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Search Results (1,407)

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Keywords = stress–fatigue life

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13 pages, 269 KiB  
Article
Work Engagement and Compassion Fatigue Among Nursing Professionals During the COVID-19 Pandemic: A Cross-Sectional and Single-Center Study Using the ProQOL-BR and UWES-9 Scales
by Juliana Lima da Cunha, Luciano Garcia Lourenção, José Gustavo Monteiro Penha, Francisco Rosemiro Guimarães Ximenes Neto, Daiani Modernel Xavier, Vagner Ferreira do Nascimento, Adriane Maria Netto de Oliveira, Daniela Menezes Galvão, Alberto de Oliveira Redü and Natália Sperli Geraldes Marin dos Santos Sasaki
COVID 2025, 5(8), 124; https://doi.org/10.3390/covid5080124 - 2 Aug 2025
Viewed by 105
Abstract
Objectives: This study investigated levels of work engagement and the occurrence of compassion fatigue among nursing professionals during the COVID-19 pandemic. Methods: A cross-sectional, descriptive, and correlational study was conducted at a Brazilian university hospital between February and April 2022. The Brazilian versions [...] Read more.
Objectives: This study investigated levels of work engagement and the occurrence of compassion fatigue among nursing professionals during the COVID-19 pandemic. Methods: A cross-sectional, descriptive, and correlational study was conducted at a Brazilian university hospital between February and April 2022. The Brazilian versions of the Utrecht Work Engagement Scale (UWES-9) and the Professional Quality of Life Scale (ProQOL-BR) were administered. Results: High levels of compassion satisfaction (44.9 points), low levels of burnout (21.0 points), and low levels of secondary traumatic stress (22.8 points) were observed. No professional demonstrated a profile consistent with compassion fatigue. Engagement levels were high for dedication (5.3) and moderate for vigor (4.9), absorption (4.5), and overall engagement (4.9). Burnout showed moderate negative correlations with vigor (r = −0.611, p = 0.005) and dedication (r = −0.599, p = 0.019). Compassion satisfaction showed moderate positive correlations with vigor (r = 0.522, p < 0.001) and dedication (r = 0.572, p < 0.001). The overall engagement score was moderately and positively correlated with compassion satisfaction (r = 0.532, p < 0.001). Conclusions: This study identified high levels of work engagement, especially regarding dedication, and low levels of compassion fatigue among nursing professionals. The data suggest that even amid the emotional and physical demands imposed by the pandemic, participants preserved their emotional well-being and maintained a positive relationship with their work. Full article
(This article belongs to the Section COVID Clinical Manifestations and Management)
18 pages, 5167 KiB  
Article
Comparative Study of Local Stress Approaches for Fatigue Strength Assessment of Longitudinal Web Connections
by Ji Hoon Kim, Jae Sung Lee and Myung Hyun Kim
J. Mar. Sci. Eng. 2025, 13(8), 1491; https://doi.org/10.3390/jmse13081491 - 1 Aug 2025
Viewed by 142
Abstract
Ship structures are subjected to cyclic loading from waves and currents during operation, which can lead to fatigue failure, particularly at locations with structural discontinuities such as welds. Although various fatigue assessment methods have been developed, there is a lack of experimental data [...] Read more.
Ship structures are subjected to cyclic loading from waves and currents during operation, which can lead to fatigue failure, particularly at locations with structural discontinuities such as welds. Although various fatigue assessment methods have been developed, there is a lack of experimental data and comparative studies for actual ship structure details. This study addresses this limitation by evaluating the fatigue strength of longi-web connections in hull structures using local stress approaches, including hot spot stress, effective notch stress, notch stress intensity factor, and structural stress methods. Finite element analyses were conducted, and the predicted fatigue lives and failure locations were compared with experimental results. Although there are some differences between each method, all methods are valid and reasonable for predicting the primary failure locations and evaluating fatigue life. These findings provide a basis for considering suitable fatigue assessment methods for welded ship structures with respect to joint geometry and failure mechanisms. Full article
(This article belongs to the Section Ocean Engineering)
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24 pages, 4287 KiB  
Article
Integrated Design of Materials and Structures for Flexible Base Asphalt Pavement
by Bin Huang, Qinxue Pan, Xiaolong Chen, Jia Hu and Songtao Lv
Materials 2025, 18(15), 3602; https://doi.org/10.3390/ma18153602 - 31 Jul 2025
Viewed by 226
Abstract
Current asphalt pavement structural design methods often lack a strong quantitative link to materials’ mixtures and mechanical properties and typically ignore the significant tensile–compressive disparities of materials, resulting in notable analysis errors. This study employed the dual-modulus theory to numerically analyze flexible base [...] Read more.
