Experimental Investigation of Stress Distributions in 3D Printed Graded Plates with a Circular Hole

An experimental investigation is presented for the stress distributions in functionally graded plates containing a circular hole. On the basis of the authors’ previously constructed theoretical model, two kinds of graded plates made of discrete rings with increasing or decreasing Young’s modulus were designed and fabricated in virtue of multi-material 3D printing. The printed graded plates had accurate size, smooth surface, and good interface. The strains of two graded plates under uniaxial tension were measured experimentally using strain gages. The stresses were calculated within the range of linear elastic from the measured strains and compared with analytical theory. It is found that the experimental results are consistent with the theoretical results, and both of them indicate that the stress concentration around the hole reduces obviously in graded plates with radially increasing Young’s modulus, in comparison with that of perforated homogenous plates. The successful experiment in the paper provides a good basis and support for the establishment of theoretical models and promotes the in-depth development of the research field of stress concentration in functionally graded plates.     

Experimental Study on Compression Failure of Composite Laminates with Prefabricated Surface Cracks

A new compression test fixture was designed in the present work to study the damage tolerance of composite laminates with surface cracks or notches. The compression failure behaviors of CCF300/5228A quasi-isotropic composite laminates with prefabricated surface cracks were studied experimentally. Through the size design of the test fixture and specimens and an application of a simple test method, the complex crack growth process was captured. The experimental results showed that the compression failure modes were mainly affected by crack angles and depths, and there were two typical failure modes, which were local intra- and inter-laminar damage propagating from the crack tips and delamination growth induced from the crack leading edge. This study verified the validity of the test fixture and test method, and revealed the compression failure mechanisms of composite laminates with surface cracks.     

Notch Effects on the Stress Intensity Factor and on the Fatigue Crack Path for Eccentric Circular Internal Cracks in Elliptically Notched Round Bars under Tensile Loading

In this paper, stress intensity factor (SIF) solutions are numerically obtained for notched bars subjected to tensile loading containing an eccentric circular inner crack located in the cross-section corresponding to the notch root. The finite element method and the J-integral have been used to obtain the SIF and to analyze the effect on it of three elliptical notch geometries (of equal radial depth). The results show how the SIF is greater in the notched bars than in the smooth bar and within the former when the axial semi-axis of the notch rises, its effect being greater as the diameter and eccentricity of the inner crack increase. In addition, the fatigue growth of an eccentric crack induces an increase in such eccentricity, greater as the notch axial semi-axis increases. The cause of these phenomena can be attributed to the constraint loss caused by the notch, which also facilitates bending of the specimen due to the asymmetry generated by the crack eccentricity.     

Experimental and Numerical Study of a Rebar-Prestressed Cylinder Concrete Pipe (RPCCP) under Internal Load

In order to study the load-bearing failure characteristics of a RPCCP under internal load, a field prototype test was designed, and a finite element model was established. An internal load was applied up to 2.0 MPa step by step and the force variation law of each part was obtained. During the production of the RPCCP, by wrapping prestressed steel bars around the concrete core with a cylinder, the core was subjected to an initial precompression stress. In the loading process, the protective cover cracked first, from where the concrete core gradually changed from the initial compression state to a tension state, finally cracking from the inner and outer diameter. The stresses of the cylinder and steel bars increased steadily with the internal load and did not yield. The finite element calculation results were in good agreement with the test results, and the influence characteristics of the tension control stress of the steel bar and the concrete strength on the failure of the RPCCP under internal load were discussed. The results showed that the internal load of the protective cover was independent of the tension control stress, but decreases with a decrease in concrete strength, while the load corresponding to the concrete core entering plasticity is related to the tension control stress and the concrete strength, and the relationships were basically linear.     

