Traditional Steel Research Articles

Hydrogen Embrittlement of Galvanized Press-Hardened Steels: A Review

Press-hardened steels (PHS), as an alternative to traditional steels and aluminum alloys, combine great mechanical performance with low manufacturing costs. PHS are martensitic steels with ultimate tensile strength (UTS) up to 2000 MPa. These steels are commonly coated with zinc-based coatings (PHS GI) consisting of multiple Zn–Fe phases to enhance corrosion resistance. However, similar to all high-strength steels, PHS are known for their elevated susceptibility to hydrogen embrittlement (HE). Absorption of atomic hydrogen into the steel lattice can lead to a transition from a ductile to a brittle fracture mechanism and decrease the stress necessary for fracture initiation. This review examines the microstructure of PHS GI with a focus on how the manufacturing process influences key parameters of the coating. The material’s susceptibility to HE is discussed in the following sections, along with the potential for hydrogen introduction through corrosion in atmospheric environments. The relationship between the content of hydrogen and its effects on fracture behavior is discussed, along with the corrosion behavior of PHS GI. The potential areas for future research and development of PHS GI with increased HE resistance are proposed.

Synthesis and Evaluation of Polyurethane as Waterproof Adhesion Layer for Steel Bridge Deck

Service life of traditional steel bridge deck pavement is significantly shortened due to the failure of waterproof adhesion. To improve the interlayer bonding performance and extend its service life, polyurethane is proposed as a waterproof adhesion layer (WAL) for a steel bridge deck. This study aims to synthesize polyurethane WAL by free radical solution polymerization under different types and dosages of crosslinking agents as well as the mixing ratio of an acrylic co-blend. Tensile properties, water resistance, glass transition temperatures, thermal stability, and adhesive strength of the polyurethane binder are evaluated. The results demonstrate that polyurethane WAL yields desirable performance by using a hydroxyl molar ratio of 1/3 and an acrylic co-blend of 65%. Specifically, the tensile strength and breaking elongation of polyurethane WAL reach the maximum values of 6.466 MPa and 268.4%, respectively. The water absorption rate of polyurethane WAL is less than 4%. Glass transition temperatures of polyurethane WAL are between −80 °C and 60 °C, respectively. Polyurethane WAL features remarkable high- and low-temperature performance and thermal stability. Finally, adhesion strength between polyurethane WAL and the steel plate reaches up to 5.21 MPa. The outcome of this study facilitates the design and application of polyurethane waterproofing adhesion layers for steel bridge decks.

A Magnetic Climbing Robot for Steel Bridge Inspection

Abstract. The maintenance of traditional steel bridges presents many significant challenges due to the fact that bridges of different ages and standards vary in design, structural complexity and technical difficulty. In light of these considerations, it is clear that maintenance personnel must possess a wealth of professional expertise and experience in order to effectively address the diverse and intricate maintenance challenges that arise. Moreover, the maintenance process entails high-risk operations such as high-altitude work and welding, which pose a threat to the safety of construction personnel. Therefore, this study introduces a magnetic adsorption robot designed to address the low efficiency and high costs of traditional maintenance methods. This robot features a dual robotic arm mechanism and modeled using the Denavit Hartenberg (D-H) parameter method. Electromagnetic adsorption is utilized to achieve wall adhesion, and direct power supply is provided through DC power to control weight. The robot can perform flexible remote control operations through the HC-05 Bluetooth module. The experimental results show that the robot exhibits robust adhesion and obstacle crossing ability on steel surfaces, thereby enabling unimpeded movement within the steel structure. In addition, the robot is now capable of performing overhaul procedures via remote control.

