Search Results (306)

Due to the limitations of high speed and short time in plasma-spraying experiments, this study established a simulation model of Y₂O₃ multi-particle deposition to discuss the influence of laser loading on coating-deposition behavior and performance. According to the simulation results, the temperature of coating particles under laser loading displays a gradient distribution, with the surface having the highest temperature. The particles deposit on the substrate to form uniform pits of a certain depth. Plastic deformation causes maximum stress to occur at the edges of the pits and maximum strain to occur on the sidewall of the pits. The deposition region had both compressive and tensile stresses, and laser loading greatly reduced the tensile stresses’ magnitude while having less of an impact on the particle strains. Laser assistance promotes further melting of particles, reduces coating thickness, lowers coating porosity to 3.94%, increases hardness to 488 MPa, reduces maximum pore size from 68 µm to 32 µm, and causes particle sputtering to gradually evolve from being disc-shaped to being finger-shaped, creating cavities at the coating edges. The comparison between the surface morphology and the cross-section pores of the experimentally prepared coating verified the rationality and viability of the simulation work. Full article

This work expands the processing window of the laser powder bed fusion (LPBF) processing of WE43 magnesium alloy by evaluating laser powers and scanning speeds up to 400 W and 1200 mm/s, and their effect on densification, microstructure, and electrochemical performance. Relative density of 99.9% was achieved for 300 W and 800 mm/s, showing that the use of high laser power is not a limitation for the manufacturing of Mg alloys, as has been usually considered. Microstructural characterisation revealed refined grains and the presence of RE-rich intermetallic particles, while microhardness increased with height due to thermal gradients. Electrochemical testing in 3.5 wt.% NaCl solution, a more aggressive media than those already used, indicated that the corrosion of samples with density values below 99% is conditioned by the porosity; however, above this value, in the WE43, the corrosion evolution is more related to the microstructure of the samples, according to electrochemical evaluation. This study demonstrates the viability of high-energy LPBF processing for WE43, offering optimised mechanical and corrosion properties for biomedical and structural applications. Full article

Real-time quality monitoring using molten pool images is a critical focus in researching high-quality, intelligent automated welding. To address interference problems in molten pool images under complex welding scenarios (e.g., reflected laser spots from spatter misclassified as porosity defects) and the limited interpretability of deep learning models, this paper proposes a multi-granularity spatiotemporal representation learning algorithm based on the hybrid enhancement of handcrafted and deep learning features. A MobileNetV2 backbone network integrated with a Temporal Shift Module (TSM) is designed to progressively capture the short-term dynamic features of the molten pool and integrate temporal information across both low-level and high-level features. A multi-granularity attention-based feature aggregation module is developed to select key interference-free frames using cross-frame attention, generate multi-granularity features via grouped pooling, and apply the Convolutional Block Attention Module (CBAM) at each granularity level. Finally, these multi-granularity spatiotemporal features are adaptively fused. Meanwhile, an independent branch utilizes the Histogram of Oriented Gradient (HOG) and Scale-Invariant Feature Transform (SIFT) features to extract long-term spatial structural information from historical edge images, enhancing the model’s interpretability. The proposed method achieves an accuracy of 99.187% on a self-constructed dataset. Additionally, it attains a real-time inference speed of 20.983 ms per sample on a hardware platform equipped with an Intel i9-12900H CPU and an RTX 3060 GPU, thus effectively balancing accuracy, speed, and interpretability. Full article

