Search Results (775)

A vertical-type high-speed twin-roll caster can cast strips at a speed of 60 m/min. However, ripple marks, which are typical surface defects on strips cast using a twin-roll caster, also appear on strips cast using this caster. In the present study, Al-5%Mg was used because severe ripple marks occur on Al-5%Mg strips. The influences of the molten-metal head (50, 100, and 150 mm), which is a characteristic parameter for this caster, the molten-metal temperature (645, 685, and 735 °C), and the nozzle thickness on ripple marks were investigated. The nozzle thickness was an important factor in eliminating ripple marks, and a nozzle thickness of 3 mm was suitable for eliminating them. No relationship was found between ripple marks and surface cracks. The surface cracks decreased as the roll load decreased, and a roll load of 5 N/mm was suitable. Based on the obtained results, the optimum nozzle shape and casting conditions for casting strips without ripple marks or cracks were clarified. Full article

With increasingly stringent restrictions on SF₆ greenhouse gas emissions, C₄F₇N-based gas mixtures have attracted considerable attention as promising alternatives for high-voltage circuit breakers; however, their relatively weaker arc-quenching capability poses significant challenges for interruption chamber design at high voltage levels. In this study, a 3.5% C₄F₇N/83.5% CO₂/13% O₂ gas mixture was used as the arc-extinguishing medium in a 550 kV environmentally friendly gas circuit breaker. Based on a magnetohydrodynamic (MHD) model considering PTFE nozzle ablation effects, systematic optimization studies were conducted on key structural parameters of the puffer-type interruption chamber, including the exhaust hole diameter, nozzle throat diameter and length, arcing contact diameter, and downstream expansion angle. Simulations under arcing times of 9.9 ms and 11.4 ms were performed to evaluate chamber pressure, axial temperature, extinction peak voltage, and post-arc conductance characteristics. The results indicate that extending the nozzle throat straight section to 70 mm, enlarging the exhaust hole, and increasing the moving contact radius can effectively enhance pressure buildup, reduce arc-core temperature, and improve dielectric recovery capability. Under the 11.4 ms arcing condition, the optimized structure achieved an extinction peak voltage of 6972.4 V and a G200 value of 0.731 ms, demonstrating substantially improved interruption performance. These findings reveal the synergistic relationship between arcing time and structural parameters and provide theoretical guidance for the engineering design of environmentally friendly high-voltage gas circuit breakers. Full article

In this work, Direct Numerical Simulation (DNS) investigates the combustion behaviour of a reactive transverse lean premixed jet of an ammonia blend (10% NH₃, 11% H₂, 16% O₂ and 63% N₂ by volume) injected through a rectangular nozzle in a pre-heated non-vitiated air crossflow at a pressure of 5 bar. The configuration has been chosen from a Reynolds-Averaged Navier–Stokes (RANS) test campaign to ensure low NO and low unburned fuel, while maintaining a high temperature profile at the turbine inlet. The DNS shows that the flame stabilises on the leeward side of the rectangular jet, within and downstream of the recirculation region, while high scalar dissipation and short residence times prevent persistent anchoring on the windward side. Joint statistics reveal that the reaction does not follow a constant equivalence ratio path, since intermediate progress states are shifted towards leaner mixtures by entrainment, dilution and differential diffusion. The strongest heat-release and displacement-speed events occur in localised regions where mixture state, stretch and flame-front geometry act jointly. The displacement-speed budget is mainly controlled by the chemical source term, with diffusion reducing the net propagation speed and stratification-induced cross terms remaining small. Under intense stretch, positively curved flame elements exhibit larger displacement speeds, indicating a coupled effect of curvature, preferential diffusion and local radical transport. NO formation is dominated by fuel-nitrogen chemistry: HNO and NH₂ are the main NO-producing routes, whereas N₂ and N₂O provide the dominant NO-sink channels. The DNS predicts an outlet-averaged NO level of 400 dppm, while extended-domain RANS calculations indicate that longer residence times could reduce it below 100 dppm. Full article

