Stress Development Research Articles

Effectiveness Spatiotemporal of Pressure Unloading and Gas Extraction in Remote Upper Protected Seam Mining.

Severe gas hazards are increasing in deep mining areas, and there exists an enormous traditional challenge for protected seam mining. In this work, we conducted a multifaceted investigation into the spatiotemporal effectiveness exerted by pressure unloading from a distant safeguarded stratum in concert with the application of gas extraction methodologies. The stress and displacement evolution in the protected coal seam (PCS) are analyzed by applying Flac3D, and then positives are verified by the measurement of coal seam deformation and investigation of the unloading boundary. The results show that diminution coefficient of 0.62, and record an expansive deformation rate of 5.83%. The opportune temporal window for effective gas drainage is discerned, with its time window spans from 58 to 67 days as the expanse between 350 and 400 m progresses at the working face. Continuous and effective gas extraction occurs when transverse cracks in the PCS reach an optimal state of pressure relief. The final cumulative gas extraction was 320,300 m3 with an extraction efficiency of 34.3%. A residual gas volume of 3.68 m3/t and a residual gas pressure of 0.5 MPa reflect the efficient gas extraction.

Study on Geological Deformation of Supercritical CO2 Sequestration in Oil Shale after In Situ Pyrolysis

After the completion of in situ pyrolysis, oil shale can be used as a natural place for CO2 sequestration. However, the effects of chemical action and formation stress-state changes on the deformation of oil shale should be considered when CO2 is injected into oil shale after pyrolysis. In this study, combined with statistical damage mechanics, a transverse isotropic model of oil shale with coupled damage mechanisms was established by considering the decreased mechanical properties and the chemical damage caused by CO2 injection. The process of injecting supercritical CO2 into oil shale after pyrolysis was simulated by COMSOL6.0. The volume distribution of CO2 and the stress evolution in oil shale were analyzed. It is found that CO2 injection into oil shale after pyrolysis will not produce new force damage, and the force damage caused by the decrease in the mechanical properties of oil shale after pyrolysis can offset the ground uplift caused by CO2 injection to a certain extent. Under the combined action of chemical damage and mechanical damage, the uplift of a formation with a thickness of 200 m is only 10 cm. The injection of supercritical CO2 is beneficial for maintaining the stability of oil shale after in situ pyrolysis.

Operando chemo-mechanical evolution in LiNi0.8Co0.1Mn0.1O2 cathodes.

Ni-rich LiNi x Co y Mn z O2 (NCMxyz, x+y+z=1, x≥0.8) layered oxide materials are considered the main cathode materials for high-energy-density Li-ion batteries. However, the endless cracking of polycrystalline NCM materials caused by stress accelerates the loss of active materials and electrolyte decomposition, limiting the cycle life. Hence, understanding the chemo-mechanical evolution during (de)lithiation of NCM materials is crucial to performance improvement. In this work, an optical fiber with με resolution is designed to in operando detect the stress evolution of a polycrystalline LiNi0.8Co0.1Mn0.1O2 (P-NCM811) cathode during cycling. By integrating the sensor inside the cathode, the stress variation of P-NCM811 is completely transferred to the optical fiber. We find that the anisotropy of primary particles leads to the appearance of structural stress, inducing the formation of microcracks in polycrystalline particles, which is the main reason for capacity decay. The isotropy of primary particles reduces the structural stress of polycrystalline particles, eliminating the generation of microcracks. Accordingly, the P-NCM811 with an ordered arrangement structure delivered high electrochemical performance with capacity retention of 82% over 500 cycles. This work provides a brand-new perspective with regard to understanding the operando chemo-mechanical evolution of NCM materials during battery operation, and guides the design of electrode materials for rechargeable batteries.

Sustained Strain Applied at High Rates Drives Dynamic Tensioning in Epithelial Cells.

