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23 pages, 6936 KB  
Article
Innovative Calcium L-Lactate/PDMS-Based Composite Foams as Core for Sandwich Materials for the Thermopassive Regulation of Buildings
by Mario Ávila-Gutiérrez, Emanuele Previti, María Orfila, Ilenia Acquaro, Luigi Calabrese, Candida Milone and Emanuela Mastronardo
Energies 2025, 18(22), 5940; https://doi.org/10.3390/en18225940 - 12 Nov 2025
Abstract
The substantial impact of the heating and cooling of the construction sector on global warming necessitates a focus on effective thermal insulation solutions to mitigate high CO2 emissions. Thus, the development of efficient low-temperature thermochemical energy storage (TCES) materials offers a promising [...] Read more.
The substantial impact of the heating and cooling of the construction sector on global warming necessitates a focus on effective thermal insulation solutions to mitigate high CO2 emissions. Thus, the development of efficient low-temperature thermochemical energy storage (TCES) materials offers a promising approach to improve thermal regulation. This study explores the morphological, physicochemical, and thermal properties of a silicon composite (PDMS foam) filled with calcium L-lactate (CaL) (0–70 wt.%) for the core sandwich thermopassive regulation of buildings. Furthermore, CaL was incorporated into a composite form to improve the handling and processability of the final sandwich material, as CaL is available in powder form. The results demonstrated that the filler is entirely confined within the polymer matrix (FTIR and ESEM). Additionally, the CaL-PDMS composites showed fully reversible dehydration/hydration abilities over a water vapor hydration–dehydration cycle within a temperature range suitable for low-temperature TCES, with no performance loss due to salt confinement. Regarding the energy density, the 70 wt.% CaL-PDMS composites achieved a value up to 955 MJ/m3, making it an excellent candidate for low-temperature energy storage in the construction sector as compared to other similar composites. These findings contribute to the development of new thermopassive regulation techniques for building materials. Full article
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25 pages, 6452 KB  
Article
Design Optimization of Direct Combustion Process in Regenerative Thermal Oxidizer at Low Concentration of Coal Mine Gas Using Advanced Computational Models
by Jida Zhang, Dong Wang, Zhongkuan Wei, Sheng Li, Junhui Yang, Shiyang Jia, Zhongcheng Ma, Chengmin Chen and Krishnaswamy Nandakumar
Fluids 2025, 10(11), 293; https://doi.org/10.3390/fluids10110293 - 12 Nov 2025
Abstract
Coal mine gas with methane concentrations below 8% cannot sustain stable self-combustion, posing significant challenges for safe utilization and greenhouse gas mitigation. To address this limitation, we developed a large-scale industrial square rotary regenerative thermal oxidizer (RTO) capable of high-efficiency oxidation under ultra-low [...] Read more.
Coal mine gas with methane concentrations below 8% cannot sustain stable self-combustion, posing significant challenges for safe utilization and greenhouse gas mitigation. To address this limitation, we developed a large-scale industrial square rotary regenerative thermal oxidizer (RTO) capable of high-efficiency oxidation under ultra-low methane conditions. This work integrates multi-scale computational fluid dynamics (CFD) modeling, laboratory and pilot-scale physical experiments, and multi-physics coupled simulations to capture the complex interactions of fluid flow, species transport, and thermal response in regenerative ceramics. Compared with conventional circular or three-bed RTOs, the proposed square rotating design achieves 13% higher heat storage utilization, 15% smaller floor area, and enhanced spatial uniformity of the temperature field. Multi-scale simulations reveal that increasing methane molar fraction (CH4) from 0.012 to 0.017 raises the peak temperature from 1280 K to 1350 K, reduces the burnout height from 1.18 m to 1.15 m, and, under constant oxygen supply, extends the high-temperature zone to 1450 K with a stabilized burnout position at 1.06 ± 0.01 m. Incorporating a 15° conical expansion combustion chamber increases local turbulent kinetic energy by 17.4%, accelerating oxidation while maintaining methane removal rates > 98% within an optimized bottom blowing time of 30–90 s. This study not only provides validated design thresholds for ultra-low concentration methane oxidation—such as temperature windows, buffer zones, and switching cycles—but also offers an engineering framework for scaling RTO systems to industrial coal mine applications. This advances both energy recovery efficiency and methane emission control, demonstrating clear advantages over existing RTO configurations. Full article
(This article belongs to the Special Issue Turbulence and Combustion)
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17 pages, 3862 KB  
Article
Study of Heat Transfer Characteristics of PCMs Melting Inside Aluminum Foams
by Farjad Shahid Hasan Khan and Andrea Diani
Materials 2025, 18(22), 5130; https://doi.org/10.3390/ma18225130 - 11 Nov 2025
Abstract
This study examines the thermal performance of phase change material (PCM)–metal foam composites under base heating, a configuration more relevant to compact thermal energy storage (TES) and electronics-cooling applications, compared to the widely studied side-heated case. Metal foams with pore densities of 10, [...] Read more.
