Search Results (271)

This study presents an experimental investigation into the seismic performance of seismically deficient reinforced concrete (RC) bridge columns retrofitted with passive and active confinement systems. Four single-cantilever RC columns, representing 1/3-scale bridge piers, were constructed with poor transverse reinforcement detailing to simulate seismic deficiency. One column was left un-strengthened for baseline comparison, while the remaining three were retrofitted using: (1) a CFRP jacket, (2) welded Fe-SMA plates, and (3) bolted Fe-SMA plates. All columns were subjected to quasi-static lateral cyclic push-only loading reaching extreme drift levels exceeding 16% and high loading rates up to 6 mm/s. The study specifically explores the confinement effectiveness of CFRP and thermally activated Fe-SMA plates, comparing their contributions to lateral strength, ductility, energy dissipation, failure mode, and damage suppression. The results show that while the as-built column failed at 3.65% drift due to brittle flexural-shear failure, all retrofitted columns demonstrated significantly enhanced ductility, drift capacity, and post-peak behaviour. The CFRP and Fe-SMA jackets effectively delayed damage initiation, minimized core degradation, and improved energy dissipation. The bolted Fe-SMA system exhibited the highest and full restoration of lateral strength, while the welded system achieved the greatest increase in cumulative energy dissipation of around 40%. This research highlights the practical advantages and seismic effectiveness of Fe-SMA and CFRP confinement systems under extreme drift levels. However, future work should explore full-scale column applications, refine anchorage techniques for improved composite interaction, and investigate long-term durability under cyclic environmental conditions. Full article

With the advancement of welding technology, the demand for 70S-6 welding wire steel has steadily increased in industries such as construction, automotive, pressure vessels, and line pipe manufacturing. To optimize the production process of the target material, this study utilized the finite-element software ABAQUS to numerically simulate the multi-pass finish rolling process of 70S-6 welding wire steel. The study investigates the effects of the key rolling parameters—pass distribution (8/10/12 passes), finish rolling temperature (860/880/900 °C), and rolling speed (0.5 Vp/1.0 Vp/1.5 Vp, here Vp denotes the reference industrial rolling speed) on the rolling force, temperature field, and equivalent stress/strain during finish rolling. The results show that the increased number of passes homogenizes deformation, reduces local stress concentration and enhances mechanical properties. Specifically, 12 passes reduce the peak rolling force from 250,972 N to 208,124 N, significantly enhancing stress and temperature uniformity across the section. Increasing the finish rolling temperature lowers the pass-averaged flow stress and attenuates rolling-force fluctuations. At 880 °C, the simulated core–surface temperature gradient is minimal (50 °C), whereas at 900 °C the gradient increases (80 °C) but the rolling-force histories exhibit a lower peak level and smaller low-frequency oscillations; thus 880 °C is preferable when through-thickness thermal uniformity is targeted, while 900 °C is more suitable when a smoother load response is required. Increasing the finish rolling speed from 0.5 Vp to 1.5 Vp reduces the peak rolling force from 233,165 N to 183,665 N and significantly damps low-frequency load oscillations. However, it concurrently intensifies stress localization at the outer-surface tracking points P3/P4, which are in direct contact with the rolls, where the local equivalent stress approaches 523 MPa, even though the overall strain distribution along the bar length becomes more uniform. Overall, the optimal processing window is identified as a 12-pass schedule, a finish rolling temperature of 880–900 °C, and a rolling speed of 1.0–1.5 Vp, which can improve both rolling quality and temperature and stress and strain uniformity. Full article

The Finite Element Method is an indispensable tool for analyzing the transient thermal phenomena in welding processes. This study aims to simulate the temperature field during Gas Metal Arc Welding of an AISI 304L V-groove butt joint, employing a volumetric heat source model. The numerical simulations were conducted using ABAQUS SIMULIA^® (version 6.11-3) on a plate measuring 200 mm × 50 mm × 9.5 mm. For validation, the numerical results were compared against experimental data obtained at the Welding Engineering Research Laboratory of Federal University of Rio Grande. A parametric study was performed by varying the geometric parameter b (controlling the volumetric heat distribution depth) to enhance the model’s accuracy and achieve the closest approximation to experimental observations. The calibrated volumetric source demonstrated high accuracy, yielding low percentage differences between predicted and experimental peak temperatures: 1.02%, 2.50%, and 4.44% at the 4 mm, 8 mm, and 12 mm thermocouple positions, respectively. Full article

