High-strength Wire Research Articles

Numerical Analysis and Theoretical Study on the Interfacial Bonding Behavior of High-Strength Steel Stainless Wire Mesh-Reinforced ECC and Concrete

In order to investigate the interfacial bonding properties of high-strength steel stainless wire mesh-reinforced ECC (HSSWM-ECC) and concrete, a finite element model was established for two types of interfaces based on experimental research. The results show that the failure modes observed in the 21 groups of simulations can be classified into three categories: debonding failure, ECC extrusion failure and concrete splitting failure. The failure mode was mainly affected by the type of interface. The effective anchorage length is inversely proportional to the strength of the concrete and proportional to the stiffness and thickness of the HSSWM-ECC. The capacity of the roughening interface is positively correlated with the concrete strength and bonding length, but negatively correlated with the interfacial width ratio. Increasing both the number and width of grooves within the effective range enhances the interfacial capacity, whereas higher concrete strengths tend to reduce it. Based on the above results, calculation models for the effective anchorage length and bearing capacity were established separately for the two types of interfaces. The theoretical model for the interfacial bonding property between HSSWM-ECC and concrete has been refined. These advancements establish a theoretical groundwork for the design of concrete structures strengthened with HSSWM-ECC.

Deep learning-based automated identification on vortex-induced vibration of long suspenders for the suspension bridge

Large amplitude vortex-induced vibration (VIV) of long suspenders, caused by vortex-shedding and wake flow, will decrease the service life of high-strength wires and its anchorage systems, hence listed as an essential monitoring indicator of the structural health monitoring system in the suspension bridges. Traditionally, a static vibration amplitude limitation is usually predefined and used to identify VIV from continuously monitored acceleration data of bridge suspenders. Due to the complexity of the starting vibration of the suspenders, it may not be able to flexibly adapt to the suspenders VIV under different conditions. In addition, transient but significant vibration events may not be captured since it relies only on static vibration amplitude limits without considering the temporal information of vibration. To address the above-mentioned issues, a novel framework to autonomously identify the suspenders VIV is proposed using the multimodal fusion techniques with deep neural networks. The main contributions of the methodology are: i) by calculating the wind field and vibration characteristic, two vibration response parameters are identified as indexes for the identification of suspenders VIV based on the significant difference method of big data analysis; ii) Two different modal information of time history images and power spectral density (PSD) sequences are used as inputs to the convolutional neural network (CNN) and bidirectional long short-term memory (BiLSTM) to extract the suspenders vibration response features from the time and frequency domain perspectives, respectively; and iii) The multimodal information is concentrated and enhanced by the multi-head attention (MHA) mechanism to achieve automated identification of the suspenders VIV. The proposed framework is validated with data collected from a full-scale long-span suspension bridge in comparison with the base model. The results show that the proposed framework can efficiently identify the full-cycle development process of the suspenders VIV. This study provides a convenient strategy for suspenders VIV identification, which can be used for bridge management and vibration mitigation device design.

Effect of trace niobium on the microstructure and properties of full-pearlite steel used in the high-strength hypereutectoid wire rods

The present study investigated the impact of 20–80 ppm Nb on the microstructure and properties of hypereutectoid pearlite steel. Remarkably, even trace amounts of Nb exhibited a favorable effect on the refinement of austenite grain. The addition of the Nb element resulted in a reduction of pearlite transition temperature, leading to a decrease of approximately 13% in lamellar spacing and 11% in the size of pearlite colonies. Furthermore, the dragging effect of the Nb element on the carbon atoms in hypereutectoid steel facilitated the control and refinement of network carbides. These findings offer valuable theoretical guidance for the production of ultra-high-strength wire rods. When the Nb content reached 80 ppm, it promoted the precipitation of (Ti, V)C, while simultaneously improving the morphology of square carbides. The grain refining strengthening mechanism accounted for about 70% of the overall strengthening effect observed in high carbon wire rods, with the influence of the Nb element primarily targeting grain refinement. Consequently, the incorporation of minute quantities of Nb presents a promising avenue for the development of ultra-high-strength hypereutectoid wire rods, offering significant potential for enhancing their strength properties.

