Search Results (648)

In the casting and rolling production process, surface longitudinal cracks are a typical casting defect. Tracing the causes of longitudinal cracks online and controlling the key parameters leading to their formation in a timely manner can enhance the stability of casting and rolling production. To this end, the influencing factors of longitudinal cracks were analyzed, a data integration storage platform was constructed, and a tracing model was established using empirical rule analysis, statistical analysis, and intelligent analysis methods. During the initial production phase of a casting machine, longitudinal cracks occurred frequently. The tracing results using the LightGBM-SHAP method showed that the relative influence of the narrow left wide inner heat flow ratio of the mold was significant, followed by the heat flow difference on the wide symmetrical face of the mold and the superheat of the molten steel, with weights of 0.135, 0.066, and 0.048, respectively. Based on the tracing results, we implemented online emergency measures. By controlling the cooling intensity of the mold, we effectively reduced the recurrence rate of longitudinal cracks. Root cause analysis revealed that the total hardness of the mold-cooling water exceeded the standard, reaching 24 mg/L, which caused scaling on the mold copper plates and uneven cooling, leading to the frequent occurrence of longitudinal cracks. After strictly controlling the water quality, the issue of longitudinal cracks was brought under control. The online application of the tracing method for the causes of longitudinal cracks has effectively improved efficiency in resolving longitudinal crack problems. Full article

Carbon fiber-reinforced polymer (CFRP) composites are widely used in aerospace due to their excellent strength-to-weight ratio and tailorable properties. However, these properties critically depend on the CFRP curing cycle. The commonly adopted manufacturer-recommended curing cycle (MRCC), designed to accommodate the most conservative conditions, involves prolonged curing times and high energy consumption. To overcome these limitations, this study proposes an efficient and adaptable method to determine the optimal curing cycle. The effects of varying heating rates on resin dynamic and isothermal–exothermic behavior were characterized via reaction kinetics analysis using differential scanning calorimetry (DSC) and rheological measurements. The activation energy of the reaction system was substituted into the modified Sun–Gang model, and the parameters were estimated using a particle swarm optimization algorithm. Based on the curing kinetic behavior of the resin, CFRP compression molding process orthogonal experiments were conducted. A weighted scoring system incorporating strength, energy consumption, and cycle time enabled multidimensional evaluation of optimized solutions. Applying this curing cycle optimization method to a commercial epoxy resin increased efficiency by 247.22% and reduced energy consumption by 35.7% while meeting general product performance requirements. These results confirm the method’s reliability and its significance for improving production efficiency. Full article

Soft manipulators have garnered significant research attention in recent years due to their flexibility and adaptability. However, the inherent flexibility of these manipulators imposes limitations on their load-bearing capacity and stability. To address this, this study compares various variable stiffness technologies and proposes a novel design concept: leveraging the phase-change characteristics of low-melting-point alloys (LMPAs) with distinct melting points to fulfill the variable stiffness requirements of soft manipulators. The pneumatic structure of the manipulator is fabricated via 3D-printed molds and silicone casting. The manipulator integrates a pneumatic working chamber, variable stiffness chambers, heating devices, sensors, and a central channel, achieving multi-stage variable stiffness through controlled heating of the LMPAs. A steady-state temperature field distribution model is established based on the integral form of Fourier’s law, complemented by finite element analysis (FEA). Subsequently, the operational temperatures at which the variable stiffness mechanism activates, and the bending performance are experimentally validated. Finally, stiffness characterization and kinematic performance experiments are conducted to evaluate the manipulator’s variable stiffness capabilities and flexibility. This design enables the manipulator to switch among low, medium, and high stiffness levels, balancing flexibility and stability, and provides a new paradigm for the design of soft manipulators. Full article

The technological process of the centrifugal casting of short and long castings is examined during development. The values of the technological parameters at applying heat-resistant coating on the working surface of metal molds were established. With a high-speed camera, the temperature of the free surface during the pouring of the melts was measured. Research experiments were conducted. A mathematical model of the centrifugal casting process with a horizontal axis was created. Full article

