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17 pages, 7927 KB  
Article
Gas Leakage and Hazard Area Division in a Converter Fan Room: Based on the Actual Leakage Site
by Zeng Long, Furan Zheng, Qi Wang, Hongqing Zhu, Xianhui Xu, Xiliang Liu and Shunyu Yue
Sustainability 2026, 18(2), 756; https://doi.org/10.3390/su18020756 - 12 Jan 2026
Viewed by 237
Abstract
Converter gas is highly susceptible to leakage during the recovery and utilization process, which threatens personnel security and sustainable industrial development. To address this issue, a numerical model was established based on an actual converter fan room, and the accuracy of the simulation [...] Read more.
Converter gas is highly susceptible to leakage during the recovery and utilization process, which threatens personnel security and sustainable industrial development. To address this issue, a numerical model was established based on an actual converter fan room, and the accuracy of the simulation was verified through comparison with actual measurement data. In this study, the gas leakage flow field, diffusion trajectories, and hazard zone gradations were analyzed. Results showed that the gas contamination was significantly influenced by the leakage direction, leakage location, and structural boundary. The jet dominated the gas dispersion near the leakage source, with similar initial diffusion characteristics across different scenarios. Then, the diffusion velocity decayed rapidly within a distance of 0.6 m. Obstacles can significantly promote vortex formation, restrict the gas dispersion path, and reduce the extent of the hazardous area. In addition, it can be found that the far-field velocity under downward leakage was the highest, presenting the greatest risk of poisoning. At a height of 1.6 m, a lethal zone with a radius of 0.8 m was formed directly beneath the leakage hole. This work can guide the optimization of the monitoring program and emergency planning for converter gas leakage accidents. Full article
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23 pages, 4022 KB  
Review
On the Counter-Rotating Tori and Counter-Rotating Parts of the Kerr Black Hole Shadows
by Daniela Pugliese and Zdenek Stuchlík
Universe 2025, 11(12), 417; https://doi.org/10.3390/universe11120417 - 17 Dec 2025
Viewed by 472
Abstract
We review some aspects of accretion disks physics, spacetime photon shell and photon orbits, related to retrograde (counter-rotating) motion in Kerr black hole (BH) spacetimes. In this brief review, we examine the counter-rotating components of the Kerr BH shadow boundary, under [...] Read more.
We review some aspects of accretion disks physics, spacetime photon shell and photon orbits, related to retrograde (counter-rotating) motion in Kerr black hole (BH) spacetimes. In this brief review, we examine the counter-rotating components of the Kerr BH shadow boundary, under the influence of counter-rotating accretion tori, accreting flows and proto-jets (open critical funnels of matter, associated with the tori) orbiting around the central BH. We also analyze the redshifted emission arising from counter-rotating structures. Regions of the shadows and photon shell are constrained in their dependence of the BH spin and observational angle. The effects of the counter-rotating structures on these are proven to be typical of the fast-spinning BHs, and accordingly can be observed only in the restricted classes of the Kerr BH spacetimes. This review is intended as a concise guide to the main properties of counter-rotating fluxes and counter-rotating disks in relation to the photon shell and the BH shadow boundary. Our findings may serve as the basis for different theoretical frameworks describing counter-rotating accretion flows with observable imprints manifesting at the BH shadow boundary. The results can eventually enable the distinction of counter-rotating fluxes through their observable imprints, contributing to constraints on both the BH spin and the structure of counter-rotating accretion disks. In particular, photon trajectories and their impact parameters can manifest in the morphology of the BH shadow. Such features, when accessible through high-resolution imaging and spectral or polarization measurements, could provide a direct avenue for testing different theoretical models on accretion disk dynamics and their BH attractors. Full article
(This article belongs to the Collection Open Questions in Black Hole Physics)
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31 pages, 4381 KB  
Article
Real-Time Forecasting of a Fire-Extinguishing Agent Jet Trajectory from a Robotic Fire Monitor Under Disturbances
by Irina Pozharkova and Sergey Chentsov
Robotics 2025, 14(12), 188; https://doi.org/10.3390/robotics14120188 - 14 Dec 2025
Viewed by 588
Abstract
This article presents a methodology for real-time forecasting of a fire-extinguishing agent jet trajectory from a robotic fire monitor under wind influence, which can significantly displace the impact area position and complicate targeting. The proposed methodology is designed for controlling firefighting robots in [...] Read more.
