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Search Results (251)

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Keywords = subsurface damage

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16 pages, 2671 KiB  
Article
Experimental Study on Cavity Formation and Ground Subsidence Behavior Based on Ground Conditions
by Sungyeol Lee, Jaemo Kang, Jinyoung Kim, Myeongsik Kong and Wonjin Baek
Appl. Sci. 2025, 15(14), 7744; https://doi.org/10.3390/app15147744 - 10 Jul 2025
Viewed by 113
Abstract
Ground subsidence is a significant geotechnical hazard in urban areas, leading to property damage, casualties, and broader societal issues. This study investigates the mechanisms of cavity formation and ground subsidence through laboratory model tests using Korean standard sand and marine clay under controlled [...] Read more.
Ground subsidence is a significant geotechnical hazard in urban areas, leading to property damage, casualties, and broader societal issues. This study investigates the mechanisms of cavity formation and ground subsidence through laboratory model tests using Korean standard sand and marine clay under controlled conditions. A transparent soil box apparatus was fabricated to simulate sewer pipe damage, with model grounds prepared at various relative densities, groundwater levels, and fines contents. The progression of cavity formation and surface collapse was observed and quantitatively analyzed by measuring the time to cavity formation and ground subsidence, as well as the mass of discharged soil. Results indicate that lower relative density accelerates ground subsidence, whereas higher density increases cavity volume due to greater frictional resistance. Notably, as the fines content increased, a tendency was observed for ground subsidence to be increasingly suppressed, suggesting that cohesive clay particles can limit soil loss under seepage conditions. These findings provide valuable insights for selecting backfill materials and managing subsurface conditions to mitigate ground subsidence risks in urban infrastructure. Full article
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33 pages, 25988 KiB  
Article
Erosion Resistance Assessment of Grass-Covered Embankments: Insights from In Situ Overflow Tests at the Living Lab Hedwige-Prosper Polder
by Davy Depreiter, Jeroen Vercruysse, Kristof Verelst and Patrik Peeters
Water 2025, 17(13), 2016; https://doi.org/10.3390/w17132016 - 4 Jul 2025
Viewed by 190
Abstract
Grass-covered levees commonly protect river and estuarine areas against flooding. Climate-induced water level changes may increasingly expose these levees to overflow events. This study investigates whether grass-covered levees can withstand such events, and under what conditions failure may occur. Between 2020 and 2022, [...] Read more.
Grass-covered levees commonly protect river and estuarine areas against flooding. Climate-induced water level changes may increasingly expose these levees to overflow events. This study investigates whether grass-covered levees can withstand such events, and under what conditions failure may occur. Between 2020 and 2022, full-scale overflow tests were conducted at the Living Lab Hedwige-Prosperpolder along the Dutch–Belgian Scheldt Estuary to assess erosion resistance under varying hydraulic conditions and vegetation states. A custom-built overflow generator was used, with instrumentation capturing flow velocity, water levels, and erosion progression. The results show that well-maintained levees with intact grass cover endured overflow durations up to 30 h despite high terminal flow velocities (4.9–7.7 m/s), without structural damage. In contrast, levee sections with pre-existing surface anomalies, such as animal burrows, slope irregularities, surface damage, or reed-covered soft soils, failed rapidly, often within one to two hours. Animal burrows facilitated subsurface flow and internal erosion, initiating fast, retrograde failure. These findings highlight the importance of preventive maintenance, particularly the timely detection and repair of anomalies. Once slope failure begins, the process unfolds rapidly, leaving no practical window for intervention. Full article
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25 pages, 11796 KiB  
Article
Fiber Orientation Effects in CFRP Milling: Multiscale Characterization of Cutting Dynamics, Surface Integrity, and Damage Mechanisms
by Qi An, Jingjie Zhang, Guangchun Xiao, Chonghai Xu, Mingdong Yi, Zhaoqiang Chen, Hui Chen, Chengze Zheng and Guangchen Li
J. Compos. Sci. 2025, 9(7), 342; https://doi.org/10.3390/jcs9070342 - 2 Jul 2025
Viewed by 295
Abstract
During the machining of unidirectional carbon fiber-reinforced polymers (UD-CFRPs), their anisotropic characteristics and the complex cutting conditions often lead to defects such as delamination, burrs, and surface/subsurface damage. This study systematically investigates the effects of different fiber orientation angles (0°, 45°, 90°, and [...] Read more.
