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The emergence of graphene paper comprising well-stacked graphene flakes has promoted the application of graphene-based materials in diverse fields such as energy storage devices, membrane desalination, and actuators. The fundamental properties of graphene paper such as mechanical, electrical, and thermal properties are critical to the design and fabrication of paper-based devices. In this study, the interlayer interactions in graphene paper were investigated by double cantilever beam (DCB) fracture tests. Graphene papers fabricated by flow-directed stacking of electrochemically exfoliated few-layer graphene flakes were mechanically separated into two parts, which generated force-displacement responses of the DCB sample. The analysis based on fracture mechanics revealed that the interlayer separation energy of the graphene paper was 9.83 ± 0.06 J/m2. The results provided a fundamental understanding of the interfacial properties of graphene papers, which will be useful for developing paper-based devices with mechanical integrity. [ABSTRACT FROM AUTHOR]

In supporting the stable operation of high-penetration renewable energy grids, flywheel energy storage systems undergo frequent charge–discharge cycles, resulting in significant stress fluctuations in the rotor core. This paper investigates the fatigue life of flywheel energy storage rotors fabricated from 30Cr2Ni4MoV alloy steel, attempting to elucidate the material's mechanical properties, crack propagation behavior, and impact of internal defects on fatigue life. Tensile tests reveal that the material exhibited high yield (992 MPa) and tensile strengths (1130 MPa). The Paris formula is used to model crack growth rates, ending in good agreement with the experimental data. Fatigue tests at various stress conditions highlight the material's significant variability in fatigue life and emphasize the need for reliable design approaches. This paper also demonstrates that internal defect size and location critically affect fatigue life, calling for improvements in forging inspection standards. Overall, the present study provides a comprehensive analysis of 30Cr2Ni4MoV steel's suitability for flywheel rotors, balancing safety, and operational efficiency. [ABSTRACT FROM AUTHOR]

The failure of a proximal humerus internal locking system (PHILOS) used in a pantalar arthrodesis was investigated in this paper. PHILOS constructs are hybrids using locking and non-locking screws. Both the plate and the screws used in the fusion were obtained for analysis. However, only the plate failure analysis is reported in this paper. The implant had failed in several pieces. Optical and scanning electron microscopic analyses were performed to characterize the failure mode(s) and fracture surface. The chemical composition and mechanical properties of the plate were determined and compared to controlling specifications to manufacture the devices. We found that equivalent tensile strength exceeded at the locations of high stress, axial, and angular displacement and matched the specification at the regions of lower stress/displacement. Such a region-wise change in mechanical properties with in vivo utilization has not been reported in the literature. Evidence of inclusions was qualitatively determined for the stainless steel 316L plate failing the specifications. Pitting corrosion, scratches, discoloration and debris were present on the plate. Fracture surface showed (1) multi-site corrosion damage within the screw holes forming a 45° maximum shear force line for crack-linking, and (2) crack propagation perpendicular to the crack forming origin that may have formed due to the presence of inclusions. Fracture features such as beach marks and striations indicating that corrosion may have initiated the crack(s), which grew by fatigue over a period of time. In conclusion, the most likely mechanism of failure for the device was due to corrosion fatigue and lack of bony in-growth on the screws that may have caused loosening of the device causing deformity and pre-mature failure. [ABSTRACT FROM AUTHOR]

In this paper, hip implants made of Ti-6Al-4V titanium alloy are analyzed numerically using Extended Finite Element Method XFEM. The combined effect of corrosion and fatigue was considered here since this is a common cause of failure of hip implants. Experimental testing of Ti-6Al-4V alloy was performed to determine its mechanical properties under different working environments, including normal, salty, and humid conditions. The integrity and life of the hip implant were assessed using the Linear Elastic Fracture Mechanics (LEFM) approach. For this purpose, the conditional fracture toughness Kq using CT specimens from all three groups (normal, humid, salty conditions) were determined. This provided insight into how different aggressive environments affect the behavior of Ti-6Al-4V alloy; i.e., how much its resistance to crack growth would degrade depending on conditions corresponding to the real exploitation of hip implants. Next, analytical and XFEM analyses of fatigue behavior in terms of the number of cycles were performed for all three groups, and the obtained results showed good agreement, confirming the validity of the integrity assessment approach shown in this work, which also represented a novel approach since fatigue and corrosion effects were investigated simultaneously. [ABSTRACT FROM AUTHOR]

Coal mining under the Quaternary thick loose layer affects key strata breakage, Bed-separations development, ground subsidence, and other studies. This paper presents a method for solving the deflection of a large-deflection inclined thin plate under a thick loose-layer cover with additional lateral loads and midplane forces. The methods presented are based on the principle of large-deflection of thin-plate, energy method, and fracture mechanics theory. The 7225 work face in Anhui Province, China, was studied. Combined with the large-deflection inclined thin plate model, the initial breakage distance within the main roof plate was calculated to be 33 m with the initial breakage angle of 61.2°, and the period breakage distance was calculated to be 21 m with the period breakage angle of 55.4°. The distribution range of "Vertical Three Zones" from 7225 working face to the ground, including the height of the caved zone is 38.07 m, the height of the fractured zone is 41.13 m, and the height of the curved zone with the thick loose layer removed is 187.56 m. During the dynamic development of the principal key strata (PKS), the deflection value develops from 0 mm to 2714 mm with 7225 working face mining, and the maximum value of the spatial volume is 56,485 m3, which is verified by Three-dimensional Discrete Element Code (3DEC) numerical simulation. The dynamic development of Bed-separation within the overlying strata, with a maximum development height of 545.2 mm and a maximum volume of 11,228.1 m3 of the Bed-separation cavity. The dynamic development of the Bed-separation height and the cavity under different mining length and width conditions of the working face are also discussed. The large-deflection inclined thin plate model proposed in this paper effectively explores the dynamic deflection and fragmentation law of the overlying strata induced by the inclined working face of Longwall mining and provides a theoretical basis and computational model for quantitatively evaluating the dynamic development of the Bed-separation cavity. [ABSTRACT FROM AUTHOR]

This paper forms part of an ongoing investigation into the tools required in linear elastic fracture mechanics (LEFM) for evaluating the durability of components designed for limited life replacement. In this study, we demonstrate that the USAF 'Characteristic K' method, when combined with the Hartman–Schijve adaptation of the NASGRO crack growth formula, can predict the impact of underloads on the propagation of small cracks in aluminum alloy AA7050-T7451 with reasonable accuracy. The published da/dN versus ΔK small crack growth curves associated with five specific underload spectra are examined. It is found that, in each case, there is reasonably good agreement between the predicted and the measured curves. To the best of the author's knowledge, this paper is the first to highlight the ability of the USAF Characteristic K approach, when coupled with the Hartman–Schijve equation, to reasonably accurately predict the growth of small cracks subjected to a range of underload spectra. [ABSTRACT FROM AUTHOR]