Evaluating the load-bearing capacity of corroded cables in long-span cable-stayed bridges: A stochastic corrosion field simulation approach

In cable-stayed bridges, cables are the primary load-bearing components. The corrosion of high-strength steel wires within these cables can degrade their bearing capacity, which in turn impacts the safety and durability of long-span cable-stayed bridges. To address this concern, a three-dimensional random field model was proposed in this study to evaluate the residual bearing capacity of corroded cables. This model considers the random distribution of the strength of high-strength wires along both axial and cross-sectional directions caused by corrosion. Subsequently, a three-dimensional spatial correlation model was developed based on field test results from two stay cables in service on an actual bridge. This model represents the strength distribution of corroded high-strength steel wires within the cable. Finally, the evaluation model developed in this study was employed to assess the bearing performance of two corroded cables with different degrees of corrosion. The results were then compared with test outcomes. The results show that the proposed evaluation model can accurately estimate the bearing performance of corroded cables.

A stochastic modeling method for three-dimensional corrosion pits of bridge cable wires and its application

ABSTRACT Cables have usually served as critical and vulnerable structural components in long span cable-supported bridges. Cable inspections revealed that corrosion, fatigue or coupled corrosion-fatigue were the ones of the main failure mechanisms. This paper proposed a stochastic modelling method for three-dimensional (3-D) corrosion pits of high-strength bridge wires, which can be applied to rapid fatigue life evaluation according to mass loss caused by surface corrosion pits of bridge wires nondestructively. High-strength steel wire specimens dismantled from the cable-stayed bridge served for 15 years were scanned to obtain the original surface corrosion data. The spatial position coordinate of corrosion pits were considered as random variable and can be well fitted by uniform distribution. While the number of corrosion pits can be fitted with generalized extreme value (GEV) distribution. The uniform corrosion depth du, which can be equivalent to mass loss rate, was calculated as the input corrosion parameter for 3-D corrosion pit modelling. The maximum pitting depth dmax for the steel wire was found to be associated with du. The geometric parameters for individual corrosion pits were recognized as pit depth d, depth-to-width ratio d/b, and aspect ratio b/a, which were fitted with different probability distributions. What follows is 3-D spatial corrosion pits simulation based on the individual corrosion parameter that were sampled and combined from the corresponding probabilistic distributions. Hereafter, fatigue life evaluation of corroded wires was conducted based on equivalent surface defect method and compared with the experimental results, verifying the effectiveness of the proposed modelling approaches.

Mechanical behavior and deformation mechanism of <?A3B2 ACK?>high-strength metallic wires

Mechanical behavior and deformation mechanism of <?A3B2 ACK?>high-strength metallic wires

Effect of carbon content on strength and toughness of deposited metal for 1000 MPa-grade high-strength welding wire

The microstructure and mechanical properties of the deposited metal of 1000 MPa-grade marine steel welding wire were observed and tested using characterization methods such as OM, SEM, TEM, XRD, and EBSD. The influence of carbon content (0.061–0.080 wt%) on the structure of the deposited metal was examined, with the strengthening and toughening mechanisms of the deposited metal elucidated. The results indicated that the deposited metal structure primarily consisted of lath bainite, martensite, and a small amount of retained austenite as the carbon content increased from 0.061 wt% to 0.080 wt%; the proportion of martensite increases, while bainite and retained austenite decrease. Additionally, the lath morphology changes from “interwoven” to “parallel.” The yield strength of the deposited metal increases from 915 MPa to 1007 MPa, while the impact energy at −50 ℃ decreases from 120 J to 59 J. The increase in martensite proportion contributed to the enhanced strength of the deposited metal. Solid solution and dislocation strengthening are the primary strengthening methods. The observation of the impact fracture section revealed that the bainite was segmented and refined. In contrast, the “intertwined” morphology of plate-striped bainite/martensite and high-angle grain boundaries hinders crack propagation, thereby improving the low-temperature impact toughness.

