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The synchronization control of its dual hydraulic cylinder moving beam in fatigue testing machine requires robustness and high synchronization accuracy. The synchronization control accuracy is affected by the time-varying nonlinearity of parameters, mutual coupling and load disturbance of the multi-cylinder system affect. A novel control strategy with single-cylinder self-immunity and double-cylinder fuzzy single neuron is proposed to overcome the slow compensation response and poor robustness of dynamic adjustability. First the working principle of the moving beam synchronization system of the fatigue testing machine is described, then the mathematical simulation model of the asymmetric single and double cylinders and their synchronization control system are established to carry out the simulation analysis of the tracking performance and synchronization performance. Finally the experimental is setup to verify the simulation analysis. The results show that the designed synchronization controller can meet the application requirements of the fatigue testing machine moving beam extremely well.

Moisture accelerates the degradation of asphalt properties, significantly impacting the service life of roads. Therefore, this study uses simplified viscoelastic continuous damage theory and employs frequency scanning, linear amplitude scanning, and fatigue–healing–fatigue tests with a dynamic shear rheometer. The objective is to investigate the effects of aging time, moisture conditions, and aging temperature on the fatigue and self-healing performance of SBS (Styrene–Butadiene–Styrene block copolymer)-modified asphalt, nano-SiO[sub.2]-modified asphalt, and nano-SiO[sub.2]/SBS composite modified asphalt in a moisture-rich environment. The results indicate that nano-SiO[sub.2] powder enhances the low-temperature performance of modified asphalt, whereas the SBS modifier reduces temperature sensitivity and increases the recovery percentage after deformation. Compared to SBS-modified asphalt, the deformation resistance of nano-SiO[sub.2]/SBS composite modified asphalt has increased by about 30%, while nano-SiO[sub.2]-modified asphalt shows relatively poor deformation resistance. The fatigue performance of SBS-modified asphalt deteriorates under moisture, whereas the addition of nano-SiO[sub.2] powder improves its fatigue life. Nano-SiO[sub.2]/SBS composite modified asphalt exhibits strong self-healing capabilities. Although self-healing can enhance the fatigue life of modified asphalt, moisture inhibits this improvement after self-healing.

Laser powder bed fusion (LPBF) is an emerging additive manufacturing technique that is currently adopted by a number of industries for its ability to directly fabricate complex near-net-shaped components with minimal material wastage. Two major limitations of LPBF, however, are that the process inherently produces components containing some amount of porosity and that fabricated components tend to suffer from poor repeatability. While recent advances have allowed the porosity level to be reduced to a minimum, consistent porosity-free fabrication remains elusive. Therefore, it is important to understand how porosity affects mechanical properties in alloys fabricated this way in order to inform the safe design and application of components. To this aim, this article will review recent literature on the effects of porosity on tensile properties, fatigue life, impact and fracture toughness, creep response, and wear behavior. As the number of alloys that can be fabricated by this technology continues to grow, this overview will mainly focus on four alloys that are commonly fabricated by LPBF—Ti-6Al-4 V, Inconel 718, AISI 316L, and AlSi10Mg.

Despite being designed considering infinite fatigue-life, failures of motor crankshafts forged from DIN 34CrNiMo6 steels have been reported in Brazilian power plants. As such, the present work aims to discuss the failure of a crankshaft within this context, with the purpose of verifying whether the stresses developed in critical locations of the component were in accordance with the steel’s fatigue limits, as well as if the material exhibits an adequate resistance to crack propagation. Taking into consideration a set of critical-plane stress-based multiaxial fatigue criteria, namely Findley, Matake, McDiarmid and Susmel and Lazzarin, the fatigue behaviour of the material is analysed and discussed. Furthermore, da/dN versus ΔK experiments were carried out with the purpose of determining the DIN 34CrNiMo6 steel’s crack growth threshold ΔK[sub.th] and comparing it to the ΔK[sub.th] of three other commercially available steels (DIN 42CrMo4, SAE 4140 and SAE 4340). The selected multiaxial fatigue criteria indicated that the stresses developed throughout the component were not sufficient to drive the crankshaft to failure, thus indicating safety. On the other hand, the DIN 34CrNiMo6 steel presented the lowest ΔK[sub.th] (6.6MPam[sup.1/2]) among all the considered steels (10.86, 12.38 and 7.22MPam[sup.1/2] for the DIN 42CrMo4, SAE 4140 and SAE 4340, respectively), therefore being susceptible to shorter fatigue lives in comparison to the other materials.

