Search Results (164)

Objectives: Although 3D-printing has been identified as a promising technique for personalised medicine manufacturing, developing complex formulations that are suitable for the process can be challenging. This study evaluates the use of a mixture design for the targeted development of an optimised formulation designed for the 3D-printing of oral dosage forms containing the drug sertraline hydrochloride featuring immediate-release drug dissolution. Methods: The polymers Eudragit E PO, Kollidon 17 PF and hydroxypropyl cellulose were compared in simple screening experiments regarding their extrudability, printability and disintegration. A combination of Eudragit E PO and Kollidon 17 PF proved superior and therefore served as the basis for the mixture design. The resulting blends were processed via hot melt extrusion to produce filaments, which were then measured for bending stress using a 3-point-bending-test, and 3D-printed sample plates were used to determine the crystallinity index of sertraline hydrochloride using X-ray diffraction in a previously identified range with low interference from the other components. The formulation was optimised using statistically based models with the aim of minimising the bending stress to obtain flexible, process-robust filaments and simultaneously minimising the crystallinity index with the intention of improving the solubility of the drug by maximising its amorphous content. Results: The filaments made from the optimised formulation could be reliably printed, and the amorphous state of the active ingredient therein was confirmed. The oral dosage forms produced from these showed immediate release characteristics in an acidic medium. Conclusions: This study demonstrates the advantages of a mixture design for optimising complex formulations in a time- and resource-efficient way and could serve as a basis for other research groups to develop innovative, customisable drug delivery systems more effectively. Full article

Wood–plastic composites (WPCs) are polymeric materials, usually thermoplastic, filled with wood flour or fibers. They are relatively durable and stiff and resistant to water. They are also, importantly, relatively cheap compared to materials with similar properties. The WPCs market has grown significantly in recent years, mainly thanks to the increasing construction and automotive markets. Currently, the global WPCs market is forecasted to reach about USD 15 billion by 2030, increasing at an impressive compound annual increase rate of about 12% until 2030. There are some review articles on WPCs written from many different points of view, e.g., the type of materials used (polymers, fillers, auxiliaries), the method of manufacturing and processing, processing properties (thermal and rheological) and functional properties, methods of designing composite products and designing (modeling) forming processes. In this article, we will summarize these different points of view and will present a thorough literature review of rheology and material processing, and more specifically, the modeling of WPCs processing. This work will be presented in relation to state-of-the-art research in the field of modeling the processing of other polymeric materials, i.e., standard (neat) polymers and polymer blends. The WPCs’ processing is significantly different from that of standard plastics due to the differences in thermo-rheological properties, diverse structures, etc. So far, the global WPCs processing models have only been developed for both gravity-fed and starve-fed single-screw extrusion. The models for twin-screw extrusion, both co-rotating and counter-rotating, as well as for injection molding, have still not been developed. WPCs show a yield stress and wall slip when extruding, which must be considered when modeling the process. As the slippage on the screw and barrel grows, the process throughput and pressure diminish, but as the slippage on the die grows, the throughput grows and the pressure diminish. As the yield stress in the screw grows, the process throughput and pressure grow, whereas as the yield stress in the die grows, the throughput diminishes and the pressure grows. Full article

To address the critical challenge of synergistically enhancing both high-temperature mechanical properties and thermal conductivity in neutron-absorbing materials for dry storage of spent nuclear fuel, this study proposes an innovative strategy. This approach involves the controlled distribution, size, and crystalline states of nano-Al₂O₃ within an aluminum matrix. By combining plastic deformation and heat treatment, we aim to achieve a structurally integrated functional design. A systematic investigation was conducted on the microstructural evolution of Al₂O₃/10 wt.% B₄C/Al composites in their forged, extruded, and heat-treated states. We also examined how these states affect high-temperature mechanical properties and thermal conductivity. The results indicate that applying hot extrusion deformation along with optimized heat treatment parameters (500 °C for 24 h) allows for a lamellar dispersion of nano-Al₂O₃ and a crystallographic transition from amorphous to γ-phase. As a result, the composite demonstrates a tensile strength of 144 MPa and an enhanced thermal conductivity of 181 W/(m·K) at 350 °C. These findings provide theoretical insights and technical support for ensuring the high density and long-term safety of spent fuel storage materials. Full article

