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Search Results (1,054)

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Keywords = infrared thermography (IT)

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17 pages, 2369 KiB  
Article
An Automatic Ear Temperature Monitoring Method for Group-Housed Pigs Adopting Infrared Thermography
by Changzhen Zhang, Xiaoping Wu, Deqin Xiao, Xude Zhang, Xiaopeng Lei and Sicong Lin
Animals 2025, 15(15), 2279; https://doi.org/10.3390/ani15152279 - 4 Aug 2025
Abstract
The goal of this study was to develop an automated monitoring system based on infrared thermography (IRT) for the detection of group-housed pig ears temperature. The aim in the first part of the study was to recognize pigs’ ears by using neural network [...] Read more.
The goal of this study was to develop an automated monitoring system based on infrared thermography (IRT) for the detection of group-housed pig ears temperature. The aim in the first part of the study was to recognize pigs’ ears by using neural network analysis (SwinStar-YOLO). In the second part of the study, the goal was to automatically extract the maximum and average values of the temperature in the ear region using morphological image processing and a temperature matrix. Our dataset (3600 pictures, 10,812 pig ears) was processed using 5-fold cross-validation before training the ear detection model. The model recognized pigs’ ears with a precision of 93.74% related to threshold intersection over union (IoU). Correlation analysis between manually extracted and algorithm-derived ear temperatures from 400 pig ear samples showed coefficients of determination (R2) of 0.97 for maximum and 0.88 for average values. This demonstrates that our proposed method is feasible and reliable for automatic pig ear temperature monitoring, serving as a powerful tool for early health warning. Full article
(This article belongs to the Special Issue Infrared Thermography in Animals)
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17 pages, 1097 KiB  
Article
Mapping Perfusion and Predicting Success: Infrared Thermography-Guided Perforator Flaps for Lower Limb Defects
by Abdalah Abu-Baker, Andrada-Elena Ţigăran, Teodora Timofan, Daniela-Elena Ion, Daniela-Elena Gheoca-Mutu, Adelaida Avino, Cristina-Nicoleta Marina, Adrian Daniel Tulin, Laura Raducu and Radu-Cristian Jecan
Medicina 2025, 61(8), 1410; https://doi.org/10.3390/medicina61081410 - 3 Aug 2025
Viewed by 125
Abstract
Background and Objectives: Lower limb defects often present significant reconstructive challenges due to limited soft tissue availability and exposure of critical structures. Perforator-based flaps offer reliable solutions, with minimal donor site morbidity. This study aimed to evaluate the efficacy of infrared thermography [...] Read more.
Background and Objectives: Lower limb defects often present significant reconstructive challenges due to limited soft tissue availability and exposure of critical structures. Perforator-based flaps offer reliable solutions, with minimal donor site morbidity. This study aimed to evaluate the efficacy of infrared thermography (IRT) in preoperative planning and postoperative monitoring of perforator-based flaps, assessing its accuracy in identifying perforators, predicting complications, and optimizing outcomes. Materials and Methods: A prospective observational study was conducted on 76 patients undergoing lower limb reconstruction with fascio-cutaneous perforator flaps between 2022 and 2024. Perforator mapping was performed concurrently with IRT and Doppler ultrasonography (D-US), with intraoperative confirmation. Flap design variables and systemic parameters were recorded. Postoperative monitoring employed thermal imaging on days 1 and 7. Outcomes were correlated with thermal, anatomical, and systemic factors using statistical analyses, including t-tests and Pearson correlation. Results: IRT showed high sensitivity (97.4%) and positive predictive value (96.8%) for perforator