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7 pages, 481 KB

Open AccessProceeding Paper

Working Fluid Selection for Biogas-Powered Organic Rankine Cycle-Vapor Compression Cycle

by Muhammad Talha, Nawaf Mehmood Malik, Muhammad Tauseef Nasir, Waqas Khalid, Muhammad Safdar and Khawaja Fahad Iqbal

Mater. Proc. 2025, 23(1), 1; https://doi.org/10.3390/materproc2025023001 - 25 Jul 2025

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Abstract

The worldwide need for energy as well as environmental challenges have promoted the creation of sustainable power solutions. The combination of different working fluids is used for an organic Rankine cycle-powered vapor compression cycle (ORC-VCC) to deliver cooling applications. The selection of an [...] Read more.

The worldwide need for energy as well as environmental challenges have promoted the creation of sustainable power solutions. The combination of different working fluids is used for an organic Rankine cycle-powered vapor compression cycle (ORC-VCC) to deliver cooling applications. The selection of an appropriate working fluid significantly impacts system performance, efficiency, and environmental impact. The research evaluates possible working fluids to optimize the ORC-VCC system. Firstly, Artificial Neural Network (ANN)-derived models are used for exergy destruction ( E d t o t ) and heat exchanger total heat transfer capacity ( U A t o t ). Later on, multi-objective optimization was carried out using the acquired models for E d t o t and U A t o t using the Genetic Algorithm (GA) followed by the Technique for Order of Preference by Similarity to Ideal Solution (TOPSIS). The optimization results showcase Decane ORC-R600a VCC as the best candidate for the ORC-VCC system; the values of E d t o t and U A t o t were found to be 24.50 kW and 6.71 kW/K, respectively. The research data show how viable it is to implement biogas-driven ORC-VCC systems when providing air conditioning capabilities. Full article

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8 pages, 3432 KB

Open AccessProceeding Paper

Enhanced Electrochemical Energy Storage via FeCoS/RGO Composites

by Muhammad Tariq and Mohsin Ali Marwat

Mater. Proc. 2025, 23(1), 2; https://doi.org/10.3390/materproc2025023002 - 25 Jul 2025

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Abstract

Supercapacitors are considered a bridge between batteries and capacitors due to their significant energy density, as well as power density. Herein, we prepared two novel electrodes of Fe_0.8Co_0.2S and Fe_0.8Co_0.2S/rGO composites and analyzed their supercapacitor [...] Read more.

Supercapacitors are considered a bridge between batteries and capacitors due to their significant energy density, as well as power density. Herein, we prepared two novel electrodes of Fe_0.8Co_0.2S and Fe_0.8Co_0.2S/rGO composites and analyzed their supercapacitor performance. The results indicated that Fe_0.8Co_0.2S/rGO, prepared through co-precipitation and annealing, exhibited a higher specific capacitance value and improved electrochemical properties in comparison to Fe_0.8Co_0.2S due to the synergistic effect of rGO with Fe_0.8Co_0.2S. X-ray diffraction (XRD) confirmed the desired phases of Fe_0.8Co_0.2S, while scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDS) verified the microstructures and desired elements. Cyclic voltammetry (CV) confirmed an enhanced oxidation current from +25 mA to +49 mA at 10 mV/s, while galvanometric charge–discharge (GCD) showed an enhanced discharge time from 78 s to 300 s. As a result, the specific capacitance and energy density were enhanced from 74.3 F/g to 285.7 F/g and 2.84 Wh/kg to 10.9 Wh/kg, respectively. This contributed to a more than 283% increase in specific capacitance, as well as energy density. Overall, Fe_0.8Co_0.2S/rGO shows great potential for small-scale energy storage devices. Full article

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9 pages, 1792 KB

Open AccessProceeding Paper

A Comparative Analysis of the Impact Behavior of Honeycomb Sandwich Composites

by Yasir Zaman, Shahzad Ahmad, Muhammad Bilal Khan, Babar Ashfaq and Muhammad Qasim Zafar

Mater. Proc. 2025, 23(1), 3; https://doi.org/10.3390/materproc2025023003 - 29 Jul 2025

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Abstract

The increasing need for materials that are both lightweight and strong in the aerospace and automotive sectors has driven the extensive use of composite sandwich structures. This study examines the impact response of honeycomb sandwich composites fabricated using the vacuum-assisted resin transfer molding [...] Read more.

