Search Results (143)

Cavitation-induced degradation of metallic materials presents a significant challenge for engineers and users of equipment operating with high-velocity fluids. For any metallic material, the mechanical strength and ductility characteristics are controlled by the mobility of dislocations and their interaction with other defects in the crystal lattice (such as dissolved foreign atoms, grain boundaries, phase separation surfaces, etc.). The increase in mechanical properties, and consequently the resistance to cavitation erosion, is possible through the application of heat treatments and cold plastic deformation processes. These factors induce a series of hardening mechanisms that create structural barriers limiting the mobility of dislocations. Cavitation tests involve exposing a specimen to repeated short-duration erosion cycles, followed by mass loss measurements and surface morphology examinations using optical microscopy and scanning electron microscopy (SEM). The results obtained allow for a detailed study of the actual wear processes affecting the tested material and provide a solid foundation for understanding the degradation mechanism. The tested material is the Ni-based alloy INCONEL 625, subjected to stress-relief annealing heat treatment. Experiments were conducted using an ultrasonic vibratory device operating at a frequency of 20 kHz and an amplitude of 50 µm. Microstructural analyses showed that slip bands formed due to shock wave impacts serve as preferential sites for fatigue failure of the material. Material removal occurs along these slip bands, and microjets result in pits with sizes of several micrometers. Full article

In recent decades, the application of composite materials in aerostructures has significantly increased, with modern commercial aircraft progressively replacing aluminum alloys with composite components. This shift is exemplified by comparing the material compositions of the Boeing 777 and the Boeing 787 (Dreamliner). The Boeing 777 incorporates approximately 50% aluminum alloy and 12% composite materials, whereas the Dreamliner reverses this ratio, utilizing around 50% composites and 12% aluminum alloy. While metals remain advantageous due to their availability and ease of machining, composites offer greater potential for property tailoring to meet specific performance requirements. They also provide superior strength-to-weight ratios and enhanced resistance to corrosion and fatigue. To ensure the reliability of composites in aerospace applications, comprehensive testing under various loading conditions, particularly impact, is essential. Impacts were performed on quasi-isotropic (QIT) carbon-fiber reinforced epoxy panels with stainless steel, round-nosed and flat-ended impactors with rubber discs of 1-, 1.5- and 2 mm thickness, adhered to the flat-ended impactor to simulate the transition between hard and soft impact loading conditions. QIT composite panels were tested in this research employing similar lay-ups often being implemented in aircraft wings and other structures. The rubber discs were applied in the flat-ended impactor case but not for the round-nosed impactor due to the limited adhesion between the rubber and the rounded stainless-steel surface. Impact energies of 7.5, 15 and 30 J were investigated, and the performance of the panels was evaluated using force-time and force-displacement data alongside post-impact ultrasonic C-scan imaging to assess the damaged area. Damage was observed at all three energy values for the round-nosed impacts but only at the highest impact energy when using the flat-ended impactor, leading to the hardness study with adhered rubber discs being performed at 30 J. The most noticeable difference with the addition of rubber discs was the reduction in the damage in the plies nearest the top (impacted) surface. This suggests that the rubber reduces the severity of the impact, but increasing the thickness of the rubber from 1 to 2 mm does not notably increase this effect. Indentation clearly plays a significant role in promoting delamination at low-impact energies for the round-nosed impactors. Full article

Performing fatigue characterisation is often an expensive task, being both time consuming and expensive. Taking that into account, ultrasonic fatigue testing is an interesting solution, since it can be thousands of times faster than traditional experiments. In ultrasonic fatigue testing, excitation frequencies are in the order of magnitude of 20 kHz, while common fatigue testing frequencies are typically approximately a few hundreds of Hz. Although promising, ultrasonic fatigue testing has some challenges, like high strain rates, heat generation and complex specimen design. Regarding the latter, since the working principle of ultrasonic fatigue tests relies on exciting the specimen in one of its natural frequencies, finding a specimen geometry to resonate at this given frequency might be challenging. Additionally, some materials often present challenges associated with high temperature during tests. The goal of this paper is to provide guidelines for specimen design, encompassing the effects of critical factors and their impact on important test parameters, like temperature and dimensions. The proposed methodology developed a parameter able to quantify the heat generation severity during ultrasonic fatigue testing for several materials based on their physical properties. Moreover, the effects of the geometry and material properties in the temperature during loading cycles, with special focus on thermal gradients were enumerated. Full article

