Integrity and Failure Analysis of Cement Sheath Subjected to Coalbed Methane Fracturing

Perforation and fracturing are typically associated with the development of coalbed methane wells.As the cement sheath is prone to failure during this process,in this work,the effects of the casing pressure,elastic modulus of the cement,elastic modulus of the formation,and casing eccentricity on the resulting stresses are analyzed in the frame of a finite element method.Subsequently,sensitivity response curves of the cement sheath stress are plotted by normalizing all factors.The results show that the maximum circumferential stress and Mises stress of the cement sheath increase with the casing internal pressure,elastic modulus of the cement and casing eccentricity.As the elastic modulus of the formation increases,the maximum circumferential stress of the cement sheath decreases,and its maximum Mises stress increases slightly.The cement sheath undergoes tensile failure during coalbed methane fracturing.The stress sensitivity of the cement sheath to the influential parameters is in the following order:casing internal pressure>elastic modulus of cement sheath>casing eccentricity>elastic modulus of formation.

Failure analysis of the needle valve body of R18CrNi8 steel

A needle valve is a key component of a diesel injector.The needle valve body of the diesel engine, made of R18CrNi8 steel, cracked and failed during the working process.The cracking failure reasons for the carburized injector valve body through chemical composition analysis, metallographic examination, scanning electron microscope(SEM) analysis, and energy spectrum analysis, were investigated.The results reveal that the original material of the needle valve is in conformity with the manufacturing requirement.Due to the high carburizing quenching temperature, the best carburized layer structure was not obtained, and the machining defect from which the crack emanated was not identified.The cracks expanded and eventually led to fracture under the action of altered stress and the high-temperature combustion environment during the operation of the engine.

PROGRESSIVE FAILURE ANALYSIS OF LAMINATED COMPOSITES WITH TRANSVERSE SHEAR EFFECTS

This paper deals with the progressive failure analysis of composite laminates. Triangular elements which include the transverse shear effects are us.d for the stress analysis. A new method for the calculation of the shear correction factors is presented. Several failure criteria are used to check the first ply failure and distinguish the laminate failure modes into fiber breakage or buckling, matrix cracking and delamination. After the failure is detected, the stiffness of the failed ply is modified according to the failure modes. The ultimate strength of the laminate is obtained by an iterative way. Several examples are given in the paper for stress analysis and progressive failure analysis of composite laminates.

Tribological Properties and Failure Analysis of PTFE Composites used for Seals in the Transmission Unit

The sealing rings are one of the most important components as the sealing devices in the wet clutch unit of a heavy vehicle. The sealing ring, made from PTFE composites, was subjected to serious wear on the sealing surface, but the mating metal surface only had slight abrasion. A specialized test rig was designed for wear research and failure analysis of the sealing ring. The composition analyses of the ring material, working conditions and wear surface characteristics by visual inspection and tribological properties as well as microscopic analysis with scanning electron microscope was performed to determine the wear mechanism and failure causes. Results revealed that the wear of PTFE composites was characterized by abrasion and adhesion after a certain duration testing, and the wear mechanism changed to thermal fatigue and abrasive wear in the stage of intense wear. The thermal deformation and fatigue were primarily responsible for the rapid wear of the PTFE composites for the sealing rings.

Failure analysis of AZ31 magnesium alloy sheets based on the extended GTN damage model

Based on the Gurson-Tvergaard-Needleman （GTN） model and Hill＇s quadratic anisotropic yield criterion, a combined experimental-numerical study on fracture initiation in the process of thermal stamping of Mg alloy AZ31 sheets was carried out. The aim is to predict the formability of thermal stamping of the Mg alloy sheets at different temperatures. The presented theoretical framework was implemented into a VUMAT subroutine for ABAQUS/EXPLICIT. Internal damage evolution due to void growth and coalescence developed at different temperatures in the Mg alloy sheets was observed by scanning electron microscopy （SEM）. Moreover, the thermal effects on the void growth, coalescence, and fracture behavior of the Mg alloy sheets were analyzed by the extended GTN model and forming limit diagrams （FLD）. Parameters employed in the GTN model were determined from tensile tests and numerical iterative computation. The distribution of major and minor principal strains in the specimens was determined from the numerical results. Therefore, the corresponding forming limit diagrams at different stress levels and temperatures were drawn. The comparison between the predicted forming limits and the experimental data shows a good agreement.

