Search Results (41)

This study presents the optimization of a laser ablation process designed to achieve the precise removal of polyamide coatings from ultra-thin platinum wires. Removing polymer coatings is a critical challenge in high-reliability manufacturing processes such as aerospace thermocouple fabrication. The ablation process must not only ensure the complete removal of the polyamide insulation but also maintain the tensile strength of the wire to withstand mechanical handling in subsequent manufacturing stages. Additionally, the exposed platinum surface must exhibit low surface roughness to enable effective soldering and be free of thermal damage or residual debris to pass strict visual inspections. The wires have a total diameter of 65 µm, consisting of a 50 µm platinum core encased in a 15 µm polyamide coating. By utilizing a UV laser with a wavelength of 355 nm, average power of 3 W, a repetition rate range of 20 to 200 kHz, and a high-speed marking system, the process parameters were systematically refined. Initial attempts to perform the ablation in an air medium were unsuccessful due to inadequate thermal control and incomplete removal of the polyamide coating. Hence, a water-assisted ablation technique was explored to address these limitations. Experimental results demonstrated that a scanning speed of 1200 mm/s, coupled with a line spacing of 1 µm and a single ablation pass, resulted in complete coating removal while ensuring the integrity of the platinum substrate. The incorporation of a water layer above the ablation region was considered crucial for effective heat dissipation, preventing substrate overheating and ensuring uniform ablation. The laser’s spot diameter of 20 µm in air and a focal length of 130 mm introduced challenges related to overlap control between successive passes, requiring precise calibration to maintain consistency in coating removal. This research demonstrates the feasibility and reliability of water-assisted laser ablation as a method for a high-precision, non-contact coating material. Full article

Platinum wires, known for their excellent electrical conductivity and durability, are widely used in high-precision industries, such as aerospace and automotive. These wires are typically coated with polyamide for protection; however, specific manufacturing processes require the coating to be selectively removed. Although traditional chemical stripping methods are effective, they are associated with high costs, safety concerns, and long processing times. As a result, laser ablation has emerged as a more efficient, precise, and cleaner alternative, especially at the microscale. In this study, ultraviolet nanosecond laser ablation was applied to remove polyamide coatings from ultra-thin platinum wires in a water-assisted environment. The presence of water enhances the process by promoting thermal management and minimizing debris. Key processing parameters, including the scanning speed, overlap percentage, and line distance, were evaluated. The optimal result was achieved at a scanning speed of 1200 mm/s, line distance of 1 µm, and single loop in water-ambient, where coating removal was complete, surface roughness remained low, and wire tensile strength was preserved. This performance is attributed to the effective energy distribution across the wire surface and reduced thermal damage due to the heat dissipation role of water, along with controlled overlap that ensured full coverage without overexposure. A thin, well-maintained water layer confined above the apex of the wire played a crucial role in regulating the thermal flow during ablation. This setup helped shield the delicate platinum substrate from overheating, thereby maintaining its mechanical integrity and preventing substrate damage throughout the process. This study primarily focused on analyzing the main effects and two-factor interactions of these parameters using Analysis of Variance (ANOVA). Interactions such as Speed × Overlap and Speed × Line Distance were statistically examined to identify the influence of combined factors on tensile strength and surface roughness. In the second phase of experimentation, the parameter space was further expanded by increasing the line distance and number of loops to reduce the overlap in the X-direction. This allowed for a more comprehensive process evaluation. Again, conditions around 1200 mm/s and 1500 mm/s with 2 µm line distance and two loops offered favorable outcomes, although 1200 mm/s was selected as the optimal speed due to better consistency. These findings contribute to the development of a robust, high-precision laser processing method for ultra-thin wire applications. The statistical insights gained through ANOVA offer a data-driven framework for optimizing future laser ablation processes. Full article

