Search Results (1,478)

The experimental tests needed for the estimation of the fatigue limit generally require extensive time and many specimens. A valid but not standardized alternative is the thermographic analysis of the self-heating phenomenon. The present work is aimed at using Infrared thermography to determine the fatigue limit in two kinds of Ti-6Al-4V samples obtained by hot rolling: (1) with the standard dog-bone shape (unnotched specimen) and (2) with two opposed semicircular notches at the sides (notched specimen). Uniaxial tensile experiments are performed on unnotched samples, and the surface temperature variation during loading is monitored. The stress corresponding to the end of the thermoelastic stage gives a rough indication of the fatigue limit. Then, fatigue tests at different sinusoidal loads are performed, and the thermographic signal is monitored and processed. The results obtained using lock-in thermography in dissipative mode, e.g., analyzing the second harmonic, showed a sudden change in slope when the applied stress exceeded a certain limit. This slope change is related to the fatigue limit. In addition, the ratio between the fatigue limits obtained for notched and unnotched specimens, e.g., the fatigue strength reduction factor, is consistent with literature values based on the selected geometry. Full article

Sustainable deepwater drilling for oil and gas offers significant potential. In this work, we synthesized a nanoscale collapse-prevention agent by grafting didecyldimethylammonium chloride onto spherical nano-silica and characterized it using Fourier-transform infrared spectroscopy, thermogravimetric analysis, zeta-potential, and particle-size measurements, as well as SEM and TEM. Adding 1 wt% of this agent to a bentonite slurry only marginally alters its rheology and maintains acceptable low-temperature flow properties. Microporous-membrane tests show filtrate passing through 200 nm pores drops to 55 mL, demonstrating excellent plugging. Core-immersion studies reveal that shale cores retain integrity with minimal spalling after prolonged exposure. Rolling recovery assays increase shale-cutting recovery to 68%. Wettability tests indicate the water contact angle rises from 17.1° to 90.1°, and capillary rise height falls by roughly 50%, reversing suction to repulsion. Together, these findings support a synergistic plugging–adsorption–hydrophobization mechanism that significantly enhances wellbore stability without compromising low-temperature rheology. This work may guide the design of high-performance collapse-prevention additives for safe, efficient deepwater drilling. Full article

In the industrial practice of metal forming, the consistent and reasonable characterization of the material behavior under the coupling effect of strain, strain rate, and temperature on the material flow stress is very important for the design and optimization of process parameters. The purpose of this work was to establish an appropriate constitutive model to characterize the rheological behavior of a hot-formed steel plate (22MnB5 steel) produced through the TSCR (Thin Slab Casting and Rolling) process under practical deformation temperatures (150–250 °C) and strain rates (0.001–3000 s⁻¹). Subsequently, the material flow behavior was modeled and predicted using the Johnson–Cook flow stress constitutive model. In this study, uniaxial tensile tests were conducted on 22MnB5 steel at room temperature under varying strain rates, along with elevated-temperature tensile tests at different strain rates, to obtain the engineering stress–strain curves and analyze the mechanical properties under various conditions. The results show that during room-temperature tensile testing within the strain rate range of 10⁻³ to 300 s⁻¹, the 22MnB5 steel exhibited overall yield strength and tensile strength of approximately 1500 MPa, and uniform elongation and fracture elongation of about 7% and 12%, respectively. When the strain rate reached 1000–3000 s⁻¹, the yield strength and tensile strength were approximately 2000 MPa, while the uniform elongation and fracture elongation were about 6% and 10%, respectively. Based on the experimental results, a modified Johnson–Cook constitutive model was developed and calibrated. Compared with the original model, the modified Johnson–Cook model exhibited a higher coefficient of determination (R²), indicating improved fitting accuracy. In addition, to predict the material’s damage behavior, three distinct specimen geometries were designed for quasi-static strain rate uniaxial tensile testing at ambient temperature. The Johnson–Cook failure criterion was implemented, with its constitutive parameters calibrated through integrated finite element analysis to establish the damage model. The determined damage parameters from this investigation can be effectively implemented in metal forming simulations, providing valuable predictive capabilities regarding workpiece material performance. Full article