Produced well flow is controlled through valves placed in the Christmas tree. Being mostly gate-type valves, they isolate the well from the surface when commanded or automatically in an emergency. The reliability of these valves is essential for subsea wells, as maintenance and replacement involve high cost, time, and HSE risks. Their design must withstand harsh conditions such as high temperature, pressure, solid particles, and corrosive environments. However, failures caused by leakage, cold welding, and the erosion of sealing elements are still common. These issues motivated the initial stage of this research, which experimentally showed that replacing the current tungsten carbide (WC) coating with polycrystalline diamond compact (PDC) material reduces friction and wear due to its high hardness and thermal stability. Based on these results, a 3D subsea gate valve model was developed and simulated in Ansys Fluent 2024 R2 under API slurry test conditions using the Oka erosion and Discrete Phase Models. A comparative analysis of WC and PDC coatings for a 5-inch gate valve exposed to a 2% sand slurry (250–400 μm) showed that PDC reduces the erosion depth by 77.6% and extends the valve lifetime by 4.5 times. The findings support the use of PDC for improved erosion resistance in subsea valve applications. Full article

This study investigates the use of steel and cast iron for producing cast furnace rolls to replace welded rolls, which often fail from cracks and limited durability. Casting had not been previously considered by the manufacturer, but rising demands for durability and quality make it a promising alternative. Material selection focused on mechanical properties, wear resistance, and production costs. To ensure casting quality, Magmasoft 6.0 software was applied for detailed simulation of casting, solidification, and cooling. Results showed that steel alloys (GS-34CrMo4 and GS-20Mn5) are prone to shrinkage and porosity, which cannot be fully avoided even with feeders. In contrast, GJS-500-7 cast iron exhibited low shrinkage tendency and minimal defects, proving suitable for production while reducing costs. It also offers lower weight and efficient metal use, improving cost-effectiveness. Detected defects were concentrated in the central casting area, where they have little impact on functionality. Based on sixteen simulations, GJS-500-7 cast iron emerged as the most suitable material for furnace rolls thanks to its thermal resistance, castability, low porosity, and ability to meet required specifications. This process optimization represents an efficient, cost-effective choice, improving final product quality and creating new opportunities for the manufacturer. Full article

This work investigates the creep damage behavior and life prediction of Bi-based brazing alloys and their corresponding joints under intermittent over-temperature conditions, and proposes an integrated real-time monitoring and analytical framework. Temperature–time histories of structural components are acquired using both fixed and mobile infrared thermography systems to quantify thermal fluctuations. These data are subsequently coupled with a materials database and an enhanced Kachanov–Rabotnov creep damage constitutive model to simulate the evolution of thermally induced stresses and the accumulation of damage. Structural parameters, including weld seam thickness and porosity, are incorporated to perform sensitivity analyses. Experimental findings reveal a pronounced decline in the yield strength of the Bi-based brazing alloy with increasing temperature, identifying this degradation as the principal driver of creep failure. Fractographic observations show intergranular rupture characteristics during creep, in distinct contrast to the transgranular fracture mechanisms observed under tensile loading. Model predictions exhibit excellent concordance with experimental data and faithfully capture the life evolution across varying thermal–mechanical conditions. The results demonstrate that the proposed system enables real-time assessment of the health state, residual life, and failure risk of critical components. Moreover, it provides a robust theoretical foundation and practical guidance for operational safety management and maintenance decision-making in large enclosed containment structures, including those employed in nuclear power systems. Full article

Additive manufacturing technologies are no longer limited to rapid prototyping but are increasingly used for low-volume production of functional end-use components. Among advanced AM techniques, HP Multi-Jet Fusion (MJF) stands out for its high precision and efficiency. Polyamides, thanks to their balanced mechanical and thermal properties, are commonly used as building materials in this technology. However, these materials are notoriously difficult to bond with conventional adhesives. This study investigates the shear strength of bonded joints made from two frequently used MJF materials—PA12 and glass-bead-filled PA12—using four different industrial adhesives. Experimental procedures were conducted according to ASTM standards. Specimens for single-lap-shear tests were fabricated on an HP MJF 4200 series printer, bonded using a custom jig, and tested on a Zwick-Roell Z250 electro-mechanical testing machine. Surface roughness of the adherends was measured with a 3D optical microscope to assess its influence on bonding performance. The polyurethane-based adhesive (3M Scotch-Weld DP620NS) demonstrated superior performance with maximum shear strengths of 5.0 ± 0.35 MPa for PA12 and 4.4 ± 0.03 MPa for PA12GB, representing 30% and 17% higher strength, respectively, compared to epoxy-based alternatives. The hybrid cyanoacrylate–epoxy adhesive (Loctite HY4090) was the only system showing improved performance with glass-bead-reinforced substrate (16.5% increase from PA12 to PA12GB). Statistical analysis confirmed significant differences between adhesive types (F_3,24 = 31.37, p < 0.001), with adhesive selection accounting for 65.7% of total performance variance. In addition to the experimental work, a finite element-based numerical simulation was performed to analyze the distribution of shear and peel stresses across the adhesive layer using Siemens Simcenter 3D 2406 software with the NX Nastran solver. The numerical results were compared with analytical predictions from the Volkersen and Goland–Reissner models. Full article

