Search Results (91)

Material extrusion additive manufacturing (MEAM) has emerged as a versatile and widely adopted 3D printing technology due to its cost-effectiveness and ability to process a diverse range of materials. However, achieving consistent part quality and repeatability remains a challenge, mainly due to variations in process parameters and material behavior during fabrication. In-situ monitoring and advanced process control systems have been increasingly integrated into MEAM to address these issues, enabling real-time detection of defects, optimization of printing conditions, reliability of fabricated parts, and enhanced control over mechanical properties. This review examines the state-of-the-art in-situ monitoring techniques, including thermal imaging, vibrational sensing, rheological monitoring, printhead positioning, acoustic sensing, image recognition, and optical scanning, and their integration with process control strategies, such as closed-loop feedback systems and machine learning algorithms. Key challenges, including sensor accuracy, data processing complexity, and scalability, are discussed alongside recent advancements and their implications for industrial applications. By synthesizing current research, this work highlights the critical role of in-situ monitoring and process control in advancing the reliability and precision of MEAM, paving the way for its broader adoption in high-performance manufacturing. Full article

Industrially applied bioelectrochemical systems require long-term stable operation, and hence the control of biofilm accumulation on the electrodes. An optimized application of biofilm control mechanisms presupposes on-line, in-situ monitoring of the accumulated biofilm. Heat transfer sensors have successfully been integrated into industrial systems for on-line, non-invasive monitoring of biofilms. In this study, a mathematical model for the description of the sensitivity of a heat transfer biofilm sensor was developed, incorporating the hydrodynamic conditions of the fluid and the geometrical properties of the substratum. This model was experimentally validated at different flow velocities by integrating biofilm sensors into cylindrical pipes and planar mesofluidic flow cells with a carbonaceous substratum. Dimensionless sensor readings were correlated with the mean biovolume measured gravimetrically, and optical coherence tomography was used to determine the sensors’ sensitivity. The biofilm sensors applied in the planar flow cells revealed an increase in sensitivity by a factor of 6 compared to standard stainless steel pipes, as well as improved sensitivity at higher flow velocities. Full article

Over the past few decades, a significant number of large concrete structures with deterioration problems related to the alkali–silica reaction (ASR) have been identified in Portugal and worldwide. Assessing the condition of ASR-affected concrete dams involves both diagnosis and prognosis. Diagnosis evaluates the structure’s current state, while prognosis predicts deterioration and safety implications. This is key to estimate the period during which the structure will effectively perform its function, and essential for the timely and cost-effective planning of the necessary mitigation, rehabilitation, and/or reconstruction works. This article aims to contribute to the ongoing discussion of this topic by the scientific and technical community and, therefore, presents the methodology adopted to assess the condition of a severely ASR-affected concrete dam in Portugal, the Alto Ceira dam, in which the concrete was produced with susceptible to ASR quartzitic aggregates and that was decommissioned and replaced by a new one in 2014. The article provides a brief review of the diagnosis and prognosis of the ASR in concrete dams, presents and analyses the results from laboratory testing (including chemical, microstructural, physical, mechanical, and expansion tests), in-situ testing, structural monitoring systems, visual inspections, and numerical modelling, aiming at assessing ASR impacts and evidencing the utility of the reported methodology on the appraisal of ASR-affected structures. Full article

The temperature and strain fields monitoring during the preparation process of buoyancy materials, as well as the health status after molding, are important for mastering the mechanical properties of buoyancy materials and ensuring the safety of operators and equipment. This paper proposes a short and high-density femtosecond fiber Bragg grating (fs-FBG) array based on different temperature coefficients fibers. By optimizing the parameters of femtosecond laser point-by-point writing technology, high-performance fs-FBG arrays with millimeter level gating length and millimeter level spatial resolution were prepared on two types of fibers. These were successfully embedded in buoyancy materials to achieve in-situ online monitoring of the curing process and after molding. The experimental results show that the fs-FBG array sensor has good anti-chirp performance and achieves online monitoring of millimeter-level spatial resolution. Intelligent buoyancy materials can provide real-time feedback on the health status of equipment in harsh underwater environments. The system can achieve temperature monitoring with an accuracy of 0.56 °C and deformation monitoring with sub-millimeter accuracy; the error is in the order of micrometers, which is of great significance in the field of deep-sea exploration. Full article

