Search Results (528)

Despite being designed considering infinite fatigue-life, failures of motor crankshafts forged from DIN 34CrNiMo6 steels have been reported in Brazilian power plants. As such, the present work aims to discuss the failure of a crankshaft within this context, with the purpose of verifying whether the stresses developed in critical locations of the component were in accordance with the steel’s fatigue limits, as well as if the material exhibits an adequate resistance to crack propagation. Taking into consideration a set of critical-plane stress-based multiaxial fatigue criteria, namely Findley, Matake, McDiarmid and Susmel and Lazzarin, the fatigue behaviour of the material is analysed and discussed. Furthermore, $da/dN$ versus $\mathsf{\Delta }K$ experiments were carried out with the purpose of determining the DIN 34CrNiMo6 steel’s crack growth threshold $\mathsf{\Delta }{K}_{th}$ and comparing it to the $\mathsf{\Delta }{K}_{th}$ of three other commercially available steels (DIN 42CrMo4, SAE 4140 and SAE 4340). The selected multiaxial fatigue criteria indicated that the stresses developed throughout the component were not sufficient to drive the crankshaft to failure, thus indicating safety. On the other hand, the DIN 34CrNiMo6 steel presented the lowest $\mathsf{\Delta }{K}_{th}$ ($6.6\mathrm{M}\mathrm{P}\mathrm{a}{\mathrm{m}}^{1/2}$) among all the considered steels ($10.86$, $12.38$ and $7.22\mathrm{M}\mathrm{P}\mathrm{a}{\mathrm{m}}^{1/2}$ for the DIN 42CrMo4, SAE 4140 and SAE 4340, respectively), therefore being susceptible to shorter fatigue lives in comparison to the other materials. Full article

The growing use of weathering steel in bridge engineering has highlighted the increasing impact of fatigue damage caused by the combined effects of welding residual stress and vehicular loading. This study investigates the fatigue performance of Q500qENH weathering steel bridge decks by proposing a coupled analysis method for residual stress and fatigue crack growth, utilizing collaborative simulations with Abaqus 2023 and Franc3D 7.0. An interaction model integrating welding-induced residual stress fields and dynamic vehicular loads is developed to systematically examine crack propagation patterns in critical regions, including the weld toes of the top plate and the weld seams of the U-ribs. The results indicate that the crack propagation rate at the top plate weld toe exhibits the most rapid progression, reaching the critical dimension (two-thirds of plate thickness) at 6.98 million cycles, establishing this location as the most vulnerable failure point. Residual stresses significantly amplify the stress amplitude under tension–compression cyclic loading, with life degradation effects showing 48.9% greater severity compared to pure tensile stress conditions. Furthermore, parametric analysis demonstrates that increasing the top plate thickness to 16 mm effectively retards crack propagation, while wheel load pressures exceeding 1.0 MPa induce nonlinear acceleration of life deterioration. Based on these findings, engineering countermeasures including welding defect control, optimized top plate thickness (≥16 mm), and wheel load pressure limitation (≤1.0 MPa) are proposed, providing theoretical support for fatigue-resistant design and maintenance of weathering steel bridge decks. Full article

Taking a typical carburized alloy steel for heavy-duty gears as the research object, this work regulates carburizing–quenching and tempering processes to conduct a layer-by-layer analysis of gradient-distributed microstructures and mechanical properties in the carburized layer. The effects of tempering temperature on martensite evolution, mechanical properties, and wear resistance were specifically investigated. Results demonstrate that carburizing–quenching followed by cryogenic treatment generates high-carbon martensite at the surface, progressively transitioning to lath martensite towards the core. Low-temperature tempering promotes fine carbide precipitation, while elevated temperatures cause carbide coarsening. Specimens tempered at 175 °C achieve surface hardness of 800 HV and near-surface compressive yield strength of 2940 MPa. These samples exhibit 13% lower wear mass loss compared to 240 °C tempered counterparts, demonstrating superior wear resistance characterized by relatively flat wear surfaces, uniform contact stress distribution, and reduced cross-sectional plastic deformation zones. Key strengthening mechanisms at lower tempering temperatures involve solution strengthening, dislocation strengthening, and partial precipitation strengthening from carbides. Coherent carbides formed under these conditions impede fatigue dislocation motion via shearing mechanisms to suppress plastic deformation and fatigue crack initiation under contact fatigue stress, thereby enhancing wear performance. Full article

