Fracture and Structural Integrity: The Podcast

Fracture and Structural Integrity: The Podcast@fis_podcast

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Modified elastic-plastic model: implementation algorithm and comparison of computational efficiency with the elastic-viscoplasti
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Modified elastic-plastic model: implementation algorithm and comparison of computational efficiency with the elastic-viscoplasti

The most important element of mathematical models of thermomechanical processing of metals and alloys is the constitutive model. In recent decades, multilevel physically-oriented constitutive models (CMs) have found widespread application. The first two-level model was the rigid-plastic theory of J. Taylor,a rigorous mathematical justification of which was developed by J. Bishop and R. Hill (TBH type models). The main disadvantage of this model is the uncertainty of the choice of active slip systems when more than 5 systems are activated. Despite this, the TBH models have become widespread, and its basic provisions have been preserved in many later developments. It seems that limiting the number of active slip systems to 5 has no physical justification and is determined only by the numerical procedure for implementing the model. Since the 1970s, elastic-viscoplastic models have emerged; it has been shown that as the velocity sensitivity parameter tends to zero, the macroparameters determined in the modeling converge to a solution using an elastic-plastic model. However, the system of equations becomes rigid, requiring the use of implicit schemes and extremely small time steps, which significantly reduces the computational efficiency. The paper proposes a modification of elastic-plastic model of the TBH type, in which a procedure for overcoming the above-mentioned drawback is proposed. To compare the computational efficiency of the elastic-plastic and elastic-viscoplastic models, a series of numerical experiments was carried out.

Utilizing cylindrical and cubical specimens with edge notch to determine size-independent fracture quantities of rock materials
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Utilizing cylindrical and cubical specimens with edge notch to determine size-independent fracture quantities of rock materials

The compliance method was first applied to short rod specimens to determine the nonlinear fracture toughness of rock materials by ISRM (International Society for Rock Mechanics) in the 1980s. In this study, utilizing the techniques of the J-integral and the crack closure integral (CCI), crucial linear elastic fracture mechanics expressions for straight-notched disk bending (SNDB) specimens, whose tests are simpler than those for short bar specimens, and single-notch cube bending (SNCB) specimens are initially derived to estimate crack propagation states in rock samples. Andesite-based SNDB specimens from the literature are examined using the compliance approach, and a strong correlation is observed between the compliance approach and the nonlinear approach reported in the literature. Subsequently, limestone-based SNCB specimens and beams containing cracks are produced and tested under bending. The fracture test data are estimated using the peak load approach, and the results of the comparative analysis are found to be satisfactorily consistent for both beams and SNCB specimens. The findings of this study reveal that the non-Hookean fracture quantities of rocks can be adequately determined using SNDB and SNCB specimens of a single size.

Reduction of cracks in concrete slabs through the incorporation of polypropylene synthetic fiber
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Reduction of cracks in concrete slabs through the incorporation of polypropylene synthetic fiber

In Peru, research on cracking in concrete slabs has been limited, partly due to the perception that cracks do not pose an immediate problem. However, their cumulative effect over the long term can compromise structural durability, highlighting the need for further study. This research was conducted according to the recommendations of ASTM C1579, which establishes procedures for evaluating shrinkage cracking in concrete mixes with and without fiber reinforcement. The main objective was to determine the optimal proportion of polypropylene synthetic fiber that maximizes the reduction in the appearance and formation of cracks. Three dosages were evaluated: DM-01 (500 g/m³), DM-02 (1000 g/m³), and DM-03 (2000 g/m³), compared to a reference concrete (MP) during a 35-day curing period. The results indicated that dosage DM-02 (1000 g/m³) exhibited the best performance, with reductions of 18.41% in average crack thickness, 11.46% in total crack length, and 32.43% in the number of cracks compared to the control concrete. Furthermore, the Mann-Whitney U test applied to DM-02 and MP showed that the average crack thickness at 28 days (p = 0.073) showed a trend toward statistical significance, suggesting a possible reduction in crack thickness with the addition of fibers. In contrast, mixes DM-01 and DM-03 showed heterogeneous results, without substantial improvements in any of the variables; in particular, DM-03 registered an increase in crack thickness. It is concluded that a moderate fiber dosage (DM-02) is the most suitable option, since both a deficiency and an excess of fiber can compromise the material's effectiveness against cracking.

