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Search Results (1,162)

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27 pages, 4509 KiB  
Article
Numerical Simulation and Analysis of Performance of Switchable Film-Insulated Photovoltaic–Thermal–Passive Cooling Module for Different Design Parameters
by Cong Jiao, Zeyu Li, Tiancheng Ju, Zihan Xu, Zhiqun Xu and Bin Sun
Processes 2025, 13(8), 2471; https://doi.org/10.3390/pr13082471 - 5 Aug 2025
Abstract
Photovoltaic–thermal (PVT) technology has attracted considerable attention for its ability to significantly improve solar energy conversion efficiency by simultaneously providing electricity and heat during the day. PVT technology serves a purpose in condensers and subcoolers for passive cooling in refrigeration systems at night. [...] Read more.
Photovoltaic–thermal (PVT) technology has attracted considerable attention for its ability to significantly improve solar energy conversion efficiency by simultaneously providing electricity and heat during the day. PVT technology serves a purpose in condensers and subcoolers for passive cooling in refrigeration systems at night. In our previous work, we proposed a switchable film-insulated photovoltaic–thermal–passive cooling (PVT-PC) module to address the structural incompatibility between diurnal and nocturnal modes. However, the performance of the proposed module strongly depends on two key design parameters: the structural height and the vacuum level of the air cushion. In this study, a numerical model of the proposed module is developed to examine the impact of design and meteorological parameters on its all-day performance. The results show that diurnal performance remains stable across different structural heights, while nocturnal passive cooling power shows strong dependence on vacuum level and structural height, achieving up to 103.73 W/m2 at 10 mm height and 1500 Pa vacuum, which is comparable to unglazed PVT modules. Convective heat transfer enhancement, induced by changes in air cushion shape, is identified as the primary contributor to improved nocturnal cooling performance. Wind speed has minimal impact on electrical output but significantly enhances thermal efficiency and nocturnal convective cooling power, with a passive cooling power increase of up to 31.61%. In contrast, higher sky temperatures degrade nocturnal cooling performance due to diminished radiative exchange, despite improving diurnal thermal efficiency. These findings provide fundamental insights for optimizing the structural design and operational strategies of PVT-PC systems under varying environmental conditions. Full article
(This article belongs to the Special Issue Numerical Simulation of Flow and Heat Transfer Processes)
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33 pages, 3972 KiB  
Article
A Review and Case of Study of Cooling Methods: Integrating Modeling, Simulation, and Thermal Analysis for a Model Based on a Commercial Electric Permanent Magnet Synchronous Motor
by Henrry Gabriel Usca-Gomez, David Sebastian Puma-Benavides, Victor Danilo Zambrano-Leon, Ramón Castillo-Díaz, Milton Israel Quinga-Morales, Javier Milton Solís-Santamaria and Edilberto Antonio Llanes-Cedeño
World Electr. Veh. J. 2025, 16(8), 437; https://doi.org/10.3390/wevj16080437 - 4 Aug 2025
Abstract
The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of [...] Read more.
The efficiency of electric motors is highly dependent on their operating temperature, with lower temperatures contributing to enhanced performance, reliability, and extended service life. This study presents a comprehensive review of state-of-the-art cooling technologies and evaluates their impact on the thermal behavior of a commercial motor–generator system in high-demand applications. A baseline model of a permanent magnet synchronous motor (PMSM) was developed using MotorCAD 2023® software, which was supported by reverse engineering techniques to accurately replicate the motor’s physical and thermal characteristics. Subsequently, multiple cooling strategies were simulated under consistent operating conditions to assess their effectiveness. These strategies include conventional axial water jackets as well as advanced oil-based methods such as shaft cooling and direct oil spray to the windings. The integration of these systems in hybrid configurations was also explored to maximize thermal efficiency. Simulation results reveal that hybrid cooling significantly reduces the temperature of critical components such as stator windings and permanent magnets. This reduction in thermal stress improves current efficiency, power output, and torque capacity, enabling reliable motor operation across a broader range of speeds and under sustained high-load conditions. The findings highlight the effectiveness of hybrid cooling systems in optimizing both thermal management and operational performance of electric machines. Full article
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19 pages, 4156 KiB  
Article
Experimental and Numerical Analyses of Diameter Reduction via Laser Turning with Respect to Laser Parameters
by Emin O. Bastekeli, Haci A. Tasdemir, Adil Yucel and Buse Ortac Bastekeli
J. Manuf. Mater. Process. 2025, 9(8), 258; https://doi.org/10.3390/jmmp9080258 - 1 Aug 2025
Viewed by 103
Abstract
In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber [...] Read more.
