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The presence of high longitudinal stresses near the contact interface leads to the initiation and propagation of cracks. This work investigates the mitigating effects of undercuts and surface coatings of functionally graded materials (FGM) on the peak stresses in cylindrical contacts using finite element analysis. A rigid indenter of a cylindrical profile in contact with a flat half-space with undercuts on both sides of the contact region is considered for contact analysis. The effect of the presence of undercuts is studied, with its size and location from the contact edge being the parameters. An undercut of larger radius decreases the peak longitudinal stress in the contact region when only normal loading as well as combined normal and tangential loading is applied. While contact pressure increases with an increase in undercut radius under normal loading only, undercut radius and position have negligible effect under combined loading. The peak stresses in the contact region are found to decrease with a decrease in modulus ratio and an increase in the thickness of FGM coating. The combined effect of undercut and FGM coating reduces the peak longitudinal stress significantly for an optimum combination of undercut radius, undercut position, and modulus ratio. [ABSTRACT FROM AUTHOR]

• A BV-DL method for predicting DWRD is presented. • The real DWRD of a rail vehicle is obtained with the help of 3DCT. • A laser displacement sensor-based method is used to verify the reliability of the 3DCT model. • A traditional image processing method and two DL methods are compared with the methods proposed in this paper. Large displacements between the wheel and rail lead to track damage or even train derailment. Detecting dynamic wheel-rail displacement (DWRD) can provide a technical means for discriminating the operational health status of rail vehicles and formulating active control strategies. In this paper, a new method, which fuses binocular vision (BV) and deep learning (DL), is proposed to detect the DWRD online, the method is abbreviated as BV-DL. First, a binocular camera is used to capture the dynamic wheel-rail contact video online, while two lasers are equipped to focus on the wheel-rail contact region to locate some keypoints in the wheel-rail contact images. Then, an ROI (region of interest) detection network is proposed to recognize the wheel-rail contact region automatically, and a keypoint detection network is proposed to detect the wheel-rail pixel displacement (WRPD). Finally, a 3D coordinate transformation (3DCT) model is built to calculate the wheel-rail world displacement in real-time, i.e., the DWRD between the keypoints. To test the performance of the method, a laser displacement sensor-based method is used to verify the reliability of the 3DCT model. Meanwhile, a traditional image processing method, a MobileNet V3-based method, and a YOLOX-s-based method are introduced to predict the WRPD. Experimental results show that compared with the four methods, the proposed BV-DL method can achieve optimal results in pixel coordinate calculation and 3D coordinate computation. [ABSTRACT FROM AUTHOR]

Investigating tool wear in refill friction stir spot welding (RFSSW) is essential for understanding its limitations and improving its efficiency. Increasing the tool's service life is important to push the technology's readiness level and transfer the technology from the laboratory to industrial applications. In this study, the quasi-static lap shear performance of AA6061-T6 similar welded spots was investigated and tool wear was continuously monitored until tool failure at 3450 welding cycles. Furthermore, the fundamentals of the wear mechanisms in RFSSW were further elucidated. The investigation shows that it is possible to achieve steady quasi-static lap shear performance of the spot welds over advancing tool wear by adjusting the heat input to compensate for losses in frictional heat generation efficiency (related to tool profile changes by abrasion). A subsequent tool failure case analysis showed the main causes for the continuous wear degradation of the shoulder. Tool wear was driven by plastic deformation of the hot-work tool steel and subsequent break-out of tool steel ridges, introducing big hard particles into the contact region between the moving and rotating tools. In addition, the formation and detachment of Fe-Al intermetallic compounds counteract with the rotating tools and increase tool wear. [Display omitted] • The ultimate lap shear force remains stable at 7.7 kN until 3450 welded spots. • Increasing rotational speed can offset the reduced heat input caused by tool wear. • Higher rotational speed accelerates the tool's wear rate. • Additional heat input during idle due to the fracture of tool steel fragments. • Formation and fracture of Fe-Al intermetallic compounds contribute to tool wear. [ABSTRACT FROM AUTHOR]

