Search Results (555)

The purpose of this paper is to examine the application and development of CAD/CAM technologies in the modern metal cutting industry, with a focus on their role in increasing production accuracy, efficiency, and sustainability. The study presents an industrial case of laser cutting of AISI 304 stainless-steel sheets, in which two approaches are compared under identical material and technological parameters: conventional manual nesting and automatic nesting based on algorithms implemented in a CAD/CAM environment. The methodology evaluates both layouts using clear technical and economic indicators, including number of parts per sheet, material utilization, cutting time, weight of scrap, and cost per sheet. For the analyzed batch, automatic nesting increases the number of parts per sheet from 44 to 76 (≈73%), reduces the unused sheet area from 61% to 39%, and shortens the cutting time from 12 to 9 min (≈25%), which leads to a reduction in material waste by about 36% and cost savings of approximately 314 EUR per sheet. As a result, the process becomes more efficient and reliable, supporting sustainable and digital manufacturing goals. The findings confirm the importance of algorithmic optimization in CAD/CAM systems for enhancing industrial competitiveness, enabling effective resource management, and facilitating the transition towards Industry 5.0. Full article

High regeneration energy demand remains a critical barrier to the large-scale deployment of ethanolamine-based (MEA-based) CO₂ capture. This study adopts an Al₂O₃ ceramic-membrane heat exchanger (CMHE) to recover both sensible and latent heat from the stripped gas. Experiments confirm that heat and mass transfer within the CMHE follow a coupled mechanism in which capillary condensation governs trans-membrane water transport, while heat conduction through the ceramic membrane dominates heat transfer, which accounts for more than 80%. Guided by this mechanism, systematic structural optimization was conducted. Alumina was identified as the optimal heat exchanger material due to its combined porosity, thermal conductivity, and corrosion resistance. Among the tested pore sizes, CMHE-4 produces the strongest capillary-condensation enhancement, yielding a heat recovery flux (q value) of up to 38.8 MJ/(m² h), which is 4.3% and 304% higher than those of the stainless steel heat exchanger and plastic heat exchanger, respectively. In addition, Length-dependent analyses reveal an inherent trade-off: shorter modules achieved higher q (e.g., 14–42% greater for 200-mm vs. 300-mm CMHE-4), whereas longer modules provide greater total recovered heat (Q). Scale-up experiments demonstrated pronounced non-linear performance amplification, with a 4 times area increase boosting q by only 1.26 times under constant pressure. The techno-economic assessment indicates a simple payback period of ~2.5 months and a significant reduction in net capture cost. Overall, this work establishes key design parameters, validates the governing transport mechanism, and provides a practical, economically grounded framework for implementing high-efficiency CMHEs in MEA-based CO₂ capture. Full article

Among corrosive environments, Cl⁻ is one of the most aggressive anions which can cause electrochemical corrosion and the resultant failures of alloys, and the increase in Cl⁻ concentration will further deteriorate the passive film in many conventional alloys. Here, we report single-phase Nb₂₅Mo₂₅Ta₂₅Ti₂₀W₅C_x (x = 0.1, 0.3, 0.8 at.%) refractory high-entropy alloys (RHEAs) with excellent corrosion resistance in high-concentration NaCl solutions. According to potentiodynamic polarization, electrochemical impedance spectroscopy, corroded morphology and the current–time results, the RHEAs demonstrate even better corrosion resistance with the increase in NaCl concentration to 23.5 wt.%, significantly superior to 304 L stainless steel. Typically, the corrosion current density (i_corr) and over-passivation potential (E_t) reached the lowest and highest value, respectively, in the 23.5 wt.% NaCl solution, and the i_corr (2.36 × 10⁻⁷ A/cm²) of Nb₂₅Mo₂₅Ta₂₅Ti₂₀W₅C_0.1 alloy is nearly two orders lower than that of 304 L stainless steel (1.75 × 10⁻⁵ A/cm²). The excellent corrosion resistance results from the formation of passive films with fewer defects and more stable oxides. Moreover, with the addition of the appropriate C element, the RHEAs also demonstrated improved strength and plasticity simultaneously, for example, the Nb₂₅Mo₂₅Ta₂₅Ti₂₀W₅C_0.3 alloy exhibited an average yield strength of 1368 MPa and a plastic strain of 19.7%. The present findings provide useful guidance to address the conflict between the excellent corrosion resistance and high strength of advanced alloys. Full article

