Search Results (27)

The standard EN 13906-2 forms the essential basis for the design and calculation of helical tension springs. It is used not only nationally, but throughout Europe and internationally in the spring industry and by spring users. With regard to cyclic design, the standard only refers to fatigue tests to be carried out. There are no formulas for the analytical calculation of the existing stresses in the loops and no methods or diagrams for determining the permissible stresses for tension springs. Even in the technical literature, there are no reliable analytical formulas for calculating the existing stresses for extension springs with different loop shapes. This article presents solutions for determining existing stresses using numerical calculations, which are necessary for performing fatigue strength analysis for tension springs. Full article

Lightweight composite structures like fiber metal laminates (FMLs) are widely used to manufacture aircraft structures and substitute metallic parts. While the superior mechanical performance of FMLs, including their high specific strength and excellent impact and fatigue resistance, has gained the interest of many researchers in the aerospace manufacturing industry, there are still some challenges that need to be considered. Conventional approaches like lay-up techniques and autoclave molding can achieve the relatively simple FML parts with large radii and profiles required for aircraft fuselages and flat skins. However, these methods are not suitable for forming complex-shaped structural parts due to the limited failure strain of fiber-reinforced materials and complex failure modes of the laminates. This research puts forward a new methodology that combines the hydroforming and subsequent curing process to investigate the feasibility of manufacturing complex aircraft parts like fairings made by FMLs. In this research, wrinkle formations are analyzed under various parameters during the hydroforming process. The geometrical shape of the initial blanks and the parameters, including blank holder force and cavity pressure, have been optimized to avoid flange edge wrinkles, and the addition of local support materials contributes to improving local wrinkling in the sharp corners. A finite element model (FEM) taking material laws, interlayer contacts, and boundary conditions into account is used to predict the dynamic hydroforming process of the fiber metal laminate, and experimental works are carried out for its verification. It is expected that the proposed method will reduce both costs and time, as well as reducing laminate defects. Thus, this method offers great potential for future applications related to manufacturing complex-shaped aerospace parts. Full article

In actual service, asphalt pavement is subjected to freeze–thaw cycles and ultraviolet radiation (UV) over the long term, which can easily lead to mixture aging, enhanced brittleness, and structural damage, thereby reducing pavement durability. This study focuses on the influence of freeze–thaw cycles and ultraviolet aging on the performance of recycled asphalt mixtures. Systematic indoor road performance tests were carried out, and a fatigue prediction model was established to explore the comprehensive effects of recycled asphalt pavement (RAP) content, environmental action (ultraviolet radiation + freeze–thaw cycle), and other factors on the performance of recycled asphalt mixtures. The results show that the high-temperature stability of recycled asphalt mixtures decreases with the increase in environmental action days, while higher RAP content contributes to better high-temperature stability. The higher the proportion of old materials, the more significant the environmental impact on the mixture; both the flexural tensile strain and flexural tensile strength decrease with the increase in environmental action time. When the RAP content increased from 30% to 50%, the bending strain continued to decline. With the extension of environmental action days, the decrease in the immersion Marshall residual stability and the freeze–thaw splitting strength became more pronounced. Although the increase in RAP content can improve the forming stability, the residual stability decreases, and the freeze–thaw splitting strength is lower than that before the freeze–thaw. Based on the fatigue test results, a fatigue life prediction model with RAP content and freeze–thaw cycles as independent variables was constructed using the multiple nonlinear regression method. Verification shows that the established prediction model is basically consistent with the change trend of the test data. The research results provide a theoretical basis and optimization strategy for the performance improvement and engineering application of recycled asphalt materials. Full article

Cost reduction has always been a high priority target in modern management. Concentrating on material strength, the huge potential is recognized for cost reduction in finding the material fatigue coefficients by reduction the number and time required for testing specimens. The aim of this study is to evaluate the accuracy of several fatigue parameter estimation methods by comparing them with reference test data obtained for six different steel materials. In the literature, several estimation methods can be found. Those methods rely on tension or hardness tests. The concern is about the accuracy of those methods; therefore, a basic case was investigated involving estimation methods and comparing them to reference data from a physical test. The case was selected in a manner that allowed the verification of combined low and high cycle fatigue. As a result, the estimation methods produced a very wide range of fatigue life predictions, but some of them were quite accurate. This leads to the conclusion that estimation methods can be a step forward for finding the fatigue material properties; however, a study should be undertaken on which methods are the most suitable for the material family used. Full article