This article presents a methodology for real-time forecasting of a fire-extinguishing agent jet trajectory from a robotic fire monitor under wind influence, which can significantly displace the impact area position and complicate targeting. The proposed methodology is designed for controlling firefighting robots in conditions where visual monitoring of the impact area is impeded by factors such as: obscuration of the fire-extinguishing agent flow by smoke, low visibility of its fragmented particles against the background environment, and long-range jet discharge. Trajectory forecasting is implemented using a neural network model. The training and verification of this model are performed with datasets constructed from the results of numerical simulations of fire-extinguishing agent motion under wind influence, based on Computational Fluid Dynamics (CFD) methods. Experimentally obtained data are used for the validation of the trained neural network model and the selected CFD models. The paper describes the methodology for conducting full-scale tests of fire monitors; a photogrammetric algorithm for generating validation datasets from the test results; an algorithm for calculating target characteristics, which describe the jet trajectory and are consistent with experimental data, used for forming training and verification datasets based on simulation; and a procedure for selecting Computational Fluid Dynamics models and their parameters to ensure the required accuracy. The article also presents the results of an experimental evaluation of the developed methodology’s effectiveness for real-time prediction of the water jet trajectory from a fire monitor under various control and disturbance parameters. Full article
(This article belongs to the Special Issue Applications of Neural Networks in Robot Control)
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35 pages, 10852 KB  
Article
Unsteady Flow and Loading Characteristics of Rotating Spheres During Underwater Ejection
by Hao Xu, Mingyang Wang, Zhou Zhou, Tiezhi Sun and Guiyong Zhang
J. Mar. Sci. Eng. 2025, 13(12), 2331; https://doi.org/10.3390/jmse13122331 - 8 Dec 2025
Cited by 1 | Viewed by 660
Abstract
This study systematically investigates the evolution of the flow field and cavitation behavior during the underwater launch of a rotating sphere. By comparing surface pressure distribution, cavitation evolution, flow separation locations, and re-entrant jet formation under various rotational conditions, this study reveals the [...] Read more.
This study systematically investigates the evolution of the flow field and cavitation behavior during the underwater launch of a rotating sphere. By comparing surface pressure distribution, cavitation evolution, flow separation locations, and re-entrant jet formation under various rotational conditions, this study reveals the significant influence of rotation on both the cavitation processes and sphere’s motion trajectory. It is found that under rotational conditions, cavity detachment tends to occur earlier on the front side, and the re-entrant jet develops more fully, reaching maximum length and intensity at a moderate angular velocity. In additionally, rotation alters the cavity interface and overall flow structure, resulting in noticeable differences in surface wetting, pressure distribution, and separation behavior between the front and rear sides. As the rotational speed increases, flow separation points become less distinct, and pressure fluctuations on the rear side intensify, indicating that rotation plays a critical role in modulating underwater cavitation dynamics. The findings provide theoretical insights into flow control and cavitation risk assessment for underwater launches of rotating bodies. Full article
(This article belongs to the Section Ocean Engineering)
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23 pages, 7150 KB  
Article
Influence of a Sloped Bottom on a 60-Degree Inclined Dense Jet Discharged into a Stationary Environment: A Large Eddy Simulation Study
by Xinyun Wang and Abdolmajid Mohammadian
J. Mar. Sci. Eng. 2025, 13(12), 2309; https://doi.org/10.3390/jmse13122309 - 4 Dec 2025
Cited by 1 | Viewed by 427
Abstract
In the present study, numerical simulations were conducted to investigate the behavior of a 60° inclined dense jet discharged onto horizontal (0°) and sloped (5°) bottoms in a stagnant environment. The objective was to evaluate the capability of Large Eddy Simulation (LES) in [...] Read more.
