Impact Analysis of Microscopic Defect Types on the Macroscopic Crack Propagation in Sintered Silver Nanoparticles

Sintered silver nanoparticles(AgNPs)arewidely used in high-power electronics due to their exceptional properties.However,the material reliability is significantly affected by various microscopic defects.In this work,the three primary micro-defect types at potential stress concentrations in sintered AgNPs are identified,categorized,and quantified.Molecular dynamics(MD)simulations are employed to observe the failure evolution of different microscopic defects.The dominant mechanisms responsible for this evolution are dislocation nucleation and dislocation motion.At the same time,this paper clarifies the quantitative relationship between the tensile strain amount and the failure mechanism transitions of the three defect types by defining key strain points.The impact of defect types on the failure process is also discussed.Furthermore,traction-separation curves extracted from microscopic defect evolutions serve as a bridge to connect the macro-scale model.The validity of the crack propagation model is confirmed through tensile tests.Finally,we thoroughly analyze how micro-defect types influence macro-crack propagation and attempt to find supporting evidence from the MD model.Our findings provide a multi-perspective reference for the reliability analysis of sintered AgNPs.

Damage and failure characteristics of rock similar materials with pre-existing cracks

In order to further study the damage and failure mechanism for rock similar materials,this study investigated the mechanical properties and failure characteristics,law of damage space development,and damage evolution characteristics for rock similar materials with pre-existing cracks of varying length under uniaxial compression load.The equipment used in this study is the self-developed YYW-Ⅱ strain controlled unconfined compression apparatus and the PCIE-8 acoustic emission monitoring system.Results show that,as the length of pre-existing crack increases:(1) the peak and residual strength reduces,and the peak axial strain and the strain during the initial compression phase increases;(2) the major failure mode is changed from shear failure to tensile failure along a vertical plane that passes the middle of the pre-existing crack;(3) The damage increases during the stable and accelerated development stage,and the effect of the pre-existing cracks is more during the accelerated development stage than the stable development stage.

A method to model the effect of pre-existing cracks on P-wave velocity in rocks

Crack closure is one of the reasons inducing changes of P-wave velocity of rocks under compression.In this context,a method is proposed to investigate the relationships among P-wave velocity,pre-existing cracks,and confining pressure based on the discrete element method(DEM).Pre-existing open cracks inside the rocks are generated by the initial gap of the flat-joint model.The validity of the method is evaluated by comparing the P-wave velocity tested on a sandstone specimen with numerical result.As the crack size is determined by the diameter of particles,the effects of three factors,i.e.number,aspect ratio,and orientation of cracks on the P-wave velocity are discussed.The results show that P-wave velocity is controlled by the(i.e.number) of open micro-cracks,while the closure pressure is determined by the aspect ratio of crack.The reason accounting for the anisotropy of P-wave velocity is the difference in crack number in measurement paths.Both of the number and aspect ratio of cracks can affect the responses of P-wave velocity to the applied confining pressure.Under confining pressure,the number of open cracks inside rocks will dominate the lowest P-wave velocity,and the P-wave velocity of the rock containing narrower cracks is more sensitive to the confining pressure.In this sense,crack density is difficult to be back-calculated merely by P-wave velocity.The proposed method offers a means to analyze the effect of pre-existing cracks on P-wave velocity.

Effects of pre-existing cracks and infillings on strength of natural rocks--Cases of sandstone, argillite and basalt

This study aims to examine the influence of pre-existing discontinuities on the strengths of four natural rocks of different origins.A series of unconfined compression tests was performed on specimens of two types of sandstones,argillite and basalt that contain open and filled cracks.It was found that the presence of cracks tends to decrease the overall strength for all studied rocks;however,the magnitude of strength reduction is related to the property of rock.The larger strength decrease was observed for the relatively harder argillite and basalt,compared to the softer sandstone.It was also found that the infill material could increase the strength of rock specimens,while the obtained strength depended on the characteristics of the fill material.

