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Numerous metals can be processed using the additive manufacturing process laser-based powder bed fusion of metals (PBF-LB/M, ISO/ASTM 52900). The main advantages of additive manufacturing technologies are the high degree of design freedom and the cost-effective implementation of lightweight structures. This could be profitable for gears with increased power density, combining reduced mass with considerable material strength. Current research on additively manufactured gears is focused on developing lightweight structures but is seldom accompanied by simulations and even less by mechanical testing. There has been very little research into the mechanical and material properties of additively manufactured gears. The purpose of this study is to investigate the behavior of lightweight structures in additively manufactured gears under static loads.

This research identifies the static load-carrying capacity of helical gears with different lightweight structures produced by PBF-LB/M with the case hardening steel 16MnCr5. A static gear loading test rig with a maximum torque at the pinion of T₁ = 1200 Nm is used. Further focus is set on analyzing material properties such as the relative density, microstructure, hardness depth profile and chemical composition.

All additively manufactured gear variants show no failure or plastic deformation at the maximum test load. The shaft hub connection, the lightweight hub designs and the gearing itself are stable and intact regarding their form and function. The identified material characteristics are comparable to conventionally manufactured gears (wrought and machined), but also some particularities were observed.

This research demonstrates the mechanical strength of lightweight structures in gears. Future research needs to consider the dynamic load-carrying capacity of additively manufactured gears.

This paper presents the experimental and numerical results of the bending properties of low-height prestressed T-beams. The purpose is to study the bearing capacity, failure state and strain distribution of low-height prestressed T-beams.

First, two 13 m-long full-size test beams were fabricated with different positions of prestressed steel bundles in the span. The load–deflection curves and failure patterns of each test beam were obtained through static load tests. Secondly, the test data were used to validate the finite element model developed to simulate the flexural behavior of low-height prestressed T-beams. Finally, the influence of different parameters (the number of prestressed steel bundles, initial prestress and concrete strength grade) on the flexural performance of the test beams is studied by using a finite element model.

The test results show that when the distance of the prestressed steel beam from the bottom height of the test beam increases from 40 to 120 mm, the cracking load of the test beam decreases from 550.00 to 450.00 kN, reducing by 18.18%, and the ultimate load decreases from 1338.15 to 1227.66 kN, reducing by 8.26%, therefore, the increase of the height of the prestressed steel beam reduces the bearing capacity of the test beam. The numerical simulation results show that when the number of steel bundles increases from 2 to 9, the cracking load increases by 183.60%, the yield load increases by 117.71% and the ultimate load increases by 132.95%. Therefore, the increase in the number of prestressed steel bundles can increase the cracking load, yield load and ultimate load of the test beam. When the initial prestress is from 695 to 1,395 MPa, the cracking load increases by 69.20%, the yield load of the bottom reinforcement increases by 31.61% and the ultimate load increases by 3.97%. Therefore, increasing the initial prestress can increase the cracking load and yield load of the test beam, but it has little effect on the ultimate load. The strength grade of concrete increases from C30 to C80, the cracking load is about 455.00 kN, the yield load is about 850.00 kN and the ultimate load is increased by 4.90%. Therefore, the improvement in concrete strength grade has little influence on the bearing capacity of the test beam.

Based on the experimental study, the bearing capacity of low-height prestressed T-beams with different prestressed steel beam heights is calculated by finite element simulation, and the influence of different parameters on the bearing capacity is discussed. This method not only ensures the accuracy of bearing capacity assessment, but also does not require a large number of samples and has a certain economy. The study of prestressed low-height T-beams is of great significance for understanding the principle and application of prestressed technology. Research on the mechanical behavior and performance of low-height prestressed T beams can provide a scientific basis and technical support for the design and construction of prestressed concrete structures. In addition, the study of prestressed low-height T-beams can also provide a reference for the optimization design and construction of other structural types.

When the reinforced concrete beams are reinforced by bonding steel plates to the bottom, excessive use of steel plates will make the reinforced concrete beams become super-reinforced beams, and there are security risks in the actual use of super-reinforced beams. In order to avoid the occurrence of this situation, the purpose of this paper is to study the calculation method of the maximum number of bonded steel plates to reinforce reinforced concrete beams.

