Thermo, Volume 5, Issue 4 (December 2025) – 13 articles

Heat input always plays a crucial role in enhancing penetration depth within the heat-affected zone (HAZ) of the orbital TIG welding process. The heat tint, in addition, caused by heat input, is a decisive factor for the quality of sanitary tube welds, which AWS D18.2 strictly regulates. Therefore, controlling heat input to achieve complete penetration while maintaining an acceptable heat tint level is considered essential in sanitary tube welding. For this reason, this study conducted 27 experimental welds with variations in the parameters of the Orbital TIG Welding process to determine the optimal welding parameters for sanitary tubes with an outer diameter of Ø38.1 mm and a thickness of 1.65 mm. Taguchi analysis identified the optimal parameter combination to achieve full penetration as a welding current of 100 A, an arc length of 1.5 mm, and a welding speed of 5 mm/s. In addition, the use of internal backing gas and arc time significantly improved the heat tint level of the welds produced under the proposed parameter set. Full article

The present study aims to experimentally investigate pool boiling heat transfer characteristics, such as critical heat flux (CHF) and boiling heat transfer coefficient (BHTC), of pure distilled water (d-H₂O) and functionalised graphene nanoplatelet (f-GnPs)–d-H₂O nanofluids using a nichrome (Ni-Cr) test wire as the heating element. The distilled water (dH₂O) and GnP (5–10 nm and 15 µm, Cheap Tubes, USA) were chosen as the base fluid and nanomaterial, respectively. The GnP was chemically functionalized and dispersed in dH₂O using a probe sonicator. The nanofluids were characterized by measuring the zeta potential distribution and pH to ensure stability on day 1 and day 10 following preparation. The results show that the zeta potential values range from −31.6 mV to −30.6 mV, while the pH values range from 7.076 to 7.021 on day 1 and day 10, respectively. The novelty of the present study lies in the use of f-GnPs with a controlled size and stable nanofluid, confirmed through zeta potential and pH analysis, to determine the heat transfer behaviour of a Ni-Cr test wire under pool boiling conditions. The pool boiling heat transfer characteristics, such as CHF and BHTC, were observed using the fabricated pool boiling heat transfer test facility. Initially, the dH₂O and f-GnP–dH₂O nanofluids were separately placed in a glass container and heated using a pre-heater to reach their saturation point of 100 °C. The electrical energy was gradually increased until it reached the critical point of the Ni-Cr test wire, i.e., the burnout point, at which it became reddish-yellow hot. The CHF and BHTC were predicted from the experimental outputs of voltage and current. The results showed an enhancement of ~15% in the CHF at 0.1 vol% of f-GnPs. The present study offers a method for enhancing two-phase flow characteristics for heat pipe applications. Full article

Coal-to-Synthetic Natural Gas (SNG) plays a crucial role in China’s decarbonization strategy but faces significant sustainability challenges due to its carbon-intensive nature. This study integrates Life Cycle Assessment (LCA) with Box–Behnken Design and Response Surface Methodology (BBD-RSM) to quantify and optimize key parameters for emission reduction. The LCA results indicate that 90.48% of total emissions originate from the SNG production stage, while coal mining accounts for 9.38%, leading to a carbon intensity of 660.92 g CO₂^eq/kWh, second only to conventional coal power. Through BBD-RSM optimization, the optimal parameter combination was identified as a raw coal selection rate of 62.5%, an effective calorific value of 16.75 MJ/kg, and a conversion efficiency of 83%, corresponding to an energy-based rate of return (ERR) of 49.79%. The optimized scenario demonstrates a substantial reduction in total life-cycle emissions compared with the baseline, thereby improving the environmental viability of coal-to-SNG technology. Furthermore, this study employs the energy-based rate of return (ERR) as a normalization and comparative evaluation metric to quantitatively assess emission reduction potential. The ERR, combined with BBD-RSM, enables a more systematic exploration of emission-driving factors and enhances the application of statistical optimization methods in the coal-to-SNG sector. The findings provide practical strategies for promoting the low-carbon transformation of the coal-to-SNG industry and contribute to the broader advancement of sustainable energy development. Full article

