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dr hab. inż. Wojciech Macek
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- Associate professor at Institute Of Mechanics And Machine Design
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total: 113
Catalog Publications
Year 2025
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Comparative assessment of entire bending-torsion fracture surface for 10HNAP steel using different optical measurement techniques
PublicationThis research aims to compare two microscopic measurement techniques: Confocal and Focus Variation, for the assessment of the entire fracture surface method. The measurements were conducted using the Sensofar S Neox 3D and Alicona InfiniteFocus G4 optical profilometers. Surface parameters were assessed for the entire fracture regions of the 10HNAP structural steel ring V-notched specimen. Fatigue test were performed under combination...
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Development of dual nozzle slurry extrusion 3D printer by integrating material extrusion and photopolymerization for the fabrication of engineered ceramics
PublicationThis research focuses on developing a dual-nozzle slurry-based extrusion 3D printer capable of fabricating intricate zirconia structures. The designed 3D printer combines material extrusion and photopolymerization technologies to improve material diversity, precision, and cost-effectiveness. The 3D printer design incorporates ultraviolet curing to instantly cure extruded zirconia slurry thereby, eliminating the need for a step-wise...
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Effect of Zirconia addition on Laser powder bed fusion of Inconel 718-zirconia Composite
PublicationThis study investigates the integration of zirconia (ZrO2) as a reinforcing agent in the Inconel 718 matrix to potentially enhance material hardness and high-temperature oxidation resistance. Employing laser powder bed fusion (LPBF), 3D composite parts of Inconel 718-ZrO2 were systematically fabricated, varying the zirconia mass. The primary objectives encompass exploring the impact of zirconia on the microstructure, micro-hardness,...
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Effects of process parameters on dynamic and static load capacity of EN AW-2024-T3 aluminum alloy joints prepared by friction stir welding
PublicationThis study investigates the impact of friction-stir welding (FSW) process parameters on the mechanical performance and fracture behavior of EN AW-2024-T3 aluminum alloy joints. A series of static and dynamic mechanical tests were conducted on six welded samples, revealing that the joint strength and fracture characteristics are highly sensitive to FSW parameters, particularly tool rotational rate, pin length, and traverse speed....
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Enhancing Internal Cooling Channel Design in Inconel 718 Turbine Blades via Laser Powder Bed Fusion: A Comprehensive Review of Surface Topography Enhancements
PublicationInconel 718, a widely utilized Ni-based superalloy in the aerospace industry, is renowned for its exceptional mechanical properties, high-temperature corrosion resistance, and thermal stability, making it an ideal material for turbine blades operating under extreme conditions of up to 2200 °C and high-pressure. Traditional single crystal casting, the prevalent manufacturing method for turbine blades, poses inflexibility challenges....
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Fatigue Damage Evolution in SS316L Produced by Powder Bed Fusion in Different Orientations with Reused Powder Feedstock
PublicationBackground Metal Laser Powder Bed Fusion Melting (LPBF-M) is considered economically viable and environmentally sustainable because of the possibility of reusing the residual powder feedstock leftover in the build chamber after a part build is completed. There is however limited information on the fatigue damage development of LPBF-M samples made from reused feedstock. Objective In this paper, the stainless steel 316 L (SS316L)...
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Fractography of Haynes 282 alloy manufactured by DMLS after tensile and HCF
PublicationIn this paper, the fracture surface topography of additively manufactured Haynes 282 alloy subjected to tensile and high-cycle fatigue loading was investigated. Haynes 282 alloy bars were printed in three different directions relative to the base plate (0°, 45°, and 90°) via Direct Metal Laser Sintering (DMLS) under an argon protective atmosphere. The specimens were subjected to monotonic tensile loading and fatigue testing under...
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Measurement Technique Comparison in the Entire Fracture Surface Topography Assessment for Additively Manufactured Materials
PublicationThis paper focuses on comparing the three microscopic measurement techniques, confocal, focus variation, and point for focus, for the evaluation of entire fracture surface topographies. The measurements were performed using a Sensofar S Neox 3D optical profilometer and the Mitutoyo QV Apex 302 vision measuring system. The test specimens required for measuring were printed through laser powder bed fusion (LPBF) technology using...
