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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.

The purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.

No methodology was used because the paper is a review article.

no fundings.

Herein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

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.