Search Results (348)

Electrical Discharge Machining (EDM) enables precision post-weld finishing of AISI 304 stainless steel, but stochastic spark overlaps make the fatigue-critical maximum peak-to-valley height (R_max) difficult to predict. This study develops a validated physics-based framework quantifying how crater overlap governs R_max evolution. Experiments on unwelded AISI 304 cylinders—proxying weld metal while excluding heat-affected zone (HAZ) effects—used Central Composite Design (20 trials, 900–9380 μJ discharge energies). Profilometry and scanning electron microscopy (SEM) correlated the crater size, overlap intensity, micro-cracking, and R_max escalation from 18 to 85 μm. Primary and secondary crater formation under minimum and maximum overlap configurations were simulated using a 2D axisymmetric finite element model with Gaussian heat flux and temperature-dependent thermophysical properties. The predictive metric R_max,num = (d_initial + d_secondary)/2 achieved 11–19% average error against the experimental R_max,exp, with complementary valley depth (R_v) validation at 13% error. The Specimen 7 outlier (~50% error) reveals the limitations of deterministic modelling under stochastic debris accumulation and plasma instability at intermediate energies. Crater overlap generates secondary dimples, sharp inter-crater peaks, and rim micro-crack networks, driving the 4.7-fold R_max increase—approaching International Institute of Welding (IIW) fatigue thresholds (<25 μm for high-cycle categories). The framework explicitly links the discharge energy, plasma channel radius (R_pc), and overlap geometry to surface topography, enabling process optimization (I·t_on < 60 A·s maintains R_max < 25 μm). Mesh independence (<2.5% convergence) and six centre-point replicates (CV = 4.2%) confirm robustness. This validated upper-bound R_max predictor supports the digital co-optimization of welding and EDM parameters for aerospace/energy applications, with planned extensions to stochastic 3D models incorporating adaptive remeshing and real weld topographies. Full article

Air-shielding radial ultrasonic rolling electrochemical micromachining (AS-RUREMM) is proposed to fabricate high-quality micro-dimple textures on cylindrical SS304 surfaces while suppressing stray corrosion. In AS-RUREMM, an annular air sheath coaxially envelopes the electrolyte jet to confine the wetting footprint, and radial ultrasonic vibration is superimposed on a rolling cathode with micro-protrusions to intensify local mass transport and stabilize the interelectrode environment. A conductivity-centered theoretical framework is established to link air-sheathing-induced gas–liquid distribution, ultrasonic gap modulation, and the resulting current-density localization. Multiphysics simulations in COMSOL 5.3 clarify that moderate air pressure forms a stable confined gas–liquid structure that narrows the effective conductive pathway, whereas excessive air pressure increases intermittency and weakens effective gap conductivity. Experiments on SS304 tubes validate the confinement mechanism: compared with RUREMM, AS-RUREMM produces smaller pit width and depth but a higher depth-to-width ratio, indicating enhanced localization and reduced peripheral over-etching. The simulated cross-sectional profiles agree with measurements, with an overall deviation within 6%. Parameter studies identify an optimal operating window, and the combination of 0.18 MPa air pressure and 12 V pulse voltage provides the highest aspect ratio while maintaining stable machining. SEM/EDX analyses further support the improved process controllability under air shielding through reduced stray corrosion and composition changes consistent with a more regulated electrochemical dissolution environment. Full article

To reduce mold costs in composite forming, multi-point tooling technology has been integrated into the hot diaphragm forming process. However, this approach still faces several challenges, including time-consuming prepreg layup, high energy consumption, and poor surface quality. This study proposes a heating pad-assisted multi-point thermoforming process: the prepreg is embedded in the thermal functional layers, placed on the lower mold, and formed via the downward movement of the upper mold to accomplish mold closure. Instead of the conventional rectangular array, this study adopted multi-point tooling with a hexagonal pin arrangement. Compared to traditional configurations, this hexagonal layout increases the punch support area by 9.8%, while its dense punch arrangement improves the accuracy of the molded curved surface. Taking a saddle-shaped surface as the target, a prototype part was fabricated. Subsequent analysis of the part’s surface quality identified three defects: dimples, fiber distortion, and ridge protrusions. The surface dimples were eliminated by adjusting the distance between the upper and lower molds. Notably, ridge protrusion is a defect unique to the hexagonal pin arrangement. We conducted a detailed analysis of its causes and solutions, finding that this defect arises from the combined effect of the pin arrangement and the saddle-shaped surface. Through a series of height compensation experiments, the maximum deviation at the ridges was reduced from 0.46 mm to approximately 0.35 mm, which is consistent with the deviation of defect-free areas. This work demonstrates that the multi-point hot-pressing process provides a potential, efficient, and low-cost method for manufacturing double-curvature composite components, whose effectiveness has been verified through the saddle-shaped case study. Full article