Application of the thermography method for determining the fatigue limit of a nickel alloy produced by wire‑arc additive manufac
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Application of the thermography method for determining the fatigue limit of a nickel alloy produced by wire‑arc additive manufac

The development of additive technologies for manufacturing safety‑critical components operating under vibration must be accompanied by a careful analysis of the material’s resistance to high‑cycle fatigue (HCF). This paper presents a technique for the rapid assessment of the fatigue limit of nickel alloys fabricated by wire‑and‑arc additive manufacturing (WAAM). The technique grounded in infrared thermography (IRT), utilizes the self‑heating effect during cyclic loading. The technique realisation involves choosing specimen design, test equipment, the number and parameters of loading blocks, self‑heating indicators, and result‑processing procedures that account for material specifics. It is shown that the rate of temperature rise at the specimen surface at the start of each loading block can serve as an indicator of self‑heating. Experimental data on the fatigue limit of specimens made from the heat‑resistant alloy Inconel 625 produced by WAAM are obtained. Validation of the developed method is performed by comparing the fatigue limit derived from IRT with the results of conventional fatigue testing and the corresponding S–N curve. For additive nickel alloys, the proposed accelerated fatigue‑limit assessment allows a substantial reduction in the number of specimens and the time required to select technological parameters and refine additive manufacturing processes compared with traditional fatigue testing.

Coupling crystal plasticity and microstructure in SLM manufactured 316L parts: model development and experimental assessment
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Coupling crystal plasticity and microstructure in SLM manufactured 316L parts: model development and experimental assessment

Additive manufacturing is extensively used for the production of complex-shaped parts from metals and polymers. Because of the influence of various physical factors, the structure of materials processed under different processing conditions may vary considerably, altering their properties. Application of a multi-level crystal plasticity approach helps explicitly describe the structure of materials at different scale levels. It makes possible the evaluation of basic mechanical properties of the samples fabricated by layer-wise laser melting. In this work, a two-level statistical constitutive model is suggested for calculation the main mechanical characteristics (elastic modulus, offset yield stress) of the AISI 316L stainless steel samples produced by selective laser melting. The model explicitly considers the grain structure and texture of metal parts, twinning defects, and residual stresses in the as-build structure of materials. Under predefined loading conditions, the primary mechanism of inelastic deformation is through intra-granular slips of edge dislocations. Thus, the mechanism of material hardening has been described by a modified form of the Hall-Petch law, where the boundaries of grains and original twins are counted as effective barriers to dislocations. All model parameters are properly identified based on own experimental data and the data found in literature. The elastic moduli and yield stresses are calculated at different residual deformations and are found to be in fair agreement with experiments.

Machine learning-assisted fracture prediction: Integrating synthetic and experimental data for quasi-static notch failure analys
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Machine learning-assisted fracture prediction: Integrating synthetic and experimental data for quasi-static notch failure analys

Machine learning has emerged as a powerful tool in various scientific fields for developing data-driven models, reducing the need for extensive physical testing. In this study, the fracture load was first predicted using Theory of Critical Distances (TCD) for experimental data. Further, this study presents a machine learning-based framework for the prediction of quasi-static fracture loads of U-notched polycarbonate specimens using a combination of experimental and synthetic data. Experimental data was obtained for eleven notch configurations, while synthetic data was generated through fracture mechanics-based simulations using PYMAPDL. XGBoost was trained on experimental and synthetic training datasets, evaluated against a fixed randomly selected experimental test set. Model performance was evaluated using MAPE, MAE, RMSE values as R2 varied significantly with test set sampling and random state selection. This study systematically evaluates how varying the proportion of synthetic data influences model performance, offering a scalable strategy to minimize experimental dependence without compromising accuracy. Experiment-only dataset provided the highest accuracy, while hybrid models performed reasonably well. The full dataset model combining all experimental and synthetic data, achieved the most robust and accurate predictions, with errors ranging within ±5% and yielding the lowest MAPE of 1.18% and MAE of 78.73 N. It is suggested that synthetic data can significantly enhance the training of machine learning models, but cannot completely replace the experimental data, especially in critical applications.

Modified multi-scale constitutive model of Aluminum:  complex loading with variable thermal conditions
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Modified multi-scale constitutive model of Aluminum: complex loading with variable thermal conditions

During manufacturing of parts from metals and alloys through forming and subsequent thermal and mechanical treatments the materials are often subjected to complex loading. In such cases materials significantly change their structure, which determines the operational characteristics of a finished product. Therefore, for digital design of technological processes aimed at improving the functional characteristics of products, it is promising to develop mathematical models that adequately describe the material structure evolution during forming, thermal and mechanical processes including complex loading. This work considers the previously developed two-level constitutive models of aluminum under complex loading accompanied by temperature variations. The model parameters were calibrated to the experimental data of simple shear loading of aluminum specimens. The resulting deformation curves for aluminum subjected to simulated reversed simple shear loading with temperature variations, as well as loading involving strain-path changes, correspond well to the experimental data. The observed effects arising under the considered complex loading conditions are explained through analysis of the obtained description of the intragranular dislocation slip mechanisms. The study results demonstrate the applicability of multilevel constitutive models for comprehensive descriptions of the effects observed in the material during thermal and mechanical treatments.

