Search Results (896)

Prognostic and Health Management (PHM) strategies are gaining increasingly more traction in almost every field of engineering, offering stakeholders advanced capabilities in system monitoring, anomaly detection, and predictive maintenance. Primary flight control actuators are safety-critical elements within aircraft flight control systems (FCSs), and currently, they are mainly based on Electro-Hydraulic Actuators (EHAs) or Electro-Hydrostatic Actuators (EHSAs). Despite the widespread diffusion of PHM methodologies, the application of these technologies for EHAs is still somewhat limited, and the available information is often restricted to the industrial sector. To fill this gap, this paper provides an in-depth analysis of state-of-the-art EHA PHM strategies for aerospace applications, as well as their limitations and further developments through a Systematic Literature Review (SLR). An objective and clear methodology, combined with the use of attractive and informative graphics, guides the reader towards a thorough investigation of the state of the art, as well as the challenges in the field that limit a wider implementation. It is deemed that the information presented in this review will be useful for new researchers and industry engineers as it provides indications for conducting research in this specific and still not very investigated sector. Full article

Basalt-fiber-reinforced polymer (BFRP) composites, utilizing a natural high-performance inorganic fiber, exhibit excellent weathering resistance, including tolerance to high and low temperatures, salt fog, and acid/alkali corrosion. They also possess superior mechanical properties such as high strength and modulus, making them widely applicable in aerospace and shipbuilding. This study experimentally investigated the mechanical properties of BFRP plates under various strain rates (10⁻⁴ s⁻¹ to 10³ s⁻¹) and directions using an electronic universal testing machine and a split Hopkinson pressure bar (SHPB).The results demonstrate significant strain rate dependency and pronounced anisotropy. Based on experimental data, relationships linking the strength of BFRP composites in different directions to strain rate were established. These relationships effectively predict mechanical properties within the tested strain rate range, providing reliable data for numerical simulations and valuable support for structural design and engineering applications. The developed strain rate relationships were successfully validated through finite element simulations of low-velocity impact. Full article

Magnetic gears (MGs) are attracting increasing attention in power transmission systems due to their contactless operation principles, low frictional losses, and high efficiency. However, the broad application potential of these technologies requires a comprehensive evaluation of engineering parameters, such as material selection, energy efficiency, and structural design. This review focuses solely on solid-core magnetic gear systems designed using laminated electrical steels, soft magnetic composites (SMCs), and high-saturation alloys. This review systematically examines the topological diversity, torque transmission principles, and the impact of various core materials, such as electrical steels, soft magnetic composites (SMCs), and cobalt-based alloys, on the performance of magnetic gear systems. Literature-based comparative analyses are structured around topological classifications, evaluation of material properties, and performance analyses based on losses. Additionally, the study highlights that aligning material properties with appropriate manufacturing methods, such as powder metallurgy, wire electrical discharge machining (EDM), and precision casting, is essential for the practical scalability of magnetic gear systems. The findings reveal that coaxial magnetic gears (CMGs) offer a favorable balance between high torque density and compactness, while soft magnetic composites provide significant advantages in loss reduction, particularly at high frequencies. Additionally, application trends in fields such as renewable energy, electric vehicles (EVs), aerospace, and robotics are highlighted. Full article

Helical milling presents a promising alternative to conventional drilling for hole production, offering superior surface quality and improved production efficiency. While this technique has been extensively applied in the aerospace industry, its potential for machining common engineering materials, such as AISI 1045 steel, remains underexplored in the literature. This study addresses this gap by systematically evaluating the influence of key process parameters—cutting speed (V_c), axial depth of cut (a_p), and tool diameter (D_t)—on hole quality attributes, including surface roughness, burr formation, and nominal diameter accuracy. A full factorial experimental design (2³) was employed, coupled with analysis of variance (ANOVA), to quantify the effects and interactions of these parameters. The results reveal that, with a higher V_c, it is possible to reduce surface roughness (R_a) by 30% to 40%, while an increased a_p leads to a 50% increase in R_a. Additionally, D_t emerged as the most critical factor for nominal diameter accuracy, reducing geometrical errors by 1% with a larger D_t. Burr formation was predominantly observed at the lower end of the hole, highlighting challenges specific to this technique. These findings provide valuable insights into optimizing helical milling for low-carbon steels, offering a foundation for broader industrial adoption and further research. Full article

