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A new cyclic cohesive zone fatigue damage model is proposed to address the fatigue problem spanning high and low cycle stages. The new damage model is integrated with the damage extrapolation technique to improve calculation efficiency. The model's effectiveness in regulating the low-cycle fatigue evolution rate, overall fatigue damage evolution rate, and stress level at the fatigue turning point is assessed through the comparison of the S-N curves. The fatigue damage model's high precision is proved based on the minor deviation of stress at the turning point of the S-N curve from the actual scenario. Finally, the fatigue damage evolution is simulated considering the effects of pre-load pressure and welding residual stress. It is observed that laser welding induces a significant residual tensile stress, accelerating fatigue damage evolution, while compressive loading impedes fatigue damage progression.

A multi-physics simulation model has been established to investigate the influence of Laser powder bed fusion parameters on the spatial composition distribution and grain growth mechanism of the single-track printed dissimilar alloys. Our study shows that alloy composition gradient isosurfaces can be used to visualize the spatial distribution of alloy composition for miscible dissimilar alloys. When the melt pool aspect ratio changes from large to small, the grain growth transitions from the temperature gradient mode to composition gradient mode and then to the mixed mode. Our experimental observations show that in extreme cases, the curved grain angle can reach 272°.

For the sake of realizing the safety detection of natural gas and petroleum pipeline welds, this paper designs a ferromagnetic pipeline weld magnetic flux leakage detector based on the calculation of the magnetic circuit of the detection probe, with the magnetization direction perpendicular to the traveling direction. The traditional pipeline magnetic flux leakage detection device uses a detection system mode in which the magnetization direction is parallel to the direction of travel. However, due to the structural characteristics of the weld, the traditional detection system mode is not applicable. Since the weld magnetic flux leakage detector needs to travel along the direction of the weld, the detector designed in this paper rotates the magnetizer 90 degrees along the direction of the weld seam so that the magnetization direction is perpendicular to the direction of travel, breaking through the technical barrier that make traditional magnetic flux leakage detection devices unsuitable for weld detection. The detection device includes a magnetizing structure, a data sampling device, and a driving and traveling device. The magnetic flux leakage signal collected by the detector is converted into a digital image in the form of a grayscale matrix. Using mathematical morphology and chain code algorithms in image processing technology, a pipeline weld defect inversion software system is developed, and a preliminary quantitative analysis of pipeline weld defects is achieved. The application of this technology enables the inspection and protection of oil and gas pipeline welds throughout their life cycle, broadens the scope of existing inspection objects, and is of great safety significance for ensuring national public security.

In this study, CoCrMo cuboid samples were deposited on a CuZrCr substrate using laser powder bed fusion (L-PBF) technology to investigate the influence of process parameters and laser remelting strategies on the mechanical properties and interface characteristics of multi-metals. This study found that process parameters and laser scanning strategies had a significant influence on the mechanical properties and interface characteristics. Samples fabricated with an EV ≤ 20 J/mm3 showed little tensile ductility. As the volumetric energy density (EV) increased to a range between 40 J/mm3 and 100 J/mm3, the samples achieved the desired mechanical properties, with a strong interface combining the alloys. However, an excessive energy density could result in cracks due to thermal stress. Laser remelting significantly improved the interface properties, especially when the EV was below 40 J/mm3. Variances in the EV showed little influence on the hardness at the CuZrCr end, while the hardness at the interface and the CoCrMo end showed an increasing and decreasing trend with an increase in the EV, respectively. Interface characterization showed that when the EV was greater than 43 J/mm3, the main defects in the L-PBF CoCrMo samples were thermal cracks, which gradually changed to pores with a lack of fusion when the EV decreased. This study provides theoretical and technical support for the manufacturing of multi-metal parts using L-PBF technology.

Track irregularities directly affect the quality and safety of railway vehicle operations. Quantitative detection and real-time monitoring of track irregularities are of great importance. However, due to the frequent variable vehicle speed, vehicle operation is a typical non-stationary process. The traditional signal analysis methods are unsuitable for non-stationary processes, making the quantitative detection of the wavelength and amplitude of track irregularities difficult. To solve the above problems, this paper proposes a quantitative detection method of track irregularities under non-stationary conditions with variable vehicle speed by order tracking analysis for the first time. Firstly, a simplified wheel–rail dynamic model is established to derive the quantitative relationship between the axle-box vertical vibration and the track vertical irregularities. Secondly, the Simpson double integration method is proposed to calculate the axle-box vertical displacement based on the axle-box vertical acceleration, and the process error is optimized. Thirdly, based on the order tracking analysis theory, the angular domain resampling is performed on the axle-box vertical displacement time-domain signal in combination with the wheel rotation speed signals, and the quantitative detection of the track irregularities is achieved. Finally, the proposed method is validated based on simulation and field test analysis cases. We provide theoretical support and method reference for the quantitative detection method of track irregularities.

