Search Results (348)

Electrified steam methane reforming (eSMR) is emerging as a promising technology for the decarbonization of the chemical industry and low-carbon hydrogen production by coupling renewable electricity with renewable gaseous feedstocks such as biomethane. In this work, structured Ni-based catalysts washcoated on highly thermally conductive SiC open-cell foams (OCFs) were developed and evaluated for biomethane steam-reforming operating conditions. Two catalyst formulations, 30 wt.% Al₂O₃_30 wt.% CeO₂_20 wt.%Ni and SiC_30 wt.% Al₂O₃_30 wt.%Ce_0.25Zr0.75 O₂_20 wt.%Ni, were tested in a laboratory-scale indirectly electrically heated reformer. The high thermal conductivity of the SiC-structured support ensured efficient heat transfer throughout the reactor, limiting radial temperature gradients to below 10 °C. Both catalyst formulations exhibited excellent catalytic performance; however, the Ce_0.25Zr0.75O₂-promoted catalyst achieved the best results, maintaining equilibrium methane conversion at a gas hourly space velocity above 7000 h⁻¹ while reaching a specific electrical energy consumption of 2.06 kWh/Nm³ of produced H₂ projected for industrial-scale efficiency. Notably, these performances were obtained with a catalyst loading approximately 20–50% lower than that of conventional commercial alumina pellet catalysts. XRD characterization did not reveal the formation of crystalline graphitic carbon after catalytic operation. Furthermore, the structural evolution of the Ce–Zr–O highlights the active role of the mixed oxide in promoting redox processes and maintaining catalytic activity under reaction conditions. Overall, these results demonstrate that the combination of highly conductive SiC-structured supports and Ce–Zr-promoted Ni catalysts significantly enhances both the thermal and catalytic efficiency of eSMR. The proposed catalyst provides a promising route toward compact, energy-efficient, and decentralized hydrogen production from biomethane, supporting the electrification and decarbonization of future hydrogen generation technologies. Full article

This study develops a 3D computational fluid dynamics model of a polymer electrolyte fuel cell cathode gas channel with seven discrete liquid breakthrough inlets, one gas inlet, and a two-phase outlet. Two-phase flow and droplet evolution on the gas diffusion layer are simulated using the volume-of-fluid method in OpenFOAM. The model agrees well with reported experimental and numerical data in terms of droplet size, morphology, and detachment behavior. Results show that breakthrough geometry governs droplet dynamics: circular openings promote stronger aerodynamic loading and earlier detachment, while sharp-cornered geometries (e.g., triangular and polygonal) stabilize droplets and prolong residence time. Among all investigated geometries, the circular breakthrough exhibits the highest drainage efficiency, in agreement with recent experimental studies demonstrating that laser-drilled circular pores facilitate water removal and reduce oxygen mass-transfer resistance in polymer electrolyte fuel cells. Complex interactions with the gas diffusion layer surface, gas channel walls, and corners lead to coalescence, sliding, and rivulet formation. Force decomposition reveals the competition among aerodynamic, capillary, adhesion, and shear forces. The study provides a mechanistic basis for geometry-controlled water transport and guidance for gas diffusion layer design and water management. Full article