Molds readily grow on wet books, documents, and other library materials where they ruin them chemically, mechanically, and aesthetically. Poor maintenance of libraries, failures of Heating, Ventilation, and Air Conditioning (HVAC) systems, roof leaks, and storm damage leading to flooding can all result in accelerated fungal growth. Moreover, when fungal spores are present at high concentrations in the air, they can be linked to severe respiratory conditions and possibly to other adverse health effects in humans. Climate change and the accompanying storms and floods are making the dual potential of fungi to biodegrade library holdings and harm human health more common. This essay is intended for microbiologists without much background in mycology who are called in to help librarians who are dealing with mold outbreaks in libraries. Our goal is to demystify aspects of fungal taxonomy, morphology, and nomenclature while also recommending guidelines for minimizing mold contamination in library collections. Full article

In this study, polymer matrix composites based on high-density polyethylene (HDPE) and recycled HDPE (HDPEr) were reinforced with zinc oxide nanoparticles (ZnO NPs). Four formulations (M1-M4) with HDPE/HDPEr/ZnO NP mass ratios of 50/50/0, 48/47/5, 45/45/10, and 43/42/15 were produced via melt injection molding. Disc-shaped samples (Ø30 ± 0.1 mm × 2 ± 0.1 mm) were evaluated in unaged and aged states (840 h at 100% humidity and 100 °C) using scanning electron microscopy, X-ray diffraction, ultraviolet–visible and Fourier-transform infrared spectroscopy, water absorption, thermal resistance, and mechanical and dielectric testing. Among all composites, M2 showed the best performance, with the highest aging resistance (estimated lifetime of 3891 h in humidity and 2361 h in heat). It also exhibited superior mechanical properties, with the highest indentation hardness, Vickers hardness, and elastic modulus before (0.042 GPa, 3.846 HV, and 0.732 GPa) and after aging under humidity (0.042 GPa, 3.932 HV, 0.706 GPa) and elevated temperature (0.085 GPa, 7.818 HV, 1.871 GPa). Although ZnO NPs slightly reduced electrical resistivity, M2 showed the most stable dielectric properties. In its unaged state, M2 had 22%, 30%, and 3% lower surface resistivity, volume resistivity, and dielectric strength, respectively, than M1 polymer. M2 was identified as the optimal formulation, combining mechanical strength, dielectric stability, and resistance to moisture and heat. Full article

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent properties and quality. A true physical phenomenon occurring in the RTM process, especially when using vegetable fibers, is related to the absorption of resin by the fiber during the infiltration process. The real effect is related to the slowdown in the advance of the fluid flow front, increasing the mold filling time. This phenomenon is little explored in the literature, especially for non-isothermal conditions. In this sense, this paper does a numerical study of the liquid injection process in a closed and heated mold. The proposed mathematical modeling considers the radial, three-dimensional, and transient flow, variable injection pressure, and fluid viscosity, including the effect of liquid fluid absorption by the reinforcement (fiber). Simulations were carried out using Computational Fluid Dynamic tools. The numerical results of the filling time were compared with experimental results, and a good approximation was obtained. Further, the pressure, temperature, velocity, and volumetric fraction fields, as well as the transient history of the fluid front position and injection fluid volumetric flow rate, are presented and analyzed. Full article

The weight reduction is a key objective in modern engineering, particularly in the automotive industry, to enhance vehicle performance and reduce the carbon footprint. In this context aluminum alloys are widely used in structural automotive applications, often through forging processes that enhance mechanical properties compared to the results for casting. However, the high cost of forging can limit its economic feasibility. Low pressure forging (LPF) combines the benefits of casting and forging, employing controlled pressure to fill the mold cavity and improve metal purity. This study investigates the effectiveness of the LPF process in optimizing the mechanical properties of AlSi7Mg aluminum alloy by evaluating the influence of three different magnesium content levels. The specimens underwent T6 heat treatment (solubilization treatment followed by artificial aging), with varying aging times and temperatures. Microstructural analysis and tensile tests were conducted to determine the optimal conditions for achieving superior mechanical strength, contributing to the design of lightweight, high-performance components for advanced automotive applications. The most promising properties were achieved with a T6 treatment consisting of solubilization at 540 °C for 6 h followed by aging at 180 °C for 4 h, resulting in mechanical properties of σ_y 280 MPa, σ_m 317 MPa, and A% 3.5%. 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

