Steel Research Articles

Investigating the behavior of vertical trapezoidal CSSWs stiffened with flat steel plate

Steel shear wall (SSW) is an efficient system used to construct and improve many structures over the past decades. The main weakness of the traditional flat plate SSW is the premature buckling of the plate, for which the corrugated steel shear wall (CSSW) is a suitable alternative. However, the reduced resistance of CSSW compared to flat SSWs is a disadvantage. In this research, their reinforcement by flat steel plates with different dimensions and thicknesses has been used to improve the behavior of vertical trapezoidal steel shear walls (VTSSW). The samples studied in this research were subjected to cyclic loading after verification in Abaqus finite element software. The outcomes showed that reinforcing CSSWs with flat plates increased strength and energy absorption between 6 to 63% and 16 to 92%, respectively. Also, the equivalent viscous damping has increased between 5 and 82%. Also, due to strengthening the CSSWs, the pinching phenomenon in the hysteresis curves has been reduced, and the sudden decrease in strength after buckling in the CSSWs without stiffener has been significantly reduced.

Enhancing EDM Productivity for Plastic Injection Mold Manufacturing: An Experimental Optimization Study

Electrical erosion molding (EDM) is an unconventional machining technology widely used in the manufacture of injection molds for plastics injection molding for the creation of complex cavities and geometries. However, EDM productivity can be challenging, directly influencing mold manufacturing time and cost. This work aims to improve EDM productivity in the context of mold manufacturing for plastics injection molding. The research focuses on the optimization of processing parameters and strategies to reduce manufacturing time and increase process efficiency. Through a rigorous experimental approach, this work demonstrates that the optimization of EDM parameters and strategies can lead to significant productivity gains in the manufacture of plastic injection molds without compromising part quality and accuracy. This research involved a series of controlled experiments on a Mitsubishi EA28V Advance die-sinking EDM machine. Different combinations of pre-cutting parameters and processing strategies were investigated using copper electrodes on a heat-treated steel plate. Productivity was evaluated by measuring the volume of material removed, and geometrical accuracy was checked on a coordinate measuring machine. The experimental results showed a significant increase in productivity (up to 61%) by using the “processing speed priority” function of the EDM machine, with minimal impact on geometric accuracy. Furthermore, the optimized parameters led to an average reduction of 12% in dimensional deviations, indicating improved geometric accuracy of the machined parts. This paper also provides practical recommendations on the selection of optimal EDM processing parameters and strategies, depending on the specific requirements of plastic injection mold manufacturing.

Study on Mechanical Properties and Fatigue of Cold-rolled Steel Plate for Distribution Transformer

The oil tank steel plate of the distribution transformer is covered with welds, and the fatigue failure of the oil tank often occurs in the internal defects of fillet welds. Given the above problems, this paper puts forward the bearing capacity calculation formula of cold-rolled steel plate and carries on the force analysis of steel plate and the fatigue analysis of weld through finite elements. Based on the theory of plastic limit design, the ultimate flexural bearing capacity of the control section of steel plate members is proposed. The calculation formula of equivalent structural stress is given based on the calculation method of structural stress and linear elastic fracture mechanics, and the calculation method of fatigue life and fatigue cumulative damage is given. Then, the elastic-plastic equation is solved according to three criteria: Mises yield criterion, plastic flow criterion, and strengthening criterion. Based on the above numerical simulation analysis, the mechanical model of steel plate weld is constructed, the mesh is divided, the boundary conditions are restricted and the same load is applied. ABAQUS analysis results show that the stress distribution curve of the connector has a maximum value at X = 80 mm and X = 210 mm, that is, the top surface of the connector steel plate has an obvious stress concentration at 80 mm and 210 mm. When the length of the weld is not more than 60 times the size of the welding foot, the full section of the core plate will yield, and the maximum stress value of the weld element will not exceed the tensile strength value of the welding material. The error of the results calculated by the formula in this paper is mostly within 10%, and the rest is basically within 20%. Therefore, the bearing capacity formula of the steel plate in this paper has ideal calculation accuracy and can provide effective guidance for the design of distribution transformer oil tanks.