With the growing interest in metal additive manufacturing using laser powder bed fusion (LPBF), there is a need for advanced in-situ nondestructive evaluation (NDE) methods that can dynamically monitor manufacturing process-related variations, that can be used as a feedback mechanism to further improve the manufacturing process, leading to parts with improved microstructural properties and mechanical properties. Current NDE techniques either lack sensitivity beyond build layer, are costly or time-consuming, or are not compatible for in-situ integration. In this research, we develop an electrical resistance diagnostic for in-situ monitoring of powder fused regions during laser powder bed fusion printing. The technique relies on injecting current into the build plate and detecting voltage differences from conductive variations during printing using a simple, cheap four-point electrode array directly connected to the build plate. A computational model will be utilized to determine sensitivities of the approach, and preliminary experiments will be performed during the printing process to test the overall approach. Full article

Predictive weather-based models are widely used to schedule irrigation through the estimation of crop evapotranspiration. However, perceiving real-time crop water requirements remains a challenge. This research aims at field validating and exploiting a low-cost IoT soil moisture tensiometer prototype to consequently compare weather-based irrigation to soil water moisture-based irrigation in terms of yield and crop water productivity. The prototype is based on the ESP32 microcontroller and BMP180 barometric sensor. When compared to a mechanical tensiometer, the IoT prototype proved its accuracy, registering an average R² equal to 0.8 and an RMSE range of 4.25–7.1 kPa. In a second step, the irrigation of a Romaine lettuce field (Lactuca sativa L.) cultivated under a drip system was managed according to two different scenarios: (1) using the data feed from the IoT tensiometers, irrigation was performed to keep the soil water potential between −15 and −25 kPa; (2) using the data provided by the in-situ weather station to estimate the crop water requirements. When comparing the yield, no significant difference was registered between the two scenarios. However, the water productivity was significantly higher, registering a 36.44% increment in scenario 1. The experiment highlights the water-saving potential achievable through real-time monitoring of soil moisture conditions. Since it is a low-cost device (82.20 USD), the introduced prototype facilitates deploying and managing a fleet of sensors for soil water potential live mapping. Full article

This paper reports the conversion of a waste to a conducting material, exploiting the ability to adsorb pollutant organic dyes. Leather waste was carbonized at 800 °C in an inert nitrogen atmosphere. The resulting biochar was used for in-situ deposition of polypyrrole nanotubes produced by the oxidative polymerization of pyrrole in the presence of methyl orange. The composites of carbonized leather with deposited polypyrrole nanotubes of various composition were compared with similar composites based on globular polypyrrole. Their molecular structure was characterized by infrared and Raman spectra. Both conducting components formed a bicontinuous structure. The resistivity was newly determined by a four-point van der Pauw method and monitored as a function of pressure applied up to 10 MPa. The typical conductivity of composites was of the order of 0.1 to 1 S cm⁻¹ and it was always higher for polypyrrole nanotubes than for globular polypyrrole. The method also allows for the assessment of mechanical features, such as powder fluffiness. The conductivity decreased by 1–2 orders of magnitude after treatment with ammonia but still maintained a level acceptable for applications operating under non-acidic conditions. The composites were tested for dye adsorption, specifically cationic methylene blue and anionic methyl orange, using UV-vis spectroscopy. The composites were designed for future use as functional adsorbents controlled by the electrical potential or organic electrode materials. Full article

To make supercapattery devices feasible, there is an urgent need to find electrode materials that exhibit a hybrid mechanism of energy storage. Herein, we provide a first report on the capability of lithium manganese sulfates to be used as supercapattery materials at elevated temperatures. Two compositions are studied: monoclinic Li₂Mn(SO₄)₂ and orthorhombic Li₂Mn₂(SO₄)₃, which are prepared by a freeze-drying method followed by heat treatment at 500 °C. The electrochemical performance of sulfate electrodes is evaluated in lithium-ion cells using two types of electrolytes: conventional carbonate-based electrolytes and ionic liquid IL ones. The electrochemical measurements are carried out in the temperature range of 20–60 °C. The stability of sulfate electrodes after cycling is monitored by in-situ Raman spectroscopy and ex-situ XRD and TEM analysis. It is found that sulfate salts store Li⁺ by a hybrid mechanism that depends on the kind of electrolyte used and the recording temperature. Li₂Mn(SO₄)₂ outperforms Li₂Mn₂(SO₄)₃ and displays excellent electrochemical properties at elevated temperatures: at 60 °C, the energy density reaches 280 Wh/kg at a power density of 11,000 W/kg. During cell cycling, there is a transformation of the Li-rich salt, Li₂Mn(SO₄)₂, into a defective Li-poor one, Li₂Mn₂(SO₄)₃, which appears to be responsible for the improved storage properties. The data reveals that Li₂Mn(SO₄)₂ is a prospective candidate for supercapacitor electrode materials at elevated temperatures. Full article

