Refill friction stir spot welding (RFSSW): a review of processing, similar/dissimilar materials joining, mechanical properties and fracture mechanism

Refill friction stir spot welding(RFSSW)provides a novel method to join similar and/or dissimilar metallic materials without a key-hole in the center of the joint.Having the key-hole free characterization,the similar/dissimilar RFSSW joint exhibits remarkable and endurable characteristics,including high shear strength,long fatigue life,and strong corrosion resistance.In the meanwhile,as the key-hole free joint has different microstructures compared with conventional friction stir spot welding,thus the RFSSW joint shall possess different shear and fatigue fracture mechanisms,which needs further investigation.To explore the underlying failure mechanism,the similar/dissimilar metallic material joining parameters and pre-treatment,mechanical properties,as well as fracture mechanisms under this novel technology will be discussed.In details,the welding tool design,welding parameters setting,and the influence of processing on the lap shear and fatigue properties,as well as the corrosion resistance will be mainly discussed.Moreover,the roadmap of RFFSW is also discussed.

Experimental study on similarity materials for soft rock of deep-buried tunnels

When every parameter is properly scaled down in accordance with some similarity coefficients, it is possible to study the physical-mechanical properties of rock mass with a scale model. To identify the key mechanisms of soft rock in deep buried tunnels, the proper sand, binder and ratio were selected. During the process, the model manufacture technology was introduced and typical tests were done and the results were presented. The physical and meehanieal properties effects caused by each composition were discussed. It is shown that the physical and mechanical properties of chosen ratio material such as uniaxial compressive strength tests, elasticity modulus, tensile strength, internal frictional angle, and Poisson＇s ratio meet with similarity relationship well. The physical and mechanical properties of deep soft rock are simulated successfully.

Similarity criteria and coal-like material in coal and gas outburst physical simulation

Coal and gas outburst is one of the main gas hazards in coal mines. However, due to the risks of the coal and gas outburst, the field test is difficult to complete. Therefore, an effective approach to studying the mechanism and development of outburst is to conduct the similar physical simulation. However, the similarity criteria and similar materials in outburst are the key factors which restrict the development of physical simulation. To solve those problems, this paper has established similarity criteria base on mechanics model, solid-fluid coupling model and energy model, and presented high similar materials. Combining with three groups of similar number, and considering similar mechanical parameters and deformation and failure regularity, the similarity criteria of outburst is determined on the basis of the energy model. According to those criteria, we put forward a similar material consists of pulverized coal, cement, sand, activated carbon, and water. The similar material has high compressive strength and the accordant characteristics with the raw coal, include density, porosity, adsorption, desorption. The new research is promising for preventing and controlling gas hazards in the future.

Experimental research on coal seam similar material proportion and its application

In this paper, the optimization design of the low strength mechanical test and orthogonal test have been analyzed in order to simulate the mechanical properties of thick and extra-thick coal seam accurately in a similar material simulation test. The results show that the specimen can reach a wider range of strength when cement has been used compared to that of gypsum, suggesting that cement is more suitable for making coal seam in similar material simulation tests. The uniaxial compressive strength is more sensitive to cement than coal or sand. The proportion of coal and sand do not play a decisive role in uniaxial compressive strength. The uniaxial compressive strength and specimen density decrease as the mass percent of coal and aggregate–binder ratio rise. There is a positive correlation between uniaxial compressive strength and density. The No. 5 proportion(cement: sand: water: activated carbon: coal = 6:6:7:1.1:79.9)was chosen to be used in the similar material simulation test of steeply dipping and extra-thick coal seam with a density of 0.913 g/cm^3 and an uniaxial compressive strength of 0.076 MPa which are in accordance with the similarity theory. The phenomenon of overburden stratum movement, fracture development and floor pressure relief were obtained during the similar material simulation test by using the proportion.

Similar material simulation of time series system for induced caving of roof in continuous mining under backfill

With the help of similar material simulation test,time series system for induced caving of roof in continuous mining under complex backfill in ore body No.92 of Tongkeng Tin Mine was studied. According to the similarity theory,a two-dimensional similar simulation test-bed was constructed. The stress and displacement that change along with the advance of mining were acquired and analyzed automatically by data system. The processes of continuous mining of ore-block in 5 intervals and artificial induced caving of roof were simulated. The results of the test show that ore body remained as safety roof in thickness of 15 m guarantees the safe advance of stoping work face. Caving of safety roof puts in practice at the first two mining intervals when the third interval of continuous mining is finished,and one interval as the safety distance should be kept all the time between stopping and caving. While mining in the last interval,pre-slotting should be implemented first of all,and the roof of the last two mining intervals is caved simultaneously. Only this kind of time series system can be an efficient and safe way for induced caving of roof in continuous mining.

Study on relation between tectonic stress and coal-mining subsidence with similar material simulation

Using a minitype and stress-type test device for similar material simulation of coal-mining subsidence, the relation between tectonic stress and coal-mining subsidence was successfully simulated, furthermore, the test period of similar material simulation was obviously shortened and the test process was more dexterous and convenient. To do simi-lar material simulation with the minitype and stress-type test device was feasible and high-efficient. Bringing two models with the same geological and mining conditions to bear lateral compressive stress and tensile stress respectively and simulating the process of underground mining, the test results indicate that: under the compressive stress, the col-lapse of the coal roof occurs belatedly and the damaged range in cover of coal seam is smaller, therefore the movement and deformation of the cover and its damage to the ground geological environment are not evident; whereas under tensile stress, the situation is contrary to which mentioned above. A conclusion was obtained from the test that the ground environment hazards in coal mining areas were controlled by the regional geo-logical tectonic stress field.