Analytical and Finite Element Analysis of the Rolling Force for the Three-Roller Cylindrical Bending Process

In the roll bending process, the rolling force acting on the roller shafts is one of the most important parameters since, on the one hand, it determines the process settings including the pre-loading, and, on the other hand, its distribution and size may affect the integrity of both the bending system and the final product. In this study, the three-roller bending process was modeled using a two-dimensional plane–strain finite element method, and the rolling force was determined as a function of plate thickness, upper roller diameter, and yield strength for various API steel grades. Based on the numerical simulation results, a critical bending angle of 41° was identified and the rolling systems were divided into two categories, of less than or equal to, and greater than 41°, and an analytical model for predicting the maximum rolling force was developed for each category. To determine the optimal pre-tensioning force, two optimization formulations were proposed by minimizing the maximum equivalent stress and the absolute maximum displacement. The rolling forces predicted by the analytical models were found to be in good agreement with the numerical simulation results, with relative errors generally less than 10%. The predictive analytical models developed in this study capture well the complex deformation behavior that occurs during the roll bending process of steel plates, providing guidelines and predictions for industrial applications of this process.

Experimental and Numerical Characterization of Local Properties in Laser-Welded Joints in Thin Plates of High-Strength–Low-Alloy Steel and Their Dependence on the Welding Parameters

Laser welding on thin plates of high-strength steel is increasing in various industrial applications. The mechanical behavior of welded joints depends on their local properties, which in turn depend on the welding parameters applied to join the base material. This work characterizes the local properties of butt-welded joints of thin plates of high-strength–low-alloy (HSLA) steel. This study focuses on the effect of welding parameters on the microstructure, tensile response, microhardness, and weld bead profile. For this purpose, a factorial experimental design was formed, covering a heat input range from 53 to 75 J/mm. This study identified the main effects and interactions of welding speed and laser power on the weld bead profile and on its width. The microstructure, weld bead width, hardness, and tensile mechanical properties were significantly influenced by heat input. Furthermore, numerical simulations on real weld bead profiles revealed high values of the stress concentration factor and suggested a correlation with heat input.

Axial compressive behaviour and design of concrete-filled wire arc additively manufactured steel tubes

The axial compressive behaviour of concrete-filled wire arc additively manufactured (WAAM) steel tubular columns is investigated experimentally in this paper. Firstly, the manufacture of a series of WAAM steel plates and tubes is described. The results of tensile testing performed on coupons cut from the WAAM plates, to obtain the mechanical properties of the printed material, are summarised. 3D laser scanning was employed to generate digital models and to capture the geometric features of the WAAM steel test specimens. Concrete was then cast into the WAAM steel tubes, creating a total of nine concrete-filled steel tubular (CFST) specimens of different diameters, thicknesses and lengths that were subjected to compressive loading. The axial compressive load-deformation responses and ultimate loads of the specimens were obtained and the influence of the as-built surface undulations of the WAAM sections was assessed. Comparisons of the test results against existing structural design provisions highlight the need to consider the influence of the weakening effect of the geometric undulations that are inherent to the WAAM process on the structural response of CFST sections, in order to achieve safe-sided strength predictions.

Investigating the Role of TiC Precipitation in Dynamic Recrystallization Behavior of a Novel Ship Steel

This study examines the single‐pass thermal compression behavior of Ti‐bearing ship plate steel across a temperature range of 850–1150 °C and strain rates from 0.01 to 7 s−1, employing the Gleeble‐2000D thermomechanical simulator. It delves into the evolution of TiC precipitation and dynamic recrystallization (DRX), along with the austenite decomposition transformation during hot compression and subsequent cooling. Active dynamic recrystallization commences at deformation temperatures above 1050 °C, facilitated by the diminished pinning pressure of TiC carbides. This leads to the development of fine DRX austenite grains, influenced by an increase in strain rates and a decrease in temperature. Simultaneously, the fraction of TiC dispersions decreases as the deformation temperature increases, yet they maintain a consistent size of 5–10 nm. The refined particle size is attributed to their low interfacial energy with the austenite matrix, determined by the first principle to be 0.21 J m−2. Due to the severe deformation and numerous dispersions, specimens subjected to a thermal deformation regime at 850 °C and a strain rate of 7 s−1 present a peak in hardness, reaching a maximum of 324 HV. The Ti microalloying approach offers pivotal insights into improving the rollability and mechanical characteristics of ship plate steel.

