Search Results (992)

Waste valorization in construction materials offers a promising pathway to reducing environmental burdens while promoting circular resource strategies in the built environment. This study develops a novel composite mortar formulated with sustainable materials and alternative aggregates, namely polyethylene terephthalate (PET) particles recovered from post-consumer plastic waste and bottom ash from thermal power generation. Natural pumice was incorporated to improve the lightness and the thermal insulation, with cement serving as the binder. The mix design was systematically optimized using the Taguchi method to enhance performance while minimizing carbon emissions. The resulting mortar, produced at both laboratory and small-scale commercial levels, demonstrated favorable technical properties: dry density of 1.3 g/cm³, compressive strength of 5.96 MPa, thermal conductivity of 0.27 W/(m*K), and water absorption of 16.1%. After exposure to 600 °C, it retained 60.6% of its strength and exhibited only a 10.1% mass loss. These findings suggest its suitability for non-load-bearing urban components where sustainability, thermal resistance, and durability are essential. The study contributes to global sustainability goals, particularly Sustainable Development Goal (SDG) 11, 12, and 13, by illustrating how waste valorization can foster resilient construction while reducing the environmental footprint of cities. Full article

Machining is a fundamental manufacturing process that entails the controlled removal of material from a workpiece to achieve desired shapes and dimensions. Super duplex stainless steel (SDSS) 2507 is a high-performance alloy which is notable for its superior mechanical strength and excellent corrosion resistance, making it particularly suitable for deployment in aggressive service environments, including offshore structures, subsea equipment, chemical industries, and marine engineering systems. Its low thermal conductivity, high hardness, and rapid work hardening pose significant challenges during dry machining, leading to accelerated tool wear. This study investigates the dry machining of SDSS 2507 by employing TiAlN-PVD (physical vapor deposition)-coated cutting inserts deposited to address these issues. The Taguchi method of experimental design was employed to evaluate the influence of key machining parameters on tool wear. The results demonstrated that PVD-coated inserts offered excellent wear resistance. Furthermore, the Taguchi signal-to-noise (S/N) ratio analysis and analysis of variance (ANOVA) identified feed rate as the primary factor influencing tool wear, with depth of cut and cutting speed ranking as secondary factors. This study highlights the effectiveness of tools with coatings for the dry machining of SDSS 2507-type difficult-to-machine material, offering a reliable solution for enhancing tool life and operational efficiency in industrial applications. Full article

Additive manufacturing via fused deposition modeling (FDM) offers a versatile method for fabricating complex polymer parts; however, enhancing their mechanical properties remains a significant challenge, particularly for biopolymers such as polylactic acid (PLA). PLA is widely used in 3D printing due to its biodegradability and ease of processing, but its relatively low mechanical strength and impact resistance limit its broader applications. This study explores the reinforcement of PLA with boron nitride nanoplatelets (BNNPs) to improve its mechanical properties. This study also aims to optimize key FDM process parameters, such as reinforcement content, nozzle temperature, printing speed, layer thickness, and sample orientation, using a Taguchi L27 design. Results show that the addition of 0.04 wt.% BNNP significantly improves the mechanical properties of PLA, enhancing tensile strength by 44.2%, Young’s modulus by 45.5%, and impact strength by over 500% compared to pure PLA. Statistical analysis (ANOVA) reveals that printing speed and nozzle temperature are the primary factors affecting tensile strength and Young’s modulus, while impact strength is primarily influenced by nozzle temperature and reinforcement content. Machine learning models, such as CatBoost and Gaussian process regression, predict mechanical properties with high accuracy (R² > 0.98), providing valuable insights for tailoring PLA/BNNP composites and optimizing FDM process parameters. This integrated approach presents a promising path for developing high-performance, sustainable nanocomposites for advanced additive manufacturing applications. Full article

Producing solid biofuels with high calorific value and high storage stability under limited energy consumption has become a crucial focus in the global energy field. Low temperature torrefaction below 300 °C is a common method for producing solid biofuels. However, this approach limits the carbon content and higher heating value (HHV) of the resulting biochar. Sodium percarbonate is a solid oxidant that can assist in the pyrolysis of organic molecules during the torrefaction to increase carbon content of biochar. Incorporating sodium percarbonate as a strategic additive presents a viable means to address the constraints associated with the torrefaction technologies. This study blended sodium percarbonate with spent coffee grounds (SCGs) to prepare torrefied SCG solid biofuels with high calorific value and high carbon content. Based on the Taguchi method with L9 orthogonal arrays, torrefaction temperature is identified as the most influential factor affecting higher heating value (HHV). Results from FTIR, water activity, hygroscopicity, and mold observation confirmed that torrefied SCGs blended with 0.5 wt% sodium percarbonate (0.5TSSCG) exhibited good storage stability. They were not prone to mold growth under ambient temperature and pressure. 0.5TSSCG with a carbon content of 61.88 wt% exhibited a maximum HHV of 29.42 MJ∙kg⁻¹. These findings indicate that sodium percarbonate contributes to increasing the carbon content and HHV of torrefied SCGs, enabling partial replacement of traditional coal consumption. Full article

