Search Results (118)

The cast nickel-based superalloy K417G exhibits excellent high-temperature strength, but non-equilibrium solidification during casting can cause defects such as irreparable interdendritic microporosity, which significantly degrades its fatigue and creep properties. This study uses hot isostatic pressing (HIP) to eliminate internal flaws such as porosity in the K417G alloy, aiming to improve its mechanical properties. We investigated the microstructure and mechanical properties of K417G under two thermal conditions: solution heat treatment (SHT) and hot isostatic pressing (HIP). The results indicate that HIP significantly reduces microporosity. Compared to SHT, HIP improves the mechanical performance of K417G. The creep fracture mechanism shifts from intergranular brittle fracture (SHT) to ductile fracture (HIP). Consequently, HIP increases the alloy′s creep life approximately threefold and raises its fatigue limit by about 20 MPa. This improvement is attributed to pore density reduction, which decreases stress concentration zones and homogenizes the microstructure, thereby impeding fatigue crack nucleation and extending the crack incubation period. Full article

High-Bandwidth Memory (HBM) enables the bandwidth required by modern AI and high-performance computing, yet its three dimensional stack traps heat and amplifies thermo mechanical stress. We first review how conventional solutions such as heat spreaders, microchannels, high density Through-Silicon Vias (TSVs), and Mass Reflow Molded Underfill (MR MUF) underfills lower but do not eliminate the internal thermal resistance that rises sharply beyond 12layer stacks. We then synthesize recent hybrid bonding studies, showing that an optimized Cu pad density, interface characteristic, and mechanical treatments can cut junction-to-junction thermal resistance by between 22.8% and 47%, raise vertical thermal conductivity by up to three times, and shrink the stack height by more than 15%. A meta-analysis identifies design thresholds such as at least 20% Cu coverage that balances heat flow, interfacial stress, and reliability. The review next traces the chain from Coefficient of Thermal Expansion (CTE) mismatch to Cu protrusion, delamination, and warpage and classifies mitigation strategies into (i) material selection including SiCN dielectrics, nano twinned Cu, and polymer composites, (ii) process technologies such as sub-200 °C plasma-activated bonding and Chemical Mechanical Polishing (CMP) anneal co-optimization, and (iii) the structural design, including staggered stack and filleted corners. Integrating these levers suppresses stress hotspots and extends fatigue life in more than 16layer stacks. Finally, we outline a research roadmap combining a multiscale simulation with high layer prototyping to co-optimize thermal, mechanical, and electrical metrics for next-generation 20-layer HBM. Full article

Aiming at the problems of serious pavement temperature diseases, low efficiency and high loss of ice-breaking methods, high occupancy rate of waste tires and the low utilization rate and insufficient durability of rubber particles, this paper aims to improve the service level of roads and ensure the safety of winter pavements. A pavement material with high efficiency, low carbon and environmental friendliness for active snow melting and ice breaking is developed. Firstly, NaOH, NaClO and KH550 were used to optimize the treatment of rubber particles. The hydrophilic properties, surface morphology and phase composition of rubber particles before and after optimization were studied, and the optimal treatment method of rubber particles was determined. Then, the optimized rubber particles were used to replace the natural aggregate in the polyurethane gel mixture by the volume substitution method, and the optimum polyurethane gel dosages and molding and curing processes were determined. Finally, the influence law of the road performance of RPGM was compared and analyzed by means of an indoor test, and the ice-breaking effect of RPGM was explored. The results showed that the contact angles of rubber particles treated with three solutions were reduced by 22.5%, 30.2% and 36.7%, respectively. The surface energy was improved, the element types on the surface of rubber particles were reduced and the surface impurities were effectively removed. Among them, the improvement effect of the KH550 solution was the most significant. With the increase in rubber particle content from 0% to 15%, the dynamic stability of the mixture gradually increases, with a maximum increase of 23.5%. The maximum bending strain increases with the increase in its content. The residual stability increases first and then decreases with the increase in rubber particle content, and the increase ranges are 1.4%, 3.3% and 0.5%, respectively. The anti-scattering performance increases with the increase in rubber content, and an excessive amount will lead to an increase in the scattering loss rate, but it can still be maintained below 5%. The fatigue life of polyurethane gel mixtures with 0%, 5%, 10% and 15% rubber particles is 2.9 times, 3.8 times, 4.3 times and 4.0 times higher than that of the AC-13 asphalt mixture, respectively, showing excellent anti-fatigue performance. The friction coefficient of the mixture increases with an increase in the rubber particle content, which can be increased by 22.3% compared with the ordinary asphalt mixture. RPGM shows better de-icing performance than traditional asphalt mixtures, and with an increase in rubber particle content, the ice-breaking ability is effectively improved. When the thickness of the ice layer exceeds 9 mm, the ice-breaking ability of the mixture is significantly weakened. Mainly through the synergistic effect of stress coupling, thermal effect and interface failure, the bonding performance of the ice–pavement interface is weakened under the action of driving load cycle, and the ice layer is loosened, broken and peeled off, achieving efficient de-icing. Full article