In this study, a novel direct laser beam turning (DLBT) approach is proposed for the precision machining of AISI 308L austenitic stainless steel, which eliminates the need for cutting tools and thereby eradicates tool wear and vibration-induced surface irregularities. A nanosecond-pulsed Nd:YAG fiber laser (λ = 1064 nm, spot size = 0.05 mm) was used, and Ø1.6 mm × 20 mm cylindrical rods were processed under ambient conditions without auxiliary cooling. The experimental framework systematically evaluated the influence of scanning speed, pulse frequency, and the number of laser passes on dimensional accuracy and material removal efficiency. The results indicate that a maximum diameter reduction of 0.271 mm was achieved at a scanning speed of 3200 mm/s and 50 kHz, whereas 0.195 mm was attained at 6400 mm/s and 200 kHz. A robust second-order polynomial correlation (R2 = 0.99) was established between diameter reduction and the number of passes, revealing the high predictability of the process. Crucially, when the scanning speed was doubled, the effective fluence was halved, considerably influencing the ablation characteristics. Despite the low fluence, evidence of material evaporation at elevated frequencies due to the incubation effect underscores the complex photothermal dynamics governing the process. This work constitutes the first comprehensive quantification of pass-dependent diameter modulation in DLBT and introduces a transformative, noncontact micromachining strategy for hard-to-machine alloys. The demonstrated precision, repeatability, and thermal control position DLBT as a promising candidate for next-generation manufacturing of high-performance miniaturized components. Full article
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32 pages, 1970 KiB  
Review
A Review of New Technologies in the Design and Application of Wind Turbine Generators
by Pawel Prajzendanc and Christian Kreischer
Energies 2025, 18(15), 4082; https://doi.org/10.3390/en18154082 - 1 Aug 2025
Viewed by 143
Abstract
The growing global demand for electricity, driven by the development of electromobility, data centers, and smart technologies, necessitates innovative approaches to energy generation. Wind power, as a clean and renewable energy source, plays a pivotal role in the global transition towards low-carbon power [...] Read more.
The growing global demand for electricity, driven by the development of electromobility, data centers, and smart technologies, necessitates innovative approaches to energy generation. Wind power, as a clean and renewable energy source, plays a pivotal role in the global transition towards low-carbon power systems. This paper presents a comprehensive review of generator technologies used in wind turbine applications, ranging from conventional synchronous and asynchronous machines to advanced concepts such as low-speed direct-drive (DD) generators, axial-flux topologies, and superconducting generators utilizing low-temperature superconductors (LTS) and high-temperature superconductors (HTS). The advantages and limitations of each design are discussed in the context of efficiency, weight, reliability, scalability, and suitability for offshore deployment. Special attention is given to HTS-based generator systems, which offer superior power density and reduced losses, along with challenges related to cryogenic cooling and materials engineering. Furthermore, the paper analyzes selected modern generator designs to provide references for enhancing the performance of grid-synchronized hybrid microgrids integrating solar PV, wind, battery energy storage, and HTS-enhanced generators. This review serves as a valuable resource for researchers and engineers developing next-generation wind energy technologies with improved efficiency and integration potential. Full article
(This article belongs to the Special Issue Advancements in Marine Renewable Energy and Hybridization Prospects)
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17 pages, 5022 KiB  
Article
The Impact of Elevated Printing Speeds and Filament Color on the Dimensional Precision and Tensile Properties of FDM-Printed PLA Specimens
by Deian Dorel Ardeljan, Doina Frunzaverde, Vasile Cojocaru, Raul Rusalin Turiac, Nicoleta Bacescu, Costel Relu Ciubotariu and Gabriela Marginean
Polymers 2025, 17(15), 2090; https://doi.org/10.3390/polym17152090 - 30 Jul 2025
Viewed by 238
Abstract
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 [...] Read more.
