Search Results (301)

Aluminum foam materials have gained significant attention over the past decade, particularly in the automotive industry, due to their excellent stiffness-to-weight ratio and superior energy absorption capabilities. In this study, a multiscale numerical material model was developed to accurately and efficiently simulate the vibrational behavior of aluminum foams. The foam specimens were categorized into four density classes based on their measured mass and calculated volume. Two specimens were selected to conduct CT (computerized tomography) scans and quantify the volume of air in their density class. Based on the CT measurements, a representative volume element (RVE) was built using ANSYS Material Designer (MD). The newly obtained material was employed in conducting normal mode numerical simulations. The resonance frequencies and response amplitudes were compared with physical experiments and showed correlation within 3%. These findings underscore the efficacy of using CT scans in foam to develop material models and accurately predict structural behavior. By conducting comprehensive investigations and numerical simulations, we established a correlation between physical tests and simulation results, highlighting the reliability of the developed models. Full article

With increasing popularity of food delivery services, the microbial safety of transported meals should be ensured. An effect of the type of a meal (cooked rice; mashed potatoes; mushroom sauce), inner primary packaging (sugarcane bagasse [SB] tray; polypropylene [PP] tray), secondary container (polyester/polyethylene foam/aluminum foil [PPA] bag; PP box) on the time interval of the internal hot ready-to-eat (RTE) meal temperature decrease to the value critical for Bacillus cereus growth (40 °C) was tested during a simulated delivery; in aliquot samples of the same meals, B. cereus growth was quantified presuming a natural contamination of the meals. Type of a meal had no effect on the tested time interval (p > 0.05). Packaging a meal in the PP tray as compared to the SB tray and inserting primary trays into the PP box instead of PPA bag delayed (p < 0.05) the internal meal temperature decrease by 50 and 15 min, respectively. Average B. cereus counts in the naturally contaminated meals after the four-hour culturing at 40 °C was 2.99 log CFU·g⁻¹. It was concluded that a hot RTE meal delivered up to four hours under the tested conditions is not likely to facilitate B. cereus growth above unacceptable levels. Full article

In this study, the effects of different heat sink designs on the cold side of the modules in a thermoelectric generator (TEG) system placed between the compressor and the intercooler of a turbocharged tractor on the system performance were numerically analyzed. In the current literature, heat sinks used in TEG modules generally consist of plate fins. In this study, by using perforated and slotted fins, the thermal boundary layer behaviors were changed and there was an attempt to increase the heat transfer from the cold surface compared to plate fins. Thus, the performance of the TEG system was also increased. When looking at the literature, it is seen that there are studies which aim to increase the performance of TEG modules by changing the dimensions of p and n type semiconductors. However, there is no study aiming to increase the performance of TEG modules by making changes on the plate fins of the heat sinks used in these modules and thus increasing the heat transfer amount. In this respect, this study offers important results for the literature. According to the numerical analysis results, the total TEG output power, output voltage, and thermal efficiency obtained for S0.5H15 were 6.2%, about 3%, and about 5% higher than those for PF, respectively. In addition, the pressure drop values obtained for different heat sinks, except for aluminum foam, were approximately close to each other. In cases with TEG systems where different heat sinks were used, the intercooler inlet air temperatures decreased by approximately 3.4–3.5% compared to the case without the TEG system. This indicates that the use of TEG will positively affect the improvement in engine efficiency. Full article

Doors are considered vulnerable to failure in structures when subjected to extreme loads, such as blasts. Consequently, blast-resistant doors are designed to withstand blast pressure in important structures. This study developed a multi-layer Steel, Aluminum Foam, and Steel–Concrete–Steel composite door panel with Energy Absorption Connectors (SAFSCS-EACs) under near and far field blast loading using finite element analysis in LS-DYNA. Three dynamic response modes were observed based on the crushing strength of energy absorption connectors (EACs) for the SAFSCS-EAC composite door under both near and far field blasts. In addition, the membrane stretching phenomena was observed in the face steel plate. The AF shows a local densification in near field blasts and a global densification in far field blasts. For the SCS panel, a punching-like failure and a global flexural failure were observed in near and far field blasts, respectively. AF has a high energy absorption capacity as a first energy absorption layer, while the EAC also effectively dissipates blast energy through the rotation of the plastic hinges of curved steel plates, thereby reducing the damage to the SCS panel and increasing the door’s structural integrity. Moreover, to check the influence of the curved steel plate thickness of EACs and the core concrete thickness, a parametric study was carried out. The results showed that the blast resistance performance of the SAFSCS-EAC composite door could increase by appropriately designing the EAC curved steel plates’ thickness and ensuring that the compression displacement of the EAC under blast is close to its densification displacement. Additionally, increasing concrete thickness can reduce the degree of damage to the steel–concrete–steel composite panel during the blast, but it leads to a reduction in the energy dissipation of the EAC. Full article