Film cooling has been increasingly applied in turbine blade cooling design due to its excellent cooling performance. Although film-cooled blades demonstrate superior cooling effectiveness, the perforation design on blade surfaces compromises structural integrity, making fatigue failure prone to occur at cooling holes. Previous studies by domestic and international scholars have extensively investigated factors influencing film cooling effectiveness, including blowing ratio and hole geometry configurations. However, most research has overlooked the investigation of fatigue life in film-cooled blades. This paper systematically investigates blade fatigue life under various cooling air parameters by analyzing the relationships among cooling effectiveness, stress distribution, and fatigue life. Results indicate that maximum stress concentrations occur at cooling hole locations and near the blade root at trailing edge regions. While cooling holes effectively reduce blade surface temperature, they simultaneously create stress concentration zones around the apertures. Both excessive and insufficient cooling air pressure and temperature reduce thermal fatigue life, with optimal parameters identified as 600 K cooling temperature and 0.75 MPa pressure, achieving a maximum thermal fatigue life of 3400 cycles for this blade configuration. A thermal shock test platform was established to conduct fatigue experiments under selected cooling conditions. Initial fatigue damage traces emerged at cooling holes after 1000 cycles, with progressive damage expansion observed. By 3000 cycles, cooling holes near blade tip regions exhibited the most severe failure, demonstrating near-complete functional degradation. These findings provide critical references for cooling parameter selection in practical aeroengine applications of film-cooled blades. Full article

This study investigates the microstructural evolution and mechanical degradation mechanisms of cold-drawn 310S stainless steel subjected to repeated thermal cycling between 900 °C and room temperature. The results reveal that thermal cycling induces significant lattice distortion, dislocation accumulation, and recrystallization, leading to grain refinement and increased tensile strength. However, these microstructural changes also initiate subsurface cracks and reduce ductility. TGA analysis confirms thermal weight loss from decarburization, especially under oxidative atmospheres. EPMA analysis and tensile tests after thermal cycling reveal that surface cracks formed during thermal cycling act as origins for transgranular crack propagation under tensile stress, significantly reducing fracture resistance. Bending fatigue tests further demonstrate that thermally fatigued specimens exhibit inferior fatigue life compared to raw material, confirming the deteriorating mechanical properties of 310S stainless steel after thermal cycling. Overall, the combined effects of thermal and mechanical fatigue degrade the structural integrity of 310S stainless steel, revealing that lattice distortion and subsurface cracking are the key factors in its embrittlement and reduced fatigue performance. Full article

