Search Results (230)

Recent studies have demonstrated that the utilisation of aluminium in electrical applications has increased substantially, particularly in the context of power cables. The substitution of copper with aluminium in cable fabrication is predominantly driven by economic considerations. When designing such cables, it is imperative to ascertain their functional properties, including their electrical conductivity and mechanical properties, and their operational properties, which include rheological, thermal, and material fatigue resistance. This is to ensure that the aluminium and copper cables are compatible. The primary challenge confronting researchers in this domain pertains to predicting and forecasting the failure of overhead cables during their operational lifecycle. One of the most significant and prevalent operational hazards is fatigue damage. This article presents the experimental results of fatigue tests on single Al and Cu wires in various states of mechanical reinforcement. The parameters of the Wöhler curve were determined, and a comparative analysis of the morphology of fatigue damage in single copper and aluminium wires was performed. It was found that copper wires are more fatigue-resistant than aluminium wires. In the case of high-cycle fatigue, this difference can amount to 10⁶ cycles. An analysis of fatigue fracture morphology showed that fractures have a developed surface and that plastic deformation makes a significant contribution in the case of low-cycle fatigue. In the case of high-cycle fatigue, many cracks were observed in the copper wires. No such cracks were observed in the aluminium wires. Full article

Thousands of coastal reinforced concrete structures using HRB400 bars have served for over three decades in China. Their reinforcement simultaneously endures chloride corrosion and seismic action, yet studies on performance degradation remain limited. This paper investigates the low-cycle fatigue (LCF) behavior of HRB400 bars under various strain amplitudes, systematically analyzing corrosion morphology, cyclic stress–strain response, fatigue life, and underlying mechanisms. Corrosion is induced by an adjusted accelerated method that replicates field conditions. Observations reveal that corrosion pits act as primary crack initiation sites. Crack paths and fracture surfaces progressively follow the local pit geometry as strain and corrosion grow. The detrimental effect of corrosion on LCF life is more pronounced for smaller bars. At a γ of around 8%, 20 mm bars lose 60.7% of the half cycles to failure at ε = ±1.5%, but only 37.5% at ε = ±5.0%. Predictive corrosion-inclusive strain amplitude (ε_a)–fatigue life models are proposed, yielding R² = 0.952 (16 mm) and 0.928 (20 mm). A unified LCF predictive model, calibrated on a database of 310 corroded/uncorroded bar tests, is established. The final model comprehensively considers the characteristics of rebars, seismic action, and corrosion damage, improving the conventional relationship between LCF life and seismic loading. This work contributes to the understanding of the fatigue behavior of HRB400 bars and provides support for time-dependent seismic reliability analysis of aging reinforced concrete structures in corrosive environments. Full article

The development of sustainable and energy-efficient asphalt pavements is essential to address the growing demand for climate-neutral transportation infrastructure. This study investigates the structural design and functional performance of low rolling resistance asphalt mixtures utilizing reclaimed asphalt pavement (RAP) and warm mix asphalt (WMA) technologies. Ten mixtures with WMA additive—including asphalt concrete (AC) and stone mastic asphalt (SMA) with and without RAP—were evaluated for volumetric and mechanical performance. Laboratory results show that RAP addition did not compromise compaction nor indirect tensile strength ratio (ITSR), and in some cases improved these properties. SMA and SMA RAP-modified mixtures achieved the highest resistance to rutting (as low as 5.0% rut depth), while AC and SMA mixtures both demonstrated low rolling resistance (coefficients of energy loss 0.00604–0.00636). Resistance to low-temperature cracking was strong for all mixtures, with thermal stress restrained specimen test (TSRST) fracture temperatures ranging from −32.8 °C to −36.0 °C. SMA mixtures generally exhibited superior resistance to fatigue (up to 63 με at 1 million cycles). Overall, three asphalt mixtures with different particle size distribution containing 14% RAP and a WMA additive (SMA 8 S_1 R, SMA 8 S_3 R, and AC 11 VS_2 R) demonstrated the best balance of rolling resistance, durability, and circularity, and are recommended for field trials to support climate-neutral and sustainable road infrastructure. These results encourage broader adoption of circular practices in road infrastructure projects, contributing to lower emissions and life-cycle costs. Full article