When it comes to developing new titanium alloys for biomaterials, β metastable alloys have been gaining the most attention from researchers, as they have a lower elastic modulus and the microstructure can be altered by adding other elements and heat treatments (HT), which makes the material a promising biomaterial. The Ti-10Mo-Mn alloys were melted in an arc furnace. After ingot casting, a homogenization treatment (#T) was carried out, followed by the mechanical processing of hot rolling (#1) and subsequent annealing HT (#2). This work aimed to analyze the influence of some HT on the phase constituents, percentages, morphologies, distributions and selected mechanical properties, such as microhardness and elastic modulus in Ti-10Mo-xMn system alloys, ranging from 0 to 8% by weight. The results showed that alloys with low manganese content, classified as metastable, were sensitive to the HT in this study. From 4% manganese, the alloys had a stable β phase and were, therefore, not sensitive to the HT. The hardness of the alloys with 0 and 2% manganese remained high, possibly due to the presence of the omega phase. The elastic modulus increased from the hot rolling condition (#1) to annealing condition (#2) in all compositions. The Ti-10Mo-2Mn#1 alloy stood out among the alloys studied. It showed the lowest elastic modulus (~87 GPa), making it suitable for use as a biomaterial. Full article

This paper describes a laboratory set-up designed to support hands-on learning of heat transfer principles in aerospace engineering education. Developed within the framework of experiential and project-based learning, the set-up enables students to experimentally characterize the convective coefficient of a cooling fan and the thermo-optical properties of aluminum plates with different surface coatings, specifically their absorptivity and emissivity. A custom-built, LED-based radiation source (the ESAT Sun simulator) and a calibrated temperature acquisition system are used to emulate and monitor radiative heating under controlled conditions. Simplified physical models are developed for both the ESAT Sun simulator and the plates that capture the dominant thermal dynamics via first-order energy balances. The laboratory workflow includes real-time data acquisition, curve fitting, and thermal model inversion to estimate the convective and thermo-optical coefficients. The results demonstrate good agreement between the model predictions and observed temperatures, which supports the suitability of the set-up for education. The proposed activities can strengthen the student’s understanding of convective and radiative heat transport in aerospace applications while also fostering skills in data analysis, physical and numerical reasoning, and system-level thinking. Opportunities exist to expand the material library, refine the physical modeling, and evaluate the long-term pedagogical impact of the educational set-up described here. Full article

This article presents experimental results for motive nozzles with profiled supersonic parts of parabolic, hyperbolic, and elliptical shapes, compared to conical nozzles with unprofiled supersonic parts. This study examined the effect of nozzle geometry and profile on thermodynamic and flow parameters of the vaporization process. The measured parameters included outlet pressure, flow velocity, and mass vapor content, along with dimensionless efficiency indicators, such as relative outflow velocity and the velocity coefficient. Graphical dependencies of these parameters on the relative initial underheating, (1 − ε_s0), were obtained. This parameter represents the ratio of the pressure difference between inlet and saturation conditions (at inlet temperature) to the inlet pressure. The results show that profiled nozzles operate effectively over a wider range of (1 − ε_s0) = 0.20–0.45, compared to conical unprofiled nozzles. The vaporization constant for profiled nozzles remained at b_n ≈ (2/3)^0.5 along their length. The velocity coefficients for profiled designs were 4–6% higher, and the volumetric vapor content at the outlet was also greater, indicating a more efficient vaporization process. Overall, the findings demonstrate that profiling the supersonic section of a motive nozzle improves the operating range, flow characteristics, and vaporization quality compared to conventional conical designs. Full article