Engineering practice of reducing ground subsidence by grouting into overburden bed-separated and similar model experiment

The subsidence prediction theory under the condition of grouting into bedseparated was developed. Reducing ground subsidence by grouting was carried out on eight fully-mechanized top-coal caving faces, by using the continuous grouting in multiple-layer to obtain experiment results of reducing subsidence under fully mining. The similar material model that can be dismantled under the condition of constant temperature and constant humidity was developed. The model was used to simulate the evolution of overburden bed-separated under such constraints of temperature and humidity, at the same time, and to test the hardening process of similar materials.

Experimental study on the movement law of overlying rock non-pillar coal overhead mining

Pillarless coal mining technology is a new practical technology.Based on the compensating mechanical behavior of the Negative Poisson’s Ratio(NPR)anchor cable on the roof,the roadway was successfully retained by the top cutting and pressure relief technology.This study utilizes the Digital Speckle Monitoring(DIC monitoring),stress-strain monitoring,and infrared thermal imaging systems to conduct physical model experiment of similar materials from the displacement,stress-strain,and temperature fields to investigate in depth the fracture change law of the overlying rock.In addition,it uses FLAC3D numerical simulation to invert the surface displacement settlement.The results show that the non-pillar overhead mining under the 110 mining method has little influence on the rock crack in the middle of the coal seam,and the crack development area is mainly concentrated in the overlying rock mass of the upward coal seam.The compensatory mechanical behavior of NPR anchor cable and the dilatation characteristics of rock mass have a good effect of retaining roadway along goaf,and can also reduce surface settlement.The 110 mining method provides a scientific basis for ecological environment protection and the development of other kilometer deep soft rock high ground stress underground projects.

A Physical Simulation Test for the RockBurst in Tunnels

According to the test results of the physical and mechanical properties of similar materials in various quality mixture, a type of material with obvious tendency of rockburst was selected to produce a large-size model to simulate rockburst phenomena in tunnels. The prototype model comes from a typical section of diversion tunnels in Jinping Hydropower Station in China. The simulation of excavating tunnels is carried out by opening a hole in the model after loading. The modeling results indicated that under the condition of normal stresses in the model boundaries the arch top, spandrel and side walls of the tunnel produced an obvious jump reaction of stress and strain and the acoustic emission counts of the surrounding rock also increased rapidly in a different time period after the "tunnel" excavation, showing the clear features of rockburst. The spalling, buckling and breaking occurred in the surrounding rock of model in conditions of over loading. It is concluded that the modeling tunnel segment in Jinping Hydropower Station is expected to form the tensile rockburst with the pattern of spalling, buckling and breaking.

Modeling rock specimens through 3D printing: Tentative experiments and prospects

Current developments in 3D printing （3DP） technology provide the opportunity to produce rock-like specimens and geotechnical models through additive man- ufacturing, that is, from a file viewed with a computer to a real object. This study investigated the serviceability of 3DP products as substitutes for rock specimens and rock-type materials in experimental analysis of deformation and failure in the laboratory. These experiments were performed on two types of materials as follows： （1） compressive experiments on printed sand-powder specimens in different shapes and structures, including intact cylinders, cylinders with small holes, and cuboids with pre-existing cracks, and （2） com- pressive and shearing experiments on printed polylactic acid cylinders and molded shearing blocks. These tentative tests for 3DP technology have exposed its advantages in produc- ing complicated specimens with special external forms and internal structures, the mechanical similarity of its product to rock-type material in terms of deformation and failure, and its precision in mapping shapes from the original body to the trial sample （such as a natural rock joint）. These experiments and analyses also successfully demonstrate the potential and prospects of 3DP technology to assist in the deformation and failure analysis of rock-type materials, as well as in the sim- ulation of similar material modeling experiments.

Bolt-grouting combined support technology in deep soft rock roadway

Analyzing the mineral composition, mechanical properties and ground stress testing in surrounding rock,the study investigated the failure mechanism of deep soft rock roadway with high stress. The boltgrouting combined support system was proposed to prevent such failures. By means of FLAC3D numerical simulation and similar material simulation, the feasibility of the support design and the effectiveness of support parameters were discussed. According to the monitoring the surface and deep displacement in surrounding rock as well as bolt axial load, this paper analyzed the deformation of surrounding rock and the stress condition of the support structure. The monitor results were used to optimize the proposed support scheme. The results of field monitors demonstrate that the bolt-grouting combined support technology could improve the surround rock strength and bearing capacity of support structure, which controlled the great deformation failure and rheological property effectively in deep soft rock roadway with high stress. As a result, the long term stability and safety are guaranteed.

Physical simulation of rock burst induced by stress waves

The behavior of stress wave propagation in rock walls and the process of rock bursts were simulated by application tests of material similar to rock. Results show that 1) the attenuation characteristics of stress waves were related to the material proper-ties, stress waves attenuate more quickly in soft material and 2) when the explosion load was applied at the top of the roadway, the number and the length of the cracks increased with a decrease in the distance between the explosive point and roof of the roadway. When the distance was 280 mm, only some chips appeared near the source, when the distance was 210 mm, some small cracks started to appear near the road-rib and when the distance was reduced to 140 mm, larger cracks appeared at the road-rib. It can be concluded that, under a given stress the number of cracks is closely related to the intensity of stress waves. The cracks in the sur-rounding rock can be reduced by controlling the intensity of the stress waves and rock bursts can be avoided to some extent by pre-venting the formation of layered crack structures. A new experimental approach has been provided for studying rock bursts by using physical simulation.