Structural Integrity Assessment Research Articles

Structural Integrity Evaluation Of 3D Printed Graphene-Reinforced Pla Notched Plates Using Failure Assessment Diagrams

Abstract Failure Assessment Diagrams (FADs) constitute a well-known structural integrity evaluation tool that allows structural components containing crack-like defects to be assessed through a simultaneous analysis of fracture and plastic-collapse processes. FADs are included in the most recognized structural integrity assessment procedures/standards, such as BS7910 and API 579/ASME FFS-1, and their use is generally limited to metallic components containing crack-like defects. On the other hand, structural responsibilities are being assumed by 3D printed composites, and particularly by those obtained through FFF (Fused Filament Fabrication), beyond their most extended use as prototyping materials. The resulting structural components may contain notch-type defects (e.g., grooves, corners, holes, etc.) that determine their corresponding structural integrity. Thus, it is necessary to define structural integrity assessment criteria for this kind of materials when containing any kind of stress risers, beyond crack-like defects. This work justifies the use of BS7910 Level 1 FAD, coupled with a notch correction derived from the Theory of Critical Distances (TCD), to analyze graphene-reinforced PLA plates subjected to pure tensile loading conditions and containing U- and V-notches. The results reveal that, for U- and V-notches, the assessment points representing the plates at failure are located within the FAD area corresponding to unsafe conditions, providing conservative evaluations with moderate safety margins. For plates containing circular holes, the proposed approach provides unsafe predictions.

Machine Vision AI in Railroad Safety: Advanced Inspection Techniques

This article explores the transformative impact of machine vision AI in railroad safety, focusing on advanced inspection techniques. It examines the integration of technologies such as line scan cameras, LiDAR, and IoT sensors in enabling comprehensive 360-degree inspections of railway infrastructure and rolling stock. The article discusses key innovations in continuous monitoring, data processing, and AI-driven analysis, highlighting their potential to significantly enhance defect detection accuracy, reduce maintenance costs, and prevent accidents. Real-world applications in structural integrity assessment and overhead line inspection are presented, along with an analysis of current challenges and future developments in the field. The article underscores the paradigm shift from reactive to proactive maintenance strategies, promising a safer and more efficient future for rail transport.

Application of ANN Concepts for Prediction of Crack Growth and Remaining Life of Circumferentially Cracked Piping Components under Different Loading Scenarios

This paper presents the details of Artificial Neural Network (ANN) based models to predict crack depth and remaining life of circumferentially part-through cracked piping components used in the nuclear industry. Crack growth data from experimental studies on (i) straight pipes made up of SA 312 Type 304LN stainless steel having part-through circumferential notch under combined bending and torsion and (ii) dissimilar metal pipe weld joints having circumferential through-wall crack in the weld were used. The dissimilar metal pipe weld joint is made up of SA312 Type 304LN austenitic stainless steel and SA508 Gr. 3 Cl. 1 low alloy carbon steel and joined by Nickel-rich Inconel alloy weld. About 75% of the mixed experimental data has been used for development of model and the remaining data for validation. For the development of ANN model, (i) back propagation technique (ii) sigmoidal transfer functions and (iii) Levenberg-Marquardt algorithm are used. The maximum percentage difference observed between the predicted and the experimental results for crack depth and remaining life was 19.59% and 15.78% respectively. The efficiency of the developed model was verified using several statistical parameters. The developed models are useful for the structural integrity assessment of piping components under different loading scenarios.

Evaluation of ultrasonic non-destructive inspection methods for structural integrity assessment of freight train axles

Evaluation of ultrasonic non-destructive inspection methods for structural integrity assessment of freight train axles

The Role of Welding in Fracture Mechanics Development

The role of welding in fracture mechanics development is considered from historical point of view. Starting point was analysis of Schenectady ship failure during the II World War, leading to development of linear elastic, as well as elastic-plastic fracture mechanics, soon afterwards. Two case studies are described to illustrate weldment fracture mechanics and structural integrity assessment.