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
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18 pages, 7553 KiB  
Article
Investigating Experimental and Computational Fluid Dynamics of 3D-Printed TPMS and Lattice Porous Structures
by Guru Varun Penubarthi, Kishore Bhaskar Suresh Babu, Senthilkumar Sundararaj and Shung Wen Kang
Micromachines 2025, 16(8), 883; https://doi.org/10.3390/mi16080883 - 29 Jul 2025
Viewed by 189
Abstract
This study investigates the capillary performance and wetting behavior of SLA (Stereolithography) 3D-printed porous structures, focusing on TPMS (triply periodic minimal surfaces)-Gyroid, Octet, Diamond, and Isotruss lattice designs. High-speed imaging was used to analyze droplet interactions, including penetration, spreading, and contact angles, with [...] Read more.
This study investigates the capillary performance and wetting behavior of SLA (Stereolithography) 3D-printed porous structures, focusing on TPMS (triply periodic minimal surfaces)-Gyroid, Octet, Diamond, and Isotruss lattice designs. High-speed imaging was used to analyze droplet interactions, including penetration, spreading, and contact angles, with 16 μL water droplets dropping from 30 mm at 0.77 m/s. Results showed variable contact angles, with Isotruss and Octet having higher angles, while Diamond faced measurement challenges due to surface roughness. Numerical simulations of TPMS-Gyroid of 2 mm3 unit cells validated the experimental results, and Diamond, Octet, and Isotruss structures were simulated. Capillary performance was assessed through deionized (DI) water weight–time (w-t) measurements, identifying that the TPMS-Gyroid structure performed adequately. Structures with 4 mm3 unit cells had low capillary performance, excluding them from permeability testing, whereas smaller 2 mm3 structures demonstrated capillary effects but had printability and cleaning issues. Permeability results indicated that Octet performed best, followed by Isotruss, Diamond, and TPMS-Gyroid. Findings emphasize unit cell size, beam thickness, and droplet positioning as key factors in optimizing fluid dynamics for cooling, filtration, and fluid management. Full article
(This article belongs to the Special Issue Micro Thermal Devices and Their Applications, 2nd Edition)
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30 pages, 78202 KiB  
Article
Climate-Adaptive Architecture: Analysis of the Wei Family Compound’s Thermal–Ventilation Environment in Ganzhou, China
by Xiaolong Tao, Xin Liang and Wenjia Liu
Buildings 2025, 15(15), 2673; https://doi.org/10.3390/buildings15152673 - 29 Jul 2025
Viewed by 424
Abstract
Sustainable building design is significantly impacted by the local climate response knowledge ingrained in traditional architecture. However, its integration and dissemination with contemporary green technologies are limited by the absence of a comprehensive quantitative analysis of the regulation of its humid and temperature [...] Read more.
Sustainable building design is significantly impacted by the local climate response knowledge ingrained in traditional architecture. However, its integration and dissemination with contemporary green technologies are limited by the absence of a comprehensive quantitative analysis of the regulation of its humid and temperature environment. The Ganzhou Wei family compound from China’s wind–heat environmental regulation systems are examined in this study. We statistically evaluate the synergy between spatial morphology, material qualities, and microclimate using field data with Thsware and Ecotect software in a multiscale simulation framework. The findings indicate that the compound’s special design greatly controls the thermal and wind conditions. Cold alleyways and courtyards work together to maximize thermal environment regulation and encourage natural ventilation. According to quantitative studies, courtyards with particular depths (1–4 m) and height-to-width ratios (e.g., 1:1) reduce wind speed loss. A cool alley (5:1 height–width ratio) creates a dynamic wind–speed–temperature–humidity balance by lowering summer daytime temperatures by 2.5 °C. It also serves as a “cold source area” that moderates temperatures in the surrounding area by up to 2.1 °C. This study suggests a quantitative correlation model based on “spatial morphology–material performance–microclimate response,” which offers a technical route for historic building conservation renovation and green renewal, as well as a scientific foundation for traditional buildings to maintain thermal comfort under low energy consumption. Although based on a specific geographical case, the innovative analytical methods and strategies of this study are of great theoretical and practical significance for promoting the modernization and transformation of traditional architecture, low-carbon city construction, and sustainable building design. Full article
(This article belongs to the Section Building Energy, Physics, Environment, and Systems)
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17 pages, 3811 KiB  
Article
Enhanced Cooling Performance in Cutting Tools Using TPMS-Integrated Toolholders: A CFD-Based Thermal-Fluidic Study
by Haiyang Ji, Zhanqiang Liu, Jinfu Zhao and Bing Wang
Modelling 2025, 6(3), 73; https://doi.org/10.3390/modelling6030073 - 28 Jul 2025
Viewed by 272
Abstract
The efficient thermal management of cutting tools is critical for ensuring dimensional accuracy, surface integrity, and tool longevity, especially in the high-speed dry machining process. However, conventional cooling methods often fall short in reaching the heat-intensive zones near the cutting inserts. This study [...] Read more.