The increasing need for materials that are both lightweight and strong in the aerospace and automotive sectors has driven the extensive use of composite sandwich structures. This study examines the impact response of honeycomb sandwich composites fabricated using the vacuum-assisted resin transfer molding (VARTM) technique. Two configurations were analyzed, namely carbon–honeycomb–carbon (CHC) and carbon–Kevlar–honeycomb–Kevlar–carbon (CKHKC), to assess the effect of Kevlar reinforcement on impact resistance. Charpy impact testing was conducted to evaluate energy absorption, revealing that CKHKC composites exhibited significantly superior impact resistance compared to CHC composites. The CKHKC composite achieved an average impact strength of 70.501 KJ/m², which is approximately 73.8% higher than the 40.570 KJ/m² recorded for CHC. This improvement is attributed to Kevlar’s superior toughness and energy dissipation capabilities. A comparative assessment of impact energy absorption further highlights the advantages of hybrid Kevlar–carbon fiber composites, making them highly suitable for applications requiring enhanced impact performance. These findings provide valuable insights into the design and optimization of high-performance honeycomb sandwich structures for impact-critical environments. Full article

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10 pages, 1309 KB

Open AccessProceeding Paper

A Sustainable Approach to Cooking: Design and Evaluation of a Sun-Tracking Concentrated Solar Stove

by Hasan Ali Khan, Malik Hassan Nawaz, Main Omair Gul and Mazhar Javed

Mater. Proc. 2025, 23(1), 4; https://doi.org/10.3390/materproc2025023004 - 29 Jul 2025

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Abstract

Access to clean cooking remains a major challenge in rural and off-grid areas where traditional fuels are costly, harmful, or scarce. Solar cooking offers a sustainable solution, but many existing systems suffer from fixed positioning and low efficiency. This study presents a low-cost, [...] Read more.

Access to clean cooking remains a major challenge in rural and off-grid areas where traditional fuels are costly, harmful, or scarce. Solar cooking offers a sustainable solution, but many existing systems suffer from fixed positioning and low efficiency. This study presents a low-cost, dual-axis solar tracking parabolic dish cooker designed for such regions, featuring adjustable pot holder height and portability for ease of use. The system uses an Arduino UNO, LDR sensors, and a DC gear motor to automate sun tracking, ensuring optimal alignment throughout the day. A 0.61 m parabolic dish with ≥97% reflective silver-coated mirrors concentrates sunlight to temperatures exceeding 300 °C. Performance tests in April, June, and November showed boiling times as low as 3.37 min in high-irradiance conditions (7.66 kWh/m²/day) and 6.63 min under lower-irradiance conditions (3.86 kWh/m²/day). Compared to fixed or single-axis systems, this design achieved higher thermal efficiency and reliability, even under partially cloudy skies. Built with locally available materials, the system offers an affordable, clean, and effective cooking solution that supports energy access, health, and sustainability in underserved communities. Full article

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10 pages, 1457 KB

Open AccessProceeding Paper

A Semi-Automated Framework for Standardized Vertebral Measurement with Enhanced Reproducibility in Lumbar Spine MRI Analysis

by Muhammad Hasan Masrur, Rana Talha Khalid, Khair Ul Wara, Abdul Alber, Faizan Ahmad, Zainab Bibi and Jawad Hussain

Mater. Proc. 2025, 23(1), 5; https://doi.org/10.3390/materproc2025023005 - 30 Jul 2025

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Abstract

A semi-automated framework for vertebral measurement has been developed to overcome clinical limitations of subjectivity and poor reproducibility in spinal assessment. The framework integrates watershed segmentation with level-set functions and deterministic cylindrical modeling to convert pixel-based measurements to physical dimensions, achieving 2% reproducibility [...] Read more.