Study on Shear Creep Characteristics of the Discontinuities with Different 3D Morphologies

The rheological phenomenon of rock mass affects the long-term safety of rock mass engineering. In this study, gneiss samples with different 3D morphologies are prepared by splitting tests and are tested through multi-step creep tests. The long-term strength of rock discontinuities is determined by using several methods. The test results show that as the 3D morphological parameter increases, the creep deformation, creep rate, and the duration of failure all decrease. The long-term strength of rock discontinuities is linearly related to the 3D morphological parameter. Based on the principle of damage mechanics for rock mass, a damage variable is introduced in the creep model, and an improved non-linear Burgers model is established. Research results are of great theoretical significance and practical value for the design, construction, and long-term safety of rock mass engineering.     

Study on Mandrel Forging and Necking Process of a Hollow Shaft with an Inner Stepped Hole

An advanced process of mandrel forging and necking (MFN) was proposed for a hollow shaft with an inner stepped hole. The conventional mandrel forging process with an equal-diameter mandrel was used to form the outer stepped preform, and then the preform was formed into the hollow shaft with an inner stepped hole using the MFN process. A numerical simulation model was established to study the effect of the pressing reduction and the rotation angle on the MFN process. A preforming design method based on the isometric radius difference was given according to the principle of the equal volume, and the parameter relationships between the outer and inner stepped shapes were clarified. The experimental deformation laws of the MFN process were consistent with those obtained by the simulation. The MFN process and its preforming design method provide a new free forging approach for large hollow forgings with inner stepped holes.     

Quantitative Assessment of the Influence of Tensile Softening of Concrete in Beams under Bending by Numerical Simulations with XFEM and Cohesive Cracks

Results of the numerical simulations of the size effect phenomenon for concrete in comparison with experimental data are presented. In-plane geometrically similar notched and unnotched beams under three-point bending are analyzed. EXtended Finite Element Method (XFEM) with a cohesive softening law is used. Comprehensive parametric study with the respect to the tensile strength and the initial fracture energy is performed. Sensitivity of the results with respect to the material parameters and the specimen geometry is investigated. Three different softening laws are examined. First, a bilinear softening definition is utilized. Then, an exponential curve is taken. Finally, a rational Bezier curve is tested. An ambiguity in choosing material parameters and softening curve definitions is discussed. Numerical results are compared with experimental outcomes recently reported in the literature. Two error measures are defined and used to quantitatively assess calculated maximum forces (nominal strengths) in comparison with experimental values as a primary criterion. In addition, the force—displacement curves are also analyzed. It is shown that all softening curves produce results consistent with the experimental data. Moreover, with different softening laws assumed, different initial fracture energies should be taken to obtain proper results.     

Numerical Investigation of the Influence of Ultimate-Strength Heterogeneity on Crack Propagation and Fracture Toughness in Welded Joints

The mechanical properties of dissimilar metal-welded joint materials are heterogeneous, which is an obstacle to the safety evaluation of key welded structures. The variation of stress–strain conditions at the crack tip caused by mismatch of material mechanical properties in dissimilar metal-welded joints is an important factor affecting crack propagation behavior. To understand the influence of uneven distribution of ultimate strength of the base metal and the welded metal on the crack propagation path, fracture toughness, as well as the mechanical field at the crack tip in the small-scale yield range, the user-defined field variable subroutine method is used to express continuous variation characteristics of welded joint ultimate strength in finite element software. In addition, the J-integral during crack propagation is calculated, and the effect of the ultimate strength on the J-integral and the stress field at the crack tip are analyzed. The results show that as the crack propagation direction is perpendicular to the direction of ultimate strength, the gradient of ultimate strength increases from |G_y|= 50 to |G_y|= 100 MPa/mm, the crack deflection angle increases by 0.018%, and the crack length increases by 1.46%. The fracture toughness of the material decreased slightly during crack propagation. Under the condition that the crack propagation direction is the same as the direction of ultimate strength, the crack propagation path is a straight line. As the gradient of ultimate strength increases from G_x = 50 to G_x = 100 MPa/mm, the crack propagation length decreases by 5.17%, and the slope of fracture toughness curve increases by 51.63%. On the contrary, as the crack propagates to the low ultimate strength side, the crack propagation resistance decreases, the ultimate strength gradient increases from G_x = −100 to G_x = −50 MPa/mm, and the slope of the fracture toughness curve decreases by 51.01%. It is suggested to consider the relationship between crack growth behavior and ultimate strength when designing and evaluating the structural integrity of cracks at the material interface of dissimilar metal-welded joints.     

