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The study aims to provide a basis for the effective use of safety-related information data and a quantitative assessment way for the occurrence probability of the safety risk such as the fatigue fracture of the key components.

The fatigue crack growth rate is of dispersion, which is often used to accurately describe with probability density. In view of the external dispersion caused by the load, a simple and applicable probability expression of fatigue crack growth rate is adopted based on the fatigue growth theory. Considering the isolation among the pairs of crack length a and crack formation time t (a∼t data) obtained from same kind of structural parts, a statistical analysis approach of t distribution is proposed, which divides the crack length in several segments. Furthermore, according to the compatibility criterion of crack growth, that is, there is statistical development correspondence among a∼t data, the probability model of crack growth rate is established.

The results show that the crack growth rate in the stable growth stage can be approximately expressed by the crack growth control curve da/dt = Q•a, and the probability density of the crack growth parameter Q represents the external dispersion; t follows two-parameter Weibull distribution in certain a values.

The probability density f(Q) can be estimated by using the probability model of crack growth rate, and a calculation example shows that the estimation method is effective and practical.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

This research addresses the diverse characteristics of existing railway steel bridges in China, including variations in construction age, design standards, structural types, manufacturing processes, materials and service conditions. It also focuses on prominent defects and challenges related to heavy transportation conditions, particularly low live haul reserves and severe fatigue problems.

The study encompasses three key aspects: (1) Adaptability assessment: It begins with assessing the suitability of existing railway steel bridges for heavy-haul operations through comprehensive analyses, experiments and engineering applications. (2) Strengthening: To combat frequent crack defects in the vertical stiffener end structure of girder webs, fatigue performance tests and reinforcement scheme experiments were conducted. These experiments included the development of a hot-spot stress S-N curve for this structure, validating the effectiveness of methods like crack stop holes, ultrasonic hammering and flange angle steel. (3) Service life extension: Research on the cruciform welded joint structure (non-fusion transfer type) focused on fatigue performance over the long life cycle. This led to the establishment of a fatigue S-N curve, enhancing Chinese design codes.

The research achieved several significant outcomes: (1) Successful implementation of strengthening and retrofitting measures on a 64-m single-span double-track railway steel truss girder on an existing heavy-duty line. (2) Post-reinforcement, a substantial 26% to 32% reduction in live haul stress on bridge members was achieved. (3) The strengthening and retrofitting efforts met design expectations, enabling the bridge to accommodate vehicles with a 30-ton axle haul on the railway line.

This research systematically tackles challenges and defects associated with Chinese existing railway steel bridges, providing valuable insights into adaptability assessment, strengthening techniques and service life extension methods. Furthermore, the development of fatigue S-N curves and the successful implementation of bridge enhancements have practical implications for improving the resilience and operational capacity of railway steel bridges in China.

This paper comprehensively addresses the influence of chopped strand mat glass fiber-reinforced polymer (GFRP) patch configurations such as geometry, dimensions, position and the number of layers of patches, whether a single or double patch is used and how well debonding the area under the patch improves the strength of the cracked aluminum plates with different crack lengths.

Single-edge cracked aluminum specimens of 150 mm in length and 50 mm in width were tested using the tensile test. The cracked aluminum specimens were then repaired using GFRP patches with various configurations. A three-dimensional (3D) finite element method (FEM) was adopted to simulate the repaired cracked aluminum plates using composite patches to obtain the stress intensity factor (SIF). The numerical modeling and validation of ABAQUS software and the contour integral method for SIF calculations provide a valuable tool for further investigation and design optimization.

The width of the GFRP patches affected the efficiency of the rehabilitated cracked aluminum plate. Increasing patch width WP from 5 mm to 15 mm increases the peak load by 9.7 and 17.5%, respectively, if compared with the specimen without the patch. The efficiency of the GFRP patch in reducing the SIF increased as the number of layers increased, i.e. the maximum load was enhanced by 5%.

This study assessed repairing metallic structures using the chopped strand mat GFRP. Furthermore, it demonstrated the superiority of rectangular patches over semicircular ones, along with the benefit of using double patches for out-of-plane bending prevention and it emphasizes the detrimental effect of defects in the bonding area between the patch and the cracked component. This underlines the importance of proper surface preparation and bonding techniques for successful repair.

The goal of this work is to create a computational finite element model to perform thermoelastic stress analysis (TSA) with the usage of a non-ideal load frequency, containing the effects of the material thermal properties.

Throughout this document, the methodology of the model is presented first, followed by the procedure and results. The last part is reserved to results, discussion and conclusions.