A semi-automated framework for vertebral measurement has been developed to overcome clinical limitations of subjectivity and poor reproducibility in spinal assessment. The framework integrates watershed segmentation with level-set functions and deterministic cylindrical modeling to convert pixel-based measurements to physical dimensions, achieving 2% reproducibility error. Interactive region-of-interest selection enables the effective handling of multi-vertebrae cases while preserving clinical expertise input. Validation using a lumbar spine MRI dataset on 515 patients confirms measurements fall within established anatomical parameters for L3–L5 vertebrae. This methodology provides a transparent, reproducible approach for standardized vertebral assessment that balances automation with clinical reasoning, offering immediate implementation potential without the computational demands and regulatory challenges associated with complex AI systems. Full article

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8 pages, 810 KB

Open AccessProceeding Paper

Towards Cost Modelling for Rapid Prototyping and Tooling Technology-Based Investment Casting Process for Development of Low-Cost Dies

by Samina Bibi and Muhammad Sajid

Mater. Proc. 2025, 23(1), 6; https://doi.org/10.3390/materproc2025023006 - 30 Jul 2025

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Abstract

In precision manufacturing, selecting the most economically viable process is essential for low-volume, high-complexity applications. This study compares the machining process (MP), conventional investment casting (CIC), and rapid prototyping (RP) through a mathematical cost model based on the activity-based costing (ABC) approach. The [...] Read more.

In precision manufacturing, selecting the most economically viable process is essential for low-volume, high-complexity applications. This study compares the machining process (MP), conventional investment casting (CIC), and rapid prototyping (RP) through a mathematical cost model based on the activity-based costing (ABC) approach. The model captures detailed cost drivers across design, logistics, production, and environmental dimensions. Results show that MP incurs the highest production cost (94.45%) but minimal logistics (3.43%). CIC bears the highest total cost and significant production overhead (93.2%), while RIC achieves the lowest total cost, driven by major savings in production (84.6%) and labor. Although RIC has slightly higher logistics than MP, it demonstrates superior economic efficiency for small-batch, high-accuracy production. This study provides a unified quantitative framework for cost comparison and offers valuable guidance for manufacturers aiming to enhance efficiency, sustainability, and profitability across diverse fabrication strategies. Full article

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12 pages, 953 KB

Open AccessProceeding Paper

Lie Optimal Solutions of Heat Transfer in a Liquid Film over an Unsteady Stretching Surface with Viscous Dissipation and an External Magnetic Field

by Haris Ahmad, Chaudhry Kashif Iqbal, Muhammad Safdar, Bismah Jamil and Safia Taj

Mater. Proc. 2025, 23(1), 7; https://doi.org/10.3390/materproc2025023007 - 30 Jul 2025

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Abstract

A lie point symmetry analysis of flow and heat transfer under the influence of an external magnetic field and viscous dissipation was previously conducted using a couple of lie point symmetries of the model. In this article, we construct a one-dimensional optimal system [...] Read more.

A lie point symmetry analysis of flow and heat transfer under the influence of an external magnetic field and viscous dissipation was previously conducted using a couple of lie point symmetries of the model. In this article, we construct a one-dimensional optimal system for the flow model to extend the previous analysis. This optimal system reveals all the solvable classes of the flow model by deducing similarity transformations, reducing flow equations, and solving the obtained equations analytically. A general class of solutions that encompasses all the previously known lie similarity solutions is provided here. Full article

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11 pages, 3090 KB

Open AccessProceeding Paper

Investigating Mesh Sensitivity in Linear and Non-Linear Buckling Analysis of Composite Cylindrical Shells

by Shahmeer Khalid Chatha, Muhammad Sher Ali, Muhammad Noman Butt and Muhammad Usman

Mater. Proc. 2025, 23(1), 8; https://doi.org/10.3390/materproc2025023008 - 31 Jul 2025

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Abstract

This study investigates mesh sensitivity in the buckling analysis of composite cylindrical shells using the finite element methods. Two Carbon Fiber-Reinforced Plastic (CFRP) models with distinct layups were subjected to linear (Eigenvalue) and non-linear (Riks) analyses under axial compression. Mesh sizes ranging from [...] Read more.

