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This study aims to solve the problem of weld quality inspection, for the aluminum alloy profile welding structure of high-speed train body has complex internal shape and thin plate thickness (2–4 mm), the conventional nondestructive testing method of weld quality is difficult to implement.

In order to solve this problem, the ultrasonic creeping wave detection technology was proposed. The impact of the profile structure on the creeping wave detection was studied by designing profile structural test blocks and artificial simulation defect test blocks. The detection technology was used to test the actual welded test blocks, and compared with the results of X-ray test and destructive test (tensile test) to verify the accuracy of the ultrasonic creeping wave test results.

It is indicated that that X-ray has better effect on the inspection of porosities and incomplete penetration defects. However, due to special detection method and protection, the detection speed is slow, which cannot meet the requirements of field inspection of the welding structure of aluminum alloy thin-walled profile for high-speed train body. It can be used as an auxiliary detection method for a small number of sampling inspection. The ultrasonic creeping wave can be used to detect the incomplete penetration welds with the equivalent of 0.25 mm or more, the results of creeping wave detection correspond well with the actual incomplete penetration defects.

The results show that creeping wave detection results correspond well with the actual non-penetration defects and can be used for welding quality inspection of aluminum alloy thin-wall profile composite welding joints. It is recommended to use the echo amplitude of the 10 mm × 0.2 mm × 0.5 mm notch as the criterion for weld qualification.

In order to develop high-strength, high-toughness and high-wear-resistance rails suitable for the development and application of heavy-haul railways.

Based on the trial production of 60 kg·m⁻¹ bainite rails, the Zeiss inverted optical microscope, transmission electron microscope and static hydraulic universal tester were used to test the microstructure and property of rail base metal and welded joints. Meanwhile, a trial laying of rails, wing rails of frogs and switch rails for turnouts was performed to systematically analyze their strength, toughness and wear resistance.

The results show that the base metal of 60 kg·m⁻¹ bainite rail is of a uniform microstructure, with a carbide-free bainite matrix, a few of stable residual austenite and M/A islands, and it features high hardness, good wear resistance and good strength-toughness balance. The welded joint is of a uniform microstructure and has good properties.

A bainite rail, laid in a curve section of heavy-haul railway is able to serve for 48 months with a gross traffic tonnage of nearly 600 million tons, whose service life is more than one time longer than that of pearlite rail; the service life of the wing rail of frog and the switch rail for turnout with 60 kg·m⁻¹ bainite rails is 3–4 times longer than that with U75V rails, and no serious damage occurs. The bainite rails also have strong peeling and spalling resistance.

In view of the difficulty in determining the key parameters d in the Corten-Dolan model, based on the introduction of small loads, damage degrees and stress states to the Corten-Dolan model and the existing improved model, the sequential effects of the adjacent two-stage load were further considered.

Two improved Corten-Dolan models were established on the basis of modifying the parameter d by two different methods, namely, increasing stress ratio coefficient as well as considering the effects of loading sequence and damage degree as independent influencing factors respectively. According to the test data of the welded joints of common materials (standard 45 steel), alloy materials (standard 16Mn steel) and Q235B steel, the validity and feasibility of the above two improved models for fatigue life prediction were verified.

Results show that, compared with the traditional Miner model and the existing Corten-Dolan improved model, the two improved models have higher prediction accuracy in the fatigue life prediction of welding materials whether under two-stage load or multi-stage load.

Because the mathematical expressions of the models are relatively simple and need no multi-layer iterative calculation, it is convenient to predict the fatigue life of welded structure in practical engineering.

The purpose of this paper is to demonstrate the impact of the welding sequence on the substrate plate distortion during the wire and arc additive manufacturing (WAAM) process. This paper also aims to show the capability of finite element simulations in the prediction of those thermally induced distortions.

An experiment was conducted in which solid aluminum blocks were manufactured using two different welding sequences. The distortion of the substrates was measured at predefined positions and converted into bending and torsion values. Subsequently, a weakly coupled thermo-mechanical finite element model was created using the Abaqus simulation software. The model was calibrated and validated with data gathered from the experiments.

The results of this paper showed that the welding sequence of a part significantly affects the formation of thermally induced distortions of the final part. The calibrated simulation model was able to capture the different distortion behavior attributed to the welding sequences.

Within this work, a simulation model was developed capable of predicting the distortion of WAAM parts in advance. The findings of this paper can be used to improve the design of WAAM welding sequences while avoiding high experimental efforts.

This research addresses the diverse characteristics of existing railway steel bridges in China, including variations in construction age, design standards, structural types, manufacturing processes, materials and service conditions. It also focuses on prominent defects and challenges related to heavy transportation conditions, particularly low live haul reserves and severe fatigue problems.

The study encompasses three key aspects: (1) Adaptability assessment: It begins with assessing the suitability of existing railway steel bridges for heavy-haul operations through comprehensive analyses, experiments and engineering applications. (2) Strengthening: To combat frequent crack defects in the vertical stiffener end structure of girder webs, fatigue performance tests and reinforcement scheme experiments were conducted. These experiments included the development of a hot-spot stress S-N curve for this structure, validating the effectiveness of methods like crack stop holes, ultrasonic hammering and flange angle steel. (3) Service life extension: Research on the cruciform welded joint structure (non-fusion transfer type) focused on fatigue performance over the long life cycle. This led to the establishment of a fatigue S-N curve, enhancing Chinese design codes.

