Search Results (90)

Weld quality plays a critical role in ensuring the structural integrity and long-term performance of critical piping systems used across petrochemical, oil and gas, marine, and healthcare sectors. Although gas tungsten arc welding, shielded metal arc welding, and gas metal arc welding are widely applied in pipe fabrication, existing studies often examine these processes independently and provide limited insight into the comparative influence of process parameters on weld morphology, microstructure, and mechanical performance. This review consolidates findings from recent research to evaluate how welding current, arc voltage, heat input, travel speed, shielding gas composition, and joint preparation interact to affect weld bead geometry, heat-affected zone evolution, tensile properties, hardness, and overall weld integrity in piping systems. The primary objective of this review is to critically compare fusion welding process parameter optimization strategies and to identify unresolved challenges in achieving controlled weld root geometry for high-integrity piping applications. Recent industrial failure investigations, particularly in ethylene oxide service piping, further underscore the importance of weld root control. Several documented leak events were traced to excessive root protrusion and inadequate interpretation of non-destructive testing data, where elevated reinforcement disrupted internal flow and promoted turbulence-induced degradation. These recurring issues highlight a broader industry challenge and strengthen the need for improved root-height optimization in critical piping applications. A significant research gap is identified in the limited optimization of weld root reinforcement, particularly in gas tungsten arc welding processes, where most reported studies document root heights exceeding 3 mm. Achieving a root height below 2 mm, which is an important requirement for reducing flow-induced turbulence and meeting industry acceptance criteria, remains insufficiently addressed. This review highlights this gap and outlines future research opportunities involving advanced parameter optimization and improved process monitoring techniques. The synthesis presented here provides a comprehensive reference for enhancing weld quality in critical piping systems and establishes a pathway for next-generation welding strategies aimed at producing high-integrity weld joints compliant with the American Society of Mechanical Engineers B31.3 requirements. Full article

The emulsification of a molten fusible metal alloy in a liquid epoxy matrix with its subsequent curing is a novel way to create a highly concentrated phase-change material. However, numerous challenges have arisen. The high interfacial tension between the molten metal and epoxy resin and the difference in their viscosities hinder the stretching and breaking of metal droplets during stirring. Further, the high density of metal droplets and lack of suitable surfactants lead to their rapid coalescence and sedimentation in the non-cross-linked resin. Finally, the high differences in the thermal expansion coefficients of the metal alloy and cross-linked epoxy polymer may cause cracking of the resulting phase-change material. This work overcomes the above problems by using nanosilica-induced physical gelation to thicken the epoxy medium containing Wood’s metal, stabilize their interfacial boundary, and immobilize the molten metal droplets through the creation of a gel-like network with a yield stress. In turn, the yield stress and the subsequent low-temperature curing with diethylenetriamine prevent delamination and cracking, while the transformation of the epoxy resin as a physical gel into a cross-linked polymer gel ensures form stability. The stabilization mechanism is shown to combine Pickering-like interfacial anchoring of hydrophilic silica at the metal/epoxy boundary with bulk gelation of the epoxy phase, enabling high metal loadings. As a result, epoxy shape-stable phase-change materials containing up to 80 wt% of Wood’s metal were produced. Wood’s metal forms fine dispersed droplets in epoxy medium with an average size of 2–5 µm, which can store thermal energy with an efficiency of up to 120.8 J/cm³. Wood’s metal plasticizes the epoxy matrix and decreases its glass transition temperature because of interactions with the epoxy resin and its hardener. However, the reinforcing effect of the metal particles compensates for this adverse effect, increasing Young’s modulus of the cured phase-change system up to 825 MPa. These form-stable, high-energy-density composites are promising for thermal energy storage in building envelopes, radiation-protective shielding, or industrial heat management systems where leakage-free operation and mechanical integrity are critical. Full article