This study examines the thermal performance of phase change material (PCM)–metal foam composites under base heating, a configuration more relevant to compact thermal energy storage (TES) and electronics-cooling applications, compared to the widely studied side-heated case. Metal foams with pore densities of 10, 20, and 40 PPI, but identical porosity (volumetric value), were impregnated with two PCMs (paraffin RT55 and RT64HC) and tested under varying heat fluxes. The thermophysical properties of three PCMs (RT42, RT55, and RT64HC) were first characterized using the T-history method. A control case consisting of pure PCM revealed significant thermal lag between the heater and the PCM, whereas the inclusion of a metal foam improved temperature uniformity and accelerated melting. The results showed that PPI variation had little influence on melting completion time, while PCM type, viz., melting temperature, strongly affected duration. Heat flux was the dominant parameter: higher input power substantially reduced melting times, although diminishing returns were observed at elevated heat fluxes. An empirical correlation from the literature, originally developed for side-heated foams, was applied to the base-heated configuration and reproduced the main melting trends, though it consistently underpredicted completion times at high fluxes. Overall, embedding PCMs in metal foams enhances heat transfer, mitigates localized overheating, and enables more compact and efficient TES systems. Future work should focus on developing correlations for non-adiabatic cases, exploring advanced foam architecture, and scaling the approach for practical energy storage and cooling applications. Full article
(This article belongs to the Special Issue Advances in Porous Lightweight Materials and Lattice Structures)
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19 pages, 7784 KB  
Article
A 4-Year Field Experiment on an Urban Permeable Sidewalk on Its Runoff and Surface Temperature Performance
by Chi-Feng Chen, Cheng-Han Lin and Jen-Yang Lin
Urban Sci. 2025, 9(11), 473; https://doi.org/10.3390/urbansci9110473 - 11 Nov 2025
Abstract
Permeable pavement is commonly used for urban stormwater management and urban heat island mitigation. It has been proven that permeable pavement has such benefits; however, the clogged permeable pavement could lose its function, and there are relatively few studies on its long-term monitoring. [...] Read more.
