Search Results (199)

The integrity of bolted components primarily relies on the quality of interfacial contact, which is achieved by maintaining prescribed bolt torque levels. However, challenges arise from corrosion-induced bolt head damage, potentially compromising the bolt preload, and quantifying such effects remains unanswered. Many studies often compare bolt corrosion’s effects to bolt loosening as both affect the interfacial contact stresses to some extent. This technical study aimed to investigate whether a correlation exists between the impact of bolt head damage and the different levels of bolt torque. Guided wave ultrasonic testing (UT) was implemented for this investigation. Laboratory experiments were conducted to monitor the transmission of ultrasonic signals across the bolted interface first during the bolt-tightening process. Once the highest bolt torque was achieved, the process was repeated for a simplified corrosion scenario, simulated by artificially damaging the bolt head in a controlled manner. The analysis focused on studying the transmission of signal energy for both scenarios. The findings revealed different trends for the signal energy transmission during bolt tightening, which are subjective to the inspection frequency. On the contrary, even at an advanced level of bolt head damage corresponding to 16% mass loss, no clear or monotonic trend was observed in the total transmitted energy. While the total energy remained relatively stable across all inspection frequencies, distinct waveform changes, such as energy redistribution and the emergence of additional wave packets, were observed. The findings emphasize the need for more advanced waveform-based analysis techniques to detect and interpret subtle changes caused by bolt degradation. Full article

Composite electrodeposited coatings hold significant potential for marine and aerospace applications due to their synergistic corrosion resistance and wear durability, yet nanoparticle agglomeration and interfacial incompatibility persistently undermine their performance. Conventional dispersion techniques—mechanical agitation, surfactants, or high-energy methods—fail to resolve these issues, often introducing residual stresses, organic impurities, or thermal damage to substrates. This study addresses these challenges through a novel thermal-assisted alkaline etching (TAE) protocol that synergistically removes surface oxides and enhances colloidal stability in β-SiC nanoparticles. By combining NaOH-based etching with low-temperature calcination (250 °C), the method achieves oxide-free SiC surfaces with elevated hydrophilicity and a ζ-potential of −25 mV, enabling submicron clustering (300 nm) without surfactants. Electrodeposited Co/SiC coatings incorporating TAE-SiC exhibited current-modulated reinforcement, achieving optimal SiC incorporation (5.9 at% Si) at 8 A/dm² through electrophoretic–hydraulic synergy, along with uniform cross-sectional distribution validated by SEM. Tribological assessments revealed shorter wear tracks in TAE-SiC-enhanced coatings compared to their untreated counterparts, suggesting enhanced interfacial coherence despite a comparable mass loss. Demonstrating scalability through cost-effective aqueous-phase chemistry, this methodology provides a generalized framework applicable to other ceramic-reinforced systems (e.g., Al₂O₃ and TiC), offering transformative potential for next-generation protective coatings in harsh operational environments. Full article

In order to determine the failure reason for the non-working area of a cracked A-pillar hot-stamping die insert, various instruments were used to detect the properties and microstructures of the cracks and matrix. The results show that the cracks are located in the area where the oxidative corrosion is more serious, and the cracks do not appear in the pitting area, verifying that crack initiation is related to the stress concentration on the upper half of the inner wall of the cooling channel. Meanwhile, pores and cracks exist in the grain boundary and crystal, making the impact energy of the die steel poor. Therefore, crack initiation and propagation easily occur along the brittle oxide layer. In summary, the die insert is damaged by stress-induced corrosion. In engineering applications of hot-stamping dies, we should pay more attention to the cracking of the cooling channel caused by stress and corrosion. Full article

We studied the influence of annealing on the magnetic properties and microstructure of ultrathin (metallic nucleus diameter ≈ 5 μm, total diameter ≈ 19 μm) Heusler-type NiMnGa glass-coated microwires prepared using the Taylor–Ulitovsky method. The as-prepared NiMnGa microwires exhibit unexpectedly strong magnetic anisotropy, characterized by a coercivity exceeding 3 kOe at room temperature. Furthermore, their Curie temperature (T_c) lies above room temperature. Additionally, a spontaneous exchange bias of approximately 120 Oe is observed in the as-prepared sample at 100 K. Annealing the microwires leads to a decrease in coercivity, spontaneous exchange bias, and T_c values. Notably, the annealing process shifts the T_c of the samples closer to room temperature, making them more suitable for magnetic solid-state refrigeration applications. Moreover, the hysteresis observed in the temperature dependence of magnetization for the samples annealed for 1 h and 2 h, along with the magnetic softening observed at around 260 K, is attributed to a first-order phase transformation. The observed changes are discussed in the context of internal stress relaxation after annealing, the nanocrystalline structure of both the as-prepared and annealed samples, the recrystallization process, and the magnetic ordering of phases identified in the as-prepared sample and those appearing during recrystallization. The glass coating on microwires offers benefits like better flexibility and resistance to damage and corrosion. However, it is important to recognize that this coating can substantially alter the microwires’ magnetic characteristics. Consequently, precise control over the annealing process is vital to obtain the specific martensitic transformation needed. Full article