Aluminum foam is expected to be a leading candidate for lightweight parts due to its light weight and excellent shock-absorption and sound-absorption properties. In order to use it as a part, it is essential to form it into the desired shape. However, the cell walls that form the pores are composed of thin aluminum. When aluminum foam is formed, the cell walls easily fracture and the pores collapse. This results in the loss of the properties of the aluminum foam. Past studies have shown that press forming aluminum foam immediately after foaming, while it is still in the softened state, prevents cell wall failure and pore deformation. In this study, we attempted to perform a continuous process from the foaming of the precursor to the press forming of aluminum foam for three precursors, for the purpose of the continuous production of aluminum foam with desired shapes. It was shown that it is possible to continuously and sequentially foam the precursors by heating and press forming the foamed samples. In addition, aluminum foam with a similar shape, porosity, and pore structure can be fabricated using the continuous process. Also, it was shown that aluminum foam with complex shapes can also be continuously fabricated by using a complex-shaped die. Furthermore, it was indicated that the use of a die in press forming can shorten the cooling time and reduce the production time. Full article

Geopolymer foam concrete (GFC) is a green, lightweight material produced by introducing bubbles into the geopolymer slurry. The raw materials for GFC are primarily silicon–aluminum-rich minerals or solid waste. Lead–zinc tailings (LZTs), as an industrial solid waste with high silicon–aluminum content, hold significant potential as raw materials for building materials. This study innovatively utilized LZTs to prepare GFC, incorporating MK, GGBS, and alkali activators as silicon–aluminum-rich supplementary materials and using H₂O₂ as a foaming agent, successfully producing GFC with excellent properties. The effects of different LZT content on the pore structure and various macroscopic properties of GFC were comprehensively evaluated. The results indicate that an appropriate addition of LZT effectively optimizes the pore structure, resulting in uniform pore distribution and pore shapes that are more spherical. Spherical pores exhibit better geometric compactness. The optimal LZT content was determined to be 40%, at which the GFC exhibits the best compressive strength, thermal conductivity, and water resistance. At this content, the dry density of GFC is 641.95 kg/m³, the compressive strength reaches 6.50 MPa after 28 days, and the thermal conductivity is 0.176 (W/(m·K)). XRD and SEM analyses indicate that under the combined effects of geopolymerization and hydration reactions, N–A–S–H gel and C–S–H gel were formed. The preparation of GFC using LZTs shows significant potential and research value. This study also provides a feasible scheme for the recycling and utilization of LZTs. Full article

A high-porosity micro-arc oxidation (MAO) functional coating was fabricated on aluminum foam substrate through micro-arc oxidation technology, developing a structurally and functionally integrated bulk catalyst support material. Orthogonal experiments were employed to determine the optimal electrical parameters for achieving maximum coating porosity, with systematic investigations into the effects of electrolyte temperature and sodium tetraborate additives on pore characteristics. The phase composition, surface morphology, and elemental distribution of the porous coating were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), energy-dispersive spectroscopy (EDS), X-ray photoelectron spectroscopy (XPS), and transmission electron microscopy (TEM). Mercury intrusion porosimetry was applied to quantify the total pore area and pore size distribution. By means of secondary micro-arc oxidation, the catalyst was distributed in a gradient on the coating cross-section, which greatly improved the utilization rate of the catalyst. The formation mechanism of the porous coating was discussed, and the specific surface area of the fabricated catalyst-loaded materials was as high as (1.4~6.3) × 10⁴ m²/m³, which provided a large number of attachment sites for catalyst particles. Full article