Diagnostics and experimental analysis of 3D printed concrete structural elements
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Diagnostics and experimental analysis of 3D printed concrete structural elements

This study investigates the structural behaviour of elements produced by extrusion-based 3D concrete printing (3DCP). Six full-scale columns with intentional imperfections were tested in three-point bending and subsequently analysed through fragment testing. Compressive strength (16.6–32.2 MPa), flexural tensile strength (1.96 MPa parallel vs. 1.27 MPa perpendicular), ultrasonic pulse velocity, bulk density, and water absorption were measured. The results confirmed pronounced anisotropy and strong correlations between physical and mechanical properties. A simplified FEM model, calibrated with fragment data, reproduced global stiffness but not brittle delamination. The combined methodology offers a basis for diagnostics and quality control of 3DCP elements.

Study on mechanical, wear, corrosion and fracture characteristics of Al7075 by modifying nano sized Magnesium (n-Mg) element
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Study on mechanical, wear, corrosion and fracture characteristics of Al7075 by modifying nano sized Magnesium (n-Mg) element

Aluminum alloys are widely used in the automobile industry because of their excellent mechanical strength, low weight, and remarkable resistance to corrosion and wear. The purpose of this study is to investigate how the microstructure, mechanical properties, and corrosion resistance of the Al7075 alloy are affected by the addition of nano sized magnesium (n-Mg) particulates. Stir casting was used to fabricate the alloy samples, which had varied wt. % of n-Mg (0, 1, 1.5, 2, and 2.5 wt. %). By studying corrosion, wear, microstructural, and mechanical characteristics, the impact of n-Mg dispersion was assessed. The findings provided crucial information on magnesium's function in fortifying aluminum by demonstrating that optical micrographs depicted a homogeneous distribution of n-Mg particles within the Al7075 matrix. Magnesium at the nanoscale improved the alloy's strength, reduced dislocation motion, and refined the grain structure. However, as evidenced by a decrease in impact energy, the addition of magnesium also resulted in decreased toughness and ductility. Tensile strength, hardness, wear resistance, as well as corrosion resistance all improved by roughly 9.21%, 15.73%, 18.82%, and 23.80%, respectively, in the modified Al7075 alloy.

The effect of energy director on ultrasonic consolidation of multilayered composites (laminates) made from unidirectional PEEK/C
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The effect of energy director on ultrasonic consolidation of multilayered composites (laminates) made from unidirectional PEEK/C

The study aims at assessing the effects of the ultrasonic consolidation parameters and the insertion of energy directors from the commercially available polyetheretherketone film ~250 µm thick on the structure and mechanical properties of the layered composites (laminates). Commercially available polyetheretherketone-based prepregs reinforced with tapes of unidirectional carbon fibers were ultrasonically consolidated with and without energy directors from neat polyetheretherketone film using an ‘UZPS-7’ ultrasonic welding machine. The laminates without the energy directors consisted of 16 prepreg layers, while 7 and 6 layers of the prepregs and the energy directors, respectively, included the other ones to ensure similar thicknesses during subsequent interlaminar shear strength tests. In the laminates with the energy directors, prolonging the ultrasonic duration allowed for the prepreg interfaces to be virtually blurred, increasing the interlaminar shear strength value up to the maximum level of 60 MPa. With the energy directors, excessive melting and spreading of the polymer occurred at the prolonged ultrasonic durations, increasing the number of discontinuities at the layer interfaces, including delamination and the impregnation of the prepregs with the excessive binder. The ultrasonic duration of 800 ms was the most rational, as it enabled to reduce the damaging effect of applied ultrasonic vibrations on the joined layers (prepregs), increasing the interlaminar shear strength value above 50 MPa.

Fatigue properties of a spring element for mounts with tunable stiffness made of C85S+QT sheet steel
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Fatigue properties of a spring element for mounts with tunable stiffness made of C85S+QT sheet steel

Mounting stiffness has an important impact on a system’s structural dynamics and also on the durability of many structures. Mounts with tunable stiffness allow adapting a system’s structural dynamic behavior. Furthermore, they can be used to emulate elastic behavior of adjacent structures in test benches for components and substructures, e.g. for designing simplified, but accurate fatigue tests. For these applications, the tunable mounts themselves need to have sufficient fatigue strength. In this paper, results of experimental fatigue tests with such mounts are reported, providing material and geometry related fatigue data for four different configurations. Based on these experimental results, numerical parameter studies and analytical correlations, fatigue strength and stiffness approxima-tions are proposed for a wider range of geometries. This enables efficient pre-dimensioning of the tunable mounts starting from basic requirements.