Powder injection molding (PIM) has been used to produce nearly net-shaped samples of tungsten-based alloys. These alloys have been previously shown to have favorable characteristics when compared with standard ITER-grade tungsten. Six different alloys were produced with this method: W-1TiC, W-2Y₂O₃, W-3Re-1TiC, W-3Re-2Y₂O₃, W-1HfC and W-1La₂O₃-1TiC. These were tested alongside ITER-grade tungsten in the PSI-2 linear plasma device under ITER-relevant plasma and heat loads to assess their suitability for use in a fusion reactor. All materials showed good behavior when exposed to the lower pulse number tests (≤1000 ELM-like pulses), although standard tungsten performed slightly better, with no observable difference in surface roughness. High-power shots, namely one laser pulse of 1.6 GWm⁻², revealed that samples containing yttria are more prone to melting and droplet ejection. After high pulse number tests (10,000 and 100,000 pulses), with and without plasma, the reference tungsten showed the most cracking and highest surface roughness of all materials, while the PIM samples seemed to have a higher resistance to cracking. This can be attributed to the higher ductility of these alloys, particularly those containing rhenium. This means that tungsten-based alloys, whether produced via PIM or other methods, could potentially be used in certain areas of a fusion reactor. Full article

High-Bandwidth Memory (HBM) enables the bandwidth required by modern AI and high-performance computing, yet its three dimensional stack traps heat and amplifies thermo mechanical stress. We first review how conventional solutions such as heat spreaders, microchannels, high density Through-Silicon Vias (TSVs), and Mass Reflow Molded Underfill (MR MUF) underfills lower but do not eliminate the internal thermal resistance that rises sharply beyond 12layer stacks. We then synthesize recent hybrid bonding studies, showing that an optimized Cu pad density, interface characteristic, and mechanical treatments can cut junction-to-junction thermal resistance by between 22.8% and 47%, raise vertical thermal conductivity by up to three times, and shrink the stack height by more than 15%. A meta-analysis identifies design thresholds such as at least 20% Cu coverage that balances heat flow, interfacial stress, and reliability. The review next traces the chain from Coefficient of Thermal Expansion (CTE) mismatch to Cu protrusion, delamination, and warpage and classifies mitigation strategies into (i) material selection including SiCN dielectrics, nano twinned Cu, and polymer composites, (ii) process technologies such as sub-200 °C plasma-activated bonding and Chemical Mechanical Polishing (CMP) anneal co-optimization, and (iii) the structural design, including staggered stack and filleted corners. Integrating these levers suppresses stress hotspots and extends fatigue life in more than 16layer stacks. Finally, we outline a research roadmap combining a multiscale simulation with high layer prototyping to co-optimize thermal, mechanical, and electrical metrics for next-generation 20-layer HBM. Full article

Foundry aluminum-silicon (Al-Si) alloys, especially those containing Cu and/or Mg, are widely used in casting processes for fabricating lightweight parts. This study focuses on the optimization of the solution heat treatment parameters within the T6 heat treatment of an innovative AlSi7Cu0.5Mg0.3 secondary alloy, aiming at achieving energy savings and reducing the environmental impact related to the production of foundry components for the automotive industry. Different combinations of solution times and temperatures lower than those typically adopted in industrial practice were evaluated, and their effects on tensile properties were investigated on samples machined from as-cast and T6-treated castings produced by pouring the alloy into a steel permanent mold. Thermal analysis (TA) and differential thermal analysis (DTA) were performed to monitor the solidification sequence of microstructural phases as well as their dissolution on heating according to the proposed solution heat treatments. Microstructural analysis by light microscopy (LM) and scanning electron microscopy (SEM), together with Brinell hardness testing, was also carried out to assess the effects of heat treatment parameters. The results suggested that a shorter solution heat treatment set at a temperature lower than that currently adopted for the heat treatment of the studied alloy can still ensure the required mechanical properties while improving productivity and reducing energy consumption. Full article