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On the Cover: Fatigue Damage Evolution in SS316L Produced by Powder Bed Fusion in Different Orientations with Reused Powder Feedstock
PublicationOn the Cover: Fatigue Damage Evolution in SS316L Produced by Powder Bed Fusion in Different Orientations with Reused Powder Feedstock. Exp Mech (2025). https://doi.org/10.1007/s11340-025-01179-w
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Study of vibrational surface topography measurement errors of LPBF Inconel 718 alloy after shot peening process
PublicationA study of surface topography can provide valuable information on the product. Since the material finishing relies on the measured topography, the manufacturing process can be controlled by studying the roughness. The Laser Power Bed Fusion (LPBF) materials belong to the commonly used surfaces in the industry. Measuring this type of material with a contactless method can be found in many practical implementations. The white light interference...
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The influence of printing strategies on the fatigue crack growth behaviour of an additively manufactured Ti6Al4V Grade 23 titanium alloy
PublicationThe selective laser melting (SLM) process, a type of laser powder-bed fusion (LPBF) in additive manufacturing (AM), uses a high-power density laser to melt metallic powders. This study involved 3D printing Compact Tension (CT) specimens from titanium alloy Ti6Al4V, known for its rigidity, corrosion resistance, and biocompatibility, making it suitable for aerospace and medical applications. To predict fatigue life, it is essential...
Year 2024
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Active Kriging-based conjugate first-order reliability method for highly efficient structural reliability analysis using resample strategy
PublicationEfficient structural reliability analysis method is crucial to solving reliability analysis of complex structural problems. High-computational cost and low-failure probability problems greatly limit the efficiency in structural reliability analysis problems, causing the safety and reliability of the structure to be questioned. In this work, a highly efficient structural reliability analysis method coupling active Kriging algorithm...
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An image processing approach for fatigue crack identification in cellulose acetate replicas
PublicationThe cellulose acetate replication technique is an important method for studying material fatigue. However, extracting accurate information from pictures of cellulose replicas poses challenges because of distortions and numerous artifacts. This paper presents an image processing procedure for effective fatigue crack identification in plastic replicas. The approach employs thresholding, adaptive Gaussian thresholding, and Otsu binarization...
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Artificial Neural Network based fatigue life assessment of riveted joints in AA2024 aluminum alloy plates and optimization of riveted joints parameters
PublicationThe objective of this paper is to provide the fatigue life of riveted joints in AA2024 aluminum alloy plates and optimization of riveted joints parameters. At first, the fatigue life of the riveted joints in AA2024 aluminum alloy plates is obtained by experimental tests. Then, an artificial neural network is applied to estimate the fatigue life of riveted lap joints based on the number of lateral and longitudinal holes, punch pressure,...
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Comprehensive exploration of technological tensioning effects in welded thin plate girders: an in-depth investigation
PublicationThin-walled plate girders are widely used in structures and construction due to their effectiveness in transferring loads. The permanent deformations of the girder lead to a lack of stability, which necessarily leads to its replacement. Replacing permanently deformed thin-walled load-bearing structures requires large financial outlays. Technological prestressing is one of the most effective methods for studying and treating permanent...
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Corrigendum to “An investigation on residual stress and fatigue life assessment of T-shape welded joints” [Eng. Fail. Anal. 141 (2022) 106685]
PublicationThis paper aims to quantitatively evaluate the residual stress and fatigue life of T-type welded joints with a multi-pass weld in different direction. The main research objectives of the experimental test were to test the residual stress by changing direction along with multiple wielding passes and determine the fatigue life of the welded joints. The result shows that compressive residual stress increases in the sample gradually...
