Stress Concentration Area Research Articles

Characterization of hygrothermal, gas pressure and stress characteristics for poplar wood during unilateral surface densification

Unilateral surface compression in wood presents notable benefits, including reduced wood volume loss and energy consumption, rendering a highly promising and extensive utilization. However, shortcomings in compressed wood arise due to unclear gas pressure, temperature, and moisture content distribution within the wood during hot pressing. In this paper, the temperature and pressure distribution were analyzed utilizing an optical fiber temperature and pressure measurement system within the wood during hot pressing. Moreover, the moisture content, stress and strain in each layer at the end of hot pressing were discussed extensively. The results showed that the wood surface layer (SL) and subsurface layer (SSL) maximum temperature values were similar even with different layer thicknesses. Under sealing conditions, SL and SSL temperatures were generally 6 ℃ to 7 ℃ higher compared to unsealing conditions. The gas pressure maximum value exhibited an opposite order, gradually transferring to the core layer (CL) and declining as the processing time extended. During compression treatment, moisture migrated from the hot end to the cold within the wood. The moisture content displayed significant differences between the middle and end parts of the wood under unsealed conditions, with the disparity becoming more pronounced further away from the hot end. The transition region of the compressed wood served as a stress concentration area, experiencing the highest levels of stress. The dense region followed with the second highest stress levels, while the un-densified region exhibited the least amount of stress. Under the same process parameters, the thickness had little influence on the distribution of dense layers.

Assessment of Tunnel Lining Stability through Integrated Monitoring of Fiber Bragg Grating Strain and Structural Deformation.

Tunnel excavation induces the stress redistribution of the surrounding rock. Structural cracks may develop in the secondary lining due to this stress redistribution and bias pressure, consequently affecting the overall construction safety of the tunnel. This paper aims to achieve real-time monitoring of the excavation stability of the lining structure by integrating two monitoring technologies: structural deformation monitoring and fiber grating strain monitoring. Additionally, it proposes a method to simultaneously measure the thermal strain and applied stress-strain of the structure. By analyzing the displacement and deformation of the lining structure, its stability can be preliminarily evaluated in the short term. To achieve long-term real-time monitoring and a more accurate assessment of the tunnel structure's stability, the paper introduces fiber Bragg grating (FBG) strain sensor monitoring technology. First, based on the geological stratigraphy information obtained from the exploration, a simulation model of the tunnel under different section bias angles is established. The displacement and stress concentration areas of the lining structure are then analyzed to optimize the sensor deployment array and provide a theoretical basis for the sensor arrangement. FBG strain sensors are installed on the surface of the structure to measure thermal strain and loading stress-strain, whereas FBG temperature sensors measure local temperature. The findings indicate that following tunnel excavation, the maximum daily strain differences at K107+043 and K107+240 were 126.87 µε and 209.38 µε, respectively. After a period of rock disturbance, the average daily strain differences due to applied stress-strain were 16.8 µε and 12.65 µε, respectively. The thermal strain was close to the daily strain difference. Therefore, after the rock disturbance subsided, the strain fluctuations in the lining structure were mainly caused by local temperature changes, and the surrounding rock tended to stabilize. This offers a viable method for evaluating structural stability post-tunnel excavation.

Study on key parameters of buckling deformation instability and fracture of rock beams and asymmetric distribution law of stope stress.