Current asphalt pavement structural design methods often lack a strong quantitative link to materials’ mixtures and mechanical properties and typically ignore the significant tensile–compressive disparities of materials, resulting in notable analysis errors. This study employed the dual-modulus theory to numerically analyze flexible base asphalt pavements under varied configurations, revealing how critical structural responses and fatigue life evolve. This examination also determined optimal layer mixes through mechanical parameter modeling for integrated material–structure design. The results showed that fundamental responses and fatigue life vary nonlinearly with thickness and modulus. The effect of modulus outweighed that of thickness, with the effects of the tensile modulus being more pronounced than compressive ones, and surface transverse strain being most sensitive to both. The recommended compressive–tensile modulus ratios were about 1.5, 2.0, and 1.2 for upper, lower, and base layers, respectively. By using this integrated design method, the optimized pavement structures achieved superior stress distribution, significantly extending the base service life. As a result, more realistic design lifetimes were obtained. Full article
(This article belongs to the Section Construction and Building Materials)
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21 pages, 2799 KiB  
Article
Structural Integrity Assessments of an IMO Type C LCO2 Cargo Tank
by Joon Kim, Kyu-Sik Park, Inhwan Cha and Joonmo Choung
J. Mar. Sci. Eng. 2025, 13(8), 1479; https://doi.org/10.3390/jmse13081479 - 31 Jul 2025
Viewed by 103
Abstract
With the rise of carbon capture and storage, liquefied carbon dioxide (LCO2) has emerged as a promising medium for large-scale marine transport. This study evaluates the structural integrity of an IMO Type C cargo tank for a medium-range LCO2 carrier [...] Read more.
With the rise of carbon capture and storage, liquefied carbon dioxide (LCO2) has emerged as a promising medium for large-scale marine transport. This study evaluates the structural integrity of an IMO Type C cargo tank for a medium-range LCO2 carrier under four conditions: ultimate limit state, accidental limit state, hydrostatic pressure test, and fatigue limit state, based on IGC Code and classification rules. Seventeen load cases were analyzed using finite element methods with multi-step loading to ensure stability. The highest stress occurred at the pump dome–shell junction due to geometric discontinuities, but all stress and buckling criteria were satisfied. The fatigue damage from wave-induced loads was negligible, with low-cycle fatigue from loading/unloading operations governing the fatigue life, which exceeded 31,000 years. The findings confirm the tank’s structural robustness and its suitability for safe, efficient medium-pressure LCO2 transport. Full article
(This article belongs to the Special Issue New Advances in the Analysis and Design of Marine Structures)
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14 pages, 3504 KiB  
Article
Optimizing Aortic Arch Stent-Graft Performance Through Material Science: An Exploratory Study
by Xiaobing Liu, Linxuan Zhang, Zongchao Liu and Shuai Teng
Materials 2025, 18(15), 3592; https://doi.org/10.3390/ma18153592 - 31 Jul 2025
Viewed by 226
Abstract
Thoracic endovascular aortic repair (TEVAR) for cardiovascular diseases often encounters complications that are closely linked to the mechanical properties of stent-grafts. Both the design and material properties influence device performance, but the specific impacts of material properties remain underexplored and poorly understood. This [...] Read more.
