Search Results (97)

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

Background: Precision medicine refers to the formulation of personalized drug regimens according to the individual characteristics of patients to achieve optimal efficacy and minimize adverse reactions. Additive manufacturing (AM), also known as three-dimensional (3D) printing, has emerged as an optimal solution for precision drug delivery, enabling customizable and the fabrication of multifunctional structures with precise control over morphology and release behavior in pharmaceutics. However, the influence of 3D printing parameters on the printed tablets, especially regarding in vitro and in vivo performance, remains poorly understood, limiting the optimization of manufacturing processes for controlled-release profiles. Objective: To establish the fabrication process of 3D-printed controlled-release tablets via comprehensively understanding the printing parameters using fused deposition modeling (FDM) combined with hot-melt extrusion (HME) technologies. HPMC-AS/HPC-EF was used as the drug delivery matrix and carbamazepine (CBZ) was used as a model drug to investigate the in vitro drug delivery performance of the printed tablets. Methodology: Thermogravimetric analysis (TGA) was employed to assess the thermal compatibility of CBZ with HPMC-AS/HPC-EF excipients up to 230 °C, surpassing typical processing temperatures (160–200 °C). The formation of stable amorphous solid dispersions (ASDs) was validated using differential scanning calorimetry (DSC), hot-stage polarized light microscopy (PLM), and powder X-ray diffraction (PXRD). A 15-group full factorial design was then used to evaluate the effects of the fan speed (20–100%), platform temperature (40–80 °C), and printing speed (20–100 mm/s) on the tablet properties. Response surface modeling (RSM) with inverse square-root transformation was applied to analyze the dissolution kinetics, specifically t_50% (time for 50% drug release) and Q_4h (drug released at 4 h). Results: TGA confirmed the thermal compatibility of CBZ with HPMC-AS/HPC-EF, enabling stable ASD formation validated by DSC, PLM, and PXRD. The full factorial design revealed that printing speed was the dominant parameter governing dissolution behavior, with high speeds accelerating release and low speeds prolonging release through porosity-modulated diffusion control. RSM quadratic models showed optimal fits for t_50% (R² = 0.9936) and Q_4h (R² = 0.9019), highlighting the predictability of release kinetics via process parameter tuning. This work demonstrates the adaptability of polymer composite AM for tailoring drug release profiles, balancing mechanical integrity, release kinetics, and manufacturing scalability to advance multifunctional 3D-printed drug delivery devices in pharmaceutics. Full article

Efficient superhydrophobic oil–water separation materials are essential for environmental remediation and industrial wastewater treatment. In this study, by optimizing printing parameters, such as printing speed, extrusion multiplier, and layer height, we achieved high-precision 3D porous architectures with uniform pore sizes. The pore size could reach 677.3 µm, with a maximum deviation of less than 36.1 µm. Additionally, we successfully printed pores as small as 186.7 µm, representing the smallest FFF-printed pore size reported in the literature. The printed structures were modified using a spray-coating method, achieving a superhydrophobic surface with a water contact angle of 158.2°. The material was tested in a continuous oil–water separation system, maintaining stable oil removal performance for 24 h. The highest separation efficiency reached 88.6%, demonstrating strong durability and long-term applicability. This study establishes a scalable, low-cost approach for fabricating highly efficient 3D superhydrophobic porous materials, offering new opportunities for continuous oil spill cleanup and industrial wastewater treatment. Full article

Blue maize is rich in bioactive compounds which are at risk of extinction due to monoculture practices. Carrot bagasse, considered a byproduct of the food industry, contains compounds that have been shown to benefit human health while also enhancing sustainability. Ellagic acid can prevent and assist in the treatment of various pathologies. Extrusion is a process characterized by its use of low energy, which minimizes the degradation of nutrients and bioactive compounds compared to other technologies. The objective of this research was to develop a functional food with high value of sensorial acceptance, desirable physicochemical, and antioxidant properties, using an 85:13:2% mixture of nixtamalized blue maize flour, carrot bagasse flour, and ellagic acid, processed with optimal conditions of extrusion determined with a surface response model. Operational conditions using a central rotatable experimental design were die temperature (DT = 120–170 °C), and screw speed (SS = 50–240 rpm), while response variables were physicochemical properties (expansion index, bulk density, breaking force, water absorption index and water solubility index) and antioxidant activity (free phenols inhibition of ABTS and DPPH). Sensory analysis, bromatological characterization and ellagic acid content determination with HPLC-DAD in reversed phase were also made. The optimal operational conditions were found to be DT = 144 °C and SS = 207 rpm, resulting in a mixture with high sensorial acceptability on a five-point hedonic scale. The optimized functional food may be used to promote the utilization of endemic ingredients and reduce food waste in the treatment of pathologies and prevention of diseases due to its high antioxidant activity attributed to phenolic and terpene compounds. Full article

