Search Results (4,905)

This study addresses the fundamental problem of representing the rheological properties of heterostructured materials composed of metals that differ significantly in their crystal structure, stacking fault energy, and related characteristics. The necessity of accounting for essential strengthening mechanisms is highlighted. The study is based on experimental results related to the fabrication of a multilayer, heterogeneous system via multistage wire drawing, supported by microstructural analysis, microhardness measurements, and numerical simulations employing various flow-stress models. A discussion is presented regarding the effectiveness of these models in representing the deformation behavior of the investigated materials. The primary materials examined were a multilayer system composed of microalloyed steel and titanium. The obtained results indicate that, in addition to incorporating strengthening mechanisms, it is necessary to consider significant microstructural changes affecting microstructure evolution—particularly grain refinement induced by continuous recrystallization and the effects of strain hardening. Moreover, the findings point to the potential intensification of strengthening associated with pile-up mechanisms, linked to the development of dislocation substructures and the possible fragmentation of the hard phase in the vicinity of the more ductile microalloyed steel phase. In conclusion, the discussion integrates measurements of rheological properties obtained through tensile tests, supported by microstructural analysis, digital image correlation (DIC), and microhardness measurements, which collectively demonstrate the effectiveness of the adopted analytical approach. Full article

Forming tools adjustable by tensile elastic deformations offer opportunities for improved process control and reduced wear in high-volume metal forming processes such as ironing. However, the lack of tensile and fatigue data for hardened cold-work tool steels limits their broader adoption. This study investigates the mechanical performance of three tool steels—Vanadis^®4 Extra SuperClean, Vancron^® SuperClean, and Caldie^®—through uniaxial tensile and fatigue testing, supplemented by destructive static and fatigue/wear tests on specimens representative of an adjustable ironing punch. Non-coated specimens exhibited ultimate tensile strengths above 2700 MPa with approximately 2% plastic strain, while coated specimens fractured in a brittle manner between 1600–1900 MPa. Fatigue life at stress ranges between 1450–1750 MPa varied from several thousand to over four million cycles, with crack initiation linked to non-metallic inclusions and precipitates 10–30 $\mathsf{\mu }$m in size. Finite element simulations accurately linked failure observed in uniaxial tests to the component-level tests, confirming that first principal stress is a reliable predictor for punch failure. All punch specimens withstood ${10}^6$ cycles at diameter changes up to 140 $\mathsf{\mu }$m (4‰), with coated punches exhibiting minimal wear and non-coated ones showing localized surface damage. The findings support material and coating selection for adjustable forming tools and highlight opportunities for further optimization. Full article

Geometric discontinuities are unavoidable in additively manufactured polymer components and can significantly alter their mechanical response; however, their effects are rarely quantified in a systematic and geometry-comparative manner. In this study, the tensile behavior of FDM-printed PLA+ specimens with three different geometries—dog-bone, circular-hole, and U-notched (manufactured and tested in accordance with ASTM D638 (Type IV))—was experimentally and numerically investigated. Tensile tests were conducted using a universal testing machine equipped with an extensometer, while finite element simulations were performed using an experimentally calibrated Ramberg–Osgood-based elastic–plastic material model. The dog-bone specimens exhibited an ultimate tensile strength (UTS) of 41–43 MPa and a Young’s modulus of 3.06 GPa, representing the intrinsic material response under nearly homogeneous stress conditions. Circular-hole specimens maintained comparable strength (38–42 MPa) but showed reduced ductility (1.4–1.6%) and a slightly increased apparent modulus of 3.17 GPa due to localized deformation. In contrast, U-notched specimens displayed the highest apparent modulus (≈5.30 GPa) and nominal UTS (46–49 MPa), accompanied by a pronounced reduction in ductility (0.9–1.0%), indicating severe stress concentration and predominantly brittle fracture behavior. Finite element analysis showed excellent agreement with experimental results, with peak von Mises stresses reaching approximately 42 MPa for all geometries, corresponding closely to the experimentally measured tensile strength. These results demonstrate that geometric discontinuities strongly govern stress localization, apparent stiffness, and fracture initiation in FDM-printed PLA+ components. The validated Ramberg–Osgood-based modeling framework provides a reliable tool for predicting geometry-dependent mechanical behavior under quasi-static loading and supports geometry-aware design of additively manufactured polymer structures. Full article