Residual Fatigue Life Estimation of Damaged Welded Structures

This paper presents a finite element modeling procedure to determine of crack growth behaviour of butt welded joints under the subject of load for mode I. This paper presents a computation procedure to determine the ratio of fatigue crack growth in butt welded plates for mode I fracture mechanics loading conditions. The presence of residual stresses in welded structures can significantly affect the material’s resistance to fatigue under cyclic loading. The presence of tensile residual stresses adversely affects the fatigue crack growth rate increased it. Change of microstructure and hardening material as a result of the welding process also has a negative impact on the growth of the crack. Accurate prediction and reliable assessment of the residual stress are important for the structural integrity and residual life assessment of welded parts design. Although there are several techniques for the determination of residual stresses, the finite element method (FEM) is one of the most convenient and useful. This paper presents a finite element modeling procedure to determine of crack growth behaviour of butt welded joints under tensile load for mode I. Keywords: Welding, Residual stress, Residual life, Crack growth, FEM, Butt welded joint

Guidance for structural integrity assessment of smooth pipe elbows containing defects using R6

Recently, guidance for fracture assessment of defective elbows using the R6 failure assessment diagram (FAD) method has been included in R6 Revision 4 Amendment 13 (2023). This paper provides an overview of the new guidance and supporting validation. The guidance is validated using 75 cases of 3-D finite element (FE) elastic-plastic J results of smooth pipe elbows of various geometries with axial/circumferential internal/external semi-elliptical/extended/fully-circumferential surface cracks under internal pressure, in-plane/out-of-plane bending moment, torsion and various load combinations, by comparing the FE-based Option 3 failure assessment curves (FAC) with the R6 Option 2 FAC. The results show that, for 74 out of 75 cases, the FE-based Option 3 data points are above the R6 Option 2 FAC with reasonable conservatism when the guidance for evaluating the elbow stress intensity factor and limit load is followed. In other words, following the new guidance can lead to reasonably conservative assessment results.

New insights into physical origins of dynamic strain aging in Ti-2Al-2.5Zr alloy and influence on LCF and HCF behaviors

The multi-step strain aging tests were meticulously designed in this work to reveal the physical mechanisms of static strain aging (SSA) and dynamic strain aging (DSA) behaviors in Ti-2Al-2.5Zr alloy for the first time. It was revealed that the shuffling mechanism of interstitial oxygen atoms combined with the pinning effect of locally-generated cross-slip on the movement of screw dislocations were responsible for the occurrence of strain aging. Furthermore, the effects of DSA on the low-cycle fatigue (LCF) and high-cycle fatigue (HCF) properties were elucidated in Ti-2Al-2.5Zr alloy. Results showed that the sensitivity of DSA to cyclic loading was attributed to the generation of numerous residual edge dislocation segments through local cross-slip, facilitating the formation of dislocation veins which inhibited the formation of persistent slip bands (PSBs) and led to the significantly cyclic hardening. Finally, it was emphasized that the phenomenon of DSA should be carefully considered for the structural integrity assessment of Ti-2Al-2.5Zr alloy and several suggestions were provided.

Structural integrity assessment of pipe elbows: Burst test and finite element analysis

In this study, the failure pressures of pipe elbows were compared with those predicted using Level 3 numerical assessment method (Finite Element Method). Four 90-degree pipes elbows representing a pristine pipe, a pipe with a single corrosion defect, a pipe with longitudinally aligned interacting defects, and a pipe with a circumferentially aligned interacting defects, were subjected to internal pressure based on the ASME B31.3–2012 Burst Test standard until failure. The Sch-80 pipes were made of ASTM A234 WPB steel with a wall thickness and bending radius of 12.7 mm and 305 mm respectively. The corrosion defects were simulated on the exterior surface of the pipe elbows using computer numerical control (CNC) machine to generate a machined version of the corrosion defect. The results revealed that corrosion defects significantly reduce the burst pressure of pipe elbows, with longitudinally aligned interacting defects causing the largest reduction of 20.9 % compared to pristine pipe. The comparison between the Level 3 numerical assessment method and burst test showed close agreement with a maximum difference of 4.79 %, confirming the accuracy and reliability of the numerical method.

Advancement of bridge health monitoring using magnetostrictive sensor with machine learning techniques

ABSTRACT With the increasing demand for sustainable infrastructure maintenance, it has become very important to predict the health condition of the structures in real-time. This study investigates the application of machine learning techniques for assessing the structural health of prototype beam bridges. By employing magnetostrictive sensors, which convert mechanical vibrations into electrical energy, the research aims to perform frequency analysis to predict dominant frequencies in a prototype beam bridge. Data were collected using a Digital Storage Oscilloscope and a Data Acquisition Card, followed by comprehensive feature extraction and dimensionality reduction. Machine learning models, including Random Forest and Deep Neural Networks, were utilised to classify waveform types and predict vibration frequencies. The Random Forest model achieved a classification accuracy of 86.16% and a mean absolute percentage error of 4.33% in frequency prediction, highlighting its superior accuracy and reliability for continuous bridge health monitoring. These results demonstrate the potential to revolutionise modern infrastructure maintenance practices by enabling real-time, automated assessments of structural integrity.

