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In fire resistance tests (FRTs) of building materials, a crucial criterion to pass the test procedure is to avoid the leakage of the hot flue gases caused by gaps and cracks occurring due to the thermal exposure. The present study's aim is to calculate the deformation of a steel door, which is embedded within a wall made of bricks, and qualitatively determine the flue gas leakage.

A computational fluid dynamics/finite element method (CFD/FEM) coupling was introduced representing an intermediate approach between a one-way and a full two-way coupling methodology, leading to a simplified two-way coupling (STWC). In contrast to a full two way-coupling, the heat transfer through the steel door was simulated based on a one-way approach. Subsequently, the predicted temperatures at the door from the one-way simulation were used in the following CFD/FEM simulation, where the fluid flow inside and outside the furnace as well as the deformation of the door were calculated simultaneously.

The simulation showed large gaps and flue gas leakage above the door lock and at the upper edge of the door, which was in close accordance to the experiment. Furthermore, it was found that STWC predicted similar deformations compared to the one-way coupling.

Since two-way coupling approaches for fluid/structure interaction in fire research are computationally demanding, the number of studies is low. Only a few are dealing with the flue gas exit from rooms due to destruction of solid components. Thus, the present study is the first two-way approach dealing with flue gas leakage due to gap formation.

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.

The purpose of the work is to provide a comprehensive review of the digital image correlation (DIC) technique for those who are interested in performing the DIC technique in the area of manufacturing.

No methodology was used because the paper is a review article.

no fundings.

Herein, the historical development, main strengths and measurement setup of DIC are introduced. Subsequently, the basic principles of the DIC technique are outlined in detail. The analysis of measurement accuracy associated with experimental factors and correlation algorithms is discussed and some useful recommendations for reducing measurement errors are also offered. Then, the utilization of DIC in different manufacturing fields (e.g. cutting, welding, forming and additive manufacturing) is summarized. Finally, the current challenges and prospects of DIC in intelligent manufacturing are discussed.

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 study aims to improve the availability of regenerative braking for urban metro vehicles by introducing a sensorless operational temperature estimation method for the braking resistor (BR) onboard the vehicle, which overcomes the vulnerability of having conventional temperature sensor.

In this study, the energy model based sensorless estimation method is developed. By analyzing the structure and the convection dissipation process of the BR onboard the vehicle, the energy-based operational temperature model of the BR and its cooling domain is established. By adopting Newton's law of cooling and the law of conservation of energy, the energy and temperature dynamic of the BR can be stated. To minimize the use of all kinds of sensors (including both thermal and electrical), a novel regenerative braking power calculation method is proposed, which involves only the voltage of DC traction network and the duty cycle of the chopping circuit; both of them are available for the traction control unit (TCU) of the vehicle. By utilizing a real-time iterative calculation and updating the parameter of the energy model, the operational temperature of the BR can be obtained and monitored in a sensorless manner.

In this study, a sensorless estimation/monitoring method of the operational temperature of BR is proposed. The results show that it is possible to utilize the existing electrical sensors that is mandatory for the traction unit’s operation to estimate the operational temperature of BR, instead of adding dedicated thermal sensors. The results also validate the effectiveness of the proposal is acceptable for the engineering practical.

The proposal of this study provides novel concepts for the sensorless operational temperature monitoring of BR onboard rolling stocks. The proposed method only involves quasi-global electrical variable and the internal control signal within the TCU.

This study aims to propose a vertical coupling dynamic analysis method of vehicle–track–substructure based on forced vibration and use this method to analyze the influence on the dynamic response of track and vehicle caused by local fastener failure.

The track and substructure are decomposed into the rail subsystem and substructure subsystem, in which the rail subsystem is composed of two layers of nodes corresponding to the upper rail and the lower fastener. The rail is treated as a continuous beam with elastic discrete point supports, and spring-damping elements are used to simulate the constraints between rail and fastener. Forced displacement and forced velocity are used to deal with the effect of the substructure on the rail system, while the external load is used to deal with the reverse effect. The fastener failure is simulated with the methods that cancel the forced vibration transmission, namely take no account of the substructure–rail interaction at that position.

The dynamic characteristics of the infrastructure with local diseases can be accurately calculated by using the proposed method. Local fastener failure will slightly affect the vibration of substructure and carbody, but it will significantly intensify the vibration response between wheel and rail. The maximum vertical displacement and the maximum vertical vibration acceleration of rail is 2.94 times and 2.97 times the normal value, respectively, under the train speed of 350 km·h⁻¹. At the same time, the maximum wheel–rail force and wheel load reduction rate increase by 22.0 and 50.2%, respectively, from the normal value.

This method can better reveal the local vibration conditions of the rail and easily simulate the influence of various defects on the dynamic response of the coupling system.

It is of great significance to study the influence of subgrade filling on permafrost temperature field in permafrost area for the smooth construction and safe operation of railway.

The paper builds up the model for the hydrothermal coupling calculation of permafrost using finite element software COMSOL to study how permafrost temperature field changes in the short term after subgrade filling, on which basis it proposes the method of calculation for the concave distortion of freezing front in the subgrade-covered area.

The results show that the freezing front below the subgrade center sinks due to the thermal effect of subgrade filling, which will trigger hydrothermal erosion in case of sufficient moisture inflows, leading to the thawing settlement or the cracking of the subgrade, etc. The heat output of soil will be hindered the most in case of July filling, in which case the sinking and the distortion of the freezing front is found to be the most severe, which the recovery of the permafrost temperature field, the slowest, constituting the most unfavorable working condition. The concave distortion of the freezing front in the subgrade area increases with the increase in temperature difference between the filler and ground surface, the subgrade height, the subgrade width and the volumetric thermal capacity of filler, while decreases with the increase of the thermal conductivity of filler. Therefore, the filler chose for engineering project shall be of small volumetric thermal capacity, low initial temperature and high thermal conductivity whenever possible.