Permeable pavement is commonly used for urban stormwater management and urban heat island mitigation. It has been proven that permeable pavement has such benefits; however, the clogged permeable pavement could lose its function, and there are relatively few studies on its long-term monitoring. This study monitored an in-use permeable sidewalk in central Taipei City, Taiwan, and presented its four-year performance. In the study area, the permeable sidewalk occupies nearly half of the drainage area. The onsite data showed that the average runoff reduction rate in the first year (2021) was 41.2% but decreased to 28.8% in the fourth year (2024). The differences in runoff reduction rate between different rainfall patterns are also discussed. If the permeable pavement is not cleaned, it might lose its permeability after 7 years. The results of the surface temperature monitoring show that the average surface temperature of permeable pavement is maintained at 28.8 °C over the four-year period, whereas the surface temperature of impermeable pavement increases annually. This finding verified that permeable pavement is helpful in stabilizing surface temperatures in urban areas, thereby combating the warming environment. In addition, Wet Bulb Globe Temperature (WBGT) was tested in this study. The results of WBGT showed that the WBGT above the permeable pavement is lower than that on impermeable pavements by about 1–2 °C from 12 p.m. to 16 p.m. This implies that permeable pavement may contribute to a comfortable thermal environment for the public. The results of this study provide crucial information for maintaining permeable pavement and enhancing its beneficial functions. Full article
(This article belongs to the Topic Sustainable Built Environment, 2nd Volume)
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20 pages, 4278 KB  
Article
City-Specific Drivers of Land Surface Temperature in Three Korean Megacities: XGBoost-SHAP and GWR Highlight Building Density
by Hogyeong Jeong, Yeeun Shin and Kyungjin An
Land 2025, 14(11), 2232; https://doi.org/10.3390/land14112232 - 11 Nov 2025
Abstract
Urban heat island (UHI), a significant environmental issue caused by urbanization, is a pressing challenge in modern society. To mitigate it, urban thermal policies have been implemented globally. However, despite differences in topographical and environmental characteristics between cities and within the same city, [...] Read more.
Urban heat island (UHI), a significant environmental issue caused by urbanization, is a pressing challenge in modern society. To mitigate it, urban thermal policies have been implemented globally. However, despite differences in topographical and environmental characteristics between cities and within the same city, these policies are largely uniform and fail to reflect contexts, creating notable drawbacks. This study analyzed three cities in Korea with high land surface temperatures (LSTs) to identify factors influencing LST by applying Extreme Gradient Boosting (XGBoost) with Shapley Additive explanations (SHAP) and Geographically Weighted Regression (GWR). Each variable was derived by calculating the average values from May to September 2020. LST was the dependent variable, and the independent variables were chosen based on previous studies: Normalized Difference Vegetation Index (NDVI), Normalized Difference Built-up Index (NDBI), ALBEDO, Population Density (POP_D), Digital Elevation Model (DEM), and SLOPE. XGBoost-SHAP was used to derive the relative importance of the variables, followed by GWR to assess spatial variation in effects. The results indicate that NDBI, reflecting building density, is the primary factor influencing the thermal environment in all three cities. However, the second most influential factor differed by city: SLOPE had a strong effect in Daegu, characterized by surrounding mountains; POP_D had greater influence in Incheon, where population distribution varies due to clustered islands; and DEM was more influential in Seoul, which contains a mix of plains, mountains, and river landscapes. Furthermore, while NDBI and ALBEDO consistently contributed to LST increases across all regions, the effects of the remaining variables were spatially heterogeneous. These findings highlight that urban areas are not homogeneous and that variations in land use, development patterns, and morphology significantly shape heat environments. Therefore, UHI mitigation strategies should prioritize improving urban form while incorporating localized planning tailored to each region’s physical and socio-environmental characteristics. The results can serve as a foundation for developing strategies and policy decisions to mitigate UHI effects. Full article
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26 pages, 3883 KB  
Article
A Study on a New Moss for Moss-Based Green Roofs in Roof Surface Temperature Mitigation and Carbon Capture
by Seungjae Kim, Trieu-Vuong Dinh, Byeong-Gyu Park, Sang-Woo Lee, Kweon Jung, Haegeun Chung and Jo-Chun Kim
Atmosphere 2025, 16(11), 1277; https://doi.org/10.3390/atmos16111277 - 11 Nov 2025
Abstract
Two prototype moss-based green roof systems were developed and evaluated using a newly cultivated strain of Racomitrium japonicum (Dozy & Molk.) to investigate their feasibility in mitigating rooftop heat and enhancing carbon sequestration under actual urban conditions. Flat and sloped-type green roof systems [...] Read more.
