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During the construction process of the China Railway Track System (CRTS) I type filling layer, the nonwoven fabric bags have been used as grouting templates for cement asphalt (CA) emulsified mortar. The porous structure of nonwoven fabrics endowed the templates with breathability and water permeability. The standard requires that the volume expansion rate of CA mortar must be controlled within 1%–3%, which can generate expansion pressure to ensure that the cavities under track slabs are filled fully. However, the expansion pressure caused some of the water to seep out from the periphery of the filling bag, and it would affect the actual mix proportion of CA mortar. The differences in physical and mechanical properties between the CA mortar under track slabs and the CA mortar formed in the laboratory were studied in this paper. The relevant results could provide important methods for the research of filling layer materials for CRTS I type and other types of ballastless tracks in China.

During the inspection of filling layer, the samples of CA mortar from different working conditions and raw materials were taken by uncovering the track slabs and drilling cores. The physical and mechanical properties of CA mortar under the filling layer of the slab were systematically analyzed by testing the electrical flux, compressive strength and density of mortar in different parts of the filling layer.

In this paper, the electric flux, the physical properties and mechanical properties of different parts of CA mortar under the track slab were investigated. The results showed that the density, electric flux and compressive strength of CA mortar were affected by the composition of raw materials for dry powders and different parts of the filling layer. In addition, the electrical flux of CA mortar gradually decreased within 90 days’ age. The electrical flux of samples with the thickness of 54 mm was lower than 500 C. Therefore, the impermeability and durability of CA mortar could be improved by increasing the thickness of filling layer. Besides, the results showed that the compressive strength of CA mortar increased, while the density and electric flux decreased gradually, with the prolongation of hardening time.

During 90 days' age, the electrical flux of the CA mortar gradually decreased with the increase of specimen thickness and the electrical flux of the specimens with the thickness of 54 mm was lower than 500 C. The impermeability and durability of the CA mortar could be improved by increasing the thickness of filling layer. The proposed method can provide reference for the further development and improvement of CRTS I and CRTS II type ballastless track in China.

This study aims to enhance merging of additive manufacturing (AM) techniques with powder injection molding (PIM). In this way, the prototypes could be 3D-printed and mass production implemented using PIM. Thus, the surface properties and mechanical performance of parts produced using powder/polymer binder feedstocks [material extrusion (MEX) and PIM] were investigated and compared with powder manufacturing based on direct metal laser sintering (DMLS).

PIM parts were manufactured from 17-4PH stainless steel PIM-quality powder and powder intended for powder bed fusion compounded with a recently developed environmentally benign binder. Rheological data obtained at the relevant temperatures were used to set up the process parameters of injection molding. The tensile and yield strengths as well as the strain at break were determined for PIM sintered parts and compared to those produced using MEX and DMLS. Surface properties were evaluated through a 3D scanner and analyzed with advanced statistical tools.

Advanced statistical analyses of the surface properties showed the proximity between the surfaces created via PIM and MEX. The tensile and yield strengths, as well as the strain at break, suggested that DMLS provides sintered samples with the highest strength and ductility; however, PIM parts made from environmentally benign feedstock may successfully compete with this manufacturing route.

This study addresses the issues connected to the merging of two environmentally efficient processing routes. The literature survey included has shown that there is so far no study comparing AM and PIM techniques systematically on the fixed part shape and dimensions using advanced statistical tools to derive the proximity of the investigated processing routes.

This paper presents an experimental investigation in establishing the relationship between FDM process parameters and tensile strength of polycarbonate (PC) samples using the I-Optimal design.

I-optimal design methodology is used to plan the experiments by means of Minitab-17.1 software. Samples are manufactured using Stratsys FDM 400mc and tested as per ISO standards. Additionally, an artificial neural network model was developed and compared to the regression model in order to select an appropriate model for optimisation. Finally, the genetic algorithm (GA) solver is executed for improvement of tensile strength of FDM built PC components.

This study demonstrates that the selected process parameters (raster angle, raster to raster air gap, build orientation about Y axis and the number of contours) had significant effect on tensile strength with raster angle being the most influential factor. Increasing the build orientation about Y axis produced specimens with compact structures that resulted in improved fracture resistance.

The fitted regression model has a p-value less than 0.05 which suggests that the model terms significantly represent the tensile strength of PC samples. Further, from the normal probability plot it was found that the residuals follow a straight line, thus the developed model provides adequate predictions. Furthermore, from the validation runs, a close agreement between the predicted and actual values was seen along the reference line which further supports satisfactory model predictions.

This study successfully investigated the effects of the selected process parameters - raster angle, raster to raster air gap, build orientation about Y axis and the number of contours - on tensile strength of PC samples utilising the I-optimal design and ANOVA. In addition, for prediction of the part strength, regression and ANN models were developed. The selected ANN model was optimised using the GA-solver for determination of optimal parameter settings.

The proposed ANN-GA approach is more appropriate to establish the non-linear relationship between the selected process parameters and tensile strength. Further, the proposed ANN-GA methodology can assist in manufacture of various industrial products with Nylon, polyethylene terephthalate glycol (PETG) and PET as new 3DP materials.