Fatigue Behavior and Fracture Surface Analysis of Corroded High-Strength Bridge Cable Wires.

Bridge cable wires suffer from alternating stress and environmental erosion, leading to premature failure prior to its design life. This paper investigates the fatigue and mechanical behaviors of corroded bridge cable wires with a zinc-aluminum (Zn-Al) alloy coating. Based on the salt spray corrosion test and microstructure analysis, the anti-corrosion resistance and corrosion appearance characteristics of the Zn-Al alloy coating and galvanized coating were investigated. The Zn-Al alloy coating was superior in resistance to corrosion fatigue for the improvement in toughness and the generation of anti-corrosion Zn-Al and Fe-Zn-Al phases. Equations of the accelerated corrosion depth of the steel wires had been regressed to roughly estimate the corrosion life of the Zn-Al alloy coating, which can reach 29.1 years with a thickness of 70 μm. The fatigue and mechanical properties of the bare wires after the salt spray test were further studied based on tensile tests and fatigue tests. The fatigue properties of the bridge cable wire would decrease with the corrosion degree due to the deterioration and embrittlement of materials, where ductility characterized by the elongation rate was the most affected. Fracture surfaces of the wires were captured and analyzed based on a method for recognizing graphical contours. Insufficient fatigue life may occur in the steel wires after corrosion and increase with the degree of corrosion. The pit depth logarithmically weakened the fatigue life of steel wires for the weakening of fatigue toughness and the bearing area. The flat fracture was more common with a single fatigue source, while multiple fatigue sources led to step-like fractures for the generation of multiple dispersed crack propagation regions. Corrosion fatigue was more sensitive to the existence of fatigue sources than the reduction. Multiple initiation sources significantly reduced the fatigue life due to the cracking facilitation of the joint effect of multiple pits. The electrochemical reactions of corrosion can lead to material embrittlement and a reducing effect on the fracture toughness of the steel wires.

Carbon Dioxide Corrosion Mechanisms: Historical Development and Key Parameters of CO2-H2O Systems

The recent failures in flexible pipes have motivated the exhaustive research of corrosion mechanisms on high-strength carbon steel armor wires that are the main structural compounds of those structures that mostly operate in seawater environments in the presence of carbon dioxide (CO2) and confined spaces. Recently, the literature reported discoveries about electrolyte properties (as Fe+2(aq)/HCO3-(aq.) ratio) and supersaturation, near neutral pH inside the confined space, multiphase reactions of contaminants present in CO2 gas, the formation and dissolution mechanism of FeCO3 film, and interaction of CO2 gas impurities with the corrosion scale. Therefore, this review is aimed at presenting an up-to-date narrative of the CO2 corrosion phenomenon in carbon steel, connecting background fundamentals with current data studies.

Biomechanical Comparison of Banarji Knot with Various Sliding Locking Knots

Abstract Background: The most essential part of arthroscopic shoulder surgery is tying a secure knot. A knot should be a low profile, nonbulky, and more stable construct. In the present research, we have compared the biomechanical performance of the new sliding locking knot-the Banarji knot, with two different sliding locking knots: The Samsung Medical Centre (SMC) Knot and the Weston Knot. Methods: Two samples of arthroscopic sliding locking knot, Banarji knot with three and five half hitches were taken. They were named Banarji Knots 1 and 2 in the study. The SMC Knot and Weston Knot were taken for comparison with the Banarji Knot. All knots were prepared with high-strength suture material fiber wire (Arthrex, Naples, FL, USA) and were tested in Bose Testing Machine to evaluate the load to failure of knots taken in the research. The statistical significance was determined using a P = 0.05. Results: The maximum load to failure was higher with the Banarji Knot, and it showed significantly better performance when compared with other knots taken in this study. The maximum load to failure in Banarji Knot 1 was 23% and 17% higher than SMC Knot and Weston groups, respectively, and that for Banarji Knot 2 was 29% and 22% higher than SMC and Weston groups, respectively. Conclusion: The Banarji knot is a low-profile, stronger, and stable knot. The biomechanical properties of the Banarji knot were better, and the load to failure was superior to SMC and Weston Knot.