This paper presents the results of an extensive investigation into the durability of cold spray repairs to corrosion damage in AA7075-T7351 aluminium alloy specimens where, prior to powder deposition, the surface preparation involved grit blasting. In this context, it is shown that the growth of small naturally occurring cracks in cold spray repairs to simulated corrosion damage can be accurately computed using the Hartman–Schijve crack growth equation in a fashion that is consistent with the requirements delineated in USAF Structures Bulletin EZ-SB-19-01, MIL-STD-1530D, and the US Joint Services Structural Guidelines JSSG2006. The relatively large variation in the da/dN versus ΔK curves associated with low values of da/dN highlights the fact that, before any durability assessment of a cold spray repair to an operational airframe is attempted, it is first necessary to perform a sufficient number of tests so that the worst-case small crack growth curve needed to perform the mandated airworthiness certification analysis can be determined. [ABSTRACT FROM AUTHOR]

It is currently a challenge to accurately predict the deformation and fracture behavior of metal parts in automobile crashes. Many studies have shown that the deformation and fracture behavior of materials are significantly affected by the stress state during automobile crashes with complex stress state characteristics. In order to further promote the application of die-cast magnesium alloys in automobiles, it is particularly important to study the material deformation and fracture behavior of die-cast magnesium alloys. In this paper, the mechanical properties of the AM60B die-cast magnesium alloy sheet under four stress states (shear, tension, R10 notch tension, and cupping) were designed and tested. Based on the von Mises isotropic constitutive model and Swift weighted Hockett–Sherby hardening model, the plastic constitutive model of die-cast magnesium alloy was established. Based on the plastic model and the fracture model (JC, MMC, and DIEM) considering the influence of three stress states, the deformation and fracture behavior of the AM60B die-cast magnesium alloy front-end members in three-point bending were predicted by experiments and finite element simulation. The experimental results show that the deformation mode and loading–displacement curve trend of the AM60B die-cast magnesium alloy front members are the same, the crack initiation point and crack initiation time are the same, and the crack shape is similar. The results show that the complex stress state constitutive model parameters and the DIEM fracture model obtained in this paper can accurately predict the deformation and fracture failure behavior of the AM60B die-cast magnesium alloy sheet. [ABSTRACT FROM AUTHOR]

The high-cycle bending fatigue experiment is one of the most important necessary steps in guiding the crankshaft manufacturing process, especially for high-power engines. In this paper, an accelerated method was proposed to shorten the time period of this experiment. First, the loading period was quickened through the prediction of the residual fatigue life based on the unscented Kalman filtering algorithm approach and the crack growth speed. Then, the accuracy of the predictions was improved obviously based on the modified training section based on the theory of fracture mechanics. Finally, the fatigue limit load analysis result was proposed based on the predicted fatigue life and the modified SAFL (statistical analysis for the fatigue limit) method. The main conclusion proposed from this paper is that compared with the conventional training sections, the modified training sections based on the theory of fracture mechanics can obviously improve the accuracy of the remaining fatigue life prediction results, which makes this approach more suitable for the application. In addition, compared with the system's inherent natural frequency, the fatigue crack can save the experiment time more effectively and thus is superior to the former factor as the failure criterion parameter. [ABSTRACT FROM AUTHOR]

Ultrasonic-assisted inner diameter machining is a slicing method for hard and brittle materials. During this process, the sawing force is the main factor affecting the workpiece surface quality and tool life. Therefore, based on indentation fracture mechanics, a theoretical model of the cutting force of an ultrasound-assisted inner diameter saw is established in this paper for surface quality improvement. The cutting experiment was carried out with alumina ceramics (99%) as an exemplar of hard and brittle material. A six-axis force sensor was used to measure the sawing force in the experiment. The correctness of the theoretical model was verified by comparing the theoretical modeling with the actual cutting force, and the influence of machining parameters on the normal sawing force was evaluated. The experimental results showed that the ultrasonic-assisted cutting force model based on the six-axis force sensor proposed in this paper was more accurate. Compared with the regular tetrahedral abrasive model, the mean value and variance of the proposed model's force prediction error were reduced by 5.08% and 2.56%. Furthermore, by using the proposed model, the sawing processing parameters could be updated to improve the slice surface quality from a roughness Sa value of 1.534 µm to 1.129 µm. The proposed model provides guidance for the selection of process parameters and can improve processing efficiency and quality in subsequent real-world production. [ABSTRACT FROM AUTHOR]

Mixed mode fracture is a widely studied topic, while the coupling effects of mixed mode cracking are unclear. In this paper, elastic fracture behaviors and the coupling effects of the mixed mode cracks are studied in detail based on the finite element method, experimental study and linear elastic fracture mechanics. Results show that there always exist II-III coupling effects at the crack tips of mixed mode cracks, which have many effects on the crack tip field and crack propagation behavior. It is found that a mode II component at the tip of a mixed mode crack is the main reason for crack deflection, while the mode III components show no effect. For any mixed mode crack, mode II components at the crack tip can be divided as that by mode II loading which causes plane crack propagation, and by the coupling effect which causes spatial crack propagation. On this basis, a new fracture criterion suitable for any mixed mode crack is proposed, combined with the coupling effect and the linear elastic superposition principle. The research in this paper provides a solution to the problem of an II-III coupling effect in mixed mode fracture research and further promotes the development of fracture mechanics. [ABSTRACT FROM AUTHOR]

The primary focus of this paper is to investigate the application of ANSYS Workbench 19.2 software's advanced feature, known as Separating Morphing and Adaptive Remeshing Technology (SMART), in simulating the growth of cracks within structures that incorporate holes. Holes are strategically utilized as crack arrestors in engineering structures to prevent catastrophic failures. This technique redistributes stress concentrations and alters crack propagation paths, enhancing structural integrity and preventing crack propagation. This paper explores the concept of using holes as crack arrestors, highlighting their significance in increasing structural resilience and mitigating the risks associated with crack propagation. The crack growth path is estimated by applying the maximum circumferential stress criterion, while the calculation of the associated stress intensity factors is performed by applying the interaction integral technique. To analyze the impact of holes on the crack growth path and evaluate their effectiveness as crack arrestors, additional specimens with identical external dimensions but without any internal holes were tested. This comparison was conducted to provide a basis for assessing the role of holes in altering crack propagation behavior and their potential as effective crack arrestors. The results of this study demonstrated that the presence of a hole had a significant influence on the crack growth behavior. The crack was observed to be attracted towards the hole, leading to a deviation in its trajectory either towards the hole or deflecting around it. Conversely, in the absence of a hole, the crack propagated without any alteration in its path. To validate these findings, the computed crack growth paths and associated stress intensity factors were compared with experimental and numerical data available in the open literature. The remarkable consistency between the computational study results for crack growth path, stress intensity factors, and von Mises stress distribution, and the corresponding experimental and numerical data, is a testament to the accuracy and reliability of the computational simulations. [ABSTRACT FROM AUTHOR]