Epithelial cells experience long lasting loads of different magnitudes and rates. How they adapt to these loads strongly impacts tissue health. Yet, much remains unknown about their stress evolution under sustained strain. Here, by subjecting cell pairs to sustained strain, we report a bimodal stress response, where in addition to the typically observed stress relaxation, a subset of cells exhibits a dynamic tensioning process with significant elevation in stress within 100s, resembling active pulling-back in muscle fibers. Strikingly, the fraction of cells exhibiting tensioning increases with increasing strain rate. The tensioning response is accompanied by actin remodeling, and perturbation to actin abrogates it, supporting cell contractility's role in the response. Collectively, our data show that epithelial cells adjust their tensional states over short timescales in a strain-rate dependent manner to adapt to sustained strains, demonstrating that the active pulling-back behavior could be a common protective mechanism against environmental stress.

Relaxation of residual stress in welded plates during long life fatigue loading

The presence of residual stress in welded components can have a significant impact on fatigue response. Residual stresses were assessed in thick welded A36 cantilever specimens (T-specimens) at the fatigue critical area. Testing involved subjecting the T-specimens to varying bending stresses and load cycles, leading to different levels of local plasticity at the weldtoe. Extensive X-ray diffraction (XRD) measurements were conducted to analyze the residual stress distribution near the weldtoe. Residual stress states were evaluated in both as-welded specimens and those subjected to fatigue loading with strain amplitudes up to 0.001 at the weldtoe stress concentration zone. The findings suggest that fatigue loading can induce changes in the welding-induced residual stress field, ranging from moderate to significant alterations. Therefore, fatigue life predictions should consider the potential evolution of residual stresses due to cyclic loading, including the effects of cyclic stress relaxation in fatigue life calculations.

Development of Compaction Localization in Leitha Limestone: Finite Element Modeling Based on Synchrotron X‐Ray Imaging

AbstractThe mechanical behavior and failure mode of porous rocks vary with their microstructures. The formation of compaction bands (CBs) has been captured with high precision via in situ synchrotron CT and kinematic characteristics can be attained by image analysis. However, the stress characteristics cannot be directly evaluated from images, and how porosity heterogeneity triggers local instability and leads to the formation of CBs is not yet fully understood. To address this problem, we established a finite element (FE) model of the solid skeleton of a Leitha limestone sample based on X‐ray μCT data, considering the heterogeneity of pores and plastic hardening, and reproduced the evolution of strain localization and CBs. Our results revealed that the heterogeneity of porosity has a profound influence on the formation and propagation of CBs. Precursory stresses always appear very early around the pores where compaction bands develop, and the stress state of most points in CBs is quasi‐uniaxial compression, which has significantly high maximum principal stress σ1 in a direction subparallel to the sample axis, causing yield then compaction failure. Also, using a simplified FE mesh and ignoring the fracture of particles underestimate the extreme stress and porosity reduction—these can be improved by using fine mesh and involving grain‐scale fracture mechanics. Our study proves the feasibility and reliability of the CT‐FE simulation scheme, which can be extended to investigating the stress distribution and evolution of different rock types with a spectrum of failure modes if in situ CT data of rock deformation is available.

Elastoplastic mechanical behavior analysis of surface-coated Zircaloy-4 cladding under multi-field coupling

The elastoplastic mechanical behavior of Zircaloy-4 (Zr-4) cladding, coated with chromium (Cr) or FeCrAl on its surface, is explored under the coupled effects of multi-field coupling. Utilizing the Finite Element Software ABAQUS, simulations are conducted to calculate the evolution of stress and strain over two complete fuel cycles. Comparisons are drawn between the coated and uncoated Zircaloy-4 cladding materials. The results indicate that the application of surface coatings significantly mitigates stress levels in the cladding during the first fuel cycle. During the second fuel cycle, all three types of cladding exhibit relatively minor plastic strain, which is attributed to the unloading and reloading process between cycles. Notably, the plastic zone propagates from the interior to the exterior of the cladding. When compared to traditional Zircaloy-4 cladding, the coated cladding exhibits improved elastoplastic mechanical behavior. The operational mechanism of the coating for different stresses in cylindrical coordinates and its response to unloading and reloading cycles are also investigated. Specifically, the coated claddings exhibit an evident delay in reaching full plasticity compared to uncoated claddings. Furthermore, FeCrAl coating material initially shows good performance, and it needs to be verified in more aspects in the future. Results and Conclusions in this paper can provide reference and guidance for future experiments.