Overhead transmission lines are critical carriers for power delivery, directly influencing the security of the power system. In high-altitude areas, special environmental conditions such as low air pressure and intense solar radiation significantly change the heat absorption and dissipation characteristics of conductors. Therefore, it is necessary to correct the overhead conductors’ ampacity in such areas to ensure safe operation. However, the ampacity calculation method and high-altitude ampacity correction coefficients proposed in existing standards have significant limitations, and there are also large errors in the calculation results. Therefore, based on the system of partial differential equations proposed in the “Guidelines for Calculating the Current-Carrying Capacity of Transmission Conductors at High Altitudes” and the suggestions for high-altitude meteorological parameter modifications from existing standards, this paper establishes a three-dimensional finite element model to study the ampacity calculation method for overhead conductors in high-altitude areas. The results show that a significant thermal shielding effect exists among bundled conductors, and meteorological condition variations significantly influence the temperature distribution of the conductors and their surrounding space. At altitudes of 4000~5000 m, the altitude correction coefficient for both twin-bundle and quad-bundle conductors is −0.06 A∙m⁻¹ under specific conservative conditions. Full article

Rising summer temperatures are increasing the demand for shading solutions and indoor cooling technologies. Given the substantial surface area of gable roofs, their effective shading plays a significant role in thermal management. While modern buildings often feature heat-insulated roofs equipped with photovoltaic panels or infrared-reflective coatings, such measures are frequently unsuitable for traditional, particularly heritage-protected structures. For this specific category of buildings, ventilated infrared (IR) shielding elements installed on the underside of rafters offer a promising approach to reduce surface temperatures and limit radiative heat transfer to attics or upper living spaces. This study evaluates performance-optimized IR shading systems for heritage roofs, focusing on material selection and emissivity effects. Results indicate that ventilated OSB panels with low-emissivity coatings achieve up to 53% thermal load reduction compared to unshielded conditions. Ventilation of the rafter fields emerges as the critical factor for the functional performance of such IR shading elements. Full article

The fluorescent dyes 9-aminoacridine (9-AA) and acridine orange (AO) are known mutagens that induce frameshift mutations in cells by intercalating between DNA bases. However, these chemicals can also affect other cellular components, such as proteins. In this study, we tested the ability of 9-AA and AO to induce heat shock in bacteria using the following methods: lux-biosensors based on Escherichia coli cells with the luxCDABE genes transcriptionally fused to heat shock-specific inducible promoters, RT-qPCR, and nanoDSF. We demonstrated that acridine dyes not only induce mutagenesis but also cause heat shock in bacterial cells. AO significantly reduced the melting temperature of proteins and strongly activated σ^E- and σ³²-dependent promoters, but not PluxC, which is activated by elevated temperatures via a different mechanism. In contrast, 9-AA weakly denatured the proteins and induced the σ^E-dependent promoter; however, it activated the σ³²-dependent promoters and PluxC, supporting the hypothesis that the σ³² heat shock response system is activated via hairpin RNA denaturation by 9-AA. The study on the application of lux-biosensors was hampered by the high general toxicity and luminescence shielding effect of AO, and RT-qPCR’s sensitivity was insufficient for detection of the response to 9-AA. Thus, methodologically, it is justified to conduct a comprehensive study of substances that cause heat shock or affect bioluminescence by both RT-qPCR and lux-biosensors. Full article

The design of high-precision total temperature probes for aero-engines is constrained by the massive computational cost of high-fidelity simulations. This paper overcomes this barrier by introducing a surrogate model-based optimization framework for a dual-shield probe. A computationally efficient data-driven framework is established, merging conjugate-heat-transfer Computational Fluid Dynamics (CFDs), a Support Vector Regression (SVR) model, and a Genetic Algorithm (GA), which collectively replace the traditional costly design loop. The surrogate model’s exceptional predictive fidelity is confirmed, and this approach obtains improvement in measurement accuracy, successfully reducing the temperature deviation and meeting the stringent requirement. Finally, the demonstrated framework is geometry-agnostic, establishing a generalizable and cost-effective strategy for the rapid design of high-performance thermometric components in gas turbine systems. Full article