The rising demand for aluminium and environmental concerns highlight the need for a circular economy using recycled alloys. This study examines the effect of shot peening on the high-cycle fatigue life of secondary AlZn10Si8Mg alloys with different iron contents: Alloy A (0.14 wt.% Fe) and Alloy B (0.56 wt.% Fe). Although both alloys showed similar tensile properties, Alloy B had higher porosity and finer β-Al₅FeSi intermetallics. Shot peening was applied at 100% and 1000% coverage to evaluate changes in surface roughness, porosity, residual stresses, and fatigue performance. The treatment significantly reduced surface-connected porosity via plastic deformation, enhancing fatigue life despite increased roughness. Fatigue tests showed a 21% increase in fatigue limit for Alloy A and a 6% gain for Alloy B at higher coverage. Fractographic analysis revealed that 95% of fatigue cracks initiated at surface pores. Residual stress measurements confirmed compressive stresses were limited to the near-surface layer, with minimal influence on subsurface crack propagation. Overall, shot peening proves to be an effective method for improving fatigue resistance in recycled aluminium alloys, even in alloys with elevated iron content, reinforcing their potential for structural applications under cyclic loading. Full article

The electrochemical behavior and corrosion fatigue property of the surface-strengthened EA4T axle steel subjected to foreign object damage (FOD) is investigated in this study. It is found that the corrosion resistance can be enhanced after being impacted by the foreign object due to the introduced hardening layer. Specifically, compared to the smoothed sample, the 167 m/s sample exhibited a 13.88% higher corrosion potential (E_corr) and a 67.61% lower current density (i_corr). The facture surface demonstrates that the corrosion pits on the surface are the main crack initiation location for the smoothed specimens. In contrast, for the surface-damaged specimens, cracks initiate around the crater. The foreign object impact speed has a significant influence on the corrosion fatigue strength; specifically, the faster the impact velocity, the greater the surface damage of the axle specimen, and the shorter its fatigue life at the same stress level. To address the combined influence of size effect and surface defects on fatigue performance, we constructed an improved Kitagawa–Takahashi (KT) diagram by incorporating the theoretical corrosion fatigue limit of full-scale axles with a surface damage of 270 MPa based on conditional probability density function (CPDF). Comparative analysis demonstrates that the revised KT diagram defines a narrower yet more conservative fatigue loading safety zone than the standard KT diagram. This refinement enhances reliability in practical applications where surface imperfections and scale effects dominate failure mechanisms. Full article

The article presents an analysis of the mechanical properties of S700MC steel, which represents advanced low-alloy high-strength steels. The influence of microstructure, shaped by a controlled thermo-mechanical rolling process, on the strength, ductility, and resistance to cracking and fatigue of the material is discussed. Particular attention is paid to the anisotropy of mechanical properties resulting from the orientation relative to the rolling direction, manifested by variations in yield strength, tensile strength, and total elongation of the specimens. The analysis also includes the material’s behavior under dynamic conditions, where the steel’s strength increases with the strain rate. Experimental investigations conducted using the digital image correlation (DIC) method enabled a detailed assessment of local strains and fracture characteristics of specimens subjected to both static and dynamic testing. The results showed that specimens cut along the rolling direction exhibited, on average, 6.4% higher tensile strength and 6.8% higher yield strength compared to those cut transversely. Moreover, dynamic loading led to an increase in load-bearing capacity of over 10% compared to static tests. The obtained data are highly relevant from the perspective of structural design, where the selection of material orientation and the consideration of strain rate effects are crucial for ensuring the reliability of components made from S700MC steel. Full article

This study investigated the effect of laser shock peening (LSP) treatment on the fatigue performance of Q355D steel butt-welded joints. The results demonstrate that LSP sig-nificantly enhances joint fatigue resistance through gradient hardening in surface lay-ers, introduction of high-magnitude residual compressive stress fields, and micro-structural refinement. Specifically, microhardness increased across all joint zones with gradient attenuation of strengthening effects within an approximately 700 μm depth. LSP effectively suppressed residual tensile stress concentration in regions beyond 4 mm on both sides of the weld. Fatigue tests confirmed that LSP substantially extended joint fatigue life: by 113–165% in the high-stress region (250–270 MPa) and 46–63% in the medium-low-stress region (230–240 MPa). Fractographic analysis further revealed reduced fatigue striation spacing and lower microcrack density in LSP-treated speci-mens, reflecting the synergistic effect of residual compressive stress fields and micro-structural refinement in retarding crack propagation. This work substantiates LSP as an effective method for enhancing fatigue resistance in Q355D steel welded joints. Full article