The mechanical and structural design of railway vehicles is heavily influenced by their lifetime. Because fatigue is a significant factor that impacts the longevity of railway components, it is imperative that the fatigue resistance properties of crucial components, like leaf springs, be thoroughly investigated. This research investigates the fatigue resistance of 51CrV4 steel under bending and axial tension, considering different stress ratios across low-cycle fatigue (LCF), high-cycle fatigue (HCF), and very-high-cycle fatigue (VHCF) regimes, using experimental data collected from this work and prior research. Data included fractographic analyses aiming to help in understanding some of failures for different loads. The presence of geometric discontinuities, such as notches, amplifies stress concentrations, requiring a probabilistic approach to fatigue assessment. To address notch effects, the theory of critical distances (TCD) was employed to evaluate fatigue strength. TCD model was integrated in fatigue statistical models, such as the Walker model (WSN) and the Castillo–Fernández-Cantelli model adapted for mean stress effects (ACFC). Extending the application of the TCD theory, this research provides an improved probabilistic fatigue model that integrates notch sensitivity, mean stress effects, and fatigue regimes, contributing to more reliable design approaches of railway leaf springs or other components produced in 51CrV4 steel. Full article

Fatigue damage failure is a process where the mechanical properties of different materials continuously degrade under the action of cyclic loads. The cumulative analysis of fatigue damage has a significant impact on the service structure of major equipment. This paper starts from the mechanism of fatigue damage evolution, comprehensively considers the influence of the order of high-low cycle load mixed cyclic loading on the fatigue life performance, and based on the Manson-Halford nonlinear fatigue damage accumulation theory and the mechanism of relative cumulative damage, a new nonlinear damage accumulation fatigue life model is established, and a fatigue damage accumulation influencing factor D_cr is introduced to improve the prediction accuracy of the model. The new model proposed in this paper is verified through multi-level fatigue load data. By comparing the prediction results with other models under the same experimental conditions, the fatigue life prediction error precision of the new model is the best in similar cases, generally with an error precision between 10% and 20%, which proves the effectiveness and accuracy of the nonlinear damage accumulation model proposed in this paper. At the same time, the improved method in this paper has better stability while ensuring prediction accuracy. Full article

Damaged material invariably exhibits a lower resonance frequency than undamaged material due to its reduced stiffness. Under fatigue loading, damage accumulates until failure, so changes in resonance frequency can be utilised as a variable to predict fatigue life. Conventional fatigue life prediction methods have a low success rate, prompting the exploration of alternative approaches. We have presented a novel method for predicting the fatigue life of spruce wood based on changes in resonance frequency during fatigue, using a representative specimen (i.e., one out of five specimens tested, with four used for static strength reference). We conducted a low-cycle fatigue test and monitored the resonance frequency alongside the dynamic and static modulus of elasticity. All three types of data were employed to predict fatigue life using between 40% and 100% of the measurement data. Of the two fatigue life prediction methods investigated, the Weibull cycle density distribution using resonance frequency measurements proved most appropriate. The error decreases monotonically with the amount of resonance frequency measurement data used for fatigue life prediction, reaching its lowest value of 1% when the full resonance frequency dataset is used. The proposed fatigue life prediction method should be further validated with a larger sample size, as fatigue is inherently a statistical phenomenon. Full article

This study addresses the selection and application of composite materials for aerospace systems operating in extreme environmental conditions, with a particular focus on high-altitude pseudo-satellites (HAPS). This research is centered on the development of a 400 kg autonomous aerial vehicle (AAV) capable of sustained operations at altitudes of up to 30 km. KMU-3’s microstructure, comprising high-modulus carbon fibers (5–7 µm diameter) in a 5-211B epoxy matrix, provides a high specific strength (1000–2500 MPa), low density (1.6–1.8 g/cm³), and thermal stability (−60 °C to +600 °C), ensuring structural integrity in stratospheric conditions. The mechanical, thermal, and aerodynamic properties of KMU-3-based truss structures were evaluated using finite element method (FEM) simulations, computational fluid dynamics (CFD) analysis, and experimental prototyping. The results indicate that ultra-thin KMU-3 with a wall thickness of 0.1 mm maintains structural integrity under dynamic loads while minimizing overall mass. A novel thermal bonding technique employing 5-211B epoxy resin was developed, resulting in joints with a shear strength of 40 MPa and fatigue life exceeding 10⁶ cycles at 50% load. The material properties remained stable across the operational temperature range of −60 °C to +80 °C. An optimized fiber orientation (0°/90° for longerons and ±45° for diagonals) enhanced the resistance to axial, shear, and torsional stresses, while the epoxy matrix ensures radiation resistance. Finite element method (FEM) and computational fluid dynamics (CFD) analyses, validated by prototyping, confirm the performance of ultra-thin (0.1 mm) truss structures, achieving a lightweight (45 kg) design. These findings provide a validated, lightweight framework for next-generation HAPS, supporting extended mission durations under harsh stratospheric conditions. 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