Multilayer plastic films (MPFs) are widely used in the food industry. Despite its widespread use, the recycling of MPF remains a challenge due to its complex structure. Solvent-based recycling is more complex and costly than conventional mechanical recycling, which remains the most widely used method despite its technical and economic limitations. This study investigates the conventional mechanical recycling of post-consumer MPF without separating its constituent layers. Samples were prepared using a thermal extrusion cycle with the control of temperature, speed and sample size to improve the melt state, homogeneity and mechanical response of the mixture. The results of the physicomechanical characterization in this research study show that the proper selection of the extrusion parameters for a fine multilayer waste of 2 mm particle size, has a positive impact, for instance, on the final maximum strength of the recycled material, demonstrating an increase of up to 40 and 70% in tensile and flexural properties, respectively. The proposed mechanical recycling of post-consumer MPF without separation of its constituents can produce a material with mechanical properties comparable to those of low-density polyethylene and polypropylene. These findings could significantly benefit the recycling industry by reducing plastic pollution and allowing for creating new products with specific mechanical properties tailored for different applications. Full article

In the present study, composites Cu–Ti₃SiC₂ were obtained via extrusion-based additive manufacturing technology. The composite was characterized in terms of its structure, mechanical properties, and tribological properties. The use of a low-energy additive manufacturing technique allows for the avoidance of the decomposition of the MAX phase while obtaining bulk samples. The optimal composition of 50 vol.% of Ti₃SiC₂ and 50 vol.% of Cu was selected based on the flow rate of feedstock melt and the density of the samples. The resulting composite exhibited a dense copper matrix with Ti₃SiC₂ and TiC inclusions, achieving 97% density and 62% IACS electrical conductivity. Tribological tests under varying loads, speeds, and temperatures demonstrated that increasing the load and speed increased the coefficient of friction and the wear rate, while higher temperatures reduced friction due to surface oxidation. Full article

This study optimizes the 3D extrusion printing parameters—water-to-flour ratio (X₁), temperature (X₂), and printing speed (X₃)—for raw (RFB) and extruded (EFB) dehulled Andean fava bean flours to maximize print quality and minimize structural defects. A 2³ central composite design combined with response surface methodology (RSM) was used to identify the optimal conditions for achieving geometric precision, surface homogeneity, and textural stability. Physicochemical analyses showed that extrusion cooking substantially modified the composition and rheology of the flour. Compared with RFB, EFB exhibited lower protein and fiber contents, a higher proportion of digestible carbohydrates, and reduced rheological parameters (τ₀, K, G′, G″), which facilitated printing. The evaluation of different parameter combinations revealed notable differences between the two flours, with X₁ and X₂ exerting the greatest influence on print quality. For RFB, the highest desirability (0.853) was achieved at X₁ = 0.806, X₂ = 23.18 °C, and X₃ = 2470.5 mm/min, yielding more uniform and firmer printed structures. In contrast, EFB reached a desirability of 0.844 at X₁ = 1.66 °C, X₂ = 56.82 °C, and X₃ = 1505.43 mm/min, indicating its outstanding geometric accuracy and robustness. In conclusion, raw flour requires higher hydration and lower temperatures to prevent excessive viscosity. In contrast, extruded flour benefits from low water and high temperatures to achieve stable structures and firm textures. These findings demonstrate the feasibility of using Andean fava bean flour in 3D food printing to create nutrient-dense, functional foods with improved printability. This work offers practical applications for developing personalized foods—such as customized meals for individuals with specific dietary requirements—while contributing to sustainable and secure food production. Future research should address long-term storage, post-printing drying methods, and scaling production. Full article