Vibration control is a critical aspect of engineering, particularly in structures and mechanical systems where excessive oscillations can lead to fatigue, noise, or failure. Vibration suppression is essential in aerospace, automotive, civil, and industrial applications to enhance performance and longevity of systems. Piezoelectric shunt circuits (PSCs) offer a passive or semi-active approach to damping vibrations by leveraging the electromechanical properties of piezoelectric materials. Traditional passive damping methods, such as viscoelastic materials, are effective but lack adaptability. Active control systems, while tunable, require external power and complex electronics, increasing cost and weight. Piezoelectric shunt circuits provide a middle ground, utilizing piezoelectric transducers bonded to a structure and connected to an electrical circuit to dissipate vibrational energy as heat or store it electrically. This review synthesizes the fundamental mechanisms, circuit designs, and practical applications of this technology. It also presents the modeling of lumped and distributed parameter systems coupled with PSCs. It complements the recent reviews and primarily focuses on the period from 2019 to date in addition to the earlier seminal works on the subject. It explores the principles, configurations, advantages, and limitations of piezoelectric shunt circuits for vibration control, alongside recent advancements and potential future developments. It sheds light on the research gaps in the literature that future work may tackle. Full article

CuCrZr/GH4169 multi-material structures combine the high thermal conductivity of copper alloys with the high strength of nickel-based superalloys, making them suitable for aerospace components that require efficient heat dissipation and high strength. However, additive manufacturing of such dissimilar metals faces challenges, with each laser powder bed fusion (LPBF) and laser directed energy deposition (LDED) process having its limitations. This study employed an LPBF-LDED integrated additive manufacturing (LLIAM) approach to fabricate CuCrZr/GH4169 components. CuCrZr segments were first produced by LPBF, followed by LDED deposition of GH4169 layers using optimized laser parameters. The microstructure, composition, and mechanical properties of the fabricated components were analyzed. Results show a sound metallurgical bond at the CuCrZr/GH4169 interface with minimal porosity and cracks (typical defects at the interface), achieved by exceeding a threshold laser energy density. Elemental interdiffusion forms a 100–200 μm transition zone, with a smooth hardness gradient (97 HV0.2 to 240 HV0.2). Optimized specimens exhibit tensile failure in the CuCrZr region (234 MPa), confirming robust interfacial bonding. These findings demonstrate LLIAM’s feasibility for CuCrZr/GH4169 and underscore the importance of balancing thermal conductivity and mechanical strength in multi-material components. These findings provide guidance for manufacturing aerospace components with both high thermal conductivity and high strength. Full article

High-temperature performance is crucial for dielectric capacitors, especially in military and aerospace applications, as they offer superior charge–discharge rates and power density compared to supercapacitors and batteries. However, the stability of polymers based on commercial dielectric capacitors under extreme environmental conditions (i.e., ≥100 °C) presents significant challenges. Herein, with polyimide (PI) as the matrix, a middle layer is produced that is rich in zero-dimensional nanoparticles, BaTiO₃ (0DBTO@PI), to enhance dielectric polarization. The upper and lower layers integrate two-dimensional laminated Al₂O₃ (2DAO@PI) as thermal conductive and insulating layers to improve heat dissipation and electrical insulation. The composites combine polarization enhancement and thermal management to synergistically improve high-temperature capacitive energy storage. As a result, the designed composite capacitors maintain good performance at temperatures > 150 °C. Even at 200 °C, it retains 2.36 J cm⁻³ (a 203% increase over pure PI), demonstrating unprecedented stability under extreme temperatures. Layer-specific functionalization provides a new and significant paradigm for designing high-temperature polymer-based energy storage films. Full article

