Search Results (101)

In hybrid wire arc additive manufacturing with interlayer friction stir processing (UAMFSP), refined microstructures are produced in aluminum alloy builds; however, the thermal parameters governing layer-resolved defect evolution remain poorly understood. In this study, a correlative mechanistic framework is presented in which post-peak cooling rate is identified as a plausible controlling factor for porosity evolution in UAMFSP Al 4043 three-layer walls. A multi-scale characterization is performed by employing infrared thermography, quantitative optical grain morphology analysis (N  =  10,346 grains, Layers 1–3), scanning electron microscopy from 250× to 35,000×, and image-based porosity quantification from calibrated SEM fields. This primary quantitative comparison is established between L1 and L3 only; Layer 2 is excluded from the 250× quantitative analysis owing to its thermally distinct cooling regime and is treated separately. A counterintuitive layer-dependent porosity gradient is reported, wherein the upper layer (L3) exhibited 80% higher porosity (2.90 ± 1.18%) and 107% higher pore density (4283  ±  900 pores/mm²) than the bottom layer (L1), despite recording a 26% lower peak FSP surface temperature (195.1 vs. 263.2 °C) (n = three fields per layer; Cohen’s d ≈ 1.7). Based on these results, the post-peak cooling rate, rather than peak temperature, is identified as a plausible controlling factor for void consolidation quality, as evidenced by the observation that L3 cools at −12.3 °C/s versus −16.2 °C/s for L1, which is consistent with prolonged high-temperature dwell and reduced plastic-flow-assisted pore closure in the upper layer. The anomalously rapid cooling of L2 (−46.9 °C/s), attributed to a bilateral thermal gradient between the substrate and the air-cooled free surface, places it in a thermally distinct regime; accordingly, L2 is utilized exclusively for high-magnification SEM characterization in this study. High-magnification SEM imaging (12,000×–35,000×) revealed a frequent spatial co-location of sub-micron pores with fragmented Al–Si eutectic particles, which is consistent with preferential void persistence near particle–matrix interfaces. Grain morphology also exhibits non-monotonic evolution with build height, with mean circularity following the order L3 (0.645) > L1 (0.621) > L2 (0.569), and the equiaxed grain fraction ranging from 25.5% (L2) to 36.1% (L3) (ANOVA: F = 56.2, p = 5.15 × 10⁻²⁵), while the mean equivalent grain diameter remained below 3.4 μm across all layers. Overall, the outcomes of this study establish post-peak cooling rate, rather than peak temperature, as a plausible controlling factor for void consolidation quality in UAMFSP builds, with the caveat that complete causal isolation requires controlled single-variable experiments. These outcomes are presented as a first mechanistic framework for this class of hybrid process and are intended to motivate targeted controlled experiments, subsurface thermal characterization, and expanded porosity sampling in future investigations of multi-layer additive–deformation manufacturing of Al-based alloys. Full article

Integrating a heat exchanger (HEX) into the cooling duct of a high-power fuel-cell-based aircraft presents a critical trade-off between thermal performance and aerodynamic penalties. The present study addresses this challenge through the design and system-level analysis of a HEX integrated into the cooling duct. Developed as part of the Clean Aviation project FAME, the design features a rectangular inlet, a circular outlet, and a tilted HEX. The evaluation is performed using high-fidelity Large Eddy Simulations (LESs). The HEX is modeled with a porous media approach based on the Darcy–Forchheimer equation, while the simulations are carried out using a self-adapted version of the pisoFoam solver, termed pisoTempFoam, to account for heat transfer. The study reveals that while component-level design choices, such as a straight inlet and tilted HEX configuration, successfully mitigate local flow separation and duct-induced losses, a critical system-level performance issue emerges. The analysis demonstrates that the cooling duct design, when subjected to realistic operational conditions, generates the high pressure head to overcome the resistance of the HEX. The external aerodynamic analysis also indicates that the HEX resistance is a critical factor, and without overcoming it the system fails to capture the required air mass flow rate, compromising thermal management. The findings highlight the necessity to optimize the design, by an adapted duct shape or an auxiliary fan, to overcome the HEX-induced pressure drop. The porous media approach is thereby validated as an effective tool for rapid system-level design analysis, despite its inherent limitation in capturing detailed downstream turbulence. Full article