Three-dimensional (3D) food printing, a relatively new food-processing method, was explored using gelatinized sweet potato starch (SPS) as a food ink. Prior to the production of intricate 3D shapes, this study focused on the precise extrusion of filaments, specifically the optimization of the printing conditions for nozzle diameters of 1.5 and 4.0 mm to produce filaments with an acceptable appearance and size. The rheological and mechanical properties of the (SPS) sol were also determined to describe the extrudability and shape retention of the food materials. The optimization process employed the Response Surface Methodology (RSM) and a desirability function to generate mathematical models of the width and height of the filaments as functions of the moisture content, the print temperature, and the print speed. The generated mathematical models were used to determine the optimum printing conditions. Hence, for the 1.5 mm nozzle, the optimum condition was at 82% moisture content, 57 °C print temperature, and 10 mm/s print speed, with a desirability of 0.842. In contrast, for the 4.0 mm nozzle, the optimum condition was at 82.3% moisture content, 50 °C print temperature, and 5 mm/s print speed, with a desirability of 0.911. The optimized filaments are expected to be used in 3D food printing to create 3D shapes. Full article

Exhaust piping in diesel engines is subject to severe thermal stress arising from high-temperature, high-pressure gas flows, and spray cooling with atomizing nozzles has become a widely adopted method to safeguard structural reliability. However, at present, the understanding of the spray fragmentation mechanism of two-phase flow under low inlet pressure is still not comprehensive. This study establishes a three-dimensional model of a gas–liquid impinging-jet nozzle and applies a coupled Volume-of-Fluid to Discrete-Phase-Model (VOF–DPM) approach to resolve the liquid breakup process in detail. High-speed imaging experiments were carried out to validate the numerical results. Orthogonal tests were conducted at five pressure levels for both gas and water—0.28, 0.24, 0.20, 0.16, and 0.12 MPa—producing 25 data pairs of spray cone angle and Sauter Mean Diameter (SMD). Within the 0–0.3 MPa air inlet pressure range explored here, raising the pressure consistently reduced the SMD and widened the cone angle, although both trends weakened as the pressure increased. Water inlet pressure exhibited a nonlinear influence, with local extrema appearing in the higher-pressure region. The overall SMD reached a minimum of 34.12 μm and a maximum of 149.04 μm. Using these 25 data points, a genetic algorithm was employed to optimize the pressure ratio under the constraint of total hydraulic power, yielding optimization strategies for different power budgets. An additional outcome of the simulation was the identification of a structural weakness: by reshaping the original flat impingement surface into a full conical surface, atomization quality improved by 29.36% under identical boundary conditions. These findings clarify the atomization mechanism of gas–liquid impinging jets under low inlet pressure and offer practical guidance for nozzle optimization. Full article

Three-dimensional scaffolds based on triply periodic minimal surfaces (TPMSs) have attracted growing interest in bone tissue engineering because of their high interconnectivity and ability to combine high porosity with mechanical integrity. However, in fused deposition modeling (FDM), printed architecture may systematically deviate from the nominal design, thereby affecting structural fidelity and mechanical performance. This study investigated the influence of FDM processing parameters and nozzle diameter on the effective microarchitecture and compressive elastic modulus of polycaprolactone (PCL) gyroid scaffolds. First, a Taguchi L18 design was used to evaluate the effects of extrusion temperature, printing speed, and flow rate on pore size for two nozzle diameters (0.4 and 0.3 mm). In a second experimental stage, prismatic specimens fabricated at three nominal porosity levels were compression-tested to determine the elastic modulus (E), and measured porosity (ϕ) was quantified by densimetric measurements. A systematic mismatch was observed between the nominal design and the printed scaffold architecture, with both pore size and measured porosity consistently lower than their intended values. The dominant process parameter associated with pore-size variability was nozzle-specific: extrusion temperature contributed most for the 0.4 mm nozzle, whereas printing speed contributed most for the 0.3 mm nozzle. In compression, E decreased with increasing measured porosity, and statistical analysis showed that the E–ϕ relationship was nozzle-dependent. Overall, these findings support a process–structure–property interpretation based on the effective printed microarchitecture rather than on nominal design parameters alone. The experimental stiffness ranges obtained here also provide an exploratory mechanical contextualization relative to reported trabecular bone domains, without implying site-specific scaffold selection. Full article

