Search Results (135)

This article presents experimental and numerical studies on the creep deformation of 7055-T6 Al and 2197-T8 Al-Li T-joints. Firstly, the optimal process parameters for creep tensile tests (CATs) are determined to be 155 °C, 130 MPa, and 8 h. Based on this, different modes of ultrasonic vibration are introduced. It is found that under the same amplitude, the creep limit of intermittent vibration is 64.7‰ to 97.2‰ higher than that of continuous vibration, and the tensile strength of the former specimens is significantly better than that of the latter. Further analysis reveals that during long-duration or high-amplitude vibrations, the joint material exhibits hardening effects, while short-duration, low-amplitude intermittent vibrations result in softening effects. When the amplitude is 12.53 μm, the material exhibits optimal comprehensive mechanical properties, with yield strengths, tensile strengths, and elongations of 402.1 MPa, 429.3 MPa, and 7.9%, respectively. Additionally, based on the mechanisms of superposition and acoustic softening effects, an improved creep aging constitutive model is established, which incorporates the creep process, stress superposition, and ultrasonic softening changes and is applied in ABAQUS. It is found that at an amplitude of 12.53 μm, the residual stress in the joint is more thoroughly eliminated and distributed more evenly, measuring 97.35 MPa. Moreover, the creep strain calculated using the above model in a finite element analysis shows a high degree of agreement with the experimental results, indicating that the proposed model can more accurately predict the creep deformation behavior of FSWed T-joints during the CAT process. Full article

A quick method to access the tensile strength of concrete is often required during surveys. However, it is not always clear which method is the most effective or whether a certain method can be simplified or adjusted. Recently, pull-off tests on floors and walls have become more common for measuring the tensile strength of concrete, although the results can be interpreted in different ways. This research compares different types of pull-off testing with the standard tensile splitting strength test, which is considered destructive. This study revealed differences between the pull-off and tensile splitting strength test results. Among the three pull-off methods, the standard method showed the least deviation and appeared to be most closely with uniaxial tensile strength. The rectangular method resulted in 33% to 35% lower strength, likely due to increased stress concentration compared to the standard circular method. The straight-to-surface method proved unreliable, as strength depended on the failure area size. Additionally, a high correlation was found between concrete density, ultrasonic pulse velocity (UPV) (r = 0.81–0.88), and rebound hardness, indicating that the pull-off test results closely reflect changes in concrete density and UPV. Full article

TA1 titanium bipolar plates for hydrogen fuel cells are prone to plastic instability phenomena such as wrinkling during the stamping process, which adversely affects the forming quality. This study applies an ultrasonic-vibration energy field, aligned with the direction of stretching, in a plate diagonal tensile testing scenario based on the Blaha effect. The impact of varying thicknesses and vibration amplitudes on the anti-wrinkling performance of TA1 titanium sheets is investigated. Through a combined analysis of load–displacement curves and wrinkle height measurements using a super-depth-of-field microscope, by examining the forming load, the onset of wrinkling, and the wrinkle height at buckling locations, this study explores the deformation behavior of the thin sheet and the wrinkle suppression mechanism under the coupled effects of the ultrasonic-vibration field and scale. The results show that as the thickness decreases, the anti-wrinkling ability of the TA1 titanium sheet diminishes. The ultrasonic-vibration energy field reduces the yield stress and flow stress of the material, promoting wrinkling during the elastic deformation stage. Moreover, the 0.075 mm thick TA1 titanium sheet experiences local secondary wrinkling during the plastic deformation stage. Additionally, the ultrasonic-vibration energy field effectively reduces the forming load of the sheet and suppresses wrinkling within a certain range of amplitudes. These findings provide experimental evidence for the ultrasonic-vibration-assisted stamping process of titanium bipolar plates. Full article

The diagnosis of post-stressed anchor rods is essential for maintaining the service and ensuring the safety of Electricité de France (EDF) structures. These rods are critical for the mechanical strength of structures and electromechanical components. Currently, the standard method for estimating the effective tension of post-stressed tie rods with a free length involves measuring the residual force using a hydraulic jack. However, this method can be costly, impact the structure’s operation, and pose risks to employees. Until now, there has been no reliable on-field approach to estimating residual tension using a lightweight setup. This research introduces a nondestructive method using multimodal ultrasonic guided waves to evaluate the residual tension of anchor rods with a few centimeters free at one end. The methodology was developed through both laboratory experiments and simulations. This new method allows for the extraction of dispersion curves for the first three modes, bending, torsional, and longitudinal, using time–frequency analysis and enables the estimation of the steel bar’s properties. Future work will focus on applying this methodology in the field. Full article

