PurposePipelines are subject to pits, holes and cracks after staying in service for a while, especially in harsh environments. To repair the pipelines, composite materials are used, due to composite materials' low cost, high-corrosion resistance and easy handling. This study aims to investigate the reliability of the blister test for evaluating the bonding strength of multiwall carbon nanotube (MWCNT) on woven carbon-reinforced epoxy.Design/methodology/approach Flexural, hardness and Izod impact tests were used to evaluate MWCNT effect on the epoxy by adding different amounts, 0.2, 0.4, 0.6, 0.8 and 1 wt. %, of MWCNT, to be compared with pure epoxy.FindingsThe results showed that 0.8 wt.% gives the highest strength. The experimental results of 0.8 wt.% MWCNT reinforced carbon composite was compared with the finite element model under blister test, and the results showed high similarities.Originality/valueEvaluation of the reliability and the advantages of MWCNT considering the high aspect ratio and high tensile strength, which is more than 15 times compared to steel, MWCNT enhances the strength, stiffness and toughness of epoxy used as a matrix in repairing pipelines, which leads to an increase in the resistance of composite materials against oil internal pressure before delamination.

PurposeThis article aims to investigate and model the effects of welding-generated thermal cycle on the resulting residual stress distribution and its role in the initiation and propagation of fatigue failure in thick shaft sections.Design/methodology/approachExperimental and numerical techniques were applied in the present study to explore the relationship(s) between welding residual-stress distribution and fatigue failure characteristics in a hydropower generator shaft. Experimental techniques included stereomicroscopy, optical and scanning electron microscopy (SEM), chemical analysis and mechanical testing. Finite element modelling (FEM) was used to model the shaft welding cycle in terms of thermal (temperature) history and the associated development of residual stresses within the weld joint.FindingsExperimental analyses have confirmed the suitability of the used material for the intended application and confirmed the failure mode to be low cycle fatigue. The observed failure characteristics, however, did not match with the applied loading in terms of design stress levels, directionality and expected crack imitation site(s). FEM results have revealed the presence of a sharp stress peak in excess of 630 MPa (about 74% of material's yield strength) around weld start point and a non-uniform residual stress distribution in both the circumferential and through-thickness directions. The present results have shown very close matching between FEM results and observed failure characteristics.Practical implicationsThe present article considers an actual industrial case of a hydropower generator shaft failure. Present results are valuable in providing insight information regarding such failures as well as some preventive design and fabrication measures for the hydropower and other power generation and transmission sector.Originality/valueThe presence of the aforementioned stress peak around welding start/end location and the non-uniform distribution of residual-stress field are in contrast to almost all published results based on some uniformity assumptions. The present FEM results were, however, the only stress distribution scenario capable of explaining the failure considered in the present research.

PurposeThis article focuses on the low-velocity impact (LVI) output of carbon nanotubes (CNTs)’ reinforcement circular plates, considering agglomeration size effect and clumping of CNTs’ inner side of the agglomerations.Design/methodology/approachA representative volume element (RVE) is used to determine the nanocomposite properties reinforced with agglomerated CNTs with random orientation. First-order shear deformation theory (FSDT) is used to obtain the motion equations of LVI analysis. These equations are handled by developing a Ritz method and Lagrangian mechanics. To extract the mass and stiffness matrices, terms with second and higher degrees are ignored.FindingsFormulation validation is performed by providing various examples, including comparisons with other research and ABAQUS FE code. The effects of agglomeration size, clumping of CNTs’ inner side of the agglomerations, CNT volume fraction and impact location on the responses of impact load, projectile displacement and plate deflection are analytically studied. These achievements illuminate how the influence of agglomeration size is very small on the impact response. Also, the influence of clumping of CNTs’ inner side of the agglomerations is significant, and as it increases, the displacement values and impact time increase, and the impact force decreases.Originality/valueIn this article, to avoid additional calculations, the parameters of the mass matrix and the stiffness coefficients are linearized to obtain the equations of motion of the impact on the circular plate.