Efficient gas drainage in soft coal seams is commonly impeded by two coupled issues: coal-fines-induced clogging of screens and boreholes, and instability of the borehole wall. To overcome these limitations, an in situ grouted porous polyurethane system was developed for borehole completion. The polyurethane slurry, consisting of isocyanate, polyether polyol, catalyst, foam stabilizer, cell-opening agent, cross-linker, and water as a blowing agent, was formulated to coordinate foaming and gelation kinetics. By adjusting the type and dosage of catalyst, the gel time could be precisely controlled within 10–1500 s to suit different construction requirements. After curing, the material exhibited an interconnected open-cell structure with a porosity of approximately 83%, permeability greater than 4 D, and a uniaxial compressive strength of about 1.72 MPa. Mercury intrusion porosimetry revealed a highly connected, multiscale pore network, with an accessible porosity of 78.9%, a median pore size of 125 μm, and a dominant pore-size range of 1–301 μm, indicating favorable conditions for gas flow. Flow-through experiments under simulated methane drainage showed that coal-fine production is strongly dependent on flow rate: fines generation was negligible at flow rates ≤20 L/min and became noticeable at around 30 L/min. Scanning electron microscopy confirmed that coal fines were confined to the upper ~5 mm of the consolidation layer, where bridging and straining within small near-surface pores limited deeper penetration. Although near-surface fines deposition reduced permeability from the intrinsic polyurethane value (~4.0 D) to ~2.0 D, the permeability stabilized above ~1.5 D under dynamic conditions. Overall, these laboratory-scale results demonstrate that the porous polyurethane can effectively intercept coal fines within a shallow surface zone, provide sufficient mechanical support to stabilize the borehole, and maintain high permeability under the tested conditions, suggesting its potential as a candidate material for enhancing methane drainage performance in soft coal seams. Further field validation and comparative studies against conventional completion systems are needed to assess its true engineering viability. Full article

Hypersonic air-breathing propulsion via the Oblique Detonation Wave Engine (ODWE) offers superior thermodynamic efficiency compared to conventional scramjets by utilizing a stationary oblique detonation wave (ODW). While fundamental research has predominantly focused on two-dimensional planar wedges, realistic applications feature axisymmetric conical configurations. Over a cone, radial Taylor–Maccoll (TM) compression decelerates the flow and, in the mixed flow regime, establishes a localized subsonic pocket near the cone surface. However, the unsteady structures, triple-point kinetics, and cellular evolution under the competing influences of stabilizing TM compression and destabilizing Prandtl–Meyer (PM) expansions induced by a finite-length cone remain poorly understood. To address this gap, high-resolution numerical simulations of axisymmetric conical ODWs on a finite cone (semi-cone angle θ = 49°) were conducted at an inflow Mach number of Ma₀ = 7.5 using OpenFOAM. The methodology solves the reactive Euler equations coupled with a single-step Arrhenius model and three levels of adaptive mesh refinement to resolve fine-scale wave structures. Numerical results reveal that the localized subsonic pocket completely obliterates the smooth ZND-like initiation zone typical of purely supersonic configurations. Within this subsonic channel, acoustic disturbances propagate upstream against the bulk flow at a relative velocity of c − u, bypassing the supersonic wave-blocking effect to continuously impinge upon the detonation front. This acoustic feedback loop disrupts shock–reaction coupling, accelerating wave front bifurcation into single triple-point, dual triple-point, and PM-affected segments. Shock polar analysis validates that upstream-facing triple points exhibit greater shock strength, driving slow upstream migration and causing adjacent triple points to collide and reform into distinct, chaotic cell morphologies. Trajectory tracking confirms that the mixed flow cells are substantially larger and more chaotic than supersonic cases, directly reflecting amplified perturbations from the subsonic pockets. These insights provide crucial design criteria for optimizing cone angles to suppress irregular modes and stabilize conical ODWs. Full article

This study presents a computational and experimental aerodynamic characterisation of a full-scale 5.5 m diameter, six-sail horizontal-axis windmill of the traditional Cretan Lasithi type, equipped with flexible woven polyester sails that act as a passive load-control mechanism. Seventeen operating points spanning wind speeds of 2.3–18.3 m/s were simulated in OpenFOAM using a transient sliding-mesh Arbitrary Mesh Interface formulation with the k–ω SST turbulence closure on a 2.3 million cell grid, selected on the basis of a four-level grid convergence study. CFD simulations identify three distinct aerodynamic regimes: a drag-dominated high-TSR regime (λ > 2.1), a mixed lift–drag working range with peak loading near λ ≈ 1.4–1.5, and a deep-stall regime in which boundary-layer separation propagates from root to tip as λ falls below 1.0. Field measurements conducted at the Energy Systems Synthesis Lab of the Hellenic Mediterranean University in compliance with IEC 61400-12-1:2005(E) confirm that rotor speed stabilises passively at 55–58 RPM above 13 m/s without any active control mechanism; CFD predictions agree with measured power output within 8–12% across the 2–13 m/s attached-flow envelope. The combined evidence indicates that passive overspeed self-regulation is driven by aeroelastic sail deformation, reducing effective disc solidity at high wind speeds, a mechanism that rigid-geometry CFD correctly identifies in trend but cannot quantify in magnitude. The primary limitation of the present work is the rigid-sail assumption of the CFD model, which requires a two-way coupled fluid–structure interaction extension as a future step. Full article