A Review on the Recent Process of Lazy Wave Risers

Lazy wave risers (LWRs) are designed with equidistant buoyancy blocks attached in the lower half of the riser, allowing the riser to take on an arch shape under the buoyancy forces provided by buoyancy blocks. This arch configuration can provide flexibility to the LWR arrangement and effectively isolate the dynamic responses between the offshore floating structure and the riser’s touchdown zone (TDZ). Its design and application aim to address the issues of dynamic response and fatigue damage that traditional steel catenary risers (SCRs) face in deep water and complex marine environments. Given that research on the LWRs in the field of ocean engineering is not sufficiently abundant, the structural characteristics, hydrodynamic loads, global responses, fatigue damage assessment, and structural optimization progress of LWRs are systematically reviewed in this paper to provide references for researchers in related fields. Among these topics, the global response of LWRs is the main point of this review. This section details the theoretical analysis and numerical modeling methods employed in the study of LWRs’ global response, explores the research advancements in the vortex-induced vibration (VIV) related to LWRs, and discusses corresponding experimental studies. Finally, the installation, transfer, and repair processes of LWRs are investigated. Additionally, the importance of leveraging advanced technologies from other fields and combining them with current advanced algorithms is emphasized in efforts to assess fatigue damage and optimize the structures of LWRs, ultimately achieving complementary advantages.

Experimental investigation on the post-fire mechanical properties of YSt-355FR (0.1 % Mo) low-alloyed fire-resistant steel

Fire-resistant steel (YSt-355FR (0.1 % Mo)) has become the most utilized structural steel due to its superior performance at elevated temperatures compared to traditional structural steel at both the material and structural levels. However, its performance after exposure to fire remains questionable. This study investigates the post-fire performance of cold-formed fire-resistant steel at the material level. A total of 132 steel coupons and 84 Charpy test specimens were exposed to temperatures ranging from 100°C to 1000°C. These temperature-exposed steel coupons were subjected to four different cooling conditions: furnace cooling (FC), air cooling (AC), water-jet cooling (WJC), and water cooling (WC). Tensile tests were performed on the cooled steel coupons to obtain post-fire stress-strain curves, from which the residual mechanical properties were determined. Charpy impact tests were also conducted on the cooled steel specimens to obtain impact energies and identify the fracture patterns. Key observations regarding the post-fire behavior of fire-resistant steel in terms of strength, deformability, stiffness, and toughness parameters were made. Both the exposure temperature and the cooling condition significantly influence the post-fire performance of fire-resistant steel. Fire-resistant steel demonstrates superior post-fire behavior compared to traditional structural steel. Constitutive equations were proposed to predict the mechanical properties of fire-resistant steel under various post-fire conditions, and a sound reliability analysis was performed to examine the reliability of the predicted design parameters compared to the test results. The findings presented in this paper are significant as no prior investigation has assessed the post-fire performance of fire-resistant steel; thus, they may encourage the steel construction industry to prefer fire-resistant steel over traditional structural steels and promote the reuse of temperature-exposed fire-resistant steel for sustainable construction.

New route for fabricating low-carbon ductile martensite to optimize the stretch-flangeability of dual-phase steel

Traditional cold-rolling dual-phase steel (CR sheet), limited by poor stretch-flangeability as indicated by the hole expansion rate (HER), faces challenges in manufacturing complex automobile parts. To address this, a new type of hot-rolling dual-phase steel with an 800 MPa grade (manufactured by tyipical thin slab continuous casting and rolling process, TSCCR) was designed to replace the traditional one. The TSCCR sheet, with a lower carbon content of 0.047wt.%, compared to 0.093wt.% in the CR sheets, features 40.6% martensite significantly higher than 28.2% in the CR sheet. This increased martensite content, despite being softer and more ductile due to its low hardness, compensates for the tensile strength in the TSCCR sheet. Furthermore, the TSCCR sheet exhibits a unique heterostructure characterized by uneven carbon distribution from the ferrite/austenite interface to other boundaries/interfaces, estimated by the negligible partition local equilibrium (NPLE) model of ferrite transformation. This unique heterostructure diminishes the mechanical disparity between ferrite and martensite, resulting in a higher yield strength of 568 MPa, compared to 456 MPa in the CR sheet. During uniaxial tension, the ferrite and ductile martensite in the TSCCR sheet initiate cooperative plastic deformation earlier than in the CR sheet, despite initially having fewer favorable slip systems in the TSCCR martensite. The low working hardening rate of the TSCCR sheet facilitates the forming layered structure of ferrite and martensite during necking compared to the CR sheet. Consequently, the HER of the TSCCR sheet sharply increased by 144% compared to the CR sheet. This enhancement in HER can be attributed to the crack initiation area, longer crack propagation path, and higher crack propagation resistance facilitated by the ductile martensite, culminating in superior HER.

