Steel Wire Research Articles

Load Bearing Capacity and Failure Analysis of Fibrous Plaster Wads

ABSTRACT Fibrous plaster is a culturally significant material used in high-status buildings from the late nineteenth century. Fibrous plaster ceilings are typically suspended using load-bearing fibrous plaster wads, which are attached to roof structure components. Understanding the behaviour of wads is highly significant, with important safety implications emphasised by the partial collapse of the Apollo Theatre ceiling in 2013. This study demonstrates an original, innovative test method for fibrous plaster wads that enables quantification of load capacities, with manufactured specimens representative of historic in situ wads. The methodology is rigorously evaluated for traditional and alternative wad designs, reinforced with hessian scrim or continuous fibre glass (CFG) mat, with and without steel wires in looped (untwisted) or looped-twisted configurations. Tensile tests generated load-displacement characteristics and determined failure modes including cracking of plaster, deformation and tearing of fibrous reinforcement, and if present, plastic failure of a wire. Results demonstrate that hessian performs better than CFG in axial tension and inclusion of a wire increases tensile load capacity and ductility. An industry standard repair wad with hessian and looped-twisted wire can typically support 3 kN. Looped wire performed better in isolation than looped-twisted wire, with higher peak loads and greater ductility, while looped-twisted wire carried a greater load as part of a fibrous plaster composite wad. The test methodology and findings have revealed new insights into the mechanical behaviour of wads which will inform commercial practice and conservation of historic buildings, preserving important heritage and promoting safe longevity.

Efficient manufacture of high-performance electroplated diamond wires utilizing Cr-coated diamond micro-powder

The slicing of silicon ingots using electroplated diamond wires is a fundamental process in the creation of semiconductor devices such as chips and photovoltaic cells. Composite electroplating, a process that uses nickel (Ni) plating to fix diamond particles onto a steel wire, is a critical step in the manufacturing of these diamond wires. In this work, chromium (Cr)-coated diamond was used to achieve rapid and high-quality composite electroplating, thereby aiding the production of high-performance diamond wire saws. The Cr-coated diamond micro-powder was prepared utilizing vacuum slow evaporation technology at a temperature of 850 °C. This resulted in a uniform and firm Cr coating that was firmly bonded to the diamond surface via Cr3C2. Subsequent electrochemical tests were conducted in the composite electroplating bath. Linear scanning voltammetric curves revealed that the Cr-coated diamond was capable of inducing a more positive shift in the overpotential of Ni deposition, thus enhancing the reaction beyond that of uncoated diamond micro-powder. Additionally, the electrochemical impedance spectra indicated a decrease in charge transfer resistance during composite electroplating, attributable to the conductivity of the Cr-coated diamond. Electroplated diamond wires incorporating Cr-coated diamond demonstrated a greater abrasive density per unit length. SEM results showed that Ni was able to deposit on the Cr-coated diamond surface, resulting in the abrasives being completely covered by the Ni plating. The Cr-coated diamond wire exhibits a stronger resistance to abrasive detachment after cutting, which could increase the diamond-protrusion of the wire. The utilization of Cr-coated diamond micro-powder as an abrasive is anticipated to enhance the manufacturing efficiency of diamond wires and improve product quality, thereby promoting advancements in hard and brittle material processing technology.

Reliability assessment of bridge hangers based on fault tree with response surface

Bridge hangers play a crucial role in transmitting forces and supporting bridge structures. The condition of these hangers directly impacts the overall safety of the bridge. However, they are susceptible to fatigue failure due to cyclic loads like wind and vehicle traffic. Therefore, evaluating the fatigue performance of bridge hangers is vital. Typically made up of multiple parallel steel wires, the failure of even one wire can affect the fatigue performance of the entire hanger. This underscores the importance of considering the individual components’ impact on the system as a whole. This study presents a time-dependent reliability assessment model for bridge hangers based on the S-N curve of steel wire. Additionally, a system-level reliability assessment model is developed using fault tree analysis, taking into account the influence of broken wires and stress redistribution on the hanger system. The model is solved using response surface methodology, and through five numerical simulations, the study examines the effect of key parameters, including the number of broken wires, equivalent structural stress, and total cycles on the system’s reliability.