During the machining of unidirectional carbon fiber-reinforced polymers (UD-CFRPs), their anisotropic characteristics and the complex cutting conditions often lead to defects such as delamination, burrs, and surface/subsurface damage. This study systematically investigates the effects of different fiber orientation angles (0°, 45°, 90°, and 135°) on cutting force, chip formation, stress distribution, and damage characteristics using a coupled macro–micro finite element model. The model successfully captures key microscopic failure mechanisms, such as fiber breakage, resin cracking, and fiber–matrix interface debonding, by integrating the anisotropic mechanical properties and heterogeneous microstructure of UD-CFRPs, thereby more realistically replicating the actual machining process. The cutting speed is kept constant at 480 mm/s. Experimental validation using T700S/J-133 laminates (with a 70% fiber volume fraction) shows that, on a macro scale, the cutting force varies non-monotonically with the fiber orientation angle, following the order of 0° < 45° < 135° < 90°. The experimental values are 24.8 N/mm < 35.8 N/mm < 36.4 N/mm < 44.1 N/mm, and the simulation values are 22.9 N/mm < 33.2 N/mm < 32.7 N/mm < 42.6 N/mm. The maximum values occur at 90° (44.1 N/mm, 42.6 N/mm), while the minimum values occur at 0° (24.8 N/mm, 22.9 N/mm). The chip morphology significantly changes with fiber orientation: 0° produces strip-shaped chips, 45° forms block-shaped chips, 90° results in particle-shaped chips, and 135° produces fragmented chips. On a micro scale, the microscopic morphology of the chips and the surface damage characteristics also exhibit gradient variations consistent with the experimental results. The developed model demonstrates high accuracy in predicting damage mechanisms and material removal behavior, providing a theoretical basis for optimizing CFRP machining parameters. Full article
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23 pages, 1053 KiB  
Article
Inverse Gravimetric Problem Solving via Prolate Ellipsoidal Parameterization and Particle Swarm Optimization
by Ruben Escudero González, Zulima Fernández Muñiz, Antonio Bernardo Sánchez and Juan Luis Fernández Martínez
Mathematics 2025, 13(12), 2017; https://doi.org/10.3390/math13122017 - 18 Jun 2025
Viewed by 233
Abstract
We present a method for 3D gravity inversion using ellipsoidal parametrization and Particle Swarm Optimization (PSO), aimed at estimating the geometry, density contrast, and orientation of subsurface bodies from gravity anomaly data. The subsurface is modeled as a set of prolate ellipsoids whose [...] Read more.
We present a method for 3D gravity inversion using ellipsoidal parametrization and Particle Swarm Optimization (PSO), aimed at estimating the geometry, density contrast, and orientation of subsurface bodies from gravity anomaly data. The subsurface is modeled as a set of prolate ellipsoids whose parameters are optimized to minimize the misfit between observed and predicted anomalies. This approach enables efficient forward modeling with closed-form solutions and allows the incorporation of geometric and physical constraints. The algorithm is first validated on synthetic models with Gaussian noise, successfully recovering complex multi-body configurations with acceptable uncertainty. A statistical analysis based on multiple PSO runs provides interquartile ranges (IQRs) to quantify inversion stability. The method is then applied to a real microgravity dataset from the Nirano Salse mud volcanoes (northern Italy) using a field acquisition strategy previously described in the literature. Unlike earlier studies based on commercial software, our inversion uses the ellipsoidal–PSO framework. The best-fitting model includes four ellipsoids (two low- and two high-density), reproducing the main features of the observed Bouguer anomaly with a prediction error of 20–25%. The inferred geometry suggests that fluid migration is controlled by fault-related damage zones rather than shallow reservoirs. This method is robust, interpretable, and applicable to both synthetic and real cases, with potential uses in geotechnical, volcanic, and hydrogeological studies. Full article
(This article belongs to the Special Issue Inverse Problems in Science and Engineering)
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14 pages, 2123 KiB  
Article
Influence of Grinding Parameters on Surface Roughness and Subsurface Crack Damage Depth of Sapphire Crystal
by Yingqi Hou, Yufei Gao and Chunfeng Yang
Materials 2025, 18(11), 2461; https://doi.org/10.3390/ma18112461 - 24 May 2025
Viewed by 441
Abstract
Single sapphire crystals has been widely used in technology such as light emitting diodes, lasers, high-temperature and high-voltage devices, special windows, and optical systems, and grinding is an important process of their machining. In order to reveal the influence of the grinding wheel [...] Read more.
