Search Results (28)

As a critical barrier for power network safety, insulating materials are susceptible to internal microcracks, delamination, and other hidden defects that can trigger dielectric strength degradation and space charge accumulation, ultimately leading to insulation breakdown. Ultrasonic shear wave non-destructive testing enables defect identification without damaging the material. Therefore, this paper focuses on the identification and imaging of internal defects in insulating components using ultrasonic shear waves. First, a physical model for ultrasonic shear wave NDT is established. Based on the refraction and reflection characteristics of ultrasonic waves in materials with different acoustic impedances, a defect localization formula is derived. Through simulation verification, for the three defects set at different positions in the defect model, the positioning error is less than 0.5 mm. Subsequently, defects such as circular holes, triangular shapes, cracks, and bottom grooves were simulated. Analysis of the echo data revealed a correlation between the distance from the sensor to the defect and the echo amplitude. For groove defect imaging, the differential SAFT algorithm was employed, achieving a width error of 1 mm for imaging a 2 mm wide by 5 mm high groove, clearly presenting the defect morphology. Finally, an imaging software program for defect structure reconstruction was developed based on the simulation model presented in this article. We collected side and back view data through the constructed ultrasonic transverse wave non-destructive testing experimental platform, and visualized defects in insulation materials with grooves using this ultrasonic imaging program. This study achieved defect localization and imaging through simulation of various defect types combined with synthetic aperture focused imaging algorithms, providing a reference for visualization and industrial application of ultrasonic shear wave non-destructive testing technology. Full article

Cracks and holes are commonly found in wooden components, and ancient Chinese wooden buildings, represented by the Yingxian Wooden Pagoda, demonstrate the ability to work with defects. This study systematically investigated the effects of longitudinal cracks and circular holes on the load-bearing capacity of wooden beams through four-point bending experiments on 1580 specimens. The study focuses on load-bearing capacity as the core indicator and provides calculation formulas for the section weakening coefficient and damage tolerance coefficient to quantitatively evaluate the impact of defects. Research has found that the harmfulness of a defect strongly depends on its position within the wooden beam. In the horizontal direction, when the longitudinal crack is located in the pure bending section of the wooden beam, it has little effect on the load-bearing capacity of the wooden beam. Once it deviates to the transverse bending section, the load-bearing capacity of the wooden beam significantly decreases. The hole is most dangerous when it is located in the horizontal center of the wooden beam, and it is also dangerous when it is near the loading point. In the vertical direction, the crack has the greatest impact on the load-bearing capacity of the wooden beam when it is located in the middle-height layer or its vicinity, while its impact decreases when it is close to the top and bottom surfaces of the wooden beam. Holes have the least impact when approaching the middle-height layer, which is different from the impact pattern of cracks. In addition, the hazard increases when the hole is located in the tension zone of the wooden beam, and decreases when it is located in the compression zone. The anisotropy and fiber structure of wood are the microscopic basis for the damage-tolerance mechanical behavior of timber beams. Full article

Fused Deposition Modeling (FDM) is an extensively employed additive manufacturing method for producing precise and complicated polymer models, with its industrial applications expanding under various loading conditions. A review of existing research highlights the insufficient investigation of the influence of geometric discontinuities in additively manufactured polylactic acid (PLA) members under fatigue loads. This study aims to analyze the combined effects of build orientation and geometric discontinuities on the static and fatigue performance and damage evolution of 3D-printed PLA. To achieve improved fabrication quality and minimize process-induced defects, the quasi-static tensile tests were conducted on specimens printed in on-edge orientation with a concentric infill pattern and the flat direction with a rectilinear infill pattern. The test results have shown that on-edge-printed objects have reduced micro-voids and improved layer bonding, resulting in a 19% increase in tensile strength compared to the flat-printed specimens. Consequently, this configuration was adopted for three specimen types, e.g., smooth, semi-circular edge-notched, and central-holed, tested under axial fatigue with a 0.05 load ratio. Fatigue test findings indicate that the stress concentration is more pronounced around central holes than near edge notches, leading to shorter fatigue life. This phenomenon is consistent with its effects under static tensile loading. Furthermore, using Digital Image Correlation (DIC) technique, damage initiation, progression, and failure mechanisms were analyzed in detail. According to fractographic analysis, the micro-voids in the 3D-printed specimens serve as potential regions for the initiation of multiple fatigue cracks. Additionally, the inherent internal defects can interact with geometric discontinuities, thereby weakening the fatigue performance. Full article

