Search Results (427)

This paper catalogues a series of experiments we conducted to explore how to 3D print a DC electric motor. The individual parts of the electric motor were 3D printed but assembled by hand. First, we focused on a rotor with soft magnetic properties, for which we adopted ProtoPasta^TM, which is a commercial off-the-shelf PLA filament incorporating iron particles. Second, we focused on the stator permanent magnets, which were 3D printed through binder jetting. Third, we focused on the wire coils, for which we adopted a form of laminated object manufacture of copper wire. The chief challenge was in 3D printing the coils, because the winding density is crucial to the performance of the motor. We have demonstrated that DC electric motors can be 3D printed and assembled into a functional system. Although the performance was poor due to the wiring problem, we showed that the other 3D printing processes were consistent with high performance. Nevertheless, we demonstrated the principle of 3D printing electric motors. Full article

Thermoplastic in situ Automated Fiber Placement (AFP) is an additive manufacturing method currently investigated for its suitability for the production of aerospace-grade composite structures. A considerable expense in this process is the manufacturing and preparation of a mold in which a composite part can be manufactured. One approach to lowering these costs is the use of a 3D-printable thermoplastic mold. However, AFP lay-up on a 3D-printed mold differs from the usage of a traditional metallic mold in various aspects. Most notable is a reduced stiffness of the mold, a lower thermal conductivity of the mold, and the need for varied process parameters of the AFP process. This study focuses on the investigation of the difference in mechanical and morphological characteristics of laminates produced on metallic and polymeric molds. To this end, the tensile strength and the interlaminar shear strength of laminates manufactured on each substrate were measured and compared. Additionally, morphological analysis using scanning electron microscopy and differential scanning calorimetry was performed to compare the crystallinity in laminates. No statistically significant difference in mechanical or morphological properties was found. Thus, thermoplastics were shown to be a suitable material for non-heated molds to manufacture in situ AFP composites. Full article

In advanced structural applications—aerospace and automotive—fiber-laminated composite (FRP) materials are increasingly used for their superior strength-to-weight ratios, making the reliability of their mechanical joints a critical concern. Mechanically fastened joints play a major role in ensuring the structural stability of FRP Composite structures; however, accurately predicting their failure behavior remains a major challenge due to the anisotropic and heterogeneous nature of composite materials. This paper presents a progressive damage modeling approach to investigate the failure modes and joint strength of mechanically fastened carbon fiber-laminated (CFRP) composite joints. A 3D constitutive model based on continuum damage mechanics was developed and implemented within a three-dimensional finite element framework. The joint model comprises a composite plate, a steel plate, a steel washer, and steel bolts, capturing realistic assembly behavior. Both single- and double-lap joint configurations, featuring single and double bolts, were analyzed under tensile loading. The influence of clamping force on joint strength was also investigated. Model predictions were validated against existing experimental results, showing a good correlation. It was observed that double-lap joints exhibit nearly twice the strength of single-lap joints and can retain up to 85% of the strength of a plate with a hole. Furthermore, double-lap configurations support higher clamping forces, enhancing frictional resistance at the interface and load transfer efficiency. However, the clamping force must be optimized, as excessive values can induce premature damage in the composite before external loading. The stiffness of double-bolt double-lap (3DD) joints was found to be approximately three times that of single-bolt single-lap (3DS) joints, primarily due to reduced rotational flexibility. These findings provide useful insights into the design and optimization of composite bolted joints under tensile loading. Full article

In today’s aviation industry, research and studies are carried out to manufacture and design lightweight, high-performance materials. One of the materials developed in line with this goal is glass laminate aluminum-reinforced epoxy (GLARE), which consists of thin aluminum sheets and S2-glass/epoxy layers. Because of its high impact resistance and excellent fatigue and damage tolerance properties, GLARE is used in different aircraft parts, such as the wing, fuselage, empennage skins, and cargo floors. In this study, a survey was carried out and a low-velocity impact model for GLARE materials was developed using the ABAQUS (2014) version V6.14 software and compared with the results of low-velocity impact tests performed according to the American Society for Testing and Materials (ASTM) D7136 standard. This article introduces a novel integrated approach that combines detailed numerical modeling with experimental validation of GLARE 4A FMLs under low-velocity impact. Leveraging ABAQUS, a robust FEM featuring explicit analysis, cohesive resin interfaces, and custom VUMAT subroutines was developed to accurately simulate energy absorption, dent depth, and delamination. The precise model’s predictions align well with test results performed according to ASTM D7136 standards, exhibiting less than a 0.1% deviation in the displacement (dent depth)–time response, along with deviations of 4.3% in impact energy–time and 5.2% in velocity–time trends at 5.5 ms. Full article