The efficient thermal management of cutting tools is critical for ensuring dimensional accuracy, surface integrity, and tool longevity, especially in the high-speed dry machining process. However, conventional cooling methods often fall short in reaching the heat-intensive zones near the cutting inserts. This study proposes a novel internal cooling strategy that integrates triply periodic minimal surface (TPMS) structures into the toolholder, aiming to enhance localized heat removal from the cutting region. The thermal-fluidic behaviors of four TPMS topologies (Gyroid, Diamond, I-WP, and Fischer–Koch S) were systematically analyzed under varying coolant velocities using computational fluid dynamics (CFD). Several key performance indicators, including the convective heat transfer coefficient, Nusselt number, friction factor, and thermal resistance, were evaluated. The Diamond and Gyroid structures exhibited the most favorable balance between heat transfer enhancement and pressure loss. The experimental validation confirmed the CFD prediction accuracy. The results establish a new design paradigm for integrating TPMS structures into toolholders, offering a promising solution for efficient, compact, and sustainable cooling in advanced cutting applications. Full article
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19 pages, 6832 KiB  
Article
Study on the Optimization of Textured Coating Tool Parameters Under Thermal Assisted Process Conditions
by Xin Tong, Xiyue Wang, Xinyu Li and Baiyi Wang
Coatings 2025, 15(8), 876; https://doi.org/10.3390/coatings15080876 - 25 Jul 2025
Viewed by 281
Abstract
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 [...] Read more.
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 article belongs to the Special Issue Cutting Performance of Coated Tools)
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29 pages, 4447 KiB  
Article
Cooling Systems for High-Speed Machines—Review and Design Considerations
by Matthew Meier and Elias G. Strangas
Energies 2025, 18(15), 3954; https://doi.org/10.3390/en18153954 - 24 Jul 2025
Viewed by 470
Abstract
High-speed machines are attractive to many industries due to their small size and light weight, but present unique cooling challenges due to their increased loss and reduced surface area. Cooling system advancements are central to the development of faster, smaller machines, and as [...] Read more.
High-speed machines are attractive to many industries due to their small size and light weight, but present unique cooling challenges due to their increased loss and reduced surface area. Cooling system advancements are central to the development of faster, smaller machines, and as such, are constantly evolving. This paper presents a review of classical and state-of-the-art cooling systems. Each cooling method—air cooling, indirect liquid cooling, and direct liquid cooling—has potential use in cooling high-speed machines, but each comes with unique considerations, which are discussed. An example design process highlights the interdependence of the electromagnetic and thermal design choices, illustrating the necessity of integrating the electromagnetic and thermal designs in a holistic approach. Full article
(This article belongs to the Special Issue Advances in Permanent Magnet Synchronous Generator)
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15 pages, 6193 KiB  
Article
Microscopy Study of (Ti,Nb)(C,N) Precipitation in Microalloyed Steels Under Continuous Casting Conditions
by Fangyong Xu, Daoyao Liu, Wei Wang, Brian G. Thomas, Tianxu Wu, Kun Xu and Zhan Zhang
Materials 2025, 18(15), 3445; https://doi.org/10.3390/ma18153445 - 23 Jul 2025
Viewed by 240
Abstract
The continuous casting of Ti-Nb microalloyed steel was simulated with high temperature confocal laser scanning microscopy (HTCLSM). Evolution of the sample surface morphology was observed in-situ, during cooling conditions chosen to represent different locations in a cast slab. Calculations with a thermodynamics model [...] Read more.