PurposeThe conflicting results on the corrosion characteristics of aluminium matrix composites reinforced with agrarian waste have stimulated an investigation on the hardness and corrosion rate of sugar palm fibre ash (SPFA) reinforced LM26 Al/alloy composite by varying the SPFA from 0 to 10 wt% in an interval of 2 wt%. This paper aims to discuss the aforementioned issue.Design/methodology/approachThe composites were produced via stir-casting and the hardness was determined using a Vickers hardness testing machine, corrosion rate was examined through the weight loss method by immersion in 0.5, 1.0 and 1.5 M hydrochloric acid (HCl) at temperatures of 303, 318, and 333 K for the maximum duration of 120 h. The morphological study was conducted using a scanning electron microscope (SEM) on the samples before and after immersion in HCl.FindingsThe incorporation of SPFA improved the hardness of the alloy from 58.22 to 93.62 VH after 10 wt% addition. The corrosion rate increases with increased content of SPFA, the concentration of HCl and temperature. The least corrosion rate of 0.0272 mpy was observed for the LM26 Al alloy in 0.5 M after 24 h while the highest corrosion rate of 0.8511 mpy was recorded for LM26 Al/10 wt% SPFA in 1.5 M HCl acid after 120 h. The SEM image of corroded samples revealed an increased number of pits with increased SPFA content.Research limitations/implicationsThe work is limited to SPFA up to 10 wt% as reinforcement in LM26 Al alloy, the use of HCl as corrosion medium, temperatures in the range of 303–333 K, and a weight loss method were used to evaluate the corrosion rate.Originality/valueThe corrosion rate was determined for LM26 Al/SPFA composites with various amounts of SPFA in 0.5, 1.0 and 1.5 M HCl at 303, 318 and 333 K and compared with the matrix alloy.

PurposeRegeneratively cooled thrust chamber is a key component of reusable liquid rocket engines. Subjected to cyclic thermal-mechanical loadings, its failure can seriously affect the service life of engines. QCr0.8 copper alloy is widely used in thrust chamber walls due to its excellent thermal conductivity, and its mechanical and fatigue properties are essential for the evaluation of thrust chamber life. This paper contributes to the understanding of the damage mechanism and material selection of regeneratively cooled thrust chambers for reusable liquid rocket engines.Design/methodology/approachIn this paper, tensile and low-cycle fatigue (LCF) tests were conducted for QCr0.8 alloy, and a Chaboche combined hardening model was established to describe the elastic-plastic behavior of QCr0.8 at different temperatures and strain levels. In addition, an LCF life prediction model was established based on the Manson–Coffin formula. The reliability and accuracy of models were then verified by simulations in ABAQUS. Finally, the service life was evaluated for a regenerative cooling thrust chamber, under the condition of cyclic startup and shutdown.FindingsIn this paper, a Chaboche combined hardening model was established to describe the elastoplastic behavior of QCr0.8 alloy at different temperatures and strain levels through LCF experiments. The parameters of the fitted Chaboche model were simulated in ABAQUS, and the simulation results were compared with the experimental results. The results show that the model has high reliability and accuracy in characterizing the viscoplastic behavior of QCr0.8 alloy.Originality/value(1)The parameters of a Chaboche combined hardening constitutive model and LCF life equation were optimized by tensile and strain-controlled fatigue tests of QCr0.8 copper alloy. (2) Based on the Manson–Coffin formula, the reliability and accuracy of constitutive model were then verified by simulations in ABAQUS. (3)Thermal-mechanical analysis was carried out for regeneratively cooled thrust chamber wall of a reusable liquid rocket engine, and the service life considering LCF, creep and ratcheting damage was analyzed.