detection. A total of nine minor complications occurred, predominantly in patients with diabetes mellitus and/or elevated glycemia (p = 0.05). Larger flap-to-defect ratios (A/C and B/C) correlated with increased complications in propeller flaps, while smaller ratios posed risks for V-Y and Keystone flaps. Thermal analysis indicated significantly lower flap temperatures and greater temperature gradients in flaps with complications by postoperative day 7 (p < 0.05). CRP levels correlated with glycemia and white blood cell counts, highlighting systemic inflammation’s impact on outcomes. Conclusions: IRT proves to be a reliable, non-invasive method for perforator localization and flap monitoring, enhancing surgical planning and early complication detection. Combined with D-US, it improves perforator selection and perfusion assessment. Thermographic parameters, systemic factors, and flap design metrics collectively predict flap viability. Integration of IRT into surgical workflows offers a cost-effective tool for optimizing reconstructive outcomes in lower limb surgery. Full article
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19 pages, 1894 KiB  
Article
Utility of Infrared Thermography for Monitoring of Surface Temperature Changes During Horses’ Work on Water Treadmill with an Artificial River System
by Urszula Sikorska, Małgorzata Maśko, Barbara Rey and Małgorzata Domino
Animals 2025, 15(15), 2266; https://doi.org/10.3390/ani15152266 - 1 Aug 2025
Viewed by 133
Abstract
Water treadmill (WT) exercise is used for horses’ rehabilitation and training. Given that each training needs to be individualized for each horse, the goal is to assess whether infrared thermography (IRT) can serve as a non-invasive tool for daily monitoring of individual training [...] Read more.
Water treadmill (WT) exercise is used for horses’ rehabilitation and training. Given that each training needs to be individualized for each horse, the goal is to assess whether infrared thermography (IRT) can serve as a non-invasive tool for daily monitoring of individual training and rehabilitation progress in horses undergoing WT exercise. Fifteen Polish Warmblood school horses were subjected to five WT sessions: dry treadmill, fetlock-depth water, fetlock-depth water with artificial river (AR), carpal-depth water, and carpal-depth water with AR. IRT images, collected pre- and post-exercise, were analyzed for the mean temperature (Tmean) and maximal temperature (Tmax) across 14 regions of interest (ROIs) representing the body surface overlying specific superficial muscles. While on a dry treadmill, Tmean and Tmax increased post-exercise in all ROIs; wetting of the hair coat limited surface temperature analysis in ROIs annotated on limbs. Tmax over the m. brachiocephalicus, m. trapezius pars cervicalis, m. triceps brachii, and m. semitendinosus increased during walking in carpal-depth water, which therefore may be suggested as an indirect indicator of increased activity related to forelimb protraction and flexion–extension of the limb joints. Tmax over the m. latissimus dorsi and m. longissimus increased during carpal-depth WT exercise with active AR mode, which may be suggested as an indicator of increased workload including vertical displacement of the trunk. Full article
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21 pages, 5706 KiB  
Article
The Impact of Drilling Parameters on Drilling Temperature in High-Strength Steel Thin-Walled Parts
by Yupu Zhang, Ruyu Li, Yihan Liu, Chengwei Liu, Shutao Huang, Lifu Xu and Haicheng Shi
Appl. Sci. 2025, 15(15), 8568; https://doi.org/10.3390/app15158568 (registering DOI) - 1 Aug 2025
Viewed by 93
Abstract
High-strength steel has high strength and low thermal conductivity, and its thin-walled parts are very susceptible to residual stress and deformation caused by cutting heat during the drilling process, which affects the machining accuracy and quality. High-strength steel thin-walled components are widely used [...] Read more.