High-speed electrical discharge machining (EDM) is crucial for drilling aerospace components, but the fatigue effects of its recast layer are still not well understood. This study investigates the fatigue behavior of high-speed EDM-processed specimens using ultrasonic fatigue testing and microscopic analysis. The recast layer showed a 20.4% increase in hardness and a 16.5% decrease in elastic modulus compared to the base material. Fatigue cracks originated from microcracks, pores, and inclusions within the recast layer, as well as at its interface with the substrate. Microscopic crack initiation was influenced by defect interactions, while macroscopic crack initiation occurred near the maximum hole diameter perpendicular to the loading direction due to stress concentration. The specimens exhibited bimodal fatigue life: shorter lifetimes were observed when macroscopic stress concentrations overlapped with recast layer defects such as cracks and voids, while defect-free regions significantly extended durability. The non-uniform distribution of the recast layer critically links microstructural heterogeneity to variations in fatigue failure. These findings highlight how recast layer characteristics influence crack nucleation and life variability in EDM-processed components, offering valuable insights for optimizing machining parameters to reduce fatigue risks in critical aerospace applications. Full article

Integrating machine learning into additive manufacturing offers transformative opportunities to optimize material properties and design high-performance, fatigue-resistant structures for critical applications in aerospace, biomedical, and structural engineering. This study explores mechanistic machine learning techniques to tailor microstructural features, leveraging data from ultrasonic fatigue tests where very high cycle fatigue properties were assessed up to $1\times {10}^{10}$ cycles. Machine learning models predicted critical fatigue thresholds, optimized process parameters, and reduced design iteration cycles by over 50%, leading to faster production of safer, more durable components. By refining grain orientation and phase uniformity, fatigue crack propagation resistance improved by 20–30%, significantly enhancing fatigue life and reliability for mission-critical aerospace components, such as turbine blades and structural airframe parts, in an industry where failure is not an option. Additionally, the machine learning-driven design of metamaterials enabled structures with a 15% weight reduction and improved yield strength, demonstrating the feasibility of bioinspired geometries for lightweight applications in space exploration, medical implants, and high-performance automotive components. In the area of titanium and aluminum alloys, machine learning identified key process parameters such as temperature gradients and cooling rates, which govern microstructural evolution and enable fatigue-resistant designs tailored for high-stress environments in aircraft, biomedical prosthetics, and high-speed transportation. Combining theoretical insights and experimental validations, this research highlights the potential of machine learning to refine microstructural properties and establish intelligent, adaptive manufacturing systems, ensuring enhanced reliability, performance, and efficiency in cutting-edge engineering applications. Full article

The valve stem made of 20CrMo1V1A has low surface resistance and high susceptibility to corrosion, significantly curtailing its service life. To address these issues, a high-quality ultrasonic rolling (USR) technology was applied to the 20CrMo1V1A stainless steel valve stem to enhance its corrosion resistance and mechanical properties. Subsequently, fatigue and corrosion tests were conducted on the valve stem. The results indicate that USR produces surfaces with a roughness average (Ra) of 0.3 μm and a gradient nanostructure on the valve stem surface. This unique microstructural modification resulted in a 27% improvement in surface hardness and nearly a three-fold grain size reduction. Additionally, the friction coefficient and electrochemical corrosion rate dropped by 47% and 32%, respectively. Therefore, USR was applicable for enhancing multiple properties of valve components as an additional final processing step for achieving high-performance valve stems. Full article

Fatigue crack defects in metallic materials significantly reduce the remaining useful life (RUL) of parts. However, much of the existing research has focused on identifying single-millimeter-scale cracks using individual nonlinear ultrasonic responses. The identification of subtle parameters from complex ultrasonic responses of micro-crack groups remains a significant challenge in the field of nondestructive testing. We propose a novel multi-harmonic nonlinear response fusion identification method integrated with a deep learning (DL) model to identify the subtle parameters of micro-crack groups. First, we trained a one-dimensional convolutional neural network (1D CNN) with various time-domain signals obtained from finite element method (FEM) models and analyzed the sensitivity of different harmonic nonlinear responses to various subtle parameters of micro-crack groups. Then, high harmonics were fused to perform a decoupled identification of multiple subtle parameters. We enhanced the Dempster–Shafer (DS) evidence theory used in decision fusion by accounting for different sensitivities, achieving an identification accuracy of 93.73%. Building on this, we assigned sensor weights based on our proposed new conflict measurement method and further conducted decision fusion on the decision results from multiple ultrasonic sensors. Our proposed method achieves an identification accuracy of 95.68%. Full article