Evaluation of the 3D Printing Accuracy of a Dental Model According to Its Internal Structure and Cross-Arch Plate Design: An In Vitro Study

The amount of photopolymer material consumed during the three-dimensional (3D) printing of a dental model varies with the volume and internal structure of the modeling data. This study analyzed how the internal structure and the presence of a cross-arch plate influence the accuracy of a 3D printed dental model. The model was designed with a U-shaped arch and the palate removed (Group U) or a cross-arch plate attached to the palate area (Group P), and the internal structure was divided into five types. The trueness and precision were analyzed for accuracy comparisons of the 3D printed models. Two-way ANOVA of the trueness revealed that the accuracy was 135.2 ± 26.3 µm (mean ± SD) in Group U and 85.6 ± 13.1 µm in Group P. Regarding the internal structure, the accuracy was 143.1 ± 46.8 µm in the 1.5 mm-thick shell group, which improved to 111.1 ± 31.9 µm and 106.7 ± 26.3 µm in the roughly filled and fully filled models, respectively. The precision was 70.3 ± 19.1 µm in Group U and 65.0 ± 8.8 µm in Group P. The results of this study suggest that a cross-arch plate is necessary for the accurate production of a model using 3D printing regardless of its internal structure. In Group U, the error during the printing process was higher for the hollowed models.     

Experimental Study on Coupling Influence of Temperature and Confining Pressure to Deformation and Strength Characteristics of Rock-like Material with Pre-Existing Crack

In this paper, destructive compression tests under the coupled influence of temperatures (20–60 °C) and confining pressures (0–7 MPa) were carried out on rock-like material with pre-existing crack to explore the deformation and strength characteristics. The stress–strain curves of rock-like material under the coupled influence of temperatures and confining pressures were obtained. Meanwhile, the correlations of peak stress, peak strain, and average Young’s modulus with temperatures and confining pressures were obtained. The results of the experiments indicate that, firstly, the compressive strength decreased and the deformation increased due to the influence of pre-existing cracks; the combined effect of initial cracks, temperature, and confining pressure gave rise to a more complicated mechanism of soft rock deformation. Secondly, the deformation of rock-like material was affected by initial cracks, confining pressures, and temperatures, but the influence of temperature was lower than that of confining pressure and initial crack. The failure mode of rock-like material was brittle at the confining pressure of 0 and 1 MPa and plastic at the confining pressure of 5 and 7 MPa. The critical confining pressure value of failure mode for rock-like material was 3 MPa. Thirdly, the peak strength and peak strain of rock-like material increased with confining pressure. Temperature had less influence on the rock-like material strength and peak strain than confining pressure. Lastly, Young’s modulus decreased with temperature and confining pressure.     

Experimental and Numerical Study on the Penetration Performance of a Shaped Charge

In guided ammunition, because a shaped energy jet warhead is located behind the control cabin (including the guidance cabin, the steering gear cabin, and the flight control cabin), the penetration order of a shaped energy jet is the control cabin and the target plate. In order to obtain maximum penetration depth by a shaped energy jet into a Q235 steel plate, the penetration performance of shaped energy jets was studied by numerical simulation and experimental verification. Firstly, the penetration performance of a warhead under different conditions at a certain explosion height is studied, which is the penetration performance of a Q235 steel plate with and without the control cabin. Secondly, the numerical simulation results are verified by experimental method. The numerical simulation and experimental results showed that, after penetration of the shaped energy jet warhead into the control cabin, it continued to penetrate the 20 mm-thick Q235 steel plate. At a certain explosion height, the maximum penetration depth of the shaped energy jet warhead into the Q235 steel plate was about 80 mm. Alongside the numerical simulation and experiment, the armor-breaking process of the shaped charge jet was analyzed theoretically. The results show that when the shaped energy jet warhead is located behind the control cabin, although the control cabin will have a certain impact on the penetration ability of shaped energy jet, the penetration performance of the residual jet still has the ability to penetrate light armor.     

