Search Results (766)

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

A novel stainless steel with high Mn and Mo content (much higher than traditional stainless steel), designated CH241SS, was developed as a potential replacement for Cr-Mo-V alloy steel in the cold forging applications of precision industry. Through carbon reduction in an environmentally friendly manner and a two-stage heat treatment process, the hardness of as-cast CH241 was tailored from HRC 37 to HRC 29, thereby meeting the industrial specifications of cold-forged steel (≤HRC 30). X-ray diffraction analysis of the as-cast microstructure revealed the presence of a small amount of ferrite, martensite, austenite, and alloy carbides. After heat treatment, CH241 exhibited a dual-phase microstructure consisting of ferrite and martensite with dispersed Cr(Ni-Mo) alloy carbides. The CH241 alloy demonstrated excellent high-temperature stability. No noticeable softening occurred after 72 h for the second-stage heat treatment. Based on the mechanical and room-temperature tensile fatigue properties of CH241-F (forging material) and CH241-ST (soft-tough heat treatment), it was demonstrated that the CH241 stainless steel was superior to the traditional stainless steel 4xx in terms of strength and fatigue life. Therefore, CH241 stainless steel can be introduced into cold forging and can be used in precision fatigue application. The relevant data include composition design and heat treatment properties. This study is an important milestone in assisting the upgrading of the vehicle and aerospace industries. Full article

The increasing need for materials that are both lightweight and strong in the aerospace and automotive sectors has driven the extensive use of composite sandwich structures. This study examines the impact response of honeycomb sandwich composites fabricated using the vacuum-assisted resin transfer molding (VARTM) technique. Two configurations were analyzed, namely carbon–honeycomb–carbon (CHC) and carbon–Kevlar–honeycomb–Kevlar–carbon (CKHKC), to assess the effect of Kevlar reinforcement on impact resistance. Charpy impact testing was conducted to evaluate energy absorption, revealing that CKHKC composites exhibited significantly superior impact resistance compared to CHC composites. The CKHKC composite achieved an average impact strength of 70.501 KJ/m², which is approximately 73.8% higher than the 40.570 KJ/m² recorded for CHC. This improvement is attributed to Kevlar’s superior toughness and energy dissipation capabilities. A comparative assessment of impact energy absorption further highlights the advantages of hybrid Kevlar–carbon fiber composites, making them highly suitable for applications requiring enhanced impact performance. These findings provide valuable insights into the design and optimization of high-performance honeycomb sandwich structures for impact-critical environments. Full article

This paper explores the impact of applying a powder additive in the form of halloysite and mullite on the thermal protection properties of a composite. The authors used CES R70 epoxy resin with CES H72 hardener, modified by varying the amount of powder additive. The composite samples were exposed to a mixture of combustible gases at a temperature of approximately 1000 °C. The primary parameters analyzed during this study were the temperature on the rear surface of the sample and the ablative mass loss of the tested material. The temperature increase on the rear surface of the sample, which was exposed to the hot stream of flammable gases, was measured for 120 s. Another key parameter considered in the data analysis was the ablative mass loss. The charred layer of the sample played a crucial role in this process, as it helped block oxygen diffusion from the boundary layer of the original material. This charred layer absorbed thermal energy until it reached a temperature at which it either oxidized or was mechanically removed due to the erosive effects of the heating factor. The incorporation of mullite reduced the rear surface temperature from 58.9 °C to 49.2 °C, and for halloysite, it was reduced the rear surface temperature to 49.8 °C. The ablative weight loss dropped from 57% to 18.9% for mullite and to 39.9% for halloysite. The speed of mass ablation was reduced from 77.9 mg/s to 25.2 mg/s (mullite) and 52.4 mg/s (halloysite), while the layer thickness loss decreased from 7.4 mm to 2.8 mm (mullite) and 4.4 mm (halloysite). This research is innovative in its use of halloysite and mullite as functional additives to enhance the ablative resistance of polymer composites under extreme thermal conditions. This novel approach not only contributes to a deeper understanding of composite behavior at high temperatures but also opens up new avenues for the development of advanced thermal protection systems. Potential applications of these materials include aerospace structures, fire-resistant components, and protective coatings in environments exposed to intense heat and flame. 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