The type 120 emergency valve is an essential braking component of railway freight trains, but corresponding diaphragms consisting of natural rubber (NR) and chloroprene rubber (CR) exhibit insufficient aging resistance and low-temperature resistance, respectively. In order to develop type 120 emergency valve rubber diaphragms with long-life and high-performance, low-temperatureresistant CR and NR were processed.

The physical properties of the low-temperature-resistant CR and NR were tested by low-temperature stretching, dynamic mechanical analysis, differential scanning calorimetry and thermogravimetric analysis. Single-valve and single-vehicle tests of type 120 emergency valves were carried out for emergency diaphragms consisting of NR and CR.

The low-temperature-resistant CR and NR exhibited excellent physical properties. The elasticity and low-temperature resistance of NR were superior to those of CR, whereas the mechanical properties of the two rubbers were similar in the temperature range of 0 °C–150 °C. The NR and CR emergency diaphragms met the requirements of the single-valve test. In the low-temperature single-vehicle test, only the low-temperature sensitivity test of the NR emergency diaphragm met the requirements.

The innovation of this study is that it provides valuable data and experience for future development of type 120 valve rubber diaphragms.

The “chiralisation” of Euclidean polygonal tessellations is a novel, recent method which has been used to design new auxetic metamaterials with complex topologies and improved geometric versatility over traditional chiral honeycombs. This paper aims to design and manufacture chiral honeycombs representative of four distinct classes of 2D Euclidean tessellations with hexagonal rotational symmetry using fused-deposition additive manufacturing and experimentally analysed the mechanical properties and failure modes of these metamaterials.

Finite Element simulations were also used to study the high-strain compressive performance of these systems under both periodic boundary conditions and realistic, finite conditions. Experimental uniaxial compressive loading tests were applied to additively manufactured prototypes and digital image correlation was used to measure the Poisson’s ratio and analyse the deformation behaviour of these systems.

The results obtained demonstrate that these systems have the ability to exhibit a wide range of Poisson’s ratios (positive, quasi-zero and negative values) and stiffnesses as well as unusual failure modes characterised by a sequential layer-by-layer collapse of specific, non-adjacent ligaments. These findings provide useful insights on the mechanical properties and deformation behaviours of this new class of metamaterials and indicate that these chiral honeycombs could potentially possess anomalous characteristics which are not commonly found in traditional chiral metamaterials based on regular monohedral tilings.

To the best of the authors’ knowledge, the authors have analysed for the first time the high strain behaviour and failure modes of chiral metamaterials based on Euclidean multi-polygonal tessellations.

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 papers aims to study lattice structures in terms of geometric variables, manufacturing variables and material-based variants and their correlation with compressive behaviour for their application in a methodology for the design and development of personalized elastic therapeutic products.

Lattice samples were designed and manufactured using extrusion-based additive manufacturing technologies. Mechanical tests were carried out on lattice samples for elasticity characterization purposes. The relationships between sample stiffness and key geometric and manufacturing variables were subsequently used in the case study on the design of a pressure cushion model for validation purposes. Differentiated areas were established according to patient’s pressure map to subsequently make a correlation between the patient’s pressure needs and lattice samples stiffness.

A substantial and wide variation in lattice compressive behaviour was found depending on the key study variables. The proposed methodology made it possible to efficiently identify and adjust the pressure of the different areas of the product to adapt them to the elastic needs of the patient. In this sense, the characterization lattice samples turned out to provide an effective and flexible response to the pressure requirements.

This study provides a generalized foundation of lattice structural design and adjustable stiffness in application of pressure cushions, which can be equally applied to other designs with similar purposes. The relevance and contribution of this work lie in the proposed methodology for the design of personalized therapeutic products based on the use of individual lattice structures that function as independent customizable cells.

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.

Polymer laser powder bed fusion (PBF-LB/P) is an additive manufacturing technology that is sustainable due to the possibility of recycling the powder multiple times and allowing the fabrication of gears without the aid of support structures and subsequent assembly. However, there are constraints in the process that negatively affect its adoption compared to other additive technologies such as material extrusion to produce gears. This study aims to demonstrate that it is possible to overcome the problems due to the physics of the process to produce accurate mechanism.

Technological aspects such as orientation, wheel-shaft thicknesses and degree of powder recycling were examined. Furthermore, the evolving tooth profile was considered as a design parameter to provide a manufacturability map of gear-based mechanisms.

Results show that there are some differences in the functioning of the gear depending on the type of powder used, 100% virgin or 50% virgin and 50% recycled for five cycles. The application of a groove on a gear produced with 100% virgin powder allows the mechanism to be easily unlocked regardless of the orientation and wheel-shaft thicknesses. The application of a specific evolutionary profile independent of the diameter of the reference circle on vertically oriented gears guarantees rotation continuity while preserving the functionality of the assembled mechanism.

In the literature, there are various studies on material aging and reuse in the PBF-LB/P process, mainly focused on the powder deterioration mechanism, powder fluidity, microstructure and mechanical properties of the parts and process parameters. This study, instead, was focused on the functioning of gears, which represent one of the applications in which this technology can have great success, by analyzing the two main effects that can compromise it: recycled powder and vertical orientation during construction.

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.