Search Results (30)

As a core load-bearing component for railway vehicles, rails are largely responsible for the safety and stability of train operation, and their service performance is inherently governed by material microstructure. In this study, rails with varied pearlite interlamellar spacing were prepared and laid on field tracks for 8 months of service testing to investigate the influence of pearlite interlamellar spacing on rail wear and rolling contact fatigue (RCF). The results indicate that decreasing pearlite interlamellar spacing facilitated tread work hardening and reduced cumulative wear loss of rails. At the early service stage, rails with coarse pearlite lamellae exhibited earlier RCF crack initiation and longer crack morphologies, while rails featuring finer pearlite lamellae exhibited the latest-occurring crack initiation. With prolonged service duration, wear loss rose continuously, and the tread hardening rate first increased sharply and then tended to gradually become stable. Obvious differences in damage evolution were observed for rails with different pearlite interlamellar spacing. Coarse-lamellar rail suffered sparse short cracks dominated by wear; fine-lamellar rail developed dense fast-growing cracks controlled by RCF; and medium-lamellar rail achieved a relatively good balance between wear and RCF. A competitive relationship exists between wear and RCF during rail service. Reasonable regulation of pearlite interlamellar spacing facilitates a balanced evolution of wear and RCF, which provides a feasible microstructural optimization strategy for improving the service performance and service life of pearlitic rails. Full article

Laser powder bed fusion (LPBF) of high-strength aluminum alloy 7075 (AA7075) is severely limited by hot cracking. However, the underlying mechanisms, particularly the coupling between thermal fields, solidification microstructure, and cracking behavior, remain insufficiently clarified. This study elucidates these mechanisms by integrating experimental characterization with thermal simulation to investigate the temperature field, microstructure, and cracking relationships in both AA7075 and a crack-resistant 7075-Er-Zr alloy. Results show that coarse hot crack morphology is highly dependent on linear energy density E_L. In AA7075, E_L < 450 J/m promotes laterally inclined cracks (short, narrow cracks extending from the melt pool boundary toward the track center), whereas E_L higher than that value leads to the continuous centerline cracks (long, wide cracks along the track center). Fine microcracks are also observed at melt pool boundaries. The 7075-Er-Zr alloy demonstrates superior crack resistance. At E_L = 600 J/m, longitudinal centerline cracks still penetrate along the track, but the alloy achieves crack-free tracks at 200 W with scanning speeds above 1000 mm/s, otherwise exhibiting only short discontinuous cracks. Microcracks at melt pool boundaries are markedly suppressed in the modified alloy. The enhanced crack resistance is attributed to Er/Zr-induced grain refinement and a transition to an equiaxed grain structure, which disrupts intergranular gaps. Critically, thermal simulations identify an annular region with a peak temperature gradient. In AA7075, this region develops aligned columnar grains that facilitate both microcracks and centerline cracks. In the 7075-Er-Zr alloy, microcracks are fully eliminated within this region. However, a residual crystallographic texture persists in the annular region, which promotes the continued occurrence of centerline cracks under high energy density (e.g., E_L = 600 J/m). The annular region remains a critical weak link, and its microstructural control determines the prevailing crack type. This work provides a fundamental understanding of the thermal-microstructural origins of cracking and offers a theoretical foundation for developing crack-resistant aluminum alloys via LPBF. Full article

Traditional enzyme-induced carbonate precipitation (EICP) technology for brick crack rehabilitation is commonly plagued by solution clogging and low repair efficiency. To overcome these technical limitations, a novel centrifugal cementation method was proposed in this study, with its core innovation lying in decoupling the EICP reaction from the masonry reinforcement process. After the complete reaction of urease with the cementation solution, a high-concentration calcium carbonate colloid was extracted via centrifugation, which was then mixed with fine sand to prepare a repair mortar for direct injection into brick cracks. The experimental results, based on a single-factor design with a fixed soybean powder concentration (180 g/L, peak urease activity), showed that the maximum flexural strength of the repaired bricks reached 2.31 MPa, recovering as much as 122.9% of that of the cracked unrepaired bricks. Furthermore, the flexural strength of the repaired bricks exhibited a significant positive correlation with the calcium carbonate content (20–100%) and curing time (3–28 days). Phase analysis indicated that the repair mortar was primarily composed of calcite and quartz. The high shear force generated by centrifugation triggered explosive nucleation of calcium carbonate, and spherical calcite particles were formed through Ostwald ripening, exhibiting a distinct characteristic of decoupling between the spherical morphology and calcite crystal phase. The centrifugal cementation method proposed in this study achieves excellent short-term repair effects for masonry structures under laboratory conditions, thus providing a novel technical approach for the crack rehabilitation of masonry structures. Full article