The growing need for lightweight, customizable electromagnetic wave absorbers with weather resistance in aerospace and electromagnetic compatibility applications motivates this study, which addresses the limitations of conventional materials in simultaneously achieving structural efficiency, broadband absorption, and environmental durability. We propose a fused deposition modeling (FDM)-based approach for fabricating lightweight wave-absorbing structures using acrylonitrile-styrene-acrylate (ASA)/multi-walled carbon nanotube (MWCNT) composites. Results demonstrate that CST Studio Suite simulations reveal a minimum reflection loss of −18.16 dB and an effective absorption bandwidth (RL < −10 dB) of 3.75 GHz for the 2 mm-thick composite plate when the MWCNT content is 2%. Through FDM fabrication and structural optimization, significant performance enhancements are achieved: The gradient honeycomb design with larger dimensions achieved an effective absorption bandwidth of 6.56 GHz and a minimum reflection loss of −32.60 dB. Meanwhile, the stacked stake structure exhibited a broader effective absorption bandwidth of 10.58 GHz, with its lowest reflection loss reaching −22.82 dB. This research provides innovative approaches for developing and manufacturing tailored lightweight electromagnetic wave-absorbing structures, which could be valuable for aerospace stealth technology and electromagnetic compatibility solutions. 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

The aerospace industry is increasingly turning to composite materials due to their exceptional strength, stiffness, and beneficial physical properties. However, increased reliance on carbon fibre composites has substantial environmental implications, particularly concerning waste management. Recycling these materials is a potential solution to these sustainability issues, provided the recycled fibres retain adequate mechanical strength and durability. This study evaluates the mechanical capabilities of recycled carbon fibres in a scaled-down aircraft spar model (AMT-600 GURI), contrasting them with the capabilities of conventional spars. The primary objective is to ascertain whether recycled composites can fulfil the stringent structural requirements of aerospace applications, employing both simulation and experimental validation methods. The recycled carbon fibre composites were manufactured using hand lay-up and vacuum bagging techniques, and their properties were validated through rigorous tensile and compressive strength testing. These validated results were then used to inform a finite element model developed in HyperWorks software. Simulations revealed that the recycled spar achieved maximum stress values of 3.87 MPa under lift forces, a slight increase of +8.95% compared to the original spar, and 55.05 MPa under drag forces, a significant improvement of +36%. Aerodynamic evaluations further confirmed the structural resilience of the recycled spar, with displacement measurements of 141.4 mm for lift and 504.8 mm for drag, closely aligning with the original spar’s performance. In summary, this study demonstrates that recycled carbon fibre composites can serve as effective substitutes for traditional aerospace materials, thereby supporting sustainability initiatives without compromising performance. The outlined approach provides a reliable framework for incorporating recycled materials. Full article

Automated fiber placement (AFP) composites exhibit complex mechanical behaviors due to manufacturing-induced mesostructural variations, including resin-rich regions and tow gaps that significantly influence both local stress distributions and global material responses. This study presents a hierarchically nested modeling framework based on the Parametric High-Fidelity Generalized Method of Cells (PHFGMC) to predict the effective elastic properties and nonlinear mechanical response of AFP composites. The PHFGMC model integrates micro- and meso-scale analyses using representative volume elements (RVEs) derived from micrographs of AFP composite laminates to capture these manufacturing-induced characteristics. Multiple RVE configurations with varied gap patterns are analyzed to quantify the influence of mesostructural features on global stress–strain response. Predictions for linear and nonlinear elastic behaviors are validated against experimental results from carbon fiber/epoxy AFP specimens, demonstrating good quantitative agreement with measured responses. A cohesive extension of the PHFGMC framework further captures damage initiation and crack propagation under transverse tensile loading, revealing failure mechanisms specifically associated with tow gaps and resin-rich areas. By systematically accounting for manufacturing-induced variability through detailed RVE modeling, the nested PHFGMC framework enables the accurate prediction of global mechanical performance and localized behavior, providing a robust computational tool for optimizing AFP composite design in aerospace and other high-performance applications. Full article