Corn is an important economic and food crop, and the corn threshing process is an important link in the processing of corn, but the damage rate in the threshing process has always been a problem, causing difficulties in subsequent processing and storage. To address the high damage rate in corn ear threshing, a texture analyzer was used to measure the fracture force of Boyun 88 and Zhengdan 958 corn varieties in the triaxial direction, and a CT scanning imaging system was used to analyze the connection mode between the carpopodium and the corn cob. The connection between the carpopodium and corn cob, as well as the fracture process of the carpopodium, was simulated. Finally, high-speed photography was used to study the corn ear threshing process. The results indicated that the fracture force of the carpopodium under radial tension was significantly greater than that under axial and tangential shear. Additionally, the simulated fracture stress value of the carpopodium exceeded its actual fracture stress value. Under radial stress, the fracture force between the carpopodium and corn cob exhibited more uniformity on the contact surface. When a tangential load was applied, it was observed that the force chain shifted and dissipated along the axis during corn kernel extrusion. High-speed photography on a discrete test bench revealed that corn kernel dispersion, extrusion, and force transfer facilitated the movement and migration of surrounding kernels, with the force transfer process resembling a “trapezoid”. This study offers theoretical guidance for corn threshing with low damage and an analysis of the threshing process. Full article

The aim of this study was to produce texturized vegetable proteins (TVPs) from faba bean protein via low-moisture extrusion. The effect of extrusion variables including temperature (110, 125, and 140 °C at the die), feed moisture content (30, 35, and 40%), and screw speed (200, 300, and 400 rpm) on the TVP properties were investigated. An increase in feed moisture content or extruder temperature reduced the specific mechanical energy and torque by 40–45% during extrusion. An increase in feed moisture created TVPs with lower bulk densities and rehydration ratios while an increase in extruder temperature or screw speed increased the bulk density of the TVPs. An increase in screw speed also caused a decrease in the water holding capacity of the milled TVP flours. The TVP flours had a 33–70% higher oil holding capacity than the raw material. The texture profile showed that an increase in feed moisture influenced TVP hardness, gumminess, and chewiness with higher values compared to the treatments with lower moisture contents. Springiness, cohesiveness, and resilience were more affected by a change in screw speed with higher values at 200 rpm. The best parameters were selected (125 °C, 40% MC, 300 rpm) to produce TVP to use as a partial (hybrid burger) and complete (vegan burger) replacement of beef in a burger patty. The replacement of 25% beef with TVPs in a hybrid burger increased the cooking yield and moisture retention and decreased the thickness and diameter change compared to the beef burger without TVPs. In a vegan formulation, the faba bean TVP burger had lower cooking yield and moisture retention than commercial products. Full article

Polymeric materials made from renewable sources that can biodegrade in the environment are attracting considerable attention as substitutes for petroleum-based polymers in many fields, including additive manufacturing and, in particular, Fused Deposition Modelling (FDM). Among the others, poly(hydroxyalkanoates) (PHAs) hold significant potential as candidates for FDM since they meet the sustainability and biodegradability standards mentioned above. However, the most utilised PHA, consisting of the poly(hydroxybutyrate) (PHB) homopolymer, has a high degree of crystallinity and low thermal stability near the melting point. As a result, its application in FDM has not yet attained mainstream adoption. Introducing a monomer with higher excluded volume, such as hydroxyvalerate, in the PHB primary structure, as in poly(hydroxybutyrate-co-valerate) (PHBV) copolymers, reduces the degree of crystallinity and the melting temperature, hence improving the PHA printability. Blending amorphous poly(lactic acid) (PLA) with PHBV enhances further PHA printability via FDM. In this work, we investigated the printability of two blends characterised by different PLA and PHBV weight ratios (25:75 and 50:50), revealing the close connection between blend microstructures, melt rheology and 3D printability. For instance, the relaxation time associated with die swelling upon extrusion determines the diameter of the extruded filament, while the viscoelastic properties the range of extrusion speed available. Through thoroughly screening printing parameters such as deposition speed, nozzle diameter, flow percentage and deposition platform temperature, we determined the optimal printing conditions for the two PLA/PHBV blends. It turned out that the blend with a 50:50 weight ratio could be printed faster and with higher accuracy. Such a conclusion was validated by replicating with remarkable fidelity high-complexity objects, such as a patient’s cancer-affected iliac crest model. Full article