Two prototype moss-based green roof systems were developed and evaluated using a newly cultivated strain of Racomitrium japonicum (Dozy & Molk.) to investigate their feasibility in mitigating rooftop heat and enhancing carbon sequestration under actual urban conditions. Flat and sloped-type green roof systems (2 m × 2 m each) were developed and installed on a rooftop to investigate their performance in summer (from June to August 2025). The moss-based systems reduced rooftop surface temperature by an average of 6–10 °C during daytime and retained approximately 1.5–2.5 °C of heat at night, thereby contributing to cooling and thermal buffering. The moss layer effectively reduced solar radiation heating of the underlying soil. Despite exposure to intense sunlight and high summer temperatures, the moss maintained a consistent growth rate of 3–5 mm per month. The annual carbon sequestration capacity of the prototype system was estimated at approximately 0.3 kg C/m2.year, which is comparable to values reported for other vegetation types. These findings indicate that moss-based green roofs incorporating the newly cultivated moss strain have practical potential for urban heat island mitigation and carbon capture. Full article
(This article belongs to the Section Climatology)
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28 pages, 4842 KB  
Article
Cooling Effects of Roof Greenings at Residential Buildings—Consideration of a Hydraulic Connection to the Interior
by Andreas Ratka, Wolfgang Ernst and Matthias Wörlein
CivilEng 2025, 6(4), 60; https://doi.org/10.3390/civileng6040060 - 10 Nov 2025
Abstract
Within the scope of this article is the presentation of a modelling and measurement approach for the effects of roof greenings and the application of the approach to evaluate the influence of roof greenings upon the thermal conditions inside a typical residential building. [...] Read more.
Within the scope of this article is the presentation of a modelling and measurement approach for the effects of roof greenings and the application of the approach to evaluate the influence of roof greenings upon the thermal conditions inside a typical residential building. It is shown that overheating in summer can be reduced, and thermal comfort for inhabitants can be increased. The cooling is caused by the transpiration of plants and by the evaporation of water from the substrate. Other relevant physical effects are the shading of plants and the increase in the heat capacity of the building. In state-of-the-art buildings, a layer with a high insulating effect is incorporated into the envelope. This leads to the effect that a huge fraction of the cooling power is taken from the outside of the building and only a smaller part is taken from the inside. In order to mitigate this decoupling, a hydraulic connection between the greening and the interior of the building is introduced. To evaluate the effect of the inside cooling, the difference in the number of yearly hours with overheating in residential buildings is estimated. In addition, the reduction in energy demand for the climatisation of a typical residential building is calculated. The used methods are as follows: (1) Performance of laboratory and free field measurements. (2) Simulation of a typical residential building, using a validated approach. In summary, it can be said that green roofs, in particular with hydraulic connections, can significantly increase the interior thermal comfort and potentially reduce the energy required for air conditioning. Full article
(This article belongs to the Topic Energy Systems in Buildings and Occupant Comfort)
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35 pages, 109889 KB  
Article
Unregulated Vertical Urban Growth Alters Microclimate: Coupling Building-Scale Digital Surface Models with High-Resolution Microclimate Simulations
by Jonatas Goulart Marinho Falcão, Luiz Felipe de Almeida Furtado, Gisele Silva Barbosa and Luiz Carlos Teixeira Coelho
Smart Cities 2025, 8(6), 191; https://doi.org/10.3390/smartcities8060191 - 10 Nov 2025
Abstract
Rio de Janeiro’s favelas house over 20% of the city’s population in just 5% of its territory, with Rio das Pedras emerging as a critical case study: ranking as Brazil’s fifth most populous favela and its most vertically intensified. This study quantifies how [...] Read more.