Three-dimensional (3D) concrete printing (3DCP) has gained significant attention over the last decade due to its many claimed benefits. The absence of effective real-time quality control mechanisms, however, can lead to inconsistencies in extrusion, compromising the integrity of 3D-printed structures. Although the importance of quality control in 3DCP is broadly acknowledged, research lacks systematic methods. This research investigates the feasibility of using ultrasonic pulse velocity (UPV) as a practical, in situ, real-time monitoring tool for 3DCP. Two different groups of binders were investigated: limestone calcined clay (LC³) and zeolite-based mixes in binary and ternary blends. Filaments of 200 mm were extruded every 5 min, and UPV, pocket hand vane, flow table, and viscometer tests were performed to measure pulse velocity, shear strength, relative deformation, yield stress, and plastic viscosity, respectively, in the fresh state. Once the filaments presented printing defects (e.g., filament tearing, filament width reduction), the tests were concluded, and the open time was recorded. Isothermal calorimetry tests were conducted to obtain the initial heat release and reactivity of the supplementary cementitious materials (SCMs). Results showed a strong correlation (R² = 0.93) between UPV and initial heat release, indicating that early hydration (ettringite formation) influenced UPV and determined printability across different mixes. No correlation was observed between the other tests and hydration kinetics. UPV demonstrated potential as a real-time monitoring tool, provided the mix-specific pulse velocity is established beforehand. Further research is needed to evaluate UPV performance during active printing when there is an active flow through the printer. Full article

Background/Objectives: In the twin-screw wet granulation (TSWG) process, accurate measurement of residence time distribution (RTD) is critical, as it characterizes material transport kinetics and mixing behavior. It plays a critical role in evaluating the homogeneity and stability of the granulation process and optimizing process parameters. It is necessary to overcome the limitations arising from the complex and time-consuming procedures of conventional RTD determination methods. Methods: This study proposes a new RTD detection method based on image processing. It uses black dye as a tracer to obtain RTD curve data, and the effects of process parameters such as tracer dosage, screw speed, and feeding rate on the RTD were investigated. Results: The results show that the established method can accurately determine RTD and that the tracer dosage has no significant effect on the detection results. Further analysis revealed that the screw speed is negatively correlated with the mean residence time (MRT). As the speed increases, not only does the MRT shorten, but its distribution also decreases. Similarly, an increase in the feeding rate also leads to a decrease in the MRT and distribution, but it is worth noting that lower feeding rates are beneficial for achieving a state close to mixed flow, while excessively high feeding rates are not conducive to sufficient mixing of materials in the extruder. Conclusions: The RTD detection method provides a reliable parameter basis and theoretical guidance for the in-depth study of the TSWG process and the development of quality control strategies. Full article

Room-temperature rotary swaging was conducted on microalloyed high-ductility Mg-0.7Sm-0.3Zr alloy rods to investigate microstructural and mechanical variations across different swaging passes and radial positions. The results indicate that following room-temperature rotary swaging, the alloy rods exhibit a large number of tensile twins and low-angle grain boundaries, leading to significant grain refinement. After two swaging passes, the microstructure exhibits a pronounced radial gradient, characterized by progressively finer grain sizes from the core to the edge regions, with a hardness difference of 3.8 HV between the edge and the core. After five swaging passes, the grain size was refined from an initial 4.37 μm to 2.02 μm. The yield strength and ultimate tensile strength of the alloy increased from 157 MPa and 210 MPa in the extruded state to 292 MPa and 302 MPa, respectively. This observed strengthening is primarily attributed to grain refinement, dislocation hardening, and texture strengthening, with grain refinement playing the dominant role. The grain refinement process during rotary swaging can be divided into two stages: in the initial stage, coarse grains are subdivided by tensile twinning; in the later stage, high-stress-induced grain boundary bulging leads to new dynamic recrystallization, further refining the microstructure. Full article

