Microcrack Initiation Research Articles

Experimental investigation on fracture propagation in shale fractured by high-temperature carbon dioxide

The productivity of shale reservoirs was significantly enhanced by the high-temperature CO2 fracturing technique. The injection of high-temperature CO2 into the formation induced rock fracture propagation, creating advantageous pathways for fluid flow. In this research, a self-developed in situ high-temperature convective heat simulation experimental apparatus was employed to systematically conduct simulated experiments on high-temperature CO2 fractured shale under different influencing factors. The experimental results demonstrated that the permeability of CO2 increased as the injection temperature increased. The rock fracture pressure was effectively reduced by high-temperature CO2 fractured shale. Higher complexity was observed in fracture propagation, accompanied by a substantial increase in microcracks and branching fractures. The shale fracture pressure increased with increasing triaxial stress and CO2 injection rate. The confining pressure restricted the further propagation of fractures under relatively high stress conditions, thereby reducing the width and density of fractures, lowering the fracture complexity. Nevertheless, the thermal shock effect of the fluid was exacerbated as the injection rate of high-temperature CO2 increased. The initiation of microcracks was facilitated by the intensification of local thermal stress in shale, inducing multiple curved fractures and forming a more complex fracture network. Compared to horizontal bedding shale, the fracture pressure of vertical bedding shale was relatively higher during high-temperature CO2 fracturing. In addition, the geometric morphology of fracture propagation was more complex, characterized by rougher fracture surfaces, leading to a greater improvement in reservoir reconstruction volume. This research contributed to the optimization of CO2 resource utilization, provided experimental evidence for the application of high-temperature convection fracturing technology in in situ shale conversion projects.

Initial temperature conduction process and fracture response of rock impacted by ultra-low-temperature fluid: A case study of polymethyl methacrylate

Injecting ultra-low-temperature fluids, such as liquid carbon dioxide (CO2) and liquid nitrogen (LN2), into deep, low-permeability reservoirs for fracturing is an emerging waterless fracturing technology. When these fluids enter the reservoir, they rapidly exchange heat with the fracture walls, triggering intense cold shock, which influences fracture development. Although many scholars have studied the effects of nitrogen freezing and thawing on coal seams, the initial thermal exchange and cold shock process when LN2 first enters the rock mass remains unclear. This paper uses the visualizable material polymethyl methacrylate (PMMA) as the research object, conducting low-temperature impact experiments under different preset temperatures (20 °C, 40 °C, 60 °C, and 80 °C) to investigate the impact of thermal exchange during cold shock on PMMA fracturing. The results show: (1) During LN2 impact, PMMA's temperature changes in three stages: slow cooling (micro-cracks initiation), rapid cooling (formation of long fractures), and temperature recovery (crack formation completion). (2) In prolonged impacts, PMMA temperature decreases linearly, while in short-term cyclic impacts, temperature decreases exponentially with faster recovery, increasing the likelihood of micro-cracks formation. (3) Temperature differences have a dual effect on crack formation and propagation: they significantly enhance internal thermal stress, leading to rapid micro-cracks initiation and expansion, while also causing uneven temperature gradients in the crack propagation region, shifting fracture modes from tensile to complex composite failures and promoting secondary crack formation. However, a significant temperature differential may result in the development of a singular crack propagation path, hindering the formation of complex fracture networks. These findings offer theoretical insights into fracture network formation in waterless fracturing of low-permeability reservoirs.

Experimental study on the Mode l fracture toughness of frozen silty clay incorporating Digital image correlation

To investigate the effects of initial moisture content and temperature on the Mode I fracture toughness (KIc) of frozen silty clay, a series of three-point bending tests were conducted. Rectangular specimens with prefabricated cracks were tested, and digital image correlation (DIC) technology was employed to analyze the microscopic characteristics at the crack tip. The results indicate that the Mode I fracture toughness of frozen silty clay increases with decreasing temperature and increasing initial moisture content. Temperature governs the failure mode, with plastic failure predominantly occurring at high temperatures and brittle failure at low temperatures. Based on the load–displacement curves and DIC recordings, the macroscopic fracture process of the specimens can be categorized into three stages: elastic deformation, formation of the failure surface, and specimen failure. Additionally, the crack propagation process can be further divided into three stages: initiation and development of microcracks, transition from microcracks to macroscopic cracks, and rapid development of macroscopic cracks. These findings provide critical insights for slope stability research in cold regions and offer new perspectives for engineering design and construction in similar environments.