Thoracic endovascular aortic repair (TEVAR) for cardiovascular diseases often encounters complications that are closely linked to the mechanical properties of stent-grafts. Both the design and material properties influence device performance, but the specific impacts of material properties remain underexplored and poorly understood. This study aims to fill this gap by systematically investigating how material science can modulate stent-graft mechanics. Four types of bare nitinol stents combined with expanded polytetrafluoroethylene (e-PTFE) or polyethylene terephthalate (PET) grafts were modeled via finite element analysis, creating eight stent-graft configurations. Key mechanical properties—flexibility, crimpability, and fatigue performance—were evaluated to dissect material effects. The results revealed that nitinol’s properties significantly influenced all performance metrics, while PET grafts notably enhanced flexibility and fatigue life. No significant differences in equivalent stress were found between PET and e-PTFE grafts, and both had minimal impacts on radial force. This work underscores the potential of material science-driven optimization to enhance stent-graft performance for improved clinical outcomes. Full article
(This article belongs to the Special Issue Advances in Porous Lightweight Materials and Lattice Structures)
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23 pages, 3478 KiB  
Article
Research on Fatigue Life Prediction Method of Spot-Welded Joints Based on Machine Learning
by Shanshan Li, Zhenfei Zhan, Jie Zou and Zihan Wang
Materials 2025, 18(15), 3542; https://doi.org/10.3390/ma18153542 - 29 Jul 2025
Viewed by 247
Abstract
Spot-welding joints are widely used in modern industries, and their fatigue life is crucial for the safety and reliability of structures. This paper proposes a method for predicting the fatigue life of spot-welding joints by integrating traditional structural stress methods and machine learning [...] Read more.
Spot-welding joints are widely used in modern industries, and their fatigue life is crucial for the safety and reliability of structures. This paper proposes a method for predicting the fatigue life of spot-welding joints by integrating traditional structural stress methods and machine learning algorithms. Systematic fatigue tests were conducted on Q&P980 steel spot-welding joints to investigate the influence of the galvanized layer on fatigue life. It was found that the galvanized layer significantly reduces the fatigue life of spot-welding joints. Further predictions of fatigue life using machine learning algorithms, including Random Forest, Artificial Neural Networks, and Gaussian Process Regression, demonstrated superior prediction accuracy and generalization ability compared to traditional structural stress methods. The Random Forest algorithm achieved an R2 value of 0.93, with lower error than traditional methods. This study provides an effective tool for the fatigue life assessment of spot-welding joints and highlights the potential application of machine learning in this field. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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25 pages, 9220 KiB  
Article
Investigation of Stress Intensity Factors in Welds of Steel Girders Within Steel–Concrete Composite Structures
by Da Wang, Pengxin Zhao, Yuxin Shao, Wenping Peng, Junxin Yang, Chenggong Zhao and Benkun Tan
Buildings 2025, 15(15), 2653; https://doi.org/10.3390/buildings15152653 - 27 Jul 2025
Viewed by 339
Abstract
Fatigue damage in steel–concrete composite structures frequently initiates at welded joints due to stress concentrations and inherent defects. This study investigates the stress intensity factors (SIFs) associated with fatigue cracks in the welds of steel longitudinal beams, employing the FRANC3D–ABAQUS interactive technique. A [...] Read more.
Fatigue damage in steel–concrete composite structures frequently initiates at welded joints due to stress concentrations and inherent defects. This study investigates the stress intensity factors (SIFs) associated with fatigue cracks in the welds of steel longitudinal beams, employing the FRANC3D–ABAQUS interactive technique. A finite element model was developed and validated against experimental data, followed by the insertion of cracks at both the weld root and weld toe. The influences of stud spacing, initial crack size, crack shape, and lack-of-penetration defects on Mode I SIFs were systematically analyzed. Results show that both weld root and weld toe cracks are predominantly Mode I in nature, with the toe cracks exhibiting higher SIF values. Increasing the stud spacing, crack depth, or crack aspect ratio significantly raises the SIFs. Lack of penetration defects further amplifies the SIFs, especially at the weld root. Based on the computed SIFs, fatigue life predictions were conducted using a crack propagation approach. These findings highlight the critical roles of crack geometry and welding quality in fatigue performance, providing a numerical foundation for optimizing welded joint design in composite structures. Full article
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28 pages, 4633 KiB  
Review
Innovative Strategies in Hernia Mesh Design: Materials, Mechanics, and Modeling
by Evangelia Antoniadi, Nuno Miguel Ferreira, Maria Francisca Vaz, Marco Parente, Maria Pia Ferraz and Elisabete Silva
Materials 2025, 18(15), 3509; https://doi.org/10.3390/ma18153509 - 26 Jul 2025
Viewed by 431
Abstract
Hernia is a physiological condition that significantly impacts patients’ quality of life. Surgical treatment for hernias often involves the use of specialized meshes to support the abdominal wall. While this method is highly effective, it frequently leads to complications such as pain, infections, [...] Read more.
