Search Results (141)

Under long-term marine environmental loading, deep-water risers are highly susceptible to fatigue damage, and the accumulation of local damage may lead to global structural failure. In this study, the fatigue damage mechanism and crack growth behavior of a girth-welded riser are systematically investigated. Full-scale radial fatigue test results of risers are referenced, and the experimental process is reproduced through numerical simulation. A finite element model of a girth-welded riser is established. The fatigue crack growth process is subsequently simulated, yielding the crack propagation path and crack growth rate curves. By comparison with experimental results, the characteristics of the crack growth process are analyzed, and the feasibility and accuracy of numerical simulations in predicting fatigue crack growth in riser girth welds are verified. A relatively accurate prediction model for fatigue crack growth in risers is proposed. To further improve the accuracy of crack growth prediction, a machine learning-based correction model is developed. On the basis of available in-service inspection data, a correction strategy is proposed in which the predicted crack growth process is dynamically updated with measured crack growth data. The proposed approach establishes a theoretical foundation for accurate and forward prediction of fatigue fracture damage in riser structures. Full article

Three-edge bearing (TEB) tests and a crack-width-dependent load-carrying model were used to assess the combined effects of recycled glass fiber-reinforced polymer (rGFRP) short fibers and glass fiber-reinforced polymer (GFRP) bars in concrete pipes. Using the force method, a circumferential statically indeterminate ring analysis was formulated to obtain internal forces at critical sections and the neutral-axis position. Fiber distribution was simulated by means of Monte Carlo sampling, and single-filament pull-out tests were fitted to relate embedded length to pull-out force, enabling calculation of the fiber-bridging contribution at cracked sections. Ten specimen types with different bar/fiber schemes were tested under external pressure to validate the model. Predicted cracking and ultimate loads agreed with measurements, with most errors within ±20%. Adding 1% (vol.) rGFRP fibers increased the cracking load by 11.81% and the ultimate load by 0.45%. Without fibers, replacing steel bars with equal-area GFRP bars increased the cracking load by 1.35% but reduced the ultimate load by 35.45%. For all specimens, the load–maximum crack-width relation was strongly linear (R² > 0.93). The proposed approach and dataset support engineering use of recycled GFRP materials for crack control and load-carrying design of concrete pipes. Full article

The utilization of hydrogen as a clean energy carrier requires an assessment of existing natural gas pipelines with respect to hydrogen embrittlement (HE). In this study, the structural integrity and hydrogen sensitivity of X52 (L360) pipeline steel from the Bulgarian gas transmission network after 31 years of service were investigated, focusing on production (longitudinal) and girth (circumferential) welded joints. Hydrogen content was measured in the base metal, production weld and girth weld before and after electrochemical charging, while in situ hydrogen charging during tensile testing was applied to simulate service conditions. Mechanical behavior was evaluated by tensile tests, and microstructural and fracture characteristics were analyzed by SEM and TEM. The results show significant spatial variations in hydrogen concentration, related to local microstructural heterogeneity and hydrogen trapping. In the as-operated state, fracture was localized mainly in the heat-affected zone. Hydrogen charging led to a pronounced reduction in ductility (approximately twofold), whereas yield and tensile strengths were only slightly affected. Failure analyses indicate a transition toward more brittle fracture mechanisms, dominated by quasi-cleavage and intergranular cracking in the as-charged state, with hydrogen embrittlement susceptibility indices demonstrating higher hydrogen sensitivity of the girth-welded joints. Full article

In marine renewable energy applications, offshore steel pipelines are subjected to complex combined loads during installation and operation, leading to significant plastic deformation and potential catastrophic fracture. To accurately characterize pipeline fracture failure, this study develops an enhanced failure assessment framework based on the Modified Mohr–Coulomb (MMC) criterion, integrating experimental parameter evaluation with numerical simulation for in-service offshore pipelines. The key parameters of the MMC model were determined directly from in-service pipeline samples to account for operational degradation. First, the plastic parameters were obtained by fitting the Swift hardening law to uniaxial tensile tests. Fracture parameters were then calibrated using a suite of five notched tensile specimens. Mesh sensitivity was analyzed using CT experiments to establish a suitable mesh size for the MMC-based damage model, enabling precise characterization of crack evolution from initiation to final tearing. Unlike prior applications, this framework is employed to investigate the response of X80 pipelines under combined tension, bending, and external pressure loading. Three-dimensional finite element models were developed to systematically analyze the stress–strain response, moment–curvature behavior, and evolution of hoop stress distribution. Results show that while the failure stress remains relatively stable under varying external pressure, both the critical strain and critical curvature increase markedly with pressure, by up to 20.9%. They also reveal a pronounced hierarchy in the influence of crack geometry on the failure behavior. Crack depth dominates failure sensitivity, affecting critical strain and pressure response far more than crack width or length. The reduction in failure stress for deep cracks under 12 MPa external pressure is over three times greater than for shallow cracks. In contrast, variations in crack length exert the most negligible influence on failure characteristics, with observed discrepancies of less than 6%. Overall, this research provides a high-precision failure prediction framework for in-service pipelines by quantitatively analyzing failure behavior under combined loads. It effectively characterizes failure evolution paths that differ from design conditions and dynamically tracks the residual fracture resistance after time-dependent degradation, offering a fundamental reference for the reliability assessment of pipelines in complex marine environments. Full article