This study investigates mesh sensitivity in the buckling analysis of composite cylindrical shells using the finite element methods. Two Carbon Fiber-Reinforced Plastic (CFRP) models with distinct layups were subjected to linear (Eigenvalue) and non-linear (Riks) analyses under axial compression. Mesh sizes ranging from 50 mm to 2.5 mm were tested using Abaqus. The results revealed that the non-linear analysis is more mesh-sensitive and computationally demanding. Model-1 showed better convergence in non-linear analysis, with <1% error, while Model-2 favored linear analysis, with <0.5% error at finer meshes. The comparison of models results with the experimental data highlights the importance of an empirical correction factor. These findings provide practical guidelines for mesh selection in composite shell analysis. Full article

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11 pages, 1887 KB

Open AccessProceeding Paper

Experimental Evaluation of Coefficient of Friction for Fretting Regimes

by Shumaila Fatima, Shahid Mehmood, Muhammad Awais Hamza, Atta Ur Rahman, Hafiz Samama Sumair, Soban Ullah, Muhammad Ammar Nasir, Muhammad Ehtisham and Husnain Zulfiqar Ali

Mater. Proc. 2025, 23(1), 9; https://doi.org/10.3390/materproc2025023009 - 31 Jul 2025

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Abstract

This study investigates the coefficient of friction (COF) and wear behavior in fretting regimes—stick, stick–slip, and gross sliding—under dry and oil-lubricated conditions. Fretting tests were conducted by increasing oscillation amplitude from a few micrometers to 48 µm. In dry conditions, displacement amplitude initially [...] Read more.

This study investigates the coefficient of friction (COF) and wear behavior in fretting regimes—stick, stick–slip, and gross sliding—under dry and oil-lubricated conditions. Fretting tests were conducted by increasing oscillation amplitude from a few micrometers to 48 µm. In dry conditions, displacement amplitude initially rose rapidly, stabilizing after about 5 million load cycles, indicating steady-state behavior. The friction ratio (FR) surged early, peaking between 0.7 and 1.0, before declining to stable values, suggesting a shift from adhesive to stable frictional interaction. The minimal slip amplitude confirmed the predominance of the stick regime. Conversely, in oil-lubricated conditions, displacement amplitude stabilized after an initial increase, achieving higher amplitudes than in dry tests. The FR started below 0.2, gradually increasing to a peak around 10,000 load cycles for higher oscillation amplitudes (e.g., 15 µm), reflecting the lubricant’s role in reducing metal-to-metal contact. COF curves in lubricated tests showed smoother transitions and lower peak values compared to dry tests. These findings highlight the lubricant’s effectiveness in minimizing adhesion and enhancing sliding efficiency, offering insights for optimizing material performance in engineering applications. Full article

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8 pages, 1843 KB

Open AccessProceeding Paper

Designing a Sustainable Organic Rankine Cycle for Remote Geothermal Heat Sources in Pakistan

by Muhammad Shoaib Ijaz, Marig Shabbir Ansari, Aftab Sabghatullah, Intesar Alam and Muhammad Qasim Zafar

Mater. Proc. 2025, 23(1), 10; https://doi.org/10.3390/materproc2025023010 - 31 Jul 2025

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Abstract

This paper discusses a thorough analysis, as well as the design, of an environmentally friendly, single-stage Organic Rankine Cycle (ORC) system, particularly optimized for untapped geothermal applications in Pakistan that are secluded and off-grid, to tackle the severe energy crises choking this country [...] Read more.

This paper discusses a thorough analysis, as well as the design, of an environmentally friendly, single-stage Organic Rankine Cycle (ORC) system, particularly optimized for untapped geothermal applications in Pakistan that are secluded and off-grid, to tackle the severe energy crises choking this country and its resources. Keeping in mind its Global Warming Potential (GWP), as well as its performance in the ORC, r600a was chosen as the operating fluid. This study focuses on varying the temperature, pressure, and mass flow rate of not only the geothermal reservoir but that of the operating fluid in the ORC as well. The impacts of adjusting these parameters on the net power output, cycle efficiency, and component-wise exergy destruction, as well as the total exergy destruction, are examined extensively. Analyses of the component-wise exergy destruction found that the maximum exergy destruction occurred in the evaporator, whereas it was discovered that decreasing the condenser pressure below 350 kPa led to negative exergy destruction values, although the total exergy destruction remained positive. Full article

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9 pages, 1843 KB

Open AccessProceeding Paper

Numerical Modelling of Void Closure Diffusion Model

by Muhammad Akif, Massab Junaid, Tauheed Shehbaz and Fahd Nawaz Khan

Mater. Proc. 2025, 23(1), 11; https://doi.org/10.3390/materproc2025023011 - 5 Aug 2025

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Abstract

A void closure analytic model for the diffusion bonding of titanium TC4 alloy is developed in this study, in which an FEA-based deformation mechanism is coupled with a numerical analysis for diffusion. The focus was to evaluate the effect of pressure and the [...] Read more.