Bridges play a key and controlling role in transportation systems. Steel bridges are favored for their high strength, good seismic performance, and convenient construction. As important node connectors of steel bridges, high-strength bolts are extremely susceptible to damage such as corrosion and loosening. Therefore, accurate identification of bolt loosening is crucial. First, a new type of adhesive piezoelectric sensor is designed and prepared using PMN-PT piezoelectric single-crystal materials. The PMN-PT sensor and polyvinylidene fluoride (PVDF) sensor are subjected to steel plate fixed frequency load and swept frequency load tests to test the performance of the two sensors. Then, a steel plate component connected by high-strength bolts is designed. By applying exciter square wave load to the structure, the vibration response characteristics of the structure are analyzed to identify the loosening of the bolts. In addition, a piezoelectric smart washer sensor is designed to make up for the shortcomings of the adhesive piezoelectric sensor, and the effectiveness of the piezoelectric smart washer sensor is verified. Finally, a bolt loosening index is proposed to quantitatively evaluate the looseness of the bolt. The results show that the sensitivity of the PMN-PT sensor is 21 times that of the PVDF sensor. Compared with the peak stress change, the natural frequency change is used to identify the bolt loosening more effectively. Piezoelectric smart washer sensor and bolt loosening indicator can be used for bolt loosening identification. Full article

In this study, the effect of plastic residual strain on the corrosion behavior of ZK60 magnesium alloy was systematically revealed using a research method combining experimental characterization and numerical simulation. Based on the multiphysical field coupling theory, a numerical model containing deformation field, corrosion phase field, and material transfer field was constructed, and the dynamic simulation of plastic residual strain-induced corrosion damage was successfully realized. Tafel polarization curves obtained from electrochemical tests were fitted to the key parameters of the secondary current distribution. The kinetic parameter L controlling the corrosion rate in the phase-field model was innovatively determined by the inverse calibration method, and a quantitative relationship between the kinetics of electrochemical corrosion and the phase-field theory was established. The corrosion depth distribution of the pre-strained specimens is quantitatively characterized and the results are in agreement with the finite element simulation results. The coupled strain-corrosion analysis method proposed in this study provides a theoretical basis for the design and life prediction of corrosion resistance of components under complex stress states. Full article

Thermoplastic fiber metal laminates (FMLs) are hybrid material systems that consist of a thin aluminum alloy sheet bonded to plies of fiber-reinforced adhesive. They provide excellent properties like fatigue strength, damage-tolerant properties, and inherent resistance to corrosion. However, they are still challenging materials in terms of the metal–composite interface, which is the weakest link in this material system. In this paper, an experimental–numerical method for the determination of the fracture stress and energy for metal–composite interlayer is presented and verified. The proposed method utilizes four different experimental tests: DCB test (interface opening—mode I), ENF test (interface shearing—mode II), MMB test (mixed-mode I+II—opening with the shearing of the interface) and three-point bending test (3PB). For each test, digital twin in the form of a numerical model is prepared. The established numerical models for DCB and ENF allowed us to determine fracture stress and energy for mode I and mode II, respectively. On the basis of the numerical and experimental (from the MMB test) data, the B-K exponent is determined. Finally, the developed material model is verified in a three-point bending test, which results in mixed-mode conditions. The research is conducted on the thermoplastic FML made of aluminum alloy sheet and glass fiber reinforced polyamide 6. The research presented is complemented by fundamental mechanical tests, image processing and Scanning Electron Microscopy (SEM) analysis. As an effect, for the tested material, fracture parameters are determined using the described method. Full article

Heavy rolling contact fatigue (RCF) may be caused by wheel surface defects under the influence of rail corrosion, which threatens the operational safety of rail vehicles. To investigate the role of surface defects on wheel RCF damage under the influence of rail corrosion, a salt spray tester was used to corrode the rails, an impact testing machine was employed to create surface defects, and RCF tests were completed. The role of surface defects on wheel RCF damage was studied by monitoring the wheel defect surface and cross-section. The results indicate that the tendencies of the RCF crack extension of surface defects of different sizes are similar, and they all extend in a C-shape along the tangential force direction. However, the larger the defect size, the later the crack is initiated. The leading edge material is continuously squeezed into the defect by the tangential force, and a larger plastic deformation layer is formed, which causes the RCF at the leading edge to crack more severely. Meanwhile, under the effect of combined normal force and shear stress, the leading edge crack intersects with the middle edge crack, and the leading edge material is spalled off first. Wheel RCF damage and wear are aggravated by rail corrosion, the longer the corrosion time, the more serious the RCF damage and wear, and the earlier the material spalling time, the lower the fatigue life. Full article

