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In this paper, the C80 special coal gondola car was taken as the subject, and the load test data of the car body at the center plate, side bearing and coupler measured on the dedicated line were broken down to generate the random load component spectrums of the car body under five working conditions, namely expansion, bouncing, rolling, torsion and pitching according to the typical motion attitude of the car body.

On the basis of processing the measured load data, the random load component spectrums were equivalently converted into sinusoidal load component spectrums for bench test based on the principle of pseudo-damage equivalence of load. Relying on the fatigue and vibration test bench of the whole railway wagon, by taking each sinusoidal load component spectrum as the simulation target, the time waveform replication (TWR) iteration technology was adopted to create the drive signal of each loading actuator required for the fatigue test of car body on the bench, and the drive signal was corrected based on the equivalence principle of measured stress fatigue damage to obtain the fatigue test loads of car body under various typical working conditions.

The fatigue test results on the test bench were substantially close to the measured test results on the line. According to the results, the relative error between the fatigue damage of the car body on the test bench and the measured damage on the line was within the range of −16.03%–27.14%.

The bench test results basically reproduced the fatigue damage of the key parts of the car body on the line.

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.

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.

In view of the difficulty in determining the key parameters d in the Corten-Dolan model, based on the introduction of small loads, damage degrees and stress states to the Corten-Dolan model and the existing improved model, the sequential effects of the adjacent two-stage load were further considered.

Two improved Corten-Dolan models were established on the basis of modifying the parameter d by two different methods, namely, increasing stress ratio coefficient as well as considering the effects of loading sequence and damage degree as independent influencing factors respectively. According to the test data of the welded joints of common materials (standard 45 steel), alloy materials (standard 16Mn steel) and Q235B steel, the validity and feasibility of the above two improved models for fatigue life prediction were verified.

Results show that, compared with the traditional Miner model and the existing Corten-Dolan improved model, the two improved models have higher prediction accuracy in the fatigue life prediction of welding materials whether under two-stage load or multi-stage load.

Because the mathematical expressions of the models are relatively simple and need no multi-layer iterative calculation, it is convenient to predict the fatigue life of welded structure in practical engineering.

Bearings in electric machines often work in high speed, light load and vibration load conditions. The purpose of this paper is to find a new fatigue damage accumulation rating life model of ball bearings, which is expected for calculating fatigue life of ball bearings more accurately under vibration load, especially in high speed and light load conditions.

A new fatigue damage accumulation rating life model of ball bearings considering time-varying vibration load is proposed. Vibration equations of rotor-bearing system are constructed and solved by Runge–Kutta method. The modified rating life and modified reference rating life model under vibration load is also proposed. Contrast of the three fatigue life models and the influence of dynamic balance level, rotating speed, preload of ball bearings on bearing’s fatigue life are analyzed.

To calculate fatigue rating life of ball bearings more accurately under vibration load, especially in high speed and light load conditions, the fatigue damage accumulation rating life model should be considered. The optimum preload has an obvious influence on fatigue rating life.

This paper used analytical method and model that is helpful for design of steel ball bearing in high speed, light load and vibration load conditions.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-05-2019-0180/

This study aims to research the development trend, research status, research results and existing problems of the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge.

Based on the investigation and analysis of the development history, structure form, structural parameters, stress characteristics, shear connector stress state, force transmission mechanism, and fatigue performance, aiming at the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge, the development trend, research status, research results and existing problems are expounded.

The shear-compression composite joint has become the main form in practice, featuring shortened length and simplified structure. The length of composite joints between 1.5 and 3.0 m has no significant effect on the stress and force transmission laws of the main girder. The reasonable thickness of the bearing plate is 40–70 mm. The calculation theory and simplified calculation formula of the overall bearing capacity, the nonuniformity and distribution laws of the shear connector, the force transferring ratio of steel and concrete components, the fatigue failure mechanism and structural parameters effects are the focus of the research study.

This study puts forward some suggestions and prospects for the structural design and theoretical research of the steel–concrete composite joint of railway long-span hybrid girder cable-stayed bridge.