Magnesium (Mg) alloys are gaining widespread use in the automotive and construction industries for their potential to enhance performance and lower manufacturing costs, making them ideal for lightweight structural applications. However, despite these advantages, extruding Mg alloys remains technically challenging due to their inherently limited formability and the strong crystallographic textures that form during deformation. This study aimed to comprehensively characterize the ductile fracture behavior of ZM51M Mg alloy round bars under various stress states and to improve the reliability of ductile failure predictions through the application and calibration of multiple uncoupled damage criteria. Tensile and compressive tests were conducted on specimens of varying geometries (dogbone, notched R5, shear, uniaxial compression, and plane strain compression specimens) and dimensions, meticulously cut along the extrusion direction of the round bar. These tests encompassed a wide spectrum of stress–strain responses and fracture characteristics, including uniaxial tension, uniaxial compression, and shear-dominated states. An inverse analysis approach, involving iterative numerical simulation coupled with experimental data, was employed to precisely determine fracture strains from the test results. The plastic deformation behavior was accurately modeled using the combined Swift–Voce hardening law. Subsequently, three prominent uncoupled ductile fracture criteria—Rice–Tracey, DF2014, and DF2016—were calibrated against the experimental data. The DF2016 criterion demonstrated superior predictive accuracy, consistently yielding the most accurate fracture strain predictions and significantly outperforming the Rice–Tracey and DF2014 criteria across the tested stress states. The findings of this work provide significant insights for improving the assessment of formability and fracture prediction in Mg alloys. This research directly contributes to overcoming the challenges associated with their inherent formability limitations and complex deformation textures, thereby facilitating more reliable design and broader adoption of Mg alloys in advanced lightweight structural solutions. Full article

Aiming to address the problems of many temperature control disturbances and the hysteresis of control output in existing rice noodle extruders, a temperature control method for a rice noodle extruder based on adaptive particle swarm optimization (APSO) optimization model predictive control (MPC) was designed. Firstly, the temperature control principle of the rice noodle extruder is analyzed by combining the structure of the rice noodle extruder. The temperature balance equation of the barrel is constructed by thermodynamic analysis, and the temperature prediction model is established. The APSO algorithm is further selected to perform the adaptive parameter identification of the model based on the collected input/output data. Then, aiming at high-precision temperature control, the objective function is constructed by combining the temperature prediction value and the reference trajectory, and the objective function is optimized to obtain the optimal control sequence. At the same time, the feed rate is selected as feedforward, the feed rate change is monitored by detecting the feed screw speed, and the optimal control sequence is corrected to eliminate the interference caused by the fluctuation of the feed rate. The experimental results show that the maximum temperature overshoot under different parameter combinations is 7.75%, the steady-state error is within ±1 °C, and the longest adjustment time is 1228 s. Compared with fuzzy PID control, it has stronger adaptability and higher control accuracy. Full article

This review presents a comprehensive analysis of polypropylene (PP) fibre incorporation in three-dimensional printed concrete (3DPC), focusing on the material behaviour in both fresh and hardened states. PP fibres play a critical role in improving rheological properties such as buildability, flowability, and extrudability. While increased fibre content enhances interlayer bonding and shape retention through the fibre bridging mechanism, it also raises yield stress and viscosity, which may compromise extrudability. In the hardened state, PP fibres contribute to improvements in compressive and flexural strength up to an optimal dosage, beyond which performance may decline due to fibre clustering and reduced packing density. When aligned with the printing direction, fibres are particularly effective in mitigating shrinkage-induced cracking by redistributing internal tensile stress. However, their inclusion can lead to a slight increase in porosity and promote mechanical anisotropy. This review also discusses mix design parameters, fibre characteristics, and experimental protocols, while identifying key research gaps including the lack of standardized testing methods, limited understanding of fibre orientation effects, and insufficient exploration of hybrid fibre systems. Based on the synthesis of reported studies, optimal print quality and structural consistency have been associated with the use of 6 mm long fibres, nozzle diameters of 4 to 6 mm, and printing speeds ranging from 40 to 60 mm/s. Overall, PP fibre reinforcement shows strong potential for enhancing the structural integrity and dimensional stability of 3D-printed concrete, while emphasizing the need for further studies to optimize its use in practice. Full article