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Corrigendum to “Fatigue life improvement using low transformation temperature weld material with measurement of residual stress” [Int. J. Fatigue 164 (2022) 107137]
PublicationWelding processes often produce high levels of tensile residual stress. Low transformation temperature (LTT) welding wires utilise phase transformation strains to overcome the thermal contraction of a cooling weld. In this paper, the residual stress within each weld was quantified using the milling/strain gauge method, being the strain change measured as the weldment was milled away. The fatigue tests were conducted under uniaxial...
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Cyclic deformation and fracture behaviour of additive manufactured maraging steel under variable-amplitude loading
PublicationThe cyclic deformation and fracture behaviour of 18Ni300 maraging steel produced by laser beam powder bed fusion is studied under variable-amplitude loading. The tests were conducted under fully-reversed strain-controlled conditions with a loading sequence comprising three ascending cycles and three descending cycles repeated sequentially until failure. After the tests, fracture surfaces were examined using height and volume surface...
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Effects of polymer sealant interlayer on quality of EN AW-2024-T3 aluminum alloy lap joint prepared by friction stir welding
PublicationThis study investigates the influence of polymer interlayers on the mechanical properties and fracture behavior of friction stir welded EN AW-2024-T3 aluminum alloy joints. Aqualock AL 6002 (Adhesive_1) and 3M Adhesion Promoter 86A (Adhesive_2) were selected as polymeric sealants for EN AW-2024-T3 aluminum alloy interfaces. Force analysis revealed that the choice of polymer interlayer significantly affects the axial force during...
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Entire fracture surface topography parameters for fatigue life assessment of 10H2M steel
PublicationIn this paper, the entire fracture surface approach was used to assess an effect of 280,000 h of exploitation under internal pressure of 2.9 MPa and high temperature of 540 °C on the fatigue response of 10H2M (10CrMo9–10) power engineering steel. The mechanical testing was carried out on the hourglass specimens produced from the as-received, unused pipeline and the same material after long-time exploitation. The uniaxial tensile...
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Evaluation of high-frequency roughness measurement errors for composite and ceramic surfaces after machining
PublicationPrecise characterisation of surface topography is of the greatest importance since many factors directly affect the accuracy of the whole measurement process. In this paper, the variety of surface topographies from machined composite and ceramic workpieces was studied with a special emphasis on the measurement results. Surfaces were subjected to the ground diamond, honing and milling processes. Measurement results were analysed...
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Experimental study of the impact of notches and holes made in the front edge of adherends on the properties of static and fatigue strength of adhesive joints
PublicationThe paper presents the results of experimental studies aimed at determining the effect of holes and notches at the front edge of adherends on the strength of adhesive joints. Single-lap joints made of S235JR steel sheets joined with Araldite 2014-2 epoxy adhesive were tested. Comparative tests of static strength in the shear test as well as high-cycle fatigue strength tests were carried out. Joints with three holes with a diameter...
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Fatigue behaviour of SLM maraging steel under variable-amplitude loading
PublicationOne of the most challenging issues for additive manufactured materials is fatigue endurance. Engineering components often operate under complex, variable amplitude loadings, in which existing technological imperfections promote fatigue cracks growth and damage of elements eventually. In this study the effects of different variable-amplitude strain levels on fatigue life, 18Ni300 steel was tested. The work presents various behaviours...
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Fracture surface topography measurements analysis of low-alloyed corrosion resistant steel after bending-torsion fatigue tests
PublicationIn this paper, an assessment of a topography measurement method for fracture surfaces of 10HNAP steel after bending-torsion fatigue tests was performed. Surface roughness was measured by using a non-contact Focus Variation Microscopy (FVM) technique in which the non-measured points (NMPs) and outliers (spikes) were removed by the application of general methods. The results revealed, that the optical measurement method introduced...
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Kriging-assisted hybrid reliability design and optimization of offshore wind turbine support structure based on a portfolio allocation strategy
PublicationIn recent years, offshore wind power generation technology has developed rapidly around the world, making important contributions to the further development of renewable energy. When designing an Offshore Wind Turbine (OWT) system, the uncertainties in parameters and different types of constraints need to be considered to find the optimal design of these systems. Therefore, the Reliability-Based Design Optimization (RBDO) method...