This study investigates the influence of thermal conductivity and hardness on computer numerical control (CNC) turning performance, focusing on key machining metrics—material removal rate (MRR), surface roughness (R_a), and surface waviness (W_a)—across five engineering materials: aluminum 6061, brass C26000, bronze C51000, carbon steel 1020, and stainless steel 304. Experimental results reveal a strong correlation between material properties and machining efficiency. Materials with high thermal conductivity (>100 W/m·K) exhibited up to 38% higher MRR and improved surface integrity compared to low-conductivity counterparts. Aluminum 6061 achieved the highest MRR (7.5 mm³/min at a 0.25 mm/rev feed rate), with the lowest R_a (~0.58 µm) and W_a (~0.4576 µm), confirming its excellent machinability and heat dissipation. Conversely, stainless steel 304, characterized by low thermal conductivity (16 W/m·K) and high hardness (210 HBW), recorded the lowest MRR (1.125 mm³/min), elevated R_a (>1.0 µm), and substantial waviness (W_a ~0.9442 µm), indicating severe tool wear and thermal deformation. A multivariable regression model incorporating cutting speed, feed rate, thermal conductivity, and hardness was developed to predict MRR, achieving high predictive accuracy (R² > 0.92) for high-conductivity materials. Deviations of ±0.5 mm³/min were observed in harder, low-conductivity materials due to nonlinear effects such as strain hardening and thermal expansion. Measurement uncertainty analysis, with an estimated expanded uncertainty of ±2.5% for MRR and ±0.02 µm for surface metrics, ensures the reliability of these findings. These results underscore the importance of material-specific machining parameter optimization to enhance productivity, surface quality, and tool longevity in high-precision industries, including aerospace, automotive, and biomedical manufacturing. Full article

Recently, there has been an increasing emphasis on improving the performance of metal components across various industries, such as automotive, aerospace, electronics, medical devices, and military applications. However, the challenges related to efficient heat generation and transfer in equipment and devices are becoming increasingly critical. A solution to these issues involves the adoption of a metal–composite hybrid structure, designed to efficiently manage heat, while substituting conventional metal components with polymer–carbon composites. In this study, nanopores were formed on the metal surface using an anodization process, serving as the basis for creating 3D-printed polymer/metal hybrid constructions. Various surface treatments, including plasma treatment, mixed electrolyte anodization, and etching, were applied to the metal surface to enhance the bonding strength between the 3D-printed polymer and the aluminum alloy. These processes were essential for developing lightweight polymer/metal hybrid structures utilizing a range of 3D-printed polymer filaments, such as polylactic acid, thermoplastic polyurethane, acrylonitrile butadiene styrene, polypropylene, thermoplastic polyester elastomer, and composite materials composed of polymer and carbon. In particular, the hybrid structures employing polymer–carbon composite materials demonstrated excellent heat dissipation characteristics, attributed to the remarkable conductive properties of carbon fibers. These technologies have the potential to effectively address the device heat problem by facilitating the development of lightweight hybrid structures applicable across various fields, including automotive, mobile electronics, medical devices, and military applications. Full article

Lattice structures have the characteristics of light weight, excellent heat dissipation and mechanical properties. Because of excellent properties, lattice structures have been widely used in aerospace, automobile manufacturing, biomedical and other fields. At present, additive manufacturing is the mainstream method for manufacturing lattice structures. This study reviews the existing literature on additive manufacturing of lattice structures, introduces manufacturing methods, and summarizes the influencing factors of forming quality. In addition, the topology optimization of the unit cell and the gradient design of the lattice structure are discussed, and the future research direction of the lattice structure is proposed. Full article

Microporous metal materials have promising applications in the high-temperature industry for their high heat exchange efficiency. However, due to their complex internal structure, analyzing the heat transfer mechanisms presents a great challenge. This I confirm work introduces a mathematical model to accurately calculate the radiative thermal conductivity of microporous open-cell metal materials. The finite element and lattice Boltzmann methods were employed to calculate the thermal conduction and thermal radiation conductivities separately and validated for aluminum foams, with the relative errors all less than 9.3%. The results show that the thermal conductivity of microporous metal materials mainly increased with an increase in temperature and volume-specific surface area but decreased with an increase in porosity. Analysis of the spectral radiation characteristics shows that the surface plasmon polariton resonance and the magnetic polariton resonance appearing at the gas–solid interface of the metal foam significantly increase the dissipation effect of the gas–solid interface, further reducing the metal foam’s heat transfer efficiency. This indicates the potential of this work for use in the design of specific microporous metal materials like energy management devices or heat transfer exchangers in the aerospace industry. Full article