The moving deformation of the strata and the redistribution of stope stress after mining show asymmetrical characteristics, which do not conform to the symmetrical structural characteristics of the original rock beam fracture. To further analyze the deformation of rock beams and the asymmetry law of stope pressure distribution after strata caving, the detailed process of instability and deformation of composite rock beams before failure was revealed through similar material simulation, theoretical analysis, and numerical simulation. Through similar simulation experiments, the structural characteristics of strata caving were observed. After excavation, the caving angle near the open-off cut side of the model is greater than that on the stop-mining line side. The maximum bending moment of the rock beam is located at the open-off cut side. The rock beam fracture is located on the partial open-off cut side in the middle of the rock beam. The rock beam on the open-off cut side is easy to shear slip and not easy to hinge. The rock beam in front of the advancing direction of the working face is easily hinged. Based on the structural characteristics of strata caving, considering the thickness of the composite rock beam, the two-hinged arch mechanical model for rock beam fracture is established. On this basis, the key parameters of rock beam instability and fracture such as limit load, additional horizontal stress, limit break distance, and break position are analyzed. Based on the deformation characteristics of two hinged arches, the caving structure and the asymmetric distribution mechanism of stress redistribution during the deformation of overburden in stope are explained. Finally, the deformation of rock beam and the asymmetry of stress distribution in stope are verified by numerical calculation. The results show that the concentrated stress value of the coal pillar at the open-off cut side is greater than that in front of the working face. There is a pressure relief area behind the working face, and the pressure relief area has a certain range. The range of stress concentration area, pressure relief area, and stress value tend to be stable, and only the range of the original rock stress zone expands when the working face is advanced to a certain distance. The asymmetric distribution of compaction stress in goaf is related to the buckling deformation of strata.

Influence of Incident Orientation on the Dynamic Response of Deep U-Shaped Cavern Subjected to Transient Loading

In deep rock engineering, caverns are often disturbed by engineering loads from different directions. To investigate the dynamic response of deep U-shaped caverns under different incident orientations, a theoretical solution of the dynamic stress concentration factor along the cavern boundary was derived based on the wave function expansion and conformal mapping method, and the failure characteristics around the cavern were further investigated by PFC2D (Particle Flow Code in two dimensions). As the incident orientation increases from 0° to 90°, the dynamic compressive stress concentration area transforms from both the roof and the floor to the sidewalls, and the peak dynamic stress concentration factor of the roof decreases from 2.98 to −0.20. The failure of the floor converts from dynamic compression shear failure to dynamic tensile failure. Compared to a stress wave incident from the curved boundary, a stress wave incident from the flat boundary causes severer damage. When the stress wave is incident from the sidewall, the cavern with a larger height-to-width (h/w) ratio exhibits severer damage. Conversely, the cavern with a smaller h/w ratio tends to fail as the stress wave is incident from the floor. This paper provides a basic understanding of dynamic responses of the deep U-shaped cavern.

A finite element analysis of a low-profile femoral neck system of screws in sleeves in a vertical femoral neck fracture model

BackgroundFemoral neck system (FNS) has exhibited some drawbacks, such as non-fit of the plate with the lateral femoral cortex, postoperative pain, and the potential risk of subtrochanteric fractures. We have developed a low-profile FNS system that addresses some compatibility issues in FNS. In this study, we conducted finite element analysis on the 1-hole FNS (1 H-FNS), 2-holes FNS (2 H-FNS), and low-profile FNS (LP-FNS) and compared their biomechanical performance.MethodsAfter the mesh convergence analysis, we established three groups of 1 H-FNS, 2 H-FNS, and LP-FNS. The interfragmentary gap, sliding distance, shear stress, and compressive stress and the bone-implant interface compression stress, stiffness, and displacement were determined under the neutral, flexion, or extension conditions of the hip joint, respectively. The stress and displacement of the femur after the implant removal were also investigated.Results(1) There were no obvious differences among the three FNS groups in terms of the IFM distance. However, the LP-FNS group showed less rotational angle compared with conventional FNS (neutral: 1 H-FNS, -61.64%; 2 H-FNS, -45.40%). Also, the maximum bone-implant interface compression stress was obviously decreased under the neutral, flexion, or extension conditions of the hip joint (1 H-FNS: -6.47%, -20.59%, or -4.49%; 2 H-FNS: -3.11%, 16.70%, or -7.03%; respectively). (2) After the implant removal, there was no notable difference in the maximum displacement between the three groups, but the maximum von Mises stress displayed a notable difference between LP-FNS and 1 H-FNS groups (-15.27%) except for the difference between LP-FNS and 2 H-FNS groups (-4.57%).ConclusionsThe LP-FNS may not only provide the same biomechanical stabilities as the 1 H-FNS and 2 H-FNS, but also have more advantages in rotational resistance especially under the neutral condition of the hip joint, in the bone-implant interface compression stress, and after the implant removal. In addition, the 1 H-FNS and 2 H-FNS have similar biomechanical stabilities except for the maximum von Mises stress after the implant removal. The femur after the LP-FNS removal not only is subjected to relatively little stress but also minimizes stress concentration areas.