Aluminium plays a key role in developing modern energy technologies, from electrical systems to high-energy materials, providing a combination of functionality, economy, and reliability, but the oxide film on its particles reduces the effective reactivity. This work aims to increase the reactivity of aluminum powder by mechanochemical treatment using modifiers. The materials used were aluminum powder of the ASD brand and graphite of the GL-1 brand. The experiment subjected aluminum powder to mechanochemical treatment (MCT) with different graphite contents. It was shown that MCT significantly increases active aluminum content in the powder due to partial destruction of the oxide film on its surface. In addition, morphological analyses confirm the destruction of the oxide, the graphite coating, and the appearance of lamellar structures measuring 0–58 µm. Thermal analysis shows that the primary exothermic peak shifts from 662.6 °C to 653.9 °C for Al + 10% graphite, and the heat released increases by 27%, which means lower activation energy and more complete oxidation. However, at 20% graphite, the thermal gain decreases, since carbon shields the metal areas. Thus, the optimal content is 10% graphite: at this ratio, the best thermochemical behavior of the powder is achieved. The data obtained indicate that the MCT of aluminum powder with graphite effectively increases its reactivity. The resulting aluminum powders with modified particle surfaces facilitate the development of new technologies for the creation of various high-energy solid propellant systems. For rocket engines, preference is given to solid rocket propellant (SRP), which is a mixture of substances (components) capable of burning in the absence of air, producing a large amount of gaseous working fluid heated to a high temperature, providing thrust. Full article

Non-equipotentiality in a grounding device can cause thermal heating in the screens of control cables that are grounded on both sides of high-voltage substations. At the same time, there is currently no approach for assessing the thermal endurance of cable screens that takes into account the configuration of the grounding device, the properties of the ground, and the connection. This paper presents a methodology for the experimental and computational determination of the thermal endurance of control cable shields in secondary circuits of 220–500 kV substations under short-circuit (SC) conditions. The method is based on full-scale imitation experiments using a sinusoidal current generator and verified numerical modeling in the ORU-M software. The potential and current density distribution in the cable shields were determined. The results showed that current densities in some circuits exceed permissible levels, confirming the risk of thermal damage. It was found that reconfiguring the grounding system—by densifying ground electrodes and increasing connections between grounding points—can reduce current density to acceptable values. The presented method allows for reliable assessment of the thermal endurance of cable shields without decommissioning the substation, making it suitable for the design and modernization of high-voltage facilities. Full article

The thermal insulation performance of liquid hydrogen (LH₂) storage tanks is critical for long-distance transportation. The active cooled shield (ACS) technologies, such as the liquid nitrogen cooled shield (LNCS) and the vapor hydrogen cooled shield (VHVCS) are important thermal insulation methods. Many researchers installed the VHVCS inside the multilayer insulation (MLI) and obtained the optimal position. However, the MLI layer is often thinner than the vacuum interlayer between the inner and outer tanks, and there is a large vacuum interlayer between the outermost side of MLI and the inner wall of the outer tank. It is unknown whether the insulation performance can be improved if we install ACS in the mentioned vacuum interlayer and separate a portion of the MLI to be installed on the outer surface of ACS. In this configuration, the number of inner MLI (IMLI) layers and the ACS position are interdependent, a coupling that has not been thoroughly investigated. Therefore, thermodynamic models for MLI, MLI-LNCS, and MLI-VHVCS schemes were developed based on the Layer-by-Layer method. By applying Robin boundary conditions, the temperature distribution and heat leakage of the MLI scheme were predicted. Considering the coupled effects of IMLI layer count and ACS position, a co-optimization strategy was adopted, based on an alternating iterative search algorithm. The results indicate that for the MLI-LNCS scheme, the optimal number of IMLI layers and LNCS position are 36 layers and 49%, respectively. For the MLI-VHVCS scheme, the optimal values are 21 layers and 39%, respectively. Compared to conventional MLI, the MLI-LNCS scheme achieves an 88.09% reduction in heat leakage. However, this improvement involves increased system complexity and higher operational costs from LN₂ circulation. In contrast, the MLI-VHVCS scheme achieves a 62.74% reduction in heat leakage, demonstrating that using sensible heat from cryogenic vapor can significantly improve the thermal insulation performance of LH₂ storage tanks. The work of this paper provides a reference for the design and optimization of the insulation scheme of LH₂ storage tanks. Full article