Surface Air-Cooled Oil Coolers (SACOCs) can become a critical component in managing the increasing thermal loads of modern turbofan engines. Installed within the bypass duct, SACOCs utilize high-mass flow bypass air for convective heat rejection, reducing reliance on traditional Fuel-Oil Heat Exchangers. This review explores SACOC design principles, integration challenges, aerodynamic impacts, and performance trade-offs. Emphasis is placed on the balance between thermal efficiency and aerodynamic penalties such as pressure drop and flow distortion. Experimental techniques, including wind tunnel testing, are discussed alongside numerical methods, and Conjugate Heat Transfer modeling. Presented studies mostly demonstrate the impact of fin geometry and placement on both heat transfer and drag. Optimization strategies and Additive Manufacturing techniques are also covered. SACOCs are positioned to play a central role in future propulsion systems, especially in ultra-high bypass ratio and hybrid-electric architectures, where traditional cooling strategies are insufficient. This review highlights current advancements, identifies limitations, and outlines research directions to enhance SACOC efficiency in aerospace applications. Full article

This review presents a comprehensive synthesis of recent advances in the tensile performance of adhesively bonded joints, focusing on applied aspects and modeling developments rather than providing a full theoretical analysis. Although many studies have addressed individual joint types or modeling techniques, an integrated review that compares joint configurations, modeling strategies, and performance optimization methods under tensile loading remains lacking. This work addresses that gap by examining the mechanical behavior of key joint types, namely, single-lap, single-strap, and double-strap joints, and highlighting their differences in stress distribution, failure mechanisms, and structural efficiency. Modeling and simulation approaches, including cohesive zone modeling, extended finite element methods, and virtual crack closure techniques, are assessed for their predictive accuracy and applicability to various joint geometries. This review also covers material and geometric enhancements, such as adherend tapering, fillets, notching, bi-adhesives, functionally graded bondlines, and nano-enhanced adhesives. These strategies are evaluated in terms of their ability to reduce stress concentrations and improve damage tolerance. Failure modes, adhesive and adherend defects, and delamination risks are also discussed. Finally, comparative insights into different joint configurations illustrate how geometry and adhesive selection influence strength, energy absorption, and weight efficiency. This review provides design-oriented guidance for optimizing bonded joints in aerospace, automotive, and structural engineering applications. Full article

The interaction between thermal fields and mechanical loads in thin-walled cylindrical shells introduces complex dynamic behaviors relevant to aerospace and mechanical engineering applications. This study investigates the axial stress wave propagation in a circular cylindrical shell subjected to combined thermal gradients and time-dependent harmonic compression. A semi-analytical model based on Donnell–Mushtari–Vlasov (DMV) shells theory is developed to derive the governing equations, incorporating elastic, inertial, and thermal expansion effects. Modal solutions are obtained to evaluate displacement and stress distributions across varying thermal and mechanical excitation conditions. Empirical Mode Decomposition (EMD) and Instantaneous Frequency (IF) analysis are employed to extract time–frequency characteristics of the dynamic response. Complementary Finite Element Analysis (FEA) is conducted to assess modal deformations, stress wave amplification, and the influence of thermal softening on resonance frequencies. Results reveal that increasing thermal gradients leads to significant reductions in natural frequencies and amplifies stress responses at critical excitation frequencies. The combination of analytical and numerical approaches captures the coupled thermomechanical effects on shell dynamics, providing an understanding of resonance amplification, modal energy distribution, and thermal-induced stiffness variation under axial harmonic excitation across thin-walled cylindrical structures. Full article