[Display omitted] • Cu-Ni NPs can tribologically induced the degradation of PAO6 to form a carbon-based tribofilm. • Macroscale low friciton can achieved by lubricating a steel/TiN sliding interface with PAO6 containing 0.1 wt% Cu-Ni NPs. • The addition of Cu-Ni NPs to PAO6 effectively enhances the lubricating performance of PAO6 in the steel/TiN system. In this study, the tribological behavior of TiN coatings lubricated with a polyalphaolefin (PAO)-based oil containing Cu-Ni bimetallic nanoparticles was investigated under a maximum contact pressure of 0.9 GPa in reciprocating ball-on-disk mode. The addition of 0.1 wt% Cu-Ni nanoparticles to PAO6 reduced the friction coefficient to 0.018 and also decreased the wear rate of TiN coatings to 4.23 × 10-7 mm3/Nm. X-ray photoelectron spectroscopy (XPS) and Raman spectroscopy revealed the deposition of Cu-Ni nanoparticles and carbon-based tribofilms on the contact region of the tribopairs. These originated from the tribo-induced degradation of the polyalphaolefin molecule in PAO6 + 0.1 %Cu-Ni nanoparticles, which helped decrease the COF and wear. Moreover, a comparative analysis suggested that the presence of nickel in the Cu-Ni nanoparticles had a catalytic effect during sliding. They facilitated the in situ formation of carbon-based film due to the degradation of polyalphaolefins under the combined effects of frictional heat and contact stress, demonstrating a self-repair capability. [ABSTRACT FROM AUTHOR]

As a novel two-dimensional material, a well understanding of mechanical properties of graphyne under various loading conditions is essential for its blooming applications. However, the buckling mechanism of graphyne under local loads is still unclear, which hinders the development of its related nanodevices. In this work, the buckling behavior of graphyne under local indentation is studied by molecular dynamics simulation and theoretical analysis. It is found that the theoretical prediction of the critical indentation depth for buckling of graphyne agrees well with that from molecular dynamics simulation. The buckling morphology lies in the intermediate region between the contact region and the outer boundary. The critical indentation depth and the buckling morphology can be tuned by adopting various geometric and material parameters. The results should be helpful for not only guiding various applications of graphyne, but also improving the development of nanomechanics. • The buckling behavior of graphyne under local indentation is studied by molecular dynamics simulation and theoretical analysis. • The theoretical prediction of the critical indentation depth for buckling of graphyne agrees with that from molecular dynamics simulation. • The critical indentation depth and the buckling morphology can be tuned by adopting various geometric and material parameters. [ABSTRACT FROM AUTHOR]

The objective of this study is to investigate the frictionally adhesive nanocontact characteristics between a sliding rigid cylinder and an exponentially graded coating–substrate structure. Adhesive forces are modeled using the Maugis–Dugdale adhesive theory, while the Steigmann–Ogden surface mechanical theory describes the surface effects of the graded coating. Within the contact region, normal and tangential tractions adhere to the extended Amontons' friction law. The governing equations and boundary conditions of the nanocontact problem are reformulated into Fredholm integral equations, which are solved numerically using Gauss–Jacobi quadratures and a self-designed iterative algorithm. Validation against existing literature results demonstrates the accuracy and reliability of the proposed solution method and numerical algorithm. Extensive parametric studies are conducted to investigate the effects of various parameters, including surface material properties, coefficient of friction, Tabor's parameter, inhomogeneity index of the exponentially graded coating, and external loads. Results reveal that sliding friction significantly influences adhesive nanocontact, affecting nanocontact boundaries, contact traction distribution, and adhesive region boundaries. Additionally, surface effects play a crucial role, leading to smaller nanocontact length and maximum pressure but larger adhesive zone. Furthermore, the interplay between sliding friction, surface effects, and adhesion is underscored, emphasizing the importance of considering these factors in the analysis of sliding nanocontact problems involving graded materials. Ultimately, this work provides a comprehensive solution framework for addressing such complex nanocontact scenarios, offering insights valuable to the field of materials science and engineering. • Frictional adhesion in graded coatings brings novel insights on nanocontact mechanics. • Maugis–Dugdale adhesive theory leads to accurate modeling of adhesive forces. • Surface effects results in smaller nanocontact length and larger adhesive zone. • Gauss–Jacobi quadrature and self-designed algorithm produce robust numerical solutions. • Interplay of sliding friction, surface effects, and adhesion are elucidated. [ABSTRACT FROM AUTHOR]