Damage characteristics of gas extraction boreholes under different crustal stresses and their effects on gas extraction

AbstractTo investigate the effects of different crustal stresses on the stability of gas extraction boreholes, several equations were deduced. Additionally, the coupled flow‐solid model of gas extraction was constructed, given the elasticity−plasticity deformation of the coal body. Using the numerical simulation and analysis software of Comsol, a study was conducted on the deformation and damage of gas extraction boreholes under different crustal stresses. The results are as follows: with vertical stress increasing, the concentration area of shear stress, deformation amount, and the area of the plastic zone around the hole increase. Varied lateral pressure coefficients led to differing distribution positions of shear stress concentration areas and plastic zones around the hole. An increase in lateral pressure coefficient shifted the distribution positions of shear stress maximum. In addition, plastic zone, and permeability ratio maximum change from the left and right sides of the borehole to the upper and lower sides, and the larger the lateral pressure coefficient is, the worse the stability of the upper and lower sides of the borehole is. Higher lateral pressure coefficients inhibited extraction, with the effect becoming more pronounced over time. Elevated vertical stress and lateral pressure coefficients hindered negative pressure propagation in the borehole.

Novel triply periodic minimal surfaces sandwich structures: Mechanical performance and failure analysis

AbstractSandwich structures are known for their exceptional mechanical properties and widespread applications. This study integrates additive manufacturing (AM) technology, experiments, theoretical equations, and numerical simulations to investigate a novel lightweight sandwich structure with a core based on Triply Periodic Minimal Surfaces (TPMS). The core incorporates Primitive, Neovius, and Diamond structures and is designed and manufactured using AM. Three‐point bending experiments are conducted to assess bending performance, failure modes, and energy absorption capability. A numerical model is established to analyze behavior under bending loads, validated through comparison with theoretical equations and numerical simulations, focusing on stress concentration areas. A parametric study investigates the effects of skin material, thickness, and TPMS core relative density on bending performance and energy absorption capacity. Furthermore, a functionally graded core layer with a gradient change in relative density is designed to study its influence on bending performance. The parameters of the core have a decisive impact on TPMS sandwich panel performance. This study demonstrates that sandwich structures with TPMS cores can be designed to possess desirable bending performance and energy absorption capacity, providing insights for future engineering applications.Highlights A novel TPMS sandwich structure is fabricated using 3D printing technology. The gradient relative density core is introduced. The bending performance and failure behavior of the structure are evaluated. A parametric study was conducted to investigate the effects on performance.

Characteristics and analysis of static strain response on typical asphalt pavement using fiber Bragg grating sensing technology

To study the real internal strain response of asphalt pavement and provide crucial data for optimizing pavement design. By burying the fiber grating sensors on site, the strain tests of four asphalt pavement structures under different working conditions were carried out, and the results showed that the static strain time curve is viscoelastic and conforms well to the Bugers model, and the fitting coefficient of determination is 0.98. The strain response of the asphalt surface courses of the four pavement structures under static load shows a double hump variation with the transverse position, with peaks occurring directly beneath the wheel load center. The transverse strain fluctuated between tension and compression, mirroring changes in the lateral position. While longitudinal strains, always tensile, were symmetrically aligned with the centerline of the longitudinal sensors, this pattern differed notably from that of the transverse sensors. In the base layers, the strain profile typically presented a single peak, located at the wheel gap, underscoring a critical area of stress concentration. Numerically, the peak strain of asphalt surface course is larger than that of base course. The most unfavorable loading position of the base course occurs at the wheel gap of the lower base course. The most adverse loading position of the surface course appears at the wheel load at the bottom of the upper or middle course. The research results can provide data support for improving the design method of asphalt pavement.

