Search Results (149)

Icing poses significant operational and safety risks in aviation, especially for engine components such as cowls and baffles. This study explores the potential of a chemically exfoliated graphene-rich carbon platelet epoxy coating to improve the anti-icing and de-icing performance of 3003-H14 aluminum alloy, which is widely used in such applications. Chemically exfoliated graphite was incorporated into an epoxy resin, then applied to aluminum substrates. Characterization of the coated samples revealed ~30% improvement in surface Vickers hardness (HV) (HV 75.6 ± 1.15 vs. HV average of 98.3 ± 1.5) and enhanced thermal dissipation, with coated surfaces cooling from 104 °C to 22 °C in 530 s compared to 870 s for uncoated samples. While anti-icing performance was not directly evaluated, the observed improvements in thermal dissipation and surface hardness suggest that chemically exfoliated graphene-rich carbon platelet coatings could be promising for passive anti-icing applications. The literature suggests that graphene coating improves hydrophobicity, reducing ice adhesion and delaying nucleation due to its low surface energy and nanoscale roughness, thereby supporting potential passive anti-icing functionality for aircraft engine components. SEM analysis confirmed a uniform, compact coating layer. These preliminary findings indicate that chemically exfoliated graphene-rich carbon platelet coatings can deliver multifunctional performance—mechanical, thermal, and surface—making them promising candidates for passive anti-icing/de-icing solutions in engine components where conventional systems are ineffective. Full article

Hard turning has emerged as a cost-effective and flexible alternative to conventional grinding for machining hardened steels such as AISI 4340. However, its performance is significantly influenced by the choice of cooling and lubrication strategies, as well as the condition of the cutting tool. Inadequate thermal management and tool wear can lead to elevated cutting forces, high interface temperatures, degraded surface quality, and an altered microstructure. This study investigates the machinability performance of AISI 4340 alloy steel (50 HRC) using CVD-coated carbide tools under two distinct cooling/lubrication environments: minimum quantity lubrication (MQL) and cryogenic cooling (LN₂). Experiments were conducted at the beginning and end of tool life with both environments to capture the influence of tool wear on key performance indicators, including cutting force, chip temperature, surface roughness, and microstructural integrity. Results indicate that LN₂ cooling outperformed MQL in mitigating thermal loads and maintaining surface quality, particularly under worn tool conditions. LN₂ reduced cutting forces by up to 37.10%, chip temperature by 56.68%, and surface roughness by 36.95% compared to MQL. Microstructural analysis revealed significantly thinner deformation and white layers under LN₂, suggesting improved subsurface integrity. These findings highlight the potential of LN₂ cooling for enhancing the machinability of hard turning operation and improving overall performance in industrial applications. Full article

Based on a realistic three-dimensional geometric model, this study numerically investigates the influence of yttria-stabilized zirconia (YSZ) thermal barrier coatings (TBCs) on the aerothermal performance of an annular combustor by employing a conjugate heat transfer (CHT) and non-premixed reactive flow coupling approach. Considering the inner and outer liners, double-wall exhaust bends, and the full configuration of cooling holes, two cases—with and without the TBCs—were analyzed. The results reveal that the application of TBCs markedly modifies the near-wall flow structures and heat transfer characteristics. The cooling air mass flow rate decreases from 0.1211 kg/s to 0.1023 kg/s, corresponding to a 15.5% reduction in cooling load. The main recirculation zone becomes more compact, with enhanced vortex intensity, smoother velocity distribution, and improved flame stability. The high-temperature core region extends further downstream, and the peak temperature increases by approximately 80–100 K, indicating more complete combustion and greater heat retention. The outlet temperature distribution factor (OTDF) decreases from 57.34% to 44.48%, leading to a 22.4% improvement in temperature uniformity. The average wall temperatures of the inner liner, outer liner, and exhaust bend decrease by 3.7%, 8.8%, and 7.5%, respectively, with local peak reductions exceeding 250 K. The study demonstrates that the YSZ TBCs enhances the combustor’s thermal protection capability, flow stability, and temperature uniformity through a coupled mechanism of “thermal insulation–flow reconstruction–energy redistribution.” It should be noted that this study considers only the effect of the ceramic top coat of the TBCs, excluding the metallic bond coat and the thermally grown oxide (TGO) layer. Full article