The presented research is focused on the development of the bus rapid transit (BRT) system, combining the high capacity of rail transport with the flexibility of bus routes. Classic BRT systems have certain limitations, particularly concerning a single rolling stock capacity. The main motivation of the work is to find efficient and cost-effective solutions to increase passenger traffic in the BRT system while optimizing fuel consumption. The main contribution of this study is the comprehensive analysis and optimization of various configurations of trailer bus trains, which represent a flexible and cost-effective alternative to traditional single or articulated buses. Based on two schemes, four possible options for using trailer bus trains are offered, which differ in the number of sections and working engines. Among the suggested schemes of trailer bus trains, the two-section and three-section schemes with all engines running and the three-section scheme with one engine turned off are appropriate for use due to improved fuel efficiency indicators with better or acceptable traction and speed properties. Calculations carried out on a mathematical model show that, for example, a two-section bus train can provide a reduction of specific fuel consumption per passenger by 6.3% compared to a single bus at full load, while a three-section train can provide even greater savings of up to 8.4%. Selective shutdown of one of the engines in a multi-section train can lead to an additional improvement in fuel efficiency by 5–10%, without leading to a critical reduction in the required traction characteristics. Full article

The surface topography of the rolls used in skin-pass cold rolling determines the surface finish of rolled sheets. In this sense, work rolls can be intentionally textured to produce certain topographical features on the final sheet surface. The maskless electrochemical texturing method (MECT) is a potential candidate for industrial-scale application due to its reduced texturing cost and time when compared to traditional texturing methods. However, there are few studies in the literature that address the MECT method applied to the topography control of cold rolling work rolls. The present work aims to analyze the viability of surface texturing via MECT of work rolls used in skin-pass cold rolling. In this study, we first investigated how texturing occurs for tool steel using flat textured samples to facilitate the understanding of the dissolution mechanisms involved. In this case, a specially designed texturing chamber was built to texture flat samples extracted from an actual work roll. The results indicated that the anodic dissolution involved in tool steel texturing occurs preferentially in the metallic matrix around the primary carbides. Then, we textured a work roll used in pilot-scale rolling tests, which required the development of a special prototype to texture cylindrical surfaces. After texturing, the texture transfer from the work roll to the sheets was investigated. Rolling tests showed that the work roll surface textured with a dimple pattern generated a pillar-shaped texture pattern on the sheet surface, possibly due to a reverse extrusion mechanism. Full article

Time series prediction of aerodynamic noise is critical for oscillatory instabilities analyses in fluid systems. Due to the significant dynamical and non-stationary characteristics of aerodynamic noise, it is challenging to precisely predict its temporal behavior. Here, we propose a method combining variational mode decomposition (VMD) and echo state network (ESN) to accurately predict the time series of aerodynamic noise induced by flow around a cylinder. VMD adaptively decomposes the noise signal into multiple modes through a constrained variational optimization framework, effectively separating distinct frequency-scale features between vortex shedding and turbulent fluctuations. ESN then employs a randomly initialized reservoir to map each mode into a high-dimensional dynamical system, and learns their temporal evolution by leveraging the reservoir’s memory of past states to predict their future values. Aerodynamic noise data from cylinder flow at a Reynolds number of 90,000 is generated by numerical simulation and used for model validation. With a rolling prediction strategy, this VMD-ESN method achieves accurate prediction within 150 time steps with a root-mean-square-error of only 3.32 Pa, substantially reducing computational costs compared to conventional approaches. This work enables effective aerodynamic noise prediction and is valuable in fluid dynamics, aeroacoustics, and related areas. Full article

Thermomechanical processing has a significant impact on the porosity and mechanical properties of AISI 316L stainless steel produced by laser powder bed fusion (L-PBF). This work evaluated the effect of three heat treatment conditions: as-built (HT0), annealed at 650 °C for 3 h with air cooling (HT1), and annealed at 1050 °C for 1 h followed by water quenching (HT2), combined with cold and hot rolling at different strain levels. The most pronounced improvement was observed after 20% hot rolling followed by water quenching (HR + WQ), which reduced porosity to 0.05% and yielded the most spherical pores, with a circularity factor ($f_{circle}$) of 0.90 and an aspect ratio (AsR) of 1.57. At elevated temperatures, the matrix becomes more pliable, which promotes pore closure and helps reduce stress concentrations. On the other hand, applying heat treatment without causing deformation resulted in the pores growing and increasing porosity in the build direction. The fractography supported these findings, showing a transition from brittle to more ductile fracture surfaces. Heat treatment combined with plastic deformation effectively reduced internal defects and improved both structural integrity and strength. Full article