Experimental studies on fatigue behavior are usually conducted on servo-hydraulic testing machines that are expensive and have high maintenance costs. In this work, a much simpler testing machine was developed, intended mainly for delamination fatigue tests on composite materials. After a literature review on the methods and parameters of such tests, the machine was designed, and its parts manufactured and assembled into a fully operational testing machine. Additionally, the electrical components and the control and data acquisition software were also developed and implemented. Finally, several mode II delamination fatigue tests were conducted using the end-notched flexure test. The results were consistent with the well-known Paris law, which for composite materials relates the crack propagation rate to the strain-energy release rate range. Therefore, the developed machine seems to be an excellent alternative to the highly costly testing machines.

Under cyclic loading, fatigue limits Δσ[sub.FL] and fatigue crack growth (FCG) thresholds ΔΚ[sub.th] are usually examined using the S-N (or ε-N) and FCG da/dN-ΔK approaches, respectively. Historically, these two approaches are treated as a separate domain. This separation was due to the recognition that the nonuniform local stress field ahead of a crack differs significantly from the uniform stress field in a smooth specimen under axial fatigue loading. At present, there are no reliable approaches to analyzing these two regions in a unified way. In this paper, we first attempt to relate the experimental results of a cracked sample in the near-threshold region to the S-N fatigue limit of a smooth pull-push specimen. Then establish analytically the local stress intensity factor range ΔK at the process/damage zone ahead of the crack utilizing the local stress equal to Δσ[sub.FL] in a smooth specimen. Doing such an analysis, we can account the variations between the applied and the local stress ratios R (=min stress/max stress) for both cracked and smooth samples. The proposed relationship between ΔK[sub.th] and Δσ[sub.FL] would enable the development of a unified framework for fatigue analysis methods to predict damage evolution under low-stress in-service loading conditions.

Electrochemical polishing (ECP) is an efficient and low-cost technology for polishing difficult-to-machine materials with complex structures. However, when an environmentally friendly neutral salt solution is used as the polishing electrolyte, a dense passivation film forms on the surface of passive metals, such as titanium alloy, with a serious detrimental effect on the polishing efficiency and surface quality. In this paper, we introduce an ECP method assisted by a high-speed flow of micro-abrasive particles (ECFAP). The contribution of the flowing micro-abrasive particles in the ECP process enables the electrochemical dissolution and abrasive polishing to occur simultaneously on the workpiece surface. The high-speed abrasive particles remove the passivation film formed under ECP, thereby improving the polishing efficiency and quality. We carried out the comparative tests of conventional ECP and the proposed ECFAP on a Ti6Al4V alloy in 10% NaNO[sub.3] electrolyte; the results show that, while the matrix material forms a soft high-impedance passivation film under ECP, this film is removed by the high-speed flowing abrasive particles under ECFAP. The proposed ECFAP method improves both the polishing efficiency and the surface quality. Finally, ECFAP-treated specimens with an optimum voltage of 3 V for 10 min exhibited an average surface roughness of 0.0953 µm.

Weld defects such as porosity, inclusion, burn-through, and lack of penetration are difficult to detect and control effectively in an orthotropic steel deck (OSD), which will be a fatigue crack initiation site and lead to several fatigue cracking. The crack growth behavior in defective welded joints is different from that of defect-free joints. This study investigates crack–inclusion interaction for rib-to-deck welded joints in OSDs based on numerical simulation and linear elastic fracture mechanics (LEFM). A refined finite element model of a half U-rib with cracks and inclusions was established by using the FRANC3D-ABAQUS interactive technology. The full processes of the crack–inclusion interaction from approaching and penetrating were accurately simulated. Critical parameters, including the stress intensity factor (SIF), the shape factor, the growth rate, and the growth direction were analyzed. The stiff and soft inclusions amplify and shield the SIF of cracks when the crack grows to the local area of inclusions. During the entire process of crack growth, the soft and stiff inclusion accelerate and inhibit the crack growth, respectively. The stiff inclusion will lead to asymmetric growth of the crack shape, where the portion of the crack away from the inclusions has a higher growth rate. The soft and stiff inclusions will attract and repel the direction of crack growth at the proximal point, respectively.

It is not completely understood fatigue strength at this time due to its complex formation mechanism. Therefore, in order to address this issue, machine learning has been used to examine the important factors involved in predicting fatigue strength. In this study, a hybrid model was proposed based on the modified bagging method by combining XGBoost and LightGBM, in which the hyperparameters of the models were optimized by a grey wolf algorithm. Moreover, an interpretable method, referred to as Shapley additive explanations (SHAP), was introduced to explain the fatigue strength predictions made by ML models. The SHAP values were calculated, and feature importance of fatigue strength by XGBoost, LightGBM and the hybrid model was discussed. The final results demonstrated that the SHAP method had major potential for interpreting fatigue strength predictions, which would provide constructive guidance for the development of antifatigue steel material in the future.