In response to the problem of high energy consumption caused by inefficient temperature control of energy storage aggregates in traditional building envelope structures, this study developed a decanoic acid–stearic acid composite phase-change ceramsite aggregate to improve the thermal performance of buildings and promote the utilization of solid waste resources. Based on the theory of minimum melting, composite phase-change materials were screened through thermodynamic models. The capric acid–stearic acid (CA-SA) melt system, whose theoretical phase-transition temperature falls within the building indoor thermal environment control range (18–26 °C), was preferred as the experimental object of this study, and its characteristics were verified through step cooling curves and thermal property tests. Subsequently, the ceramsite adsorption process was optimized, and the encapsulation process was studied. Finally, the encapsulation performance was evaluated through thermal stability and stirring crushing rate tests. The results showed that the phase-transition temperature of the decanoic acid–stearic acid melt system was 24.83 °C, which accurately matched the indoor thermal environment control requirements. The ceramsite particles treated by a physical vibrating screen can reach equilibrium after 30 min of adsorption at room temperature and pressure, which is both efficient and economical. The encapsulation layer of sludge biochar cement slurry with a water–cement ratio of 0.5 and a biochar content of 3% has both thermal conductivity and encapsulation integrity. The thermal stability test showed that the percentage of leakage of sludge biochar cement slurry and epoxy resin encapsulated aggregates was 0%, and the thermal stability rating was “very stable”. However, the percentage of leakage of unencapsulated and spray-coated encapsulated aggregates was as high as 193% and 40%, respectively. The results of the mixing and crushing rate test show that although the mixing and crushing rate of sludge biochar cement slurry encapsulation is slightly higher, its production cost is much lower than that of epoxy resin, and it is also environmentally friendly. This study improves the thermal performance of buildings by using composite phase-change ceramsite aggregate, and simultaneously realizes the resource utilization of sludge biochar, providing a solution for building energy saving and efficiency that combines environmental and engineering value. Full article

Laser direct energy deposition (LDED) has been widely employed in surface modification and remanufacturing. Achieving high-precision geometries and superior mechanical properties in cladding layers remains a persistent research focus. In this study, an Fe-based alloy was deposited on an AISI 1045 substrate via a wide-beam laser cladding system. Single-track multi-layer samples were prepared with varying z-increment (Z_d), interlayer dwell time (T_I) and laser scanning speed (V) values. The geometry, microstructure, microhardness and wear resistance of the samples were analyzed. Experimental results showed that an estimated Z_d can ensure a constant standoff distance of the laser head and resulting geometric accuracy improvement. Planar grains form at the layer–substrate bonding interface and transition to columnar grains adjacently, while dendrites and equiaxed grains are distributed in the middle and top regions of the layer. The coating layer exhibits much better wear resistance and friction properties than the substrate. The cooling rate can be substantially increased by either raising V or prolonging T_I, resulting in refined grain structures and enhanced microhardness. Real-time monitoring and controlling the mean cooling rate have been demonstrated to be effective strategies for enhancing cladding layer performance. Full article

Laser cladding with ultrafast cooling rates enables effective fabrication of metallic glass matrix composite (MGMC) coatings, significantly enhancing the hardness, corrosion resistance, and mechanical properties of metallic substrates. In this study, a multi-layer Zr₆₅Al_7.5Ni₁₀Cu_17.5 (at. %) MGMC coating was successfully fabricated by laser cladding technology. The effects of the region-dependent microstructural evolution on micro-mechanical properties and corrosion resistance were systematically investigated. The results indicated that the high impurity content of the powder feedstock promoted the crystallization of the coating during laser cladding. Moreover, coarse columnar crystals in the bottom region of the coating nucleated epitaxially at the coating/substrate interface and propagated along the thermal gradient parallel to the building direction, while dendritic crystals dominated the middle region under moderate thermal gradients. In the top region, fine dendritic and equiaxed crystals deposited in the amorphous matrix, due to the lowest thermal gradient and the highest cooling rate. Correspondingly, nanoindentation results revealed that the top region exhibited peak hardness (H), maximum elastic modulus (E), and optimal H/E ratio, exceeding values in both the bottom region and substrate. Simultaneously, the metallic glass matrix composite coating demonstrated significantly better corrosion resistance than the substrate due to its amorphous phase and protective passive film formation. This work advances amorphous solidification theory while expanding applications of metallic glasses in surface engineering. Full article

Thermal barrier coating (TBC) around film-cooling holes is a key failure location for turbine blade TBC. This study built a numerical model. The model used conjugate heat transfer (CHT) and sequential thermal-stress calculation methods. It analyzed the temperature and stress fields in the TBC around film-cooling holes. The holes had different inclination angles (30°, 45°, and 60°). It also explored the balance between cooling effectiveness and stress at these angles. Results show that increasing the film-cooling hole angle reduces the cooling film coverage area significantly. Cooling effectiveness becomes worse. The temperature field near the holes is complex. Sharp temperature gradients exist there. An inverse temperature gradient appeared in the top coat (TC) layer at the hole exit. Stress in the TBC was analyzed next. Analysis was conducted under rated operating conditions. Analysis was also completed after 500 h of creep under these conditions. Stress concentration around the holes is obvious. At room temperature, Mode I cracks easily form upstream of the holes. Mode II cracks easily form downstream. Under rated conditions, mixed-mode cracks (I + II) easily form downstream. The coating experiences larger stress at room temperature. This means that the coating is more likely to spall during cooling. Increasing the hole angle can reduce stress concentration. It can also lower the chance of crack formation. However, a larger angle increases the normal momentum of the cooling jet. This reduces film coverage. Therefore, after considering both cooling effectiveness and TBC failure, the 45° film-cooling hole is optimal. Full article