This study conducts systematic experimental and numerical investigations to address the parameter calibration issue in the discrete element model of seashells, aiming to establish a high-fidelity numerical model that accurately characterizes their macroscopic mechanical behavior, thereby providing a basis for optimizing parameters of seashell crushing equipment. Firstly, intrinsic parameters of seashells were determined through physical experiments: density of 2.2 kg/m³, Poisson’s ratio of 0.26, shear modulus of 1.57 × 10⁸ Pa, and elastic modulus of 6.5 × 10¹⁰ Pa. Subsequently, contact parameters between seashells and between seashells and 304 stainless steel, including static friction coefficient, rolling friction coefficient, and coefficient of restitution, were obtained via the inclined plane method and impact tests. The reliability of these contact parameters was validated by the angle of repose test, with a relative error of 5.1% between simulation and measured results. Based on this, using ultimate load as the response indicator, the PlackettBurman experimental design was employed to identify normal stiffness per unit area and tangential stiffness per unit area as the primary influencing parameters. The Bonding model parameters were then precisely calibrated through the steepest ascent test and design, resulting in an optimal parameter set. The error between simulation results and physical experiments was only 3.8%, demonstrating the high reliability and accuracy of the established model and parameter calibration methodology. Full article

Steel and prestressed concrete traction poles can be fixed to reinforced concrete pile foundations using typical bolted connections. The stainless steel fastening screw is connected to the ordinary steel foundation pile reinforcement by friction welding under specific friction welding process parameters. From the perspective of the structural strength of the connection between the traction pole and the foundation pile, regarding the transfer of tensile and shear forces through a single anchor bolt, the yield strength of stainless steel bolts should be R_e,min ≥ 345 MPa for M30 anchors, R_e,min ≥ 310 MPa for M36 anchors and R_e,min ≥ 300 MPa for M42 anchors. This requirement is reliably met by martensitic stainless steels, while other stainless steels have yield strengths below the required minimum. What truly determines the foundation pile’s load capacity is not the satisfactory mechanical strength of the stainless steel (here, the parameters are met), but the quality of the friction-welded end connection between the reinforcement and the threaded bars. Incorrect selection of the type of prestressing steel in the analyzed connection can have enormous consequences for foundation pile manufacturers. Annual production of foundation piles amounts to thousands of units, and an incorrect decision made by the pile designer at the design stage can result in significant financial losses and a high risk to human life. This article presents the results of studies on friction-welded connections of M30, M36, and M42 threaded bars made of austenitic 1.4301 (AISI 304) and martensitic 1.4021 (AISI 420) stainless steel with B500SP reinforcement bars. The tests yielded negative results for 1.4021 (AISI 420) steel, despite its yield strength exceeding R_e ≥ 360 MPa. Full article

The adjustable-ring-mode (ARM) scanning laser was used to perform butt welding on 0.5 mm thick TA1 titanium alloy and 304 stainless steel (SS304) thin sheets, with 1.2 mm diameter AZ61S magnesium alloy welding wire as the filling material. Microhardness test results show that the hardness distribution presented a trend of being higher in the base metals on both sides and lower in the middle filling area, with no hardening observed in the weld zone. For all specimens subjected to horizontal and axial weld bending tests, the bending angle reached 108° without any cracks occurring. When the ring power was in the range of 800–1000 W, or the scanning frequency was between 100 and 200 Hz, all the average tensile strengths of the welded joints were more than 80% of that of the AZ61S filling material (approximately 240 MPa); the maximum average tensile strength stood at 281.2 MPa, which is equivalent to 93.7% of the AZ61S. As the ring power or scanning frequency increased further, the tensile strengths of the joints showed a decreasing trend. The remelting effect of the trailing edge of the ARM laser under high energy conditions, or the scouring of the turbulent molten flow induced by the scanning beam, damages the weak links at the newly formed solid–liquid interface and increases the Fe concentration in the molten pool. This leads to a thicker FeAl interface layer during growth, thereby resulting in a decline in the mechanical properties of the welded joints. Full article

This study investigates the microstructure and mechanical properties of a dissimilar joint formed by rotary friction welding, which joins TC4 titanium alloy to 304 stainless steel using an Inconel 718 interlayer. The welding parameters were as follows: a friction time of 9 s, a friction pressure of 160 MPa, an upset time of 2 s, a forging pressure of 250 MPa, and a rotational speed of 1400 rpm. Microstructural analysis revealed the formation of intermetallic compounds (IMCs), including Fe₂Ti, Ni₃Ti, NiCrFe, FeNi₃, Ti₂Ni, and FeNi, at the TC4/Inconel 718 interface, while Ni₃Ti and FeNi₃ IMCs were identified at the Inconel 718/304SS interface. The tensile tests demonstrated that the joint with the Inconel 718 interlayer (TC4/Inconel 718/304SS) achieved an ultimate tensile strength (UTS) of 717.73 MPa and an elongation of 13.05%. In contrast, the direct joint without the interlayer (TC4/304SS) exhibited a lower UTS of 631.58 MPa and a reduced elongation of 7.39%. Therefore, the introduction of the Inconel 718 interlayer significantly improved joint quality, increasing tensile strength by 13.64% and elongation by 76.59%. More importantly, the interlayer effectively inhibited the formation of brittle Ti-Fe intermetallic compounds, which are typically detrimental to joint performance. Full article

