Search Results (55)

This study proposes a new method for rolling steel balls using spiral discs. The aim of the study was to investigate whether the proposed method could be used to produce balls with a diameter of 63 mm, as well as to determine the effect of tool geometry and the number of billets on process stability, force, and the energy parameters of the rolling process. Numerical simulations were performed using Forge^® NxT v.4.0. The billet for rolling was made of C60 steel and preheated to 1050 °C. The following cases of ball rolling were simulated: Ball rolling using flat discs with single, double, and triple spiral impressions made on their working surface, and ball rolling using tapered discs for two different configurations of the working system. The rolling process was examined in terms of ball shape, internal defect formation, temperature distribution, as well as force and energy parameters. The results showed that the rolling process conducted using tapered discs and by flat discs with single and double impressions produced correctly shaped balls without internal cracks. It was also found that discs with double impressions were more advantageous than the single-impression ones in terms of energy consumption, while the use of discs with triple spiral impressions led to higher tool load and reduced product quality despite the high efficiency of these discs. The system comprising one disc with an external conical working surface and one disc with an internal conical working surface yielded the best results with the lowest energy consumption and power demand. The findings of this study demonstrate that ball rolling using spiral discs is a promising alternative to standard skew rolling methods. Full article

The crystal structure evolution and phase transformation of single-crystal germanium during temperature-assisted nanomachining were investigated using the molecular dynamics method. The differences in surface atomic distribution, material removal volume, subsurface damage depth, surface roughness, and normal cutting force of single-crystal germanium under two different cutting depths at preheating temperatures of 300 K, 450 K, 600 K, 750 K, and 900 K were compared. The results show that with the increase in cutting depth, the material removal amount and subsurface damage depth increase. In addition, as the temperature increases, the thermal softening effect mitigates brittle fracture at low temperatures can reduce the brittle fracture at low temperatures, and the material removal mode also transitions from brittle fracture to plastic shear, which makes the internal stress of the workpiece balanced and thus conducive to forming a better machined surface. However, constrained by the size effect, it is difficult to explain the machining mechanism of single-crystal germanium cutting at the macroscopic level. Therefore, this study innovatively simulated the heating input via temperature control, revealing the machining mechanism of single-crystal germanium cutting at different temperatures from a microscopic perspective. The results show that increasing cutting depth enlarges material removal volume and subsurface damage. More importantly, preheating induces a non-monotonic transition in material removal behavior: from brittle fracture at 300 K to stable plastic shear between 450 K and 750 K, and eventually to thermally induced tearing above 750 K. An optimal processing window is identified—450 K minimizes subsurface damage, while 750 K maximizes removal efficiency. These findings provide quantitative guidance for selecting preheating temperatures in ultra-precision machining of brittle semiconductors. Full article

Glass preheating prior to laser scanning is expected to enhance internal modification morphology; however, its effect on weld seam topology and welding strength have not been investigated. In the current work, the effects of preheating on ultrafast laser (184 fs and 10 ps) internal modification and welding strength of borosilicate glass slides are investigated. For the internal modification experiments, pulse energy of 30–100 µJ and repetition rate of 10 kHz are used by focusing a laser beam at the interface of optically contacted slides at room temperature (RT ≈ 23 °C), 150 and 200 °C. Welding is conducted by a pulse energy of 4.5–18 µJ and repetition rate of 200 kHz using pre-clamped glass slides with a scanning speed of 10 mm/s at RT and 150 °C. Also, for welding, the optimum number of scans and hatching spacing are identified. Filamentation experiments show that discoloration is not significant when preheat temperature reaches 200 °C. Compared to 10 ps, pulse duration of 184 fs can produce a 19% narrower plasma-modified region at both RT and 150 °C and a 13% wider heat-affected zone at 150 °C. Welding using optimum conditions of 5 scans and 200 µm hatch, and “crack-free” laser parameters produces an average strength of: 50 ± 3.2 MPa at RT and 40 ± 2 MPa at 150 °C for 184 fs compared to 35 MPa at RT and 32 MPa at 150 °C for 10 ps, using 10 replicates each. However, the welding strength upon preheating to 150 °C using 184 fs is still 25% higher compared to average reported laser welding bonding strength, while the 10 ps strength is within the reported average. The enhanced welding strength for 184 fs can be attributed to reduced microcracking, especially when “crack free” combinations are utilized. Full article