This paper presents a highly linear two-stage InGaP/GaAs power amplifier integrated circuit (PAIC) using a dynamic predistorter for 5G small-cell applications. The proposed predistorter, based on a diode-connected transistor, utilizes a supply voltage to accurately control the linearization characteristics by adjusting its dc current. It is connected in parallel with an inter-stage of the two-stage PAIC through a series configuration of a resistor and an inductor, and features a shunt capacitor at the base of the transistor. These passive components have been optimized to enhance the linearization performance by managing the RF signal’s coupling to the diode. Using these optimized components, the AM−AM and AM−PM nonlinearities arising from the nonlinear resistance and capacitance in the diode can be effectively used to significantly flatten the AM−AM and AM−PM characteristics of the PAIC. The proposed predistorter was applied to the 2.6 GHz two-stage InGaP/GaAs HBT PAIC. The IC was tested using a 5 × 5 mm² module package based on a four-layer laminate. The load network was implemented off-chip on the laminate. By employing a continuous-wave (CW) signal, the AM−AM and AM−PM characteristics at 2.55–2.65 GHz were improved by approximately 0.05 dB and 3°, respectively. When utilizing the new radio (NR) signal, based on OFDM cyclic prefix (CP) with a signal bandwidth of 100 MHz and a peak-to-average power ratio (PAPR) of 9.7 dB, the power-added efficiency (PAE) reached at least 11.8%, and the average output power was no less than 24 dBm, achieving an adjacent channel leakage power ratio (ACLR) of −40.0 dBc. Full article

Today, numerous advanced options exist for analyzing and measuring magnetic hysteresis loops and core loss across a broad spectrum of applications. Most of these systems are compact and ready to use, fulfilling the measurement and data processing requirements for laminated iron cores according to the standards. However, modeling newly developed materials with complex structures or the high-frequency behavior of iron cores, and the computation of dynamic hysteresis properties’ temperature dependence, are still challenging problems in the field. Moreover, these standardized measurement tools are relatively expensive, and most of them represent a black box that impedes research and further development. This paper presents the development of a cheap and accessible measurement system that is explicitly designed for recording the hysteresis properties of 3D-printed iron cores. The paper presents a comprehensive overview of the design process, components, circuitry, and simulations integral to this project. The paper presents a completed circuit simulation conducted using LTspice and validation of the prototype’s measurement performance. The measurements obtained with the proposed system show good agreement with those of the reference setup, demonstrating its accuracy and practical applicability. Full article

Electromagnetic interference (EMI) shielding is critical for maintaining signal integrity in high-speed electronic packaging. However, conventional shielding approaches face limitations in process complexity and spatial efficiency. In this study, an EMI shielding film based on trimodal silver (Ag) ink and low-dielectric polyimide (PI) resin was developed and comprehensively evaluated. The fabricated film exhibited an average shielding effectiveness (SE) of −99.7 dB in the 6–18 GHz frequency range and demonstrated a 50% increase in electrical conductivity after lamination (from 0.752 × 10⁵ S/m to 1.13 × 10⁵ S/m). The horizontal thermal conductivity reached 34.614 W/m·K, which was 3.4 times higher than the vertical value (10.249 W/m·K). Signal integrity simulations showed significant reductions in near-end crosstalk (NEXT, 77.8%) and far-end crosstalk (FEXT, 65%). Moreover, cyclic bending tests confirmed excellent mechanical durability, with a normalized resistance change below 0.6 after 1000 cycles at a bending radius of 4 mm. Notably, the film enabled a 50% reduction in signal line spacing while maintaining signal integrity, even without strict compliance with the 3W Rule. These results demonstrate the potential of the proposed EMI shielding film as a high-performance solution for advanced packaging applications requiring high-frequency operation, thermal management, and mechanical flexibility. Full article