Hernia is a physiological condition that significantly impacts patients’ quality of life. Surgical treatment for hernias often involves the use of specialized meshes to support the abdominal wall. While this method is highly effective, it frequently leads to complications such as pain, infections, inflammation, adhesions, and even the need for revision surgeries. According to the Food and Drug Administration (FDA), hernia recurrence rates can reach up to 11%, surgical site infections occur in up to 21% of cases, and chronic pain incidence ranges from 0.3% to 68%. These statistics highlight the urgent need to improve mesh technologies to minimize such complications. The design and material composition of meshes are critical in reducing postoperative complications. Moreover, integrating drug-eluting properties into the meshes could address issues like infections and inflammation by enabling localized delivery of antibiotics and anti-inflammatory agents. Mesh design is equally important, with innovative structures like auxetic designs offering enhanced mechanical properties, flexibility, and tissue integration. These advanced designs can distribute stress more evenly, reduce fatigue, and improve performance in areas subjected to high pressures, such as during intense coughing, sneezing, or heavy lifting. Technological advancements, such as 3D printing, enable the precise fabrication of meshes with tailored designs and properties, providing new opportunities for innovation. By addressing these challenges, the development of next-generation mesh implants has the potential to reduce complications, improve patient outcomes, and significantly enhance quality of life for individuals undergoing hernia repair. Full article
(This article belongs to the Section Biomaterials)
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15 pages, 8574 KiB  
Article
Hydrogen Embrittlement Resistance of an Optimized Additively Manufactured Austenitic Stainless Steel from Recycled Sources
by Mattia Cabrioli, María Silva Colmenero, Matteo Vanazzi, Luisa E. Mondora, Gianluca Acquistapace, Fabio Esposito and Michela Giovanardi
Corros. Mater. Degrad. 2025, 6(3), 34; https://doi.org/10.3390/cmd6030034 - 26 Jul 2025
Viewed by 191
Abstract
In the framework of hydrogen production and storage for clean energy generation, the resistance to hydrogen embrittlement of a newly developed austenitic stainless steel is presented. Gas-atomized metal powders prepared from secondary-sourced metals were employed to manufacture test specimens with Laser Powder Bed [...] Read more.
In the framework of hydrogen production and storage for clean energy generation, the resistance to hydrogen embrittlement of a newly developed austenitic stainless steel is presented. Gas-atomized metal powders prepared from secondary-sourced metals were employed to manufacture test specimens with Laser Powder Bed Fusion (LPBF) technology. After machining and exposure to a controlled, pressurized hydrogen atmosphere at high temperature, the effect of hydrogen charging on the mechanical performance under static and dynamic conditions was investigated. The stabilizing effect of the optimized chemical composition is reflected in the absence of degradation effects on Yield Stress (YS), Ultimate Tensile Stress (UTS), and fatigue life observed for specimens exposed to hydrogen. Moreover, despite a moderate reduction in the elongation at fracture observed by increasing the hydrogen charging time, ductility loss calculated as Relative Reduction of Area (RRA) remains substantially unaffected by the duration of exposure to hydrogen and demonstrates that the austenitic steel is capable of resisting hydrogen embrittlement (HE). Full article
(This article belongs to the Special Issue Hydrogen Embrittlement of Modern Alloys in Advanced Applications)
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15 pages, 2217 KiB  
Article
Energy-Based Approach for Fatigue Life Prediction of Additively Manufactured ABS/GNP Composites
by Soran Hassanifard and Kamran Behdinan
Polymers 2025, 17(15), 2032; https://doi.org/10.3390/polym17152032 - 25 Jul 2025
Viewed by 269
Abstract
This study examines the effectiveness of energy-based models for fatigue life prediction of additively manufactured acrylonitrile butadiene styrene (ABS)/graphene nanoplatelet (GNP) composites. The effects of varying GNP weight percentages and filament raster orientations on the fatigue life of the samples were investigated theoretically. [...] Read more.