To address the shortage of natural sand and the unclear mechanism of lithology’s influence on the application of manufactured sand, this study explores the applicability of neutral rock manufactured sand in asphalt mixtures. Taking neutral diabase manufactured sand as the research object, a series of tests including the Marshall test, water stability test, high- and low-temperature stability test, and surface free energy (SFE) test were conducted to systematically analyze the effects of aggregate lithology on the volumetric indicators, road performance, and interface adhesion of asphalt mixtures. Additionally, the improvement effect of cement as an anti-stripping agent was verified. The results show that lithology of manufactured sand significantly regulates the performance of asphalt mixtures. In terms of volumetric indicators, the limestone manufactured sand mixture has the smallest void ratio (3.81%), while the diabase manufactured sand mixture has the largest (5.81%), requiring an appropriate increase in the mixing ratio of diabase manufactured sand to optimize the compaction effect. For water stability, the short-term performance ranks as diabase ≈ limestone > granite, and the long-term durability ranks as limestone > diabase > granite. A least-squares linear regression model demonstrated that the polar component of aggregate surface free energy exhibits a strong positive correlation with asphalt–aggregate adhesion work (R² = 0.92), which quantitatively explains variations in the 48 h immersed Marshall residual stability ratio among different lithologies. Regarding high-temperature stability, the order is diabase > limestone > granite. Thanks to its low crushing value and strong angularity, the diabase manufactured sand mixture achieves a dynamic stability of 12,629 times/mm at 60 °C, showing the best rutting resistance. In terms of low-temperature performance, the diabase manufactured sand mixture exhibits the optimal initial crack resistance (maximum flexural strain of 2757 με) and long-term durability (strain attenuation rate of 11.7% after 30 cycles), while the granite manufactured sand mixture fails to meet the design requirements. Adding 1.5%~2.0% cement can significantly improve the adhesion between manufactured sand and asphalt, with more obvious enhancement effects on granite and diabase, thereby optimizing water stability and high-temperature stability. The research results provide theoretical support and technical reference for the scientific selection and engineering application of fine aggregates in asphalt pavements. Full article

Mechanical milling is a relevant preliminary processing operation that is widely used for the reuse of various types of agro-industrial waste. The objective of this study was to conduct milling experiments of hazelnut (Corylus avellana L.) shell waste at different times (0.5, 1 and 1.5 min) and subsequently evaluate the particle size distribution (PSD) of the powders obtained by sieving methodology. In addition, flowability parameters were determined for the particles retained on the sieves, and their morphology and microstructure were examined using several microscopy techniques. The results demonstrated that the hazelnut shells were successfully fractionated under the milling conditions investigated (short milling times ≤ 1.5 min), and the histograms of the PSD exhibited a wide dispersion of sizes (≤1.7 mm). The particles retained from sieve₁₀₀ to residue exhibited poor or no flow, attributable to the high degree of cohesion between them. Morphological analysis based on optical microscopy and image analysis revealed that there was an increase in the aspect ratio parameter when the particle size decreased, meaning that the particles had elongated shapes. Microscopic analysis (SEM, AFM and CLSM) showed that the particles exhibited complex shapes and a comparable microstructure, comprising tightly packed clusters of sclerenchyma cells. From the microscopy images obtained (SEM and AFM), it was inferred that the cracks generated during blade impacts propagate along the middle lamella of the cells, allowing the cluster-like arrangement to be preserved. The CLSM results demonstrated that as the size of hazelnut shell particles decreases, the exposure of lignin on its surface is favored. The findings of this study demonstrate that hazelnut shell waste can be readily pre-processed using a blade grinder, thereby facilitating its reuse in applications that demand fine particle sizes (e.g., bioadsorption of pollutants and the production of biocomposite materials). Likewise, the results concerning the flowability parameters, microstructural arrangement, and morphological features of the different particle fractions obtained are crucial variables that must be considered. These variables significantly influence the possible applications for the revalorization of this type of agro-industrial waste. Full article