High-strength steel has high strength and low thermal conductivity, and its thin-walled parts are very susceptible to residual stress and deformation caused by cutting heat during the drilling process, which affects the machining accuracy and quality. High-strength steel thin-walled components are widely used in aerospace and other high-end sectors; however, systematic investigations into their temperature fields during drilling remain scarce, particularly regarding the evolution characteristics of the temperature field in thin-wall drilling and the quantitative relationship between drilling parameters and these temperature variations. This paper takes the thin-walled parts of AF1410 high-strength steel as the research object, designs a special fixture, and applies infrared thermography to measure the bottom surface temperature in the thin-walled drilling process in real time; this is carried out in order to study the characteristics of the temperature field during the thin-walled drilling process of high-strength steel, as well as the influence of the drilling dosage on the temperature field of the bottom surface. The experimental findings are as follows: in the process of thin-wall drilling of high-strength steel, the temperature field of the bottom surface of the workpiece shows an obvious temperature gradient distribution; before the formation of the drill cap, the highest temperature of the bottom surface of the workpiece is distributed in the central circular area corresponding to the extrusion of the transverse edge during the drilling process, and the highest temperature of the bottom surface can be approximated as the temperature of the extrusion friction zone between the top edge of the drill and the workpiece when the top edge of the drill bit drills to a position close to the bottom surface of the workpiece and increases with the increase in the drilling speed and the feed volume; during the process of drilling, the highest temperature of the bottom surface of the workpiece is approximated as the temperature of the top edge of the drill bit and the workpiece. The maximum temperature of the bottom surface of the workpiece in the drilling process increases nearly linearly with the drilling of the drill, and the slope of the maximum temperature increases nearly linearly with the increase in the drilling speed and feed, in which the influence of the feed on the slope of the maximum temperature increases is larger than that of the drilling speed. Full article
(This article belongs to the Special Issue Machine Automation: System Design, Analysis and Control)
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19 pages, 1889 KiB  
Article
Infrared Thermographic Signal Analysis of Bioactive Edible Oils Using CNNs for Quality Assessment
by Danilo Pratticò and Filippo Laganà
Signals 2025, 6(3), 38; https://doi.org/10.3390/signals6030038 - 1 Aug 2025
Viewed by 174
Abstract
Nutrition plays a fundamental role in promoting health and preventing chronic diseases, with bioactive food components offering a therapeutic potential in biomedical applications. Among these, edible oils are recognised for their functional properties, which contribute to disease prevention and metabolic regulation. The proposed [...] Read more.
Nutrition plays a fundamental role in promoting health and preventing chronic diseases, with bioactive food components offering a therapeutic potential in biomedical applications. Among these, edible oils are recognised for their functional properties, which contribute to disease prevention and metabolic regulation. The proposed study aims to evaluate the quality of four bioactive oils (olive oil, sunflower oil, tomato seed oil, and pumpkin seed oil) by analysing their thermal behaviour through infrared (IR) imaging. The study designed a customised electronic system to acquire thermographic signals under controlled temperature and humidity conditions. The acquisition system was used to extract thermal data. Analysis of the acquired thermal signals revealed characteristic heat absorption profiles used to infer differences in oil properties related to stability and degradation potential. A hybrid deep learning model that integrates Convolutional Neural Networks (CNNs) with Long Short-Term Memory (LSTM) units was used to classify and differentiate the oils based on stability, thermal reactivity, and potential health benefits. A signal analysis showed that the AI-based method improves both the accuracy (achieving an F1-score of 93.66%) and the repeatability of quality assessments, providing a non-invasive and intelligent framework for the validation and traceability of nutritional compounds. Full article
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15 pages, 2737 KiB  
Article
Thermogenic Activation of Adipose Tissue by Caffeine During Strenuous Exercising and Recovery: A Double-Blind Crossover Study
by Dany Alexis Sobarzo Soto, Diego Ignácio Valenzuela Pérez, Mateus Rossow de Souza, Milena Leite Garcia Reis, Naiara Ribeiro Almeida, Bianca Miarka, Esteban Aedo-Muñoz, Armin Isael Alvarado Oyarzo, Manuel Sillero-Quintana, Andreia Cristiane Carrenho Queiroz and Ciro José Brito
Metabolites 2025, 15(8), 517; https://doi.org/10.3390/metabo15080517 - 1 Aug 2025
Viewed by 237
Abstract
Background/Objectives: To investigate acute caffeine (CAF: 375 mg, ≈4.8 mg/kg body mass) effects on energy expenditure (EE) and substrate kinetics during high-intensity interval exercise in individuals with high (HBAT) versus low (LBAT) brown adipose tissue activity using time-trend polynomial modeling. Methods: This [...] Read more.