This study examines the effectiveness of energy-based models for fatigue life prediction of additively manufactured acrylonitrile butadiene styrene (ABS)/graphene nanoplatelet (GNP) composites. The effects of varying GNP weight percentages and filament raster orientations on the fatigue life of the samples were investigated theoretically. The required stress and strain values for use in energy-based models were obtained by solving two sets of Neuber and Ramberg–Osgood equations, utilizing the available values of notch strength reduction factors at each load level and the average Young modulus for each composite material. Results revealed that none of the studied energy-based models could accurately predict the fatigue life of the samples across the entire high- and low-cycle fatigue regimes, with strong dependence on the stress ratio (R). Instead, a novel fatigue life prediction model was developed by combining two existing energy-based models, incorporating stress ratio dependence for cases with negative mean stress. This model was tested for R values roughly between −0.22 and 0. Results showed that, for all samples at each raster orientation, most of the predicted fatigue lives fell within the upper and lower bounds, with a factor of ±2 across the entire range of load levels. These findings highlight the reliability of the proposed model for a wide range of R values when mean stress is negative. Full article
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21 pages, 11034 KiB  
Article
Effect of Pre-Hoop Expansion Deformation on High-Temperature Mechanical Properties of Zirconium Plate at 400 °C
by Haidong Qi, Li You and Xiping Song
Metals 2025, 15(8), 827; https://doi.org/10.3390/met15080827 - 23 Jul 2025
Viewed by 222
Abstract
The role of pre-hoop expansion deformation on high-temperature mechanical properties of zirconium at 400 °C was investigated. The results showed that with the increase in the pre-strain, the yield strength and ultimate strength increased while the elongation decreased, all in a linear way. [...] Read more.
The role of pre-hoop expansion deformation on high-temperature mechanical properties of zirconium at 400 °C was investigated. The results showed that with the increase in the pre-strain, the yield strength and ultimate strength increased while the elongation decreased, all in a linear way. The creep life had a significant decrease as the creep stress exceeded 276 MPa. The fatigue–creep results indicated that as the stress ratio was less than 0.7, the deformation process was dominated by fatigue (the fatigue–creep life first increased and then decreased), while as the stress ratio was higher than 0.7, the deformation process was dominated by creep (the fatigue–creep life decreased monotonically). The dwell time had a negative effect on the fatigue–creep life. The stress field simulation results indicated that there existed a compressive stress zone, a stress transition zone, and a tensile stress zone around the pre-hoop expansion deformation zone. The compressive stress was beneficial while the tensile stress was harmful for the high-temperature mechanical properties of the zirconium plate. Full article
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11 pages, 740 KiB  
Article
Quality-of-Life Trajectories and Perceived Stress in Women Treated for Uterine Cancer: A Six-Month Prospective Study
by Razvan Betea, Camelia Budisan, Livia Stanga, Maria Cezara Muresan, Zoran Laurentiu Popa, Cosmin Citu, Adrian Ratiu and Veronica Daniela Chiriac
Healthcare 2025, 13(15), 1787; https://doi.org/10.3390/healthcare13151787 - 23 Jul 2025
Viewed by 206
Abstract
Background and Objectives: Uterine cancer is the most common gynaecologic malignancy in developed countries, yet the psychosocial sequelae of treatment are incompletely described. This prospective, single-centre study quantified six-month changes in the quality of life (QoL) and perceived stress in women with [...] Read more.