The effect of induction heating on alumina ceramics and alumina ceramic composites based on α-Al₂O₃ nanopowders (additives: SiC, Si₃N₄, SiO₂, ZrO₂) has been examined. Various factors such as the structure, grain size, distribution of elements, hardness, fracture toughness, and wear rate of hot-pressed ceramic materials were assessed. Despite achieving improved densification of alumina ceramics at a higher temperature of 1720 °C, there is a consistent trend toward a decline in hardness and fracture toughness. Heating at lower temperatures of 1300–1500 °C results in the development of a strengthened surface layer with a fine-grained structure enriched with carbon. Therefore, the wear rate behavior of such ceramics differs from the behavior of samples made at higher temperatures of 1600–1720 °C. This fact indicates the presence of a non-thermal microwave effect of induction heating. The incorporation of additives to alumina leads to the formation of novel structures with altered crack propagation patterns. The optimal ceramic composite, containing 5 wt. % SiC, displayed superior hardness and the lowest wear rate when compared to pure alumina ceramics. Across all investigated composites, a short dwell time at 1700 °C results in an enhancement of the mechanical properties. Full article

Plastic film, also known as low-density polyethylene (LDPE), poses serious environmental challenges due to mass production, short life cycle, and poor waste management. The main aim of this paper was to examine the suitability of using agricultural waste film as a binder in construction composites instead of the traditional cement slurry. Molten at temperatures of around 120–150 °C wastes was mixed with fine sand and gravel aggregate as filler. Twelve samples consisting of different mixtures were produced—F20, F25, F30, F35, F40, F45, F50, F60, F70, F80, F90, and F100—where a given number indicates the weight ratio of film waste to aggregate used. The composites were subjected to various tests, including volumetric density, compressive strength, and flexural strength. The volumetric density ($\rho$) of the composites decreased with increasing amounts of waste. Composites containing 100% recyclate (F100) depicted density, $\rho$ = 0.74 g/cm³, was 50.7% lower than for a composite that contained 20% recyclate (F20). The highest soakability was recorded in F20 (2.19%). Subsequently, the absorbency tested in composites decreased with increasing recyclate content. Compression strength (σ_comp) was highest for F40 (σ_comp = 39.46 MPa). In contrast, F20 had the lowest recorded compressive strength value (σ_comp = 11.13 MPa) and was 71.8% lower than F40. F70 had the highest recorded flexural strength value (σ_flex = 27.77 MPa). The other composites showed lower strength for higher amounts of recyclate and the amount of sand. SEM imaging proved that the contact zone between the aggregate grains and the bonding phase of the recycled film was consistent, with no anomalies, cracks, or voids. The results prove that LDPE film waste is suitable for use as a binder in building composites. However, appropriately selecting proportions of the recyclate, sand, and gravel aggregate is crucial to obtain a composite with technical parameters similar to those of cementitious composites. Full article

One of the most significant challenges for 3D printing of construction elements from cementitious materials is the control of cracking caused by various contraction–shrinkage mechanisms, such as drying, chemical, plastic and autogenous shrinkage. This study addresses the effects of incorporating fine aggregates (maximum size ≤ 1.18 mm), both natural and recycled, as well as short (6 mm long) polypropylene (PP) fibres on the control of cracking in cementitious mixtures based on Portland cement. Admixtures and/or mineral additions (modifiers), such as metakaolin, micro-silica, calcium carbonate, and fine powders obtained from construction and demolition wastes were used in the mixtures. Mini-slump, flow rate and buildability tests were used to characterize the mixtures in their fresh state. Extrudability was evaluated using laboratory-scale 3D printing tests conducted with a plunger–piston extrusion system. It was demonstrated that the physical characteristics of the aggregates directly influence the extrusion capacity. Mixtures containing natural aggregates exhibited greater fluidity and lower water demand than those containing recycled aggregates. The results indicated that the maximum allowable volume of fibres was 0.75%. To evaluate the cracking susceptibility of the mixtures, both with and without reinforcement, hollow beams composed of seven layers were printed, and subsequently the elements were exposed to the outdoor natural environment and inspected for a period of 90 days. The inclusion of the PP fibres effectively prevented the occurrence of fissures and/or cracks associated with shrinkage phenomena throughout the inspection period, unlike in unreinforced mixtures, which cracked after 14 days of exposure to the environment. Full article