This study investigates the influence of process parameters on the fabrication and mechanical performance of Scalmalloy^® lattice structures produced via laser powder bed fusion (PBF-LB) and their mechanical responses at different cell size. A full-factorial design of experiments was employed to evaluate the effect of scan speed, hatch distance, and downskin power on internal porosity and dimensional accuracy. Regression models revealed significant relationships, with optimised parameters identified at a scan speed of 700 mm/s, hatch distance of 0.13 mm, and downskin power of 80 W. Mechanical characterisation through tensile tests of bulk samples and compression tests of lattice structures highlighted the strengthening effects of the heat treatment. Experimental data on quasi-elastic gradient and yield strength were compared to predictions from the Ashby–Gibson model, revealing a partial agreement but noticeable deviations attributed to cell geometry and manufacturing defects. The scaling laws observed differed from the classical model, particularly in the yield strength exponent, indicating the need for empirical models tailored to metallic lattices. This work provides key insights into the optimisation of PBF-LB parameters for Scalmalloy^® and underlines the complex interplay between process parameters, structural design, and mechanical behaviour. Full article

This paper presents the results of a comprehensive study of the structure, phase composition, thermal corrosion, and tribological properties of multilayer gradient coatings based on YSZ/NiCrAlY obtained using detonation spraying. X-ray phase analysis showed that the coatings consist entirely of metastable tetragonal zirconium dioxide (t’-ZrO₂) phase stabilized by high temperature and rapid cooling during spraying. SEM analysis confirmed the multilayer gradient phase distribution and high density of the structure. Wear resistance, optical profilometry, wear quantification, and coefficient of friction measurements were used to evaluate the operational stability. The results confirm that the structural parameters of the coating, such as porosity and phase gradient, play a key role in improving its resistance to thermal corrosion and CMAS melt, which makes such coatings promising for use in high-temperature applications. It is shown that a dense and thick coating effectively prevents the penetration of aggressive media, providing a high barrier effect and minimal structural damage. Tribological tests in the temperature range from 21 °C to 650 °C revealed that the best characteristics are observed at 550 °C: minimum coefficient of friction (0.63) and high stability in the stage of stable wear. At room temperature and at 650 °C, there is an increase in wear due to the absence or destabilization of the protective layer. Full article

This paper presents three realizations of a complete set with a horn antenna and a focusing Gradient Index (GRIN) lens in X-band. The set was specifically designed for advancing additive manufacturing (AM) of polymers with different materials and techniques. The set has three constituent parts: a horn antenna, a support, and a lens. The horn antenna is the active element and must be electrically conductive; it was manufactured with Rigid10K acrylic resin and subsequently metallized using an electroless process. The support needed to be light, robust, and electrically transparent, so that Polyamide 11 (PA11) was used. The lens realization was intended for a dielectric material whose permittivity varies with its density. Therefore, the dielectric permittivity and loss tangent of different polymeric materials used in AM at 2.45, 6.25, and 24.5 GHz were measured. In addition, stochastic and gyroid mesh structures have been studied. These structures allow for printing a volume that presents porosity, enabling control over material density. Measuring the dielectric characteristics of each material with each density enables the establishment of graphs that relate them. The sets were then manufactured, and their frequency response and radiation diagram were measured, showing excellent results when compared with the literature. Full article

As the demand for advanced cooling solutions increases with the rise in artificial intelligence and high-performance computing, efficient thermal management becomes critical, particularly for data centers and electronic systems. Triply Periodic Minimal Surface (TPMS) heat sinks have shown superior thermal performance over conventional designs by enhancing heat transfer efficiency. In this study, a novel Fischer–Koch-S (FKS) TPMS heat sink was experimentally tested with four porosity configurations, 0.6 (identified as P6), 0.7 (identified as P7), 0.8 (identified as P8), and a gradient porosity ranging from 0.6 to 0.8 (identified as P678) along the flow direction, under a mass flow rate range of 0.012 to 0.019 kg/s. Key thermal parameters including surface temperature, thermal resistance, heat transfer coefficient, and Nusselt number were analyzed and compared to the conventional straight-channel heat sink (SCHS) using numerical modeling. Among all configurations, the P6 design demonstrated the best performance, with surface temperature differences ranging from 13.1 to 14.2 °C at 0.019 kg/s and a 54.46% higher heat transfer coefficient compared to the P8 design at the lowest mass flow rate. Thermal resistance decreased consistently with an increasing mass flow rate, with P6 achieving a 31.8% reduction compared to P8 at 0.019 kg/s. The P678 gradient design offered improved temperature uniformity and performance at higher mass flow rates. Nusselt number ratios confirmed that low-porosity and gradient TPMS designs outperform the SCHS, with performance advantages increasing as the mass flow rate rises. To further enhance the experimental process, a deep learning model based on a Temporal Convolutional Network (TCN) was developed to predict steady-state surface temperatures using early-stage time-series data, to reduce test time and enable efficient validation. Full article