Effect of pearlite nanoclay reinforcements on the mechanical and tribological behaviour of AA7076 metal nanocomposites
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Effect of pearlite nanoclay reinforcements on the mechanical and tribological behaviour of AA7076 metal nanocomposites

Aluminium alloy composites are extensively utilised in the aerospace, automobile, and marine industries due to their lightweight structure and high strength-to-density ratio. However, there remains significant potential to further improve these composites for advanced applications by enhancing their strength-to-weight ratio, corrosion resistance, wear resistance, and temperature performance. This study investigates the mechanical and tribological properties of AA7076 alloy reinforced with varying concentrations (1.0 and 1.5 wt.%) of perlite nanoclay. These composites were synthesized using a motorised stir casting process and characterised through tensile, wear, and hardness tests. Results showed that 1.5 wt. % perlite nanoclay composite exhibited the most significant improvements, with hardness, tensile strength, and wear resistance increasing by 32%, 38%, and 59%, respectively, compared to the base AA7076 alloy. Finite element simulations in ANSYS Workbench predicted tensile strengths in close agreement (within 5 – 8%) with experimental results, validating the strengthening effects of nanoclay. The enhancements are attributed to the homogeneous dispersion of nanoclay particles, strong interfacial bonding, and their role in restricting dislocation motion. These findings establish perlite nanoclay as a cost-effective and sustainable reinforcement for aluminium alloy, well-suited for demanding applications in automotive, aerospace, and marine industries, offering a promising combination of lightweight design and superior performance.

Experimental and 3D numerical analysis on the effect of specimen thickness on fracture toughness of Al6061-SiC-cenosphere hybrid
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Experimental and 3D numerical analysis on the effect of specimen thickness on fracture toughness of Al6061-SiC-cenosphere hybrid

This study examines the fracture toughness of Al6061 alloy-based hybrid composites reinforced with silicon carbide particles and cenosphere microspheres. Aluminum alloy Al6061 is widely utilized in structural applications due to its balanced mechanical properties, and its hybridization with SiC and cenosphere reinforcements enhances its performance under critical loading conditions. The effect of specimen thickness on fracture toughness was examined by fabricating compact tension specimens in accordance with ASTM E399 standards, with thickness-to-width ratios ranging from 0.2 to 0.7. Controlled fatigue cracks were introduced, and both experimental testing and finite element simulations were conducted to assess the critical stress intensity factor and crack propagation behaviour across different thicknesses. Results show that the fracture toughness is constant after the B/W ratio of 0.5 and above, states as plane strain fracture toughness. The 3wt% SiC and 6wt% cenosphere in Al6061 shows the highest fracture toughness up to 15.56 MPa√m, due to the effective stress distribution and interfacial bonding. The fractography using the scanning electron microscopy reveals that particle debonding is major failure mechanism, with microcracking in 3wt% cenosphere composites and crack deflection and stress transfer at high reinforcement contents. Experimental results were well matched with the simulation model with ±10% differences, proving its validity.

Consecutive shock waves and fatigue loads: action invariants as optimization parameters under Laser Shock Peening
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Consecutive shock waves and fatigue loads: action invariants as optimization parameters under Laser Shock Peening

The criteria for optimizing shock-wave modes to increase the fatigue life of aircraft engine alloys are discussed with reference to laser shock peening (LSP). They are based on the self-similarity of plastic wave fronts and the kinetics of fatigue cracks related to the Swegle-Grady power law of structured plastic wave fronts and the Paris power law of fatigue crack advance. It is shown that the self-similar patterns and the power-law relationships of structured wave fronts at shock pulse amplitudes of 1-10 GPa and strain rates of 105-109 s-1 correspond to “action invariants” that determine the dissipative properties (stored energy) of materials caused by multiscale defect development. The relationship between the “action invariants” of structured plastic waves, the fatigue crack kinetics and the structural scaling invariants is shown using the 3D data of qualitative fracture surface profilometry. The methodological principles for studying material behavior under successive shock-wave and fatigue loads have been developed to optimize LSP processes and thus to ensure maximum fatigue life.

Experimental field analysis of damage-failure transition in composite material with a stress concentrator under cyclic loading (
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Experimental field analysis of damage-failure transition in composite material with a stress concentrator under cyclic loading (

Predicting the failure of carbon fiber composites remains a challenge due to the complex evolution of damage, where the collective behavior of defects like pores and microcracks dictates material strength. The objective of this work is to elucidate the transition from damage accumulation to final failure under cyclic loading by analyzing the integral structural characteristics of the material. A methodology combining microtomography and digital image correlation (DIC) was employed to monitor damage evolution in situ. The analysis of DIC-derived strain fields during block cyclic loading pinpointed the critical transition stage to failure. Furthermore, Bayesian Gaussian Mixture models were used for threshold segmentation and cluster analysis, revealing that mechanical loading induces distinct populations of small and large pores. The main results show that while the overall pore orientation distribution remains consistent, the clustering and ordering of pores evolve differently under cyclic loads compared to quasi-static conditions. Specifically, unloaded samples exhibit three distinct pore clusters based on orientation, a structure that is altered by cyclic loading through pore expansion and coalescence, which ultimately reduces specimen strength. These insights advance the understanding of damage criticality in composites and provide a foundation for developing more accurate predictive models.