Fingerplate expansion joints are commonly used in bridges to accommodate large movements in bridge decks, often due to thermal expansion or contraction. Although these joints are designed to last the bridge’s lifetime, they have experienced premature degradation under high-volume vehicular loads. Damage to these joints can compromise structural integrity and endanger public safety. To address this, a series of experimental fatigue tests were conducted to simulate cyclic vehicular loading, with the goal of identifying the controlling failure modes and refining design practices for fingerplate expansion joints. The study involved constructing fingerplate joint specimens based on standard Missouri Department of Transportation (MoDOT) designs, incorporating three design variables: fingerplate thickness, flange stiffeners, and concrete embedment. Additionally, two optimized designs were developed and tested under both fatigue and static loading conditions. Two distinct failure types were observed in the specimens. Specimens with flange stiffeners experienced fatigue failure, characterized by crack propagation through the back weld of the fingerplate to the supporting beam. In contrast, specimens without flange stiffeners failed due to serviceability issues, as they could not sustain the required load before reaching the maximum allowable deformation, leading to buckling of the supporting beam’s top flange. The optimized designs showed no fatigue degradation and exhibited increased ultimate strengths compared to the standard MoDOT designs. Overall, a thicker fingerplate improved the stiffness and fatigue performance of the expansion joint, while bolted connections effectively eliminated the crack propagation fatigue failure observed in many specimens and in the field. Full article

The bogie serves as a critical structural component in high-speed trains, subjected to dynamic loads throughout its operational lifecycle. Enhancing the fatigue life of the bogie necessitates not only ensuring welding quality but also effectively managing welding residual stresses during the manufacturing process. In this study, an efficient and simplified thermal–elastoplastic finite element method was developed based on the ABAQUS software platform, and its reliability and applicability were validated through comparison with measured data. The computational approach was employed to investigate the distribution characteristics of welding residual stresses in a weathering steel bogie beam, with particular emphasis on the influence of different welding sequences on residual stress distribution. Simulated results demonstrate that the welding sequence significantly influences the residual stress distribution and magnitude within the beam. The numerical simulation methodology developed in this study offers a powerful tool for optimizing welding sequences to regulate residual stresses during the fabrication of bogie structures. Full article

This study presents an integrated experimental and numerical investigation of the Refill Friction Stir Spot Welding (RFSSW) process applied to dissimilar aluminum alloys. The primary objective is to evaluate the mechanical and thermal behavior of the joints and to identify key process parameters influencing weld quality. Experimental welding trials were performed on aluminum alloy sheets using RFSSW, followed by shear testing and metallographic analysis to assess joint integrity, microstructure evolution, and fracture behavior. Infrared thermography and temperature sensors were employed to monitor heat distribution during welding. In parallel, a finite element model was developed to simulate the thermal cycle and stress distribution within the welded region. The numerical results showed good agreement with the experimental data, particularly regarding peak temperature and cooling trends at specific distances from the tool center. The findings demonstrate that RFSSW can successfully join dissimilar aluminum alloys with minimal defects when optimized parameters are applied. The combination of experimental observations and FEM simulation provides valuable insights into the underlying thermomechanical phenomena and offers a foundation for further process optimization. Full article

Molybdenum-rhenium (Mo-Re) alloys, especially those with low Re content, have great potential in fabricating nuclear components. However, the extremely high melting point and high brittleness of Mo-Re alloys make them difficult to weld. In this study, laser welding was used to prepare single-pass remelted joint of Mo-5Re alloy with welding parameters of laser power 2800 W, welding speed 2 m·min⁻¹ and argon gas flow rate 20 L·min⁻¹. The microstructure of the remelted joint was investigated by the optical microscopy and the scanning electron microscopy. The microhardness distribution of the joint was analyzed. In addition, the temperature field, residual stress, and angular distortion of the joint were investigated by both numerical and experimental methods. The results show that columnar grains grew from the fusion boundary toward the center of the weld pool, and equiaxed grains formed in the central region of the fusion zone (FZ). In the heat-affected zone (HAZ), the grains transformed from initial elongated into equiaxed grains. The electron backscatter diffraction (EBSD) results revealed that high-angle grain boundaries (HAGBs) dominated in FZ. Oxide/carbide particles at grain boundaries and inside the grains can be inferred from contrast results. The average microhardness of FZ was 170 ± 5 (standard deviation) HV, which was approximately 80 HV lower than that of the base metal (250 ± 2 HV). Softening phenomenon was also observed in HAZ. The calculated weld pool shape showed high consistency with the experimental observation. The peak temperature (296 °C) of the simulated thermal cycling curve was ~8% higher than the measured value (275 °C). The residual stress calculation results indicated that FZ and its vicinity exhibited high levels of longitudinal tensile residual stresses. The simulated peak longitudinal residual stress (509 MPa) was ~30% higher than the measured value (393 MPa). Furthermore, both the simulation and experimental results demonstrated that the single-pass remelted joint of Mo-5Re alloy produced only minor angular distortion. The obtained results are very useful in understanding the basic phenomena and problems in laser welding of Mo alloys with low Re content. Full article

