the strands. The internal Al layer showed elliptical deformation marks also associated with Al₂O₃ debris. Both Al₂O₃ and Si particles are efficient abrasive material, which associated with slight relative motion of metallic surfaces (clamp/strand and strand/strand) can promote fretting wear. Two types of fracture surface of the Al strands were identified: 45° and quasi-normal surfaces, the former being the predominant type. Delamination and particle detachment were the mechanisms of superficial degradation observed on the Al strands, indicating that the rupture of the strands occurred under a gross slip fretting regime induced by sub-conductor oscillation. Inspection of the internal surface of as-cast Al–10%Si spacer clamps revealed different stages of intense circumferential wear caused by the preferential cracking and particle detachment of the eutectic constituent of the as-cast microstructure. This intense wear reduces the clamping contact pressure, which allows higher displacement amplitude and leads to the critical fretting regime. Finally, a few suggestions are discussed to minimise the occurrence of future failures.     

A probabilistic model for cleavage fracture with a length scale--parameter estimation and predictions of stationary crack experiments

This study presents a large experimental investigation in the transition temperature region on a modified A508 steel. Tests were carried out on single-edge-notch-bend specimens with three different crack depth over specimen width ratios to capture the strong constraint effect on fracture toughness. Three test temperatures were considered, covering a range of 85 °C. All specimens failed by cleavage fracture prior to ductile tearing. A recently proposed probabilistic model for the cumulative failure by cleavage was applied to the comprehensive sets of experimental data. This modified weakest link model incorporates a length scale, which together with a threshold stress reduce the scatter in predicted toughness distributions as well as introduces a fracture toughness threshold value. Model parameters were estimated by a robust procedure, which is crucial in applications of probabilistic models to real structures. The conformity between predicted and experimental toughness distributions, respectively, were notable at all the test temperatures.     

Case Study of an Aerosol Explosion and a Method to Determine Explosion Temperatures

A failure analysis case study is presented for a two-piece aerosol containing tetrafluoroethane, commonly referred to as Refrigerant 134a. A gentleman was preparing to recharge the air conditioning system of an automobile when the bottom exploded off the aerosol container, propelling the body of the aerosol container like a rocket, which hit the man in the eye and blinded him in that eye. The aerosol was never connected to the air conditioner, therefore backpressure from the air conditioner (AC) compressor was ruled out as a cause for the explosion. The objective of the study was to determine why the aerosol exploded. Several recently developed test methods were used, including two types of heat-to-burst tests and a puncture chamber to measure the pressure-versus-temperature behavior of aerosols. More common test methods were also used, such as water bath pressure tests, hydro pressure burst tests, pneumatic pressure burst tests, hardness measurements, weight measurements, metallography, scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and an accident scenario recreation. A semi-empirical correlation between the hardness and weights of the container bottoms was used to determine the explosion temperature and/or pressure. This semi-empirical correlation agrees in principle with an analysis of the explosion pressures using finite-element analysis (FEA). The root cause for the explosion was determined to be a lack of strength of the bottom of the two-piece aerosol coupled with heating the aerosol to temperatures significantly above room temperature.     

锅炉炉管爆破原因分析

对在爆裂的水冷壁管正常管段和鼓包处所取的试样分别进行化学分析、金相检验、硬度测定和高温拉伸试验。分析结果表明，在近烧嘴的炉管长期处于超温工作状态，引起该部位材质严重劣化，高温强度不断下降，当该部位的高温强度低于锅炉炉管对材质所要求的技术条件即会发生爆裂。对炉管的继续使用提出了应急的预防措施。     

Schäden durch kerbinduzierte Schwingbrüche

Failures by notch induced fatigue fractures Notches produce local stress concentrations and promote the formation of fatigue cracks. Characteristic types of notches as a result of design, manufacturing and operation are presented and remedial measures are discussed. Examples demonstrate the effect of different kinds of notches on various components.     

轴齿轮断齿失效分析

通过对轴齿轮断口形貌、硬度测试及金相组织等试验进行分析表明，齿根处没有进行硬化处理造成齿根处抗疲劳性能不足是导致轴齿轮疲劳断裂的主要原因，另外齿根过渡处倒角过小，且存在纵向刀痕引起了较大应力集中也是导致轴齿轮疲劳断裂的原因。     

Sicherer und wirtschaftlicher Betrieb von Kraftwerken – Ergebnis der Forschung im Bereich Werkstoffe,Auslegung und Instandhaltung

Safe and Economic Operation of Power Plants – Research Results in the Field of Materials, Design and Maintenance Components of power plants which undergo high temperatures are subjected to complex loading situations. The requirements on the used materials result from the special operation conditions of the plants and have to be adjusted to the steadily growing requirements on higher efficiency of the complete power plant as well as to those of safe and economic operation. The expenses for control and downtimes are directly connected with economic efficiency and availability. However, in case of new procedures or components it is not possible to revert to the existing know‐how. Different failure mechanisms than known before can occur. The same goes for the load situation. Therefore the knowledge base has to be extended to in‐advance or even parallely running scientific examinations that life assessment and maintenance strategies can be applied which guarantee the operational reliability and the efficiency of the plant. The main emphasis of these F&E works has to be put on condition monitoring based on actual operational data, the standard materials’ and component’s behaviour (deformation, damage and failure behaviour) in connection with design of components and the related material laws. In the framework of applied AVIF projects, following problems are handled:. – qualification of materials by determinating parameters related to practise. – optimal design of components by making available material laws and numerical tools. – economic manufacturing of components by qualifying processing methods such as welding. – The results can be transferred to concepts for safe and economic operation of power plants, especially for newly introduced materials for which there is no operational experience available.     

Reliability evaluation and optimisation of imperfect inspections for a component with multi-defects

In this paper, a model is developed to evaluate the reliability and optimise the inspection schedule for a multi-defect component. The model uses a non-homogeneous Poisson process (NHPP) method in conjunction with a delay time approach. The inspections are designed to detect any defects in the component, however it can be imperfect. The defect is a definable state before a functional failure happens to the component. Occurrences of defects are assumed to follow an NHPP and a defect will be minimally repaired if it is identified during an inspection. It is shown that the failures occurring in an interval of inspection will also follow an NHPP. The situation of imperfect inspections and non-constant inspection intervals are considered. An algorithm is presented to optimise the intervals of inspections in order to maximise the reliability of the component, and the properties of the algorithm are shown. A numerical example with parametric study is given to show the performance of the model and the algorithm.