Coal-fired power units remain integral to electricity supply in many regions while facing increasingly stringent environmental expectations. Bridging reliable generation with sustainability requires more than end-of-pipe controls; it demands continuous intelligence embedded in plant operations. This study introduces an industry-oriented monitoring framework that transforms historical operational records into actionable foresight, enabling on-the-fly orchestration of combustion conditions to anticipate sulfur oxide (SOx) concentrations. Leveraging 919 empirical data points collected in 2019 from Unit 8 of the Taichung Thermal Power Plant, the framework integrates robust data governance, targeted feature curation, and a neural network-based analytics core. Eight process variables—sulfur content, coal feed rate, fixed carbon, grinding rate, calorific value, excess air, air flow, and boiler efficiency—emerge as the most influential drivers through systematic selection and feature importance attribution. The resulting forecasting module exhibits near-perfect alignment with observed emissions (R² = 0.99), enabling near-real-time guidance for setpoint adjustments and facilitating compliance strategies under varying load and fuel-quality conditions. Beyond accuracy, the system is architected for scalability and portability, aligning with Industry 4.0 paradigms by coupling continuous sensing, data-driven decision support, and stakeholder transparency. By reframing emission oversight as a proactive, intelligent service rather than a static reporting function, the proposed approach advances operational resilience, regulatory compliance, and community trust, with direct implications for resource efficiency and circular economy initiatives across heavy industry. The framework reduces potential SOx emissions and improves energy utilization efficiency under varying operational conditions. This approach contributes to environmental sustainability by enabling proactive emission reduction and cleaner production practices. It supports regulatory compliance and aligns with global sustainability goals, including SDG 7 and SDG 13. Full article

Laminar co-flow in microchannels typically results in stratified streams with diffusion-limited mixing. This work presents an additively manufactured microfluidic platform that integrates a pulse tank and a transverse injection nozzle into an otherwise straight channel, enabling pulse-driven mixing and droplet generation using air-pressure actuation alone. In Device A, transverse pulsed injection disrupted the stratified interface and significantly enhanced mixing compared with the no-pulse case, as confirmed by an entropy-based mixing index. In Device B, pulsed injection into a continuous oil phase enabled stable droplet-on-demand generation with pressure-tunable droplet diameter in a straight circular channel. The devices operated in a laminar regime, with representative Reynolds, Péclet, and capillary numbers confirming diffusion-limited baseline mixing and stable dripping-type droplet formation. The results demonstrate that pulse-driven injections in a simple, additively manufactured geometry provide an effective, low-complexity approach to mixing enhancement and droplet generation without external fields or complex channel designs. Full article

The dielectric elastomer is a category of electroactive polymer capable of having large deformation under electric excitation and vice versa. They show great potential for the proper maneuvering of small-scale aerial vehicles due to low density and fast actuation, and the successful design demands a proper prediction of their overall dynamic characteristics. However, these characteristics cannot be accurately predicted from lower-order material approximation and/or one specific elastomer shape under a specific flow velocity, pretension, and relaxation. In this research, a comprehensive modal and aerodynamic analysis for the VHB 4910 dielectric elastomer membrane of three different shapes is computationally investigated under different electric excitations, pretensions, and flow velocities using the higher-order Ogden model. A finite element model and a two-way, fully coupled fluid–structure interaction model are developed to obtain vibration and aerodynamic characteristics, respectively, for different membrane shapes. It is found that the variation in electric excitation, pretension, and air velocity is influential in altering the overall dynamics of the membrane and is unique to specific shapes. The rectangular membrane shows a higher vibration frequency for the fundamental mode, whereas the circular membrane provides higher frequencies in higher modes. Increased relaxation for a membrane prestretch higher than the moderate range of stretch ratio ($\lambda$ = 3) demonstrates a slight increase in lift coefficient within a small range of angle of attack, followed by a decrease after exceeding that range. Both the rectangular and elliptical membranes show more flexibility to delay the stall compared to the circular membrane. The circular membrane is observed to have more potential for enhancing the aerodynamic performance and altering the flow field within a certain range of electric excitation and pretension. Computational results are compared with published experimental results to validate the corresponding models. Full article

