Search Results (58)

Fused deposition modeling (FDM) printing has become increasingly popular for exploring advanced material matrices with a polymeric base. This study uses a low-energy method to investigate the metallization process on a surface created by 3D printing. This involves using an acrylic-paint-based solution to disperse the copper (Cu) powder on a polylactic acid (PLA) substrate, allowing for an evaluation of the fabricated samples’ mechanical, morphological, absorbance, and capacitance properties. The study findings indicate a gradual increase in tensile strength as the content of Cu in the acrylic paint layer on the PLA substrate increases. There was a clear and consistent increase in the tensile strength of the specimen, ranging from 13.5 MPa (sample 1) to 15.6 MPa (sample 5). Similarly, the percentage of strain at failure also showed a noticeable increase, ranging from 4.2% (sample 1) to 8.6% (sample 5). The scanning electron microscopy (SEM) investigation revealed the presence of completely enveloped Cu particles in acrylic paint on the FDM-printed surface of the PLA. The Ultraviolet–Visible Diffuse Reflectance Spectroscopy (UV–Vis DRS) indicated a significant change in the absorbance pattern as the copper content in the layer increased. The augmented absorbance values serve as an advantage because they demonstrate enhanced UV light interaction, which correlates with the increase in capacitance measurements of 6 to 8 pF. This result suggests that the fabricated sample potentially leads to favorable alterations in material characteristics for applications that demand stable capacitance alongside improved mechanical properties. The SEM analysis supported the observed trends. Full article

Hybrid composite materials have been widely used to advance the mechanical responses of fiber-reinforced composites by utilizing different types of fibers and fillers in a single polymeric matrix. This study incorporated three types of fibers: basalt woven fiber and steel (AISI304) wire meshes with densities of 100 and 200. These fibers were mixed with epoxy resin to generate plain composite laminates. Three fundamental mechanical tests (tensile, compression, and shear) were conducted according to the corresponding ASTM standards to characterize the steel wire mesh/basalt/epoxy FRP composites used as plain composite laminates. To investigate the flexural behavior of the hybrid laminates, various layer configurations and thickness ratios were examined using a design of experiments (DoE) matrix. Hybrid samples were chosen for flexural testing, and the same procedure was employed to develop a finite element (FE) model. Material properties from the initial mechanical testing procedure were integrated into plain and hybrid composite laminate simulations. The second FE model simulated the behavior of hybrid laminates under flexural loading; this was validated through experimental data. The results underwent statistical analysis, highlighting the optimal configuration of hybrid composite laminates in terms of flexural strength and modulus; we found an increase of up to 25% in comparison with the plain composites. This research provides insights into the potential improvements offered by hybrid composite laminates, generating numerical models for predicting various laminate configurations produced using hybrid steel wire mesh/basalt/epoxy FRP composites. Full article

Friction stir welding (FSW) has been recognized as a revolutionary welding process for marine applications, effectively tackling the distinctive problems posed by maritime settings. This review paper offers a comprehensive examination of the current advancements in FSW design, specifically within the marine industry. This paper provides an overview of the essential principles of FSW and its design, emphasizing its comparative advantages when compared with conventional welding techniques. The literature review reveals successful implementations in the field of shipbuilding and offshore constructions, highlighting design factors as notable enhancements in joint strength, resistance to corrosion, and fatigue performance. This study examines the progress made in the field of FSW equipment and procedures, with a specific focus on their application in naval construction. Additionally, it investigates the factors to be considered when selecting materials and ensuring their compatibility in this context. The analysis of microstructural and mechanical features of FSW joints is conducted, with a particular focus on examining the impact of welding settings. The study additionally explores techniques for mitigating corrosion and safeguarding surfaces in marine environments. The study also provides a forward-looking perspective by proposing potential areas of future research and highlighting the issues that may arise in the field of FSW for maritime engineering. The significance of incorporating environmental and economic considerations in the implementation of FSW for extensive marine projects is emphasized. Full article

Frames made of polymer composites are increasingly used in the aerospace, automotive, and agricultural industries. A frequently used technology in the production line of composite frames is winding rovings onto a non-load-bearing frame to form the structure using an industrial robot and a winding head, which is solidified through a subsequent heat-treatment pressure process. In this technology, the most difficult procedure is the winding of the curved parts of a composite frame. The primary concern is to ensure the proper winding angles, minimize the gaps and overlaps, and ensure the homogeneity of the wound layers. In practice, the curved frame parts very often geometrically form sections of a torus. In this work, the difficulty of achieving a uniform winding of toroidal parts is described and quantified. It is shown that attaining the required winding quality depends significantly on the geometrical parameters of the torus in question. A mathematical model with a detailed procedure describing how to determine the number of rovings of a given width on toroidal parts is presented. The results of this work are illustrated with practical examples of today’s industrial problems. Full article