Numerical study on micro-fracture mechanism of rock dynamic failure induced by abrupt unloading under high in-situ stresses

Rock burst is a kind of severe engineering disaster resulted from dynamic fracture process of rocks. The macro failure behaviors of rocks are primarily formed after experiencing the initiation, propagation, and coalescence of micro-cracks. In this paper, the grain-based discretized virtual internal bond model is employed to investigate the fracturing process of unloaded rock under high in-situ stresses from the micro-fracture perspective. The simulated micro-fracturing process reveals that the longitudinal stress waves induced by unloading lead to the visible unloading effect. The influences of in-situ stresses, mineral grain sizes, and grain heterogeneity on rock macro and micro fracture are investigated. Micro-crack areas of tensile and shear cracks and micro-crack angles are statistically analyzed to reveal the rock micro-fracture characteristics. The simulated results indicate that the combined effect of the stress state transition and the unloading effect dominates the rock unloading failure. The vertical and horizontal in-situ stresses determine the stress state of surrounding rock after unloading and the unloading effect, respectively. As the vertical stress increases, the stress level after unloading is higher, and the shear failure characteristics become more obvious. As the horizontal stress increases, the unloading effect increases, leading to the intensification of tensile failure. The mineral grain size and grain heterogeneity also have nonnegligible influences on rock unloading failure. The micro-fracture perspective provides further insight into the unloading failure mechanism of deep rock excavation.

Interaction of propagating crack with microstructure in CGI: In situ tensile test and numerical simulation

Compacted graphite iron (CGI) is a double-phase material, in which complex graphite morphology greatly influences crack initiation and propagation. Despite its wide use and considerable past research on the fracture behaviour of CGI, the understanding of the interaction of propagating cracks with CGI's microstructure is still limited. In this study, a novel method is employed that integrates scanning electron microscopy (SEM) and an optical high-speed camera. This approach allows the clear visualisation of microstructures before and after fracture, as well as the calculation of crack-propagation rate during tensile tests. It is also revealed for the first time that in the case of graphite particles situated at a specific distance from the primary crack path, the initiation of secondary micro-cracks, near particles does not occur. A critical distance from the main crack path for crack initiation is analysed. Further, finite-element simulations are developed to study the effect of microstructure on the fracture behaviour of the tested microstructures. A Johnson-Cook (JC) damage model is calibrated and used in all simulations. The crack path and velocity of simulation results are in good agreement with the experimental data, demonstrating that the JC damage model can be used to predict the crack initiation and propagation of CGI. It is found that interface debonding and crack initiation always tend to appear near the tip of vermicular graphite. Thus, large vermicular graphite particles can affect negatively the toughness of CGI. Graphite particles situated farther from the primary crack significantly reduce the likelihood of crack initiation in that specific location. Furthermore, large nodular graphite particles absorb energy and generate secondary cracks, while small graphite particles have little effect on the crack-path direction. The newly discovered fracture mechanisms and simulation results provide new insights for the design and manufacture of metal-matrix composites (e.g., Al/SiC) with optimal mechanical properties.

In situ analysis of three-dimensional microcrack propagation in cross-ply laminates using synchrotron radiation X-ray computed tomography

This study utilized synchrotron radiation X-ray computed tomography to investigate the initiation and propagation of microcracks in cross-ply carbon fiber-reinforced polymer (CFRP) laminates under mechanical loading. Initially, static tensile loads were applied to detect microcracks within a ply thickness of 160 μm. The crack propagation was subsequently characterized, extending across adjacent carbon fibers and along the interfaces of individual fibers into the material's interior. The experiment was repeated with cyclic loading, where the laminates were imaged periodically. Analysis of the images revealed the presence of microcracks and provided insights into their progression from the point of initiation. Notably, microcracks exhibited the initiation toward the interior of the material rather than across the neighboring carbon fibers, whereas their propagation is more significant across the adjacent carbon fibers particularly under the static loading. Under cyclic loading, however, the crack propagation toward the interior of the material was more pronounced, implying different propagation behavior than when under static loading. These findings were also validated through the distribution of energy release rate and stress triaxiality along the crack tip calculated by finite element analysis.