This work presents a combined numerical and experimental investigation into the laser machining of aluminum alloy Al 1050 H14 using a high-power Continuous Wave (CW) fiber laser. Advanced three-dimensional, coupled thermal–structural Finite Element Method (FEM) simulations are developed to model key laser–material interaction processes, including laser-induced plastic deformation, laser etching, and engraving. Cases for both static single-shot and dynamic linear scanning laser beams are investigated. The developed numerical models incorporate a Gaussian heat source and the Johnson–Cook constitutive model to capture elastoplastic, damage, and thermal effects. The simulation results, which provide detailed insights into temperature gradients, displacement fields, and stress–strain evolution, are rigorously validated against experimental data. The experiments are conducted on an integrated setup comprising a 2 kW TRUMPF CW fiber laser hosted on a 3-axis CNC milling machine, with diagnostics including thermal imaging, thermocouples, white-light interferometry, and strain gauges. The strong agreement between simulations and measurements confirms the predictive capability of the developed FEM framework. Overall, this research establishes a reliable computational approach for optimizing laser parameters, such as power, dwell time, and scanning speed, to achieve precise control in metal surface treatment and modification applications. Full article

The abnormal pore pressure is possibly generated through a comprehensive process including geological, physical, geochemical, or hydrodynamic factors. Generally, all mechanisms are abstracted as four typical categories, namely skeleton deformation, pore fluid mass increase, temperature change, and other mechanisms. Traditional methods for evaluating reservoir overpressure often only consider the influence of a single factor and lack mathematical methods for a comprehensive explanation of reservoir overpressure. Therefore, this article is dedicated to proposing a comprehensive mathematical model, incorporating effective mean stress, shear stress, temperature, pore collapse-induced plastic deformation, time-dependent skeleton deformation, and pore fluid mass increase, to account for pore pressure generation in sedimentary basins. The effects of various factors on pore pressure generation are analyzed, and case studies are conducted. Main conclusions are drawn that both the compressibility of sediments and the porosity at the surface control the pore pressure generation rate and vertical gradient. The pore pressure generation rate and vertical gradient in deep formation are larger than those in shallow formation. The higher compressibility and lower porosity at the surface lead to a greater pore pressure generation rate and vertical gradient during the skeleton deformation. The lower compressibility and a lower porosity at the surface can cause a higher pore pressure change rate and vertical gradient during the pore pressure mass increase and temperature change. By comparison, mechanical loading plays a more important role in pore pressure generation rate and vertical gradient than aquathermal pressuring. Full article

The Cu-Cr-Zr alloy is regarded as an optimal material for high-end electronic information industries owing to its high electrical strength, high conductivity, and outstanding softening resistance. Nevertheless, the impacts of Cr content and microstructure evolution on performance enhancement during the processing stage remain unclear. In this research, Cu-xCr-0.1Zr alloys with varying Cr contents were fabricated via the thermo-mechanical approach. The microstructure evolution, as well as the mechanical and electrical properties before and after aging were investigated. It was discovered that Cr can mitigate the grain deformation degree of the copper alloy during cold rolling, notably augment the proportion of large-angle grain boundaries, and diminish the dislocation density induced by plastic deformation. As the Cr content increases, the conductivity of the sample declines from 86% IACS (0Cr) to 34.1% IACS (1.8Cr), and the tensile strength rises from 435 MPa (0Cr) to 542 MPa (1.8Cr) after cold rolling; the conductivity decreases from 89.4% IACS (0Cr) to 77.3% IACS (1.8Cr), and the tensile strength increases from 278 MPa to 607 MPa (1.0Cr). Based on the comprehensive outcomes, the aged 1.0Cr sample, with a tensile strength of 607 MPa and a conductivity of 80.9% IACS, satisfies the performance requirements of high-strength and high-conductivity copper alloys. Full article

Side flaps are critical structural components of flat freight wagons, directly affecting cargo safety during transportation and playing an essential role in loading and unloading operations. Over the years, their reliability has been well established, with standardized designs available in UIC technical datasheets. Despite this standardization, the introduction of newly manufactured or redesigned components necessitates technological validation through Finite Element Method (FEM) simulations and/or physical testing. This requirement holds irrespective of whether the component in question adheres to existing standards or is a novel development. This study presents the creation and application of computational models for the structural sizing and strength assessment of side flaps for flat wagons. The models are verified through a series of physical tests conducted by a research team at the Technical University of Sofia. Full article

Severe plastic deformation is an effective process to modify materials’ structures. In this work, its new modification entitled channel angular extrusion was applied to a metastable metal-matrix composite consisting of a Ag matrix and spherical Cu particulates. During this process, the rod sample deforms in an inhomogeneous way and exhibits a gradient microstructure that is characterized by ellipsoidal Cu particulates at the edge of the sample but elongated and fragmented rectangular ones in the center. In addition to the different shapes, the edge and center of the sheet also differ in preferential orientations: the ⟨110⟩ direction predominates in the center of the sheet, while the ⟨111⟩ direction dominates at the sheet edge. The changed angle of the {111} shear plane relative to the extrusion direction explains these differences. Full article