Numerical Optimization of Functionally Graded Ti-HAP Material for Tibial Bone Fixation System

Functionally graded materials (FGMs) are heterogeneous composites characterized by outstanding properties. They are built from two or more components with a gradient distribution of chemical composition along a given direction. A promising graded material for biomedical engineering as an implant could be a FGM made of titanium (Ti) and hydroxyapatite (HAP). It would allow us to counteract the difference between the stiffness modulus of pure titanium and bone tissue. Moreover, it can be a good solution to the problem of stress shielding for bone fixation plates made of conventional titanium or steel. The presented paper aims to perform micromechanical modeling and optimization of a functionally Ti-HAP graded plate, followed by numerical analysis of a fractured tibia stabilization system under specific boundary conditions. Finite element analysis was performed using ANSYS Workbench 2021 software. The models of the FGM plate and tibial fixation system were made using the Space Claim tool. The ANSYS software allowed the optimization of the model considered and the selection of the appropriate structural parameters of the FGM Ti-HAP material. In general, the results proved that the osteosynthesis plate built of graded Ti-HAP material resulted in lower bone stress compared to titanium and steel plates. The results obtained confirmed the validity of the design and the possibility to use functionally graded Ti-HAP bone fixation plates.

Investigation of a piezoelectric ultrasonic surface wave transducer that minimizes structural scattering

Abstract The Structural of ultrasonic surface wave transducers affects structural scattering. A numerical model of an ultrasonic surface wave transducer was established. Numerical simulations and dynamic acoustic analysis were performed to systematically assess, the effects of the transducer parameters, such as the front and back angles, matching layer, and front wedge shape on structural scattering. The results show that the acoustic amplitude of the transducer structure scattered waves is basically stable when the back angle of the wedge is 64° -68 °and the front angle is 65°-85°. The amplitude obtained from a transducer with orthogonal slots and a front uniform matching layer is 61% lower for the primary structure scattering, 56% lower for the secondary structure scattering.
When equipped with the upper matching layer, the amplitude of the secondary structural scattering echo is reduced by 78.2%. The experimental results show that the transducer with orthogonal slots on the wedge and a matching layer at the front and upper edges has a signal-to-noise ratio of 19.6dB when detecting the echo signal of a ϕ8 through-hole in a welded steel plate, indicating good detection capability. The experiment validates the numerical simulation results. The proposed transducer can be used for structural monitoring of welded structures and detecting flaws.

Impact behavior of the SCS panel with hybrid energy absorbing components: Experimental and analytical studies

A new steel-concrete-steel panel with front aluminum foam layer and rear energy absorbing connector (SCS-FL-EAC) was firstly developed. The dynamic behavior of SCS-FL-EAC was studied through conducting drop-weight impact tests. Three stages of impact process of SCS-FL-EAC were identified. The aluminum foam layer and energy absorbing connector were crushed under impact loading. The aluminum foam layer reached densification, and a local indention was observed beneath the projectile. Plastic hinges were also found at the corners of the pleated steel plate of the energy absorbing connector. The SCS panel exhibited the combination of bi-linear global flexural deformation and local deformation. Furthermore, the effects of aluminum foam layer on the impact resistant performances of SCS-FL-EAC were investigated. The results indicated that the inclusion of the aluminum foam layer effectively mitigated inertial effects and reduced the maximum impact force. Additionally, the SCS-FL-EAC demonstrated improved impact-resistant performances with an increased thickness of the aluminum foam layer. Furthermore, an analytical model was proposed to predict the force and displacement responses of SCS-FL-EAC subjected to impact load, and the predicted impact responses showed good agreement with experimental results.

An analytical method to determine the ultimate shear strength of continuous steel plate girders

An analytical method to determine the ultimate shear strength of continuous steel plate girders

Flexural behavior of circular concrete-filled steel tube members reinforced with annular stiffener

This paper presents a study on the flexural performance of a novel concrete-filled steel tube (CFST) member reinforced with an internal annular stiffener. The annular stiffener is composed of curved steel plates, and the circumferential plate serves as the interface connector. Four-point bending tests were conducted on the four new composite beams and two traditional CFST counterparts to investigate the flexural performance of the composite members. The failure modes, deflection distribution, flexural strength, strain distribution, and moment-curvature relationship were analyzed. The test results showed that the new composite members exhibited higher bending capacity and stiffness than their CFST counterparts. Then, a finite element (FE) model was established and validated using the test results to numerically investigate flexural behavior. The available design models for predicting the flexural capacities of the composite beams was compared. Design formulae considering the stiffener contributions were deduced to calculate the flexural strength of the composite beams based on the plastic-stress distribution method. It was demonstrated that the developed FE modeling appropriately simulated the structural behavior of the composite members. Parametric studies indicated that the use of high-strength concrete was inefficient. In addition, the comparison results indicated that the proposed design formulae were feasible for predicting the bending capacity of composite members.