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. Full article

During the last few years, the requirements for highly efficient, sustainable, and versatile materials in modern biomedicine, aircraft and aerospace industries, automotive production, and electronic and electrical engineering applications have increased. This has led to the development of new and innovative methods for material modification and optimization. This can be achieved in many different ways, but one such approach is the application of surface thin films. They can be conductive (metallic), semi-conductive (metal-ceramic), or isolating (polymeric). Special emphasis is placed on applying semi-conductive thin films due to their unique properties, be it electrical, chemical, mechanical, or other. The particular thin films of interest are composite ones of the type of transition metal oxide (TMO) and transition metal nitride (TMN), due to their widespread configurations and applications. Regardless of the countless number of studies regarding the application of such films in the aforementioned industrial fields, some further possible investigations are necessary to find optimal solutions for modern problems in this topic. One such problem is the possibility of characterization of the applied thin films, not via textbook approaches, but through a simple, modern solution using their electrical properties. This can be achieved on the basis of measuring the films’ electrical impedance, since all different semi-conductive materials have different impedance values. However, this is a huge practical work that necessitates the collection of a large pool of data and needs to be based on well-established methods for both characterization and formation of the films. A thorough review on the topic of applying thin films using physical vapor deposition techniques (PVD) in the field of different modern applications, and the current results of such investigations are presented. Furthermore, current research regarding the possible methods for applying such films, and the specifics behind them, need to be summarized. Due to this, in the present work, the specifics of applying thin films using PVD methods and their expected structure and properties were evaluated. Special emphasis was paid to the electrical impedance spectroscopy (EIS) method, which is typically used for the investigation and characterization of electrical systems. This method has increased in popularity over the last few years, and its applicability in the characterization of electrical systems that include thin films formed using PVD methods was proven many times over. However, a still lingering question is the applicability of this method for backwards engineering of thin films. Currently, the EIS method is used in combination with traditional techniques such as X-ray diffraction (XRD), X-ray photoelectron spectroscopy (XPS), energy-dispersive X-ray spectroscopy (EDX), and others. There is, however, a potential to predict the structure and properties of thin films using purely a combination of EIS measurements and complex theoretical models. The current progress in the development of the EIS measurement method was described in the present work, and the trend is such that new theoretical models and new practical testing knowledge was obtained that help implement the method in the field of thin films characterization. Regardless of this progress, much more future work was found to be necessary, in particular, practical measurements (real data) of a large variety of films, in order to build the composition–structure–properties relationship. Full article

A new, simple machine was developed to address a long-standing challenge in biomedical and mechanical engineering: how to enhance the primary stability and long-term integration of screws and implants in low-density or heterogeneous materials, such as bone or composite substrates. Traditional screws often rely solely on external threading for fixation, leading to limited cohesion, poor integration, or early loosening under cyclic loading. In response to this problem, we designed and built a novel device that leverages a unique mechanical principle to simultaneously perforate, collect, and compact the substrate material during insertion. This mechanism results in an internal material interlock, enhancing cohesion and stability. Drawing upon principles from physics, chemistry, engineering, and biology, we evaluated its biomechanical behavior in synthetic bone analogs. The maximum insertion (MIT) and removal torques (MRT) were measured on synthetic osteoporotic bones using a digital torquemeter, and the values were compared directly. Experimental results demonstrated that removal torque (mean of 21.2 Ncm) consistently exceeded insertion torque (mean of 20.2 Ncm), indicating effective material interlocking and cohesive stabilization. This paper reviews the relevant literature, presents new data, and discusses potential applications in civil infrastructure, aerospace, and energy systems where substrate cohesion is critical. The findings suggest that this new simple machine offers a transformative approach to improving fixation and integration across multiple domains. Full article

The current research trends of production engineering are based on optimizing the machining process concerning human and environmental factors. High-performance materials, such as hardened steels, nickel-based alloys, fiber-reinforced polymer (FRP) composites, and titanium alloys, are classified as hard-to-cut due to their ability to maintain strength at high operating temperatures. Due to these characteristics, such materials are employed in applications such as aerospace, marine, energy generation, and structural. The purpose of this article is to investigate the machinability of these alloys under various cutting conditions. The purpose of this article is to compare cryogenic cooling and cryogenic processing from the perspective of machinability and sustainability in the manufacturing process. Compared to conventional machining, hybrid techniques, which mix cryogenic and minimal quantity lubricant, led to significantly reduced cutting forces of 40–50%, cutting temperatures and surface finishes by approximately 20–30% and more than 40%, respectively. A carbon footprint is determined by several factors including power consumption, energy requirements, and carbon dioxide emissions. As a result of the cryogenic technology, the energy consumption, power consumption, and CO₂ emissions were reduced by 40%, 28%, and 35%. Full article

Liquid rocket engines occasionally experience abnormal phenomena with unclear mechanisms, causing difficulty in design improvements. To address the above issue, a data mining method that combines ante hoc explainability, post hoc explainability, and prediction accuracy is proposed. For ante hoc explainability, a feature selection method driven by data, models, and domain knowledge is established. Global sensitivity analysis of a physical model combined with expert knowledge and data correlation is utilized to establish the correlations between different types of parameters. Then a two-stage optimization approach is proposed to obtain the best feature subset and train the prediction model. For the post hoc explainability, the partial dependence plot (PDP) and SHapley Additive exPlanations (SHAP) analysis are used to discover complex patterns between input features and the dependent variable. The effectiveness of the hybrid feature selection method and its applicability under different noise combinations are validated using synthesized data from a high-fidelity simulation model of a pressurization system. Then the analysis of the causes of a large vibration phenomenon in an active engine shows that the prediction model has good accuracy, and the feature selection results have a clear mechanism and align with domain knowledge, providing both accuracy and interpretability. The proposed method shows significant potential for data mining in complex aerospace products. Full article