The present study deals with the problem of irregular temperature distribution, simultaneous under-firing and over-firing, and their resultant efficiency and quality problems in a mechanical lime vertical kiln powered by domestic waste flue gas. The numerical simulation and structure optimization were carried out based on a 150 kg/h pilot-scale kiln. This combined model was built on the ANSYS Fluent 2022 R1 platform with UDF and UDS, incorporating limestone decomposition kinetics to enable the solution of gas and solid energy equations separately, and simulation of complex transfer and reaction processes. To correct the separation of flows at one inlet, a symmetric four-direction (00, 900, 1800, 2700) air intake plan was suggested. The findings show that this design essentially transforms the internal flow field into uniform and symmetrical temperature and concentration distributions. The calcination region contained both gas and solid temperatures in the optimum range to produce active lime. Specifically, the optimized kiln achieved a temperature range of 1190–1450 K in the calcination zone, a decomposition rate of approximately 82.7% (compared to 5.3% in the original model), and an increase in effective CaO content from 81.7% to 87.7%, with validation errors below 15%. It was demonstrated that the model is reliable, since the outlet simulated values correlated well with the measured ones. The preheating, calcining, and cooling zones’ heights of the optimized kiln adhered to the design requirements. This research is innovative in its application of a multi-physics coupling model with a varying heat source in a kiln and, in turn, identifies the synergism improvement process in the flow, temperature, concentration, and reaction fields. Full article

The increasing global demand for energy has accelerated the depletion of identified conventional resources, highlighting the need for sustainable alternatives. Geothermal energy, a renewable resource derived from the Earth’s internal heat, offers a reliable solution for both power generation and direct use applications. We present a comprehensive investigation of medium-enthalpy geothermal reservoirs in the Prinos–Kavala Basin, Northern Aegean, Greece. We firstly integrate geological, geophysical, and geochemical data from 66 wells across Prinos–Kavala basin to analyze the temperature distribution in the reservoir. The methodology includes the correction of bottom-hole temperatures and estimation of the geothermal gradients. A 1-D semi-steady-state well temperature modeling technique was applied to estimate the expected production wellhead temperature and assess its suitability for surface heating applications. Results reveal significant spatial heterogeneity in geothermal gradients and reservoir properties, with overpressured conditions confirmed in key zones. The integration of 3D reservoir model and isothermal mapping (>90 °C) identifies zones with high geothermal potential, supporting optimal exploitation strategies. The estimated production wellhead temperatures support the utilization of the produced brine heat content for various applications, among them the pre-heating of a CO₂ stream to be injected within the CCS framework for wellbore thermal stress management purposes. The findings demonstrate the value of reservoir characterization for sustainable geothermal development in complex tectonic settings. Full article

This study presents the first application of Machine Learning (ML) models to optimise Powder Bed Fusion using Laser Beam (PBF-LB) process parameters for H13 steel fabricated on a 350 °C preheated building platform. A total of 189 cylindrical specimens were produced for training and testing machine learning (ML) models using variable process parameters: laser power (250–350 W), scanning speed (1050–1300 mm/s), and hatch spacing (65–90 $\mathsf{\mu }$m). Eight ML models were investigated: 1. Support Vector Regression (SVR), 2. Kernel Ridge Regression (KRR), 3. Stochastic Gradient Descent Regressor, 4. Random Forest Regressor (RFR), 5. Extreme Gradient Boosting (XGBoost), 6. Extreme Gradient Boosting with limited depth (XGBoost LD), 7. Extra Trees Regressor (ETR) and 8. Light Gradient Boosting Machine (LightGBM). All models were trained using the Fast Library for Automated Machine Learning & Tuning (FLAML) framework to predict the relative density of the fabricated samples. Among these, the XGBoost model achieved the highest predictive accuracy, with a coefficient of determination $R^2=0.977$, mean absolute percentage error MAPE = 0.002, and mean absolute error MAE = 0.017. Experimental validation was conducted on 27 newly fabricated samples using ML predicted process parameters. Relative densities exceeding 99.6% of the theoretical value (7.76 g/cm³) for all models except XGBoost LD and KRR. The lowest MAE = 0.004 and the smallest difference between the ML-predicted and PBF-LB validated density were obtained for samples made with LightGBM-predicted parameters. Those samples exhibited a hardness of 604 ± 13 HV0.5, which increased to approximately 630 HV0.5 after tempering at 550 °C. The LightGBM optimised parameters were further applied to fabricate a part of a forging die incorporating internal through-cooling channels, demonstrating the efficacy of machine learning-guided optimisation in achieving dense, defect-free H13 components suitable for industrial applications. Full article