The design and production of goods have been completely transformed by additive manufacturing (AM), which makes it possible to create components with intricate and complex geometries that were previously impossible or impractical to produce. However, current technologies continue to produce coarse-surfaced metal components that typically exhibit fatigue properties, resulting in component failure and unfavorable friction coefficients on the printed part. Therefore, to improve the surface quality of the fabricated parts, post-processing of AM-created components is required. With emphasis on electroless nickel plating, ChemPolishing (CP), and ElectroPolishing (EP), this study investigates post-processing methods for stainless steel that is additively manufactured (AM). The rough surfaces created by additive manufacturing (AM) restrict direct use. While ElectroPolishing (EP) achieves high material removal rates but may not be consistent, ChemPolishing (CP) offers uniform smoothening. Nickel plating enhances additive manufacturing (AM) products’ resistance to wear and scratches and corrosion protection. To optimize nickel deposition, medium (6%–9%) and high (10%–13%) phosphorus nickel was tested using the L9 Taguchi design of experiments (DOE). Mechanical properties, including scratch resistance and adhesion, were evaluated using the TABER 5900 reciprocating (Taber Industries, North Tonawanda, NY, USA) abraser apparatus, a 5 N scratch test, and ASTM B-733 thermal shock method. Surface analysis was performed with the KEYENCE VHX-7000 microscope (Keyence Corporation, Itasca, IL, USA), and chemical composition before and after nickel deposition was assessed via the ThermoFisher Phenom XL scanning electron microscope (SEM, Thermo Fisher Scientific, Waltham, MA, USA) Optimal processing conditions, determined using Qualitek-4 software, Version 20.1.0 revealed improvements in both surface finish and mechanical robustness. This comprehensive analysis underscores the potential of nickel-coated additive manufacturing (AM) parts for enhanced performance, offering a pathway to more durable and efficient additive manufacturing (AM) applications. Full article

Background: Pomegranate peel (Punica granatum L.) is a rich source of phenols, particularly ellagitannins, highlighting punicalagin, a bioactive compound with recognized antioxidant potential. However, efficient recovery and purification methods are required to enable its application in food and health-related products. This study aimed to obtain a partially purified fraction of punicalagin from pomegranate peel using optimized extraction and purification strategies. Methods: A Taguchi L9 (3)³ experimental design was employed to optimize ultrasound-assisted extraction, evaluating extraction time (10, 20, 30 min), ethanol concentration (20, 40, 80%), and solid-to-solvent ratio (1:12, 1:14, 1:16). Total polyphenol content was quantified using the Folin–Ciocalteu method. Extracts obtained under optimized conditions were concentrated by rotary evaporation and subjected to semipurification using flash chromatography with Amberlite XAD-16 resin. Subsequently, the fractions were lyophilized and analyzed by HPLC/ESI/MS. Results: The Statistica software determined the optimal conditions for polyphenol extraction (20 min, 40% ethanol, 1:12), with the signal-to-noise (S/N) ratio reaching 88.43 ± 0.66, surpassing the predicted value of 77.42. Flash chromatography yielded four fractions, and HPLC/ESI/MS analysis revealed the presence of ellagitannins in all of them, with fraction number 2 showing the highest relative abundance of punicalagin (89.25%). Conclusions: The combination of ultrasound-assisted extraction and flash chromatography proved effective for obtaining punicalagin-rich fractions from pomegranate peel, supporting its potential for nutraceutical applications. Full article

The traditional Mahalanobis–Taguchi System (MTS) employs two main strategies for multi-class classification: the partial binary tree MTS (PBT-MTS) and the multi-tree MTS (MT-MTS). The PBT-MTS relies on a fixed binary tree structure, resulting in limited model flexibility, while the MT-MTS suffers from its dependence on pre-defined category partitioning. Both methods exhibit constraints in adaptability and classification efficiency within complex data environments. To overcome these limitations, this paper proposes an innovative Adaptive Tree-structured Mahalanobis–Taguchi System (ATMTS). Its core breakthrough lies in the ability to autonomously construct an optimal multi-layer classification tree structure. Unlike conventional PBT-MTS, which establishes a Mahalanobis Space (MS) containing only a single category per node, ATMTS dynamically generates the MS that incorporates multiple categories, substantially enhancing discriminative power and structural adaptability. Furthermore, compared to MT-MTS, which depends on prior label information, ATMTS operates without predefined categorical assumptions, uncovering discriminative relationships solely through data-driven learning. This enables broader applicability and stronger generalization capability. By introducing a unified multi-objective joint optimization model, our method simultaneously optimizes structure construction, feature selection, and threshold determination, effectively overcoming the drawbacks of conventional phased optimization approaches. Experimental results demonstrate that ATMTS outperforms PBT-MTS, MT-MTS, and other mainstream classification methods across multiple benchmark datasets, achieving significant improvements in the accuracy and robustness of multi-class classification tasks. Full article