Characterization of loading, relaxation, and recovery behaviors of high‐density polyethylene using a three‐branch spring‐dashpot model

AbstractThis paper presents an analysis of the stress evolution of high‐density polyethylene (HDPE) at loading, relaxation, and recovery stages in a multi‐relaxation‐recovery (RR) test. The analysis is based on a three‐branch spring‐dashpot model that uses the Eyring's law to govern the viscous behavior. The spring‐dashpot model comprises two viscous branches to represent the short‐ and long‐term time‐dependent stress responses to deformation, and a quasi‐static branch to represent the time‐independent stress response. A fast numerical analysis framework based on genetic algorithms was developed to determine values for the model parameters so that the difference between the simulation and the experimental data could be less than 0.08 MPa. Using this approach, values of the model parameters were determined as functions of deformation and time so that the model can simulate the stress response at loading, relaxation, and recovery stages of the RR test. The simulation also generated 10 sets of model parameter values to examine their consistency. The study concludes that the three‐branch model can serve as a suitable tool for analyzing the mechanical properties of HDPE, and values for the model parameters can potentially be used to characterize the difference among PEs for their mechanical performance.Highlights Developed computer programs to determine parameter values automatically. Explained the unusual stress drop during stress recovery after unloading. Evaluated the statistical range of the parameter values for the good fitting.

Model experimental study on the mechanism of collapse induced by leakage of underground pipeline

The evolution and mechanism of ground collapse caused by underground water pipeline leakage have become increasingly significant as more urban areas experience collapses. Based on the principle of similarity, and considering the engineering context of road collapses in Anqing City, Anhui Province, this study designed a 3 m × 2 m × 2 m rupture-collapse model test device. Digital Image Correlation (DIC) technology was employed to investigate the erosion process and collapse mechanisms caused by underground pipeline leakage. The results indicate that groundwater seepage provides the driving force for collapses, combined with the migration space provided by defects, collectively triggering the collapses. When groundwater seepage is minimal, the cohesive forces between soil particles maintain soil stability. As groundwater seepage increases, the soil particle framework is eroded, leading to soil structure destabilization and collapse initiation. The depth of collapse significantly influences stress evolution: stress evolution intensity beneath and above the collapse pit is positively correlated with the distance from the collapse pit bottom, but negatively correlated with the distance from the defect. The research provides insights for the early warning and management of ground collapse.

Characterization of energy-driven damage mechanism and gas seepage in coal under mining-induced stress conditions

Gas seepage and progressive failure of coal are common energy-driven mining phenomena. A comprehensive understanding of the energy-driving mechanism behind the catastrophic behavior of mining-induced coal is fundamental to innovating the technology of coal and gas co-mining. Thus, this study simulated three typical mining stress evolution process in protective coal-seam mining (PCM), top-coal caving mining (TCM), and non-pillar mining (NM) to investigate the energy evolution and distribution patterns of coal. The results indicate a strong correlation between energy dissipation and gas seepage. By transitioning from PCM and TCM to NM, the peak elastic strain energy of gas-bearing coal increased by 155.92 %, and the ratio of peak dissipative energy decreased from 51 % to 41 %. Under the PCM stress path, gas seepage decreased the energy storage by 13.52 %, whereas the pre-mining pressure relief and enhanced permeability simulation increased in peak dissipation energy by 49.66 %. Using the cumulative dissipative energy as a damage variable reveals that the degree of coal damage evolution under PCM is higher than other mining methods. Based on the energy-driven damage mechanism, a new coal permeability model was established, and its comparison with classical permeability model demonstrated its excellent fitting effectiveness.