Before a new type of engine is introduced into civil aviation, it must comply with various safety regulations. These regulations include the analysis of secondary damage caused by the re-ingestion of a tooth fragment. The purpose is to prevent crack propagation through the gear rim, which would lead to catastrophic failure. In this context, identification of the initial crack location is crucial to determine the crack propagation path. Therefore, this paper presents a technique to determine and validate a constitutive material model and fracture locus for case-hardened spur gears. As the modelling of the surface-hardened layer is computationally intensive, it is necessary to homogenise the model. This paper comprehensively reviews and discusses the associated effects and errors. To determine the plastic behaviour of the case-hardened external gear (30CrNiMo8) and the nitrided internal gear (35CrAlNi7-10), the widely acknowledged Johnson–Cook material model is implemented using compression and Vickers indenter tests to define the necessary parameters. The fracture locus implementation is also based on the Johnson–Cook method and an axial shift of the fracture locus based on the hardness profile of the spur gears is determined by quasi-static pulsator tests. For validation, a project-specific gearbox test rig is used, enabling consistent ingestion of defined fragments. In addition, to check the likelihood of a tooth flank crack and to validate the results, a simplified ingestion experiment is performed. [ABSTRACT FROM AUTHOR]

This paper presents the results of computer simulations of fracture in three laboratory tests: the three-point bending of a notched beam cut from sandstone, the pull-out test of a self-undercutting anchor fixed in sandstone, and the pull-out test of a bar embedded in concrete. Five material failure criteria were used: Rankine, Coulomb–Mohr, Drucker–Prager, Ottosen–Podgórski, and Hoek–Brown. These criteria were implemented in the Abaqus® FEA system to work with the crack propagation modeling method—extended finite element method (X-FEM). All criteria yielded similar force–displacement relationships and similar crack path shapes. The improved procedure gives significantly better, close-to-real crack propagation paths than can be obtained using the standard subroutines built into the Abaqus® system. [ABSTRACT FROM AUTHOR]

In this paper, the effectiveness of reinforcements for flexible pavements is evaluated through an analysis of reflective cracking. Different stiffness and thickness reinforcements are considered for the rehabilitation of an already cracked pavement. The effect of the reinforcement is assessed from two different perspectives: (i) the ability to reduce stresses in the rehabilitated pavement layers, and (ii) the capacity to mitigate the crack propagation from deeper layers. A finite element model (FEM) is adopted to study the stress and strain state of the pavement layers. The pavement model has been properly validated, transitioning from a simply supported beam scheme to an elastic multilayer model. In addition, to represent crack propagation, fracture evolution is analyzed using Linear Elastic Fracture Mechanics (LEFMs) and Paris' law. The effect of different reinforcements on the pavement is then simulated. The results show that the reinforcement performance is strictly dependent on the interlayer thickness and stiffness. In particular, high stiffness reinforcements (geomembranes) show increasing effectiveness with stiffness, both in terms of reflective cracking and stress reduction. Conversely, low stiffness reinforcements (SAMIs) show a variable trend with the stiffness modulus. In fact, extremely low stiffness is effective in slowing down crack propagation but is detrimental to the wearing course's stress condition. However, as the stiffness increases, the likelihood of cracking in the wearing course decreases, though only a small beneficial effect is registered for crack propagation in the base layer. [ABSTRACT FROM AUTHOR]

In this paper, we propose a new approach for numerically simulating the growth of cracks in unidirectional composite materials, termed extended isogeometric analysis, evaluating the maximum stress intensity factor and T-stress. To validate our approach, we used a small anisotropic plate with two edge cracks, beginning with formulating the governing equations based on the energy integral method, Stroh's Formula, and the Elastic Law describing the behaviour of anisotropic materials, while considering boundary conditions and initial states. A MATLAB code was developed to solve these equations numerically and to post-process the tensile stress and the stress intensity factor (SIF) in the first mode. The results for the SIF closely match those obtained using the extended finite element method (X-FEM), with a discrepancy of only 0.0021 Pa·m0.5. This finding underscores the credibility of our approach. The extended finite element method has demonstrated robustness in predicting crack propagation in composite materials in recent years, leading to its adoption by several widely used software packages in various industries. [ABSTRACT FROM AUTHOR]

The key performance parameters of proppant are mainly the crushing rate and fracture conductivity, which are usually evaluated using physical experimental methods. However, the testing method for fracture conductivity has limitations, such as its long time-consumption, high testing costs, instability, and even the presence of large errors in testing results under the same conditions. The purpose of this paper is to propose a calculation method that can replace physical experiments. Firstly, we analyze the random and deterministic phenomena in the contact relationship between proppant particles from a microscopic perspective. Subsequently, we develop a physical model of the microscopic arrangement of these particles, enabling us to conduct further computer simulations of their microscopic configuration. Secondly, we conduct a microscopic mechanical analysis of the contact between proppant particles and between particles and boundaries and establish a corresponding mathematical model. Then, utilizing the simulation and mechanical analysis results of the proppant, we calculate the crushing rate. Considering the crushing rate of proppant, we improve the Kozeny–Carmen equation to determine the fracture permeability, and subsequently calculate the fracture conductivity. Finally, the calculated results are compared with the experimental results. The results show that the calculated values for the proppant crushing rate and fracture conductivity matched well with experimental data, and that the model's calculation values were more accurate. As the number of simulations increased, the accuracy of the calculation results became higher. Research shows that the fracture conductivity is influenced by factors such as the particle size, microstructure, and crushing rate. Numerical calculation methods can replace physical experiments and provide theoretical support for engineering applications of hydraulic fracturing proppant materials. [ABSTRACT FROM AUTHOR]

(1) Modeling and characterization of ductile fracture in metals is still a challenging task in the field of computational mechanics. Experimental testing offers specific responses in the form of crack-mouth (CMOD) and crack-tip (CTOD) opening displacement related to applied force or crack growth. The main aim of this paper is to develop a phase-field-based Finite Element Method (FEM) implementation for modeling of ductile fracture in stainless steel. (2) A Phase-Field Damage Model (PFDM) was coupled with von Mises plasticity and a work-densities-based criterion was employed, with a threshold to propose a new relationship between critical fracture energy and critical total strain value. In addition, the threshold value of potential internal energy—which controls damage evolution—is defined from the critical fracture energy. (3) The material properties of AISI 316L steel are determined by a uniaxial tensile test and the Compact Tension (CT) specimen crack growth test. The PFDM model is validated against the experimental results obtained in the fracture toughness characterization test, with the simulation results being within 8% of the experimental measurements. (4) The novel implementation offers the possibility for better control of the ductile behavior of metallic materials and damage initiation, evolution, and propagation. [ABSTRACT FROM AUTHOR]

Wire and arc additive manufacturing (WAAM) offers promise in creating large complex structures due to its flexibility and high material deposition rates. The nickel-based alloy IN718 is favoured for WAAM due to its weldability and compatibility. However, WAAM can introduce issues like anisotropic grain structure, porosity, and residual stresses which can lead to directional variations in tensile, fatigue, and fracture behaviour. This paper studied the WAAM process of IN718, utilising cold metal transfer (CMT). The optimised CMT-WAAM parameters for IN718 were identified to as a wire feed speed of 8–10 m/min and a torch travel speed of 0.5–0.7 m/min, resulting in stable deposition and minimal defects. Nevertheless, columnar grain structures were observed in the build direction (BD), with coarse grains in the wall-length direction (WD). This anisotropic microstructure coupled with stress concentrators, contributes to the directional dependence observed in tensile properties, fatigue endurance, and crack growth. The investigation revealed superior ductility in the BD compared to the WD. Interestingly, the fatigue endurance testing showed a longer life in the WD compared with the BD, attributed to stronger stress concentrators in the BD specimens. However, when examining a cracked specimen, the fatigue crack propagated faster in the WD rather than the BD. [ABSTRACT FROM AUTHOR]

