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23 pages, 2593 KiB  
Article
Preliminary Comparison of Ammonia- and Natural Gas-Fueled Micro-Gas Turbine Systems in Heat-Driven CHP for a Small Residential Community
by Mateusz Proniewicz, Karolina Petela, Christine Mounaïm-Rousselle, Mirko R. Bothien, Andrea Gruber, Yong Fan, Minhyeok Lee and Andrzej Szlęk
Energies 2025, 18(15), 4103; https://doi.org/10.3390/en18154103 (registering DOI) - 1 Aug 2025
Abstract
This research considers a preliminary comparative technical evaluation of two micro-gas turbine (MGT) systems in combined heat and power (CHP) mode (100 kWe), aimed at supplying heat to a residential community of 15 average-sized buildings located in Central Europe over a year. Two [...] Read more.
This research considers a preliminary comparative technical evaluation of two micro-gas turbine (MGT) systems in combined heat and power (CHP) mode (100 kWe), aimed at supplying heat to a residential community of 15 average-sized buildings located in Central Europe over a year. Two systems were modelled in Ebsilon 15 software: a natural gas case (benchmark) and an ammonia-fueled case, both based on the same on-design parameters. Off-design simulations evaluated performance over variable ambient temperatures and loads. Idealized, unrecuperated cycles were adopted to isolate the thermodynamic impact of the fuel switch under complete combustion assumption. Under these assumptions, the study shows that the ammonia system produces more electrical energy and less excess heat, yielding marginally higher electrical efficiency and EUF (26.05% and 77.63%) than the natural gas system (24.59% and 77.55%), highlighting ammonia’s utilization potential in such a context. Future research should target validating ammonia combustion and emission profiles across the turbine load range, and updating the thermodynamic model with a recuperator and SCR accounting for realistic pressure losses. Full article
(This article belongs to the Special Issue Clean and Efficient Use of Energy: 3rd Edition)
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15 pages, 3882 KiB  
Article
Performance of Low-Cost Energy Dense Mixed Material MnO2-Cu2O Cathodes for Commercially Scalable Aqueous Zinc Batteries
by Gautam G. Yadav, Malesa Sammy, Jungsang Cho, Megan N. Booth, Michael Nyce, Jinchao Huang, Timothy N. Lambert, Damon E. Turney, Xia Wei and Sanjoy Banerjee
Batteries 2025, 11(8), 291; https://doi.org/10.3390/batteries11080291 (registering DOI) - 1 Aug 2025
Abstract
Zinc (Zn)-based batteries have attracted significant interest for applications ranging from electric bikes to grid storage because of its advantageous properties like high abundance, non-toxicity and low-cost. Zn offers a high theoretical capacity of two electrons per atom, resulting in 820 mAh/g, making [...] Read more.
Zinc (Zn)-based batteries have attracted significant interest for applications ranging from electric bikes to grid storage because of its advantageous properties like high abundance, non-toxicity and low-cost. Zn offers a high theoretical capacity of two electrons per atom, resulting in 820 mAh/g, making it a promising anode material for the development of highly energy dense batteries. However, the advancement of Zn-based battery systems is hindered by the limited availability of cathode materials that simultaneously offer high theoretical capacity, long-term cycling stability, and affordability. In this work, we present a new mixed material cathode system, comprising of a mixture of manganese dioxide (MnO2) and copper oxide (Cu2O) as active materials, that delivers a high theoretical capacity of ~280 mAh/g (MnO2 + Cu2O active material) (based on the combined mass of MnO2 and Cu2O) and supports stable cycling for >200 cycles at 1C. We further demonstrate the scalability of this novel cathode system by increasing the electrode size and capacity, highlighting its potential for practical and commercial applications. Full article
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30 pages, 939 KiB  
Article
Electricity-Related Emissions Factors in Carbon Footprinting—The Case of Poland
by Anna Lewandowska, Katarzyna Joachimiak-Lechman, Jolanta Baran and Joanna Kulczycka
Energies 2025, 18(15), 4092; https://doi.org/10.3390/en18154092 (registering DOI) - 1 Aug 2025
Abstract
Electricity is a significant factor in the life cycle of many products, so the reliability of greenhouse gas (GHG) emissions data is crucial. The article presents publicly available sources of emission factors representative of Poland. The aim of the study is to assess [...] Read more.