Nitric acid-modified amorphous alloy fiber and its effects on mechanical properties of ultra-high performance concrete (UHPC)

The traditional steel fiber UHPC has the phenomenon of low strength and poor durability, which can not give full play to the practical value of UHPC. Nevertheless, amorphous alloy fibres possess notable strength, flexibility and corrosion resistance. The incorporation of amorphous alloy fibres into ultra-high performance concrete (UHPC) has been demonstrated to enhance the strength and toughness of UHPC. However, the surface of amorphous alloy fibres is characterised by a smooth and hydrophobic quality, which presents a challenge in terms of the interface bond with the cement matrix. In order to address this issue, three concentrations of nitric acid (HNO3, 2 mol/L, 4 mol/L and 6 mol/L) were employed to modify the surface of amorphous alloy fibres, and then the amorphous alloy fibres were incorporated into the cement matrix for fiber pull-out test, compression, flexural strength and impact testing. The changes in the physical and chemical properties of the amorphous alloy fibres before and after modification were analysed, and the effects on the interface bond strength and dynamic and static mechanical properties of UHPC were studied by means of SEM. The results demonstrate that the adhesion strength of the modified amorphous alloy fibre with 4 mol/L HNO3 is the most robust, with an increase of 18.7 % in compressive strength, 13.8 % in flexural strength, and 5.4 % in impact resistance. The method has been demonstrated to be effective in strengthening and toughening the cement matrix with HNO3-modified amorphous alloy fibres.

Assessment of the impact behavior of CLF-1 steel with Charpy V-notch testing and miniature Charpy V-notch testing

China Low-activation Ferrite steel (CLF-1), as one of the structural materials developed in China for fusion reactors, is a Reduced activation Ferritic/Martensitic (RAFM) steel modeled after the traditional T91 steel (9Cr-1Mo-0.2V-0.08Nb). For fusion reactor materials, the Charpy impact testing is an important method to assess their notch sensitivity. In this study, Charpy impact tests were conducted on CLF-1 steel using Charpy V-notch specimens (CVN) and Miniature Charpy V-notch specimens (Kleinstprobe, KLST) to assess the impact behavior of CLF-1 steel, and data normalization was performed on the KLST specimen. The results show that as the specimen size of CLF-1 steel decreased, the curves of impact absorbed energy, lateral expansion, and shear fracture appearance shifted towards lower temperatures, and the impact absorbed energy significantly decreased. Both the macroscopic and microscopic characteristics of the specimens obtained from the experiments indicated that KLST specimens could achieve the same fracture characteristics as CVN specimens. Additionally, at the same experimental temperature, KLST specimens exhibited a higher proportion of ductile fracture regions.

Surface modification of fibres with silane for enhancing the durability of FRP composites as reinforcement for seawater sea sand concrete (SWSSC): A review

This review discusses the necessity of surface modification to effectively use fibre-reinforced polymers (FRPs) as reinforcements for seawater and sea sand concrete (SWSSC). FRPs can be a viable reinforcement material for SWSSC as an alternative to the traditional carbon steel reinforcement that will suffer unacceptably high rates of corrosion due to the very high chloride content of the SWSSC environment. FRPs exhibit mechanical properties similar to steels but suffer insignificant degradation/corrosion due to chloride. However, the fibres in certain FRPs (such as basalt FRPs and glass FRPs) suffer degradation due to attack by the alkaline environment of concrete, causing degradation in fibre-matrix interfacial strength and loss of FRPs’s overall mechanical strength and durability. Therefore, fibres used in such FRPs require suitable surface modification to ameliorate their degradation, enabling their practical use as reinforcements of SWSSC. While carbon fibre-reinforced polymers (CFRPs) demonstrate superior resistance to alkali-induced degradation, their widespread use in large-scale civil engineering is hindered by high costs. In this review, more economic alternatives, i.e., basalt fibre-reinforced polymers (BFRPs) and glass fibre-reinforced polymers (GFRPs) are critically reviewed. To enhance the durability of FRPs and mitigate alkali-induced degradation of the basalt/glass fibres, suitable surface modifications are necessary to safeguard the mechanical properties of FRPs. Underpinned by a comprehensive discussion on the necessity of surface modification of fibres for the use of FRPs in SWSSC environment, this review focuses on the potential of advanced approaches for surface modifications of the fibres, i.e., coatings of silanes, and silanes impregnated with graphene nanoplatelets (GNPs), graphene oxide (GO) and its functionalised derivatives or metal oxides (such as SiO2, ZrO2, Al2O3, TiO2 and CeO2). This review critically discusses the opportunities for suitable surface modification of basalt and glass fibres for enabling the durable use of FRPs as reinforcements for sweater sea sand concrete.