Recycled aluminum–silicon alloys provide significant environmental benefits by reducing the consumption of raw materials and lowering carbon emissions. However, their industrial application is limited by the presence of iron-based intermetallic compounds and the insufficient investigation in the literature regarding their effects on mechanical behavior. This study focuses on a recycled EN 42000 alloy, comprising 95% recycled aluminum, with a focus on the effect of its elevated iron content (0.447 wt%) on aging behavior and mechanical performance. Laboratory-scale specimens were produced through gravity die casting and subjected to T6 heat treatment, consisting of solution, quenching, and artificial aging from 160 °C to 190 °C for up to 8 h. To investigate overaging, analyses were conducted at 160 °C and 170 °C for durations up to 184 h. Tensile tests were conducted on specimens aged under the most promising conditions. Based on innovative quality indices and predictive modeling, aging at 160 °C for 4.5 h was identified as the optimal condition, providing a well-balanced combination of strength and ductility (YS = 258 MPa, UTS = 313 MPa, and e% = 3.9%). Mechanical behavior was also assessed through microstructural and fractographic analyses, highlighting the capability of EN 42000 to achieve properties suitable for high-performance automotive components. Full article

Pomegranates are rich in nutrients and classified among ready-to-eat fruits and vegetables. Although this ready-to-eat produce offers convenience, it presents risks associated with pathogenic microorganisms, highlighting the need for pre-sale disinfection. Ultraviolet light-emitting diodes (UV-LEDs) constitute an innovative non-thermal processing technology for food products, offering reduced heat generation and lower energy consumption compared to traditional ultraviolet (UV) irradiation methods. This study analyzed the effects of UV-LED technology on pomegranate seed quality over 0 to 5 days of storage. The results demonstrated significant increases in anthocyanins, polyphenols, ascorbic acid, and the antioxidant capacity in pomegranate following treatment, peaking on day 3. In contrast, the control group showed declining trends. After treatment, the aerobic mesophilic counts and counts of mold and yeast levels during storage measured between 2.73–3.23 log CFU/g and 2.56–3.29 log CFU/g, respectively, significantly lower than the control group. Non-targeted metabolomic analysis showed that UV-LED treatment prompted modifications in the biosynthetic pathways of flavonoids, flavonols, and anthocyanins. The expression of peonidin-3-O-rutinoside chloride increased by 46.46-fold within the anthocyanin biosynthesis pathway. In conclusion, UV-LED treatment represents a potential approach to the disinfection of ready-to-eat fruits and vegetables. Full article

Crosslinked phenolic resin was prepared using hexamethylenetetramine (HMTA) as a crosslinking agent in hydrochloric acid solution. The ablation-heat-resistant material was prepared by a pressure-assisted RTM (resin transfer molding) process with reinforcing material (quartz fibre 2.5D needle-punched fabric/satin fibre cloth/fibre mesh tire) and matrix (crosslinked phenolic resin). The thermal stability of the cured product was studied by a thermogravimetric analyser (TG and DTG). The mechanical properties, heat resistance, and ablation properties of the composites were tested. The ablation morphology, element analysis, and phase structure of the composites were analysed by scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), and X-ray diffraction (XRD), respectively. The results show that the phenolic resin has a lower initial viscosity and a longer pot life at 80 °C, and a higher carbon residue rate (70.18%). The tensile strength of the composites is close to 40 MPa, the tensile modulus is higher than 1.35 GPa, the compression modulus is higher than 10 MPa, and the elongation at break is higher than 1.55%. SiO₂, SiC, and ZrO₂ ceramic phases were formed after ablation, which effectively improved the ablation performance of the composites. Full article