This study presents a simulation modeling of the gravity filling of a sand casting mold with gray cast iron EN-GJL-250. An analysis of the fluid flow, the nature of the filling of the casting mold, and the possibility of forming defects, such as voids and porosity due to metal shrinkage during the crystallization process, was performed. The simulation was performed using specialized software for simulating metal casting processes. The software allows the modeling of fluid dynamics and thermal conditions during the filling of the casting mold. The results obtained show the influence of the design of the sprue system, pouring temperature, and casting geometry on the movement of the fluid flow and the crystallization of the metal. The simulation also allows the visualization of turbulence and temperature gradients, helping to localize areas prone to defects. The results of this study could improve the quality of the specific casting and aid in selecting appropriate technology for the casting of a small series of high-quality castings. Full article

This study investigates the long-term durability and crystallization-induced degradation mechanisms of alkali-activated slag (AAS) mortars with varying water-to-binder ratios (w/b, 0.4, 0.45, 0.5) under semi-immersion in 5 wt.% sodium sulfate solution. Through 360 d of exposure, the evolution of physical–mechanical properties (mass change, open porosity, compressive/flexural strength) and ion migration patterns (SO₄²⁻, Na⁺, Ca²⁺) were analyzed to unravel the interplay between pore structure, ion transport, and crystallization-induced deterioration. Results demonstrated that higher w/b ratios exacerbated surface crystallization and spalling due to accelerated ion transport and pore coarsening. Early-stage strength gains (up to 25.15% at 120–180 d) stemmed from pore refinement via sulfate deposition and continued slag hydration. However, prolonged exposure triggered microstructural degradation, with open porosity increasing by 58.9% and strength declining by 30.6% at 360 d for a w/b of 0.5 compared to a w/b of 0.4. This was driven by crystallization pressure and the decalcification of hydration products. Ion migration analysis revealed SO₄²⁻ enrichment in evaporation area and outward Na⁺ diffusion, establishing supersaturation gradients that aligned with crystallization damage progression. These findings provide critical insights for optimizing AAS mortar formulations to mitigate sulfate crystallization risks in semi-immersed environments. Full article

Advancements in load-bearing tissue repair increasingly demand biomaterials that not only support structural integrity but also interact dynamically with the physiological environment. This review examines the latest progress in smart biomaterials designed for skeletal reconstruction, with emphasis on mechanoresponsive scaffolds, bioactive composites, and integrated microsensors for real-time monitoring. We explore material formulations that enhance osseointegration, resist micromotion-induced loosening, and modulate inflammatory responses at the bone–implant interface. Additionally, we assess novel fabrication methods—such as additive manufacturing and gradient-based material deposition—for tailoring stiffness, porosity, and degradation profiles to match host biomechanics. Special attention is given to sensor-augmented platforms capable of detecting mechanical strain, biofilm formation, and early-stage implant failure. Together, these technologies promise a new class of bioresponsive, diagnostic-capable constructs that extend beyond static support to become active agents in regenerative healing and post-operative monitoring. This multidisciplinary review integrates insights from materials science, mechanobiology, and device engineering to inform the future of implantable systems in skeletal tissue repair. Full article