The size of wind turbine blades is increasing rapidly, and they are being installed in remote offshore locations. Consequently, it is essential to focus on improving the design and maintenance procedures in the blade industry to meet the growing demand. Of particular concern is the long-term operational performance of the wind turbine blade trailing edge. In this paper, we discuss the application of durability and damage tolerance analysis (DADTA) approaches to trailing edge service life prediction. DADTA is mandated in the aerospace sector to support airworthiness certification and to provide an updated life prediction of the structure based on the different stages of their service life. The DADTA framework has two main parts: durability and damage tolerance analysis. The durability part uses a structural fatigue approach based on a damage accumulation method during the initial design phase to predict the lifespan of a structure without defects. On the other hand, the damage tolerance analysis part uses a fracture mechanics approach and a damage growth method to update the lifespan prediction of a structure during the operation stages. This is achieved by utilizing sensors and inspection data as inputs while the structure is in service. Both these methods are comprehensive and have merits; however, their broad adoption in the wind turbine blade industry is still lacking. The current paper provides an extensive review of these methods and shows how these can be applied to the wind turbine blade industry, specifically for predicting the structural design life of the trailing edge of composite wind turbine blades. The review includes (a) defining wind turbine trailing edge failure modes, (b) trailing edge design procedures, and (c) a detailed discussion of the application of durability and damage tolerance analysis for trailing edge life prediction. Overall, this review paper would be of special interest to blade designers and would guide researchers and engineers interested in life prediction methodologies based on DADTA approaches for wind turbine blades. [ABSTRACT FROM AUTHOR]

This paper presents an extensive literature review focusing on the utilisation of crack tip plasticity as a crucial parameter in determining and enhancing crack growth models. The review encompasses a comprehensive analysis of various methodologies, predominantly emphasising numerical simulations of crack growth models while also considering analytical approaches. Although experimental investigations are not the focus of this review, their relevance and interplay with numerical and analytical methods are acknowledged. The paper critically examines these methodologies, providing insights into their advantages and limitations. Ultimately, this review aims to offer a holistic understanding of the role of crack tip plasticity in the development of effective crack growth models, highlighting the synergies and gaps between theoretical, experimental, and simulation-based approaches. [ABSTRACT FROM AUTHOR]

Adhesively bonded doublers and adhesively bonded repairs are extensively used to extend the operational life of metallic aircraft structures. Consequently, this paper focuses on the tools needed to address sustainment issues associated with both adhesively bonded doublers and adhesively bonded repairs to (metallic) aircraft structures, in a fashion that is consistent with the building-block approach mandated in the United States Air Force (USAF) airworthiness certification standard MIL-STD-1530D and also in the United States (US) Joint Services Structural Guidelines JSSG-2006. In this context, it is shown that the effect of biaxial loads on cohesive crack growth in a bonded doubler under both constant amplitude fatigue loads and operational flight loads can be significant. It is also suggested that as a result, for uniaxial tests to replicate the cohesive crack growth seen in adhesively bonded doublers and adhesively bonded repairs under operational flight loads, the magnitude of the applied load spectrum may need to be continuously modified so as to ensure that the crack tip similitude parameter in the laboratory tests reflects that seen in the full-scale aircraft. [ABSTRACT FROM AUTHOR]

The heterogeneity of welded joints' microstructure affects their mechanical properties, which can vary significantly in relation to specific weld zones. Given the dimensional limitations of the available test volumes of such material zones, the determination of mechanical properties presents a certain challenge. The paper investigates X welded joint of S690QL1 grade high strength steel (HSS), welded with slightly overmatching filler metal. The experimental work is focused on tensile testing to obtain stress-strain properties, as well as fracture mechanics testing. Considering the aforementioned limitations of the material test volume, tensile testing is carried out with mini tensile specimens (MTS), determining stress-strain curves for each characteristic weld zone. Fracture mechanical testing is carried out to determine the fracture toughness using the characteristic parameters. The experimental investigation is carried out using the single edge notch bend (SENB) specimens located in several characteristic welded joint zones: base metal (BM), heat affected zone (HAZ), and weld metal (WM). Fractographic analysis provides deeper insight into crack behavior in relation to specific weld zones. The numerical simulations are carried out in order to describe the fracture behavior of SENB specimens. Damage initiation and evolution is simulated using the ductile damage material behavior. This paper demonstrates the possibility of experimental and numerical determination of fracture mechanics behavior of characteristic heterogeneous welded joint zones and their influence on crack path growth. [ABSTRACT FROM AUTHOR]

Investigating the constitutive relationship and the damage failure mechanism of solid propellants is of significance for improving the safety, storage period and use efficiency of solid rocket motors. This paper focuses on the complex mechanical response behavior of composite solid propellants under loads and introduces experimental research on quasi-static and dynamic mechanical properties. Limited by the accuracy of instruments and testing methods, the research progress of macroscopic constitutive models, mesoscopic mechanical models and microscopic molecular models is summarized from the perspective of numerical simulations based on model scale and modeling methods. This paper tracks the historical progress of key models and summarizes the main achievements and prospects in this field. The research in this paper has high scientific and theoretical significance and engineering application value. It can provide an important reference and guidance for the structural optimization and performance improvement of solid propellants and lay a solid foundation for the development of solid rocket motors. [ABSTRACT FROM AUTHOR]

This paper investigates the fracture mechanical properties of concrete, using crushed concrete aggregates (CCA) and granulated blast furnace slag (GGBS) for partial cement replacement. CCAs made from prefabricated concrete replace 100% of the fine and coarse fractions in concrete recipes with w/c ratios of 0.42 and 0.48. Two pre-treatment methods, mechanical pre-processing (MPCCA) and accelerated carbonation (CO2CCA), are investigated for quality improvements in CCA. The resulting aggregates show an increased density, contributing to an increase in the concrete's compressive strength. The novelty of this paper is the superposition of the effects of the composite parts of concrete, the aggregate and the cement mortar, and their contributions to concrete fracture. Investigations are directed toward the influence of fine aggregates on mortar samples and the influence of the combination of coarse and fine aggregates on concrete samples. The physical and mechanical properties of the aggregates are correlated with mortar and concrete fracture properties. The results show that CCA concrete achieves 70% of the fracture energy values of concrete containing natural aggregates, and this value increases to 80% for GGBS mixes. At lower w/c ratios, MPCCA and CO2CCA concretes show similar fracture energies. CO2CCA fine aggregates are the most effective at strengthening the mortar phase, showing ductile concrete behavior at a w/c ratio of 0.48. MPCCA aggregates contribute to higher compressive strengths for w/c ratios of 0.42 and 0.48. Thus, mechanical pre-processing can be improved to produce CCA, which contributes to more ductile concrete behavior. [ABSTRACT FROM AUTHOR]

