Search results

This paper aims to present the novel stacked machine learning approach (SMLA) to estimate low-cycle fatigue (LCF) life of SAC305 solder across structural parts. Using the finite element simulation (FEM) and continuous damage mechanics (CDM) model, a fatigue life database is built. The stacked machine learning (ML) model's iterative optimization during training enables precise fatigue predictions (2.41% root mean square error [RMSE], R² = 0.975) for diverse structural components. Outliers are found in regression analysis, indicating potential overestimation for thickness transition specimens with extended lifetimes and underestimation for open-hole specimens. Correlations between fatigue life, stress factors, nominal stress and temperature are unveiled, enriching comprehension of LCF, thus enhancing solder behavior predictions.

This paper introduces stacked ML as a novel approach for estimating LCF life of SAC305 solder in various structural parts. It builds a fatigue life database using FEM and CDM model. The stacked ML model iteratively optimizes its structure, yielding accurate fatigue predictions (2.41% RMSE, R² = 0.975). Outliers are observed: overestimation for thickness transition specimens and underestimation for open-hole ones. Correlations between fatigue life, stress factors, nominal stress and temperature enhance predictions, deepening understanding of solder behavior.

The findings of this paper highlight the successful application of the SMLA in accurately estimating the LCF life of SAC305 solder across diverse structural components. The stacked ML model, trained iteratively, demonstrates its effectiveness by producing precise fatigue lifetime predictions with a RMSE of 2.41% and an “R²” value of 0.975. The study also identifies distinct outlier behaviors associated with different structural parts: overestimations for thickness transition specimens with extended fatigue lifetimes and underestimations for open-hole specimens. The research further establishes correlations between fatigue life, stress concentration factors, nominal stress and temperature, enriching the understanding of solder behavior prediction.

The authors confirm the originality of this paper.

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 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.

This study investigates the fitting techniques for notch fatigue curves, seeking a more reliable method to predict the lifespan of welded structures.

Building on the fatigue test results of butt and cruciform joints, this research delves into the selection of fitting methods for the notch fatigue curve of welded joints. Both empirical formula and finite element methods (FEMs) were employed to assess the notch stress concentration factor at the toe and root of the two types of welded joints. Considering the mean stress correction and weld misalignment coefficients, the notch fatigue life curves were established using both direct and indirect methods.

An engineering example was employed to discern the differences between the direct and indirect approaches. The findings highlight the enhanced reliability of the indirect method for fitting the fatigue life curve.

While the notch stress approach is extensively adopted due to its accurate prediction of component fatigue life, most scholars have overlooked the importance of its curve fitting methods. Existing literature scantily addresses the establishment of these curves. This paper offers a focused examination of fatigue curve fitting techniques, delivering valuable perspectives on method selection.

The long-span continuous rigid-frame bridges are commonly constructed by the section-by-section symmetrical balance suspension casting method. The deflection of these bridges is increasing over time. Wet joints are a typical construction feature of continuous rigid-frame bridges and will affect their integrity. To investigate the sensitivity of shear surface quality on the mechanical properties of long-span prestressed continuous rigid-frame bridges, a large serviced bridge is selected for analysis.

Its shear surface is examined and classified using the damage measuring method, and four levels are determined statistically based on the core sample integrity, cracking length and cracking depth. Based on the shear-friction theory of the shear surface, a 3D solid element-based finite element model of the selected bridge is established, taking into account factors such as damage location, damage number and damage of the shear surface. The simulated results on the stress distribution of the local segment, the shear surface opening and the beam deflection are extracted and analyzed.

The findings indicate that the main factors affecting the ultimate shear stress and shear strength of the shear surface are size, shear reinforcements, normal stress and friction performance of the shear surface. The connection strength of a single or a few shear surfaces decreases but with little effect on the local stress. Cracking and opening mainly occur at the 1/4 span. Compared with the rigid “Tie” connection, the mid-span deflection of the main span increases by 25.03% and the relative deflection of the section near the shear surface increases by 99.89%. However, when there are penetrating cracks and openings in the shear surface at the 1/2 span, compared with the 1/4 span position, the mid-span deflection of the main span and the relative deflection of the cross-section increase by 4.50%. The deflection of the main span increases with the failure of the shear surface.