Background/Objectives: To investigate acute caffeine (CAF: 375 mg, ≈4.8 mg/kg body mass) effects on energy expenditure (EE) and substrate kinetics during high-intensity interval exercise in individuals with high (HBAT) versus low (LBAT) brown adipose tissue activity using time-trend polynomial modeling. Methods: This is a randomized, double-blind crossover study in which 35 highly-trained males [HBAT-CAF, HBAT-PLA (Placebo), LBAT-CAF, LBAT-PLA] performed 30-min treadmill HIIE. Infrared thermography (IRT) assessed BAT activity by measuring supraclavicular skin temperature (SST). Breath-by-breath ergospirometry measured EE (kcal/min) and carbohydrate (CHO), lipid (LIP), and protein (PTN) oxidation. We applied second- and third-order polynomial regression models to depict the temporal trajectories of metabolic responses. Results: HBAT groups showed 25% higher sustained EE versus LBAT (p < 0.001), amplified by CAF. CHO oxidation exhibited biphasic kinetics: HBAT had 40% higher initial rates (0.75 ± 0.05 vs. 0.45 ± 0.04 g/min; p < 0.001) with accelerated decline (k = −0.21 vs. −0.15/min; p = 0.01). LIP oxidation peaked later in LBAT (40 vs. 20 min in HBAT), with CAF increasing oxidation by 18% in LBAT (p = 0.01). HBAT-CAF uniquely showed transient PTN catabolism (peak: 0.045 g/min at 10 min; k = −0.0033/min; p < 0.001). Conclusions: BAT status determines EE magnitude and substrate-specific kinetic patterns, while CAF exerts divergent modulation, potentiating early glycogenolysis in HBAT and lipolysis in LBAT. The HBAT-CAF synergy triggers acute proteolysis, revealing BAT-mediated metabolic switching. Full article
(This article belongs to the Special Issue Energy Metabolism in Brown Adipose Tissue)
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22 pages, 2499 KiB  
Article
Low-Power Vibrothermography for Detecting Barely Visible Impact Damage in CFRP Laminates: A Comparative Imaging Study
by Zulham Hidayat, Muhammet Ebubekir Torbali, Nicolas P. Avdelidis and Henrique Fernandes
Appl. Sci. 2025, 15(15), 8514; https://doi.org/10.3390/app15158514 (registering DOI) - 31 Jul 2025
Viewed by 113
Abstract
This study explores the application of low-power vibrothermography (LVT) for detecting barely visible impact damage (BVID) in carbon fibre-reinforced polymer (CFRP) laminates. Composite specimens with varying impact energies (2.5–20 J) were excited using a single piezoelectric transducer with a nominal centre frequency of [...] Read more.
This study explores the application of low-power vibrothermography (LVT) for detecting barely visible impact damage (BVID) in carbon fibre-reinforced polymer (CFRP) laminates. Composite specimens with varying impact energies (2.5–20 J) were excited using a single piezoelectric transducer with a nominal centre frequency of 28 kHz, operated at a fixed excitation frequency of 28 kHz. Thermal data were captured using an infrared camera. To enhance defect visibility and suppress background noise, the raw thermal sequences were processed using principal component analysis (PCA) and robust principal component analysis (RPCA). In LVT, RPCA and PCA provided comparable signal-to-noise ratios (SNR), with no consistent advantage for either method across all cases. In contrast, for pulsed thermography (PT) data, RPCA consistently resulted in higher SNR values, except for one sample. The LVT results were further validated by comparison with PT and phased array ultrasonic testing (PAUT) data to confirm the location and shape of detected damage. These findings demonstrate that LVT, when combined with PCA or RPCA, offers a reliable method for identifying BVID and can support safer, more efficient structural health monitoring of composite materials. Full article
(This article belongs to the Special Issue Application of Acoustics as a Structural Health Monitoring Technology)
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17 pages, 1893 KiB  
Article
Tracking Heat Stress in Broilers: A Thermographic Analysis of Anatomical Sensitivity Across Growth Stages
by Rimena do Amaral Vercellino, Irenilza de Alencar Nääs and Daniella Jorge de Moura
Animals 2025, 15(15), 2233; https://doi.org/10.3390/ani15152233 - 29 Jul 2025
Viewed by 224
Abstract
This study aimed to identify anatomical regions and developmental stages in broiler chickens that serve as reliable thermographic indicators of acute heat stress. Broilers aged 14, 21, 35, and 39 days were exposed to controlled heat stress, and surface temperatures across 12 anatomical [...] Read more.