Electricity is a significant factor in the life cycle of many products, so the reliability of greenhouse gas (GHG) emissions data is crucial. The article presents publicly available sources of emission factors representative of Poland. The aim of the study is to assess their strengths and weaknesses in the context of the calculation requirements of carbon footprint analysis in accordance with the GHG Protocol. The article presents the results of carbon footprint calculations for different ranges of emissions in the life cycle of 1 kWh of electricity delivered to a hypothetical organization. Next, a discussion on the quality of the emissions factors has been provided, taking account of data quality indicators. It was concluded that two of the emissions factors that are compared—those based on the national consumption mix and the residual mix for Poland—have been recognized as suitable for use in carbon footprint calculations. Beyond the calculation results, the research highlights the significance of the impact of the selection of emissions factors on the reliability of environmental analysis. The article identifies methodological challenges, including the risk of double counting, limited transparency, methodological inconsistency, and low correlation of data with specific locations and technologies. The insights presented contribute to improving the robustness of carbon footprint calculations. Full article
27 pages, 2072 KiB  
Article
Modeling and Characteristic Analysis of Mistuned Series–Series-Compensated Wireless Charging System for EVs
by Weihan Li, Yunhan Han and Chenxu Li
Energies 2025, 18(15), 4091; https://doi.org/10.3390/en18154091 (registering DOI) - 1 Aug 2025
Abstract
Cumulative mistuning effects in electric vehicle wireless charging systems, arising from component tolerances, coil misalignments, and aging-induced drifts, can significantly degrade system performance. To mitigate this issue, this work establishes an analysis model for mistuned series–series-compensated wireless power transfer (WPT) systems. Through equivalent [...] Read more.
Cumulative mistuning effects in electric vehicle wireless charging systems, arising from component tolerances, coil misalignments, and aging-induced drifts, can significantly degrade system performance. To mitigate this issue, this work establishes an analysis model for mistuned series–series-compensated wireless power transfer (WPT) systems. Through equivalent simplification of mistuned parameters, we systematically examine the effects of compensation capacitances and coil inductances on input impedance, output power, and efficiency in SS-compensated topologies across wide load ranges and different coupling coefficients. Results reveal that transmitter-side parameter deviations exert more pronounced impacts on input impedance and power gain than receiver-side variations. Remarkably, under receiver-side inductance mistuning of −20%, a significant 32° shift in the input impedance angle was observed. Experimental validation on a 500 W prototype confirms ≤5% maximum deviation between calculated and measured values for efficiency, input impedance angle, and power gain. Full article
(This article belongs to the Special Issue Wireless Charging Technologies for Electric Vehicles)
16 pages, 24404 KiB  
Article
Oxidation of HfB2-HfO2-SiC Ceramics Modified with Ti2AlC Under Subsonic Dissociated Airflow
by Elizaveta P. Simonenko, Aleksey V. Chaplygin, Nikolay P. Simonenko, Ilya V. Lukomskii, Semen S. Galkin, Anton S. Lysenkov, Ilya A. Nagornov, Artem S. Mokrushin, Tatiana L. Simonenko, Anatoly F. Kolesnikov and Nikolay T. Kuznetsov
Corros. Mater. Degrad. 2025, 6(3), 35; https://doi.org/10.3390/cmd6030035 (registering DOI) - 1 Aug 2025
Abstract
Ultrahigh-temperature ceramic composites based on hafnium diboride have a wide range of applications, including as components for high-speed aircraft and energy generation and storage devices. Consequently, developing methodologies for their fabrication and studying their properties are of paramount importance, in particular in using [...] Read more.