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Laser-textured cross-hatched surface topography analysis with evaluation of high-frequency measurement noise
PublicationThe precision of surface roughness determination using ISO 25178 parameters relies on various factors that directly impact the measurement process. In industry applications, the contactless roughness measurement reduces data collection time. However, it introduces several potential errors, including those stemming from the environment. One of the main types of errors encountered during topography analysis is measurement noise,...
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Mechanical Properties of Additively Manufactured Polymeric Materials—PLA and PETG—For Biomechanical Applications
PublicationThe study presented herein concerns the mechanical properties of two common polymers for potential biomedical applications, PLA and PETG, processed through fused filament fabrication (FFF)—Material Extrusion (ME). For the uniaxial tension tests carried out, two printing orientations—XY (Horizontal, H) and YZ (Vertical, V)—were considered according to the general principles for part positioning, coordinates, and orientation typically...
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Numerical Determination of the Load-Bearing Capacity of a Perforated Thin-Walled Beam in a Structural System with a Steel Grating
PublicationThis article presents the results of numerical simulations of a structural system consisting of steel perforated thin-walled beams and a steel grating. The simulations were conducted using the finite element method. The analysis took into account physical and geometric nonlinearity as well as the contact between the steel grating and the beams. The main goal of the research was to develop load-bearing curves for the main beam in...
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On the use of uniaxial one-parameter damage laws for estimating fatigue life under multiaxial loading
PublicationThe goal of this paper is to evaluate the capabilities of different one-parameter fatigue laws to estimate crack initiation in notched components under multiaxial loading. Fatigue damage is accounted for through stress-based, strain-based, and energy-based approaches while the cyclic plasticity at the notch-controlled process zone is estimated using linear-elastic simulations. The results show that energy-based formulations established...
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Orientation effects on the fracture behaviour of additively manufactured stainless steel 316L subjected to high cyclic fatigue
PublicationIn this paper, stainless steel 316L (SS316L) bars were additively manufactured (AM) in three orientations (Z – vertical, XY – horizontal, ZX45 – midway between vertical and horizontal) by using the Laser Powder Bed Fusion Melting (LPBF-M) method. The AM specimens were subjected to load control fatigue testing under full tension and compression (R = -1) at stress amplitudes ±350, ±400 and ±450 MPa. The XY and ZX45 printing orientations...
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Prediction of the fatigue lifetime of PUR structural elements using a combined experimental-numerical approach
PublicationThis paper presents a method for estimating the fatigue life of polyurethane elastomeric components. A rubber replacement - polyurethane of hardness 80ShA commonly used in vibration damping systems, for example, in motor vehicle suspensions, was used for the study. A metal-rubber bushing component was selected for analysis, and numerical analysis was carried out along with a fatigue model proposal based on a modification of the...
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Roughness measurement results evaluation of 6082 aluminium alloy specimens after fatigue bending tests
PublicationIn this paper, the topography of 6082 aluminium alloy specimens after fatigue bending tests was studied with a comprehensive evaluation of measurement noise caused by vibration. Roughness results were acquired by contactless Focus Variation Microscopy (FVM). Studied data were pre-processed, removing the non-measured points and outliers with regular methods, respectively, and high-frequency noise was considered. The variations in...
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Saint-Venant torsion based on strain gradient theory
PublicationIn this study, the Saint-Venant torsion problem based on strain gradient theory is developed. A total form of Mindlin's strain gradient theory is used to acquire a general Saint-Venant torsion problem of micro-bars formulation. A new Finite Element formulation based on strain gradient elasticity theory is presented to solve the Saint-Venant torsion problem of micro-bars. Moreover, the problem is solved for both micro and macro...