The high-pile beam slab structure is a commonly employed design for riverbank wharves; however, the wharf structure may incur damage due to various factors during long-term operation, resulting in potential safety concerns. To illustrate this, an investigation was conducted on a high-pile beam slab wharf, which included on-site examination, testing, and large-scale three-dimensional numerical simulation. The effects of gravity, ship impact, earthquake, lateral impact, water, and crane change were considered to explore the causes of cracking in the wharf concrete components. The results indicated that crane modification significantly augmented loads, precipitating notable deformation (92% increase in maximum vertical displacement), and the maximum tensile stress exceeded concrete tensile strength. The inadequate thickness of the steel reinforcement protective layer caused concrete carbonation, steel exposure, and corrosion, reducing structural capacity. The presence of defects in the pile foundation has been shown to result in high stress concentrations, which can lead to deformation and damage. There was a 58% increase in vertical displacement in the concrete components above the affected area compared to intact piles. Based on analysis of the results, appropriate measures for strengthening and correction have been proposed to ensure the safety and durability of the wharf. A comprehensive multifactor evaluation and 3D simulation of the actual dimensions are recommended to ensure the safety of wharf structures. Full article

Ni-based superalloys with enhanced environmental resistance at high temperatures are crucial for advanced gas turbine engines. The new polycrystalline nickel-based superalloy has excellent mechanical properties, but as a low-Cr, high-alloying superalloy, its environmental resistance has never been investigated. The hot corrosion behavior of the nickel-based superalloy under molten salt conditions and its effect on its tensile properties were investigated in this paper. The results showed the following: The diffusion of the Cr, Al, and Ni elements governs the majority of the corrosion process, resulting in the production of an environmentally damaged organization with internal sulfidation and surface oxidation. The Wagner model predicts the inability to form a dense Al oxide scale on the surface because the crucial generation condition of external Al oxides is not met. In addition, the growth stress in the damage scales is the main cause of cracking and spalling in the isothermal corrosion process. Due to the increased local stress concentration brought on by this environmental degradation, the sulfide scale acts as a fracture source, guiding the matrix cracking and influencing the tensile properties of the alloy. Full article

Hip joint implants are among the most prevalent types of medical implants utilized for the replacement of damaged joints. The utilization of modern implant materials, such as cobalt–chromium alloys, stainless steel, titanium, and other titanium alloys, is accompanied by challenges, including the toxicity of certain elements (e.g., aluminum, vanadium, nickel) and excessive Young’s modulus, which adversely impact biomechanical compatibility. A mismatch between the stiffness of the implant material and the bone tissue, known as stress shielding, can lead to adverse outcomes such as bone resorption and implant loosening. Recent studies have shifted the focus to β-titanium alloys due to their exceptional biocompatibility, corrosion resistance, and low Young’s modulus, which is close to the Young’s modulus of bone tissue (10–30 GPa). In this study, the microstructure, mechanical properties, and phase stability of the Ti-38Zr-11Nb alloy were investigated. Energy dispersion spectrometry was employed to confirm the homogeneous distribution of Ti, Zr, and Nb in the alloy. A subsequent microstructural analysis revealed the presence of elongated β-grains subsequent to rolling and quenching. Furthermore, grinding contributed to the process of recrystallization and the formation of subgrains. X-ray diffraction analysis confirmed the presence of a stable β-phase under any heat treatment conditions, which can be explained by the use of Nb as a β-stabilizer and Zr as a neutral element with a weak β-stabilizing effect in the presence of other β-stabilizers. Furthermore, the modulus of elasticity, as determined by tensile testing, exhibited a decline from 85 GPa to 81 GPa after annealing. Mechanical tests demonstrated a substantial enhancement in tensile strength (from 529 MPa to 628 MPa) concurrent with a 32% reduction in elongation to fracture of the samples. These alterations are attributed to microstructural transformations, including the formation of subgrains and the rearrangement of dislocations. This study’s findings suggest that the Ti-38Zr-11Nb alloy has potential as a material of choice due to its lower Young’s modulus compared to traditional materials and its stable β-phase, which enhances the implant’s durability and reduces the risk of brittle phases forming over time. This study demonstrates that the corrosion resistance of titanium grade 2 and Ti-38Zr-11Nb is comparable. The material in question exhibited no evidence of cytotoxic activity in the context of mammalian cells. Full article