This paper presents a critical and comprehensive review of the application of mining waste, specifically waste rock and tailings, in asphalt pavements, with the aim of synthesizing performance outcomes and identifying key research gaps. A systematic literature search yielded a final dataset of 41 peer-reviewed articles for detailed analysis. Bibliometric analysis indicates a notable upward trend in annual publications, reflecting growing academic and practical interest in this field. Performance-based evaluations demonstrate that mining wastes, particularly iron and copper tailings, have the potential to enhance the high-temperature performance (i.e., rutting resistance) of asphalt binders and mixtures when utilized as fillers or aggregates. However, their effects on fatigue life, low-temperature cracking, and moisture susceptibility are inconsistent, largely influenced by the physicochemical properties and dosage of the specific waste material. Despite promising results, critical knowledge gaps remain, particularly in relation to long-term durability, comprehensive environmental and economic Life-Cycle Assessments (LCA), and the inherent variability of waste materials. This review underscores the substantial potential of mining wastes as sustainable alternatives to conventional pavement materials, while emphasizing the need for further multidisciplinary research to support their broader implementation. Full article

The study investigates the influence of microstructures on fatigue behavior and failure mechanisms of the α-β titanium alloy Ti6246, fabricated via Powder Bed Fusion-Laser Beam (PBF-LB). In particular, the investigation assesses the effect of two post-processing heat treatments, namely α-β annealing at 875 °C (AN875) and solution treatment at 825 °C followed by aging at 500 °C (STA825), on the alloy’s rotating and bending fatigue behavior. The results indicate that the STA825 condition provides superior fatigue resistance (+25%) compared to AN875, due to the presence of a finer bilamellar microstructure, characterized by thinner primary α lamellae (α_p) and a more homogeneous distribution of secondary α lamellae (α_s) within the β matrix. Additionally, an investigation conducted using the Kitagawa–Takahashi (KT) approach and the El-Haddad model, based on the relationship between the fatigue limit and defect sensitivity, revealed improved crack propagation resistance from pre-existing defects (ΔK_th) for the STA825 condition compared to AN875. Notably, the presence of fine α_s after aging for STA825 is effective in delaying crack nucleation and propagation at early stages, while refined α_p contributes to hindering macrocrack growth. The fatigue behavior of the STA825-treated Ti6246 alloy was even superior to that of the PBF-LB-processed Ti64, representing a viable alternative for the production of high-performance components in the automotive and aerospace sectors. Full article

Limited recovery of the viscoelastic properties of aged asphalt on RAP surfaces at ambient temperature reduces interface fusion and bonding with new emulsified asphalt, degrading pavement performance and limiting large-scale promotion and high-value applications of the emulsified asphalt cold recycled mixture (EACRM). Therefore, a cold regenerant was independently prepared to rapidly penetrate, soften, and activate aged asphalt at ambient temperature in this paper, and its effects on the volumetric composition, mechanical strength, and pavement performance of EACRM were systematically investigated. The results showed that as the cold regenerant content increased, the air voids, indirect tensile strength (ITS), and high-temperature deformation resistance of EACRM decreased, while the dry–wet ITS ratio, cracking resistance, and fatigue resistance increased. Considering the comprehensive pavement performance requirements of cold recycled pavements, the optimal content of the activated cold regenerant for EACRM was determined to be approximately 0.6%. Full article

Conventional asphalt is prone to cracking in cold climates due to its poor flexibility and limited ability to regulate temperature. This study investigates the use of low-temperature microencapsulated phase-change materials (MPCMs) to improve both the thermal storage and low-temperature performance of asphalt. MPCMs were incorporated into asphalt through physical blending at various concentrations. The physical, thermal, and rheological properties of the asphalt were then systematically evaluated. Tests included penetration, softening point, ductility, thermogravimetric analysis (TGA), and dynamic shear rheometer (DSR). The addition of MPCMs increased penetration and ductility. It slightly reduced the softening point and viscosity. These changes suggest improved flexibility and workability at low temperatures. Rheological tests showed reductions in rutting and fatigue factors. This indicates better resistance to thermal and mechanical stresses. Bending Beam Rheometer (BBR) results further confirmed that MPCMs lowered creep stiffness and increased the m-value. These findings demonstrate improved crack resistance under cold conditions. Thermal cycling tests also showed that MPCMs delayed the cooling process and reduced temperature fluctuations. This highlights their potential to enhance both energy efficiency and the durability of asphalt pavements in cold regions. Full article