The escalating demands of industrial applications, particularly those involving severe wear, temperature, and corrosive environments, present significant challenges for the long-term strength of critical components, often fabricated from high-value materials such as super duplex stainless steel alloys. Super duplex can withstand the corrosive environment (in particular, crevice corrosion and pitting damage) and maintain mechanical integrity sufficient for high-pressure pumping applications such as seawater injection and crude oil. Conventional repair methodologies frequently result in component rejection due to process-induced distortions or detrimental phase transformations, contributing to substantial material waste and hindering the adoption of circular economy principles. This research addresses this issue by developing and validating a novel repair process utilizing laser metal deposition (LMD) additive manufacturing. The research focuses on establishing optimized process parameters to ensure the salvaging and restoration of damaged super duplex components while preserving their requisite mechanical integrity and corrosion resistance, in accordance with industry standards. Comprehensive characterization, including microstructural analysis, chemical composition verification, hardness profiling, and mechanical fatigue testing, confirms the efficacy of the LMD repair process. This work demonstrates the potential for extending the service life of critical components, thereby promoting resource efficiency and contributing to a more sustainable and resilient industrial paradigm. Full article

This paper presents the results of an analysis of the mechanical properties of the S420M steel samples collected both perpendicular and parallel to the rolling direction. The scope of the analysis included the following: a static tensile test, a hardness measurement, a low-cycle fatigue test, and a microstructure analysis of the analysed material. During the analysis, it was found that the rolling direction had little effect on the most important strength parameters determined in the static tensile test, but had a significant effect on the fatigue properties. During fatigue testing, a significant reduction in fatigue life (from 50% to almost 300%) was observed for samples perpendicular to the rolling direction. The largest reduction in fatigue life was observed at the ε_ac = 0.25% strain level (almost 300%), while the smallest was at ε = 0.25% (50%). A comparative analysis of the results of constant-amplitude and programmed fatigue tests confirmed the validity of using accelerated life tests to determine the low-cycle fatigue properties of construction materials. The results of the experimental verification of the Palmgren–Miner linear hypothesis of fatigue damage accumulation confirmed the significant influence of the material data on the results of fatigue life calculations. Full article

This paper presents a comprehensive on-site decision-making framework for assessing the structural integrity of a jacket-type offshore platform in the Gulf of Mexico, installed at a water depth of 50 m. Six critical analyses—(i) static operation and storm, (ii) dynamic storm, (iii) strength-level seismic, (iv) seismic ductility (pushover), (v) maximum wave resistance (pushover), and (vi) spectral fatigue—are performed using SACS V16 software to capture both linear and nonlinear interactions among the soil, piles, and superstructure. The environmental conditions include multi-directional wind, waves, currents, and seismic loads. In the static linear analyses (i, ii, and iii), the overall results confirm that the unity checks (UCs) for structural members, tubular joints, and piles remain below allowable thresholds (UC < 1.0), thus meeting API RP 2A-WSD, AISC, IMCA, and Pemex P.2.0130.01-2015 standards for different load demands. However, these three analyses also show hydrostatic collapse due to water pressure on submerged elements, which is mitigated by installing stiffening rings in the tubular components. The dynamic analyses (ii and iii) reveal how generalized mass and mass participation factors influence structural behavior by generating various vibration modes with different periods. They also include a load comparison under different damping values, selecting the most unfavorable scenario. The nonlinear analyses (iv and v) provide collapse factors (Cr = 8.53 and RSR = 2.68) that exceed the minimum requirements; these analyses pinpoint the onset of plasticization in specific elements, identify their collapse mechanism, and illustrate corresponding load–displacement curves. Finally, spectral fatigue assessments indicate that most tubular joints meet or exceed their design life, except for one joint (node 370). This joint’s service life extends from 9.3 years to 27.0 years by applying a burr grinding weld-profiling technique, making it compliant with the fatigue criteria. By systematically combining linear, nonlinear, and fatigue-based analyses, the proposed framework enables robust multi-hazard verification of marine platforms. It provides operators and engineers with clear strategies for reinforcing existing structures and guiding future developments to ensure safe long-term performance. Full article