Background and Objectives: Uterine cancer is the most common gynaecologic malignancy in developed countries, yet the psychosocial sequelae of treatment are incompletely described. This prospective, single-centre study quantified six-month changes in the quality of life (QoL) and perceived stress in women with newly diagnosed uterine cancer and explored clinical moderators of change. Methods: Participants completed four validated self-report questionnaires: the 36-item Short-Form Health Survey (SF-36), the 26-item World Health Organization Quality-of-Life-BREF (WHOQOL-BREF), the 30-item EORTC QLQ-C30 and the 10-item Perceived Stress Scale (PSS-10) before therapy and again six months after surgery ± adjuvant chemoradiation. Subgroup analyses were performed for stage (FIGO I–II vs. III–IV). Results: Mean SF-36 Physical Functioning improved from 58.7 ± 12.1 to 63.1 ± 12.6 (Δ = +4.4 ± 7.3; p = 0.000, d = 0.36). PSS declined from 24.1 ± 5.6 to 20.8 ± 5.4 (Δ = −3.3 ± 5.0; p < 0.001, d = 0.66). The WHOQOL-BREF Physical and Psychological domains rose by 4.4 ± 6.9 and 3.5 ± 7.3 points, respectively (both p < 0.01). EORTC QLQ-C30 Global Health increased 5.1 ± 7.6 points (p < 0.001) with parallel reductions in fatigue (−5.4 ± 9.0) and pain (−4.8 ± 8.6). Advanced-stage patients showed larger reductions in stress (ΔPSS −3.5 ± 2.5 vs. −2.3 ± 2.3; p = 0.036) but similar QoL gains. ΔPSS correlated inversely with ΔWHOQOL Psychological (r = −0.53) and ΔSF-36 Mental Health (r = −0.49) and positively with ΔEORTC Global Health (r = −0.42) (all p < 0.001). Conclusions: Over six months, multimodal uterine cancer treatment was associated with clinically meaningful QoL improvements and moderate stress reduction. Greater stress relief paralleled superior gains in psychological and global health indices, highlighting the importance of integrative survivorship care. Full article
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11 pages, 1205 KiB  
Article
Impact of Catheter Ablation on Functional Capacity and Cardiac Stress Markers in Patients with Premature Ventricular Contractions
by Vasileios Cheilas, Athanasios Dritsas, Antonios Martinos, Evangelia Gkirgkinoudi, Giorgos Filandrianos, Anastasios Chatziantoniou, Ourania Kariki, Panagiotis Mililis, Athanasios Saplaouras, Anna Kostopoulou, Konstantinos Letsas and Michalis Efremidis
Med. Sci. 2025, 13(3), 95; https://doi.org/10.3390/medsci13030095 - 23 Jul 2025
Viewed by 635
Abstract
Background: Premature ventricular contractions (PVCs) are common arrhythmias associated with symptoms such as fatigue and, in severe cases, PVC-induced cardiomyopathy. Catheter ablation (CA) is a primary treatment for symptomatic PVCs, particularly when pharmacological therapies fail or are undesired. While improvements in: quality-of-life following [...] Read more.
Background: Premature ventricular contractions (PVCs) are common arrhythmias associated with symptoms such as fatigue and, in severe cases, PVC-induced cardiomyopathy. Catheter ablation (CA) is a primary treatment for symptomatic PVCs, particularly when pharmacological therapies fail or are undesired. While improvements in: quality-of-life following ablation are documented, its impact on functional capacity remains underexplored. Objectives: This study evaluated the impact of CA on functional capacity and cardiac stress markers in patients with symptomatic PVCs using cardiopulmonary exercise testing (CPET) and NT-proBNP levels. Methods: A total of 30 patients underwent successful PVC ablation and completed baseline and follow-up CPET evaluations under the Bruce protocol. PVC burden, left ventricular ejection fraction (LVEF), NT-proBNP levels, and CPET parameters, including VO2 max, METS, ventilatory efficiency, and anaerobic threshold (AT), were analyzed pre- and post-ablation. Results: PVC burden significantly decreased post-ablation (23,509.3 ± 10,700.47 to 1759 ± 1659.15, p < 0.001). CPET revealed improved functional capacity, with VO2 max increasing from 24.97 ± 4.16 mL/kg/min to 26.02 ± 4.34 mL/kg/min (p = 0.0096) and METS from 7.16 ± 1.17 to 7.48 ± 1.24 (p = 0.0103). NT-proBNP significantly decreased (240.93 ± 156.54 pg/mL to 138.47 ± 152.91 pg/mL, p = 0.0065). LVEF and ventilatory efficiency metrics (VE/VO2 and VE/VCO2) remained stable. Conclusions: Catheter ablation improves functional capacity, reduces cardiac stress, and minimizes medication dependency in patients with symptomatic PVCs. These findings support the utility of ablation in enhancing aerobic capacity and overall exercise performance. Full article
(This article belongs to the Section Cardiovascular Disease)
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13 pages, 2500 KiB  
Article
The Impact of Gear Meshing in High-Speed EMU Gearboxes on Fatigue Strength of the Gearbox Housing
by Changqing Liu, Shouguang Sun and Qiang Li
Technologies 2025, 13(8), 311; https://doi.org/10.3390/technologies13080311 - 22 Jul 2025
Viewed by 242
Abstract
As high-speed electric multiple units (EMUs) advance in speed and complexity, quasi-static design methods may underestimate the fatigue risks associated with high-frequency dynamic excitations. This study quantifies the contribution of gear meshing-induced vibrations (2512 Hz) to fatigue damage in EMU gearbox housings, revealing [...] Read more.