Strain-softening model for granite and sandstone based on experimental and discrete element methods

Combing macroscopic experimental method and mesoscopic numerical method, this study analyses the strain-softening behaviours of granite and sandstone. From the macroscopic perspective, the stress–strain curves of granite and sandstone under different confining pressures are studied by laboratory triaxial compression test. Variations of post-peak reduction modulus and critical plastic shear strain versus confining stress are obtained. Evolution of strength parameters at peak, residual and strain-softening stage are proposed. Then a method to develop the strain-softening model of hard and soft rocks is presented. From the mesoscopic perspective, based on the laboratory test results, the parameters of discrete element method PFC for the samples of the granite and sandstone are calibrated. Comparing the basically consistent results of laboratory experiment and numerical simulation, the feasibility of discrete element method is verified. Evolutions of mesoscopic crack propagation and mesoscopic particle displacement field in the complete failure process are analysed. Typical stresses of granite sample and sandstone sample in the failure stage are investigated. Above combined macroscopic experimental method and mesoscopic numerical method systematically analyse the characteristics of hard rock and soft rock in the strain-softening stage. Failure process and mechanical property of hard rock and soft rock are revealed at the macroscopic and mesoscopic levels. The initiation and propagation process of micro-cracks in rock are thoroughly investigated. The research results provide a scientific foundation for the analyse of strain-softening behaviour of hard rock and soft rock. The result shows that both the mesoscopic numerical method and macroscopic experimental method indicate that the failure pattern of sandstone is influenced by both confining pressure and axial stress, while granite is mainly affected by axial stress.

Evolution of precipitate and its effect on the degradation of impact toughness in a carbon and nitrogen-controlled 316 stainless steel during thermal aging at 650 °C

Impact toughness degradation and microstructure evolution of a carbon and nitrogen-controlled 316 stainless steel during long-term aging at 650 °C for up to 8800 h were investigated. The degradation of impact toughness during aging can be divided into three stages: a rapid decrease during stage I (the first 400 h), a slow decrease during stage II (from 400 to 3200 h), and the stable stage during stage III (up to 8800 h). P enrichment at the M23C6/γ interface is induced by the rejection of P during the formation of M23C6 carbide, and the M23C6/γ interface is preferred location for crack initiation. An increase in the amount of grain boundary M23C6 carbides increases the crack initiation sites, resulting in a rapid decrease of impact toughness during stage I. The ongoing rejection of Ni and Si during the coarsening of M23C6 carbide is beneficial for the nucleation of M6C carbide. The micro-crack initiation at the M23C6/M6C and M6C/γ interfaces is introduced, and a semi-continuous network of M23C6 carbide along grain boundary promotes the crack propagation, leading to a further decrease of impact toughness during stage II. The nearly continuous precipitate morphology is induced through continued growth of grain boundary M23C6 and M6C carbides. The propagation of micro-cracks along the M6C/γ, M23C6/γ, and M23C6/M6C interfaces leads to the mostly intergranular fracture, thus the impact energy tends to be stable during stage III.

Multiscale study of interfacial properties of carbon fiber reinforced polyphthalazine ether sulfone ketone resin matrix composites

In view of the limitations of traditional research tools on interfacial failure mechanisms in fiber/PPESK composites, this work proposes a multiscale research tool to carry out an in-depth study of the interfacial behavior between fibers and matrix. Based on microdroplet debonding tests, at the mesoscopic scale, the influence of residual thermal stress on the interface damage mode is explored through finite element (FEM) simulations. The evolution mechanism of composite material interfaces in spatial and temporal dimensions is examined based on changes in interfacial stress distribution, energy dissipation, and damage morphology during the debonding process, which can be summarized as follows: accompanied by elastic-plastic deformation and friction effects, the progressive process from localized to complete failure presents a dominant Type II damage mode at the interface. To further explore the interface failure mechanism at the molecular level, an interface model of CF/PPESK composite materials was established using molecular dynamics (MD) method. By monitoring the atom movement trend, the "fiber-matrix displacement synergistic effect" in the interfacial shear damage process was revealed, thereby establishing a multiscale mapping relationship of composite material interface. Based on this, the combination of FEM and MD was utilized to investigate the interface damage process of composite materials under different service conditions and to reasonably predict the initiation and expansion of microcracks. This study provides a pioneering perspective on interface damage research in composite materials with a "top-down" multiscale approach.