A void closure analytic model for the diffusion bonding of titanium TC4 alloy is developed in this study, in which an FEA-based deformation mechanism is coupled with a numerical analysis for diffusion. The focus was to evaluate the effect of pressure and the temperature on the bonded ratio. As the value of bonding pressure or the bonding temperature increased, the bonding time decreased. The dependence of bonded ratio and time was modeled as an exponential curve. The geometrical model for the mechanism was utilized so that it can incorporate the void division aspect in the process of diffusion bonding. Full article

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8 pages, 1557 KB

Open AccessProceeding Paper

Multi-Sensor Indoor Air Quality Monitoring with Real-Time Logging and Air Purifier Integration

by Muhammad Afrial, Muneeza Rauf, Muhammad Nouman, Muhammad Talal Khan, Muhammad Arslan Rizwan and Naqash Ahmad

Mater. Proc. 2025, 23(1), 12; https://doi.org/10.3390/materproc2025023012 - 5 Aug 2025

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Abstract

Most people utilize their time indoors, either at home or in the workplace. However, certain human interventions badly affect the indoor atmosphere, causing potential health problems for occupants. This study aims to propose an air monitoring device integrated with an air purifier that [...] Read more.

Most people utilize their time indoors, either at home or in the workplace. However, certain human interventions badly affect the indoor atmosphere, causing potential health problems for occupants. This study aims to propose an air monitoring device integrated with an air purifier that monitors the pollutants affecting the indoor environment and automatically turns on/off the air purifier based on the pollution level. In the system, MQ7, MQ2, DHT11, and GP2Y1010AU0F sensors are integrated with ESP32 to detect indoor air pollutants, e.g., carbon monoxide (CO), methane (CH₄), temperature, humidity, and PM2.5. Data were collected for 30 days by mounting a proposed device in different indoor locations, including a poorly ventilated average living room, an indoor kitchen, and a crowded office space. The emission of carbon monoxide (CO) and methane (CH₄) was at 29.4 ppm and 10.9 ppm, PM2.5 was detected as 3 µg/m³, and the temperature and humidity were at 23 °C and 28%, respectively. Utilizing the Wi-Fi ability of ESP32, the data were transferred to the ThingSpeak IoT platform for the live tracking and analysis of the indoor atmosphere. Observing the measured data, the proposed system’s accuracy was calculated by comparing the results against a known standard device, which was estimated to be 95%. To protect the designed system, a protective case was also designed. Full article

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13 pages, 4100 KB

Open AccessProceeding Paper

Simulation and Experimental Validation of a Microfluidic Device Used for Cell Focusing and Sorting Based on an Inertial Microfluidics Technique

by Muhammad Zulfiqar, Fizzah Asif, Emad Uddin, Muhammad Irfan, Ch Abdullah, Sibghat Ullah, Danish Manshad and Hamza Mohsin

Mater. Proc. 2025, 23(1), 13; https://doi.org/10.3390/materproc2025023013 - 6 Aug 2025

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Abstract

Cell separation is a major process in biomedicine and diagnostics and in the food and pharmaceutical industries. In this paper, a channel design is proposed for cell separation based on a passive cell sorting technique and sheath less flow. Initially, erythrocytes and monocytes [...] Read more.

Cell separation is a major process in biomedicine and diagnostics and in the food and pharmaceutical industries. In this paper, a channel design is proposed for cell separation based on a passive cell sorting technique and sheath less flow. Initially, erythrocytes and monocytes are injected into the designed channel, and the behavior of the particles is observed. The erythrocyte and monocyte are 8 μm and 20 μm in size, respectively. The final design is tested for different cross-sectional areas and particle sizes; 20 μm is the largest particle size that can be sorted with this design. Particles are separated due to inertial migration because the forces that focus the particles in the channels, in the form of different streams, deepen the lift force on the inertia of the moving particles. The lift force pushes the particles toward the wall, while the Dean force causes them to rotate near to the wall, stabilizing their positions. The lift and Dean forces depend on the inertia of the particles and topology of the channel, respectively. In this research, cell sorting is quantified by the distance between the two separated particles, and the trend of Δ x x versus Q is discussed. The channel throughput is also quantified in terms of the minimum and maximum allowable flow rates. Particles are best sorted by critical flow rate and Dean number. This hook-shaped design is created using polymethyl siloxane (PDMS), which is ideally suited for use in lab-on-chip (LOC) devices for continuous filtration and particle separation. The design is also experimentally tested and validated with the simulation results. Full article

