Search Results (56)

This study examines the effect of elevated printing speeds (100–600 mm/s) on the dimensional accuracy and tensile strength of PLA components fabricated via fused deposition modeling (FDM). To isolate the influence of printing speed, all other parameters were kept constant, and two filament variants—natural (unpigmented) and black PLA—were analyzed. ISO 527-2 type 1A specimens were produced and tested for dimensional deviations and ultimate tensile strength (UTS). The results indicate that printing speed has a marked impact on both geometric precision and mechanical performance. The optimal speed of 300 mm/s provided the best compromise between dimensional accuracy and tensile strength for both filaments. At speeds below 300 mm/s, under-extrusion caused weak layer bonding and air gaps, while speeds above 300 mm/s led to over-extrusion and structural defects due to thermal stress and rapid cooling. Black PLA yielded better dimensional accuracy at higher speeds, with cross-sectional deviations between 2.76% and 5.33%, while natural PLA showed larger deviations of up to 8.63%. However, natural PLA exhibited superior tensile strength, reaching up to 46.59 MPa, with black PLA showing up to 13.16% lower UTS values. The findings emphasize the importance of speed tuning and material selection for achieving high-quality, reliable, and efficient FDM prints. Full article

Purpose: The aim of this study was to compare the effect of rotary (air-driven, electric-driven) and oscillating (piezoelectric ultrasonic) handpieces on the quality of crown preparation, marginal integrity, and internal adaptation of monolithic zirconia crowns. Materials and Methods: Seventy-two standardized premolar preparations were performed using the air-driven handpiece with a guide pin-ended tapered fissure diamond bur on a modified dental surveyor. The finishing process utilized three handpiece types (n = 24/group) with fine/superfine diamond burs under controlled force with a fixed number of rotations and controlled advancement time. Marginal/internal adaptation was evaluated via the triple-scan technique; defects (marginal, axial, and occlusal) were quantified based on predefined criteria through the inspection of the Standard Tessellation Language (STL) file. Results: One-way ANOVA with Tukey HSD and Kruskal–Wallis with Dunn–Bonferroni tests were utilized. The marginal gap showed no significant differences (p > 0.05, η² = 0.04). The electric handpiece outperformed the ultrasonic (p = 0.023, η² = 0.105) in internal adaptation, while the air-driven showed no differences (p > 0.05). The ultrasonic handpiece produced fewer marginal defects than the air-driven (p = 0.039, ε² = 0.132), but more axial defects (median 9 vs. 6, p = 0.014, ε² = 0.168) than the electric handpiece and occlusal defects (5 vs. 3, 4 p = 0.007, p = 0.015, ε² = 0.227) than rotary handpieces. The air-driven handpiece exhibited comparable defect numbers to the electric handpiece without statistical significance (p > 0.05). Conclusions: Handpiece selection had a small effect on marginal adaptation but more pronounced effects on overall defect formations and internal adaptation. The ultrasonic handpiece’s decreased marginal defects but variable axial/occlusal results reveal technological constraints, whereas rotary handpieces’ consistency reflects their operator-dependent nature. Full article

In three-phase three-post insulators, air gaps and crack defects are important sources of partial discharge and surface flashover. Using finite element analysis software, this study created a three-dimensional simulation model to investigate the effect of these defects on electric field distribution. The effects of crack defects and air gaps of different sizes and locations on the electric field distribution were then methodically investigated. According to the results, the most significant electric field distortion is caused by air gap defects close to the phase A conductor, and the distortion is exacerbated by shorter air gap lengths. Air gap length has much less effect on the electric field in the phase B conductor. There is no obvious change in electric field strength with the radius of air gap defects (0.1–2 mm). The electric field strength is negatively correlated with crack height; greater height reduces distortion, while crack width and depth are positively correlated with the surrounding field strength; greater dimensions increase distortion. Full article