In the present study, numerical simulations were conducted to investigate the behavior of a 60° inclined dense jet discharged onto horizontal (0°) and sloped (5°) bottoms in a stagnant environment. The objective was to evaluate the capability of Large Eddy Simulation (LES) in capturing both the kinematic and mixing characteristics of inclined dense jets interacting with different bottom boundaries. A Reynolds-Averaged Navier–Stokes (RANS) model was also included for comparison. The LES simulations successfully reproduced the key kinematic and mixing characteristics, including the jet trajectory, centerline peak location, impact point, and terminal rise height, and showed strong agreement with the experimental observations. LES also predicted the concentration distributions and variations along both the horizontal and sloped bottoms, whereas the RANS model tended to underestimate both geometrical and dilution properties. A Gaussian fitting function was proposed to estimate the concentration distribution under both bottom conditions. Analysis of the spreading layer indicated that the concentration profiles exhibited self-similarity. Energy spectrum analysis showed that the sloped bottom enhanced shear-induced turbulence, thereby improving the mixing efficiency. Results confirm the reliability of LES for describing jet–bed interactions and emphasize the influence of bed slope on jet dilution and mixing behavior. Full article
(This article belongs to the Section Physical Oceanography)
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22 pages, 13714 KB  
Article
Numerical Simulation of Flow-Field Characteristics of a Submerged Pre-Mixed Abrasive Water Jet Impinging on a Wall
by Jinfa Guan, Jimiao Duan, Peili Zhang, Sichen He, Shiming Chen, Jian Wang and Jun Xiao
Processes 2025, 13(11), 3647; https://doi.org/10.3390/pr13113647 - 11 Nov 2025
Viewed by 581
Abstract
To investigate the flow-field characteristics of a submerged pre-mixed abrasive water jet impinging on a wall, a physical model of the conical–cylindrical nozzle and computation domain of a submerged pre-mixed abrasive-water-jet flow field were established. Based on the software of FLUENT 2022R2, numerical [...] Read more.
To investigate the flow-field characteristics of a submerged pre-mixed abrasive water jet impinging on a wall, a physical model of the conical–cylindrical nozzle and computation domain of a submerged pre-mixed abrasive-water-jet flow field were established. Based on the software of FLUENT 2022R2, numerical simulation of the solid–liquid two-phase flow characteristics of the submerged pre-mixed abrasive water jet impinging on a wall was conducted using the DPM particle trajectory model and the realizable kε turbulence model. The simulation results indicate that a “water cushion layer” forms when the submerged pre-mixed abrasive water jet impinges on a wall. Tilting the nozzle appropriately facilitates the rapid dispersion of water and abrasive particles, which is beneficial for cutting. The axial-jet velocity increases rapidly in the convergent section of the nozzle, continues to accelerate over a certain distance after entering the cylindrical section, reaches its maximum value inside the nozzle, and then decelerates to a steady value before exiting the nozzle. In addition, the standoff distance has minimal impact on the flow-field characteristic inside the nozzle. When impinging on a wall surface, rapid decay of axial-jet velocity generates significant stagnation pressure. The stagnation pressure decreases with increasing standoff distance for different standoff-distance models. Considering the effects of standoff distance on jet velocity and abrasive particle dynamics, a standoff distance of 5 mm is determined to be optimal for submerged pre-mixed abrasive-water-jet pipe-cutting operations. When the submergence depth is less than 100 m, its effect on the flow-field characteristics of a submerged pre-mixed abrasive water jet impinging on a wall surface remains minimal. For underwater oil pipelines operating at depths not exceeding 100 m, the influence of submergence depth can be disregarded during cutting operations. Full article
(This article belongs to the Special Issue Numerical Simulation of Oil and Gas Storage and Transportation)
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27 pages, 21880 KB  
Article
General Relativistic Effect on Sitnikov Three-Body Problem: Restricted Case
by Hideyoshi Arakida
Astronomy 2025, 4(4), 21; https://doi.org/10.3390/astronomy4040021 - 3 Nov 2025
Viewed by 1122
Abstract
We investigate the effect of general relativity on the Sitnikov problem. The Sitnikov problem is one of the simplest three-body problems, in which the two primary bodies (a binary system) have equal mass m and orbit their barycenter, while the third body is [...] Read more.