PurposeThe present findings report a significant influence of disc profile and thickness on the order of excitation leading to critical speed condition. Certain transverse modes of vibration of the disc have been obtained to be more susceptible to get excited while recording the lowest critical speeds.Design/methodology/approachNumerical simulation using finite-element method has been adopted due to the complicated geometry, complex loadings and intricate analytical formulation. A comprehensive analysis of exclusive as well as combination of thermal and centrifugal loads has been taken up to determine the intensity and characteristics of the individual/combined effects.FindingsThe typical gas turbine disc profile has been analyzed to predict the critical speed under the factual working condition of an aero-engine. FEM analysis of uniform and variable thickness discs have been carried out under stationary, rotating and rotating-thermal considerations while emphasizing the effect of disc profile and thickness. Centrifugal stresses developed due to rotational effect result in unceasing stiffening of the discs with higher stiffening for a greater number of nodal diameters. On the other hand, a role reversal of thermal effect from stiffening to softening is figured out with increasing numbers of nodal diameters. However, the discs are subjected to an overall stiffening effect on account of the combined centrifugal and thermal loading, with the effect decreasing with an increase in disc thickness. Under the combined loading, the order of excitation leading to critical speed condition is dependent on disc profile and thickness. Moreover, the vibrational modes (0,1) and (0,2) are identified as more prominent adverse modes corresponding to lowest critical speeds.Practical implicationsThe present findings are expected to serve as guidelines during the design phase of gas turbine discs of aeroengine applications.Originality/valueThe present work deliberates on the simulation and analysis of gas turbine disc specific to aeroengine application. The real-life disc geometry has been analyzed with due consideration of major factual operating conditions to identify the critical speed. The identification of various critical speed using numerical analysis can help to reduce the number of experimental tests required for certification.

PurposePredicting the critical velocity is crucial at the instability threshold for shell and tube heat exchangers in order to prevent tube failure due to vibrations. In this study, the vibration response of an aluminum tube bundle subjected to water cross flow was analyzed experimentally. Aluminum tubes are preferred over steel tubes because of aluminum tubes' excellent corrosion resistance, ease of manufacture, and high thermal efficiency.Design/methodology/approachThe fluid elastic instability and vortex shedding mechanisms in a finned tube array of aluminum tubes with a base tube diameter of 19.05 mm and pitch of 34 mm were investigated. The current study considers parallel triangular finned tube arrays with fin heights of 3 mm and 6 mm with a uniform fin thickness and fin pitch. The plain tube array was tested to compare the finned tube array results. The tube vibration response was measured using an accelerometer mounted on the middle tube of the third row. In order to define the fluid elastic instability behavior of various tube arrays, the critical velocity at the instability threshold is measured. By finding the Strouhal number at the small peaks before instability, the vortex shedding behavior of the tube arrays is examined.FindingsThe results reveal that the critical velocity at instability for coarse finned tube arrays increases as the fin height increases. The effect of the tube material is evaluated by comparing the results with those previously reported for parallel triangular tube arrays made of steel. Finally, the occurrence of vortex shedding in a tube array is confirmed based on the Reynolds number and Strouhal number relationship. The instability constant K for the plain tube array of steel and aluminum material are 4.97 and 4.87, respectively.Originality/valueThis paper provides the research findings on the effect of fin height on coarse density finned tube array. This will add substantial knowledge to the literature in the field of fluid elastic instability and vortex shedding, which is needed for the safe functioning of shell and tube heat exchangers.

PurposeIn order to promote the development of modern manufacturing towards high-precision, high-quality intelligence and precision, this paper puts forward the concept of physical manufacturing and conducts a more in-depth theoretical discussion on its basic connotation and characteristics, based on which the application of physical manufacturing in cutting and autoclave curing molding of composite material is briefly introduced.Design/methodology/approachAs a brand-new manufacturing concept, physical manufacturing determines the optimal process parameters according to multidisciplinary simulations, which emphasizes the physical characteristics about long life and high reliability of the processed products, and makes intelligent adjustment of process parameters according to the changes in the environment and equipment status during manufacturing.FindingsThe concept of physical manufacturing has pioneering significance for the basic research and development of advanced manufacturing technology, which helps to further improve production efficiency, reduce production costs and improve product quality.Originality/valueThe concept of physical manufacturing was first proposed, which emphasizes the analysis, reasoning, perception, and deduction during the manufacturing process, to achieve high-quality processing of products.

