Search Results (943)

This paper focuses on the failure mechanism of a pre-stressed CFRP cantilever beam under laser ablation. During testing, a mass was applied to the CFRP cantilever beam to achieve a pre-stressed state, and the laser power densities varied from 500 to 1500 W·cm⁻². Corresponding scanning electron microscope (SEM) tests were also performed on the ablation zone and fracture surface to analyze the failure mechanism. The results showed that the CFRP beam failed in compression at the bottom surface, which was due to a decrease in local stiffness and strength caused by heat softening, rather than by ablation damage on the top surface. The failure time decreased from 19.64 s to 6.52 s as the power density (500–1500 W·cm⁻²) and pre-stress loading (300–750 N·cm) increased, indicating that pre-stress loading has a more significant influence on the failure time of CFRP beams compared to power density. Full article

The rapid development of high-power-density semiconductor devices has rendered conventional thermal management techniques inadequate for handling their extreme heat fluxes. This manuscript presents and implements an embedded microchannel cooling solution for such devices. By directly integrating micropillar arrays within the near-junction region of the substrate, efficient forced convection and flow boiling mechanisms are achieved. Finite element analysis was first employed to conduct thermo–fluid–structure simulations of micropillar arrays with different geometries. Subsequently, based on our simulation results, a complete multilayer microstructure fabrication process was developed and integrated, including critical steps such as deep reactive ion etching (DRIE), surface hydrophilic/hydrophobic functionalization, and gold–stannum (Au-Sn) eutectic bonding. Finally, an experimental test platform was established to systematically evaluate the thermal performance of the fabricated devices under heat fluxes of up to 1200 W/cm². Our experimental results demonstrate that this solution effectively maintains the device operating temperature at 46.7 °C, achieving a mere 27.9 K temperature rise and exhibiting exceptional thermal management capabilities. This manuscript provides a feasible, efficient technical pathway for addressing extreme heat dissipation challenges in next-generation electronic devices, while offering notable references in structural design, micro/nanofabrication, and experimental validation for related fields. Full article

With the rapid development of information technology and semiconductor technology, the iteration speed of electronic devices has accelerated in an unprecedented manner, and the market demand for miniaturized, highly integrated, and highly intelligent devices continues to rise. But when these electronic devices operate at high power, the electronic components generate a large amount of integrated heat. Due to the limitations of existing heat dissipation channels, the current heat dissipation performance of electronic packaging materials is struggling to meet practical needs, resulting in heat accumulation and high temperatures inside the equipment, seriously affecting operational stability. For electronic devices that require high energy density and fast signal transmission, improving the heat dissipation capability of electronic packaging materials can significantly enhance their application prospects. In order to improve the thermal conductivity of composite materials, hexagonal boron nitride (h-BN) was selected as the thermal filling material in this paper. The BMI resin was structurally modified through molecular structure design. The results showed that the micro-branched structure and h-BN synergistically improved the thermal conductivity and insulation performance of the composite material, with a thermal conductivity coefficient of 1.51 W/(m·K) and a significant improvement in insulation performance. The core mechanism is the optimization of the dispersion state of h-BN filler in the matrix resin through the free volume in the micro-branched structure, which improves the thermal conductivity of the composite material while maintaining high insulation. Full article

Using solid particulates as a heat transfer medium for concentrated solar power (CSP) systems has many advantages, positioning them as a superior option compared with conventional heat transfer media such as steam, oil, air, and molten salt. However, a critical imperative lies in the comprehensive evaluation of the properties of potential solid particulates intended for utilization under such extreme thermal conditions. This paper undertakes an exhaustive examination of both ambient and high-temperature thermophysical properties of four naturally occurring particulate materials, Riyadh white sand, Riyadh red sand, Saudi olivine sand, and US olivine sand, and one well-known engineered particulate material. The parameters under scrutiny encompass loose bulk density, tapped bulk density, real density, sintering temperature, and thermal conductivity. The results reveal that the theoretical density decreases with the increase in temperature. The bulk density of solid particulates depends strongly on the particulate size distribution, as well as on the compaction. The tapped bulk density was found to be larger than the loose density for all particulates, as expected. The sintering test proved that Riyadh white sand is sintered at the highest temperature and pressure, 1300 °C and 50 MPa, respectively. US olivine sand was solidified at 800 °C and melted at higher temperatures. This proves that US olivine sand is not suitable to be used as a thermal energy storage and heat transfer medium in high-temperature particle-based CSP systems. The experimental results of thermal diffusivity/conductivity reveal that, for all particulates, both properties decrease with the increase in temperature, and results up to 475.5 °C are reported. Full article

