Life Prediction Of Structures Research Articles

Tension Performance Prediction and Experiment of Optical Smart Composites Using Micromechanical Failure Theory

Abstract Embedding fiber optic sensors in composites can long-term instantly monitor the deformation and damage within the composite structure, which realizes structural health monitoring and life prediction. However, fiber embedding generally brings damage in terms of the composite material integrity and continuity, resulting the extreme stress concentration in the interface of the optical fiber and composite. Therefore, the mechanical properties of the composite material are potentially influenced unfavorably. To investigate the influence of microstructures such as optical fibers on the macroscopic tensile mechanical properties of composites, this paper develops a progressive damage analysis model inspired by the micromechanical failure theory. The established model can predict the stiffness and strength properties of fiber smart composites. The model is further verified by comparing the obtained tensile failure mechanism with the experimental results. The results show that the maximum relative error of the destructive load is only 3%, which demonstrates the accuracy and validity of the model. The work of this paper can provide guides for the optimization and strength prediction of smart composite structures with embedded optical fibers.

Thermal–structural response and life prediction of lattice regenerative cooling thrust chambers in liquid rocket engines based on a simplified viscoplastic model

With advances in aerospace technology, the reusability of liquid rocket engines has become the focus of considerable research interest. Traditional channel-type regenerative cooling thrust chambers often experience plastic deformation and microcracks, which limit their lifespan. This study proposed a novel lattice regenerative cooling thrust chamber using a simplified viscoplastic model and ABAQUS finite element software to simulate thermal–structural responses under different pressure conditions. The lattice structure not only enhanced the cooling efficiency and reduced the structural weight but also mitigated the plastic deformation and high-temperature creep of the inner wall. At an inner-wall temperature of 820 K, creep damage was significant. Compared to that of traditional chambers, the lattice structure of the proposed chamber exhibited different mechanical behavior and failure modes, with a more uniform stress distribution and initial failure occurring at the lattice nodes. The proposed design avoided the “doghouse” effect evident in traditional chambers, achieving an inner-wall lifespan of up to 202 cycles, a 359 % improvement. The high design flexibility of the lattice structure in the cooling channels enabled enhanced thrust chamber longevity. The study results provide new insights and technical support for next-generation liquid rocket engine designs.

Fatigue characterization and life prediction of flexible lattice structures based on DLP processes

This study investigated the effects of cell configuration and relative density on the fatigue performance of truss-like lattice structures. Among the lattice structures examined, simple cube cells exhibited the highest fatigue strength across all relative densities. Numerical simulation results indicated that the S-N curves of the structures demonstrated pronounced power-law behavior as the volume fraction changed. The influence of various geometric factors on the power-law model parameters is discussed in detail. The power-law coefficient is influenced by the unit cell configuration and relative density; however, the power-law index is not affected by relative density and depends solely on the unit cell configuration. A fatigue life prediction model based on the Ashby-Gibson model was proposed. Finally, the reliability of the numerical simulation results was experimentally verified, with the predicted results of the model showing good agreement with the test data.

The hysteresis loop on the near-threshold fatigue crack growth curves generated by stepped load reduction and constant-amplitude loading methods in a Ni-based superalloy

Fatigue crack growth (FCG) tests were conducted on compact tension specimens made of a Ni-based superalloy to investigate the near-threshold FCG behaviors using both the stepped load reduction method (LRM) and the constant-amplitude loading method (CALM) at three stress ratios (R = 0.05, 0.5 and 0.7) under ambient condition. It is found that after the FCG threshold being approached by the LRM, a remarkable hysteresis plateau occurs on the subsequent FCG curve generated by the CALM for R ≤ 0.5, resulting a hysteresis loop on the near-threshold region, but the situation becomes complicated at R = 0.7. In the appearance of hysteresis plateau, the FCG life to fracture can be over 107 cycles longer than that without hysteresis plateau. For FCG rate faster than 10−8 m/cycle, the fractography is dominated by transgranular feature which is insensitive to the microstructure of the alloy. In the hysteresis plateau region where FCG rate is lower than 10−9 m/cycle, fractography shows a wide optical dark zone where microstructure-sensitive crystallographic facet feature dominates, while when no hysteresis at R = 0.7, the optical dark zone is too narrow for the fracture feature transition so that crystallographic facet, transgranular as well as mosaic features can be observed simultaneously. As FCG in the hysteresis plateau under the CALM can be significantly slower than that under the stepped LRM, it is recommend that the stepped LRM should be used to generate the material basic FCG curves for fatigue life prediction of high durability structures.