This study aims to investigate the microstructural alterations, mechanical properties, sliding wear behavior, and corrosion properties of Al-15%Mg₂Si composites with different contents of yttria-stabilized zirconia (YSZ). Al-15%Mg₂Si composites with the different contents of YSZ (0, 3, 6, and 9 wt.%) were fabricated using the stir-casting technique. The fabricated composites were characterized by means of optical microscopy (OM), scanning electron microscopy (SEM) equipped with energy-dispersive spectroscopy (EDS), Vickers hardness tester, linear reciprocating tribometer (LRT), and electrochemical test. The results showed that with the introduction of YSZ particles, the average size of the primary Mg₂Si particles in the base composite was 137.78 µm, which was reduced to 88.36 µm after adding 9 wt.% YSZ. The aspect ratio of Mg₂Si particles also decreased from 3, for the base composite, to 1.27 in the composite containing 9 wt.% YSZ. Moreover, the hardness value displays an incremental trend from 102.72 HV, as recorded for the base in situ composite, to 126.44 HV in the composite with 9 wt.% YSZ. On top of that, the Al-15%Mg₂Si-9%YSZ demonstrates exceptional wear resistance, with the lowest wear rate of 0.46 mm³/km under a 25 N applied load. Its average coefficient of friction (COF) was recorded at 0.42, which is lower than both the 3 and 6 wt.% of YSZ-containing composites. The smoother worn surface in Al-15%Mg₂Si-9%YSZ hybrid composite implies the abrasion phenomenon, as dominant wear behavior is milder than the other fabricated composites. On top of that, the Al-15%Mg₂Si-9%YSZ also possesses optimum corrosion resistance. The corrosion rate is 0.080 mmpy, comparable to the 0.164 mmpy rate obtained in the in situ composite. Full article

In fiber-reinforced polymer (FRP) composite laminate structures operating under fluctuating stresses, interface delamination is seen as one of the significant damage mechanisms. The constant degradation of their relatively low interlaminar strength and stiffness are the primary reasons for delamination. This study develops an interlaminar fatigue damage model to quantify the mechanics of the damage process and address the reliability of composite structures. The model considers the failure process in two stages: (1) damage due to degradation of interlaminar elastic properties, and (2) damage due to dissipation of fracture energy through the damage evolution process. The model is examined for a case study of mode I fatigue loading of a carbon-fiber-reinforced polymer (CFRP) composite laminate. The results show that the interlaminar normal stress is confined to the crack front region, with tensile stress peaks at 70% of the interlaminar strength. Furthermore, a stable interface crack growth is predicted initially, followed by a sudden crack “jump” at 14,000 cycles. The simulation results are compared with the experimental data, with very good agreement, showing a successful validation of the fatigue model. Full article

The enhancement of fuel economy and the emission of greenhouse gases are the key growing challenges around the globe that drive automobile manufacturers to produce lightweight vehicles. Additionally, the reduction in the weight of the vehicle could contribute to its recyclability and performance (for example crashworthiness and impact resistance). One of the strategies is to develop high-performance lightweight materials by the replacement of conventional materials such as steel and cast iron with lightweight materials. The lightweight composite which is commonly referred to as fiber-reinforced plastics (FRP) composite is one of the lightweight materials to achieve fuel efficiency and the reduction of CO₂ emission. However, the damage of FRP composite under impact loading is one of the critical factors which affects its structural application. The bumper beam plays a key role in bearing sudden impact during a collision. Polymer composite materials have been abundantly used in a variety of applications such as transportation industries. The main thrust of the present paper deals with the use of high-strength glass fibers as the reinforcing member in the polymer composite to develop a car bumper beam. The mechanical performance and manufacturing techniques are discussed. Based on the literature studies, glass fiber-reinforced composite (GRP) provides more promise in the automotive industry compared to conventional materials such as car bumper beams. Full article