Single sapphire crystals has been widely used in technology such as light emitting diodes, lasers, high-temperature and high-voltage devices, special windows, and optical systems, and grinding is an important process of their machining. In order to reveal the influence of the grinding wheel speed, grinding depth, and feed rate on the ground surface quality of sapphire crystals, a three-factor and five-level orthogonal experiment was designed and completed. Variance and range analysis was conducted on the experimental results using the surface roughness Ra and subsurface crack damage depth (SSD) as evaluation indicators, and optimized parameter combinations were explored. Furthermore, mathematical prediction models for the power regression of the Ra and SSD were established based on the experimental data. The research results indicate that within the range of the process parameters used in this experiment, the grinding process did not achieve the full ductile removal of the material. Some of the material was removed in a brittle mode, forming fractured pits on the ground surface, and median crack propagation occurred in the subsurface, forming a subsurface microcrack damage layer. The influence of the grinding parameters on the Ra and SSD showed a consistent trend, which was that the parameter with the greatest impact was the grinding wheel speed, followed by the feed rate and grinding depth. The Ra and SSD obtained under the optimized grinding parameter combination were 0.326 μm and 2.86 μm, respectively. The research results provide an experimental basis and guidance for improving the surface quality of sapphire crystals during grinding. Full article
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10 pages, 3522 KiB  
Communication
Mapping of Lapping-Induced Subsurface Damage in Planar Fused Silica Glass Based on Polarized Laser Scattering Method
by Mingchuan Gao, Yi Guo, Chenxi Liu, Chuanxin He and Qian Bai
Materials 2025, 18(11), 2417; https://doi.org/10.3390/ma18112417 - 22 May 2025
Viewed by 385
Abstract
Fused silica glass is a critical material in many industries due to its superior physicochemical properties. The detection of subsurface damage (SSD) poses fundamental challenges that directly affect the performance of fused silica glass. The polarized laser scattering (PLS) detection method has significant [...] Read more.
Fused silica glass is a critical material in many industries due to its superior physicochemical properties. The detection of subsurface damage (SSD) poses fundamental challenges that directly affect the performance of fused silica glass. The polarized laser scattering (PLS) detection method has significant advantages in SSD detection, but damage mapping has not yet been achieved. This paper proposes an SSD mapping method based on the PLS detection results. The relationship between the PLS detection signals and the SSD depths of fused silica glass is established, and an SSD mapping diagram is successfully generated. Unlike existing studies that only provide local quantitative SSD depth, SSD mapping achieves simultaneous visualization of SSD location, depth, and uniformity of SSD distribution across the entire region, which provides guidance to determine the lapping or polishing parameters in the subsequent processes. Full article
(This article belongs to the Section Optical and Photonic Materials)
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15 pages, 4107 KiB  
Article
Characteristics of Heat-Depleted Thermal Water Re-Injection-Induced Water–Rock Interactions in a Sandstone Reservoir Containing Carbonate and Silicate Minerals (Szentes, Hungary)
by Eszter Sendula, Richárd Albrecht, Catarina Conceição de Castro, Eszter Keresztény-Borbás, Zsuzsanna Szabó-Krausz and János Kovács
Minerals 2025, 15(5), 513; https://doi.org/10.3390/min15050513 - 13 May 2025
Viewed by 477
Abstract
A thorough understanding of the chemistry involved in reinjecting heat-depleted geothermal water into poorly consolidated sandstone is vital for the effective design of treatments targeting subsurface rock formations. The intricate chemical interactions occurring within sandstone systems can result in the dissolution of certain [...] Read more.