Vapor chambers (VCs) are efficient heat spreaders that rely on wicks to realize the circulation of a phase-changing working liquid and can be used to address heat dissipation problems in electronic devices, aerospace, and satellite equipment. In this study, we propose a novel vapor chamber with biomimetic wick structures and composite lattice supports to enhance the thermal management and load-bearing performance of vapor chambers. The experiments and COMSOL multiphysics 6.1 simulation results indicate that the biomimetic design can improve the startup performance, thermal management, and load-bearing performance of the VC. Compared to conventional VCs, at a filling ratio of 20% the biomimetic VC reduces the time to reach a steady state by 11.7% and improves the uniformity of temperature by 7.74%. This study provides a novel design concept for VCs and verifies the operating performance of vapor in high heat flux density cases, providing a reference for the innovative design and enhanced heat transfer of phase change-based thermal management equipment. Full article

Electrification has become increasingly common in aerospace due to climate change concerns. After successful applications in general aviation aircraft, electrification is now addressing subregional (up to 19 passengers) and regional aircraft (around 80 passengers). Megawatt-class electric motors are needed both to drive propellers and to act as high-power generators in hybrid–electric propulsion systems. Power levels for this class of aircraft require a proper design of heat management systems capable of dissipating a much higher quantity of heat than that dissipated by traditional cooling systems. The technical solution here explored is based on the addition into a diathermic base liquid of nanoparticles, which can increase (by up to 30%) the thermal conductivity of the refrigerant, also providing large surface area enhancing the heat transfer capacity of base liquids. The Italian Aerospace Research Centre (CIRA), as part of the European research initiative Optimised Electric Network Architectures and Systems for More-Electric Aircraft (ORCHESTRA), developed a thermal management system (TMS) based on impinging jets technology for a 1 MW electric motor. In this work, a numerical verification of the possibility for nanofluids to improve the heat exchange efficiency of a submerged oil impinging jets TMS designed to directly cool the inner components of a 1 MW motor is conducted. Investigations aimed to analyse two nanoparticle types (alumina and graphite) added to diathermic oil with concentrations between 1% and 5% by volume. The application of nanofluids significantly increases final thermal conductivity with respect to conventional coolants, a 60% improvement in heat transfer at a fixed mass flow rate is achieved. Electric motor maximum temperatures are approximately 10% lower than those achieved with solely diathermic oil. This result is significant as a safety margin is needed in all cases where a sudden increase in power occurs. Full article

Internal combustion (IC) engines are used widely as the primary power source for automobiles of all types, cars, motorcycles, and trucks. Because of the high combustion temperatures involved in the operation, the excess heat is removed by means of extended fins that increase the surface area for adequate cooling. Significant improvement in the heat dissipation characteristics of the engine cylinder can be achieved by optimizing the design of these fins. The aim of this study is to evaluate the thermal performance of engine cylinder fins using an analytical system of finite element analysis (ANSYS FEA) software, using a direct optimization (DO) approach to identify optimal fin design. Analysis shows that fin length and width play critical roles in improving cooling efficiency, lowering the maximum temperature within the cylinder to 549.46 K and enhancing total heat flux to 7225.31 W/m², which is a 25.87% increase from the generic design, capable of heating removal of 5740.22 W/m². The current fin design is effective but could be improved in heat dissipation, mainly at fin tips. To optimize thermal performance while minimizing material costs, a balanced fin dimension is recommended. Alternative materials, transient heating analysis, and experimental verification may be examined in the future to achieve a total understanding of fin geometry and behavior under real operating conditions. These insights lay a foundation to accelerate cooling systems development in the automotive, aerospace, and heavy equipment industries, where efficient heat transfer is key for performance and long-term durability. Full article