The content of Cu²⁺ in lubricants is an essential indicator for determining the quality of the lubricant and predicting mechanical failure. Finding an effective and sensitive method for detecting Cu²⁺ in lubricants is of great importance in oil monitoring. In this work, AgInS₂ (AIS) and AgInS₂-ZnS (ZAIS) nanoparticles (NPs) were synthesized by a simple one-step approach via in-situ surface modification by oleylamine. The as-synthesized AIS and ZAIS NPs exhibit good dispersion stability in various apolar media. The photoluminescence (PL) of AIS and ZAIS NPs as lubricating additives could reflect and monitor the lubrication state of steel-copper pairs due to the quenching effect of Cu²⁺ from the friction process. With an optimum concentration of 0.5 wt% in paraffin oil, the friction coefficient of the AIS and ZAIS NPs at 100 N was decreased by 56.8 and 52.1% for steel-steel contacts, respectively. ZAIS was observed to be more effective than AIS in improving anti-wear (AW) and extreme pressure (EP) properties, with a load-bearing capacity of up to 1100 N. Characterization of the wear tracks by SEM and XPS indicates that a tribofilm composed of metal sulfides and oxides was formed during the lubricating process. This work not only reveals AIS and ZAIS NPs as a new class of promising candidates for lubricating additives but also unveils their potential for monitoring lubricant conditions and exploring lubricant service life. Full article

Post annealing treatment is generally needed for additively manufactured titanium alloy to decompose metastable phases, alleviate residual stress, and improve ductility. In this work, in-situ electrical resistivity and line profile analysis of X-ray diffraction were utilized for monitoring phase transformation behaviors and dislocation evolutions of a laser powder bed fusion-built Ti-6Al-4V alloy under post annealing treatment. Besides, hardness and tensile tests were adopted for revealing the effects of phase transformation and dislocation evolutions on the mechanical properties. The results indicated that post annealing treatment decomposed martensitic α′ into lamellar α + β and eliminated dislocations efficiently. The martensite decomposition rate increased with the annealing temperature. Annealing at 700 °C for 4 h eliminated 98% of the dislocations, and further annealing has only a limited influence on the dislocation density. Annealing at 700 °C for 16 h is beneficial for achieving a high ductility of 10.3% owing to the favorable equilibrium lamellar α + β microstructure. These findings provide valuable insights for optimizing post annealing treatment procedures to enhance the mechanical properties of additively manufactured Ti-6Al-4V alloys. Full article

Soil moisture (SM) is a bridge between the atmosphere, vegetation and soil, and its dynamics reflect the energy exchange and transformation between the three. Among SM at different soil profiles, root zone soil moisture (RZSM) plays a significant role in vegetation growth. Therefore, reliable estimation of RZSM at the regional scale is of great importance for drought warning, agricultural yield estimation, forest fire monitoring, etc. Many satellite products provide surface soil moisture (SSM) at the thin top layer of the soil, approximately 2 cm from the surface. However, the acquisition of RZSM at the regional scale is still a tough issue to solve, especially in the semi-arid areas with a lack of in situ observations. Linking the dynamics of SSM and RZSM is promising to solve this issue. The soil moisture analytical relationship (SMAR) model can relate RZSM to SSM based on a simplified soil water balance equation, which is suitable for the simulation of soil moisture mechanisms in semi-arid areas. In this study, the Xiliaohe River Basin is the study area. The SMAR model at the pixels where in situ sites were located is established, and parameters (a, b, s_w2, s_c1) at these pixels are calibrated by a genetic algorithm (GA). Then the spatial parameters are estimated by the random forest (RF) regression method with the soil, meteorological and vegetation characteristics of the study area as explanatory variables. In addition, the importance of soil, climatic and vegetation characteristics for predicting SMAR parameters is analyzed. Finally, the spatial RZSM in the Xiliaohe River Basin is estimated by the SMAR model at the regional scale with the predicted spatial parameters, and the variation of the regional SMAR model performance is discussed. A comparison of estimated RZSM and in-situ RZSM showed that the SMAR model at the point and regional scales can both meet the RMSE benchmark from NASA of 0.06 cm³·cm⁻³, indicating that the method this study proposed could effectively estimate RZSM in semi-arid areas based on remotely sensed SSM data. Full article