The continuous casting of Ti-Nb microalloyed steel was simulated with high temperature confocal laser scanning microscopy (HTCLSM). Evolution of the sample surface morphology was observed in-situ, during cooling conditions chosen to represent different locations in a cast slab. Calculations with a thermodynamics model of carbonitride precipitate formation agreed with the transmission electron microscopy (TEM) analysis that fine reliefs observed on the sample surface were actually caused by interior precipitation of (Ti,Nb)(C,N). Precipitation and the resulting reliefs changed with location beneath the slab surface, simulated casting speed, and steel composition. With the same casting speed and steel composition, reliefs in the simulated slab surface sample appeared earlier and were larger than in the slab center. With increased casting speed, reliefs were observed later and decreased in size. With increased titanium or niobium content, reliefs appeared earlier and increased in number. TEM measurement showed that the precipitate diameters were mainly smaller than 4 nm, with a few between 4 and 8 nm. The property of surface reliefs observed via HTCLSM correlated qualitatively with the number and size of internal precipitates measured with TEM, showing this to be an effective tool for indirectly characterizing nanoscale secondary phase precipitation inside the sample. Full article
(This article belongs to the Section Metals and Alloys)
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30 pages, 23469 KiB  
Article
Computational Investigations and Control of Shock Interference
by Cameron Alexander and Ragini Acharya
Appl. Sci. 2025, 15(14), 7963; https://doi.org/10.3390/app15147963 - 17 Jul 2025
Viewed by 302
Abstract
Computational fluid dynamics (CFD) has aided the development, design, and analysis of hypersonic airbreathing propulsion technologies, such as scramjets. The complex flow field in a scramjet isolator has been the subject of intense interest and study for several decades. Many features of this [...] Read more.
Computational fluid dynamics (CFD) has aided the development, design, and analysis of hypersonic airbreathing propulsion technologies, such as scramjets. The complex flow field in a scramjet isolator has been the subject of intense interest and study for several decades. Many features of this flow field also occur in supersonic wind-tunnel nozzles and diffusers. Computational analysis of these topics has frequently provided immense insight into the actual functionality and performance. Research presented in this work supports scientific investigation and understanding of a less-researched topic, which is shock–shock interference and interaction with the boundary layer in supersonic internal flows, as well as the passive control of its adverse effects to prevent the onset of unstart in a scramjet isolator. This computational investigation is conducted on a backpressured isolator and a modified three-dimensional shock-tube to represent a scramjet isolator with ram effects provided by high-pressure gas and high-speed flow provided by a supersonic inflow. Computational results for the backpressured isolator have been validated against available measured time-averaged wall pressure data. The modified shock-tube provided an opportunity to study the shock–shock interference and shock–boundary-layer interaction effects that would occur in a scramjet isolator or a ram-accelerator when the high-speed flow from the inlet interacted with the shock produced due to the combustor pressure traveling and meeting in the isolator. An assessment of wall cooling effects on these phenomena is presented for both the backpressured isolator and the modified shock-tube. Full article
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10 pages, 1640 KiB  
Communication
Investigating the Effects of the Solar Eclipse on the Atmosphere over Land and Oceanic Regions: Observations from Ground Stations and COSMIC2 Data
by Ghouse Basha, M. Venkat Ratnam, Jonathan H. Jiang and Kishore Pangaluru
Atmosphere 2025, 16(7), 872; https://doi.org/10.3390/atmos16070872 - 17 Jul 2025
Viewed by 281
Abstract
The impacts of the solar eclipse that occurred on 8 April 2024 over the United States on various atmospheric parameters are investigated. We analyzed surface and vertical profiles of temperature and humidity to understand how this eclipse affected the atmosphere from the ground [...] Read more.