The surface roughness of hole machining greatly influences the mechanical properties of parts, such as early fatigue failure and corrosion resistance. The boring and trepanning association (BTA) deep hole drilling with axial vibration assistance is a compound machining process of the tool cutting and the guide block extrusion. At the same time, the surface of the hole wall is also ironed by the axial large amplitude and low-frequency vibration of the guide block. The surface-forming mechanism is very complicated, making it difficult to obtain an effective theoretical analytical model of the surface roughness of the hole wall through kinematic analysis. In order to achieve accurate prediction of the surface quality of the hole wall, the chip-breaking mechanism and the hole wall formation mode of BTA deep hole vibration drilling were analyzed. The influence of drilling spindle speed, feed, amplitude, and vibration frequency on the surface roughness of the hole wall during BTA deep hole vibration drilling was illustrated by a single-factor experiment. A four-factor and three-level test scheme was designed by using the Box–Behnken design (BBD) experimental design method. A surface roughness prediction model for hole wall machining was established based on the response surface methodology. The accuracy of the prediction model was analyzed through ANOVA, and the complex correlation coefficient of the model was 0.9948, indicating that the prediction model can better reflect the mapping relationship between vibration drilling parameters and surface roughness. After optimization analysis and experimental verification, the obtained vibration drilling parameters can achieve smaller surface roughness. The error between the predicted value of the model and the experimental measurement value is 8.65%. The established prediction model is reliable and can accurately predict the surface roughness of the hole wall of BTA deep hole axial vibration drilling, providing a theoretical basis for the surface quality control of the machining hole wall. It can be applied to process optimization in practical production. Full article

A380-Yb (Ytterbium) alloy was prepared by the ultrasonic melting casting method, and effects of hot extrusion on the microstructure and wear properties of the alloy were studied. The results indicate that the addition of rare earth Yb can refine the microstructure of the matrix alloy. After hot extrusion (extrusion ratio of 22.56) of the as-cast A380-Yb alloy, the secondary phase in its microstructure was further refined and the distribution became more uniform. EBSD (electron backscatter diffraction) organizational analysis shows that the average GND (geometrically necessary dislocation) density of extruded rare earth aluminum alloy is significantly increased, by 16.5 times that of the cast matrix alloy. In addition, there are a large number of grains parallel to the <111> orientation and <001> orientation in the extrusion direction. The alloy undergoes dynamic recrystallization during hot extrusion, and the proportion of small-angle grain boundaries is significantly reduced. Under the same friction and wear conditions, the wear rate and average friction and wear coefficient of the extruded rare earth aluminum alloy are relatively small, reduced by 53.8% and 42.6%, respectively, compared to the cast matrix alloy. Its wear mechanism is mainly abrasive wear and slight plastic deformation. In addition, the study also found that under fixed other wear conditions, as the friction speed increases, the wear rate of the extruded rare earth aluminum alloy shows a trend of first decreasing and then increasing. However, with the increase in load, its wear rate gradually increases, and the change in wear morphology is consistent with the trend of wear rate. When the wear rate is high, the wear mechanism of the extruded aluminum alloy is mainly delamination wear and adhesive wear, and is sometimes accompanied by severe plastic deformation. When the wear rate is low, its wear mechanism is mainly abrasive wear. Full article

The objective of this study was to evaluate the applicability of zeolite Y as a catalyst for producing bisphenol F (BPF) from phenol and formaldehyde. Catalyst extrudates were prepared by extrusion after adding pseudoboehmite sol (PS) and Ludox (Lu) as alumina and silica binders, respectively. The compressive strength of the catalyst extrudates increased with the addition of Ludox. However, the formaldehyde conversion decreased as more Ludox was used as a binder, resulting in a decrease in the yield of BPF. This decrease is attributed to the reduction in the total amount of acid sites caused by the addition of Ludox. In this study, the Y_PS5_Lu5 catalyst was selected as the most suitable for BPF synthesis. In the BPF synthesis over the Y_PS5_Lu5 catalyst in a catalyst basket reactor, the optimum reaction temperature was determined to be 110 °C. The effect of stirring speed on the yield of BPF was found to be negligible in the range of 200 rpm to 350 rpm. The spent catalyst was able to recover a specific surface area and reaction activity similar to those of a fresh catalyst through regeneration in an air atmosphere at 500 °C. When the Y_PS5_Lu5 extruded catalyst was used in a continuous reaction in a fixed-bed reactor, there was no noticeable deactivation of the catalyst at low space velocities of the reactants. However, when the space velocity was increased to 18.0 h⁻¹, catalyst deactivation was clearly observed. This suggests that periodic regeneration of the catalyst is inevitable in a continuous reaction using the Y_PS5_Lu5 extruded catalyst. Full article