Failure analysis of polycrystalline diamond compact cutters for breaking rock by bending waves theory

The breakage mechanism of the polycrystalline diamond compact(PDC) cutters was analyzed by the energy theory of bending waves. The cutting tests of granite block were conducted on a multifunctional testing device by using the cutter at three kinds of negative fore angles of 30°, 45° and 60°. The results show that, when the edge of the PDC layer is broken, the layer of tungsten cobalt is broken a little under the angle of 30°, while the layer of tungsten cobalt is broken continuously under the angle of 60°, their maximum depths are about 2 and 7 mm respectively in the two cases. The eccentric distance mainly depends on the negative fore angle of the cutter. When the cutter thrusts into the rock under an attack angle of 60°, the energy of bending waves reaches the maximum since the eccentric distance is the maximum. So the damage of cutter is the most serious. This test result is consistent with the conclusion of theoretical analysis well. The eccentric distance from the axial line of cutter to the point of action between the rock and cutter has great effect on the breakage of the cutter. Thus during the process of cutting, the eccentric distance should be reduced to improve the service life of PDC cutters.

Time between failures model and failure analysis of CNC system

To provide basis for the reliability improvement design of CNC system, the failure data of a type of CNC system in one year are collected under field conditions in workshops. The distribution model parameters of time between failures are estimated by least square method and hypothesis testing is done by d-test method. It is proved that the time between failures of the CNC system follows Weibull distribution and the system has entered into the wear-out failure period. The failure positions and failure causes are analyzed further to indicate the weak subsystems of the CNC system. It can be found that servo unit, electrical system, detecting unit and power supply are principal failure positions and the main failure cause is breakage of components. The corresponding improvement measures are put forward. The paper provides a reference to reliability design and analysis of CNC system for the manufacturer and has great guidance to using and maintaining CNC system for the user.

MMM testing and failure analysis of fastening bolts on reciprocating compressor cylinder cover

To avoid the serious accidents caused by the failure fastening bolts on reciprocating compressor cylinder cover,a new nondestructive testing(NDT) technology,metal magnetic memory(MMM) testing,was applied to safety evaluating and failure analyzing for the fastening bolts.Based on the dynamic stress calculation of the failure bolts,MMM testing was carried out at workshop.Given are the MMM stress distribution characteristics of the failure bolts and fracture faces.It has been found that the MMM signal variation amplitude of the crack transition zone in the fracture surface is minimal,that of the crack initiation zone is in the middle,and that of the tear fracture zone is maximal.The failure reasons were analyzed with MMM effect.The results of the metallographic examination showed that the validity and feasibility of MMM testing and failure analysis.This means MMM technology is a new,fast and validity method of failure analysis.

Review on failure analysis of interconnections in power devices

Interconnections in microelectronic packaging are not only the physical carrier to realize the function of electronic circuits,but also the weak spots in reliability tests.Most of failures in power devices are caused by the malfunction of interconnections,including failure of bonding wire as well as cracks of solder layer.In fact,the interconnection failure of power devices is the result of a combination of factors such as electricity,temperature,and force.It is significant to investigate the failure mechanisms of various factors for the failure analysis of interconnections in power devices.This paper reviews the main failure modes of bonding wire and solder layer in the interconnection structure of power devices,and its failure mechanism.Then the reliability test method and failure analysis techniques of interconnection in power device are introduced.These methods are of great significance to the reliability analysis and life prediction of power devices.

FAILURE ANALYSIS AND INSPECTION OF CRACKING OF IN-SERVICE CATALYTIC REGENERATOR

The special subject 'research on life prediction technology of important in-service pressure' mainly analyzes the failure mechanism of large-sized important and criticalin-service pressure vessels under the action of working medium and investigates safety assessmentand life prediction technology with a view to enhance the operation reliability of in-servicepressure vessels in China. Based on a series of accident investigation and test & measuringresearch, the cause of cracking of catalytic regenerator is analyzed and the in-line non-destructiveexamination method and failure prevention measures for the cracking of catalytic regenerator areproposed.

Failure analysis of air fan blades

The failure of all 12 blades of an air fan was investigated by metallurgical and mechanical experiments and an examina-tion of the fracture surface. The experimental results show that the cast aluminium-silicon alloy without any modification had a number of material defects, such as coarse grains, a loose structure, a large number of shrinkage holes, a long and thin bold-pin shaped silicon-phase, poor material strength and serious brittleness. In addition, installed on the spindle without elastic conjunction, blade No.10 vibrated and inevitably.spun off due to the large centrifugal force. Therefore, blade No.10 first cracked at the locking handle, then broke at the root, which caused all the other 11 blades to be broken by the crack of blade No.10.

