Search Results (642)

The formation of hard/brittle layers (HBLs) forming in proximity to the transition-layer interface during the welding process of stainless steel clad plates constitutes a pivotal element in determining the limitations on joint homogeneity and toughness. In order to elucidate their formation mechanisms and develop viable suppression routes, S31603/Q420qENH clad plates were utilised to fabricate five butt joints. This was achieved by varying the carbon content of the welding consumables and the heat input in the transition layer. A programme was conducted that combined microstructural and microhardness characterisation, mechanical testing, and numerical welding simulations. The findings indicate that base-layer consumables with comparatively elevated carbon content (w(C) ≥ 0.06%) expeditiously engender a constricted, localised hardened band in close proximity to the transition-layer interface. This is characterised by the predominance of martensite and Cr-rich compounds of the M_xCr_y type, which function as the principal genesis of bending cracks. Conversely, the utilisation of low-carbon welding consumables has been shown to markedly reduce interfacial carbon activity and C-Cr segregation, thereby suppressing the precipitation of M_xCr_y phases and effectively decreasing the overall thickness of the HBLs. Further numerical analysis shows that moderately increasing the transition-layer heat input lowers the T_8/5 cooling rate and shifts the cooling path away from the martensite region. This transforms the interfacial microstructure from a localised hardened band into a more uniform, graded structure. These findings provide an engineerable process-control strategy for enhancing both microstructural uniformity and toughness in stainless steel clad joints. Full article

To improve the impact resistance of composite materials, this study adopted the structures in the impact region of mantis shrimp appendages as a bionic prototype, designing a composite structure with a rigid outer layer and flexible sinusoidal inner layer. Meanwhile, bionic arrangement was conducted on the fibers in three directions (X-Y, X-Z, and Y-Z planes) within the flexible layer to regulate the crack propagation path during the impact process. Finite Element Method and low-velocity impact tests were carried out to verify the structural effectiveness, analyze the energy absorption mechanism, and investigate the failure modes. Relative to the basic rigid-flexible structure, the brick-and-mortar (Y-Z) and vertical-horizontal alternating fiber (X-Y) models show a 94% and 109% improvement in kinetic energy absorption efficiency, respectively. Additionally, the catastrophic damage in the impact center area caused by crack concentration is significantly reduced. This study confirms that the bionic 3D arrangement of fibers can realize interlayer connection, optimize crack distribution, and enhance energy dissipation, thereby improving the impact resistance of composite materials. Full article

The microstructural characteristics and fracture behavior of a magnetic pole screw were investigated here. The screw threads were produced by cold thread rolling. Microstructural analysis (OM, SEM, EBSD), mechanical testing (tensile, hardness, fastening), and fracture morphology observation were conducted. The results indicate that work hardening and microstructural deformation were introduced by the gradient plastic deformation in the screw thread. The elongated microstructure of ferrite and pearlite was obtained in the deformation zones, resulting in increased hardness and decreased plasticity. The thread root subsurface experienced severe localized indentation deformation and exhibited the highest hardness. The distinct forming stress states led to a notable difference in the hardened layer depth between the thread crest and root. The torsional overload fracture was initiated at the stress-concentrated thread root, where the work-hardened microstructure exhibited a limited capacity to accommodate large plastic deformation. The crack propagation was influenced by the gradient microstructure, following three primary propagation paths: transgranular through ferrite, along the ferrite–pearlite phase interface, and cracking through lamellar pearlite. The results provide theoretical support for material design and process optimization to achieve the production of high-performance screws with high strength and hardness at the thread surface and high plasticity in the center. Full article

