Procedia Structural Integrity最新文献_第10页

About airborne fatigue life predictions by means of full-field receptances. Part B: estimating the failure distribution with spectral methods. 基于全场接收的机载疲劳寿命预测。B部分：用谱法估计失效分布。

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.011

Alessandro Zanarini

Airborne pressure fields, with their variable spectral content in the acoustic and frequency domains, can become a threatening dynamic distributed loading for many surfaces in industrial applications, thus leading to airborne fatigue. Part A of this research path retrieves the structural force spectrum, as induced by the modelled airborne pressure fields on the real thin plate tested, which becomes the dynamic excitation for the structural dynamics in this Part B, leading to cumulative damage and fatigue life considerations. Reliable and advanced full-field receptance testing – as substitution of any other numerical model about the mounted realisation of the specific components – can nowadays be made by means of optical measurements. The quality achieved in the receptance maps helps in numerically derive the strain FRFs on the sensed surfaces. With proper constitutive models, the experiment-based mapping of the equivalent stresses can be achieved. Fatigue spectral methods turn this knowledge into component’s life distributions with the unmatched mapping ability of contactless full-field techniques. Full-field optical receptance maps turn to be pivotal in accurately representing the structural dynamics when retrieving the induced force by airborne pressure fields in Part A, and when mapping the effective solicitations for the airborne fatigue life predictions of Part B.

机载压力场在声学和频域具有可变的频谱含量，在工业应用中可能成为许多表面的威胁动态分布载荷，从而导致机载疲劳。本研究路径的A部分提取了实际测试薄板上由模拟空气压力场引起的结构力谱，这成为B部分结构动力学的动力激励，从而导致累积损伤和疲劳寿命的考虑。可靠和先进的全场接收测试-作为替代任何其他数值模型的安装实现的特定组件-现在可以通过光学测量的手段。在接收图中获得的质量有助于在被测表面上数值推导应变频响。采用合适的本构模型，可以实现基于实验的等效应力映射。疲劳谱方法将这些知识转化为部件的寿命分布，具有非接触式全场技术无与伦比的映射能力。当在A部分中获取空气压力场的诱导力时，以及在绘制B部分的空气疲劳寿命预测的有效请求时，全场光学接受图对于准确表示结构动力学至关重要。

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引用次数: 0

Fatigue performance of steel components remanufactured by wire + arc additive manufacturing with as-built surface waviness 带成品表面波纹的线+弧增材制造再制造钢构件疲劳性能研究

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2025.12.289

Robin Motte , Matthieu Vander Linden , Kris Hectors , Anil Sudhakar , Wim De Waele

Apart from producing new components, Wire + Arc Additive Manufacturing (WAAM) enables the remanufacturing of worn metallic parts, supporting a circular economy. However, the as-built surface often shows significant waviness resulting from the layered bead deposition, leading to stress concentrations and thus reduced fatigue life. Finishing operations are typically performed to mitigate those effects, though omitting them could save processing time, energy consumption, and overall costs. This work investigates the fatigue performance of S355J2 steel components remanufactured by WAAM using EMK8 wire, retaining as-built surface waviness. A novel four-point bending specimen with a WAAM-filled groove was designed to replicate a surface repair. Two electric arc welding methods — conventional short-circuit and Cold Metal Transfer — were compared to assess the effect of a different heat input. The former process resulted in higher heat input during material deposition. Compared to reference curves for S355J2 and bulk WAAMed EMK8 specimens, the fatigue strength of the remanufactured specimens was seen to be reduced. The as-built surface resulted in steeper slopes of the S-N curves compared to the polished reference materials. Crack initiation was determined by infrared thermography and was seen to occur between 6 and 50% of the total fatigue life, indicating that the majority of the total fatigue life consisted of crack propagation. The fatigue cracks were monitored by digital image correlation and were seen to propagate into the S355J2 substrate material, which can be considered as dominant for the crack growth rate.