Additive manufacturing has promising potential for the development of 3D-printed protective structures such as stab-resistant body armor. However, no research to date has examined the impact of 3D printing parameters on the protective performance of such 3D-printed structures manufactured using fused filament fabrication technology. This study, therefore, investigates the effects of five key printing parameters: layer thickness, print speed, print temperature, infill density (Id), and layer width, on the mechanical and protective performance of 3D-printed polycarbonate (PC) armor. A Taguchi L₂₇ matrix was employed to systematically analyze these parameters, with toughness, stab penetration depth, and armor panel weight as the primary responses. ANOVA results, along with the Taguchi approach, demonstrated that Id was the most influential factor across all print parameters. This is because a higher Id led to denser structures, reduced voids and porosities, and enhanced energy absorption, significantly increasing toughness while reducing penetration depth. Morphological analysis supported the statistical findings regarding the role of Id on the performance of such structures. With optimized printing parameters, no penetration to the armor panels was recorded, outperforming the UK body armor standard of a maximum permitted knife penetration depth of 8 mm. Moreover, an artificial neural network (ANN) utilizing the 5-14-12-3 topology was created to predict the toughness, stab penetration depth, and armor panel weight of 3D-printed armors. The ANN model demonstrated better prediction performance for stab penetration depth compared to the Taguchi method, confirming the successful application of such an approach. These findings provide a critical foundation for the development of high-performance 3D-printed protective structures. Full article

In line with sustainable construction goals, this study investigates the synergistic use of amine-based grinding aids (GAs), triethanolamine (TEA), and triisopropanolamine (TIPA) to enhance grinding performance and cement properties. GAs were physically blended at varying TEA/TIPA ratios, and their effects on grinding efficiency, CO₂ emissions, and environmental footprint were assessed based on energy consumption per target Blaine fineness. The interaction of blended GAs with Ca²⁺ ions was modeled to understand adsorption behavior. Cement particle size distribution (PSD), Hausner ratio, Carr index, and angle of repose were analyzed to evaluate powder flowability. Scanning electron microscopy (SEM) was employed to examine microstructural changes. Finally, the Taguchi method statistically analyzed the effective parameters influencing system performance. Results demonstrated that the optimized blend containing 25% TEA and 75% TIPA improved grinding performance, enhanced polymer–ion interactions, refined PSD, and significantly increased powder flowability. Overall, the study underscores the potential of amine-based polymeric GAs in producing environmentally friendly, high-performance cement composites. Using a Taguchi design with the larger-is-better S/N criterion, the optimal formulation was determined to be 25% TEA and 75% TIPA at a dosage of 0.10%. ANOVA results indicated that the TEA content was the most significant factor, while the dosage had no statistically significant effect. Full article

This study investigates the fatigue performance of 3D-printed metal shafts fabricated via Wire Arc Additive Manufacturing (WAAM) with stacked steel ring substrates under rotating bending (ISO 1143:2021). A Taguchi L25 orthogonal array was used to analyze five process parameters: ring diameter, current intensity, torch speed, ring thickness, and contact tip to workpiece distance (CTWD). Analysis of Variance (ANOVA) identified ring diameter as the dominant factor, significantly enhancing fatigue life at 14.0 mm by reducing stress concentrations. Current intensity (125 A) and torch speed (550 mm/min) further improve weld quality and microstructure, while ring thickness (1.0 mm) and CTWD (1.5 mm) have minor effects. A linear regression model (R² = 0.9603) accurately predicts fatigue life, with optimal settings yielding 299,730 cycles. The stacked-ring configuration enables intricate structures like cooling channels, ideal for aerospace and automotive applications. The 3.5% unexplained variance suggests parameter interactions, warranting further investigation into shielding gas effects and multiaxial loading to broaden material and loading applicability. Full article