The Printed Circuit Board (PCB) manufacturing industry is a rapidly expanding sector, fueled by advanced technologies and precision-oriented production processes. The placement of Surface-Mount Device (SMD) components in PCB assembly is efficiently automated using robots and design software-generated coordinate files; however, the PCB repair process remains significantly more complex and challenging. Repairing faulty PCBs, particularly replacing defective SMD components, requires high precision and significant manual expertise, making automated solutions both rare and difficult to implement. This study introduces a novel real-time machine vision-based coordinate estimation system designed for estimating the coordinates of SMD components during soldering or desoldering tasks. The system was specifically designed for Selective Compliance Articulated Robot Arm (SCARA) robots to overcome the challenges of repairing miniature PCB components. The proposed system integrates Image-Based Visual Servoing (IBVS) for precise X and Y coordinate estimation and a simplified laser triangulation method for Z-axis depth estimation. The system demonstrated accuracy rates of 98% for X and Y axes and 99% for the Z axis, coupled with high operational speed. The developed solution highlights the potential for automating PCB repair processes by enabling SCARA robots to execute precise picking and placement tasks. When equipped with a hot-air gun as the end-effector, the system could enable automated soldering and desoldering, effectively replacing faulty SMD components without human intervention. This advancement has the potential to bridge a critical gap in the PCB repair industry, improving efficiency and reducing dependence on manual expertise. Full article

Aiming at the defects of long axial size and low torque density of the existing radial flux permanent magnet motor, this paper proposes an axial flux permanent magnet synchronous motor (AFPMM) with a double-stator and single-rotor structure based on the design requirements of the motor for mechanical dogs’ electric drive joints. The finite element method is employed to evaluate the static magnetic field, load characteristics, and associated losses. The analysis indicates that the average magnetic flux density in the air gap reaches approximately 0.95 T, with a rated torque of around 2.72 N.m, a peak torque of 7.6 N.m, and an efficiency of approximately 87.73%. The electromagnetic torque model is developed using the Maxwell tensor method, allowing for the effects of critical structural parameters on torque to be investigated. By optimizing the design for torque density, an improvement of nearly 20% is achieved. A prototype was fabricated and tested, demonstrating good agreement between simulation and experimental results. This research introduces a novel approach for designing axial flux motors with high torque and power densities. Full article

Air switchgear is an important power equipment in the transmission, transformation, and distribution process of the power system. Insulation defects can lead to partial discharge, which is one of the primary causes of air switchgear failure. Current monitoring methods primarily rely on detecting ultra-high frequency or ultrasonic signals generated by partial discharge to identify insulation defects. However, these methods are prone to external signal interference, resulting in substantial detection errors. Based on gas discharge theory and engineering practice, this paper uses three typical defects to represent the main insulation defects of air switchgear, namely metal protrusion defects, insulation layer air gap defects, and metal particle defects. After that, the validity of the numerical model to describe the partial discharge process of air switchgear insulation defects is verified by the volt-ampere characteristic curve. The discharge process of three typical defect models was investigated by using the numerical model, and the variation curves of the volume fractions of CO, NO₂, and O₃ gases at different voltage levels and different discharge durations were obtained. After analysis, the volume fractions of the three characteristic gases are unique under different defect models and partial discharge quantities. Finally, this paper designed a partial discharge inversion method based on characteristic gases, and fitted time-domain regression equations and partial discharge inversion regression equations based on the changes in volume fractions of the three characteristic gases measured. The research results of this paper provide a theoretical basis for online detection of partial discharge in high-voltage air switchgear through characteristic gases. The method proposed in this paper can also be applied to other gas-insulated equipment, such as GIS, metal-enclosed switchgear, and vacuum circuit breakers. Full article

