Failure Analysis in Metallic Materials

A special issue of Metals (ISSN 2075-4701). This special issue belongs to the section "Metal Failure Analysis".

Deadline for manuscript submissions: closed (30 June 2022) | Viewed by 11049

Special Issue Editor

Department of Engineering for Innovation, Università del Salento, 73100 Lecce, Italy
Interests: fatigue; welded joints; experimental mechanics; FEM; damage models; low-cycle fatigue; aluminum foam; residual stress
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Special Issue Information

Dear Colleagues,

The structural behavior of a mechanical component is essentially the result of the interaction of acting structural loads, geometry, and material properties. All these aspects can be modelled with sufficient accuracy and reliability in order to establish the safety of the component. For a large number of applications, the numerical and experimental tools available in the technical literature are sufficiently accurate for correct design and verification. However, these general considerations neglect several aspects that in certain cases are crucial for the safety of the component, such as residual stress, the variability of applied loads, the variability of mechanical properties, the reliability of the manufacturing process, and the corrosion and degradation of materials.

The aim of this Special Issue is to compile article that focus on determining the aspects that contribute to the failure of metallic materials. Contributions concerning the interaction of the stress/strain state and mechanical properties in determining the failure of metallic materials are welcome. Presentations of industrial cases illustrating the use of analytical, numerical, and experimental techniques for the study of the failure of metallic components in the automotive, aeronautical, and mechanical sectors are also welcome.

Prof. Dr. Riccardo Nobile
Guest Editor

Manuscript Submission Information

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Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Metals is an international peer-reviewed open access monthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

  • failure analysis
  • stress concentration
  • failure mode
  • mechanical properties
  • microstructure
  • fatigue
  • fracture mechanics

Published Papers (6 papers)

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Editorial

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2 pages, 169 KiB  
Editorial
Failure Analysis in Metallic Materials
by Riccardo Nobile
Metals 2023, 13(8), 1374; https://doi.org/10.3390/met13081374 - 31 Jul 2023
Viewed by 621
Abstract
Failure analysis is a complex task that plays a fundamental role in technical applications [...] Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)

