Search Results (1,293)

Rock fracture behavior is strongly influenced by grain size and boundary effects, which complicate the determination of fracture parameters and the interpretation of size-dependent failure. This study investigates the fracture behavior of sandstone and diorite within the framework of the boundary effect model (BEM) using three-point bending tests, acoustic emission (AE), and digital image correlation (DIC). By varying the prefabricated crack length, different values of the structural geometric parameters a_e were obtained, and the fracture toughness K_IC and tensile strength f_t were identified by regression analysis. The results show that K_IC = 0.6841 MPa·m^0.5 and f_t = 4.5625 MPa for sandstone, whereas K_IC = 2.7233 MPa·m^0.5 and f_t = 21.8218 MPa for diorite. Increasing the prefabricated crack length reduces the peak load and prolongs the pre-peak damage evolution stage. Diorite, with a larger average grain size, exhibits higher AE energy release, a higher proportion of high-energy AE events, and a larger fracture process zone (FPZ) than sandstone. Moreover, the AE energy distribution along the crack propagation direction shows a distinct “three-stage” characteristic, consistent with the non-uniform distribution of local fracture energy g_f predicted by boundary effect theory. The results indicate that BEM can reasonably characterize the fracture behavior of rocks with different grain sizes, and the identified material parameters can be used to construct a BEM-based structural failure curve for estimating nominal failure stress over a wider range of structural geometric parameters. Full article

The upscaling of turbines in the offshore wind industry has been unprecedented, as compared to 5–6 MW rated turbines 10 years ago. A typical 20–26 MW rated turbine in modern commercial applications (MingYang MySE 18.X-20 MW installed in 2025 and 26 MW prototype by Dongfang Electric tested in 2025) has been demonstrated. This scaling has been made possible by increasing rotor diameters (>250 m) and hub heights (>150–180 m) to achieve capacity factors of up to 55–65%, annual energy generation of more than 80 GWh/turbine, and significant decreases in levelised cost of energy (LCOE) to current values of up to 63–65 USD 2023/MWh globally averaged in 2023 (with minor variability in 2024 due to market changes and new regional areas). The paper analyses turbine upscaling over three levels of hierarchy, including turbine scale—rated capacity and physical aspect, project scale—multi-gigawatts of farms, and market scale—the global pipeline > 1500 GW level, and combines techno-economic evaluation, structural evaluation of loads, and infrastructure needs assessment. The upscaling has the advantage of reducing the number of turbines dramatically (e.g., 500 to 67 turbines in a 1 GW farm, as turbine size is increased to 15 MW) and balancing-of-plant (BoP) CAPEX (turbine-to-turbine foundations and cables) by some 20 to 30 percent per unit of capacity, and serial production learning rates of between 15 and 18% per doubling of capacity. But the problems that come with the increase in ultra-large designs are nonlinear increments in mass and load (i.e., blade-root and tower-bending moments), logistical constraints (blades > 120 m, nacelle up to 800–1000 tonnes demanding special vessels and ports), supply-chain issues (rare-earth materials, vessel shortages increase day rates by 30–50%), and technology limitations (aeroelastic compounded by numerical differences between reference 5 MW, 10 MW, and 15 MW models), it becomes evident that there is a significant increase in deflections of the tower and blades and platform surge/pitch responses with continued increases in power levels, but without a correspondingly mature infrastructure. The regional differences (mature ports of Europe vs. U.S. Jones Act restrictions vs. scale-up of vessels/manufacturing in China) lead to the necessity of optimisation depending on the context. The analysis concludes that, to the extent of mature markets with adapted logistics, continuous upscaling is an effective business strategy and can result in 5 to 12 percent further reductions in LCOE, but beyond that point, gains become marginal or even negative, as risks and costs increase. The competitiveness of the future depends on multi-scale/multi-market-based approaches—modular-based families of turbines, programmatic standardisation, vibration control innovations, and industry coordination towards supply-chain alignment and standards. Its major strength is that it transcends mere size–cost relationships and shows how nonlinear structural processes, aero-hydro-servo-elastic interactions, and bottlenecks in logistical systems are becoming more determinant of the efficiency of ultra-large turbines. The study demonstrates that upscaling turbines has LCOE benefits through the support of associated improvements in installation facility, supply-chain preparedness, and structural vibration control potential, based on the comparisons of quantitative loads, techno-economic scaling trends, and regional market differentiation. Full article