Ultrahigh-temperature ceramic composites based on hafnium diboride have a wide range of applications, including as components for high-speed aircraft and energy generation and storage devices. Consequently, developing methodologies for their fabrication and studying their properties are of paramount importance, in particular in using them as an electrode material for energy storage devices with increased oxidation resistance. This study investigates the behavior of ceramic composites based on the HfB2-HfO2-SiC system, obtained using 15 vol% Ti2AlC MAX-phase as a sintering component, under the influence of subsonic flow of dissociated air. It was determined that incorporating the modifying component (Ti2AlC) altered the composition of the silicate melt formed on the surface during ceramic oxidation. This modification led to the observation of a protective antioxidant function. Consequently, liquation was observed in the silicate melt layer, resulting in the formation of spherical phase inhomogeneities in its volume with increased content of titanium, aluminum, and hafnium. It is hypothesized that the increase in the high-temperature viscosity of this melt prevents it from being carried away in the form of drops, even at a surface temperature of ~1900–2000 °C. Despite the established temperature, there is no sharp increase in its values above 2400–2500 °C. This is due to the evaporation of silicate melt from the surface. In addition, the electrochemical behavior of the obtained material in a liquid electrolyte medium (KOH, 3 mol/L) was examined, and it was shown that according to the value of electrical conductivity and specific capacitance, it is a promising electrode material for supercapacitors. 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 (registering DOI) - 1 Aug 2025
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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20 pages, 27453 KiB  
Article
Natural and Anthropogenic Influence on the Physicochemical Characteristics of Spring Water: The Case Study of Medvednica Mountain (Central Croatia)
by Ivan Martinić and Ivan Čanjevac
Limnol. Rev. 2025, 25(3), 36; https://doi.org/10.3390/limnolrev25030036 (registering DOI) - 1 Aug 2025
Abstract
During the period from 2020 to 2024, 900 springs were mapped on the southern slopes of Medvednica Mountain Nature Park. Physicochemical parameters (temperature, pH, and electrical conductivity) were measured at 701 of these springs using a portable multimeter, and results were analyzed in [...] Read more.
During the period from 2020 to 2024, 900 springs were mapped on the southern slopes of Medvednica Mountain Nature Park. Physicochemical parameters (temperature, pH, and electrical conductivity) were measured at 701 of these springs using a portable multimeter, and results were analyzed in relation to local lithology and human activities. This research provides the first results of this kind in this study area, aiming to expand the knowledge on local springs and to support the future protection and management of spring ecosystems. Springs on the Medvednica mountain showed substantial variation in measured parameters. The temperature ranged from 3.4 to 18.9 °C, reflecting local hydrological conditions, aquifer characteristics, and seasonal variability. Electrical conductivity (EC) ranged between 41 μS/cm and 2062 μS/cm, determined by both hydrogeological settings and anthropogenic impacts such as winter road salting. The pH values showed moderate variability, remaining mostly within neutral levels. These results emphasize the importance of continued monitoring and further research of Medvednica springs, in order to highlight their importance and to preserve their ecological and hydrological roles. Full article
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19 pages, 10949 KiB  
Article
Segmentation Control in Dynamic Wireless Charging for Electric Vehicles
by Tran Duc Hiep, Nguyen Huu Minh, Tran Trong Minh, Nguyen Thi Diep and Nguyen Kien Trung
Electronics 2025, 14(15), 3086; https://doi.org/10.3390/electronics14153086 (registering DOI) - 1 Aug 2025
Abstract
Dynamic wireless charging systems have emerged as a promising solution to extend the driving range of electric vehicles by enabling energy transfer while the vehicle is in motion. However, the segment-based charging lane structure introduces challenges such as pulsation of the output power [...] Read more.
Dynamic wireless charging systems have emerged as a promising solution to extend the driving range of electric vehicles by enabling energy transfer while the vehicle is in motion. However, the segment-based charging lane structure introduces challenges such as pulsation of the output power and the need for precise switching control of the transmitting segments. This paper proposes a position-sensorless control method for managing transmitting lines in a dynamic wireless charging system. The proposed approach uses a segmented charging lane structure combined with two receiving coils and LCC compensation circuits on both the transmitting and receiving sides. Based on theoretical analysis, the study determines the optimal switching positions and signals to reduce the current fluctuation. To validate the proposed method, a dynamic wireless charging system prototype with a power rating of 3kW was designed, constructed, and tested in a laboratory environment. The results demonstrate that the proposed position-sensorless control method effectively mitigates power fluctuations and enhances the stability and efficiency of the wireless charging process. Full article
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28 pages, 4460 KiB  
Article
New Protocol for Hydrogen Refueling Station Operation
by Carlos Armenta-Déu
Future Transp. 2025, 5(3), 96; https://doi.org/10.3390/futuretransp5030096 (registering DOI) - 1 Aug 2025
Abstract
This work proposes a new method to refill fuel cell electric vehicle hydrogen tanks from a storage system in hydrogen refueling stations. The new method uses the storage tanks in cascade to supply hydrogen to the refueling station dispensers. This method reduces the [...] Read more.