Influence of Water Cover on the Blast Resistance of Circular Plates

Abstract Explosion containment vessels (ECVs) can effectively limit the range of potential hazards, and improving their blast resistance is an important research topic. Placing ECVs underwater is an excellent and promising method. The effect of water covering on the blast resistance of circular plates was investigated experimentally and numerically in this paper. First, blast experiments of circular water-covered and bare plates were conducted, and strain responses were obtained. The effect of water on the maximum strain as well as the high-level strain crests was investigated based on experimental results. Then, numerical simulations were carried out using ansys/autodyn and validated by experimental results. The displacement and strain response at the center of the circular plate with different water cover heights were analyzed. The experimental and numerical results show that water can effectively reduce the peak dynamic response of the steel plate and increase the vibration period of the steel plate. The center of the circular plate is the most dangerous position under confined blast loading, regardless of whether the plate is covered with water or not. The results from numerical simulations also clearly show that the blast resistance of the steel plate will first be improved and then stable with the increase of the water cover height. The work in this paper can provide a useful reference for the design and protection of explosion containment vessels.

Tension performance of joint made in cold-formed square tube with self-tapping screw connections

The tension behavior of cold-formed square tube (CFST) screw connections was investigated experimentally and numerically. Ten test specimens were fabricated from the square tubes connected by external steel plates and internal tube applying self-tapping screws such that the number of screws was varied. In addition, the mechanical properties of the single-screw connections were obtained through single shear tests. Experimental results revealed that an increase in the number of screws led to higher bearing capacity and stiffness in the specimens. Shear failure of the screws was observed as the primary failure mode. When the number of the screws was equal in both types of the specimens, those with the internal tube exhibited superior tensile behavior than the ones with external steel plates. Subsequently, finite element (FE) models of the test specimens were developed. Upon validation of the test results, an extensive parametric study was conducted to further examine the influence of the design parameters on the tensile behavior of the CFST screw connections. Variation of the arrangement of screws, wall thickness of steel plates and their strength had only a minor influence on the tension behavior, and steel strength had little influence on the tension behavior and the number, spacing, and diameter of the screws were the key parameters affecting the tension behavior of the CFST screw connections. Based on the test results and FE analyses, the existing calculation method was modified, and a formula for calculating the tensile bearing capacity of the CFST screw connections was obtained. Comparison with the results indicate that the formula was conservative and reliable for determining the tensile capacity of CFST screw connections.

Dynamic and quasi static stiffness characterization of a lamination stack of an electric motor

The development of electric motors for automotive applications requires precise material models to simulate structural strength and NVH (Noise, Vibration, and Harshness) properties. Modeling the behavior of lamination stacks, composed of stacked steel plates, presents significant challenges. This study conducted dynamic and quasi-static experiments at various preload levels on an unmodified automotive lamination stack. Significant discrepancies were identified between stiffness values obtained from static and dynamic measurements. Consequently, using dynamically obtained stiffness values in static models, and vice versa, leads to inaccuracies and should be avoided. These results enhance the precision and efficiency of simulations used in the design and optimization of electric motors.

Transverse compressive behavior of plain and polypropylene fiber-reinforced concrete infilled steel tubes as hybrid steel-concrete nodes for discrete reticulated shell structures

This study investigates using concrete infilled steel tubes as hybrid nodes for discrete reticulated shell structures under compressive loading transverse to the tube axis. Three configurations were tested: empty, plain concrete infilled and polypropylene fiber-reinforced concrete infilled steel tubes. Displacement-controlled loading was applied through welded steel plates. Simplified beam theory models and nonlinear finite element analysis were used to evaluate the structural behavior. The concrete infilled steel tube specimens had higher stiffness and load-bearing capacity than the empty ones. The structural behavior of the concrete infilled specimens could be split into pre- and post-split-tensile cracking phases. No significant difference was found between the plain and fiber-reinforced concrete specimens under loads up to 1500 kN, which was the load limit of the testing machine. An additional fiber-reinforced concrete specimen, tested on a higher capacity machine, had a load-bearing capacity of 2400 kN and exhibited ductile failure.