In the present work, a study of the structural defects in HfO₂ thin films deposited by dip-coating on p-type silicon substrates treated under different conditions, such as air-annealing, ultraviolet irradiation, and simultaneous annealing–UV irradiation, is presented. HfO₂ thin films were analyzed by grazing incidence X-ray diffraction, Raman spectroscopy, optical fluorescence, atomic force microscopy, and UV-Vis diffuse reflectance. Films treated at 200 °C and 350 °C present peaks corresponding to monoclinic HfO₂. After UV treatment, the films became amorphous. The combination of annealing at 350 °C with UV treatment does not lead to crystalline peaks, suggesting that UV treatment causes extensive structural damage. Fluorescence spectroscopy and UV-Vis spectroscopy suggest that films present oxygen vacancies as their main structural defects. A reduction in oxygen vacancies after the second thermal treatment was observed, but in contrast, after UV irradiation, fluorescence spectroscopy indicated that more defects are created within the mobility gap, irrespective of the simultaneous annealing at 350 °C. An electronic band diagram was proposed assigning the observed fluorescence bands and optical transitions, which, in turn, explain the electrical properties of the films. The results suggest that the electronic structure of HfO₂ films can be tailored with a careful choice of thermal annealing conditions along with the controlled creation of defects using UV irradiation, which could open the way to multiple applications of the materials either in microelectronics, optoelectronics, as well as in photocatalytic/electrocatalytic applications such as photodegradation and hydrogen generation. Full article

A carbon brush/collector ring set will have phenomena such as firing and ablation during operation, which is due to the existence of various abnormal contact modes of the brush/ring during operation, thus changing the carbon brush/collector ring interface state. To analyze the effects of different contact modes on the performance of the brush/ring, in this paper, we construct the contact modes of the air gap (loss of contact leads to the existence of a small gap between the two surfaces), direct contact (contact with abrasive particulate media), and surface porosity contact (contact when there is a large pit on the surface of the collector ring due to manufacturing quality defects and abnormal abrasion), and analyze the effects of the various states on the core parameters such as current conduction, ring surface damage, and carbon brush abrasion, which provide a basis for the active suppression of the damage. Full article

In the valve hall of the converter station of a UHV transmission project at high altitudes, the shielding sphere and the wall/floor form a large-size sphere–plane long air gap. Burr defects on the surface of the shielding sphere can affect its discharge characteristics. The streamer-to-leader transition is a key process in the discharge of the long air gap. The existing research is limited to the discharge characteristics of small-size electrodes at low altitudes and cannot be directly extended to those of large-size electrodes at high altitudes. Therefore, this paper constructs a discharge test platform with optical–electrical synchronous detection at an altitude of 2200 m. The instantaneous optical power, electric field intensity, high potential current, and other physical parameters during the discharge in the long air gap of a 1.3 m diameter sphere–plane system were collected for both a sphere electrode with burrs and one without burrs. The injection current of the initial streamer was used as the input variable and substituted into Gallimberti’s model to analyse the transformation process of the streamer stem’s vibrational energy into translational energy. A modified model that is more suitable for high altitudes was developed by taking into account convective diffusion and the thermal expansion of the streamer, and the influence of burr defects on the characteristics of the transition from streamer to leader was analysed and compared with the experimental results. Overall, burr defects reduced the duration of the streamer-to-leader transition and facilitated discharge. The analysis results generally agree with the experimental results. The research results are of great significance for the design of the valve hall insulation in converter stations at high altitudes. Full article