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 this study is to develop and test the causal relationships between alcohol consumption, social support, illness perception, fatigue and functional status among persons with liver cirrhosis. The hypothesized model was developed based on the theory of unpleasant symptoms.

A cross-sectional study was conducted among 400 persons with liver cirrhosis by stratified random sampling. Data were collected at outpatient departments from four public hospitals across three regions in Thailand. Six self-report questionnaires were utilized to collect data from March to August 2020. The developed model was verified via a structural equation modeling analysis.

The proposed model fit with the empirical data considering from χ²/df = 2.397 (p = 0.061), root mean square error of approximation (RMSEA) = 0.056, comparative fit index (CFI) = 0.985, Tucker–Lewis index (TLI) = 0.981, and standardized root mean square residual (SRMR) = 0.048. The model explained 71.30% of the total variance in functional status. Social support was the most influential factor affecting functional status both directly and indirectly through illness perception. Illness perception had a negative direct effect on functional status and a positive indirect effect on functional status through fatigue. Fatigue had a negative direct effect on functional status. Alcohol consumption was found as the lowest influential factor affecting functional status.

This is the first study that explores the characteristics of functional status among persons with liver cirrhosis comprehensively. A causal relationship among various variables found in this study would shed light as important fundamental data for developing interventions to enhance functional status among this population.

There are a number of different approaches for calculating creep-fatigue (CF) damage for design, such as the French nuclear code RCC-MRx, the American ASME III NH and the British R5 assessment code. To acquire estimates for the CF damage, that are not overly conservative, both the cyclic material softening/hardening and the potential changes in relaxation behavior have to be considered. The data presented here and models are an initial glimpse of the ongoing European FP7 project MATISSE effort to model the softening and relaxation behavior of Grade 91 steel under CF loading. The resulting models are used for calculating the relaxed stress at arbitrary location in the material cyclic softening curve. The initial test results show that softening of the material is not always detrimental. The initial model development and the pre-assessment of the MATISSE data show that the relaxed stress can be robustly predicted with hold time, strain range and the cyclic life fraction as the main input parameters. The paper aims to discuss these issues.

Engineering models have been developed for predicting cyclic softening and relaxation for Gr. 91 steel at 550 and 600°C.

A simple engineering model can adequately predict the low cycle fatigue (LCF) and CF softening rates of Gr. 91 steel. Also a simple relaxation model was successfully defined for predicting relaxed stress of both virgin and cyclically softened material.

The data are not yet complete and the models will be updated when the complete set of data in the MATISSE project is available.

The models described can be used for predicting P91 material softening in an arbitrary location (n/N_f0) of the LCF and CF cyclic life. Also the relaxed stress in the softened material can be estimated.

The models are simple in nature but are able to estimate both material softening and relaxation in arbitrary location of the softening curve. This is the first time the Wilshire methodology has been applied on cyclic relaxation data.

The safety and reliability of high-speed trains rely on the structural integrity of their components and the dynamic performance of the entire vehicle system. This paper aims to define and substantiate the assessment of the structural integrity and dynamical integrity of high-speed trains in both theory and practice. The key principles and approaches will be proposed, and their applications to high-speed trains in China will be presented.

First, the structural integrity and dynamical integrity of high-speed trains are defined, and their relationship is introduced. Then, the principles for assessing the structural integrity of structural and dynamical components are presented and practical examples of gearboxes and dampers are provided. Finally, the principles and approaches for assessing the dynamical integrity of high-speed trains are presented and a novel operational assessment method is further presented.

Vehicle system dynamics is the core of the proposed framework that provides the loads and vibrations on train components and the dynamic performance of the entire vehicle system. For assessing the structural integrity of structural components, an open-loop analysis considering both normal and abnormal vehicle conditions is needed. For assessing the structural integrity of dynamical components, a closed-loop analysis involving the influence of wear and degradation on vehicle system dynamics is needed. The analysis of vehicle system dynamics should follow the principles of complete objects, conditions and indices. Numerical, experimental and operational approaches should be combined to achieve effective assessments.

The practical applications demonstrate that assessing the structural integrity and dynamical integrity of high-speed trains can support better control of critical defects, better lifespan management of train components and better maintenance decision-making for high-speed trains.