The Polish Free-Electron Laser (PolFEL), which is currently under construction in the National Centre for Nuclear Research in Świerk near Warsaw, will comprise an electron gun and from four to six cryomodules, each accommodating two nine-cell TESLA RF superconducting resonant cavities. To cool the superconducting resonant cavities, the cryomodules will be supplied with superfluid helium at a temperature of 2 K. Other requirements regarding the cooling power of PolFEL result from the need to cool the power couplers for the accelerating cryomodules (5 K) and thermal shields, which limit the heat inleaks due to radiation (40–80 K). The machine will utilize several thermodynamic states of helium, including two-phase superfluid helium, supercritical helium, and low-pressure helium vapours. Supercritical helium will be supplied from a cryoplant by a cryogenic distribution system (CDS)—transfer line and valve boxes—where it will be thermodynamically transformed into a superfluid state. This article presents the architecture of the CDS, discusses several design solutions that could have been decided on with the use of second law analysis, and presents the design methodology of the chosen CDS elements. Full article

The Volumetric Neutron Source (VNS) is a pivotal facility proposed for advancing fusion nuclear technology, particularly for the qualification of breeding blanket systems, a key component of DEMO and future fusion reactors. This study focuses on the design and optimisation of the VNS Thermal Shield, adopting a multidisciplinary approach to address its thermal and structural behaviours. The Thermal Shield plays a crucial role in protecting superconducting magnets and other cryogenic components by limiting heat transfer from higher-temperature regions of the tokamak to the cryostat, which operates at temperatures between 4 K and 20 K. To ensure both thermal insulation and structural integrity, multiple design iterations were conducted. These iterations aimed to reduce electromagnetic (EM) forces induced during magnet charge and discharge cycles by introducing strategic cuts and reinforcements in the shield design. The optimisation process included the evaluation of various aluminium alloys and composite materials to achieve a balance between rigidity and weight while maintaining structural integrity under EM and mechanical loads. Additionally, an integrated thermal study was performed to ensure effective temperature management, maintaining the shield at an operational temperature of around 80 K. Cooling channels were incorporated to homogenise temperature distribution, improving thermal stability and reducing thermal gradients. This comprehensive approach demonstrates the viability of advanced material solutions and design strategies for thermal and structural optimisation. The findings reinforce the importance of the VNS as a dedicated platform for testing and validating critical fusion technologies under operationally relevant conditions. Full article

Lead–bismuth eutectic alloy (LBE, Pb_44.5Bi_55.5) has emerged as a promising candidate for use in advanced nuclear and solar energy systems due to its favorable thermophysical characteristics and radiation shielding capabilities. The aim of this research is to assess the applicability of the induction melting technique to synthesize LBE. This paper presents a comprehensive evaluation of the structural, thermophysical, and radiation shielding properties of the obtained LBE sample. Various techniques were employed to investigate the solid-to-liquid eutectic transformation, phase composition, morphology, and homogeneity of the obtained material. Experimental and theoretical determinations on density, void, molar volume, thermal conductivity, heat capacity, thermal diffusivity, and electrical conductivity were performed. Radiation shielding performance over photon energies ranging from 0.015 to 15 MeV was simulated using the Phy-X/PSD program. The results revealed the eutectic structure comprising Pb₇Bi₃ and Bi phases with near-ideal stoichiometry and a melting point of 127.6 °C. The alloy demonstrated a small void that corresponds to a high degree of sample compaction, high specific heat capacity, moderate thermal conductivity, low thermal diffusivity, and effective radiation shielding. These findings confirm that LBE obtained by the induction melting technique possesses the necessary structural stability and functional properties for integration into nuclear reactor and solar thermal technologies. Full article