With Aligned Formable Fibre Technology (AFFT^™), fibers are reformatted into highly oriented epoxy prepreg tapes, enabling the structural reuse of recycled composite waste. The present study investigates whether discontinuous fiber laminates produced with AFFT^™ can be characterized and optimized with the same finite-element workflows long established for continuous fiber composites and whether the resulting structures meet demanding stiffness targets. Initially, various manufacturing methods were adopted, including vacuum bagging, compression molding at 7 bar to simulate autoclave conditions, and compression molding at 90 bar, comprising the three most reasonable manufacturing processes for AFFT^™ laminates. Experimentally measured orthotropic properties were introduced into a finite-element model representing an idealized bicycle top tube, which was chosen as a case study. A genetic algorithm screened candidate stacking sequences, minimizing the combined bending-and-torsion deflection. The best lay-ups reduced deformation by more than 30% compared to a quasi-isotropic baseline, showing that well-oriented short fibers can significantly contribute to the stiffness of composites. Tubes produced with the optimized lay-up were tested in three-point bending tests, and the measured stiffness matched simulations within 5%. These results confirm a key point for sustainable engineering: despite the absence of continuous fibers, conventional simulation strategies accurately predict the performance of AFFT^™ laminates and can be used as the basis for effective genetic optimization. This validation is significant: it enables the design of stiff, high-performance structures from recycled materials using established, cost-effective methods. By proving that optimization strategies developed for traditional continuous fiber composites apply to AFFT^™, this study offers a trusted and accessible pathway to scale circular economy solutions in next-generation composite products. Full article

Ultra-high-performance concrete (UHPC) has been widely investigated for its superior strength and durability; however, despite extensive research on fibre reinforcement, limited attention has been given to validating fibre surface modification strategies at the structural scale. Improvements in fibre–matrix bonding are commonly demonstrated through single-fibre tests, with limited evidence of their translation into the mechanical performance of UHPC elements. This study investigates the influence of bioinspired surface-modified steel fibres on the mechanical behaviour of UHPC, focusing on whether interfacial enhancements lead to measurable structural-scale performance gains. Steel fibres were coated under mild aqueous conditions and incorporated into UHPC at a volume fraction of 1%. Compressive strength was evaluated at 7, 14, 28, 56, and 90 days, while flexural behaviour was assessed at 7 and 28 days using three-point bending tests on notched beams and four-point bending tests on prisms. The incorporation of surface-modified fibres resulted in consistent strength enhancement at all curing ages. Compared with mixes containing uncoated fibres, compressive strength increased by approximately 15% at 7 days and remained 5–7% higher at later ages up to 90 days. More pronounced improvements were observed in flexural performance, with coated specimens exhibiting up to 51% higher peak load at 7 days and 29–32% higher peak load at 28 days in both bending configurations. These results demonstrate that fibre surface modification effectively enhances both early-age and long-term mechanical performance of UHPC, confirming that interfacial bond improvements are directly translated into structural-scale response. The findings highlight fibre surface engineering as a practical approach for improving the mechanical efficiency of UHPC without altering mix composition or fibre dosage. Full article