Numerical Modeling of Distributed Macro-Synthetic Fiber and Deformed Bar Reinforcement to Resist Shear

Macro-synthetic fibers are increasingly used in concrete as secondary reinforcement to control temperature and shrinkage cracks, improving durability by limiting crack widths. However, their impact on the shear strength of structural elements remains underexplored, particularly when used in combination with traditional steel reinforcement. To address this knowledge gap, this study developed and calibrated a non-linear numerical model to simulate the shear response of macro-synthetic fiber-reinforced concrete (PFRC) elements, using finite element software VecTor2. The model was calibrated with experimental data from PFRC panels subjected to pure shear loading, incorporating a custom concrete tension-softening model to capture the contribution of fibers. Validation against a broad range of PFRC beam experiments from the literature demonstrated the model’s accuracy, achieving an average predicted-to-experimental shear strength ratio of 0.99 (COV = 5.5%). Additionally, the model successfully replicated key response characteristics such as deformation patterns, crack propagation, and residual strength. The proposed modeling approach provides valuable insights into the interaction between fiber volume and transverse reinforcement. It also serves as a powerful tool for future numerical studies, addressing the existing data gap on PFRC behavior and exploring the synergistic effects of macro-synthetic fibers and steel reinforcement on shear strength.

Performance of concrete beams strengthened with FRP rods: A review

Ductility is a critical property in structural engineering, ensuring that beams can undergo significant deformation before failure, thereby giving plenty of notice before disastrous collapse. This study investigates the ductility properties of constructions that have been reinforced using FRP rods, which are increasingly popular due to their corrosion resistance, superior strength with low mass, and durability. Traditional steel reinforcement has well-documented ductility properties, but FRP bars, due to their brittle nature, pose challenges in achieving the desired ductility levels in structural applications. This research evaluates various factors influencing FRP-reinforced beams' ductility, including the type of FRP material, the hybridization of FRP with other reinforcing materials, and the effect of utilizing fibres in the mixtures to enhance the mechanical characterstics of concrete. Studies have indicated that the ductility of beams can be enhanced using hybrid rebar systems, which integrate steel and fibre reinforced polymer. However, complex and expensive production methods limit their practical application. Using steel bars with FRP bars can significantly incresese seriviceability requiremts such as crack width and deflection, but they also lower corrosion resistance, especially in aggressive environments. The beams' overall ductile behavior is primarily determined by the concrete's characteristics. Fibres greatly increase the mechanical characteristics, toughness, and ductility of the concrete mix, strengthening the bond between bars and the concrete and improving the overall performance of the beam.

Enhancing compressive behaviour of seawater sea sand concrete filled hybrid carbon-glass FRP tubes exposed to seawater: Effect of thickness

This study presents a novel investigation into the impact of tube thickness on the residual compressive strength of sea water sea sand concrete (SWSSC) filled filament wound hybrid fibre-reinforced polymer (HFRP) tubes, positioning them as innovative alternatives to traditional concrete-filled steel tubes in corrosive marine environments. The research explores tube thicknesses of 2 mm, 3 mm, and 4 mm, employing a unique hybrid configuration of 50 % carbon fibre reinforced polymer (CFRP) internal layers and 50 % glass fibre reinforced polymer (GFRP) external layers. This study examines the effect of these configurations on compressive mechanical properties, microstructural characteristics, and damage progression under alkaline and seawater conditions. Additionally, the research evaluates cross-ply and hoop orientations as variables in filament winding fibre orientation. A comprehensive set of 108 hybrid tubes were filled with an alkaline solution to simulate the SWSSC environment and exposed to seawater at varying temperatures and durations. Accelerated aging experiments were conducted in the laboratory to assess the long-term compressive performance of SWSSC-filled HFRP tubes exposed to seawater. Long-term compressive strength predictions were made using the Arrhenius theory, based on short-term accelerated aging data. The accelerated test data revealed maximum compressive strength reductions of 33 %, 15 %, and 17 % for 2 mm, 3 mm, and 4 mm cross-ply HFRP tubes, respectively, after 150 days of exposure at 60 °C. For hoop HFRP tubes, the corresponding reductions were 19 %, 18 %, and 17 %. Thicker tubes (3 mm and 4 mm) with sufficient internal CFRP layers protect external GFRP layers from alkaline damage, akin to pure CFRP tubes. Thinner tubes (2 mm) exhibit similar performance to GFRP tubes as alkaline damage spreads from their less substantial internal CFRP layers to the outer GFRP layers. For cross-ply tubes, the recommended strength reduction factors are 0.6 for 2 mm, 0.8 for 3 mm, and 0.8 for 4 mm thicknesses. For hoop tubes, the suggested factors are 0.7 for 2 mm, 0.7 for 3 mm, and 0.8 for 4 mm thicknesses. This study shows the innovative potential of tailored hybrid HFRP tubes in enhancing the durability and performance of marine infrastructure.