To address the challenges of extracting rolling bearing degradation information and the insufficient performance of conventional convolutional networks, this paper proposes a rolling bearing degradation state identification method based on the improved monopulse feature extraction and a one-dimensional dilated residual convolutional neural network (1D-DRCNN). First, the fault pulse envelope waveform features are extracted through phase scanning and synchronous averaging, and a two-stage grid search strategy is employed to achieve FCC calibration. Subsequently, a 1D-DRCNN model is constructed to identify rolling bearing degradation states under different working conditions. The experimental study collects the vibration signals of nine degradation states, including the different sizes of inner and outer ring local faults as well as normal conditions, to comparatively analyze the proposed method’s rapid calibration capability and feature extraction quality. Furthermore, t-SNE visualization is utilized to analyze the network response to bearing degradation features. Finally, the degradation state identification performance across different network architectures is compared in pattern recognition experiments. The results show that the proposed improved feature extraction method significantly reduces the iterative calibration computational burden while effectively extracting local fault degradation information and overcoming complex working condition influence. The established 1D-DRCNN model integrates the advantages of dilated convolution and residual connections and can deeply mine sensitive features and accurately identify different bearing degradation states. The overall recognition accuracy can reach 97.33%. Full article

This paper addresses the problem of controlling quadcopters operating in an environment characterized by unpredictable disturbances such as wind gusts. From a control point of view, this is a nonstandard, highly challenging problem. Fundamentally, these quadcopters are high-order dynamical systems characterized by an under-actuated and highly nonlinear model with coupling between several state variables. The main objective of this work is to achieve a trajectory by tracking desired altitude and attitude. The problem was tackled using a robust control approach with a multi-loop nonlinear controller combined with extended Kalman filtering (EKF). Specifically, the flight control system consists of two regulation loops. The first one is an outer loop based on the backstepping approach and allows for control of the elevation as well as the yaw of the quadcopter, while the second one is the inner loop, which allows the maintenance of the desired attitude by adjusting the roll and pitch, whose references are generated by the outer loop through a standard PID, to limit the 2D trajectory to a desired set path. The investigation integrates EKF technique for sensor signal processing to increase measurements accuracy, hence improving robustness of the flight. The proposed control system was formally developed and experimentally validated through indoor tests using the well-known Parrot Mambo unmanned aerial vehicle (UAV). The obtained results show that the proposed flight control system is efficient and robust, making it suitable for advanced UAV navigation in dynamic scenarios with disturbances. Full article

In this work, we report the identification of a novel quaternary intermetallic phase (Al₂₁GdCrTi) formed during the solidification of a novel Al-Gd-Cr-Ti alloy, which has not been previously documented in the literature to the best of our knowledge. The study also provides a detailed analysis of microstructure evolution, texture behavior, and the mechanical strengthening effect of rolling processes, along with neutron absorption performance. XRD analysis reveals that the intensity of (022), (113) planes of the as-hot-cold-rolled sample is higher than that of the as-cast due to the change in the direction of some grains in these planes during rolling. The results indicate that the studied alloys scatter neutrons about 100 times less than a nearly pure aluminum alloy. The hardness of the as-cast alloy increased from 36 to 53 HV after cold rolling and to 50 HV after hot rolling-cold rolling. Hot-cold-rolled alloy has a yield strength of 160 MPa and an ultimate tensile strength of 181 MPa, while maintaining an elongation of 11.3%. The studied alloys, containing 4.2 wt.% of the alloying elements 3.8Gd, 0.2Cr, and 0.2Ti (Al-3.8Gd-0.2Cr-0.2Ti), exhibited a yield strength 28 MPa higher than those containing 21 wt.% of the alloying elements 5Cu, 6Gd, and 8Bi (Al-5Cu-6Gd-8Bi). The studied alloys form the basis for the development of high-technology Al-Gd alloys for neutron shielding. Full article

This study addresses the urgent demand for high-precision manufacturing of curved components by developing a fully servo-driven multi-axis controlled four-roll bending machine. By integrating a modular symmetric roller system design with a distributed hierarchical motion control architecture, we achieved substantial enhancements in scalability, forming stability, and machining accuracy. The mechanical system underwent static simulation optimization using SolidWorks Simulation, ensuring maximum stress in the guiding mechanism was controlled below $7.118\times {10}^3$ N/m². ABAQUS-based roll-bending dynamic simulations validated the geometric adaptability and process feasibility of the proposed mechanical configuration. A master-slave dual-core control architecture was implemented in the control system, enabling synchronized error ≤ 0.05 mm, dynamic response time ≤ 10 ms, and positioning accuracy of ±0.01 mm through collaborative control of the master controller and servo drives. Experimental validation demonstrated that the machine achieves bending errors within 1%, with an average forming error of 0.798% across various radii profiles. The arc integrity significantly outperforms conventional equipment, while residual straight edge length was reduced by 86.67%. By adopting fully servo-electric cylinder actuation and integrating a C#-developed human–machine interface with real-time feedback control, this research effectively enhances roll-bending precision, minimizes residual straight edges, and exhibits broad industrial applicability. Full article

