Search Results (593)

Thermal effects critically influence the design and construction of steel-concrete composite cable-stayed bridges, where material thermal mismatch complicates structural responses. Current code-specified temperature gradient models inadequately address long-span bridges. This study employs in-situ monitoring of the Chibi Yangtze River Bridge to propose a refined vertical temperature gradient model, utilizing an exponential function for the concrete deck and a linear function for the steel web. Finite element analysis across six construction stages reveals: (1) Under negative temperature gradients, the concrete deck develops tensile stresses (2.439–2.591 MPa), approximately 30% lower than code-predicted values (3.613–3.715 MPa), highlighting risks of longitudinal cracking. (2) At the maximum double-cantilever stage, transverse stress distributions show pronounced shear lag effects, positive shear lag in deck sections connected to crossbeams and negative shear lag in non-connected sections. The proposed model reduces tensile stress conservatism in codes by 30–33%, enhancing prediction accuracy for composite girders. This work provides critical insights for thermal effect management in long-span bridge construction. Full article

Ultra-long pool structures used in mine water treatment projects are typical large-volume concrete structures that are highly susceptible to cracking due to the combined effects of cement hydration heat, seasonal temperature variations, and internal water pressure. Such cracking can compromise the durability and long-term service performance of the structure. In this study, distributed fiber optic sensing and finite element analysis were conducted to observe the response of ultra-long pool structures under thermal–load effects. System comparison shows that the average error between the monitored peak thermal strain values and the corresponding simulated values is within 9%. Parametric analysis using the validated simulation model indicates that the hydration protocol with temperatures of 15 °C (casting), 55 °C (peak), and 15 °C (stable), a temperature drop of −20 °C, and loading conditions in sub-pools 3+6 and sub-pools 1+3+5 are the most unfavorable scenarios for inducing tensile stress. When a temperature drop of −20 °C is combined with loading conditions in sub-pools 3+6 or sub-pools 1+3+5, the tensile stress in the pool structure increases by 30% compared to the stress induced by loading alone. This indicates that during the service life of the pool structure, extreme temperature variations combined with mechanical loading may result in localized cracking. This study provides a comprehensive understanding of ultra-long pool behavior during construction and service phases, supporting effective maintenance and long-term durability. Full article

Facing challenges of low efficiency and severe wear in deep hard formations with conventional drilling bits, this study investigates the synergistic rock-breaking technology combining a pulsed CO₂ laser with mechanical bits. The background highlights the need for novel methods to enhance drilling speed in high-strength, abrasive strata where traditional bits struggle. The theoretical analysis explores the thermo-mechanical coupling mechanism, where pulsed laser irradiation rapidly heats the rock surface, inducing thermal stress cracks, micro-spallation, and strength reduction through mechanisms like mineral thermal expansion mismatch and pore fluid vaporization. This pre-damage layer facilitates subsequent mechanical fragmentation. The research employs finite element numerical simulations (using COMSOL Multiphysics with an HJC constitutive model and damage evolution criteria) to model the coupled laser–mechanical–rock interaction, capturing temperature fields, stress distribution, crack propagation, and assessing efficiency. The results demonstrate that laser pre-conditioning significantly achieves 90–120% higher penetration rates compared to mechanical-only drilling. The dominant spallation mechanism proves energy-efficient. Conclusions affirm the feasibility and significant potential of CO₂ laser-assisted drilling for deep formations, contingent on optimized laser parameters, composite bit design (incorporating laser transmission, multi-head layout, and environmental protection), and addressing challenges, like high in-situ stress and drilling fluid interference through techniques like gas drilling. Future work should focus on high-power laser downhole transmission, adaptive control, and rigorous field validation. Full article

The microcrack initiation and evolution behavior of Fe-C alloy under uniaxial tensile loading are investigated using molecular dynamics (MD) simulations. The model is stretched along the z-axis at a strain rate of 2 × 10⁹ s⁻¹ and temperatures ranging from 300 to 1100 K, aiming to elucidate the microscopic deformation mechanisms during crack evolution under varying thermal conditions. The results indicate that the yield strength of Fe-C alloy decreases with a rising temperature, accompanied by a 25.2% reduction in peak stress. Within the temperature range of 300–700 K, stress–strain curves exhibit a dual-peak trend: the first peak arises from stress-induced transformations in the internal crystal structure, while the second peak corresponds to void nucleation and growth. At 900–1100 K, stress curves display a single-peak pattern, followed by rapid stress decline due to accelerated void coalescence. Structural evolution analysis reveals sequential phase transitions: initial BCC-to-FCC and -HCP transformations occur during deformation, followed by reversion to BCC and unidentified structures post-crack formation. Elevated temperatures enhance atomic mobility, increasing the proportion of disordered/unknown structures and accelerating material failure. Higher temperatures promote faster potential energy equilibration, primarily through accelerated void growth, which drives rapid energy dissipation. Full article

