Search Results (1,316)

To address the demands of large-scale production in the photovoltaic industry for laminators with a small footprint, low energy consumption, and high encapsulation quality, this paper presents research on the structural design, simulation optimization, and performance validation of a multi-layer laminator for photovoltaic modules. Different from existing single-layer or double-layer structures, this paper proposes for the first time an eight-layer, three-stage overall scheme, develops modular lamination units, completes the design of core systems, and achieves multi-chamber coordination. Simulation validation was conducted on the temperature uniformity of the heating plates and the thermo-mechanical coupling under vacuum conditions. A prototype, model HCDL2743DSiT, was developed and subjected to a 30-day production trial. The results show that the equipment reaches a vacuum degree of 92 Pa within 100 s and drops to 38 Pa within 120 s; the temperature uniformity error of the heating plates is ±1.3 °C; the maximum positioning deviation of the transmission is ±2.8 mm. All core indicators meet the design requirements, and the module encapsulation pass rate reaches 99.9%. At the same production rate, the footprint is reduced by approximately 72% compared with that of a traditional double-layer laminator, achieving dual optimization of space utilization and energy consumption and providing technical equipment support for the high-efficiency encapsulation of photovoltaic modules. Full article

In the aerospace industry, thin-web gears are preferred for achieving high power-density transmission. However, thin-webbed structures always lead to out-of-plane resonance during the transmission process, which commonly happens in helical gears, manifesting as severe vibration at a specific rotational speed. To address this, a shaft–web–ring dynamic model is proposed. The shaft, gear web, and gear ring are modelled based on the Timoshenko straight beam, Mindlin plate, and Timoshenko bent beam theory. Simultaneously, the potential energy caused by the time-varying meshing stiffness is coupled to the gear ring. The kinetic and potential energies of each discretized finite element of the components are derived based on elastic deformation theory, and the governing equations of each element are obtained using Hamilton’s principle. The model is verified through a modal experiment. The comparison with traditional rotor-gear models has demonstrated the significance of gear body flexibility in helical gears with thin webs. The effects of the web thickness and helix angle on dynamic response are studied, revealing that gear web elasticity and an appropriately high helix angle can effectively reduce vibrations at the support bearing, prevent excessive vibrations, and contribute to vibration and noise reduction in the transmission system. Full article

The global expansion of wind energy increases the need for sustainable recycling strategies for glass fiber-reinforced plastic (GFRP) from end-of-life wind turbine blades (WTB). Mechanical recycling is currently the most economically and ecologically viable technology. This study compares post-industrial (PI) waste from laminate cutoffs and post-consumer (PC) GFRP waste from end-of-life WTBs to investigate the influence of waste origin, pretreatment of shredded GFRP, different particle sizes and various matrix formulations on the tensile modulus and tensile strength of pressed bulk molding compounds produced with virgin epoxy resin. Thermogravimetric analysis showed a fiber content of up to 70 wt.%, but the resin residues on the embedded glass fibers dimmish a sufficient bonding of the new matrix system. Finer GFRP fractions consistently yielded higher tensile modulus and strength, with PI and pretreated PC materials performing best. The findings of this study demonstrate that controlled particle size distribution, impurity removal and optimized resin viscosity are key factors to achieve reliable mechanical performance and enable high-value recycling routes for glass fiber composite waste. Full article

The use of cellulosic reinforcement fillers, including cellulose and holocellulose, in the development of sustainable biopolymer composites has become increasingly essential and continues to attract significant attention in the composite industry. This study aimed to improve the structural and morphological characteristics of the polyhydroxybutyrate (PHB) matrix by incorporating cellulosic fillers—namely, α-cellulose and holocellulose produced via a green processing method—and to evaluate the effect of hemicellulose, present in holocellulose and exhibiting compatibilizing capability, on the overall performance of PHB-based blends. For this, the PHB matrix was first dissolved in chloroform, after which the cellulosic fillers were incorporated into the PHB–chloroform mixtures at 1 wt.% to provide the best homogeneous fiber dispersion. The PHB and cellulosic filler mixtures were blended at 500 rpm with a magnetic mixer for 30 min, and the resulting composite was cast onto a Teflon plate. Scanning electron microscopy (SEM), X-ray diffraction (XRD), and Fourier transform infrared (FTIR) spectroscopy were used to characterize the morphological and structural analysis of the obtained biopolymer-based composites. Thermogravimetric analysis (TG-DTG) was used to determine the thermal properties. The results obtained confirmed the presence of cellulosic fillers in the PHB matrix using FTIR, XRD, and SEM. In contrast to holocellulose, α-cellulose in the PHB matrix was shown to create a more organized structure. Both α-cellulose and holocellulose reinforcements were found to have similar effects on the thermal properties of the PHB matrix. Compared with neat PHB, the amount of residual char was found to be more than 36-fold in the sample containing α-cellulose and more than 41-fold in the sample containing holocellulose. Full article