We investigate the effect of general relativity on the Sitnikov problem. The Sitnikov problem is one of the simplest three-body problems, in which the two primary bodies (a binary system) have equal mass m and orbit their barycenter, while the third body is treated as a test particle under Newtonian gravity. The trajectory of the test particle is perpendicular to the orbital plane of the binary (along z-axis) and passes through the barycenter of the two primaries. To study the general relativistic contributions, we first derive the equations of motion for both the binary and the test particle based on the first post-Newtonian Einstein–Infeld–Hoffmann equation, and integrate these equations numerically. We examine the behavior of the test particle (third body) as a function of the orbital eccentricity of the central binary e, the dimensionless gravitational radius λ, which characterizes the strength of general relativistic effect, and the initial position of the test particle z¯0. Our numerical calculations reveal the following; as general relativistic effects λ increase and the eccentricity e of the binary orbit grows, the distance r¯ between the test particle and the primary star undergoes complicated oscillations over time. Consequently, the gravitational force acting on the test particle also varies in a complex manner. This leads to a resonance state between the position z¯ of the test particle and the distance r¯, causing the energy E of the test particle to become E0. This triggers the effective ejection of the test particle due to the gravitational slingshot effect. In this paper, we shall refer to this ejection mechanism of test particle as the “Sitnikov mechanism.” As a concrete phenomenon that becomes noticeable, the increase in general relativistic effects and the eccentricity of the binary orbit leads to the following: (a) ejection of test particles from the system in a shorter time, and (b) increasing escape velocity of the test particle from the system. As an astrophysical application, we point out that the high-velocity ejection of test particles induced by the Sitnikov mechanism could contribute to elucidating the formation processes of astrophysical jets and hyper-velocity stars. Full article
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15 pages, 90200 KB  
Review
Optical Diagnostics Applications to Laboratory Astrophysical Research
by Wei Sun, Dawei Yuan, Zhe Zhang, Jiayong Zhong and Gang Zhao
Lights 2025, 1(1), 3; https://doi.org/10.3390/lights1010003 - 31 Oct 2025
Viewed by 720
Abstract
Laboratory astrophysics is an emerging interdisciplinary field bridging high-energy-density plasma physics and astrophysics. Optical diagnostic techniques offer high spatiotemporal resolution and the unique capability for simultaneous multi-field measurements. These attributes make them indispensable for deciphering extreme plasma dynamics in laboratory astrophysics. This review [...] Read more.
Laboratory astrophysics is an emerging interdisciplinary field bridging high-energy-density plasma physics and astrophysics. Optical diagnostic techniques offer high spatiotemporal resolution and the unique capability for simultaneous multi-field measurements. These attributes make them indispensable for deciphering extreme plasma dynamics in laboratory astrophysics. This review systematically elaborates on the physical principles and inversion methodologies of key optical diagnostics, including Nomarski interferometry, shadowgraphy, and Faraday rotation. Highlighting frontier progress by our team, we showcase the application of these techniques in analyzing jet collimation mechanisms, turbulent magnetic reconnection, collisionless shocks, and particle acceleration. Future trajectories for optical diagnostic development are also discussed. Full article
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31 pages, 17070 KB  
Article
WRF Simulations of Passive Tracer Transport from Biomass Burning in South America: Sensitivity to PBL Schemes
by Douglas Lima de Bem, Vagner Anabor, Damaris Kirsch Pinheiro, Luiz Angelo Steffenel, Hassan Bencherif, Gabriela Dornelles Bittencourt, Eduardo Landulfo and Umberto Rizza
Remote Sens. 2025, 17(20), 3483; https://doi.org/10.3390/rs17203483 - 19 Oct 2025
Viewed by 1142
Abstract
This single high-impact case study investigates the impact of planetary boundary layer (PBL) representation on long-range transport of Amazon fire smoke that reached the Metropolitan Area of São Paulo (MASP) from 15 to 20 August 2019, using the WRF model to compare three [...] Read more.