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8 pages, 3709 KB

Open AccessProceeding Paper

Performance Assessment of Fe_0.5Cu_0.5S/rGO Hybrid Composite as Potential Material for Advanced Energy Storage Applications

by Anusha Arif, Hasnain Murtaza, Mohsin Ali Marwat, Muhammad Ramzan Abdul Karim and Shariq Ijaz

Mater. Proc. 2025, 23(1), 14; https://doi.org/10.3390/materproc2025023014 - 8 Aug 2025

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Abstract

Transition metal sulfides have found a popular spot in research for super capacitive materials due to their enhanced power density and conductivity. This study reports the preparation of a hybrid iron copper sulfide, Fe_0.5Cu_0.5S/rGO, composite via the co-precipitation method. [...] Read more.

Transition metal sulfides have found a popular spot in research for super capacitive materials due to their enhanced power density and conductivity. This study reports the preparation of a hybrid iron copper sulfide, Fe_0.5Cu_0.5S/rGO, composite via the co-precipitation method. The structural and morphological characterization was carried out using X-ray diffraction (XRD) and scanning electron microscopy (SEM), which confirmed the successful integration of Fe_0.5Cu_0.5S with rGO. The composite exhibited a high specific capacitance of 416.91 F/g at 1 A/g, 330.65% higher than 96.81 F/g of Fe_0.5Cu_0.5S and outstanding cyclic stability. The enhanced performance can be attributed to the synergistic effects of Fe_0.5Cu_0.5S and rGO, facilitating efficient charge transfer kinetics, ion diffusion, and structural stability, making it a promising candidate for high-performing supercapacitor applications. Full article

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2048 KB

Open AccessProceeding Paper

Polysaccharide-Based Composite Material for Improved Food Packaging

by Khushbakht Ali Khan, Khudija Khan, Muhammad Hassan Lakhesar, Muhammad Waqas, Tauseef Ahmed, Ali Turab Jafry, Asim Yaqub, Huma Ajab and Shahid Ali Khan

Mater. Proc. 2025, 23(1), 15; https://doi.org/10.3390/materproc2025023015 - 8 Jun 2025

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Abstract

A gradual surge in the population on Earth has increased the demand for food. Various synthetic materials have been used for food packaging for a long time. These materials are contaminating our environment and disrupting human life and that of other species. This [...] Read more.

A gradual surge in the population on Earth has increased the demand for food. Various synthetic materials have been used for food packaging for a long time. These materials are contaminating our environment and disrupting human life and that of other species. This study was conducted to minimize the impact of the pollution caused by using plastics for conventional packaging. A green approach to synthesizing packaging material that prevents food contamination with improved mechanical properties was adopted. Firstly, extracts were obtained from grapes and tomatoes and dissolved into four different solvents, i.e., de-ionized water, dichloromethane, ethyl acetate, and n-hexane. Three different extract solutions were made in de-ionized water, varying the fraction of the extract and de-ionized water. The extracts were then tested for the presence of various phytochemicals. The solutions were then combined with cyclodextrin, starch, alginate, and polyvinyl alcohol, all of which are biodegradable, non-cytotoxic, and pocket-friendly. Calcium chloride was also added because it acts as a firming agent and a desiccant. This resulted in the formation of a total of six membranes with four different solvents. These membranes had varying degrees of biodegradability and antibacterial properties. Various phytochemicals, such as saponins, flavonoids, terpenoids, carotenoids, tannins, phenols, and steroids, were found in the fruit extracts. These phytochemicals act as anti-microbial and anti-fungal agents. Out of the six different membranes that were synthesized, the membrane with a 7:3 composition of crude extract to de-ionized water showed the best results for use as a packaging material, as it showed the best antibacterial properties and good reported biodegradability. The FTIR results for this membrane showed bands at around 3500 cm⁻¹, indicating the presence of -OH and -NH functionality since these bands overlap and cannot be distinguished at this position. The shoulder band indicates the presence of carboxylic acid -OH. Integrating biopolymers with fruit extracts enhances the nutritional value of food and provides an eco-friendly and cost-effective approach to packaging material synthesis. The synthesized membranes are cost-effective as they contain fruit extracts from grapes and tomatoes; starch; and cyclodextrin. The extracts obtained from the fruits were inexpensive, as 300 mL of extract cost around 300 Rs. The synthesized membranes had functional advantages such as biodegradability and providing an enhanced shelf life to food products. Hence, they reduce the losses caused by food spoilage. Another driver of their cost effectiveness is that they can reduce waste disposal costs on the one hand and environmental pollution on the other hand. Full article