In this numerical and experimental study, the effects of the width, length, and height parameters of a mirror arm on the drag coefficients of two side-view mirror models were investigated. The analyses were performed according to fractional factorial Taguchi L9 experiment plans. In the wind tunnel, a constant-temperature hot-wire anemometer and a pressure scanner system were used to measure velocity and static pressures, respectively. A realizable k-ε turbulence model with a scalable wall function was applied in the simulations, and the velocity was kept constant at 30 m/s. Means of the drag coefficient, signal/noise values, and analysis of variance were used to evaluate the parameters’ effects. The results showed that the drag coefficients increased with arm height. The increase in arm width decreased the drag coefficient to a limited extent, while the aspect ratio (width/height) showed a strong negative correlation with the drag coefficient. The high aspect ratios resulted in streamlined geometries around the mirror arm and delayed flow separations. The numerical analysis results showed good agreement with the experimental values for both mirror models. Full article

Electric vehicle (EV) battery thermal management systems have gradually improved owing to the increasing power demand of EVs. This study aims to optimize the channel geometry of sandwich double-sided cold plates for EV battery cooling under 100% state of charge and 2C-rate charging conditions. For precise and accurate optimization, the conventional one-dimensional analysis model of the sandwich double-sided cold plate was converted into a three-dimensional computational fluid dynamics (CFD) model. Non-dimensional parameters were selected as the main variables of the channel geometry, and nine additional channel shapes were derived based on them. Battery modules with the derived channel shapes were subjected to CFD analysis in the Reynolds number range of 500 to 20,000. The goodness factor was calculated from these correlations, and optimization was performed using the Taguchi method. The results revealed that the wetted area of the channel had a greater impact on battery cooling than the number of channels. This study proposed more generalized design guidelines by employing non-dimensionalized parameters across a wide range of Reynolds numbers. The rectangular channel-based correlations developed in this study showed improved prediction accuracy compared to conventional annular pipe-based correlations and are expected to be applicable to various battery thermal management system designs in the future. Full article

This paper assesses the feasibility of metakaolin (MK)-based geopolymer (GP) composite as an environmentally friendly substitute for cement-based composite in repair applications. The Taguchi orthogonal array method was used to find the optimum GP mix in terms of mechanical properties and adhesion to concrete substrates. Four key parameters, each with three levels, are investigated including the alkaline activator-to-MK ratio (A/M: 1, 1.2, 1.4), the sodium silicate-to-sodium hydroxide ratio (S/H: 2.0, 2.5, 3.0), sodium hydroxide (SH) molarity (12, 14, 16), and curing temperature (30, 45, 60 °C). The evaluated properties include flowability, compressive strength, splitting tensile strength, flexural strength, ultrasonic pulse velocity, and bond strength under various interface configurations. Experimental results demonstrated that the performance of MK-based GP composite was primarily governed by the A/M ratio and sodium hydroxide molarity. The Taguchi optimization method revealed that the mix design featuring A/M of 1.4, SS/SH of 2, 16 M sodium hydroxide, and curing at 60 °C yielded notable improvements in compressive and bond strengths compared to conventional cement-based composites. Full article

Welding is a technological variant of the electric resistance spot-welding process in which the machined protrusion on the surface is heated and rapidly deformed, and the small molten zone formed at the interface is then forged to form the weld spot. The paper analyses the effects of projection welding parameter values for thin, low-carbon aluminized steel sheets. Two sets of 16 welded samples having three or five protrusions were performed and analyzed using the Taguchi method. The microstructural aspects were analyzed in cross sections made through the welded points, highlighting the expulsion or accumulated effects of the Al-Si alloy protective layer and the formation of intermetallic compounds. To estimate the effect of welding parameters, the samples were subjected to tensile strength tests, and the fracture mode was evaluated. It was found that the values of the breaking forces were close for the two types of samples analyzed, for identical values of the welding regime parameters, but the elongation at break was double in the case of samples with five protrusions. The breaking force increased from 10.9 kN for samples with three protrusions to 11.4 kN for samples with five protrusions, for the same values of welding parameters. Full article

Aircraft engine turbine discs operate under extreme conditions that limit their service life. Laser cladding of AlCoCrFeNi HEA coatings presents a viable solution to enhance their durability. This study optimizes the laser cladding process parameters—specifically, laser power, scanning speed, and powder feed rate—using the Taguchi method in conjunction with grey relational analysis. The optimal parameter set (1450 W, 480 mm/min, 4 r/min) resulted in a coating with a width of 2.93 mm, a height of 1.20 mm, a dilution rate of 22.6%, and a hardness of 532 HV. The optimized process significantly improved hardness by approximately 15% while reducing dilution and elemental segregation in comparison to the initial parameters. This research illustrates the effectiveness of multi-objective optimization in enhancing coating performance, providing a practical approach for the surface strengthening of critical components, such as turbine discs in aircraft engines, under extreme conditions. Full article