Preliminary Failure Analyses of Loaded Hot Water Bottles

Hot water bottles are widely utilised for their therapeutic advantages, such as relieving muscle tension and imparting warmth. However, the increasing frequency and potential risks associated with bursting or failure necessitate a detailed examination of the contributing factors as their failure is not fully understood in a scientific manner. With the apparent lack of analysis of hot water bottles in the literature, this study employs, for the first time, a dual methodology involving finite-element (FE) analysis conducted in ABAQUS and experimental validation to systematically investigate the underlying mechanisms leading to failure incidents. Through FE modelling and analysis, the stress and strain distribution within typical hot water bottles is modelled under compression loading conditions, facilitating the identification of vulnerable areas prone to failure. Experimental validation encompasses uniaxial loading compression tests on distinct specimens, generating load–displacement curves that elucidate material responses to compressive forces and highlight variations in load-bearing capacities. The study explores diverse failure modes, attributing them to stress concentration at geometric transitions and contact regions. Stress–strain curves contribute valuable insights into material characteristics, with ultimate stress values as crucial indicators of resistance to deformation and rupture. The FE analysis simulation results visualise deformation patterns and stress concentration zones. The findings illustrate that the highest stress concentration areas exist in the internal boundary of hot water bottles near the neck and cap region. This is experimentally confirmed through the bursting failures of four samples, with three failures occurring in this specific region. The findings support the guidance that users should avoid sleeping with a hot water bottle as it may fail under compression if they lay on top of it. Meanwhile, this result guides manufacturers to strengthen the weak areas of hot water bottles around the nicks and edges. This study significantly enhances our understanding of hot water bottle mechanics, thereby guiding design practice to improve overall performance and user safety. In summary, hot water bottles are commonly used but have not been investigated scientifically regarding external loading conditions and their related failure, as the current study has achieved. Identifying the weak points through experiment and simulation directs manufacturers towards required improvements in particular regions, such as the bottleneck and edge reinforcement during the design and manufacturing phases.

A Case Study of Fragmentation Improvement by Primer Placement in Kevitsa Mine

The effect of detonator placement on rock fragmentation by blasting was studied in the Kevitsa open-pit mine. Considering rock mass properties, explosives properties, and blast parameters, a comprehensive analysis of 37 production blasts confirms that the middle detonator yields finer fragmentation than the bottom detonator in the full range of investigated sizes. Meanwhile, using the LS-DYNA code, a bench model with a single blasthole was built in a three-dimensional setting. A single detonator placed at two different positions—the middle and bottom—of the explosive column was analyzed in this study. By analyzing principal stress states on the plane through the blasthole axial and vertical to the bench face, the numerical results show that the middle detonator creates a stress concentration area near the bench face characterized by triaxial tension, while the bottom detonator does not. Furthermore, the middle detonator generates a larger stress concentration area with biaxial tension near the bench face than the bottom detonator. Considering that triaxial and biaxial tensions are more favorable to fragmentation than uniaxial tension, it can be concluded from simulation results that these areas with triaxial tension and biaxial tension in the middle detonator are a significant factor contributing to achieving better fragmentation, compared to the bottom detonator. The middle detonator position has replaced the bottom detonator position in the Kevitsa mine.

Ultimate strength failure mechanism and optimization design of marine composite deck grillage structures with opening

In this paper, the ultimate bending strength and the failure mechanism of the marine composite deck grillage structure are experimentally and numerically investigated, before the optimization design is conducted to enhance the ultimate bearing capacity. The ultimate strength experiment of the composite deck grillage structure is first carried out. Based on the improved progressive failure method and the cohesive damage theory, the numerical simulation considering fiber failure, matrix failure, shear failure and adhesive layer failure is conducted and the predicted strains, load–displacement curves, and failure modes of the specimen are compared with the experimental ones to verify the accuracy of the present method. Both experimental and predicted results show that the stiffeners and the laminated deck near the opening are the stress concentration areas, and the matrix failure is main failure mode. The optimization results show that the suitable panel thickness can reduce the stress concentration effect and avoid premature fracture in localized areas due to stress concentration. The increase of the stiffener heights can significantly increase the ultimate strength and the bending stiffness. These findings can provide support for the design of composite deck grillage structures in ships.