Simulation on dynamic characteristics of TC4 cutting with crack defects

Titanium alloys play an important role in aerospace and other fields.However,after precision forging and cold rolling process,some defects will appear on the subsurface of titanium alloy bars,thus reducing the surface quality and precision of turning process.This study aimed at exploring the effect of crack defects on TC4 cutting.Firstly,the finite element cutting simulation model of TC4 material with crack defects was established in ABAQUS.Then,the cutting parameters such as cutting force,stress concentration,chip morphology,residual stress were obtained by changing the variables such as the size and height of crack defects.Finally,the turning experiment was carried out on centerless lathe.The results show that the cutting force changes abruptly when the defect position is located on the cutting path,the maximal stress occurs at the tip of the defect,and the mutation of stress value is more serious with the increase of defect size;the buckling deformation of chip morphology occurs and becomes less serious with the increase of the distance between the defect position and the workpiece surface;the surface residual stress near the defect is related to the stress when the tool is close to the defect,the larger defect size and the closer to the machined surface,the greater the residual stress.Therefore,under certain processing conditions,the TC4 material should avoid large size defects or increase the distance between defects and the machined surface,so as to obtain better and stable surface quality.

Molecular dynamics study on mechanical behaviors of Ti/Ni nanolaminate with a pre-existing void

Metallic nanolaminated materials possess excellent mechanical properties due to their unique modulation structures and interfacial properties.However,how microdefects affect their mechanical properties is still uncertain.To evaluate the influences of void location(in the crystalline layer and the Ti/Ni interface),void diameter(d)and thickness of the intermediate layer(h)on overall tensile behaviors,various types of defective Ti/Ni nanolaminates with pre-existing void are established by the molecular dynamics method in this work.The results indicate that the strength and plastic deformation mechanisms are strongly dependent on those determinants.Yield stresses of Ti/Ni nanolaminates decrease distinctly with increasing void diameter,while peak stresses with a void in the crystalline layer decrease with increasing d/h.Different void locations lead eventually to disparate initial plastic deformation carriers around the void,and various evolutions in the microstructure of the defective Ti/Ni nanolaminates.The Ti/Ni interface plays a significant role in the tensile process.The semi-coherent interface impedes new grains and lattice dislocations from passing across the interface,while the incoherent interface facilitates dislocations generating and sliding along the interface,and absorbs the dislocations moving to the interface.The results also indicate that the strain rate significantly affects the evolution of the microstructure and the tensile properties of defective Ti/Ni nanolaminates.

A Rapid Crack Detection Technique Based on Attention for Intelligent M&O of Cross-Sea Bridge

Rapid and accurate segmentation of structural cracks is essential for ensuring the quality and safety of engineering projects.In practice,however,this task faces the challenge of finding a balance between detection accuracy and efficiency.To alleviate this problem,a lightweight and efficient real-time crack segmentation framework was developed.Specifically,in the network model system based on an encoding-decoding structure,the encoding network is equipped with packet convolution and attention mechanisms to capture features of different visual scales in layers,and in the decoding process,we also introduce a fusion module based on spatial attention to effectively aggregate these hierarchical features.Codecs are connected by pyramid pooling model(PPM)filtering.The results show that the crack segmentation accuracy and real-time operation capability larger than 76%and 15 fps,respectively,are validated by three publicly available datasets.These wide-ranging results highlight the potential of the model for the intelligent O&M for cross-sea bridge.

Elimination of cracks in stainless steel casings via 3D printed sand molds with an internal topology structure

The important supporting component in a gas turbine is the casing,which has the characteristics of large size,complex structure,and thin wall.In the context of existing 3DP sand casting processes,casting crack defects are prone to occur.This leads to an increase in the scrap rate of casings,causing significant resource wastage.Additionally,the presence of cracks poses a significant safety hazard after the casings are put into service.The generation of different types of crack defects in stainless steel casings is closely related to casting stress and the high-temperature concession of the sand mold.Therefore,the types and causes of cracks in stainless steel casing products,based on their structural characteristics,were systematically analyzed.Various sand molds with different internal topology designs were printed using the 3DP technology to investigate the impact of sand mold structures on high-temperature concession.The optimal sand mold structure was used to cast casings,and the crack suppression effect was verified by analyzing its eddy current testing results.The experimental results indicate that the skeleton structure has an excellent effect on suppressing cracks in the casing.This research holds important theoretical and engineering significance in improving the quality of casing castings and reducing production costs.

