Search Results (161)

Phosphorylated cellulose is proposed as a bio-resin for the removal of heavy metals, as a substitute for synthetic polymer-based materials. Phosphorylation is carried out using kraft pulp fibers as the cellulose source, with phosphate esters and urea as reactants to prevent significant fiber degradation. Herein, phosphorylated fibers, with three types of counterions (sodium, ammonium, or hydrogen), are used in adsorption trials involving four individual metals: nickel, copper, cadmium, and lead. The Langmuir isotherm model is applied to determine the maximum adsorption capacities at four different temperatures (10, 20, 30, and 50 °C), enabling the calculation of the Gibbs free energy (ΔG), entropy (ΔS), and enthalpy (ΔH) of adsorption. The results show that the adsorption capacity of phosphorylated fibers is equal or even higher than that of commercially available resins (1.7–2.9 vs. 2.4–2.6 mmol/g). However, the nature of the phosphate counterion plays an important role in the adsorption capacity, with the alkaline form showing a superior ion exchange capacity than the hybrid form and acid form (2.7–2.9 vs. 2.3–2.7 vs. 1.7–2.5 mmol/g). The thermodynamic analysis indicates the spontaneous (ΔG = (-)16–(-)30 kJ/mol) and endothermic nature of the adsorption process with positive changes in enthalpy (0.45–15.47 kJ/mol) and entropy (0.07–0.14 kJ/mol·K). These results confirm the high potential of phosphorylated lignocellulosic fibers for ion exchange applications, such as the removal of heavy metals from process or wastewaters. Full article

Modern aerospace engineering places increasing emphasis on materials that combine low weight with high mechanical performance. Fiber metal laminates (FMLs), which merge metal layers with fiber-reinforced composites, meet this demand by delivering improved fatigue resistance, impact tolerance, and environmental durability, often surpassing the performance of their constituents in demanding applications. Despite these advantages, inspecting such thin, layered structures remains a significant challenge, particularly when they are difficult or impossible to access. As with any new invention, they always come with challenges. This study examines the effectiveness of the fundamental anti-symmetric Lamb wave mode (A0) in detecting weak interfacial defects within Carall laminates, a type of hybrid fiber metal laminate (FML). Delamination detectability is analyzed in terms of strong wave dispersion observed downstream of the delaminated sublayer, within a region characterized by acoustic distortion. A three-dimensional finite element (FE) model is developed to simulate mode trapping and full-wavefield local displacement. The approach is validated by reproducing experimental results reported in prior studies, including the author’s own work. Results demonstrate that the A0 mode is sensitive to delamination; however, its lateral resolution depends on local position, ply orientation, and dispersion characteristics. Accurately resolving the depth and extent of delamination remains challenging due to the redistribution of peak amplitude in the frequency domain, likely caused by interference effects in the acoustically sensitive delaminated zone. Additionally, angular scattering analysis reveals a complex wave behavior, with most of the energy concentrated along the centerline, despite transmission losses at the metal-composite interfaces in the Carall laminate. The wave interaction with the leading and trailing edges of the delaminations is strongly influenced by the complex wave interference phenomenon and acoustic mismatched regions, leading to an increase in dispersion at the sublayers. Analytical dispersion calculations clarify how wave behavior influences the detectability and resolution of delaminations, though this resolution is constrained, being most effective for weak interfaces located closer to the surface. This study offers critical insights into how the fundamental anti-symmetric Lamb wave mode (A0) interacts with delaminations in highly attenuative, multilayered environments. It also highlights the challenges in resolving the spatial extent of damage in the long-wavelength limit. The findings support the practical application of A0 Lamb waves for structural health assessment of hybrid composites, enabling defect detection at inaccessible depths. Full article