This study investigates the complex relationship between fracture patterns and acoustic emission (AE) mechanisms during triaxial deformation experiments on Westerly granite under various confining pressures (5, 10, 20, and 40 MPa). Using numerical simulations with the Particle Flow Code (PFC2D, 6.0, Itasca Consulting Group Inc., Minneapolis, MN, USA), this research emphasizes the significant influence of confining pressure on crack development, AE events, spatiotemporal distribution, energy dissipation, and peak stress in the samples. AE source mechanisms, categorized into T-Type, C-Type, and S-Type, show the dominance of T-Type fractures during post-peak unstable failure and the emergence of C-Type fractures as precursors to critical damage. Additionally, increasing confining pressure is found to correlate with changes in fracture dynamics, evidenced by an increase in big events and a decrease in small events. The analysis of b-values across different pressures reveals fluctuations that indicate change in fracture features. Fractures originate in the model center and propagate towards both ends as loading progresses, ultimately leading to failure. In summary, these findings provide important insights into the fracture patterns of granite and the underlying mechanisms of AE release. Moreover, they carry practical implications for identifying failure precursors and for the potential application of early warning systems in rock engineering. Full article

Accurate quantification of the crack-tip driving force $\left(∆K\right)$ is fundamental to predicting the fatigue life of engineering structures. Analytical formulations of $∆K$ are rarely available for components with complex geometries. In such cases, finite element (FE) analysis has become a widely accepted approach for determining $∆K$. In this study, an FE-based solution for the crack-tip driving force of a fatigue crack in an asymmetric L-shaped bell crank geometry, a representative complex structure, is established. The structure is fabricated from AISI 410 martensitic stainless steel. The FE-predicted $∆K_I$ for crack growth in the Paris regime has been independently validated using the fractal crack-tip driving force model. Results show that the fatigue crack in the bell crank structure is driven by a combined Mode-I (opening) and Mode-II (shearing) crack-tip loading along a curved crack-path trajectory, as dictated by the asymmetric stress distribution. The fatigue crack edge exhibits fractality with fractal dimensions ranging from 1.00 (Euclidean) to 1.18 along the crack length ($a-a_0$) up to 9.947 mm. The FE-calculated crack-tip driving forces of the bell crank structure are comparable with those computed based on the corrected crack edge fractal dimensions, thus validating the FE simulation outcomes. The resulting fatigue crack growth rates, determined from crack-tip driving forces based on validated FE-computed contour integrals, are comparable to those obtained from the ASTM standard tests. Full article

The punching shear capacity of reinforced ultra-high-performance concrete (UHPC) two-way slabs in applications such as floor slabs and bridge decks has attracted increasing attention. However, due to the insufficient consideration of the internal force transmission path and failure mechanism, existing empirical formulas exhibit limited accuracy for predicting the punching shear capacity of reinforced UHPC slabs. Therefore, based on the critical shear crack theory (CSCT), this study proposes a specific theoretical model where the tensile strain-hardening behavior and tensile strength of UHPC, the punching shear-span ratio, and the reinforcement ratio are comprehensively considered. In the proposed model, the steel fiber bridging contribution is derived via the variable engagement method (VEM), for which an equation describing the bond strength between steel fibers and UHPC matrix was developed. The feasibility of the proposed model was validated through an established experimental database. Furthermore, the effects of several key parameters on the punching shear behavior of reinforced UHPC slabs were analyzed. The results show that the proposed models can accurately predict the punching shear capacity and ultimate rotation angle of reinforced UHPC slabs. With increasing slab thickness, UHPC strength, and reinforcement ratio, the punching shear capacity increases, whereas the corresponding ultimate rotation angle and steel fiber contribution ratio decrease. Increasing the fiber volume fraction enhances both the fiber contribution and the punching shear capacity. For slabs with higher UHPC strength, the reinforcing effect of a higher reinforcement ratio is more pronounced. Full article