Alkaline nickel zinc batteries feature high safety, low cost and eco-friendly characteristics, making them highly promising for large-scale energy storage deployment. However, their practical application is severely constrained by the cathode’s electrical conductivity, available active sites, and cycling stability. Herein, vertical 2D hierarchical flake-like NiCoS_x arrays were in situ grown on nickel foam (NF) via a facile alkali-free solvothermal and in situ sulfidation approach. This highly interconnected and open porous flaky structure significantly shortens the ion diffusion pathways, exposes abundant redox-active sites, and accelerates electron transport, imparting excellent rate performance and superior long-cycle stability to the material. The optimized NiCoS_x/NF electrode achieves a high specific capacity of 323 mAh g⁻¹ at 0.5 A g⁻¹, along with excellent capacity retention capability. Assembled with a commercial Zn anode, the NiCoS_x/NF//Zn full battery delivers 124 mAh g⁻¹ at 3 A g⁻¹, and maintains 112.5% of the initial capacity after 500 cyclic tests. Moreover, the assembled NiCoS_x/NF//Zn full cell possesses a high energy density of 615.2 Wh kg⁻¹ along with a power density of 38.6 kW kg⁻¹ (based on the mass of positive electrode active materials). This unique vertical 2D open hierarchical structure plays a crucial role in enhancing the electrochemical performance of cobalt sulfide cathodes and provides valuable insights for the design of high-performance alkaline zinc-based battery electrodes. Full article

There is increasing interest in structured layered double hydroxide (LDH)-based catalysts because they combine tunable acid–base/redox chemistry with reactor architectures that can reduce diffusion lengths, improve heat management, and lower pressure-drop penalties. This review evaluates LDH, LDH-derived oxide (LDO/MMO), reduced metal/LDO, reconstructed hydroxide-rich, and mixed dynamic states integrated into honeycomb monoliths, open-cell foams, meshes/felts, thin films, washcoats, coated plates, microchannels, capillaries, and additively manufactured lattices. To move beyond descriptive comparison, the literature is assessed using unified evaluation dimensions: operative active state, support architecture, coating/integration route, active-phase loading, coating thickness and uniformity, reactor-volume-normalized productivity or STY, ΔP/L, axial/radial thermal gradients, time-on-stream, coating loss, regeneration recovery, and pilot-readiness. Representative benchmarks illustrate both the promise and reporting gaps of the field: NiFe-LDH-derived monoliths for CO₂ methanation have reached ~70% CO₂ conversion at 300 °C with >90% CH₄ selectivity and only 0.7% post-test mass loss; NiFe-LDH/iron-foam monoliths retained 85% ozone conversion after 168 h; high-entropy LDH-derived oxides showed T50/T90 values of 246/254 °C for toluene oxidation; and Au/LDH capillary films achieved 31.9% glycerol carbonate yield and 3.78 g h⁻¹ g⁻¹ productivity. The strongest current cases are pollution abatement and CO₂ methanation, whereas biomass upgrading, fine-chemical flow, high-entropy coatings, and photo/electrocatalytic films require deeper module-level validation. Overall, structured LDH catalysts should be treated as coupled chemistry–coating–reactor systems whose performance must be judged simultaneously by activity, accessible catalyst inventory, transport efficiency, pressure drop, thermal profile, durability, regeneration, and manufacturability. Full article