Innovative measurement system for saber curvature observation in straightening processes

High-strength wire materials are usually available as strip material and are subjected to a forming process such as punch-bending to produce parts for the electronics industry, for example. During the manufacturing process of the semi-finished product, residual stresses and plastic deformations are introduced into the wire by rolling and drawing processes. Straightening machines are used in the production lines to compensate for these. To increase the sustainability of these production lines, the straightening process is an essential step. Before the continuous manufacturing process starts, the straightening process must be set up and the optimal roller positions must be found. Once the process is set up, the roller position settings are usually not changed. Due to missing measurement systems for the straightening quality, it is not possible to react to fluctuations in the material properties. This leads to deviations in the dimensional accuracy of the components to be produced and thus to an increase in the rejection rate in the manufacturing processes.This paper presents two innovative measuring systems that can detect changes in saber curvature in flat wire during the straightening process. With the help of this information, the quality of the straightening process can be recorded during the running process. This enables the chance to build a control structure for the straightening quality and thus to implement demand-oriented straightening of semi-finished products. On the one hand, this means that the flat wire no longer must be overbent, which means that the strength of the material is not reduced anymore. On the other hand, the sensor information collected can be passed on to downstream processes. This creates the possibility of networking for the individual processes in a production line. This makes an important contribution to the development of intelligent manufacturing processes in line with the guiding principle of Industry 4.0.

Novel Straightening-Machine Design with Integrated Force Measurement for Straightening of High-Strength Flat Wire.

In a punch-bending machine, wire products are manufactured for a wide range of industrial sectors, such as the electronics industry. The raw material for this process is flat wire made of high-strength steel. During the manufacturing process of the flat wire, residual stresses and plastic deformations are induced into the wire. These residual stresses and deformations fluctuate over the length of the semi-finished product and have a negative effect on the final product quality. Straightening machines are used to reduce this influence to a minimum. So far, the adjustment of a straightening machine has been performed manually, which is a lengthy and complex task even for an experienced worker. This inevitably leads to the use of inefficient straightening strategies and causes high rejection rates in the entire production process. Due to a lack of sensor information from the straightening operation, application of modern feedback control methods has not been practicable. This paper presents a novel design for a straightening machine with an integrated, precise straightening force measurement. By simultaneously monitoring the position of the straightening rollers, state variables of the straightening operation can be derived. Additionally, a tension control for feeding the flat wire is introduced. This is implemented to mitigate the disturbing effects caused by irregularities in the wire-feeding process. In the results of this article, the high precision of the developed force measurement design and its possible applications are shown.

Controllable and Reversible Assembly of Nanofiber from Natural Macromolecules via Protonation and Deprotonation.

Nanofiber is the critical building block for many biological systems to perform various functions. Artificial assembly of molecules into nanofibers in a controllable and reversible manner will create "smart" functions to mimic those of their natural analogues and fabricate new functional materials, but remains an open challenge especially for nature macromolecules. Herein, the controllable and reversible assembly of nanofiber (CSNF) from natural macromolecules with oppositely charged groups are successfully realized by protonation and deprotonation of charged groups. By controlling the electrostatic interaction via protonation and deprotonation, the size and morphology of the assembled nanostructures can be precisely controlled. A strong electrostatic interaction contributes to large nanofiber with high strength, while poor electrostatic interaction produces finer nanofiber or nanoparticle. And especially, the assembly, disassembly, and reassembly of the nanofiber occurs reversibly through protonation and deprotonation, thereby paving a new way for precisely controlling the assembly process and structure of nanofiber. The reversible assembly allows the nanostructure to dynamically reorganize in response to subtle perturbation of environment. The as-prepared CSNF is mechanical strong and can be used as a nano building block to fabricate high-strength film, wire, and straw. This study offers many opportunities for the biomimetic synthesis of new functional materials.