High strain rate tensile deformation of similar and dissimilar AA6082 and AA7075 friction-stir-welded blanks

Friction-stir-welding process has become an established solid-state technique for joining of dissimilar lightweight materials over the past decade by overcoming fundamental welding challenges such as solidification cracking, phase segregation and surface oxidation. Despite these unique capabilities, the resulting microstructure feature in the weld zone consisting of fine grains with a high dislocation density, challenges further heat treatment and forming processes. Hence, a high solution annealing temperature results in degradation of the adjusted microstructure and in a lower to reduced mechanical properties in case of dissimilar joints of precipitation-hardenable aluminum alloys. Subsequent hot forming therefore involves a great effort and requires further heat treatment steps. Thus, the present study investigates the effect of a recently introduced novel thermo-mechanical forming process on local deformation behavior of similar as well as dissimilar joints processed by friction-stir-welding technique of thin-walled AA6082 and AA7075 blanks. To avoid the complete elimination of the adjusted microstructure, the welding process is performed after a thermo-mechanical process consisting of solution annealing, die cooling and peak aging. Uniaxial tensile tests are then carried out at high strain rates ranging from ε˙ = 40 s-1 to ε˙ = 400 s-1. The results show an increase in yield and ultimate tensile strength as well as in total elongation after failure with increasing strain rates. As the strain rate increases, the flow stress of similar weld of AA7075 is higher than those of AA6082 and the dissimilar weld of AA6082 and AA7075. Local deformation measurements reveal higher strain localization in the welded zone for similar welds, which leads to micro-crack initiation and failure due to strain accumulation. Microstructure analysis shows very fine equiaxed grain structure in the nugget zone and homogenous distribution of precipitates after friction stir welding process, which explain the plastic deformation behavior.

Microdeformation and strengthening mechanism of 3D printed TC4/TC11 gradient titanium alloy subjected to tensile loading

3D printing of heterogeneous alloys holds promising application potentials in industry, especially in the field of aerospace. However, the relationship between the microstructure and mechanical properties of heterogeneous gradient titanium alloys produced by this technique, especially the micromechanical properties and mechanisms within the gradient zones, remains largely unexplored. In this study, we investigated the tensile micromechanical properties and deformation mechanism of 3D printed TC4/TC11 titanium alloy using the digital image correlation method in combination with scanning electron microscopy. The results show that this heterogeneous gradient titanium alloy possesses superior tensile properties. Furthermore, we elucidated the influence of microstructure and grain size on the alloy’s mechanical properties. Notably, an increased presence of secondary α phases and refined grain size were found to reduce the likelihood of microcrack initiation and propagation. Interestingly, all samples fractured on the TC4 side, with the microcracks predominantly extending at a 45° angle to the tensile direction. This observation underscores the necessity for optimizing the fabrication process of the TC4 alloy. Additionally, the strengthening mechanism of the gradient-bonded region of the alloy was also explored. The heterogeneous deformation-induced strengthening was identified as a key factor enhancing the strength of the dual alloyed zone. Collectively, this study provides valuable insights for optimizing the 3D printing process of heterogeneous gradient titanium alloys. It also lays a solid foundation for future investigation in this burgeoning field.

Effect of wall thickness on the microstructure and properties of a fourth-generation single crystal superalloy

This study investigated the effect of various thicknesses (0.3–1.5 mm) on the as-cast and heat-treated microstructures of the fourth-generation single crystal superalloy. The microstructures and fracture characteristics of samples with various thicknesses were analyzed after high-temperature stress rupture tests at 1100 ℃/137 MPa. The results showed that as the alloy thickness increased from 0.3 mm to 1.5 mm, the degree of segregation between dendritic core and inter-dendritic significantly increased. The increased segregation was attributed to the slower solidification rate of the 1.5 mm-thick sample compared to the 0.3 mm-thick sample. Lower solidification rates and higher degrees of dendritic segregation enhanced the area fraction of eutectics, the primary dendrite arm spacing (PDAS), the and area fraction of pores. After stress rupture tests, the rupture life of the alloy increased from 81 h to 333 h. It was observed that in the 0.3 mm-thick sample, microcracks initiated at the surface and extended into the matrix. On the contrary, as for the 1.5 mm-thick sample, microcracks initiated at the matrix and propagated towards the surface. To evaluate the influence of oxidation, interrupted stress rupture tests were conducted in air atmosphere to investigate the thickness debit effect. Surface oxidation led to the initiation of microcracks on the surface and change the morphology and area fraction of the internal γ′ phase, as well as the effective load-bearing area of the samples. TEM and EBSD were employed to characterize the deformation characteristics of samples with various thicknesses, and the influence of thickness on deformation mechanisms was discussed as well.