Water-based lubricants are abundant in nature; however, they perform poorly in mechanical systems. Based on research into synovial fluid lubrication a water-based liposomal lubricant was developed using a phospholipid (DSPC) and stearic acid (SA). Compared to pure water the liposomal DSPC lubricant improved wear and friction performance, although it underperforms a low viscosity oil such as hexadecane. The inclusion of SA encapsulated within the liposome further improves the performance to a level comparable to hexadecane. Improved performance is achieved due to the following factors: a) DSPC-SA lubricant forms a growing multi bilayer structure in the contact region thereby decreasing wear b) the electrostatic charge associated with the structure allows for retention of the film within the contact area thereby decreasing friction and wear c) liposomes allow for utilisation of insoluble additives within water-based lubricants. The optimal liposomal lubricant tested demonstrates a 63 % reduction of the coefficient of friction and a 99 % reduction in resulting wear compared to DI water alone, thereby providing an avenue for effective utilisation of water in mechanical systems. • Novel DSPC-SA water-based liposomal lubricant improves wear and friction. • DSPC-SA lubricant forms a stable multi-bilayer structure in contact. • Liposomal encapsulation enables use of hydrophobic additives in water. • DSPC-SA (50 %) achieves friction and wear performance comparable to hexadecane. • Reductions of 63 % in friction coefficient and 99 % in wear area achieved vs. DI water. [ABSTRACT FROM AUTHOR]

This work investigates the Ohmic contact mechanism and low resistance Ohmic contact preparation for GaN-based high electron mobility transistors (HEMTs) with GaN/AlN superlattice (SL) barriers. The electrical and microstructural characterization of Ti/Al/Ni/Au contacts shows that the formation of Ohmic contacts primarily depends on the TiN islands formed by Ti diffusion in the barrier layer, which is the main reason for the high contact resistance of GaN/AlN SLs HEMTs under conventional high-temperature annealing. A grid deep-recess technique is proposed to establish direct contact between TiN interfacial layer, the barrier, and the two-dimensional electron gas through the sidewalls. This novel technique achieves an Ohmic contact with a low contact resistance of 0.31 Ω mm at low temperatures (700 °C). Furthermore, increased grid deep-recess density effectively reduces contact resistance due to the additional contribution from the conduction width. It is also noteworthy that after complete removal of the barrier layer, the impact of recess depth on contact characteristics is minimal, greatly reducing the process complexity of grid deep-recess technique. Consequently, GaN/AlN SLs HEMTs fabricated using the grid deep-recess technique exhibit significant improvements in on-resistance, transconductance and saturation current. These results are expected to expand the potential application of GaN/AlN SL barrier layers in radio frequency and power devices. [ABSTRACT FROM AUTHOR]

Liquid-aluminum tends to adhere to some surfaces rather than others, and the underlying mechanism of the differences in adhesion of liquid-aluminum on different surfaces is still unclear. This manuscript takes liquid-aluminum/aluminum and liquid-aluminum/silicon interfaces as research objects, revealing that solid aluminum surface is aluminophilic but the solid silicon surface is aluminophobic, mainly due to differences in interfacial thermal conductance (ITC) between two interfaces. We also investigate effect of surface temperature on adhesion characteristics of liquid-aluminum on aluminum/silicon surfaces, and decode the reasons from lattice integrity and phonon spectra. It is shown that vibrational state with intact lattice excites fewer low frequency phonons with increasing surface temperature, resulting in a decrease in ITC and thus adhesion force. In diffusion state where lattice is fractured resulting from high temperature, interfacial adhesion is increased due to surface defects. [ABSTRACT FROM AUTHOR]

In the transition to safer, more energy-dense solid state batteries, polymer–ceramic composite electrolytes may offer a potential route to achieve simultaneously high Li-ion conductivity and enhanced mechanical stability. Despite numerous studies on the polymer–ceramic composite electrolytes, disagreements persist on whether the polymer or the ceramic is positively impacted in their constituent ionic conductivity for such composite electrolytes, and even whether the interface is a blocking layer or a highly conductive lithium ion path. This lack of understanding limits the design of effective composite solid electrolytes. By thorough and critical analysis of the data collected in the field over the last three decades, we present arguments for lithium conduction through the bulk of the polymer, ceramic, or their interface. From this analysis, we can conclude that the unexpectedly high conductivity reported for some ceramic–polymer composites cannot be accounted for by the ceramic phase alone. There is evidence to support the theory that the Li-ion conductivity in the polymer phase increases along this interface in contact with the ceramic. The potential mechanisms for this include increased free volume, decreased crystallinity, and modulated Lewis acid–base effects in the polymer, with the former two to be the more likely mechanisms. Future work in this field requires understanding these factors more quantitatively, and tuning of the ceramic surface chemistry and morphology in order to obtain targeted structural modifications in the polymer phase. [ABSTRACT FROM AUTHOR]