This study focuses on investigating the fatigue and wear behaviour of carbon fibre reinforced polymer (CFRP) gears, which have shown promising potential as lightweight and high-performance alternatives to conventional gears. The gears were fabricated via an autoclave process using an 8-layer composite made of T300 plain weave carbon fabric and ET445 resin and were tested in pair with a 42CrMo4 steel pinion and under nominal tooth bending stress ranging from 60 to 150 MPa. In-situ temperature monitoring was performed, using an infrared camera, and wear rates were regularly assessed. The result of the wear test indicates adhesive wear and three-body abrasion wear mechanisms between the CFRP gears and the steel counterpart. A finite element analysis was performed to examine the in-mesh contact and root stress behaviour of both new and worn gears at various loads and a specified running time. The results point to a substantial divergence from ideal meshing and stress conditions as the wear level is increased. The fatigue results indicated that the CFRP gears exhibited superior performance compared to conventional plastic and composite short-fibrous polymer gears. The described composite gear material was additionally compared with two other composite configurations, including an autoclave-cured T700S plain weave prepreg with DT120 toughened resin and a vacuum-impregnated T300 spread plain weave carbon fabric with LG 900 UV resin. The study found that the use of the T700S-DT120 resulted in additional improvements. Full article

Polyethylene terephthalate (PET) is known to be highly inert, and this makes it difficult to be metallized. In addition, Pt electroless plating is rarely reported in the metallization of polymers. In this study, the metallization of biocompatible Pt metal is realized by supercritical CO₂ (sc-CO₂)-assisted electroless plating. The catalyst precursor used in the sc-CO₂ catalyzation step is an organometallic compound, palladium (II) acetylacetonate (Pd(acac)₂). The electrical resistance is evaluated, and a tape adhesion test is utilized to demonstrate intactness of the Pt layer on the PET film. The electrical resistance of the Pt/PET with 60 min of the Pt deposition time remains at a low level of 1.09 Ω after the adhesion test, revealing positive effects of the sc-CO₂ catalyzation step. A tensile test is conducted to evaluate the mechanical strength of the Pt/PET. In-situ electrical resistances of the specimen are monitored during the tensile test. The fracture strength is determined from the stress value when the short circuit occurred. The fracture strength is 33.9 MPa for a specimen with 30 min of the Pt deposition time. As the Pt deposition time increases to 45 min and 60 min, the fracture strengths reach 52.3 MPa and 65.9 MPa, respectively. The promoted fracture strength and the decent electrical conductivity demonstrate the advantages toward biomedical devices. Full article

Elastomeric bearings are widely used in bridges to support the superstructure, to transfer loads to substructures, and to accommodate movements induced by, for example, temperature changes. Bearing mechanical properties affect the bridge’s performance and its response to permanent and variable loadings (e.g., traffic). This paper describes the research carried out at Strathclyde towards the development of smart elastomeric bearings that can be used as a low−cost sensing technology for bridge and/or weigh−in−motion monitoring. An experimental campaign was performed, under laboratory conditions, on various natural rubber (NR) specimens enhanced with different conductive fillers. Each specimen was characterized under loading conditions that replicated in−situ bearings to determine their mechanical and piezoresistive properties. Relatively simple models can be used to describe the relationship between rubber bearing resistivity and deformation changes. Gauge factors (GFs) in the range between 2 and 11 are obtained, depending on the compound and the applied loading. Experiments were also carried out to show that the developed model can be used to predict the state of deformation of the bearings under random loadings of different amplitudes that are characteristic of the passage of traffic over a bridge. Full article

Compared with single or twin tunnels, the pressure arch effect of deeply buried, symmetrically distributed triple tunnels are more complex and less studied. In this paper, the arching responses are in-situ measured in the deeply buried, symmetrically distributed triple tunnels of Badaling Great Wall station. Numerical research is subsequently conducted to investigate the formation and development of the pressure arch of triple tunnels. Then, the influencing law of buried depth on pressure arch behavior is systematically studied. Based on monitoring data, the rock pressure distribution is asymmetric about the axis of the triple tunnels, and the arching response of the middle tunnels is more significant than that of the left and right tunnels. According to numerical analysis, a combined large pressure arch may be easily formed across the triple tunnels. The pre-arching and double-arching effects are also numerically observed during triple tunnel excavations. The inner boundary of the pressure arch of the middle tunnel is 14.0 m, nearly two times higher than those of the left and right tunnels. This simulation result indicates that the mechanical state of the middle tunnel is the least desirable. Moreover, the critical arching depth of closely spaced tunnels is 1.75 times that of a single tunnel. Compared with a single tunnel, the support of triple tunnels should be additionally strengthened. Full article