Background: The incremental exercise test is commonly used to measure maximal oxygen uptake (VO₂max), but an additional verification test is often recommended as the “gold standard” to confirm the true VO₂max. Therefore, the aim of this study was to compare the peak oxygen uptake (VO₂peak) obtained in the ramp incremental exercise test and that in the verification test performed on different days at submaximal intensity. Additionally, we examined the roles of anaerobic performance and respiratory muscle strength. Methods: Sixteen physically active men participated in the study, with an average age of 22.7 ± 2.4 (years), height of 178.0 ± 7.4 (cm), and weight of 77.4 ± 7.3 (kg). They performed the three following tests on a cycle ergometer: the Wingate Anaerobic Test (WAnT), the ramp incremental exercise test (IET_RAMP), and the verification test performed at an intensity of 85% (VER₈₅) maximal power, which was obtained during the IET_RAMP. Results: No significant difference was observed in the peak oxygen uptake between the IET_RAMP and VER₈₅ (p = 0.51). The coefficient of variation was 3.1% and the Bland–Altman analysis showed a high agreement. We found significant correlations between the total work performed in the IET_RAMP, the anaerobic peak power (r = 0.52, p ≤ 0.05), and the total work obtained in the WAnT (r = 0.67, p ≤ 0.01). There were no significant differences in post-exercise changes in the strength of the inspiratory and expiratory muscles after the IET_RAMP and the VER₈₅. Conclusions: The submaximal intensity verification test performed on different days provided reliable values that confirmed the real VO₂max, which was not limited by respiratory muscle fatigue. This verification test may be suggested for participants with a lower anaerobic mechanical performance. Full article

Today, there are many diagnostic methods and advanced measurement techniques enabling the correct diagnosis and assessment of the type and degree of wear of cogwheels (gears, pumps, etc.). The present study presents an analysis of the surface defects of a cogwheel of an oil pump prototype (3PW-BPF-24). The test object operated for a certain number of hours under controlled operating and environmental parameters. The damage to the surface layer was caused by fatigue phenomena and previous thermo-chemical treatment. On the basis of the significant percentage share (~30%) of residual austenite in the volume of the diffusion layer, a hypothetical conclusion was drawn about the suboptimal parameters of the thermo-chemical treatment process (in relation to the chemical composition of the analyzed pinion). A large number of research studies indicate that the significant presence of residual austenite causes a decrease in tooth surface hardness, the initiation of brittle cracks, a sharp decrease in fatigue strength, an increase in brittleness and a tendency to develop surface layer cracks during operation. High-resolution 3D scans of randomly selected pitting defects were used in the detailed study of the present work. It was indicated that the analysis of the morphology of surface defects allowed some degree of verification of the quality of the heat/chemical treatment. The martensitic transformation of residual austenite under controlled (optimum) repeated heat treatment conditions could significantly improve the durability of the pinion (cogwheel). In the case analyzed, the preferred treatment was the low-temperature treatment. The paper concludes with detailed conclusions based on the microscopic and macroscopic investigations carried out. Full article

This paper deals with a surface-hardened forged steel that is commonly used for powertrain components like gears, axles or crankshafts. In order to increase static and fatigue strength and to minimise wear, surface treatments like induction hardening lead to a significant microstructural change within heat-affected zones. The aim of this study was to elaborate a method for a reliable computational estimation of the local fatigue strength by considering local material properties. The method is based on experimental test results, where specimens were extracted from forged crankshafts and further heat-treated to investigate the fatigue strength of the unhardened and hardened material condition. The experimental test data were fundamental in defining elaborated Haigh diagrams, enabling a more reliable local fatigue assessment. The comparison of the component safety within the fatigue strength verification for a crankshaft section under alternate bending resulted in $28\%$-more progressive dimensioning of surface hardened layers. Full article

A certain number of hole-like defects will occur in aluminum alloys under cyclic loading. The internal holes will reduce the strength of the material and cause stress concentration, which will aggravate the development of fatigue damage. A classification method of defect features based on X-ray CT damage data is proposed. The random hole distribution model is established through the linear congruence method and the region division method. The hole parameter is introduced as the intermediate variable of the 3D reconstruction model of internal defects. In the mesoscopic stage, the function relationship between the distribution of random holes and the fatigue life is established based on the coupling relationship between the number and proportion of pores and the fatigue life. In the macroscopic stage, the relationship between the random holes and the macroscopic crack growth life is established by taking the crack length as the damage variable. The crack propagation rate decreased with the increase in the number of holes. The prediction model of the whole life stage is established using the life function from microcrack initiation to macroscopic crack propagation. Finally, the validity of the whole stage fatigue life prediction model is demonstrated through the comparison and verification of experiments, which provides a certain engineering value for the life estimation of 6061-T6 aluminum alloy materials. Full article