These conclusions can guide the analysis of deflection development in long-span prestressed continuous rigid-frame bridges.

In order to improve the computation efficiency of the four-point rainflow algorithm, a new fast four-point rainflow cycle counting algorithm (FFRA) using a novel loop iteration mode is proposed.

In this new algorithm, the loop iteration mode is simplified by reducing the number of iterations, tests and deletions. The high efficiency of the new algorithm makes it a preferable candidate in fatigue life online estimation of structural health monitoring systems.

The extensive simulation results show that the extracted cycles by the new FFRA are the same as those by the four-point rainflow cycle counting algorithm (FRA) and the three-point rainflow cycle counting algorithm (TRA). Especially, the simulation results indicate that the computation efficiency of the FFRA has improved an average of 12.4 times compared to the FRA and an average of 8.9 times compared to the TRA. Moreover, the equivalence of cycle extraction results between the FFRA and the FRA is proved mathematically by utilizing some fundamental properties of the rainflow algorithm. Theoretical proof of the efficiency improvement of the FFRA in comparison to the FRA is also given.

This merit makes the FFRA preferable in online monitoring systems of structures where fatigue life estimation needs to be accomplished online based on massive measured data. It is noticeable that the high efficiency of the FFRA attributed to the simple loop iteration, which provides beneficial guidance to improve the efficiency of existing algorithms.

This paper aims to investigate the bonding of the photonic integrated circuit (PIC) chip with the heat sink using the AlNi self-propagating soldering method.

Compared to industrial optical modules, optical modules for aerospace applications require better reliability and stability, which is hard to achieve via the dispensing adhesive process that is used for traditional industrial optical modules. In this paper, 25 µm SAC305 solder foils and the AlNi nanofoil heat source were used to bond the back of the PIC chip with the heat sink. The temperature field and temperature history were analyzed by the finite element analysis (FEA) method. The junction-to-case thermal resistance is 0.0353°C/W and reduced by 85% compared with the UV hybrid epoxy joint.

The self-propagating reaction ends within 2.82 ms. The maximum temperature in the PIC operating area during the process is 368.5°C. The maximum heating and cooling rates of the solder were 1.39 × 107°C/s and −5.15 × 106°C/s, respectively. The microstructure of SAC305 under self-propagating reaction heating is more refined than the microstructure of SAC305 under reflow. The porosity of the heat sink-SAC305-PIC chip self-propagating joint is only 4.7%. Several metastable phases appear as AuSn3.4 and AgSn3.

A new bonding technology was used to form the bonding between the PIC chip with the heat sink for the aerospace optical module. The reliability and thermal resistance of the joint are better than that of the UV hybrid epoxy joint.

Firefighter Personal Protective Equipment (PPE) is the only barrier between the firefighter and hazardous environment. Gloves are a crucial component of the multi-component PPE. Over time the gloves have reduced the intensity of hand injuries, yet further improvement in terms of material selection and glove design is required to strike the balance between protection and comfort. Focusing on the material aspect, the purpose of this study is to present literature analysis on material selection and testing for firefighter gloves.

The study conducted a literature analysis on material selection and characterization of firefighter PPE. The review summarizes and evaluates past work addressing the characterization of firefighter gloves in accordance with NFPA 1971 requirements and points out found research gaps to aid with foundation of future research.

The study summarizes several research works to inform readers about the material selection and characterization of firefighter gloves. Based on the analyzed literature, the study resulted in material specification sheets for firefighter gloves. The developed material specification sheets provide information in terms of crucial material properties to be incorporated for accurate functioning of firefighter gloves, testing methods to validate those material properties and materials from analyzed literature exhibiting desired properties.

With large research addressing firefighter PPE, only limited studies focus specifically on gloves. Thus, this study provides a literature analysis covering material selection and testing for gloves. A consolidated firefighter gloves material specification document, which does not appear to be available in the literature, will provide a foundation for the development and characterization of firefighter gloves to better serve the functions along with ensuring user comfort.