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In this research, the free vibration sensitivity analysis of cracked fiber metal laminated (FML) beams is investigated numerically and experimentally. The effects of single and double cracks on the frequency of the cantilever beams are simulated using the finite element method (FEM) and compared to the experimental results.

In FEM analysis, the crack defect is simulated by the contour integral technique without considering the crack growth. The specimens are fabricated with an aluminum sheet, woven carbon fiber and epoxy resin. The FML specimens are constructed by bonding five layers as [carbon fiber-epoxy/Al/carbon fiber-epoxy/Al/carbon fiber-epoxy]. First, the location and length of cracks are considered input factors for the frequency sensitivity analysis. Then, the design of the experiment is produced in the cases of single and double cracks to compute the frequency of the beams in the first and second modes using the FEM. The mechanical shaker is used to determine the natural frequency of the specimens. In addition, the predicted response values of the frequency for the beam are used to compare with the experimental results.

Consequently, the results of the sensitivity analysis demonstrate that the location and length of the crack have significant effects on the modes.

Effective interaction diagrams are introduced to investigate crack detection for input factors, including the location and length of cracks in the cases of single and double cracks.

This study aims to identify the location of cracks in composite plates using a normalized mode shape curve algorithm. Crack in any structure is a destructive occurrence. Detecting these cracks early is pivotal for ensuring safety and preventing potential accidents. To prevent failure of structures, it is crucial to detect these cracks effectively and take the necessary precautions. Hence, crack detection and localization techniques are used to avoid sudden failures of structures while in operation.

An experimental modal analysis is conducted on composite plates with and without cracks to determine the natural frequencies and mode shapes. For this purpose, an impact hammer, uniaxial accelerometer and four-channel vibration analyzer are used to find the natural frequencies and mode shapes. Numerical modal analysis is performed on no crack and cracked composite plates using ANSYS software, and these are validated by the experimental modal analysis results. The normalized mode shapes algorithm is trained using test data of the first three natural frequencies collected from numerical modal analysis on different cracked composite plates for localization of crack.

The natural frequencies derived from both experimental modal analysis and numerical modal analysis exhibit a variance of 9.6%. The estimation of the crack location is achieved with exceptional precision by intersecting the first three normalized mode shapes. The first three normalized mode shape curve intersections provide a solid indication of the crack’s location. As the difference in error between the actual and estimated crack locations is only 0.9%.

This study introduces the first application of experimental modal analysis in conjunction with the normalized mode shape curve algorithm for localizing cracks in composite plates. The normalization process of mode shapes, derived from experimental modal analysis, forms a fundamental component of the mode shape curve algorithm specifically designed for crack localization. Combining experimental modal analysis with a specific algorithm of normalizing mode shapes is used to identify and locate cracks within these composite plates.

In the present study, the application of a recent damage plasticity model is presented for nonlinear dynamic analysis of the Koyna gravity dam. This is a single surface isotropic damage plasticity concrete model, which is based on the decomposition of stresses and was proposed in a previous study. The theoretical aspects of the model are initially reviewed, and a few preliminary verification examples are illustrated. Thereafter, the HHT-α (i.e. Hilber–Hughes–Taylor) algorithm is presented for nonlinear dynamic analysis of concrete gravity dams.

Based on the prepared tools, nonlinear behavior of the Koyna Dam is studied by applying the invoked damage plasticity model. For this purpose, three cases are considered for the present study. Case A, which is based on the linear model, is mainly used for comparative purposes. The other two cases (B and C) correspond to the nonlinear (i.e. damage plasticity) model. The basic data for these two cases are similar. However, the employed damping algorithms are different and correspond to constant and variable damping algorithms, respectively. This means that the damping matrix is either kept constant or updated for all iterations of different time increments through the course of analysis.

The time histories of horizontal displacement at the dam crest were initially compared for the three cases: the linear Case A, and two nonlinear Cases B and C. It was observed that nonlinear cases’ responses begin to deviate from the corresponding linear case after the time of about 4.3 s. However, the amount of change for Case C (i.e. variable damping) was much greater than for Case B (i.e. constant damping). This was manifested initially in the peaks of response. It was also noticed that the period of response changed slightly for Case B in comparison with the linear Case A, while this change was significant for Case C. The obtained tensile and compressive damages were subsequently compared for the two nonlinear cases. For constant damping Case B, it was noticed that tensile damage occurred in the D/S face kink and on the U/S face slightly at a lower elevation. Moreover, it had a scattered nature. However, in variable damping Case C, it was noticed that tensile damage was much more localized and acted similar to a discrete crack. Of course, both cases also show tensile damages at the dam’s heel. In regard to compressive damages, it is observed that low values are occurring for both nonlinear cases as expected.

The application of a recent single surface isotropic damage plasticity concrete model is presented for nonlinear dynamic analysis of the Koyna gravity dam. The nonlinear response of the dam is investigated for two different damping algorithms. Moreover, the influence of variable characteristic length is also investigated in the latter part of this study.

An investigation was conducted into the impact of various process parameters on the surface and subsurface quality of glass-ceramic materials, as well as the mechanism of material removal and crack formation, through the use of ultrasonic-assisted grinding.

A mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. A series of simulations and experiments were conducted to investigate the impact of process parameters on crack depth, surface roughness, and surface topography during ultrasonic-assisted surface and axial grinding. Additionally, the mechanism of crack formation was explored.

During ultrasonic-assisted grinding, the average grinding forces are between 0.4–1.0 N, which is much smaller than that of ordinary grinding (1.0–3.5 N). In surface grinding, the maximum surface stresses between the workpiece and the tool gradually decrease with the tool speed. The surface stresses of the workpiece increase with the grinding depth, and the depth of subsurface cracks increases with the grinding depth. With the increase of the axial grinding speed, the subsurface damage depth increases. The roughness increases from 0.780um/1.433um.

A mathematical model of crack propagation in ultrasonic-assisted grinding was established, and the mechanism of crack formation was described through the model. The deformation involved in the grinding process is large, and the FEM-SPH modeling method is used to solve the problem that the results of the traditional finite element method are not convergent and the calculation efficiency is low.

The purpose of this study is to optimize and improve conventional welding using EMF assisted technology. Current industrial production has put forward higher requirements for welding technology, so the optimization and improvement of traditional welding methods become urgent needs.

External magnetic field assisted welding is an emerging technology in recent years, acting in a non-contact manner on the welding. The action of electromagnetic forces on the arc plasma leads to significant changes in the arc behavior, which affects the droplet transfer and molten pool formation and ultimately improve the weld seam formation and joint quality.

In this paper, different types of external magnetic fields are analyzed and summarized, which mainly include external transverse magnetic field, external longitudinal magnetic field and external cusp magnetic field. The research progress of welding behavior under the effect of external magnetic field is described, including the effect of external magnetic field on arc morphology, droplet transfer and weld seam formation law.

However, due to the extremely complex physical processes under the action of the external magnetic field, the mechanism of physical fields such as heat, force and electromagnetism in the welding has not been thoroughly analyzed, in-depth theoretical and numerical studies become urgent.

During the forming process, aluminum alloy sheets develop various types of textures and are subjected to cyclic loading as structural components, resulting in fatigue damage. This study aims to develop polycrystalline models with different orientation distributions and incorporate suitable fatigue indicator parameters to investigate the effect of orientation distribution on the mechanical properties of Al-7.02Mg-1.78Zn alloys under cyclic loading.

In this study, a two-dimensional polycrystalline model with 150 equiaxed grains was constructed based on optical microscope images. Subsequently, six different orientation distributions were assigned to this model. The fatigue indicator parameter of strain energy dissipation is utilized to analyze the stress response and fatigue crack driving force in polycrystalline models with different orientation distributions subjected to cyclic loading.

The study found that orientation distribution significantly influences fatigue crack initiation. Orientation distributions with a larger average Schmid factor exhibit reduced stress response and lower fatigue indicator parameters. Locations with a larger average Schmid factor experience greater plastic deformation and present a higher risk for fatigue crack initiation. RVE with a single orientation undergoes more rotation to reach cyclic steady state under cyclic loading due to the ease of deformation transfer.

Currently, there are no reports in the literature on the calculation of fatigue crack initiation for Al-Mg-Zn alloys using the crystal plasticity finite element method. This study presents a novel strategy for simulating the response of Al-7.02Mg-1.78Zn materials with different orientation distributions under symmetric strain cyclic loading, providing valuable references for future research.

The aim of this paper is to study the effect of laser shock peening (LSP) on mechanical behaviour of the laser-directed energy deposition (LDED)-based printed 15-5 PH stainless steel with U and V notches. The study specifically concentrates on the evaluation of effect of scan strategy, machining and LSP processing on microstructural, texture evolution and fatigue behaviour of LDED-printed 15-5 PH steel.

For LSP treatment, 15-5 PH steel was printed using LDED process with bidirectional scanning strategy (XX [θ = 0°) and XY [θ = 90°]) at optimised laser power of 600 W with a scanning speed of 300 mm/min and a powder feed rate of 3 g/min. Furthermore, LSP treatment was conducted on the V- and U-notched fatigue specimens extracted from LDED-built samples at laser energy of 3.5 J with a pulse width of 10 ns using laser spot diameter of 3 mm. Post to the LSP treatment, the surface roughness, fatigue life assessment and microstructural evolution analysis is performed. For this, different advanced characterisation techniques are used, such as scanning electron microscopy attached with electron backscatter diffraction for microstructure and texture, X-ray diffraction for residual stress (RS) and structure information, Vicker’s hardness tester for microhardness and universal testing machine for low-cycle fatigue.

It is observed that both scanning strategies during the LDED printing of 15-5 PH steel and laser peening have played significant role in fatigue life. Specimens with the XY printing strategy shows higher fatigue life as compared to XX with both U- and V-notched conditions. Furthermore, machining and LSP treatment led to a significant improvement of fatigue life for both scanning strategies with U and V notches. The extent of increase in fatigue life for both XX and XY scanning strategy with V notch is found to be higher than U notch after LSP treatment, though without LSP samples with U notch have a higher fatigue life. As fabricated sample is found to have the lowest fatigue life as compared to machines and laser peened with both scan strategies.