This study developed a combined computational-experimental approach to investigate crack kinking in thick adhesively bonded Glass Fibre Reinforced Polymer (GFRP) composite joints, focusing on the adhesive joints found at wind turbine blade trailing edges. Double Cantilever Beam (DCB) tests were performed on composite joints with a 10-mm thick epoxy adhesive, representative of trailing-edge joints. Finite Element (FE) models included cross-ply GFRP composites and an adhesive layer. Subsequently, both the composite/adhesive interfaces and voids were explicitly modelled, allowing separate and combined evaluations of their effects on crack kinking. A cohesive zone model was used to capture the fracture along the composite/adhesive interfaces, while a Drucker-Prager plasticity model combined with a ductile damage model was used for the adhesive. The numerical findings indicated that crack kinking in FE simulations with explicit interfaces was primarily governed by the lower fracture resistance of the composite/adhesive interface relative to that of the bulk adhesive. Voids with a total volume fraction of approximately 1% were modelled by randomly deleting cubic 1 mm C3D8R elements in the adhesive layer to reproduce the voids typically observed in thick adhesive joints. The predicted crack paths closely matched experimental results. Simulations with voids revealed that voids above or below the adhesive midplane caused crack deflection toward the nearest interface. In models combining both features, cracks were consistently redirected toward the composite/adhesive boundary near voids, reproducing experimental observations. These results provide new insights into trailing-edge adhesive joint failure and establish a foundation for better modelling and design. Full article

This research examines how atmospheric plasma spraying torch power and coating thickness jointly affect the adhesion strength, microstructure, porosity, and flexural behavior of $A{l}_2{O}_3$ coatings on 100Cr6 steel substrates. Optical microscopy, SEM and EDS mapping, 3D surface-roughness analysis, Vickers hardness testing (HV2) on polished cross-sections, and three-point bending of extracted beams were employed to develop a processing–structure–property map. This multi-technique approach enables the cross-validation of processing–structure–property relationships and supports a robust identification of the optimal power–thickness condition by jointly considering porosity (densification), adhesion strength, flexural response and failure mode. All conditions resulted in an average surface roughness Ra of approximately 1.0 µm. Increasing torch power to 45 kW generally reduced cross-sectional porosity, except at 500 µm, where globular pores appeared. Hardness (HV2) increased with power and peaked at the intermediate thickness (500 µm); adhesion up to 63 MPa was recorded for the 300 µm/45 kW coating. Flexural strength was highest at 500 µm and was consistently greater at 45 kW than at 39 kW. Fractography showed a shift in failure mode from interface-driven delamination at 39 kW to more cohesive, tortuous intra-coating cracks at 45 kW, aligned with improved splat bonding and crack-path deflection. An intermediate thickness of 500 µm deposited at 45 kW is thus identified as an optimal condition to balance densification and crack-path tortuosity, leading to enhanced hardness and flexural performance. Full article

This paper examines the applicability of the fracture forming limits (FFLs) derived from conventional monotonic upset compression tests for assessing the formability of non-monotonic strain loading paths. The work uses a simple test specimen subjected to various non-monotonic deformation histories, and combines experimental force measurements, digital image correlation, finite element analysis, and scanning electron microscopy (SEM) to characterize strain loading paths and crack opening mechanisms under varying testing parameters. Results demonstrate that non-monotonic strain loading paths can result in fracture strains that differ from those obtained through conventional monotonic bulk formability tests in the effective strain versus stress triaxiality space, depending on the considerations made in the transition between different loading stages. Consequently, reliance on monotonic test data may lead to inaccurate predictions of cracking in multi-stage industrial bulk forming processes. Full article