The impact of using prestressed CFRP bars on the development of flexural strength

Abstract The load-carrying capacity and ductility of conventional steel reinforcement may be greatly increased by using ordinary and prestressed carbon fiber-reinforced polymer (CFRP) bars, resulting in reinforced concrete structures with greater sturdiness. This research investigates the flexural behavior of CFRP-prestressed beams with bonded tendons as opposed to conventional steel-prestressed beams. This article examines a less explored topic that often fails because post-tensioned beams with unbonded CFRP tendons are crushed by concrete. The linear-elastic behavior of CFRP accounts for much of the experimentally observed considerable variations in flexural characteristics between CFRP and steel-prestressed beams. Compared to unbonded CFRP specimens, bonded CFRP specimens are much stronger. Our knowledge of CFRP reinforcement in concrete infrastructure is advanced by this work, which highlights the need for better design techniques to increase strength and ductility. It is recommended that CFRP bars be bonded with epoxy resin to restrict fast energy dissipation and avoid concrete failure. As a result, CFRP-reinforced concrete beams will react less linearly and more ductilely. CFRP may improve prestressed concrete beam performance and lifespan in a number of scenarios, as shown by comparative research with traditional steel reinforcement. Six 1,800–mm-long RC beams with a 200 × 300 mm cross-section were examined and divided into three groups, analyzing important loading phases (i.e., cracked, ultimate, and mid-span deflection) using CFRP bars as prestressed tendons to replace the bottom steel rebars. The load-carrying capabilities and ductility of CFRP-reinforced beams were much greater than those of the reference beam. A single beam using normal CFRP bars for reinforcement showed a 21.2 mm mid-span deflection and an ultimate load of 157.2 kN, with a 57.7-kN fractured load. Another beam with normal CFRP bars also showed enhanced performance, with a mid-span deflection of 21.2 mm, an ultimate load of 160.6 kN, and a cracking load of 57.5 kN.

GFRP-Reinforced Concrete Columns: State-of-the-Art, Behavior, and Research Needs

This comprehensive review paper delves into the utilization of Glass Fiber-Reinforced Polymer (GFRP) composites within the realm of concrete column reinforcement, spotlighting the surge in structural engineering applications that leverage GFRP instead of traditional steel to circumvent the latter’s corrosion issues. Despite a significant corpus of research on GFRP-reinforced structural members, questions about their compression behavior persist, making it a focal area of this review. This study evaluates the properties of GFRP bars and their impact on the structural behavior of concrete columns, addressing variables such as concrete type and strength, cross-sectional geometry, slenderness ratio, and reinforcement specifics under varied loading protocols. With a dataset spanning over 250 publications from 1988 to 2024, our findings reveal a marked increase in research interest, particularly in regions like China, Canada, and the United States, highlighting GFRP’s potential as a cost-effective and durable alternative to steel. However, gaps in current knowledge, especially concerning Ultra-High-Performance Concrete (UHPC) reinforced with GFRP, underscore the necessity for targeted research. Additionally, the contribution of GFRP rebars to compressive column capacity ranges from 5% to 40%, but current design codes and standards underestimate this, necessitating new models and design provisions that accurately reflect GFRP’s compressive behavior. Moreover, this review identifies other critical areas for future exploration, including the influence of cross-sectional geometry on structural behavior, the application of GFRP in seismic resistance, and the evaluation of the size effect on column strength. Furthermore, the paper calls for advanced studies on the long-term durability of GFRP-reinforced structures under various environmental conditions, environmental and economic impacts of GFRP usage, and the potential of Artificial Intelligence (AI) and Machine Learning (ML) in predicting the performance of GFRP-reinforced columns. Addressing these research gaps is crucial for developing more resilient and sustainable concrete structures, particularly in seismic zones and harsh environmental conditions, and fostering advancements in structural engineering through the adoption of innovative, efficient construction practices.