In the design and manufacturing of pressure vessels, the quality of welded joints and their operational safety are critical considerations. Weld quality classification is closely linked to its impact on fatigue performance. In this study, aluminum alloy welds with varying levels of porosity were produced by adjusting welding parameters, and X-ray inspection was used to assess porosity levels. Representative welds corresponding to different quality grades were selected to fabricate fatigue specimens, and their fatigue lives were determined. The influence of quality grades on the residual fatigue life of aluminum alloy welded sheets was systematically analyzed. The results indicate that, under identical loading conditions, the fatigue life of specimens with defects is significantly reduced compared to defect-free specimens. This reduction becomes more pronounced as the quality grade decreases—corresponding to an increase in circular hole defects. Specifically, for 5083 aluminum alloy, transitioning from Grade I to Grade III results in fatigue life reductions of approximately 25%, 35%, and 50%, respectively. Full article

Perforation, a common well completion method in oil and gas exploitation, introduces structural defects in casings that alter their mechanical properties. Based on engineering specifications, this study calculates critical loads (i.e., collapse pressure and yield pressure) and the triaxial equivalent stress for casings. Four load cases were selected for analysis: uniform external pressure, uniform internal pressure, external pressure with axial compression, and internal pressure with axial tension. The equivalent stresses around circular, elliptical, pentagonal, and hexagonal perforation defects were computed. A self-defined perforation influence coefficient was used to evaluate changes in mechanical performance. Results show that circular defects have the least effect on the mechanical properties of the casing. Maximum equivalent stress occurs along the hole centerline parallel to the casing axis and increases with greater disparity between ellipse axes or smaller polygon angles. High shot density (>24 holes/m) and large phase angle (60°) generally enhance safety, but an optimal combination exists. Under tensile loads near cracked defects, crack propagation may lead to fracture. For elliptical defects with cracks, the Mode I stress intensity factor grows faster with greater axis disparity, accelerating crack tip stress and deformation, and raising fracture risk. Cracks perpendicular to tensile stress influence the stress intensity factor more significantly than parallel ones. Full article

In modern manufacturing, ensuring quality control for geometric features is critical, yet detecting anomalies in circular components remains underexplored. This study proposes a real-time defect detection framework for metal parts with holes, optimized for deployment on a Raspberry Pi 5 edge device. We fine-tuned and evaluated three deep learning models ResNet50, EfficientNet-B3, and MobileNetV3-Large on a grayscale image dataset (43,482 samples) containing various hole defects and imbalances. Through extensive data augmentation and class-weighting, the models achieved near-perfect binary classification of defective vs. non-defective parts. Notably, ResNet50 attained 99.98% accuracy (precision 0.9994, recall 1.0000), correctly identifying all defects with only one false alarm. MobileNetV3-Large and EfficientNet-B3 likewise exceeded 99.9% accuracy, with slightly more false positives, but offered advantages in model size or interpretability. Gradient-weighted Class Activation Mapping (Grad-CAM) visualizations confirmed that each network focuses on meaningful geometric features (misaligned or irregular holes) when predicting defects, enhancing explainability. These results demonstrate that lightweight CNNs can reliably detect geometric deviations (e.g., mispositioned or missing holes) in real time. The proposed system significantly improves inline quality assurance by enabling timely, accurate, and interpretable defect detection on low-cost hardware, paving the way for smarter manufacturing inspection. Full article

This study investigates the influence of drilling-induced delamination damage on the compressive mechanical behavior of open-hole carbon fiber-reinforced composite laminates and explores the failure mechanisms under dual-defect coupling effects. Specimens with circular delamination defects of varying sizes were fabricated by embedding polytetrafluoroethylene (PTFE) films during the layup process. Ultrasonic C-scan and digital image correlation (DIC) techniques were used to monitor delamination propagation and deformation behavior. A cohesive zone-based numerical model was developed and validated against experimental results to reveal the three-stage failure process in single-defect cases. The validated model was then used to analyze the coupling effects of dual defects (same side and opposite side). The results show that dual delamination defects significantly reduce the compressive load-bearing capacity of open-hole composite laminates. Specifically, same-side defects exhibit a failure mode similar to single-defect structures, while opposite-side defects display a unique failure behavior characterized by dual-crack propagation, further reducing the compressive load-bearing capacity. Full article