Metastable β titanium alloys with low elastic modulus and excellent plasticity represent highly attractive materials for biomedical stent application. Our work shows that Zr plays a crucial role in regulating β stability to significantly reduce the modulus and enhance plasticity. A series of Ti-25Nb-2Mo-xZr (x = 0, 3, 9, 12 wt%) alloys were designed based on the d-electron theory, and the influence of Zr content on the microstructure, mechanical properties, and deformation mechanism were systematically investigated. The results demonstrated that as the Zr content increases, the β phase stability was significantly enhanced. This leads to, first, the suppressed formation of the high modulus α″ phase and ω phase, which results in the decrease in apparent overall elastic modulus. Second, the dominant mode of deformation shifts from martensite dislocation slip (0Zr) to martensitic variant reorientation (3Zr), then to stress-induced martensite transform (SIMT, 9Zr), and finally to a combination of SIMT and deformation twinning (12Zr). Such shifting effectively increases the alloy’s tensile plasticity. Among the series, the Ti-25Nb-2Mo-12Zr alloy exhibited the lowest elastic modulus of 56.3 GPa, together with the highest elongation to failure of 48.2%, demonstrating that the alloy possesses considerable potential for biomedical applications. Full article

The milled surface topography of NiTi SMA critically affects its frictional behavior, corrosion resistance, and biocompatibility, which are essential for biomedical and aerospace applications. This study combines simulation and single-factor experiments to investigate the coupling behavior among surface topography evolution, work hardening, plastic deformation, and residual stress evolution. Results showed that increasing feed per tooth led to a significant rise in surface residual height and an improvement in surface isotropy. With the increase in feed per tooth, the error between the experimental and simulated heights gradually decreased from 105.6% to 30.9%, indicating that both material properties and feed per tooth strongly affect residual profile formation in the feed direction. In addition, larger feed per tooth intensifies work hardening and plastic deformation but reduces surface residual stress, thereby increasing microhardness. These effects can mitigate material rebound and improve surface profile accuracy. The results provide a direct basis for controlling the surface integrity of NiTi SMA components through machining parameter optimization, enabling precise tailoring of functional surface characteristics, such as wear performance, chemical stability, and biological response, which is of critical importance for high-end biomedical implants and aerospace systems. Full article

Diamond coring bits exhibit stable rock-breaking and coring processes as well as a long service life. However, when drilling in complex and challenging formations are characterized by high hardness, strong plasticity, and high abrasiveness, issues such as low rock-breaking efficiency, rapid failure, and shortened service life frequently occur. To prevent premature bit failure and enhance rock-breaking efficiency, this study investigated the effects of drilling pressure and rotational speed on rock-breaking performance through bench-scale experiments using typical rock samples. A total of 15 experimental groups were included in this study, with one independent trial performed for each group. ROP is calculated as the ratio of effective drilling depth to time consumed, and MSE is derived based on axial force, torque, and rock-breaking volume. The experimental results indicated that (1) sandstone is more sensitive to rotational speed, whereas limestone and dolomite are more sensitive to drilling pressure; (2) the minimum mechanical specific energy (MSE) of sandstone was achieved at a drilling pressure of 15 kN and rotational speed of 50 r/min; (3) limestone exhibited the lowest MSE at 10 kN drilling pressure and 50 r/min rotational speed; and (4) dolomite showed the minimum energy consumption at 10 kN drilling pressure and 25 r/min rotational speed. On this basis, this paper establishes a cutting mechanics model for single-crystal diamond and a working load calculation model for the entire bit, respectively. The cutting mechanics model for single-crystal diamond is re-established based on Hertzian contact theory and elastic-plastic deformation theory. The findings of this study are expected to provide a working load calculation method for diamond coring bits in typical complex and challenging drilling formations and offer technical support for the design of coring bit cutting structures and the development of customized new products. It should be noted that the conclusions of this study are limited to the experimental parameter range (drilling pressure: 5–15 kN; rotational speed: 25–80 r/min), and their applicability under higher load conditions requires further verification. Full article