This article reviews the linear solvers available in OpenFOAM and assesses their impact on the convergence behaviour of the SIMPLE algorithm. The discretisation of transport equations in CFD results in large and sparse linear systems, for which the choice of linear solver strongly influences the computational time. Although the solver does not change the final discrete solution, the difference in speed and robustness between the solvers can be more than one order of magnitude. A brief overview is given concerning how the velocity and pressure fields are decoupled in OpenFOAM, followed by a detailed review of the main linear solver families, including direct methods, basic iterative methods, multigrid methods and Krylov subspace methods, with attention to their practical strengths and weaknesses. The performance of the most advanced solvers is evaluated on a full-scale non-reacting kiln case consisting of 2.3 million cells. The pressure-corrector equation is identified as the main bottleneck in the SIMPLE algorithm. The conjugate gradient (CG) solver with a multigrid (MG) preconditioner is found to be the fastest and most stable method, achieving speed-ups of up to a factor of 7 compared to the slower advanced methods. Using MG as a preconditioner also improves the robustness of the Bi-CGStab method. Full article

Foam injection moulding (FIM) enables lightweight thermoplastic parts, but current process simulations do not resolve microstructure formation. This work presents a micro-scale CFD framework for FIM that captures gas–melt interaction and bubble morphology. A two-phase, compressible volume-of-fluid solver (OpenFOAM) with surface tension and viscoelastic Phan–Thien–Tanner rheology is coupled to a nucleation pre-processor based on classical nucleation theory, which places bubbles stochastically using macro-scale pressure and temperature histories. The approach was demonstrated on a plate geometry using a 2D through-thickness section to investigate bubble nucleation, deformation, coalescence, and interaction under realistic process conditions. The simulations reproduced characteristic morphology trends across the thickness. In particular, the predicted aspect ratio and orientation show the expected skin–core behaviour and agree qualitatively with experimental observations. These results demonstrate that the framework can describe morphology development beyond simplified spherical-cell assumptions and provides a proof of concept for multiscale coupling between macro-scale process conditions and micro-scale foam structure evolution. A simplified surrogate growth representation was used to enable bubble expansion; however, a physically based mass-transfer model is required for quantitatively accurate growth kinetics. Full article

The miniaturization of medical ultrasound imaging transducers is currently limited by the thick backing layers required to dissipate backward acoustic energy. To address this, a novel hybrid composite backing material was developed by interpenetrating a three-dimensional open-cell nickel foam skeleton with a traditional tungsten-powder/epoxy-resin matrix. Two groups of composite samples with varying pores per inch (PPI) were fabricated, and their acoustic properties were systematically characterized. Experimental results indicated that the 100 PPI composite achieved macroscopic acoustic attenuation coefficients of 62.6 dB/cm at 5 MHz and 84.2 dB/cm at 7.5 MHz. These values are roughly three times higher than conventional backing materials, while maintaining a suitable acoustic impedance of 10.81 MRayl. A 5 MHz transducer utilizing a 5.0 mm layer of this proposed backing achieved a −60 dB two-way pulse-echo insertion loss, effectively eliminating backside interference with performance comparable to a 16.5 mm conventional backing. This structural strategy successfully reduces the required backing axial dimension by over 60% without compromising transducer bandwidth, offering a viable material solution for miniaturized ultrasonic transducers. Full article