First of all, when establishing the limit failure state of the reinforced member, this paper comprehensively considers the role of the tensile steel bar and steel plate and takes the load effect before reinforcement as the negative contribution of the maximum number of bonded steel plates that can be used for reinforcement. Through the definition of the equivalent tensile strength, equivalent elastic modulus and equivalent yield strain of the tensile steel bar and steel plate, a method to determine the relative limit compression zone height of the reinforced member is obtained. Second, based on the maximum ratio of (reinforcement + steel plate), the relative limit compression zone height and the equivalent tensile strength of the tensile steel bar and steel plate of the reinforced member, the calculation method of the maximum number of bonded steel plates is derived. Then, the static load test of the test beam is carried out and the corresponding numerical model is established, and the reliability of the numerical model is verified by comparison. Finally, the accuracy of the calculation method of the maximum number of bonded steel plates is proved by the numerical model.

The numerical simulation results show that when the steel plate width is 800 mm and the thickness is 1–4 mm, the reinforced concrete beam has a delayed yield platform when it reaches the limit state, and the failure mode conforms to the basic stress characteristics of the balanced-reinforced beam. When the steel plate thickness is 5–8 mm, the sudden failure occurs without obvious warning when the reinforced concrete beam reaches the limit state. The failure mode conforms to the basic mechanical characteristics of the super-reinforced beam failure, and the bending moment of the beam failure depends only on the compressive strength of the concrete. The results of the calculation and analysis show that the maximum number of bonded steel plates for reinforced concrete beams in this experiment is 3,487 mm². When the width of the steel plate is 800 mm, the maximum thickness of the steel plate can be 4.36 mm. That is, when the thickness of the steel plate, the reinforced concrete beam is still the balanced-reinforced beam. When the thickness of the steel plate, the reinforced concrete beam will become a super-reinforced beam after reinforcement. The calculation results are in good agreement with the numerical simulation results, which proves the accuracy of the calculation method.

This paper presents a method for calculating the maximum number of steel plates attached to the bottom of reinforced concrete beams. First, based on the experimental research, the failure mode of reinforced concrete beams with different number of steel plates is simulated by the numerical model, and then the result of the calculation method is compared with the result of the numerical simulation to ensure the accuracy of the calculation method of the maximum number of bonded steel plates. And the study does not require a large number of experimental samples, which has a certain economy. The research result can be used to control the number of steel plates in similar reinforcement designs.

This review paper seeks to enhance knowledge of how pre-loading affects reinforced concrete (RC) beams under fire. It investigates key factors like deflection and load capacity to understand pre-loading's role in replicating RC beams' actual responses to fire, aiming to improve fire testing protocols and structural fire engineering design.

This review systematically aggregates data from existing literature on the fire response of RC beams, comparing scenarios with (WP) and without pre-loading (WOP). Through statistical tools like the two-tailed t-test and Mann–Whitney U-test, it assesses deflection extremes. The study further examines structural responses, including flexural and shear behavior, ultimate load capacity, post-yield behavior, stiffness degradation and failure modes. The approach concludes with a statistical forecast of ideal pre-load levels to elevate experimental precision and enhance fire safety standards.

The review concludes that pre-loading profoundly affects the fire response of RC beams, suggesting a 35%–65% structural capacity range for realistic simulations. The review also recommended the initial crack load as an alternative metric for determining the pre-loading impact. Crucially, it highlights that pre-loading not only influences the fire response but also significantly alters the overall structural behavior of the RC beams.

The review advances structural fire engineering with an in-depth analysis of pre-loading's impact on RC beams during fire exposure, establishing a validated pre-load range through thorough statistical analysis and examination of previous research. It refines experimental methodologies and structural design accuracy, ultimately bolstering fire safety protocols.

The purpose of this study is to propose a simplifying approach for modelling a reliability test. Modelling the reliability tests of printed circuit board (PCB)/microelectronic component assemblies requires the adoption of several simplifying assumptions. This study introduces and validates simplified assumptions for modeling a four-point bend test on a PCB/wafer-level chip scale packaging assembly.