Study on Bonding Behavior between High Toughness Resin Concrete with Steel Wire Mesh and Concrete

This paper investigates the interfacial bonding behavior between high toughness resin concrete with steel wire mesh (HTRCS) and concrete. A total of five sets of fifteen double shear specimens were tested for parameters including concrete strength and material properties of HTRCS composites. The test results showed that the failure mode of DS1 specimens was partial debonding and fracture, and the rest of the specimens were the fracture of HTRCS. The concrete strength and reinforcement ratios of HTRCS composites were positively correlated with interfacial adhesion properties. When the concrete strength was increased from C30 to C40 and C50, the ultimate load increased by 43.4% and 43.2%, respectively. The ultimate load capacity increased by 32.1%, with the reinforcement ratio of HTRCS composites increasing from 1.05% to 1.83%. Moreover, the bonding slip model and the bearing capacity formula for the interface between HTRCS composites and concrete were proposed, and the calculation values were in good agreement with the test values, with an average value of 0.978.

Unraveling short-term O2 contamination on under deposit corrosion of X65 pipeline steel in CO2 saturated solution

The impact of short-term O2 contamination on the deposit-covered pipeline steel under a CO2-saturated solution was investigated using steel coupon and wire beam electrode. Results show that the brief exposure to O2 destroyed the FeCO3 film, and converted it into porous iron oxides, weakening its protection property. However, upon CO2 reinjection, the dense FeCO3 film regrew soon underneath the damaged FeCO3 layer on the bare steel, restoring its protective properties. Conversely, the localized corrosion beneath the deposits persisted and worsened, fueled by macro-cell current between the bare steel and the deposit-covered steel.

Effect of Different Magnetic Field Types on Microstructure and Properties of Deposited Metal Prepared from High-Strength Steel Wire

Effect of Different Magnetic Field Types on Microstructure and Properties of Deposited Metal Prepared from High-Strength Steel Wire

Change in the Spatial Position of Mini-implants During Distal Movement of the Entire Maxillary Dentition: An Observational CBCT Study.

To determine the change in the sagittal and vertical position of mini-implants placed in the maxilla during distal movement of the entire maxillary dentition. Overall, 28 mini-implants (1 placed on each side in 14 patients) were evaluated in healthy patients aged 15 to 25 years old. CBCTs were taken immediately after leveling and aligning prior to distalization (T1) and after 6 months (T2) to evaluate the distal movement of the maxillary teeth and position of the mini-implants. The vertical and sagittal angulation of each mini-implant was measured at T1 and T2. The linear distance between the mini-implant and the alveolar crest, the maxillary sinus, the maxillary second premolar, and the maxillary first permanent molar were measured. The change in angulation and the linear displacement of the miniimplant were evaluated in the vertical and sagittal plane. Wilcoxon signed rank test was performed to determine if there was a statistically significant change in the position of the mini-implant. Vertically, there was a significant change in the linear distance between the mini-implant and the alveolar crest on the right side (P ≤ .006) as well as the miniimplant and the maxillary sinus on the left side (P ≤ .003). Sagittally, there was a statistically significant rotation of the miniimplant occlusally (left side P ≤ .004 and right side P ≤ .002). The head and tip of the mini-implant were displaced toward the maxillary second premolar and away from the maxillary first permanent molar, respectively. There was a significant relative displacement of the mini-implant anteriorly away from the maxillary first permanent molar (left side P ≤ .026 and right side P ≤ .041) and closer to the maxillary second premolar (left side: P ≤ .011 and right side: P ≤ .002). There was a statistically and clinically significant rotation of the mini-implant in the vertical and sagittal direction during distal movement of the entire maxillary arch. The linear displacement of the mini-implant was more pronounced in the sagittal direction than the vertical direction.

Review of Rotating System for Closing Die of Steel Wires Stranding Machine

The stranding machine utilized for armouring of all electric cables, electric wiring, mechanical motion control cables, clutch wire, wire ropes and structural components or communication cable. It uses for shielding on a cable, tube or liner. This machine is used in industrial apparatus in producing of electric wire and electric cable. It’s a device to manufacturing of mechanical motion control cables, clutch wire and wire ropes. In this paper, we review the development of rotating system for closing die of the stranding machine. We have investigated the problems solutions like undesired tube is rotation so inner jam problem, tube twist problem, poor surface finish and poor stranding quality so the methods of the current machine to be adopted to resolve the problem. The study result into elimination of inner jamming and twisting of tube which Improve the in quality and surface finish of cable and reduce wastages orlosses.