This work presents an innovative hydrothermal approach for fabricating flexible piezoelectric PZT thin films on 20 μm titanium foil substrates using TiO₂ and SrTiO₃ (STO) interlayers. Three heterostructures (Ti/PZT, Ti/TiO₂/PZT, and Ti/TiO₂/STO/PZT) were synthesized to enable low-temperature growth and improve ferroelectric performance for advanced flexible MEMS. Characterizations including XRD, PFM, and P–E loop analysis evaluated crystallinity, piezoelectric coefficient d₃₃, and polarization behavior. The results demonstrate that the multilayered Ti/TiO₂/STO/PZT structure significantly enhances performance. XRD confirmed the STO buffer layer effectively reduces lattice mismatch with PZT to ~0.76%, promoting stable morphotropic phase boundary (MPB) composition formation. This optimized film exhibited superior piezoelectric and ferroelectric properties, with a high d₃₃ of 113.42 pm/V, representing an ~8.65% increase over unbuffered Ti/PZT samples, and displayed more uniform domain behavior in PFM imaging. Impedance spectroscopy showed the lowest minimum impedance of 8.96 Ω at 10.19 MHz, indicating strong electromechanical coupling. Furthermore, I–V measurements demonstrated significantly suppressed leakage currents in the STO-buffered samples, with current levels ranging from 10⁻¹² A to 10⁻⁹ A over ±3 V. This structure also showed excellent fatigue endurance through one million electrical cycles, confirming its mechanical and electrical stability. These findings highlight the potential of this hydrothermally engineered flexible heterostructure for high-performance actuators and sensors in advanced MEMS applications. 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

High-speed trains have revolutionized modern transportation with their exceptional speeds, yet the essence of this technological breakthrough resides in the train’s wheels. These components are engineered to endure extreme mechanical stresses while ensuring high safety and reliability. In this paper, we selected the rim and web as representative components of the wheel and conducted a comprehensive and systematic study on their microstructure and mechanical properties. The wheels are typically produced through integral forging. To improve the mechanical performance of the wheel/rail contact surface (i.e., the tread), the rim is subjected to surface quenching or other heat treatments. This endows the rim with strength and hardness second only to the tread and lowers its ductility. This results in a more isotropic structure with improved fatigue resistance in low-cycle and high-cycle regimes under rotating bending. The web connects the wheel axle to the rim and retains the microstructure formed during the forging process. Its strength is lower than that of the rim, while its ductility is slightly better. The web satisfies current property standards, although the microstructure suggests further optimization may be achievable through heat treatment refinement. Full article

Multi-laser processing is increasingly adopted in laser powder bed fusion (L-PBF) to improve productivity and enable the fabrication of larger components, but its impact on part quality and performance remains a critical concern. This study investigates the microstructure, tensile properties, and fatigue performance of components fabricated by L-PBF using single- and multiple-laser configurations. Both strategies were evaluated under varying layer thicknesses and gas flow conditions with optimized process parameters. Microstructural analysis revealed defects such as lack-of-fusion, porosity and microcracks in multiple-laser builds with reduced gas flow. However, the density and microhardness results showed negligible differences between single and multiple-laser builds. Tensile testing indicated that single-laser builds exhibited superior strength and ductility, whereas multiple-laser builds demonstrated reduced performance due to localized defects such as lack-of-fusion and microcracks. Low-cycle fatigue testing results showed that optimized multiple-laser strategies could achieve performance comparable to that of single-laser builds while improving productivity. The results also revealed that the gas flow becomes more pronounced with multiple-laser processing, where more spatter is generated due to the interactions of the lasers in a small scan area, and that reduced gas flow leads to fatigue degradation due to increased defect density. The results from this study clearly highlight the importance of gas flow, laser overlap, border optimization, and defect mitigation strategies in producing multiple-laser produced components with mechanical properties and fatigue performance comparable to those of single-laser produced L-PBF components. Full article

