Search Results (36)

The prediction of fatigue life is critical in the design process, and current models offer a viable alternative to costly and time-consuming experimental fatigue testing. The constitutive fatigue model used integrates low-cycle and high-cycle fatigue behavior. This model is grounded on the concept of fatigue damage evolution and incorporates a moving endurance surface within the stress space, eliminating the need for ambiguous cycle-counting methods. An interesting observation is that many polymers exhibit macroscopic fatigue characteristics, specifically, the form of the $S-N$ curve similar to those observed in metals. Consequently, all fatigue model parameters were expressed in terms of the well-established Coffin–Manson–Basquin model parameters. However, the constitutive mathematical modeling itself is computationally time-consuming, particularly when applied to predict high-cycle fatigue across large design spaces. Therefore, the proposed model was utilized exclusively to generate high-quality data for training machine learning models that offer significantly improved computational efficiency. The high-cycle fatigue design of polymers and other ductile materials, traditionally dependent on expensive and time-consuming experimental methods, is now expedited through an advanced modeling framework that combines constitutive mathematical modeling with AI-based approaches. Full article

The flexible positioning platform is a critical structural component in the ultra-high acceleration macro–micro motion platform, enabling precise positioning across multiple scales. However, under high-frequency start–stop cycles and prolonged multi-condition operation, it is prone to fatigue damage induced by random vibrations, which poses a threat to system reliability. This study proposes a method for evaluating and optimizing the platform’s performance under random vibration based on power spectral density (PSD) analysis. In accordance with the IEC 60068-2-64 standard, representative load spectra from Tables A.8 and A.6 were selected as excitation inputs. Frequency-domain analyses of stress, strain, and displacement were conducted using ANSYS Workbench 2022R1 in conjunction with the nCode platform, incorporating the Gaussian three-sigma probability interval. The results reveal that stress and deformation are highly concentrated in the hinge region, indicating a structural vulnerability. Fatigue life predictions were carried out using the Dirlik method and Miner’s linear damage rule under various PSD loading conditions. The findings demonstrate that hinge stiffness is a key factor influencing vibration resistance and service life. This research provides theoretical support for the design optimization of flexible structures operating in complex random vibration environments. Full article

Rupture discs are critical safety devices for pressure vessels, yet defining replacement intervals for discs that have not ruptured remains challenging due to limited quantitative life-prediction methods. This study investigates forward-acting rupture discs made of 316 L stainless steel and Inconel 600 under three test conditions: low pressure at room temperature, low pressure at elevated temperature, and ultra-high pressure at elevated temperature. Static hold life and fatigue life were measured over a range of operating ratios R = P_w/P_b. To model life–ratio relationships while avoiding far-reaching extrapolation, static life was fitted with a log-normal accelerated-life (AFT) model and fatigue life with a Basquin relation following ASTM E739, reporting 95% prediction bands. Predictions were restricted to validated domains (static: R ≥ 0.86) and truncated at five times the groupwise maximum observed life/cycles. Results show a consistent trend for both materials and all conditions: life decreases as R increases, with steep sensitivities within the observed range. At matched R, Inconel 600 generally exhibits longer life than 316 L. Qualitative failure analysis under constant and cyclic loading indicates progressive plastic deformation, local thinning, and a concomitant reduction in bursting pressure until failure. The proposed in-range predictive framework provides actionable guidance for determining conservative replacement intervals for rupture discs. Full article

Conventional fatigue life prediction models for sucker rods, such as the Normal Distribution Basquin model and Miner’s Rule, have notable limitations. This research introduces a new fatigue life prediction model for ultra-high-strength sucker rods by employing a three-parameter Weibull distribution and incorporating material tensile strength. Tensile and fatigue tests were conducted on sucker rods to gather life data at various stress levels. Subsequent P-S-N curve fitting and life prediction analyses showed that the fatigue life data conformed to both normal and Weibull distributions, with the Weibull distribution providing a superior fit. A comparison of S-N curves at a 50% failure probability demonstrated that the three-parameter Weibull model more accurately matches experimental data across both high-cycle and low-cycle fatigue regimes. Fatigue life estimates indicated average prediction errors of 12.50% for the normal distribution model and 5.39% for the Weibull distribution model, confirming the enhanced accuracy of the proposed method. “The new model more precisely captures the actual fatigue behavior of ultra-high-strength sucker rods by considering fatigue life under varying tensile forces and ultimate tensile strength, offering valuable support for assessing fatigue durability and ensuring operational safety in oilfield operations while reducing maintenance costs”. 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