Research

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17 pages, 20692 KiB  
Article
Oil-Pipe Cracking and Fitness-for-Service Assessment
by Jin-Heng Luo, Li-Feng Li, Li-Xia Zhu, Liang Zhang, Gang Wu and Xin-Wei Zhao
Metals 2022, 12(8), 1236; https://doi.org/10.3390/met12081236 - 22 Jul 2022
Cited by 1 | Viewed by 1368
Abstract
A new D457 × 7.1 X65ERW oil pipeline leaked twice during the pressure test. The two failed oil pipes belonged to the same batch of products from the same manufacturer. Failure analysis showed that the cracks in the 1# and 2# cracking pipes [...] Read more.
A new D457 × 7.1 X65ERW oil pipeline leaked twice during the pressure test. The two failed oil pipes belonged to the same batch of products from the same manufacturer. Failure analysis showed that the cracks in the 1# and 2# cracking pipes propagated from the outer surface of the pipe wall to the inner surface along the weld fusion line. The inclusion phase distributed in chains in the weld zone is speculated to be the root cause of the cracking in the pressure test. The fitness-for-service of this batch of steel pipes was analyzed using the failure-assessment chart technique. The batch of steel pipes could be used safely under the design pressure of 10 MPa, and the re-evaluation period of three years was recommended for the pipeline based on the fatigue results of the steel-pipe weld zone. Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)
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21 pages, 14236 KiB  
Article
Effect of Mechanical Properties of Rail and Wheel on Wear and Rolling Contact Fatigue
by Jung-Won Seo, Hyun-Moo Hur and Seok-Jin Kwon
Metals 2022, 12(4), 630; https://doi.org/10.3390/met12040630 - 06 Apr 2022
Cited by 9 | Viewed by 3248
Abstract
Rolling contact fatigue (RCF) and wear are important problems for the wheel and rail. RCF and wear is caused by contact stress and the slip ratio between the wheel and the rail. The material properties of the wheel and rail are an important [...] Read more.
Rolling contact fatigue (RCF) and wear are important problems for the wheel and rail. RCF and wear is caused by contact stress and the slip ratio between the wheel and the rail. The material properties of the wheel and rail are an important factor to prevent the degradation caused by RCF and wear. In this study, the mechanical properties and fatigue characteristics of the two types of wheel and rail were evaluated, and the effects on wear and contact fatigue were examined. We found that the crack growth rate and the hardness were important factors in the contact fatigue and the wear. The rail steel with a higher crack growth rate and hardness had a low resistance to contact fatigue with large size damage. The hardness ratio and the total hardness are important factors in evaluating the wear resistance. In addition, we found that the residual stress increased proportionally to the maximum shear stress. Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)
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16 pages, 12324 KiB  
Article
Experimental and Numerical Study on the Protective Behavior of Weldox 900 E Steel Plates Impacted by Blunt-Nosed Projectiles
by Yahui Shi, Ang Hu, Taisheng Du, Xinke Xiao and Bin Jia
Metals 2022, 12(1), 141; https://doi.org/10.3390/met12010141 - 12 Jan 2022
Cited by 6 | Viewed by 1736
Abstract
To demonstrate the importance of incorporating Lode angle into fracture criterion in predicting the penetration resistance of high-strength steel plates, ballistic tests of blunt-nosed projectiles with a diameter of 5.95 mm impacted 4 mm thick Weldox 900 E steel plates were conducted. Impacting [...] Read more.
To demonstrate the importance of incorporating Lode angle into fracture criterion in predicting the penetration resistance of high-strength steel plates, ballistic tests of blunt-nosed projectiles with a diameter of 5.95 mm impacted 4 mm thick Weldox 900 E steel plates were conducted. Impacting velocity range was 136.63~381.42 m/s. The fracture behavior and the ballistic limit velocities (BLVs) were obtained by fitting the initial-residual velocities of the projectiles. Subsequently, axisymmetric finite element (FE) models parallel to the tests were built by using Abaqus/Explicit software, and the Lode-independent Johnson–Cook (JC) and the Lode-dependent ASCE fracture criterion were incorporated into the finite element model for numerical simulation. Meanwhile, to verify the sensitivity of the mesh size in the numerical simulation, different mesh sizes were used in the shear plug area of the target. It can be found that Weldox 900 E steel has obvious mesh size sensitivity by comparing the experimental results and numerical simulation, and the JC fracture criterion and the ASCE fracture criterion predicted similar BLV for the same mesh size. Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)
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10 pages, 3325 KiB  
Article
Microstructure and Failure Processes of Reactor Pressure Vessel Austenitic Cladding
by Jan Štefan, Jan Siegl, Jan Adámek, Radim Kopřiva and Michal Falcník
Metals 2021, 11(11), 1676; https://doi.org/10.3390/met11111676 - 20 Oct 2021
Cited by 2 | Viewed by 1269
Abstract
This paper is dedicated to an experimental program focused on the evaluation of microstructure and failure mechanisms of WWER 440 type nuclear reactor pressure vessel cladding made from Sv 08Kh19N10G2B stainless steel. Static fracture toughness tests performed on standard precracked single edge bend [...] Read more.
This paper is dedicated to an experimental program focused on the evaluation of microstructure and failure mechanisms of WWER 440 type nuclear reactor pressure vessel cladding made from Sv 08Kh19N10G2B stainless steel. Static fracture toughness tests performed on standard precracked single edge bend specimens revealed extreme variations in fracture toughness values, J0.2. Fractured halves of test specimens were subject to detailed fractographic and metallographic analyses in order to identify the causes of this behavior and to determine the relationship between local microstructure, failure mode and fracture toughness. Results indicated that fracture toughness of the cladding was adversely affected by the brittle cracking of sigma particles which caused a considerable decrease in local ductile tearing resistance. Extreme variations in relative amounts of sigma phase, as well as the extreme overall structural heterogeneity of the cladding determined in individual specimens, provided a reasonable explanation for variations in fracture toughness values. Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)
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Review

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16 pages, 4036 KiB  
Review
Dealing with the Fracture Ductile-to-Brittle Transition Zone of Ferritic Steels Containing Notches: On the Applicability of the Master Curve
by Sergio Cicero and Sergio Arrieta
Metals 2021, 11(5), 691; https://doi.org/10.3390/met11050691 - 23 Apr 2021
Cited by 3 | Viewed by 1572
Abstract
Characterizing the fracture resistance of ferritic steels operating within their Ductile-to-Brittle Transition Zone (DBTZ) has been successfully addressed through the development of the well-known Master Curve (MC). This tool assumes that fracture, in the presence of crack-like defects, is controlled by weakest-link statistics [...] Read more.
Characterizing the fracture resistance of ferritic steels operating within their Ductile-to-Brittle Transition Zone (DBTZ) has been successfully addressed through the development of the well-known Master Curve (MC). This tool assumes that fracture, in the presence of crack-like defects, is controlled by weakest-link statistics and follows a three-parameter Weibull distribution. When dealing with notch-type defects, there is no standardized solution to predict the fracture resistance within the DBTZ, but the authors have published some works demonstrating that the MC can also be applied in different ways to characterize ferritic steels containing notches. One of these ways is the direct application of the MC methodology, providing a specific reference temperature (T0N) for each material and notch radius. This work reviews this initial attempt to apply the MC in notched conditions, assessing the validity of the main MC hypotheses (initially valid for cracked conditions) when analyzing notch-type defects and providing experimental validation on steels S275JR, S355J2, S460M and S690Q. Full article
(This article belongs to the Special Issue Failure Analysis in Metallic Materials)
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