High-temperature pipelines, as core facilities in the fields of petrochemical and power, are constantly exposed to extreme working conditions ranging from 450 to 600 °C, facing risks of stress corrosion, creep damage, and other defects. Traditional shutdown inspections are time-consuming and costly. Meanwhile, existing electromagnetic acoustic transducers (EMATs) are restricted by their high-temperature tolerance (≤500 °C) and short-term stability (effective working duration < 5 min). This paper proposes a high-frequency circumferential guided wave (CLamb wave) EMAT based on a Halbach permanent magnet array. Through magnetic circuit optimization (Halbach array) and multi-layer insulation design, it enables continuous and stable detection on the surface of 600 °C pipelines for 10 min. The simulations revealed that the Halbach array increased the magnetic flux density by 1.4 times and the total displacement amplitude by 2 times at a magnet’s large lift-off (9 mm). The experimental results show that the internal temperature of the sensor remained stable below 167 °C at 600 °C. It was capable of detecting the smallest defect of a φ3 mm half-hole (depth half of the wall thickness), with a signal attenuation rate of only 0.32%/min. The signal amplitude of Q235 pipelines under high-temperature short-term detection (<5 min) was 1.5 times higher than that at room temperature. However, material degradation under high temperature led to insufficient long-term stability. This study breaks through the bottleneck of long-term detection of high-temperature EMATs, providing a new scheme for efficient online detection of high-temperature pipelines. Full article

The aircraft landing gear system is vital in ensuring the aircraft’s functional completeness and operational safety. The mechanical structures of the landing gear must withstand significant operational forces, including repeated high-intensity impact loads, throughout their service life. At the same time, they must resist environmental degradation, such as corrosion, temperature fluctuations, and humidity, to ensure structural integrity and long-term reliability. Under this premise, investigating material-related mechanical failures in the landing gear is of great significance for preventing landing gear failures and ensuring aviation safety. Compared to failure investigations, structural health monitoring (SHM) plays a more active role in failure prevention for aircraft landing gears. SHM technologies identify the precursors of potential failures and continuously monitor the operational or health conditions of landing gear structures, which facilitates condition-based maintenance. This paper reviews various landing gear material-related failure investigations. The review suggests a significant portion of these failures can be attributed to material fatigue, which is either induced by abnormal high-stress concentration or corrosion. This paper also reviews a series of load monitoring-based landing gear SHM studies. It is revealed that weight and balance measurement, hard landing detection, and structure load monitoring are the most typical monitoring activities in landing gears. An analytical discussion is also presented on the correlation between reviewed landing gear failures and SHM activities, a comparison of sensors, and the potential shift in load-based landing gear SHM in response to the transition of landing gear design philosophy from safe life to damage tolerance. Full article

Restoring and strengthening existing bridges is more economically and environmentally feasible, as cement production in new RC bridges significantly contributes to CO₂ emissions. Additionally, the production of composite carbon materials for strengthening RC structures does not require a large amount of energy, unlike the production of steel for reinforcement, which requires a significant amount of electricity and, accordingly, causes a significant amount of CO₂ emissions. This is why this article presents a comprehensive review of the damage, calculations, and strengthening of RC bridge structures. It examines the main types of damage, including mechanical impacts, material fatigue, corrosion processes, seismic actions, and thermal loads. The mechanisms of their formation, correlations with environmental factors, and operational conditions are detailed. Examples of damage from real engineering objects are provided to assess the scale of the problem. Approaches to the calculation of RC bridge structures are analyzed, particularly methods for modeling the stress–strain state, considering crack formation and material degradation. Key studies by Ukrainian and foreign researchers are highlighted, identifying areas for further methodological improvement. Special attention is given to traditional and modern strengthening methods, including the use of steel elements, composites, and carbon strips. A comparative analysis of the effectiveness of different strengthening approaches is conducted. The conclusion emphasizes the need for further development of existing diagnostic, calculation, and strengthening methods. The integration of innovative materials and technologies is particularly relevant for enhancing the durability of bridges under modern operational loads. Full article

High-rise pile cap structures, such as sea-crossing bridges, suffer from long-term degradation due to continuous corrosion and scour, which seriously endangers structural safety. However, there is a lack of research on this topic. This study focused on the long-term performance and dynamic response of bridge pile foundations, considering scour and corrosion effects. A refined modeling method for bridge pile foundations, considering scour-induced damage and corrosion-induced degradation, was developed by adjusting nonlinear soil springs and material properties. Furthermore, hydrodynamic characteristics and long-term performance, including hydrodynamic phenomena, wave force, energy, displacement, stress, and acceleration responses, were investigated through fluid–structure coupling analysis and pile–soil interactions. The results show that the horizontal wave forces acting on the high-rise pile cap are greater than the vertical wave forces, with the most severe wave-induced damage occurring in the wave splash zone. Steel and concrete degradation in the wave splash zone typically occurs sooner than in the atmospheric zone. The total energy of the structure at each moment under load is equal to the sum of internal energy and kinetic energy. Increased corrosion time and scour depth result in increased displacement and stress at the pile cap connection. The long-term dynamic response is mainly influenced by the second-order frequency (62 Hz). Full article