System failure analysis based on DEMATEL–ISM and FMECA

A new method of system failure analysis was proposed. First, considering the relationships between the failure subsystems,the decision making trial and evaluation laboratory(DEMATEL) method was used to calculate the degree of correlation between the failure subsystems, analyze the combined effect of related failures, and obtain the degree of correlation by using the directed graph and matrix operations. Then, the interpretative structural modeling(ISM) method was combined to intuitively show the logical relationship of many failure subsystems and their influences on each other by using multilevel hierarchical structure model and obtaining the critical subsystems. Finally, failure mode effects and criticality analysis(FMECA) was used to perform a qualitative hazard analysis of critical subsystems, determine the critical failure mode, and clarify the direction of reliability improvement.Through an example, the result demonstrates that the proposed method can be efficiently applied to system failure analysis problems.

Failure analysis of 18CrNi3MoA drilling tails

The fracture of a drilling tail made of 18CrNi3MoA steel in the exchanging water hole was analyzed in terms of inclusions, prior austenite grain size, carburized layers, and fatigue fracture morphology by means of optical microscopy, quantitative metallography, and scanning electron microscopy （SEM）. Fatigue crack initiation and propagation on the drilling tail were also studied. The results showed that the fracture on the drilling tail was not induced by inclusions and the distribution inhomogeneity of prior austenite grain size. Instead, be- cause the outside surface of the exchanging water hole was not continuously geometric, there was a great deal of stress concentration in those areas under continuous twisting, axial impact, and corrosion of mineral water. Thus three crack sources emerged in these areas. Initial cracks centered on these sources spread from the outside surface to the inside surface, and eventually the drilling tail ruptured. Furthermore, the fractograph of the region around the crack sources exhibited a typical ductile dimple fracture pattern, and cracks initiated on the outside sur- face of the carburized layers of the exchanging water hole. Three crack sources could be the sources of fatigue crack propagation. Based on the analysis of fatigue crack propagation, it was further demonstrated that fatigue damage originated from the outside surface of the ex- changing water hole.

Progressive Failure Analysis of Quasi-isotropic Self-reinforced Polyethylene Composites by Comparing Unsupervised and Supervised Classifications of Acoustic Emission Data

Unsupervised and supervised pattern recognition( PR)techniques are used to classify the acoustic emission( AE) data originating from the quasi-isotropic self-reinforced polyethylene composites,in order to identify the various mechanisms in the multiangle-ply thermoplastic composites. Ultra-high molecular weight polyethylene / low density polyethylene( UHMWPE / LDPE)composites were made and tested under quasi-static tensile load. The failure process was monitored by the AE technique. The collected AE signals were classified by unsupervised and supervised PR techniques, respectively. AE signals were clustered with unsupervised PR scheme automatically and mathematically. While in the supervised PR scheme,the labeled AE data from simple lay-up UHMWPE / LDPE laminates were utilized as the reference data.Comparison was drawn according to the analytical results. Fracture surfaces of the UHMWPE / LDPE specimens were observed by a scanning electron microscope( SEM) for some physical support. By combining both classification results with the observation results,correlations were established between the AE signal classes and their originating damage modes. The comparison between the two classifying schemes showed a good agreement in the main damage modes and their failure process. It indicates both PR techniques are powerful for the complicated thermoplastic composites. Supervised PR scheme can lead to a more precise classification in that a suitable reference data set is input.

Failure Analysis of Railway Forklifts and Their Current Reliability Levels

The number of forklifts ranks first among the material handling machinery in railway goods yards. It is important to analyze their failures and to assess their reliability. In this paper, the failure distribution, failure modes and laws of failure distribution of railway forklifts are analyzed based on the field data. The comprehensive assessment of the reliability level of the railway forklifts is also presented according to the reliability index system of forklifts.