A study of the effect of coconut fiber on reinforced concrete beams subjected to combined bending and shear

This review paper examines the impact of coconut fiber reinforcement on the behavior of reinforced concrete beams subjected to combined bending and shear. Coconut fibers, also known as coir fibers, are a sustainable and cost-effective alternative to traditional steel reinforcement. The use of coconut fibers in concrete has shown promise in enhancing the ductility, energy absorption capacity, fracture resistance, and durability of concrete structures. The study highlights the mechanical properties and applications of coconut fiber reinforced concrete (CFRC) and investigates the effects of varying fiber content on concrete performance. Factors affecting the properties of fiber-reinforced concrete, such as the relative fiber matrix index, volume of fibers, aspect ratio of fibers, fiber orientation, workability, compaction, size of coarse aggregate, and mixing techniques, are also discussed. Understanding these factors is crucial for designing and constructing durable and sustainable concrete structures.

Eccentric compression performance of coral concrete-filled aluminum alloy tube (CCFAT) circular short columns

Coral concrete, utilizing coral reef bodies in place of traditional aggregates, shows promising prospects use in island projects. The use of aluminum alloy-reinforced coral concrete columns effectively enhances the load-bearing capacity of these structures. This study aims to investigate the performance of aluminum alloy circular tube-reinforced coral concrete short columns under eccentric compression. The study involved designing fifteen short columns for eccentric compression experiments, focusing on key parameters such as aluminum content (α), eccentricity (e0), and coral concrete strength (fc). The study obtained failure modes, bearing capacities, and load-deformation relationships, and analyzed the impacts of aluminum content, eccentricity, coral concrete strength, and hoop coefficient (ξa) on the columns’ strength, stiffness, and ductility. Subsequently, a finite element parameter expansion analysis using Abaqus was performed. Ultimately, a correction coefficient model was developed, compared with existing international specifications, and used to establish a suitable calculation model for the bearing capacity of CCFAT eccentric short columns. The results indicated that CCFAT eccentric short columns predominantly experienced bending failure. The stresses in the aluminum alloy round tube can reach the conditional yield strength, effectively collaborating with the concrete. The load-deformation relationship did not exhibit an intensification stage, and the lateral deflection curves tended to follow sinusoidal half-wave patterns. During the initial loading stage, adherence to the plane-section assumption was observed, with the hoop effect primarily manifesting in the compression zone. The strength index showed an approximately quadratic relationship with ξa, the stiffness index showed a positive correlation with ξa, and the ductility index demonstrated a strong positive association with ξa. The correction coefficient model, along with AIJ (2001), can be employed for calculating the bearing capacity of CCFAT eccentric short columns. This study introduces the novel concept of aluminum alloy tube-reinforced coral concrete columns as a composite structure for island civil engineering construction. Beyond the benefits of traditional steel tube concrete, these composite columns are expected to reduce engineering costs, shorten construction timelines, and address durability concerns through the incorporation of marine coral stones and fragments as concrete aggregates.

Study on the initial corrosion characteristics of weathering steel bridges with corrugated steel webs

In this study, the characteristics and influencing factors of the early corrosion evolution process of the weathering steel (WS) bridge in northwest China were examined, revealing the seldom-studied corrosion evolution law of the corrugated web of weathering steel. The corrosion losses and average corrosion thickness of WS bridge components were measured and evaluated. The results revealed that compared with traditional flat steel webs, the corrosion of corrugated steel webs was enhanced in the vertical direction and at the wave peak, and resulted in a more complex corrosion pattern. The trend of the rust layer on the inner and outer surfaces of the box girder is related to the stage characteristics of the corrosion products. The appearance of microscopic characteristics of the rust layer is periodic, with the rust layer thickness, colour, and particle size varying with the bridge’s location. The development of the corrosion pit followed a lognormal distribution, and the corrosion rate was balanced in the radial and depth directions. These results can serve as a basis for designers or inspectors to design WS bridge structures, select correct corrosion allowances, and improve corrosion monitoring and detection techniques.

