Search Results (195)

Under random wave loading, the crack growth rate exhibits jump-like cycle-to-cycle variations, which limit the direct use of efficient integration schemes such as the Euler method. In addition, the crack growth life is highly sensitive to the initial crack size and aspect ratio, while the initial defects are often difficult to determine accurately in practice, leading to increased uncertainty in life assessment. To address these issues, a cycle-scaling-based crack size accumulation method for random loading is proposed. A predictor–corrector improved Euler method is then established, and a fourth-order Runge–Kutta scheme incorporating the cycle-scaling transformation is derived. Furthermore, based on spectral analysis theory, a mapping between the wave spectrum and the crack-tip stress intensity factor response spectrum is developed. A stress intensity factor range sequence is generated by concatenating short-term sea states, thereby providing a random loading input that preserves the required statistical characteristics. Finally, a 21,000-TEU container ship is analyzed as a case study to investigate crack growth evolution for different initial aspect ratios. The results show that the crack aspect ratio gradually converges to a particular trend during propagation. A convergent aspect ratio curve is fitted. And a unified life assessment curve is constructed. An equivalent transformation is used to map an arbitrary initial crack shape and size to an equivalent convergent aspect ratio crack. As a result, fatigue life can be rapidly estimated using a single “initial crack size–fatigue life” curve, providing support for crack growth life assessment and the definition of defect acceptance limits for ship hull structures. Full article

Fatigue crack propagation in friction stir welded joints significantly affects aircraft structural integrity. This study investigates the influence of welding speed, rotational speed, specimen thickness, loading frequency, and stress ratio on the fatigue crack growth rate. Four classical machine learning models with different structures—Deep Back-Propagation Network, Random Forest, Support Vector Regression, and K-Nearest Neighbors—were employed to predict fatigue crack growth behavior. The results show that all models achieve strong predictive performance. For FSWed joints, Deep BP and KNN exhibit comparable performance (R² > 0.98) on the training data, indicating similar learning capabilities with sufficient data coverage. Notably, KNN achieves the fastest training time (<0.3 s), while all models require less than 5 s of computation time. These results demonstrate that machine learning-based models provide an efficient and reliable alternative for rapid fatigue crack growth evaluation, supporting damage-tolerant design and structural integrity assessment in aircraft engineering. Full article

In this study, a boride cladding layer with Mo₂FeB₂ hard phase was prepared on the GCr15 steel via plasma cladding. The phase composition, microstructure, thermal fatigue resistance, microhardness, and wear resistance of the boride cladding layer were investigated. The results revealed that the hard phases in the boride cladding layer were Mo₂FeB₂ and (Cr,Fe)₂₃(C,B)₆, while the binder phase consisted of α-Fe martensite. When the thermal fatigue times increased, the indentation crack length extended in a quadratic pattern, and the crack propagation rate increased. Crack propagation in the cladding layer occurred via both transgranular and intergranular modes. When the thermal fatigue temperature was below 600 °C, the cladding layer exhibited good thermal stability, and a reliable metallurgical bond was formed between the cladding layer and the GCr15 steel substrate. The microhardness of the cladding layer reached 1022.1 HV_0.5, approximately 2.6 times that of the GCr15 steel. The mass loss of the cladding layer increased with the increase in wear load and wear time. The wear of the cladding layer was mainly three-body abrasion wear, resulting from brittle spalling of the hard phase on the worn surface. This study demonstrates the potential of Mo₂FeB₂-based cladding layers for extending the service life of high-value industrial components. Full article

Carbon-fibre reinforced polymer (CFRP) laminates are susceptible to both static and fatigue-driven delamination. Predicting this type of failure in curved composite structures, often referred to as delamination by unfolding, remains a critical challenge. This work presents the development of a Virtual Crack Closure Technique (VCCT)-based computational method for simulating fatigue-driven delamination propagation under non-constant mixed-mode conditions. The fatigue delamination growth model follows a phenomenological approach based on a Paris–Erdogan-based power-law relationship, where the delamination propagation rate depends on the strain energy release rate. This methodology has been implemented as a user-defined subroutine, UMIXMODEFATIGUE, for Abaqus, integrating the effects of load ratio and mode mixity conditions while leveraging the mode separation provided by VCCT. The proposed approach is validated against an experimental case involving a four-point bending test applied to an L-shaped CFRP curved beam specimen with a unidirectional layup. Unlike the existing standard configuration, the proposed test campaign introduces a non-adhesive Teflon foil insert at the bend, placed within the midplane layers to act as a delamination initiator, representing a manufacturing defect. In addition to the testing machine, digital image correlation (DIC) is used to monitor delamination length. The simulation method developed accurately predicts fatigue delamination propagation under varying mode mixity at the delamination front. By improving delamination modelling in composites, this approach supports timely maintenance and helps prevent fatigue failures. Additionally, it deepens the understanding of how the mode mixity influences the delamination propagation process. Full article