Failure Analysis of Austenitic Stainless Steel Implant Screws and Prospection of Chemical Composition Using Artificial Intelligence

In this work, austenitic stainless steel screws employed in a locking compression plate for veterinarian use were investigated. These types of implants are widely utilized in bone fractures healing. Two surgical screws were extracted due to the observation of slight superficial red rust colorizing on one of the screw implants, visual evidence of probable screw rusting. From the same implant, another screw was extracted simultaneously without visual evidence of rusting. In order to characterize and analyze the different behavior of both screws, the chemical composition was characterized by atomic absorption and energy dispersive X-ray spectroscopy (EDS) coupled to a scanning electron microscope (SEM). Also, the screws were studied by metallography, optical microscopy (OM), Vickers microhardness tests, and SEM analysis. On the other hand, a prospection for alloy chemical composition limits of these types of implants was performed based on the Schaeffler-Delong diagram and the ASTM F-138 standard. To analyze the effect of the chemical composition, heat treatment, microstructure, pitting resistance equivalent number (PRE) and stacking fault energy (SFE), a genetic algorithm (GA) and an artificial neural network (ANN) were used. In accordance with the elemental analysis, the surgical screws do not fulfill the ranges of the chemical composition established by the ASTM F-138 standard. Furthermore, there were found differences between the microstructures of the screws. In regard to the prospection, the results of GA and ANN support the proposed chemical composition region on the Schaeffler-Delong diagram. The corrosion failure was associated with severe plastic deformation and the presence of precipitates. The proposal can minimize the cause of failures in these types of austenitic stainless steel implants.

FUZZY FAILURE ANALYSIS OF COAL PILLARS FOR SUBSIDENCE CONTROL

Randomness and fuzziness involved in rock failure analysis are discussed in the present paper.Fuzzy stochastic process is introduced to simulate pillar/strata deformation process.Study shows that the evolution from damage to failure of the rock materials under complex stress environments conforms to diffusion process.Coal pillar strength is analyzed using fuzzy failure analysis in two coal mines.

Analysis on the Failure Causes of the Collapsed Tubing in an Oil Well

Due to the influence of multiple factors such as internal and external formation and mechanical pressure, medium corrosion and construction operation environment, a tubing collapse failure occurred in an oil well. In order to determine the failure cause of the tubing, physical and chemical tests and mechanical properties analysis were carried out on the failed tubing sample and the intact tubing. The results show that the chemical composition, ultrasonic and magnetic particle inspection, metallographic test, Charpy impact energy and external pressure mechanical property test of the failed tubing all meet the requirements of API Spec 5CT-2021 standard, but the yield strength of the failed tubing does not meet the requirements of API Spec 5CT-2021 standard. Through the analysis of the working conditions, it can be seen that the anti-extrusion strength of the tubing collapse does not meet the API 5C3 anti-extrusion strength standard. The failure type of the well tubing is tubing collapse caused by large internal and external pressure difference.

Reliability analysis of carbon fiber rod-reinforced umbilical cable under tension using an improved sampling method

The umbilical cable is a vital component of subsea production systems that provide power,chemical agents,control signals et al.,and its requirement for reliability is exceedingly high.However,as the umbilical cable is a composite structure comprising multiple functional units,the reliability analysis of such cables involves numerous parameters that can impact calculation efficiency.In this paper,the reliability analysis of a new kind of umbilical cable with carbon fiber rod under tension is analyzed.The global dynamic analytical model is first established to determine the maximum tension load,then the local analytical model of umbilical cable including each unit are constructed by finite element method(FEM).Based on the mechanical analytical model,the reliability of umbilical cable under tension load is studied using response surface method(RSM)and Monte Carlo method.During the calculation process,a new tangent plane sampling method to calculate the response surface function(RSF)is proposed in this paper,which could make sampling points faster come close to the RSF curve,and it is proved that the calculation efficiency increases about 33%comparing with traditional method.

Blasting induced dynamic stress concentration and failure characteristics of deep-buried rock tunnel

In this study,the dynamic stress concentration factors(DSCF)around a straight-wall arch tunnel(SWAT)were solved analytically utilizing the complex variable function methods and Duhamel’s integral.The effects of wavelength,incident angle,and blasting rising time on the DSCF distribution were analyzed.Theoretical results pointed out dynamic disturbances resulting in compressive stress concentration in the vertical direction and tensile stress in the incident direction.As the wavelength and rising time increased,there was a tendency for the amplitude of stress concentration to initially rise and then converge.Moreover,a series of 3D FEM models were established to evaluate the effect of different initial stress states on the dynamic failure of the tunnel surrounding rock.The results indicated that the failure of the surrounding rock was significantly influenced by the direction of the static maximum principal stress and the direction of the dynamic disturbance.Under the coupling of static and blasting loading,damage around the tunnel was more prone to occur in the dynamic and static stress concentration coincidence zone.Finally,the damage modes of rock tunnel under static stress and blasting disturbance from different directions were summarized and a proposed support system was presented.The results reveal the mechanisms of deep-buried rock tunnel destruction and dynamically triggered rockburst.