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.

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.

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 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.

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.

Tensile Mechanical Behavior and Failure Mechanism of a Plain-Woven SiCf/SiC Composites at Room and Elevated Temperatures

Ceramic matrix composites (CMCs) are the preferred materials for solving advanced aerospace high-temperature structural components;it has the comprehensive advantages of higher temperature (~1500˚C) and low density. In service environments, CMCs exhibit complex damage mechanisms and failure modes, which are affected by constituent materials, meso-architecture and inhere defects. In this paper, the in-plane tensile mechanical behavior of a plain-woven SiCf/SiC composite at room and elevated temperatures was investigated, and the factors affecting the tensile strength of the material were discussed in depth. The results show that the tensile modulus and strength of SiCf/SiC composites at high temperature are lower, but the fracture strain increases and the toughness of the composites is enhanced;the stitching holes significantly weaken the tensile strength of the material, resulting in the material is easy to break at the cross-section with stitching holes.

A generalized rough set-based information flling technique for failure analysis of thruster experimental data

Interval-valued data and incomplete data are two key problems for failure analysis of thruster experimental data and have been basically solved by the proposed methods in this paper. Firstly, information data acquired from the simulation and evaluation system formed as intervalvalued information system （IIS） is classified by the interval similarity relation. Then, as an improvement of the classical rough set, a new kind of generalized information entropy called ＂H＇-information entropy＂ is suggested for the measurement of uncertainty and the classification ability of IIS. There is an innovative information filling technique using the properties of H＇-information entropy to replace missing data by some smaller estimation intervals. Finally, an improved method of failure analysis synthesized by the above achievements is presented to classify the thruster experimental data, complete the information, and extract the failure rules. The feasibility and advantage of this method is testified by an actual application of failure analysis, whose performance is evaluated by the quantification of E-condition entropy.

Reliability test and failure analysis of high power LED packages

A new type application specific light emitting diode （LED） package （ASLP） with freeform polycarbonate lens for street lighting is developed, whose manufacturing processes are compatible with a typical LED packaging process. The reliability test methods and failure criterions from different vendors are reviewed and compared. It is found that test methods and failure criterions are quite different. The rapid reliability assessment standards are urgently needed for the LED industry. 85℃/85 RH with 700 mA is used to test our LED modules with three other vendors for 1000 h, showing no visible degradation in optical performance for our modules, with two other vendors showing significant degradation. Some failure analysis methods such as C-SAM, Nano X-ray CT and optical microscope are used for LED packages. Some failure mechanisms such as delaminations and cracks are detected in the LED packages after the accelerated reliability testing. The finite element simulation method is helpful for the failure analysis and design of the reliability of the LED packaging. One example is used to show one currently used module in industry is vulnerable and may not easily pass the harsh thermal cycle testing.

Quality assurance test and failure analysis of SiPM arrays of GECAM satellites

Background The Gravitational wave high-energy Electromagnetic Counterpart All-sky Monitor(GECAM)satellite developed a SiPM-based gamma-ray detector to monitor the gravitational wave-related GRBs and guide subsequent observations in other wavelengths of EM.Purpose As all the available SiPM devices belong to commercial grade,quality assurance tests need to be performed in accordance with the aerospace specifcations.Methods In the SiPM application of GECAM,quality assurance experiments were conducted.The mechanism of the failure of SiPM devices was analyzed during the development process.Result Based on the quality assurance test results,the fnal pass rate of SiPM array was 95%.Based on the failure analysis,it was found that a piece of SiPM had a leakage channel after longtime operation due to device defects.Conclusion According to the accumulated experience,in the reliability test of SiPM,it is necessary to pay special attention to test the impedance of each pin of SiPM to ground and confrm that the power switch state of SiPM is controllable.

Strength and failure characteristics of marble spheres subjected to paired point loads

Failure of irregular rock samples may provide implications in the rapid estimation of rock strength,which is imperative in rock engineering practice.In this work,analytical,experimental and numerical investigations were carried out to study the mechanical properties and failure characteristics of rock spheres under paired point loads.Analytical solutions indicted that with the increase in sample size(contact angle)and decrease in Poisson’s ratio,the uneven tensile stress in theta direction decreased.Then laboratory experiments were carried out to investigate the load characteristics and failure mode of spherical marble samples with different sizes subjected to a pair of diametral point loads.The discrete element method(DEM)was adopted to study the failure process of rock spheres.The effect of the sphere diameter on the point load contact angle was examined in terms of peak load,crushed zone distribution and energy dissipation.Experimental and numerical results showed that the samples primarily fail in tension,with crushed zones formed at both loading points.With increase in the sample size,the contact angle,crushed area and total work increase.As the specimen diameter increases from 30 mm to 50 mm,the peak load on the specimen increases from 3.6 kN to 8.8 kN,and the percentage of crushed zone(ratio of crushing zone to sample radius,d/r)increased from 0.191 to 0.262.The results of the study have implications for understanding the failure of irregular rock specimens under point loading conditions and their size effects.