PurposeIn order to explore the damage probability of bridge engineering in the event of earthquake in the construction stages, the analysis method of seismic vulnerability in the construction stages is proposed in this paper.Design/methodology/approachBased on the joint simulation function of construction stage conditions and seismic response conditions of MIDAS/Civil finite element analysis software, combined with the method of IDA analysis and compared the relationship between demand and capacity.FindingsThe research shows that: (1) the average seismic loss in different construction stages varies greatly; (2) the seismic vulnerability varies greatly in different construction stages. The vulnerability of the bridge in stage 6 is determined by the longitudinal direction of bridge. Therefore, during the construction of the whole bridge, we should focus on strengthening the disaster and loss prevention strategy of earthquake insurance in the longitudinal direction of bridge. (3) The application of the secondary dead load mainly affects the fragilityin the longitudinal direction of bridge, but has little effect on the fragility in the transversal direction of bridge.Originality/valueThis paper is to explore the seismic vulnerability of a typical simply supported continuous bridge during the construction stages, and to trace the entire construction stage of a typical simply supported continuous bridge. According to the characteristics of the system transformation in the actual construction steps, demand-capacity ratios were established based on incremental dynamic analysis (IDA) and performance indicators of moment curvature and stability, and the seismic vulnerability research is carried out for the construction stages prone to earthquake damage. Furthermore, it provides a basis for seismic risk assessment of such bridges in different construction stages.

PurposeIn order to determine the range of medium temperature zone of road asphalt, it is hoped that the evolution of viscoelastic characteristics of road asphalt under medium temperature state can be deeply explored.Design/methodology/approachIn this paper, the needle penetration test and temperature scanning test were designed for 90# and 70# bitumen as test materials, and the boundary of medium temperature zone of 90# and 70# bitumen was accurately determined by data analysis method. A mathematical model was established based on principal component analysis, and a comprehensive evaluation index was proposed to evaluate the evolution of temperature viscoelastic characteristics of road asphalt by means of standardization and rotational dimensionality reduction.FindingsThe test results show that the medium temperature zone of 90# asphalt is [−5 ± 1°C, 38 ± 1°C], and the medium temperature zone of 70# asphalt is [0 ± 1°C, 51 ± 1°C]. According to the viscoelastic response of road asphalt in the medium temperature zone, the medium temperature zone can be divided into three evolution stages: weak viscoelastic stage, viscoelastic equilibrium stage, strong viscoelastic weak stage. Analysis based on the intrinsic viscosity fillip target describing the various intrinsic viscoelastic index represents the viscoelastic properties of bitumen from different angles, and limitations inherent stick fillip for target put forward the integrated the inherent stick fillip mark information, as well as targeted and accurate evaluation of road asphalt temperature comprehensive evaluation indexes in the evolution of the viscoelastic properties of IM-T. Finally, the temperature data of asphalt pavement in several representative regions of China are compared with the determined medium temperature region, and it is proved that the research on the evolution of viscoelastic characteristics of asphalt pavement under the medium temperature condition has important practical significance.Originality/valueThe boundary of medium temperature zone of 90# and 70# base asphalt was determined, and the viscoelastic characteristic evolution of road asphalt under medium temperature state was studied deeply. Aiming at the limitation of intrinsic viscoelastic index, a comprehensive evaluation index IM-T which not only integrates the information of intrinsic viscoelastic index but also can accurately evaluate the evolution of temperature viscoelastic characteristics in road asphalt is proposed.