This work experimentally investigates the behavior of a new indoor air conditioning system based on the application of Peltier cells in a Horizontal Air–Ground Heat Exchanger (HAGHE). To this end, a laboratory-scale prototype focusing exclusively on the terminal section of the system was developed and tested under controlled conditions. A series of configurations was tested, each representing an evolution of the previous one. The results highlight the strong dependence of system performance on airflow velocity, applied voltage, and heat dissipation effectiveness, demonstrating both the potential and the critical limitations of the proposed configurations. The most promising results were obtained in the advanced (fourth and fifth) configurations, yielding average temperature increases of approximately +1.9 °C on the hot flow and decreases ranging from −1.0 °C to −1.7 °C on the cold flow at moderate total voltages (40–50 V) and higher airflow velocities (0.5–0.6 m/s). In line with the principles of the circular economy, the prototype was constructed using recycled materials, including plastic pipes and Peltier cells recovered from discarded devices. Full article

To meet 2050 climate targets, the construction sector must reduce CO₂ emissions and transition toward circular material flows. Recycled aggregates (RA) derived from construction and demolition waste (CDW) and industrial byproducts such as oil shale ash (OSA) show potential for use in concrete, although their application remains limited by standardisation and performance limitations, particularly in structural uses. This study aims to develop and evaluate low-strength, resource-efficient concrete mixtures with full replacement of natural aggregates (NA) by CDW-derived aggregates, and partial or full replacement of cement CEM II by OSA–metakaolin (MK) binder, targeting non-structural 3D-printing applications. Mechanical performance, printability, cradle-to-gate life cycle assessment, eco-intensity index, and transport-distance sensitivity for RA were assessed to quantify the trade-offs between structural performance and global warming potential (GWP) reduction. Replacing NA with RA reduced compressive strength by ~11–13% in cement-based mixes, while the aggregate type had a negligible effect in cement-free mixtures. In contrast, full cement replacement by OSA-MK binder nearly halved compressive strength. Despite the strength reductions associated with the use of waste-derived materials, RA-based cement-free 3D-printed specimens achieved ~30 MPa in compression and ~5 MPa in flexure. Replacing CEM II with OSA-MK and NA with RA lowered GWP by up to 48%, with trade-offs in the air-emission, toxicity, water and resource categories driven by the OSA supply chain. The cement-free RA mix achieved the lowest GWP and best eco-intensity, whereas the CEM II mix with RA offered the most balanced multi-impact profile. The results show that regionally available OSA and RA can enable eco-efficient, structurally adequate 3D-printed concrete for construction applications. Full article

A dew-point evaporative air cooler incorporating a novel segmented heat exchange design, demarcated according to the humidity state of moist air, is proposed. The system employs a porous fibrous material to create a wetted evaporative surface, which is continuously maintained in a moistened condition through a self-wicking water supply mechanism to enhance latent heat transfer. Circular fins are installed on the heat exchanger’s partition surface once the moist air reaches saturation, thereby improving sensible heat exchange between the dry and wet channels. The performance of a prototype was evaluated under controlled conditions in a standard enthalpy chamber. Experimental results indicate that, under typical summer conditions (inlet dry-bulb and wet-bulb temperatures of 33.8 °C and 25.4 °C, respectively), with an air mass flow ratio of 0.7 and an air velocity of 1.5 m/s, the wet-bulb effectiveness reaches 114.4% and the dew-point effectiveness achieves 84.8%. The maximum temperature reduction occurs in the sensible heat exchange section, reaching up to 6.1 °C, demonstrating its substantial sensible heat recovery capability. The device exhibits an energy efficiency ratio (EER) ranging from 9.1 to 31.8. The proposed compact configuration not only enhances energy efficiency but also reduces material costs by approximately 15.4%, providing a valuable reference for the future development of dew-point evaporative cooling systems in residential buildings. Full article