This work systematically investigates the high-cycle fatigue (HCF) properties and fatigue crack growth (FCG) behavior of hot-rolled dual-phase (DP) steels with comparable tensile strength but distinctly different yield strength (458 MPa for the FG sample and 355 MPa for the CG sample), grain sizes and morphologies. Contrary to the conventional Hall–Petch relationship, the coarse-grained (CG) sample demonstrates superior fatigue performance. This enhancement is reflected in its higher fatigue strength, combined with an elevated FCG threshold and a reduced FCG rate in the Paris regime of FCG behavior. Fracture morphologies and FCG path analyses reveal that this enhanced fatigue resistance attributes to pronounced crack path tortuosity in the CG microstructure. The tortuous crack path enhances roughness-induced crack closure effects in the near-threshold regime while promoting more frequent crack deflection during stable propagation, collectively reducing the effective driving force for crack growth. The experimental evidence confirms that properly designed CG microstructures with appropriate phase distribution can provide superior fatigue resistance in hot-rolled DP steels. Full article

To obtain fatigue crack propagation properties of ordinary concrete commonly employed in bridge construction, 48 replicate single-edge notched beam specimens were fabricated using C50 plain concrete. Twelve of these were subjected to monotonic loading to determine their static capacity; the remaining 36 were fatigue-loaded with various combinations of maximum stress level and stress ratio under three-point bending. Visual observation, strain gauges, and the compliance method were used to determine the evolution of crack length during fatigue loading. The fatigue crack growth rates were then evaluated for each specimen using linear regression. This study shows that the fracture surface under fatigue loading exhibits greater zigzagging than under monotonic loading, with multiple microcracks coalescing. The elastic compliance method captures the three-stage development of fatigue crack well, and the derived equivalent crack size is consistently smaller than surface measurements. Significant scatter exists in the test data; however, the crack growth rate and stress intensity factor range follow a straight line on logarithmic scales, indicating that the Paris Law applies to plain concrete. The slope and intercept of C50 concrete, based on 27 fatigue-failed specimens, follow a Normal distribution, with means of 16.46 and −24.81 (in N-mm units), and coefficients of variation of 0.38 and −0.38, respectively. The corresponding mean and coefficient of variation for slope and intercept by the Forman Equation are 14.80 and 0.42 and −21.18 and −0.44, respectively. The fatigue crack in C50 concrete of this study shows a faster growth rate (46.7% larger slope) than that in lower-strength concrete in the literature. With further research needs identified, this study contributes to a better understanding of the fatigue crack growth properties of ordinary structural concrete, providing valuable information for fatigue assessment and service-life extension of existing concrete bridges. Full article

Fiber reinforcement is a promising solution to several problems, however, the impact of fiber characteristics on the mechanical behavior and reinforcement mechanisms of asphalt mixtures remains unclear. Therefore, two distinct forms of basalt fiber—chopped basalt fiber (CBF) and flocculent basalt fiber (FBF)—were employed. A comprehensive experimental program was conducted, encompassing macroscopic and microscopic analyses through semi-circular bending tests integrated with digital image correlation, four-point bending fatigue tests, and dynamic modulus tests. Results indicate that both fiber types significantly improve crack resistance, with FBF demonstrating superior performance. Compared with the ordinary mixture, the flexibility index and fracture energy of the FBF-reinforced asphalt mixture increased by 59.7% and 30.6%, respectively. Fibers exert a crack-bridging effect, delaying the transition of the crack propagation stage by 1.25–2.21 s and reducing the crack propagation rate by 39.6–55.4%. Although fatigue life decreased with increasing strain levels, basalt fibers substantially enhanced fatigue resistance, with FBF-reinforced asphalt mixture achieving 20–40% higher N_f,50 values than CBF. Dynamic modulus tests revealed that fibers reduce modulus at low temperatures while increasing it at high temperatures, with more pronounced reinforcement effects observed in high-frequency regions. These findings underscore the importance of fiber morphology in optimizing asphalt mixture design and provide a theoretical basis for optimizing fiber-reinforced pavement materials to achieve long-term durability under complex environmental and traffic load conditions. Full article