The application of additive manufacturing technology in the field of nuclear power is becoming increasingly promising. The low-cycle fatigue behavior of Z2CN19-10 controlled-nitrogen-content stainless steel (SS) was investigated by fatigue equipment, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and transmission electron microscopy (TEM), including additive manufactured (AM) and forged materials. The results showed that the microstructure of the AM material exhibited anisotropy for the X, Y, and Z directions. The tensile and impact properties of the X, Y, and Z directions in AM material were similar. The fatigue life (N_f) of X- and Y-direction specimens was better than that of Z-direction specimens. The tensile, impact, and fatigue properties of all AM materials were lower than those of the forged specimens. The Z direction specimens of AM material showed the best plastic strain by the highest transition fatigue life (N_T) during the fatigue strain amplitude at 0.3% to 0.6%. The forged specimens showed the best fatigue properties under the plastic strain amplitude control mode. Fatigue fracture surfaces of AM and forged materials exhibited multi- and single-fatigue crack initiation sites, respectively. This could be attributed to the presence of incompletely melted particles and manufacturing defects inside the AM specimens. The dislocation morphology of AM and forged fatigue specimens was observed to study the low-cycle fatigue behaviors in depth. Full article

In the global energy sector, water-bearing reservoir-typed gas storage accounts for about 30% of underground gas storage (UGS) reservoirs and is vital for natural gas storage, balancing gas consumption, and ensuring energy supply stability. However, when constructing the UGS in the M gas reservoir, selecting suitable areas poses a challenge due to the complicated gas–water distribution in the multi-layered water-bearing gas reservoir with a long production history. To address this issue and enhance energy storage efficiency, this study presents an integrated geomechanical-hydraulic assessment framework for choosing optimal UGS construction horizons in multi-layered water-bearing gas reservoirs. The horizons and sub-layers of the gas reservoir have been quantitatively assessed to filter out the favorable areas, considering both aspects of geological characteristics and production dynamics. Geologically, caprock-sealing capacity was assessed via rock properties, Shale Gouge Ratio (SGR), and transect breakthrough pressure. Dynamically, water invasion characteristics and the water–gas distribution pattern were analyzed. Based on both geological and dynamic assessment results, the favorable layers for UGS construction were selected. Then, a compositional numerical model was established to digitally simulate and validate the feasibility of constructing and operating the M UGS in the target layers. The results indicated the following: (1) The selected area has an SGR greater than 50%, and the caprock has a continuous lateral distribution with a thickness range from 53 to 78 m and a permeability of less than 0.05 mD. Within the operational pressure ranging from 8 MPa to 12.8 MPa, the mechanical properties of the caprock shale had no obvious changes after 1000 fatigue cycles, which demonstrated the good sealing capacity of the caprock. (2) The main water-producing formations were identified, and the sub-layers with inactive edge water and low levels of water intrusion were selected. After the comprehensive analysis, the I-2 and I-6 sub-layer in the M 8 block and M 14 block were selected as the target layers. The numerical simulation results indicated an effective working gas volume of 263 million cubic meters, demonstrating the significant potential of these layers for UGS construction and their positive impact on energy storage capacity and supply stability. Full article

Polymer blending techniques enable the tailoring of desired properties for diverse applications. This study investigates the effect of PMMA content on the thermomechanical, chemical, mechanical, and fatigue life properties of PC/ABS/PMMA (polycarbonate/acrylonitrile–butadiene–styrene/polymethylmethacrylate) ternary blends. To this end, various characterization analyses, as well as tensile, impact, and fatigue tests, were conducted. The results indicate that the viscoelastic modulus improves with increasing PMMA content in ternary blends. Furthermore, PC/ABS/PMMA blends exhibit an immiscible phase morphology. The elastic modulus, yield strength, and tensile strength increase with higher PMMA content, while the elongation at break and impact strength decrease. Fatigue strength and the fatigue strength exponent were found to vary nonlinearly with PMMA content. Compared to PC/ABS blends, PC/ABS/PMMA blends demonstrated improvements of approximately 12% to 58% and 26% to 117% in hysteresis energy and the dynamic elastic modulus, respectively. Additionally, fatigue life cycles improved by 5% to 11% at low stress amplitudes. This experimental study provides comprehensive insight into the complex interplay among the chemical, thermomechanical, mechanical, and fatigue properties of ternary PC/ABS/PMMA blends, highlighting their potential for applications requiring balanced or tailored structural and material characteristics. Full article