This study aimed to identify anatomical regions and developmental stages in broiler chickens that serve as reliable thermographic indicators of acute heat stress. Broilers aged 14, 21, 35, and 39 days were exposed to controlled heat stress, and surface temperatures across 12 anatomical regions were recorded using infrared thermography. Thermal response metrics (maximum, minimum, and mean peak variation) were analyzed with repeated-measures ANOVA and eta squared (η2) to quantify the strength of physiological responses. Principal component and cluster analyses grouped body regions based on their thermal sensitivity. The comb and wattle consistently showed the highest temperature increases (ΔT = 2.3–4.1 °C) and strongest effect sizes (η2 ≥ 0.70), establishing them as primary thermoregulatory markers. As age increased, more body regions—especially peripheral zones like the drumstick and tail—exhibited strong responses (η2 > 0.40), indicating an expansion of thermoregulatory activity. Cluster analysis identified three distinct sensitivity groups, confirming anatomical differences in thermal regulation. Thermographic responses to heat stress in broilers depend on age and region. The comb and wattle are the most reliable biomarkers, while peripheral responses grow more prominent with maturity. These findings support the use of targeted, age-specific infrared thermography for monitoring poultry welfare. Full article
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22 pages, 13186 KiB  
Article
Detection of Steel Reinforcement in Concrete Using Active Microwave Thermography and Neural Network-Based Analysis
by Barbara Szymanik, Maja Kocoń, Sam Ang Keo, Franck Brachelet and Didier Defer
Appl. Sci. 2025, 15(15), 8419; https://doi.org/10.3390/app15158419 (registering DOI) - 29 Jul 2025
Viewed by 228
Abstract
Non-destructive evaluation of reinforced concrete structures is essential for effective maintenance and safety assessments. This study explores the combined use of active microwave thermography and deep learning to detect and localize steel reinforcement within concrete elements. Numerical simulations were developed to model the [...] Read more.
Non-destructive evaluation of reinforced concrete structures is essential for effective maintenance and safety assessments. This study explores the combined use of active microwave thermography and deep learning to detect and localize steel reinforcement within concrete elements. Numerical simulations were developed to model the thermal response of reinforced concrete subjected to microwave excitation, generating synthetic thermal images representing the surface temperature patterns of reinforced concrete, influenced by subsurface steel reinforcement. These images served as training data for a deep neural network designed to identify and localize rebar positions based on thermal patterns. The model was trained exclusively on simulation data and subsequently validated using experimental measurements obtained from large-format concrete slabs incorporating a structured layout of embedded steel reinforcement bars. Surface temperature distributions obtained through infrared imaging were compared with model predictions to evaluate detection accuracy. The results demonstrate that the proposed method can successfully identify the presence and approximate location of internal reinforcement without damaging the concrete surface. This approach introduces a new pathway for contactless, automated inspection using a combination of physical modeling and data-driven analysis. While the current work focuses on rebar detection and localization, the methodology lays the foundation for broader applications in non-destructive testing of concrete infrastructure. Full article
(This article belongs to the Special Issue Innovations in Artificial Neural Network Applications)
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26 pages, 6348 KiB  
Article
Building Envelope Thermal Anomaly Detection Using an Integrated Vision-Based Technique and Semantic Segmentation
by Shayan Mirzabeigi, Ryan Razkenari and Paul Crovella
Buildings 2025, 15(15), 2672; https://doi.org/10.3390/buildings15152672 - 29 Jul 2025
Viewed by 321
Abstract
Infrared thermography is a common approach used in building inspection for identifying building envelope thermal anomalies that cause energy loss and occupant thermal discomfort. Detecting these anomalies is essential to improve the thermal performance of energy-inefficient buildings through energy retrofit design and correspondingly [...] Read more.