The ductility and exhibition of the multiple, fine, self-controlled cracking of strain-hardening cementitious composites (SHCCs) under tension has made them attractive for enhancing the durability of civil infrastructure. These fine cracks are key to preventing the ingress of water and harmful chemicals into the structure and thereby achieving steel reinforcement. However, several studies have suggested that the short-term fine cracks shown in the laboratory may end up exceeding the acceptable crack widths that are specified in design codes when SHCC members are subjected to sustained constant loads. In real structures, however, the load is also shared by the steel reinforcement in the member, so the SHCC within may not be under a constant load; therefore, the crack widening will not be as severe. This study focuses on the creep behaviour of SHCCs when they are applied as an external layer on reinforced concrete to enhance durability. A novel approach to simulate various stress–strain regimes in such systems is developed by using a fixture to share a sustained moment exclusively between a reinforcement member and SHCC. The developed load-sharing system allows stresses within the reinforcement and SHCC to be monitored against time during the imposed loading, while ensuring access to the SHCC layer for instrumentation and monitoring of strain/cracking. The time-dependent widening of cracks in the SHCC layer is found to be much less significant than that under constant loading, so resistance to water/chemical penetration can still be ensured in the long term. The obtained information on the variation in stress, strain, and crack opening with time will be useful for the development of a general model for the creep behaviour of SHCC members. Full article

This study assesses the influence of extra-short extra-fine steel fibers on the performance of self-compacting concrete (SCC) modified with fly ash. Replacing standard steel fibers with volume fractions ranging from 0%, 1.5%, 3%, 5% and 6%, the study optimizes the mix design for enhanced workability and mechanical properties. The findings reveal that, although the addition of steel fibers had a negative effect on the flowability, the cohesion is significantly improved, providing a basis for a significant improvement in the mechanical properties. The optimal fiber content is identified at 5%, achieving the highest compressive strength of 71.7 MPa, split tensile strength of 8.2 MPa, and flexural strength of 12.8 MPa at 28 d. However, further increases in fiber content beyond 5% lead to a deceleration in compressive and splitting tensile strength improvement and a 27.5% drop in flexural strength at 28 d. The study also emphasizes the good dispersion within the concrete, which helps to enhance its ductility and crack resistance, to some extent. Full article

Si₃N₄ ceramic as a tool material shows promising application prospects in high-speed machining fields; however, the required high mechanical properties and low-cost preparation of Si₃N₄ ceramic tool materials restrict its application. Herein, synergistic reinforced Si₃N₄ ceramic tool materials were fabricated by adding β-Si₃N₄ seeds, inexpensive Si₃N₄ whiskers and TiC particles into coarse commercial Si₃N₄ powder (D₅₀ = 1.5 μm), then sintering by hot-pressing with low temperature and short holding time (1600 °C—30 min—40 MPa). The phase assemblage, microstructure evolution and toughening mechanisms were investigated. The results reveal that the sintered Si₃N₄ ceramics with synergistic reinforcement, compared to those with individual reinforcement, present an enhancement in relative density (from 94.92% to 97.15%), flexural strength (from 467.56 ± 36.48 to 809.10 ± 45.59 MPa), and fracture toughness (from 8.38 ± 0.19 to 10.67 ± 0.16 MPa·m^1/2), as well as a fine Vickers hardness of 16.86 ± 0.19 GPa. Additionally, the various reinforcement modes of Si₃N₄ ceramics including intergranular fracture, crack deflection, crack bridging and whiskers extraction were observed in crack propagation, arising from the contributions of the added β-Si₃N₄ seeds, Si₃N₄ whiskers and TiC particles. This work is expected to serve as a reference for the production of ceramic cutting tools. Full article

Due to its high carrier mobility and electron transmission, the phenyl-C₆₁-butyric acid methyl ester (PC₆₁BM) is usually used as an electron transport layer (ETL) in perovskite solar cell (PSC) configurations. However, PC₆₁BM films suffer from poor coverage on perovskite active layers because of their low solubility and weak adhesive ability. In this work, to overcome the above-mentioned shortcomings, 30 nm thick PC₆₁BM ETLs with different concentrations were modeled. Using a 30 nm thick PC₆₁BM ETL with a concentration of 50 mg/mL, the obtained performance values of the PSCs were as follows: an open-circuit voltage (V_oc) of 0.87 V, a short-circuit current density (J_sc) of 20.44 mA/cm², a fill factor (FF) of 70.52%, and a power conversion efficiency (PCE) of 12.54%. However, undesired fine cracks present on the PC₆₁BM surface degraded the performance of the resulting PSCs. To further improve performance, multiple different thicknesses of ZnO interface layers were deposited on the PC₆₁BM ETLs to release the fine cracks using a thermal evaporator. In addition to the pavement of fine cracks, the ZnO interface layer could also function as a hole-blocking layer due to its larger highest occupied molecular orbital (HOMO) energy level. Consequently, the PCE was improved to 14.62% by inserting a 20 nm thick ZnO interface layer in the PSCs. Full article