除了生产新部件外，线+弧增材制造（WAAM）还可以对磨损的金属部件进行再制造，从而支持循环经济。然而，由于层状珠沉积，构建后的表面经常显示出明显的波浪形，导致应力集中，从而降低疲劳寿命。完成操作通常是为了减轻这些影响，尽管省略它们可以节省处理时间、能源消耗和总体成本。本文研究了采用EMK8钢丝进行WAAM再制造的S355J2钢构件的疲劳性能，并保留了构件的表面波纹度。设计了一种具有waam填充槽的新型四点弯曲试件来复制表面修复。两种电弧焊方法-传统短路和冷金属转移-进行比较，以评估不同热量输入的影响。前一种工艺在材料沉积过程中导致更高的热量输入。与S355J2和散装WAAMed EMK8试样的参考曲线相比，再制造试样的疲劳强度有所降低。与抛光的参考材料相比，构建的表面导致S-N曲线的斜率更陡。裂纹萌生由红外热像仪确定，裂纹萌生发生在总疲劳寿命的6% ~ 50%之间，表明裂纹扩展占总疲劳寿命的大部分。利用数字图像相关技术对疲劳裂纹进行了监测，发现裂纹扩展到S355J2基体材料中，这可以认为是裂纹扩展速率的主导因素。

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引用次数: 0

Impact strength optimization of dual-adhesive joints by cohesive zone modelling 基于黏聚区建模的双胶结接头冲击强度优化

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.013

L.A.S. Maia , R.D.S.G. Campilho , J.F.B. Martins , A.J.A. Vieira , D.C. Gonçalves , K. Madani

Industries such as aerospace and automotive prioritize safety, making impact resistance a crucial factor in structural performance. Dual-adhesive joints (DAJ), which combine a stiff adhesive in the central region with a more flexible adhesive at the edges, enhance stress distribution and improve joint durability, providing a more reliable and efficient bonding solution. This work aims to improve the DAJ impact behaviour with steel adherends by applying geometrical modifications (outer and inner chamfers, and adhesive fillets) and considering different adhesive combinations. A numerical study was conducted using cohesive zone modelling (CZM), encompassing an analysis of peel (s_y) and shear (t_xy) stresses, maximum load (P_m), and dissipated energy (U). Validation with experimental data was successfully carried out. The strategic use of DAJ combinations and targeted geometric modifications can effectively enhance the impact behaviour of adhesively bonded joints.

航空航天和汽车等行业优先考虑安全性，使抗冲击性成为结构性能的关键因素。双胶粘接（DAJ）是一种结合了中部较硬的胶粘剂和边缘较软的胶粘剂，增强了应力分布，提高了接缝的耐久性，提供了一种更可靠、更高效的粘接解决方案。这项工作的目的是通过应用几何修改（外部和内部倒角，以及胶粘剂圆角）和考虑不同的胶粘剂组合来改善钢附着的DAJ冲击性能。使用内聚区建模（CZM）进行了一项数值研究，包括剥离（sy）和剪切（xy）应力、最大载荷（Pm）和耗散能量(U)的分析。用实验数据进行了验证。有策略地使用DAJ组合和有针对性的几何修改可以有效地提高粘接接头的冲击性能。

引用次数: 0

Evaluation of a railway coach crashworthiness for the purpose of certification 以发证为目的的铁路客车耐撞性评估

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.078

Christian J. Silva , Rogério F.F. Lopes , Alexandre M. Löw , Vasco B. Gomes , Nuno V. Ramos , Pedro M.G.J. Moreira , João S. Silva , Rodrigo S. Andrade

Railway vehicle structures must comply with strict safety regulations to ensure integrity and passive safety. A key requirement is a crashworthiness analysis under EN 15227, as collisions pose significant risks to passengers. This study evaluates the structural behaviour of a railway coach in head-on collisions, following EN 15227 criteria. Finite Element Method (FEM) simulations with a dynamic explicit model were performed, enabling virtual testing that reduces development time and costs while maintaining high standards. The analysis identifies vulnerable areas in current structures, aiming to enhance passenger safety and regulatory compliance. A modified structure was also studied, and both designs were compared in terms of survival space and structural deceleration. The findings provide insights into how structural changes influence crashworthiness performance.

铁路车辆结构必须遵守严格的安全规定，以确保完整性和被动安全。EN 15227的一个关键要求是耐撞性分析，因为碰撞对乘客构成重大风险。本研究根据EN 15227标准评估铁路客车在正面碰撞中的结构行为。采用动态显式模型进行有限元模拟，实现虚拟测试，减少开发时间和成本，同时保持高标准。该分析确定了当前结构中的脆弱区域，旨在提高乘客安全和法规遵从性。研究了一种改进的结构，并对两种设计进行了生存空间和结构减速度的比较。研究结果为结构变化如何影响耐撞性能提供了见解。

引用次数: 0

In situ process monitoring with respect to mechanical properties of additively manufactured parts 有关增材制造零件机械性能的现场过程监测

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.079

Y. Bakir , I. Zetková

Laser Powder Bed Fusion (LPBF) is governed by intricate interactions between laser settings and material characteristics, which collectively influence melt pool formation, energy absorption, and defect generation. Key parameters such as laser power, scanning speed, beam size, and layer thickness play a critical role in determining the energy absorption behavior and the resulting melting mechanisms. Absorptivity and melt pool depth are especially responsive near the transition between conduction and keyhole melting modes, where thermal properties and energy input become closely linked.