Optimisation of process-induced residual stresses in composite laminates by different genetic algorithm and finite element simulation coupling methods

To address the residual stress induced during the cure of fibre reinforced thermoset polymer composites, two different approaches were suggested for coupling a non-dominated sorting genetic algorithm (NSGA-II) with finite element (FE) simulations based on a viscoelastic constitutive law. These two approaches were proposed with consideration of different ways of integrating NSGA-II and the FE model. In Approach A, NSGA-II was performed based on results from a series of simulations under various combinations of cure variables. Alternatively, Approach B employed NSGA-II to iteratively update and optimise the cure profile for subsequent simulations. Results indicated that both approaches achieved simultaneous reductions in cure time and macroscale residual stress, with Approach B showing further improvements due to the direct coupling between the NSGA-II and simulations. Specifically, the maximum residual stress and cure time optimised by Approach A were reduced by 5%–9% and 22%–50% respectively, while those obtained by Approach B were reduced by 7%–10% and 32%–49% respectively, compared to those based on the manufacturer recommended cure profile. The evolution of stress in composites based on optimised cure profiles from these two approaches was also elucidated. Additionally, microscale modelling further revealed a 3%–5% reduction in the average residual stress within a representative volume element (RVE) model was also shown, depending upon the approach adopted. Ultimately, by combining a NSGA-II and FE simulations, the optimisation of cure time and residual stress at the macroscale and cure time together with a reduction of microscale stress could be realised.

Superior Lightness-Strength and biocompatibility of bio-inspired heterogeneous glass sponge Ti6Al4V lattice structure fabricated via laser powder bed fusion

Ti6Al4V lattice structures (LSs) have great potentials in medical implants due to their excellent biocompatibility and high strength-to-weight ratio. This paper investigates the manufacturability and performance of unique Ti6Al4V heterogeneous glass sponge (GS) LSs fabricated via laser powder bed fusion (LPBF). Compared with the commonly used LSs, including Cross, body-centered cubic (BCC), Diamond and octet-truss (OCT), Ti6Al4V GS LSs exhibit the strongest compressive strength and energy absorption ability of 58 MPa and 23.84 J/cm3, respectively. Finite element (FE) models are established to evaluate the macroscopic deformation, microscopic stress and strain evolution in the solid struts of five different LSs. Local plastic stresses are found to generate near the nodes of Cross, BCC, Diamond and OCT LSs, thus forming plastic hinges, while the GS LSs can evenly transfer local plastic stresses to the grid-like rods of each layer, eventually showing a uniform stress distribution. Moreover, all the LSs are featured with satisfactory biocompatibility concerning cytotoxicity, cell proliferation, and cell attachment. The results indicate that the Ti6Al4V GS LSs can address the conflict between lightness and strength simultaneously, thus achieving excellent energy absorption performance, compressive properties and great biocompatibility, endowing it with tremendous application potential in the field of medical implants.

Assessment of Microseismic Events via Moment Tensor Inversion and Stress Evolution to Understand the Rupture of a Hard–Thick Rock Stratum

Assessment of Microseismic Events via Moment Tensor Inversion and Stress Evolution to Understand the Rupture of a Hard–Thick Rock Stratum

Hydrogen penetration into the NiTi superelastic alloy investigated in-situ by synchrotron diffraction experiments

Microstructural changes induced by a hydrogen permeation into the NiTi superelastic alloy were investigated in-situ using the X-ray synchrotron diffraction. A new design of an electrochemical cell enabled to uncover time and position dependent processes under a flat alloy surface exposed to the cathodic hydrogen. The diffraction data supported by thermo-elastic FEM calculations helped to quantify an evolution of compressive stresses in the B2 austenitic phase hosting hydrogen atoms. The compressive stress state initiates a formation of martensitic phases starting from the exposed surface layer and advancing into the alloy volume with increasing time of hydrogen charging. We have performed the ab-initio DFT study in order to rationalize volumetric changes associated with variations in the B2 austenite and B19′ martensite lattice parameters. The numerical results also contributed to the identification of a new hydride phase with orthorhombic crystal structure and lattice parameters a = 0.8505 nm, b = 0.7366 nm and c = 0.4722 nm.