Infrared thermography is a common approach used in building inspection for identifying building envelope thermal anomalies that cause energy loss and occupant thermal discomfort. Detecting these anomalies is essential to improve the thermal performance of energy-inefficient buildings through energy retrofit design and correspondingly reduce operational energy costs and environmental impacts. A thermal bridge is an unwanted conductive heat transfer. On the other hand, an infiltration/exfiltration anomaly is an uncontrollable convective heat transfer, typically happening around windows and doors, but it can also be due to a defect that comprises a building envelope’s integrity. While the existing literature underscores the significance of automatic thermal anomaly identification and offers insights into automated methodologies, there is a notable gap in addressing an automated workflow that leverages building envelope component segmentation for enhanced detection accuracy. Consequently, an automatic thermal anomaly identification workflow from visible and thermal images was developed to test it, utilizing segmented building envelope information compared to a workflow without any semantic segmentation. Therefore, building envelope images (e.g., walls and windows) were segmented based on a U-Net architecture compared to a more conventional semantic segmentation approach. The results were discussed to better understand the importance of the availability of training data and for scaling the workflow. Then, thermal anomaly thresholds for different target domains were detected using probability distributions. Finally, thermal anomaly masks of those domains were computed. This study conducted a comprehensive examination of a campus building in Syracuse, New York, utilizing a drone-based data collection approach. The case study successfully detected diverse thermal anomalies associated with various envelope components. The proposed approach offers the potential for immediate and accurate in situ thermal anomaly detection in building inspections. Full article
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22 pages, 5346 KiB  
Article
Numerical Study of Stud Welding Temperature Fields on Steel–Concrete Composite Bridges
by Sicong Wei, Han Su, Xu Han, Heyuan Zhou and Sen Liu
Materials 2025, 18(15), 3491; https://doi.org/10.3390/ma18153491 - 25 Jul 2025
Viewed by 331
Abstract
Non-uniform temperature fields are developed during the welding of studs in steel–concrete composite bridges. Due to uneven thermal expansion and reversible solid-state phase transformations between ferrite/martensite and austenite structures within the materials, residual stresses are induced, which ultimately degrades the mechanical performance of [...] Read more.
Non-uniform temperature fields are developed during the welding of studs in steel–concrete composite bridges. Due to uneven thermal expansion and reversible solid-state phase transformations between ferrite/martensite and austenite structures within the materials, residual stresses are induced, which ultimately degrades the mechanical performance of the structure. For a better understanding of the influence on steel–concrete composite bridges’ structural behavior by residual stress, accurate simulation of the spatio-temporal temperature distribution during stud welding under practical engineering conditions is critical. This study introduces a precise simulation method for temperature evolution during stud welding, in which the Gaussian heat source model was applied. The simulated results were validated by real welding temperature fields measured by the infrared thermography technique. The maximum error between the measured and simulated peak temperatures was 5%, demonstrating good agreement between the measured and simulated temperature distributions. Sensitivity analyses on input current and plate thickness were conducted. The results showed a positive correlation between peak temperature and input current. With lower input current, flatter temperature gradients were observed in both the transverse and thickness directions of the steel plate. Additionally, plate thickness exhibited minimal influence on radial peak temperature, with a maximum observed difference of 130 °C. However, its effect on peak temperature in the thickness direction was significant, yielding a maximum difference of approximately 1000 °C. The thermal influence of group studs was also investigated in this study. The results demonstrated that welding a new stud adjacent to existing ones introduced only minor disturbances to the established temperature field. The maximum peak temperature difference before and after welding was approximately 100 °C. Full article
(This article belongs to the Section Construction and Building Materials)
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16 pages, 2673 KiB  
Article
Thermal and Volumetric Signatures of the Mullins Effect in Carbon Black Reinforced Styrene-Butadiene Rubber Composites
by Nicolas Candau, Guillaume Corvec, Noel León-Albiter and Miguel Mudarra Lopez
J. Compos. Sci. 2025, 9(8), 393; https://doi.org/10.3390/jcs9080393 - 24 Jul 2025
Viewed by 315
Abstract
This paper investigates the interplay between rubber network damage, carbon black (CB) network damage, heat exchange, and voiding mechanisms in filled Styrene-butadiene rubber (SBR) under cyclic loading. To do so, three carbon black filled SBR composites, SBR5, SBR30 and SBR60 are studied. The [...] Read more.