The 60 kg/m U75V rail serves as the predominant rail type within China’s high-speed rail network. This study comprehensively evaluates the fatigue behavior of U75V rails through experimental investigations encompassing monotonic tensile testing, high-cycle fatigue characterization, and fatigue crack propagation analysis. All specimens were extracted from standardized 60 kg/m high-speed rail sections to ensure material consistency. Firstly, monotonic tensile tests were conducted to determine the fundamental mechanical properties of the U75V rail. Secondly, uniaxial tension–compression fatigue tests were conducted to establish the S-N and P-S-N relationships of the U75V rail. Lastly, fatigue crack propagation analysis was carried out on three compact tension specimens under three incremental loading forces. Monotonic tensile test results demonstrated full compliance of the material’s basic mechanical properties with Chinese national standards. Fatigue crack propagation results indicated that the crack growth rate of the U75V rail was not only related to the stress-intensity range ∆K but was also correlated with the loading force range ∆F due to a typical crack tip shielding effect, i.e., plasticity-induced crack closure effect. The derived fatigue performance parameters and crack growth mechanism provide essential inputs for predictive fatigue life modeling of high-speed rail infrastructure and development of refined finite element models for fatigue analysis. Full article

Hydrogen-assisted fatigue cracking presents a critical challenge to the structural integrity of legacy carbon steel natural gas pipelines being repurposed for hydrogen transport, posing a major barrier to the deployment of hydrogen infrastructure. This study systematically evaluates the fatigue crack growth (FCG) behavior of API 5L X60 pipeline steel under varying hydrogen–natural gas (H₂–NG) blending conditions to assess its suitability for long-term hydrogen service. Experiments are conducted using a custom-designed autoclave to replicate field-relevant environmental conditions. Gas mixtures range from 0% to 100% hydrogen by volume, with tests performed at a constant pressure of 6.9 MPa and a temperature of 25 °C. A fixed loading frequency of 8.8 Hz and load ratio (R) of 0.60 ± 0.1 are applied to simulate operational fatigue loading. The test matrix is designed to capture FCG behavior across a broad range of stress intensity factor values (ΔK), spanning from near-threshold to moderate levels consistent with real-world pipeline pressure fluctuations. The results demonstrate a clear correlation between increasing hydrogen concentration and elevated FCG rates. Notably, at 100% hydrogen, API X60 specimens exhibit crack propagation rates up to two orders of magnitude higher than those in 0% hydrogen (natural gas) conditions, particularly within the Paris regime. In the lower threshold region (ΔK ≈ 10 MPa·√m), the FCG rate (da/dN) increased nonlinearly with hydrogen concentration, indicating early crack activation and reduced crack initiation resistance. In the upper Paris regime (ΔK ≈ 20 MPa·√m), da/dNs remained significantly elevated but exhibited signs of saturation, suggesting a potential limiting effect of hydrogen concentration on crack propagation kinetics. Fatigue life declined substantially with hydrogen addition, decreasing by ~33% at 50% H₂ and more than 55% in pure hydrogen. To complement the experimental investigation and enable predictive capability, a modular machine learning (ML) framework was developed and validated. The framework integrates sequential models for predicting hydrogen-induced reduction of area (RA), fracture toughness (FT), and FCG rate (da/dN), using CatBoost regression algorithms. This approach allows upstream degradation effects to be propagated through nested model layers, enhancing predictive accuracy. The ML models accurately captured nonlinear trends in fatigue behavior across varying hydrogen concentrations and environmental conditions, offering a transferable tool for integrity assessment of hydrogen-compatible pipeline steels. These findings confirm that even low-to-moderate hydrogen blends significantly reduce fatigue resistance, underscoring the importance of data-driven approaches in guiding material selection and infrastructure retrofitting for future hydrogen energy systems. Full article