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Sintering Parameter Investigation for Bimetallic Stainless Steel 316L/Inconel 718 Composite Printed by Dual-Nozzle Fused Deposition Modeling
PublicationFused deposition modeling (FDM) nowadays offers promising future applications for fabricating not only thermoplastic-based polymers but also composite PLA/Metal alloy materials, this capability bridges the need for metallic components in complex manufacturing processes. The research is to explore the manufacturability of multi-metal parts by printing green bodies of PLA/multi-metal objects, carrying these objects to the debinding...
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Strain energy density and entire fracture surface parameters relationship for LCF life prediction of additively manufactured 18Ni300 steel
PublicationIn this study, the connection between total strain energy density and fracture surface topography is investigated in additively manufactured maraging steel exposed to low-cycle fatigue loading. The specimens were fabricated using laser beam powder bed fusion (LB-PBF) and examined under fully-reversed strain-controlled setup at strain amplitudes scale from 0.3% to 1.0%. The post-mortem fracture surfaces were explored using a non-contact...
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The Smith-Watson-Topper parameter and fracture surface topography relationship for additively manufactured 18Ni300 steel subjected to uniaxial variable-amplitude loading
PublicationIn this paper, the association between Smith-Watson-Topper (SWT) parameter and fracture surface topography is studied in additively manufactured maraging steel exposed to variable-amplitude fatigue loading. The post-failure fracture surfaces were examined using a non-contact 3D surface topography measuring system and the entire fracture surface method. The focal point is on the correspondence between fatigue characteristics, articulate...
Year 2023
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A brief note on entire fracture surface topography parameters for 18Ni300 maraging steel produced by LB-PBF after LCF
PublicationThe concept of entire fracture surface investigation is helpful in explaining fatigue phenomena. In this paper, this method has been applied for 18Ni300 maraging steel using a 3D measurement system. Before post-mortem analysis, the specimens produced by laser beam powder bed fusion (LB-PBF) were tested under low-cycle fatigue (LCF) for eight strain amplitudes in the interval 0.3% to 1.0%. The attention was placed on the relationship...
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A novel hybrid adaptive framework for support vector machine-based reliability analysis: A comparative study
PublicationThis study presents an innovative hybrid Adaptive Support Vector Machine - Monte Carlo Simulation (ASVM-MCS) framework for reliability analysis in complex engineering structures. These structures often involve highly nonlinear implicit functions, making traditional gradient-based first or second order reliability algorithms and Monte Carlo Simulation (MCS) time-consuming. The application of surrogate models has proven effective...
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Effect of austempering temperature on microstructure and cyclic deformation behaviour of multiphase low-carbon steel
PublicationThis paper examined the cyclic deformation behaviour of multiphase low-carbon steel that was subjected to austempering heat treatments at four temperatures (190 °C, 230 °C, 275 °C, and 315 °C) below the martensite start temperature (Ms = 353 °C). The tests were conducted at room temperature, under fully reversed strain-controlled conditions, with strain amplitudes in the range 0.5–1.0%. The microstructure was observed by transmission...
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Effect of bending-torsion on fracture and fatigue life for 18Ni300 steel specimens produced by SLM
PublicationIn this study, different fracture surfaces caused by fatigue failure were generated from 18Ni300 steel produced by selective laser melting (SLM). Hollow round bars with a transverse hole were tested under bending-torsion to investigate the crack initiation mechanisms and fatigue life. Next, the post-failure fracture surfaces were examined by optical profilometer and scanning electron microscope. The focus is placed on the relationship...
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Fatigue life prediction of notched components under size effect using strain energy reformulated critical distance theory
PublicationNotch and size effects show significant impact on the fatigue performance of engineering components, which deserves special attention. In this work, a strain energy reformulated critical distance theory was developed for fatigue life prediction of notched components under size effect. Experimental data of different notched specimens manufactured from GH4169, TC4, TC11 alloys and low carbon steel En3B were used for model validation...