Distributed Embedded System for Multiparametric Assessment of Infrastructure Durability Using Electrochemical Techniques.

We present an autonomous system that remotely monitors the state of reinforced concrete structures. This system performs real-time follow-up of the corrosion rate of rebars (iCORR), along with other relevant parameters such as temperature, corrosion potential (ECORR), and electrical resistance of concrete (RE), at many of a structure's control points by using embedded sensors. iCORR is obtained by applying a novel low-stress electrochemical polarization technique to corrosion sensors. The custom electronic system manages the sensor network, consisting of a measurement board per control point connected to a central single-board computer in charge of processing measurement data and uploading results to a server via 4G connection. In this work, we report the results obtained after implementing the sensor system into a reinforced concrete wall, where two well-differentiated representative areas were monitored. The obtained corrosion parameters showed consistent values. Similar conclusions are obtained with ECORR recorded in rebars. With the iCORR follow-up, the corrosion penetration damage diagram is built. This diagram is particularly useful for identifying critical events during the corrosion propagation period and to be able to estimate structures' service life. Hence, the system is presented as a useful tool for the structural maintenance and service life predictions of new structures.

Investigation of the mechanical and durability properties of concrete containing modified fly ash and modified zeolite powder: An effective transport model for sulfate ions in concrete

The application of conventional fly ash and zeolite powder in the field of concrete durability is limited. In this study, durability tests coupling dry-wet cycling and sulfate erosion were conducted on concrete with varying dosages of modified fly ash (MFA) and modified zeolite powder (MZP). The compressive strength, failure mode, water absorption rate, and ion concentration changes were systematically investigated. The reaction products and structure were analyzed through SEM, EDS, and XRD tests, correlating with macroscopic parameters. An effective transport model for sulfate ions in concrete was established, considering the material influence coefficient km and the effective diffusion coefficient De. The results indicate that a higher content of Ca phases in MFA leads to a reduction in concrete early strength, while later stages exhibit rapid strength growth due to pozzolanic reactions. MZP contains a significant amount of Al and Si phases, which promote both early and later-stage concrete strength. MFA and MZP enhance the resistance of concrete to sulfate erosion, with MZP exhibiting a significantly superior improvement effect compared to MFA. This is attributed to the following factors: on the one hand, the addition of MFA and MZP reduces the porosity and improves the pore structure of concrete, thus delaying the diffusion of sulfate ions into the concrete; on the other hand, the pozzolanic reactions of MFA and MZP consume available calcium hydroxide, leading to the formation of C–S–H and C-A-S-H gels, which densify the microstructure and reduce the probability of leaching erosion of hydration products, thereby limiting the formation of ettringite. The applicability and reliability of the sulfate-ion effective transport model were verified based on experimental data. The model can be employed to predict the distribution of sulfate ions in different types of concrete under various erosion durations, reducing workload and providing a theoretical basis for the durability design and service life prediction of concrete structures in sulfate environments.

A simplified fatigue model for CFRP-strengthened RC beams under the coupling action of a hot–wet/saline environment and cyclic loading

Reinforced concrete (RC) structures in subtropical coastal areas are subjected to the combined influences of temperature, humidity, and salt exposure. Previous studies on the fatigue failure of fiber-reinforced polymer (FRP)-RC structures did not consider the coupling effect of the environment and loading. In this study, a simplified hot–wet/saline environmental fatigue model was developed to consider the linear influence of environmental parameters, including temperature, humidity, and salinity. Then, a closed environmental box was self-designed to provide the temperature–saline environment. By simulating a subtropical coastal environment with typical salinity levels (0, 3, and 5 wt% NaCl) and temperatures (10, 35, and 50 °C), fatigue tests were conducted on 38 typical carbon fiber-reinforced polymer–RC beams. In assessing the simplified model’s predictive accuracy, the average errors for estimating the fatigue limits and lives in the validation groups with or without saline conditions were 4.1 % and 33.7 %, respectively. The simplified model indicated that higher unit temperature and humidity similarly reduced the fatigue limit and that higher salinity decreased the fatigue limit by approximately 7.2 times greater than temperature or humidity. This research provides valuable insights into the strength design and life prediction of RC structures in the offshore or subsea regions of subtropical coastal areas.