The global transition from petrochemical to sustainable bio-based plastics has been strongly supported by electrospinning (ES), a versatile nanotechnology enabling the fabrication of ultrathin fibers with multifunctional properties. The solution ES process alongside the uniform fibers, a characteristic “beads-on-string” morphology, consisting of alternating cylindrical and spindle-like segments, is frequently observed. Once considered undesirable, these structures are now recognized as functional fibrous architectures with enhanced properties. This work explores the valorization of beaded fibers through combined experimental characterization and modeling, aiming to evaluate the impact of beading on drug diffusion and delivery performance. Poly(3-hydroxybutyrate) (PHB) was selected as the model biopolyester and dipyridamole (DPD) as the model drug. Ultrathin fibers were fabricated using the laboratory electrospinning device, EFV-1 (ICP, Moscow, Russia). The distance between the capillary nozzle and the anodic collector was set to 180 mm, with the capillary tip radius equal to 0.35 mm, and applied voltage between the electrodes was kept constant at 18 kV. Drug release profiles were obtained by simulating DPD diffusion in ellipsoidal (beads) and cylindrical fiber domains. Ultrathin fibers were fabricated by solution electrospinning under environmental conditions (at ambient temperature, 50% relative humidity). Morphology was analyzed via SEM, thermal properties via DSC, and structure via FTIR spectroscopy at different temperatures, including the melting point (~170 °C). Drug release kinetics were monitored using a UV-Vis spectroscopy. The impact of DPD diffusion within the ellipsoidal and cylindrical constituents of polymer filaments was considered to modulate release profiles for the development of innovative pharmaceutical platforms. Diffusion controlled drug release was computationally modeled using a specially designed simulation program, in good agreement with experimental data. The results demonstrate that morphological parameters significantly affect diffusion and release kinetics. The controlled exploitation of bead-on-string architectures may enable the design of electrospun materials with tunable absorption of pollutant filtration, mechanical performance, and flexibility in drug release profiles, for sustainable biopolymers like PHB. Full article

A new biomass pyrolyzer, named Biochar Oven, has been developed using flameless combustion technology, which provides uniform high temperature in the pyrolysis reactor. A computational fluid dynamics (CFD) model of flameless combustion was developed to analyze how the fuel inlet depth controls the reaction and heat transfer to a vertical biomass pyrolysis reactor. The combustor was modeled using the k–ε turbulence model, the discrete ordinates radiation model, and species transport with the reaction. The fuel nozzle relative depth ratios (RDR) of chamber height and equivalence ratios (ER) were varied to obtain optimal combustion and heat transfer performance. The internal recirculation ratio (Z) was calculated to evaluate the flameless combustion condition, with maximum values generally found at RDR 0.73 for each ER. Increasing depth strengthens the mixing zone closer to the reactor wall. With an ER of 0.9 and RDR of 0.73, the wall heat flux is up to 16.36 kW m⁻², the average wall reactor temperature is up to 900 °C, and the heat transfer efficiency is up to 59.79%. These flow patterns and chamber–reactor results indicate that deeper nozzle insertions (RDR 0.73) provide better overall performance by improving recirculation intensity, wall heat flux, and heat transfer efficiency with lower CO emissions. Full article

High-pressure liquid CO₂ jets possess the characteristics of low-temperature cooling and dry, residue-free impact, which makes this technology particularly suitable for removing hydroxyl-terminated polybutadiene (HTPB) propellant from decommissioned solid rocket motors. However, existing studies lack multi-objective optimization of impact efficiency and CO₂ consumption, which limits their engineering applications and further promotion. In this study, a high-accuracy quadratic Response Surface Methodology (RSM) relating process parameters to damaged volume was established using a Box–Behnken design (BBD) combined with three-dimensional topography scanning. A theoretical model for CO₂ consumption was developed based on the Homogeneous Equilibrium Model (HEM). On this basis, the Non-dominated Sorting Genetic Algorithm II (NSGA-II) was used to obtain the Pareto-optimal set for maximizing propellant damaged volume and minimizing CO₂ consumption. The results indicate that nozzle diameter has the most significant effect on damaged volume and exhibits a strong interaction with jet pressure. The knee-point solution gives a jet pressure of 15.35 MPa, a stand-off distance of 5 mm, and a nozzle diameter of 1.8 mm. Compared with the initial condition, this compromise condition increases the damaged volume by 72% while increasing CO₂ consumption by only 4.9%. Furthermore, the temperature in the impact zone was reduced to a minimum of −92.4 °C, with no thermal accumulation observed. These findings reveal the influence of liquid CO₂ jet process parameters on impact efficiency and CO₂ consumption, providing a theoretical basis and parameter references for its engineering application in the safe removal of propellants from decommissioned solid rocket motors. Full article