The geometry of the melt pool is also affected by the chosen scan strategy and powder properties. Finer and more uniformly distributed powders typically improve energy absorption and promote more stable melt pool formation. This results in higher part density and deeper melt pools across various alloy systems, including titanium, aluminum, and copper.

Real-time monitoring technologies, such as infrared pyrometry may allow for dynamic classification of melting regimes during the build process. Furthermore, adjustments in scan strategy can refine thermal behavior and improve part quality. The impact of these parameters varies with material type, highlighting the importance of tailoring process conditions to specific powder characteristics to achieve optimal performance.

激光粉末床熔融（LPBF）是由激光设置和材料特性之间复杂的相互作用控制的，这些相互作用共同影响熔池的形成、能量吸收和缺陷的产生。激光功率、扫描速度、光束尺寸和层厚等关键参数在决定能量吸收行为和熔化机制方面起着关键作用。吸收率和熔池深度在传导和锁孔熔化模式之间的过渡附近特别敏感，在那里热性能和能量输入密切相关。所选择的扫描策略和粉末性质也会影响熔池的几何形状。更细和更均匀分布的粉末通常改善能量吸收，促进更稳定的熔池形成。这导致更高的零件密度和更深的熔池跨越各种合金系统，包括钛，铝和铜。实时监测技术，如红外热分析法，可以在构建过程中对熔化状态进行动态分类。此外，调整扫描策略可以改善热行为，提高零件质量。这些参数的影响因材料类型而异，突出了为实现最佳性能而定制特定粉末特性的工艺条件的重要性。

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引用次数: 0

Investigation of printability and mechanical properties of Hastelloy X (HX) manufactured by Laser Powder Bed Fusion (L-PBF) 激光粉末床熔融（L-PBF）制备哈氏合金X （HX）的可印刷性和力学性能研究

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.068

M. Turhan , I. Zetková , M. Zetek , J. Hruška

This paper deals with 3D printed parts which are being investigated in the printability and mechanical properties of Hastelloy X (HX) powder by Laser Powder Bed Fusion (L-PBF) technology. HX material is widely used in the industry, which is required for oxidation resistance, fabricability, and high-temperature strength applications. The objective of the research is to print the unit of the heat exchanger by doing experimental prints through manipulating scanning strategies and altering the support structures. There are many samples printed for mechanical tests such as tensile, creep, and fatigue to be exposed to supercritical water environment, in nitrogen, and in air environment at different temperatures and different durations. Each print is evaluated, and outcomes are applied on the next print. By doing this, to achieve more stable prints and verifying and comparing the mechanical properties with industrial applications. Some issues such as support structures (especially block support), and residual stresses are addressed to be worked on the further research for HX material at the end of the research.

采用激光粉末床熔融（L-PBF）技术对哈氏合金X （HX）粉末的可打印性和力学性能进行了研究。HX材料在工业上应用广泛，对抗氧化性、可加工性、高温强度等应用要求较高。本研究的目的是通过控制扫描策略和改变支撑结构来进行实验打印，以实现热交换器单元的打印。在不同温度和不同时间的超临界水环境、氮气环境和空气环境中，有许多打印样品用于拉伸、蠕变和疲劳等力学试验。每个打印都被评估，结果应用于下一个打印。通过这样做，实现更稳定的打印，并与工业应用验证和比较机械性能。在研究的最后，对HX材料的支撑结构（特别是块状支撑）和残余应力等问题进行了研究。

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引用次数: 0

Condition-Based Monitoring System for a Stamping Press 冲压压力机状态监测系统

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.072

Carolina Francisco , Hugo Mesquita Vasconcelos , Susana Dias , Pedro J.S.C.P. Sousa , Paulo J. Tavares , Pedro M.G.J. Moreira , Tiago T.M. Soares , António da S. Guedes

Stamping presses are essential in manufacturing due to their ability to produce components with high speed, precision and repeatability. However, unplanned downtime due to equipment failure can disrupt production and raise costs. While preventive maintenance schedules, commonly used by manufacturers, help reduce these risks, their time-based nature can lead to unnecessary stoppages and may miss emerging faults that develop between inspections. Condition-based systems capable of estimating the current condition of a press and detecting potential component faults offer significant advantages, as it can lead to energy and cost savings, as well as increased productivity and product quality.