During circumferential tensioning of prestressing strands in U-shaped aqueducts, longitudinal tensile stresses may develop and impair crack resistance. Most existing studies rely on three-dimensional finite element (FE) simulations. Although accurate, FE modeling is time-consuming and unsuitable for rapid scheme evaluation during construction. To overcome this limitation, the U-shaped aqueduct was first simplified as a cylindrical shell and the feasibility of this idealization was verified. An approximate analytical solution was then derived from cylindrical shell theory to predict the longitudinal stress induced by circumferential prestressing. Practical factors, including non-uniform wall thickness, non-equidistant strand spacing, and strand positional deviations, were incorporated to improve engineering applicability. FE results confirm good agreement, with RMSE of 0.055–0.169 MPa and NRMSE of 2.3–19.6%, where the upper bound occurs only in localized regions. The method was further applied to an engineering project to optimize the tensioning scheme. With a rational interval-tensioning procedure, the peak longitudinal tensile stress was reduced by 31.6%. Overall, the proposed approach enables rapid stress estimation and supports preliminary screening and optimization of circumferential tensioning schemes. Full article

Powder bed compaction can be used to control powder bed density in binder jetting additive manufacturing. Applying a forward-rotating roller to the powder bed is one of the methods for powder bed compaction. Both the compaction rotation speed and compaction thickness are critical parameters affecting the powder packing density and resultant printed sample integrity. However, their joint effects have not been investigated for roller-compaction-assisted binder jetting. This paper reports an experimental study to investigate the effects of the compaction rotation speed and the compaction thickness on powder bed density and the printed sample quality (in terms of distortion and cracks). The experimental results showed that powder bed density was not affected by changing compaction rotation speed but was enhanced by increasing compaction thickness. Small compaction thickness did not cause any observable distortions or cracks in the printed samples at any compaction rotation speed. Large compaction thickness caused printed samples to distort and crack under specific conditions. At large compaction thickness, compaction rotation speed significantly affected both the direction and extent of the printed sample distortion. Samples with improved density and integrity were achieved in the center of the build platform at large compaction thickness and at a compaction circumferential speed larger than the compaction traverse speed. These results can help optimize binder jetting additive manufacturing for printed sample quality. Full article

In the field of oil and gas transportation, X80 pipelines are susceptible to localized plastic deformation caused by mechanical impact or geological activity. This leads to the formation of dents and the introduction of pre-strain, thereby affecting the structural integrity and fatigue life. This study systematically investigates the influence mechanism of pre-strain on the high-cycle fatigue performance of dented regions in X80 steel. Fatigue tests conducted across pre-strain levels of 1%, 2%, and 3% revealed that the induced plastic strain significantly degrades fatigue performance. Under constant stress amplitude, fatigue life decreases markedly with increasing pre-strain, a trend driven by the accumulation of micro-damage. Furthermore, a parametric P-S-N curve model that incorporates both pre-plastic strain and reliability was developed, providing a basis for quantitatively assessing the impact of pre-strain. By combining finite element analysis with the Smith-Watson-Topper (SWT) critical plane method, it was predicted that fatigue cracks in unconstrained dent primarily initiate at the dent periphery, with the critical plane orientation perpendicular to the circumferential direction, which aligns well with field observations. Parametric analysis indicates that the maximum operating pressure is the dominant factor affecting the fatigue life of the dented pipelines. This research elucidates the material-level fatigue failure characteristics of dented X80 pipelines and provides theoretical insights for life prediction and engineering protection. Full article