This study investigates the influence of surface texturing on temperature distribution in lubricated sliding contacts using infrared thermography. The work addresses the broader challenge of understanding thermal effects in conformal hydrodynamic contacts, where localized heating and viscosity variations can significantly affect tribological performance. A pin-on-disc configuration was employed, featuring steel pins with laser-etched micro-dimples that slid against a sapphire disc, allowing for thermal imaging of the contact zone. A dual-bandpass filter infrared thermography technique was developed and rigorously calibrated to distinguish between the temperatures of the steel surface and the lubricant film. Friction measurements and laser-induced fluorescence were used in parallel to assess contact conditions and the behavior of the lubricant film. The results show that surface textures can alter local frictional heating and contribute to non-uniform temperature distributions, particularly in parallel contact geometries. Lubricant temperature was consistently higher than the surface temperature, highlighting the role of shear heating within the fluid film. However, within the tested parameter range, no unambiguous viscosity-wedge signature was identified beyond the dominant temperature-driven viscosity reduction captured by the in situ correction. The method provides a novel means of experimentally resolving temperature fields in sliding textured contacts, offering a valuable foundation for validating thermo-hydrodynamic models in lubricated tribological systems. Full article

Phenyl-silicone rubber is the elastomer of choice for cryogenic and high-temperature static seals, yet quantitative links between thermo-oxidative aging and sealing reliability are still lacking. Here, sub-ambient (−70 °C to 25 °C) and room-temperature mechanical tests, compression set aging, SEM, FT-IR, and finite-element simulations are integrated to trace how aging translates into contact-pressure decay of an Omega-profile gasket. Compression set rises monotonically with time and temperature; an Arrhenius model derived from 80 to 140 °C data predicts 34 d (10% set) and 286 d (45% set) of storage life at 25 °C. SEM reveals a progressive shift from ductile dimple fracture to brittle, honeycomb porosity, while FT-IR confirms limited surface oxidation without bulk chain scission. Finite element analyses show that contact pressure always peaks at the two lateral necks; short-term aging increases in the shear modulus C₁₀ from 1.87 to 2.27 MPa, raising CPRESS by 8~21%, yet this benefit is ultimately offset by displacement loss from compression set (8.0 mm to 6.1 mm), yielding a net pressure reduction of 0.006 MPa. Critically, even under the most severe coupled condition (56 days aging with compression set), the predicted CPRESS remains above the 0.1 MPa leak-tightness criterion across the entire cryogenic service envelope. This framework provides deterministic boundaries for temperature, aging duration, and allowable preload relaxation, enabling risk-informed maintenance and replacement scheduling for safety-critical phenyl-silicone seals. Full article

This study systematically investigates the microstructural evolution and mechanical properties of GH2787 superalloy following solution treatment at 1140 °C and subsequent aging within the temperature range of 770 °C to 920 °C. The results indicate that aging at 770 °C and 820 °C promotes the precipitation of a high density of finely dispersed γ′ precipitates with minimal interparticle spacing. In contrast, a significant coarsening of the γ′ particles, accompanied by a sparse distribution and a notable increase in interparticle spacing, was observed at the higher aging temperatures of 870 °C and 920 °C. Mechanical characterization reveals that the ultimate tensile strength (UTS) and yield strength (YS) experienced a moderate decrease as the aging temperature increased from 770 °C to 820 °C, followed by a pronounced drop at 870 °C and 920 °C. Conversely, the impact toughness exhibited a non-monotonic trend: it gradually decreased, reaching a minimum at 820 °C, before rapidly increasing with further rises in aging temperature. Quantitative analysis of the strengthening contributions demonstrates that solid-solution and precipitation strengthening are the dominant mechanisms. The marked decline in yield strength at elevated aging temperatures is primarily attributed to the diminished precipitation strengthening effect due to γ′ coarsening. Furthermore, the variation in impact toughness can be linked to the proportion and size of dimples observed on the fracture surfaces, indicating a transition in the fracture mechanism driven by microstructural evolution. Full article