Numerical and Experimental Study on the Direct Chill Casting of Large-Scale AA2219 Billets via Annular Coupled Electromagnetic Field

The internal coupled electromagnetic melt treatment (ICEMT) method is firstly proposed to produce high-quality and large-sized aluminum alloy billets. A three-dimensional model was established to describe the ICEMT process of direct chill casting (DC casting). The effect of ICEMT on the fluid flow patterns and temperature field in the DC casting of ϕ880 mm AA2219 billets is numerically analyzed. Moreover, the mechanisms of the ICEMT process on grain refinement and macrosegregation were discussed. The calculated results indicate that the electromagnetic field appears to be coupled circinate at the cross section of the melt, the fluid flow becomes unstable accompanied by the bias flow, and the temperature profiles are significantly more uniform. An experimental verification was conducted and the results prove that compared with traditional direct chill casting, the microstructures of the AA2219 large-scale billet under the ICEMT process are uniform and fine.     

Comparing the Fracture Resistance and Modes of Failure in Different Types of CAD/CAM Zirconia Abutments with Internal Hexagonal Implants: An In Vitro Study

Three groups of zirconia abutments (n = 5) consisting of different connection designs or manufacturers were investigated (All-Zr, ASC-Zr, and AM-Zr groups). All-electric dynamic test instruments were used to place static loading on a specimen with a crosshead speed set at 1 mm/min. A Kruskal–Wallis test and a post hoc Mann–Whitney U test were used for statistical evaluation. The mean fracture resistance was 252.37 ± 82.79 N for the All-Zr group, 384.62 ± 45.24 N for ASC-Zr group, and 361.83 ± 90.31 N for the AM-Zr group. The difference of fracture resistance between the three groups was marginally significant (Kruskal–Wallis test, p = 0.054), with the ASC zirconia abutment tending to have higher fracture resistance than the full zirconia abutment. The modes of failure among the three types of abutments are different. The All-Zr group showed an oblique fracture line starting from the buccal aspect at the region of the implant platform. While the ASC-Zr and AM-Zr groups showed a relatively horizontal fracture line with a greater distance from the implant platform. The titanium inserts cannot significantly improve the fracture resistance of the zirconia abutment. However, they may alter the modes of failure, allowing buccal fracture surfaces of the zirconia abutments to be placed away from the implant platform, thereby protecting the implant–abutment connection.     

Experimental Study on Mechanical Properties and Failure Laws of Granite with Artificial Flaws under Coupled Static and Dynamic Loads

Rock is the main construction material of rock engineering, such as the engineering of mines and tunnels; in addition, its mechanical properties and failure laws are of great significance to the stability evaluation of rock engineering, especially under the conditions of coupled static–static stresses. In this study, granite specimens were manufactured with artificial flaws. Coupled static and dynamic loads tests were carried out with a modified split Hopkinson pressure bar (SHPB) apparatus; and six typical levels of axial pre-stresses and three crack inclination angles were designed. Three-dimensional digital image correlation (3D-DIC) was also applied to record and analyze the fracturing process and damage evolution of the specimens. The test results show that there was no compaction stage in the stress–strain curve under combined dynamic and static loading. The dynamic strength of the specimens increased first and then decreased with the increase in the static pressure; moreover, the specimens reached the maximum dynamic strength when the static pressure was 10% UCS. The dynamic strength decreased first and then increased with the increase in the crack inclination angle; and the lowest strength appeared when the inclination angle was 45°. The change in axial compression had a significant influence on the failure mode, and the failure mode gradually transformed from shear–tensile failure to shear failure with the increase in the pre-stress. The tensile strain was usually generated at the end of the fractures or near the rock bridge. When the axial pressure was small, the tensile strain zone parallel to the loading direction was easily generated; and when the axial pressure was large, a shear strain zone developed, extending along the diagonal direction. The research results can provide a theoretical reference for the correct understanding of the failure mechanisms of granite and its engineering stability under actual conditions.     