This paper investigates the interplay between rubber network damage, carbon black (CB) network damage, heat exchange, and voiding mechanisms in filled Styrene-butadiene rubber (SBR) under cyclic loading. To do so, three carbon black filled SBR composites, SBR5, SBR30 and SBR60 are studied. The study aims to quantify molecular damage and its role in inducing reversible or irreversible heat flow and voiding behavior to inform the design of more resilient rubber composites with improved fatigue life and thermal management capabilities. The study effectively demonstrated how increasing carbon black content, particularly in SBR60, leads to a shift from mostly reversible to irreversible and cumulative damage mechanisms during cyclic loading, as evidenced by thermal, volumetric, and electrical resistivity changes. In particular, we identify a critical mechanical energy of 7 MJ.m−3 associated with such transition. These irreversible changes are strongly linked to the damage and re-arrangement of the carbon black filler network, as well as the rubber chains network and the formation/growth of voids, while reversible mechanisms are likely related to rubber chains alignment associated with entropic elasticity. Full article
(This article belongs to the Special Issue Composites: A Sustainable Material Solution, 2nd Edition)
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20 pages, 28281 KiB  
Article
Infrared-Guided Thermal Cycles in FEM Simulation of Laser Welding of Thin Aluminium Alloy Sheets
by Pasquale Russo Spena, Manuela De Maddis, Valentino Razza, Luca Santoro, Husniddin Mamarayimov and Dario Basile
Metals 2025, 15(8), 830; https://doi.org/10.3390/met15080830 - 24 Jul 2025
Viewed by 330
Abstract
Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser [...] Read more.
Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser welding plays a crucial role in assembling such materials, offering high flexibility and fast joining capabilities for thin aluminium sheets. However, welding these materials presents specific challenges, particularly in controlling heat input to minimize distortions and ensure consistent weld quality. As a result, numerical simulations based on the Finite Element Method (FEM) are essential for predicting weld-induced phenomena and optimizing process performance. This study investigates welding-induced distortions in laser butt welding of 1.5 mm-thick Al 6061 samples through FEM simulations performed in the SYSWELD 2024.0 environment. The methodology provided by the software is based on the Moving Heat Source (MHS) model, which simulates the physical movement of the heat source and typically requires extensive calibration through destructive metallographic testing. This transient approach enables the detailed prediction of thermal, metallurgical, and mechanical behavior, but it is computationally demanding. To improve efficiency, the Imposed Thermal Cycle (ITC) model is often used. In this technique, a thermal cycle, extracted from an MHS simulation or experimental data, is imposed on predefined subregions of the model, allowing only mechanical behavior to be simulated while reducing computation time. To avoid MHS-based calibration, this work proposes using thermal cycles acquired in-line during welding via infrared thermography as direct input for the ITC model. The method was validated experimentally and numerically, showing good agreement in the prediction of distortions and a significant reduction in workflow time. The distortion values from simulations differ from the real experiment by less than 0.3%. Our method exhibits a slight decrease in performance, resulting in an increase in estimation error of 0.03% compared to classic approaches, but more than 85% saving in computation time. The integration of real process data into the simulation enables a virtual representation of the process, supporting future developments toward Digital Twin applications. Full article
(This article belongs to the Special Issue Manufacturing Processes of Metallic Materials)
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17 pages, 3279 KiB  
Article
Rapid Assessment of Ti-6Al-4V Fatigue Limit via Infrared Thermography
by Chiara Colombo, Antonio Salerno, Arthur Teyssiéras and Carlo Alberto Biffi
Metals 2025, 15(8), 825; https://doi.org/10.3390/met15080825 - 23 Jul 2025
Viewed by 261
Abstract
The experimental tests needed for the estimation of the fatigue limit generally require extensive time and many specimens. A valid but not standardized alternative is the thermographic analysis of the self-heating phenomenon. The present work is aimed at using Infrared thermography to determine [...] Read more.