Plasma stimulation is a form of waterless fracturing as it requires that only the wellbore be filled with an aqueous fluid. The technique creates multiple fractures propagating in different directions around the wellbore. The intent of this paper is to present an experimental and numerical investigation of the degree of competitiveness of plasma stimulation with hydraulic fracturing, especially in the case of stimulating tight formation. Several cases were run experimentally. The samples included limestone and sandstone to investigate plasma fracturing in different rock types. In addition, the main goal of the experiments was to study the creation of fracture(s) under confining stresses, the type of rock, the amount of electrical energy used in the experiment, and the length of the wire to generate the plasma reaction. A laboratory plasma equipment was designed and used to accomplish the experimental work. The experiments were then numerically matched using a finite element numerical simulator, HOSS developed by LANL (Los Alamos National Lab). HOSS was developed to simulate high-strain-rate fractures such as those created by plasma stimulation. It accounts for mixed-mode fracture mechanics which are tensile and shear fractures. The simulator governing equations obey the conservation of mass and momentum in a solid-mechanics sense and account for the nonlinear deformation of rock material. The matching of the experiment allowed us to validate the HOSS simulation of the process and showed that the numerical results are in good agreement with the experimental work. Using the HOSS simulator, we also investigated the effect of higher energy levels and/or short release time on a cement rock model. The pressure profile that is developed due to the energy release can vary in the peak pressure and the release time. The results showed that the plasma fracturing technique is an effective stimulation method in sandstone and limestone. Plasma fractures were developed in the rock samples and extended from the sample wellbore to the outer boundaries. The shape of the pressure pulse has an impact on the developed fractures. Moreover, the effect of plasma stimulation on natural fractures was studied numerically. It was found that natural fractures can arrest the plasma-generated fractures that propagate from the wellbore to the outer boundaries. However, new fractures may develop in the rock starting from the natural fracture tips. [ABSTRACT FROM AUTHOR]

Competing risks models, also known as weakest-link models, are utilized to analyze diverse strength distributions exhibiting multi-modality, often attributed to various types of defects within the material. The weakest-link theory posits that a material's fracture is dictated by its most severe defect. However, multimodal problems can become intricate due to potential censoring, a common constraint stemming from time and cost limitations during experiments. Additionally, determining the mode of failure can be challenging due to factors like the absence of suitable diagnostic tools, costly autopsy procedures, and other obstacles, collectively referred to as the masking problem. In this paper, we investigate the distribution of strength for multimodal failures with censored data. We consider both full and partial maskings and present an EM-type parameter estimate for the Birnbaum-Saunders distribution under competing risks. We compare the results with those obtained from other distributions, such as lognormal, Weibull, and Wald (inverse-Gaussian) distributions. The effectiveness of the proposed method is demonstrated through two illustrative examples, as well as an analysis of the sensitivity of parameter estimates to variations in starting values. [ABSTRACT FROM AUTHOR]

In this paper, a series of low-temperature CVN (Charpy V-notch impact test) and DWTT (drop-weight tear test) experiments were carried out to deal with the intensifying contradiction of strength and toughness of ultra-high-strength pipeline steel. The fracture behavior and toughening mechanisms of ultra-high-strength pipeline steel were investigated using scanning electron microscopy, transmission electron microscopy and backscattered electron diffraction systems. The results show that DWTT fractures in ultra-high-strength pipeline steel had a variety of unconventional morphological features compared to CVN fractures, including ridge protrusion in ductile fracture conditions and a large-size fracture platform in brittle fracture conditions. Therefore, DWTT fractures contained more information about the material fracturing process, and could better reflect the actual process of material fracturing. In ultra-high-strength pipeline steel, fine-grained granular bainite caused cracks to undergo large deflections or frequent small transitions, which consumed additional energy and improved toughness. In contrast, large-sized granular bainite, which consisted of low-angle grain boundaries, did not effectively prevent crack propagation when it encountered cracks, which was not conducive to improved toughness. Moreover, the M/A constituents in large-sized granular bainite aggregated, cracked, or fell off, which could easily lead to the formation of microcracks and was also detrimental to toughening. [ABSTRACT FROM AUTHOR]

This paper presents a probabilistic method to predict fatigue crack growth for surface flaws in pipelines using a particle filtering method based on Bayes theorem. The random response of the fatigue behavior is updated continuously as measured data are accumulated by the particle filtering method. Fatigue crack growth is then predicted through an iterative process in which particles with a high probability are reproduced more during the update process, and particles with a lower probability are removed through a resampling procedure. The effectiveness of the particle filtering method was confirmed by controlling the depth and length direction of the cracks in the pipeline and predicting crack growth in one- and two-dimensional cases. In addition, the fatigue crack growth and remaining service life with a 90% confidence interval were predicted based on the findings of previous studies, and the relationship between the fatigue crack growth rate and the crack size was explained through the Paris' law, which represents fatigue crack growth. Finally, the applicability of the particle filtering method under different diameters, aspect ratios, and materials was investigated by considering the negative correlation between the Paris' law parameters. [ABSTRACT FROM AUTHOR]

Detecting gear rim fatigue cracks using vibration signal analysis is often a challenging task, which typically requires a series of signal processing steps to detect and enhance fault features. This task becomes even harder in helicopter planetary gearboxes due to the complex interactions between different gear sets and the presence of vibration from sources other than the planetary gear set. In this paper, we propose an effectual processing algorithm to isolate and enhance rim crack features and to trend crack growth in planet gears. The algorithm is based on using cepstrum editing (or liftering) of the hunting-tooth synchronous averaged signals (angular domain) to extract harmonics and sidebands of the planet gears and low-pass filtering and minimum entropy deconvolution (MED) to enhance extracted fault features. The algorithm has been successfully applied to a vibration dataset collected from a planet gear rim crack propagation test undertaken in the Helicopter Transmission Test Facility (HTTF) at DSTG Melbourne. In this test, a seeded notch generated by an electric discharge machine (EDM) was used to initiate a fatigue crack that propagated through the gear rim body over 94 load cycles. The proposed algorithm demonstrated a successful isolation of incipient fault features and provided a reliable trending capability to monitor crack progression. Results of a comparative analysis showed that the proposed algorithm outperformed the traditional signal processing approach. [ABSTRACT FROM AUTHOR]

This paper presents a numerical approach for investigating fatigue delamination propagation in composite stiffened panels loaded in compression in the post-buckling field. These components are widely utilized in aerospace structures due to their lightweight and high-strength properties. However, fatigue-induced damage, particularly delamination at the skin–stringer interface, poses a significant challenge. The proposed numerical approach, called the "Min–Max Load Approach", allows for the calculation of the local stress ratio in a single finite element analysis. It represents the ratio between the minimum and maximum values of the stress along the delamination front, enabling accurate evaluation of the crack growth rate. The methodology is applied here in conjunction with the cohesive zone model technique to evaluate the post-buckling fatigue behavior of a composite single-stringer specimen with an initial delamination. Comparisons with experimental data validate the predictive capabilities of the proposed approach. [ABSTRACT FROM AUTHOR]