Wood is a versatile material; however, it is susceptible to changes when exposed to extreme temperatures. This study investigated the physical, chemical, and mechanical properties of raulí (Nothofagus alpina) under different thermal stress conditions. The results showed that the moisture content at temperatures below 5 °C exhibited a significant reduction from 9.7% to 7.5% within the first 20 days. Conversely, under extreme cold (−20 °C), significant changes only occurred after 60 days, with an increase from 9.7% to 11%. At higher temperatures (50 °C, 95 °C, and 120 °C), moisture content dropped sharply after 40 days, nearing 0%. Additionally, analysis showed minor color changes in samples at low temperatures: RW2 (20 d; 5 °C, ΔE* = 3.46) and RW7 (40 d; 5 °C, ΔE* = 0.61); however, color changes were observed at higher temperatures (95–120 °C). RW15 (60 d; 120 °C, ΔE* = 37.16), indicating the degradation of cell wall polymers. Mechanical testing using three-point bending demonstrated that controlled heat treatments can improve the modulus of elasticity (MOE), modulus of rupture (MOR), and fracture energy. The most significant improvements were obtained at 120 °C for 60 days, with increases in MOE, MOR, and fracture energy of 22%, 60%, and 118%, respectively, compared to untreated wood. Full article

This study develops a multi-scale fiber-reinforced cementitious composite (MFRC) by hybridizing calcium carbonate whisker (CW), polyvinyl alcohol (PVA) fiber, and steel fiber. The interfacial micromechanical properties between steel fiber/matrix and PVA fiber/matrix under the influence of CW were systematically examined through single-fiber pull-out tests. The two-dimensional and three-dimensional distribution characteristics of fibers in the MFRC were analyzed using backscattered electron imaging (BSE) and X-ray computed tomography (X-CT), respectively. Based on the fiber distribution characteristics, flexural strength prediction models were developed with R² values of 0.79 (2D) and 0.82 (3D). Experimental validation via splitting tensile tests and three-point bending tests confirmed the model’s effectiveness in simultaneously predicting splitting tensile strength (R² = 0.89) and flexural strength (R² = 0.93). These findings demonstrate the reliability and universality of the proposed model for predicting flexural–tensile strength in an MFRC. Full article

Bending-dominated lattice structures offer superior stability but suffer from low stiffness and natural frequencies, posing resonance risks in aerospace applications. To address this, a novel Membrane-Wrapped Lattice (MWL) encapsulated by a micrometer-scale metallic film is proposed. A theoretical framework based on the tension-compression asymmetry of the membrane is established to analyze the influence of membrane thickness on the neutral axis shift, ultimately deriving analytical formulations for flexural stiffness and natural frequencies. MWL specimens with varying membrane thicknesses (0–50 μm) were fabricated via selective laser melting and adhesive bonding, then subjected to three-point bending and vibration tests. Results demonstrate that wrapping with a 50 μm 316 L stainless steel membrane increases the flexural stiffness by 128% and the fundamental natural frequency by 85%. The experimental measurements align well with theoretical and numerical predictions, validating this lightweight, high-stiffness design strategy. Full article

This paper presents an experimental and numerical study on the effect of steel fiber distribution on the flexural behavior of self-compacting mortars (FRSCMs). Six FRSCM mixtures were modeled in ABAQUS as prismatic specimens (40 × 40 × 160 mm³) subjected to static three-point bending. The methodology involved two steps: (i) preparation of six mortar variants composed of three layers with different hooked steel fiber dosages (20, 30, and 40 kg/m³ for M20, M30, and M40) assembled in various configurations to study fiber distribution effects; (ii) numerical modeling of prismatic specimens in ABAQUS, using structured meshing with C3D8R hexahedral elements. Each layer was meshed separately with aligned nodes to ensure proper assembly. Our results highlight the strong influence of fiber distribution: despite identical fiber content (90 kg/m³ of hooked steel fibers), flexural strength varied across beam configurations. Layered casting led to an increase in flexural strength of up to 71.83% compared to the reference. The numerical predictions closely matched the experimental results, with relative errors ranging from 1% to 8.13% for most variants, demonstrating the reliability of the model. The larger discrepancies observed for specimens M324 and M342 are attributed to the limitation of the study to the elastic domain, as damage and plasticity effects were not included in the simulations. The distribution and orientation of fibers (particularly steel fibers) in a cementitious matrix, namely concrete or cement mortar, has been the subject of several studies aimed at determining the best mechanical performance of fiber-reinforced concrete. The proposed modeling approach of bending mechanical behavior allows us to predict the effects of fiber distribution in fluid mortars and reinforced self-compacting mortars, thereby reducing the need for extensive experimental testing. It also represents a significant improvement over existing approaches reported in the literature. Full article