Modern aerospace engineering places increasing emphasis on materials that combine low weight with high mechanical performance. Fiber metal laminates (FMLs), which merge metal layers with fiber-reinforced composites, meet this demand by delivering improved fatigue resistance, impact tolerance, and environmental durability, often surpassing the performance of their constituents in demanding applications. Despite these advantages, inspecting such thin, layered structures remains a significant challenge, particularly when they are difficult or impossible to access. As with any new invention, they always come with challenges. This study examines the effectiveness of the fundamental anti-symmetric Lamb wave mode (A0) in detecting weak interfacial defects within Carall laminates, a type of hybrid fiber metal laminate (FML). Delamination detectability is analyzed in terms of strong wave dispersion observed downstream of the delaminated sublayer, within a region characterized by acoustic distortion. A three-dimensional finite element (FE) model is developed to simulate mode trapping and full-wavefield local displacement. The approach is validated by reproducing experimental results reported in prior studies, including the author’s own work. Results demonstrate that the A0 mode is sensitive to delamination; however, its lateral resolution depends on local position, ply orientation, and dispersion characteristics. Accurately resolving the depth and extent of delamination remains challenging due to the redistribution of peak amplitude in the frequency domain, likely caused by interference effects in the acoustically sensitive delaminated zone. Additionally, angular scattering analysis reveals a complex wave behavior, with most of the energy concentrated along the centerline, despite transmission losses at the metal-composite interfaces in the Carall laminate. The wave interaction with the leading and trailing edges of the delaminations is strongly influenced by the complex wave interference phenomenon and acoustic mismatched regions, leading to an increase in dispersion at the sublayers. Analytical dispersion calculations clarify how wave behavior influences the detectability and resolution of delaminations, though this resolution is constrained, being most effective for weak interfaces located closer to the surface. This study offers critical insights into how the fundamental anti-symmetric Lamb wave mode (A0) interacts with delaminations in highly attenuative, multilayered environments. It also highlights the challenges in resolving the spatial extent of damage in the long-wavelength limit. The findings support the practical application of A0 Lamb waves for structural health assessment of hybrid composites, enabling defect detection at inaccessible depths. Full article

Surrogate modeling has been rapidly evolving in the field of aerospace engineering, further reducing the cost of computational analyses. These models often require large amounts of information to learn the underlying process, which is at odds with obtaining and using the highest-fidelity data. This study assesses the efficacy of multi-fidelity modeling (MFM) to improve simulation accuracy while reducing computational cost. A database of hovering rotor simulations with perturbations of the rotor design and operating conditions was first generated using two different fidelity levels of the OVERFLOW 2.4D Computational Fluid Dynamics software. MFM was then used to quantify the effectiveness of this approach for the development of accurate surrogate models. Multi-fidelity models based on Gaussian Process Regression (GPR) were derived for hovering rotor performance prediction given the geometric rotor blade inputs that currently include twist, planform, airfoil, and the collective pitch angle. The MFM approach was consistently more accurate at predicting the hold-out test data than the surrogate model with high-fidelity data alone. An MFM using just 20% of the available high-fidelity training data was as accurate as a solely high-fidelity model trained on 80% of the available data, representing an approximate fourfold reduction in computational cost. Full article

The aim of the present study is to investigate the influence of Nickel–Hexagonal Boron Nitride (Ni-hBN) nanocomposite coatings, deposited using the pulse reverse current electrodeposition technique. This experimental study focuses on assessing the tribological and corrosion properties of the produced coatings on the SS304 substrate. The microhardness of the as-deposited (AD) sample and heat-treated (HT) sample were 49% and 83.8% higher compared to the control sample. The HT sample exhibited a grain size which was approximately 9.7% larger than the AD sample owing to the expansion–contraction mechanism of grains during heat treatment and sudden quenching. Surface roughness reduced after coating, where the Ni-hBN-coated sample measured a roughness of 0.43 µm compared to 0.48 µm for the bare surface. The average coefficient of friction for the AD sample was 42.4% lower than the bare surface owing to the self-lubricating properties of nano hBN. In particular, the corrosion rate of the AD sample was found to be 0.062 mm/year, which was lower than values reported in other studies. As such, findings from the present study can be particularly beneficial for applications in the automotive and aerospace industries, where enhanced wear resistance, reduced friction, and superior corrosion protection are critical for components such as engine parts, gears, bearings and shafts. Full article