Amidst global imperatives for sustainable energy and environmental remediation, carbon aerogels (CAs) present a transformative alternative to conventional carbon materials (e.g., activated carbon, carbon fibers), overcoming limitations of disordered pore structures, unmodifiable surface chemistry, and functional inflexibility. This review systematically examines CA-based electrochemical systems as its primary focus, analyzing fundamental charge-storage mechanisms and establishing structure–property–application relationships critical to energy storage performance. We critically assess synthesis methodologies, emphasizing how stage-specific parameters govern structural/functional traits, and detail multifunctional modification strategies (e.g., heteroatom doping, composite engineering) that enhance electrochemical behavior through pore architecture optimization, surface chemistry tuning, and charge-transfer kinetics acceleration. Electrochemical applications are extensively explored, including the following: 1. Energy storage: supercapacitors (dual EDLC/pseudocapacitive mechanisms) and battery hybrids. 2. Electrocatalysis: HER, OER, ORR, and CO₂ reduction reaction (CO₂RR). 3. Electrochemical processing: capacitive deionization (CDI) and electrosorption. Beyond this core scope, we briefly acknowledge CA versatility in ancillary domains: environmental remediation (heavy metal removal, oil/water separation), flame retardancy, microwave absorption, and CO₂ capture. Full article

Introducing and compacting lignocellulosic biomass in aluminum structures, though recommendable in terms of higher sustainability, the potential use of agro-waste and significant weight reduction, still represents a challenge. This is due to the variability of biomass performance and to its limited compatibility with the metal. Another question may concern possible moisture penetration in the structure, which may reduce environmental resistance and result in local degradation, such as wear or even corrosion. Despite these limitations, this hybridization enjoys increasing success. Two forms are possibly available for this: introduction into metal matrix composites (MMCs), normally in the form of char from biomass combustion, or laminate reinforcement as the core for fiber metal laminates (FMLs). These two cases are treated alongside each other in this review, first because they may represent two combined options for recycling the same biomass into high-profile structures, aimed primarily at the aerospace industry. Moreover, as discussed above, the effect on the aluminum alloy can be compared and the forces to which they are subjected might be of a similar type, most particularly in terms of their hardness and impact. Both cases considered, MMCs and FMLs involved over time many lignocellulosic residues, starting from the most classical bast species, i.e., flax, hemp, sisal, kenaf, etc., and extending also to less diffuse ones, especially in view of the introduction of biomass as secondary, or residual, raw materials. Full article

In the context of global environmental pollution and energy shortages, the use of lightweight designs of railway vehicles has become a key technological approach to improve energy efficiency and reduce carbon emissions. The use of lightweight and high-strength materials such as carbon-fiber-reinforced composites to replace traditional metal vehicle structures holds great application potential. In this study, random track loads and ballast impact loads that may occur during service were considered, and a finite-element model of the electric locomotive coupling protective cover was established. The impact resistance of CFRP, GFRP, and their interlayer hybrid configurations (C/G/C and G/C/G) against structural and ballast impacts were investigated. The calculation results showed that the CFRP protective cover exhibited the best structural impact resistance (with the lowest Tsai–Wu strength failure values), but it also had the largest maximum deformation displacement (2.36 mm) under ballast impact conditions. In contrast, the GFRP protective cover had a higher Tsai–Wu strength failure value, indicating that it had worse structural impact resistance, but it had a lower maximum deformation displacement (2.20 mm) under ballast impact conditions, demonstrating superior ballast impact resistance. The impact resistances of the hybrid-layered protective covers fell between those of the CFRP and GFRP in terms of the structural impact, while their ballast-impact resistance surpassed those of single-fiber configurations. Full article