Multi-layer conductive structures, especially those with features like bolt holes, are vulnerable to hidden corrosion and cracking, posing a serious threat to equipment integrity. Early defect detection is vital for implementing effective maintenance strategies. However, the subtle signals produced by these defects necessitate highly sensitive non-destructive testing (NDT) techniques. Analytical modeling plays a critical role in both enhancing defect-detection capabilities and guiding the design of highly sensitive sensors for these complex structures. Compared to the finite element method (FEM), analytical approaches offer advantages, such as faster computation and high accuracy, enabling a comprehensive analysis of how sensor and material parameters influence defect detection outcomes. This paper introduces a novel T-core eddy current sensor featuring a central air gap. Utilizing the vector magnetic potential method and a truncated region eigenfunction expansion (TREE) method, an analytical model was developed to investigate the sensor’s interaction with multi-layer conductive materials containing a hidden hole. The model yielded closed-form expressions for the induced eddy current density and coil impedance. A comparative study, implemented in Matlab, analyzed the eddy current distribution generated by T-core, E-core, I-core, and air core sensors under identical conditions. Furthermore, the study examined how the impedance of the T-core sensor changed at different excitation frequencies between 100 Hz and 10 kHz when positioned over a multi-layer conductor with a hidden air hole. These findings were then compared to those obtained from E-core, I-core, and air-core sensors. The analytical results were validated through finite element simulations and experimental measurements, exhibiting excellent agreement. The study further explored the influence of T-core design parameters, including the air gap radius, dome radius, core column height, and relative permeability of the T-core material, on the inspection sensitivity. Finally, the proposed T-core sensor was used to evaluate crack and hole defects in conductors, demonstrating its superior sensitivity compared to I-core and air core sensors. Although slightly less sensitive than the E-core sensor, the T-core sensor offers advantages, including a more compact design and reduced material requirements, making it well-suited for inspecting intricate and confined surfaces of the target object. This analytical model provides a valuable tool for designing advanced eddy current sensors, particularly for applications like detecting bolt hole defects or measuring the thickness of non-conductive coatings in multi-layer conductor structures. Full article

In response to the typical decay and fracture defects of composite insulators, a three-dimensional electrically and thermally coupled simulation physical model was constructed based on the finite element method, and the local electric field distortion and temperature rise were analyzed. The study confirms that the insulator interface’s axial electric and thermal fields show a U-shaped curve; the interface field strength is the largest. There is an electric field gradient difference between the mandrel and the sheath, and the thermal field is concentrated at the mandrel and the interface. The field strength at the edge of the defect is the largest, the aberrant electric field at the defect shows a sawtooth shape, and the temperature rise is concentrated in the defect area. The degradation is fast in the air gap, the etching hole diameter direction, and the carbonation channel axial direction. The larger the defect volume, the larger the aberration in the electric field and temperature rise. Water vapor air gaps, breakdown holes, and carbonized channels have the most pronounced electric field and temperature changes. The functional relationship between electric field aberration, temperature rise, and defect volume is established. The results provide a basis for the protection of insulator decay-like fracture. Full article

This study explores the flexural behavior of continuous fiber-reinforced composite sandwich structures built entirely using material extrusion additive manufacturing. The continuous fiber additive manufacturing system used in this study works sequentially, thus enabling the addition of fiber reinforcement just in the face sheets, where it is most effective. Three-point bending tests were carried out on sandwich panel specimens built using thermoplastic reinforced with continuous glass fiber to quantify the effect of fiber reinforcement and infill density in the flexural properties and failure mode. Sandwich structures containing continuous fiber reinforcement had higher flexural strength and rigidity than unreinforced sandwiches. On the other hand, an increase in the lattice core density did not improve the flexural strength and rigidity. The elastic modulus of fiber-reinforced 3D-printed sandwich panels exceeded the predictions of the analytical models; the equivalent homogeneous model had the best performance, with a 15% relative error. However, analytical models could not correctly predict the failure mode: wrinkle failure occurs at 75% and 30% of the critical load in fiber-reinforced sandwiches with low- and high-density cores, respectively. Furthermore, no model is currently available to predict interlayer debonding between the matrix and the thermoplastic coating of fiber layers. Divergences between analytical models and experimental results could be attributed to the simplifications in the models that do not consider defects inherent to additive manufacturing, such as air gaps and poor interlaminar bonding. Full article