Rock fragmentation by blasting influences ore recovery and the cost of downstream operations. The development of electronic detonators makes it possible to improve fragmentation by controlling the initiation timing in blasting projects, and the effect of the mechanism of delay timing on rock fragmentation should be studied. Fragmentation of granite bench specimens with different initiation timing was investigated in blast experiments. Conclusions are obtained by studying the surface strain field and post-blast specimens. A total of six blasting tests were carried out on granite bench specimens with four boreholes each having a diameter of 10 mm and a length of 450 mm. Each borehole used pentaerythritol tetranitrate (PETN) as the explosive charge, which was approximately 4.84 g with a charge diameter of 5.5 mm. Delay times between adjacent boreholes in the same row were set as 0, 50, 100, 150, 200, and 250 µs. The surface strain field of the bench specimen under blast loading was analyzed using three-dimensional digital image correlation (3D-DIC) techniques based on two cameras that captured high-speed images. Additionally, the post-blast specimen was also observed and recorded. Fragments of each bench specimen were carefully collected, weighed, and sieved with a set of sieves, including very fine particles. According to the 3D-DIC analysis for bench specimens, the propagation pattern of the main strain concentration zone transformed from horizontal to vertical with the increase in inter-hole delay. The maximum blast excavation weight was obtained by the bench specimen with an inter-hole delay of 100 µs, while the bench specimen with the longest inter-hole delay (250 µs) obtained the minimum blast excavation weight. By combining the results for blast excavation weight with the results from fragment size distribution analysis of all specimens, the optimal inter-hole delay was 200 µs. Compared to simultaneous detonation, the median size was decreased by about 14.5% for the inter-hole delay of 200 µs. The results of experiments show that delay time significantly influences rock fragmentation, but the stress wave superposition in short delays cannot improve rock fragmentation. For long delays, the blast-induced crack propagation time should be regarded as an influential factor when choosing the proper delay time. The experimental findings of this study could provide a better understanding of the effect of the mechanism of delay time on rock fragmentation. Full article

Roof weighting failures of pre-driven recovery rooms may cause huge economic losses and even casualties. The excessive dynamic load from the sliding of the broken main roof rock block causes the recovery room roof and inner supports to lose their support capacity during the last weighting. Discrete element software UDEC was used to investigate the surrounding rock deformation of the pre-driven recovery room with the main roof break at different positions. The results show that when the recovery room’s length from the main roof rock layer’s fracture region is short, the immediate roof is subjected to high deviatoric stress and the occurrence of horizontal stress concentration due to the deflection of the fractured rocks, and eventually the roof supports fail owing to the development of macroscopic shear crack zones. In this research, the hydraulic fracturing technique was applied to pretreat the main roof (fine-grained sandstone) of the 31108 panel at Huoluowan Coal Mine. Field observations suggest that the strength and duration of the periodic weighting after hydraulic fracturing treatment are both significantly reduced, effectively maintaining the bearing layer performance of the roof of the recovery room and coal pillar walls. The proposed fracturing design offers an effective method of ground control to the coal mines facing roof weighting failures of recovery rooms. Full article

This work investigates the equilibrium stage of the crack propagation of a fine-grained soil after several drying and wetting cycles (shrinkage and swelling hysteresis). This stage is found to be crucial in practical engineering since the soil continues to show its irreversible hydraulic settlement, which is a potential risk for some severe structural damages. The shrinkage area and the shrinkage crack area were determined by using the image processing method. For the cyclic experimental investigations, the shrinkage cracks were followed during six months of successive wetting and drying cycles for two samples (with two different initial water contents). These long-term tests were completed by some short term single drying path tests performed on samples prepared at different initial states. The results showed the existence of a unique equilibrium stage at the end of the wetting and drying cycles for the two studied samples. The equilibrated soil subsidence was separated into two parts: the reversible settlement of the equilibrium stage and the irreversible settlements cumulated during successive wetting and drying cycles. At the equilibrium stage, the reversible deformation was 5.9% and the irreversible deformation was 3.8%. A simplified theoretical approach was also used to predict the cracking equilibrium stage and its soil subsidence. The fitted parameters of the theoretical approach for each cycle were stabilized to confirm the existence of this equilibrium stage. Full article