In adhesive bonding, two different substrate materials are joined together, usually by forming chemical bonds. The adhesive can stick things together. The loading rate and deformation mode can easily change the mechanical properties of the adhesive material. Hence, a vital aim of the current study is to evaluate the strain rate effect on the damage response of adhesive joints for Mode I loading scenarios. The adherend material was aluminum AL6061-T6, and Araldite 2015 was the adherent material. This experiment for delamination had a prescribed adherend size of 200 mm × 25 mm × 3 mm and an adhesive thickness of 0.5 mm. In situations where the strain rate affects the failure mechanism, a displacement rate of 5, 50, or 500 mm/min is sufficient to attain the failure mechanism. A double cantilever beam (DCB) specimen was employed to construct the FE model geometry for simulation. A hybrid experimental–FE technique was utilized to extract the properties of the adhesive interface. FE simulation has proven to have an excellent correlation with the experimental findings. Full article

Mechanical behavior of 3D-printed poly(lactic) acid material is an open topic for research on the reliability assessment of structures in marine and offshore industries. This article presents the mechanical and morphological properties of poly(lactic) acid specimens using the laminated object manufacturing technique. The effect was experimentally investigated on 3D-printed discs joined together to make a laminated test specimen. The specimen was prepared and tested under different infill patterns, viz. linear, triangular, and honeycomb structure, 50–90% infill density, and under varying disc thickness ranging from 3.4–5.6 mm. The maximum compressive strength of 42.47 MPa was attained for the laminated specimen with 70% infill, honeycomb pattern, and disc thickness of 3.4 mm (six discs), whereas the linear infill pattern has shown the least compressive performance of 22.40 MPa. The result of the study suggested that the honeycomb infill pattern with 90% infill density and six discs provides the optimum set of parameters for the 3D printing of PLA samples for maximization of compressive strength, especially for laminated object manufactured specimens. The Taguchi L9 orthogonal analysis (OA) suggested a significant influence on the infill pattern and the number of discs, contributing 51.60% and 48.29%, respectively, towards the compressive strength. Scanning Electron Microscopy (SEM) and toolmaker microscopic images have supported the observed experimental mechanical results for the laminated object manufactured specimens. The used technique of laminated object-manufactured components in the current study may have effective usage in marine and structural engineering fields. Full article

A growing fatigue crack in metallic materials and structures exhibits multifractal features that inherit signatures of the crack growth rate behavior of the material. This study exploits the recently established multifractal fatigue crack growth model to quantify the characteristic fatigue crack growth rate response of the AISI 410 martensitic stainless steel using an L-shaped bell crank structure. The objective is to demonstrate that the fatigue crack growth rate response of the material could be established by quantifying the fractality of the growing crack. The fractal approach avoids the need of the crack geometry factor when calculating the crack tip driving force. The fractal analysis of the crack image employs the box-counting algorithm to determine the fractal dimension along the edge of the crack length. The analysis is confined to the power law crack growth rate stage (Paris crack growth regime). Results show that the fatigue crack growth path in the bell crank structure is dictated by the Mode I (opening) component of the crack loading. The distribution of fractal-based fatigue crack growth rate data is within the 99% confidence limit of the median crack growth response by the Paris equation. Thus, the model could be employed for prediction of the fatigue crack growth response of engineering structures where the crack geometry factor is not readily available. Full article

Friction stir welding (FSW) is one of the primary fabrication techniques for joining different components, and it has become popular, especially in aluminum alloy structures for marine applications. The welded joint with the friction stir process greatly depends on the process parameters, i.e., feed rate, rotational speed, and pin profile of the tool. In the current study, plates of aluminum 5451 alloy were joined by the FSW technique, and the Taguchi method was used to find the process parameters at an optimal level. The maximum value of tensile strength, i.e., 160.6907 MPa, was achieved using optimum welding conditions of a tool rotation speed of 1400, a feed rate of 18 mm/min, and the tool pin with threads. The maximum value of hardness, i.e., 81.056 HV, was achieved using optimum conditions of 1200 tool rotational speed and a feed rate of 18 mm/min with a tool pin profile having threads. In addition, the contribution in terms of the percentage of each input parameter was found by the analysis of variance (ANOVA). The ANOVA results revealed that the pin profile of the tool has the maximum contribution of 67.77% and 62.42% in achieving the optimum value of tensile strength and hardness, respectively. The study also investigated the joint efficiency of the friction stir welded joint, hardness at the weld zone, and metallography on FSW samples at the optimized level. The effectiveness and reliability of FSW joints for shipping industry applications can be observed by joint efficiency. That was investigated at optimum conditions, and it comes out to be 80.5%. Full article