The development of lightweight, high-strength structural systems is a persistent pursuit in modern civil engineering. This paper presents an experimental study on a novel hybrid beam concept in which a sawn timber core is fully bonded with an externally applied Carbon Fiber-Reinforced Polymer (CFRP) laminate, fabricated through a controlled hand lay-up process. The design seeks to exploit the complementary characteristics of the two materials: timber provides compressive resistance and serves as a permanent formwork, while the CFRP carries tensile stresses with high efficiency. Fourteen hybrid beams, with variations in the number of longitudinal CFRP layers (one, two or, three), the presence or absence of longitudinal CFRP layers bonded along the top and bottom surfaces, and the presence or absence of circumferential wrapping in the pure bending region, were tested under four-point bending alongside two solid timber control beams. The results demonstrate that circumferential wrapping is a critical design detail. Wrapped beams consistently failed by tensile rupture of the CFRP—the intended failure mode—and exhibited ultimate moments 15–20% higher than their unwrapped counterparts. Beams with two longitudinal CFRP layers offered the most favorable balance between strength enhancement and material efficiency; adding a third layer shifted the failure mode to crushing of the timber core, indicating a core-limited condition. All hybrid beams showed pronounced linear-elastic behavior up to sudden brittle failure, with performance variability attributable to the inherent inhomogeneity of wood and the sensitivity of the hand lay-up process. The study provides quantitative data and mechanistic insights that support the design and application of bonded CFRP–timber hybrid beams as efficient structural members. Full article

Additive manufacturing enables the fabrication of personalized protective equipment with locally tailored mechanical properties. In this work, a low-cost scan-to-print workflow is proposed for the fused filament fabrication (FFF) of personalized dual-zone shin guards combining a stiff outer load-distribution layer with a compliant inner energy-absorbing layer. Subject-specific leg geometry was acquired via structured-light 3D scanning and used to design a shin guard with two 3.5 mm thick zones (total thickness 7 mm). Foamable filaments of PLA, ASA, and TPU were employed to manufacture unfoamed and foamed regions by controlling extrusion temperature. Mechanical performance was assessed through three-point bending tests and dynamic finite element impact simulations. Unfoamed PLA and ASA exhibited flexural strengths of approximately 88 MPa and 72 MPa, respectively, while foaming reduced these values by about 74%. Dual-zone configurations partially restored stiffness, reaching 41 MPa for PLA and 29 MPa for ASA. TPU showed lower flexural stresses with a smaller reduction of 23% upon foaming. Impact simulations revealed maximum deformations of 1.97 mm and 2.02 mm for PLA and ASA outer zones, respectively, while TPU exhibited large deformations leading to penetration of the 3.5 mm thick inner layer. The results demonstrate that dual-zone designs manufactured via foaming-enabled FFF can effectively balance stiffness, weight, and impact response for personalized shin guard applications. Full article