Finite Element Analysis of Jumbo Rig Assembly for Tunneling

This paper describes the force acting the assembly of the jumbo rig for tunneling.The finite element analysis is used to calculate this machine structure on its different working states.

Impact of failure mode and effects analysis-based emergency management on the effectiveness of craniocerebral injury treatment

BACKGROUND Craniocerebral injuries encompass brain injuries,skull fractures,cranial soft tissue injuries,and similar injuries.Recently,the incidence of craniocerebral injuries has increased dramatically due to the increased numbers of traffic accidents and aerial work injuries,threatening the physical and mental health of patients.AIM To investigate the impact of failure modes and effects analysis(FMEA)-based emergency management on craniocerebral injury treatment effectiveness.METHODS Eighty-four patients with craniocerebral injuries,treated at our hospital from November 2019 to March 2021,were selected and assigned,using the random number table method,to study(n=42)and control(n=42)groups.Patients in the control group received conventional management while those in the study group received FMEA theory-based emergency management,based on the control group.Pre-and post-interventions,details regarding the emergency situation;levels of inflammatory stress indicators[Interleukin-6(IL-6),C-reactive protein(CRP),and procalcitonin(PCT)];incidence of complications;prognoses;and satisfaction regarding patient care were evaluated for both groups.RESULTS For the study group,the assessed parameters[pre-hospital emergency response time(9.13±2.37 min),time to receive a consultation(2.39±0.44 min),time needed to report imaging findings(1.15±4.44 min),and test reporting time(32.19±6.23 min)]were shorter than those for the control group(12.78±4.06 min,3.58±0.71 min,33.49±5.51 min,50.41±11.45 min,respectively;P<0.05).Pre-intervention serum levels of IL-6(78.71±27.59 pg/mL),CRP(19.80±6.77 mg/L),and PCT(3.66±1.82 ng/mL)in the study group patients were not significantly different from those in the control group patients(81.31±32.11 pg/mL,21.29±8.02 mg/L,and 3.95±2.11 ng/mL respectively;P>0.05);post-intervention serum indicator levels were lower in both groups than pre-intervention levels.Further,serum levels of IL-6(17.35±5.33 pg/mL),CRP(2.27±0.56 mg/L),and PCT(0.22±0.07 ng/mL)were lower in the study group than in the control group(30.15±12.38 pg/mL,3.13±0.77 mg/L,0.38±0.12 ng/mL,respectively;P<0.05).The complication rate observed in the study group(9.52%)was lower than that in the control group(26.19%,P<0.05).The prognoses for the study group patients were better than those for the control patients(P<0.05).Patient care satisfaction was higher in the study group(95.24%)than in the control group(78.57%,P<0.05).CONCLUSION FMEA-based craniocerebral injury management effectively shortens the time spent on emergency care,reduces inflammatory stress and complication risk levels,and helps improve patient prognoses,while achieving high patient care satisfaction levels.

Improved Reliability Analysis Method Based on the Failure Assessment Diagram

With the uncertainties related to operating conditions,in-service non-destructive testing（NDT） measurements and material properties considered in the structural integrity assessment,probabilistic analysis based on the failure assessment diagram（FAD） approach has recently become an important concern.However,the point density revealing the probabilistic distribution characteristics of the assessment points is usually ignored.To obtain more detailed and direct knowledge from the reliability analysis,an improved probabilistic fracture mechanics（PFM） assessment method is proposed.By integrating 2D kernel density estimation（KDE） technology into the traditional probabilistic assessment,the probabilistic density of the randomly distributed assessment points is visualized in the assessment diagram.Moreover,a modified interval sensitivity analysis is implemented and compared with probabilistic sensitivity analysis.The improved reliability analysis method is applied to the assessment of a high pressure pipe containing an axial internal semi-elliptical surface crack.The results indicate that these two methods can give consistent sensitivities of input parameters,but the interval sensitivity analysis is computationally more efficient.Meanwhile,the point density distribution and its contour are plotted in the FAD,thereby better revealing the characteristics of PFM assessment.This study provides a powerful tool for the reliability analysis of critical structures.