Asphalt pavement cracking is an important factor affecting its service life. Under certain conditions, the self-healing behavior of asphalt itself can repair pavement cracks. However, the self-healing ability of asphalt itself is limited. In order to strengthen the self-healing ability of asphalt, the microcapsule wrapped with a repair agent is pre-mixed into the asphalt mixture. When the crack occurs and spreads to the surface of the microcapsule, the microcapsule ruptures and the healing agent flows out to realize the self-healing of the crack. Current microcapsules are mostly prepared with healing agents and bio-oil as core materials, and their high-temperature resistance to rutting is poor. While the epoxy resin contains a three-membered cyclic ether, it can undergo ring-opening polymerization to bond and repair the asphalt matrix. In addition, research on microcapsules mainly focuses on the self-healing properties of microcapsule-modified asphalt. In fact, before adding microcapsules to asphalt to improve its self-healing performance, it is necessary to ensure that the asphalt has a good road performance. On this basis, the self-healing performance of asphalt is improved, thereby extending the service life of asphalt pavement. Therefore, two-component epoxy self-healing microcapsules (E-mic and G-mic) were first prepared in this paper. Then, a temperature scanning test, rheological test of bending beams, and linear amplitude scanning test were, respectively, conducted for the microcapsule/asphalt to evaluate its road performance, including the high-temperature performance, low-temperature crack resistance, and fatigue performance. Finally, the self-healing performance of microcapsules/asphalt was tested. The results showed that the self-developed epoxy self-healing microcapsules were well encapsulated and presented as spherical micron-sized particles. The average particle size of the E-mic was approximately 23.582 μm, while the average particle size of the G-mic was approximately 22.440 μm, exhibiting a good normal distribution. In addition, they can remain intact and unbroken under high-temperature conditions. The results of road performance tests indicated that the microcapsule/asphalt mixture exhibits an excellent high-temperature resistance to permanent deformation, low-temperature crack resistance, and fatigue resistance. The self-healing test demonstrated that the microcapsule/asphalt exhibited an excellent self-healing performance. When the microcapsule content was 4%, the self-healing rate reached its optimal level of 67.8%, which was 149.2% higher than that of the base asphalt. Full article

The fatigue resistance of cement-stabilized macadam (CSM) plays a vital role in ensuring the long-term durability of pavement structures. However, limited cementitious material (CM) content often leads to high packing voids, which significantly compromise fatigue performance. Existing studies have rarely explored the coupled mechanism between pore structure and fatigue behavior, especially in the context of solid-waste-based CMs. In this study, a cost-effective alkali-activated sludge gasification slag (ASS) was proposed as a sustainable CM substitute for ordinary Portland cement (OPC) in CSM. A dual evaluation approach combining cross-sectional image analysis and fatigue loading tests was employed to reveal the effect pathway of void structure optimization on fatigue resistance. The results showed that ASS exhibited excellent cementitious reactivity, forming highly polymerized C-A-S-H/C-S-H gels that contributed to a denser microstructure and superior mechanical performance. At a 6% binder dosage, the void ratio of ASS–CSM was reduced to 30%, 3% lower than that of OPC–CSM. The 28-day unconfined compressive strength and compressive resilient modulus reached 5.7 MPa and 1183 MPa, representing improvements of 35.7% and 4.1% compared to those of OPC. Under cyclic loading, the ASS system achieved higher energy absorption and more uniform stress distribution, effectively suppressing fatigue crack initiation and propagation. Moreover, the production cost and carbon emissions of ASS were 249.52 CNY/t and 174.51 kg CO₂e/t—reductions of 10.9% and 76.2% relative to those of OPC, respectively. These findings demonstrate that ASS not only improves fatigue performance through pore structure refinement but also offers significant economic and environmental advantages, providing a theoretical foundation for the large-scale application of solid-waste-based binders in pavement engineering. Full article

This article presents a review on the applications of basalt fibers and their composites in infrastructures. The characteristics and advantages of high-performance basalt fibers and their composites are firstly introduced. Then, the article discusses strengthening using basalt fiber sheets and BFRP bars or grids, followed by concrete structures reinforced with BFRP bars, asphalt pavements, and cementitious composites reinforced with chopped basalt fibers in terms of mechanical behaviors and application examples. The load-bearing capacity of the strengthened structures can be increased by up to 60%, compared with those without strengthening. The lifespan of the concrete structures reinforced with BFRP can be extended by up to 50 years at least in harsh environments, which is much longer than that of ordinary reinforced concrete structures. In addition, the fatigue cracking resistance of asphalt can be increased by up to 600% with basalt fiber. The newly developed technologies including anchor bolts using BFRPs, self-sensing BFRPs, and BFRP–concrete composite structures are introduced in detail. Furthermore, suggestions are proposed for the forward-looking technologies, such as long-span bridges with BFRP cables, BFRP truss structures, BFRP with thermoplastic resin matrix, and BFRP composite piles. Full article

This study presents a numerical model for analyzing fatigue crack growth in 42CrMo4 steel pivot bolts under different heat treatments and service loads. The finite element method (FEM) in the ANSYS Workbench environment (version 2019R1) (SMART Crack Growth), along with algorithms based on Paris’s law implemented in MATLAB (version R2016a), was used. The results highlight the significant influence of heat treatment on fatigue resistance and serve as a basis for optimizing design parameters and improving the durability of the structural components. Full article