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The main objective of the present research is to investigate the benefits of using geogrid reinforcement in minimizing the rate of deterioration of ballasted rail track geometry resting on soft clay and to explore the effect of load amplitude, load frequency, presence of geogrid layer in ballast layer and ballast layer thickness on the behavior of track system. These variables are studied both experimentally and numerically. This paper examines the effect of geogrid reinforced ballast laying on a layer of clayey soil as a subgrade layer, where a half full scale railway tests are conducted as well as a theoretical analysis is performed.

The experimental tests work consists of laboratory model tests to investigate the reduction in the compressibility and stress distribution induced in soft clay under a ballast railway reinforced by geogrid reinforcement subjected to dynamic load. Experimental model based on an approximate half scale for general rail track engineering practice is adopted in this study which is used in Iraqi railways. The investigated parameters are load amplitude, load frequency and presence of geogrid reinforcement layer. A half full-scale railway was constructed for carrying out the tests, which consists of two rails 800 mm in length with three wooden sleepers (900 mm × 90 mm × 90 mm). The ballast was overlying 500 mm thick clay layer. The tests were carried out with and without geogrid reinforcement, the tests were carried out in a well tied steel box of 1.5 m length × 1 m width × 1 m height. A series of laboratory tests were conducted to investigate the response of the ballast and the clay layers where the ballast was reinforced by a geogrid. Settlement in ballast and clay, was measured in reinforced and unreinforced ballast cases. In addition to the laboratory tests, the application of numerical analysis was made by using the finite element program PLAXIS 3D 2013.

It was concluded that the settlement increased with increasing the simulated train load amplitude, there is a sharp increase in settlement up to the cycle 500 and after that, there is a gradual increase to level out between, 2,500 and 4,500 cycles depending on the load frequency. There is a little increase in the induced settlement when the load amplitude increased from 0.5 to 1 ton, but it is higher when the load amplitude increased to 2 ton, the increase in settlement depends on the geogrid existence and the other studied parameters. Both experimental and numerical results showed the same behavior. The effect of load frequency on the settlement ratio is almost constant after 500 cycles. In general, for reinforced cases, the effect of load frequency on the settlement ratio is very small ranging between 0.5 and 2% compared with the unreinforced case.

Increasing the ballast layer thickness from 20 cm to 30 cm leads to decrease the settlement by about 50%. This ascertains the efficiency of ballast in spreading the waves induced by the track.

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.

The purpose of this work is to optimize the monitoring of vibrations on dynamometric test rigs for railway brakes. This is a quite demanding application considering the continuous increase of performances of high-speed trains that involve higher testing specifications for brake pads and disks.

In this work, authors propose a mixed approach in which relatively simple finite element models are used to support the optimization of a diagnostic system that is used to monitor vibration levels and rotor-dynamical behavior of the machine. The model is calibrated with experimental data recorded on the same rig that must be identified and monitored. The whole process is optimized to not interfere with normal operations of the rig, using common inertial sensor and tools and are available as standard instrumentation for this kind of applications. So at the end all the calibration activities can be performed normally without interrupting the activities of the rig introducing additional costs due to system unavailability.

Proposed approach was able to identify in a very simple and fast way the vibrational behavior of the investigated rig, also giving precious information concerning the anisotropic behavior of supports and their damping. All these data are quite difficult to be found in technical literature because they are quite sensitive to assembly tolerances and to many other factors. Dynamometric test rigs are an important application widely diffused for both road and rail vehicles. Also proposed procedure can be easily extended and generalized to a wide value of machine with horizontal rotors.

Most of the studies in literature are referred to electrical motors or turbomachines operating with relatively slow transients and constant inertial properties. For investigated machines both these conditions are not verified, making the proposed application quite unusual and original with respect to current application. At the same time, there is a wide variety of special machines that are usually marginally covered by standard testing methodologies to which the proposed approach can be successfully extended.

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.

The purpose of this paper is to review cases of artificial reefs built through additive manufacturing (AM) technologies and analyse their ecological goals, fabrication process, materials, structural design features and implementation location to determine predominant parameters, environmental impacts, advantages, and limitations.

The review analysed 16 cases of artificial reefs from both temperate and tropical regions. These were categorised based on the AM process used, the mortar material used (crucial for biological applications), the structural design features and the location of implementation. These parameters are assessed to determine how effectively the designs meet the stipulated ecological goals, how AM technologies demonstrate their potential in comparison to conventional methods and the preference locations of these implementations.

The overview revealed that the dominant artificial reef implementation occurs in the Mediterranean and Atlantic Seas, both accounting for 24%. The remaining cases were in the Australian Sea (20%), the South Asia Sea (12%), the Persian Gulf and the Pacific Ocean, both with 8%, and the Indian Sea with 4% of all the cases studied. It was concluded that fused filament fabrication, binder jetting and material extrusion represent the main AM processes used to build artificial reefs. Cementitious materials, ceramics, polymers and geopolymer formulations were used, incorporating aggregates from mineral residues, biological wastes and pozzolan materials, to reduce environmental impacts, promote the circular economy and be more beneficial for marine ecosystems. The evaluation ranking assessed how well their design and materials align with their ecological goals, demonstrating that five cases were ranked with high effectiveness, ten projects with moderate effectiveness and one case with low effectiveness.

AM represents an innovative method for marine restoration and management. It offers a rapid prototyping technique for design validation and enables the creation of highly complex shapes for habitat diversification while incorporating a diverse range of materials to benefit environmental and marine species’ habitats.