This work proposes a new method to refill fuel cell electric vehicle hydrogen tanks from a storage system in hydrogen refueling stations. The new method uses the storage tanks in cascade to supply hydrogen to the refueling station dispensers. This method reduces the hydrogen compressor power requirement and the energy consumption for refilling the vehicle tank; therefore, the proposed alternative design for hydrogen refueling stations is feasible and compatible with low-intensity renewable energy sources like solar photovoltaic, wind farms, or micro-hydro plants. Additionally, the cascade method supplies higher pressure to the dispenser throughout the day, thus reducing the refueling time for specific vehicle driving ranges. The simulation shows that the energy saving using the cascade method achieves 9% to 45%, depending on the vehicle attendance. The hydrogen refueling station design supports a daily vehicle attendance of 9 to 36 with a complete refueling process coverage. The carried-out simulation proves that the vehicle tank achieves the maximum attainable pressure of 700 bars with a storage system of six tanks. The data analysis shows that the daily hourly hydrogen demand follows a sinusoidal function, providing a practical tool to predict the hydrogen demand for any vehicle attendance, allowing the planners and station designers to resize the elements to fulfill the new requirements. The proposed system is also applicable to hydrogen ICE vehicles. Full article
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25 pages, 11507 KiB  
Article
Accurate EDM Calibration of a Digital Twin for a Seven-Axis Robotic EDM System and 3D Offline Cutting Path
by Sergio Tadeu de Almeida, John P. T. Mo, Cees Bil, Songlin Ding and Chi-Tsun Cheng
Micromachines 2025, 16(8), 892; https://doi.org/10.3390/mi16080892 (registering DOI) - 31 Jul 2025
Abstract
The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of [...] Read more.
The increasing utilization of hard-to-cut materials in high-performance sectors such as aerospace and defense has pushed manufacturing systems to be flexible in processing large workpieces with a wide range of materials while also delivering high precision. Recent studies have highlighted the potential of integrating industrial robots (IRs) with electric discharge machining (EDM) to create a non-contact, low-force manufacturing platform, particularly suited for the accurate machining of hard-to-cut materials into complex and large-scale monolithic components. In response to this potential, a novel robotic EDM system has been developed. However, the manual programming and control of such a convoluted system present a significant challenge, often leading to inefficiencies and increased error rates, creating a scenario where the EDM process becomes unfeasible. To enhance the industrial applicability of this robotic EDM technology, this study focuses on a novel methodology to develop and validate a digital twin (DT) of the physical robotic EDM system. The digital twin functions as a virtual experimental environment for tool motion, effectively addressing the challenges posed by collisions and kinematic singularities inherent in the physical system, yet with proven 20-micron EDM gap accuracy. Furthermore, it facilitates a CNC-like, user-friendly offline programming framework for robotic EDM cutting path generation. Full article
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22 pages, 8473 KiB  
Article
Designing a Power Supply System for an Amphibious Robot Based on Wave Energy Generation
by Lishan Ma, Fang Huang, Lingxiao Li, Qiang Fu, Chunjie Wang and Xinpeng Wang
J. Mar. Sci. Eng. 2025, 13(8), 1466; https://doi.org/10.3390/jmse13081466 - 30 Jul 2025
Abstract
As the range of applications for amphibious robots expands, higher demands are being placed on their working time and working range. This paper proposed a power supply system for an amphibious robot based on wave energy generation, which can convert wave energy into [...] Read more.
As the range of applications for amphibious robots expands, higher demands are being placed on their working time and working range. This paper proposed a power supply system for an amphibious robot based on wave energy generation, which can convert wave energy into electric energy to enhance endurance. First, the no-load induced electromotive force, magnetic line distribution vector diagrams, and magnetic density cloud diagrams of the cylindrical and flat generators were compared by finite element simulation, which determined that the cylindrical structure has better power generation performance. Then, the electromagnetic parameters of the cylindrical generator were analyzed using Ansys Maxwell, and the final dimensions were determined. Finally, the wave motion was simulated using a swing motor, and the effects of different cutting speeds for the actuator before and after rectification, as well as series-parallel capacitance on the power generation performance of the designed generator, were experimentally analyzed. This provides a potential solution to enhance the working time and working range of amphibious robots. Full article
(This article belongs to the Section Ocean Engineering)
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25 pages, 6699 KiB  
Article
Protecting Power System Infrastructure Against Disruptive Agents Considering Demand Response
by Jesús M. López-Lezama, Nicolás Muñoz-Galeano, Sergio D. Saldarriaga-Zuluaga and Santiago Bustamante-Mesa
Computers 2025, 14(8), 308; https://doi.org/10.3390/computers14080308 - 30 Jul 2025
Abstract
Power system infrastructure is exposed to a range of threats, including both naturally occurring events and intentional attacks. Traditional vulnerability assessment models, typically based on the N-1 criterion, do not account for the intentionality of disruptive agents. This paper presents a game-theoretic approach [...] Read more.