This single high-impact case study investigates the impact of planetary boundary layer (PBL) representation on long-range transport of Amazon fire smoke that reached the Metropolitan Area of São Paulo (MASP) from 15 to 20 August 2019, using the WRF model to compare three PBL schemes (MYNN 2.5, YSU, and BouLac) and three source-tagged tracers. The simulations are evaluated against MODIS-derived aerosol optical depth (AOD), the Light Detection and Ranging (LiDAR) time–height curtain over MASP, and HYSPLIT forward trajectories. Transport is diagnosed along the source-to-MASP pathway using six-hourly cross-sections and two integrative metrics: the projected mean wind in the 700–600 hPa layer and the vertical moment of tracer mass above the boundary layer. Outflow and downwind impact are strongest when a persistent reservoir between 2 and 4 km coexists with projected winds for several hours. In this episode, MYNN maintains an elevated 2–5 km transport layer and matches the observed arrival time and altitude, YSU yields a denser but delayed column, and BouLac produces discontinuous pulses with reduced coherence over the city. A negatively tilted trough, jet coupling, and a nearly stationary front establish a northwest-to-southeast corridor consistent across model fields, trajectories, and satellite signal. Seasonal robustness should be assessed with multi-event, multi-model analyses. Full article
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20 pages, 13754 KB  
Article
Understanding the Correlations Between the Formation of Columnar Structures and Suspension Properties for Suspension Plasma-Sprayed Thermal Barrier Coatings
by Yachen Feng, Wenhan Jiao, Pengyun Xu, Xiaomu Sui, Guijie Liu, Xianghua Zhan, Changfeng Fan and Mingli Lv
Coatings 2025, 15(10), 1132; https://doi.org/10.3390/coatings15101132 - 1 Oct 2025
Viewed by 785
Abstract
Columnar-structured thermal barrier coatings deposited via the suspension plasma spray process have attracted significant attention due to their long thermal cycling life and high cost-effectiveness. In this work, the effects of suspension properties, including solvent type, viscosity, and particle size, on the formation [...] Read more.
Columnar-structured thermal barrier coatings deposited via the suspension plasma spray process have attracted significant attention due to their long thermal cycling life and high cost-effectiveness. In this work, the effects of suspension properties, including solvent type, viscosity, and particle size, on the formation of different coating microstructures were investigated via a comparative study. Two different kinds of solvents (water and ethanol) and particles of different sizes (D50 = 0.45 μm and 1.2 μm) were used to prepare suspensions for coating deposition, respectively. When using suspensions containing small-sized particles as feedstock, coatings deposited from the ethanol-based suspension showed columnar microstructures with inter-column crevices, while the water-based suspension resulted in cracked–columnar microstructures, showing a mixture of columns and cracks. When the large-sized particles were used to prepare the suspension, both the ethanol-based suspension and the water-based suspension resulted in homogeneous coating microstructures. The formation mechanism of different microstructures was investigated by modelling the diverted plasma jet and the in-flight particle movement during the impingement period. Particles smaller than 2 μm were strongly affected by the diverted plasma gas, showing obvious oblique impinging trajectories, while particles larger than 3 μm kept their original trajectories and impinged on the substrate orthogonally. The formation mechanism of different microstructures was elaborated by analyzing the impinging trajectories of particles transitioning from different suspensions. Full article
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17 pages, 3338 KB  
Review
An Overview of Oil Spill Modeling and Simulation for Surface and Subsurface Applications
by M. R. Riazi
J. Exp. Theor. Anal. 2025, 3(4), 29; https://doi.org/10.3390/jeta3040029 - 23 Sep 2025
Viewed by 1776
Abstract
In this review paper, we briefly discuss the occurrence of oil spills and their behavior under natural sea conditions and clean-up methods, as well as their environmental and economic impacts. We discuss methodologies for oil spill modeling used to predict the fate of [...] Read more.