Investigating the simulation test and acoustic emission characteristics of structural-control type rockbursts in deep underground environments

Deep underground projects are in a complex in-situ stress environment, and rock burst disasters induced by the hard and brittle failure of the rock mass are prone to occur around the tunnel openings. In this study, we aim to investigate the impacts of geological weak surfaces in rock masses on rockbursts and the spatiotemporal evolution of microcracks during the development of rockbursts. To achieve this objective, two sets of cubic specimens containing a circular through-hole were designed. One set of specimens had prefabricated unfilled cracks around the openings. Subsequently, the rockburst development process within the deep tunnel was replicated by subjecting both groups of specimens to identical gradient loading using a true triaxial test system. During the test, a micro camera was used to record the failure of the borehole wall in real-time, and an acoustic emission monitoring system was utilized to capture the stress waves released during structural damage. Finally, a multi-level synergistic analysis of the rockburst damage mechanism was carried out based on the macro-imaging data and micro-acoustic emission data. The results show that failure in high-stress environments within tunnels mainly includes microcrack initiation, particle ejection, crack propagation, local cracking, slabbing spalling, damage penetration, and rockburst damage. The time–frequency domain information of acoustic emission signals is highly perceptive and representative of the structural damage state of the specimens. The mutation characteristics observed in time-domain parameters, such as acoustic emission amplitude, event rate, ringing, and cumulative energy, correspond to drastic alterations in the internal structure of the rock. The distribution characteristics of frequency-domain parameters, such as acoustic emission peak frequency, dominant frequency energy, and frequency centroid, reflect different crack scales and damage modes. The diffusion of frequency centroid indicates that the damage and failure patterns within the rock are evolving towards a more complex direction. The energy magnitude of acoustic emissions represents the damage intensity during the development of rockburst. The root causes of induced structural-control type rockbursts in deep hard brittle rock masses are the combined effects of localized high-stress concentrations and large-scale discontinuous geological structures, such as natural joints, fissures, and structural planes. The naturally occurring large-scale through-type geological weak surfaces within the rock mass reduce the strength of the surrounding rock, alter the location of stress concentration, and change the initial damage characteristics. Moreover, they promote the evolution of rockbursts, thereby increasing their destructive intensity.

Influence of initial stresses and stress paths on the deformation and failure mechanism of sandy slate

Rocks exhibit various mechanical properties under different stress conditions, with changes during unloading having significant implications for geological engineering safety. This study carried out triaxial loading and unloading mechanical tests on sandy slate to investigate its mechanical properties, deformation characteristics, and failure mechanisms at different initial stress levels and stress paths. The results showed that during the unloading process, the deformation modulus (E) of the sandy slate decreased, and the Poisson's ratio (μ) gradually increased. This indicates that significant volume expansion of the rock is the dominant factor in its deformation and failure. The exponential function can be used to describe the evolution of E and μ with confining pressure during unloading. The damage stress of the rock under unloading conditions was lower than that under loading conditions, suggesting that unloading led to an earlier onset of volumetric expansion in the sandy slate. Under conditions where the initial axial stress level approached the damage stress, the mechanical properties were most significantly affected by unloading. Compared to loading conditions, when the initial axial stress level was at 70% of the peak strength, the cohesion (c) decreased by 15.77 to 29.37%, while the internal friction angle (φ) increased by 1.88 to 5.14%. The rock's failure process can be divided into four stages based on the development of microcracks. Unloading during the stages of microcrack initiation and propagation can lead to tensile cracks of varying degrees, resulting in different mechanical properties and failure characteristics under loading and unloading conditions.