The operational ability of a unit or mechanism depends mainly on the quality of the mechanically produced working surfaces. Many materials can be assigned to a group of hard-to-cut materials that includes titanium- and aluminum-based alloys, a new class of heat-resistant alloys, SiCp/Al composites, hard alloys, and other alloys. The difficulties in their machining are related not only to the high temperatures achieved on the contact pads under mechanical load and the extreme cutting conditions but also to the properties of those materials, which affect the adhesion of the chip to the tool faces, hindering chip flow. One of the possible solutions to reduce those effects and improve the operational life of the tool, and as a consequence, the final quality of the working surface of the unit, is texturing the rake face of the tool with microgrooves or nanogrooves, microholes or nanoholes (pits, dimples), micronodes, cross-chevron textures, and other microtextures, the depth of which is in the range of 3.0–200.0 µm. This review is addressed at systematizing the data obtained on micro- and nanotexturing of PCD tools for cutting hard-to-cut materials by different techniques (fiber laser graving, femto- and nanosecond laser, electrical discharge machining, fused ion beam), additionally subjected to fluorination and dip- and drop-based coatings, and the effect created by the use of the textured PCD tool on the machined surface. Full article

The flexible micro-structured surface found in biological skins exhibits remarkable drag reduction properties, inspiring applications in the aerospace industry, underwater exploration, and pipeline transportation. To address the challenge of efficiently replicating such structures, this study presents a composite flexible polymer film with a bio-inspired micro-dimple array, fabricated via an integrated process of precision milling, polishing, and micro-injection molding using thermoplastic polyurethane (TPU). We systematically investigated the influence of key injection parameters on the shape accuracy and surface quality of the film. The experimental results show that polishing technology can significantly reduce mold core surface roughness, thereby enhancing film replication accuracy. Among the parameters, melt temperature and holding time exerted the most significant effects on shape precision PV and bottom roughness R_a, while injection speed showed the least influence. Under optimized conditions of a melt temperature of 180 °C, injection speed of 60 mm/s, holding pressure of 7 MPa, and holding time of 13 s, the film achieved a micro-structure shape accuracy of 13.502 μm and bottom roughness of 0.033 μm. Numerical simulation predicted a maximum drag reduction rate of 10.26%, attributable to vortex cushion effects within the dimples. This performance was experimentally validated in a flow velocity range of 0.6–2 m/s, with the discrepancy between simulated and measured drag reduction kept within 5%, demonstrating the efficacy of the proposed manufacturing route for flexible bio-inspired drag reduction film. Full article

This paper presents an experimental study on the influence of surface texturing on friction and film thickness in the hydrodynamic lubrication regime. Using a pin-on-disk tribometer equipped with light-induced fluorescence microscopy, simultaneous measurements were conducted on smooth and textured samples under parallel and inclined surface conditions. The circular faces of the pins were partially or fully covered by circular laser-machined textures consisting of dimples with depths of 5 or 10 µm, diameters of 50 or 100 µm, and coverage density of 20%. The results demonstrate that while texturing significantly reduces friction and increases film thickness in parallel gaps, with partial inlet coverage being the most effective, its impact is minimal in inclined wedge gaps. The study further reveals that the global geometric wedge dominates over texture effects in inclined contacts and that in-texture cavitation, prevalent in parallel conditions, is suppressed by surface inclination. Three distinct contributions of the textures were discussed: a global hydrodynamic effect, a local hydrodynamic effect, and the influence of surface non-flatness (waviness). The findings suggest that texturing is primarily beneficial for acting as a pseudo-wedge or as surface roughness in contacts where a physical wedge is absent. Full article