Stability Analysis of Yebatan Underground Cavern Surrounding Rock based on Crack Evolution Theory

The deformation properties of rock are closely related to the effect of crack closure, generation and expansion in the rock. In this paper, the stress-crack strain evolution constitutive model is used to determine the relaxation damage zone of the surrounding rock based on the change regulation of the crack closure ratio during the whole process of surrounding rock damage, and the model is embedded into FLAC3D software, and then the stability evaluation of the surrounding rock of the cavern group under unsupported and supported conditions is carried out for the underground plant of Yebatan hydropower station. The excavation simulation shows that the displacement of the cavern surrounding rock increases with the excavation step, and the influence of the fault on the displacement of the surrounding rock is very significant. The high stress concentration area is distributed in the arch top of the plant, the tailwater connection hole, the arch top and the bottom of the tail chamber, and the tensile stress area is mainly distributed in the high side wall of the underground plant and the tail chamber. The crack closure ratio index was used to quantitatively evaluate the degree of relaxation damage of the surrounding rock, indicating that the relaxation damage area is influenced by the fault, and the volume of the surrounding rock damage area under the system support is significantly reduced compared with the unsupported working condition, showing the effectiveness of the support measures.

Triaxial behavior of unreinforced and geogrid-reinforced calcareous gravelly sand: Experiment and discrete element modelling

Geogrid reinforcement is a feasible technique for improving the mechanical and deformation behaviors of calcareous gravelly sand that is predominantly distributed in reclaimed foundations as construction materials. However, the shear behavior of geogrid-reinforced calcareous gravelly sand still remains unclear. In this paper, a series of large-scale drained consolidated triaxial compression tests (the specimen 300 mm in diameter by 600 mm in height) were conducted to investigate the effects of confining pressure, moisture content and geogrid inclusion on the mechanical and deformation behaviors of calcareous gravelly sand. The dilation effect, strain-softening behavior, reinforcing effect and particle breakage characteristics of unreinforced and geogrid-reinforced calcareous gravelly sand were comprehensively analyzed and discussed. Additional analysis was also performed from a microscopic perspective using the three-dimensional discrete numerical modelling. The experimental results indicate that calcareous gravelly sand exhibited a greater resistance to strain-softening tendency, and produced a higher susceptibility to crushing under the same input energy than calcareous coarse sand. Geogrid inclusion can effectively mitigate the susceptibility of calcareous gravelly sand to volumetric dilation through constraining the lateral expansion within the reinforced zone, and thus substantially increased the peak shear strength. Moreover, particle breakage appeared to be insensitive to geogrid reinforcement and water content, but increased significantly with increasing confining pressures. The numerical results further indicate that the mechanical response of geogrids was regulated by axial strain and confining pressure. As axial strain was greater than 10%, increased confining pressure resulted in a wider area of stress concentration within the geogrid meshes, and the upper geogrid sustained a greater contact force and tensile strain. The findings in this study are of practical significance for the design and construction of structures in calcareous gravelly sand reinforced with geogrids.

DESIGN AND ANALYSIS OF PRESSURE VESSEL USING DIFFERENT MATERIALS

This project explores the field of Finite Element Analysis (FEA) in relation to pressure vessels that have different head configurations, while ensuring that the cylindrical volume and thickness remain uniform. The project adheres to ASME standards, specifically Section VIII, Division I, and focuses on designing a pressure vessel that can withstand a pressure of 8 bar within a volume of 24 liters. The main objective of using FEA is to identify areas of stress concentration in each head design. In industrial settings, pressure vessels play a crucial role in containing fluids or gases under varying pressures. The choice of head configuration significantly impacts the distribution of stress and the overall structural strength. This project specifically utilizes ANSYS software for static and thermal analyses to compare stress distribution in pressure vessels with flat heads, elliptical heads, and other common head designs. The goal is to identify configurations that exhibit lower stress levels, with a particular emphasis on practical scenarios that favor elliptical heads. Additionally, the project explores finite element modeling techniques to evaluate pressure vessels made from different materials such as Nimonic 80A and SA516 Gr70 under high-stress conditions