Renewable energy is a promising substitute for fossil fuels when corelated with P2G technology. To optimise P2G efficiency, there is a need to increase hydrogen fraction in the fuel stream. Simultaneously gas microturbines are widely applied in many industry sectors. These devices are often equipped with diffusion combustors. This situation was investigated in this paper. The P2G and gas microturbines may be integrated together in the future leading to the application of hydrogen-enriched fuel. Hydrogen-enriched fuel causes increase in combustion temperature and velocity. In a nonadapted combustor, these phenomena could result in an increase of NOx emissions and risk of material overheating and failure. In order to adapt the combustors for hydrogen-enriched fuel, the concept of autonomous internal flue gases recirculation (IFGR) system was applied to this issue. In this paper, the IFGR system applied to gas microturbine was studied in terms of hydrogen-enriched fuel application. The obtained exhaust gases recirculation ratios were too low to affect the combustion process as it was expected. The observed combustion modifications in the combustor were hardly linked to the air flow modification in the liner, due to IFGR system implementation. After CFD studies, the proposed IFGR system does not seem to provide the expected effects. [ABSTRACT FROM AUTHOR]

The paper deals with research focused on the use of fillers in the field of polymeric materials produced by additive technology SLA (stereolithography). The aim of the research is to evaluate 3D printing parameters, the mechanical properties (tensile strength, hardness), and the interaction of individual phases (polymer matrix and filler) in composite materials using SEM analysis. The tested fillers were cotton flakes and ground carbon fibres in different proportions. For the photosensitive resins, the use of cotton flakes as filler was found to have a positive effect on the mechanical properties not only under static but also under cyclic loading, which is a common cause of material failure in practice. The cyclic stress reference value was set at an amplitude of 5–50% of the maximum force required to break the pure resin in a static tensile test. A positive effect of fillers on the cyclic stress life of materials was demonstrated. The service life of pure resin was only 168 ± 29 cycles. The service life of materials with fillers increased to approximately 400 to 540 cycles for carbon fibre-based fillers and nearly 1000 cycles for cotton flake-based fillers, respectively. In this paper, new composite materials suitable for the use of SLA additive manufacturing techniques are presented. Research demonstrated the possibilities of adding cotton-based fillers in low-cost, commercially available resins. Furthermore, the importance of material research under cyclic loading was demonstrated. [ABSTRACT FROM AUTHOR]

This paper first examines crack growth in a range of tests on additively manufactured (AM) and conventionally manufactured Inconel 718. It is shown that whereas when the crack growth rate (da/dN) is plotted as a function of the range of the stress intensity factor (ΔK), the crack growth curves exhibit considerable scatter/variability, when da/dN is expressed in terms of the Schwalbe crack driving force (Δκ), then each of the 33 different curves essentially collapse onto a single curve. This relationship appears to hold over approximately six orders of magnitude in da/dN. The same phenomenon also appears to hold for 20 room temperature tests on both conventionally and additively manufactured Inconel 625. Given that the 53 studies examined in this paper were taken from a wide cross section of research studies it would appear that the variability in the da/dN and ΔK curves can (to a first approximation) be accounted for by allowing for the variability in the fatigue threshold and the cyclic fracture toughness terms in the Schwalbe crack driving force. As such, the materials science community is challenged to address the fundamental science underpinning this observation. [ABSTRACT FROM AUTHOR]

There are also many other metals and alloys (e.g., superalloys, Ti alloys, and Mg alloys) used in different applications, and the corresponding relationship between microstructures and properties also needs to be comprehensively understood. Metallic materials are mostly a combination of metallic elements, such as iron, aluminum, magnesium, titanium and manganese, which may also include small amounts of non-metallic elements, such as carbon, nitrogen and oxygen. Contributions Eleven papers, including two review papers and nine research papers, have been published focusing on the microstructure-related deformation and fracture behavior of steels, superalloys, titanium alloys and so on. [Extracted from the article]

The airworthiness certification of military aircraft requires a durability analysis be performed using linear elastic fracture mechanics (LEFM). Furthermore, such analyses need to use a valid small crack growth equation. This paper focuses on the effect of rough surfaces and the effect of machining the surface on the durability of AM parts using LEFM and a valid small crack growth equation for the material. To this end, this paper analyses the effect of surface roughness on wire and arc additively manufactured (WAAM) Ti-6Al-4V titanium parts and the effect of machining on the durability of a part. The analysis reveals that the life of the component is a relatively strong function of the degree of surface roughness, and that the durability of a specimen is a strong function of the local radius of the curvature of the trough. It also appears that surfaces with tall narrow roughness will not overly benefit from partial machining of the surface. [ABSTRACT FROM AUTHOR]

Recent explosions and impact events have highlighted the exposure of civil structures, prompting the need for resilient new constructions and retrofitting of existing ones. Laminated glass panels, particularly in glazed facades, are increasingly used to enhance blast resistance. However, the understanding of glass fragments and their interaction with the interlayer is still incomplete. This paper investigates experimentally the quasi-static and dynamic responses of cured and uncured polymers for seven different materials—two different products of polyvinyl butyral (PVB), two ethylene vinyl acetate products (EVA), one product of thermoplastic polyurethane (TPU), and two SentryGlas products (SG)—that were tested between 21 and 32 °C (69.8 and 89.6 °F), which is the recommended room temperature. In these experiments, the responses of PVB, EVA, TPU, and SG were evaluated under a quasi-static strain rate of 0.033 s−1 and compared to the results under a relatively higher strain rate of 2 s−1. Moreover, the high strain rate loading of the materials was accomplished using a drop-weight testing appliance to evaluate the engineering stress–strain response under strain rates between 20 and 50 s−1. The results demonstrated that with strain rates of 20 s−1, PVB behaved like a material with viscoelastic characteristics, but at 45 s−1 strain rates, PVB became a non-elastic material. SG, on the other hand, offered both a high stiffness and a high level of transparency, making it a very good alternative to PVB in structural applications. In contrast, after the maximum stress point, the response to the failure of the seven materials differed significantly. The tests provided ample information for evaluating alternative approaches to modeling these different materials in blast events. [ABSTRACT FROM AUTHOR]

The failure of premature thermal cycling spalling off is the bottleneck problem currently faced by yttrium oxide partially stabilized zirconia (YSZ) ceramic-based sealing coatings. Studies on the thermal cycling performance of coatings with "brick-mud" structures were carried out by experimental and simulation methods in this paper. The results showed that, as the thickness of "mud" layer increased, the bonding strength of the "brick-mud" structure coatings gradually decreased. When the thickness of the "mud" layer was about 3 μm and 10 μm, the thermal cycling lives of the T1 and T2 coatings were improved by 90.0% and 135.7%, respectively, compared with conventional coating (T0 coating), while that of the T3 coating (containing thick "mud" layers of about 20 μm) was decreased by 81.4%. The stress field of M2 "mud" layers with different thicknesses was subjected to a comprehensive effect by thermal mismatch stress and pores in "brick" layer. Compared with the medium and thick "mud" layers, the thin "mud" layer sustained obvious larger σ 22   m a x and σ 12   m a x , indicating its potential for the preferential initiation of transverse microcracks. In addition, the thin "mud" layer withstood the largest σ 11   m a x and had the strongest potential for longitudinal crack growth. Both transverse and longitudinal cracking could consume energy during thermal cycling and reduce the stress concentration at the top coating/bond coating interface. These were the main reasons for the improvements in the thermal cycling performances of the T1 and T2 coatings. The degree of crack deflection and the capacity of energy dissipation in the "mud" layer increased significantly with its thickness. However, the propagation length of transverse cracks also gradually increased in the meantime. Especially when the "mud" layer was 20 μm, the length of the transverse cracks increased rapidly. Thus, early interlayer delamination failure occurred in the T3 coating during thermal cycling. [ABSTRACT FROM AUTHOR]

