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Maintenance is one of the most critical and expensive operations during the life cycle of metallic structures, in particular in the aeronautic industry. However, early detection of fatigue cracks is one of the most demanding operations in global maintenance procedures. In this context, non-destructive testing using image techniques may represent one of the best solutions in such situations, especially thermal stress analyses (TSA) using infrared thermography. The purpose of this paper is to access and characterize the main stress profile calculated through temperature variation, for different load frequencies.

In this paper, a cyclic load is applied to an aluminum sample component while infrared thermal image is being acquired. According to the literature and experiments, a cyclic load applied to a material results in cyclic temperature variation.

Frequency has been shown to be an important parameter in TSA evaluations, increasing the measured stress profile amplitude. The loading stimulation frequency and the maximum stress recorded show a good correlation (R² higher than 0.995). It was verified that further tests and modeling should be performed to fully comprehend the influence of load frequency and to create a standard to conduct thermal stress tests.

This work revealed that the current infrared technology is capable of reaching far more detailed thermal and spatial resolution than the one used in the development of TSA models. Thus, for the first time the influence of mechanical load frequency in the thermal profiles of TSA is visible and consequentially the measured mechanical stress.

Friction stir welding lap joints of aluminum alloy AA6082-T6 were joined using two distinct configurations. The purpose of this paper is to study the effect of the welding line direction on the fatigue life of the specimens. For that purpose, specimens with the welding line parallel to the loading direction and with the welding line perpendicular to the loading direction were designed and manufactured. Fatigue tests were performed under constant amplitude load and stress ratio of R=0.1. As shown in previous studies, the hook defect plays a decisive role in the mechanical behavior of the joint, in particular when submitted to fatigue. The specimen geometry with the welding line parallel to the loading direction showed a superior fatigue behavior: for a given number of cycles to rupture, the level of stress is approximately twice as high as for the perpendicular configuration.

Two finite element models were created in order to study the behavior of the welded zone and, in particular, to compare influence of the hook defect in both configurations.

The specimen geometry with the welding line parallel to the loading direction showed a superior fatigue behavior: for a given number of cycles to rupture, the level of stress is approximately twice as high as for the perpendicular configuration.

The main objective of this work is to study the effect of the welding line direction on the fatigue life of the specimens. For that purpose, specimens with the welding line parallel to the loading direction and with the welding line perpendicular to the loading direction were designed and manufactured. Fatigue tests were performed under constant amplitude load and stress ratio of R=0.1. As shown in previous studies, the hook defect plays a decisive role in the mechanical behavior of the joint, in particular when submitted to fatigue.

The vehicle´s body front pillar should absorb most of the striker kinetic energy, while only a fraction of that is absorbed by the door structure. This study aims to discuss the aforementioned issue. In this test the striker is a virtual entity. Six uniaxial strain gauges are installed throughout the door. Additionally, contactless 3D digital image correlation (DIC) allows to assess the major door panel’s continuous deformation and strain fields.

A coach is a large and heavy long-distance passenger transport vehicle. Their structural certification, classifies coaches as M3 Class III vehicles. New coach structures’ designs need analyses of each sub-system for critical pre-validation of the entire structure, aiming driver and passenger carrier safety. Also, a thorough examination due to increased travel speed is needed.

Experimental pseudo-dynamic (PSD) results were compared and validated using finite element method (FEM) with two pieces of distinct FEM software (Abaqus® and PamCrash®). The time dependent solution was carried out by explicit techniques. Results by FEM and PSD test showed good agreement, evidencing the reliability of the tools selected. Results by PamCrash® were closer to the experimental data.

R-29 is truck-only regulation, however can be adapted to coaches in case of a frontal collision. The present work focuses on the impact behavior of the passenger front door subsystem.

As a first validation the entire structure, the behavior of a vehicle door, under in-plane impacts was studied. The corresponding deformation energy absorbed by the frontal passenger coach door under virtual impacts of a swinging striker was assessed using a PSD approach.

Fused Filament Fabrication (FFF) is an extrusion-based manufacturing process using fused thermoplastics. Despite its low cost, the FFF is not extensively used in high-value industrial sectors mainly due to parts' anisotropy (related to the deposition strategy) and residual stresses (caused by successive heating cycles). Thus, this study aims to investigate the process improvement and the optimization of the printed parts.

In this work, a meshless technique – the Radial Point Interpolation Method (RPIM) – is used to numerically simulate the viscoplastic extrusion process – the initial phase of the FFF. Unlike the FEM, in meshless methods, there is no pre-established relationship between the nodes so the nodal mesh will not face mesh distortions and the discretization can easily be modified by adding or removing nodes from the initial nodal mesh. The accuracy of the obtained results highlights the importance of using meshless techniques in this field.

Meshless methods show particular relevance in this topic since the nodes can be distributed to match the layer-by-layer growing condition of the printing process.