Biogas has been identified as a sustainable resource of renewable and clean energy because of its social, economic, and environmental benefits. In this work, the analysis of a biogas combined cycle power plant coupled with a carbon capture and utilization (CCU) technology and an organic Rankine cycle (ORC) was considered. The integrated process was subjected to a multi-objective assessment considering energy, economic, environmental, and safety items. The CCU system was taken to produce syngas as a value-added product, and the use of different working fluids for the ORC, namely, R1234yf, R290, and R717, was also examined. Such working fluids were selected to represent options with varying environmental and inherent safety implications. It was shown that the integration of the CCU and ORC components to the biogas cycle plant can provide significant benefits that include a 48.65 kt/year syngas production, a decrease in carbon capture energy penalty by 33%, and a reduction in e-CO₂ emissions above 80% with respect to the stand-alone power plant. Comparison with conventional technologies also showed important environmental benefits. The analysis of inherent safety showed that the selection of working fluids for the ORC can have a significant impact on the process risk. From the set of working fluids considered in this work, R717 provided the best choice for the integrated system based on its lowest operational risk and the highest electricity production (355 kWe). The multi-objective approach used in this work allowed the quantification of benefits provided by the integration of CCUs and ORCs with respect to the base process within an overall economic, sustainability, and inherent safety assessment. Full article

This study systematically investigates the variation in the ceiling flame tilt angle in an immersed tube tunnel under the combined effect of longitudinal ventilation and sidewall smoke extraction. The experimental program considers different longitudinal velocities, various sidewall smoke exhaust rates and multiple relative distances between the fire source and the sidewall exhaust outlet, aiming to comprehensively reveal the flame tilt angle under multi-factor coupling conditions. Experiments were carried out in a reduced-scale tunnel model (6.64 m long, 0.96 m wide and 0.5 m high). A porous gas burner supplied a steady heat release, with its distance from the sidewall exhaust outlet systematically varied. Results indicate that the flame tilt angle decreases as the distance between the fire source and the sidewall exhaust outlet increases. A theoretical model was developed to predict the flame tilt angle by incorporating both the sidewall smoke exhaust rate and the relative fire source–exhaust distance. The model accounts for mass loss due to smoke extraction, estimated from the local longitudinal velocity distribution. Predictions from the proposed model agree well with the experimental data. Full article

The decarbonization of hard-to-defossilize sectors, such as international maritime transport, requires innovative, and at times disruptive, energy solutions that combine efficiency, scalability, and climate benefits. Therefore, power-to-liquid (PtL) routes have stood out for their potential to use low-emission electricity for the production of synthetic fuels, via electrolytic hydrogen and CO₂ capture. However, the high energy demand inherent to these routes poses significant challenges to large-scale implementation. Moreover, PtL routes are usually at most neutral in terms of CO₂ emissions. This study evaluates, from a thermo-energetic perspective, the optimization potential of an e-methanol synthesis route through integration with a biomass oxy-fuel combustion process, making use of electrolytic oxygen as the oxidizing agent and the captured CO₂ as the carbon source. From the standpoint of a first-law thermodynamic analysis, mass and energy balances were developed considering the full oxygen supply for oxy-fuel combustion to be met through alkaline electrolysis, thus eliminating the energy penalty associated with conventional oxygen production via air separation units. The balance closure was based on a small-scale plant with a capacity of around 100 kta of methanol. In this integrated configuration, additional CO₂ surpluses beyond methanol synthesis demand can be directed to geological storage, which, when combined with bioenergy with carbon capture and storage (BECCS) strategies, may lead to net negative CO₂ emissions. The results demonstrate that electrolytic oxygen valorization is a promising pathway to enhance the efficiency and climate performance of PtL processes. Full article