Digital twin-based identification of crystal plastic material parameters for weld joints of orthotropic steel decks

The identification of crystal plasticity (CP) material parameters is indispensable for using CP models to simulate and understand the microcrack initiation and propagation of orthotropic steel decks (OSD). This study proposes a digital twin (DT)-based framework for identifying CP material parameters of weld joints of OSD by fusing multiscale CP finite element model (CPFEM) with macroscale stress–strain material tests. The material tests of the specimen (physical entity) cut from the weld joints of OSD and sliced to the centimeter scale are carried out using the standard dynamic test system. The CPFEM simulation is used to develop a multiscale virtual entity to map the physical entity. The particle swarm optimization algorithm is used to fuse the CPFEM simulation with the material test data to identify CP material parameters and produce a DT. The results demonstrate that the CP material parameters identified by the proposed framework are more accurate than those identified by a single representative volume element method. The results also show that the DT-based identification of CP material parameters has high applicability.

The role of the interfaces and cross-links on the mechanical behavior of mineralized collagen fibrils. A numerical approach

Mechanical properties of bone tissue are highly dependent on its hierarchical structure. The presence of microcracks and diffuse damage in lamellar bone is correlated with the failure of the collagen-mineral interface in mineralized collagen fibrils (MCF). The main goal of this work is to evaluate the mechanical behavior of the interfaces and quantify the stiffness loss of the MCF associated with different failure mechanisms, under controlled in-plane displacement. Additionally, we aim to study the role of the cross-links on the fibril mechanical response, beyond the interface failure. Inter- and intra-microfibrilar cross-links are analyzed. In order to address the first issue, a detailed representative volume of the MCF is analyzed by means of the finite element method, under the assumption of plane strain and periodic boundary conditions. In this model the interfaces between constituents are modeled with an exponential cohesive law. Enzymatic cross-links, located at the molecular terminals connecting each 4D (D=67nm) staggered molecules, are represented by non-linear springs. Three in-plane controlled deformations are applied. The results of this work provide the anisotropic stiffness loss of the tissue involved in the different failure mechanisms at the nano-scale length. The initiation of microcracks and the presence of damage zones are compatible with the failure mechanisms observed at interfaces. Interface failure entails a progressive stiffness loss, bringing a non-linear behavior of bone. The strength obtained for the longitudinal maximum deformation is more than 20 times the transverse strength and 3.5 times the shear strength. The quantification of the reduction percentage in the elastic moduli and the shear stiffness when the fibril is damaged, has a potential application in improving failure criteria based on degradation of elastic constants. When longitudinal elongation is applied, the mechanical contribution of the cross-links in delaying the failure initiation of the interface is shown. Likewise, results of this work confirm the scarce influence of the cross-links in the strain range analyzed. Additionally, a three-dimensional numerical model of several microfibrils is defined with the aim of analyzing the mechanical relevance of inter- and intra-microfibrilar cross-links, beyond the interface failure. Results confirm that cross-links transfer the load when strain increases, being highlighted the mechanical competence of the trivalent cross-links.

New insights of the microcrack initiation induced by Mo addition in Ni-based single crystal superalloys during creep at 900 °C

Mo has received much attention in Ni-based single crystal superalloys as a main strengthening element at elevated temperatures above 1000 °C. However, the effects of Mo addition in new generation single crystal superalloys at medium temperature conditions are still not clear. This paper investigated the creep property at 900 °C and 392 MPa in a 4th generation Ni-based single crystal superalloy with different Mo contents, indicating that Mo addition decreased the creep life and induced large amounts of microcracks. Higher Mo content could weaken the interface strength by inducing more stacking faults, causing crack initiation along the interface. The elemental segregation along the stacking faults triggered the nucleation of other precipitates, which could further lead to cracks. The precipitation of topologically close-packed (TCP) phases introduced by more Mo addition caused crack initiation along the interfaces between the TCP phases and γ′ phase. By investigating the microcrack formation induced by Mo during creep at 900 °C, we provided a new perspective for the alloy design.

Study on fatigue properties with composite waveform and variable amplitude of TC21 titanium alloy pulsed laser-arc hybrid welded joints

TC21 titanium alloy is widely used in the manufacturing of key components such as aerospace industry, its welded structure in actual service is often subjected to the cyclic loading with composite waveform and variable amplitude and leads to fatigue failure. Therefore, in this work, the composite waveform and variable amplitude fatigue properties of TC21 titanium alloy pulsed laser-arc hybrid welded joints were investigated in this paper, and the micro-deformation mechanism and crack initiation mechanism of welded joints under different initial maximum cyclic stresses were revealed. The results indicated that the micro-deformation mechanism was the competition between twinning and dislocation slip in the α′ phase at low stress. When the initial maximum cyclic stress increased, the generation and slip of dislocation dominated, and the main distribution of dislocations gradually transitioned from the α′ phase to the β phase. This caused the phase transition in the β phase to the α phase, which increased the energy at the α/β phase interface and reduced the resistance of fatigue microcrack initiation accordingly, thus promoting fatigue failure. In addition, pores were the main factor of fatigue failure for welded joints. Therefore, in this work, the influence of defect size, location and shape on the fatigue life of welded joints was considered to develop a fatigue life prediction model based on the control parameter Z-parameter and equivalent stress amplitude. The predicted composite waveform and variable amplitude fatigue life of TC21 titanium alloy welded joints was within the triple error band.