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2877 KB

Open AccessProceeding Paper

Rolling Elements Fault Diagnosis Using Autoregressive Feature Extraction and Fuzzy C-Means Classification

by Rafey Mehmood Alam, Emad Uddin and Wajid Khan

Mater. Proc. 2025, 23(1), 16; https://doi.org/10.3390/materproc2025023016 - 8 Jul 2025

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Abstract

This research aims to develop an unsupervised machine learning technique for ball bearing fault detection and fault diagnosis. It evaluates vibration signals through Autoregression (AR) models and Fuzzy C-means (FCM) clustering for experimental data from bearings under degradation and fault conditions. FCM clustering [...] Read more.

This research aims to develop an unsupervised machine learning technique for ball bearing fault detection and fault diagnosis. It evaluates vibration signals through Autoregression (AR) models and Fuzzy C-means (FCM) clustering for experimental data from bearings under degradation and fault conditions. FCM clustering attained almost 97.7% accuracy in fault classification, with robustness validated across the sensor orientations (vertical/horizontal accelerometers) and with rotational speeds of 40 and 50 Hz. The major outcomes indicate the significance of the training data size on order evaluation and the stability of anomaly detection using three-sigma thresholds. Comparative analyses are made that showcase effective performance of the AR+FCM approach over conventional methods (e.g., K-means with statistical features) in clustering metrics (Silhouette Score and Dunn Index). Some of the challenges observed include reduced accuracy under speed variations and transient loads. The system’s unsupervised nature and generalization capability make it appropriate for real-time industrial applications, offering a credible setting for early-stage fault diagnosis and health monitoring. Full article

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17 pages, 3452 KB

Open AccessProceeding Paper

Design and Performance Optimization of Battery Pack with AI-Driven Thermal Runaway Prediction

by Jalal Khan, Sher Jan, Sami Ifitkhar, Ajmal Yaqoob, Ubaid Ur Rehman, Taqi Ahmad Cheema, Shahid Alam and Usman Habib

Mater. Proc. 2025, 23(1), 17; https://doi.org/10.3390/materproc2025023017 - 8 Aug 2025

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Abstract

Battery thermal management is a critical factor in ensuring the performance, safety, and longevity of electric vehicle (EV) battery packs. This study investigates the effectiveness of a forced air convection cooling system, optimized cell spacing and suitable configuration in maintaining optimal battery cell [...] Read more.

Battery thermal management is a critical factor in ensuring the performance, safety, and longevity of electric vehicle (EV) battery packs. This study investigates the effectiveness of a forced air convection cooling system, optimized cell spacing and suitable configuration in maintaining optimal battery cell temperatures. A 3D computational model was developed to analyze the temperature distribution of a battery pack under varying airflow velocities, cell spacings and configurations. The numerical simulations were validated through experimental testing, demonstrating a strong correlation between simulated and measured results. The findings reveal that with a 2 m/s velocity of the fan, the battery’s maximum temperature is reduced by 7% compared to the case of natural convection, while the fan consumed only 4% of the battery pack available capacity. An AI algorithm was trained on the experimental data obtained to perform data-driven predictions of failures. The results provide valuable insights for optimizing air cooling systems in EV applications. Future work will explore the effect of non-uniform air flow distribution in reducing the risk of thermal runaway and avoiding hot spots in the battery pack for optimal performance. Full article

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