Extrusion-based polymer three-dimensional (3D) printing, specifically fused deposition modeling (FDM), has been garnering increasing interest from industry, as well as from the research and academic communities, due to its low cost, high speed, and process simplicity. However, bed adhesion failure remains an obstacle to diversifying the materials and expanding the industrial applications of the FDM 3D-printing process. Therefore, this study focused on an investigation of the surface treatment methods for aluminum (Al) foil and their applications to 3D printer beds to enhance the bed adhesion of a 3D-printed polymer filament. Two methods of etching with sodium hydroxide and anodization with phosphoric acid were individually used for the surface treatment of the Al foil beds and then compared with an untreated foil. The etching process removed the oxide layer from the Al foil and increased its surface roughness, while the anodizing process enhanced the amount of hydroxide functional groups and contributed to the formation of nano-holes. As a result, the surface-anodized aluminum foil exhibited a higher affinity and bonding strength with the 3D-printed polymers compared with the etched and pristine foils. Through the increase in the success rate in 3D printing with various polymers, it became evident that utilizing surface-treated Al foil as a 3D printer bed presents an economical solution to addressing bed adhesion failure. Full article

Three-dimensional (3D) bioprinting has emerged as an important technique for fabricating tissue constructs with precise structural and compositional control. However, developing suitable bioinks with biocompatible crosslinking mechanisms remains a significant challenge. This study investigates extrusion-based bioprinting (EBB) using uniaxial or coaxial nozzles with enzymatic crosslinking (EC) to produce 3D tissue constructs in vitro. Initially, low-molecular-weight dextran-tyramine and hyaluronic acid-tyramine (LMW Dex-TA/HA-TA) bioink prepolymers were evaluated. Enzymatically pre-crosslinking these prepolymers, achieved by the addition of horseradish peroxidase and hydrogen peroxide, produced viscous polymer solutions. However, this approach resulted in inconsistent bioprinting outcomes (uniaxial) due to inhomogeneous crosslinking, leading to irreproducible properties and suboptimal shear recovery behavior of the hydrogel inks. To address these challenges, we explored a one-step coaxial bioprinting system consisting of enzymatically crosslinkable high-molecular-weight hyaluronic acid-tyramine conjugates (HMW HA-TA) mixed with horseradish peroxidase (HRP) in the inner core and a mixture of Pluronic F127 and hydrogen peroxide in the outer shell. This configuration resulted in nearly instantaneous gelation by diffusion of the hydrogen peroxide into the core. Stable hydrogel fibers with desirable properties, including appropriate swelling ratios and controlled degradation rates, were obtained. The optimized bioink and printing parameters included 1.3% w/v HMW HA-TA and 5.5 U/mL HRP (bioink, inner core), and 27.5% w/v Pluronic F127 and 0.1% H₂O₂ (sacrificial ink, outer shell). Additionally, optimal pressures for the inner core and outer shell were 45 and 80 kPa, combined with a printing speed of 300 mm/min and a bed temperature of 30 °C. The extruded HMW HA-TA core filaments, containing bovine primary chondrocytes (BPCs) or 3T3 fibroblasts (3T3 Fs), exhibited good cell viabilities and were successfully cultured for up to seven days. This study serves as a proof-of-concept for the one-step generation of core filaments using a rapidly gelling bioink with an enzymatic crosslinking mechanism, and a coaxial bioprinter nozzle system. The results demonstrate significant potential for developing designed, printed, and organized 3D tissue fiber constructs. Full article