Achieving an excellent balance of strength, plasticity, and stretch flangeability in a 1000 MPa grade TRIP-assisted bainitic ferrite steel

To address the requirements for safety enhancement, weight reduction, and emission reduction, a novel transformation-induced plasticity-assisted bainitic ferrite (TBF) steel was processed by involving a pre-quenching (PQ) process. This steel was designed with varying PQ temperatures to achieve different fractions of intercritical ferrite and bainite, and its influence on mechanical properties of TBF steels was thoroughly investigated through tensile tests and hole expansion tests. The results demonstrated that the introduction of high-temperature PQ treatment before heat treatment can dramatically accelerate the formation of austenite during the secondary annealing process, thereby facilitating a more sufficient bainitic transformation in the subsequent isothermal process. With the increase of PQ temperature from 750 to 900 °C, abundant intercritical ferrite was replaced by lathy bainite. In comparison with conventional specimens, the high-temperature PQ treatment could reduce the fraction of intercritical ferrite and martensite-austenite (M-A) islands, in favor of delaying the initiation of microvoid and microcrack and improving local formability. In summary, the P-900 specimen exhibited optimal comprehensive mechanical properties, with the highest yield strength of 657 MPa, ultimate tensile strength of 1081 MPa, elongation of 28.7%, and hole expansion ratio of 35.1%.

Experimental study on the creep acoustic emission of fractured sandstone reinforced by anchor rods

To investigate the reinforcement and crack-stopping effect of anchor rods on fractured rock masses, Triassic sandstone from the Xiaolangdi Reservoir area was selected and fabricated into double-fractured specimens. Subsequently, 1 and 2 horizontal anchor rods were used to reinforce the double-fractured sandstone specimens sequentially. Using the RLJW-2000 rock rheological servo tester and the PCI-II type acoustic emission (AE) tester, indoor uniaxial compression creep and AE tests were conducted under the same experimental conditions for the unanchored, singly-anchored, and doubly-anchored sandstone specimens. Based on the experimental results, the creep mechanical characteristics and the three-dimensional spatial evolution of the AE events of the specimens with different numbers of anchor rods were analysed. This study focuses on the reinforcement and crack-stopping effect of anchor rods on fractured rock masses. The experimental results indicate the following: (1) Compared with those of the unanchored specimens, the creep failure strengths of the singly- and doubly-anchored specimens increase by 7.79 % and 22.14 %, respectively. (2) At a stress level of 60 MPa, the axial strains of the single-anchor and double-anchor specimens decreased by 8.41 % and 32.97 %, respectively, compared to the corresponding strain of the unanchored specimen, and the radial strains decreased by 9.21 % and 28.13 %, respectively. (3) Anchor rods have a good reinforcement effect on fractured sandstone, enhancing specimen strength and reducing deformation. (4) With an increase in the number of anchor rods, the reinforcement effect of anchor rods on fractured rock masses strengthened, and the reinforcement effect of double anchors was superior to that of single anchors. (5) Compared with those of the unanchored specimens, under relatively low stress levels, when the AE events extended to the area where the anchor rods were located, the number of AE events for both types of specimens decreased significantly, forming a blank area in the AE events, and the blank area of the double-anchored specimens was larger than that of the single-anchored specimens. (6) With increasing stress, many AE events originated, expanded, and passed through the anchor rod area, indicating that the specimen was about to undergo creep instability failure. (7) The evolution characteristics of the AE events are in good agreement with those of the macroscopic cracks on the specimen surface. The AE characteristics indicate that anchor rods have a significant crack-stopping effect on fractured rock masses, suppressing the initiation, expansion, connection, and penetration of internal microcracks in the specimens. Moreover, the crack-stopping effect of double anchors is superior to that of single anchors.