This study probabilistically assesses magma ascent by modeling dike propagation as a fully coupled fluid-flow, thermo-mechanical problem, explicitly accounting for the stochastic heterogeneity of the crustal host rock. We study felsic (rhyolite) lava flow and two distinct basaltic feeding regimes that correspond to the conditions necessary to produce the contrasting pāhoehoe and ʻaʻā surface morphologies. Basaltic dikes demonstrate high propagation efficiency to the surface (pāhoehoe-feeding regime 99.5%; ʻaʻā-feeding regime 97.5%), whereas rhyolite dikes have an 89% failure rate, attributed to significant friction. Both regimes represent distinct constructal approaches aimed at maximizing flow persistence. The pāhoehoe-feeding regime is a thermally regulated, stable design characterized by low-velocity, cooling-dominated dynamics. Its slow, persistent flow allows for significant conductive heating of the surrounding rock wall, creating an efficient, pre-heated thermal conduit. In contrast, the ʻaʻā-feeding regime is a mechanically dominated design governed by high-velocity, stochastic dynamics. This morphology is driven by forceful flow, and its thermal budget is supplemented by intense viscous dissipation (internal friction). Rhyolite magma flow fails upon losing constructal viability, driven by a coupled mechanical–thermal cascade. The sequence begins when a mechanical barrier halts the magma velocity, which triggers a freezing event and leads to permanent arrest. Full article

A numerical model was developed to simulate a fluidized bed reactor for isobutane dehydrogenation. First, we constructed a hydrodynamic model of catalyst particle fluidization and a kinetic model for three chemical reactions in a simple lab-scale reactor (H = 70 cm, D = 2.8 cm). Experimental studies and numerical simulation of the laboratory reactor were carried out at four temperatures: 550, 575, 600, and 625 °C. The product yield results from the computational fluid dynamics simulation show a close match to the experimental data. The optimal process temperature in the laboratory reactor is 575 °C, at which the isobutylene yield is ~46.03 wt%. With decreasing temperature, the isobutylene yield decreases, and it rises as temperature increases. However, with rising temperature, the total yield of by-products increases on average to 20 wt%. We compared the CFD simulation results for two laboratory reactor models: a 3D model and a 2D axisymmetric model. For gas phase fractions, absolute deviations ranged from 0.01 to 1.12%, while relative deviations were between 0.006% and 0.114%. However, there are differences in the solid-phase particle dynamics. Second, we applied the constructed CFD model to simulate an industrial-scale reactor (H = 23.81 m, D = 4.6 m). In addition to its size, the industrial reactor differs from the laboratory reactor in its heating principle. In this configuration, the gas, preheated to 550 °C, and the catalyst particles, at 650 °C, are fed into the entire volume. The objective of this study is to test the performance of the model, which was verified on a laboratory reactor, for simulating an industrial reactor. Temperature fields and zones of reaction product formation are analyzed. The average isobutylene yield is ~31.88 wt%, which is consistent with the operation of real reactors but lower than the results for the laboratory reactor at all temperatures. The industrial reactor is more challenging to heat uniformly. It contains many internal elements that affect the movement of the gas–solid system. Overall, the model developed for the laboratory reactor has proven to be suitable for CFD modeling of an industrial reactor. Full article