Rio de Janeiro’s favelas house over 20% of the city’s population in just 5% of its territory, with Rio das Pedras emerging as a critical case study: ranking as Brazil’s fifth most populous favela and its most vertically intensified. This study quantifies how uncontrolled vertical growth in informal settlements disrupts microclimate dynamics, directly impacting thermal comfort. Using high-resolution geospatial analytics, we integrated digital surface models (DSMs) derived from LiDAR and photogrammetric data (2013, 2019, and 2024) with microclimatic simulations to assess urban morphology changes and their thermal effects. A spatiotemporal cadastral analysis tracked vertical expansion (new floors) and demolition patterns, while ENVI-met simulations mapped air temperature anomalies across decadal scenarios. Results reveal two key findings: (1) rapid, unregulated construction has significantly altered local airflow and surface energy balance, exacerbating the urban heat island (UHI) effect; (2) microclimatic simulations consistently recorded elevated temperatures, with the most pronounced impacts in densely built zones. These findings underscore the need for public policies to mitigate such negative effects observed in informal settlement areas. Full article
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15 pages, 543 KB  
Article
Factors Influencing Post-Transport Behavior, Physiological Responses, and Meat Quality Traits of Japanese Black Cattle
by Gianne Bianca Manalo, Jitsuo Mizowaki, Kazunori Mizukami, Makoto Iwamoto, Kenta Koike, Masayuki Nagase, Mitsushi Kobayashi and Shigeru Ninomiya
Animals 2025, 15(22), 3255; https://doi.org/10.3390/ani15223255 - 10 Nov 2025
Abstract
Adverse effects of transportation arise from the buildup of various stressors, which collectively compromise animal welfare. This study aimed to assess short-term behavioral responses, physiological stress, and meat quality as indicators of welfare in Japanese Black cattle on arrival at the slaughter facility. [...] Read more.
Adverse effects of transportation arise from the buildup of various stressors, which collectively compromise animal welfare. This study aimed to assess short-term behavioral responses, physiological stress, and meat quality as indicators of welfare in Japanese Black cattle on arrival at the slaughter facility. A total of 154 animals from different production farms were observed. Generalized linear mixed models were used, with fixed effects including animal type, weight, season, source, loading size, distance, transport experience, and their interaction with time periods. Significant post-transport behaviors and elevated cortisol concentration were observed, particularly in heifers, lighter animals, those transported in summer, from multiple farms, at high loading sizes, or without prior transport experience. Steers, heavier animals, and the same farm groups yielded higher carcass weights, while cattle transported under low loading size had improved marbling scores and a higher probability of achieving A5-grade carcasses. These findings suggest that management practices should focus on animals most susceptible to transport stress and strategies such as mitigating heat stress, transporting animals from the same production farm, and reducing loading sizes should be implemented to improve welfare and meat quality upon arrival. Full article
(This article belongs to the Section Cattle)
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25 pages, 4843 KB  
Article
Radiofrequency-Induced Thermal Modulation Reduces Senescence-Induced Collagen Fiber Degradation in Facial Ligaments of Animal Models
by Seyeon Oh, Hyoung Moon Kim, Gwahn Woo Cheon, Geebum Kim, Kuk Hui Son and Kyunghee Byun
Cells 2025, 14(22), 1757; https://doi.org/10.3390/cells14221757 - 10 Nov 2025
Abstract
Age-related changes in facial ligaments contribute to altered facial shape and soft tissue descent. Radiofrequency (RF) has been utilized for skin rejuvenation by promoting collagen fiber contraction and synthesis through increased expression of heat shock proteins (HSPs). The primary component of ligamentous collagen [...] Read more.