As a critical aerospace structural material, the fatigue crack propagation behavior and fatigue life of the nickel-based GH4169 superalloy are directly related to the service safety of engineering components. The crack closure effect is one of the key factors influencing the fatigue life of metallic materials. At present, the finite element method (FEM) is widely used to investigate fatigue crack propagation in metals. However, the commercial software ABAQUS 2021b employs the conventional Paris law for crack growth simulation, which neglects the influence of crack closure. In addition, ABAQUS cannot simultaneously perform fatigue life prediction and crack path prediction within a single numerical model. To overcome these limitations, the bi-prism-based single-lens (BSL) three-dimensional digital image correlation (3D DIC) technique was employed to experimentally investigate the crack closure behavior during fatigue crack propagation in GH4169 compact tension (CT) specimens. A new parameter, termed the crack opening ratio (COR), was introduced to quantitatively characterize the crack closure effect. Furthermore, a self-developed plugin was implemented on the ABAQUS platform through secondary development, enabling the numerical model to incorporate the influence of crack closure during fatigue crack propagation. The plugin automatically records the crack tip coordinates at each propagation step, calculates the stress intensity factors near the crack tip, and predicts the corresponding fatigue life, thereby integrating crack path prediction and fatigue life prediction within a unified framework. The results demonstrate that the COR effectively characterizes the crack closure effect in the numerical model, and the predicted fatigue life agrees with experimental results within an 11% deviation once the crack reaches a certain length. Full article

As the core load-transfer medium in bonded structures, the adhesive layer critically governs overall reliability, with Mode I fracture representing its dominant failure mechanism under tensile loading. This study systematically compares the eXtended Finite Element Method (XFEM) and its two coupled variants—the XFEM-Cohesive Zone Model (CZM) and XFEM-Virtual Crack Closure Technique (VCCT)—in simulating Mode I fractures of adhesive joints. Key comparisons include predictions of stress distribution, load-transfer evolution, and crack propagation paths, all validated through Double Cantilever Beam (DCB) simulations and experiments. Results show that standard XFEM accurately predicts initial stiffness (error < 8%) but overestimates peak load by 10.7%. XFEM-CZM maintains errors below 8% for both stiffness and peak load, while XFEM-VCCT achieves exceptional peak-load accuracy (error < 1%) but overestimates stiffness. In crack evolution, standard XFEM yields an idealized propagation path, whereas the coupled methods reveal a distinct three-stage process. Stress/strain fields in standard XFEM remain stable during propagation, while the coupled approaches exhibit interfacial irregularities before crack arrival, followed by tip concentration and band-like transfer during stable growth. Each method offers distinct advantages, underscoring that selection should align with specific research objectives and modeling requirements. Full article

Earthen materials are attractive sustainable building solutions due to their low embodied energy and ecological benefits. However, their inherent weaknesses, such as low strength and poor durability, severely restrict modern engineering applications. Traditional physical or chemical modification methods struggle to balance significant improvement in mechanical performance with the preservation of their core sustainable attributes. To overcome this long-standing challenge, this study proposes a paradigm-shifting solution: a prefabricated monolithic lattice–earth composite wall structure. This system abandons the single-material-centered modification approach. Instead, through macroscopic system-level composite design, reinforced concrete lattices and earthen blocks are prefabricated into integral wall panels in a factory. These panels then work collaboratively with the peripheral frame through reliable integral connections. Via quasi-static tests and theoretical analysis on four scaled wall specimens with different design parameters, this study systematically reveals the working mechanism and performance regulation principles of this composite system. The core findings indicate: (1) The system achieves multiple seismic defense lines and a controllable energy dissipation path through a sequential damage mechanism: “earthen material cracking and friction → lattice yielding and energy dissipation → final defense by the frame.” (2) The ratio of the equivalent lateral stiffness of the prefabricated wall panel to the stiffness of the outer frame is a key dimensionless design parameter controlling the failure mode (ductile shear or brittle bending), and the lattice configuration is an effective means to adjust this parameter. (3) Based on tests and an equivalent stiffness model, quantitative design guidelines are proposed, focusing on optimizing lattice density (recommended: 3–4 lattice columns), limiting the aspect ratio (preferably ≤1.5), and ensuring “strong connections.” This study demonstrates that the system, without sacrificing the intrinsic sustainable advantages of earthen materials, successfully endows them with high performance, meeting modern seismic code requirements and potential for prefabricated construction through system integration innovation. It provides a new path with theoretical foundation and practical feasibility to resolve the core contradiction in the modernization of traditional earthen buildings—the incompatibility between ecological attributes and engineering performance. This lays an important foundation for developing next-generation high-performance green building structural systems. Full article