Oil shale, an unconventional oil and gas resource, can generate the required hydrocarbons through high-temperature pyrolysis. In situ conversion extraction technology utilizes downhole heaters to directly inject high-temperature heat into the oil shale layer to achieve the effect of oil and gas recovery. For the metal material components of the combustion heaters, the uneven temperature fields experienced during the start of operations, processing, and end of operations can lead to fatigue conditions, such as high-temperature creep, micro-damage, and micro-deformation due to thermal effects. To prevent the occurrence of the aforementioned issues, it is necessary to conduct fatigue life analysis of downhole combustion heaters. By combining actual combustion heater operation experiments with finite element simulation, this paper analyzes the impact of temperature, structure, and stress amplitude on the fatigue life of heaters. The results indicate that the fatigue life of the heaters is most significantly influenced by the metal gaskets, and the higher the exhaust gas temperature, the lower the fatigue life of the heater. Heating operations significantly reduce the fatigue life of the heater, while cooling operations have almost no effect on the fatigue life. Circular-pore metal gaskets have a higher fatigue life than those with a square hole shape. Considering only the thickness of the metal gaskets, the thicker the gasket, the higher the fatigue life. Stress amplitude has the most significant impact on the fatigue life of the heater; when the stress amplitude is doubled, the metal gaskets quickly undergo fatigue damage. Full article

With the increasing demand for drag reduction, energy consumption reduction, and low weight in civil aircraft, high-precision microgroove preparation technology is being developed internationally to reduce wall friction resistance and save energy. Compared to mechanical processing, chemical etching, roll forming, and ultrafast laser processing, nanosecond lasers offer processing precision, high efficiency, and controllable thermal effects, enabling low-cost and high-quality preparation of microgrooves. However, the impact of nanosecond laser etching on the fatigue performance of substrate materials remains unclear, leading to controversy over whether high-precision shape control and fatigue performance enhancement in microgrooves can be achieved simultaneously. This has become a bottleneck issue that urgently needs to be addressed. This paper focuses on the current research status of nanosecond laser processing quality control for microgrooves and the research status of laser effects on enhancing the fatigue performance of substrate materials. It identifies the main existing issues: (1) how to induce surface residual compressive stress through the thermo-mechanical coupling effect of nanosecond lasers to suppress micro-defects while ensuring high-precision shape control of fixed microgrooves; and (2) how to quantify the regulation of nanosecond laser process parameters on residual stress distribution and fatigue performance in the microgroove area. To address these issues, this paper proposes a collaborative strategy for high-quality shape control and surface strengthening in fixed microgrooves, an analysis of multi-dimensional fatigue regulation mechanisms, and a new method for multi-objective process optimization. The aim is to control the geometric accuracy error of the prepared surface microgrooves within 5% and to enhance the fatigue life of the substrate by more than 20%, breaking through the technical bottleneck of separating “drag reduction design” from “fatigue resistance manufacturing”, and providing theoretical support for the integrated manufacturing of “drag reduction-fatigue resistance” in aircraft skins. Full article

This study investigates the mechanical and fatigue behaviour of friction stir composite joints fabricated from an aluminum alloy (AA6082-T6) and a glass fibre-reinforced polymer (Noryl^® GFN2) under different service temperature conditions. The joints were tested under both quasi-static and cyclic loading at three different temperatures (23, 75, and 130 °C). Fracture surfaces were analyzed, and the probabilistic S–N curves were derived using Weibull distribution. Results indicated that increasing the service temperature caused a non-linear decrease in both the quasi-static and fatigue strength of the joints. Compared to room temperature, joints tested at 75 °C and 130 °C showed a 10% and 50% reduction in average tensile strength, respectively. The highest fatigue strength occurred at 23 °C, while the lowest was at 130 °C, in line with the quasi-static results. Fatigue stress-life plots displayed a semi-logarithmic nature, with lives ranging from 10² to 10⁵ cycles for stress amplitudes between 7.7 and 22.2 MPa at 23 °C, 7.2 to 19.8 MPa at 75 °C, and 6.2 to 13.5 MPa at 130 °C. The joints’ failure occurred in the polymeric base material close to joints’ interface, highlighting the critical role of the polymer in limiting joints’ performance, as confirmed by thermal and scanning electron microscopy analyses. Full article