In this study, simplifying assumptions were used. These involved substituting dynamic imposed displacement loading with an equivalent static loading, replacing the spherical shape of the interconnections with simplified shapes (cylindrical and cubic) and transitioning from a three-dimensional modelling approach to an equivalent two-dimensional model. The validity of these simplifications was confirmed through both quantitative and qualitative comparisons of the numerical results obtained. The maximum principal plastic strain in the solder balls and copper pads served as the criteria for comparison.

The simplified hypotheses were validated through quantitative and qualitative comparisons of the results from various models. Consequently, it was determined that the replacement of dynamic loading with equivalent static loading had no significant impact on the results. Similarly, substituting the spherical shape of interconnections with an equivalent shape and transitioning from a three-dimensional approach to a two-dimensional one did not substantially affect the precision of the obtained results.

This study serves as a valuable resource for researchers seeking to model accelerated reliability tests, particularly in the context of four-point bending tests. The results obtained in this study will assist other researchers in streamlining their numerical models, thereby reducing calculation costs through the utilization of the simplified hypotheses introduced and validated herein.

Fuselage structures are subjected to combinations of axial, bending, shear and differential pressure loads. The validation of advanced metallic and composite fuselage designs against such loads is based on the full-scale testing of the fuselage barrel, which, however, is highly demanding from a time and cost viewpoint. This paper aims to assist in scaling-down the experimentation to the stiffened panel level which presents the opportunity to validate state-of-the-art designs at higher rates than previously attainable.

Development of a methodology to successfully design tests at the stiffened panel level and realize them using advanced, complex and adaptable test-rigs that are capable of introducing independently a set of distinct load types (e.g. internal overpressure, tension, shear) while applying appropriate boundary conditions at the edges of the stiffened panel.

A baseline test-rig configuration was developed after extensive parametric modelling studies at the stiffened panel level. The realization of the loading and boundary conditions on the test-rig was facilitated through innovative supporting and loading system set-ups.

The proposed test bench is novel and compared to the conventional counterparts more viable from an economic and manufacturing point of view. It leads to panel responses, which are as close as possible to those of the fuselage barrel in-flight and can be used for the execution of static or fatigue tests on metallic and thermoplastic curved integrally stiffened full-scale panels, representative of a business jet fuselage.

The purpose of this paper is to present a wall-climbing robot platform for heavy-load with negative pressure adsorption, which could be equipped with a six-degree of freedom (DOF) collaborative robot (Cobot) and detection device for inspecting the overwater part of concrete bridge towers/piers for large bridges.

By analyzing the shortcomings of existing wall-climbing robots in detecting concrete structures, a wall-climbing mobile manipulator (WCMM), which could be compatible with various detection devices, is proposed for detecting the concrete towers/piers of the Hong Kong-Zhuhai-Macao Bridge. The factors affecting the load capacity are obtained by analyzing the antislip and antioverturning conditions of the wall-climbing robot platform on the wall surface. Design strategies for each part of the structure of the wall-climbing robot are provided based on the influencing factors. By deriving the equivalent adsorption force equation, analyzed the influencing factors of equivalent adsorption force and provided schemes that could enhance the load capacity of the wall-climbing robot.

The adsorption test verifies the maximum negative pressure that the fan module could provide to the adsorption chamber. The load capacity test verifies it is feasible to achieve the expected bearing requirements of the wall-climbing robot. The motion tests prove that the developed climbing robot vehicle could move freely on the surface of the concrete structure after being equipped with a six-DOF Cobot.

The development of the heavy-load wall-climbing robot enables the Cobot to be installed and equipped on the wall-climbing robot, forming the WCMM, making them compatible with carrying various devices and expanding the application of the wall-climbing robot.

A heavy-load wall-climbing robot using negative pressure adsorption has been developed. The wall-climbing robot platform could carry a six-DOF Cobot, making it compatible with various detection devices for the inspection of concrete structures of large bridges. The WCMM could be expanded to detect the concretes with similar structures. The research and development process of the heavy-load wall-climbing robot could inspire the design of other negative-pressure wall-climbing robots.