Additive manufacturing (AM) offers the advantages of direct near-net-shape production, reduced material waste, and shortened production lead time, showing great potential to revolutionise the manufacturing industry. The flexible movements of the deposition head and the build platform allow directed energy deposition (DED) to conduct the repair process of damaged high-value metallic parts. However, the resulting heterogeneous microstructure and its effect on the mechanical properties of the repaired parts have not been widely realised. In this work, the repair of Monel alloy parts, known for their excellent mechanical properties and high corrosion resistance, was conducted by the laser-DED process with low and high laser power settings, respectively. Different from the fine, equiaxed grains in the original part, the as-deposited Monel alloy consists of large columnar grains. The mechanical performance across the interface between the original and newly deposited material was tested and analysed along horizontal and vertical loading directions. The yield strength and elongation of repaired Monel alloy parts were 409.1 MPa and 35.2% along the horizontal loading direction, which both significantly surpass the corresponding values along the vertical loading direction. This study lays the groundwork for designing a laser-DED process to achieve high performance for repaired metallic parts.

Experiments on Laser powder bed fusion (LPBF) of powdered Ti on Al2O3 substrate were conducted and the interface formation was studied using a multi-material fluid dynamics model. Results show that the melt pool is relatively shallow, with relatively flat interlayer interface under LPBF’s conduction mode. In this condition, a thin sheath of molten Al2O3 forms and acts as a lubricating film for the molten Ti, leading to Rayleigh instability due to high flow inertia. Keyhole formation penetrates the Al2O3 substrate, resulting in a wavy interlayer interface. The recoil pressure from the keyhole and overall melt inertia are suppressed by the highly viscous molten Al2O3, thereby improving single-track melt pool stability. However, the thermal expansion coefficient difference between Ti and Al2O3 led to the formation of transverse cracks. Achieving a defect-free metal-on-ceramic single track remains a challenge, despite this study serving as a guide for melt track and interface control.

ABSTRACTFlexoelectric effect can be used to design actuators to control engineering structures including beams, plates, and shells. Multiple flexoelectric actuators method has the advantage of less stress concentration and better control effect, but the mode-dependent optimal actuator locations could influence the flexoelectric actuation effect significantly. In this work, a neural network model is established to study the optimal combinations of multiple flexoelectric actuators on a rectangular plate. In the physical model, an atomic force microscope (AFM) probe was employed to generate an electric field gradient in the flexoelectric patch, so that flexoelectric control force and moment can be obtained. Multiple flexoelectric actuators on the plate was considered. Case studies showed that the flexoelectricity induced stress mainly concentrate near the probe, the size and shape of the flexoelectric patch have limited effect on the actuation, hence, only the actuator positions were choosing as the input of the ANN model. Using the prediction of the neural network model, the driving effect of a large number of actuators at different positions can be quickly obtained, and the optimal position of the actuator can be analyzed more accurately.

The nuclear and petrochemical industries often require multi-metal parts that are corrosion-resistant, heat-resistant, and possess high strength to enhance equipment safety and reduce downtime. Additive manufacturing technology enables the rapid and flexible processing of multi-metal parts to meet these stringent demands. This study is aimed at investigating the interface hardness between CoCrMo/IN625 to determine optimal processing parameters that can be utilized in manufacturing reliable and durable multi-metal parts. The result indicates that when the volumetric energy density, Ev, is at or below 20 J/mm3, microfluidic forces are unable to sufficiently diffuse between the two metals, leading to insufficient diffusion, and the high hardness CoCrMo acts as a support, resulting in a significantly higher interface hardness. As Ev increases, intense recoil pressure within the microfluidic forces disrupts the melt pool, allowing for full diffusion between the two metals. The fully diffused high-hardness CoCrMo has been diluted by the low-hardness IN625, thus reducing the interface hardness. Considering the interface hardness, strength, and printing efficiency (time and energy consumption), we recommend a range of 35 J/mm3 < Ev ≤ 75 J/mm3. In this range, the average values for interface hardness and tensile strength of the samples are approximately 382 HV and 903 MPa, respectively.