Investigation on the desulphurisation process by powder injection during RH refining process of non-oriented silicon steel

In the present study, the desulphurisation process by powder injection during RH (Ruhrstahl-Heraeus) refining process was studied by establishing a kinetic model. The predicted results by the model were compared with experimental data obtained from industrial trials to verify its accuracy. The effects of the desulphuriser particle diameter, desulphuriser composition and powder injection rate on the desulphurisation process were analysed and discussed. Results show that the desulphuriser particle diameter and powder injection rate considerably affected the desulphurisation process. By decreasing the desulphuriser particle diameter and increasing the powder injection rate, the reaction area between desulphuriser particles and liquid steel considerably increased. Therefore, the desulphurisation rate and ratio increased. When the desulphuriser particle diameter decreased from 3.0 to 0.1 mm, the desulphurisation ratio increased from 44.6% to 88.4%. The ratio increased from 32.8% to 62.2% for 3.0 mm desulphuriser particles when the powder injection rate increased from 100 to 250 kg min−1. Furthermore, an increase in the desulphuriser basicity and CaO/Al2O3 ratio improved the sulphur capacity and accelerated the desulphurisation process. The desulphuriser used herein had a low sulphur partition ratio, and thus it yielded a lower desulphurisation ratio than the CaO-SiO2-Al2O3 desulphuriser.

Effect of al content on microstructure and corrosion resistance of Zn-Al-Mg alloy

In order to solve the solidification microstructure of Zn-1.7Al-1.1Mg alloy on the surface of steel plate during hot dip plating, the solidification path and microstructure of Zn-1.7Al-1.1Mg alloy were studied by Thermo-Calc thermodynamic software, differential thermal analysis (DSC) and scanning electron microscopy (SEM). The results show that during cooling from melting to room temperature, Zn-1.7Al-1.1Mg alloy begins to precipitate Zn-rich η phase at 386.5 °C, binary eutectic structure consisting of η phase and Mg2Zn11 at 350.0 °C, and ternary eutectic structure consisting of η phase, Al-rich metastable β phase and Mg2Zn11 at 343.4 °C,at 276.7 °C, β phase transforms into stable aluminum-rich α and η phases.

Numerical Analyses of Ultrasonic Atomization Utilizing Acoustic Effects of a Beam Diaphragm

To study mechanisms of jet atomization, a novel method of experimentation utilizing the resonation of diaphragms made from thin steel plates has been previously developed. In the experiments, a diaphragm covered by a film of water emitted acoustic sounds, and jet atomization from the water film was observed. Experiments using diaphragms composed of different materials and fast Fourier transformation analysis of the acoustic sound revealed that jet atomization occurred under limited surface conditions of the diaphragm and a specific range of frequency. In this article, the dynamics of a resonating body composed of the diaphragm and water film were analyzed using the finite element method with a combination of theoretical analyses of surface waves of water, such as the well-known Lang’s equation. The present FEA results, from harmonic response analyses with consideration of viscous damping effect due to interaction between the diaphragm and water film, precisely confirmed the results of FFT analysis previously obtained by the experiment. Specifically, the peak frequency of the frequency response agreed well with the FFT results, and the shift of the peak frequency and attenuation due to the interaction in the analyses corresponded with the difference in surface conditions between the hydrophilic and hydrophobic materials of the diaphragm in the experiments. Our interpretation of the mechanism of jet atomization is expanded by the present numerical results.

Preparation and properties of silica isophorone diisocyanate microcapsules for self-healing anticorrosive coatings

ABSTRACT Traditional anticorrosion coatings often suffer from reduced effectiveness or even complete failure due to the formation of microcracks. Isophorone diisocyanate (IPDI) can form a polyurea structure without a catalyst in the presence of water, which can protect the underlying metal from corrosion. In this study, an anticorrosion coating with self-healing properties was developed by incorporating microcapsules containing IPDI into the coating formulation. Silica-based self-healing microcapsules were synthesized via interfacial polymerization, using tetraethyl orthosilicate as the precursor and IPDI as the core material. The effects of core-to-wall ratio, reaction temperature, different emulsifiers, and emulsifier ratios on the microcapsule properties were investigated. The results demonstrated that microcapsules prepared using a composite emulsifier system of cetyltrimethylammonium bromide (CTAB) and OP-10 at a 1:1 ratio, with a core-to-wall ratio of 1:1, and a reaction temperature of 75°C, exhibited a smooth surface, spherical shape, and excellent encapsulation efficiency. The maximum core content achieved was 81.2 wt%. An epoxy coating embedded with these self-healing microcapsules was subjected to scratching damage. After applying water to the surface and allowing it to stand for 2 days, the scratches healed, and the steel plate surface remained free from corrosion, indicating excellent self-healing performance.