The frictional resistance of impeller machinery blades such as aircraft engines, gas turbines, and wind turbines has a decisive impact on their efficiency and energy consumption. Inspired by the micro-tooth structure on the surface of shark skin, microstructural drag reduction technology has become a cutting-edge research direction for improving aerodynamic performance and a continuous focus of researchers over the past 20 years. However, the significant difficulty in fabricating microstructures on three-dimensional curved surfaces has led to the limited widespread application of this technology in engineering. Addressing the issue of drag reduction and efficiency improvement for small axial flow fans (local Reynolds number range: (36,327–40,330), this paper employs Design of Experiments (DOE) combined with high-precision numerical simulation to clarify the drag reduction law of bionic microgroove surfaces and determine the dimensions of bionic microstructures on fan blade surfaces. The steady-state calculation uses the standard k-ω model and simpleFoam solver, while the unsteady Large Eddy Simulation (LES) employs the pimpleFoam solver and WALE subgrid-scale model. The dimensionless height (h⁺) and width (s⁺) of microgrooves are in the range of 8.50–29.75, and the micro-grooved structure achieves effective drag reduction. The microstructured surface is fabricated on the suction surface of the blade via a spray coating process, and the dimensions of the microstructures are determined according to the drag reduction law of grooved flat plates. Aerodynamic performance tests indicate that the shaft power consumed by the bionic fan blades during the tests is significantly reduced. The maximum static pressure efficiency of the bionic fan with micro-dimples is increased by 2.33%, while that of the bionic fan with micro-grooves is increased by 3.46%. The fabrication method of the bionic microstructured surface proposed in this paper is expected to promote the engineering application of bionic drag reduction technology. Full article

In this study, the asymmetrical rolling technique was employed to fabricate 75 μm-thick Ti-6Al-4V ultra-thin strips from the initial 0.45 mm sheet without intermediate annealing, aiming for applications in fuel cell bipolar plates. The rolled strips exhibited good surface quality without cracking. In order to enhance both the mechanical response and the shaping capability of Ti-6Al-4V strips produced by asymmetric rolling, the material was subjected to annealing at various temperatures, and the resulting changes in microstructural features and mechanical performance were systematically examined. The findings indicated that the cold-rolled Ti-6Al-4V exhibited a microstructure primarily composed of subgrains with an average size of approximately 0.41 μm, a feature that contributed to improved corrosion resistance and enhanced ductility after annealing. When the alloy was subjected to heat treatment within the range of 650–800 °C, it was observed that annealing temperatures below 700 °C favored microstructural changes governed predominantly by recovery processes and the onset of recrystallization. At 700 °C, the grains became equiaxed and uniformly distributed, and the dislocation density significantly decreased. The tensile strength reached 887 MPa, while the elongation increased to 13.7%, achieving an excellent strength-ductility balance. Once the annealing temperature rose above 700 °C, noticeable grain growth took place, accompanied by a more pronounced grain-size gradient and a renewed increase in dislocation density. Meanwhile, the dimples observed on the fracture surface became finer, collectively contributing to a decline in tensile elongation. The Ti-6Al-4V ultra-thin strip annealed at 700 °C was used for bipolar plate stamping, producing fine micro-channels with an aspect ratio of 0.43. Finally, TiN coating was applied to the surface, which significantly improved the corrosion resistance and reduced the interfacial contact resistance (ICR), meeting the performance requirements for bipolar plates. Full article

This review article focuses first on the historical development of present understanding of gap junction channel architecture, one of its goals being to enlighten younger generations of scientists about the early steps of this field that begun over half a century ago. Early findings on gap junction architecture are reviewed as follows. The channels cross the membrane and project from the membrane surfaces; they are made of six subunits (hexamers) and show dimples on both ends, which represent inner and outer openings of the channel. Images of the central dimples on both channel ends (channel pores) seen in freeze-fracture replicas correspond to the electron-opaque spots visible in negatively stained sections and in isolated junctions. The channels are linked to each other extracellularly. Calmodulin (CaM) is a major accessory protein of gap junctions that is involved in channel gating and gap junction formation and is also likely to play a key role in determining different patterns of channel aggregation. Full article