Offshore platforms need to be made, from the start of their construction, to withstand the extreme environmental conditions they will be facing. This study investigates the welding-induced residual stress and distortion in a Y-shaped tubular joint extracted from an offshore wind turbine jacket substructure. While similar joints are commonly used in offshore platforms, their welding behavior remains underexplored in the existing literature. The joint configuration is representative of critical load-bearing connections commonly used in offshore platforms exposed to harsh marine environments. A finite element model has been developed to simulate the welding process in a typical offshore tubular joint through thermal and mechanical simulation. Validation of the model has been achieved with results against reference experimental data, with temperature and distortion errors of 3.9 and 5.3%, respectively. Residual stress and distortions were analyzed along predefined paths in vertical, transverse, and longitudinal directions. A mesh sensitivity study was conducted to balance computational efficiency and result accuracy. Furthermore, clamped and free displacement boundary conditions are analyzed, demonstrating reduced deformation and stress for the second case. Full article

The combined effect of sulfate-reducing bacteria (SRB) and a microstructure on the stress corrosion behavior of heat-affected zones (HAZs) in pipeline steel for shale gas field applications was investigated. The results show that when the peak heating temperature reached 1020 °C, a coarse microstructure formed during multiple thermal cycles (MTCs), and Widmanstätten structures appeared in the HAZ. In the simulated environment, SRB intensified localized pitting corrosion of both the base metal and the HAZ. The welding HAZ was softened by the MTCs, and significant microcrack growth was observed in the presence of SRB. Among all subzones, the coarse-grained HAZ (CGHAZ) was the most susceptible to stress corrosion cracking (SCC) under shale gas service conditions. Cracks initiated at the metal surface and propagated vertically into the material. SRB activity further increased the SCC sensitivity of the CGHAZ. Full article

Heat source parameters are critical input variables in welding thermal analysis, directly and significantly affecting the accuracy of the temperature field distribution, welding distortion, and residual stress prediction. This is particularly important in safety-critical welded structures, where high-precision heat source parameter identification is essential for ensuring the thermal simulation accuracy and mechanical performance reliability. Traditional parameter identification methods based on finite element simulations or experiments have limitations in adapting to complex working conditions and variable environments. To address this, this paper proposes the Heat Source Parameter Identification Network (HSPINet) model based on a residual convolutional neural network (ResNet) architecture with an attention mechanism capable of extracting key features from the weld morphology of T-joint structures, while accounting for the influence of process parameters and joint dimensions to achieve efficient and accurate identification of heat source parameters. This study not only enhances the intelligence level of heat source parameter identification but also provides a practical, intelligent tool for welding simulation and thermal field evaluation in complex industrial applications, demonstrating significant theoretical value and broad applicability in laser processing and manufacturing scenarios. Full article

Welding, as a critical process for achieving permanent material joining through localized heating or pressure, is extensively applied in mechanical manufacturing and transportation industries, significantly enhancing the assembly efficiency of complex structures. However, the associated localized high temperatures and rapid cooling often induce uneven thermal expansion and contraction, leading to complex stress evolution and residual stress distributions that compromise dimensional accuracy and structural integrity. In this study, we propose a combined heat source model based on the geometric characteristics of the weld pool to simulate the arc welding process of large flange shafts made of Fe-C-Mn-Cr low-alloy medium carbon steel. Simulations were performed under different welding durations and shaft diameters, and the model was validated through experimental welding tests. The results demonstrate that the proposed model accurately predicts weld pool geometry (depth error of only 2.2%) and temperature field evolution. Meanwhile, experimental and simulated deformations are presented with 95% confidence intervals (95% CI), showing good agreement. Residual stresses were primarily concentrated in the weld and heat-affected zones, exhibiting a typical “increase–steady peak–decrease” distribution along the welding direction. A welding duration of 90 s effectively reduced residual stress differentials perpendicular to the welding direction by 19%, making it more suitable for medium carbon steel components of this scale. The close agreement between simulation and experimental data verifies the model’s reliability and indicates its potential applicability to the welding simulation of other large-scale critical components, thereby providing theoretical support for process optimization. Full article