A thorough understanding of the chemistry involved in reinjecting heat-depleted geothermal water into poorly consolidated sandstone is vital for the effective design of treatments targeting subsurface rock formations. The intricate chemical interactions occurring within sandstone systems can result in the dissolution of certain minerals and the subsequent precipitation of others, which may significantly contribute to damage within the formation. This process can alter the physical properties of the rock, potentially leading to reduced permeability and other challenges in resource extraction. Thus, it is imperative to monitor not only the concentration of various chemical species present in the geothermal water and sandstone, but also the spatial distribution of these geochemical reactions. By doing so, we can better predict and mitigate their potential adverse effects on rock formations, ensuring the long-term success and efficiency of geothermal energy extraction and other subsurface activities. In this study, we conducted laboratory experiments using both model and natural formation waters, as well as rock samples, to investigate water–rock interactions in a sandstone reservoir in the Szentes area of Hungary. Geochemical models were run with two different thermodynamic databases to simulate laboratory experiments, predict the effects of heat-depleted geothermal water reinjection into the reservoir, and assess predictions of different geochemical databases. Our study shows that calcite dissolves while quartz, kaolinite, and dolomite form. Other mineral reactions, however, remain less certain. The PHREEQC database indicates chlorite dissolution along with the formation of small amounts of feldspars and hematite, whereas the Thermoddem database predicts montmorillonite dissolution and chlorite precipitation. The reservoir porosity and permeability are expected to change over time as a result of mineral reactions. Modeling results, however, indicate negligible porosity changes as the reservoir reaches equilibrium state. The general concept proposed here, which focuses on the geochemical properties of the reinjected water and reservoir, provides a framework for detailed analysis of the geothermal system—a critical step for ensuring sustainable geothermal operations. Full article
(This article belongs to the Special Issue Petrological and Geochemical Characteristics of Reservoirs)
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18 pages, 2613 KiB  
Review
Research Advances in Underground Bamboo Shoot Detection Methods
by Wen Li, Qiong Shao, Fan Guo, Fangyuan Bian and Huimin Yang
Agronomy 2025, 15(5), 1116; https://doi.org/10.3390/agronomy15051116 - 30 Apr 2025
Viewed by 483
Abstract
Underground winter bamboo shoots, prized for their high nutritional value and economic significance, face harvesting challenges owing to inefficient manual methods and the lack of specialized detection technologies. This review systematically evaluates current detection approaches, including manual harvesting, microwave detection, resistivity methods, and [...] Read more.