Effect of the stress state on ultimate strain energy density in the failure of reinforced epoxy resin
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Effect of the stress state on ultimate strain energy density in the failure of reinforced epoxy resin

Epoxy resin reinforced with 10% of TiO2 and pure epoxy resin are taken to exemplify the possibility of constructing a fracture locus for engineering organic polymers as a dependence of ultimate strain energy density in cohesive failure on the stress triaxiality factor in the range  and the Lode–Nadai coefficient . The fracture loci are based on the results of compressive testing of cylindrical specimens, tensile and compressive testing of bell-shaped specimens, dishing of thick-walled cup-shaped specimens, shearing of oblique dog-bone-shaped specimens. The tests were performed at 25 and −50 °C. The obtained dependences are approximated by interpolation formulas, and they can be used to predict the failure of structural components made of organic polymer materials mechanically affected under conditions of a complex stress state.

Certain issues in the analytical integration of the Boussinesq problem
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Certain issues in the analytical integration of the Boussinesq problem

The Boussinesq solution, one of the fundamental problems in the theory of elasticity, enables an analysis of stresses and strains (displacements) in a semi-elastic space subject to surface loads. This solution has a form of formulas for displacements evoked by a concentrated force; these formulas can be treated as Green functions for calculation of displacements (and then – stresses) in a half-space loaded in any way at its surface z = 0. The study presents difficulties met during the analytical integration of the Green functions in the Mathematica environment as well as methods of coping with these difficulties. The authors are going to present particular issues which can be quite surprising and confusing, for example a failure to obtain a close result for definite integrals in Wolfram Mathematica or differences between results of calculations of the sum of integrals and the integral of the sums. The results of the study can help in establishing more exact benchmarks for the numerical methods applied in the analysis of settlement under foundations as well as other contact issues of the theory of elasticity based on the Boussinesq solution.

A novel procedure for accurately measuring the Mode II fracture toughness of steel fiber reinforced self-compacting concrete
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A novel procedure for accurately measuring the Mode II fracture toughness of steel fiber reinforced self-compacting concrete

Most research on the mode II fracture toughness of fiber-reinforced concrete (FRC) has intentionally avoided bridging fibers at pre-notch surfaces by using a through-thickness crack (TTC) that cuts the entire thickness, including fibers in this region. The objective of the present research is to accurately measure mode II fracture toughness (KIIC) using double-notched cube (DNC) specimens on steel fiber reinforced self-compacting concrete (SFRSCC). The effects of precrack-to-specimen width ratios (a/w), i.e., a/w = 0.3, 0.4, and 0.5, and fiber volume fraction percentage (Vf%), i.e., Vf% = 1% and 1.5% were investigated. A comparison between KIIC measured through specimens having the TTC concept, i.e., the absence of fiber bridging on the surfaces of the pre-notch, and those with the presence of fiber bridging on the surfaces of the pre-notch, i.e., the matrix crack (MC) concept. For greater clarity, the SCC specimens were cast without fibers with (MC/C) or without fiber bridging on the pre-crack surfaces to determine the unique effect of the presence of fiber bridging on the pre-crack surfaces on enhancing KIIC. The results showed that DNC specimens with MC consistently obtained the highest mode KIIC for all values of a/w, indicating the greatest resistance to crack growth. KIIC​ increased as the a/w ratio increased. MC/C method, i.e., the presence of fibers behind the crack front only, showed more effectiveness on the KIIC than the TTC, i.e., the presence of fibers ahead of the crack front only. In general, the MC is an accurate method for measuring KIIC of FRC.

Optimization of austenitic and ferritic steels for deep drawing.Part 2: FEM analyses with damage development
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Optimization of austenitic and ferritic steels for deep drawing.Part 2: FEM analyses with damage development

Deep drawing of sheet metal is a crucial industrial process due to its high productivity and low cost per unit produced. Stainless steels are ideal for this process, given their high deformability compared to other steels. Despite its apparent simplicity, understanding how the material deforms during deep drawing is essential to predict the final result. From this point of view, simulation via finite element modelling (FEM) represents a rapid and cost-effective alternative to experimental testing. When properly calibrated, FEM models allow for analysing stress and strain distribution, identifying areas at risk of failure, calculating final wall thickness, and optimizing die geometry. This research led to the development of a FEM model capable of simulating deep drawing under different operating conditions, steel types (AISI 304 and AISI 430) and lubrication. The model was calibrated and validated by comparing the numerical results with those obtained from a series of Erichsen tests. To ensure the accuracy of the true stress-strain curves, the steels were thoroughly characterized through tensile tests, Erichsen tests, and metallographic analyses. A specific method was also developed to represent the true stress-strain curve beyond necking, up to physical failure of the steel. The experiment was conducted according to the principles of DoE (Design of Experiments), combined with statistical analysis using the ANOVA technique.