Artificial neural network-enhanced mathematical simulation based on Carrera unified formulation for dynamic analysis and structural integrity assessment of advanced nanocomposites reinforced tunnel structures

This article presents the application of the Carrera Unified Formulation (CUF) for dynamic analysis and structural integrity assessment of advanced nanocomposite-reinforced tunnel structures. CUF offers a generalized framework that simplifies the modeling of complex structures, providing an efficient approach to address the dynamic behavior of nanocomposites. Advanced nanocomposites, which enhance mechanical performance and durability, are increasingly used in critical infrastructure such as tunnel systems. Traditional methods often fall short in capturing the intricate interactions within these materials, particularly under dynamic loads. CUF overcomes these challenges by incorporating higher-order theories and multi-scale analysis, allowing for accurate prediction of displacements, stresses, and potential failure modes. To further validate the results, an Artificial Neural Network (ANN) model is trained using simulated data, ensuring robust predictions for various loading conditions. The ANN assists in approximating the dynamic response and integrity of the structure, enabling real-time assessments with minimal computational expense. The combined CUF-ANN approach demonstrates high accuracy and efficiency, making it a reliable tool for the structural integrity assessment of nanocomposite-reinforced tunnels. This study highlights the significant potential of integrating CUF and ANN for the analysis and design of advanced engineering structures subjected to dynamic environmental conditions.

Fracture studies on cruciform bend specimens of pressure vessel steel subjected to thermo-mechanical loading

The safety of a nuclear power plant during incidents, such as a Loss of Coolant Accident (LOCA), heavily relies on conducting a comprehensive structural integrity assessment of both the Reactor Pressure Vessel (RPV) and its components, specifically to withstand Pressurized Thermal Shock (PTS). PTS is characterized by a combination of steep temperature gradient, resulting from the injected emergency coolant during a LOCA, and internal pressure within the RPV. Majority of the reported fracture assessment studies on RPV steel, whether experimental or numerical investigations, have predominantly focused on standard uniaxial specimens at iso-thermal loading conditions. To better simulate the thermal shock scenario in RPVs, the present work aims to assess the impact of a biaxial stress field on both fracture parameters (crack mouth opening displacement and J-integral) and plastic collapse load. This assessment is conducted through experimental and numerical investigations, both with and without prior transient thermal load. Fracture experiments are performed on cruciform bend specimens, featuring two different biaxiality ratios (1:1 and 2:1). Moreover, numerical studies on cruciform specimens are conducted using finite element analysis to validate and corroborate the observations derived from the fracture experiments.

New insights into fracture and cracking simulation of quasi-brittle materials based on the NMMD model

The simulation of crack-induced failure is of vital importance for the safety and integrity assessment of solids and structures but still challenging. Being the foremost approach, fracture mechanics is plagued by the logical inconsistency in dealing with crack and non-cracked region, and to make matters worse, it has been contradicted by the ongoing experiments that the fracture energy is not a material constant irrelevant to geometry even for the unsophisticated situations. In this paper, based on the recently proposed nonlocal macro-meso-scale consistent damage (NMMD) model, it is demonstrated that the logical consistency of governing equations either on crack-tip or off crack-tip plays a crucial role in the complete solution of cracking problems. To this end, the central themes of fracture mechanics, including the definition of an idealized crack, the separated equilibrium laws and the cracking criteria attached to crack-tip, are firstly revisited. Then, after a concise description of NMMD model with emphasis on the geometrical transmission form micro- to macro-scale and the physical–mechanical translation from geometry to energy, it is theoretically proved that the geometry-based damage zone reproduces idealized crack as a limit when the nonlocal characteristic length, i.e., the influence radius in NMMD model, tends to zero. As a result, the separated equilibrium laws of fracture mechanics can be covered by NMMD model with a unified set of governing equations that does not distinguish between points at crack surface and at non-cracked region. This advantage permits NMMD model to be well-suited to analyze both crack-induced failure problems with and without pre-existing cracks in the absence of additional cracking criteria. In contrast, owing to its macro-meso-scale consistent feature, a new criterion for kinking angle of crack, the maximum stress intensity factor (SIF) of mode-I, can be derived from NMMD model. Some representative numerical examples are also presented to further confirm the above intrinsic link to fracture mechanics. In particular, the superiority of the NMMD model is demonstrated by capturing not only the non-constant fracture parameters (especially the fracture energy) but also the cracking initiation not from the pre-existing crack-tips, which are revealed by experimental results but contradict fracture mechanics. These investigations imply that the NMMD model could provide a potential avenue to understand when and how cracks nucleate and propagate based on a two-scale perspective.