Three-dimensional mechanical characteristics analysis of double-shoulder tool joint under complex loads

Taking a new type of special threaded drill pipe joint as the research object, a 3D nonlinear finite element model of the double-shoulder tool joint (DSJ) including the engage and retract groove structure is established by considering the factors of structural asymmetry and contact of each engaging surface. ABAQUS/Explicit finite element method (FEM) is used to study the stress and contact pressure distribution characteristics of the critical structure of DSJ under make-up torque and axial tension. The accuracy of the finite element model was verified by combining with a full-scale physical test, and the connection strength and sealing performance of DSJ are evaluated. The results show that the stress concentration occurs at the key structure of DSJ under the make-up torque. The geometry size and structural discontinuity at the transition fillet of the double-shoulder structure have a significant effect on the stress and contact pressure distribution on the shoulder. Under axial tension, the stress level and stress concentration area of the whole joint and the key structure change, especially in the thread section. The sealing performance on the shoulder decreases significant, while that of the thread section increases slightly. The test results are consistent with the finite element analysis findings, and this joint shows good mechanical properties, which can meet the design requirements of drilling tool manufacturers and provide data support for its optimal design and application.

Study on Spontaneous Combustion Risk Areas in Narrow Coal Pillar-Utilized Deep Mining and Double-Pipe Liquid CO2 Injection Technology

ABSTRACT Coal spontaneous combustion (CSC) in goafs, one of the most serious disasters in coal mines, not only wastes resources and destroys the ecological environment, but also causes casualties. As global underground mining gradually shifts to the deep, this problem becomes increasingly prominent. Deep mining is operated in a complex mechanical environment characterized with high stress, high permeability, high temperature, and strong mining disturbance. To avoid stress concentration areas, narrow coal pillars are often utilized in roadway excavation along the goaf. However, narrow coal pillars are likely to fracture and lose stability during the mining process. Consequently, goaf areas of two adjacent working faces might connect, which promotes the CSC risk in the goaf. Most of the current researches are focused on CSC risk areas under shallow mining conditions and the CSC-gas coupling disasters, yet research on CSC risk areas in the goaf triggered by narrow coal pillars under deep mining conditions is rarely reported. Moreover, there is a lack of relevant means to prevent and extinguish fires. This study takes the narrow coal pillar-utilized 130,205 working face in Yangchangwan Coal Mine as the research object. First, the development of coal pillar fractures was simulated by adopting the discrete element method of PFC. Besides, on-site monitoring and FLUENT numerical simulation were conducted to identify CSC risk areas in the goaf of the narrow coal pillar-utilized working face. Finally, a double-pipe liquid CO2 injection technology was proposed for fire prevention and extinguishing. The following beneficial results were obtained. Affected by high stress in deep mining, the coal pillar collapses, which expands the range of the oxidation zone on the return side. Meanwhile, the adjacent goaf is also exposed to CSC risk. Double-pipe liquid CO2 injection can effectively reduce air leakage near the working face and suppress spontaneous combustion of residual coal by inerting the goaf. This study can provide guidance and reference for fire prevention and extinguishing in goafs under the condition of narrow coal pillar-utilized deep mining.

Magnetic leakage behavior assessment in pipeline stress-concentrated areas using improved force-magnetic coupling model.

Magnetic flux leakage (MFL) technology is remarkable for its capability to detect pipeline geometric deformation and general corrosion defects. However, it cannot characterize the MFL behavior in stress-concentrated areas, thereby greatly challenging the subsequent pipeline maintenance. This study suggests that the MFL characteristics of pipeline in stress-concentrated areas are caused by the combined effect of the face magnetic charge on the deformed end-face and the body magnetic charge of the dislocation stack. In addition, an improved force-magnetic coupling model of the pipeline in stress-concentrated areas is established based on the magnetic dipole model and Jiles-Atherton (J-A) theory. In the verification experiment, the Q235 steel plate is magnetized along the extension direction (axis of the pipeline) through the solenoid coil to obtain the distribution law of the MFL signal in the stress-concentrated area under different excitation intensities. The results show that with the increase in excitation intensity, the deformation of the MFL field signal caused by the end-face of the stress-concentrated area gradually increases to a stable state. Moreover, the internal stress of the MFL field signal generated by the pipe dislocation rapidly increases to a peak value and then decays exponentially to a certain base value. The overall change trend is in good agreement with the calculation results of the established force-magnetic coupling model. Meanwhile, the differentiation research between deformation and internal stress MFL field signals under different magnetic field intensities can provide a reliable theoretical basis for the subsequent accurate identification and quantification of pipeline stress-concentrated areas.