This study presents a comprehensive analysis of hydration heat-induced temperature and stress fields in a U-shaped aqueduct during the casting phase, integrating field measurements and numerical simulations. The key findings are as follows: (1) Thermal Evolution Characteristics: Both experimental and numerical results demonstrated consistent thermal behavior, characterized by a rapid temperature rise, subsequent rapid cooling, and eventual stabilization near ambient conditions. The peak temperature is observed at the centroid of the bearing section’s base slab, reaching 83.8 °C in field tests and 87.0 °C in simulations. (2) Stress Field Analysis: Numerical modeling reveals critical stress conditions in the outer concrete layers within high-temperature zones. The maximum tensile stress reaches 6.37 MPa, exceeding the allowable value of the tensile strength of the current concrete (1.85 MPa) by 244%, indicating a significant risk of thermal cracking. (3) Temperature Gradient and Cooling Rate Anomalies: Both methodologies identify non-compliance with critical control criteria. Internal-to-surface temperature differentials exceed the 25 °C threshold. Daily cooling rates at monitored locations surpass 2.0 °C/d during the initial 5–6 days of the cooling phase, elevating cracking risks associated with excessive thermal gradients. (4) Mitigation Strategy Proposal: Implementation of a hydration heat control system is recommended; compared to single-layer systems, the proposed mid-depth double-layer steel pipe cooling system (1.2 m/s flow) reduced peak temperature by 23.8 °C and improved cooling efficiency by 28.7%. The optimized water circulation maintained thermal balance between concrete and cooling water, achieving water savings and cost reduction while ensuring structural quality. (5) The cooling system proposed in this paper has certain limitations in terms of applicable environment and construction difficulty. Future research can combine with a BIM system to dynamically control the tube cooling system in real time. Full article

Supercritical carbon dioxide (Sc-CO₂) thermal shock fracturing emerges as an innovative rock fragmentation technology combining environmental sustainability with operational efficiency. This study establishes a thermo-hydro-mechanical coupled model to elucidate how in situ stress magnitude and anisotropy critically govern damage progression and fluid dynamics during Sc-CO₂ thermal shock fracturing. Key novel findings reveal the following: (1) The fracturing mechanism integrates transient hydrodynamic shock with quasi-static pressure loading, generating characteristic bimodal pressure curves where secondary peak amplification specifically indicates inhibited interwell fracture coalescence under anisotropic stress configurations. (2) Fracture paths undergo spatiotemporal reorientation—initial propagation aligns with in situ stress orientation, while subsequent growth follows thermal shock-induced principal stress trajectories. (3) Stress heterogeneity modulates fracture network complexity through confinement effects: elevated normal stresses perpendicular to fracture planes reduce pressure gradients (compared to isotropic conditions) and delay crack initiation, yet sustain higher pressure plateaus by constraining fracture connectivity despite fluid leakage. Numerical simulations systematically demonstrate that stress anisotropy plays a dual role—enhancing peak pressures while limiting fracture network development. This demonstrates the dual roles of the technology in enhancing environmental sustainability through waterless operations and reducing carbon footprint. Full article

During the long-term operation of salt cavern gas storage, multiple injections and extractions of gas will cause periodic temperature changes in the storage, resulting in thermal fatigue damage to the surrounding rock of the salt cavern and seriously affecting the stability of the storage. This article takes the salt rock samples after thermal fatigue treatment as the research object, adopts a uniaxial compression test, and combines DIC and Acoustic Emission (AE) technology to study the influence of different temperatures and cycle times on the mechanical properties of salt rock. The results indicate that as the number of cycles and upper limit temperature increase, thermal stress induces continuous propagation of microcracks, leading to continuous accumulation of structural damage, enhanced radial deformation, and intensified local displacement concentration, causing salt rock to enter the failure stage earlier. The initial stress for expansion and the volume expansion at the time of failure both show a decreasing trend. After 40 cycles, the compressive strength and elastic modulus decreased by 23.8% and 27.4%, respectively, and the crack failure mode gradually shifted from tension-dominated to tension-shear composite. At the same time, salt rock exhibits typical “elastic-plastic creep” behavior under uniaxial compression, but the uneven expansion and thermal fatigue effects caused by periodic temperature changes suppress plastic slip, resulting in an overall decrease in peak strain energy. The proportion of elastic strain energy increases from 21% to 38%, and the deformation process shows a trend of enhanced elastic dominant characteristics. The changes in the physical and mechanical properties of salt rock under periodic temperature effects revealed by this study can provide an important theoretical basis for the long-term safe operation of underground salt cavern storage facilities. Full article