In recent years, construction engineering technology has been developing rapidly, and the application of curtain walls inside modern buildings is also increasing. However, with the increasing number of curtain wall orders, most factories are facing challenges in the market due to low productivity caused by a low balance rate of curtain wall production lines. This paper is useful in improving the balance rate of the curtain wall production line; firstly, we use the improved genetic algorithm to obtain the optimal sequencing scheme of the curtain wall production line. Then, the optimization plan is validated through FLEXSIM simulation, and the results show that the device utilization rate of each workstation reaches 80%. Finally, this paper designs an intelligent production factory for curtain walls, and then builds an intelligent production line for curtain wall columns for experiments. The experimental results show that the workstation operation time has been reduced from 360 s to 300 s; the production line balance rate has increased from 57.04% to 91.60%. Therefore, it can be concluded that the modified genetic algorithm is valid in improving the balance rate of curtain wall production lines and raising the production efficiency of enterprises.

In order to study the internal flow characteristics of the electric submersible pump (ESP) when the gas–liquid two-phase flow is conveyed by the variable frequency variable speed operation and the change of the imported gas content, the impeller of the Q10# ESP is taken as the research object, based on the Eulerian-Eulerian non-homogeneous phase. The flow model, the unsteady Reynolds time-averaged N-S equation, and the standard k-ε turbulence model are used for transient simulation calculations of the gas–liquid two-phase flow in the impeller of the ESP. Calculations show that with the rotation of the impeller, the gas phase is unevenly distributed in the flow channel. The gas phase is mainly concentrated on the inlet side of the flow channel near the front cover, and the gas phase exhibits periodic aggregation and diffusion in the flow channel. When the impeller speed increases, the period of periodic accumulation and diffusion of gas in the flow channel is shortened and the gas concentration in the impeller decreases, the overall flow velocity in the flow channel increases, and the pressure difference between the inlet and outlet increases. The pressure difference between the two sides of the blade is proportional to the speed of the impeller, and the fluctuation frequency of the blade surface also increases. As the gas content increases, the maximum concentration of gas phase in the flow channel increases. The area occupied by the high concentration of gas phase in the flow channel expands toward the blade’s working surface, and periodically accumulates, diffuses, and grows. The gas-liquid splitting area shrinks toward the front cover side and the pump. The internal pressure increases slightly, the main flow velocity increases, and the vortex action range increases.

This study aims to resolve the problems of low precision, poor flexibility and unstable operation in the control performance of loading robots with long telescopic booms and heavy loads. Firstly, the kinematics and dynamics of long-arm heavy-duty robots are analyzed, and the dynamics model of a long-arm heavy-duty robot is established using the Lagrange method. A new power-hybrid sliding-mode approach law is proposed, and a hybrid force/position control strategy is used to control long-arm heavy-duty robots. The position control of long-arm heavy-duty robots uses a new sliding-mode adaptive control to improve the position accuracy of important joints, and PD control is used to force control the other joints. The two-stage telescopic arm is flexible and the long-arm heavy-load robot is simulated. The simulation results show that the long-arm heavy-load robot obtained using the improved sliding-mode adaptive control algorithm has good track-tracking and jitter-suppression effects. The new power-hybrid sliding-mode controller designed in this paper reduces the jitter amplitude of the end-effector of long-arm heavy-duty robots by 28.75%, 10.92% and 16.22%, respectively, compared with the existing new approach law sliding-mode controller. The simulation results show that the proposed power-hybrid reaching law sliding-mode controller can effectively reduce the amplitude difference of the end-effector. Finally, the force/position control strategy is combined with force-based impedance control, and the design process of impedance controller parameters is introduced, which provides a reference for the trajectory-tracking and vibration-suppression of end-effectors of long-arm heavy-duty robots.