Micromechanism insights and constitutive modeling for deformation in a novel high manganese austenitic steel

We explore the mechanical behavior and microstructural evolution of a novel high manganese austenitic steel (HMAS), extensively applied in underground engineering and structural construction. Our investigation focuses on two variants of HMAS, namely HMAS-1.9 and HMAS-10, which exhibit distinct yield strengths and elongation behaviors. Electron backscatter diffraction (EBSD), transmission electron microscopy (TEM) and X-ray diffraction (XRD) were employed to elucidate the evolution of microstructures during plastic deformation. Based on these experimental results, we developed a new phenomenological multiscale constitutive model that captures the mechanical behavior of HMAS, integrating micromechanisms and microstructural evolutions. Optimized with the MATLAB genetic algorithm toolbox, this model was successfully implemented in a uniaxial tensile finite element model (FEM) within ABAQUS, proving its efficacy in predicting both macroscopic flow stress and microstructural evolutions. Our findings highlight the important roles of initial grain size, dislocation density, and twin fraction in determining the mechanical properties of HMAS. Throughout the deformation process, both HMAS variants demonstrate similar plastic deformation behaviors, characterized by comparable rates of increase in dislocation density and twinning fraction, accompanied by a consistent trend of grain refinement. These findings not only deepen our understanding of the complex relationship between microstructure and mechanical properties of the HMAS steel, but also provide an effective multiscale constitutive modeling approach for predicting its deformation behavior.

Residual stresses prediction in transition metal nitrides sputtered coatings using artificial neural network and experimental evaluation of surface morphology

In the production of transition metal nitride hard coatings under specific deposition conditions, the resulting residual stresses play a critical role in determining the mechanical properties, adhesion, and overall performance of the coatings. In this work, an artificial neural network (ANN) that utilizes feed-forward architecture is used to predict the average residual stress in titanium nitride (TiN) coatings with different coating thickness. These coatings are manufactured under varying bias voltages and temperature on substrate. The impact of variations in coating thickness, bias voltage, and temperature on development of internal residual stresses and changes in microstructure within sputtered coatings have been gathered from existing literature. The data collected is within the context of fibrous (zone I) and mix columnar and fibrous structure (combined zone) as defined by an existing structure zone model. The model is trained with experimental data from literature. The model is trained with experimental data from literature. The validation of the ANN model is carried out by comparing the predictions with experimental results. X-ray diffraction is used to analyze the residual stresses, preferred orientation, and the structure (zone I and combined zone) of produced coatings under different sputtering parameters. The regression and performance curves are used to assess the efficacy of ANN model. The coefficient of determination of trained model and mean square error are 0.9918 and 0.35, respectively. The predicted results show good agreement with experimental and subsequently AFM grain morphology analysis captures the growth mechanisms involved in the residual stresses evolution.

Comprehensive Understanding of TGO Morphology Effect on the Thermal Barrier Coatings Failure Under Free Edges

Abstract The growth stresses induced by the thermally grown oxide (TGO) will be amplified at the free-edge site, making the free-edge site a weak part of the thermal barrier coatings (TBCs). In this study, the TBCs failure behavior is investigated based on different TGO morphologies under free edges. The thermomechanical model is established by creating straight lines and simplified sinusoidal curves, respectively. Dynamic TGO growth is realized by the secondary development of the subroutine. The cohesive element is inserted at the TC/TGO interface to simulate the delamination. The stress evolution near different TGO morphologies under the influence of the free edge are examined. In addition, the interfacial cracking behavior near the free edge is also explored. The results show that the appearance of the free edge will deteriorate the stress condition in the nearby area, change the preferred cracking area, and induce the earlier failure behavior. The straight line morphology has the most “friendly” stress distribution. The sinusoidal curves have peaks and valleys, and different areas of the TGO shape are different under the influence of the free edge, but all of them have the effect of stress “convergence”. These results can provide significant guidance to develop the next-generation advanced TBCs.