To address this need, a monitoring system was developed alongside the manufacturing of a new servo motorized stamping press. The system utilizes multi-sensor data collected from strategically placed sensors on the press. Sensor signals are filtered by dedicated modules and transmitted to a computer, where algorithms analyze the data to evaluate the press’s condition. The results of the estimated condition, along with the sensor data, are displayed on a dashboard also operating as an interface to manage data processing. The system’s modular architecture enables flexible integration or removal of sensors according to evolving requirements.

This paper describes the early stage of developing the monitoring system, including the design of the system architecture and the definition of the sensing plan. To support the development and validation of the processing algorithms, data were collected from a stamping presses ensuring representative signal characteristics for press operation.

冲压压力机在制造业中是必不可少的，因为它们能够以高速，精度和可重复性生产组件。然而，由于设备故障导致的计划外停机可能会破坏生产并增加成本。虽然制造商通常使用的预防性维护计划有助于降低这些风险，但其基于时间的性质可能导致不必要的停机，并可能错过在检查之间出现的新故障。基于状态的系统能够估计压力机的当前状态并检测潜在的组件故障，这具有显著的优势，因为它可以节省能源和成本，并提高生产率和产品质量。为了满足这一需求，在制造新型伺服电动冲压机的同时，还开发了一套监控系统。该系统利用从印刷机上战略性放置的传感器收集的多传感器数据。传感器信号通过专用模块过滤后传输到计算机，计算机通过算法分析数据来评估压力机的状况。估计条件的结果以及传感器数据显示在仪表板上，仪表板也作为管理数据处理的界面。该系统的模块化架构能够根据不断变化的需求灵活地集成或移除传感器。本文描述了监控系统开发的早期阶段，包括系统架构的设计和传感方案的定义。为了支持处理算法的开发和验证，从冲压机上收集数据，确保压力机操作的代表性信号特征。

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引用次数: 0

On the applicability of mean stress correction models in the very high cycle fatigue regime (VHCF) 平均应力修正模型在甚高周疲劳状态下的适用性

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.056

J.A. Alves , M.V. Pereira

The objective of this research was to evaluate the applicability of mean stress correction models (Goodman, Gerber, Soderberg, and ASME) beyond their conventional validation boundaries (failures between 1E4–1E7 cycles) for predicting fatigue life in the very high cycle fatigue (VHCF) regime (failures after 1E7 cycles). Cyclic tests were performed on a high-strength structural steel under fully reversed and partially reversed loading conditions to compare experimental results with fatigue life predictions from these models. The material was tested under both fully reversed and mean stress loading conditions to determine fatigue life. Each model was employed to calculate the equivalent stress amplitude for fitting Basquin curves. Statistical tools were subsequently used to compare the Basquin curve derived from each model with the experimental curve obtained under fully reversed loading. The linear models (Goodman and Soderberg) demonstrated better agreement with experimental VHCF data, whereas the quadratic models exhibited greater inconsistency in the VHCF regime.

本研究的目的是评估平均应力修正模型（Goodman, Gerber， Soderberg和ASME）在常规验证边界（1E4-1E7循环失效）之外预测极高循环疲劳（VHCF）状态（1E7循环失效）疲劳寿命的适用性。在完全反向和部分反向加载条件下，对一种高强度结构钢进行了循环试验，将试验结果与这些模型的疲劳寿命预测进行了比较。在完全反向和平均应力加载条件下对材料进行了测试，以确定疲劳寿命。利用各模型计算等效应力幅值，拟合Basquin曲线。随后使用统计工具将每个模型得出的Basquin曲线与完全反向加载下得到的实验曲线进行比较。线性模型（Goodman和Soderberg）与实验VHCF数据表现出更好的一致性，而二次模型在VHCF制度中表现出更大的不一致性。

引用次数: 0

On cohesive fracture behaviour of ultrahigh-strength lath-martensitic tendon-rods for structural engineering 结构工程用超高强度板条-马氏体筋棒内聚断裂行为研究