Threaded component fatigue failure is a severe issue in cyclically loaded mechanical systems, and the service life in these systems is controlled primarily by stress concentration at the thread root, especially in loading regimes dominated by bending. Rounded thread profiles such as knuckle threads have been thought to improve fatigue performance, although this is mostly due to the assumption being made on the basis of axial loading, the numerical stress analysis, and/or isolated stress-concentration analyses. This paper presents an experimental study on the fatigue behavior of knuckle-thread and conventional screw-thread specimens manufactured from AISI 1045 steel under rotating bending loading to determine the effects of thread geometry on fatigue life and damage mechanisms. Fatigue testing was conducted at varying stress levels to develop comparative stress–life (S–N) curves, the analytical relation being used in determining the stress-concentration factor, and standard literature techniques have been used in the analysis of fracture-surface in order to investigate the behavior of crack initiation and propagation. Results indicate that knuckle threads exhibit a lower stress concentration factor (K_t ≈ 1.59) than screw threads (K_t ≈ 2.11), resulting in longer fatigue life at the same nominal stress level, particularly in the high-cycle life regime. Fractographic research also indicates that knuckle threads enhance delayed crack initiation and more evenly distributed circumferential crack propagation, but screw threads show highly localized crack initiation and rapid radial propagation of cracks, resulting in earlier unstable fracture. These findings provide new experimental evidence that the improved fatigue performance of knuckle threads during rotating bending is linked to fundamental change in fatigue damage mechanism rather than to stress alleviation alone, thereby offering quantitative supporting guidance in designing fatigue-sensitive threaded components to experience cyclic bending. Full article

To investigate the mechanical properties, energy evolution, and failure behavior of coal–rock composite structures under mining disturbances, a mining-induced stress path was designed based on the actual stress evolution ahead of a mining face. Triaxial tests were carried out under these stress conditions on coal–rock composite samples at various confining pressures, supplemented by conventional triaxial compression tests for comparison. The results show that the coal–rock composite samples exhibited marked brittle failure under mining-induced stress, with no sign of the brittle–ductile transition observed in conventional triaxial tests as the confining pressure increased. Using dual circumferential extensometers, it was found that the circumferential deformation of the coal and rock was initially governed by their intrinsic mechanical properties and later controlled by crack propagation. At higher confining pressures, the growth rate of circumferential strain at failure increased significantly, indicating that deeper excavations result in more severe unloading-induced failure. Comparative analysis revealed that the coal component had a higher elastic energy density and faster energy accumulation and release rates than the rock, identifying coal as the dominant medium for elastic energy storage and release within the composite samples. Furthermore, at peak stress in mining-induced stress tests, the coal showed less circumferential deformation than in conventional tests, while the rock exhibited the opposite trend, confirming the presence of a bonding constraint effect at the coal–rock interface. These findings enhance our understanding of the mechanical behaviors and failure mechanisms of coal–rock composites under mining disturbances, thus providing practical guidance for ensuring safety and efficiency in deep coal mining. Full article

Steel plates with open holes are common in engineering structures such as bridges and towers for pipeline penetrations and connections. These openings, however, induce significant stress concentration under alternating tension–compression loading (stress ratio R = −1), drastically accelerating fatigue crack initiation and threatening structural integrity. Effective identification and mitigation of such stress concentrations is crucial for enhancing the fatigue resistance of perforated components. This study proposes a closed-loop methodology integrating theoretical weak zone identification, targeted CFRP reinforcement, and experimental validation to improve the fatigue performance of open-hole steel plates. Analytical solutions for dynamic stresses around the hole were derived using complex function theory and conformal mapping, identifying critical stress concentration angles. Experimental tests compared unreinforced and CFRP-reinforced specimens in terms of circumferential strain distribution, dynamic stress concentration behavior, and fatigue life. Results indicate that Carbon fiber-reinforced polymer (CFRP) reinforcement significantly reduces stress concentration near 90°, smooths polar strain distributions, and slows strain decay. The S–N curves shift upward, indicating extended fatigue life under identical stress amplitude and increased allowable stress at identical life cycles. Comparison with standardized design curves confirms that reinforced specimens meet higher fatigue categories, providing practical design guidance for perforated plates under alternating loads. This work establishes a systematic framework from theoretical prediction to experimental verification, offering a reliable reference for engineering applications. Full article

The rehabilitation of critical water-conveyance infrastructure plays a fundamental role in the water–energy nexus and constitutes a key strategy for extending the operational lifetime of hydropower facilities. These interventions are aligned to the United Nations’ 2030 Agenda, which declare that ensuring access to affordable, reliable, sustainable, and modern energy systems is essential for long-term energy security. This paper presents a field-validated, non-thermal repair methodology developed for the Chivor II hydropower penstock, a critical water conduction tunnel used for energy production in Colombia, that has been affected by a circumferential fatigue crack. Due to the geometric confinement of the penstock within the rock mass, conventional thermal or stress-relief treatments were unfeasible. Therefore, the proposed methodology uses controlled material removal with a welding sequence designed to release stored elastic energy and induce compressive stresses through the Poisson effect. Its main contribution is demonstrated through pilot-scale validation and full-scale implementation under real operating conditions, achieving 50% reduction in tensile stresses and left 99% of the examined surface under compression, which represents effective residual-stress stabilization, structural recovery, and hydraulic reliability. The methodology ensures reliable water conveyance for hydropower generation and can be applied to other pressurized conduits and pipelines where accessibility and heat treatment are constrained, strengthening SDGs 7 and 9 on clean energy, water sustainability, and resilient infrastructure. Full article