Data-driven online prediction of remaining fatigue life of a steel plate based on nonlinear ultrasonic monitoring

Online monitoring fatigue damage and remaining fatigue life (RFL) prediction of engineering structures are essential to ensure safety and reliability. A data-driven online prediction method based on nonlinear ultrasonic monitoring was developed to predict the RFL of the structures in real-time. Nonlinear ultrasonic parameters were obtained to monitoring the fatigue degradation. A Bayesian framework was employed to continuously compute and update the RFL distributions of the structures. Nonlinear ultrasonic experiments were performed on the fatigue damaged Q460 steel to validate the developed prediction methodology. The result indicates that the developed method has high prediction accuracy and can provide effective information for subsequent decision-making.

Crack propagation simulation and overload fatigue life prediction via enhanced physics-informed neural networks

The fatigue crack growth simulation and life prediction of structures are implemented in this paper based on the physics-informed neural networks (PINNs). Firstly, the enhanced PINNs are proposed by introducing the crack tip asymptotic displacement fields, so that the crack tip stress intensity factors can be calculated accurately even when the number of collocation points is small and the distribution grid is regular. The enhanced PINNs essentially transform the solution of elastic body containing crack into the optimization of minimizing the constructed loss functions, and can invert the fracture parameters. Then, an automatic crack propagation simulation method is developed based on the enhanced PINNs. The network architecture and the overall node distribution can be unchanged during the crack propagation process, and only new crack surfaces need to be processed and corresponding loss functions need to be modified. Because the nodal refinement around crack-tip is not required, this simulation method is convenient and can accurately predict the mixed-mode crack propagation path. Finally, the fatigue crack growth life algorithm considering overload is developed, where the effect of each overload can be captured by the cycle-by-cycle method. Based on this algorithm, the retardation behavior can be characterized and the fatigue life of structure under the load spectrum with periodic overloads can be accurately predicted. The sufficient examples are given to verify the feasibility and accuracy of the method proposed in this paper.

Study on time range of definite integral in derivation process of chloride ion diffusion theoretical model of concrete

In the study of the durability of concrete structures, the chloride ion diffusion coefficient (Dt) is a key parameter that directly affects the prediction of concrete's service life. This study aims to explore the relationship between the chloride ion diffusion coefficient in concrete and the "curing age (tref)" and "exposure time (t)." By conducting long-term curing and seawater exposure experiments on three different mixes of high-performance concrete samples, we collected experimental data with a curing age of 3 years and a seawater exposure time of 4.5 years. Through in-depth analysis of these data, we found that there is a significant power function relationship between the chloride ion diffusion coefficient and exposure time, while the relationship with curing age is not significant. This finding suggests that in the derivation of the concrete chloride ion diffusion theory model, the time range of the definite integral of Dt should be from 0 to t, rather than from tref to tref+t. Furthermore, we have validated the concrete life prediction model using actual data from the Swedish Marine Exposure Station, further confirming the accuracy and reliability of our research results. This study provides a more scientific and accurate theoretical basis for the durability assessment and service life prediction of concrete structures.