Investigating the Flexural Properties of Reinforced Concrete T-Beams Strengthened with High-Strength Steel Wire Mesh and Polyurethane Cement

Investigating the Flexural Properties of Reinforced Concrete T-Beams Strengthened with High-Strength Steel Wire Mesh and Polyurethane Cement

Sulphide stress corrosion in SAE 1070 steel wire used in the tensile armour of flexible pipelines: Effect of induced superficial defects

This research aims to investigate and quantify potential damage resulting from induced superficial defects on the surface of wires use on tensile armor of flexible pipes. Different values of kt factors and H2S concentration in aggressive gas mixtures with CO2, were analysed to determine the operational conditions that do not result in rupture of the tensile reinforcement during service, under the conditions studied. The tests were based on NACE TM0316 standard, using a 4-point bend test. Two superficial notches were created, which generated known stress concentration factor Kt values of 1.5 and 2.0, and three gaseous concentrations (220, 700, and 1100 ppm of H2S in CO2) were used. After bending tests, the samples were evaluated by metallographic and fractographic analysis, weight loss and liquid penetrant inspection. The results were then analysed using analysis of variance (ANOVA). Only the samples exposed to 220 ppm of H2S in CO2 did not rupture at both Kt values. However, for the Kt value of 2.0, cracks were observed in the longitudinal direction of the wires, originating from the machined notch. Additionally, the samples exposed to 700 ppm and 1100 ppm of H2S had a significantly higher damage score (approximately 15x) than the samples exposed to 220 ppm, regardless of the Kt value.

Rotational Control and Retraction of Maxillary Canine Using Self-Ligating Empower Brackets: An In Vivo Study.

Interest in self-ligating brackets is generally smoother and more comfortable. To compare rate of retraction and rotational control of maxillary canines with self-ligating MBT brackets on one side and conventional MBT brackets on the other side of the maxillary arch. Ten subjects with a mean age range of 18 to 25 years were selected. For each patient in the maxillary arch, bonding was performed with 0.022-inch slot conventional MBT brackets on one side and 0.022-inch slot self-ligating MBT brackets on the other side. Stainless steel 0.009-inch ligatures are used for conventional ligation. Retraction of canines was performed with 0.019 × 0.025-inch stainless steel wires using NiTi closed coil springs with eyelets of 12 mm and 9 mm. The force of retraction was measured using a dynamometer. Dental casts were made at each time interval to record the canine retraction rate (in mm) and rotation (in degrees). The mean difference in the retraction rate was 0.045 mm/month between self-ligating and conventional brackets, respectively (P > 0.05). The mean difference of total rotation of canines with self-ligating and conventional brackets was 1.5°, which gives evidence that there was less rotation of canines with self-ligating brackets. There was no statistically significant difference in canine retraction rates between conventional and self-ligating brackets. Secure ligation with the self-ligating brackets showed better rotational control than the conventional brackets.

Centrifuge Modeling of the Monotonic Capacity of Offshore Ring Anchors in Sand

The development of offshore wind technology has become a feasible solution to meet the increasing demands for clean and renewable energy. The United States has a total of 4250GW offshore wind energy potential; however, 65% of it is in deep water zones (Lopez et al., 2022) where wind turbines with fixed foundations typically are economically and technically unfeasible. In those situations, floating turbines supported by subsea anchors are a more competitive solution. Based on previous studies, ring anchors can be more material-efficient than piles and caissons because they require less material. Ring anchors also perform better than drag anchors due to their greater embedment depth. To further understand the behavior of ring anchors in saturated sand, a series of centrifuge load tests were performed at the University of California Davis Center for Geotechnical Modeling (CGM) at an acceleration of 70g. This test series investigated the effect of the anchor embedment depth and loading angle on the monotonic loading behavior. The ring anchor models were embedded in dense saturated sand, and then connected to an actuator using taut steel wire ropes. Sensors were used to measure the line tension, displacement, and inclination. The results indicate that the ring anchors mobilize greater capacities as their embedment depth is increased and when they are loaded at angles close to the horizontal direction, while vertical loading leads to the smallest capacity. The anchor displacement during the tests deviated slightly from the loading direction, showing a horizontal deviation at the earlier stages of the tests and a vertical one after the peak load. Furthermore, soil disturbance induced by the anchor installation was found to have a strong effect on the vertical capacity of the ring anchors. Overall, this study provides valuable information regarding the monotonic loading behavior of ring anchors which can aid in their future field deployment.

