Abstract The effect of 200 days of cyclic weathering test (CWT) and 1,000 h of salt spray test (SST) on the performance of polyurethane (PU) coating was investigated. A 200 μm coating was applied to a composite and cured before CWT and SST ageing studies. CWT was conducted in ten cycles (each cycle: −40°C for 5 days, 70°C for 5 days, 40°C and 90% RH for 5 days, and salt fog for 5 days). Initial water immersion tests concluded that the coated specimens have 37% less water absorption than uncoated specimens. The degradation behaviour of the coating was evaluated by measuring pull-off adhesion strength, critical load from the scratch test, and wear depth from the pin-on-disk test. Similarly, the surface characteristics of the coating were studied by SEM, gloss value, and contact angle. CWT ageing caused a decrease in gloss value (93–78 GU), pigment content (18–8 wt%), contact angle (92–70°), and an increase in wear depth at 20 N of applied load (45–200 µm). Similarly ageing also decreased the pull-off adhesion strength to 6.77 MPa (CWT) and 7.93 MPa (SST). CWT and SST also decreased the thermal stability by 11–13°C, considering 5 wt% loss and tensile strength of the coating from 42 to 29 MPa. The damage to the composite substrate was not significant due to prolonged exposure periods under CWT and SST, though the damage was noted in PU coating, like increased surface roughness and wear depth.

Abstract In the present research, the nanosecond short-pulsed laser with rotary drilling method was designed to process carbon fiber-reinforced polymer (CFRP) composite plate. The hole dimension, surface morphology, heat-affected zone (HAZ), and mechanical properties were analyzed. The results reveal that the CFRP composite plate could be rapidly drilled with highly qualified processing surface by the nanosecond short-pulsed laser with rotary drilling method. The figures such as circle, square, triangle, and regular hexagon could be processed with minimum hole diameter of 0.1 mm. The changing of laser scanning speed and laser power could result in the variation in diameter of hole entrance and exit, which fluctuates in scope of 35 μm. The calculated biggest taper angle is about 0.43°, but the smallest taper angle is about 0.12°. The laser drilling on CFPR composite decreases the tensile strength by about 9%, which should be ascribed to the damage of continuous carbon fiber, but it is still acceptable. The nanosecond short-pulsed laser with rotary drilling method generates a small HAZ on hole entrance but almost no HAZ in hole exit. The surface roughness of laser processed CFRP ranges from 2.925 to 4.226 μm. Comparatively, the laser scanning speed between 800 and 1,000 mm/s and laser power around 28 W would be the optimal choice, which could realize the best balance between surface quality and efficiency.

Abstract The study aims to substitute river sand used in ultra-high performance concrete (UHPC) with pond ash (PA), a waste by-product from the Sikka thermal power station in Gujarat, India, at replacement levels ranging from 0 to 20%. Also, 20% of the cement was replaced with ground granulated blast-furnace slag, which is a sustainable, eco-friendly material. As a result, this concrete is both environmentally and economically feasible. Experimental analysis evaluated the workability, compressive strength, split tensile strength, flexural strength, and microstructure of the UHPC mixtures. Incorporating 10% PA as a sand replacement enhanced the compressive strength, reaching 117 MPa at 90 days, as well as the flexural strength of 23 MPa and the split tensile strength of 14 MPa. The strength is positively impacted when 10% of the river sand is replaced with PA, while the strength of UHPC appears to be diminished if PA content is increased beyond 10% replacement of sand. Petrographic microscopy and X-ray diffraction were used to study the microstructure of UHPC made with PA. When PA was used instead of sand, the mortar mass solidified and became denser, resulting in an improved microstructure of the UHPC with fewer surface cracks. With the inclusion of PA, the calcium silica hydrate gel content of the concrete increases, and enhanced performance of UHPC up to a certain amount of replacement has been observed.