This study presents an innovative method to improve the fatigue life of 15-5 PH stainless steel by changing the microstructure, texture and RS with the adoption of a suitable scanning strategy, machining and LSP treatment as post-processing. The combination of preferred microstructure and compressive RS in LDED-printed 15-5 PH stainless steel achieved with a synergy between microstructure and RS, which is responsible to improve the fatigue life. This can be adopted for the futuristic application of LDED-printed 15-5 PH stainless steel for different applications in aerospace and other industries.

In this study, two postprocessing techniques, namely, conventional burnishing (CB) and ultrasonic-assisted burnishing (UAB), were applied to improve the fatigue behavior of 316 L stainless steel fabricated through selective laser melting (SLM). The effects of these processes on surface roughness, porosity, microhardness and fatigue performance were experimentally investigated. The purpose of this study is to evaluate the feasibility and effectiveness of ultrasonic-assisted burnishing as a preferred post-processing technique for enhancing the fatigue performance of additively manufactured components.

All samples were subjected to a sandblasting process. Next, the samples were divided into three distinct groups. The first group (as-Built) did not undergo any additional postprocessing, apart from sandblasting. The second group was treated with CB, while the third group was treated with ultrasonic-assisted burnishing. Finally, all samples were evaluated based on their surface roughness, porosity, microhardness and fatigue performance.

The results revealed that the initial mean surface roughness (Ra) of the as-built sample was 11.438 µm. However, after undergoing CB and UAB treatments, the surface roughness decreased to 1.629 and 0.278 µm, respectively. Notably, the UAB process proved more effective in eliminating near-surface pores and improving the microhardness of the samples compared to the CB process. Furthermore, the fatigue life of the as-built sample, initially at 66,000 cycles, experienced a slight improvement after CB treatment, reaching 347,000 cycles. However, the UAB process significantly enhanced the fatigue life of the samples, extending it to 620,000 cycles.

After reviewing the literature, it can be concluded that UAB will exceed the capabilities of CB in terms of enhancing the surface roughness and, subsequently, the fatigue performance of additive manufactured (AM) metals. However, the actual impact of the UAB process on the fatigue life of AM products has not yet been thoroughly researched. Therefore, in this study, this paper used the burnishing process to enhance the fatigue life of 316 L stainless steel produced through the SLM process.

Solder joint inspection plays a critical role in various industries, with a focus on integrated chip (IC) solder joints and metal surface welds. However, the detection of tubular solder joints has received relatively less attention. This paper aims to address the challenges of detecting small targets and complex environments by proposing a robust visual detection method for pipeline solder joints. The method is characterized by its simplicity, cost-effectiveness and ease of implementation.

A robust visual detection method based on the characteristics of pipeline solder joints is proposed. With the improved hue, saturation and value (HSV) color space, the method uses a multi-level template matching approach to first segment the pipeline from the background, and then match the endpoint of the pipeline to accurately locate the solder joint. The proposed method leverages the distinctive characteristics of pipeline solder joints and employs an enhanced HSV color space. A multi-level template matching approach is utilized to segment the pipeline from the background and accurately locate the solder joint by matching the pipeline endpoint.

The experimental results demonstrate the effectiveness of the proposed solder joint detection method in practical detection tasks. The average precision of pipeline weld joint localization exceeds 95%, while the average recall is greater than 90%. These findings highlight the applicability of the method to pipeline solder joint detection tasks, specifically in the context of production lines for refrigeration equipment.

The precision of the method is influenced by the placement angle and lighting conditions of the test specimen, which may pose challenges and impact the algorithm's performance. Potential avenues for improvement include exploring deep learning methods, incorporating additional features and contextual information for localization, and utilizing advanced image enhancement techniques to improve image quality.

The proposed pipeline solder joint detection method offers a novel and practical approach. The simplicity, cost-effectiveness and ease of implementation make it an attractive choice for detecting pipeline solder joints in different industrial applications.

The quantum of metal particle waste generation in manufacturing industries is posing a great concern for the environment. The iron forging industries generate a huge amount of grinding sludge (GS) waste, which is disposed into the earth. The accumulation of this waste in dump yards causes an increase in soil and air pollution levels.

In the current investigation, an effort was made to use this waste GS for the progress of aluminum-based composite. To maintain uniform distribution of reinforcing material, the friction stir processing technique was used.

The characterization based on the SEM image of the Al/GS composite revealed that uniform dispersal of reinforcement content can be attained in a single tool pass. Number of grains/inch was approximately 2,402. XRD of GS powder confirmed the presence of SiO₂, Fe₂O₃, Al₂O₃ and CaO phases. These phases proved GS to be a better reinforcement with aluminum alloy. Tensile strength and hardness were significantly improved in comparison to the aluminum alloy. Thermal expansion and corrosion weight loss were evaluated to observe the influence of GS addition.

The studies proved that the use of GS as reinforcement material can help in curbing the menace of soil pollution to a large extent.