{"title":"Enhanced Weibull Formulation for Capturing Fatigue Life Scatter in AM Alloys Supported by Fractographic Analysis","authors":"Luca Esposito , Matteo Bruno , Moreno Nacca","doi":"10.1016/j.prostr.2025.12.286","DOIUrl":"10.1016/j.prostr.2025.12.286","url":null,"abstract":"<div><div>The fatigue performance of components produced via selective laser melting technology is strongly influenced by several factors as printing process parameters, build orientation and internal defects. This study investigates the fatigue behavior of AlSi10Mg specimens with machined surfaces, emphasizing the unusually high variability in lifetimes observed in samples built in the Z direction. A refined Weibull statistical approach, accounting for defect-induced scatter and supported by fractographic analysis, is proposed. The novel bimodal probabilistic framework, calibrated through maximum likelihood estimation method, distinguishes between two dominant defect types—porosity and lack of fusion—enabling a more accurate description of fatigue life distributions. The model successfully captures defect-specific fatigue limits and offers a robust method for integrating defect morphology into lifetime predictions, with strong implications for engineering design and reliability assessment of additively manufactured components.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"76 ","pages":"Pages 50-58"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102547","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
R. Fernandes , J.S. Jesus , L.P. Borrego , J.A.M. Ferreira , R. Branco , J.D.M. Costa
{"title":"Effect of shot peening and heat treatments on the fatigue crack propagation on AlSi10Mg alloy specimens produced by L-PBF","authors":"R. Fernandes , J.S. Jesus , L.P. Borrego , J.A.M. Ferreira , R. Branco , J.D.M. Costa","doi":"10.1016/j.prostr.2025.12.285","DOIUrl":"10.1016/j.prostr.2025.12.285","url":null,"abstract":"<div><div>Laser Powder Bed Fusion (L-PBF) enables the 3D printing of components in Aluminium alloys, widely used high-performance engineering applications, whereby it is fundamental the understanding of in-service fatigue behaviour. Current paper is focused on the fatigue crack propagation of AlSi10Mg aluminium alloy using CT specimens. The tested material conditions included as-built (AB), as-built shot-peened (AB+SP), stress-relieved (SR) and stress-relieved shot-peened (SR+SP), loaded in mode I. The purpose of the work was to understand the correlation between post-built treatments, residual stresses, porosity defect levels and fatigue crack growth (FCG), including transient regime after overload applications. The porosity levels were obtained by tomography technique. The residual stress relief and their subsequent stabilization were the main mechanisms responsible for improving the fatigue crack growth resistance. The as-built shot-peened condition showed minimal influence on FCG rates in the near-threshold regime but did increase the threshold value. At higher ΔK values, the FCG behaviour of as-built and as-built shot-peened specimens was similar, and for stress-relieved specimens, shot-peening treatment provided no notable benefit, as FCG rates for stress-relieved and stress-relieved shot-peened conditions were comparable.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"76 ","pages":"Pages 43-49"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102548","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"A Homogenised Material Approach to Predict Fatigue Life of Additively Manufactured PLA with Different In-fill Levels","authors":"Mehmet F. Yaren , Luca Susmel","doi":"10.1016/j.prostr.2025.12.292","DOIUrl":"10.1016/j.prostr.2025.12.292","url":null,"abstract":"<div><div>This study presents a novel fatigue life prediction method for plain and notched polylactide (PLA) structures manufactured with different in-fill levels via additive manufacturing. The proposed method models additively manufactured PLA with internal voids as a continuous, homogeneous, linear-elastic, and isotropic material. The effect of these voids is represented by an equivalent crack, whose size is related to the void size. This approach provides a practical and accurate way to estimate the fatigue life of both plain and notched components, even when manufactured with different in-fill levels. The predicted fatigue lives agree with the experimental results obtained from specimens in different raster angles and in-fill levels.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"76 ","pages":"Pages 99-106"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102500","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Fibre-Reinforced Self-Healing Composites: Mechanical Characterisation using Acoustic Emission Technique","authors":"Claudia Barile , Vimalathithan Paramsamy Kannan","doi":"10.1016/j.prostr.2026.01.001","DOIUrl":"10.1016/j.prostr.2026.01.001","url":null,"abstract":"<div><div>The autonomous healing of polymeric matrices in the fibre-reinforced composites has received significant attention in recent years. This research investigates the ability of an intrinsically healable polymer resin to heal internal defects in a fibre-dense composite. Unstable internal defects are created in a self-healing Carbon Fibre-Reinforced Polymer composites (CFRPs) using a three-point bending setup. Mild heat is applied as an external stimulus to heal the damaged composites. Mechanical performance recovery is evaluated by testing the virgin, damaged, and healed composites under flexural loads. The test results reveal a marginal recovery of flexural properties after healing. The damage progression in the composites, as well as the rationale behind this marginal recovery of the flexural properties are evaluated using Acoustic Emission (AE) tests. Machine Learning (ML)-based unsupervised data clustering and Continuous Wavelet Transform (CWT) are employed to analyse the parameter-based and signal-based AE data, respectively. The results are further validated using microscopic analysis. These results suggest that the healing process has altered the damage progression path in the self-healing CFRPs and is responsible for the recovery of flexural properties.