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.044

P. Santos , A. Valiente , M. De Abreu , M. Iordachescu

The work examines the fracture behaviour of a lath-martensitic steel, recently employed to manufacture ultrahigh-strength tendon-bars for structural engineering. In this view, the steel was fracture tested by using fatigue pre-cracked SENT specimens and assessed on the experimental and theoretical bases respectively provided by the BS-8571 standard and Dugdale’s cohesive model. The assessment relays on the comparison of the load and J-integral versus CMOD curves resulting from the fracture tests and from the predictions of the cohesive model applied to the SENT specimen configuration on the basis of the Green function proposed by Chell, the superposition principle and the Maxwell-Betty reciprocal theorem for Hookean cracked bodies. It was found that the J-integral linearly increases with CMOD once the small-scale regime vanishes, whereas the loading process becomes asymptotically unstable. The corresponding slope and maximum load are a function of the crack size and the cohesive resistance. The comparison shows that the cohesive crack accurately models the mechanism by which the steel opposes to crack propagation when mechanically loaded and allows the cohesive resistance of the steel to be obtained from the experimental slopes and maximum loads. The values obtained are fully consistent with the condition of being a material constant and with the physical meaning attributed to it by the cohesive model.

这项工作研究了板条马氏体钢的断裂行为，这种钢最近被用于制造用于结构工程的超高强度筋棒。在此基础上，采用疲劳预裂试件进行断裂试验，并分别以BS-8571标准和Dugdale黏聚模型为实验依据和理论依据进行评估。对断裂试验的载荷和j积分与CMOD曲线的比较，以及基于Chell提出的Green函数、叠加原理和Hookean裂纹体的Maxwell-Betty互反定理对send试件结构的内聚模型的预测，进行了评估。结果表明，当小尺度状态消失时，j积分随CMOD线性增加，而加载过程渐近不稳定。相应的边坡和最大荷载是裂缝尺寸和粘聚阻力的函数。结果表明，内聚裂纹能较好地模拟钢在机械载荷作用下抗裂纹扩展的机理，并能从试验斜率和最大载荷中得到钢的内聚阻力。所得值完全符合作为材料常数的条件，也符合内聚模型赋予它的物理意义。

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引用次数: 0

The effect of gradient determination on the accuracy and performance of gradient-based fatigue damage parameters applied to scanned weld joint topologies 梯度确定对基于梯度的疲劳损伤参数应用于扫描焊缝拓扑的精度和性能的影响

Procedia Structural Integrity

Pub Date : 2026-01-01 DOI: 10.1016/j.prostr.2026.01.045

Georg Veile , Daniel Klöss , Julius Lotz , Stefan Weihe

Scanning the topology of weld geometries has the potential to improve the performance and accuracy of fatigue life assessment. However, in previous studies it has been shown that gradient based fatigue damage parameters (FDP) can be very sensitive to small notch radii. In this case, some FDP (FFS and RM) overestimated the fatigue life, leading to non-conservative results. In this paper the influence of gradient determination on the fatigue life prediction is examined. The local shear and strain gradients were reevaluated with different approaches. Evaluating the gradients with an increased Δx lead to improved accuracy and a reduction in non-conservatism. However, this approach also effected initially better performing FDP such as FDP_FGF. Increasing Δx from 0.05 to 0.20 mm led to a decrease of approx. 50% in Sd. at all FDP. Gradient determination is not the sole causative for increased scatter in fatigue life prediction using scanned weld joint topologies. This indicates that the gradients may also not be the key to reduce scatter.

扫描焊缝几何形状的拓扑结构有可能提高疲劳寿命评估的性能和准确性。然而，以往的研究表明，基于梯度的疲劳损伤参数（FDP）对小缺口半径非常敏感。在这种情况下，一些FDP （FFS和RM）高估了疲劳寿命，导致结果不保守。本文研究了梯度确定对疲劳寿命预测的影响。用不同的方法重新计算了局部剪切和应变梯度。用增大的Δx来评估梯度可以提高准确性和减少非保守性。然而，这种方法也影响了最初表现较好的FDP，如FDPFGF。将Δx从0.05增加到0.20 mm，导致约下降。50%在Sd。完全是自由民主党。在使用扫描焊缝拓扑进行疲劳寿命预测时，梯度的确定并不是导致散射增加的唯一原因。这表明梯度也可能不是减少散射的关键。

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引用次数: 0