As high-speed electric multiple units (EMUs) advance in speed and complexity, quasi-static design methods may underestimate the fatigue risks associated with high-frequency dynamic excitations. This study quantifies the contribution of gear meshing-induced vibrations (2512 Hz) to fatigue damage in EMU gearbox housings, revealing resonance amplification of local stresses up to 1.8 MPa at 300 km/h operation. Through integrated field monitoring and bench testing, we demonstrated that gear meshing excites structural modes, generating sustained, very high-cycle stresses (>10⁸ cycles). Crucially, fatigue specimens were directly extracted from in-service gearbox housings—overcoming the limitations of standardized coupons—passing the very high-cycle fatigue (VHCF) test to derive S-N characteristics beyond 10⁸ cycles. Results show a continuous decline in fatigue strength (with no traditional fatigue limit) from 10⁸ to 10⁹ cycles. This work bridges the gap between static design standards (e.g., FKM) and actual dynamic environments, proving that accumulated damage from low-amplitude gear-meshing stresses (3.62 × 10¹¹ cycles over a 12 million km lifespan) contributes to a 16% material utilization ratio. The findings emphasize that even low-magnitude gear-meshing stresses can significantly influence gearbox fatigue life due to their ultra-high frequency, warranting design consideration beyond current standards. Full article

To address the issues of cumulative plastic deformation and low-cycle fatigue cracking in ultra-high voltage (UHV) disc spring hydraulic circuit breakers under long-term cyclic high-pressure loads, which lead to internal structural changes and affect closing time stability and phase-controlled closing accuracy, this paper proposes a closing time prediction model considering the low-cycle fatigue of the operating mechanism. First, a Simulink-based simulation model of the 550 kV disc spring hydraulic operating mechanism transmission system was developed to analyze the influence of structural parameter variations on closing time under no-load conditions. Then, an objective function for judging action time stability was constructed, and the stability and influence weights of each structural parameter were calculated under different mechanical dispersion requirements using a combination of adaptive surrogate models and directional importance sampling. Results show that critical parameters such as working cylinder inner diameter, working cylinder stroke, main valve stroke, and working cylinder rod diameter significantly affect closing time, contributing approximately 25%, 20%, 15%, and 10%, respectively. Finally, a dynamic-weighted closing time prediction model was designed based on different phase-controlled accuracy requirements. Compared with no-load closing tests, under mechanical dispersion conditions of ±1 ms, ±1.5 ms, and ±2 ms, the optimized model reduced maximum deviations by 12.8%, 20.4%, and 23.3%, and narrowed fluctuation ranges by 37%, 38.3%, and 38.6%, respectively, significantly improving prediction accuracy. This work is supported by the Science and Technology Project of China Southern Power Grid (No.CGYKJXM20220346). Full article

With the rapid development of hydrogen pipelines, their safety issues have become increasingly prominent. In order to evaluate the properties of pipeline materials under a high-pressure hydrogen environment, this study investigates the hydrogen embrittlement sensitivity of X70 welded pipe in a 10 MPa high-pressure hydrogen environment, using slow strain rate testing (SSRT) and low-cycle fatigue (LCF) analysis. The microstructure, slow tensile and fatigue fracture morphology of base metal (BM) and weld metal (WM) were characterized and analyzed by means of ultra-depth microscope, scanning electron microscope (SEM), electron backscattering diffraction (EBSD), and transmission electron microscope (TEM). Results indicate that while the high-pressure hydrogen environment has minimal impact on ultimate tensile strength (UTS) for both BM and WM, it significantly decreases reduction of area (RA) and elongation (EL), with RA reduction in WM exceeding that in BM. Under the nitrogen environment, the slow tensile fracture of X70 pipeline steel BM and WM is a typical ductile fracture, while under the high-pressure hydrogen environment, the unevenness of the slow tensile fracture increased, and a large number of microcracks appeared on the fracture surface and edges, with the fracture mode changing to ductile fracture + quasi-cleavage fracture. In addition, the high-pressure hydrogen environment reduces the fatigue life of the BM and WM of X70 pipeline steel, and the fatigue life of the WM decreases more than that of the BM as well. Compared to the nitrogen environment, the fatigue fracture specimens of BM and WM in the hydrogen environment showed quasi-cleavage fracture patterns, and the fracture area in the instantaneous fracture zone (IFZ) was significantly reduced. Compared with the BM of X70 pipeline steel, although the effective grain size of the WM is smaller, WM’s microstructure, with larger Martensite/austenite (M/A) constituents and MnS and Al-rich oxides, contributes to a heightened embrittlement sensitivity. In contrast, the second-phase precipitation of nanosized Nb, V, and Ti composite carbon-nitride in the BM acts as an effective irreversible hydrogen trap, which can significantly reduce the hydrogen embrittlement sensitivity. Full article