Using the flow formulation combined with the heat transfer formulation presented here for the first time within an in-house RPIM code, an algorithm is proposed, implemented and validated for benchmark examples.

Recently, a new class of fatigue crack growth models based on elastoplastic stress‐strain histories at the crack tip region and strain‐life fatigue damage models have been proposed. The fatigue crack propagation is understood as a process of continuous crack initializations, over elementary material blocks, which may be governed by strain‐life data of the plain material. The residual stresses developed at the crack tip play a central role in these models, since they are used to assess the actual crack driving force, taking into account mean stresses and loading sequential effects. The UniGrow model fits this particular class of fatigue crack propagation models. The purpose of this paper is to propose an extension of the UniGrow model to derive probabilistic fatigue crack propagation data, in particular the derivation of the P–da/dN–ΔK–R fields.

An existing deterministic fatigue crack propagation model, based on local strain‐life data is first assessed. In particular, an alternative methodology for residual stress computation is proposed, based on elastoplastic finite element analysis, in order to overcome inconsistencies found in the analytical approximate approaches often used in literature. Then, using probabilistic strain‐life fields, a probabilistic output for the fatigue crack propagation growth rates is generated. A new probabilistic fatigue field is also proposed to take mean stress effects into account, using the Smith‐Watson‐Topper (SWT) damage parameter. The proposed models are assessed using experimental data available for two materials representative from old Portuguese bridges.

A new method to generate probabilistic fatigue crack propagation rates (P–da/dN–ΔK–R fields) is proposed and verified using puddle iron from old Portuguese bridges, usually characterized by significant scatter in fatigue properties. Also, a new probabilistic fatigue field for plain material is proposed to deal with mean stress effects.

A relation between the P–ε–N and the P–da/dN–ΔK–R fields is firstly proposed in this research. Furthermore, a new P–SWT–N field is proposed to deal with mean stress effects.

The purpose of this paper is to study the fatigue crack growth (FCG) behaviour of the steel and weldments of a railway bridge.

Tests were carried out on compact tension (CT) specimens using the thickness (B=32 mm) of a structural detail. The test matrix included three R values and three material conditions: base material (BM), heat affected zone (HAZ) and weld metal (WM). An evaluation of opening load behavior was carried out. The full field measurement of the residual stress perpendicular to the crack plane was performed using the contour technique. A simplified finite element analysis supported the interpretation of the results. Scanning electron microscopy (SEM) observation of the fracture surface of BM and HAZ specimens was carried out.

Extensive crack closure effects were found in the welded specimens. Important through‐the‐thickness variation of residual stress was found using the contour technique. The residual stress fields of HAZ and WM specimens led to slowing down the FCG rate in the initial stages of crack propagation and to uncommon fracture surfaces. When the opening load effect was taken into consideration it was found that the da/dN vs ΔK of the different types of specimens are approximately identical. The ratio (striation spacing)/(da/dN) decreases up to approximately unity as a/W increases. In the specimens analyzed, FCG rates below approximately 2E‐7 to 3E‐7 m/cycle are associated with approximately constant striation spacing values, which could be considered a conservative upper bound of the real crack growth rate.

Fatigue crack growth behavior of thick welded steel CT specimens was analyzed on the basis of tests including full field residual stress measurements, crack closure behavior and striation spacing, allowing for the simultaneous consideration of all those aspects. It is shown that the striations spacing provides no more than a conservative upper bond of the real crack propagation rate.

Part of the runway at Madeira Airport is a platform above the sea at a 60 m height, supported by a series of frames. When aircraft land on this section, a load is exerted on the structure, resulting in bending of the beams which constitute the frames. A vision-based monitoring system was devised and implemented to measure the deflection of the runway's beams when a landing occurs.

An area on the midspan of two beams, located on the area where aircraft are most likely to land, was prepared with a speckle pattern, and a camera was assembled above a column on each of the adjacent frames, enabling the computation of displacements using digital image correlation (DIC). The camera continuously acquires images of the monitored area and compares them to a reference using DIC. If a displacement is detected, a number of frames before and after this event are saved for further DIC processing.

The installed systems successfully detected several events corresponding to landings and, for each of those events, measured the deflection of the beams over time and computed displacement fields for critical images, with strain values obtained up to this point being too small to measure using the current system.

This work provides novel insights into the behaviour of a unique structure and constitutes the first use of a vision system in its structural monitoring operations. It is also a valuable development in the implementation of automated DIC monitoring systems in locations of difficult access.

The purpose of this paper is to describe the work of IDMEC, a not‐for‐profit R&D private association located in Porto and Lisbon, Portugal.

The paper focuses on IDMEC's R&D activities, focusing on aeronautics.

Together IDMEC‐Porto and INEGI provide answers to R&D challenges in the broad area of aerostructures, from fracture and fatigue problems to advanced composites for space applications.

The paper offers a concise presentation of the IDMEC's R&D activities in the field of aeronautics.