Experimental Study on the Manufacturing of Steel Inclined Walls by Directed Energy Deposition Based on Dimensional and 3D Surface Roughness Measurements

Robotic-directed energy deposition has attracted the attention of the research community and industry as a process capable of producing large metallic parts. The selection of the manufacturing conditions is a critical step in improving the process efficiency and quality of the produced parts. The present work aims at analyzing the geometry and surface topography of walls built using several conditions and inclination angles, without additional supports except for the substrate. The walls were made of AWS A5.18. ER70S-6 steel using the Wire Arc Additive Manufacturing process. The study used both dimensional and 3D topography measurements to analyze the results. As findings, the travel speed played an important role in the size of the cross-section due to the heat input to the welding zone. Heat accumulation was a critical factor in the size and accuracy of the beads. Moreover, intermediate cooling provided structures with more uniform dimensions, smaller width, and higher layer growth. The inclination of the pieces influenced the width and uniformity of the beads, generating minor imperfections on the downside of the pieces because of gravity.     

Experimental Study on the Cracking and Mechanical Properties of Lime Soil with Different Slaking Conditions of Newly Repaired Earthen City Walls

In this paper, a method to control the lime reaction by different slaking conditions is proposed to reduce the occurrence of cracks in newly repaired earthen city walls. The effects and mechanisms of the slaking time (0 h, 12 h, 24 h, 48 h and 72 h), lime content (10%, 15% and 20%), and moisture content (14%, 18% and 22%) on the cracking and mechanical properties of lime soil were analyzed by the test results of surface cracks, triaxial compression, particle gradation, pH value, X-ray diffraction and scanning electron microscope. The results show that proper slaking of lime soil specimens can reduce surface cracks and improve mechanical properties. After 12 h of appropriate slaking, the crack rate of the lime soil with 20% content decreased by 97.13%, the cohesion increased by 20.27%, and the internal friction angle decreased by 11.27%. However, the mechanical properties decreased when the slaking time was too long. After 72 h of slaking, the cohesion of 20% lime soil decreased by 8.21% and the internal friction angle increased by 2.82%. Further analysis shows that the appropriate slaking conditions can regulate the reaction rate and alkali environment, control the lime produced cementitious substances, improve the particle gradation and further reduce the occurrence of surface cracks. These results provide a basis for the restoration technology of newly repaired earthen city walls.     

Influence of Layer Thickness and Raster Angle on the Mechanical Properties of 3D-Printed PEEK and a Comparative Mechanical Study between PEEK and ABS

Fused deposition modeling (FDM) is a rapidly growing 3D printing technology. However, printing materials are restricted to acrylonitrile butadiene styrene (ABS) or poly (lactic acid) (PLA) in most Fused deposition modeling (FDM) equipment. Here, we report on a new high-performance printing material, polyether-ether-ketone (PEEK), which could surmount these shortcomings. This paper is devoted to studying the influence of layer thickness and raster angle on the mechanical properties of 3D-printed PEEK. Samples with three different layer thicknesses (200, 300 and 400 μm) and raster angles (0°, 30° and 45°) were built using a polyether-ether-ketone (PEEK) 3D printing system and their tensile, compressive and bending strengths were tested. The optimal mechanical properties of polyether-ether-ketone (PEEK) samples were found at a layer thickness of 300 μm and a raster angle of 0°. To evaluate the printing performance of polyether-ether-ketone (PEEK) samples, a comparison was made between the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) and acrylonitrile butadiene styrene (ABS) parts. The results suggest that the average tensile strengths of polyether-ether-ketone (PEEK) parts were 108% higher than those for acrylonitrile butadiene styrene (ABS), and compressive strengths were 114% and bending strengths were 115%. However, the modulus of elasticity for both materials was similar. These results indicate that the mechanical properties of 3D-printed polyether-ether-ketone (PEEK) are superior to 3D-printed ABS.     