Cracking in asphalt layers of rigid–flexible composite pavements under coupled ambient temperature fields and traffic loading represents a critical failure mode. Traditional models based on uniform temperature assumptions inadequately capture the crack propagation mechanisms. This study developed a thermo-mechanical coupling model that incorporates realistic temperature-modulus gradients to analyze the compressive-shear behavior and simulate crack propagation using the extended finite element method (XFEM) coupled with a modified Paris’ law. Key findings reveal that the asphalt layer exhibits a predominant compressive-shear stress state; increasing the base modulus from 10,000 MPa to 30,000 MPa reduces the maximum shear stress by 22.8% at the tire centerline and 8.6% at the edge; thermal stress predominantly drives crack initiation, whereas vehicle loading governs the propagation path; field validation via cored samples confirms inclined top-down cracking under thermo-mechanical coupling; and the fracture energy release rate (G_f) reaches a minimum of 155 J·m⁻² at 14:00, corresponding to a maximum fatigue life of 32,625 cycles, and peaks at 350 J·m⁻² at 01:00, resulting in a reduced life of 29,933 cycles—reflecting a 9.0% temperature-induced fatigue life variation. The proposed model, which integrates non-uniform temperature gradients, offers enhanced accuracy in capturing complex boundary conditions and stress states, providing a more reliable tool for durability design and assessment of composite pavements. Full article

Deep coal seams have low permeability and poor wettability, making gas extraction difficult. This study presents a zero-energy consumption pulsating water hammer fracturing technique that uses the gravitational potential energy of high-elevation water and the pulsating pressure waves from the water hammer effect to induce fatigue damage in coal, creating an interconnected network of cracks. The research included experiments on water hammer pressure waves, multi-physics field coupling simulations at different flow rates, and discrete element simulations to analyze the fracture behavior of underwater hammer pressure. Results showed that initial flow velocity impacts the water hammer pressure’s intensity, range, and duration. Pressure shock waves propagate as expansion and compression waves, with peaks rising from 4.99 to 19.91 MPa within a 2–12 m/s flow rate range. Water hammer pressure reduced fracture initiation pressure by 23% compared to static pressure loading and increased fracture numbers by 13.4%. With pressure amplitudes between 2–18 MPa, fractures tripled, and the damaged area grew from 2.2 to 11%. A variable frequency combination loading strategy, starting with low frequency and then high frequency, was more effective for fracture propagation. This study offers a theoretical foundation for applying this technology to enhance coal seam permeability and gas pumping efficiency. Full article

Dynamic fatigue of rocks under repeated cyclic impact is a nonconservative property, as surrounding rocks in real environments subjects them to variable impact disturbances, and the degree of damage varies under different energy level loads. To evaluate the dynamic response and fatigue damage characteristics of rocks under multi-level cyclic impacts, uniaxial cyclic impact tests were carried out on granite with various stress paths and energy levels using a modified split Hopkinson pressure bar. Dynamic deformation characteristics of specimens under different loading modes were investigated by introducing the deformation modulus of the loading stage. Evolution of macroscopic cracks during the impact process was investigated based on high-speed camera images, and the microscopic structure of damaged specimens was examined using SEM. In addition, cumulative energy dissipation was used to assess the damage of rocks. Results show that the deformation modulus of the loading stage, dynamic peak stress and strain of specimens increase with the impact energy, and the deformation modulus of the loading stage decreases as the damage level increases. Propagation rate of tensile cracks in rock was correlated with participation time of the higher energy level, which observed the following sequence: linearly decreasing > same > linearly increasing energy level, and cyclic loading of nonlinear energy level produced more tensile cracks and rock spalling than the same energy level. Compared with cyclic impacts of the same energy level, multi-level impacts form more microcracks and fatigue striations. The cumulative rate of specimen damage under the same energy change rate is as follows: linear decreasing > same > linear increasing loading. This provides a new case study for evaluating the dynamic damage, crushing efficiency and load-bearing capacity of rocks in real engineering environments. Full article