Age-related changes in facial ligaments contribute to altered facial shape and soft tissue descent. Radiofrequency (RF) has been utilized for skin rejuvenation by promoting collagen fiber contraction and synthesis through increased expression of heat shock proteins (HSPs). The primary component of ligamentous collagen fibers undergoes structural modifications with age, exhibiting increased fragmentation and a reduced collagen type I/III ratio. This study aimed to investigate whether RF irradiation alleviates senescence-related changes in facial ligaments through HSP70-mediated molecular remodeling using a UV-induced photoaging rat model. In senescent fibroblasts, RF enhanced the interaction between HSP70 and IκBα kinase (IKK)γ while reducing IκBα phosphorylation, which was associated with decreased nuclear factor-kappa B (NF-κB) activation. These RF-mediated changes were attenuated by an HSP70 inhibitor, suggesting that RF reduces NF-κB activity via HSP70 modulation. RF also suppressed expression levels of matrix metalloproteinases and SMAD7 in senescent fibroblasts. Consistent with in vitro findings, RF increased the interaction between HSP70 and IKKγ while decreasing IκBα phosphorylation and NF-κB activity in the UV-induced photoaging (senescent) facial ligaments of rat models. Furthermore, RF enhanced the collagen type I/III ratio and increased collagen fiber density within the ligaments. Scanning electron microscopy revealed that RF irradiation increased collagen fiber bundle diameter and enhanced the helical structure of those fibers. Overall, RF mitigates senescence-related changes in facial ligaments through HSP70 modulation. Considering that facial ligament laxity contributes to soft tissue descent, facial ligament-targeting approaches may promote a more youthful facial structure. RF demonstrates the possibility in reducing senescence-associated changes within facial ligaments. Full article
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21 pages, 8838 KB  
Article
Multi-Physics Coupling Mechanism of the Dynamic Sealing Performance of the O-Ring at the Neck of a Type IV Hydrogen Storage Cylinder Under Linearly Decreasing Filling Conditions
by Enhui Zhang, Xiaolong Shi, Wenchao Wang and Zhiqiang Wang
Symmetry 2025, 17(11), 1921; https://doi.org/10.3390/sym17111921 - 10 Nov 2025
Abstract
To address the degradation of O-ring material properties and reduced dynamic seal reliability caused by excessive hydrogen temperature rise in a Type IV hydrogen cylinder due to constant-flow filling strategies, this study systematically investigates the coupled mechanism by which a linearly decreasing flow [...] Read more.
To address the degradation of O-ring material properties and reduced dynamic seal reliability caused by excessive hydrogen temperature rise in a Type IV hydrogen cylinder due to constant-flow filling strategies, this study systematically investigates the coupled mechanism by which a linearly decreasing flow filling strategy maintains sealing performance through temperature rise regulation. By establishing a fluid–thermal–solid coupled mathematical model that comprehensively considers the Joule–Thomson effect, compression heat, gas swelling, and material nonlinear behavior, combined with numerical simulation methods, the sealing performance of the linear decreasing and constant-flow filling strategies was systematically compared across three key dimensions: temperature field distribution, evolution of seal ring material properties, and contact stress at the sealing interface. Results demonstrate that the linear decrease filling strategy effectively suppresses hydrogen temperature rise, achieving a 4.6% lower temperature increase at completion compared to the constant-flow strategy. Concurrently, this strategy mitigates thermally induced degradation of seal material properties, reducing contact stress fluctuations by 5% and significantly enhancing dynamic seal reliability. This research provides theoretical foundations and design support for optimizing filling protocols in high-performance hydrogen storage vessels. Full article
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15 pages, 6711 KB  
Article
Influence of Titanium Content on the Microstructure and Tensile Behavior of Cold-Spray Additively Manufactured Copper-Titanium Composites
by Jia Cheng, Jibo Huang, Haifan Li, Kejie Zhang, Tao Chen, Haiming Lan and Renzhong Huang
Materials 2025, 18(22), 5100; https://doi.org/10.3390/ma18225100 - 10 Nov 2025
Abstract
Cold-spray additive manufacturing (CSAM) is an emerging solid-state deposition technology that effectively mitigates common defects associated with conventional thermal processes, such as oxidation, phase transformation, and residual stresses. In this study, copper–titanium (Cu-Ti) composite coatings were fabricated via high-pressure CSAM using mixed powders [...] Read more.