Metal magnetic memory testing technology can not only detect macroscopic defects in ferromagnetic materials but also rapidly and conveniently detect early damage and stress concentration areas of components. Therefore, it is widely used in the nondestructive testing of ferromagnetic materials. However, the mechanism of magnetic memory detection is not yet clarified, and experimental research is unsystematic. Previous studies mainly focus on the normal and tangential components of magnetic memory signals (MMSs), and the third directional component is rarely considered, resulting in problems such as missed detection and misjudgement in practical applications. In this research, specimens without and with a circular hole defect were designed, and the correlation between the 3D MMS and the defect size, as well as the applied load, were investigated using tensile tests. Magnetic parameters were defined to characterize the stress and defect-induced abnormal magnetic change. The effects of applied load and defect size on magnetic parameters were discussed. The experimental results showed that the peak–valley difference in the 3D MMS increases with increasing load and defect size, and the peak–valley spacing in the 3D MMS is not influenced by applied load but increases with increasing defect size. The 3D MMS gradient exhibits a good correlation with the equivalent stress along the loading direction. Additionally, the applied load and defect size were quantitatively evaluated by utilizing the Lissajous figure area generated from the X and Z components of the 3D MMS. Finally, a nonlinear fitting equation for defect size evaluation was presented. This study can provide a theoretical basis for the quantitative detection and evaluation of defect size and stress in engineering applications. Full article

HOP–graphene is a graphene structural derivative consisting of 5-, 6-, and 8-membered carbon rings with distinctive electrical properties. This paper presents a systematic investigation of the effects of varying sizes, strain rates, temperatures, and defects on the mechanical properties of HOP–graphene, utilizing molecular dynamics simulations. The results revealed that Young’s modulus of HOP–graphene in the armchair direction is 21.5% higher than that in the zigzag direction, indicating that it exhibits greater rigidity in the former direction. The reliability of the tensile simulations was contingent upon the size and strain rate. An increase in temperature from 100 K to 900 K resulted in a decrease in Young’s modulus by 7.8% and 2.9% for stretching along the armchair and zigzag directions, respectively. An increase in the concentration of introduced void defects from 0% to 3% resulted in a decrease in Young’s modulus by 24.7% and 23.1% for stretching along the armchair and zigzag directions, respectively. An increase in the length of rectangular crack defects from 0 nm to 4 nm resulted in a decrease in Young’s modulus for stretching along the armchair and zigzag directions by 6.7% and 5.7%, respectively. Similarly, an increase in the diameter of the circular hole defect from 0 nm to 4 nm resulted in a decrease in Young’s modulus along both the armchair and zigzag directions, with a corresponding reduction of 11.0% and 10.4%, respectively. At the late stage of tensile fracture along the zigzag direction, HOP–graphene undergoes a transformation to an amorphous state under tensile stress. Our results might contribute to a more comprehensive understanding of the mechanical properties of HOP–graphene under different test conditions, helping to land it in potential practical applications. Full article

This paper is a summary of many of the key findings on the application of geosynthetics in tailings storage facilities. Topics include the compressibility and permeability of tailings, the equations predicting leakage through circular and non-circular geomembrane holes, the effect of the subgrade permeability, and the effect of a lateral drainage system within tailings on leakage predictions. Two commonly encountered engineering problems relating to the piping through circular geomembrane holes and the opening width of non-circular defective geomembrane seams are given to demonstrate the potential application of leakage prediction equations. Meanwhile, issues related to the subgrade imperfection and the long-term performance of both high-density polyethylene (HDPE) and bituminous geomembranes in tailings storage applications are addressed. The research highlights that an appropriate HDPE geomembrane liner can be expected to perform very well for an extremely long time, limiting leakage and contaminant migration from the facility into the surrounding environment if the liner is well constructed on a suitable subgrade. Full article

The combination of Atomic Diffusion Additive Manufacturing (ADAM) and traditional CNC machining allows manufacturers to leverage the advantages of both technologies in the production of functional metal parts. This study presents the methodological development of hybrid manufacturing for solid copper parts, initially produced using ADAM technology and subsequently machined using a 5-axis CNC system. The ADAM technology was dimensionally characterized by adapting and manufacturing the seven types of test artifacts standardized by ISO/ASTM 52902:2019. The results showed that slender geometries suffered warpage and detachment during sintering despite complying with the design guidelines. ADAM technology undersizes cylinders and oversizes circular holes and linear lengths. In terms of roughness, the lowest results were obtained for horizontal flat surfaces, while 15° inclined surfaces exhibited the highest roughness due to the stair-stepping effect. The dimensional deviation results for each type of geometry were used to determine the specific and global oversize factors necessary to compensate for major dimensional defects. This also involved generating appropriate over-thicknesses for subsequent CNC machining. The experimental validation of this process, conducted on a validation part, demonstrated final deviations lower than 0.5% with respect to the desired final part, affirming the feasibility of achieving copper parts with a high degree of dimensional accuracy through the hybridization of ADAM and CNC machining technologies. Full article