Abstract In cold areas, freeze–thaw damage seriously affects the long-term use and safe operation of concrete structures. The constitutive model is an important foundation for predicting deformation and strength characteristics of concrete materials and for the non-linear analysis of concrete structures. This study is based on the elaboration of methods for the constitutive model of damaged materials by using damage mechanics and others. This study focuses on the existing constitutive model results of concrete under the static axial compression load, dynamic load, and coupling environmental load, and analyzing the problems in existing studies. Research has shown that segmented models exhibit higher fitting accuracy of concrete freeze–thaw constitutive model under static axial compression loads. By defining coupled damage variables, it is possible to approach the actual freeze–thaw damage of concrete under environmental coupling, and attention should be paid to the differences or interactions between damage factors. In order to meet the actual engineering needs of high altitude and cold areas needs to expand the temperature range of freeze–thaw tests and consider the dynamic loads impact on concrete damage, the establishment of constitutive model of concrete under the actual freeze–thaw damage is the focus of frost-resistant durability research of hydraulic concrete in cold regions.

Abstract Mo 2 C layer was generated on the diamond surface via vacuum micro-evaporating, which was used as the reinforcement particles to fabricate diamond/Cu composites by spark plasma sintering (SPS). The effect of evaporation parameters on the forming of Mo 2 C, and the holding time on diamond/Cu composites fabrication is studied. Combined with the experiment and finite element analysis (FEA), the holding time on diamond/Cu composites influence on the thermal conductivity (TC) of composites is further discussed. The results show that the Mo 2 C area on the diamond surface would gradually enlarge and cover the diamond surface evenly with the increment in evaporation time and temperature, better vacuum micro-evaporating parameters were given as 1,000°C for 60 min. The fractures in the diamond/Cu composites are mainly ductile fractures on copper and diamond falling out from the Mo 2 C interface. It was found that sintering time would significantly influence the dissipation property of diamond/Cu composites. A comprehensive parameter for SPS was obtained at 900°C, 80 MPa for 10 min, the relative density (RD) and TC of the composites obtained under the parameter were 96.13% and 511 W/(m K). A longer sintering time would damage the Mo 2 C interlayer and further decrease the bonding between copper matrix and diamond particles, which would lower the RD and TC of composites. It can be obtained from the comparison of simulation results and experimental results that the FEA result is closer to the experimental results due to the gaps with low heat conduction, and the air in the gaps is added in the simulation process.

Abstract With the enhancement in science and technology, necessity of complex shapes in manufacturing industries have become essential for more versatile applications. This leads to the demand for lightweight and durable materials for applications in aerospace, defense, automotive, as well as sports and thermal management. Wire electric discharge machining (WEDM) is an extensively utilized process that is used for the exact and indented shaped components of all materials that are electrically conductive. This technique is suitable in practically all industrial sectors owing to its widespread application. The present investigation explores WEDM for LM6/fly ash composites to optimize different process variables for attaining performance measures in terms of maximum material removal rate (MRR) and minimum surface roughness (SR). Taguchi’s L 27 OA design of experiments, grey relational analysis, and analysis of variance (ANOVA) were employed to optimize SR and MRR. It has been noted from ANOVA that reinforcement ( R ) percentage and pulse on time are the most influential aspects for Grey Relational Grade (GRG) with their contributions of 28.22 and 18.18%, respectively. It is found that the best process variables for achieving the highest MRR and lowest SR simultaneously during the machining of the composite are gap voltage of 30 V, pulse on time of 10 µs, pulse off time of 2 µs, wire feed of 8 m/min, and R of 9%. The predicted GRG is 0.84, and the experimental GRG value is 0.86. The validation experiments at the optimized setting show close agreement between predicted and experimental values. The morphological study by optical microscopy revealed a homogenous distribution of reinforcement in the matrix which enhances the composite’s hardness and decreases the density.