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Fractographical quantitative analysis of EN-AW 2024 aluminum alloy after creep pre-strain and LCF loading
PublicationThis paper explores the applicability of a new damage parameter combining both fracture surface topography and loading features to estimate the fatigue lifetime under creep pre-strain and low-cycle fatigue loading. Fractures of EN-AW 2024 aluminum alloy caused by mixed creep and low-cycle fatigue loading are experimentally characterized and quantified via surface topography analysis. The specimens were preliminary damaged in a...
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Fractographic-fractal dimension correlation with crack initiation and fatigue life for notched aluminium alloys under bending load
PublicationIn this study, fatigue fracture surfaces of aluminium alloy 2017-T4 notched specimens were investigated under cyclic bending to find an alternative failure loading index.. The surface topographies were measured on the entire fracture area with an optical profilometer for different loading conditions. Fatigue crack initiation life Ni and total fatigue life Nf were examined using standard surface topography parameters (such as, root...
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Fracture Surface Topography Parameters for S235JR Steel Adhesive Joints After Fatigue Shear Testing
PublicationThis paper presents the experimental results of a study investigating the effect of holes and notches made on the overlap ends on the strength of adhesive joints. Single-lap joints made of S235JR steel sheets bonded with Araldite 2024-2 epoxy adhesive were tested. For comparative reasons, static shear strength tests and high-cycle fatigue strength tests were performed. Adhesive-filled joints having three holes, each with a diameter...
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NON-LOCAL VOLUMETRIC APPROACH TO ANALYSIS DEFECT'S SHAPE INFLUENCE ON SPECIMENS DURABILITY SUBJECTED TO BENDING AND TORSION
PublicationThe influence of defect features on fatigue behaviour is a complex trivial issue. Although the important advances over the last decades, the dialectical relationship between the defect orientation and durability is not clearly understood. The paper aims at studying the influence of the orientation of elliptical defects on the durability of samples made of C45 steel. Three types of samples with elliptical defects were subjected...
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Reduction in Errors in Roughness Evaluation with an Accurate Definition of the S-L Surface
PublicationCharacterization of surface topography, roughly divided into measurement and data analysis, can be valuable in the process of validation of the tribological performance of machined parts. Surface topography, especially the roughness, can respond straightly to the machining process and, in some cases, is defined as a fingerprint of the manufacturing. When considering the high precision of surface topography studies, the definition...
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Roughness evaluation of turned composite surfaces by analysis of the shape of Autocorrelation Function
PublicationIn this paper, the application of an Autocorrelation Function for the characterisation of surface topography was validated. The roughness evaluation of turned composite surfaces was supported by sophisticated studies of the Autocorrelation Function properties, considering especially the shape of the function. Details were measured with the optical method. The selection of the surface roughness evaluation procedures was carried...
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Stress Relaxation Behaviour Modeling in Rigid Polyurethane (PU) Elastomeric Materials
PublicationPolyurethane (PU) has been used in a variety of industries during the past few years due to its exceptional qualities, including strong mechanical strength, good abrasion resistance, toughness, low-temperature flexibility, etc. More specifically, PU is easily “tailored” to satisfy particular requirements. There is a lot of potential for its use in broader applications due to this structure–property link. Ordinary polyurethane items...
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The correlation of fractal dimension to fracture surface slope for fatigue crack initiation analysis under bending-torsion loading in high-strength steels
PublicationIn this study, the fractal dimension of fatigue fracture surfaces is investigated in order to find an alternative failure loading indicator. Some of many metrological factors are generalized by reducing the fracture surface structure to one factor and develop an entire fracture surface procedure by analyzing the impact of surface slope and calculation resolution. Three notched geometries are studied under cyclic bending-torsion:...
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Topography measurement methods evaluation for entire bending-fatigued fracture surfaces of specimens obtained by explosive welding
PublicationIn this paper, the methods of compensation of differences in the results of entire bending-fatigued fracture surface topographies were presented. The roughness evaluation was performed with a focus variation microscope and confocal surface topography measurement techniques. The differences in the ISO 25178 roughness parameters were investigated and procedures for their compensation were studied. It was found that various types...
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