The need to reduce polyurethane (PU) foam waste has encouraged the development of sustainable foam formulations based on recycled raw materials and environmentally friendly additives, addressing both waste management and comparable foam properties to those based on fossil resources. In the present investigation, more sustainable water-blown rigid PU foams were investigated using recycled polyol and halogen-free flame retardants (FRs) for fire-resistant insulation applications. Two series of foam formulations were prepared: a first series with virgin polyol and the inclusion of a halogen-free FR additive (6 wt%) and a second series with recycled polyol (10% added respect to the total polyol) and halogen-free FR additives (6 wt%). Two types of FR were used: FR900, specifically identified as 3,9-Dimethyl-2,4,8,10-tetraoxa-3,9-diphosphaspiro[5.5]undecane-3,9-dioxide, in powder form with 24% phosphorus content and reactive polyol based FR140, an oligomeric ethyl ethylene phosphate, in liquid form with 19% phosphorus content. The density, cellular structure, aged thermal conductivity, dimensional and hydrolytic stability, fire properties, and mechanical properties were characterized for novel foamed systems. Rigid foamed materials with very low densities around 50 kg/m³ were obtained. On the one hand, the inclusion of FR900 into the PU formulation containing virgin polyol generated foam with the lowest thermal conductivity (36.10 mW/mK) due to the smaller open cell content (11.7%) and cell size reduction (433 microns). On the other hand, the inclusion of recycled polyol reduced the foam density by 6 kg/m³ (44.1 kg/m³), increased the cell size average (848 microns) and open cell content (15.1%), maintained thermal conductivity (38.73 mW/mK), slightly improved the fire properties, and worsened the mechanical properties in comparison with the PU reference containing only virgin polyol. The results obtained by the foam containing recycled polyol and 6% FR900 are remarkable, presenting an increase in density (50.3 kg/m³) and in open cell content (73%), but a very high reduction in cell size (465 microns) and thus a low value of thermal conductivity of 37.04 mW/mK with respect to the reference material containing recycled polyol. Moreover, this PU foam containing recycled polyol and FR900 offered improved fire resistance (148.2 kW/m² of Maximum Average Rate of Heat Emission (MARHE), 179.1 kW/m² of Maximum Heat Release Rate (HRRmax), and 24.6 MJ/m² of Total Heat Release (THR)) and mechanical properties (6.97 MPa of Young’s modulus and 0.24 MPa of collapsed stress) for the construction sector. The inclusion of FR140 does not improve the properties of the foam system containing recycled polyol, mainly due to the deterioration of the cellular structure (in the open cell content and cell size). Full article

Phase-change materials (PCMs) are capable of storing or releasing a substantial amount of thermal energy within a small volume through the latent heat of fusion during phase transitions of melting and solidification, i.e., from solid to liquid or vice versa, in a near isothermal process. However, commonly used organic PCMs, such as paraffin wax, exhibit very low thermal conductivity, contributing to an adverse increase in overall thermal resistance and, thus, a slow thermal response. This limitation often becomes a bottleneck for the system from a thermal performance standpoint. To mitigate this issue, the present work explores the fabrication of heat sinks incorporating nano-structured graphitic foams, including carbon foam (CF) and expanded graphite (EG), as well as micro-structured metal foams such as open-cell copper foam (OCCF), all impregnated with a paraffin-based PCM with a melting temperature near 37 °C. This study focuses on applying passive thermal management strategies to design efficient heat sinks capable of maintaining the temperatures of battery modules and electronic circuits within an acceptable thermal safety threshold for small satellites and spacecrafts, exemplified by the OPTIMUS and Pumpkin battery modules designed for CubeSats with a nominal cross-sectional area of almost 4″ × 4″. Temperature responses and average overall thermal resistances for fabricated heat sinks are accordingly assessed and compared in a vacuum chamber to simulate space conditions. Furthermore, the impact of operating pressure on the thermal performances of various heat sinks will be investigated by executing the same tests in both atmospheric and vacuum conditions. The findings demonstrate a superior thermal performance of composite heat sinks integrating carbon foam and copper foam into the paraffin PCM compared to the baseline PCM heat sink under both vacuum and atmospheric operating pressure conditions. Full article

This paper introduced a simple, efficient method to prepare mechanically strong lignin-based foams (lignofoams) with open-cell structures using a facile baking technique. The self-expansion of lignin occurred without any additional chemical blowing agents, foaming agents, plasticizers, or lubricants. During heating, kraft lignin softened, and the internal water, either initially adsorbed or generated in situ through the dehydration of hydroxyl groups, acted as a natural blowing agent for foaming a porous foam structure. Incorporating a small amount of polypropylene (PP) enhanced mechanical properties by coating the inner walls of open cells. The porous, softened composite was then cooled to room temperature and solidified into the self-expanded lignofoam. The resulting lignofoams exhibited tunable densities ranging from 0.21 to 0.49 g/cm³ and a maximum compressive strength of 3.6 MPa. The lignofoam also showed excellent thermal insulation properties with low thermal conductive coefficients (0.057–0.098 W/mK). These features highlight the great potential of lignofoam for a bio-based thermal insulation material for construction applications. Full article