The paper investigates the arc behavior and molten metal flow during Keyhole tungsten inert gas (K-TIG) welding of dissimilar materials, Invar 36 and stainless steel (types 304, 316, 309, and 310) specifically. A high-speed camera was used to capture the contour of the molten pool in real time. Results showed that in stainless steel welding, the arc shape is bell-shaped, and the distance from the tip of the molten pool to the keyhole decreases with increasing thermal conductivity (6.76–10.86 mm). When Invar 36 was butt-welded, the arc contracted. However, when Invar 36 was welded with dissimilar materials of stainless steel, the arc deflected to the Invar 36 side. The deflection angle ranged from 29.9° to 37°, resulting in an asymmetric arc shape. The distance from the tip of the molten pool to the keyhole increased to 10.88–13.33 mm, which was about 42% higher than that of the same material welding. Metallographic analysis showed that the width of the heat affected zone on the Invar 36 side increases with the decrease in thermal conductivity of the stainless steel (1.77–2.03 mm). Differences in thermophysical properties and viscosity further led to asymmetric molten pool flow and metal accumulation behavior. This study quantified the formation mechanism of arc deflection and weld pool asymmetry in K-TIG welding of dissimilar materials. Full article

Scaling and thermal loss on the surfaces of industrial equipment and pipelines usually lead to increased energy consumption and reduced operational efficiency. To solve these severe problems, developing advanced coatings with the dual functions of scale resistance and thermal insulation is an effective approach. Inspired by the antifouling agents released from corals and the thermal insulation of goose down, we herein have developed a bioinspired hollow silica microsphere-based (BHSM) coating, exhibiting the synergistic effect of anti-scaling and thermal insulation properties. The BHSM coating is composed of aluminum phosphate (AP) as an inorganic adhesive and scale inhibitor, and hollow silica microspheres (HSMs) as a thermal insulator. In brief, the effective anti-scaling capability comes from released phosphate ions of AP adhesive for chelating with mineral ions, while the high thermal insulation results from the internal air of the HSMs. Compared to the stainless steel (SS 304), the BHSM coating exhibited ~86% scale reduction. Furthermore, the extremely low thermal conductivity of the HSMs endows the BHSM coating with excellent thermal insulation, resulting in a 20% reduction in heat loss relative to the SS 304 surface. Thus, this work presents a promising strategy for anti-scaling and thermal insulation in industrial equipment and pipelines. Full article

This study investigated the microstructure and properties of soldered joints of AISI 304 stainless steel and PMMA thermoplastic or AW-1050A aluminum alloys made using Resistance Element Soldering (RES) technology. The bimetallic element used in RES provided a mechanical joint with a thermoplastic or aluminum alloy and a soldered joint with AISI 304 steel using Sn60Pb40 solder in the core of the element. The solder in combination with the Chemet CHM-A-014 flux wetted the AISI 304 steel surface very well at a temperature of 225 °C with a contact angle of 14°. During the production of the joints, the solder melted in the bimetallic element on the AISI 304 steel side, while solid solder was retained at the point of contact with the welding electrode. The strength of the joints ranged from 25.5 to 36.4 MPa, which was less than the strength of the solder, and the joints failed at the AISI 304 steel–Sn60Pb40 solder interface. The fracture surface was predominantly formed by the solder. An intermetallic phase of FeSn₂ was identified at the interface. Full article

The pitting corrosion resistance and the tribological behaviour of a ferritic stainless steel with high Mo content (AISI 436) and a commonly employed austenitic stainless steel (AISI 304) are compared. Special attention was paid to the role of Mo in improving corrosion resistance of ferritic stainless steels. Since the surface condition is an important parameter related to the onset of pitting corrosion in the presence of chlorides, three different surface finishes were tested for both steels. Two commercial finishing grades and laboratory polishing down to 1 µm were compared. Moreover, the influence of surface condition on the tribological properties for both steels was also evaluated. The study demonstrates that surface finishing plays a decisive role in both the electrochemical and mechanical response of stainless steels. A comprehensive microstructural and tribological analysis reveals not only how commercial finishing treatments modify passive film behaviour, but also how they affect friction stability and wear mechanisms. Special emphasis is placed on the synergistic effect between molybdenum content, passive film integrity and manufacturing processes. The obtained results provide valuable insight for industrial applications where durability against chloride exposure and abrasion is critical. Full article