Tungsten carbide (WC) coatings of varying thicknesses were prepared using electrical discharge deposition technology. Relevant characterizations were conducted to analyze the residual stress in the WC coatings from a microscopic perspective, and this residual stress was measured using X-ray diffraction technology. Under isothermal conditions, a novel method for detecting the residual stress of the coatings utilizing critical refractive longitudinal (LCR) waves was employed to investigate the relationship between the residual stress of the WC coatings and their thickness. According to acoustic elastic theory, LCR stress measurement is based on the principle that stress within the material alters the propagation characteristics of ultrasonic waves. After correcting the effect of coating thickness on LCR propagation, the detection results of the LCR wave indicate that the compressive stress present in the coating may cause the substrate to exhibit a certain degree of tensile stress. At a coating thickness of 6–13 µm, as the thickness of the WC coating increases, the residual compressive stress within the coating gradually rises, leading to an increase in tensile stress on the substrate. However, at coating thicknesses of 13–16 µm, the changes in tensile stress on the substrate become minimal or even decrease, despite the continued increase in compressive stress within the WC coating. The relationship curve derived from the matrix surface aligns more closely with a quadratic function, while the curve obtained from the coating surface corresponds more to a linear function. This study employs LCR waves to detect residual stress in coatings, and the results indicate that LCR waves hold significant potential for application in the field of residual stress detection in coatings. Full article

In recent years, the excellent mechanical properties and lightweight characteristics of multi-layer hollow components have led to a surge in research focused on their forming processes. This growing interest has greatly advanced technological progress in aerospace and other related fields. In this paper, the metal flow behavior of TA15 titanium alloy at different temperatures from 840 °C to 940 °C and different strain rates from 0.001 s⁻¹ to 0.1 s⁻¹ was studied. Utilizing the finite element method, this study examined the local stress concentration, total strain distribution, thickness thinning characteristics, and pressure loading control during the superplastic forming process of the component. The integrated solid/hollow four-layer grid lightweight structural parts were successfully fabricated using the superplastic forming/diffusion bonding (SPF/DB) process. The quality of the components was evaluated using X-ray and ultrasonic C-scan detection methods. The results show that the maximum elongation of the alloy is 1340% at 900 °C/0.001 s⁻¹. When the temperature is too high, the grain size increases remarkably, and the elongation decreases. Based on the finite element simulation results, 900 °C is the best superplastic forming temperature. Under this temperature parameter, the maximum thinning rate of the core sheet is 39.7%, the SPF time is 10,000 s, the maximum thinning rate of the face sheet is 9.8%, and the SPF time is 2400 s. In addition, the solid block has a minimal effect on the thinning of the core sheet. The grid exhibits obvious stress concentration and thinning at its rounded corners, while the thickness distribution in other areas remains relatively uniform. The nondestructive testing results confirmed that the ribs of the component are fully formed, with no missing or broken ribs. The grid exhibits good geometry and high-quality diffusion bonding. The average thickness at key positions of the component is 1.84 mm, with the minimum thickness being 1.7 mm. As the size of the grid cavity decreases, the thickness of the component tends to increase gradually. The maximum error between the simulated and measured values is 4.47%, indicating good accuracy in the simulation. Additionally, the thickness distribution of the component is relatively uniform. Full article

Hydrogen storage in intermetallic compounds, known as solid-state storage, relies on a phase change by the metal alloy. This phenomenon causes a violent change in volume at the crystalline scale, inducing a change of volume for the millimetric particles and, with time, important stresses on the tanks. It is thus necessary to know the mechanical behavior of the material to report these phenomena and improve the tanks’ reliability. The present study deals with the mechanical characterization of Ti_0.5Fe_0.45Mn_0.05 alloy at different scales. First, the elastic modulus was measured by compression tests of cylindrical samples. The estimated macroscopic elastic modulus was about 198 GPa, with high variability, from 163 to 229 GPa. Secondly, ultrasonic elastic characterization together with instrumented indentation allowed an estimation of both Young’s modulus and Poisson’s ratio at 269 GPa and 0.29, respectively. Finally, the nanoindentation results, combined with SEM imaging and EDS analyses, revealed that several metallurgical phases coexist below the particle scale. Four distinct domains in terms of elasticity were clearly identified. The coherence of all these estimations is discussed and interpreted considering the true microstructure of the material and the defects present in the different samples. Full article