Cold-spray additive manufacturing (CSAM) is an emerging solid-state deposition technology that effectively mitigates common defects associated with conventional thermal processes, such as oxidation, phase transformation, and residual stresses. In this study, copper–titanium (Cu-Ti) composite coatings were fabricated via high-pressure CSAM using mixed powders with Ti contents of 3, 6, and 10 wt.%. The influence of Ti content and post-heat treatment (350–400 °C) on the tensile properties of the composites was systematically investigated. The results indicate that the ultimate tensile strength (UTS) remained consistently within the range of 265–285 MPa under all conditions, showing only a mild positive correlation with Ti content. In contrast, ductility was significantly influenced by Ti addition, with elongation decreasing markedly as the Ti content increased. Notably, the composite with 3 wt.% Ti heat-treated at 400 °C exhibited a well-balanced combination of tensile strength (270 MPa) and ductility (20% elongation). These findings demonstrate that CSAM-fabricated Cu-Ti composites possess attractive mechanical properties, which can be tailored through Ti content and heat treatment. Full article
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18 pages, 4994 KB  
Article
Parameter Optimization for Dual-Mode Operation of Unitized Regenerative Fuel Cells via Steady-State Simulation
by Yuhang Hu, Yijia Li, Yuehua Li, Fang Yang, Bin Zhang and Dan Wang
Energies 2025, 18(22), 5899; https://doi.org/10.3390/en18225899 - 10 Nov 2025
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Abstract
Mathematical modeling of unitized regenerative fuel cells (URFCs) faces significant challenges in reconciling parameter conflicts between fuel cell (FC) and electrolysis cell (EC) modes. This study establishes a COMSOL-based multi-physics framework coupling water–gas–heat–electric transport for both operational states. The critical factors associated with [...] Read more.
Mathematical modeling of unitized regenerative fuel cells (URFCs) faces significant challenges in reconciling parameter conflicts between fuel cell (FC) and electrolysis cell (EC) modes. This study establishes a COMSOL-based multi-physics framework coupling water–gas–heat–electric transport for both operational states. The critical factors associated with the model were identified through a systematic sensitivity analysis of structural and operational parameters, including temperature, exchange current density, conductivity, porosity, and flow rates. FC modes exhibited strong sensitivity to exchange current density (27.8–40.5% performance variation) and conductivity of membrane (10.1–35.6%), while temperature degraded performance (−4.2% to −4.0%). Spatial analysis revealed temperature-induced membrane dehydration and accelerated gas depletion at electrodes, thus explaining the negative correlation. EC modes were dominantly governed by temperature (8.6–9.4%), exchange current density (13.0–16.4%), and conductivity (2.5–13.3%). Channel simulations revealed that elevated temperature contributed to enhanced liquid water fluidity, while high flow rates had a relatively limited effect on mitigating species concentration gradients. Parameter optimization guided by sensitivity thresholds (e.g., porosity > 0.4 in FC GDLs, conductivity > 222 S/m in EC modes) enabled dual-mode calibration. The model achieved <4% error in polarization curve validation under experimental conditions, demonstrating robust prediction of voltage–current dynamics. This work resolves key conflicts of URFC modeling through physics-informed parameterization to provide a foundation for efficient dual-mode system design. Full article
(This article belongs to the Section D: Energy Storage and Application)
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15 pages, 1897 KB  
Article
Enabling Industrial Re-Use of Large-Format Additive Manufacturing Molding and Tooling
by Matthew Korey, Amber M. Hubbard, Gregory Haye, Robert Bedsole, Zachary Skelton, Neeki Meshkat, Ashish L. S. Anilal, Kathryn Slavny, Katie Copenhaver, Tyler Corum, Don X. Bones, William M. Gramlich, Chad Duty and Soydan Ozcan
Polymers 2025, 17(22), 2981; https://doi.org/10.3390/polym17222981 - 10 Nov 2025
Viewed by 170
Abstract
Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use [...] Read more.