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 3-10"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102506","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Energetic evaluation of tubular adhesive joints: adherend material effect","authors":"C.F.F. Gomes , R.D.S.G. Campilho , A.J.A. Vieira , D.C. Gonçalves , K. Madani","doi":"10.1016/j.prostr.2026.01.014","DOIUrl":"10.1016/j.prostr.2026.01.014","url":null,"abstract":"<div><div>Adhesive joints are widely employed due to their advantages over traditional joining methods such as welding and bolting. Among different configurations, overlap tubular adhesive joints are formed by inserting a smaller-diameter tube into a larger one, which are bonded to provide a solution with attractive strength-to-weight ratio, stress distribution, and corrosion resistance. This study numerically evaluates the performance of overlap tubular joints by comparing three adherend materials and analyzing the effect of overlap length (<em>L</em><sub>O</sub>). A numerical approach based on Cohesive Zone Models (CZM) was used and initially validated against experimental data. The results demonstrated that both the adherend and adhesive stiffness significantly impact joint strength. The highest tensile strength was observed in joints using DIN 55Si7 steel adherends bonded with the Araldite® AV138 adhesive.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 95-102"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102593","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Francisco Castro , Francisco Queirós de Melo , David Faria , Job Silva , João Nunes , Bruno Sousa , Pedro Sousa , Mário Vaz , Pedro Moreira
{"title":"An experimental evaluation of a vehicle’s center of gravity (CoG) height in motion","authors":"Francisco Castro , Francisco Queirós de Melo , David Faria , Job Silva , João Nunes , Bruno Sousa , Pedro Sousa , Mário Vaz , Pedro Moreira","doi":"10.1016/j.prostr.2026.01.077","DOIUrl":"10.1016/j.prostr.2026.01.077","url":null,"abstract":"<div><div>A vehicle’s center of gravity (CoG) height often changes in SUVs, military vehicles and heavy vehicles such as trucks or buses, due to load conditions variations. Since this parameter influences the dynamic behavior of vehicles, being considered the most important parameter for the occurrence of un-tripped rollovers, the accurate knowledge of CoG height is fundamental for the design and implementation of effective rollover prevention strategies and for improving the performance of active safety systems. Contrary to the longitudinal and lateral CoG position estimation, there isn’t any equipment that measures the CoG height position of a vehicle directly. Thus, the estimation of this parameter still remains a challenge due to the high computational burden and associated costs, despite the developments in the last 15 years.</div><div>This study proposes two different approaches for estimating the vehicle’s CoG height in motion, by using a longitudinal dynamic model which relies on a braking maneuver and a roll dynamics approach that relies on a cornering maneuver. Both methods use vehicle characteristics which are easy to measure or can be provided by the manufacturers, and the other parameters can be obtained from sensors which can easily be installed on a vehicle.</div><div>In order to validate the proposed method, experimental tests were conducted using a prototype vehicle (rc-vehicle) for various driving scenarios considering different load conditions. The consequent results were compared with ones obtained through static methods, exhibiting good accuracy. Therefore, the method proposed to estimate the CoG height position can be implemented to assist the vehicle in monitoring real-time rollover risk and improving the accuracy of vehicle safety control system, or act as a warning system to the driver.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"77 ","pages":"Pages 611-630"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146102670","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Prediction of Material Damages Based on a High-Cycle Fatigue Model and Non-destructive Testing Data","authors":"Bezhenov Sergiy","doi":"10.1016/j.prostr.2026.03.045","DOIUrl":"10.1016/j.prostr.2026.03.045","url":null,"abstract":"<div><div>In this paper, the results of the investigation of the process of fatigue fracture of the carbon steels, low-alloy steels, Ni-based, as well as Ti-based alloy specimens are presented. Samples were studied in a state of normalization of the material structure, as well as after strengthening treatment by surface plastic deformation. During the fatigue tests, the count rate of acoustic emission (AE) signals was recorded simultaneously in three frequency bands.</div><div>The fatigue test results were processed in accordance with the hypothesis of a pole in the fatigue curves of materials of the same class with different technological heredity. For this purpose, the coordinates of the fatigue curve poles for the investigated materials were determined. It has been established that the ordinates of the poles of the fatigue curves correspond to the activation energy of destruction of the volume of one mole of the metal that forms the basis of the alloy. The abscissas of the poles for different classes of steel were determined by searching for optimal values of the main statistical parameters (the maximum correlation coefficient with minimum standard deviation). An explicit connection between the abscissa of the pole and the mechanical and physical properties of the alloys under study has not been established.