Studies on the effect of weld defect on the fatigue behavior of welded structures

Structural integrity isstated as the science and technology of margin between safety and disaster. Systematic prediction of structural integrity of critical structures such ascombustion chambers,pressure vessels,nuclear reactor components,boilers etc.,ensures the human safety,environmental protection,and the economical considerations.The present work aims at prediction of fatigue behaviour of symmetric structures like pressure vessels in the presence of common welding defects such as lack of fusion( LOF),lack of penetration( LOP) and porosity.A ring type specimen which replicates the stress pattern in thepressure vessel is considered for the study of severity of weld imperfections. Initial dimensions of weld defects are arrived by performing NDT inspection.Crack growth analysis is carried out to determine the remaining life of the welded joint with defects.

Analysis of the cause of crack in cold rolling of QSn6.5-0.1 strip

In order to know the cause of cracks in cold rolling of QSn6.5 0.1 copper alloy strip, a lot of experiments and analysis were done. The microstructure changes of QSn6.5 0.1 were investigated by means of metallurgical microscope. The morphology of cracks and surface defects were examined using scanning electron microscope. Macroscopic residual stresses produced in every process during manufacturing in the QSn6.5 0.1 strip were measured by X ray diffraction method and hole drilling method. The results show that the cracks in the QSn6.5 0.1 cold rolling strip were caused due to the derivation of metallurgical defects, such as SnO 2, S, fine looses,the inverse segregation unable to clear up when milling, and the accumulation of all kinds of resi dual stresses. When the accumulation of the residual stress reaches the material′s breaking strength, the cracks will be generated. Several measures to avoid the development of these kinds of cracks were put forward, such as: controlling the casting technology, improving homogenization annealing procedure (680 ℃/7 h) and milling quality(using the second milling when necessary), working out a more reasonable rolling technology to ensure intermediate annealing in time.

Formation and control of the surface defect in hypo-peritectic steel during continuous casting:A review

Hypo-peritectic steels are widely used in various industrial fields because of their high strength,high toughness,high processability,high weldability,and low material cost.However,surface defects are liable to occur during continuous casting,which includes depression,longitudinal cracks,deep oscillation marks,and severe level fluctuation with slag entrapment.The high-efficiency production of hypo-peritectic steels by continuous casting is still a great challenge due to the limited understanding of the mechanism of peritectic solidification.This work reviews the definition and classification of hypo-peritectic steels and introduces the formation tendency of common surface defects related to peritectic solidification.New achievements in the mechanism of peritectic reaction and transformation have been listed.Finally,countermeasures to avoiding surface defects of hypo-peritectic steels duiring continuous casting are summarized.Enlightening certain points in the continuous casting of hypo-peritectic steels and the development of new techniques to overcome the present problems will be a great aid to researchers.

An Improved Coupled Dynamic Modelling for Exploring Gearbox Vibrations Considering Local Defects

Gearbox is a key part in machinery,in which gear,shaft and bearing operate together to transmit motion and power.The wide usage and high failure rate of gearbox make it attract much attention on its health monitoring and fault diagnosis.Dynamic modelling can study the mechanism under different faults and provide theoretical foundation for fault detection.However,current commonly used gear dynamic model usually neglects the influence of bearing and shaft,resulting in incomplete understanding of gearbox fault diagnosis especially under the effect of local defects on gear and shaft.To address this problem,an improved gear-shaft-bearing-housing dynamic model is proposed to reveal the vibration mechanism and responses considering shaft whirling and gear local defects.Firstly,an eighteen degree-of-freedom gearbox dynamic model is proposed,taking into account the interaction among gear,bearing and shaft.Secondly,the dynamic model is iteratively solved.Then,vibration responses are expounded and analysed considering gear spalling and shaft crack.Numerical results show that the gear mesh frequency and its harmonics have higher amplitude through the spectrum.Vibration RMS and the shaft rotating frequency increase with the spalling size and shaft crack angle in general.An experiment is designed to verify the rationality of the proposed gearbox model.Lastly,comprehensive analysis under different spalling size and shaft crack angle are analysed.Results show that when spalling size and crack angle are larger,RMS and the amplitude of shaft rotating frequency will not increase linearly.The dynamic model can accurately simulate the vibration of gear transmission system,which is helpful for gearbox fault diagnosis.