As an efficient dry separation technology, electrostatic separation exhibits significant potential for application in the sorting and recovery of carbon-rich resources from coal gasification fine slag (CGFS). The small particle size and high moisture content of CGFS particles are the main factors affecting the efficiency of separation. This study proposes a method integrating particle moisture reduction and charging promotion based on molecular sieves, with the aim of investigating its feasibility in improving the electrostatic separation efficiency of CGFS particles. The results indicate that molecular sieves can effectively adsorb moisture from the ambient humid air and the surface of particles, allowing for rapid drying of wet particles. The reduction in moisture content on the particle surfaces significantly promotes their charging capability, creating favorable conditions for electrostatic separation. After molecular-sieve-assisted charging enhancement, the carbon content in the ash-enriched positive plate product decreased by 4.96%, while the carbon content in the carbon-enriched negative plate product increased by 12.15%, indicating a significant improvement in carbon–ash separation efficiency. Correspondingly, the decarbonization efficiency of the positive plate and carbon recovery efficiency of the negative plate were increased by 21.30% and 52.17%, respectively. Furthermore, when the moisture content exceeds 10%, the phenomenon of inter-particle agglomeration can adversely affect the separation of carbon and ash particles. The most suitable operating conditions are a moisture content no higher than 10%, an electric field density of 30 kV/m, a filling molecular sieve of 400 g, and a gas velocity of 12 m/s (volumetric flow rate 84.78 m³/h). In practical industrial applications, it is advisable to consider pre-treating the particles for drying or employing secondary separation to enhance sorting accuracy. Full article

Metal anodes offer substantially higher specific and volumetric capacities than conventional anode materials such as graphite in lithium-ion batteries or hard carbon in sodium-ion batteries. However, the integration of metal anodes into solid-state batteries poses significant challenges, particularly with respect to processing, interfacial stability, and cell assembly. Anode-free solid-state batteries (AFSSBs) address these challenges by eliminating the pre-installed metal anode, instead forming the metal in situ during the initial charging (formation) step. In anode-free solid-state batteries, the quality of the interfacial contact is particularly critical, as insufficient contact can lead to locally increased current densities. Consequently, the initial metal plating during the formation step plays a decisive role in determining the homogeneity and stability of the anode interface. Furthermore, conventional battery-grade copper foils (~10 µm) are considerably thicker than required for the targeted C-rates and are difficult to use as stand-alone anode-free current collectors, thereby hindering the industrial production of anode-free solid-state batteries. In this publication, we demonstrate the application of atmospheric plasma spraying (APS) to fabricate thin copper current collectors directly on the ceramic solid electrolytes LAGP (lithium aluminium germanium phosphate) and BASE (beta-alumina solid electrolyte) with superior interface contact. No mechanical damage or diffusion of copper into the solid electrolyte nor formation of secondary phases at the interfaces were observed in SEM or EDS despite the elevated process temperature. LAGP with a thickness as low as 300 µm was successfully coated and subsequently used for plating/stripping experiments. Finally, dense sodium metal was plated at the copper-substrate interface of a 1.4 mm thick BASE sample. Full article

Crude oil tank bottoms, a mix of oil, sediment, and water from crude oil collection tanks, are a significant waste stream associated with global oil production. In benchtop testing, as an intermediate evaluative step in progressive scaling toward industrial-scale treatment to recover oil from tank bottoms and to reduce waste, sonication was applied to samples from three California oilfields using only added water and mechanical mixing. The 2.2 kg sample size, over 40 times that used in most of the testing found in literature, utilized no chemicals during treatment. The tests employed a 1:4 ratio of sludge to added water in an acrylic tank with two 500-watt drop-in plate sonicators. Trial variables included sonication frequencies of 28 or 40 kilohertz, mixing speed, treatment duration, and oil collection methods. Oil recoveries up to 98.2% with mean recoveries of 27.4% were achieved using 0.2 kilowatt-hours per kilogram sample. This study indicated sonication treatment of crude oil tank bottoms with only added water and mixing was a potentially viable approach for waste oil recovery and waste minimization and warrants further investigation at even larger scale. Full article

Composite materials are extensively used in the aeronautical and aerospace industries for their high strength-to-weight ratios but are vulnerable to barely visible impact damage (BVID), which can severely compromise structural integrity. Digital shearography (DS) provides a non-contact, full-field solution for subsurface inspection; however, low signal-to-noise ratios in raw phase maps often hinder precise damage identification. This study explores a post-processing methodology utilizing a band-pass filtering algorithm and temporal summation to isolate damage-related spatial frequencies. An in-house digital shearography system was used to inspect a carbon-fiber-reinforced polymer (CFRP) plate subjected to 13.5 J and 26.2 J impacts. Twelve phase maps, acquired during the thermal cooling stage, were processed using a multi-pass filters to systematically analyze different frequency ranges. Results demonstrate that summing multiple filtered phase maps significantly enhances the contrast of damage signatures compared to single phase maps or traditional unwrapping techniques. Furthermore, quantitative assessment using image quality metrics, such as the generalized contrast-to-noise ratio (gCNR), confirmed that optimal frequency selection is essential for an accurate damage delineation. This approach provides a robust framework for improving the reliability and sensitivity of non-destructive testing in composite structures. Full article