In this review paper, we briefly discuss the occurrence of oil spills and their behavior under natural sea conditions and clean-up methods, as well as their environmental and economic impacts. We discuss methodologies for oil spill modeling used to predict the fate of a spill under dynamic physical and chemical processes. Weathering processes such as evaporation, emulsification, spreading, dissolution, dispersion, biodegradation, and sedimentation are considered within easy-to-use modeling frameworks. We present simple models based on the principles of thermodynamics, mass transfer, and kinetics that under certain conditions can predict oil thickness, volume, area, composition, and the distribution of toxic compounds in water and air over time for various types of oil and their products. Modeling approaches for underwater oil jets, including applications related to the 2010 BP oil spill in the Gulf of Mexico, are reviewed. The influence of sea surface velocity and wind speed on oil spill mapping, spill location, oil spill trajectory over time, areas affected by light, medium, and heavy oil, and comparisons between satellite images and model predictions are demonstrated. Finally, we introduce several recently published articles on more recent oil spill incidents and the application of predictive models in different regions. We also discuss the challenges, advantages, and disadvantages of various models and offer recommendations at the end of the paper. Full article
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17 pages, 5751 KB  
Article
Laser-Induced Forward Transfer in Organ-on-Chip Devices
by Maria Anna Chliara, Antonios Hatziapostolou and Ioanna Zergioti
Photonics 2025, 12(9), 877; https://doi.org/10.3390/photonics12090877 - 30 Aug 2025
Cited by 1 | Viewed by 1366
Abstract
Laser-induced forward transfer (LIFT) bioprinting enables precise deposition of biological materials for advanced biomedical applications. This study presents a parametric analysis of the donor–receiver distances (1.0, 1.5, 2.0, 2.5, and 3.0 mm) in LIFT bioprinting, investigated through high-speed video and image analysis of [...] Read more.
Laser-induced forward transfer (LIFT) bioprinting enables precise deposition of biological materials for advanced biomedical applications. This study presents a parametric analysis of the donor–receiver distances (1.0, 1.5, 2.0, 2.5, and 3.0 mm) in LIFT bioprinting, investigated through high-speed video and image analysis of 4 × 4 spot arrays. Droplet velocity was quantified and jet trajectory characterized, revealing that increased distances reduced spatial resolution, with significant shape deterioration observed beyond 2.0 mm. Thus, a maximum 2.0 mm donor–receiver gap was determined as optimal for acceptable printing resolution. As an application, a microfluidic device was fabricated using LCD 3D printing with a biocompatible resin and glass-bottomed configuration. The chamber height was matched to the validated 2.0 mm distance, ensuring compatibility with LIFT printing. Computational fluid dynamics simulations were conducted to model fluid flow conditions within the device. Subsequently, LLC cells were successfully printed inside the microfluidic chamber, cultured under continuous flow for 24 h, and demonstrated normal proliferation. This work highlights LIFT bioprinting’s viability and precision for integrating cells within microfluidic platforms, presenting promising potential for organ-on-chip applications and future biomedical advancements. Full article
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17 pages, 2659 KB  
Article
Experimental Study on the Distribution of Boundary Shear Stress at an Overfall
by Zhangxin Qi, Zenghui Wang, Yue Pan and Pengbo Chu
Processes 2025, 13(8), 2652; https://doi.org/10.3390/pr13082652 - 21 Aug 2025
Viewed by 808
Abstract
Overfall flow, characterized by high Froude numbers and intense turbulence, generates boundary shear stress on vertical surfaces, which is considered the direct cause of headcut erosion. This study aims to analyze the hydraulic characteristics of nappe flow over a vertical or near-vertical overfall. [...] Read more.
Overfall flow, characterized by high Froude numbers and intense turbulence, generates boundary shear stress on vertical surfaces, which is considered the direct cause of headcut erosion. This study aims to analyze the hydraulic characteristics of nappe flow over a vertical or near-vertical overfall. Detailed experiments using hot-film anemometry were conducted in an indoor flume to examine the shear stress distribution on vertical surfaces under varying flow rates, overfall heights, and backwater depths. The results show that when the jet dynamic pressure head is less than the backwater depth, the dimensionless relative shear stress and relative depth relationship can be fitted with a beta probability density function. When the dynamic pressure head exceeds the backwater depth, the distribution follows a cubic polynomial form. Dimensional analysis and flow trajectory calculation methods were used to establish shear stress distribution formulas, with determination coefficients of 0.829 and 0.652, and the mean absolute percentage error (MAPE) between the measured and predicted values being 0.106 and 0.081, respectively. The findings provide valuable insights into the effects of complex flow structures on shear stress and offer essential support for the development of scour models for overfall structures. Full article
(This article belongs to the Special Issue Advances in Hydrodynamics, Pollution and Bioavailable Transfers)
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26 pages, 18712 KB  
Article
Numerical Investigation of Stage Separation Control of Tandem Hypersonic Vehicles Based on Lateral Jet
by Wenhua Guo, Jiawei Fu, Pengzhen He and Shuling Tian
Aerospace 2025, 12(4), 286; https://doi.org/10.3390/aerospace12040286 - 28 Mar 2025
Cited by 3 | Viewed by 1535
Abstract
The stage separation of hypersonic vehicles is critically challenged by severe aerodynamic interference, which induces significant attitude deviations and jeopardizes subsequent flight missions. This study investigates open-loop and closed-loop attitude control methods utilizing lateral jets to stabilize the forebody during separation. Dynamic CFD-based [...] Read more.