In this work, micro-arc oxidation (MAO) under constant- and gradient-current modes was used to modify the surface of 6061 aluminum alloy. A black coating was created in situ on the alloy surface by controlling the spark discharge parameters during MAO. Using an electrochemical workstation (Metrohm Autolab, PGSTAT302 N, Herisau, Switzerland), energy-dispersive spectroscopy (EDS, JEOL, JSM-IT500A, Tokyo Metropolis, Japan), and scanning electron microscopy (SEM, JEOL, JSM-7900F, Tokyo Metropolis, Japan), the effects of the current output modes on the coating growth rate, energy consumption, colorimetric parameters (L*, a*, b*), microstructure, and corrosion resistance were methodically examined. The findings showed that the gradient-current mode (6 → 4 → 2 A/dm²) greatly lowered the micropore size (from 3.89 μm to 1.52 μm) and improved the coating compactness (porosity dropped by 40%), and all coatings satisfied the necessary blackness criterion (L* < 30). Additionally, this mode achieved excellent corrosion resistance, as demonstrated by a one-order-of-magnitude reduction in the corrosion current density (2.55 × 10⁻⁸ A/cm² vs. 2.34 × 10⁻⁷ A/cm²), while minimizing the energy consumption (2.37 kW·h/m²·μm vs. 3.45 kW·h/m²·μm for constant current). Full article

This study systematically analyzes reservoir formation mechanisms under deep burial conditions, integrating macroscopic observations from representative ultra-deep clastic reservoirs in four major sedimentary basins in central and western China. Developing effective clastic reservoirs in ultra-deep strata (6000–8000 m) remains a critical yet debated topic in petroleum geology. Recent advances in exploration techniques and geological understanding have challenged conventional views, confirming the presence of viable clastic reservoirs at such depths. Findings reveal that reservoir quality in ultra-deep strata is preserved and enhanced through the interplay of sedimentary, diagenetic, and tectonic processes. Key controlling factors include (1) high-energy depositional environments promoting primary porosity development, (2) proximity to hydrocarbon source rocks enabling multi-phase hydrocarbon charging, (3) overpressure and low geothermal gradients reducing cementation and compaction, and (4) late-stage tectonic fracturing that significantly improves permeability. Additionally, dissolution porosity and fracture networks formed during diagenetic and tectonic evolution collectively enhance reservoir potential. The identification of favorable reservoir zones under the sedimentation–diagenesis-tectonics model provides critical insights for future hydrocarbon exploration in ultra-deep clastic sequences. Full article

Pyrolysis is an important methodology for achieving efficient and clean utilization of coal. Lump coal pyrolysis demonstrates distinct advantages over pulverized coal processing, particularly in enhanced gas yield and superior coke quality. As a critical parameter in lump coal pyrolysis, particle size significantly influences heat transfer and mass transfer during pyrolysis, yet its governing mechanisms remain insufficiently explored. This research systematically investigates pyrolysis characteristics of the low-rank coal from Ordos, Inner Mongolia, across graded particle sizes (2–5 mm, 5–10 mm, 10–20 mm, and 20–30 mm) through pyrolysis experiments. Real-time central temperature monitoring of coal bed coupled with advanced characterization techniques—including X-ray diffraction (XRD), Raman spectroscopy, Brunauer–Emmett–Teller (BET) analysis, scanning electron microscopy (SEM), gas chromatography (GC), and GC–mass spectrometry (GC-MS)—reveals particle-size-dependent pyrolysis mechanisms. Key findings demonstrate that the larger particles enhance bed-scale convective heat transfer, accelerating temperature propagation from reactor walls to the coal center. However, excessive sizes cause significant intra-particle thermal gradients, impeding core pyrolysis. The 10–20 mm group emerges as optimal—balancing these effects to achieve uniform thermal attainment, evidenced by 20.99 vol% peak hydrogen yield and maximum char graphitization. Tar yield first demonstrates a tendency to rise and then decline, peaking at 14.66 wt.% for 5–10 mm particles. This behavior reflects competing mechanisms: enlarging particle size can improve bed permeability (reducing tar residence time and secondary reactions), but it can also inhibit volatile release and intensify thermal cracking of tar in oversized coal blocks. The BET analysis result reveals elevated specific surface area and pore volume with increasing particle size, except for the 10–20 mm group, showing abrupt porosity reduction—attributed to pore collapse caused by intense polycondensation reactions. Contrasting previous studies predominantly focused on less than 2 mm pulverized coal, this research selects large-size (from 2 mm to 30 mm) lump coal to clarify the effect of particle size on coal pyrolysis, providing critical guidance for industrial-scale lump coal pyrolysis optimization. Full article