Large-format additive manufacturing (LFAM) is an enabling manufacturing technology capable of producing large parts with highly complex geometries for a wide variety of applications, including automotive, infrastructure/construction, and aerospace mold and tooling. In the past decade, the LFAM industry has seen widespread use of bio-based, glass, and/or carbon fiber reinforced thermoplastic composites which, when printed, serve as a lower-cost alternative to metallic parts. One of the highest-volume materials utilized by the industry is carbon fiber (CF)-filled polycarbonate (PC), which in out-of-autoclave applications can achieve comparable mechanical performance to metal at a significantly lower cost. Previous work has shown that if this material is recovered at various points throughout the manufacturing process for both the lab and pilot scale, it can be mechanically recycled with minimal impacts on the functional performance and printability of the material while significantly reducing the feedstock costs. End-of-life (EOL) CF-PC components were processed through industrial shredding, melt compounding, and LFAM equipment, followed by evaluation of the second-life material properties. Experimental assessments included quantitative analysis of fiber length attrition, polymer molecular weight degradation using gel permeation chromatography (GPC), density changes via pycnometry, thermal performance using dynamic mechanical analysis (DMA), and mechanical performance (tensile properties) in both the X- and Z-directions. Results demonstrated a 24.6% reduction in average fiber length compared to virgin prints, accompanied by a 21% decrease in X-direction tensile strength and a 39% reduction in tensile modulus. Despite these reductions, Z-direction tensile modulus improved by 4%, density increased by 6.8%, and heat deflection temperature (HDT) under high stress retained over 97% of its original value. These findings underscore the potential for integrating mechanically recycled CF-PC into industrial LFAM applications while highlighting the need for technological innovations to mitigate fiber degradation and enhance material performance for broader adoption. This critical step toward circular material practices in LFAM offers a pathway to reducing feedstock costs and environmental impact while maintaining functional performance in industrial applications. Full article
(This article belongs to the Special Issue Additive Manufacturing of Polymer Based Materials)
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20 pages, 11450 KB  
Article
A Novel Simulation Method for the Spatiotemporal Variation in Relative Humidity in Early Age of Polypropylene Fibers Reinforced Concrete
by Zhaohui Chen, Linsong Shen, Wangdui Gerong, Fengyou He, Hongyu Zhao and Junbo Sun
Buildings 2025, 15(22), 4032; https://doi.org/10.3390/buildings15224032 - 8 Nov 2025
Viewed by 108
Abstract
Early-age cracking remains a major durability challenge for concrete. It is primarily caused by internal restraint stresses induced by humidity and temperature gradients during hydration. Conventional approaches often fail to capture the coupled and non-uniform nature of heat and moisture transport, limiting their [...] Read more.
Early-age cracking remains a major durability challenge for concrete. It is primarily caused by internal restraint stresses induced by humidity and temperature gradients during hydration. Conventional approaches often fail to capture the coupled and non-uniform nature of heat and moisture transport, limiting their ability to predict cracking risk and evaluate mitigation strategies. To address this limitation, we characterize the spatiotemporal evolution of internal humidity and temperature using a spatial coefficient of variation. From a numerical standpoint, the influence of polypropylene fibers (PPFs) on internal relative humidity is elucidated by adopting an unconditionally stable backward-Euler finite-difference scheme to resolve multiple coupled physicochemical processes—hydration, heat release, self-desiccation, heat and moisture diffusion to the environment—and their mutual interactions. Furthermore, a one-dimensional homogeneous random-field model is proposed to quantify the spatial non-uniformity of humidity in PPF concrete. On this basis, the effects of polypropylene fibers (PPFs) in mitigating internal humidity is quantitatively revealed. Good agreement is achieved between simulations and tests, with standard deviations of 0.0119 for normal concrete and 0.0041 for PPF concrete, thereby validating the model’s predictive capability for the spatiotemporal distribution of internal relative humidity (RH) in PPF concrete. According to the numerical analysis, owing to the moisture-sorption characteristics of PPFs, at a depth of 25 mm, the internal RH in PPF concrete has decreased by 16% at 28 days, whereas normal concrete exhibits a 28% decrease. With increasing depth, the RH reduction at 28 days is approximately 13% for both PPF concrete and plain concrete, and the time-dependent evolution of RH in PPF concrete is broadly similar to that of normal concrete. Furthermore, the mitigating influence of PPFs decreases with hydration age and distance from the surface, reflecting the gradual decline of diffusion heterogeneity over time and depth. These findings provide new numerical evidence for the effectiveness of PPFs in reducing the early-age cracking risk in concrete. Full article
(This article belongs to the Section Building Materials, and Repair & Renovation)
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