In order to improve the recognition accuracy and model interpretability of metal fracture scanning electron microscope (SEM) images, this research presents an improved dual-branch model (IDBM) based on multi-scale feature fusion. This model employs VGG19 and Inception V3 as parallel branches to separately extract local texture features and global semantic features. Furthermore, it integrates channel and spatial attention mechanisms to enhance the responsiveness of discriminative regions. By integrating dual-branch features using a fixed fusion ratio of 0.8:0.2, the model was trained and validated on an image dataset comprising 800 representative fracture surface images across four categories: cleavage, dimple, fatigue, and intergranular fracture. The results indicate that under small-sample data conditions, the IDBM achieves a Validation Accuracy (Val ACC) of 99.50%, a Recall rate of 99.51%, and an Area Under The Curve (AUC) value of 0.9998, significantly outperforming single models and other fusion strategies. Through integration with class activation mapping (CAM) and feature space visualization analysis, the model exhibits strong interpretability. Furthermore, scale adaptability tests reveal that IDBM maintains stable recognition performance across a magnification range of 100 to 10,000 times, and identifies the optimal observation magnification ranges for the four types of fractures. Full article

The deposition of particulate matter on rough pipe surfaces is critical in fields such as energy, chemical engineering, and air pollution control. This study employs a combined approach utilizing the Renormalized Group (RNG) k-ɛ model and the discrete phase model (DPM). The particle deposition characteristics in circular bent pipe channels with different dimple positions were investigated. To improve simulation fidelity, a model for particle-wall rebound was developed using user-defined function (UDF). The results indicate that the dimple structure influences the deposition location of particles. Particle deposition is minimal on the lower surface and leeward side of the dimple structure. For operating conditions where St ≤ 0.27, θ = 15° yields the optimal effect on enhancing the particle deposition rate, achieving a maximum increase of 18.2%. For conditions where St ≥ 0.461, the optimal angle is θ = 30°, resulting in a maximum deposition rate increase of 14.126%. The deposition rate of dimple structures varies depending on their installation location. In this study, the deposition rate was lowest at θ = 65°. The dimple structure can serve as a sacrificial element, providing protection for the rest of the bent pipe. In the future, channels incorporating this structure can be applied to removal or air purification equipment. Full article

In this paper, the microstructure, mechanical properties, and strengthening mechanisms of hot-extruded Mg-xGd-4Y-1Sm-0.5Zr (x = 4, 7, 10, wt.%) alloys were studied. The results show that the hot extruded alloys exhibit bimodal grain structures, and with Gd content increasing, the fraction of non-dynamic recrystallized grains gradually decreases, with 46.3%, 38.6%, and 9.3%. After aging for 200 °C × 96 h, all three hot-extruded alloys reach peak-aged hardness, and as Gd content increases, the area number density of the β′ phase increases with Gd increasing, being 7.1 × 10¹⁵/m², 9.9 × 10¹⁵/m², and 16.5 × 10¹⁵/m², respectively. And the yield strength (YS) increases from 287 MPa to 345 MPa, the ultimate tensile strength (UTS) increases from 365 MPa to 418 MPa, and elongation (EL) decreases from 8.5% to 4.2%. The tensile failure mechanism is quasi-cleavage fracture. With Gd content increasing, the dimples and tear ridges on fracture surfaces gradually decrease while cleavage facets increase. The peak-aged GWS741 alloy demonstrates optimal comprehensive mechanical properties, with YS, UTS, and EL reaching 332 MPa, 409 MPa, and 7.8%, respectively. During in situ tensile testing, coarse un-DRXed grains undergo prismatic ($\{10\stackrel{\mathrm{-}}{1}0\}⟨11\stackrel{\mathrm{-}}{2}0⟩$) slip, while DRXed grains experience basal ($\left\{0001\right\}⟨11\stackrel{\mathrm{-}}{2}0⟩$) slip and twinning deformation. Even at 6.6% strain, no microcracks are observed, indicating excellent plasticity. During the tensile failure process, the main crack propagates along tortuous paths, showing crack deflection characteristics, where it either penetrates through elongated deformed grains or bypasses un-DRXed grains. Full article