Thin-walled structures have problems such as low stiffness, large deflection, and vibration. The layout of rib reinforcement in thin-walled structures plays a vital role in providing structural strength and rigidity and reducing structural weight. A multi-scale bionic topology optimization method with a cyclic variable load is proposed in this paper to optimize dynamic flexibility by simulating the growth law of leaf vein formation and distribution. A material interpolation method is adopted to penalize the material attributes of rib reinforcement according to their thickness, based on polynomial interpolation. Combined with the layout of rib reinforcement and SIMP, the mathematical model of rib reinforcement layout optimization with cyclic variable loading is proposed, and the sensitivity of thin-walled dynamic flexibility to the rib reinforcement thickness is analyzed. Two typical examples of thin-walled structures are presented to validate the proposed method. Considering the impact effect of multi-scale cyclic loads such as wind speed, pressure, and raindrops acting on the leaf vein, the natural frequencies of bionic topological structures of heart-shaped and elliptical leaf veins are increased by 63.44% and 47.2%, respectively. Considering the change in radial thickness, the mass of the automotive door inner panel with a bionic topological structure increased by 3.2%, the maximum stress value was reduced by 1.4% and 36.8%, and deformation was reduced by 37.6% and 27.1% under the anti-concave and sinking conditions, respectively. Moreover, the first-order natural frequency of the automotive door’s inner panel with a bionic topological structure increased to 30.45%, 3.7% higher than the original.

In pipelines for transporting oil and gas, multiple cracks often exist in weld joints. The interaction among the cracks should be considered as it directly affects the life span of the pipeline structures. In the current investigation, based on the fluid–solid magnetic coupling model, the virtual crack-closure technique (VCCT) is applied to systematically study the multi-crack dynamic interaction effect on pipeline welds during the crack propagation process. The results show that the existence of an auxiliary crack accelerates the main crack’s propagation. When the auxiliary crack is nearer to the main crack tip, the enhancement effect of the auxiliary crack on the main crack increases. Further, when the initial length of the auxiliary crack increases, the main crack becomes easier to propagate. Two important parameters, the distance between the two interacting crack tips and the initial size of the auxiliary crack, are studied in detail. Their interference effect on the main crack has been quantified, which is very user-friendly for engineers to conduct failure assessment and prevention for oil and gas pipes with multiple cracks at weld joints.

Fluctuated loadings from currents, waves and sea ground motions are observed on offshore steel pipelines, and they will result in small cracks to propagate continuously and cause unexpected damage to offshore/geotechnical infrastructures. In spite of the availability of efficient techniques and high-power computers for solving crack problems, investigations on the fatigue life of offshore pipelines with 3D interacting cracks are still rarely found in open literature. In the current study, systematic numerical investigations are performed on fatigue crack growth behaviours of offshore pipelines containing coplanar and non-coplanar cracks. Extended finite element method (XFEM) is adopted to simulate the fatigue crack growth. The qualitative validations of numerical results are made for certain cases with available experimental results. Parametric studies are conducted to investigate the influences of various important parameters on fatigue crack growth. The results will be helpful to assess the fatigue behaviours of steel pipeline with 3D interacting cracks. [ABSTRACT FROM AUTHOR]

Multiple cracks can be observed in many of engineering structures such as pressure vessels and pipelines. Under continuous loading conditions, these small and closely distanced multiple cracks can grow and coalesce into a large one. Subsequently, it will pose a serious challenge to the integrity and safety of the engineering structures. Although a lot of research works were carried out for predicting fatigue growth of multiple cracks, few literatures focusing on nonlinear elastic-plastic analysis of multiple cracks' fracture behaviors can be referred to. Therefore, to understand the influence of multiple cracks on integrity and safety of offshore pipelines is indeed desirable in engineering practice. In this study the systematic analyses on the fracture behaviors of two collinear 3-D cracks are performed for the pipelines subjected to a series of the loading conditions. A parametric study on the effect of different separation distances of the two interacting collinear cracks is performed. Based on the numerical results, the interaction factor is introduced to quantify the interaction of the two interacting cracks, and the proposed function for interaction factor can be useful for the preliminary fracture assessment of the surface crack affected by the interactions. Moreover, for biaxial loadings, the results indicate that the most severe fracture response can be produced by the tension load combined with high internal pressure. [ABSTRACT FROM AUTHOR]

A new framework of non-local model for the strain energy density is proposed in this paper. The global strain energy density of the representative volume element is treated as a non-local variable and can be obtained through a special integral of the local strain energy density. The local strain energy density is assumed to be dependent on both the strain and the rotation-gradient. As a result of the non-local model, a new strain gradient theory is derived directly, in which the first and second strain gradients, as well as the triadic and tetradic stress, are introduced in the context of work conjugate. For power law hardening materials, size effects in thin metallic wire torsion and ultra-thin cantilever beam bend are investigated. It is found that the result predicted by the theoretical model is well consistent with the experimental data for the thin wire torsion. On the other hand, the calculation result for the micro-cantilever beam bend clearly shows the size effect. [ABSTRACT FROM AUTHOR]