We perform molecular dynamics simulations to study deposition patterns of linear diblock copolymer solution nanodroplets on a solid surface (a wall). The current work mainly investigates the influence of the polymer concentration, chain length, and solvent–wall interactions. Polymer block–wall interaction strengths (εPa(Pb)W) are modified to simulate polymer blocks with different adsorption behaviors, such as weak adsorbable (εPa(Pb)W = 0.6), moderate adsorbable (εPa(Pb)W = 1.0), and strong adsorbable (εPa(Pb)W = 1.2) polymer blocks. The deposition patterns are summarized into diagrams, including penetrating and nonpenetrating ridge-like structures, penetrating and nonpenetrating coffee-ring structures, and multilayer structures with and without defects. We determine factors that influence the deposition structure of the droplet and unveil the mechanism of the formation process of the pattern. This work helps in understanding the deposition pattern of linear diblock copolymer solution nanodroplets, which is beneficial for potential applications involving nanodroplet evaporation. [ABSTRACT FROM AUTHOR]

In order to reduce turnout rail wear, the paper establishes a coupled dynamics model and a turnout rail wear model that consider the true profile of the turnout rail, the vehicle's continuous traction force while passing, and the operational resistance. Comparative analysis of various models for predicting turnout rail wear indicates that the wear energy model is better suited for this purpose. The ideal profile update step for the turnout rail is 0.05 mm, and the adaptive filtering algorithm, tailored to the turnout characteristics, smooths wear distribution effectively while retaining crucial data features. The wear model developed in the paper predicts wear depth that is 89.91% consistent with the measured data. The grinding model introduced in the paper significantly enhances the wheel-rail contact conditions in the turnout, with lateral and vertical vibration accelerations of the vehicle reduced by 52.56% and 30.43%, respectively, during turnout passage. The research offers theoretical support for mitigating rail wear in high-speed turnouts. [ABSTRACT FROM AUTHOR]

In contrast to conventional (n–i–p) perovskite solar cells (PSCs), inverted (p–i–n) PSCs offer enhanced stability and integrability with tandem solar cell architectures, which have garnered increasing interest. However, p–i–n cells suffer from energy level misalignment with transport layers, imbalanced transport of photo-generated electrons and holes, and significant defects with the perovskite films. Here we introduce tris(2,4,6-trimethyl-3-(pyridin-3-yl)phenyl)borane (3TPYMB), a nonionic n-type molecule that, through hydrogen bonding and Lewis acid–base reactions with perovskite surfaces or grain boundaries, enables in situ modulation of perovskite energetics, effectively mitigating the key challenges of p–i–n PSCs. The p–i–n PSCs incorporating 3TPYMB achieve a certified quasi-steady-state power conversion efficiency of 24.55 ± 0.33%, with a reverse scan efficiency of 25.58%. They also exhibit exceptional stability, with unencapsulated devices retaining 97.8% of their initial efficiency after 1,800 h of continuous operation at maximum power point under N2 atmosphere, 1 sun illumination and 60 °C conditions. The introduction of 3TPYMB, an n-type molecule into inverted perovskite solar cells, enables a power conversion efficiency of 25.6%, with devices maintaining up to 98% of the initial efficiency after 1,800 h of operation. [ABSTRACT FROM AUTHOR]

Nowadays, composite sandwich tubes are extensively utilized in the civil and aerospace industries due to their superior strength-to-weight mechanical properties. Origami-based core offers a large enhancement of the mechanical properties, yet little study research focuses on the effect of various foldcore configurations on the transverse mechanical properties of sandwich tubes, necessitating the design method for applications. This study introduces an innovative approach by incorporating origami into the composite sandwich core to enhance the transverse energy absorption capacity. The quasi-static transverse mechanical properties of carbon fibre-reinforced polymer (CFRP) sandwich tubes with foldcores are studied under three-point bending-like local compression and transverse structural compression. A systematic geometric design framework and numerical modelling technique are provided. By integrating finite element analysis and experiments, the research investigates the effects of various origami foldcore configurations and geometric parameters on transverse energy absorption capacity. The experiment setup is provided by sandwich tubular specimens with a full-diamond configuration as the foldcore. The cylindrical tubes (foldcore) of the sandwich structures were manufactured using four plies [0°]4 of T700 (T300) woven CFRP with the hot press moulding (vacuum bag using female and male moulds) technique respectively. Then, the parametric study and damage mode analysis of eight different foldcore patterns (axial Miura, circumferential Miura, diamond, Kresling, and their curved-creased counterparts) were studied. The results showed the superior energy absorption performance of the sandwich tube with Miura-pattern foldcore over the origami-pattern counterparts, nested tube, and traditional honeycomb sandwich tube with CFRP or aluminium-made cores. Therefore, the structural parameters optimisation of the Miura pattern tube was carried out by the Response Surface method (RSM) and a design strategy for increasing the energy absorption capacity was found. The findings offer guidance for designing high-specific energy absorption tubular structures for future advanced engineering applications. [ABSTRACT FROM AUTHOR]