Power system infrastructure is exposed to a range of threats, including both naturally occurring events and intentional attacks. Traditional vulnerability assessment models, typically based on the N-1 criterion, do not account for the intentionality of disruptive agents. This paper presents a game-theoretic approach to protecting power system infrastructure against deliberate attacks, taking into account the effects of demand response. The interaction between the disruptive agent and the system operator is modeled as a leader–follower Stackelberg game. The leader, positioned in the upper-level optimization problem, must decide which elements to render out of service, anticipating the reaction of the follower (the system operator), who occupies the lower-level problem. The Stackelberg game is reformulated as a bilevel optimization model and solved using a metaheuristic approach. To evaluate the applicability of the proposed method, a 24-bus test system was employed. The results demonstrate that integrating demand response significantly enhances system resilience, compelling the disruptive agent to adopt alternative attack strategies that lead to lower overall disruption. The proposed model serves as a valuable decision-support tool for system operators and planners seeking to improve the robustness and security of electrical networks against disruptive agents. Full article
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32 pages, 9710 KiB  
Article
Early Detection of ITSC Faults in PMSMs Using Transformer Model and Transient Time-Frequency Features
by Ádám Zsuga and Adrienn Dineva
Energies 2025, 18(15), 4048; https://doi.org/10.3390/en18154048 - 30 Jul 2025
Viewed by 41
Abstract
Inter-turn short-circuit (ITSC) faults in permanent magnet synchronous machines (PMSMs) present a significant reliability challenge in electric vehicle (EV) drivetrains, particularly under non-stationary operating conditions characterized by inverter-driven transients, variable loads, and magnetic saturation. Existing diagnostic approaches, including motor current signature analysis (MCSA) [...] Read more.
Inter-turn short-circuit (ITSC) faults in permanent magnet synchronous machines (PMSMs) present a significant reliability challenge in electric vehicle (EV) drivetrains, particularly under non-stationary operating conditions characterized by inverter-driven transients, variable loads, and magnetic saturation. Existing diagnostic approaches, including motor current signature analysis (MCSA) and wavelet-based methods, are primarily designed for steady-state conditions and rely on manual feature selection, limiting their applicability in real-time embedded systems. Furthermore, the lack of publicly available, high-fidelity datasets capturing the transient dynamics and nonlinear flux-linkage behaviors of PMSMs under fault conditions poses an additional barrier to developing data-driven diagnostic solutions. To address these challenges, this study introduces a simulation framework that generates a comprehensive dataset using finite element method (FEM) models, incorporating magnetic saturation effects and inverter-driven transients across diverse EV operating scenarios. Time-frequency features extracted via Discrete Wavelet Transform (DWT) from stator current signals are used to train a Transformer model for automated ITSC fault detection. The Transformer model, leveraging self-attention mechanisms, captures both local transient patterns and long-range dependencies within the time-frequency feature space. This architecture operates without sequential processing, in contrast to recurrent models such as LSTM or RNN models, enabling efficient inference with a relatively low parameter count, which is advantageous for embedded applications. The proposed model achieves 97% validation accuracy on simulated data, demonstrating its potential for real-time PMSM fault detection. Additionally, the provided dataset and methodology contribute to the facilitation of reproducible research in ITSC diagnostics under realistic EV operating conditions. Full article
(This article belongs to the Special Issue Application of Artificial Intelligence in Power and Energy Systems)
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21 pages, 6919 KiB  
Article
Symmetric Optimization Strategy Based on Triple-Phase Shift for Dual-Active Bridge Converters with Low RMS Current and Full ZVS over Ultra-Wide Voltage and Load Ranges
by Longfei Cui, Yiming Zhang, Xuhong Wang and Dong Zhang
Electronics 2025, 14(15), 3031; https://doi.org/10.3390/electronics14153031 - 30 Jul 2025
Viewed by 42
Abstract
Dual-active bridge (DAB) converters have emerged as a preferred topology in electric vehicle charging and energy storage applications, owing to their structurally symmetric configuration and intrinsic galvanic isolation capabilities. However, conventional triple-phase shift (TPS) control strategies face significant challenges in maintaining high efficiency [...] Read more.