This study investigated the microstructure, microhardness, and residual compressive stress of 14Cr12Ni3Mo2VN martensitic stainless steel treated with high-frequency induction quenching (HFIQ) and laser shock peening (LSP). Using rotating bending corrosion fatigue testing, the corrosion fatigue performance was analyzed. Results show that a microstructural gradient formed after HFIQ and LSP: the surface layer consisted of nanocrystals, the subsurface layer of short lath martensite, and the core of thick lath martensite. A hardness gradient was introduced, with surface hardness reaching 524 Hv_0.1, 163 Hv_0.1 higher than the core hardness. A residual compressive stress field was introduced near the surface, with a maximum residual compressive stress of approximately −575 MPa at a depth of 0.1 mm. Corrosion fatigue results indicate that cycle loading times of samples treated with HFIQ and LSP were 2.88, 2.04, and 1.45 times higher than untreated, HFIQ-only, and LSP-only samples, respectively. Transmission electron microscopy (TEM) characterization showed that HFIQ reduced the lath martensite size, while the ultra-high strain rate induced by LSP likely caused dynamic recrystallization, forming numerous sub-boundaries and refining grains, which increased surface hardness. The plastic strain induced by LSP introduced residual compressive stress, counteracting tensile stress and hindering the initiation and propagation of corrosion fatigue cracks. Full article

A depth precast deck panel (FDDP) is one element of the prefabricated bridge element and systems (PBES) that allows for quick un-shored assembly of the bridge deck on-site as part of the accelerated bridge construction (ABC) technology. This paper investigates the structural response of full-depth precast deck panels (FDDPs) constructed with new construction materials and connection details. FDDP is cast with normal strength concrete (NSC) and reinforced with high modulus (HM) glass fiber reinforced polymer (GFRP) ribbed bars. The panel-to-girder V-shape connections use the shear pockets to accommodate the clustering of the shear connectors. A novel transverse connection between panels has been developed, featuring three distinct female-to-female joint configurations, each with 175-mm projected GFRP bars extending from the FDDP into the closure strip, complemented by a female vertical shear key and filled with cementitious materials. The ultra-high performance fiber reinforced concrete (UHPFRC) was selectively used to joint-fill the 200-mm transverse joint between adjacent precast panels and the shear pockets connecting the panels to the supporting girders to ensure full shear interaction. Two actual-size FDDP specimens for each type of the three developed joints were erected to perform fatigue tests under the footprint of the Canadian Highway Bridge Design Code (CHBDC) truck wheel loading. The FDDP had a 200-mm thickness, 2500-mm width, and 2400-mm length in traffic direction; the rest was over braced steel twin girders. Two types of fatigue test were performed: incremental variable amplitude fatigue (VAF) loading and constant amplitude fatigue (CAF) loading, followed by monotonically loading the slab ultimate-to-collapse. It was observed that fatigue test results showed that the ultimate capacity of the slab under VAF loading or after 4 million cycles of CAF exceeded the factored design wheel load specified in the CHBDC. Also, the punching shear failure mode was dominant in all the tested FDDP specimens. Full article

Fatigue poses significant challenges for the structural integrity of monopiles, the most common type of foundation for offshore wind turbines. These structures are usually manufactured by rolling and welding together large steel plates. Offshore wind turbines are typically designed to operate for 20 years or longer, thus the number of cycles to failure ($N_f$) that these structures are required to withstand lies in the so called ultrahigh-cycle fatigue (UHCF) regime ($N_f>{10}^8$). Moreover, because, in the past few years, there has been a continuous increase in the size of monopiles, the fatigue life reduction caused by the utilization of thicker steel plates plays an important role (i.e., thickness or size effect). Different regions worldwide apply distinct codes to ensure that offshore structures can withstand fatigue damages, but most of them are tailored for the high-cycle fatigue (HCF) regime. This paper seeks to compare a selection of these codes, highlighting both differences and similarities, while also questioning their suitability in the UHCF regime and for much thicker structures (compared to the reference thickness values reported in the standards). By doing so, it aims to contribute to the ongoing efforts to optimize the efficiency of the fatigue life assessment of offshore wind infrastructures. The focus of this study is on double-V transverse butt welds and their S-N curves in air and seawater (with and without cathodic protection), while the analyzed standards are those provided by the Det Norske Veritas (DNV-RP-C203-2021), the British Standards Institution (BS 7608, including the amendments of 2015), and the European Union (EN 1993-1-9, updated in 2005). The results have been discussed in terms of the level of conservatism that each of these standards offers and in identifying the areas for further research to enable extended lives in the current and future offshore wind monopile foundations. Full article