Excellent high temperature mechanical properties of Fe2Ni2CrAlx (x= 0.9 to 1.3) multi-principal elements alloys

The high temperature mechanical properties of a family of Fe2Ni2CrAlx (x=0.9, 1.1, 1.2, 1.3 in molar ratio) multi-principal element alloys (MPEAs) were determined. The initial microstructure and grain size of Fe2Ni2CrAlx MPEAs were characterized. Effect of Al on the density, melting point and mechanical properties at elevated temperature were investigated. Fe2Ni2CrAl1.3 MPEA exhibit the lowest density of 6.78 g/cm3 and highest melting point of (1337.7 ∼ 1392.6 °C). The as-cast Fe2Ni2CrAl1.3 MPEA showed an excellent combination of strength and plasticity at elevated temperatures. Fe2Ni2CrAl1.3 MPEA showed high strength of 2119 MPa and 1722 MPa at 200 °C and 400 °C, respectively. The Fe2Ni2CrAlx alloys exhibited exceptional high-temperature plasticity, no fracture occurred even at a compressive strain above 70%. Recrystallization softening appeared at above 600 °C, the transformation of coarse equiaxed grains into subgrains were captured during plastic deformation. Significantly, the specific yield strength of the Fe2Ni2CrAl1.3 MPEA was comparable with traditional Ti based alloys and Ni-based superalloy. The fracture mechanism of Fe2Ni2CrAlx MPEAs was a combination of cleavage and slip separation. Deformation behavior and work hardening ability at elevated temperature were discussed. Finally, finite element method (FEM) was performed to capture the evolution of stress and strain under high-temperature compression.

The development of grain resolved stress fields around notch tips in soft-textured zirconium polycrystals: A three-dimensional synchrotron X-ray diffraction study

Texture, microstructure, and local grain neighbourhood contribute to the development of localized stresses in polycrystals. For hexagonal close-packed materials, crystal's elastic and plastic anisotropy can also be a major contributing factor, yet there is a paucity of experimental studies focusing on the extent of contribution of such parameters on the magnitude of localized stresses at microscales. This study focuses on addressing this knowledge gap by deforming double-edge-notched soft-textured α-zirconium specimens in-situ, while measuring grain scale tensorial stresses using high energy synchrotron X-ray diffraction. The specimens were subjected to cyclic loads to study the evolution of stresses in the vicinity of both shallow and deep notches. The soft-texture of the specimens is such that there are no c-axes of grains aligned along the macroscopic loading direction thereby inhibiting deformation twinning. The “as-measured” microstructures and notch geometries were imported into a crystal plasticity finite element model for further analysis. Results show that despite the absence of c-axes of grains aligned along loading direction, the developed stresses were substantially influenced by crystallographic orientations. Stress drop was observed near the onset of plasticity with further loading and the orientation and position effects were highlighted. A plastic deformation mechanism was revealed where, upon specimen loading, the mechanical constraints enforced during grain-grain interactions led to hardening. Accordingly, a parameter was devised to quantify the grain level hardening arising from this mechanism. It was shown that grain-scale stress concentration factors vary significantly before the onset of plasticity, but they settle in the plastic zone and with the progression of cycles.

Fatigue deformation behavior and fracture mechanism of high fatigue-resistant laser directed energy deposition fabricated titanium alloy: Effect of multi-scale microstructure

The application of the laser directed energy deposition (LDED) titanium (Ti) alloys has been severely impeded by their poor low cycle fatigue (LCF) properties in aerospace industry. Herein, we propose to improve the LCF properties of LDED-ed Ti6Al4V alloys via microstructure adjustment. A solid solution aging 850AA treatment is made to regulate the microstructure into a multi-scale composition dominated by discontinuous αGB and coarsened αP+(αS+β) phases. The LCF properties of LDED-ed Ti6Al4V with a multi-scale microstructure even outperform the wrought Ti6Al4V at high strain amplitudes. Furthermore, this multi-scale microstructure has special local plastic deformation behavior and dislocation activities under cyclic stress loading, which strongly affects the internal stress evolution and crack propagation. The fatigue softening behavior is attributed to the combined effect of back stress and friction stress. Fatigue cracks are deflected by the α/β boundary when the angle (φ) between the long axis of α lamellae and the crack direction is less than 35°. The transgranular fracture occurs when φ is close to 90° (70°–90°). Meanwhile, the fatigue crack usually propagates along the basal or prismatic planes with high Schmid factors. These findings provide novel insights into the microstructure design of LDED-ed Ti alloys with high fatigue damage tolerance.