This article provides a comprehensive overview of recent studies concerning laser heat treatment (LHT) of structural and tool steels, with particular attention to the 21NiCrMo2 steel used for carburized gear wheels. Analysis includes the influence of critical laser processing conditions—including power output, motion speed, spot size, and focusing distance—on surface microhardness, hardening depth, and microstructure development. The findings indicate that the energy density is the dominant factor that affects the outcomes of LHT. Optimal results, in the form of a high surface microhardness and a sufficient depth of hardening, were achieved within the energy density range of 80–130 J/mm², allowing for martensitic transformation while avoiding defects such as melting or cracking. At densities below 50 J/mm², incomplete hardening occurred with minimal microhardness improvement. On the contrary, densities exceeding 150–180 J/mm² caused surface overheating and degradation. For carburized 21NiCrMo2 steel, the most effective parameters included 450–1050 W laser power, 1.7–2.5 mm/s scanning speed, and 2.0–2.3 mm beam diameter. The review confirms that process control through energy-based parameters allows for reliable prediction and optimization of LHT for industrial applications, particularly in components exposed to cyclic loads. Full article

This study systematically investigates the homogenization-induced Laves phase dissolution kinetics and recrystallization mechanisms in laser powder bed fusion (L-PBF) processed IN718 superalloy. The as-built material exhibits a characteristic fine dendritic microstructure with interdendritic Laves phase segregation and high dislocation density, featuring directional sub-grain boundaries aligned with the build direction. Laves phase dissolution demonstrates dual-stage kinetics: initial rapid dissolution (0–15 min) governed by bulk atomic diffusion, followed by interface reaction-controlled deceleration (15–60 min) after 1 h at 1150 °C. Complete dissolution of the Laves phase is achieved after 3.7 h at 1150 °C. Recrystallization initiates preferentially at serrated grain boundaries through boundary bulging mechanisms, driven by localized orientation gradients and stored energy differentials. Grain growth kinetics obey a fourth-power time dependence, confirming Ostwald ripening-controlled boundary migration via grain boundary diffusion. Such a study is expected to be helpful in understanding the microstructural development of L-PBF-built IN718 under heat treatments. Full article

With their superior switching speed, GaN high-electron-mobility transistors (HEMTs) enable high power density, reduce energy losses, and increase power efficiency in a wide range of applications, such as power electronics, due to their high breakdown voltage. GaN-HEMT devices are subject to long-term reliability due to the self-heating effect and lattice mismatch between the SiC substrate and the GaN. Depletion-mode GaN HEMTs are utilized for radio frequency applications, and this work investigates three wide-bandgap (WBG) GaN HEMT fixed-frequency oscillators with output buffers. The first GaN-on-SiC HEMT oscillator consists of an HEMT amplifier with an LC feedback network. With the supply voltage of 0.8 V, the single-ended GaN oscillator can generate a signal at 8.85 GHz, and it also supplies output power of 2.4 dBm with a buffer supply of 3.0 V. At 1 MHz frequency offset from the carrier, the phase noise is −124.8 dBc/Hz, and the figure of merit (FOM) of the oscillator is −199.8 dBc/Hz. After the previous study, the hot-carrier stressed RF performance of the GaN oscillator is studied, and the oscillator was subject to a drain supply of 8 V for a stressing step time equal to 30 min and measured at the supply voltage of 0.8 V after the step operation for performance benchmark. Stress study indicates the power oscillator with buffer is a good structure for a reliable structure by operating the oscillator core at low supply and the buffer at high supply. The second balanced oscillator can generate a differential signal. The feedback filter consists of a left-handed transmission-line LC network by cascading three unit cells. At a 1 MHz frequency offset from the carrier of 3.818 GHz, the phase noise is −131.73 dBc/Hz, and the FOM of the 2nd oscillator is −188.4 dBc/Hz. High supply voltage operation shows phase noise degradation. The third GaN cross-coupled VCO uses 8-shaped inductors. The VCO uses a pair of drain inductors to improve the Q-factor of the LC tank, and it uses 8-shaped inductors for magnetic coupling noise suppression. At the VCO-core supply of 1.3 V and high buffer supply, the FOM at 6.397 GHz is −190.09 dBc/Hz. This work enhances the design techniques for reliable GaN HEMT oscillators and knowledge to design high-performance circuits. Full article