Aerostatic bearings incorporating micro-hole restrictors with diameters on the order of tens of microns demonstrate superior static and dynamic stiffness characteristics, while significantly reducing air consumption, and are increasingly adopted in precision engineering applications. This paper investigates the modelling of aerostatic bearings with micro-hole restrictors. First, a refined discharge coefficient formula is developed, incorporating the orifice length-to-diameter ratio effect using the computational fluid dynamics (CFD) simulation results on a centrally fed circular aerostatic bearing. A numerical solution scheme is proposed using the developed discharge coefficients to enable more accurate and efficient prediction of the bearing performance and flow characteristics. Finally, the proposed numerical approach is implemented using the finite difference method (FDM) and demonstrated through a circular thrust air bearing case study. The results are validated against both CFD simulations and experimental measurements, showing excellent agreement and confirming the reliability of the FDM-based numerical model. Numerical and experimental investigations consistently demonstrate that micro-hole-restricted air bearings can achieve both high load capacity and high stiffness, having the potential for application in more complex air bearing designs and systems. Full article

This paper presents a numerical study of fluid–structure interaction (FSI) applied to wind turbines, combining computational fluid dynamics (CFD) and finite element analysis (FEA). The study focuses on a 3D wind turbine blade inspired by the GE 1.5XLE model. The blade features a twisted geometry with S818, S825, and S826 aerodynamic profiles, and is made of an orthotropic composite material with variable thickness and an internal spar. The fluid domain is defined by two circular sections upstream and downstream, aligned along the Z-axis. Simulations are performed under a wind speed of 12 m/s and a rotational speed of −2.22 rad/s (Tip Speed Ratio (TSR) = 8), with air modeled as an incompressible fluid at ambient temperature. On the CFD side, a periodic and symmetric modeling approach is applied, reducing the fluid domain to one-third of the full configuration by simulating flow around a single blade and extrapolating results to the remaining ones. This method achieves a 47% reduction in computation time while maintaining high accuracy in aerodynamic results. On the FEA side, spar condensation is performed by creating a superelement using the substructuring method. This strategy reduces structural computation time by 45% while preserving reliable predictions of displacements, stresses, and natural frequencies. These results confirm the effectiveness of the proposed techniques for accurate and computationally efficient aeroelastic simulations. Full article

This study extends the application and validation of the Gibbs Free Energy Gradient Method (GMM) for modelling gasification processes, focusing on scaling up from pilot to commercial operations. The model simulates syngas production using poplar wood and olive pomace briquettes under various gasification conditions. Experimental data from a downdraft gasifier were employed to refine the model parameters, achieving accurate predictions of syngas composition with an average error below 8%. Sensitivity analyses highlight the impact of operating conditions, particularly temperature and air flow rates, on the syngas calorific value, hydrogen yield, and energy efficiency. These results emphasize the potential of biomass residues, such as olive pomace, for sustainable energy production in a circular economy context. The findings demonstrate the robustness of the GMM for predicting gasification performance and offer practical guidance for scaling up biomass-to-energy systems while optimizing efficiency and reducing waste. Full article

Emptying pressure pipelines is a routine operation during pipeline maintenance. This study investigates the emptying characteristics of pressurized pipelines with air valves under unsteady flow conditions. A mathematical model for the emptying process is developed using the rigid water column theory, exploring the influence of drain valve opening, initial air pocket length, and valve opening patterns on the transient flow behavior. The results indicate that, compared with the linear valve opening pattern, a nonlinear power function opening increases the minimum air pocket pressure head by 0.1014 m and delays its occurrence by 0.655 s. The maximum emptying velocity rises by 0.48 m/s when the opening is increased from 10% to 30%, thereby shortening the emptying time by 65.4%. However, the pressure head inside the air pocket decreases accordingly. When the air valve diameter is enlarged from 0.003 mm to 0.008 mm, the pressure recovery time is markedly reduced and the initial pressure fluctuations are attenuated. Numerical simulations based on the Heihe emptying case demonstrate that a well-planned layout of multiple air valves effectively shortens the duration of negative pressure heads. Replacing the first air valve with a 50 cm diameter circular orifice significantly raises the minimum pressure head of the pipeline and dramatically enhances the stability of emptying pressurized pipeline. Full article