As high-speed electric multiple units (EMUs) advance in speed and complexity, quasi-static design methods may underestimate the fatigue risks associated with high-frequency dynamic excitations. This study quantifies the contribution of gear meshing-induced vibrations (2512 Hz) to fatigue damage in EMU gearbox housings, revealing resonance amplification of local stresses up to 1.8 MPa at 300 km/h operation. Through integrated field monitoring and bench testing, we demonstrated that gear meshing excites structural modes, generating sustained, very high-cycle stresses (>108 cycles). Crucially, fatigue specimens were directly extracted from in-service gearbox housings—overcoming the limitations of standardized coupons—passing the very high-cycle fatigue (VHCF) test to derive S-N characteristics beyond 108 cycles. Results show a continuous decline in fatigue strength (with no traditional fatigue limit) from 108 to 109 cycles. This work bridges the gap between static design standards (e.g., FKM) and actual dynamic environments, proving that accumulated damage from low-amplitude gear-meshing stresses (3.62 × 1011 cycles over a 12 million km lifespan) contributes to a 16% material utilization ratio. The findings emphasize that even low-magnitude gear-meshing stresses can significantly influence gearbox fatigue life due to their ultra-high frequency, warranting design consideration beyond current standards. Full article
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21 pages, 13574 KiB  
Article
Effect of Processing-Induced Oxides on the Fatigue Life Variability of 6082 Al-Mg-Si Alloy Extruded Components
by Viththagan Vivekanandam, Shubham Sanjay Joshi, Jaime Lazaro-Nebreda and Zhongyun Fan
J. Manuf. Mater. Process. 2025, 9(7), 247; https://doi.org/10.3390/jmmp9070247 - 21 Jul 2025
Viewed by 422
Abstract
Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a [...] Read more.
Aluminium alloy 6082 is widely used in the automotive and aerospace industries due to its high strength-to-weight ratio. However, its structural integrity can sometimes be affected by an early fatigue failure. This study investigates the fatigue performance of extruded 6082-T6 samples through a series of fatigue tests conducted at varying stress levels. The material showed significant variability under identical fatigue conditions, suggesting the presence of microstructural defects. Scanning electron microscopy with energy-dispersive spectroscopy (SEM/EDS) and scanning transmission electron microscopy (S/TEM) were used to identify the nature and location of the defects and evaluate the underlying mechanisms influencing the fatigue performance. Computer tomography (CT) also confirmed the presence of oxide inclusions on the fracture surface and near the edges of the samples. These oxide inclusions are distributed throughout the material heterogeneously and in the form of broken oxide films, suggesting that they might have originated during the material’s early processing stages. These oxides acted as stress concentrators, initiating microcracks that led to catastrophic and unpredictable early failure, ultimately reducing the fatigue life of micro-oxide-containing samples. These results highlight the need for better casting control and improved post-processing techniques to minimise the effect of oxide presence in the final components, thus enhancing their fatigue life. Full article
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