This study introduced a systematic framework to develop practical design guidelines specifically for filament-based material extrusion of metals (MEX/M), an additive manufacturing (AM) process defined by ISO/ASTM 52900. MEX/M provides a cost-efficient alternative to conventional manufacturing methods, which is particularly valuable for rapid prototyping. Although AM offers significant design flexibility, the MEX/M process imposes distinct geometric and process constraints requiring targeted optimization. The research formulates and validates design guidelines tailored for the MEX/M using an austenitic steel 316L (1.4404) alloy filament. The feedstock consists of a uniform blend of 316L stainless steel powder and polymeric binder embedded within a thermoplastic matrix, extruded and deposited layer by layer. Benchmark parts were fabricated to examine geometric feasibility, such as minimum printable wall thickness, feature inclination angles, borehole precision, overhang stability, and achievable resolution of horizontal and vertical gaps. After fabrication, the as-built (green-state) components undergo a two-step thermal post-processing treatment involving binder removal (debinding), followed by sintering at elevated temperatures to reach densification. Geometric accuracy was quantitatively assessed through a 3D scan by comparing the manufactured parts to their original CAD models, allowing the identification of deformation patterns and shrinkage rates. Finally, the practical utility of the developed guidelines was demonstrated by successfully manufacturing an impeller designed according to the established geometric constraints. These design guidelines apply specifically to the machine and filament type utilized in this study. Full article

The development of printable, conductive, and biocompatible hydrogels has emerged as a promising strategy for the next generation of flexible and soft sensor platforms. In this study, we present a systematic investigation of alginate-based hydrogels incorporating different carbonaceous materials, natural graphite, carbon black (Vulcan V3), and activated carbon (PCO1000C), to evaluate their suitability for sensor applications. Hydrogels were formulated with varying concentrations of sodium alginate and a fixed loading of carbon additives. Each composite was characterized in terms of electrical conductivity under compression, rheological behavior, and mechanical strength. Printability was assessed using a custom-designed extrusion platform that allowed for the precise determination of the minimum force and optimal conditions required to extrude each formulation through a standard 20G nozzle. Among all tested systems, the alginate–graphite hydrogel demonstrated superior extrudability, shear-thinning behavior, and shape fidelity, making it well-suited for 3D printing or direct ink writing. A simple conductivity-testing device was developed to verify the electrical response of each hydrogel in the hydrated state. The effects of different drying methods on the final conductivity were also analyzed, showing that oven drying at 50 °C yielded the highest restoration of conductive pathways. Mechanical tests on printed structures confirmed their ability to maintain shape and resist compressive forces. Finally, the biocompatibility of the printed alginate–graphite hydrogel was validated using a standard cytotoxicity assay. The results demonstrated high cell viability, confirming the material’s potential for use in biomedical sensing environments. This work offers a robust framework for the development of sustainable, printable, and biocompatible conductive hydrogels. The combined performance in printability, mechanical integrity, electrical conductivity, and cytocompatibility highlights their promise for flexible biosensors and wearable sensor technologies. Full article