The growth of cracks between plies, i.e., delamination, in continuous fibre polymer matrix composites under cyclic-fatigue loading in operational aircraft structures has always been a very important factor, which has the potential to significantly decrease the service life of such structures. Whilst current designs are based on a 'no growth' design philosophy, delamination growth can nevertheless arise in operational aircraft and compromise structural integrity. To this end, the present paper outlines experimental and data reduction procedures for continuous fibre polymer matrix composites, based on a linear elastic fracture mechanics approach, which are capable of (a) determining and computing the fatigue crack growth (FCG) rate, da/dN, curve; (b) providing two different methods for determining the mandated worst-case FCG rate curve; and (c) calculating the fatigue threshold limit, below which no significant FCG occurs. Two data reduction procedures are proposed, which are based upon the Hartman-Schijve approach and a novel simple-scaling approach. These two different methodologies provide similar worst-case curves, and both provide an upper bound for all the experimental data. The calculated FCG threshold values as determined from both methodologies are also in very good agreement. [ABSTRACT FROM AUTHOR]

The use of fibre-reinforced polymer materials (FRPs) for the retrofitting of reinforced concrete (RC) structures has become very popular. However, the main concern for the exploitation of FRPs is their premature debonding failure modes. This paper presents two different universal models for calculating flexed RC elements strengthened with externally bonded and near-surface mounted FRP reinforcements, which were derived by coupling principles of the fracture mechanics of solids and generally accepted assumptions. The first model allows a complete analysis of the behaviour, development, and propagation of rupture of the joint. The main advantages of the proposed model, compared to existing ones, are that it does not require additional bond shear tests to identify missing factors, and it is versatile and suitable for both externally bonded reinforcements (EBR) and near surface mounted (NSM) strengthening techniques. In addition, the concrete–FRP connection is divided into zones and the current phase and length of each zone are determined, allowing for more detailed analysis of the connection at different load stages. The proposed computational model and its derivation focus on the performance of the joint between the two cracks and the distribution of the shear stresses in that joint. The second one requires fewer computations and can be fully exploited when the joint is treated as a unit, without division. The results of the calculations have been validated using the experimental database of 77 RC beams and strengthened with externally bonded and near-surface mounted carbon fibre reinforced polymer (CFRP) and glass fibre reinforced polymer (GFRP) sheets, plates, strips, and bars taken from 13 different studies. Both the prestress force and the initial stress state before strengthening were evaluated. [ABSTRACT FROM AUTHOR]

Friction stir welding (FSW) has been adopted in the aerospace industry for fabricating structural alloys due to the low melting point and high thermal conductivity of aviation aluminum alloys. However, welding residual stresses can lead to secondary deformation in friction stir welded (FSWed) structures. Additionally, microstructural characteristics impact the crack growth rates and directions in these structures. Therefore, it is necessary to investigate the effects of residual stress and microstructure on the fatigue responses of FSWed joints. In this paper, we studied the fatigue crack growth behavior of two homogeneous and dissimilar FSWed joints with varying welding parameters, namely 2024-T3 and 7075-T6. The residual stresses were measured with the X-ray diffraction method. The dislocations and precipitates in different zones of the FSWed joints were analyzed via transmission electron microscopy (TEM). The results demonstrated that the residual stress significantly affected the fatigue crack growth rate and direction; the tensile residual stress promoted fatigue crack growth and offset the decrease in the fatigue crack growth rate that occurred due to grain refinement. The results of the microstructural analysis indicated that dislocation density and sliding resistance increased with the decrease in rotational speed and led to a decreased rate of fatigue crack propagation. [ABSTRACT FROM AUTHOR]

In this paper, the fatigue crack growth rates of typical pressure vessel material 4130X under different corrosion conditions are investigated, and the effects of corrosion modes and loading frequency on the fatigue crack growth rate of 4130X are discussed. The results show that under the same loading conditions, the pre-corroded crack propagation rate is increased by 1.26 times compared with the uncorroded specimens. The plastic deformation mechanism of the crack tip in air is dominated by phase transformation but the hydrogen introduced by pre-corrosion causes a small number of dislocations at the crack tip. The crack growth rate obtained by corrosion fatigue is four times that of the uncorroded specimen, and the fracture surface shows a strong corrosion effect. The molecular dynamics simulation shows that the hydrogen atoms accumulated at the crack tip make the plastic deformation mechanism dominated by dislocation in the crack propagation process, and the coupling interaction between low frequency and the corrosion environment aggravates the hydrogen embrittlement of the crack tip. In the air condition, the loading frequency has no obvious effect on the crack growth rate: when the frequency decreases from 100 Hz to 0.01 Hz and other conditions remain unchanged, the fatigue crack growth rate increases by 1.5 times. The parameter n in the Paris expression is mainly influenced by frequency. The molecular dynamics simulation shows that low frequency promotes crack tip propagation. [ABSTRACT FROM AUTHOR]

The aim of this study is to solve a practical problem encountered in the automotive industry, especially the failure of a cracked lower control arm made of al 6062 T6 material during static and crash physical tests, and to characterize the behavior of cracked parts made of aluminum materials using the fracture mechanics parameters. As a first step, we carried out a numerical study and simulation using Abaqus/CAE 2020 software and the finite element method to determine the stress concentration and load limit capacity for different car weight cases. The von Mises stress variation shows crack initiation and propagation to be in the area of the lower control arm's attachment to the vehicle platform, where stress is concentrated. These numerical results are consistent with the experimental test results found by automotive manufacturers. Also, we find that the mechanical load that can support this part is below 4900 N for good performance. In the second step, we use the results of the first section to simulate the failure of a lower control arm with a crack defect. This paper investigates the stress intensity factor KI in mode I for different lengths (L) and depths (a) of the crack in the lower control arm using the extended finite element method (XFEM) under Abaqus/CAE. For crack failure initiation and progression, we relied on the traction separation law, specifically the maximum principal stress (MAXPS) criterion. The KI factor was evaluated for the materials steel and Al 6062 T6. The results obtained from the variation of the KI coefficient as a function of crack depth (a) and the thickness (t) show that the crack remains stable even when a depth ratio (a/t = 0.8) is reached for the steel material. However, the crack in the Aluminum 6062 T6 material becomes unstable at depth (a/t = 0.6), with a high risk of total failure of the lower control arm. [ABSTRACT FROM AUTHOR]

Kaplan turbines, as one of the well-known hydraulic turbines, are generally utilized worldwide for low-head and high-flow conditions. Any failure in each of the turbine components can result in long-term downtime and high repair costs. In a particular case, if other parts are damaged due to the impact of the broken blades (e.g., the main shaft of the turbine), the whole power plant may be shut down. On the other hand, further research on the primary causes of failures in turbines can help improve the present failure evaluation methodologies in power plants. Hence, the main objective of this paper is to present the major causes of Kaplan turbine failures to prevent excessive damage to the equipment and provide practical solutions for them. In general, turbines are mainly subjected to both Internal Object Damage (IOD) and Foreign Object Damage (FOD). Accordingly, this paper presents a state-of-the-art review of Kaplan turbine failures related to material and physical defects, deficiencies in design, deficits in manufacturing and assembly processes, corrosion failures, fatigue failure, cavitation wear, types of cavitation in hydro turbines, hydro-abrasive problems, and hydro-erosion problems. Eventually, the authors have attempted to discuss practical hints (e.g., nanostructured coatings) to prevent damages and improve the performance of Kaplan turbines. [ABSTRACT FROM AUTHOR]