The miniaturization and high integration of modern electronic devices have intensified thermal management challenges. Therefore, developing efficient heat sinks has become crucial to ensuring the stability and performance of high-performance CPUs. Previous studies have not considered the thermally demanding Intel i9 CPU; the current study targets this processor and explores the advantages of more complex minichannel path designs. In addition, this work investigates the enhanced heat transfer performance by integrating metal foams into microchannels. Using a computational approach, this study evaluates the thermal performance of uni-path, dual-path, and staggered-path (SP) minichannel heat sinks with water, Al₂O₃, and CuO nanofluids at varying Reynolds numbers. The impact of aluminum foam filling has also been examined. Results confirm that higher Reynolds numbers enhance fluid flow, reduce heat sink temperature, and improve temperature uniformity. Among the configurations, the SP heat sink combined with Al₂O₃ nanofluid achieves the best trade-off between cooling efficiency and energy consumption. While lower porosity foam and higher nanofluid volume fractions enhance heat transfer, they also increase flow resistance, leading to higher energy consumption. Due to its high specific heat capacity, Al₂O₃ nanofluid outperforms CuO, with optimal cooling observed at a 3–4% volume fraction. The performance evaluation criterion (PEC) captures the trade-off between heat dissipation and energy efficiency. It shows that the SP model with high-porosity aluminum foam and Al₂O₃ nanofluid turns out to be the most effective design. This combination maximizes cooling efficiency while minimizing excessive energy costs, demonstrating superior thermal management for high-performance microelectronic devices. Full article

Commercially pure aluminum (Al) was refined through the addition of the Al-5Ti-0.25C master alloy, resulting in the formation of Al₃Ti and TiC phases, which serve as refining agents. Open-cell metallic foams were successfully produced using the replication casting technique, with pore sizes ranging from 1.00 to 3.35 mm. For the infiltration process, refined aluminum was used, while unrefined aluminum served as a baseline reference. The resultant foams underwent multiple annealing cycles at 480 °C, with the most refined and homogeneous microstructure observed after 504 h. Comprehensive microstructural characterization was conducted utilizing scanning electron microscopy and optical microscopy. Additionally, uniaxial compression tests were performed to generate stress–strain profiles for the foams, facilitating an assessment of their energy absorption capacity. The findings indicated an enhancement in energy absorption capacity by a factor of 2.4 to 3, which can be attributed to the incorporation of Al-5Ti-0.25C and the subsequent annealing process. Full article

“Foam container + ice pack” is a common packaging form for e-commerce logistics of litchis. However, there are numerous factors affecting the temperature variation under this logistics mode, making it difficult to control the packaging temperature and litchi quality during the e-commerce logistics process. In order to explore the impact of the packaging scheme on the packaging environment temperature and the quality variation in litchis during the “foam container + ice pack” logistics process, this paper takes the number of ice packs, the terminal pre-cooling temperature of litchis, the weight of litchis, and whether to use aluminum foil insulating film as variable factors to study the impact rules of these factors on the EPS (Expanded Polystyrene) foam container environment temperature, the total number of fruit pericarp, and the marketable fruit rate. The experimental results show the following trends: the terminal pre-cooling temperature has a significant impact on the daily average temperature of the fruit layer; the packaging environment temperature of the 15 °C pre-cooling group on the first day and the second day is 5.00 °C and 2.78 °C higher than that of the 5 °C pre-cooling experimental group, respectively. Moreover, under this treatment, the growth rate of fruit pericarp fungi is relatively fast, which could reach 3.87 Lg (CFU/g) on the second day. Increasing the amount of litchis could maintain a lower temperature environment, but it will cause the relative conductivity increasing 4.12% compared with the groups with no weight increasing. Increasing the number of ice packs could significantly reduce the decline rate of fruit soluble solids in the first two days. The research results of this paper are expected to provide a certain reference for the quality assurance logistics and the formulation of long-distance transportation strategies for perishable agricultural products. Full article

The preservation and continuous monitoring of cutting tools in a computer numerical control (CNC) machine is essential for ensuring seamless transitions in the manufacturing workflow, as well as maintaining adequate part quality. The implementation of tool condition monitoring (TCM) when milling can provide the user with necessary data regarding tool life, wear, and part quality. However, it is important to broaden the application of the TCM process across a much broader class of workpiece materials to understand the effects of material properties on the condition of the tool. The aim of this paper is to investigate the efficacy of tool condition monitoring techniques while milling low- and high-yield-strength materials across varied process parameters. A Fast Fourier Transform (FFT) analysis was conducted in this research. Vibration data were acquired from both uniaxial and triaxial accelerometers to investigate irregularities in vibrational amplitudes between new and worn milling tools. The experimental results show that there is a significant increase in vibrational amplitudes for the worn tool when compared to the new tool across various frequencies, which affirms the expected increase in vibrations and cutting forces at the tool–workpiece interface from using a worn tool. The F-values and p-values calculated using an F-test with a 95% confidence interval indicated statistically significant differences in vibration data between new and worn tools across various materials, including polyurethane foam, aluminum 6061, mild steel, and stainless steel, under different cutting conditions (low, medium, and high). These results further validate the findings obtained from the FFT analysis and highlight the effectiveness of vibration-based monitoring in distinguishing tool wear under varying material characteristics and machining conditions. Full article