A phase field finite element study and evaluation of sulfide stress cracking in DCB specimen testing

The challenges presented by sour environments rich in hydrogen sulfide (H2S) underscore the necessity for a comprehensive understanding of material behavior under such conditions. The cracking susceptibility of metals and alloys used for subsurface equipment in downhole oil and gas exploration operations is particularly concerning. The NACE Double Cantilever Beam (DCB) test has emerged as a widely used quality assurance tool in the petroleum industry, leveraging fracture mechanics principles to assess the environment-assisted cracking (EAC) resistance of metals and alloys. The DCB test evaluates the fracture toughness KISSC of materials in H2S-containing environments via assessment of the crack arrest, which serves as a vital parameter in structural integrity assessments to mitigate the risk of service-related failures from sulfide stress cracking (SSC). However, various studies suggest that different test parameters, such as arm displacement and initial notch, significantly influence KISSC. This work presents a detailed numerical investigation on a comprehensive simulation of the DCB test, examining the effects of different test parameters on KISSC prediction. A coupled deformation-diffusion phase field framework is adopted to simulate SSC in DCB specimens arising from a complex interplay between material deformation, hydrogen diffusion, and fracture. The numerical results show good agreement with experimental results reported in the literature and provide deeper insights into the factors affecting crack growth and arrest in DCB testing.

Conceptual design study of the tritium breeding unit for verifying the long-term performance of the breeding blanket

Fusion reactors produce high-energy neutrons through the Deuterium-Tritium (DT) reaction. The long-term performance verification and structural integrity assessment of the breeding blanket under continuous plasma operation are essential for the development of Demonstration fusion power reactor (DEMO) breeding blankets. The Korea Institute of Fusion Energy (KFE) has been planning the construction of a test facility called the Integrated Breeding Test Facility (IBTF) that uses a linear accelerator as the neutron source. A solid beryllium target has been considered to generate fusion-like neutrons. A conceptual design of the Tritium Breeding Unit (TBU), which is a key component of the breeding blanket, has been carried out. This study evaluated tritium production under fusion-like conditions using factors such as the position and thickness of the graphite block, the thickness of the first wall, and the radial length of the breeding zone. The results showed that increasing graphite block thickness and optimizing the dimensions of the TBU enhanced tritium production. However, these changes affected the structural integrity of the TBU. The side wall of the TBU experienced membrane plus bending stress, which exceeded the Level C and D acceptance criteria under the assumption of In-Box LOCA. Measures were investigated to ensure structural integrity while improving tritium production of the TBU.

Time-convolutional network with joint time-frequency domain loss based on arithmetic optimization algorithm for dynamic response reconstruction

Structural Health Monitoring (SHM) systems provide extensive data on in-service bridges, which is crucial for evaluating structural performance. However, data loss frequently occurs due to environmental factors and technical failures. Although missing data reconstruction problem has been largely studied, the accuracy of response reconstruction in the frequency domain is often overlooked. To address this issue, this study proposes to integrate a time-frequency joint loss function within an Arithmetic Optimization Algorithm-Temporal Convolutional Network (AOA-TCN), which leverages temporal and spatial dependencies among measurement points to reconstruct missing dynamic deflection data. The time-frequency joint loss function is enhanced with linear decay weights to increase sensitivity to low-order modal contributions, with an adaptive weighting mechanism balancing loss contributions from time and frequency domains. These adaptive weight parameters are optimized through AOA to enhance the TCN's generalizability. The feasibility and effectiveness of the proposed method are first demonstrated using simulated dynamic deflection data of a finite element model of a continuous beam bridge, and then experimentally verified on a real-world simply-supported beam bridge. The results indicate that the proposed method achieves higher data reconstruction accuracy and more precise modal analysis results compared to existing methods. The Modal Assurance Criterion (MAC) between mode shapes identified using measured data and reconstructed response reached 96.9 %, proving that the proposed method is capable of reconstructing the missing structural response while retaining its frequency-domain information, which is valuable for structural integrity assessment based on modal parameter identification of operational bridges.