High forming force is often needed when high-strength and low-plasticity materials are processed by fine blanking. Too high forming force increases the load of the die and greatly increases the risk of die failure. If the forming force is reduced, the material will fracture prematurely, which will lead to poor quality parts. Aiming at this problem, a new force variation load fine-blanking technology is proposed in this paper. During the loading process, the forming force does not remain constant but changes with the blanking stroke. A 2D finite element fine-blanking model was established for the TC4 material. The mechanism of force variation fine blanking is also revealed. This paper proposes a method to design the loading route of the forming force with variable load. This method combines finite element simulation with neural network and a multi-objective genetic algorithm. Finally, the application of variable load fine blanking production and the application of traditional fine blanking production parts are verified by the experimental method. The same results are obtained from both simulation and experiment. It is found that the variable load fine blanking process can greatly reduce the load of the die on the premise of ensuring the quality of fine-blanking parts. [ABSTRACT FROM AUTHOR]

The durability assessment of additively manufactured parts needs to account for both surface-breaking material discontinuities and surface-breaking porosity and how these material discontinuities interact with parts that have been left in the as-built state. Furthermore, to be consistent with the airworthiness standards associated with the certification of metallic parts on military aircraft the durability analysis must be able to predict crack growth, as distinct from using a crack growth analysis in which parameters are adjusted so as to match measured data. To partially address this, the authors recently showed how the durability of wire arc additively manufactured (WAAM) 18Ni-250 maraging steel specimens, where failure was due to the interaction of small surface-breaking cracks with surface roughness, could be predicted using the Hartman–Schijve variant of the NASGRO crack growth equation. This paper illustrates how the same equation, with the same material parameters, can be used to predict the durability of a specimen where failure is due to surface-breaking porosity. [ABSTRACT FROM AUTHOR]

At present, PE pipelines are widely used in urban gas pipeline networks. As pipeline safety is of great importance to the gas supply, this paper focuses on the safety and reliability of PE pipes during service. First of all, this paper analyzes the aging factors of PE materials and the failure forms and mechanisms of PE pipes. Second, the performance testing methods of PE pipelines are summarized, including pipeline pressure tests, pipeline condition inspections, welded joint inspections, mechanical performance tests, and physical performance tests. In addition, life prediction methods for PE pipelines are introduced and analyzed. The methods and applicability of tensile experiments and DSC experiments based on thermal oxygen aging are both analyzed, and the corresponding experiments are also carried out. On the basis of the above research, the technical system of the integrity detection and evaluation of urban gas pipelines is finally established. The system includes the integrity detection method of urban gas pipelines and the applicability evaluation and determination of retest cycles, which can provide a reference for the safe operation of urban gas pipeline networks. [ABSTRACT FROM AUTHOR]

Metallic materials are widely employed in engineering constructions, and one of the most common failure mechanisms in metals is fatigue failure. Even though metal fatigue has been studied for almost 160 years, many problems remain unsolved. Fatigue in metal occurs when the metallic material is subjected to varying loads, resulting in failure due to damage accumulation. The fatigue process consists of a buildup of damage that leads to crack initiation, followed by a period of crack growth until the critical flaw size is reached. The sum of a start phase and a propagation phase represents the total life. To better understand the fatigue phenomenon at its different stages and predict the fatigue life, various types of prediction models have been developed and reported in the literature. This paper reviewed the different models that include microstructure scale parameters that can be used to predict how fatigue cracks start under variable amplitude loading, including the Modified Tanaka-Mura Model, Acoustic Second Harmonic Generation, and the Probability of Crack Initiation on Defects. For perfect life prediction under variable amplitude loading, a stress-based approach, a strain-based approach, and a continuum damage mechanics approach are reviewed. The purpose of this paper is to get overview of the current state of approaches to the life prediction of fatigue crack initiation with variable amplitude. Finally, gaps in knowledge about the prediction of fatigue crack initiation under variable loading at high temperatures are pointed out. [ABSTRACT FROM AUTHOR]

In this paper, the short-term behaviour of innovative aluminium–timber composite beams was investigated. Laminated veneer lumber panels were attached to aluminium beams with screws. Recently conducted theoretical, experimental, and numerical investigations have focused on aluminium–timber composite beams with almost full shear connections. However, no experiments on aluminium–timber composite beams with partial shear connections have yet been conducted. For this reason, composite action in composite beams with different screw spacing was studied in this paper. Four-point bending tests were performed on aluminium–timber composite beams with different screw spacing to study their structural behaviour (ultimate load, mode of failure, load versus deflection response, load versus slip response, and short-term stiffness). The method used for steel–concrete composite beams with partial shear connection was adopted to estimate the load bearing capacity of the investigated aluminium–timber composite beams. The resistance to sagging bending of the aluminium–timber composite beams with partial shear connections from the theoretical analyses differed by 6–16% from the resistance in the laboratory tests. In addition, four 2D numerical models of the composite beams were developed. One model reflected the behaviour of the composite beam with full shear connection. The remaining models represented the composite beams with partial shear connections and were verified against the laboratory test results. Laminated veneer lumber was modelled as an orthotropic material and its failure was captured using the Hashin damage model. The resistance to sagging bending of the aluminium–timber composite beams with partial shear connections from the numerical analyses were only 3–6% lower than the one from the experiments. [ABSTRACT FROM AUTHOR]

Machine learning has the potential to enhance damage detection and prediction in materials science. Machine learning also has the ability to produce highly reliable and accurate representations, which can improve the detection and prediction of damage compared to the traditional knowledge-based approaches. These approaches can be used for a wide range of applications, including material design; predicting material properties; identifying hidden relationships; and classifying microstructures, defects, and damage. However, researchers must carefully consider the appropriateness of various machine learning algorithms, based on the available data, material being studied, and desired knowledge outcomes. In addition, the interpretability of certain machine learning models can be a limitation in materials science, as it may be difficult to understand the reasoning behind predictions. This paper aims to make novel contributions to the field of material engineering by analyzing the compatibility of dynamic response data from various material structures with prominent machine learning approaches. The purpose of this is to help researchers choose models that are both effective and understandable, while also enhancing their understanding of the model's predictions. To achieve this, this paper analyzed the requirements and characteristics of commonly used machine learning algorithms for crack propagation in materials. This analysis assisted the authors in selecting machine learning algorithms (K nearest neighbor, Ridge, and Lasso regression) to evaluate the dynamic response of aluminum and ABS materials, using experimental data from previous studies to train the models. The results showed that natural frequency was the most significant predictor for ABS material, while temperature, natural frequency, and amplitude were the most important predictors for aluminum. Crack location along samples had no significant impact on either material. Future work could involve applying the discussed techniques to a wider range of materials under dynamic loading conditions. [ABSTRACT FROM AUTHOR]