The effects of contrast water therapy (CWT) on dehydration at moderate altitudes during training camps remain unknown. We hypothesized that CWT reduces dehydration resulting from training at moderate altitudes and improves performance, akin to conditions at sea level. A 13-day endurance training camp was held at a moderate altitude of 1100 m and included 22 university athletes, who were divided into two groups (CWT group, n = 12; control (CON) group, n = 10). The sample size was calculated based on an α level of 0.05, power (1 β) of 0.8, and effect size of 0.25 based on two-way ANOVA. Longitudinal changes over 13 days were compared using a two-group comparison model. Additionally, 16 athletes participated in an additional performance verification analysis. Subjective fatigue, body mass, and water content (total body water (TBW), extracellular water (ECW), and intracellular water) were measured using bioimpedance analysis every morning, and the titin N-terminal fragment in urine (UTF) was measured as an index of muscle damage. For performance verification, 10 consecutive jump performances (with the reactive strength index (RSI) as an indicator) were evaluated as neuromuscular function indices. The results indicated that the UTF did not significantly differ between the two groups. Moreover, the ECW/TBW values, indicative of dehydration, on days 4 and 5 in the CWT group were significantly lower than those in the CON group. However, there was no significant difference in RSI between the two groups. Therefore, although CWT reduces dehydration in the early stages of the training camp, it may not affect performance. Full article

Civil engineering structures are often loaded cyclically in addition to static loading. For the design of cyclic-loaded aluminum structures, EN 1999-1-3 provides several notch cases for a verification based on the nominal stress concept. These notch cases do not distinguish between the different available alloys exhibiting varying characteristics, such as static mechanical properties in the heat-affected zone. Furthermore, for welded details only longitudinal or transverse welding is covered without the possibility for considering inclined welding with multiaxial stress states. However, load-controlled fatigue testing of two different alloys and specimens out of base material, specimens with 45° welding and transverse welding, respectively, have shown the clear influence of alloy and weld angle on the fatigue strength of welded aluminum details. In this paper, the respective experimental and numerical results of two alloys, EN AW-6082 T6 and EN AW-5754 O/H111, and two weld angles, 45° and 90°, are presented and discussed. Full article

Based on the new high-modulus carbon fiber CCM40J-6k, which is the critical raw material of a solar panel, the molding process of a mesh face sheet combined with epoxy resin, the overall mechanical performance of a mesh face sheet combined with aluminum honeycomb, the compatibility with polyimide insulation film + solar cell circuit, and the space environment adaptability must pass a test verification and assessment as the premise for large-scale orbit applications. Therefore, based on the traditional carbon fiber M40JB-6k as a reference, a systematic verification project was conducted to apply the CCM40J-6k carbon fiber composite at the process, component, and assembly levels. Six aspects of testing and verifying items were conducted, including mechanical properties under room temperature and thermal shock conditions, bonding force of mesh nodes, comparison of the adaptability of domestic and imported carbon fiber substrates to high–low temperature alternation, the ability of domestic carbon fiber substrates to adapt to the thermal environment after laying solar cell circuits, and in-orbit lifespan of solar panels. Based on the verification results, the mechanical properties of the substrate are the same as those of the imported M40JB-6k, and the actual molding process for M40JB-6k can be utilized. Sample pieces of the substrates can withstand the thermal shock and thermal cycling tests. The bending stiffness of the sample pieces before and after the tests is 3.5%~9.6% higher, and the bending strength is 4.2%~7.2% lower. The tensile strength of mesh nodes made of domestic carbon fiber is 18.9% higher than that of mesh nodes made of imported carbon fiber. The CCM40J-6k substrate is similar to triple-junction GaAs solar cells. The change rates of the open-circuit voltage and the short-circuit current of solar panels based on domestic carbon fiber after fatigue thermal cycling with 2070 cycles are 0.55% and 0.24%, respectively. The above results indicate that the comprehensive performance of the domestic carbon fiber CCM40J-6k meets the requirements and can be applied to solar panels for solar arrays. Full article

This article presents an experimental approach to fatigue testing of cableway gondolas, carried out in accordance with the EN 13796-3 standard. Due to the limitations of the aforementioned regulations and the lack of clarity in their content, when designing and conducting fatigue tests of gondolas, there is a need to find solutions that meet the normative requirements, while ensuring the cost-effectiveness of the tests. The work presents the method of loading, receiving the degrees of freedom, the methodology of gondola strength verification and additional suggestions allowing for the satisfactory preparation of a plan of fatigue tests and their implementation. The paper shows problems and ways to solve it, what may occur during cableway gondolas fatigue test design. In addition, the work contains an extensive description and methodology for conducting research verifying the elastic and permanent deformation of the structure, using digital image correlation (DIC). The results obtained by using this method make it possible to unambiguously determine the degree of structure deformation while maintaining high accuracy and repeatability of measurements at many points of the structure. Following the presented tests, it was possible to correctly carry out fatigue tests of the nacelle in a satisfactory time (about 8 weeks), perform 5 million load cycles and verify the integrity of the structure. The presented results show the effectiveness of the adopted design assumptions and indicate the process that guarantees the correctness of the conducted fatigue tests. The prepared study may be the basis for further full-scale fatigue tests. The research object is a 6-seater gondola designed by TRANSSYSTEM S.A. Full article