This paper presents a design analysis approach for migration nozzles used in the spinning process of synthetic fibers. A migration nozzle system consists of a yarn channel, air orifices, and a yarn loading slit. The entire system was analyzed in detail using computational fluid dynamics (CFD). The design parameters considered include the cross-sectional shape of the yarn channel, as well as the diameter and number of air orifices. Two different cross-sectional shapes, square and circle, were examined. The diameter of the air orifice varied from 0.6 mm to 2.0 mm, and both single and double orifice configurations were studied. A square cross-section resulted in the formation of a secondary vortex above the main vortex, making the circular cross-section preferable. The diameter of the air orifice significantly affects the vortex flow within the yarn channel. Vortex flow characteristics were quantified in two ways: the vorticity averaged across the cross-section in the direction of the yarn channel and the vorticity at the centerline. The highest vorticity at the centerline was observed at a diameter of 1.3 mm for single air orifice and 0.9 mm for double air orifices. These CFD results were validated through comparison with corresponding experimental data. A statistical analysis confirms that the centerline vorticity, particularly in the area of the air orifice, is a key and reliable parameter for evaluating the design of migration nozzles. Full article

In this study, the oxidative upgrading of heavy oil residues using polymer-containing waste for the sustainable production of bitumen was investigated. Oxidation was performed at temperatures of 250–270 °C for 3–4 h with the addition of 2–3 wt.% polyethylene-based waste, under an air flow of 7 L/min. The physical and mechanical characterization of the resulting bitumen demonstrated compliance with oxidized modified bitumen grades OMB 100/130 and OMB 70/100. FTIR spectroscopy revealed the formation of carbonyl and sulfoxide functional groups, indicating the effective oxidative transformation of the bitumen matrix and partial incorporation of polyethylene fragments. NMR spectroscopy confirmed increased aromaticity and carbonyl content, while also detecting polyethylene-derived signals, suggesting compatibility and integration of the polymer waste into the oxidized structure. The thermal and rheological results showed that the optimal conditions for producing high-quality oxidized bitumen involved the use of 2% polymer waste at 270 °C for 4 h, yielding enhanced physical properties and chemical stability. These findings support the feasibility of using polymer-containing waste for bitumen upgrading, offering both environmental and technical advantages. The method not only improves the quality of bitumen but also contributes to waste valorization and circular economy practices in the road construction industry. Full article

Laccases, a class of multicopper oxidases found in diverse biological sources, have emerged as key green biocatalysts with significant potential for eco-friendly pollutant degradation. Their ability to drive electron transfer reactions using oxygen, converting pollutants into less harmful products, positions laccases as promising tools for scalable and sustainable treatment of wastewater, soil, and air pollution. This review explores laccase from a translational perspective, tracing its journey from laboratory discovery to real-world applications. Emphasis is placed on recent advances in production optimization, immobilization strategies, and nanotechnology-enabled enhancements that have improved enzyme stability, reusability, and catalytic efficiency under complex field conditions. Applications are critically discussed for both traditional pollutants such as synthetic dyes, phenolics, and pesticides and emerging contaminants, including endocrine-disrupting chemicals, pharmaceuticals, personal care products, microplastic additives, and PFAS. Special attention is given to hybrid systems integrating laccase with advanced oxidation processes, bioelectrochemical systems, and renewable energy-driven reactors to achieve near-complete pollutant mineralization. Challenges such as cost–benefit limitations, limited substrate range without mediators, and regulatory hurdles are evaluated alongside solutions including protein engineering, mediator-free laccase variants, and continuous-flow bioreactors. By consolidating recent mechanistic insights, this study underscores the translational pathways of laccase, highlighting its potential as a cornerstone of next-generation, scalable, and eco-friendly remediation technologies aligned with circular bioeconomy and low-carbon initiatives. Full article