The traditional analysis of the mechanical performance of steel fiber-reinforced concrete (SFRC) predominantly relies on the assumption of an ideally random fiber distribution. This approach fails to account for the significant distribution inhomogeneity caused by practical construction processes like vibration, creating a discrepancy between simulation and reality. To address this, the main aim of this study was to demonstrate the critical impact of realistic fiber distribution on mechanical behavior by integrating image recognition with meso-mechanical simulation. Multi-factor controlled experiments were conducted to investigate the influence of vibration energy, fiber content, and aggregate volume fraction. An image recognition method was developed to accurately characterize the real spatial distribution of fibers, and these data were used to construct a three-dimensional meso-scale finite element model. Compared with the traditional model assuming random distribution, the proposed model based on the actual distribution showed significantly improved agreement with experimental results in terms of crack propagation paths and reduced the prediction error of the initial cracking load by more than 16.3%. For practitioners, the key takeaway is that modeling based on the actual fiber distribution is crucial for achieving realistic simulations. Our work provides a validated methodology to incorporate real distribution data, thereby improving the reliability of numerical assessments for SFRC structures, rather than relying on idealized random distribution assumptions. Full article

This study addresses the major engineering challenges of leaving roadways along the goaf in shallow-buried coal seam tunnels through water-bearing soft rock. It focuses on three core issues: the mechanism of rock mass softening upon water exposure, large-deformation control, and directional pressure relief technology. By integrating laboratory testing, theoretical analysis, numerical simulation, and field testing methods, the evolution of macro- and micro-mechanical properties of rock under water–rock interaction can be studied. The research developed constant-resistance large-deformation rock bolts with “yielding within resistance and resisting within yielding” characteristics, revealed the mechanism of directional fracturing through shaped charge blasting, and proposed a synergistic control technology for along-the-goal rib retention: “shaped charge blasting for roof fracturing and pressure relief + reinforced rib support + debris retention devices.” Research findings indicate: increased sandstone water content triggers dissolution of calcareous cement and expansion of clay minerals, leading to rock strength degradation and accelerated deformation, yet the failure mode remains uniaxial shear failure. The developed constant-resistance large-deformation anchor core device maintains a stable working resistance of approximately 350 kN within a 396–405 mm tensile deformation range, significantly enhancing the support system’s crack-resistant capacity under pressure. The focused jet directs cracks to penetrate along predetermined paths, forming planar damage zones and effectively suppressing vertical damage to the surrounding rock. Based on field monitoring, the tunnel was divided into advance support zones, temporary support zones, and stable tunnel sections, enabling a differentiated support scheme. The engineering application achieved stable tunnel retention and safe reuse. This study provides key theoretical foundations and technical approaches for controlling rock mass stability in similar tunnel conditions. Full article

The study of the mechanical response and crack propagation behaviour of H-shaped beam-column specimens is of great significance for ensuring the safety and stability of buildings. As a connection structure that has gained ubiquity in modern shopping malls and high-rise buildings, an in-depth exploration of the failure mechanisms of H-shaped beam-column components will facilitate more accurate technical support for building maintenance and service life prediction. The present study employs a combination of drop-weight impact tests and the caustic method to systematically investigate the dynamic fracture characteristics of H-shaped beam-column joints under various prefabricated crack configurations. The results demonstrate that the number and location of cracks in H-shaped beam-column specimens have a significant impact on the propagation path and velocity. Specifically, beam-end cracks are prone to bifurcation, while column-end cracks predominantly initiate from the beam-column intersection. This phenomenon is particularly evident in specimens with prefabricated cracks at both the beam ends and column ends. The propagation of cracks at the beam ends is arrested due to the presence of compressive stress when they reach the beam-column intersection. During this period, the stress intensity of the column-end cracks increases significantly, with a growth rate of 33%. Full article