This paper describes a study of the microstructure and mechanical properties of a titanium–gallium (Ti-8 wt.% Ga) alloy using X-ray diffraction, optical metallography, micro-hardness measurements, compression and tensile testing, nanoindentation and ultrasonic velocity measurements. X-ray diffraction has shown the alloy to be wholly α Ti with no other phases present. A comparison of the hardness and elastic modulus values of the Ti-8Ga alloy with those of Ti-6Al-4V showed the former to have a significantly higher hardness, although the elastic moduli of the two alloys were broadly comparable. The study also indicated reasonable agreement between the elastic moduli obtained by nanoindentation, ultrasonic velocity measurements and tensile testing. Under compressive loading, the mean 0.2% proof stress values of the Ti-8Ga alloy were between 1066 MPa and 1083 MPa. However, under tensile conditions, the mean tensile strength was found to be only 427 MPa, and the alloy exhibited highly brittle behaviour, with specimens failing before they had undergone any appreciable plasticity. The cause of this was ascribed to high oxygen and nitrogen levels. Full article

With the widespread application of small-sized bolts in aerospace and other fields, the demand for measuring their connection structures is increasing. Currently, although ultrasonic longitudinal wave methods are commonly used for bolt pretension stress measurement, their accuracy is limited for small-sized bolts. This paper proposes a piezoelectric acoustic resonance method (PZTAR) for small-sized bolt pretension stress measurement based on acoustic elasticity theory, ultrasonic resonance principles, and a bolt stress–strain model. The method involves analyzing the ultrasonic time-domain signals of small-sized bolts under load in the frequency domain to better evaluate the changes in the ultrasonic frequencies under different pretension stress. The effectiveness of this method is verified through pretension stress measurement experiments. The results indicate that the proposed ultrasonic resonance method achieves an average error of less than 5% for M5 specification bolts. Compared to traditional ultrasonic time delay methods, the proposed method demonstrates higher measurement accuracy. Additionally, the ultrasonic resonance method exhibits better robustness during the measurement process. Full article

The residual stress significantly affects the operational safety of oil and gas pipelines. Traditional ultrasonic stress measurement methods require pipeline surface pretreatment, which reduces detection efficiency. EMAT, as a non-contact measurement method, shows promising applications for residual stress detection in oil and gas pipelines. Therefore, based on field conditions for residual stress detection in oil and gas pipelines, this study prepared X80 pipeline steel specimens with epoxy resin coatings of 0.58 mm, 1 mm, 1.58 mm, and 1.9 mm thickness to verify the influence of coating thickness on the stress measurement accuracy of EMAT. Additionally, X80 pipeline steel specimens with varying surface roughness were prepared to study the impact of surface roughness on the residual stress measurement. The results indicate that within the range of coating thickness variations, the residual stress measurement error falls in the range of 50 MPa, while the change of residual stress caused by surface roughness is less than 30 MPa. This validates the feasibility and accuracy of the EMAT method for residual stress measurement in in-service pipelines without the need for surface treatment. Full article

Bolted connections are a common feature of connection in mechanical structures, employed to secure connected parts by tightening nuts and providing preload. The preload is susceptible to various factors leading to potential bolt loosening. The acoustoelastic theory is the most common measure of a bolt structure’s stress. The present study investigates the relationship between the inherent properties of a structure and its acousticelastic properties. The modal response of the bolted structure under different preload forces is studied by translating the acoustoelastic relationship of the structure into an analysis of its intrinsic properties. The modal analysis reflects the relative change in wave velocity to be determined implicitly based on the eigenfrequencies of the structure. A frequency formulation of classical bolted structures based on acoustoelastic theory is presented in this paper to conduct the intrinsic characteristic analysis of bolted structures. The COMSOL5.4 simulation results are under the acoustic elasticity coefficients for ultrasonic wave propagation in bolt structures, as predicted by the acoustic elasticity theory, and the present solutions are compared with those available in the literature to confirm their validity. A systematic parameter study for bolted structures under the varying preloads with different material parameters, Lame elastic constants, Murnaghan third-order elastic constants, and structural parameters are presented. These results may serve as a benchmark for researchers in this field. Full article