This work had the main goal to create a model to perform TSA with the usage of non-ideal loading frequencies, considering the materials’ thermal properties. Loading frequencies out of the ideal range were applied and the model showed capable of good results. The created model reproduced acceptably the TSA, with the desired conditions.

This work creates a model to perform TSA with the usage of non-ideal loading frequencies, considering the materials’ thermal properties.

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

This article introduces the Special Issue on Sustainable Management of Heritage Buildings in long-term perspective.

It starts by reviewing the gaps in knowledge and practice which led to the creation and implementation of the research project SyMBoL—Sustainable Management of Heritage Buildings in long-term perspective funded by the Norwegian Research Council over the 2018–2022 period. The SyMBoL project is the motivation at the base of this special issue.

The editorial paper briefly presents the main outcomes of SyMBoL. It then reviews the contributions to the Special Issue, focussing on the connection or differentiation with SyMBoL and on multidisciplinary findings that address some of the initial referred gaps.

The article shortly summarizes topics related to sustainable preservation of heritage buildings in time of reduced resources, energy crisis and impacts of natural hazards and global warming. Finally, it highlights future research directions targeted to overcome, or partially mitigate, the above-mentioned challenges, for example, taking advantage of no sestructive techniques interoperability, heritage building information modelling and digital twin models, and machine learning and risk assessment algorithms.

This study aims to introduce the achievements and benefits of applying wheel/rail-force–based maintenance interval extension of the C80 series wagon in China.

Chinese wagons' existing maintenance strategy had left a certain safety margin for the characteristics of widely running range, unstable service environment and submission to transportation organization requirements. To reduce maintenance costs, China railway (CR) has attempted to extend the maintenance interval since 2020. The maintenance cycle of C80 series heavy haul wagons is extended by three months (no stable routing) or 50,000 km (regular routing). However, in the meantime, the alarming rate of the running state, a key index to reflect the severe degree of hunting stability, by the train performance detection system (TPDS) for the C80 series heavy haul wagons has increased significantly.

The present paper addresses a big data statistical way to evaluate the risk of allowing the C80 series heavy haul wagons to remain in operation longer than stipulated by the maintenance interval initial set. Through the maintenance and wayside-detector data, which is divided into three stages, the extension period (three months), the current maintenance period and the previous maintenance period, this method reveals the alarming rate of hunting was correlated with maintenance interval. The maintainability of wagons will be achieved by utilizing wagon performance degradation modeling with the state of the wheelset and the often-contact side bearing. This paper also proposes a statistical model to return to the average safety level of the previous maintenance period's baseline through correct alarming thresholds for unplanned corrective maintenance.

The paper proposes an approach to reduce safety risk due to maintenance interval extension by effective maintenance program. The results are expected to help the railway company make the optimal solution to balance safety and the economy.

The purpose of this review is to comprehensively consider the material properties and processing of additive titanium alloy and provide a new perspective for the robotic grinding and polishing of additive titanium alloy blades to ensure the surface integrity and machining accuracy of the blades.

At present, robot grinding and polishing are mainstream processing methods in blade automatic processing. This review systematically summarizes the processing characteristics and processing methods of additive manufacturing (AM) titanium alloy blades. On the one hand, the unique manufacturing process and thermal effect of AM have created the unique processing characteristics of additive titanium alloy blades. On the other hand, the robot grinding and polishing process needs to incorporate the material removal model into the traditional processing flow according to the processing characteristics of the additive titanium alloy.

Robot belt grinding can solve the processing problem of additive titanium alloy blades. The complex surface of the blade generates a robot grinding trajectory through trajectory planning. The trajectory planning of the robot profoundly affects the machining accuracy and surface quality of the blade. Subsequent research is needed to solve the problems of high machining accuracy of blade profiles, complex surface material removal models and uneven distribution of blade machining allowance. In the process parameters of the robot, the grinding parameters, trajectory planning and error compensation affect the surface quality of the blade through the material removal method, grinding force and grinding temperature. The machining accuracy of the blade surface is affected by robot vibration and stiffness.

This review systematically summarizes the processing characteristics and processing methods of aviation titanium alloy blades manufactured by AM. Combined with the material properties of additive titanium alloy, it provides a new idea for robot grinding and polishing of aviation titanium alloy blades manufactured by AM.

This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.

Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators. Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration. This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration, including a brief introduction of short-pitch irregularities, associated high frequency vibration in railway bogie, typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.

The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms. The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components. The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure, and the fatigue crack usually initiates from the defect of the weld seam. Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities. The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment, and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.

The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.