Underground winter bamboo shoots, prized for their high nutritional value and economic significance, face harvesting challenges owing to inefficient manual methods and the lack of specialized detection technologies. This review systematically evaluates current detection approaches, including manual harvesting, microwave detection, resistivity methods, and biomimetic techniques. While manual methods remain dominant, they suffer from labor shortages, low efficiency, and high damage rates. Microwave-based technologies demonstrate high accuracy and good depths but are hindered by high costs and soil moisture interference. Resistivity methods show feasibility in controlled environments but struggle with field complexity and low resolution. Biomimetic approaches, though innovative, face limitations in odor sensitivity and real-time data processing. Key challenges include heterogeneous soil conditions, performance loss, and a lack of standardized protocols. To address these, an integrated intelligent framework is proposed: (1) three-dimensional modeling via multi-sensor fusion for subsurface mapping; (2) artificial intelligence (AI)-driven harvesting robots with adaptive excavation arms and obstacle avoidance; (3) standardized cultivation systems to optimize soil conditions; (4) convolution neural network–transformer hybrid models for visual-aided radar image analysis; and (5) aeroponic AI systems for controlled growth monitoring. These advancements aim to enhance detection accuracy, reduce labor dependency, and increase yields. Future research should prioritize edge-computing solutions, cost-effective sensor networks, and cross-disciplinary collaborations to bridge technical and practical gaps. The integration of intelligent technologies is poised to transform traditional bamboo forestry into automated, sustainable “smart forest farms”, addressing global supply demands while preserving ecological integrity. Full article
(This article belongs to the Section Precision and Digital Agriculture)
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17 pages, 20014 KiB  
Article
Molecular Dynamics Study of Nanoscratching Behavior of Water-Film-Covered GaN (0001) Surface Using Spherical Diamond Abrasive
by Jiaqin Yin, Shuaicheng Feng, Yang Liu and Jian Guo
Crystals 2025, 15(5), 428; https://doi.org/10.3390/cryst15050428 - 30 Apr 2025
Viewed by 311
Abstract
Molecular dynamics (MD) simulation of nanoscratching with a spherical diamond abrasive was performed to investigate the role of water molecular film on the surface nanotribological characteristics and subsurface lattice damage of GaN (0001) at the atomic level. The simulation results indicate that the [...] Read more.
Molecular dynamics (MD) simulation of nanoscratching with a spherical diamond abrasive was performed to investigate the role of water molecular film on the surface nanotribological characteristics and subsurface lattice damage of GaN (0001) at the atomic level. The simulation results indicate that the tangential and normal forces exhibited no significant variation trend with the increase in water film thickness. Inducing a water film can alleviate the material pile-up during scratching, and the GaN surface obtained the lowest friction coefficient and wear volume when the water film thickness reached 3 nm, primarily due to the enhanced lubrication and the heat absorption by the water film in this case. Water-film-covered GaN exhibited a thinner subsurface damage layer than the bare GaN, and the damage layer thickness decreased with the increase in water film thickness for various scratching depths of 1 to 4 nm. For each scratching depth, there was an optimal water film thickness causing the minimum number of amorphization atoms. Nevertheless, the water film failed to inhibit the formation and propagation of dislocations in the scratching process, and water-film-covered GaN exhibited more dislocations than the bare one. This research has the potential to expand the comprehension of water-mediated nanotribology and the ultra-precision machining procedures of GaN. Full article
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20 pages, 7672 KiB  
Article
Stability Analysis of the Surrounding Rock of Deep Underground Engineering Under the Action of Thermal-Solid Coupling
by Xiaoyu Dou, Hongbin Shi, Yanbo Qing, Jiaqi Guo and Lipan Cheng
Buildings 2025, 15(9), 1500; https://doi.org/10.3390/buildings15091500 - 29 Apr 2025
Viewed by 435
Abstract
When developing deep subsurface infrastructure in areas with intense geothermal activity, the significant temperature gradient inevitably leads to low-temperature contraction and high-temperature expansion of the rock body, resulting in changes in the rock’s mechanical properties. These thermodynamic effects can easily lead to the [...] Read more.