Thermoplastic in situ Automated Fiber Placement (AFP) is an additive manufacturing method currently investigated for its suitability for the production of aerospace-grade composite structures. A considerable expense in this process is the manufacturing and preparation of a mold in which a composite part can be manufactured. One approach to lowering these costs is the use of a 3D-printable thermoplastic mold. However, AFP lay-up on a 3D-printed mold differs from the usage of a traditional metallic mold in various aspects. Most notable is a reduced stiffness of the mold, a lower thermal conductivity of the mold, and the need for varied process parameters of the AFP process. This study focuses on the investigation of the difference in mechanical and morphological characteristics of laminates produced on metallic and polymeric molds. To this end, the tensile strength and the interlaminar shear strength of laminates manufactured on each substrate were measured and compared. Additionally, morphological analysis using scanning electron microscopy and differential scanning calorimetry was performed to compare the crystallinity in laminates. No statistically significant difference in mechanical or morphological properties was found. Thus, thermoplastics were shown to be a suitable material for non-heated molds to manufacture in situ AFP composites. Full article

Fiber–aerogel composites have gained significant attention as high-performance thermal insulation materials due to their unique microstructure, which suppresses conductive, convective, and radiative heat transfer. At room temperature, silica aerogels in particular exhibit ultralow thermal conductivity (<0.02 W/m·K), which is two to three times lower than that of still air (0.026 W/m·K). Their brittle skeleton and high infrared transparency, however, restrict how well they insulate, particularly at high temperatures (>300 °C). Incorporating microscale fibers into the aerogel matrix enhances mechanical strength and reduces radiative heat transfer by increasing scattering and absorption. For instance, it has been demonstrated that adding glass fibers reduces radiative heat transmission by around 40% because of increased infrared scattering. This review explores the fundamental mechanisms governing radiative heat transfer in fiber–aerogel composites, emphasizing absorption, scattering, and extinction coefficients. We discuss recent advancements in fiber-reinforced aerogels, focusing on material selection, structural modifications, and predictive heat transfer models. Recent studies indicate that incorporating fiber volume fractions as low as 10% can reduce the thermal conductivity of composites by up to 30%, without compromising their mechanical integrity. Key analytical and experimental methods for determining radiative properties, including Fourier transform infrared (FTIR) spectroscopy and numerical modeling approaches, are examined. The emissivity and transmittance of fiber–aerogel composites have been successfully measured using FTIR spectroscopy; tests show that fiber reinforcement at high temperatures reduces emissivity by about 15%. We conclude by outlining the present issues and potential avenues for future research to optimize fiber–aerogel composites for high-temperature applications, including energy-efficient buildings (where long-term thermal stability is necessary), electronics thermal management systems, and aerospace (where temperatures may surpass 1000 °C), with a focus on improving the materials’ affordability and scalability for industrial applications. Full article

This paper deals with an important issue, which is the influence of failure caused by the quality of matrix post-curing on the strength of complex and difficult materials of the “new generation” such as fibre composites, particularly with a polymer matrix. In recent years, significant advances in the field of adhesive materials chemistry have led to the constant development of bonding technology. The effectiveness of bonding depends, to a large extent, on the suitable selection of the adhesive and the use of appropriate surface treatment technology. It is difficult to imagine virtually any modern industry without adhesive joints, be it the aircraft, aerospace or automotive industries, which simultaneously highlights the great importance of adhesives and adhesive materials for the present-day economy. In modern technology, it is extremely important to obtain the right combination of modern construction materials. The statistical analysis of the components showed the complexity of the layered composite structure. The proposed model of the weakest micro-volume developed in this study indirectly reflects the experimentally based curing variables that affect the stresses of the components in the composite (laminate) structure. The strength of fibrous composite structures based on the Markov chain theory considers technological aspects during hardening. The model proposed in the paper was validated on the basis of examples from the literature and experimental data obtained in the research project. The numerical results are in good agreement with the literature database and measurement data. The presented model could be a novel method, which allows better insight into the curing process of epoxy resins. Full article