This review aims to give a critical view of the wheel/rail high frequency vibration-induced vibration fatigue in railway bogie.

Vibration fatigue of railway bogie arising from the wheel/rail high frequency vibration has become the main concern of railway operators. Previous reviews usually focused on the formation mechanism of wheel/rail high frequency vibration. This paper thus gives a critical review of the vibration fatigue of railway bogie owing to the short-pitch irregularities-induced high frequency vibration, including a brief introduction of short-pitch irregularities, associated high frequency vibration in railway bogie, typical vibration fatigue failure cases of railway bogie and methodologies used for the assessment of vibration fatigue and research gaps.

The results showed that the resulting excitation frequencies of short-pitch irregularity vary substantially due to different track types and formation mechanisms. The axle box-mounted components are much more vulnerable to vibration fatigue compared with other components. The wheel polygonal wear and rail corrugation-induced high frequency vibration is the main driving force of fatigue failure, and the fatigue crack usually initiates from the defect of the weld seam. Vibration spectrum for attachments of railway bogie defined in the standard underestimates the vibration level arising from the short-pitch irregularities. The current investigations on vibration fatigue mainly focus on the methods to improve the accuracy of fatigue damage assessment, and a systematical design method for vibration fatigue remains a huge gap to improve the survival probability when the rail vehicle is subjected to vibration fatigue.

The research can facilitate the development of a new methodology to improve the fatigue life of railway vehicles when subjected to wheel/rail high frequency vibration.

The purpose of this paper is to compare the influence of relative density (RD) and strain rates on failure mechanism and specific energy absorption (SEA) of polyamide lattices ranging from bending to stretch-dominated structures using selective laser sintering (SLS).

Three bending and two stretch-dominated unit cells were selected based on the Maxwell stability criterion. Lattices were designed with three RD and fabricated by SLS technique using PA12 material. Quasi-static compression tests with three strain rates were carried out using Taguchi's L9 experiments. The lattice compressive behaviour was verified with the Gibson–Ashby analytical model.

It has been observed that RD and strain rates played a vital role in lattice compressive properties by controlling failure mechanisms, resulting in distinct post-yielding responses as fluctuating and stable hardening in the plateau region. Analysis of variance (ANOVA) displayed the significant impact of RD and emphasised dissimilar influences of strain rate that vary to cell topology. Bending-dominated lattices showed better compressive properties than stretch-dominated lattices. The interesting observation is that stretch-dominated lattices with over-stiff topology exhibited less compressive properties contrary to the Maxwell stability criterion, whereas strain rate has less influence on the SEA of face-centered and body-centered cubic unit cells with vertical and horizontal struts (FBCCXYZ).

This comparative study is expected to provide new prospects for designing end-user parts that undergo various impact conditions like automotive bumpers and evolving techniques like hybrid and functionally graded lattices.

To the best of the authors' knowledge, this is the first work that relates the strain rate with compressive properties and also highlights the lattice behaviour transformation from ductile to brittle while the increase of RD and strain rate analytically using the Gibson–Ashby analytical model.

The purpose of this paper is to describe various aspects of the visco-elastoplastic (VEP) behavior of porous-hardened concrete samples in relation to standard tests.

The problem is formulated on the basis of the rheological-dynamic analogy (RDA). In this study, changes in creep coefficient, Poisson's ratio, damage variables, modulus of elasticity, strength and angle of internal friction as a function of porosity are defined by P and S wave velocities. The RDA model provides a description of the degradation process of material properties from their peak state to their ultimate values using void volume fraction (VVF).

Compared to numerous versions of acoustic emission tracking developed to analyze the behavior of total wave propagation in inhomogeneous media with density variations, the proposed model is comprehensive in interpretation and consistent with physical understanding. The comparison of the damage variables with the theoretical variables under the assumption of spherical voids in the spherical representative volume element (RVE) shows a satisfactory agreement of the results for all analyzed samples if the maximum porosities are used for comparison.

The paper presents a new mathematical-physical method for examining the effect of porosity on the characteristics of hardened concrete. Porosity is essentially related to density variations. Therefore, it was logical to define the limit values of porosity using the strain energy density.