The heat treatment residual stress of 8Cr4Mo4V steel bearings seriously affects the contact fatigue life. The micro stress concentration at the carbide interface leads to the initiation of micro cracks. Therefore, in this paper, the systematic analysis of heat treatment residual stress of 8Cr4Mo4V steel is conducted. FEA was used to analyze the residual stress of type I after heat treatment process. Based on numerical simulation and EBSD results, CPFEM was carried out to study the distribution of type II residual stress. Using high-resolution characterization results, GPA was performed to study type III residual stress caused by crystal defects. The FEA results indicate that thermal strain and phase transformation strain dominate the macroscopic stress change before and after martensitic transformation. During the first tempering process, the phase transformation leads to the release of quenching residual stress. The large stress concentration at the carbide interface is revealed by CPFEM. High-resolution characterization of coherent interface between carbide and matrix reveals that the micro residual strain at this interface is small. Through a systematic analysis of the residual stress of 8Cr4Mo4V steel, a basis is provided for modifying the macroscopic and microscopic residual stress of heat treatment to improve the bearing performance. Full article

Exhaust manifolds accumulate creep and fatigue damage under cyclic thermal loading, leading to localized failure. Understanding a material’s mechanical behavior is crucial for accurate life assessment. This study systematically investigated the low-cycle fatigue (LCF) and creep–fatigue interaction behaviors of medium-silicon molybdenum ductile iron. It was found that QTRSi4Mo exhibited cyclic hardening at room temperature and 400 °C, whereas it exhibited cyclic softening at 600 °C and 700 °C for low-cycle stress–strain responses. During creep–fatigue tests with hold time, variations in the strain amplitude did not alter the hysteresis loop shape or the hardening/softening characteristics of the material. They only induced a slight upward shift in the yield center. Additionally, stress relaxation primarily occurred in the initial phase of the hold period, so the hold duration had little effect on the final stress value. The investigation of creep–fatigue life models highlighted that accurately characterizing the damage induced by stress relaxation during the hold stage is critical for creep damage evaluation. The calculated creep damage results differed greatly from the experimental results of the time fraction model (TF). A combined approach using the strain energy density dissipation model (T-SEDE) and the Ostergren method demonstrated excellent predictive capability for creep–fatigue life. Full article

The contact interfaces of a press-pack insulated-gate bipolar transistor (PP-IGBT) module under fluctuating thermal stress will undergo minor friction and mutual sliding during service, which results in damage to the contact surface and a decline in the thermal performance of the contact interface. Therefore, the temperature inside the module will continue to increase, leading to eventual failure. In this work, a life prediction method based on thermal resistance degradation within a PP-IGBT module is established. The junction temperature can be determined via power loss and a resistance-capacitance (RC) thermal network model, and a life prediction model of the PP-IGBT module is developed based on thermal resistance degradation. The method considers the service quality under power cycling conditions and the influence of the self-accelerating effect of damage accumulation at the contact interface of the PP-IGBT module on fatigue life. The experimental results verify that the proposed PP-IGBT module life prediction method can effectively predict service life under power cycling conditions. Full article

Subjective selection of simulation interface shapes may introduce errors in the strength and fatigue analysis of thermal barrier coatings (TBCs). However, the applicability of different interface shapes for the TBCs simulation has rarely been investigated. Based on the TBCs thermal fatigue experiment, a finite element model is established and combined with the Fruit Fly Optimization Algorithm (FOA), a TBCs life prediction model is established. Then, five typical interface shapes, sawtooth, sinusoidal, semicircular, elliptical, and trapezoidal, are identified based on fine-scale photographs of the real interface morphology of the TBCs. Finally, the interface shape with the highest simulation applicability is identified through interface stress state analysis and life prediction error analysis, and verified through experiment. The results show that the stress maximum location of the sawtooth and trapezoidal interface shapes is inconsistent with the experimental onset of damage in TBCs, which proves that the applicability of the two shapes in the simulation of TBCs is not high. When applying equivalent strain for life prediction, the life prediction errors for the semicircular interface shape, elliptical interface shape, and sinusoidal interface shape are 72.84%, 61.74%, and 58.72%, respectively. The lowest life prediction error is obtained by using data from the sinusoidal interface shape. Therefore, the sinusoidal interface shape is the most applicable simplified shape for TBC simulation. Applying sinusoidal interface shape for additional TBCs life prediction with only 13.52% error, which verifies the accuracy of the methodology and conclusions of this study. These conclusions can inform accurate strength and fatigue simulation analysis of TBCs. Full article