This study investigates the effect of goat horn powder (GHP) reinforcement on the hardness, microstructure, and mechanical properties of wood-like polyurethane composites. GHP, a keratin-based animal waste, was incorporated into the polyurethane matrix at weight fractions of 5, 10, 15, 20, and 25 wt.%. The mechanical behavior was evaluated through tensile, three-point bending, Charpy impact, and Shore D hardness tests, complemented by scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) analyses. Results indicate that GHP significantly enhances impact resistance, with 10 wt.% loading achieving a 140% improvement in impact energy compared to the neat matrix. Tensile stress improved by 12.89% at 5 wt.% loading. However, reinforcement levels exceeding 10–15 wt.% led to a decline in tensile and flexural performance due to particle agglomeration and weak interfacial adhesion. Shore D hardness increased systematically with higher GHP content across all ratios. The study demonstrates that GHP is a functional, sustainable reinforcing element that improves toughness and hardness while supporting environmental waste management. Full article

To elucidate the degradation behavior of elastic modulus in normal-strength ordinary concrete under flexural fatigue loading, this study systematically examines its evolution in C50 concrete, which is widely used in engineering applications. Based on four-point bending fatigue test data of plain concrete (PC) and reinforced concrete (RC) beams, degradation curves of the relative residual elastic modulus as a function of the cycle ratio were established. To quantitatively characterize the fatigue degradation process, two integrated indicators—the area under the curve (AUC) and the stable-stage degradation slope (|$K_{mid}$|)—were introduced to represent the degree of cumulative damage and the degradation rate of elastic modulus, respectively. These indicators were subsequently employed to evaluate the effects of maximum stress level, stress ratio, and reinforcement on elastic modulus degradation. The results show that failed PC specimens exhibited a typical three-stage S-shaped degradation pattern, whereas RC specimens primarily exhibited a two-stage degradation behavior. However, the elastic modulus of runout PC specimens remained above 93% of its initial value throughout the entire loading process. For PC specimens, under the same maximum stress level, increasing the minimum stress level from 0.10 to 0.25 resulted in a 24% decrease in |$K_{mid}$| from 0.2505 to 0.1912. At the same minimum stress level, increasing the maximum stress level from 0.75 to 0.90 led to a 94% increase in |$K_{mid}$| from 0.1912 to 0.3705. The presence of reinforcement increased AUC by 3~15% and reduced |$K_{mid}$| by 54~74%, indicating that reinforcement not only mitigated overall damage accumulation but also significantly slowed the degradation rate of the elastic modulus during the stable fatigue stage. The degradation characterization approach proposed in this study provides a simplified and practical framework for fatigue analysis of concrete components based on damage mechanics. Full article

The integration of mechanics-based analysis and materials design procedures has become central to the development of multi-material structures with tailored mechanical and dynamic performance. In this study, the dynamic and flexural behaviour of multi-material FDM sandwich beams composed of PETG face sheets and an ABS core is experimentally investigated. Seven different infill patterns Grid, Line, Wavy, Honeycomb, Gyroid, Cubic, and Triangle were implemented in the core layer to assess their influence on damping and natural frequency behaviour. Experimental modal analysis was performed using impact testing to identify the first three vibration modes. Natural frequencies were extracted from Frequency Response Functions (FRFs), and modal damping ratios were determined using the half-power bandwidth method. The reliability of the damping results was evaluated through statistical analysis. Additionally, quasi-static three-point bending tests were conducted to assess flexural strength and load-carrying capacity. The results demonstrate that infill topology has a significant impact on both dynamic and mechanical responses. In particular, geometrically complex infill patterns exhibit enhanced stiffness, higher natural frequencies, and improved damping performance. Among the investigated designs, the Triangle infill exhibited the highest natural frequency values across the first three vibration modes (f₁ ≈ 24.910 Hz, f₂ ≈ 162.609 Hz, f ≈ 466.595 Hz), indicating its superior stiffness characteristics. In terms of damping behaviour, the Cubic infill showed the highest loss factor in the first vibration mode (0.0426), while the Line and Gyroid patterns exhibited the highest damping in the second (0.0439) and third modes (0.0354), respectively. Moreover, the force–displacement results revealed that the Triangle infill exhibited the highest load-bearing capacity, further confirming its superior structural stiffness among the investigated designs (SEA = 110.83 J/kg). These findings highlight the potential of multi-material FDM for designing polymer-based sandwich structures with tailored vibration and energy dissipation characteristics. Full article