Fatigue characterization of wire arc additive manufactured AWS ER100S-G steel: fully reversed condition

To overcome the limitations associated with the conventional fabrication (e.g., casting, forging, assembly) of large-sized complex structures, in this study, we assess large format additive manufacturing (wire arc additive manufacturing) as a potential replacement using high-strength low alloy wire feedstock (AWS ER100S-G). The process/microstructure/property/fatigue correlations of AWS ER100S-G (a low carbon high strength electrode filler utilized in gas metal arc welding) fabricated by wire arc additive manufacturing (WAAM) are presented in detail. Characterization tools such as the optical microscope, scanning electron microscope with electron backscattered diffraction, μ-CT scan, and mechanical testing (tensile, hardness, fully reversed fatigue tests) were utilized to quantify the property correlation of the WAAM’d AWS ER100S-G. To identify the controlling mechanism of fatigue crack initiation and fatigue crack growth pattern, scanning electron microscopy-based fractography assessments were conducted on the fracture surface of the broken specimens. Our findings were then compared against WAAM’d chemically closed steel (e.g., AWS ER100S-1 and AWS ER70S-6) reported in the literature. Regarding fatigue performance, the AWS ER100S-1 outperformed the studied AWS ER100S-G, and the AWS ER100S-G outperformed the AWS ER70S-6.

Study on the Effect of Microstructures and Properties of Al-Mg-Mn-Zr Alloy Welding Wire by Adding Minor Sc

The low strength of welded joints of aluminum alloy welding wire materials has seriously restricted the promotion and application of high-performance aluminum alloys represented by 7A52 and 7B52 aluminum alloy. It is urgent to develop new high-strength aluminum alloy welding wire material to meet the lightweight application demand of 7××× series high-performance aluminum alloy materials in military and civilian vehicles. This paper studied the effect on microstructures, mechanical properties, and welding properties of Al-6Mg-0.3Mn-0.2Zr welding wire alloys by adding minor Sc elements. The result shows that it formed Al3Zr, Al3Sc, and Al3(Sc1-x, Zrx) primary dispersive phases in the matrix, and the Al3(Sc1-x, Zrx) primary phase, which had triple-shell microstructure composed of Al3Zr/α(Al)/Al3Sc three-layer phases enclosing individually with each other from the center to outside. These phases could promote heterogeneous nucleation during solidification and crystallization in the process of welding, resulting in strong refinement and strengthening effects in the weld-zone microstructure. The welding joint mechanical properties of both tensile strength and elongation increased with the increase of Sc contents within the range of 0–0.4%. It was reached at Rm 365 MPa/A 5% without means of heat treatment which are much higher than aluminum alloy welding wires used in current engineering when the 7B52 aluminum alloy laminated plates were welded with the prepared welding wire Al-6Mg-0.3Mn-0.2Zr alloys of 0.385% Sc.

Storage of High-Strength Steel Flux-Cored Welding Wires in Urbanized Areas

The condition of the consumables is a key factor determining the waste reduction in the welding processes and the quality of the welded joint. The paper presents the results of tests of four types of flux-cored wires dedicated for welding high-strength steels, stored for 1 month and 6 months in Poland in two urbanized areas: in a large seaside city (Gdańsk) and in Warsaw, located in the center of the country. The wires were subjected to macroscopic and microscopic (stereoscopic, SEM) observations, EDS analysis, technological tests assessing elastic properties and targetability. The degree of degradation of the wires was also tested using resistance measurements. In order to assess the effect of storing wires on the weldability of steel, the diffusible hydrogen content in deposited metal was determined by high-temperature extraction. It was found that the storage caused changes in the surface condition of the wires, affected their elasticity and electrical properties, which affects the behavior of the wires during welding. A significant influence of storage conditions on the hydrogenation of deposited metal was found: in the case of three types of wires, the level of low hydrogen processes was exceeded and the maximum result was 15.18 ml/100 g of deposited metal. It was also found that copper-plated wire showed a significantly increased resistance to storage conditions compared to non-copper-plated wires.