Aim: In addition to numerous benefits provided by nanosuspensions (NSs) (e.g., enhanced saturation solubility, increased area for interaction with fluids), they suffer from major stability, handling and compliance issues. To overcome these challenges, we evaluated the feasibility of hot melt extrusion (HME) in transforming a cinnarizine-based NS, selected as a case study, into granules for oral intake. Methods: Thermoplastic polymers, in principle compatible with the thermal behavior of the selected drug and characterized by different interaction mechanisms with aqueous fluids, were used as carriers to absorb the NS and were processed by HME. Results: The extruded granules pointed out good physio-technological characteristics, a drug content > 85% with coefficient of variation (CV) < 5% and tunable in vitro performance coherent with the polymeric carriers they were composed of. Particle size as well as the solid state of cinnarizine was checked using several analytical techniques in combination (e.g., DSC, SEM, FT-IR, Raman). Depending on the composition of the granules, and specifically for formulations processed below 85 °C, the drug was found to remain crystalline and in the desired nanoscale. Conclusions: HME turned out to be a versatile process to transform, in a single-step, NSs into multi-particulate solid products for oral administration showing a variety of release profiles. Full article

This study compares the microstructures and mechanical properties of the AlSi10Mg alloy processed by laser powder bed fusion (LPBF) after undergoing different post-processing techniques. These techniques include conventional extrusion at 350 °C (CE-350) and KOBO extrusion at both room temperature (KOBO-RT) and 350 °C (KOBO-350). The extrusion processes, regardless of the method used, effectively densified the alloy, fragmented the primary silicon network, and refined the grain structure. Notably, a microstructure analysis indicated that the CE-350 method produced the finest grains, whereas the KOBO-350 method resulted in the largest grains. From a mechanical perspective, extrusion significantly increased ductility—rising from 2.4% to more than 14% elongation—while decreasing strength compared to the as-built state. Among the extruded samples, CE-350 provided the best balance of strength and ductility, exhibiting a yield strength of 186 MPa and a ductility of 18.1% elongation. Overall, the results demonstrate that while extrusion enhances ductility, it does so at the expense of strength, with conventional extrusion yielding a more favorable property balance for this alloy under the tested conditions. Full article

The existing Al-Ce heat-resistant alloys are not extensively utilized in high-temperature applications due to their poor room-temperature mechanical properties. In this study, the Al-10Ce-3Mg-5Zn alloy was enhanced using hot extrusion and heat treatment. The as-extruded alloy exhibited bimodal intermetallic compounds and grain structures. Additionally, high-density microcracks and twins were observed in the micron-sized intermetallic compounds. Compared with the as-cast state, the as-extruded alloy demonstrated a higher ultimate tensile strength (UTS) of 317 MPa and better elongation of 11.0%. Numerous nano-sized T phases precipitated in the α-Al matrix after the heat treatment, contributing to a further rise in UTS (365 MPa). The high strength of the alloy is primarily due to its strong strain hardening capacity, fine grain strengthening, and precipitation strengthening effect. The change in elongation mainly results from the expansion of pre-existing microcracks, twin deformation, and microstructural refinement. The heat-treated alloys exhibited superior strength retention ratios at elevated temperatures (64% at 200 °C) compared to conventional heat-resistant aluminum alloys. The results of this paper indicate that hot extrusion and heat treatment are effective for developing heat-resistant Al-Ce alloys with high room-temperature strength, offering a simple process suitable for industrial production. Full article

To investigate the dynamic mechanical properties of low-alloy, high-strength steel weld metal at high temperatures, the temperature distribution equation and boundary conditions of weld metal during welding were determined. A steady-state temperature distribution model of weld metal heat loss was constructed by combining the heat loss equation and the heat source loss equation. Subsequently, a weld with Q960E high-strength steel extruded plate was used as the base material to investigate the dynamic mechanical properties of the weld metal at high temperatures. The experimental results show that the weld seam is the weakest region of the whole welded joint, and with the increase in temperature, the yield strength and tensile strength of the welded joints decrease. Heat treatment technology at high temperatures can significantly change the weld tensile strength of Q960E high-strength steel, and solid solution + aging treatment can optimize the mechanical properties of the heat-affected zone. We observed the short-term persistence of high-temperature metal at 600 °C/199 MPa and 650 °C/118 MPa; except for one 118 MPa short-term endurance test at high temperature, most samples qualified. With the increase in annealing temperature from 830 °C, the yield strength and tensile strength of the samples decreased significantly, and elongation after break increased dramatically. Full article