Hybrid interlayer hot rolling and wire arc additive manufacturing of Al-Mg alloy: Microstructure, mechanical properties and strengthening mechanism

Considering the deformation-strengthening benefits of Al-Mg alloy and the high forming efficiency offered by wire and arc additive manufacturing (WAAM), the microstructure evolution and strengthening mechanism of hybrid interlayer hot rolling and wire arc additive manufacturing (HR-WAAM) samples have been systematically investigated in this study. The results indicate that interlayer hot rolling can effectively reduce the size and number of pores, which diminishes the stress concentration areas. Additionally, rolling deformation significantly enhances the effect of dislocation strengthening. Furthermore, a high density of dislocations can promote recrystallization to refine grain size, while also improving grain orientation, all of which contribute to better stress distribution. Due to these reasons, the strength and toughness of the alloy are notably improved. The average ultimate tensile strength (UTS), yield strength (YS), and elongation (EL) values achieved by HR-WAAM samples were 338 MPa, 276 MPa, and 20.9%, respectively. These values represent increases of 28.5%, 41.5%, and 38.4% compared to conventional WAAM samples. These findings are expected to provide an efficient and cost-effective method for additive manufacturing (AM) of deformation-strengthened aluminum alloys.

Effect of sintering on stress distribution of thermal barrier coatings for high temperature blade

In the process of long-term high temperature service, thermal barrier coatings (TBCs) will inevitably be sintered, leading to pores healing and porosity decline, which will affect the microstructure and the stability of mechanical properties of TBCs. To understand the relationship between the microstructural changes of sintered TBCs and the mechanical properties, in this work, the cross-sectional microstructure of TBCs at different sintering times were investigated by scanning electron microscopy (SEM). After calculating the porosity and pore size distribution, two-dimensional (2D) numerical models were developed for five different porosities (16 %–12 %) by an improved reconstruction method with layer-by-layer labeling. Based on the results of finite element (FE) analysis after thermal cycling, it was found that the coating's irregular pore structures lead to stress concentration, which affects the mechanical properties of the coating to a great extent. For the whole TC layer, the level of stresses increases and the absolute value of maximum stress augments significantly by 46 % associated with the doubled increase of stress concentration areas with the densification of coating. For the local areas of TC layer, the changes in pore morphology led to a more complex variation in local stress fields. At the TC/BC interface, the Mises stress level tends to increase with decreasing porosity during sintering. At the TC surface, coatings with lower porosities cause higher stresses near this region. The insights gained from the numerical results contribute to a better understanding of the failure behavior of real TBCs systems and help to further remedy the deficiencies and difficulties of the experimental work.

Prediction of fretting fatigue lifetime of aluminium alloy treated with Friction Stir Processing using continuum damage mechanics

In the aviation industry, fretting fatigue represents a significantly hazardous form of fatigue failure, thus warranting substantial research attention. A key area of focus lies in enhancing the fretting fatigue resistance of aluminium alloys. This study investigates the feasibility of using Friction Stir Processing (FSP) to enhance fretting fatigue lifetime. After FSP, large-size inclusions in the Base Material (BM) are shattered, clustered inclusions are dispersed, and the preferred orientation of inclusions is disrupted. Consequently, areas of stress concentration, damage concentration and merging of hazardous zones become less, and the peak values of stress, stress triaxiality, and damage are decreased with 6–10 %. Compared to BM, the results show that the fretting fatigue lifetime of Friction Stir Processed (FSPed) material is increased by 50.1 %. Hence, FSP could emerges as a highly promising surface treatment technique for enhancing fretting fatigue performance.