Crash boxes play a vital role in improving vehicle safety by absorbing collision energy and reducing the forces transmitted to occupants. Additive manufacturing (AM) has become a powerful method for developing advanced crash boxes by enabling complex geometries. This review provides a comprehensive examination of recent progress in AM crash boxes, with a focus on three key aspects: geometric design innovations, material behavior, and manufacturing techniques. The review investigates the influence of various AM-enabled structural configurations, including tubular, origami-inspired, lattice, and bio-inspired designs, on crashworthiness performance. Among these, bio-inspired structures exhibit superior energy absorption characteristics, achieving a mean specific energy absorption $\left(SEA\right)$ of 21.51 J/g. Material selection is also explored, covering polymers, fiber-reinforced polymers, metals, and multi-material structures. Metallic AM crash boxes demonstrate the highest energy absorption capacity, with a mean $SEA$ of 28.65 J/g. In addition, the performance of different AM technologies is evaluated, including Stereolithography (SLA), Material Jetting (MJT), Selective Laser Melting (SLM), Selective Laser Sintering (SLS), Fused Deposition Modeling (FDM), and hybrid manufacturing techniques. Among these, crash boxes produced by SLM show the most favorable energy absorption performance, with a mean $SEA$ of 16.50 J/g. The findings presented in this review offer critical insights to guide future research and development in the design and manufacturing of next-generation AM crash boxes intended to enhance vehicle safety. Full article

Thermoplastic carbon fiber/aluminum alloy hybrid composite laminates fully integrate the advantages of fiber-reinforced composites and metallic materials, exhibiting high fatigue resistance and impact resistance, with broad applications in fields such as national defense, aerospace, automotive engineering, and marine engineering. In this paper, thermoplastic carbon fiber/aluminum alloy hybrid composite laminates were first prepared using a hot-press machine; then, high-velocity impact tests were conducted on the specimens using a first-stage light gas gun test system. Comparative experimental analyses were performed to evaluate the energy absorption performance of laminates with different ply thicknesses and layup configurations. High-speed cameras and finite element analysis software were employed to analyze the failure process and modes of the laminates under impact loading. The results demonstrate that fiber–metal laminates exhibit higher specific energy absorption than carbon fiber composite laminates. Meanwhile, the numerical simulation results can effectively reflect the experimental outcomes in terms of the velocity–time relationship, failure modes during the laminate impact process, and failure patterns after the laminate impact. Full article

This study investigates the fracture toughness of adhesive joints between carbon fiber-reinforced polymer composites (CFRP) and boron-alloyed high-strength steel under Mode I and II loading, based on linear elastic fracture mechanics (LEFM). Two adhesive types were examined: the excess resin from the prepreg composite, forming a thin layer, and a toughened structural epoxy (Sika Power-533), designed for the automotive industry, forming a thick layer. Modified double cantilever beam (DCB) and end-notched flexure (ENF) specimens were used for testing. The results show that using Sika Power-533 increases the critical energy release rate by up to 30 times compared to the prepreg resin, highlighting the impact of adhesive layer thickness. Joints with the thick Sika adhesive performed similarly regardless of whether uncoated or Al–Si-coated steel was used, indicating the composite/Sika interface as the failure point. In contrast, the thin resin adhesive layer exhibited poor bonding with uncoated steel, which detached during sample preparation. This suggests that, for thin layers, the resin/steel interface is the weakest link. These findings underline the importance of adhesive selection and layer thickness for optimizing joint performance in composite–metal hybrid structures. Full article

Composite rotors, attributing to their leveraging characteristics of the light weight, high strength, high rigidity, corrosion resistance, and low noise, can significantly reduce the moment of inertia and enhance equipment operational efficiency. Using carbon fiber/glass fiber hybrid-reinforced resin–matrix composites as the rotor base material, the radial stability of a rotor can be effectively increased by regulating the fiber volume content. Meanwhile, the introduction of glass fiber not only enables the transition between the metal hub and composite rim but also optimizes the cost structure of the composite system, overcoming the economic bottleneck of single carbon fiber-reinforced resin–matrix composite rotors. This paper employs the finite element method to analyze a three-dimensional model of a composite rotor, investigating the performance of its metal hub and hybrid-reinforced resin–matrix composite rim. According to the radial stress distribution of the composite rotor during operation, the mixing ratio of carbon fiber/glass fiber is adjusted. The high-speed rotation condition of the composite rotor at 18,000 revolutions per minute is simulated to verify its safety and reliability. Full article