Hydrogen-powered unmanned aerial vehicles (UAVs) offer significant advantages, such as environmental sustainability and extended endurance, demonstrating broad application prospects. However, the hydrogen fuel cells face prominent thermal management challenges during flight operations. This study established a numerical model of the fuel cell thermal management system (TMS) for a hydrogen-powered UAV. Computational fluid dynamics (CFD) simulations were subsequently performed to investigate the impact of various design parameters on cooling performance. First, the cooling performance of different fan density configurations was investigated. It was found that dispersed fan placement ensures substantial airflow through the peripheral flow channels, significantly enhancing temperature uniformity. Specifically, the nine-fan configuration achieves an 18.5% reduction in the temperature difference compared to the four-fan layout. Additionally, inlets were integrated with the fan-based cooling system. While increased external airflow lowers the minimum fuel cell temperature, its impact on high-temperature zones remains limited, with a temperature difference increase of more than 19% compared to configurations without inlets. Furthermore, the middle inlet exhibits minimal vortex interference, delivering superior thermal performance. This configuration reduces the maximum temperature and average temperature by 9.1% and 22.2% compared to the back configuration. Full article

The acceleration of climate change and increasing weather-related disasters require more active utilization of renewable energy. To maximize the use of renewable energy, energy storage is an essential part. Liquid piston gas compressors have recently drawn attention because of their applicability to compressed air-based energy storage. Aqueous foam can be used to enhance the efficiency of liquid piston gas compression by boosting heat transfer. To validate the effectiveness of the combination of liquid piston and aqueous foam in a multi-stage compression system, which can contribute to higher efficiency, the present work performed experimental study at various pressure levels. Compressions were performed with and without aqueous foam at three different initial pressure levels of 1, 2, and 3 bars. For each cycle of compression, a pressure ratio of 2 was used, and the impact of pressure levels on compression efficiency was measured. With the use of foam, isothermal efficiencies of 91.4, 88.2, and 86.6% were observed at 1, 2, and 3 bar(s), which improved by 2.2, 2.1, and 1.3% compared to the baseline compressions. To identify the cause of the effectiveness variations, the volume changes in the foam at the different pressure levels were visually compared. In higher-pressure tests, a significant reduction in the foam amount was observed, and this change may contribute to the decreased effectiveness of the technique. Full article

Infrared thermography for human skin temperature measurement, when calibrated with standard blackbodies, suffers from errors due to the mismatch in emissivity between a blackbody and human skin. This study introduces a novel calibration method utilizing a human skin-like gradient radiation source to enhance measurement accuracy. A custom radiation source with six temperature points and skin-like emissivity was developed. Thermal imagers were calibrated using this source, and their performance was compared against traditional blackbody calibration. The proposed method reduced the calibration error to 0.04 °C, a significant improvement over the 0.15 °C error obtained with blackbody calibration. Calibration with a skin-like radiation source proves superior to the blackbody method, enabling high-accuracy (less than 0.1 °C) human skin temperature measurement for improved fever screening. Full article

This study evaluates the impact of using group concept maps in the teaching of Applied Thermodynamics in the Bachelor’s Degree in Industrial Electronics and Automation Engineering. The methodology consisted of selecting topics with a high conceptual load, collaboratively creating concept maps, and subsequently evaluating them by both students and teaching staff. Students achieved average scores above 7/10 in the concept map activity, with teacher and student evaluations averaging 7.8 and 7.3, respectively. Knowledge assessment via pre- and post-tests revealed a 20% increase in concept comprehension. For example, in the topic of Principles of Thermodynamics, the percentage of correct answers on the most complex question increased from 13% in the Pre-Test to 40% in the post-test. In the topic of Refrigeration Cycles, some questions showed an improvement from 18% to 25%. The students’ perception of the activity was positive, with an average satisfaction rating of 6.9 out of 10. Furthermore, most students acknowledged that the activity helped them stay engaged with the subject matter and identify errors in their own learning. The high participation in the activity, despite its low impact on the final grade, demonstrates the students’ strong motivation for this study approach. Therefore, the implementation of concept maps not only facilitated the understanding of key concepts but also promoted critical reflection and collaborative learning, establishing itself as an effective strategy in the teaching of Applied Thermodynamics. Full article