The aim of this study was to assess the effect of printing orientation and water ageing on the flexural strength and flexural modulus of 3D printed resins for occlusal splints. Bar-shaped specimens were designed with dimensions of 64 × 10 × 3.3 mm according to ISO 20795-2:2013. Specimens were 3D printed with the Form 3B printer (Formlabs), using Dental LT Clear Resin (CL) or Comfort Resin (CO) (Formlabs), and 3 different printing orientations: as per manufacturer’s recommendation (40° N = 20), parallel (0° N = 20), or perpendicular to the build platform (90° N = 20). To simulate intraoral ageing, half of the specimens per material and printing orientation (N = 10) were stored in distilled water at 37 °C for 30 days prior to testing. Specimens were tested in a three-point bending apparatus using a universal testing machine equipped with a 50 N load cell moving at a crosshead speed of 5 mm/min. Flexural strength (MPa) and flexural modulus (GPa) data were collected and statistically processed with separate analyses for unaged and aged specimens (Two-Way or One-Way ANOVA; Tukey test; p < 0.05). As for unaged specimens, both resin materials exhibited the highest flexural strength and modulus in the 90° orientation and the lowest values in the 40° orientation group. After water aging, all groups showed reduced flexural strength and modulus, with CO displaying up to 52% loss in flexural strength and values falling below ISO thresholds. CO consistently exhibited significantly lower flexural strength and modulus than CL, irrespective of aging. Full article

To address the engineering challenges of frequent flexural deformation and instability of composite roadway roofs and the difficulty in accurately controlling the support strength range during deep coal mining, this study takes the soft–hard interbedded composite roof of the working face in the West No. 1 Mining Area of Shuangyang Coal Mine in Shuangyashan as the engineering background. Typical fine sandstone (hard rock) and tuff (soft rock) from the on-site roof were selected to prepare layered composite specimens, and indoor four-point bending tests were conducted. Combined with theoretical calculations, strain monitoring, and acoustic emission (AE) real-time localization technology, the regulatory mechanisms of three key factors—lithological combination, loading rate, and span—on the flexural mechanical properties, deformation and failure modes, and fracture evolution laws of layered composite rock masses were systematically investigated. The research results show the following: (1) The flexural performance of layered composite rock masses is dominated by the interlayer interface effect. Their flexural strength is 46.7% and 41.1% lower than that of single hard rock and soft rock specimens, respectively, and the competitive mechanism between interface slip and delamination fracture is the core inducement of strength deterioration. (2) The strength and deformation characteristics of layered composite rock masses exhibit a significant loading rate effect. When the loading rate increases from 0.002 mm/s to 0.02 mm/s, the flexural strength decreases by 51.8% and the mid-span deformation deflection reduces by 50.1%. High loading rates will exacerbate the deformation mismatch between soft and hard rock layers, trigger premature failure of interface bonding, and inhibit the full development of structural plastic deformation. (3) Increasing the span significantly optimizes the flexural bearing performance of layered composite rock masses. When the span increases from 170 mm to 190 mm, the flexural strength increases by 65.7% and the mid-span deformation deflection synchronously increases by 65.7%. A large span can extend the flexural deformation path, promote the coordinated deformation of rock layers, and suppress local stress concentration. (4) The flexural failure of layered composite rock masses is dominated by Mode II shear cracks, while single-lithology specimens are mainly dominated by Mode I tensile cracks. Loading rate and span significantly change the crack propagation mode and energy release law. This study establishes a calculation method for the equivalent flexural stiffness of layered composite rock masses and reveals the mesoscopic mechanism of flexural failure of heterogeneous layered rock masses. The research results can provide a theoretical basis and experimental support for the optimization of support schemes and the prevention and control of roof collapse hazards for composite roofs of deep coal mine roadways. Full article