During the milling process of aramid honeycomb, residual stresses arise, which will affect the surface quality of the honeycomb. Studies have shown that reasonable processing techniques can reduce residual stresses, indicating a close relationship between residual processing stresses and the processing parameters, such as technique. By investigating the changes in residual stresses after the processing of aramid honeycomb materials, the influence of processing techniques on these changes is analyzed. Leveraging the correlation between residual stresses and surface quality, this study proposes the use of residual stress as an indicator for evaluating processing techniques. The longitudinal–torsional ultrasonic vibration milling method is applied to the processing of aramid honeycombs. A single-factor experimental approach is adopted, utilizing ABAQUS 2020 software to mimic the longitudinal–torsional ultrasonic milling process. This study explores the influence patterns of various process parameters on the residual stresses generated during the milling of honeycombs. The simulation results indicate that within the selected range, the residual stress decreases as the tool rotation speed increases, while it increases with the increase in feed rate. The influence of milling depth on residual stress can be negligible. Furthermore, experiments were conducted based on the proposed correlation between residual stress and surface quality. The experimental results show good agreement with the simulation results, indicating that under reasonable process parameters, the residual stress values decrease, thereby improving the milling surface quality of aramid honeycomb materials. Therefore, measuring residual stress can serve as an effective method for evaluating the processing technique. Full article

Anti-fatigue design in the machining process of aviation material requires advanced processes to enhance the surface integrity and a holistic model which can optimize the process aiming at maximum fatigue life. In the present study, the axial ultrasonic assisted milling process was utilized to machine the Inconel 718 while the process executes the thermomechanical cutting and peening action simultaneously. To optimize the process factors, a hybrid model using a combination of regression analysis and an analytical model was developed to correlate the machining factors, i.e., vibration amplitude, cutting velocity and feed rate to fatigue life. Herein, the former was used to map the process inputs to surface integrity aspects (SIAs), viz. roughness, hardness and residual stress; then, the SIA was mapped to fatigue life through a stress-based approach. The obtained results revealed that there is close agreement between the measured and predicted values of fatigue life where the prediction error is less than two times the dispersion. On the other hand, applying ultrasonic vibration at the highest amplitude together with the maximum feed rate and cutting velocity yield significant improvement in fatigue life, i.e., three times the same condition without ultrasonic vibration in light of the enhancement of compressive residual stress and work hardening of the surface layers. Full article

Bearings play a key role in rolling mills, and the uniformity of their lubricant film directly affects the degree of wear of bearings and the safety of equipment. Due to long-term stress, the lubricant film inside the bearing is not uniformly distributed, resulting in uneven wear between the journal and the shaft tile, which increases the potential safety hazards in production. Traditional disassembly inspection methods are complex and time-consuming. Ultrasonic nondestructive testing technology, which has the advantages of nondestructive and adaptable, has become an effective means of assessing the thickness of the oil film in bearings. In this study, an experimental platform for calibrating the lubricant film thickness in bearings was constructed for the first time, and the acoustic characteristics of different thicknesses of the oil film were measured using ultrasonic detection equipment to verify the accuracy of the simulation process. The experimental results show that after discrete Fourier transform processing, the main features of the frequency channels of the reflected acoustic signals of different thicknesses of the oil film are consistent with the finite element simulation results, and the errors of the oil film thicknesses calculated from the reflection coefficients are within 10% of the set thicknesses, and the measurement ranges cover from 5 μm to 250 μm. Therefore, the above method can realize the accurate measurement of the thicknesses of the oil film in bearings. Full article

This paper presents a study on residual stress measurement in wire-arc additively manufactured (WAAM) titanium samples using the non-destructive method of phased array ultrasonics. The contour method (CM) was used for the verification of the phased array ultrasonic results. This allowed for a comparison of measurement methods to understand the effects on the distribution of residual stress (RS) within Ti-6Al-4V samples and the effectiveness of measurement of residual stress using phased array ultrasonics. From the results of the experiments, the phased array ultrasonic data were found to be in good agreement with the CM results and displayed similar residual stress distributions in the samples. The results of the individual elements of the phased array were also compared and an improvement in accuracy was found. From per-element results, anomalies were found and could be mitigated with the ability to average the results by using phased array ultrasonics. Therefore, based on these results, there is a strong case for the benefits of using phased array ultrasonics as a method of residual stress measurement for WAAM Ti-6Al-4V components over other existing residual stress measurement techniques. Full article