Fatigue life estimation of nickel-based single crystal superalloy with different inclined film cooling holes: Initial damage quantification and coupling of damage-fracture mechanics models

Quantitative assessment of the initial damage state of a structure and fatigue life prediction on this basis, especially when it is sensitive to manufacturing quality, is crucial for both engineering application and material science. Traditional solutions based on fracture or damage mechanics either require precise constitutive relationships and cumbersome physical mechanism models or simply ignore the initial damage state. This study developed a novel equivalent initial flaw size (EIFS) quantitative evaluation method for film cooling holes in Nickel-based single crystal superalloy turbine blades to address the strong correlation between the initial damage in and fatigue life of the material. The temperature and stress field differences at the edges of holes with different inclination angles were simulated using a solid-liquid-gas three-phase level-set model and considered to represent the same initial damage. Next, the coupled damage–fracture mechanics model was used to achieve equivalent crack insertion, crack propagation, and fatigue life prediction based on the EIFS. The results indicate that this method can provide a highly robust EIFS distribution interval and that the crack geometry correction factor and EIFS distribution range are weakly correlated with the loading conditions (with an error within 2 %). The EIFS-based fatigue life predictions demonstrated a notable degree of accuracy, with the majority of the predicted and experimental fatigue lives falling within a three-fold dispersion band and all predictions remaining confined within a five-fold dispersion band of the actual lifetime. These results represent a substantial advancement in accuracy compared to traditional damage mechanics predictions. Therefore, this study provides a powerful approach for evaluating the fatigue life of turbine blades considering the initial damage state and can be widely applied to guide drilling process optimization and blade fatigue analysis.

Thermal corrosion fatigue crack growth behavior and life prediction of 304SS pipeline structures in high temperature pressurized water

The influence of transient water temperature changes on the fatigue crack growth behavior of 304SS pipeline structures was studied based on high-throughput testing method through the modification of dual loop circulating water equipment. Results demonstrated that the fatigue crack growth rate gradually decreased with the decrease of cooling rate, and the crack growth rate was exponentially related to the cooling rate. Both the base material and weld of the stepped pipe showed a transgranular cracking mode, and propagated continuously by slip-oxidation mechanism. Compared with the fine equiaxed grain of the base material, the grain in the weld was coarse and the residual strain was large, and the crack growth rate of the weld was obviously higher. Then, the thermal fatigue crack growth rate model for stepped pipes was established by combining finite element thermo-mechanical coupling simulation and three-dimensional crack propagation analysis software, and the model was modified based on the experimental results.

Summary of Durability Analysis of Concrete Structures

The service life of concrete is closely related to the durability of concrete structure, with the development of infrastructure construction in our country, more and more attention has been paid to the study on the durability of concrete structure. This paper mainly analyzes the relevant factors affecting the durability of concrete structures, such as sulfate corrosion, chlorine salt corrosion, steel corrosion and concrete carbonization. At the same time, this paper studies from the perspective of life prediction of concrete structure to provide some reference for durability design of concrete structure.

Unusual Fatigue Crack Growth Behavior of Long Cracks at Low Stress Intensity Factor Ranges.

In this article, we characterize and review the unusual lack of threshold in fatigue crack growth (FCG) behavior for some alloys at low values of stress intensity factor ranges ΔK and its implications to damage-tolerant design approaches. This unusual behavior was first observed by Marci in 1996 in IMI 834 alloy. Conventional applications of linear elastic fracture mechanics to FCG analysis at constant R-ratio (or Kmax) assumes that (da/dN) decreases monotonically with decreasing ΔK and approaches the threshold value of ΔKth with (da/dN) ≤ 10-7 mm/cycle for a given R (or Kmax). However, instead of ΔK threshold behavior, some materials exhibit plateau or acceleration in da/dN rate with decreasing ΔK for long cracks tested in both constant R and Kmax conditions. This unusual (da/dN)-ΔK behavior is only observed experimentally but not understood and represents a challenge to scientists and engineers to model the safe fatigue life prediction of structures under low amplitude vibrating loads.

A phase-field fatigue fracture model considering the thickness effect

Modern aero-engine turbine structures often have variable-thickness geometries (e.g., turbine structures with complex cooling systems) that pose a significant challenge to crack analysis. The phase-field fracture method is a numerical method that has recently received considerable attention. However, phase-field fatigue fracture models that consider the effect of thickness are still lacking. To address this problem, this paper proposes a modification of the fracture toughness in the phase-field fatigue model by introducing a relationship function between material fracture toughness and thickness (Gc-B curve). We use reference experimental data to fit the Gc-B curve of GH4169 and predict the fracture toughness of specimens with other thicknesses. The predictions of the proposed model agree well with the experimental results reported in the literature. This achievement contributes significantly to the structural safety design and life prediction of aero-engine components.