Fatigue experimental characterisation of brazed joints in aluminium microchannel heat exchangers
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Fatigue experimental characterisation of brazed joints in aluminium microchannel heat exchangers

Brazing is a widely employed joining technique for aluminium components due to its cost-effectiveness and compatibility with complex geometries. However, the structural integrity of brazed joints under cyclic loading remains a scarcely addressed scientific and engineering concern. This study investigates the tensile and fatigue behaviour of aluminium 3xxx-series alloy components employed in microchannel heat exchangers—headers and multi-port extruded tubes—both in the as-received and heat-treated (brazing cycle) conditions. Tensile tests were performed on parent materials using a microtensile equipped with a Digital Image Correlation (DIC) system for accurate strain evaluation during testing. On the other hand, uniaxial fatigue tests were performed on specimens containing a representative brazed joint. Finite element analyses were used to design the fatigue specimen geometry based on stress concentrations observed in simplified heat exchanger models. Fatigue test data were employed to determine fatigue behaviour both in the finite life region of high-cycle fatigue and to characterise the fatigue endurance limit at 107 cycles. Experimental testing unveiled crack initiation consistently occurring at the brazed fillet toe near the tube lateral edge. SEM observations revealed surface-initiated cracking, ratchet marks, sub-surface inclusions and final ductile failure. Results underline the need for fatigue-based design criteria for brazed aluminium structures.

Three points bending ultrasonic fatigue resistance and vickers hardness of Tlalpujahua clay thermally treated
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Three points bending ultrasonic fatigue resistance and vickers hardness of Tlalpujahua clay thermally treated

Ultrasonic fatigue at an operating frequency of 20 kHz was conducted on thermally treated clay bricks at 500, 750, and 1000 °C with a holding time of 5 h, using a three-point bending setup to assess their fatigue endurance. A Vickers hardness test was also performed on small clay squares thermally treated at the same temperatures, showing increased hardness values. X-ray diffraction (XRD) analysis was also performed, revealing temperature-induced changes in the clay chemical composition. Specifically, the illite transformation into spinel at 1000 °C contributed to a significant increase in hardness and, consequently, a diminution in fatigue life. A finite element simulation under different applied loads was performed to evaluate the von Mises stress behavior of the clay brick. Considering the change in mechanical properties, such as bulk density, at various temperatures. The simulation results show a corresponding behavior with the values of the Vickers hardness. This study provides a perspective on the relationship between ultrasonic fatigue, Vickers hardness, and thermal treatment.

Elasto-plastic truss optimization under geometric nonlinearity using a genetic algorithm
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Elasto-plastic truss optimization under geometric nonlinearity using a genetic algorithm

This paper presents an advanced optimization methodology for truss structures, addressing both elasto-plastic design cases—where plastic deformations are controlled within predefined limits—and purely elastic scenarios, in which inelastic behavior is entirely prevented. Plastic deformations are characterized and quantified using the complementary strain energy of residual forces, providing a reliable measure of inelastic response. Additional design constraints related to load-bearing capacity and structural stability are incorporated through penalization terms, while the objective function focuses on minimizing structural weight. Serviceability restrictions are also applied to enhance the robustness of the design. Building on these considerations, the framework integrates material and geometric nonlinear finite element analysis (FEA) with a genetic algorithm (GA), enabling the automated determination of optimal cross-sectional areas for individual bar members within a predefined design domain. To further enhance safety, geometric imperfections are introduced through an integrated automatic strategy. The effectiveness of the proposed technique was validated using two benchmark numerical examples: a 37-bar planar truss and a 25-bar space truss, evaluated under multiple design scenarios. The results highlight the flexibility and reliability of the optimization framework, demonstrating substantial weight savings while fully meeting all structural performance criteria.

Optimization of austenitic and ferritic steels for deep drawing. Part 1: metallurgical and mechanical analyses
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Optimization of austenitic and ferritic steels for deep drawing. Part 1: metallurgical and mechanical analyses

Deep drawing of stainless steels thin sheets is a cold forming process used to produce components with complex geometries at limited costs. Although it seems a simple shaping technique, this technology requires a high level of know-how, essential to optimize parameters and limit production scraps. The choice of stainless steel type also plays a fundamental role, since there are austenitic and ferritic grades with improved chemical composition which should be characterized by a superior deformability when compared to the more common ones. This study investigates the formability of two austenitic and two ferritic stainless steels, AISI 304, 304 mod., AISI 430 and AISI 441, using tensile tests and Erichsen tests. From the former, the mechanical properties and anisotropy coefficients were determined along three sampling directions in respect to the rolling direction. Since the deep drawing is influenced also by some technological parameters such as the lubrication, the punch speed, and the blank-holder pressure, Erichsen tests were performed varying the deformation conditions and an Erichsen index (IE) was determined. The Erichsen samples were also subjected to metallographic and HV0.2 microhardness analyses to study the modification of the microstructure and the consequent impact on the local mechanical properties.