The present paper reports the theoretical results on the thermal performance of proposed Integrated Hybrid Nanofluid Hemi-Spherical Fin Model assuming a combination of Fe₃O₄-Ni/C₆H₁₈OSi₂ hybrid nanofluid. The model leverages the concept of symmetrical geometries and optimized nanoparticle shapes to enhance the heat flux, with a focus on symmetrical design applications in thermal engineering. The simulations are carried out by assuming a silicone oil as a base fluid, due to its exceptional stability in hot and humid conditions, enriched with superparamagnetic Fe₃O₄ and Ni nanoparticles to enhance the heat transfer capabilities, with the aim of contributing to the field of nanotechnology, electronics and thermal engineering, The focus of this work is to optimize the heat dissipation in systems that require high thermal efficiency and stability such as automotive cooling systems, aerospace components and power electronics. In addition, the study explores the influence of key parameters such as heat transfer coefficients and thermal conductivity that play an important role in improving the thermal performance of cooling systems. The overall thermal performance of the model is evaluated based on its heat flux and thermal efficiency. The study also examines the impact of the shape optimized nanoparticles in silicone oil by incorporating shape-factor in its modelling equations and proposes optimization of parameters to enhance the overall thermal performance of the system. Darcy’s flow model is used to analyse the key parameters in the system and study the thermal behaviour of the hybrid nanofluid within the fin by incorporating natural convection, temperature-dependent internal heat generation, and radiation effects. By using the similarity approach, the governing equations were reduced to non-linear ordinary differential equations and numerical solutions were obtained by using four-stage Lobatto-IIIA numerical technique due to its robust stability and convergence properties. This enables a systematic investigation of various influential parameters, including thermal conductivity, emissivity and heat transfer coefficients. Additionally, it stimulates interest among researchers in applying mathematical techniques to complex heat transfer systems, thereby contributing towards the development of highly efficient cooling system. Our findings indicate that there is a significant enhancement in the heat flux as well as improvement in the thermal efficiency due to the mixture of silicone oil and shape optimized nanoparticles, that was visualized through comprehensive graphical analysis. Quantitatively, the proposed model displays a maximum thermal efficiency of 57.5% for lamina shaped nanoparticles at $N_c$ = 0.5, $N_r$ = 0.2, $N_g$ = 0.2 and ${\Theta }_a$ = 0.4. The maximum enhancement in the heat flux occurs when $N_c$ doubles from 5 to 10 for $m_2$ = 0.2 and $N_r$ = 0.1. Optimal thermal performance is found for $N_c$, $N_r$ and $m_2$ values in the range 5 to 10, 0.2 to 0.4 and 0.4 to 0.8 respectively. Full article

Microchannels are widely used across various industries, including pharmaceuticals and biochemistry, automotive and aerospace, energy production, and many others, although they were originally developed for the computing and electronics sectors. The performance of microchannels is strongly affected by factors such as rarefaction and viscous dissipation. In the present paper, a numerical analysis of the performance of microchannels featuring rectangular, trapezoidal and double-trapezoidal cross-sections in the slip flow regime is presented. The fully developed laminar forced convection of a Newtonian fluid with constant properties is considered. The non-dimensional forms of governing equations are solved by setting slip velocity and uniform heat flux as boundary conditions. Model accuracy was established using the available scientific literature. The numerical results indicated that viscous dissipation effects led to a decrease in the average Nusselt number across all the microchannels examined in this study. The degree of reduction is influenced by the cross-section, aspect ratio and Knudsen number. The highest reductions in the average Nusselt number values were observed under continuum flow conditions for all the microchannels investigated. Full article

In Wire Arc Additive Manufacturing (WAAM), solidification grain morphology in titanium alloy tends to be columnar rather than equiaxed due to heat dissipation and repeated thermal cycles. This study demonstrates improved microstructure and anisotropic properties in Ti-6Al-4V specimens fabricated by WAAM and treated with hammer peening, resulting in a transition from columnar grains to fine equiaxed grains (~300 μm) in both single-pass and four-bead WAAM walls. The anisotropic elongation decreased by approximately 7%, and tensile strength along the building direction decreased by ~50 MPa for a single-pass wall. Additionally, small and large equiaxed prior-β grains appeared alternately due to the combined effect of hammer peening and welding deposition. The region can be categorized into three parts (MAX, MED, MIN) based on the degree of plastic strain characterized by KAM mapping of EBSD data. In current WAAM parameters, the ratio of strong (~1.5 mm) deformation field (MAX) is about 50% within one deposition layer (MAX+MIN), suggesting a new approach for producing equiaxed prior-β grains. We expect that this method will be applicable for transforming the prior-β grains from columnar to equiaxed. Furthermore, the distribution of plastic strain and phase transformation mechanisms offers innovative approaches to optimize the hammer peening process, with potential applications to optimize the process for more complex components in the aerospace and power plant industries. Full article