FeCoCrNiNb_xN (x = 0, 0.25, 0.5, 0.75, 1 molar) high-entropy nitride (HEN) films were fabricated on 304 stainless steel and Si wafers using magnetron sputtering to investigate the influence of Nb content on the microstructure, mechanical properties, and tribological performance. X-ray diffraction (XRD) analysis reveals a face-centered cubic (FCC) structure with a preferred orientation in the (200) plane, which transfers to the (111) plane as the Nb content increases. The lattice distortion induced by Nb incorporation enhanced crystallinity, with the Nb_0.5N film exhibiting the highest diffraction peak intensity and interplanar distance. Cross-sectional SEM images displayed columnar crystal structures, while the surface morphology evolved from “cauliflower-like” to smoother clusters with increasing Nb content, reducing average roughness from 7.54 nm (Nb₀) to 4.89 nm (Nb₁). The hardness and elastic modulus initially decrease, then peak at 25.56 GPa and 265.36 GPa, respectively, for the Nb₁ film, attributed to solid solution strengthening and high-entropy effects. Tribological tests demonstrated that Nb₁ achieved the lowest coefficient of friction (0.46), wear volume (1.23 × 10⁻³ mm³), and wear rate (5.11 × 10⁻⁸ mm³·N⁻¹·m⁻¹), owing to NbN phase formation, refined grains, and reduced surface roughness. The wear mechanisms are abrasive and oxidative wear. Full article

Hexafluoroethane and 1,1,1,3,3,3-hexafluoropropane (abbreviated as HFC-236fa and R-116, respectively, referred to as C₂F₆ and C₃H₂F₆ based on their molecular formulas) were selected as the object to study the corrosion effects of gas fire-extinguishing agents on different metal materials in the storage state. Typical metal materials used in storage containers including 304 stainless steel, Q235 carbon steel, 6061 aluminum alloy, H59 brass, and T2 copper were subjected to full-immersion corrosion experiments under simulated storage conditions with high-pressure and alternating high–low temperature cycles. High-definition cameras, a scanning electron microscope (SEM), high-precision electronic balances, an energy-dispersive spectrometer (EDS), and X-ray photoelectron spectroscopy (XPS) were used to explore the corrosion characteristics. The chemical reactions and mechanisms were analyzed. The results indicate the following: (1) A thin corrosion layer appears on the surface of the metal with varying degrees of severity but low prevalence. (2) The corrosion rates of C₂F₆ and C₃H₂F₆ were comparable and varied in the following order: 6061 aluminum alloy > Q235 carbon steel > H59 brass > 304 stainless steel > T2 copper. (3) C₃H₂F₆ is slightly higher than C₂F₆ in all corrosion rate values. (4) The corrosion of metal materials is mainly attributed to the reaction between metal elements and the F-containing groups produced by the cleavage of C₂F₆ and C₃H₂F₆. The generated metal halides in turn catalyze the cleavage of C₂F₆ and C₃H₂F₆. This catalytic effect may be positively correlated with the reactivity of the metal element. (5) The higher corrosive activity of C₃H₂F₆ compared to C₂F₆ is attributed to the ease of C–C bond cleavage, catalyzed by metal halogens. This study provides theoretical insights into the corrosion ability of halogenated alternatives as a replacement for halon-based fire extinguishers. Full article

Burrs are a significant machining defect affecting the quality of precision parts, and tool eccentricity may substantially influence milling burrs. Using AISI 304 stainless steel as the workpiece material, a three-dimensional thermo-mechanical coupled model for slot milling was constructed based on an explicit dynamics model. Combining the Johnson–Cook (J-C) constitutive model with the J-C shear failure criterion, simulations were conducted to obtain burr dimensions, cutting temperature distributions, and cutting force waveforms under different tool eccentricity directions and magnitudes. Results: As the eccentricity increases, the temperature of the top burr rises, and both the width of the top burr and the thickness of the exit side burr significantly increase. Under simulated conditions, the width of the top burr in down milling side increased by up to 70%. The burr dimensions under different eccentricity directions can differ by approximately 40%. Groove milling experiments revealed similar burr shapes between experimental and simulated results. Furthermore, the simulated cutting force waveforms aligned with those in the literature, indicating the reliability of the simulation outcomes. Based on these findings, it can be concluded that tool eccentricity significantly affects the dimensions of top burrs and exit side burrs. The width of top burrs and the thickness of exit side burrs are positively correlated with the tool eccentricity distance, while exit bottom burrs remain unaffected by eccentricity. These research results provide valuable reference for burr suppression in practical machining operations. Full article