Simulation and Application of a New Type of Energy-Saving Steel Claw for Aluminum Electrolysis Cells

Aluminum electrolysis is a typical industry with high energy consumption, and the energy saving of aluminum electrolysis cells is conducive to the sustainable development of the ecological environment. The current density distribution on the steel claws of conventional aluminum electrolysis cells is uneven, resulting in a large amount of power loss. Therefore, a new type of current-equalized steel claw (CESC) is designed in this paper. The ANSYS simulation study shows that the CESC can achieve a more uniform current density distribution and reduce the voltage drop by about 36 mV compared with the traditional steel claw (TSC). In addition, the use of CESC optimizes the temperature distribution of the steel claws and reduces the risk of cracking and deformation. The results of the industrial application tests are highly consistent with the simulation results, confirming the accuracy of the simulation results. The economic benefit analysis shows that using CESC saves 114.1 kWh of electricity per ton of aluminum produced. If this technology can be promoted throughout China, it is expected to save up to 4.75 billion kWh of electricity annually. The development of CESC is promising and of great significance for improving the overall technical level of the aluminum electrolysis industry.

Polyester mooring system design and evaluation of a semi-platform in south China sea

Polyester rope offers numerous advantages over traditional steel catenary mooring systems and is considered an appealing option for deep-water mooring systems. In this paper, the design and evaluation procedure of the polyester mooring system for a semi-submersible platform located in the South China Sea is presented. A fully coupled numerical model of the semi-submersible platform, including all risers and mooring lines, has been established and calibrated through wave basin testing. To simulate the elongation behavior of polyester, a static-dynamic stiffness model is employed, and the corresponding procedure for mooring evaluation is established to simulate the mooring response under extreme environmental conditions. A comprehensive fatigue analysis is also conducted for the polyester mooring system using time domain dynamic theory. The effects of Vortex-Induced Motion (VIM) on mooring fatigue damage are also considered. The results indicate that the polyester mooring system could be safely operated at the target offshore field throughout its service life. Additionally, model test calibration is a crucial procedure during the entire mooring evaluation process, and the numerical model should be adjusted appropriately to accurately reflect the dynamic behavior of the coupled system. This study also illustrates that the stiffness of the rope plays a crucial role in polyester mooring design and global performance calculations. The proposed evaluation methodology can provide a foundation for the design of polyester mooring systems and for evaluating their safety and reliability in engineering practice.

Mechanical properties of GFRP bars exposed to natural erosion environment: A case study

Unlike traditional steel bars, the long-term performance of GFRP (glass fiber reinforced plastic) bars in natural erosion environments remains unclear. This study simulated the water environment at the entrance of the Chai River, a tributary to Dianchi Lake in China, and investigated the mechanical properties of GFRP bars under varying corrosion concentrations. Microstructural analysis using SEM (scanning electronic microscopy) was also conducted to uncover the degradation mechanism. The results showed that after 180 days of immersion in natural water and exposure to environmental concentrations of 5 times, 10 times, and 20 times, the tensile strength of GFRP bars exhibited reductions of 2.8 %, 4.2 %, 7.2 %, and 9.5 %, respectively. However, the compressive strength decreased by 38.0 %, 48.6 %, 50.2 %, and 53.2 % under the same condition. As the number of corrosion cycles increased, the rate of strength decline decreased gradually. The combined action of hydroxyl ions generated through bicarbonate hydrolysis and water molecules in the solution led to the breakdown and swelling of the resin matrix, ultimately causing detachment at the fiber-resin interface. An analysis was conducted on the time-shifted regression equation of the accelerated conversion factor (ASF) under different concentrations, based on the correlation between natural erosion and acceleration testing. It was observed that a strong correlation exists between the strength retention rate and the natural erosion environment at 5 times the concentration. Finally, an improved time-shift method based on the Arrhenius theory was proposed to predict the tensile strength of GFRP bars in a natural erosion environment.