Currently, the need for resource efficiency and CO₂ reduction is growing in industrial production, particularly in the automotive sector. To address this, the industry is focusing on lightweight components that reduce weight without compromising mechanical properties, which are essential for passenger safety. Hybrid designs offer an effective solution by combining weight reduction with improved mechanical performance and functional integration. This study focuses on a one-step manufacturing process that integrates forming and bonding of hybrid systems using compression molding. This approach reduces production time and costs compared to traditional methods. Conventional Post-Mold Assembly (PMA) processes require two separate steps to combine fiber-reinforced plastic (FRP) structures with metal components. In contrast, the novel In-Mold Assembly (IMA) process developed in this study combines forming and bonding in a single step. In the IMA process, glass-mat-reinforced thermoplastic (GMT) is simultaneously formed and bonded between two metal belts during compression molding. The GMT core provides stiffening and load transmission between the metal belts, which handle tensile and compressive stresses. This method allows to produce hybrid structures with optimized material distribution for load-bearing and functional performance. The process was validated by producing a lightweight hybrid brake pedal. Demonstrating its potential for efficient and sustainable automotive production, the developed hybrid brake pedal achieved a 35% weight reduction compared to the steel reference while maintaining mechanical performance under quasi-static loading Full article

Non-destructive testing (NDT) and non-destructive evaluation (NDE) are essential tools for ensuring the structural integrity, safety, and reliability of critical systems across the aerospace, civil infrastructure, energy, and advanced manufacturing sectors. As engineered materials evolve into increasingly complex architectures such as fiber-reinforced polymers, fiber–metal laminates, sandwich composites, and functionally graded materials, traditional NDT techniques face growing limitations in sensitivity, adaptability, and diagnostic reliability. This comprehensive review presents a multi-dimensional classification of NDT/NDE methods, structured by physical principles, functional objectives, and application domains. Special attention is given to hybrid and multi-material systems, which exhibit anisotropic behavior, interfacial complexity, and heterogeneous defect mechanisms that challenge conventional inspection. Alongside established techniques like ultrasonic testing, radiography, infrared thermography, and acoustic emission, the review explores emerging modalities such as capacitive sensing, electromechanical impedance, and AI-enhanced platforms that are driving the future of intelligent diagnostics. By synthesizing insights from the recent literature, the paper evaluates comparative performance metrics (e.g., sensitivity, resolution, adaptability); highlights integration strategies for embedded monitoring and multimodal sensing systems; and addresses challenges related to environmental sensitivity, data interpretation, and standardization. The transformative role of NDE 4.0 in enabling automated, real-time, and predictive structural assessment is also discussed. This review serves as a valuable reference for researchers and practitioners developing next-generation NDT/NDE solutions for hybrid and high-performance structures. Full article

Thermoplastic fiber metal laminates (FMLs) are hybrid material systems that consist of a thin aluminum alloy sheet bonded to plies of fiber-reinforced adhesive. They provide excellent properties like fatigue strength, damage-tolerant properties, and inherent resistance to corrosion. However, they are still challenging materials in terms of the metal–composite interface, which is the weakest link in this material system. In this paper, an experimental–numerical method for the determination of the fracture stress and energy for metal–composite interlayer is presented and verified. The proposed method utilizes four different experimental tests: DCB test (interface opening—mode I), ENF test (interface shearing—mode II), MMB test (mixed-mode I+II—opening with the shearing of the interface) and three-point bending test (3PB). For each test, digital twin in the form of a numerical model is prepared. The established numerical models for DCB and ENF allowed us to determine fracture stress and energy for mode I and mode II, respectively. On the basis of the numerical and experimental (from the MMB test) data, the B-K exponent is determined. Finally, the developed material model is verified in a three-point bending test, which results in mixed-mode conditions. The research is conducted on the thermoplastic FML made of aluminum alloy sheet and glass fiber reinforced polyamide 6. The research presented is complemented by fundamental mechanical tests, image processing and Scanning Electron Microscopy (SEM) analysis. As an effect, for the tested material, fracture parameters are determined using the described method. Full article