Fractured rock masses in cold regions are subject to long-term seasonal freeze–thaw cycles. To investigate the fatigue damage characteristics of sandstone with different fracture inclinations under freeze–thaw cycling conditions, samples containing fractures of varying inclinations were prepared using sandstone from Altay, Xinjiang. After vacuum saturation and freeze–thaw cycling treatment (−30 °C to 30 °C), uniaxial cyclic loading tests were conducted to analyze strain, elastic modulus, Poisson’s ratio, and damage variables. The results showed that under cyclic loading, the strain of the sandstone exhibited a “stepwise accumulation” characteristic, with peak and residual strain increasing with the progression of the cycle. Among them, the specimen with a fracture angle of 45° exhibited the fastest strain increase before failure. The peak elastic modulus showed a “continuous decrease within each stage and an initial increase followed by a decrease between stages,” while the residual elastic modulus continued to decrease, with both experiencing a sudden, sharp drop at the end of the cycle. The peak Poisson’s ratio decreases with the number of cycles in the early stage, then transitions to logarithmic growth in the later stage, rapidly increases near failure, and finally, the residual Poisson’s ratio in the final cycle exceeds the peak Poisson’s ratio; the evolution of damage variables exhibits an S-shaped three-stage characteristic, with the initial stage showing an irreversible deformation growth rate exceeding 10% due to compaction. In the middle stage, it grows steadily due to microcrack propagation, and in the final stage, it approaches 1. Samples with steep inclination angles exhibit earlier damage initiation and faster growth rates. The study reveals that crack inclination angle influences the evolution rhythm by regulating the proportion of compaction and shear damage, providing a theoretical basis for assessing the engineering stability of fractured rocks in cold regions. Full article

This study reported the development of a novel Al-Si-Mg-based composite reinforced by micron-sized Cu-Mn binary solid solution phases and submicron-sized α-Al(Mn,Fe)Si dispersoids. The Cu-Mn binary solid solution phases were added to the melt in the form of an Al-3%CuMn master alloy, whereas α-Al(Mn,Fe)Si dispersoids were obtained via heat treatment. The microstructure analysis confirmed the presence of micron-sized Cu-Mn binary, eutectic Mg₂Si, and Al₁₅(FeMn)₃Si₂ intermetallic phases, submicron-sized α-Al(Mn,Fe)Si dispersoids, and nano-sized precipitates in the Al-based composite. At room temperature, tensile results represented a yield strength of 287 MPa and a tensile strength of 306 MPa, with an elongation of 17%. Moreover, the Al-based composite maintained a yield strength of 277 MPa up to 250 °C, with a slight increase in elongation. The composite also exhibited excellent high-temperature high-cycle fatigue properties and showed a high-cycle fatigue limit of 140 MPa at 130 °C, which is ~2.3 times higher than that of the commercial A319 alloy. A fractography study revealed that the secondary particles hindered the movement of dislocations, thus delaying crack initiation under cyclic loading at high temperatures. Additionally, Cu-Mn binary solid solutions and Al₁₅(FeMn)₃Si₂ phases were found to be effective in reducing the crack propagation rate by hindering the movement of the propagated crack. Full article

The growing use of weathering steel in bridge engineering has highlighted the increasing impact of fatigue damage caused by the combined effects of welding residual stress and vehicular loading. This study investigates the fatigue performance of Q500qENH weathering steel bridge decks by proposing a coupled analysis method for residual stress and fatigue crack growth, utilizing collaborative simulations with Abaqus 2023 and Franc3D 7.0. An interaction model integrating welding-induced residual stress fields and dynamic vehicular loads is developed to systematically examine crack propagation patterns in critical regions, including the weld toes of the top plate and the weld seams of the U-ribs. The results indicate that the crack propagation rate at the top plate weld toe exhibits the most rapid progression, reaching the critical dimension (two-thirds of plate thickness) at 6.98 million cycles, establishing this location as the most vulnerable failure point. Residual stresses significantly amplify the stress amplitude under tension–compression cyclic loading, with life degradation effects showing 48.9% greater severity compared to pure tensile stress conditions. Furthermore, parametric analysis demonstrates that increasing the top plate thickness to 16 mm effectively retards crack propagation, while wheel load pressures exceeding 1.0 MPa induce nonlinear acceleration of life deterioration. Based on these findings, engineering countermeasures including welding defect control, optimized top plate thickness (≥16 mm), and wheel load pressure limitation (≤1.0 MPa) are proposed, providing theoretical support for fatigue-resistant design and maintenance of weathering steel bridge decks. Full article