Blast-furnace staves serve as critical protective components in ironmaking, requiring synergistic optimization of slag-coating behavior and self-protection capability to extend furnace lifespan and reduce energy consumption. Traditional integer-order heat transfer models, constrained by assumptions of homogeneous materials and instantaneous heat conduction, fail to accurately capture the cross-scale thermal memory effects and non-local diffusion characteristics in multiphase heterogeneous blast-furnace systems, leading to substantial inaccuracies in predicting dynamic slag-layer evolution. This review synthesizes recent advancements across three interlinked dimensions: first, analyzing design principles of zonal staves and how refractory material properties influence slag-layer formation, proposing a “high thermal conductivity–low thermal expansion” material matching strategy to mitigate thermal stress cracks through optimized synergy; second, developing a mechanistic model by introducing the Caputo fractional derivative to construct a non-Fourier heat-transfer framework (i.e., a heat-transfer model that accounts for thermal memory effects and non-local diffusion, beyond the instantaneous heat conduction assumption of Fourier’s law), which effectively describes fractal heat flow in micro-porous structures and interfacial thermal relaxation, addressing limitations of conventional models; and finally, integrating industrial case studies to validate the improved prediction accuracy of the fractional-order model and exploring collaborative optimization of cooling intensity and slag-layer thickness, with prospects for multiscale interfacial regulation technologies in long-life, low-carbon stave designs. Full article

To address the central cracking problem in continuous casting slabs of 38CrMoAl steel, high-temperature tensile tests were performed using a Gleeble-3800 thermal simulator to characterize the hot ductility of the steel within the temperature range of 600–1200 °C. The phase transformation behavior was computationally analyzed via the Thermo-Calc software, while the microstructure, fracture morphology, and precipitate characteristics were systematically investigated using a metallographic microscope (MM), a field-emission scanning electron microscope (FE-SEM), and transmission electron microscopy (TEM). Additionally, the effects of different holding times and cooling rates on the microstructure and precipitates of 38CrMoAl steel were also studied. The results show that the third brittle temperature region of 38CrMoAl steel is 645–1009 °C, and the fracture mechanisms can be classified into three types: (I) in the α single-phase region, the thickness of intergranular proeutectoid ferrite increases with rising temperature, leading to reduced hot ductility; (II) in the γ single-phase region, the average size of precipitates increases while the number density decreases with increasing temperature, thereby improving hot ductility; and (III) in the α + γ two-phase region, the precipitation of proeutectoid ferrite promotes crack propagation and the dense distribution of precipitates at grain boundaries causes stress concentration, further deteriorating hot ductility. Heat treatment experiments indicate that the microstructures of the specimen transformed under water cooling, air cooling, and furnace cooling conditions as follows: martensite + proeutectoid ferrite → bainite + ferrite → ferrite. The average size of precipitates first decreased, then increased, and finally decreased again with increasing holding time, while the number density exhibited the opposite trend. Therefore, when the holding time was the same, reducing the cooling rate could increase the average size of the precipitates and decrease their number density, thereby improving the hot ductility of 38CrMoAl steel. Full article

Thermal stimulation represents an effective method for enhancing reservoir permeability, thereby improving geothermal energy recovery in Enhanced Geothermal Systems (EGS). The phase-field method (PFM) has been widely adopted for its proven capability in modeling the fracture behavior of brittle solids. Consequently, a coupled thermo-mechanical phase-field model (TM-PFM) was developed in COMSOL 6.2 Multiphysics to probe thermal fracturing mechanisms in reservoir rocks. The TM-PFM was validated against the analytical solutions for the temperature and stress fields under steady-state heat conduction in a thin-walled cylinder, three-point bending tests, and thermal shock tests. Subsequently, two distinct thermal fracturing modes in reservoir rock under high-temperature conditions were investigated: (i) fracture initiation driven by sharp temperature gradients during instantaneous thermal shocks, and (ii) crack propagation resulting from heterogeneous thermal expansion of constituent minerals. The proposed TM-PFM has been validated through systematic comparison between the simulation results and the corresponding experimental data, thereby demonstrating its capability to accurately simulate thermal fracturing. These findings provide mechanistic insights for optimizing geothermal energy extraction in EGS. Full article