Abstract This article aims to study the effects of corn starch and gellan gum (gellan glue) on the unconfined compressive strength of alluvial soft clay in Shanghai. Firstly, starch and gellan gum were evenly mixed into Shanghai cohesive soil in a certain proportion, and soil samples were prepared according to the optimal water content. Secondly, the unconfined compressive strength test was carried out according to the content of corn starch, gellan glue, and curing time. The strength characteristics of Shanghai soft clay under various test conditions were studied. Finally, the software for statistics and drawing was used to perform regression analysis and drawing on the experimental data. The results showed that in the unconfined compressive strength test, when the curing time was 28 days, the starch content was 3% mixed with 0.5% gellan gum, the unconfined compressive strength of the sample was the highest, and generally, it seems that the strength keep increasing with curing time.

Abstract This study investigated the influence of microbead dosages (0, 5, 10, 15, and 20%) on the frost resistance of expanded polystyrene (EPS) concrete. Five groups of EPS concrete specimens were prepared and subjected to rapid freeze–thaw tests. The freeze–thaw deterioration of EPS concrete was assessed using macroscopic indicators, including mass loss, strength loss, and dynamic elastic modulus loss. The underlying deterioration mechanism was revealed through the analysis of the EPS particle–matrix interface. A concrete damage plasticity model of EPS concrete based on damage mechanics theory was established. The results indicate that the addition of microbeads increased the strength of EPS concrete by 38–53%, reduced the strength attenuation after freeze–thaw damage by 8.1%, and improved the frost resistance level by 10–60 grades. The optimal dosage of microbeads is 15% of the cementitious material. The interfacial transition zone gaps in EPS concrete with added microbeads after freeze–thaw cycles are smaller, contributing to a more complete hydration reaction. The freeze–thaw damage model established in this study accurately reflects the freeze–thaw damage law of EPS concrete and provides a reference for studying the mechanical properties of EPS concrete under freeze–thaw cycles. The research findings of this study can enhance the strength and service life of EPS concrete, expanding its application scope as a structural material. The study provides valuable insights for future research and engineering applications related to the frost resistance of EPS concrete.

Abstract To investigate the damage evolution and failure mechanisms of fiber-reinforced composite materials under complex conditions, this study conducted in situ X-ray computed tomography (CT) compression and tensile tests on plain weave two-dimensional woven SiC/SiC composite materials. The obtained CT in situ image data captured the behavior of materials during loading and after failure. Using the image reconstruction of CT data, the actual microstructure and damage evolution of the material under six consecutive loading levels were accurately revealed. Three-dimensional visualization models of the composite material were established using image processing software to analyze the damage evolution under compression and tension, and the failure mechanisms were compared. The results showed that the compression and tension failure mechanisms of SiC/SiC composite materials were similar, with the transverse cracking of the matrix being the first mode of damage, followed by delamination between layers and longitudinal matrix cracking of fiber bundles. Specifically, in terms of compression failure, the strength of the fiber bundle itself has a greater influence, and fiber fracture is the main cause of ultimate material failure. On the other hand, the primary cause of tensile failure is the presence of porosity defects generated during material fabrication. Consequently, the tensile material fails earlier and can withstand lower loads.

Abstract In order to improve the chloride ion penetration resistance of supplementary cementitious materials (SCMs) in blended cement, this study optimizes the particle size distribution of cementitious components based on the Fuller model. Portland cement (PC), fly ash (FA), and ground granulated blast furnace slag (GGBFS) are successfully divided into four particle size ranges by precision air classifier, which are 0–8, 8–30, 30–50, and 50–80 μm, respectively. The optimum cementitious materials in four ranges based on 28-day compressive strength are determined by nine groups of orthogonal tests. The blended cement with optimal performance is obtained by GGBFS in 0–8 μm, PC in 8–30 μm, GGBFS in 30–50 μm, and FA in 50–80 μm. The results show that the blended cement with SCMs based on Fuller model have superior microstructure and chloride ion penetration resistance, which is due to their smaller pore size, a strong volcanic ash effect, and chloride ion binding ability. In addition, this research presents a novel approach for realizing the application of a large amount of SCMs in blended cement.