Based on the Johnson–Cook constitutive model and modified Coulomb's law, the study investigates the impact of various process parameters on the weld temperature field in high-strength 5052 aluminum alloy friction stir welding (FSW) for aerospace applications. Utilizing a thermo-mechanical model, the significance of rotational speed, welding speed, and indentation on the peak weld temperature is examined through Taguchi's orthogonal experimental design. S/N ratio and ANOVA results show that the rotational speed has the most significant effect on the peak temperature of the weld, followed by the amount of indentation, and the welding speed has the smallest effect, the optimal combination of welding process parameters is determined as follows:the rotational speed is 1000 rpm, the amount of indentation is 0.15 mm, and the welding speed is 1 mm/s, the ultimate tensile strength of welded joints under the parameter combination is increased by more than 40%relative to the base material, and the yield strength is increased by 113.5%. The experimental results show that the worst combination of welding process parameters, there are tunnel-type defects, the tensile fracture surface has a large number of relatively large and deep tough nests, and compared with the optimal combination of process parameters, the combination of fracture position of the Si element content is higher, its UTS is only 85.2%of the base material, much lower than the optimal parameters under the performance of the strength. The above conclusions demonstrate the robustness of the optimization method and provide an important reference for improving the quality of FSW joints. [ABSTRACT FROM AUTHOR]

The fuel rod casing tube is a crucial component in pressurized water reactor (PWR) nuclear power plants. Flow-induced vibrations in the circulating water can result in complex alternating fretting wear between the casing tube and the positioning lattice frame. Existing research on fretting wear has primarily focused on unidirectional wear, with limited investigation into composite fretting wear under complex working conditions. This study conducted impact and tangential composite fretting wear tests on Zr-4 alloy tubes under varying constant and random impact loads to examine fretting wear behavior. The findings show that the peak friction coefficients in the impact and tangential composite fretting wear tests were consistent across the three constant load conditions, with higher peak friction coefficients observed under random load conditions and a longer time required to reach these peaks during micromotion tests. Comparative analysis revealed that random impact and tangential composite fretting wear caused the most severe damage. Under constant load conditions, wear damage became more severe with increasing load, transitioning from oxidized and adhesive wear to a peeling layer as the load intensified in the impact and tangential composite fretting wear tests. [ABSTRACT FROM AUTHOR]

In this research study, surface modification of Ti64 alloy was carried out using laser surface texturing (LST). The investigation aims to explore the effects of loads, oleophilic textured surfaces, and MoS2 as a solid lubricant on the friction and wear reduction of Ti64 alloy and AISI 52100 steel tribo-pairs. Three types of LST textures (Circular, triangular, and square textures) were created on the Ti64 alloy. Subsequently, tribological experiments were performed using a ball-on-disc universal tribometer at loads of 5, 10, and 15N with a 15 Hz frequency. The worn surface was analyzed using various methods, including optical microscopy, 3D-profilometer, FESEM, EDAX analysis, and Raman spectroscopy. The study compared the coefficient of friction (COF) and wear behavior of non-textured surfaces (NTS) with those of textured surfaces (TS) under both dry sliding conditions (DSC) and lubricated sliding conditions (LSC). The results demonstrated a significant reduction in the COF and wear coefficients on the TS. Specifically, the circular texture (CiT) exhibited a remarkable reduction of 39.3%, 63.83%, and 83.6% in wear coefficients compared to the NTS tested under DSC and LSC (using pure PAO-4 and PAO-4 + 1% wt MoS2) with sliding load of 15N. DSC showed abrasion, adhesion, and delamination wear, while LSC displayed mild adhesion, delamination, and tribo-layer formation on NTS and TS. The analysis indicated that the use of LST and solid lubricant nanoparticles on a Ti64 alloy would result in improved service life and better endurance in cutting tools and tribo-mating parts. [ABSTRACT FROM AUTHOR]