In this study, to optimize the lightweight design of power battery cases for new energy vehicles and meet impact resistance requirements, the mechanical properties of honeycomb sandwich composites were experimentally investigated by varying carbon/glass fiber hybrid ratios. Carbon fiber and glass fiber hybrid laminates were used as the panel, and the aluminum honeycomb was used as the core layer to prepare sandwich composite materials through vacuum-assisted resin infusion (VARI). Then, the flexural and impact properties of honeycomb sandwich composites with different hybrid ratios were tested, respectively. The damage morphology and the damage mechanism of the hybrid composites were analyzed by 3D profile scanning. The results demonstrated that compared to glass fiber-reinforced panels, hybrid panels significantly enhanced the flexural load-bearing capacity of the sandwich composites, exhibiting maximum increases of 26.5% and 34.38% in the L direction and W direction, respectively. Carbon fiber effectively improved the impact resistance of specimens, with the maximum impact load increasing by 53.09% and energy absorption showing measurable enhancement, while glass fiber improves toughness and reduces the severity of damage. This study includes damage analysis and mechanical behavior change analysis of composite materials, which can provide a reference for the application of composite materials in the battery box shell. Full article

The composite primary structures of railway vehicles endure not only mechanical loads including tension, compression, bending, and torsion, but also external impacts, such as by the crushed stone in ballast. In the present study, the low-velocity impact response of preloaded hybrid composite laminates with different thicknesses is examined using a finite element method based on a progressive damage model. The hybrid plate consists of carbon fiber-reinforced unidirectional and woven prepregs. The progressive damage model, based on the 3D Hashin model, is validated by experiments on hybrid laminate, and further compared with the post-impact appearance obtained from CT scans. Preloading, considered to be tensile, compressive, or shear, corresponds to different positions in a bending beam with flanges and a web. Finally, the effects of impact energy, preloading, thickness, and impact angle on the dynamic response are analyzed, with an emphasis on new results and failure mechanism analysis comparing the influence of preloads under a given impact energy and different thicknesses. Full article

This study explores advanced process monitoring for one-shot drilling of aeronautical stacks made of aluminium 2024 and carbon fibre-reinforced polymer (CFRP) laminates using a 4.8 mm diameter drilling tool and unsupervised machine learning techniques. An experimental campaign is conducted to collect thrust force and torque signals at a 10 kHz sampling rate during the drilling process. These signals are employed for real-time process monitoring, focusing on material change detection and anomaly identification, where anomalies are defined as holes that fail to meet predefined quality criteria. An innovative approach based on unsupervised learning is proposed to enable automatic material change identification, signal segmentation, feature extraction, and hole quality assessment. Specifically, a semi-supervised approach based on a Gaussian Mixture Model (GMM) and 1D Convolutional AutoEncoder (1D-CAE) is employed to detect deviations from normal drilling conditions. The proposed method is benchmarked against state-of-the-art supervised techniques, including logistic regression (LR) and Support Vector Machines (SVMs). Results show that these traditional models struggle with class imbalance, leading to overfitting and limited generalisation, as reflected by the F1 scores of 0.78 and 0.75 for LR and SVM, respectively. In contrast, the proposed semi-supervised approach improves anomaly detection, achieving an F1 score of 0.87 by more effectively identifying poor-quality holes. This study demonstrates the potential of deep learning-based semi-supervised methods for intelligent process monitoring, enabling adaptive control in the drilling process of hybrid stacks and detecting anomalous holes. While the proposed approach effectively handles small and imbalanced datasets, further research into the application of generative AI could enhance performance, aiming for F1 scores above 0.90, thereby supporting adaptation in real industrial environments with high performance. Full article

Although shear horizontal waves have advantages over longitudinal waves, including a higher resolution, less wave mode conversion, and much better reflection coefficients at void and crack interfaces in nondestructive detection, they require good contact surface flatness and efficient coupling agents. In this paper, we analyze and design the basic components of the dry-coupled ultrasonic shear wave probe through theoretical analyses and numerical simulations. The admittance characteristics, resonant frequency, and electromechanical coupling coefficients of the double-laminated vibrator under different size parameters in both 2D and 3D models are simulated, and the probe structures are optimized based on the simulation results and operational requirements. The simulation results of the wave field excited by the double-laminated vibrator show the effectiveness of the optimized probe models. Additionally, the dry coupling method of the probe is simulated to study the acoustic energy distribution under various dry-coupled structures. Finally, we compare the measured admittance with the simulated values, and they are in good agreement. Full article