The ongoing rise in global electricity demand highlights the need for advanced, efficient, and environmentally responsible energy conversion technologies. This research presents a comprehensive design, modeling, and experimental validation of a tubular permanent magnet linear alternator (PMLA) integrated with a free piston engine system. Linear alternators offer a direct conversion of linear motion to electricity, eliminating the complexity and losses associated with rotary generators and enabling higher efficiency and simplified system architecture. The study combines analytical modeling, finite element simulations, and a sensitivity-based design optimization to guide alternator and engine integration. Two prototype systems, designated as alpha and beta, were developed, modeled, and tested. The beta prototype achieved a maximum electrical output of 550 W at 57% efficiency using natural gas fuel, demonstrating reliable performance at elevated reciprocating frequencies. The design and optimization of specialized flexure springs were essential in achieving stable, high-frequency operation and improved power density. These results validate the effectiveness of the proposed design approach and highlight the scalability and adaptability of PMLA technology for sustainable power generation. Ultimately, this study demonstrates the potential of free piston linear generator systems as efficient, robust, and environmentally friendly alternatives to traditional rotary generators, with applications spanning hybrid electric vehicles, distributed energy systems, and combined heat and power. Full article

Thermal camouflage technologies manipulate heat fluxes to conceal objects from thermographic detection, offering potential solutions for thermal management in high-power-density electronics. Most reported approaches are aimed at scenarios where the target is not a heat source; however, any target with a non-zero temperature emits thermal radiation described by the Stefan–Boltzmann law since the thermal radiation of an object is proportional to the fourth power of its temperature (T⁴). To address this issue, this study proposes a thermal camouflage device that considers the influence of radiative thermal transfer from the target. The underlying principle involves maintaining synchronous heat transfer separately along both the device and background surfaces. Numerical simulation confirms the feasibility of this proposed thermal camouflage strategy. Moreover, by altering some parameters related to the target such as geometry, location, temperature, and surface emissivity, excellent performance can be achieved using this device. This work advances thermal management strategies for high-power electronics and infrared-sensitive systems, with applications in infrared stealth, thermal diagnostics, and energy-efficient heat dissipation. Full article

A novel and cost-effective methodology is introduced for the precise prediction of the melting time of metals and alloys in a 700 W domestic microwave oven, using a hybrid SiC–graphite susceptor to ensure efficient heating without direct interaction with microwaves. The study includes experimental trials with multiple alloys (Sn–Bi, Zn, Zamak, and Al–Si, among others) and variable masses, whose results made it possible to construct a dimensionless model, trained with XGBoost on easily measurable thermophysical properties (specific heat, density, thermal conductivity, mass, and melting temperature). The model achieves high accuracy, with a relative error below 5%, and metrics of MAE = 4.8 s, RMSE = 6.1 s, and R² = 0.9996. The generalization of the model to different microwave powers (600–1100 W) is also validated through analytical adjustment, without the need for additional experiments. The proposal is implemented as a Python application with a graphical interface, suitable for any academic or teaching laboratory, and its performance is compared with classical models. This approach effectively contributes to the democratization of thermal testing of metals in educational and research settings with limited resources, providing thermodynamic rigor and advanced artificial intelligence tools. Full article

Direct-drive permanent magnet synchronous generators (DD-PMSGs) have been widely adopted in wind power generation systems owing to their distinctive advantages, including direct-drive operation, high power density, and superior energy conversion efficiency. However, the high power density of the generator inevitably leads to heat generation issues, which affect the reliability of the generator. To address the thermal issues in the 4.5 MW direct-drive permanent magnet synchronous generator (DD-PMSG), this paper proposes a novel forced air-cooling ventilation system. Through comprehensive computational fluid dynamics (CFD) simulations and fundamental thermodynamic analysis, the cooling performance is systematically evaluated to determine the optimal width of the stator ventilation ducts. Furthermore, based on the temperature distribution of the stator and rotor, three optimization schemes for non-uniform core segments are proposed. By comparing the ventilation cooling performance under three structural schemes, the optimal structural scheme is provided for the generator. Finally, the feasibility of the heat dissipation scheme and the accuracy of the simulation calculations are verified by fabricating a prototype and setting up an experimental platform. The above conclusions and research results can provide some reference for the design of the core ventilation ducts structure of subsequent wind turbines. Full article