Research on the vibration isolation performance of a metal rubber-disc spring shock isolation device

In view of the fact that the vibration response of the laser-emitting telescope in the combination of artillery and light equipment cannot meet the target design requirements, this paper designs a new metal rubber-disc spring shock isolation device and conducts experimental research on its vibration isolation performance. The research is conducted from the frequency sweep test and the fixed frequency test. Through the vibration isolation performance test, it is found that the natural frequency of the metal rubber-disc spring shock isolation device is lower than that of the steel wire rope vibration isolator, and the frequency domain where vibration isolation occurs is wider, with better vibration isolation performance. In the fixed frequency test, the acceleration transfer rate of the metal rubber-disc spring composite vibration isolator is significantly better than that of the steel wire rope vibration isolator in the low-frequency range. As the excitation frequency increases, the difference between the acceleration transfer rate of the steel wire rope vibration isolator and the metal rubber-disc spring composite vibration isolator gradually shrinks, and finally converges.

Effect of zinc coating on the fretting fatigue endurance of crossed steel wires

Fretting fatigue causes failures in steel wire ropes. These steel wires are usually galvanised. This zinc coating could change the crack initiation process, as it modifies the contact interface. In this study, fretting fatigue tests were performed on bright (non galvanised) and galvanised wires under ambiant air, varying independantly fretting and fatigue loadings. No significative beneficial effect of galvanisation on lifetimes was observed, contrary to what was found in litterature. Plain fretting tests and dedicated observations were performed to better interpret the influence of zinc coating.

Study of the corrosion resistance of high chromium white cast iron welds in the presence of NaOH (30% w/w)

– In the mining industry, specifically in bauxite processing, adverse working conditions demand high mechanical and chemical resistance. For such conditions, the choice of potentially resistant materials, such as high chromium white cast iron (HCr-CWI), is necessary. However, presently, there is no effective recovery of equipment made with HCr-CWI, primarily due to the machining difficulties encountered during the repair process. An alternative recovery method is being developed by the Laboratory of Metallic Materials Characterization at UFPA – LCAM, using electric arc welding with two filler metals: the ER307L stainless steel wire andsa high Mn value wire. Within this context, this study aims to investigate the corrosion resistance of the welded joint obtained with these two filler metals. The base metal (HCr-CWI) was analysed as a reference, alongside the metals generated by the welded joints, ER307L and high Mn. The samples underwent tests involving optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), and electrochemical tests for corrosion potential, polarization, and impedance. It was observed that the samples exhibited a similar matrix-carbide structure but with different organization and volumes. However, the electrochemical behaviour in terms of corrosion potential, polarization, and impedance was similar, with very close resultant values: 50 V; 3.53 μA; 0.18 kOhms, respectively. This was supported by the corrosion rate of 0.4mmpy and explained by calculations of Cr and Ni volume, which showed inverse concentration magnitudes among the samples.

Viscoelastic response of steel wire and particulate-reinforced polymer under dynamic and creep loading

Viscoelastic response of steel wire and particulate-reinforced polymer under dynamic and creep loading

Research on Intelligent Identification Algorithm for Steel Wire Rope Damage Based on Residual Network

As a load-bearing tool, steel wire rope plays an important role in industrial production. Therefore, diagnosing the fracture and damage of steel wire ropes is of great significance for ensuring their safe operation. However, the detection and identification of wire rope breakage damage mainly focus on identifying external damage characteristics, while research on inspecting internal breakage damage is still relatively limited. To address the challenge, an intelligent detecting method is proposed in this paper for diagnosing internal wire breakage damage, and it introduces residual modules to enhance the network’s feature extraction ability. Firstly, time–frequency analysis techniques are used to convert the extracted one-dimensional magnetic flux leakage (MFL) signal into a two-dimensional time–frequency map. Secondly, the focus of this article is on constructing a residual network to identify the internal damage accurately with the features of the time–frequency map of the MFL signal being automatically extracted. Finally, the effectiveness of the proposed method in identifying broken wires is verified through comparative experiments on detecting broken wires in steel wire ropes. Three common recognition methods, the backpropagation (BP) neural network, the support vector machine (SVM), and the convolutional neural network (CNN), are used as comparisons. The experimental results show that the residual network recognition method can effectively identify internal and external wire breakage faults in steel wire ropes, which is of great significance for achieving quantitative detection of steel wire ropes.