The influence of defects on the effective Young's modulus of a defective solid

It is difficult to establish structure-property relationships in a defective solid because of its inhomogeneous-geometry microstructure caused by defects. In the present research, the effects of pores and cracks on the Young’s modulus of a defective solid are studied. Based on the law of the conservation of energy, mathematical formulations are proposed to indicate how the shape, size, and distribution of defects affect the effective Young’s modulus. In this approach, detailed equations are illustrated to represent the shape and size of defects on the effective Young’s modulus. Different from the results obtained from the traditional empirical analyses, mixture law or statistical method, for the first time, our results from the finite element method （FEM） and strict analytical calculation show that the influence of pore radius and crack length on the effective Young’s modulus can be quantified. It is found that the longest crack in a typical microstructure of ceramic coating dominates the contribution of the effective Young’s modulus in the vertical direction of the crack.

Analytical solution for the stress field of hierarchical defects:multiscale framework and applications

Hierarchical defects are defined as adjacent defects at different length scales.Involved are the two scales where the stress field distribution is interrelated.Based on the complex variable method and conformal mapping,a multiscale framework for solving the problems of hierarchical defects is formulated.The separated representations of mapping function,the governing equations of potentials,and the stress field are subsequently obtained.The proposed multiscale framework can be used to solve a variety of simplified engineering problems.The case in point is the analytical solution of a macroscopic elliptic hole with a microscopic circular edge defect.The results indicate that the microscopic defect aggregates the stress concentration on the macroscopic defect and likely leads to global propagation and rupture.Multiple micro-defects have interactive effects on the distribution of the stress field.The level of stress concentration may be reduced by the coalescence of micro-defects.This work provides a unified method to analytically investigate the influence of edge micro-defects within the scope of multiscale hierarchy.The formulated multiscale approach can also be potentially applied to materials with hierarchical defects,such as additive manufacturing and bio-inspired materials.

Crack Detection in Pipes with Different Bend Angles Based on Ultrasonic Guided Wave

Pipeline plays an indispensable role in process industries,because the progressing crack-like defects of in it may result in serious accidents and significant economic losses.Therefore,it is essential to detect the cracks occurred in pipelines.The axial crack-like defects in elbows with different angle are inspected by using the T(0,1)mode guided waves,in which different configurations including 45°,90°,135°and 180°(straight pipe)are considered respectively.Firstly,the detection sensitivity for different defect location is experimentally investigated.After that,finite element simulation is used to explore the propagation behaviors of T(0,1)mode in different bend structures.Simulation and experiment results show that the crack in different areas of the elbow can affect the detection sensitivity.It can be found that the detection sensitivity of crack in the middle area of the elbow is higher compared to the extrados and intrados of the elbow.Finally,the mode conversion is also investigated when the T(0,1)crosses the bend,and the results show that bend is a key factor to the mode conversion phenomenon which presents between the T(0,1)mode and F(1,2)mode.

Experimental Study of Longitudinal and Circumferential External Defect in Pressured Cylindrical Shells

Two cylindrical vessels under internal pressure are used for this work in order to study the influence of the position and size of defects on their elastic and elastoplastic behavior. One contains two external longitudinal semi-elliptic defects of different dimensions realized diametrically opposed. The other contains the same defects but is circumferential. These defects are carried out by elect-erosion. Strain gauges are placed in the neighborhood of the defects of which the purpose is to obtain the strain distribution. This work also allows the comparison between two defects of different dimensions, which are of the same shape or different shapes. These defects are longitudinal and circumferential semi-elliptical. The position of these defects relative to the inner radius of a cylindrical pressure vessel is considered. The deformations results are discussed.