Phase change materials (PCMs) have significant potential for utilization due to their high energy storage density and excellent safety in energy storage. In this research, a flexible heat storage device using the stable supercooling of sodium acetate trihydrate composite is developed, enabling on-demand heat release through controlled solidification initiation. The solidification and heat release characteristics are investigated in experiments. The results indicate that the heat release characteristics of this heat storage device are closely linked to the crystallization process of the PCM. During the experiment, based on whether external intervention was needed for the solidification process, the PCM manifested two separate solidification modes—specifically, spontaneous self-solidification and triggered-solidification. Meanwhile, the heat release rates, temperature changes, and crystal morphologies were observed in the two solidification modes. Compared with spontaneous self-solidification, triggered-solidification achieved a higher peak surface temperature (53.6 °C vs. 46.2 °C) and reached 45 °C significantly faster (5 min vs. 15 min). Spontaneous self-solidification exhibited slower, uncontrollable heat release with dendritic crystals, while triggered-solidification provided rapid, controllable heat release with dense filamentous crystals. This controllable switching between modes offers key practical advantages, allowing the device to provide either rapid, high-power heat discharge or slower, sustained release as required by the application. According to the crystal solidification theory, the different supercooling degrees are the main reasons for the two solidification modes exhibiting different solidification characteristics. During solidification, the growth rate of SAT crystals exhibits substantial disparities across diverse experiments. In this research, the maximum axial growth rate is 2564 μm/s, and the maximum radial growth rate is 167 μm/s. Full article

With the evolution of hydroelectric generators toward larger capacity and higher rotational speeds, the significa++nt increase in power density has rendered rotor cooling technology a critical bottleneck restricting performance enhancement. Addressing the need for feasibility verification and thermodynamic characteristic analysis of evaporative cooling applied to rotors, this study innovatively proposes an internal-cooling-based evaporative cooling architecture for rotor windings. By establishing a single-channel experimental platform for a rotor evaporative cooling system, the key parameters of the system circulation flow under varying centrifugal accelerations and thermal loads are obtained, revealing the flow mechanism of the cooling system. The experimental results demonstrate that the novel architecture has outstanding heat dissipation performance. Furthermore, the experimental findings reveal that the flow characteristics of the medium are governed by the coupled effect of centrifugal acceleration and thermal load; the flow rate decreases with increasing centrifugal acceleration and increases with rising thermal load. Centrifugal acceleration reduces frictional losses in the heating pipe, leading to a decrease in the inlet–outlet pressure difference. Through the integration of experimental data with classic formulas, this study refines the friction factor model, with the modified formula showing a discrepancy of −10% to +5% compared with the experimental results. Finally, the experiment was rerun to verify the universality of the modified friction factor. Full article

As a pivotal technology and infrastructure component for modern power systems, energy storage has experienced significant advancement in recent years. A fundamental prerequisite for designing future energy storage facilities lies in the systematic evaluation of energy conversion capabilities across diverse storage technologies. This study conducted a comparative analysis between pumped hydroelectric storage (PHS) and compressed air energy storage (CAES), defining the concepts of height exergy and temperature exergy. Height exergy is the maximum work capacity of a liquid due to height differences, while temperature exergy is the maximum work capacity of a gas due to temperature differences. The temperature exergy represents innovation in thermodynamic analysis; it is derived from internal exergy and proven through the Maxwell relation and the decoupling method of internal exergy, offering a more efficient method for calculating energy storage capacity in CAES systems. Mathematical models of height exergy and temperature exergy were established based on their respective forms. A unified calculation formula was derived, and their respective characteristics were analyzed. In order to show the meaning of temperature exergy more clearly and intuitively, a height exergy model of temperature exergy was established through analogy analysis, and it was concluded that the shape of the reservoir was a cone when comparing water volume to heat quantity, intuitively showing that the cold source had a higher energy storage density than the heat source. Finally, a typical hybrid PHS–CAES system was proposed, and a mathematical model was established and verified in specific cases based on height exergy and temperature exergy. It was demonstrated that when the polytropic exponent n = 1.2, the theoretical loss accounted for the largest proportion, which was 2.06%. Full article

Recently, humanoid robots with personification behavior and high working efficiency have received significant attention. Meanwhile, high-torque-density motors, which serve as the core power source for robot joints, have also been widely researched. In this paper, a high-torque-density double-stator permanent-magnet (DSPM) motor is designed for robot joint applications, and its outer stator (OS) split ratio (the ratio between the inner and outer diameters of the OS) and inner stator (IS) split ratio (the ratio between the inner and outer diameters of the IS) are analyzed and optimized. Since the DSPM motor has different heat dissipation capabilities for the OS and IS, their different loss limitations should be considered to avoid the risk of local overheating, especially for the IS. This paper shows that the loss limitations affect the optimal OS and IS split ratios, as well as the maximum average torque. The IS loss limitation increases the optimal OS split ratio and decreases the optimal IS split ratio; however, the OS loss limitation has the opposite effect. Additionally, an investigation into the electromagnetic characteristics of the optimized DSPM motor was conducted using the finite element method. Finally, a prototype was manufactured, and the results of the temperature rise experiments verified the feasibility of the proposed DSPM motor and the effectiveness of the optimal method. Full article