The issue of water seepage poses a significant challenge in tunnel infrastructure. Wet areas are commonly used to evaluate the degree of water seepage in tunnel projects. To investigate the feasibility for numerical simulation to predict a wet area, we selected concrete test blocks with two types of defects—holes and cracks—as the research specimens. Numerical models for various seepage conditions were constructed using TOUGH2, and the results were validated through laboratory experiments. Additionally, the Shenjiamen Subsea Tunnel was simplified into a numerical model, employing TOUGH2 to forecast its future wet area performance within the scope of national standards. The outcomes of our research revealed that point seepage and line seepage exhibited circular and elliptical morphologies, respectively. Moreover, external water pressure and defect size exerted a significant influence on the expansion of the wet area. Notably, the impact of crack width surpassed that of hole diameter. Encouragingly, the numerical models generated using TOUGH2 for unsaturated concrete demonstrated excellent agreement with laboratory test results concerning the geometry, size, and pattern of the wet area. These findings signified the potential of TOUGH2 numerical simulation as a valuable tool in predicting the lifespan of tunnels. Full article

This paper deals with an experimental investigation of hole quality in Al2024-T3, which is one of the aerospace alloys used in aircraft fuselage skin due to its high level of resistance to fatigue crack propagation. The experiments are conducted with 6 mm uncoated carbide and HSS drill bits using a CNC machine under dry conditions and different drilling parameters. The characteristics of the hole quality are investigated in terms of its perpendicularity, cylindricity, circularity and hole size. An ANOVA (analysis of variance) and Pareto charts are used to analyze the effects of the drilling parameters on the hole quality. The hole quality is also assessed using a digital microscope to observe the formation of hole burrs. Moreover, scanning electron microscopy is also used to investigate the inside-hole surface defects. Further investigations are carried out using optical microscopy to inspect the post-drilling tool condition at high drilling parameters. The results show that hole quality reduces as the feed rate and spindle speed increase. However, from the ANOVA results and Pareto charts, the influence of the feed rate on the hole quality is found to be insignificant. At the same time, the type of drill bit material shows the highest percentage of contribution affecting the hole quality, following the spindle speed. The HSS drill bit shows more adhesion and built-up edges than the uncoated carbide drill bit. There were more burrs formed at the hole edges when the holes were drilled with uncoated HSS drill bits. In the same way, the SEM analysis reveals more surface deformation and damage defects inside the hole walls of holes drilled using the uncoated HSS drill bit. Full article

The magnetic flux leakage (MFL) detection technique is applied to the detection of weld defects, such as cracks and pores. As the weld has a distinct structure, there are differences in the magnetization path and leakage field intensity under different magnetization directions. According to surveys, a suitable magnetization direction can significantly enhance detection rates of small-sized defects by stimulating a stronger field signal of the defect leakage. In this study, ANSYS finite element simulation software is used to calculate the weld defect leakage field based on the quantitative analysis. Specifically, the leakage field component strengths of circular hole defects and longitudinal rectangular groove defects are compared when the magnetization direction is perpendicular or parallel to the weld. Furthermore, the characteristic rules of the defect leakage field and its components under any magnetization direction are discussed, and a weld MFL detection platform is set up for validation. According to the experimental results, the amplitude of the magnetic leakage signal during vertical magnetization of circular hole defects is only 18.6% of that during parallel magnetization. Similarly, the amplitude of the magnetic leakage signal during parallel magnetization of longitudinal crack-type defects is only 9.2%~29.3% of that during vertical magnetization. Full article

A novel three-dimensional theoretical model of magnetic flux leakage (MFL) is proposed in this paper based on the magnetic dipole model. The magnetic dipole model assumes that a ferromagnetic specimen with defects is exposed to a uniform external magnetic field that causes a uniform magnetization around the defect surface. Under this assumption, the MFL can be regarded as arising from magnetic charges on the defect surface. Previous theoretical models were mostly used to analyze simple crack defects such as cylindrical and rectangular cracks. In this paper, we developed a magnetic dipole model for more complex defect shapes such as circular truncated holes, conical holes, elliptical holes, and double-curve-shaped crack holes to complement the existing defect shapes. Experimental results and comparisons with previous models demonstrate that the proposed model provides a better approximation of complex defect shapes. Full article