Ti-Al₃Ti metal–intermetallic laminate (MIL) composites with microscale layer thickness have attracted attention in aerospace applications. However, whether millimeter-thick Ti layers can enhance the anti-penetration of Ti-Al₃Ti MIL composites under 400–1000 m/s impact velocities remains unclear. In this study, a Ti-Al₃Ti MIL composite target was prepared by hot press sintering, and the 2D finite element model validated by anti-penetration testing was used to prove that increasing the thickness of the Ti layer significantly increases the stress level and anti-penetration limit of the target. Simulations show that compared with a 0.1 mm Ti layer, a 2.5 mm Ti layer reduces the projectile residual velocity by 100% (600 m/s), 72% (800 m/s), and 38.5% (1000 m/s). With a total thickness difference of 0.1 mm, the crack propagation angles increase by 4° (0.06 mm Ti) and 14° (2.5 mm Ti) compared to a 0.4 mm Ti layer. By analyzing stress wave propagation and energy absorption during penetration, this work reveals that millimeter-thick Ti layers improve anti-penetration performance by controlling heterogeneous interface failure and the crack propagation direction through increased ductile layer thickness. These findings provide data for MIL composites and offer potential cost reductions for high-performance anti-penetration materials. Full article

Electrothermal anti-/de-icing systems are widely used in aircraft, and the structures of these systems generally consist of multiple layers laminated together. In service, laminated structures are prone to structural deformation and delamination, which can significantly affect heat conduction. Therefore, it is essential to study the temperature field of these electrically heated anti-icing structures during operation and analyse the impact of delamination damage on the temperature distribution. In this thesis, a dynamic multiphysical field study of an electric heating anti-icing structure is conducted using a thermal expansion layer-by-layer/3D solid element method. By studying the electric heating process of composite plates experiencing pre-positioned delamination, the thermal expansion layer-by-layer/3D solid element method considers the thermal convection boundary conditions as well as a constant heat source. In addition, to considering the influences of the geometric shape and delamination damage, we apply the thermal expansion layer-by-layer/3D solid element method to the electric heating anti-icing process of aerofoil structures using a coordinate transformation matrix. The calculations show that when delamination damage is located above the heating layer, the maximum temperature of the structure reaches 450 °C at 50 s, which severely affects the normal functioning of the structure. Additionally, the surface temperature of the anti-icing system decreases to the ambient temperature at the delamination. In contrast, delamination damage located below the heating layer has a minimal effect on the surface temperature distribution. Moreover, the damage caused by multiple types of damage is greater than that caused by a single type of damage. Full article

Overcoming the limitations of powder-based additive manufacturing processes is a crucial aspect for the manufacturing of patient-specific sophisticated implants with tailored properties. Within this work, a novel manufacturing process for the fabrication of polymer-based implants is proposed. This manufacturing process is inspired by the laminated object manufacturing technology and is based on using thin films as raw material, which are processed using an ultrafast laser source. Utilizing thin films as a starting material helps to avoid powder contamination during additive manufacturing, thus supporting the generation of internal cavities that can be filled with secondary phases. Additionally, the use of medical materials mitigates the burden of a later certification of potential implants. Furthermore, the ultrafast laser supports the generation of highly resolved structures smaller than the average layer thickness (from 50 to 100 µm) through material ablation. These structures can be helpful to obtain progressive part properties or a targeted stress flow, as well as a specified release of secondary phases (e.g., hydrogels) upon load. Within this work, first investigations on the joining, cutting, and structuring of thin polymer films with layer thickness of between 50 and 100 µm using a ps-pulsed laser are reported. It is shown that thin film sizes of around 50 µm could be structured, joined, and cut successfully using ultrafast lasers emitting in the NIR spectral range. Full article

The effects of opening size and braiding angle on the tensile behavior of 3D five-way braided composites were systematically studied, and the mechanical properties, failure modes, and fracture characteristics of the composites were comprehensively analyzed. Initially, a static tensile test was conducted. The results demonstrated that both the tensile strength and tensile modulus of the three-dimensional (3D) braided composites decreased as the braiding angle increased. The sensitivity of the tensile modulus to the aperture size increased significantly as the aperture increased. For specimens with varying braiding angles, smaller apertures were more effective in withstanding higher stress concentrations around the opening, with minimal impact on the tensile strength. In comparison to the laminate composites, the 3D braided composites, regardless of braiding angle, retained higher tensile strength after hole formation at the same aperture size. The fracture of the samples was observed and captured using an optical microscope. It was observed that the failure mode of the 3D braided composites progressively transitioned from fiber fractures to interface debonding with an increase in the braiding angle. After hole formation, stress concentration at the aperture edge caused crack propagation along the braiding direction. Larger apertures resulted in more severe cracks, ultimately leading to specimen failure. Full article