Corrosion protection failure test analysis of the initial damaged cable ICCP mechanism

Given the corrosion protection failure of the cable-stayed bridge cable in the actual project, the impressed current cathodic protection (ICCP) technology was used to carry out the anti-corrosion tests from steel wire scale to cable scale, analyze the corrosion protection characteristics of steel wire ICCP, deduce the corrosion factor ICCP diffusion model, and reveal the space ICCP mechanism of the initial damaged cable. The analysis shows that ICCP can effectively inhibit the corrosive effect of steel wires and cables, and reduce the loss of mechanical properties of steel wires. Its protective efficiency increases with an increase in the absolute value of its protective potential and decreases with an increase in the dead load level. ICCP has a blocking effect on the diffusion of corrosion factors in the cable space, and the corrosion spatial distribution range, corrosion factor concentration, and diffusion coefficient of the initial damaged cable decrease significantly with the increase in the absolute value of the protection potential. The open circuit potential moves in a positive direction with the development of the corrosion process, and the blocking effect of corrosive factor diffusion is transformed from the joint participation by sacrificial anode cathodic protection and ICCP to the dominance of ICCP.

A data-driven model for damage evolution of bridge stay cable

Chloride ion concentration is crucial for the reliability of stay cables, particularly when their protective covers are compromised. Previous studies have focused on the corrosion of single wires or cables over time, proposing estimation models that primarily consider corrosion duration while neglecting other significant factors. Addressing this gap, this paper establishes a corrosion damage model for stay cables considering time, temperature, humidity and inclination angle based on the diffusion characteristics of chloride ions. Firstly, We conducted accelerated corrosion experiments on stay cables in different environments to assess the characteristics of the spatial distribution of chloride ion concentrations within the cables and the mass loss characteristics of the wires. Secondly, a three-dimensional diffusion model for chloride ions in stay cables is proposed based on Fick's second law. A pivotal innovation of our research is the application of diverse machine learning techniques to explore how the diffusion coefficient of chloride ions is influenced by factors like time and environmental temperature, leading to the formulation of a sophisticated chloride ion diffusion model. Finally, by amalgamating this diffusion model with the established corrosion law for steel reinforcement, we devised a comprehensive corrosion damage evolution model for the steel wires of stay cables. The result demonstrates the anisotropic diffusion of chloride ions and its substantial correlation with the corrosion damage observed in steel wires. Notably, the PSO-BPNN method emerged as a highly accurate predictor for the diffusion coefficient of chloride ions. The model established in this paper considers a variety of influencing factors and accurately predicts the corrosion damage characteristics of stay cables, which makes an important contribution to improving the reliability of stay cables.

Corrosion fatigue mechanisms and evaluation methods of high‐strength steel wires: A state‐of‐the‐art review

AbstractCorrosion significantly degrades the fatigue performance of high‐strength steel wires. This study conducts an extensive review of corrosion fatigue in corroded steel wires based on relevant literature. It outlines corrosion fatigue evolution mechanisms and discusses various test methodologies. Six distinct approaches are employed to assess corrosion fatigue life. A three‐stage multiscale corrosion fatigue evolution process involves pitting formation and growth, short crack propagation, and long crack propagation. Advanced fatigue assessment methods like the theory of critical distances (TCD) and the strain energy density (SED) are explored for predicting the corrosion fatigue life for corroded steel wires. A model utilizes an elastoplastic corrosion fatigue damage framework to comprehensively represent the complex interactions. The physics‐data‐driven method has garnered increasing attention due to its requirement of fewer sample data and good robustness. Moreover, the reliability method underscores its pivotal role in guaranteeing the longevity of suspenders and cables in practical settings.