Polyurethane (PUR)-based artificial leathers are often used as interior materials in public area, making flame retardants (FRs) necessary. The mode of action of different FRs varies depending on the chemical class and the structure of the supplied material. Usually, FRs are designed for bulk materials like foams, e.g., for upholstery, the main application of PUR. However, in thin materials, FRs act differently, thus leaving the PUR without sufficient flame resistance. In this study, PUR films and artificial leathers were equipped with twelve commercially available, halogen-free FRs in various concentrations and combinations. Fire resistance was tested with LOI measurements, cone calorimetry, horizontal burning behavior, and thermogravimetric analyses. An organophosphorus FR proved to be the most suited for flame-resistant artificial leather. The LOI was increased from 20 to 24.2%, the peak heat release rate was reduced by about 30%, and the sample was self-extinguishing in horizontal burning behavior. Phosphinates and aluminum trihydroxide were the least efficient FRs. Combinations of bentonite with phosphorus-based FRs showed synergistic effects in reducing the probability of igniting the material. The results demonstrate that sufficient flame retardancy for PUR-based thin materials can be achieved with commercially available halogen-free FRs, paving the way for more sustainable and greener materials by substituting ecologically harmful and health-damaging FRs. Full article

Microporous metal materials have promising applications in the high-temperature industry for their high heat exchange efficiency. However, due to their complex internal structure, analyzing the heat transfer mechanisms presents a great challenge. This I confirm work introduces a mathematical model to accurately calculate the radiative thermal conductivity of microporous open-cell metal materials. The finite element and lattice Boltzmann methods were employed to calculate the thermal conduction and thermal radiation conductivities separately and validated for aluminum foams, with the relative errors all less than 9.3%. The results show that the thermal conductivity of microporous metal materials mainly increased with an increase in temperature and volume-specific surface area but decreased with an increase in porosity. Analysis of the spectral radiation characteristics shows that the surface plasmon polariton resonance and the magnetic polariton resonance appearing at the gas–solid interface of the metal foam significantly increase the dissipation effect of the gas–solid interface, further reducing the metal foam’s heat transfer efficiency. This indicates the potential of this work for use in the design of specific microporous metal materials like energy management devices or heat transfer exchangers in the aerospace industry. Full article

In this study, the mechanical behavior of AA6082 foams with Weaire–Phelan (WP) cell structures under compressive loading was analyzed. The foams were produced using the lost-PLA replication method, a cost-effective and straightforward manufacturing technique. A total of six aluminum alloy samples were fabricated and subjected to compression tests to assess both their mechanical performance and the repeatability of the results. The produced foams demonstrated a well-defined morphology and high-quality surface finish, accurately replicating the geometries of the original PLA 3D-printed templates. The experimental density of the foams closely matched theoretical values, confirming the consistency of the replication process. The compressive stress–strain response of the Weaire–Phelan cell foams displayed an initial linear elastic region, followed by three distinct plateau regions with increasing stress levels. The final densification phase occurred when the structure could no longer accommodate further plastic deformation, leading to a sharp increase in the compression load. From the stress–strain data, the specific energy absorption of the foams was calculated. The average specific energy absorption was measured to be 4 J/cm³, with a standard deviation of 0.49 J/cm³ across the six tested samples. These results indicate reliable mechanical performance and reproducibility of the manufacturing process, making these foams suitable for applications requiring energy absorption and lightweight structural components. Full article

This study investigates the effects of microencapsulated phase-change materials (PCMs) on the density and thermal conductivity of rigid polyurethane (PU) foams, alongside their mechanical properties. Introducing PCMs into the foam composition results in increased viscosity, complicating the mixing of polyol and isocyanate components. This viscosity increase can slow the foaming rate and subsequently raise the foam density, as observed in both poured and sprayed rigid PU foams containing 5% and 10% PCM, leading to density increases of up to 9%. Despite these slight density changes, the thermal conductivity remained relatively stable due to the preservation of the foam’s closed-cell structure. The mechanical evaluation revealed a decrease in compressive and tensile strength with a higher PCM content attributed to defects arising in the foam’s cellular architecture. However, adhesive strength to aluminum substrates improved, particularly with 5% PCM, possibly due to a more consistent foam structure during the slower foaming process. Differential scanning calorimetry and a dynamic mechanical analysis indicated that the incorporation of PCM increased the glass transition temperature and affected the foam’s mechanical properties. This research underscores the potential of microencapsulated PCMs to enhance the functionality of rigid PU foams while needing careful consideration of their concentration to avoid compromising the structural integrity. Full article