Damage-Accumulation-Induced Crack Propagation and Fatigue Life Analysis of a Porous LY12 Aluminum Alloy Plate.

Rivets are usually used to connect the skin of an aircraft with joints such as frames and stringers, so the skin of the connection part is a porous structure. During the service of the aircraft, cracks appear in some difficult-to-detect parts of the skin porous structure, which causes great difficulties in the service life prediction and health monitoring of the aircraft. In this paper, a secondary development subroutine in PYTHON based on ABAQUS-XFEM is compiled to analyze the cracks that are difficult to monitor in the porous structure of aircraft skin joints. The program can automatically analyze the stress intensity factor of the crack tip with different lengths in the porous structure, and then the residual fatigue life can be deduced. For the sake of safety, the program adopts a more conservative algorithm. In comparison with the physical fatigue test results, the fatigue life of the simulation results is 16% smaller. This project provides a feasible simulation method for fatigue life prediction of porous structures. It lays a foundation for the subsequent establishment of digital twins for damage monitoring of aircraft porous structures.

Structural Analysis and Service Life Prediction of Rubberized Thin Surfacing Hot Mix Asphalt

Rubberized thin surfacing hot mix asphalt (RTSHMA) is a type of flexible pavement that is currently being developed. It can provide the same good performance as asphalt concrete–wearing course (AC-WC). Based on previous research, the use of crumb rubber in the asphalt mixture can provide several advantages, such as increasing the flexibility of the mix so that the pavement is more resistant to cracking. Based on research showing the advantages of rubberized asphalt, the idea emerged to apply it in the field, namely on the Palur–Sragen City Boundary section as wearing course. The method of analysis in this study was modeling the pavement structure with the KENPAVE and BISAR 3.0 programs. The analysis results showed that the AC-WC model and RTSHMA model have the same good performance because both of them have a service life of more than twenty years, which is the standard for flexible pavements. However, RTSHMA has an advantage, i.e., the thickness layer is 25% thinner than AC-WC’s. With a thinner layer than AC-WC but the same good performance, RTSHMA is worth considering as an alternative pavement, especially for overlays.

Life prediction and optimal design of flange structure of tire unloader

Life prediction and optimal design of flange structure of tire unloader

A new mesoscopic calculation model of chloride ion erosion in recycled coarse aggregate concrete (RAC): Characteristic fractal dimension of pore structure and service life prediction

This research investigates the influence of water-cement ratio and recycled aggregate content on the chlorine erosion resistance of RAC by conducting a combination of experimental and theoretical analysis. In addition, a mathematical equation is developed to represent the chloride ion transport mechanism in RAC, taking into account fluid mechanics, energy conservation, and pore structure evolution characteristics. Furthermore, mathematical analysis and modeling are used to forecast the life of the chloride ion erosion process. The results show that both the recycled coarse aggregate replacement rate and the water-cement ratio adversely affect the chloride erosion resistance of RAC. The chloride diffusion coefficient model based on pore structure characteristic parameters exhibits high prediction accuracy. This model helps increase the use of recycled aggregates and fosters the growth of the circular economy in the construction industry sector by offering a theoretical foundation for evaluating and maintaining the durability of RAC.

Spacecraft Segment Damage Identification Method Based on Fiber Optic Strain Difference Field Reconstruction and Norm Calculation

Real-time online identification of spacecraft segment damage is of great significance for realizing spacecraft structural health monitoring and life prediction. In this paper, a damage response characteristic field inversion algorithm based on the differential reconstruction of strain response is proposed to solve the problem of not being able to recognize the small damages of spacecraft structure directly by the strain response alone. Four crack damage location identification methods based on vector norm computation are proposed, which realize online identification and precise location of structural damage events without external excitation by means of spacecraft structural working loads only. A spacecraft segment structural damage monitoring system based on fiber optic grating sensors was constructed, and the average error of damage localization based on the curvature vector 2 norm calculation was 2.58 mm, and the root-mean-square error was 1.98 mm. The results show that the method has superior engineering applicability for on-orbit service environments.