This study investigates the potential of low-cost, naturally available porous materials (PoMs), gravel, marble, flint, and sandstone, as thermal management for photovoltaic (PV) panels. Experiments were conducted in a controlled environment at a solar energy laboratory, where variables such as solar irradiance, ambient temperature, air velocity, and water flow were carefully regulated. A solar simulator delivering a constant irradiance of 1250 W/m² was used to replicate solar conditions throughout each 3 h trial. The test setup involved polycrystalline PV panels (30 W rated) fitted with cooling channels filled with PoMs of varying porosities (0.35–0.48), evaluated across water flow rates ranging from 1 to 4 L/min. Experimental results showed that PoM cooling significantly outperformed both water-only and passive cooling. Among all the materials tested, sandstone with a porosity of 0.35 and a flow rate of 2.0 L/min demonstrated the highest cooling performance, reducing the panel surface temperature by 58.08% (from 87.7 °C to 36.77 °C), enhancing electrical efficiency by 57.87% (from 4.13% to 6.52%), and increasing power output by 57.81% (from 12.42 W to 19.6 W) compared to the uncooled panel. The enhanced heat transfer (HT) was attributed to improved conductive and convective interactions facilitated by lower porosity and optimal fluid velocity. Furthermore, the cooling system improved I–V characteristics by stabilizing short-circuit current and enhancing open-circuit voltage. Comparative analysis revealed material-dependent efficacy—sandstone > flint > marble > gravel—attributed to thermal conductivity gradients (sandstone: 5 W/m·K vs. gravel: 1.19 W/m·K). The configuration with 0.35 porosity and a 2.0 L/min flow rate proved to be the most effective, offering an optimal balance between thermal performance and resource usage, with an 8–10% efficiency gain over standard water cooling. This study highlights 2.0 L/min as the ideal flow rate, as higher rates lead to increased water usage without significant cooling improvements. Additionally, lower porosity (0.35) enhances convective heat transfer, contributing to improved thermal performance while maintaining energy efficiency. Full article

The non-Darcy seepage characteristics of broken rock mass is important for analyzing the seepage and stability of rock and soil mass. At present, the research on non-Darcy seepage models considering hydraulic conditions and medium void structures has considerable room for improvement. In this study, non-Darcy seepage tests were conducted on broken rock mass under the influence of different hydraulic pressures, sample gradations, and porosities. The influence of sample gradation and porosity on the linear and nonlinear term coefficients of Forchheimer’s law, the critical criterion of non-Darcy seepage, and the seepage flow regime was clarified. The influence of hydraulic gradient on the value of traditional hydraulic conductivity was revealed. A non-Darcy equivalent hydraulic conductivity, which changed with pressure gradient, was defined, then Forchheimer’s law and Darcy’s law were modified. Results showed that the relationship between pressure gradient and flow rate highly obeyed Forchheimer’s law. The minimum value of Forchheimer number was 9.4 times the critical value. Owing to the influence of inertial force and variable seepage channels, the linear and nonlinear term coefficients of Forchheimer’s law decreased while the Forchheimer number increased with the increase of pressure gradient, sample gradation, and porosity. With high hydraulic gradient, the non-Darcy equivalent hydraulic conductivity decreased nonlinearly, causing Darcy’s law to overestimate the seepage flow in this study by 2.47–13.40 times. Finally, Forchheimer’s law and Darcy’s law were modified to consider the influence of hydraulic gradient, sample gradation, and porosity. The modified Darcy’s law does not require the determination of the seepage flow regime and can accommodate the mutual transformation and coexistence between Darcy and non-Darcy seepage. Full article