Residual stress remains a significant challenge in the widespread adoption of the Laser Powder Bed Fusion (LPBF) process, due to its detrimental impact on dimensional accuracy and post-processing requirements and hinders further processing with methods such as welding. Different strategies have already been explored to reduce or mitigate these stresses, including preheating, alternating scan strategies, and heat treatments. In this study, a less commonly investigated approach is examined: the influence of melt pool geometry—specifically layer height and track width—on the residual stresses in LPBF-manufactured 316L stainless steel. By systematically varying these parameters, the resulting internal stress states are compared by distortion measurements of cantilever parts to determine potential correlations and mechanisms of influence. The findings aim to contribute to a deeper understanding of process–structure–property relationships in LPBF and to offer a new avenue for stress control through geometrical process parameter optimization. It can be concluded that among all the strategies for preventing and mitigating residual stress in LPBF, the examined approach has a relatively small influence. The results show that increasing layer thickness and decreasing spot diameter have beneficial effects on the resulting deformations. Full article

In recent decades, pollutant emissions from the combustion of fossil fuels have become increasingly serious for the environment. The present paper reports experimental results for research carried out under laboratory conditions for a Selective Catalytic Reduction (SCR) system, implemented in different configurations on an ISUZU 4JB1 diesel engine. The obtained results allow for a comparative analysis of NOx formation as a function of diesel engine load (χ = 25–100%), at 1350, 2100, 2850, and 3600 rpm, with the engine operating under either cold (T < 343 K) or warm (T > 343 K) regimes. A preheating system for AdBlue droplets, in the form of a metal honeycomb that uses electromagnetic induction and incorporates a high-frequency generator, was introduced in the flow path of the combustion gases and tested to compare the experimental results. This system enabled temperatures of up to 643 K. A magneto-strictive system was also introduced in the SCR structure to atomize the AdBlue droplets to a minimum diameter of 3.5 μm. Using this principle, combined with preheating, the effect of calefaction was compared with the classical case of the internal heating of the SCR catalyst. For experimental purposes, piezoelectric cells dedicated to the transformation of the AdBlue solution into micro- or nano-droplets, which were entrained into the SCR by an ejector, were also used. Experimental results are presented in graphical form and reveal that the use of preheating, heating, or piezoelectric cells leads to improved NOx conversion. The tested solutions showed reductions in NOx emissions of up to eight times depending on the diesel engine load, demonstrating their strong impact on NOx reduction. Full article

The escalating demand for efficient thermal management in lithium-ion batteries necessitates precise characterization of their thermal behavior under diverse operating conditions. This study develops a three-dimensional (3D) electrochemical–thermal coupling model grounded in porous electrode theory and energy conservation principles. The model solves multi-physics equations such as Fick’s law, Ohm’s law, and the Butler–Volmer equation, to resolve coupled electrochemical and thermal dynamics, with temperature-dependent parameters calibrated via the Arrhenius equation. Simulations under varying discharge rates reveal that high-rate discharges exacerbate internal heat accumulation. Low ambient temperatures amplify polarization effects. Forced convection cooling reduces surface temperatures but exacerbates core-to-surface thermal gradients. Structural optimization strategies demonstrate that enhancing through-thickness thermal conductivity reduces temperature differences. These findings underscore the necessity of balancing energy density and thermal management in lithium-ion battery design, proposing actionable insights such as preheating protocols for low-temperature operation, optimized cooling systems for high-rate scenarios, and material-level enhancements for improved thermal uniformity. Full article