Tool wear in CNC milling increases friction and torque demand at the tool-workpiece interface, which is reflected in spindle motor current. This study develops a non-intrusive tool wear condition classification method using spindle motor current monitoring during practical CNC milling of commercial medium-carbon steel workpieces (JIS S50C/AISI SAE 1050-equivalent; as-received and non-heat-treated; nominal laboratory hardness approximately 4.3 HRC). Experiments were performed on a Tongtai MDV-508 vertical machining center at fixed cutting conditions (3000 rpm spindle speed, 2 mm axial depth of cut, 5 mm cutting width, and 300 mm/min feed rate) using eight TiAlN-coated fine-grain WC–Co solid carbide end mills (10 mm diameter, four flutes; nominal Co binder approximately 10 wt%). An oil-based HS Highstart/HS-SSHS-BH10 cutting fluid was applied through the machine external coolant nozzle in flood mode at an estimated nominal flow rate of approximately 3 L/min and near-room coolant temperature (25 ± 2 °C), and was used as supplied without dilution. A clamp-type AC current sensor was installed on one phase line supplying the spindle motor, and current was acquired using an NI-9221 module at 20 kHz. Cutting intervals were isolated by envelope-based segmentation, concatenated, and divided into 1 s windows (0.5 s overlap) for feature extraction. Three feature sets were evaluated: time-domain statistics, frequency-domain statistics, and an FFT→PCA hybrid representation. Tool states (New, Mid-life, Old) were labeled using post-process surface roughness Ra thresholds supported by microscope observation. The PCA transformation was fitted only on training data and then applied to the held-out test data. A logistic regression classifier achieved 97.44% test accuracy (152/156 windows; 95% Wilson CI: 93.59–99.00%) with the PCA-hybrid features, outperforming time-domain (89.74%) and frequency-domain (94.87%) models. The results support spindle current monitoring as a low-cost approach for quality-aligned tool condition monitoring, while the external validity remains limited to the tested machine, material, tool, coolant, and cutting-parameter combination. Full article

This study aims to demonstrate the feasibility of controlling particle size through a mathematical model in the design of industrially applicable ultrasonic spray nozzles by utilizing the vibrational characteristics of piezoelectric ceramics. A piezoelectric ceramic composition with a low sintering temperature and excellent thermal stability (Curie temperature above 300 °C) was developed and used as a ceramic vibrator. Furthermore, the resonance frequency and nozzle displacement were calculated using the COMSOL program and applied to a mathematical model to design an ultrasonic nozzle capable of producing a spray particle diameter of approximately 30 μm. The designed ultrasonic nozzle was fabricated, and its spray characteristics were analyzed. The consistency of the spray characteristics was examined by comparing them with the mathematical model based on changes in ultrasonic nozzle length, resonance frequency, and fluid viscosity. When the ultrasonic nozzle horn length was 22 mm, the resonance frequency was found to be 42.1 kHz, and at a flow rate of 65 mL/min. the average spray particle size was approximately 30–40 μm, indicating fine and uniform particles. In addition, it can be seen that as the length of the nozzle horn increases, the resonance frequency decreases, reducing the supply energy delivered to the liquid, and the particle size increases as shown in the mathematical analysis. The theoretical separation energy required to atomize pure water at a flow rate of 65 mL/min. is 2100 J, which was found to be greater than all energy loss occurring during the atomization process. However, it can be seen that as the length of the ultrasonic nozzle increases, the maximum atomization volume increases, and as viscosity increases, the energy required to separate a single atomized particle becomes greater. Full article

This study presents an experimental investigation of 3D-printed poly(lactic acid) samples (PLA) subjected to high-voltage AC stress. Although additive manufacturing is gaining importance in electrical engineering, studies on FDM-printed materials have concentrated mainly on mechanical behaviour. Their dielectric strength under oil-immersed high-voltage stress—a critical aspect for insulation applications—has not been systematically investigated. Additive manufacturing is increasingly considered for auxiliary insulating components in oil-immersed high-voltage equipment; however, process-induced voids and interlayer interfaces can intensify the local electric field and reduce dielectric strength. This work evaluates the AC breakdown strength of 3D-printed PLA specimens under oil immersion using the standard AC electrical strength test method for solid insulating materials. Two parameter sets were investigated: extrusion temperature (190–240 °C ) at a constant nozzle diameter, and nozzle diameter ($0.3$–$0.6 \mathrm{mm}$) at a constant extrusion temperature of $T_{\mathrm{e}}=200°\mathrm{C}$. Breakdown data were analysed using the standard two-parameter Weibull approach typically used in the statistical evaluation of electrical insulation breakdown strength, with the results additionally expressed in terms of the $B_{10}$, $B_{50}$, and $B_{90}$ percentiles. The experimental observations were interpreted using simplified electric-field simulations representing inter-bead and interlayer voids. The results indicate that, for a given material, there exists an optimal extrusion temperature that yields the highest electrical breakdown performance. Full article