The stage separation of hypersonic vehicles is critically challenged by severe aerodynamic interference, which induces significant attitude deviations and jeopardizes subsequent flight missions. This study investigates open-loop and closed-loop attitude control methods utilizing lateral jets to stabilize the forebody during separation. Dynamic CFD-based numerical simulations were conducted for a tandem hypersonic vehicle, analyzing trajectories and aerodynamic characteristics under free separation, open-loop, and closed-loop control. Results show that open-loop control achieves a maximum forebody pitch angle of only 0.27° at α=0°, but performance degrades drastically to 24.88° at α=2.5°, highlighting its sensitivity to freestream variations. In contrast, a cascade PID-based closed-loop control system dynamically adjusts lateral jet total pressure, reducing the maximum pitch angle to 0.006° at α=0° and maintaining it below 0.2° even at α=5.0°. The closed-loop system exhibits periodic fluctuations in jet pressure, with amplitude increasing alongside angle of attack, yet demonstrates superior robustness against aerodynamic disturbances. Flow field analysis reveals enhanced shockwave interactions and vortex dynamics under closed-loop control, effectively mitigating pitch instability. While open-loop methods are constrained to specific conditions, closed-loop control significantly broadens applicability across variable flight environments. Full article
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18 pages, 1972 KB  
Article
A Physics-Guided Parameter Estimation Framework for Cold Spray Additive Manufacturing Simulation
by Md Munim Rayhan, Abderrachid Hamrani, Md Sharif Ahmed Sarker, Arvind Agarwal and Dwayne McDaniel
Coatings 2025, 15(4), 364; https://doi.org/10.3390/coatings15040364 - 21 Mar 2025
Cited by 2 | Viewed by 1481
Abstract
This work presents a physics-guided parameter estimation framework for cold spray additive manufacturing (CSAM), focusing on simulating and validating deposit profiles across diverse process conditions. The proposed model employs a two-zone flow representation: quasi-constant velocity near the nozzle exit followed by an exponentially [...] Read more.
This work presents a physics-guided parameter estimation framework for cold spray additive manufacturing (CSAM), focusing on simulating and validating deposit profiles across diverse process conditions. The proposed model employs a two-zone flow representation: quasi-constant velocity near the nozzle exit followed by an exponentially decaying free jet to capture particle acceleration and impact dynamics. The framework employs a comprehensive approach by numerically integrating drag-dominated particle trajectories to predict deposit formation with high accuracy. This physics-based framework incorporates both operational and geometric parameters to ensure robust prediction capabilities. Operational parameters include spray angle, standoff distance, traverse speed, and powder feed rate, while geometric factors encompass nozzle design characteristics such as exit diameter and divergence angle. Validation is performed using 36 experimentally measured profiles of commercially pure titanium powder. The simulator shows excellent agreement with the experimental data, achieving a global root mean square error (RMSE) of 0.048 mm and a coefficient of determination R2=0.991, improving the mean absolute error by more than 40% relative to a neural network-based approach. Sensitivity analyses reveal that nozzle geometry, feed rate, and critical velocity strongly modulate the amplitude and shape of the deposit. Notably, decreasing the nozzle exit diameter or divergence angle significantly increases local deposition rates, while increasing the standoff distance dampens particle velocities, thereby reducing deposit height. Although the partial differential equation (PDE)-based framework entails a moderate increase in computational time—about 50 s per run, roughly 2.5 times longer than simpler empirical models—this remains practical for most process design and optimization tasks. Beyond its accuracy, the PDE-based simulation framework’s principal advantage lies in its minimal reliance on sampling data. It can readily be adapted to new materials or untested process parameters, making it a powerful predictive tool in cold spray process design. This study underscores the simulator’s potential for guiding parameter selection, improving process reliability and offering deeper physical insights into cold spray deposit formation. Full article
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