Evaluation of the Behavior of Carbon Short Fiber Reinforced Concrete (CSFRC) Based on a Multi-Sensory Experimental Investigation and a Numerical Multiscale Approach

Carbon fiber reinforcement used in concrete has become a remarkable alternative to steel fibers. Admixing short fibers to fresh concrete and processing the material with a 3D printer leads to an orientation of fibers and a material with high uniaxial strength properties, which offers an economic use of fibers. To investigate its mechanical behavior, the material is subjected to flexural and tensional tests, combining several measuring techniques. Numerical analysis complements this research. Computed tomography is used with several post-processing algorithms for separating matrix and fibers. This helps to validate fiber alignment and serves as input data for numerical analysis with representative volume elements concatenating real fiber position and orientation with the three-dimensional stress tensor. Flexural and uniaxial tensional tests are performed combining multiple measuring techniques. Next to conventional displacement and strain measuring methods, sound emission analysis, in terms of quantitative event analysis and amplitude appraisal, and also high-resolution digital image correlation accompany the tests. Due to the electrical conductibility of carbon fibers, the material’s resistivity could be measured during testing. All sensors detect the material’s degradation behavior comparably, showing a strain-hardening effect, which results from multiple, yet locally restricted and distributed, microcracks arising in combination with plastic deformation.     

An Experimental and Numerical Study of the Influence of Temperature on Mode II Fracture of a T800/Epoxy Unidirectional Laminate

Studies on mode II fracture have promoted the establishment of the delamination theory for unidirectional composite laminates at room temperature. However, under thermal conditions, the fracture behavior of composite laminates will exhibit certain differences. The delamination theory should be extended to consider the temperature effect. To achieve this goal, in this study, the mode II static delamination growth behavior of an aerospace-grade T800/epoxy composite is investigated at 23 °C, 80 °C and 130 °C. The mode II fracture resistance curve (R-curve) is experimentally determined. A fractographic study on the fracture surface is performed using a scanning electron microscope (SEM), in order to reveal the failure mechanism. In addition, a numerical framework based on the cohesive zone model with a bilinear constitutive law is established for simulating the mode II delamination growth behavior at the thermal condition. The effects of the interfacial parameters on the simulations are investigated and a suitable value set for the interfacial parameters is determined. Good agreements between the experimental and numerical load–displacement responses illustrate the applicability of the numerical model. The research results provide helpful guidance for the design of composite laminates and an effective numerical method for the simulation of mode II delamination growth behavior.     

Experimental and Numerical Study on a Non-Explosive Reactive Armour with the Rubber Interlayer Applied against Kinetic-Energy Penetrators—The ‘Bulging Effect’ Analysis

The study concerns a protection system applied against kinetic-energy penetrators (KEPs) composed of steel plates sandwiching a rubber layer. Laminated steel-elastomer armours represent non-explosive reactive (NERA) armours that take advantage of a so-called ‘bulging effect’ to mitigate KEP projectiles. Upon an impact, the side steel plates deform together with the deforming rubber interlayer. Their sudden deformation (bulging) in opposite directions disturbs long and slender KEP projectiles, causing their fragmentation. The presented discussion is based on the experimental investigation, confirming that the long-rod projectiles tend to fracture into several pieces due to the armour perforation. A numerical simulation accompanies the ballistic test providing an insight into the threat/target interactions. The presented experimental–numerical study explains the principles of the analysed protection mechanism and proves the efficiency of the materials composition making up the laminated non-reactive protection system.