This study explores the fatigue properties of EN AW-6082-T6 aluminum alloy in the gigacycle range (10⁶–10⁹ cycles), using ultrasonic resonance fatigue testing at 20 kHz in a push–pull mode with a symmetric load cycle (R = −1). A custom-built ultrasonic fatigue machine, developed at TU-Varna, comprising a generator, ultrasonic train (including a high-power transducer, booster, custom-made sonotrode, and specimen), monitoring, data logging systems, and an air-cooling capability, was used for the experiments conducted. A Bezier curve sonotrode, with an amplification ratio of 1:6, was designed and produced for the test. Hourglass-shaped specimens were designed on the base of the dynamic Young’s modulus E = 71.3 GPa, determined through the impulse resonance method (ASTM E1876-01), and validated with FEM analysis for resonance length and stress amplitude. The fatigue testing revealed a fatigue strength reduction of approximately 60 MPa between 10⁶ and 10⁹ cycles. The percentile of failure curves based on a Cactillo–Canteli model fits well with the experimental data and gives a fatigue limit at 10⁹ cycles σl = 104 MPa and “endurance strength” σw = 84 MPa. Surface crack initiation was consistently observed with predominately cleavage transgranular fractures in the fatigue zone. The present research highlights the utility of ultrasonic testing for examining fatigue behavior in the gigacycle regime. Full article

An experimental study was conducted to analyze temperature evolution during very high cycle fatigue tests. The temperature–number of cycles (T–N) curve is typically divided into three phases: Phase I—a rapid temperature increases at the start of the test, Phase II—temperature stabilization, and Phase III—a sharp temperature rise at the test’s end, coinciding with specimen fracture. The high frequencies used in ultrasonic fatigue testing can induce self-heating in specimens, but the thermal effects are not yet fully understood. Temperature is known to influence the fatigue performance of materials. To explore this, specimens were subjected to varying stress levels and intermittent loading conditions while monitoring temperature evolution using infrared thermography. The T–N curves were obtained, and S–N curves were constructed for specimens tested at room temperature. All tests were performed under fully reversed loading conditions. The experimental data were used to evaluate models commonly applied in conventional fatigue testing. Additionally, the temperature gradient at the beginning of the ultrasonic fatigue test and the heat dissipation per cycle were estimated and analyzed as potential fatigue damage parameters. These findings indicate that parameters derived from the T–N curve have significant potential for predicting very high cycle fatigue life. Full article

Costs are increasing due to the addition of alloying elements such as V, W, and Mo to prevent damage to Cr-Mo steel for fastening bolts, but field tests have shown that it is not an appropriate solution for improving physical properties through heat treatment. In this study, the characteristics of fatigue cracks using Cr-Mo steel for fastening bolts before and after UNSM (ultrasonic nanocrystal surface modification) treatment were studied using fracture mechanics and fracture analysis methods. Specifically, using untreated and UNSM-treated materials: (1) the characteristics of small surface fatigue cracks existing on the surface, and (2) the surface fatigue cracks in the depth direction were observed and analyzed. The microstructure of Cr-Mo steel was refined by severe plastic deformation (SPD) from the surface to a depth of about 100 μm according to the static load of UNSM, and the fatigue limit increased by 30% as a large compressive residual stress was formed. Additionally, like the untreated materials, fisheye cracks did not occur in UNSM-treated materials, even when inclusions were present, and all specimens fractured while forming surface cracks. Accordingly, one or more of the multiple small surface fatigue cracks (MSFC) grew and developed into a major crack that determines the fatigue life, and a major ridge was formed among the many micro-ridges in the internal direction. In other words, this major crack grew and developed a major ridge in the internal direction, determining the lifespan of the test specimen. Full article

The surface of dental materials is exposed to various prophylaxis protocols during routine dental care. However, the impact of these protocols on the functional properties of the material’s surface remains unclear. This study investigates the influence of different dental prophylaxis protocols on the surface properties and their effect on the mechanical performance of CAD-CAM restorative materials. Discs (Ø = 15 mm, thickness = 1.2 mm) were fabricated from resin composite (RC, Tetric CAD), leucite-reinforced (LEU, IPS Empress CAD), lithium disilicate (LD, IPS e.max CAD), and zirconia ceramics (ZIR, IPS e.max ZirCAD MT). The materials were subjected to six prophylactic treatments: untreated (CTRL), prophylactic paste fine (PPF), prophylactic paste coarse (PPC), pumice stone (PS), air abrasion with sodium bicarbonate jet (BJ), and ultrasonic scaling (US). Biaxial flexural fatigue tests, along with fractographic, roughness, and topographic analyses, were conducted. No significant changes in fatigue strength were observed for RC, LD, and ZIR under any prophylaxis protocols. However, LEU subjected to BJ treatment exhibited significantly reduced fatigue strength (p = 0.004), with a 22% strength reduction compared to the monotonic test and substantial surface alterations. Surface roughness analyses revealed increased roughness for RC treated with PPF, PPC, and PS compared to CTRL (p < 0.05), while LD exhibited decreased roughness following PPF, PS, and US treatments (p < 0.05). In ZIR, only the BJ protocol increased roughness (p = 0.001). In conclusion, dental prophylaxis protocols do not significantly affect the mechanical strength of RC, LD, and ZIR materials, thus allowing any protocol to be used for these materials. However, for LEU ceramics, the BJ protocol should be avoided due to its effect of reducing fatigue strength and damaging the surface. Full article