Tensile strengths of super high-strength steel strand wire ropes and wire rope open swaged socket connections at fire and post fire

PurposeThe main purpose of this study was to evaluate the tensile strengths of JIS G3549 super high-strength steel strand wire ropes (1,570 MPa-class high-carbon steels) and wire rope open swaged socket connections at fire and post fire.Design/methodology/approachSteady-state tests from ambient temperature (20 °C) to 800 °C, transient-state tests under the allowable design tensile force and tensile tests in an ambient temperature environment after heating (heating temperatures of 200–800 °C) were conducted.FindingsThe tensile strengths of the wire rope and end-connection specimens at both fire and post fire were obtained. The steel wire rope specimens possessed larger reduction factors than general hot-rolled mild steels (JIS SS400) and high-strength steel bolts (JIS F10T). The end-connection specimens with sufficient socket lengths exhibited ductile fracture of the wire rope part at both fire and post fire; however, those with short socket lengths experienced a pull-out fracture at the socket.Originality/valueThe fundamental and important tensile test results of the super high-strength steel strand wire ropes (1,570 MPa-class high-carbon steels) and wire rope open swaged socket connections were accumulated at fire and post fire, and the fracture modes were clarified. The obtained test results contribute to fire resistance performance-based design of cable steel structures at fire and fire-damage investigations to consider their reusability post fire.

Effect of outer rust layer on cathodic protection and corrosion behavior of high-strength wire hangers with sheath crack in marine rainfall environment

After the high-density polyethylene (HDPE) sheath crack, the hanger steel wires of large-span suspension bridge are prone to corrosion under the erosion of the marine rainfall environment. This study investigates the influence of the outer rust layer on the impressed current cathodic protection (ICCP) and the corrosion behavior of hanger steel wires. The corrosion morphology and corrosion products of the wire are analyzed by SEM and XRD. The result shows that in the simulated marine rainfall environment, both ICCP and removal of the outer rust layer can reduce the corrosion rate of hanger steel wires. Especially the removal of the outer rust layer can significantly improve the cathodic protection efficiency. Removing the initial outer rust layer on the surface before applying ICCP is a benefit for forming a complete and dense corrosion product layer. In addition, it contributes to the generation of Zn5(OH)8Cl2H2O and Al2O3 with stable structures in the corrosion products. These corrosion products benefit to forming a passivation film, which helps isolate the iron matrix from harmful substances.

Fabrication of a novel high-strength and high-conductivity copper-clad aluminum composite wire

Fabrication of a novel high-strength and high-conductivity copper-clad aluminum composite wire

Study on Fatigue Performance of 2200 MPa High-Strength Wire of Main Cables Based on FE-SAFE

In order to estimate the fatigue life of 2200 MPa high-strength steel wire for main cables at the outlet of the cable saddle, a fatigue loading test of a single steel wire was designed, and the value of the friction coefficient in finite element simulation and the scale factor in fatigue life analysis were determined. The fatigue life of the steel wire was analyzed by two-stage modelling. The results showed that the fatigue life of steel wire can be simulated effectively when the friction coefficient is 0.21 and the scale factor is 1.15. The fatigue life of 2200 MPa main cable wire at the saddle outlet is 4.78 million loading cycles. The research results laid a foundation for practical engineering application of high-strength steel wire for 2200 MPa main cables.