The present paper concerns a new formulation of the optimal design problem of I-shaped multistep steel beam elements, based on the study of the plastic strain spread occurring in the relevant elements, with the aim of determining the length involved by the plastic deformation related to assigned load conditions and different constrained beam schemes. Material behavior is assumed as elastic–perfectly plastic, and the hypothesis of plane cross-sections is accepted. The functions defining the plastic strain spread are analytically obtained in the framework of Euler–Bernoulli beam theory. The proposed optimal design problem is a minimum volume one and the new constraint imposed on the length of the plasticized portion ensures that the minimum volume beam element also represents a maximum plastic dissipation one. Furthermore, the solution to the optimal design problem guarantees that the obtained multistep beam element ensures protection against brittle failure of the beam end sections, provides optimal cross-sections of the different portions belonging to Class 1 and ensures a suitable minimum value of the elastic flexural stiffness to respect the constraint on the deflection. Explicit reference is made to the so-called Reduced Beam Section (RBS), which characterizes the described multistep beam elements. Actually, the proposed formulation represents an innovative approach to obtaining an optimal beam element that really satisfies all the resistance, stiffness and ductility behavioral requirements. Some numerical applications conclude the paper, and their results are confirmed by appropriate FEM analyses in ABAQUS environment. Full article

Due to their unique properties resulting from the combination of metals with different properties, bimetallic sheets are desirable in the energy, petrochemical, and shipbuilding industries. In this article, explosively welded EN AW-1050/Cu-ETP (Al/Cu) plates were used as the test material. One of the greatest advantages of Al/Cu bimetallic plates is their high deformability, which allows for easy plastic forming. The aim of this study was to determine the effect of severe plastic deformation on the microstructure and microhardness of explosively welded EN AW-1050/Cu-ETP plates. Bimetallic samples were processed using the Twist Channel Angular Pressing (TCAP) process. This process consisted of varying the number of passes and the sample orientation relative to the helical exit channel of the TCAP die. For comparative purposes, a microstructural analysis and the microhardness testing of the as-welded samples were also carried out. Microstructural analysis of TCAP-processed samples showed that the sample deformed along route Bc exhibited the most deformed weld interface profile. No cracking or delamination was observed in the Al/Cu interfacial transition layer of TCAP-processed samples. The number of passes and orientation of the bimetallic material relative to the die exit channel affected the final microhardness in the individual layers of explosively welded EN AW-1050/Cu-ETP bimetallic plate. Full article

Silica-rich dust intrusion is a persistent challenge for lubrication systems in agricultural machinery, where abrasive third-body particles can accelerate wear and shorten component service life. Here, molecular dynamics simulations are employed to elucidate how SiO₂ nanoparticle contamination degrades polyalphaolefin (PAO) boundary lubrication at the atomic scale. Two confined sliding models are compared: a pure PAO film and a contaminated PAO film containing 7 wt% SiO₂ nanoparticles between crystalline Fe substrates under a constant normal load and sliding velocity. The contaminated system exhibits a higher steady-state friction force, faster lubricant film disruption and migration, and consistently higher interfacial temperatures, indicating intensified energy dissipation. Substrate analyses reveal deeper and stronger von Mises stress penetration, increased severe plastic shear strain, elevated Fe potential energy associated with defect accumulation, and reduced structural order. Meanwhile, PAO molecules store more intramolecular deformation energy (bond, angle, and dihedral terms), reflecting stress concentration and disturbed shear alignment induced by nanoparticles. These results clarify the multi-pathway mechanisms by which abrasive SiO₂ contaminants transform PAO from a protective boundary film into an agent promoting abrasive wear, providing insights for designing wear-resistant lubricants and improved filtration strategies for particle-laden applications. Full article

This paper presents an experimental and numerical investigation of continuous reinforced concrete (RC) beams made of self-compacting concrete (SCC) strengthened with fiber-reinforced polymer (FRP) bars using the Near-Surface Mounted (NSM) method. While the majority of previous studies have focused on simply supported beams, this work examines two-span continuous beams, which are more representative of real structural behavior. Four SCC beams were tested under static loading to evaluate the influence of the FRP reinforcement position on flexural capacity and deformational characteristics. The beams were strengthened using glass FRP (GFRP) bars embedded in epoxy adhesive within pre-cut grooves in the concrete cover. Experimental results showed that FRP reinforcement significantly increased the ultimate load capacity, while excessive reinforcement reduced ductility, leading to a more brittle failure mode. A three-dimensional finite element model was developed in Abaqus/Standard using the Concrete Damage Plasticity (CDP) model to simulate the nonlinear behavior of concrete and the bond–slip interaction at the epoxy–concrete interface. The numerical predictions closely matched the experimental load–deflection responses, with a maximum deviation of less than 3%. The validated model provides a reliable tool for parametric analysis and can serve as a reference for optimizing the design of continuous SCC beams strengthened by the NSM FRP method. Full article