Textile structures with ohmic (Joule) heating capability are frequently used for personal thermal management by tuning fluctuations in human body temperature that arise due to climatic changes or for medical applications as electrotherapy. They are constructed from electrically conductive textile structures prepared in different ways, e.g., from metallic yarns, conductive polymers, conductive coatings, etc. In comparison with other types of flexible ohmic heaters, these structures should be corrosion resistant, air permeable, and comfortable. They should not loose ohmic heating efficiency due to frequent intensive washing and maintenance. In this study, the basic electrical properties of a conductive fabric composed of a polyester/cotton fiber mixture and a small amount of fine stainless-steel staple fibers (SS) were evaluated and predicted. Even though the basic conductive component of SS fibers is iron and its electrical characteristics obey Ohm’s law, the electrical behavior of the prepared fabric was highly nonlinear, resembling a more complex response than that of a classical conductor. The non-linear behavior was probably due to non-ideal, poorly defined random interfaces between individual short SS fibers. A significant time–dynamics relationship was also shown. Using the Stefan–Boltzmann law describing radiation power, we demonstrated that it is possible to predict surface temperature due to the ohmic heating of a fabric related to the input electrical power. Significant local temperature variations in the heated hybrid fabric in both main directions (warp and weft) were identified. Full article

Thermoplastic fiber–metal hybrid composite laminates exhibit superior high-temperature resistance, fatigue resistance, and impact resistance, leading to their increasingly widespread application in the defense, military, aerospace, and marine engineering sectors. In this paper, the impact resistance of laminates with different layup sequences was compared and analyzed through high-speed impact experiments, the dynamic response and failure mechanisms of laminates were explored, and the influence rules of different factors on the impact resistance of laminates were revealed. The findings indicate that distinct laminate configurations possess varying ballistic limits and failure modes. As the number of aluminum alloy layers increases along the thickness direction of laminates, the ballistic limit decreases progressively. When the aluminum alloy layer is distributed on the back of the laminate, the deformation and delamination degree of the laminate will be reduced, and the ballistic limit of the laminate will be improved. The aluminum alloy sandwich will cause more fiber damage, which is not conducive to the energy dissipation of the laminate. These research outcomes are anticipated to provide a technical foundation for the broader application of thermoplastic fiber–metal hybrid composite laminates. Full article

This study evaluates the feasibility of 3D-printed polymer composite external fixator (EF) rings as a cost-effective alternative to stainless steel fixators, focusing on hybrid fixators for complex tibial fractures. Mechanical performance was assessed in three stages: (1) evaluating the initial EF–tibia configuration under axial loading and wire pre-tension conditions; (2) analyzing the stiffness evolution and weight-bearing capacity during early healing with progressive callus formation; and (3) optimizing ring designs through numerical analysis to improve structural performance under increased pre-tension. The results showed that, for the metallic EF, the axial displacement under one-leg stance reached 8.41 mm without pre-tension, reducing to 6.83 mm at 500 N pre-tension, though transverse displacement remained significant, suggesting the need for higher wire tension. Callus formation enhanced the load-bearing capacity, as expected. However, excessive displacements persisted under the one-leg stance, indicating that full weight-bearing should be delayed beyond two weeks for a fracture gap of 3 mm. A ring design assessment showed that full-ring configurations with two wires per ring improved performance. The 3D-printed full-ring design made of carbon-fiber-reinforced polylactic acid (PLA-CF) reduced stress by 85% at 500 N pre-tension compared to the initial configuration, remaining within allowable limits. While confirming feasibility, the study highlights the need for geometric refinements to accommodate higher preloads and improve transverse stiffness. Full article