The forces generated by action potentials in muscle cells shuttle blood, food and waste products throughout the luminal structures of the body. Although non-invasive electrophysiological techniques exist1, 2–3, most mechanosensors cannot access luminal structures non-invasively4, 5–6. Here we introduce non-toxic ingestible mechanosensors to enable the quantitative study of luminal forces and apply them to study feeding in living Caenorhabditis elegans roundworms. These optical ‘microgauges’ comprise upconverting NaY0.8Yb0.18Er0.02F4@NaYF4 nanoparticles embedded in polystyrene microspheres. Combining optical microscopy and atomic force microscopy to study microgauges in vitro, we show that force evokes a linear and hysteresis-free change in the ratio of emitted red to green light. With fluorescence imaging and non-invasive electrophysiology, we show that adult C. elegans generate bite forces during feeding on the order of 10 µN and that the temporal pattern of force generation is aligned with muscle activity in the feeding organ. Moreover, the bite force we measure corresponds to Hertzian contact stresses in the pressure range used to lyse the bacterial food of the worm7,8. Microgauges have the potential to enable quantitative studies that investigate how neuromuscular stresses are affected by ageing, genetic mutations and drug treatments in this organ and other luminal organs.Nanoparticle-based ‘microgauges’ are developed for in vivo force sensing and deployed in C. elegans to investigate how mechanical force correlates with electrical signalling in neuromuscular organs. [ABSTRACT FROM AUTHOR]

Joint clearance is inevitable and affects the dynamic characteristics of deployable structures in orbit. An accurate contact force model can improve the dynamic modeling accuracy of deployable structures. This work proposes and validates an enhanced contact force model for modeling deployable structures with clearance joints. First, an enhanced continuous contact force model is presented based on a hybrid theoretical and numerical static cylindrical contact force model with a modified hysteresis damping factor obtained by reassessing energy and momentum transduction during the impact process. Subsequently, the proposed model's validity is established through comparisons with results from the finite element method. Finally, dynamic simulations for planar deployable structures demonstrate the applicability of the proposed model. The dynamic characteristics of the structures with clearance joints are studied. Results indicate that the proposed model is a reasonable approach for evaluating contact forces during the impact process of clearance joints, which undeniably influence the dynamic characteristics of deployable structures. External loads further affect the dynamic characteristics, and the clearance joints exhibit distinct contact modes, warranting further investigation. This work is vital for designing and analyzing high-precision space deployable structures in orbit. [ABSTRACT FROM AUTHOR]

The double-disk arc-contact lapping (DDACL) method is a novel for precision machining of the rolling surface of cylindrical roller. The contact characteristics of DDACL process can affect the lapping quality of the bearing roller. However, there is a limited amount of study on the contact theory of DDACL. Therefore, the objective of this research is to create a semi-analytical modeling approach that can effectively and accurately forecast the contact characteristics of DDACL. In the initial step, the spatial coordinate transformation was employed to establish accurate mathematical models that represents the surfaces of the cylindrical roller and arc groove. Subsequently, the potential contact area was determined and subdivided into discrete elements based on the differential geometry principles. The accurate flexibility of the potential contact area is achieved by utilizing the interpolation theory and considering both the global and local deformations of the roller and groove. By employing the influence coefficient method and the force-deformation coordination relation, the deformation and contact force can be calculated. Finally, the accuracy and efficiency of this calculation is confirmed through a comparison between the finite element method (FEM) and the proposed method. [ABSTRACT FROM AUTHOR]

Temperature increases of railway wheels due to frictional braking on the running surface (wheel tread) can lead to maintenance challenges such as tread wear and thermal cracking. While heating within the anticipated design range should not adversely affect the structural safety of the wheels, excessive temperature rises resulting from brake system failures can induce tensile residual stresses in the rim, potentially leading to wheel fracture. Detecting wheels with abnormal residual stresses is therefore crucial for railway safety, and monitoring residual displacements in the rim due to changes in circumferential residual stresses is an implementable approach. However, the shape of the wheel web varies, and the displacement response to thermal input differs depending on the wheel geometries. This study aims to explore general deformation behaviours related to wheel shape and elucidate the relationship between shape and heat resistance. The elastic-plastic finite element analysis employing simplified intense thermal input revealed that residual deformation after excessive thermal loading consistently results in back gauge expansion, although the deformation and stress responses differ based on the web geometry. Differences in heat resistance are indicated by the variation in the temperature at which compressive yielding due to thermal stress occurs, depending on the web shape. The residual stress detectability of each wheel is determined based on the principle that greater residual displacement at lower stress indicates higher anomaly detectability. [ABSTRACT FROM AUTHOR]