Using first-principles density functional theory (DFT) calculations and ab initio molecular dynamics (AIMD) simulations, we performed this study on the phase stability, the intrinsic redox stability, and the Li⁺ conductivity of Li₁₀Ge_xMo_1−xP₂S₁₂ (x = 0~1) superionic conductors. Molybdenum (Mo) is expected to replace expensive germanium (Ge) to lower tmaterial costs, reduce sensitivity to ambient water and oxygen, and achieve acceptable Li⁺ conductivity. The ab initio first principle molecular dynamics simulations show that room-temperature Li⁺ conductivity is 1.12 mS·cm⁻¹ for the Li₁₀Ge_0.75Mo_0.25P₂S₁₂ compound, which is comparable to the theoretical value of 6.81 mS·cm⁻¹ and the experimental measured one of 12 mS·cm⁻¹ of the Li₁₀GeP₂S₁₂ (LGPS) structure. For Li₁₀Ge_xMo_1−xP₂S₁₂ (x = 0, 0.25, 0.5 and 1) compounds, the density of states and the projection fractional wave state density were calculated. It was found that when Ge atoms were partially replaced by Mo atoms, the band gap remained unchanged at 2.5 eV, but deep level defects appeared in Mo-substituted compounds. Fortunately, this deep level defect is difficult to ionize at room temperature, so it has no effect on the electronic conductivity of Mo substitute compounds, making Mo substitution a suitable solution for electrolyte materials. The projection fractional wave state density calculation shows that the covalent bond between Mo and S is stronger than that between Ge and S, which reduces the sensitivity of Mo-substituted compounds to water and oxygen contents in the air. In addition, the partial state density coincidence curve between Li and S elements disappears in the 25% Mo-substituted compound with energies of 4–5 eV, indicating that the Li₂S by-product is decreased. Full article

The combined insulation interface of a high-voltage cable and accessories is the weakest part of a cable system. In this paper, the parameters of the dielectric constant, thermal conductivity, and elastic modulus of cross-linked polyethylene (XLPE) and silicone rubber (SIR) are obtained experimentally. On this basis, the model of a specific type of 110 kV cable and prefabricated insulation joint is established. A simulation of the electric–thermal–stress coupling field in the presence of typical defects in the main insulation–inner semi-conductive (SEMI) shielding layer (XLPE/SEMI interface) and the main insulation–silicone rubber insulation layer (XLPE/SIR interface) is studied. The simulation results show that at the XLPE/SIR interface, the electric field distortion caused by bubble defects reached 20.17 kV/mm, and the temperature rose to 56.15 °C. The effect of air-gap defects on the interface is similar to that of bubble defects. In addition, the semi-conductive impurity defects induced an increase in temperature to 56.82 °C and an increase in stress to 0.32 MPa. At the XLPE/SEMI interface, the electric field distortion induced by bubble defects was 19.98 kV/mm, and the temperature rose to 61.72 °C. The electric field distortion caused by metallic and semi-conductive defects was 8.44 kV/mm and 8.64 kV/mm, respectively. This study serves as a reference for the fault analysis and the operation and maintenance of cable accessories. Full article

This study presents the utilization of the microwave infrared thermography (MIRT) technique to identify and analyze the defects in the carbon-fiber-reinforced polymer (CFRP) composite reinforcement of concrete specimens. At first, a set of numerical models was created, comprising the broadband pyramidal horn antenna and the analyzed specimen. The utilization of the system operating at a power of 1000 W in a continuous mode, operating at frequency of 2.45 GHz, was analyzed. The specimen under examination comprised a compact concrete slab that was covered with an adhesive layer and, thereafter, topped with a layer of CFRP. An air gap represented a defect at the interface between the concrete and the CFRP within the adhesive layer. In the modeling stage, the study investigated three separate scenarios—a sample with no defects, a sample with a defect located at the center, and a sample with a numerous additional random defects located at the rim of the CFRP matte—to analyze the effect of the natural reinforcement degradation in this area. The next phase of the study involved conducting experiments to confirm the results obtained from numerical modeling. In the experiments, the concrete sample aged for 10 years with the defect in the center and naturally developed defects at the CFRP rim was used. The study employed numerical modeling to explore the phenomenon of microwave heating in complex structures. The aim was to assess the chosen antenna design and identify the most effective experimental setup. These conclusions were subsequently confirmed through experimentation. The observations made during the heating process were particularly remarkable since they deviated from earlier studies that solely conducted measurements of the sample post-heating phase. The findings demonstrate that MIRT has the capacity to be employed as a technique for detecting flaws in concrete structures reinforced with CFRP. Full article