The experimental tests needed for the estimation of the fatigue limit generally require extensive time and many specimens. A valid but not standardized alternative is the thermographic analysis of the self-heating phenomenon. The present work is aimed at using Infrared thermography to determine the fatigue limit in two kinds of Ti-6Al-4V samples obtained by hot rolling: (1) with the standard dog-bone shape (unnotched specimen) and (2) with two opposed semicircular notches at the sides (notched specimen). Uniaxial tensile experiments are performed on unnotched samples, and the surface temperature variation during loading is monitored. The stress corresponding to the end of the thermoelastic stage gives a rough indication of the fatigue limit. Then, fatigue tests at different sinusoidal loads are performed, and the thermographic signal is monitored and processed. The results obtained using lock-in thermography in dissipative mode, e.g., analyzing the second harmonic, showed a sudden change in slope when the applied stress exceeded a certain limit. This slope change is related to the fatigue limit. In addition, the ratio between the fatigue limits obtained for notched and unnotched specimens, e.g., the fatigue strength reduction factor, is consistent with literature values based on the selected geometry. Full article
(This article belongs to the Special Issue Fracture Mechanics of Metals (2nd Edition))
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18 pages, 4345 KiB  
Article
Single-Thermocouple Suspended Microfluidic Thermal Sensor with Improved Heat Retention for the Development of Multifunctional Biomedical Detection
by Lin Qin, Xiasheng Wang, Chenxi Wu, Yuan Ju, Hao Zhang, Xin Cheng, Yuanlin Xia, Cao Xia, Yubo Huang and Zhuqing Wang
Sensors 2025, 25(15), 4532; https://doi.org/10.3390/s25154532 - 22 Jul 2025
Viewed by 259
Abstract
Thermal sensors are widely used in medical, industrial and other fields, where the requirements for high sensitivity and portability continues to increase. Here we propose a suspended bridge structure fabricated using MEMS, which effectively shrinks the size and reduces heat loss. This study [...] Read more.
Thermal sensors are widely used in medical, industrial and other fields, where the requirements for high sensitivity and portability continues to increase. Here we propose a suspended bridge structure fabricated using MEMS, which effectively shrinks the size and reduces heat loss. This study reviews current sensor-related theories of heat conduction, convective heat transfer and thermal radiation. Heat loss models for suspended and non-suspended bridge structures are established, and finite element analysis is conducted to evaluate their thermal performance. The thermal performance of the suspended bridge structure is further validated through infrared temperature measurements on the manufactured sensor device. Theoretical calculations demonstrate that the proposed suspension bridge structure reduces heat loss by 88.64% compared with traditional designs. Benefiting from this improved heat retention, which was also confirmed by infrared thermography, the thermal sensor fabricated based on the suspension bridge structure achieves an ultra-high sensitivity of 0.38 V/W and a fast response time of less than 200 ms, indicating a high accuracy in thermal characterization. The correlation coefficient obtained for the sensor output voltage and input power of the sensor is approximately 1.0. Based on this design, multiple microfluidic channels with suspended bridge structures can be integrated to realize multi-component detection, which is important for the development of multifunctional biomedical detection. Full article
(This article belongs to the Section Biomedical Sensors)
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