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"81 ","pages":"Pages 260-263"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147652672","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Boundary element modeling of thermo-fatigue processes under cyclic quasi-static thermal loading","authors":"Oleh Yasniy , Iaroslav Pasternak , Dmytro Tymoshchuk , Iryna Didych , Olha Malyshevska","doi":"10.1016/j.prostr.2026.03.042","DOIUrl":"10.1016/j.prostr.2026.03.042","url":null,"abstract":"<div><div>This work applies boundary element modeling to study thermo-fatigue crack initiation and growth under cyclic quasi-static thermal loading in plane thermoelastic problems. An accurate boundary element implementation with analytical integration on quadratic elements is used, with special treatment of singular stress fields near cracks. The model considers a plate subjected to cyclic thermal loading with randomly distributed initial micro-cracks representing stochastic defect initiation. Crack nucleation is modeled probabilistically at grid nodes when local stress exceeds a critical threshold that decreases over time due to material degradation. Fatigue crack growth in existing cracks is governed by the Paris law, with propagation direction determined by the maximum hoop stress criterion. The framework combines probabilistic nucleation and deterministic crack growth into a unified multiscale scheme for thermo-fatigue simulation. Numerical experiments analyze the influence of degradation parameters, thermal loading modes, and Paris law parameters on crack evolution. Results show that crack networks are highly sensitive to both mechanical and probabilistic factors, with practical relevance for assessing thermo-fatigue in components such as mill rolls.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"81 ","pages":"Pages 244-250"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147652674","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Igor Protokovilov, Vitalii Porokhonko, Victor Shapovalov, Farit Biktagirov
{"title":"Cast Structure Evolution in Pulsed Mode Electroslag Remelting","authors":"Igor Protokovilov, Vitalii Porokhonko, Victor Shapovalov, Farit Biktagirov","doi":"10.1016/j.prostr.2026.03.028","DOIUrl":"10.1016/j.prostr.2026.03.028","url":null,"abstract":"<div><div>The results of a study on the characteristics of cast metal structure evolution in pulsed mode electroslag remelting (ESR) with layer-by-layer ingot formation are presented. Experiments were carried out on ingots of 85–220 mm diameter from carbon steels (S235JR, C22E) and a Fe–Ni–Co alloy (54Fe–29Ni–17Co). Remelting was performed in a chamber-type electroslag furnace in an argon atmosphere. Experiments were conducted under various conditions of the layer-by-layer ingot formation process. The resulting ingots were cut along their axis to study solidification patterns. It has been established that conducting ESR in a pulsed mode makes it possible to control the metal structure and produce ingots with a structure significantly finer than that obtained by conventional ESR. It is shown that during layer-by-layer formation, columnar crystals are localized within individual layers of metal and do not cross the boundaries between the deposited layers. A nearly linear relationship between the size of cast grains and the height of the deposited layer has been determined. The optimal structural refinement is achieved when the height of a single layer is maintained within the range of (0.1–0.5) × ingot diameter. For defect-free interlayer bonding the duration of melting pauses must be such that no more than 75–95% of the volume of the molten pool solidifies before the next portion is remelted. The study proposes principles for controlling cast structure in pulsed mode ESR, providing guidelines for producing ingots up to 220 mm in diameter with enhanced homogeneity.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"81 ","pages":"Pages 156-161"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147652681","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Modeling the behavior of a steel-timber trapezoidal truss with local damage to individual elements","authors":"Svyatoslav Gomon , Valentin Aleksiievets , Petro Gomon , Sviatoslav Homon , Nazarii Riabcheniuk , Diana Kaynts , Oksana Mykaylo , Yolana Golyk","doi":"10.1016/j.prostr.2026.03.033","DOIUrl":"10.1016/j.prostr.2026.03.033","url":null,"abstract":"<div><div>The work of a trapezoidal steel-wood truss with a span of 24 m with damage to individual braces was modeled in the LIRA software package. 2 geometric schemes of such trusses were considered. Three types of loads were applied to the trusses: self-weight of the roof system, snow on the entire span, and snow on half of the span. The most dangerous cases of destruction of individual elements of both trusses were modeled, which subsequently affect the operation of the truss as a whole. The truss forces were calculated during the destruction of individual elements. Suggestions were made to improve the design of cross-sections of individual elements of the studied trusses.</div></div>","PeriodicalId":20518,"journal":{"name":"Procedia Structural Integrity","volume":"81 ","pages":"Pages 192-197"},"PeriodicalIF":0.0,"publicationDate":"2026-01-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147652688","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}