In response to the challenges posed by complex and variable operating conditions of rolling bearings and the limited availability of labeled data, both of which hinder the effective extraction of key fault features and reduce diagnostic accuracy, this study introduces a model that combines a spatial attention (SA) mechanism with a multi-scale depthwise separable convolution module. The proposed approach first employs the Gramian angular difference field (GADF) to convert raw signals. This conversion maps the temporal characteristics of the signal into an image format that intrinsically preserves both temporal dynamics and phase relationships. Subsequently, the model architecture incorporates a spatial attention mechanism and a multi-scale depthwise separable convolutional module. Guided by the attention mechanism to concentrate on discriminative feature regions and to suppress noise, the convolutional component efficiently extracts hierarchical features in parallel through the multi-scale receptive fields. Furthermore, the trained model serves as a pre-trained network and is transferred to novel variable-condition environments to enhance diagnostic accuracy in few-shot scenarios. The effectiveness of the proposed model was evaluated using bearing datasets and field-collected industrial data. Experimental results confirm that the proposed model offers outstanding fault recognition performance and generalization capability across diverse working conditions, small-sample scenarios, and real industrial environments. Full article

To address the energy supply demands of the distributed marine monitoring nodes, developing marine sustainable energy sources has become imperative. This study develops a rolling-mode direct wave energy converter, with a series of dynamic simulations and forced motion experiments. Analysis with WAMIT V5.4 software achieved the typical pitch motion of the device, while ADAMS View 2020 software simulated the working process of the rolling-mode power take off. Forced motion experiments were conducted on a three-degree-of-freedom forced motion platform. The coil parameters were selected based on the open circuit voltage from the benchmark tests. Under an 18° pitch angle and a 0.6 Hz frequency, a single power take off unit could yield a peak short-circuit current of 31.22 mA and an average power density of 31.82 W/m³. Charging experiments demonstrated that two power take off units could charge the 0.1 F capacitor to 3.5 V within 5.5 min to power marine sensors. Compared to previous designs, the straight-track, rolling-mode power take off is advantageous in its startup easiness, simple structure and robustness. Full article

The winch traction system for shipboard aircraft, when operating in a marine environment, is subjected to additional forces and moments due to the complex motion of the hull. These loads pose significant threats to the safety of the aircraft during the traction process. To address the safety issues under complex sea conditions, this paper adopts harmonic functions to describe the rolling, pitching, and heaving motions of the hull. A theoretical analytical model of the three-winch traction system, considering the intricate coupling motions of the ship, is established. Unlike previous studies that often simplify ship motion or focus on single-component modeling, this work develops a complete, whole-system dynamic model integrating the winch system, rope, aircraft structure, and ship interaction. The dynamic characteristics of the small-deck winch traction system are investigated, with particular focus on the influence of the rear winch position, driving trajectory, and ship motion on the system’s dynamics and safety. This research is innovative in systematically exploring the dynamic safety behavior of a three-winch traction system operating under small-deck conditions and complex sea states. The results show that as the distance between the two rear winches increases, the lateral force on the tire decreases. Additionally, as the aircraft’s turning angle increases, the front winch rope force also increases. Moreover, with higher sea condition levels and wind scales, the maximum lateral force on the tires increases, leading to a significant reduction in the stability and safety of the winch traction system. This is particularly critical when the sea condition level exceeds 3 and the wind scale exceeds 6, as it increases the risk of tire sideslip or off-ground events. This research has substantial value for enhancing the safety and stability of winch traction systems on small decks, and also provides a theoretical basis for traction path design, winch position optimization, and the extension of the service life of key system components, demonstrating strong engineering applicability. Full article

The effect of the temperature and strain rate during the hot rolling process on the microstructural evolution in fine-grained Ni₃Al intermetallic alloy doped with Zr and B was examined in this work. The hot rolling process was carried out at an initial temperature range of 1000, 1100, and 1280 °C and at a strain rate between 3.9 × 10⁻¹ s⁻¹ and 2.5 s⁻¹. The results of the EBSD microstructural analyses revealed that dynamic recrystallization phenomena are initiated at the rolling temperature of 1100 °C, while a fraction of the dynamically recrystallized grains further increases with both the rising temperature and strain rate of the deformation process. Furthermore, to estimate the heat losses during the hot rolling processing, a non-stationary heat transfer model was formulated and then used to evaluate the experimentally received data. Full article