J-integral evaluation and structural integrity assessment using FAD for SA 312 Type 304 LN steel welded pipes with notch under m
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J-integral evaluation and structural integrity assessment using FAD for SA 312 Type 304 LN steel welded pipes with notch under m

In the present study, structural integrity of SA312 Type 304 LN steel welded pipes with through-wall crack under monotonic loading has been assessed using failure assessment diagram (FAD). Plastic capacity utilization and fracture capacity utilization are compared simultaneously using a FAD. Material’s initiation fracture toughness and J-integral evaluated using load-CMOD method were used for evaluating fracture resistance were used for generation of failure assessment diagrams. Various analytical expressions proposed by Zahoor (1989) and Takahashi (2002) were used to evaluate limit load moment (plastic capacity). Various approaches for deriving the failure assessment line were considered in this study viz, BS 7910 2A, BS 7910 2B, and SINTAP. The failure assessment lines constructed using SINTAP, BS 7910 2A level and BS 7910 2B level for SA312 Type 304 LN steel procedures yielded similar results. Limit load moment values from Takahashi were lower and hence resulted in assessment points closer to the failure assessment lines. Structural integrity assessment is very significant in deciding the safety of operation of the piping components.

Realization of introducing a non-woven veil on the interlaminar radial strength of glass-epoxy L-bend composites
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Realization of introducing a non-woven veil on the interlaminar radial strength of glass-epoxy L-bend composites

This study investigates the effect of interleaving non-woven veils and their surface areal density on the curved beam strength (CBS) and interlaminar radial stress (ILRS) of glass/epoxy L-bend composite laminates. Carbon veils with areal densities of 15, 20, and 30 g/m2 , and glass veils with 25 and 30 g/m2 were used as interleaving materials. The L-bend laminates, both interleaved and non-interleaved, were fabricated using the compression moulding technique. A four-point bending test was employed to evaluate the influence of veil interleaving and areal density on CBS and ILRS. The experimental results demonstrated that interleaving with carbon and glass non-woven veils significantly affects the performance of curved laminates. Notably, the CBS of the glass/epoxy laminate improved by 88% and 17% for specimens interleaved with 15 g/m2 carbon and 30 g/m2 glass veils, respectively. Furthermore, the ILRS of carbon veil-interleaved laminates showed a strong dependence on the veil’s areal density. In contrast, interleaving with glass veils did not exhibit a significant effect on ILRS. Finally, the fracture surfaces of the tested laminates were examined using scanning electron microscopy (SEM) to identify the various failure modes in the curved region and to understand the underlying fracture mechanisms.

Prediction of crack length in thin-walled plates under different fracture mode conditions using machine learning algorithms
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Prediction of crack length in thin-walled plates under different fracture mode conditions using machine learning algorithms

This study uses theoretical stress intensity factor data to assess how well machine learning models predict crack length. Thin-walled damage plate under various modes was evaluated based on the theoretical relation. Using theoretical data, this study implemented various ML algorithms to determine the most accurate model for thin-walled crack length prediction. The prediction/true class was used to assess each algorithm using an evaluation matrix, and each class was divided into four levels of crack length for testing and training data. According to theoretical results, SIF increases as the crack length increases, which shows that higher crack lengths cause the structures. The ability of ML algorithms trained on theoretical data to predict crack length using SIF values is investigated in this work. To estimate crack length in thin-walled structures under Mode I, Mode II, and Mode III conditions, the current work successfully evaluated the accuracy in predicting the crack length using ML algorithms. By eliminating the need for experimental/theoretical trials, the suggested ML algorithms not only simplify the process of identifying important input parameters but also provide cost-effective approaches. Finally, the results demonstrate the algorithms’ ability to yield accurate predictions.

Experimental investigation of the influence of internal defects (voids, wrinkles) on the shear properties of CFRP
S75:E05

Experimental investigation of the influence of internal defects (voids, wrinkles) on the shear properties of CFRP

The study focuses on examining the impact of internal manufacturing defects (voids and wrinkles) on the mechanical behavior of structural carbon fiber reinforced polymers (CFRP) under shear loading. Specimens of VKU/VSE1212 material with a [0/90]10 layup were artificially embedded with defects: circular voids (Ø 20 mm) and square voids (20×20 mm) at a concentration (area fraction) of 5.3%, as well as wrinkles increasing thickness by 10%. In-plane shear tests were conducted according to ASTM D7078 using a Vic-3D system for digital image correlation (DIC) to record strain fields.  Results revealed that voids at 5.3% concentration (area fraction) reduced shear strength by 2.2% (from 72.1 MPa to 70.5–70.6 MPa, regardless of geometry, indicating that the defect area, rather than its shape, governs the failure response. The shear modulus of void-containing specimens (~4.48 GPa) did not differ from defect-free specimens (~4.49 GPa). Wrinkles increased the shear modulus to 5.39 GPa due to added layers but reduced strength by ~3% (to 69.9 MPa). DIC analysis confirmed the method’s efficacy for tracking strain localization in defect zones. Failure modes across all specimens involved vertical crack formation between V-notches.  These results help systematize knowledge on of manufacturing defects on CFRP shear properties and hold practical significance for refining design tolerances in critical components, developing non-destructive testing methods, optimizing manufacturing processes.