Reflection cracks significantly compromise the service life of half-rigid asphalt pavements in cold regions. This study introduces SAKIII warm-mixed rubber–asphalt mixture (SAKIII WMRA Mix) as a stress absorption layer to address this issue. Through orthogonal tests, regression analysis, and performance comparisons with SBS-modified asphalt, the material composition, low-temperature cracking resistance, and fatigue performance of WMRAM were systematically evaluated. The results show that SAKIII WMRA Mix maintains superior road performance with 30 °C lower mixing/compaction temperatures compared to traditional hot-mix asphalt mixture. At −10 °C, its low-temperature cracking resistance improves by 40% and fatigue life extends by 35% over the SBS-modified asphalt mixture. Mechanistically, SAKIII WMRA Mix reduces reflection crack propagation by 30% and prolongs pavement service life by over 25% under equivalent traffic/climate conditions. Additionally, it decreases energy consumption by 15–20% and provides a sustainable solution for cold-region road construction. This research establishes optimized mix design methods and performance criteria for WMRAM, offering theoretical support and practical guidance for reflective crack mitigation in cold climates. The proposed technology effectively balances mechanical properties, energy efficiency, and environmental benefits, making it especially suitable for cold areas where thermal stress dominates road damage. Full article

Rigid polyurethane-based foam is an ideal choice for sandwich-panel-filling materials due to its high strength, low thermal conductivity, high adhesion, and high chemical resistivity. Since sandwich panel materials often face cyclic mechanical loads during their service, it is significant to study the design methods of fatigue-resistant rigid polyurethane foam and its fatigue failure mechanism to improve the performance of sandwich-panel-filling materials. In this study, a fatigue-resistant rubber powder/polyurethane composite material was prepared by introducing rubber powder, and its fatigue failure mechanism was systematically studied. The static mechanical test results indicate that with the introduction of 20% rubber powder, the compressive strength (at 85% strain) increased to 588 kPa. Additionally, thanks to the excellent energy absorption and dissipation properties of rubber powder, it can effectively dissipate mechanical energy during cyclic loading. The fatigue test results show that after the introduction of rubber powder, the fatigue life of the polyurethane foam material increases from 10,258 cycles (for PU, stress ratio 0.6) to 45,987 cycles (for 20R-PU, stress ratio 0.6). This study not only proves the fact that rubber powder can improve the fatigue performance of foam materials but also provides a potential option for the design of high-performance filling materials. Full article

Fatigue management is critical for high-risk professions such as pilots, firefighters, and healthcare workers, where physical and mental exhaustion can lead to catastrophic accidents and loss of life. Traditional fatigue assessment methods, including surveys and physiological measurements, are limited in real-time monitoring and user convenience. To address these issues, this study introduces a novel contactless fatigue level diagnosis system leveraging multimodal sensor data, including video, thermal imaging, and audio. The system integrates non-contact biometric data collection with an AI-driven classification model capable of diagnosing fatigue levels on a 1 to 5 scale with an average accuracy of 89%. Key features include real-time feedback, adaptive retraining for personalized accuracy improvement, and compatibility with high-stress environments. Experimental results demonstrate that retraining with user feedback enhances classification accuracy by 11 percentage points. The system’s hardware is validated for robustness under diverse operational conditions, including temperature and electromagnetic compliance. This innovation provides a practical solution for improving operational safety and performance in critical sectors by enabling precise, non-invasive, and efficient fatigue monitoring. Full article