Specifics of Experimental and Fem Approaches in Structural Integrity Assesment of Penstock Made of HSLA Steel

Taking into account the history of problems concerning high-strength low-alloyed (HSLA) steel used for manufacturing of penstocks (partly presented by authors in previous studies), this paper is oriented toward specifics on structural integrity assessment of construction in question. Experimental testing of parent material, i.e. HSLA steel, such as microstructure analysis, impact toughness testing and hardness measuring provide insight into characteristics of parent material properties. Considering geometry of penstock and specific requirements, finite element method (FEM), i.e. ABAQUS, was used to assess the structural integrity of penstock as a whole, specific the longitudinal welded joint under the different internal (working) pressure. It should be emphasized that a slight undermatching effect was investigated by FEM approach in this case. Focus is being put on plastic deformation investigation on aforementioned welded joint under maximum internal pressure of 120 bar.

Exploring the influence of specimen types on the intralaminar fracture behavior of fiber-reinforced polymer matrix composites

The accurate determination of fracture toughness of fiber-reinforced composites is critical for the assessment of structural integrity. Although there have been many studies on the intralaminar fracture behavior of composites, satisfactory results have not yet been obtained regarding the influence of specimen types. In this paper, commonly used fracture specimens (DCT, CT, ESET, pin-loaded SENT and clamped SENT specimen) are applied to study their applicability in the fracture behaviors of composites with different orientations. And the impact of data processing methods for the area method, GC-compliance and GC-stress intensity factors on fracture performance was analyzed. The results showed that the above three data processing methods have obtained relatively consistent fracture properties. Different specimens obtained significantly various results, showing a gradually decreasing trend from clamped SENT, ESET, pin-loaded SENT, CT to DCT. Furthermore, considering that the clamped SENT specimen is closest to the Mode-I fracture toughness obtained from the DCB specimen, and there is no compression damage in the experiments under different orientations, this specimen type is the most recommended specimen. Finally, the failure mechanisms of carbon fiber-reinforced composite under different specimen types and orientations were revealed. As the orientation angle increases (β from 0° to 90°), the failure mode gradually transitions from matrix cracking and interface debonding to matrix shear and fiber fracture. The above achievements will contribute to a deeper understanding of the intralaminar fracture process and failure mechanism of fiber-reinforced composites.

Plastic Limit Pressure and Stress Intensity Factor for Cracked Elbow Containing Axial Semi-Elliptical Part-Through Crack

The aim of this study is to provide a solution for the plastic limit pressure and stress intensity factor of the elbows containing a part-through axial semi-elliptical crack by considering various crack sizes. The supporting system and loading conditions of the pipeline are described. The critical part of the observed pipeline was isolated for analysis and subjected to various sizes of semi-elliptical cracks. By performing numerical analysis, results were obtained for crack dimension ratios of c/a, and depth/thickness ratios of a/t. The obtained results include plastic limit pressure and stress intensity factor. The results were analyzed with a symbolic regression algorithm, and closed-form solutions for the limit pressure and stress intensity factor were proposed. To validate pipeline integrity, the Structural Integrity Assessment Procedure (SINTAP) was applied, and the FAD (Failure Assessment Diagram) was generated for cracks below the FAD function. The failure pressure was calculated by determining the points where the loading paths intersect the FAD function.

Efficient BFGS quasi-Newton method for large deformation phase-field modeling of fracture in hyperelastic materials

The prediction of crack propagation in materials is a crucial problem in solid mechanics, with many practical applications ranging from structural integrity assessment to the design of advanced materials. The phase-field method has emerged as a powerful tool for modeling crack propagation in materials, due to its ability to accurately capture the propagation of cracks. However, current phase-field algorithms suffer from the elevated computational cost associated with the so-called staggered solution scheme, which requires extremely small time increments to advance the crack due to its inherent conditional stability. In this paper, we present, for the first time, a quantitative analysis detailing the numerical implementation and comparison of two common solution strategies for the coupled large-deformation solid-mechanics-phase-field problem, namely the quasi-Newton based Broyden–Fletcher–Goldfarb–Shanno algorithm (BFGS) and the full Newton based alternating minimization (or staggered) (AM/staggered) algorithm. We demonstrate that the BFGS algorithm is a more efficient and advantageous alternative to the traditional AM/staggered approach for solving coupled large-deformation solid-mechanics-phase-field problems. Our results highlight the potential of the quasi-Newton BFGS algorithm to significantly reduce the computational cost of predicting crack propagation in hyperelastic materials while maintaining the accuracy and robustness of the phase-field method.