When developing deep subsurface infrastructure in areas with intense geothermal activity, the significant temperature gradient inevitably leads to low-temperature contraction and high-temperature expansion of the rock body, resulting in changes in the rock’s mechanical properties. These thermodynamic effects can easily lead to the destabilization and subsequent collapse of the rock. There exists a pressing necessity to methodically evaluate the surrounding rock stability encountered in deep underground engineering under the action of thermal-solid coupling. This study constructed a multi-physical field coupling nonlinear calculation model based on a high-precision three-dimensional finite difference method, systematically analyzed the interdependent effects between the original rock temperature and excavation-induced disturbance, and then analyzed the dynamic changes in temperature, stress, and displacement fields along with plastic zone of surrounding rock of the deep underground engineering under thermal-solid coupling. The results indicate that the closer to the excavation contour surface, the lower the surrounding rock temperature, while the temperature gradient increased correspondingly. The farther away from the excavation contour face, the closer the temperature was to the original rock temperature. As the original rock temperature climbed from 30 °C to 90 °C, the increment of vault displacement was 2.45 times that of arch bottom displacement, and the influence of temperature change on vault deformation was more significant. The horizontal displacement magnitudes at the different original temperatures followed the following order: sidewall > spandrel > skewback, and at an original rock temperature of 90 °C, the sidewall horizontal displacement reached 15.31 cm. With the elevation of the original rock temperature, the distribution range and concentration degree of the maximum and minimum principal stresses increased obviously, and both were compression-dominated. The types of plastic zones in the surrounding rock were mainly characterized by shear stress-induced yielding and tensile stress-induced damage failure. When the original rock temperature increased to 90 °C, the rock mass extending up to 1.5 m from the excavation contour surface formed a large area of damage zone. The closer the working face was to the monitoring section, the faster the temperature dropped, and the displacement changed in the monitoring section. The findings offer a theoretical basis for engineering practice, and it is of great significance to ensure the safety of the project. Full article
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20 pages, 25702 KiB  
Article
Mechanism-Oriented Analysis of Core–Shell Structured CIP@SiO2 Magnetic Abrasives for Precision-Enhanced Magnetorheological Polishing
by Chunyu Li, Shusheng Chen, Zhuoguang Zheng, Yicun Zhu, Bingsan Chen and Yongchao Xu
Micromachines 2025, 16(5), 495; https://doi.org/10.3390/mi16050495 - 24 Apr 2025
Viewed by 2873
Abstract
This study addresses the critical challenge of precise control over active abrasive particles in magnetorheological polishing (MRP) through innovative core–shell particle engineering. A sol–gel synthesized CIP@SiO2 magnetic composite abrasive with controlled SiO2 encapsulation (20 nm shell thickness) was developed using tetraethyl [...] Read more.
This study addresses the critical challenge of precise control over active abrasive particles in magnetorheological polishing (MRP) through innovative core–shell particle engineering. A sol–gel synthesized CIP@SiO2 magnetic composite abrasive with controlled SiO2 encapsulation (20 nm shell thickness) was developed using tetraethyl orthosilicate (TEOS) as the silicon precursor, demonstrating significant advantages in optical-grade fused silica finishing. Systematic polishing experiments reveal that the core–shell architecture achieves a remarkable 20.16% improvement in surface quality (Ra = 1.03 nm) compared to conventional CIP/SiO2 mixed abrasives, with notably reduced surface defects despite a modest 8–12% decrease in material removal rate. Through synergistic analysis combining elastic microcontact mechanics modeling and molecular dynamics simulations, we establish that the SiO2 shell mediates stress distribution at tool–workpiece interfaces, effectively suppressing deep subsurface damage while maintaining nano-scale material removal efficiency. The time-dependent performance analysis further demonstrates that extended polishing durations with CIP@SiO2 composites progressively eliminate mid-spatial frequency errors without introducing new surface artifacts. These findings provide fundamental insights into designed abrasive architectures for precision finishing applications requiring sub-nanometer surface integrity control. Full article
(This article belongs to the Special Issue Recent Advances in Micro/Nanofabrication, 2nd Edition)
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21 pages, 11310 KiB  
Article
Experimental and Numerical Studies on the Tribological Properties of Bearing Steel 20GrNi2MoV Against W2Mo9Cr4VCo8 Steel Under Dry Sliding Process
by Li Cui, Donghui Wang, Xingyu Ma, Bo Zhang and Xin Wang
Coatings 2025, 15(5), 506; https://doi.org/10.3390/coatings15050506 - 23 Apr 2025
Viewed by 284
Abstract
In this paper, the wear characteristics of 20GrNi2MoV bearing steel under different working conditions were investigated by finite element simulation considering microscopic grain size and pin-on-disk friction experiments, and the wear mechanism during friction and wear was explained, along with a finite element [...] Read more.