Dual-active bridge (DAB) converters have emerged as a preferred topology in electric vehicle charging and energy storage applications, owing to their structurally symmetric configuration and intrinsic galvanic isolation capabilities. However, conventional triple-phase shift (TPS) control strategies face significant challenges in maintaining high efficiency across ultra-wide output voltage and load ranges. To exploit the inherent structural symmetry of the DAB topology, a symmetric optimization strategy based on triple-phase shift (SOS-TPS) is proposed. The method specifically targets the forward buck operating mode, where an optimization framework is established to minimize the root mean square (RMS) current of the inductor, thereby addressing both switching and conduction losses. The formulation explicitly incorporates zero-voltage switching (ZVS) constraints and operating mode conditions. By employing the Karush–Kuhn–Tucker (KKT) conditions in conjunction with the Lagrange multiplier method (LMM), the refined control trajectories corresponding to various power levels are analytically derived, enabling efficient modulation across the entire operating range. In the medium-power region, full-switch ZVS is inherently satisfied. In the low-power operation, full-switch ZVS is achieved by introducing a modulation factor λ, and a selection principle for λ is established. For high-power operation, the strategy transitions to a conventional single-phase shift (SPS) modulation. Furthermore, by exploiting the inherent symmetry of the DAB topology, the proposed method reveals the symmetric property of modulation control. The modulation strategy for the forward boost mode can be efficiently derived through a duty cycle and voltage gain mapping, eliminating the need for re-derivation. To validate the effectiveness of the proposed SOS-TPS strategy, a 2.3 kW experimental prototype was developed. The measured results demonstrate that the method ensures ZVS for all switches under the full load range, supports ultra-wide voltage conversion capability, substantially suppresses RMS current, and achieves a maximum efficiency of 97.3%. Full article
(This article belongs to the Special Issue Advanced Control Techniques for Power Converter and Drives)
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14 pages, 3023 KiB  
Article
Tensile and Flexural Behavior of Metal–Polymer Friction Stir Buttstrap Composite Panels
by Arménio N. Correia, Daniel F. O. Braga, Ricardo Baptista and Virgínia Infante
Polymers 2025, 17(15), 2084; https://doi.org/10.3390/polym17152084 - 30 Jul 2025
Viewed by 55
Abstract
This study investigates the friction stir joining of AA6082-T6 aluminum alloy and Noryl GFN2 polymer in a buttstrap configuration, targeting the development of lightweight cylindrical-shaped structures where the polymer provides thermal, chemical, and electrical insulation, while the aluminum ensures mechanical integrity. A parametric [...] Read more.
This study investigates the friction stir joining of AA6082-T6 aluminum alloy and Noryl GFN2 polymer in a buttstrap configuration, targeting the development of lightweight cylindrical-shaped structures where the polymer provides thermal, chemical, and electrical insulation, while the aluminum ensures mechanical integrity. A parametric analysis was carried out to assess the ability to produce friction stir buttstrap composite panels in a single processing step and assess the resulting tensile and flexural behavior. To that end, travel and rotating speeds ranging from 2150 to 2250 rpm, and 100 to 140 mm/min, respectively, were employed while keeping plunge depth and the tilt angle constant. A total of nine composite joints were successfully produced and subsequently subjected to both tensile and four-point bending tests. The tensile and flexural strength results ranged from 80 to 139 MPa, and 39 to 47 MPa, respectively. Moreover, the microstructural examination revealed that all joints exhibited a defect within the joining region and its size and shape had a significant effect on tensile strength, whereas the flexural strength was less affected with more uniform results. The joining region was also characterized by a decrease in hardness, particularly in the pin-affected region on the aluminum end of the joint, exhibiting a W-shaped pattern. Contrarily, on the polymeric end of the joining region, no significant change in hardness was observed. Full article
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