The impacts of the solar eclipse that occurred on 8 April 2024 over the United States on various atmospheric parameters are investigated. We analyzed surface and vertical profiles of temperature and humidity to understand how this eclipse affected the atmosphere from the ground to the stratosphere. Our findings show a significant response throughout the atmospheric range. The eclipse caused a decrease in shortwave radiation, leading to cooler Earth surfaces and a subsequent drop in surface temperature. This cooling effect also resulted in high relative humidity and lower wind speeds at the surface. Furthermore, GPS radio occultation data from COSMIC-2 revealed a decrease in tropospheric temperature and increase in stratospheric temperature during the eclipse. We also observed a reduction in both the temperature and height of the tropopause. The uniqueness of the present investigations lies in delineating the solar eclipse’s effects on the land and ocean. Our analysis indicates that land regions experienced a more pronounced temperature change compared to ocean regions. Full article
(This article belongs to the Section Atmospheric Techniques, Instruments, and Modeling)
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22 pages, 10008 KiB  
Article
Design and Testing of a Device to Investigate Dynamic Performance of Aero-Engine Rotor–Stator Rubbing Dynamics
by Qinqin Mu, Qun Yan, Peng Sun, Yonghui Chen, Jiaqi Chang and Shiyu Huo
Eng 2025, 6(7), 162; https://doi.org/10.3390/eng6070162 - 17 Jul 2025
Viewed by 207
Abstract
To analyze the wear performance induced by rotor–stator rubbing in an aero-engine sealing structure under authentic operating conditions, a transonic rotor system with double bearing is constructed. This system incorporates the disk, shaft, blades, joint bolts, and auxiliary support structure. The system was [...] Read more.
To analyze the wear performance induced by rotor–stator rubbing in an aero-engine sealing structure under authentic operating conditions, a transonic rotor system with double bearing is constructed. This system incorporates the disk, shaft, blades, joint bolts, and auxiliary support structure. The system was evaluated in terms of its critical speed, vibration characteristics, component strength under operational conditions, and response characteristics in abnormal extreme scenarios. A ball screw-type feeding system is employed to achieve precise rotor–stator rubbing during rotation by controlling the coating feed. Additionally, a quartz lamp heating system is used to apply thermal loads to coating specimens, and the appropriate heat insulation and cooling measures are implemented. Furthermore, a high-frequency rubbing force test platform is developed to capture the key characteristics caused by rubbing. The test rig can conduct response tests of the system with rotor–stator rubbing and abrasion tests with tip speeds reaching 425 m/s, feed rates ranging from 2 to 2000 μm/s, and heating temperatures up to 1200 °C. Test debugging has confirmed these specifications and successfully executed rubbing tests, which demonstrate stability throughout the process and provide reliable rubbing force test results. This designed test rig and analysis methodology offers valuable insights for developing high-speed rotating machinery. Full article
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28 pages, 9135 KiB  
Article
Performance Analysis of a Reciprocating Refrigeration Compressor Under Variable Operating Speeds
by Willian T. F. D. da Silva, Vitor M. Braga and Cesar J. Deschamps
Machines 2025, 13(7), 609; https://doi.org/10.3390/machines13070609 - 15 Jul 2025
Viewed by 313
Abstract
Variable-speed reciprocating compressors (VSRCs) have been increasingly used in domestic refrigeration due to their ability to modulate cooling capacity and reduce energy consumption. A detailed understanding of performance-limiting factors such as volumetric and exergetic inefficiencies is essential for optimizing their operation. An experimentally [...] Read more.
Variable-speed reciprocating compressors (VSRCs) have been increasingly used in domestic refrigeration due to their ability to modulate cooling capacity and reduce energy consumption. A detailed understanding of performance-limiting factors such as volumetric and exergetic inefficiencies is essential for optimizing their operation. An experimentally validated simulation model was developed using GT-SUITE to analyze a VSRC operating with R-600a across speeds from 1800 to 6300 rpm. Volumetric inefficiencies were quantified using a stratification methodology, while an exergy-based approach was adopted to assess the main sources of thermodynamic inefficiency in the compressor. Unlike traditional energy analysis, exergy analysis reveals where and why irreversibilities occur, linking them directly to power consumption and providing a framework for optimizing design. Results reveal that neither volumetric nor exergy efficiency varies monotonically with compressor speed. At low speeds, exergetic losses are dominated by the electrical motor (up to 19% of input power) and heat transfer (up to 13.5%). Conversely, at high speeds, irreversibilities from fluid dynamics become critical, with losses from discharge valve throttling reaching 5.8% and bearing friction increasing to 6.5%. Additionally, key volumetric inefficiencies arise from piston–cylinder leakage, which causes up to a 4.5% loss at low speeds, and discharge valve backflow, causing over a 5% loss at certain resonant speeds. The results reveal complex speed-dependent interactions between dynamic and thermodynamic loss mechanisms in VSRCs. The integrated modeling approach offers a robust framework for diagnosing inefficiencies and supports the development of more energy-efficient compressor designs. Full article
(This article belongs to the Special Issue Theoretical and Experimental Study on Compressor Performance)
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