Diamond–copper composites, due to their exceptional thermal conductivity, hold significant potential in the field of electronic device thermal management. Hot-press sintering is a promising fabrication technique with industrial application prospects; however, the thermal conductivity of composites prepared by this method has yet to reach optimal levels. In this study, tungsten was deposited on the surface of diamond particles by magnetron sputtering as an interfacial transition layer, and hot-press sintering was employed to fabricate the composites. The findings reveal that with prolonged annealing time, tungsten gradually transformed into W₂C and WC, significantly enhancing interfacial bonding strength. When the diamond volume content was 50% and the interfacial coating consisted of 2 wt.% W, 92 wt.% WC, and 6 wt.% W₂C, the composite exhibited a thermal conductivity of 640 W/(m·K), the highest value reported among hot-press sintered composites with diamond content below 50%. Additionally, the AMM (Acoustic Mismatch Model) and DMM (Diffusion Mismatch Model) models were utilized to calculate the interfacial thermal conductance between different phases, identifying the optimal interfacial structure as diamond/W₂C/WC/W₂C/Cu. This composite material shows potential for application in high-power electronic device cooling, thermal management systems, and thermoelectric conversion, providing a more efficient thermal dissipation solution for related devices. Full article

Blast-furnace staves serve as critical protective components in ironmaking, requiring synergistic optimization of slag-coating behavior and self-protection capability to extend furnace lifespan and reduce energy consumption. Traditional integer-order heat transfer models, constrained by assumptions of homogeneous materials and instantaneous heat conduction, fail to accurately capture the cross-scale thermal memory effects and non-local diffusion characteristics in multiphase heterogeneous blast-furnace systems, leading to substantial inaccuracies in predicting dynamic slag-layer evolution. This review synthesizes recent advancements across three interlinked dimensions: first, analyzing design principles of zonal staves and how refractory material properties influence slag-layer formation, proposing a “high thermal conductivity–low thermal expansion” material matching strategy to mitigate thermal stress cracks through optimized synergy; second, developing a mechanistic model by introducing the Caputo fractional derivative to construct a non-Fourier heat-transfer framework (i.e., a heat-transfer model that accounts for thermal memory effects and non-local diffusion, beyond the instantaneous heat conduction assumption of Fourier’s law), which effectively describes fractal heat flow in micro-porous structures and interfacial thermal relaxation, addressing limitations of conventional models; and finally, integrating industrial case studies to validate the improved prediction accuracy of the fractional-order model and exploring collaborative optimization of cooling intensity and slag-layer thickness, with prospects for multiscale interfacial regulation technologies in long-life, low-carbon stave designs. Full article

As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article

This paper presents the results of a comprehensive study of the structure, phase composition, thermal corrosion, and tribological properties of multilayer gradient coatings based on YSZ/NiCrAlY obtained using detonation spraying. X-ray phase analysis showed that the coatings consist entirely of metastable tetragonal zirconium dioxide (t’-ZrO₂) phase stabilized by high temperature and rapid cooling during spraying. SEM analysis confirmed the multilayer gradient phase distribution and high density of the structure. Wear resistance, optical profilometry, wear quantification, and coefficient of friction measurements were used to evaluate the operational stability. The results confirm that the structural parameters of the coating, such as porosity and phase gradient, play a key role in improving its resistance to thermal corrosion and CMAS melt, which makes such coatings promising for use in high-temperature applications. It is shown that a dense and thick coating effectively prevents the penetration of aggressive media, providing a high barrier effect and minimal structural damage. Tribological tests in the temperature range from 21 °C to 650 °C revealed that the best characteristics are observed at 550 °C: minimum coefficient of friction (0.63) and high stability in the stage of stable wear. At room temperature and at 650 °C, there is an increase in wear due to the absence or destabilization of the protective layer. Full article