Most spoilers are made from a sandwich structure with a honeycomb component as its core. However, the honeycomb core is sensitive to water ingress, causing damage to the control surface due to its weak moisture-resistance behavior. This study aimed to conduct the design and analysis of an improved composite structure for a coreless spoiler. A spoiler design of an aircraft, the A320, was used for the case study. The weaknesses of a coreless spoiler were identified through finite element analysis via Abaqus software. Multi-spar and multi-rib designs were studied and compared for topological optimization. The variables used for evaluation were the Tsai–Hill failure index and the critical buckling load. The design with the most potential was considered for parametric optimization to obtain the most satisfactory configuration. The results showed that the upper skin of the spoiler without a honeycomb core failed the Tsai–Hill criteria. Furthermore, the results show that the multi-spar configuration outperformed the multi-rib configuration. The final multi-spar configuration achieved a mass reduction of 24% from the original spoiler and an additional 6% mass reduction by re-designing the internal structures without violating the design criteria. In conclusion, the weaknesses of the spoiler without a honeycomb core have been identified, and an improved design for a coreless spoiler has been proposed. Full article

The crashworthiness of composite tubes is widely examined for various types of FRP composites. However, the use of hybrid composites potentially enhances the material characteristics under impact loading. In this regard, this study used a combination of unidirectional glass–carbon fibre reinforced epoxy resin as the hybrid composite tube fabricated by the pultrusion method. Five tubes with different length aspect ratios were fabricated and tested, in which the results demonstrate “how structural energy absorption affects by increasing the length of tubes”. Crash force efficiency was used as the criterion to show that the selected L/D are acceptable of crash resistance with 95% efficiency. Different chamfering shapes as the trigger mechanism were applied to the tubes and the triggering effect was examined to understand the impact capacity of different tubes. A finite element model was developed to evaluate different crashworthiness indicators of the test. The results were validated through a good agreement between experimental and numerical simulations. The experimental and numerical results show that hybrid glass/carbon tubes accomplish an average 25.34 kJ/kg specific energy absorption, average 1.43 kJ energy absorption, average 32.43 kN maximum peak load, and average 96.67% crash force efficiency under quasi-static axial loading. The results show that selecting the optimum trigger mechanism causes progressive collapse and increases the specific energy absorption by more than 35%. Full article

This study investigates the quasi-static axial crushing tests of eco-hybrid composites based on flax and E-glass fibres strengthened with polyester resin. Five different configurations of self-supporting webs were fabricated to investigate the crushing behaviours of this eco-hybrid composite with different stacking sequences based on intercalation and sandwich-like sequences. The effect of different open-section web profiles was also investigated. The results were plotted in load-displacement curves and the specific energy absorption (SEA), as well as the crushing force efficiency (CFE), were calculated to evaluate the crushing response of each configuration. The test results verified the crushing mechanisms related to the energy absorption depending on the stacking sequence as well as the frontal profile. In this study, all specimens with the intercalation stacking sequence have achieved higher SEA and CFE than specimens with a sandwich-like stacking sequence. In terms of the frontal profile, the sine wave hat shape had the highest CFE, up to 80% compared to other web profiles. Thus, it demonstrated the capability of a sine wave hat-shape eco-composite based on flax fibre to be applied as a crashworthy material. Full article

The Savonius wind turbine is one of the most well-known vertical axis wind turbines with insensitivity to wind direction, flow turbulence, and high torque generation. These turbines can extract up to 20% of the energy from the wind. This study numerically analyzes the performance of a modified Savonius wind turbine equipped with secondary blades and slots. The k-ε standard method is used to simulate the turbulence flow around the turbine, and the simulation is performed using the ANSYS FLUENT 18.2 commercial code. The effects of distance between the main blade and the secondary blade, position of the secondary blade, the width of the main blade’s slot, and the profile of the secondary blade on the produced torque are studied and analyzed. The simulation is performed at four wind velocities: 3, 4, 5, and 6 m/s. The results showed that the output torque at the secondary blade angular position β = 130 is higher than other angles. Furthermore, by increasing the radius of the additional blade from R = 25 to 43 mm, the torque is improved, and the area below the output torque curve is increased. Moreover, the results showed that creating a slot on the main blade equipped with a secondary blade has a significant impact on the produced torque; however, the geometrical parameters of the proposed rotors should be adjusted accurately to find the best case in terms of the produced torque. Full article