The SF₆ circuit breaker is an essential piece of high-voltage equipment in ensuring the safe operation of the power grid. Regarding the arc-extinguishing chamber, as the most essential component, its performance is directly related to the breaking capacity of the circuit breaker. This study applies the Double Distribution Function Lattice Boltzmann Method (DDF-LBM), combined with the Smagorinsky sub-grid scale (SGS) model, to systematically simulate the dynamic breaking process of a 252 kV SF₆ arc-extinguishing chamber under 50 kA breaking current conditions. Two independent distribution functions are employed to describe the fluid field and the temperature field, respectively, thereby simulating the physical flow–heat coupling process. A dynamic simulation framework is constructed using the D2Q9 model to describe the mechanical motion of the contacts and the fluid flow. The description of contact movement is achieved by dynamically updating the geometric mesh, thereby realizing fluid–solid transformation. The research results indicate that the proposed method can simulate the pressure variation of the fluid field during the breaking process. The value of the Smagorinsky constant (C_s) exhibits a non-negligible influence on the pressure field predictions. The optimal value of C_s = 0.10 is determined through analysis, and the peak pressures at the upstream and throat measurement points reach 1.11 MPa and 1.37 MPa, respectively. Numerical simulations are conducted on the dynamic breaking process of the arc-extinguishing chamber, revealing the evolution of the pressure field upstream of the nozzle and at the throat regions. This study provides new numerical simulation methods for the investigation of SF₆ arc-extinguishing chambers and establishes a foundation for the application of the Lattice Boltzmann Method in the field of high-voltage electrical appliances. Full article

The demand for materials that can operate reliably in extreme environments, including rocket nozzles, re-entry heat shields, sharp leading edges, high-velocity impact, and high-temperature energy systems, continue to drive advances in thermal–structural materials. Carbon/Carbon composites remain a leading baseline because of their low density, high-temperature mechanical retention in inert atmospheres, and excellent thermal-shock tolerance. However, long-term durability is constrained by rapid oxidation in air at elevated temperatures, limited fracture toughness and elastic modulus in many architectures, and high manufacturing cost driven by multi-cycle densification and stringent quality assurance. Consequently, contemporary strategies increasingly rely on modifying Carbon/Carbon composites with ultra-high-temperature ceramics and adopting accelerated or simplified manufacturing routes. This review synthesizes recent progress in the design, manufacture, and application of high-performance modified Carbon/Carbon composite systems for extreme aerospace environments, emphasizing composition/architecture selection, oxidation, and ablation protection, toughening concepts, and cost-aware densification. Because extreme environments performance is governed by coupled aerothermal loading, gas–surface chemistry, internal transport, recession, and thermomechanical response, the review also consolidates the multiscale modeling and software toolchains increasingly used to size thermal-protection systems, interpret experiments, and guide down-selection. Key challenges and future directions are further discussed for reusable materials and validated performances beyond ~2000 °C. Full article

Potassium nitrate and sorbitol (KNSB) is a promising low-cost solid propellant for aerospace, characterized by stable combustion and a low pressure exponent. However, its application is constrained by a deficiency in detailed numerical simulation studies for solid rocket motors (SRMs). This study develops a comprehensive numerical model for a KNSB SRM, incorporating dynamic mesh techniques to simulate real-time burning surface regression. Steady-state internal flow field analysis proves to be well-validated by literature data, with combustion pressure and thrust errors of 7.7% and 3.2%, respectively. Increasing oxidizer mass fraction from 57.5% to 70% leads to a significant temperature rise of 22.15%. Dynamic simulations reveal that thrust and pressure initially increase after ignition but later decline as the regressing surface reduces gas generation below the nozzle exhaust rate. Comparison with literature yields an average thrust error of 4.9%, with simulated trends matching documented behavior well. This research provides a robust reference for performance prediction and supports further development of KNSB SRMs. Full article