Influence of laser shock peening on the residual strains and stresses in additively manufactured TC4
S75:E04

Influence of laser shock peening on the residual strains and stresses in additively manufactured TC4

Additively manufactured materials possess significant heterogeneities and anisotropies of stiffness and strength properties between the growth and transverse directions. Residual stresses induced by the fabrication and processing stages are critical to the service life of these materials. In this work, an experimental study of the residual stress fields was conducted in samples cut from additively manufactured titanium alloy TC4. The depth profiles of residual elastic strains for various regimes of laser impact treatment were obtained on elementary samples in the form of rectangular plates of 100´20´5 mm. Five treatment regimes were studied by varying the laser power density, the spot shape, and the percentage of overlap. The dependence of relief strains and residual stress levels on the laser energy density was obtained for two laser spot shapes: a 1´1 mm square and a 2 mm diameter circle. The numerical model, validated against experimental data for both as-built and laser-peened states, provides a reliable tool for analyzing the residual stresses and strain in additively manufactured components.

Studies on influence of seashell-based filler on water absorption behaviour of bamboo-epoxy composite: mechanical and fractured
S75:E03

Studies on influence of seashell-based filler on water absorption behaviour of bamboo-epoxy composite: mechanical and fractured

The hydrophilic nature of bamboo fiber makes them prone to moisture uptake and subsequent property degradation. In this study, bamboo fiber–epoxy composites were hybridized with clamshell-derived particulate fillers to mitigate the adverse effect of moisture absorption and enhance performance. Composites with 0, 3, 6, and 9 wt% filler were fabricated via compression molding technique. Moisture absorption and its influence on tensile and flexural strength were evaluated following ASTM standards. Results revealed that unfilled composites exhibited highest water uptake and severe strength loss upon moisture exposure, whereas filler addition reduced water uptake and improved strength retention. The 6 wt% filler showed optimal performance with 30.4% reduction in water uptake, 67.5% retention of tensile strength, and 70% retention of flexural strength. Fractography analysis confirmed the role of filler acting as a barrier against moisture ingress and restricting interfacial degradation.

Numerical simulation of crack propagation in clinch joints
S75:E02

Numerical simulation of crack propagation in clinch joints

The mechanical clinching process can be used for the load-bearing structures of thin-walled steel frame halls. Numerical simulation of crack propagation in a clinching joint using finite element method (FEM) software is an important tool for the analysis and prediction of the behavior of materials under load. This study focuses on clinch joints that must withstand high loads and repeated load cycles. Crack propagation in these joints can lead to failure of the entire structure, therefore it is important to understand the mechanisms of crack propagation and predict their behavior. Using specialized software, a numerical simulation of crack propagation was prepared, including modelling of joint geometry, definition of material properties and application of loads. The simulation provides valuable information on the crack propagation process, which allows optimization of the behavior of the whole structure and the reliability of the clinch joints.

Impact of tool rotational speed on friction stir welded joints of AA2014-T6/AA5052-H32: synthesis, microstructural, mechanical a
S75:E01

Impact of tool rotational speed on friction stir welded joints of AA2014-T6/AA5052-H32: synthesis, microstructural, mechanical a

This study examines the changes in microstructure and mechanical properties of friction stir-welded (FSW) dissimilar joints between AA2014-T6 and AA5052-H32 aluminium alloys, with an emphasis on optimizing tool rotation speed for enhanced joint quality. FSW is performed at three different tool rotation speeds (860, 1160, and 1460 rpm) while maintaining a constant welding speed and tool tilt angle of 40 mm/min and 1°, respectively. The joint created at an optimal rotation speed of 860 rpm exhibits outstanding mechanical properties, with an ultimate tensile strength (UTS) of 211 ± 1.0 MPa, a yield strength of 181 ± 1.5 MPa, and an elongation of 16.1%. The joint efficiency, in comparison to the aluminium alloy AA5052-H32, is 93.8%, indicating minimal strength loss relative to the parent material. Vickers hardness tests across the weld cross-section reveal a maximum hardness of 156 ± 1.5 HV in the stir zone, closely matching the hardness of the stronger AA2014-T6 base metal. Fractographic analysis of the FSW joint made at 860 rpm indicates a predominantly ductile failure mode with micro-dimple fracture surfaces, whereas higher tool rotation speeds exhibit brittle characteristics with circular voids and tear ridges.