To improve the service life of continuous casting crystallizer, the NiCo-ZrB₂ coating was prepared using nanocomposite plating technology. Uniformly dispersed nano-ZrB₂ particles significantly enhanced the hardness and wear resistance of the coating. Upon testing, the hardness of the coating exceeded 700 HV, with a friction coefficient below 0.2, which was superior to those of pure NiCo or other nanocomposite NiCo coatings reported previously. Microscopic analysis revealed that the addition of dispersants and ultrasonic vibration treatment had facilitated the homogeneous distribution of nano-ZrB₂ within the matrix, thereby promoting the formation of numerous nano-twins. Due to dispersion strengthening, fine grain strengthening, and twinning strengthening, the wear behavior of the coating changed from fatigue wear to abrasive wear, and the wear volume was significantly reduced by 82%. The above findings could potentially extend the service life of the coating, reduce the cost of steel loss per ton, and have broad application prospects in other surface protection fields. Full article

Ultra-high-strength steels have been considered an essential material for aviation components owing to their excellent mechanical properties and superior fatigue resistance. When machining these steels, severe tool wear frequently results in poor surface quality and low machining efficiency, which is intimately linked to the friction behavior at the tool–workpiece interface. To enhance the service life of tools, the adoption of efficient cooling methods is paramount. However, the understanding of friction behavior at the tool–workpiece interface under varying cooling conditions remains limited. In this work, both air atomization of cutting fluid (AACF) and ultrasonic atomization of cutting fluid (UACF) were employed, and their spray characteristic parameters, including droplet size distribution, droplet number density, and droplet velocity, were evaluated under different air pressures. Discontinuous sliding tests were conducted on the ultra-high-strength steel against cemented carbide and the effect of spray characteristic parameters on the adhesion friction coefficient was studied. The results reveal that ultrasonic atomization significantly improved the uniformity of droplet size distribution. An increase in air pressure resulted in an increase in both droplet number density and droplet velocity under both AACF and UACF conditions. Furthermore, the thickness of the liquid film was strongly dependent on the spray characteristic parameters. Additionally, UACF exhibited a reduction of 4.7% to 9.8% in adhesion friction coefficient compared to AACF. UACF provided the appropriate combination of spray characteristic parameters, causing an increased thickness of the liquid film, which subsequently exerted a positive impact on reducing the adhesion friction coefficient. Full article

The very high cycle fatigue (VHCF) strength of welded joints made of high-strength structural materials is generally poor, which poses a serious threat to the long life and reliability of the structural components. This work employs an ultrasonic vibration fatigue testing system to investigate the biaxial fatigue failure mechanism of the welded joints. The results revealed that under uniaxial loading conditions, the propensity for fatigue failure in plate specimens was predominantly observed at the specimen surface. Regardless of whether under uniaxial or biaxial loading, the initiation of fatigue cracks in cruciform joints was consistently traced back to unfused flaws, which were primarily located at the interface between the solder and the base material. Concurrently, it was noted that the fatigue strength of cruciform joints under biaxial loading was merely 44.4% of that under uniaxial loading. The geometric peculiarities of the unfused defects led to severe stress concentrations, which significantly reduced the fatigue life of the material under biaxial loading conditions. Full article

Background: Dental instrumentation with hand-held devices is associated with discomfort, fatigue and musculoskeletal diseases or repetitive stress injuries. The goal of this in vivo study was to determine the effect of an ergonomic handle sheath on muscle work, comfort and fatigue associated with (a) piezoelectric scaling by hygienists with and without musculoskeletal disorders (MSDs), and (b) dental cavity preparation by healthy dentists using a dental micromotor. Materials and Methods: Two groups of ten hygienists each tested the piezoelectric scaler. Hygienists in Group 1 had no MSDs, while those in Group 2 had been diagnosed with MSDs. Additionally, ten dentists with no MSDs used a dental micromotor to prepare four standardized cavities. Time-based work in four muscles, comfort and fatigue were recorded in the presence and absence of an add-on soft, insulating handle sheath. Data were analyzed using a repeated measures analysis of variance model with Tukey’s post-hoc test. Results: Comfort, fatigue and muscle work were significantly better for both devices when the sheath was used. While hygienists with MSDs used more muscle work to complete the set scaling task, and the sheath-related reduction in work was somewhat greater, these MSD-related differences did not quite reach significance. Conclusions: The results of this pilot study show that the ergonomic performance of an ultrasonic scaler and a dental micromotor may be improved by the use of an ergonomic handle sheath. Full article