Through-plane electronic transport in porous membrane electrode assembly (MEA) electrodes is governed by the three-dimensional (3D) connectivity of the conducting phase. Here, we quantify the role of the spanning-cluster fraction $P_{\infty }$, defined as the fraction of conducting-phase voxels that belong to the $z$-spanning connected component in a finite reconstructed volume, on effective conductivity using scanning electron microscopy (SEM)-informed 3D reconstructions of four archetypal morphologies: a granular catalyst layer (CL), labeled CL1; a fibrous gas diffusion layer (GDL), labeled GDL1; an open-cell foam (OCF); and a micro-fibrous non-woven (MFM), labeled MFM1. Each morphology is reconstructed on a $150\times 150\times 150$ voxel grid, and $z$-spanning connectivity is identified with a 26-neighbor flood-fill algorithm. Steady-state conduction is solved by a finite-volume method (FVM) with an imposed potential difference between the z-faces and no-flux lateral boundaries. Although all samples exhibit through-thickness connectivity, the normalized conductivity ${\sigma }_{\mathrm{e}\mathrm{f}\mathrm{f}}/{\sigma }_{\mathrm{b}\mathrm{u}\mathrm{l}\mathrm{k}}$ varies widely, from $\approx 0.134$ (MFM1) to $\approx 0.706$ (OCF). The corresponding ${(P}_{\infty },{\sigma }_{eff}/{\sigma }_{bulk})$ pairs are $\left(0.996,\approx 0.306\right)$ for CL1, $\left(0.999,\approx 0.303\right)$ for GDL1, $\left(0.997,\approx 0.706\right)$ for OCF, and $\left(0.901,\approx 0.134\right)$ for MFM1. OCF exhibits the highest response due to vertically coherent channels, whereas MFM1 underperforms due to laminated constrictions; CL1 and GDL1 lie in an intermediate regime with nearly isotropic skeletons. Overall, the results show that while a $z$-spanning connected component is required for measurable conduction, the magnitude of ${\sigma }_{\mathrm{e}\mathrm{f}\mathrm{f}}$ is dictated by percolating-skeleton quality (bottlenecks, cross-sectional constrictions, and pathway alignment) rather than phase amount alone. The proposed descriptors therefore enable percolation-aware screening metrics for designing and comparing MEA-relevant GDL and CL microstructures. Full article

Head injuries remain one of the major health concerns in contact sports such as boxing. Despite the widespread use of protective gloves and helmets, their biomechanical effectiveness in mitigating head acceleration and reducing brain injury risk remains uncertain. This study aims to biomechanically assess available boxing equipment solutions and identify the brain–skull system’s response to physical forces from a boxing punch. A dedicated experimental setup was developed using mini triaxial accelerometers and a high-speed camera to measure head accelerations in a Primus unbreakable dummy. Tests were performed using gloves of different masses (0 oz, 10 oz, and 16 oz) and three head protection configurations: no helmet, rugby helmet, and boxing helmet. The resultant accelerations were analyzed and compared across test conditions. Peak wrist accelerations ranged from 195.00 to 271.77 m/s², while head accelerations did not exceed biomechanical injury thresholds. The boxing helmet, composed of multilayer polyurethane foam, did not consistently decrease acceleration; in some cases, it produced higher overloads due to increased head mass and moment of inertia. A rugby helmet made of open-cell EVA (ethylene vinyl acetate) foam with lower density exhibited more favorable energy-dissipation characteristics under low-impact conditions. Glove mass also influenced acceleration differently between male and female participants, likely due to variations in punch velocity and force generation. This work is a pilot study using two trained adult volunteers to validate the combined IMU–video measurement framework. The results serve as hypothesis-generating mechanistic observations rather than population-level effect estimates. Protective effectiveness in boxing depends on a complex interaction between material properties, geometry, and user biomechanics. Optimal equipment design should balance energy absorption and mass to minimize both linear and rotational accelerations. Future studies should integrate advanced material modeling and finite element simulations to support the development of adaptive, lightweight protective systems. Full article