In this paper, the wear characteristics of 20GrNi2MoV bearing steel under different working conditions were investigated by finite element simulation considering microscopic grain size and pin-on-disk friction experiments, and the wear mechanism during friction and wear was explained, along with a finite element model that took initial grain size and material organization into account to predict the process of subsurface crack initiation during friction. The results show that high-speed and large-load conditions have a significant effect on the wear characteristics of dry friction of pinned disks. The effect of high speed and load will greatly reduce the time of the grinding stage, and the friction coefficient can quickly reach a stable state; the roughness of the surface of the friction pair increases with the increase in load, but the roughness shows a tendency to first increase and then decrease with the increase in sliding speed. Martensitic phase transformation occurs in the friction subsurface, and the decrease in Mn element content is one of the causes of cracks on the subsurface of the material; with the increase in load and speed, the damage form of the sample disk material is changed from abrasive wear and adhesive wear to the mixture of three kinds of wear: abrasive wear, adhesive wear, and cracks. In addition, the simulation of crack initiation and growth agrees well with the experiment, which proves the accuracy of crack prediction. This study provides a reference for crack initiation prediction in the study of pinned disk friction vises. Full article
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19 pages, 6904 KiB  
Article
Modified SC Resin Pre-Coating Treatment for Rapid and Robust Repair of CFRP Laminates with Sharp Delamination Cracks
by Yi Chen, Yi Ji, Fei Cheng and Xiaozhi Hu
Polymers 2025, 17(8), 1079; https://doi.org/10.3390/polym17081079 - 16 Apr 2025
Viewed by 343
Abstract
A recent composite technique, namely Resin Pre-Coating (RPC), has demonstrated remarkably high effectiveness in the repair of Carbon Fiber-Reinforced Polymer (CFRP) composites. Compared to widely used scarf repair and injection repair, this non-destructive method offers advantages in addressing subsurface damages from the millimeter [...] Read more.
A recent composite technique, namely Resin Pre-Coating (RPC), has demonstrated remarkably high effectiveness in the repair of Carbon Fiber-Reinforced Polymer (CFRP) composites. Compared to widely used scarf repair and injection repair, this non-destructive method offers advantages in addressing subsurface damages from the millimeter to micron scale, such as edge delaminations that frequently occur due to machining or low-energy impacts. The acetone-rich RPC solution can spontaneously transport sticky resin and other toughening agents into defects through capillary action. In this study, we further improved the solution by adopting a self-curing resin (i.e., SC-RPC), reducing the repair duration from the initial 2–3 months to merely a few hours. Using this modified solution, the CFRP specimens prepared containing delamination cracks were largely restored, reaching up to 94.9% of the original compressive strength. With the additional incorporation of carbon nanotubes (CNTs), full restoration was achieved, as is evidenced by load-bearing capacities and overload failure modes comparable to those of pristine specimens. The findings of this study may help alleviate concerns regarding substandard post-repair performance and prolonged repair durations, which are frequently criticized in real-world CFRP maintenance projects. The preparation of two new formulations, SC-RPC and SC-RPC+CNT, along with the optimization of key parameters, was carefully detailed in the manuscript to ensure experimental reproducibility. Full article
(This article belongs to the Section Polymer Composites and Nanocomposites)
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23 pages, 18306 KiB  
Article
A New Double-Inclination Oblique Model to Simulate Drilling of GFRP/Al-Based Stacks: A Thermomechanical Approach
by Brahim Salem, Ali Mkaddem, Malek Habak, Yousef Dobah and Abdessalem Jarraya
Polymers 2025, 17(8), 1047; https://doi.org/10.3390/polym17081047 - 12 Apr 2025
Viewed by 447
Abstract
This paper reports an investigation of the thermomechanical behavior at the interface of GFRP/Al composite stacks when the stacking arrangement varies. A temperature-coupled damage approach was developed to simulate thermal energy transfer and damage propagation at metallic-to-composite interface. The proposed model was then [...] Read more.