The concave distortion of the freezing front under different working conditions at different times after filling can be calculated using the method proposed.

The smoothness of the high-speed railway (HSR) on the bridge may exceed the allowable standard when an earthquake causes vibrations for HSR bridges, which may threaten the safety of running trains. Indeed, few studies have evaluated the exceeding probability of rail displacement exceeding the allowable standard. The purposes of this article are to provide a method for investigating the exceeding probability of the rail displacement of HSRs under seismic excitation and to calculate the exceeding probability.

In order to investigate the exceeding probability of the rail displacement under different seismic excitations, the workflow of analyzing the smoothness of the rail based on incremental dynamic analysis (IDA) is proposed, and the intensity measure and limit state for the exceeding probability analysis of HSRs are defined. Then a finite element model (FEM) of an assumed HSR track-bridge system is constructed, which comprises a five-span simply-supported girder bridge supporting a finite length CRTS II ballastless track. Under different seismic excitations, the seismic displacement response of the rail is calculated; the character of the rail displacement is analyzed; and the exceeding probability of the rail vertical displacement exceeding the allowable standard (2mm) is investigated.

The results show that: (1) The bridge-abutment joint position may form a step-like under seismic excitation, threatening the running safety of high-speed trains under seismic excitations, and the rail displacements at mid-span positions are bigger than that at other positions on the bridge. (2) The exceeding probability of rail displacement is up to about 44% when PGA = 0.01g, which is the level-five risk probability and can be described as 'very likely to happen'. (3) The exceeding probability of the rail at the mid-span positions is bigger than that above other positions of the bridge, and the mid-span positions of the track-bridge system above the bridge may be the most hazardous area for the running safety of trains under seismic excitation when high-speed trains run on bridges.

The work extends the seismic hazardous analysis of HSRs and would lead to a better understanding of the exceeding probability for the rail of HSRs under seismic excitations and better references for the alert of the HSR operation.

3-ply cross-laminated timber (CLT) is used to investigate the thermo-mechanical performance of intermediate-size assemblies comprised of T-shaped welded slotted-in steel doweled connections and CLT beams at ambient temperature (AT), after and during non-standard fire exposure.

The first set of experiments was performed as a benchmark to find the load-carrying capacity of the assembly and investigate the failure modes at AT. The post-fire performance (PFP) test was performed to investigate the residual strength of the assembly after 30-min exposure to a non-standard fire. The fire-performance (FP) test was conducted to investigate the thermo-mechanical behavior of the loaded assembly during non-standard fire exposure. In this case, the assembly was loaded to 67% of AT load-carrying capacity and partially exposed to a non-standard fire for 75 min.

Embedment failure and plastic deformation of the dowels in the beam were the dominant failure modes at AT. The load-carrying capacity of the assembly was reduced to 45% of the ambient capacity after 30 min of fire exposure. Plastic bending of the dowels was the principal failure mode, with row shear in the mid-layer of the CLT beam and tear-out failure of the header sides also observed. During the FP test, ductile embedment failure of the timber in contact with the dowels was the major failure mode at elevated temperature.

This paper presents for the first time the thermo-mechanical performance of CLT beam-to-girder connections at three different thermal conditions. For this purpose, the outside layers of the CLT beams were aligned horizontally.

1. Load-carrying capacity and failure modes of CLT beam-to-girder assembly with T-shaped steel doweled connections at ambient temperature presented.

2. Residual strength and failure modes of the assembly after 30-min partially exposure to the non-standard fire provided throughout the post-fire performance test.

3. Fire resistance of the assembly partially exposed to the non-standard fire highlighted.

Load-carrying capacity and failure modes of CLT beam-to-girder assembly with T-shaped steel doweled connections at ambient temperature presented.

Residual strength and failure modes of the assembly after 30-min partially exposure to the non-standard fire provided throughout the post-fire performance test.

Fire resistance of the assembly partially exposed to the non-standard fire highlighted.

Internal gearings are commonly used in transmissions due to their advantages like high-power density. To ensure high efficiency, load-carrying capacity and good noise behavior, a profound knowledge of the local gear mesh is essential. The tooth contact of internal gears relates to a convex and concave surface that form a conformal contact. This is in contrast to external gears, where two convex surfaces form a contraformal contact. This paper aims at a better understanding of conformal contacts under elastohydrodynamic lubrication (EHL) to improve the design of internal gearings.

An existing numerical EHL model is used for studying the characteristic properties of a hard conformal EHL line contact. A hard contraformal EHL line contact is studied as reference. Non-Newtonian fluid behavior and thermal effects are considered. By taking into account the local contact conformity and kinematics, the effects and relevance of the curvature of the lubricant gap and micro-slip are analyzed. In a parameter study, scale effects of the contact radii on film thickness, temperature rise and friction are examined.

The curvature of the lubricant gap and effects of micro-slip are small in hard conformal EHL line contacts. For high micro-slip, it can be neglected. Hence, the modeling of conformal contacts using an equivalent geometry of the contact problem is reasonable. The parameter study shows beneficial tribological aspects of the conformal contact compared to the contraformal contact. Higher film thickness and lower fluid coefficient of friction are observed for conformal contacts, which can be attributed to lower pressures for the case of the same external normal force, or to a higher contact temperature rise for the case of equivalent contact pressure.

Despite its widespread existence, the local geometry and kinematics in hard conformal EHL line contacts like in internal gearings have been rarely studied. The findings help for a better understanding of local contact characteristics and its relevance. The quantified scale effects help to improve the efficiency and load-carrying capacity of machine elements with hard conformal EHL contacts, like internal gearings.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2022-0366/