Polymer electrolyte membrane fuel cells (PEMFCs) are emerging as the next-generation powertrain for unmanned aerial vehicles (UAVs) due to their high energy density and long operating duration. PEMFCs are subject to icing and performance degradation problems at sub-zero temperatures, especially at high altitudes. Therefore, an effective preheating system is required to ensure stable PEMFC operation in high-altitude environments. This study aimed to mathematically model a shell-and-tube heat exchanger that utilizes waste heat recovery to prevent internal and external PEMFC damage in cold, high-altitude conditions. The waste heat from the PEMFC is estimated based on the thrust of the MQ-9 Reaper, and the proposed heat exchanger must be capable of heating air to −5 °C. As the heat exchanger utilizes only waste heat, the primary energy consumption arises from the coolant pumping process. Calculation results indicated that the proposed heat exchanger design improved the overall system efficiency by up to 15.7%, demonstrating its effectiveness in utilizing waste heat under aviation conditions. Full article

This paper presents a theoretical and experimental investigation into improving the energy efficiency of electrically heated systems through thermal energy recovery. Enhancing efficiency in such systems can significantly reduce energy consumption, operating costs, and greenhouse gas emissions, particularly when electricity is generated from fossil fuels. Commercial dishwashers are inherently energy-intensive due to the need for rapid and effective cleaning. Regulatory and market pressures increasingly encourage manufacturers to develop energy-efficient technologies. This study aimed to design, develop, and incorporate a miniaturized heat exchanger to recover waste thermal energy and reduce the overall energy consumption in a commercial dishwasher. In collaboration with Norris Industries, the University of Newcastle trialed a retrofitted internal heat exchanger in representative commercial dishwasher models. The device was designed to transfer heat from discharged wash water to preheat incoming freshwater. The heat exchanger was developed based on a theoretical thermal analysis and engineered for practical integration. Experimental testing demonstrated that the system achieved up to a 50% reduction in energy use without compromising the cleaning performance or increasing the manufacturing complexity. This approach offers a scalable and effective solution for enhancing energy efficiency in commercial dishwashing. Its broader implementation could substantially reduce the energy demand and greenhouse gas emissions across the sector. Full article

A novel design of a proton exchange membrane electrolyzer is presented. In contrast to previous designs, the flow field plates are round and oriented horizontally with the feed water entering from a central hole and spreading evenly outward over the anode flow field in radial, interdigitated flow channels. The cathode flow field consists of a spiral channel with an outlet hole near the outside of the bipolar plate. This results in anode and cathode flow channels that run perpendicular to avoid shear stresses. The novel sealing concept requires only o-rings, which press against the electrolyte membrane and are countered by circular gaskets that are placed over the flow channels to prevent the membrane from penetrating the channels, which makes for a much more economical sealing concept compared to prior designs using custom-made gaskets. Hydrogen leaves the electrolyzer through a vertical outward pipe placed off-center on top of the electrolyzer. The electrolyzer stack is housed in a cylinder to capture the oxygen and water vapor, which is then guided into a heat exchanger section, located underneath the electrolyzer partition. The function of the heat exchanger is to preheat the incoming fresh water and condense the escape water, thus improving the efficiency. It also serves as internal phase separator in that a level sensor controls the water level and triggers a recirculation pump for the condensate, while the oxygen outlet is located above the water level and can be connected to a vacuum pump to allow for electrolyzer operation at sub-ambient pressure to further increase efficiency and/or reduce the iridium loading. Full article

The combustion of ammonia with oxygen presents a promising pathway for global energy transformation using carbon dioxide-neutral energy solutions and carbon capture. Ammonia, a carbon-free fuel, offers several benefits, owing to its non-explosive nature, high octane rating, and ease of storage and distribution. However, challenges such as low flammability and excessive nitrogen oxide (NO_x) emissions must be addressed. This paper explores the recent advances in ammonia oxy-combustion and highlights recent experimental and numerical research on NO_x emission traits, combustion, and flame propagation across various applications, including gas furnaces, internal combustion engines, and boilers. Furthermore, this review discusses the diverse approaches to overcoming the challenges of ammonia combustion, including oxygen enrichment, fuel blending, plasma assistance, preheating, multiple injections, and burner design modifications. By summarizing the advancements in ammonia oxy-combustion investigation, this paper aims to provide valuable insights that can serve as reference information for prospective ammonia oxy-combustion research and applications toward the transition to sustainable energy. Full article