This paper reports an investigation of the thermomechanical behavior at the interface of GFRP/Al composite stacks when the stacking arrangement varies. A temperature-coupled damage approach was developed to simulate thermal energy transfer and damage propagation at metallic-to-composite interface. The proposed model was then implemented into ABAQUS/Explicit finite element code using user-defined subroutine VUMAT finely imbricated with VDFLUX. Unlike to previous models, oblique cutting configuration (OCC) involving double-inclination of the tool was proposed to simulate finely the material removal process owing to drill action. Drilling trials involving the cutting speed and the stacking arrangement were conducted to support the proposed approach. The predictions revealed that increasing the spindle speed significantly impacts the temperature distribution and subsurface thermal damage. An exponential temperature law was derived for predicting temperature variation with the cutting speed and identifying thermal saturation at the interface. The sensitivity of the composite behavior to the stacking arrangement (GFRP → Al vs. Al → GFRP) was well highlighted. The results indicated that attacking the structure from the GFRP side results in higher interfacial temperatures due to GFRP’s lower thermal conductivity. These findings contribute to understanding the heat-affected zone in GFRP, and, hence, provide guidance to minimize thermal damage in industrial drilling of the hybrid stacks. Full article
(This article belongs to the Section Polymer Physics and Theory)
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19 pages, 31637 KiB  
Article
Effect of Bio-Based, Mixed Ester Lubricant in Minimum Quantity Lubrication on Tool Wear and Surface Integrity in Ultra-Precision Fly-Cutting of KDP Crystals
by Xuelian Yao, Feihu Zhang, Shuai Zhang, Jianfeng Zhang, Defeng Liao, Xiangyang Lei, Jian Wang and Jianbiao Du
Lubricants 2025, 13(4), 156; https://doi.org/10.3390/lubricants13040156 - 1 Apr 2025
Cited by 1 | Viewed by 639
Abstract
Potassium dihydrogen phosphate (KDP) crystals, vital for high-power laser systems, pose significant machining challenges due to their brittleness, low hardness, and hygroscopic properties. Achieving crack-free, high-precision surfaces is essential but complex. Single-point diamond fly-cutting (SPDF) is the primary method, yet it exposes tools [...] Read more.
Potassium dihydrogen phosphate (KDP) crystals, vital for high-power laser systems, pose significant machining challenges due to their brittleness, low hardness, and hygroscopic properties. Achieving crack-free, high-precision surfaces is essential but complex. Single-point diamond fly-cutting (SPDF) is the primary method, yet it exposes tools to high mechanical stress and heat, accelerating wear. In dry cutting, worn tools develop adhesive layers that detach, causing scratches and degrading surface quality. Traditional wet cutting improves surface finish but leaves residual fluids that contaminate the surface with metal ions, leading to optical degradation and fogging. To address these issues, this study explores mixed-fat-based minimum quantity lubrication (MQL) as a sustainable alternative, comparing two lubricants: biodegradable-base mixed ester lubrication (BBMEL) and hydrocarbon-based synthetic lubricant (HCBSL). A comprehensive evaluation method was developed to analyze surface roughness, tool wear, and subsurface damage under dry cutting, MQL-BBMEL, and MQL-HCBSL conditions. Experimental results show that MQL-BBMEL significantly enhances machining performance, reducing average surface roughness by 27.77% (Sa) and 44.77% (Sq) and decreasing tool wear by 25.16% compared to dry cutting, outperforming MQL-HCBSL. This improvement is attributed to BBMEL’s lower viscosity and higher proportion of polar functional groups, which form stable lubricating films, minimizing friction and thermal effects. Structural analyses confirm that MQL-BBMEL prevents KDP crystal deliquescence and surface fogging. These findings establish MQL-BBMEL as an eco-friendly, high-performance solution for machining brittle optical materials, offering significant advancements in precision machining for high-power laser systems. Full article
(This article belongs to the Special Issue High Performance Machining and Surface Tribology)
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