Development of Technology and Equipment for Non-destructive Testing of Defects in Sewing Mandrels of a Three-roll Screw Mill 30-80

The conditions of heating and cooling of piercing mandrels made of 4X5MFS steel of a three-roll screw mill 30-80 in the production of a closed cavity of steel vessels of small volume are determined.It is established that multiple cycles of heating up to 600℃ and cooling with water up to 80℃ for about 7 seconds/1 cycle lead to the formation of ridges,shells and cracks on the surface and in the volume of the tool.The loss of structural strength of the material leads to the breakdown of the mandrel during the stitching process.The technique and equipment of magnetic powder control have been developed to establish the dynamics of the growth of internal and external defects of mandrels.An equation is obtained that allows determining the increase in the number of defects in the sewing tool of a screw rolling mill.The technology of non-destructive testing made it possible to develop a rational plan for replacing the sewing mandrels,which allows for predicting the appearance of defects leading to a complex breakdown of the deforming tool at the NPO Pribor machine-building enterprise.

某电机齿轮冷挤压裂纹形成机理研究

针对材料为20Cr的某电机齿轮在冷挤压成形时内齿齿顶面上出现的裂纹缺陷,基于DEFORM-3D对其冷挤压过程进行了模拟,研究了其裂纹形成机理。有限元结果表明,内齿的金属流动速度小于中部及下部外齿的流动速度,内齿齿顶面上齿根处的金属流动速度最小,此处流动最不均匀,易产生应力集中;对齿面的最大主应力及损伤分布进行了分析,得出在内齿齿顶面上,中部及距离下端面1 mm左右的位置应力集中最明显,拉应力较大且大于材料抗拉强度,损伤值也较大且大于临界损伤值,会产生裂纹,与实际情况相符合。通过改变凹模入模角来控制成形缺陷情况,当凹模入模角为23°时,齿根处拉应力下降,损伤值减小,投入生产后次品率从原本的50%降为1%。

裂缝小目标缺陷的轻量化检测方法

及时且准确捕获井壁出现的微小裂缝,对于井筒安全意义重大.轻量化检测模型是推动井壁裂缝自动检测的关键,打破现有方法聚焦于提取深层语义信息的局限,重视浅层特征表征的几何结构信息的应用,针对井壁裂缝提出轻量化检测模型E-YOLOv5s.首先融合普通卷积、深度可分离卷积和ECA注意力机制设计轻量化卷积模块ECAConv,再引入跳跃链接构建特征综合提取单元E-C3,得到骨干网络ECSP-Darknet53,它负责显著降低网络参数,同时增强对裂缝深层特征的提取能力.然后设计特征融合模块ECACSP,利用多组ECAConv和ECACSP模块组建细颈部特征融合模块E-Neck,旨在充分融合裂缝小目标的几何信息和表征裂缝开裂程度的语义信息,同时加快网络推理速度.实验表明,E-YOLOv5s在自制井壁数据集上的检测精度相较YOLOv5s提升了4.0%,同时模型参数量和GFLOPs分别降低了44.9%、43.7%.E-YOLOv5s有助于推动井壁裂缝自动检测的应用.

针对背照式图像传感器加工工艺中Crack缺陷的分析与优化

阐述背照式CMOS图像传感器,是将硅片减薄后,在光电二极管photodiode背面搭建Color filter及Micro Lens形成的。相比前照式CMOS图像传感器,光线由背面射入,增大了光电元件感光面积,减少了光线经过布线时的损失,可以大幅提高CIS在弱光环境下的感光能力。在整个工艺中流程,深沟槽隔离DTI作为关键工艺步骤,防止光电二极管信号串扰。DTI刻蚀的形貌至关重要,决定能否顺利填充。目前业界有采用U和V型隔离槽。基于V型隔离槽形貌情况,结合填充能力,探讨加工晶圆中心区域存在Crack缺陷的问题,针对此问题,基于刻蚀角度优化V型隔离槽顶部的Bowling,通过实验对Bowling产生的机理和通过优化刻蚀菜单的方法,减小Bowling值,Bowling越小越有利于后续的填充,最终实现无Crack缺陷的方法。最终产品晶圆的良率将得到有效提高。