This study investigates the manufacturing, testing, and analysis of ultra-thick laminated polymer matrix composite (PMC) beams with the aim of developing high-performance PMC leaf springs for automotive applications. An innovative aspect of this study is the integration of Fiber Bragg Grating (FBG) sensors and thermocouples (TCs) to monitor residual strain and exothermic reactions in composite structures during curing and post-curing manufacturing cycles. Additionally, the Calibration Coefficients (CCs) are calculated using Strain Gauge measurement results under static three-point bending tests. A major part of the study focuses on developing a properly correlated Finite Element (FE) model with large deflection (LD) effects using geometrical nonlinear analysis (GNA) to understand the deformation behavior of ultra thick composite beam (ComBeam) samples, advancing the understanding of large deformation behavior and filling critical research gaps in composite materials. This model will help assess the internal strain distribution, which is verified by correlating data from FBG sensors, Strain Gauges (SGs), and FE analysis. In addition, this research focuses on the application of FBG sensors in structural health monitoring (SHM) in fatigue tests under three-point bending with the support of load-deflection sensors: a new approach for composites at this scale. This study revealed that the fatigue performance of ComBeam samples drastically decreased with increasing displacement ranges, even at the same maximum level, underscoring the potential of FBG sensors to enhance SHM capabilities linked to smart maintenance. Full article

When high-strength steel is heated to high temperatures and then cooled naturally, its ductility decreases. In earthquake-prone areas, it is necessary to evaluate the ultra-low cycle fatigue fracture (ULCF) behavior of high-strength steel structures after a fire if these structures are used continuously. However, the ULCF fracture model of high-strength steel subjected to high temperatures followed by natural cooling has not been deeply studied. In view of this, twelve notched, round bar specimens fabricated from Q460D steel and ER55-G welds were heated to 900 °C followed by natural cooling and then cyclic loading experiments and finite element analyses (FEA) were performed on these specimens. The fracture deformation obtained from the experiments was used in the FEA to calibrate the damage degradation parameter of a Cyclic Void Growth Model (CVGM) of Q460D steel and ER55-G welds under this condition. The calibrated values were 0.30 and 0.20, respectively. The calibrated CVGM was employed to predict the number of cycles and the force and displacement at the fracture moment of the notched round bar specimens. The predicted results aligned closely with the experimental results, indicating that CVGM is effective in predicting the fracture of Q460D steel and ER55-G welds following exposure to 900 °C and subsequent natural cooling. Full article

Ultra-thick offshore steel, known for its high strength, high toughness, and corrosion resistance, is commonly used in marine platforms and ship components. However, when offshore steel is in service for an extended period under conditions of high pressure, extreme cold, and high-frequency impact loads, the weld joints are prone to fatigue failure or even fractures. Addressing these issues, this study designed a narrow-gap laser wire filling welding process and successfully welded a 100-mm new type of ultra-thick offshore steel. Using finite element simulation, EBSD testing, SEM analysis, and impact experiments, this study investigates the weld’s microstructure, impact toughness, and fracture mechanisms. The research found that at −80 °C, the welded joint exhibited good impact toughness (>80 J), with the impact absorption energy on the surface of the weld being 217.7 J, similar to that of the base material (225.3 J), and the fracture mechanism was primarily a ductile fracture. The impact absorption energy in the core of the weld was 103.7 J, with the fracture mechanism mainly being a brittle fracture. The EBSD results indicated that due to the influence of the welding thermal cycle and the cooling effect of the narrow-gap process, the grains gradually coarsened from the surface of the welded plate to the core of the weld, which was the main reason for the decreased impact toughness at the joint core. This study demonstrates the feasibility of using narrow-gap laser wire filling welding for 100-mm new type ultra-thick offshore steel and provides a new approach for the joining of ultra-thick steel plates. Full article

Flexible Si-based Hf_0.5Zr_0.5O₂ (HZO) ferroelectric devices exhibit numerous advantages in the internet of things (IoT) and edge computing due to their low-power operation, superior scalability, excellent CMOS compatibility, and light weight. However, limited by the brittleness of Si, defects are easily induced in ferroelectric thin films, leading to ferroelectricity degradation and a decrease in bending limit. Thus, a solution involving the addition of an ultra-thin Al buffer layer on the back of the device is proposed to enhance the bending limit and preserve ferroelectric performance. The device equipped with an Al buffer layer exhibits a 2Pr value of 29.5 μC/cm² (25.1 μC/cm²) at an outward (inward) bending radius of 5 mm, and it experiences a decrease to 22.1 μC/cm² (16.8 μC/cm²), even after 6000 bending cycles at a 12 mm outward (inward) radius. This outstanding performance can be attributed to the additional stress generated by the dense Al buffer layer, which is transmitted to the Si substrate and reduces the bending stress on the Si substrate. Notably, the diminished bending stress leads to a reduced crack growth in ferroelectric devices. This work will be beneficial for the development of flexible Si-based ferroelectric devices with high durability, fatigue resistance, and functional mobility. Full article