Controlled geometry defects can be volumetric defects, usually located on the outer surface of the pipe, having different orientations and lengths and identical depths. This type of defect corresponds to the type obtained using a damage mechanism, as presented by API 579-1/ASME FFS-1, Part 9, called crack-type defects. The research presented in this paper was intended to evaluate the influence of controlled defects on the strength of an HDPE water pipe, PE100 (Ø 90 × 5.4), SDR 17, PN 10 bar, subjected to internal pressure. The methods applied were the internal pressure test and numerical simulation. The article’s main findings were the critical pressure P_cr, the critical time t_cr, the critical depth of defect a_cr, and the remaining service life t. The remaining service life was approximately 83 years for the pipe with a defect oriented circumferentially, and 69 years for the pipe with a defect oriented longitudinally. Full article

In recent years, construction has started on several high arch dams in the southwestern region of China, and the problem of concrete crack prevention has become prominent. During the construction period of the foundation gallery of high arch dams, the stress is high and there are many influencing factors, making it more prone to cracking, and there is relatively little systematic research on this issue. This article focuses on the cracks in the 733 m gallery of the 7th section of a super-high arch dam. Using self-developed 3D finite element software, the stress spatiotemporal distribution and influencing factors during the construction period were analyzed. Research has shown that a decrease of 4 °C in the average annual temperature inside the gallery results in an increase of approximately 0.25 MPa in surface stress on the arch and bottom plates. When poured to an elevation of 870 m, the circumferential stress caused by the self-weight on the arch of the gallery is 2.3 MPa, but it decreases to 0.9 MPa at a distance of 0.3 m from the surface of the arch. The stress at both ends of the bottom plate before and after the arch sealing is always greater than that in the middle, with a maximum stress of about 2.4 MPa. The selection of material parameters has a significant impact on the evaluation of crack resistance. When calculating the mechanical parameters of fully graded concrete, the crack resistance safety of the arch crown and bottom plate is significantly reduced. It is recommended to focus on strengthening the water cooling and “winter period” insulation measures for the arch crown and bottom plate during gallery construction and to use fully graded test parameters in simulation analysis to improve calculation accuracy and structural safety. The research results can provide reference for similar projects. Full article

Submerged floating tunnel (SFT) may be subjected to sudden explosive loads such as internal vehicle explosions, terrorist attacks, and external explosions during operation. Based on the Arbitrary Lagrange–Euler (ALE) method, the locally truncated SFT model and fluid–structure interaction model of internal air and external water are established. Spherical explosives are used to simulate the destructive impact of internal explosions at different positions of the road inside the SFT and key positions at the bottom of the road. The results show that the peak accelerations at the monitoring points caused by the explosions of vehicles on the road rapidly decay within a range of three times the radius of the SFT, and circularly distributed damage appears on the explosion-facing side of the road surface. Longitudinal extensional damage occurs at the junction of the road surface and the SFT wall as well as the bottom supporting wall. Longitudinal cracks appear on the SFT wall. The peak accelerations at the monitoring points of the internal road caused by the concealed bomb at the bottom of the SFT rapidly decay within a range of twice the radius of the SFT, and the damage to the SFT is mainly concentrated on the road surface and the supporting wall. The most dangerous direction of external underwater explosion is determined to be directly below the SFT. When the scaled distance of the explosion is less than 0.543 m/kg^1/3, the accelerations at the monitoring points of the internal road show a single-peak trend with rapid rise and decay, and circumferential through-cracks appear on the SFT wall. The supporting wall connecting the SFT wall and the internal road transmits stress to the road, causing extensive damage. Full article

Chromizing layers are widely employed in industrial applications due to their superior wear resistance and corrosion resistance. In this study, GCr15 bearing steel was chromized by a solid powder pack chromizing method, and the influence of chromizing time on the microstructure and mechanical properties of the chromized layers was systematically investigated. The results reveal the presence of fine pores dispersed both on the surface and at the chromized layers/substrate interface. The concentration of the Cr and Fe elements displays a gradient distribution throughout the layers. The chromized layers are primarily composed of (Cr,Fe)₂₃C₆ and (Cr,Fe)₇C₃ phases. With an increase in the chromizing time, the thickness and hardness of the chromized layers are gradually increased. A large number of radial and circumferential cracks are observed both within and around the indentation regions, accompanied by spalling at the edge. The brittleness of the chromized layer is increased, and the spalling phenomenon becomes more pronounced with prolonged chromizing time. The chromizing treatment significantly improves the tribological performance of GCr15 steel, reducing its wear rate to approximately one fifth of that of the untreated substrate. Full article