The construction sector presently consumes about 40% of global energy and generates 36% of CO₂ emissions, making facade retrofits a priority for decarbonising buildings. This review clarifies how ventilated facades (VFs), wall assemblies that interpose a ventilated air cavity between outer cladding and the insulated structure, address that challenge. First, the paper categorises VFs by structural configuration, ventilation strategy and functional control into four principal families: double-skin, rainscreen, hybrid/adaptive and active–passive systems, with further extensions such as BIPV, PCM and green-wall integrations that couple energy generation or storage with envelope performance. Heat-transfer analysis shows that the cavity interrupts conductive paths, promotes buoyancy- or wind-driven convection, and curtails radiative exchange. Key design parameters, including cavity depth, vent-area ratio, airflow velocity and surface emissivity, govern this balance, while hybrid ventilation offers the most excellent peak-load mitigation with modest energy input. A synthesis of simulation and field studies indicates that properly detailed VFs reduce envelope cooling loads by 20–55% across diverse climates and cut winter heating demand by 10–20% when vents are seasonally managed or coupled with heat-recovery devices. These thermal benefits translate into steadier interior surface temperatures, lower radiant asymmetry and fewer drafts, thereby expanding the hours occupants remain within comfort bands without mechanical conditioning. Climate-responsive guidance emerges in tropical and arid regions, favouring highly ventilated, low-absorptance cladding; temperate and continental zones gain from adaptive vents, movable insulation or PCM layers; multi-skin adaptive facades promise balanced year-round savings by re-configuring in real time. Overall, the review demonstrates that VFs constitute a versatile, passive-plus platform for low-carbon buildings, simultaneously enhancing energy efficiency, durability and indoor comfort. Future advances in smart controls, bio-based materials and integrated energy-recovery systems are poised to unlock further performance gains and accelerate the sector’s transition to net-zero. Emerging multifunctional materials such as phase-change composites, nanostructured coatings, and perovskite-integrated systems also show promise in enhancing facade adaptability and energy responsiveness. Full article

A novel processing route of producing CrFeNiMo, Co_0.5CrFeNiMo, and Al_0.5CrFeNiMo high-entropy alloy coatings was proposed in this work. Pre-alloyed HEAs were consolidated by spark plasma sintering (SPS) in order to fabricate electrodes for electrospark deposition (ESD) coatings on carbon steel substrates. Investigations were performed to observe aspects such as phase composition and stability, contamination level, homogeneity, elemental distribution, and microstructural integrity. The results indicated phase stability and lower porosity when increasing the SPS temperature by 50 °C for all cases, with tetragonal distortion related to the HEAs’ severe lattice distortion core effect. The coating surface analysis indicated that a continuous and compact coating was obtained, correlated with the ESD layering count, but microfissures were present after 6 layers were applied due to the reduced ductility combined with rapid cooling under Ar atmosphere. The chemical integrity of both the sintered samples and the coatings was preserved during the processing, revealing a uniform elemental distribution with no contaminations or impurities present. The results indicated successful HEA sintering and deposition, highlighting the potential of the combined SPS-ESD process for high-performance material fabrication with possible applications in aggressive environments. Full article

High-speed and conventional laser cladding technologies were used to prepare Fe-based alloy cladding layers on the surface of 45 steel, compare and analyze the microstructure, microhardness, and phase structure of the two cladding layers, and study and analyze the morphology of the molten pool under the two cladding technologies, as well as the mechanism of evolution of the microstructure of the molten pool during the solidification process. The results show that, compared with the conventional laser melting coating, the grain size of the high-speed laser melting coating is finer, and the cooling rate at the top for conventional laser melting is 5.72 × 10³ K/s, and the cooling rate for high-speed laser melting is 3.53 × 10⁵ K/s. The microhardness of the high-speed laser melting coating has been significantly improved, and the solidification rates at the top for the two types of laser melting are the highest, namely 5.84 mm/s and 24.7 mm/s; the molten pool in conventional laser melting is usually larger and deeper, presenting a wide and deep shape, whereas the high-speed laser molten pool is usually shallower and narrower, with a flatter shape, presenting a comet trail, and the fast-cooling and fast-heating effects of high-speed laser melting are more significant. Full article

The coating thickness of fuel particles is a critical parameter for ensuring the safe operation of high-temperature gas-cooled reactors. However, existing detection technologies still face limitations in measurement accuracy, efficiency, and automation. Notably, accurate thickness measurement relies on the precise identification of anomalous particles, which is hindered by several key challenges. First, incomplete particles in edge regions introduce significant interference. Second, some anomalies exhibit weak morphological features, making them difficult to detect. To address these issues, this study proposes an innovative focal attention-based large convolutional kernel network detection framework comprising three core modules. First, a Vision Transformer backbone incorporating a Large Selective Kernel Module dynamically adapts multi-scale receptive fields to enable coordinated global and local feature perception. Second, the Multi-Scale Feature Fusion Module establishes cross-layer feature interactions to enhance responses to subtle anomalies. Third, the Focal Attention Module employs a dynamic convolutional attention mechanism to strengthen the saliency representation of critical regions. Experimental results demonstrate the effectiveness of the proposed method, reducing the false detection rate and miss detection rate of anomaly detection to 1.96% and 1.9%, respectively. Full article