The research achieved several significant outcomes: (1) Successful implementation of strengthening and retrofitting measures on a 64-m single-span double-track railway steel truss girder on an existing heavy-duty line. (2) Post-reinforcement, a substantial 26% to 32% reduction in live haul stress on bridge members was achieved. (3) The strengthening and retrofitting efforts met design expectations, enabling the bridge to accommodate vehicles with a 30-ton axle haul on the railway line.

This research systematically tackles challenges and defects associated with Chinese existing railway steel bridges, providing valuable insights into adaptability assessment, strengthening techniques and service life extension methods. Furthermore, the development of fatigue S-N curves and the successful implementation of bridge enhancements have practical implications for improving the resilience and operational capacity of railway steel bridges in China.

This paper aims to provide top-level design and basic platform for intelligent application in China high-speed railway.

Based on the analysis for the future development trends of world railway, combined with the actual development needs in China high-speed railway, The definition and scientific connotation of intelligent high-speed railway (IHSR) are given at first, and then the system architecture of IHSR are outlined, including 1 basic platform, 3 business sectors, 10 business fields, and 18 innovative applications. At last, a basic platform with cloud edge integration for IHSR is designed.

The rationality, feasibility and implementability of the system architecture of IHSR have been verified on and applied to the Beijing–Zhangjiakou high-speed railway, providing important support for the construction and operation of the world’s first IHSR.

This paper systematically gives the definition and connotation of the IHSR and put forward the system architecture of IHSR for first time. It will play the most important role in the design, construction and operation of IHSR.

Poor maintenance management leads to non-negligible economic, environmental and social impacts and obstacles to the sustainable manufacturing paradigm. Studies evaluating maintenance impacts on sustainability underline growing interest in the topic, but reports on the industrial field are lacking. Therefore, this paper investigates the industrial environment and the indicators that manufacturing companies use for measuring their maintenance impacts.

In this pilot survey study, several stakeholders of production enterprises in the south of Italy were interviewed to unveil the spread of the measurement of maintenance impacts on sustainability and the indicators used by those companies.

The interview results showed a low level of awareness among stakeholders about maintenance impacts on sustainability. Maintenance stakeholders are mainly focused on technical and economic factors, whereas environmental, quality and safety stakeholders are becoming more aware of maintenance impacts on environmental and social factors. However, both groups need guidelines to define sustainability indicators to assess such impacts.

This exploratory study allowed us to investigate the current situation in industrial organisations and achieve the first variegated and diversified vision of the awareness of company stakeholders on maintenance impacts on the sustainability of several business functions. This paper provides a valuable contribution to “maintenance and sustainability” research area in production contexts and sheds light on non-negligible maintenance impacts on sustainability, providing preliminary insights on the topic and an effective basis for defining future research opportunities. Moreover, this study enables increased awareness among internal and external manufacturing company stakeholders on the role of maintenance in sustainable production.

Results – From a hardening test, we then tested with an impact tester charpy Treviolo H060. The results showed that the impact strength is escalated up to 29.09% post-hardening circle, which was observed using electrical microscope. The value of steel strength increased 2.12 J/mm² compared with earlier hardening process, which is, 1.57 J/mm². The results showed that the fracture in the welding process without the hardening process is a brittle fracture that is shown by the flat crystal structure; on the other hand, the hardening process before welding shows a form of coarse-looking structure indicating that the specimen has an impact towards which the toughness is higher.

Research Limitations/Implications – The effect influence of the hardening process to the impact strength of welded joints before and after the hardening process SMAW AISI 1050 steel hardening process. The mechanical properties test is done with the equipment impact charpy.

Practical Implications – The field we often encounter is erosion or wear out occurring in the construction, for example, many equipments such as agricultural equipment, bridges, ship construction, motor shaft, machining such as hand tools, small rings, and agricultural tools.

Originality/Value – This is the first reported research on impact strength using the hardening test.

This paper aims to present a detailed mechanical design of a seven-degrees-of-freedom mobile parallel robot for the tungsten inert gas (TIG) welding and machining processes in fusion reactor. Detailed mechanical design of the robot is presented and both the kinematic and dynamic behaviors are studied.

First, the model of the mobile parallel robot was created in computer-aided design (CAD) software, then the simulation and optimization of the robot were completed to meet the design requirements. Then the robot was manufactured and assembled. Finally, the machining and tungsten inert gas (TIG) welding tests were performed for validation.

Currently, the implementation of the robot system has been successfully carried out in the laboratory. The excellent performance has indicated that the robot’s mechanical and software designs are suitable for the given tasks. The quality and accuracy of welding and machining has reached the requirements.

This mobile parallel industrial robot is particularly used in fusion reactor. Furthermore, the structure of the mobile parallel robot can be optimized for different applications.

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.