Two-dimensional transition metal carbides/nitrides (MXenes) have shown potential in biosensors, cancer theranostics, microbiology, electromagnetic interference shielding, photothermal conversion, and thermal energy storage due to their unique electronic structure, ability to absorb a wide range of light, and tunable surface chemistry. In spite of the growing interest in MXenes, there are relatively few studies on their applications in phase-change materials for enhancing thermal conductivity and weak photo-responsiveness between 0 °C and 150 °C. Thus, this study aims to provide a current overview of recent developments, to examine how MXenes are made, and to outline the combined effects of different processes that can convert light into heat. This study illustrates the mechanisms that include enhanced broadband photon harvesting through localized surface plasmon resonance, electron–phonon coupling-mediated nonradiative relaxation, and interlayer phonon transport that optimizes thermal diffusion pathways. This study emphasizes that MXene-engineered 3D thermal networks can greatly improve energy storage and heat conversion, solving important problems with phase-change materials (PCMs), like poor heat conductivity and low responsiveness to light. This study also highlights the real-world issues of making MXene-based materials on a large scale, and suggests future research directions for using them in smart thermal management systems and solar thermal grid technologies. Full article

Lithium hydride (LiH) is one promising material for nuclear reactor shielding due to its high hydrogen content, but its poor mechanical strength and thermal conductivity pose challenges for fabricating large, crack-free ceramic components via conventional sintering. This study explores microwave sintering as a potential solution to enhance heating uniformity and reduce thermal stress during densification of bulk LiH ceramics. Using implicit function and level set methods, we numerically simulated the microwave field distribution and thermal response in both stationary and rotating samples. The results show that rotational heating improves temperature uniformity by up to 12.9% for specific samples, although uniform temperature control remains difficult through rotation alone. To mitigate stress accumulation from thermal gradients, we propose a cyclic sintering–resting strategy, which leverages LiH’s tensile strength–temperature envelope to guide safe and efficient processing. This strategy successfully reduced total sintering time from several days to 1.63 h without inducing cracks. Our findings offer practical insights into optimizing microwave sintering parameters for large-scale LiH ceramic production and contribute to enabling its application in advanced nuclear shielding systems. Full article

This paper investigates self-shielded flux-cored wires with an exothermic MnO₂-Al addition and the effect of hardfacing modes on the deposited alloy of the Fe-C-Mn system for the first time. Additionally, the paper proposes a new experimental research methodology using an orthogonal experimental design with nine experiments and three levels. At the first stage, it is proposed to use the Taguchi plan (L9) method to find the most significant variables. At the second stage, for the development of a mathematical model and optimization, a factorial design is recommended. The studied parameters of the hardfacing mode were travel speed (TS), set voltage on the power source (U_set), contact tip to work distance (CTWD), and wire feed speed (WFS). The following parameters were studied: welding thermal cycle parameters, microstructure, grain size, non-metallic inclusions, and mechanical properties. The results of the analysis showed that the listed parameters of the hardfacing modes have a different effect on the characteristics of the hardfacing process with self-shielded flux-cored wires with an exothermic addition in the filler. It was determined that for flux-cored wires with an exothermic addition, the size of the deposited metal grain size is most affected by the contact tip to work distance (CTWD). The research results showed that the travel speed (TS) had the main influence on the thermal cycle parameters (heat input, cooling time) and hardness. The analysis of the deposited metal samples showed that an increase in the travel speed had a negative impact on the number of non-metallic inclusions (NMIs) in the deposited metal. While the size of NMIs was influenced by the wire feed speed and the set voltage on the power source. Full article