Experimental and simulation analysis was conducted on the effects of 532 nm nanosecond laser-induced thermal damage on the front-side illuminated CMOS detector. The study examined CMOS detector output images at different stages of damage, including point damage, line damage, and complete failure, and correlated these with microscopic structural changes observed through optical and scanning electron microscopy. A finite element model was used to study the thermal–mechanical coupling effect during laser irradiation. The results indicated that at a laser energy density of 78.9 mJ/cm², localized melting occurs within photosensitive units in the epitaxial layer, manifesting as an irreversible white bright spot appearing in the detector output image (point damage). When the energy density is further increased to 241.9 mJ/cm², metal routings across multiple pixel units melt, resulting in horizontal and vertical black lines in the output image (line damage). Upon reaching 2005.4 mJ/cm², the entire sensor area failed to output any valid image due to thermal stress-induced delamination of the silicon dioxide insulation layer, with cracks propagating to the metal routing and epitaxial layers, ultimately causing structural deformation and device failure (complete failure). Full article

This study presents a simulation-based damage modeling and fatigue risk assessment of a reusable ceramic matrix composite thruster designed for short-duration, green bipropellant propulsion systems. The thruster is constructed from a fiber-reinforced ultra-high temperature ceramic matrix composite composed of zirconium diboride, silicon carbide, and carbon fibers. Time-resolved thermal and structural simulations are conducted on a validated thruster geometry to characterize the severity of early-stage thermal shock, stress buildup, and potential degradation pathways. Unlike traditional fatigue studies that rely on empirical fatigue constants or Paris-law-based crack-growth models, this work introduces a simulation-derived stress-margin envelope methodology that incorporates ±20% variability in temperature-dependent material strength, offering a physically grounded yet conservative risk estimate. From this, a normalized risk index is derived to evaluate the likelihood of damage initiation in critical regions over the 0–10 s firing window. The results indicate that the convergent throat region experiences a peak thermal gradient rate of approximately 380 K/s, with the normalized thermal shock index exceeding 43. Stress margins in this region collapse by 2.3 s, while margin loss in the flange curvature appears near 8 s. These findings are mapped into green, yellow, and red risk bands to classify operational safety zones. All the results assume no active cooling, representing conservative operating limits. If regenerative or ablative cooling is implemented, these margins would improve significantly. The framework established here enables a transparent, reproducible methodology for evaluating lifetime safety in ceramic propulsion nozzles and serves as a foundational tool for fatigue-resilient component design in green space engines. Full article

Conventional asphalt is prone to cracking in cold climates due to its poor flexibility and limited ability to regulate temperature. This study investigates the use of low-temperature microencapsulated phase-change materials (MPCMs) to improve both the thermal storage and low-temperature performance of asphalt. MPCMs were incorporated into asphalt through physical blending at various concentrations. The physical, thermal, and rheological properties of the asphalt were then systematically evaluated. Tests included penetration, softening point, ductility, thermogravimetric analysis (TGA), and dynamic shear rheometer (DSR). The addition of MPCMs increased penetration and ductility. It slightly reduced the softening point and viscosity. These changes suggest improved flexibility and workability at low temperatures. Rheological tests showed reductions in rutting and fatigue factors. This indicates better resistance to thermal and mechanical stresses. Bending Beam Rheometer (BBR) results further confirmed that MPCMs lowered creep stiffness and increased the m-value. These findings demonstrate improved crack resistance under cold conditions. Thermal cycling tests also showed that MPCMs delayed the cooling process and reduced temperature fluctuations. This highlights their potential to enhance both energy efficiency and the durability of asphalt pavements in cold regions. Full article

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. Full article

To address the poor thermal shock resistance and high brittleness of traditional ceramic tools, a novel Si₃N₄/Sc₂W₃O₁₂ (SNS) composite ceramic material was developed via in situ synthesis using WO₃ and Sc₂O₃ as precursors and consolidated by spark plasma sintering. Sc₂W₃O₁₂ with negative thermal expansion was introduced to compensate for matrix shrinkage and modulate interfacial stress. The effects of varying Sc₂W₃O₁₂ content on thermal expansion, residual stress, microstructure, and mechanical properties were systematically investigated. Among the compositions, SNS3 (12 wt.% Sc₂W₃O₁₂) exhibited the best overall performance: relative density of 98.8 ± 0.2%, flexural strength of 712.4 ± 30 MPa, fracture toughness of 7.5 ± 0.3 MPa·m^1/2, Vickers hardness of 16.3 ± 0.3 GPa, and an average thermal expansion coefficient of 2.81 × 10⁻⁶·K⁻¹. The formation of a spherical chain-like Sc-W-O phase at the grain boundaries created a “hard core–soft shell” interface that enhanced crack resistance and stress buffering. Cutting tests showed that the SNS3 tool reduced workpiece surface roughness by 32.91% and achieved a cutting distance of 9500 m. These results validate the potential of this novel multiphase ceramic system as a promising candidate for high-performance and thermally stable ceramic cutting tools. Full article