Plating on Plastics (PoP) requires specific surface pre-treatment steps to enable metallization. The conventional PoP industry utilizes hexavalent chromium (toxic, carcinogenic) and palladium (critical raw material) for surface etching and activation, respectively, raising significant health, environmental, and economic concerns. This work is based on a new Cr⁶⁺-free and Pd-free PoP technology that uses piranha (H₂O₂-H₂SO₄) solutions for surface etching, nickel salts for activation, and NaBH₄ for reduction, ultimately forming metallic nucleation sites for downstream electroless plating and electroplating. A comprehensive modeling approach was developed to simulate and predict unit operation performance (reaction kinetics and yields) and material properties (contact angle and adhesion) across processing stages of the new technology. State-of-the-art and data-driven modeling revealed the combinatorial relationships among process performance, the achieved properties and the different settings of process operating conditions. The results also highlighted capabilities for tuning all processes over a range of conditions, reaching desired product specifications (adhesion and thickness). The models were constructed as a Decision Support Tool (DST) serving economic, environmental, safety and Safe and Sustainable by Design (SSbD) objectives. The DST can be used through a user-friendly interface that enables the insertion of user-defined inputs and monitoring of optimization results. Full article

The thermal safety and longevity of lithium-ion batteries are critically constrained by excessive temperature rise and spatial thermal non-uniformity, particularly during high-rate discharges. Most existing numerical investigations rely on simplified heat generation models that fail to capture the spatiotemporal heterogeneity of electrochemical heat sources, leading to compromised predictive accuracy. To address this deficiency, this study develops a comprehensive three-dimensional electrochemical–thermal coupled framework, integrating the Newman pseudo-two-dimensional (P2D) electrochemical model with conjugate heat transfer and laminar flow dynamics. The predictive robustness of this framework is rigorously validated against experimental data across multiple discharge rates (3 C and 5 C). The validated model is then deployed to evaluate a water-cooled microchannel cold plate designed for prismatic $\mathrm{L}\mathrm{i}\mathrm{M}{\mathrm{n}}_2{\mathrm{O}}_4$/graphite cells under a demanding 5 C discharge. A systematic parametric investigation is conducted to quantify the effects of ambient temperature (293–343 K), microchannel number (2–6), and coolant inlet velocity (0.1–0.6 m/s) on the maximum battery temperature (${\mathrm{T}}_{\mathrm{m}\mathrm{a}\mathrm{x}}$) and temperature difference ($\mathsf{\Delta }\mathrm{T}$). Results demonstrate that the proposed system exhibits exceptional environmental robustness: over a 50 K ambient temperature span, ${\mathrm{T}}_{\mathrm{m}\mathrm{a}\mathrm{x}}$ increases by merely 2.0 K, remaining safely below the 323 K industry limit. Densifying the channel count from 2 to 6 further reduces ${\mathrm{T}}_{\mathrm{m}\mathrm{a}\mathrm{x}}$ by 1.55 K and narrows $\mathsf{\Delta }\mathrm{T}$ to 4.25 K, successfully satisfying the strict 5 K temperature uniformity standard. Furthermore, the thermal benefit of elevating inlet velocity exhibits a pronounced diminishing-return trend governed by the asymptotic reduction in bulk coolant temperature rise, dictating a critical trade-off against the quadratically escalating pumping power. Ultimately, these findings provide robust theoretical guidelines for the rational design of safe and energy-efficient battery thermal management systems. Full article

Sol–gel-based optical functional sensor coatings were developed for real-time monitoring of multiphase saponification reactions in microreactors. Various pH-sensitive indicator mixtures, including bromocresol green and bromocresol purple (BCG and BCP) and methyl red–methyl orange, were incorporated into sol–gel coatings and evaluated on test plates across pH range of 2–12. Coatings with BCG and BCP 1:3 demonstrated the most pronounced color change at high pH (11–12), with distinct hue (H) transitions providing a reliable measure of local pH. These optimized coatings were integrated into microreactor channels to track the passage of oil and NaOH slugs under varying flow rates. Hue analysis produced reproducible plateaus corresponding to NaOH-rich (H = 50°) and oil-rich (H = 41°) phases, enabling droplet-level resolution of slug flow and detection of flow-regime transitions. The sensor response was fully reversible, highlighting the robustness and reusability of the coatings. Unlike previous high-resolution fluorescence-based systems, this approach relies on simple visible-light imaging and low-cost data extraction, leaving the reaction chemistry unaltered. The results demonstrate that sol–gel coatings coupled with hue-based analysis provide a practical, noninvasive, and real-time monitoring strategy for multiphase reactions in microreactors, with potential for implementation in industrial or IoT-enabled process control systems. Full article

Flip-flow screens are widely used for the efficient separations of wet fine materials. To explore the separation characteristics of the particle and screen plate in the flip-flow screening process, a flip-flow plate impact experimental system was built. The experimental system was based on a spherical inertial measurement device and a semi-industrial flip-flow screen system. In this study, we first derive the impact mechanics equation of the flip-flow screen plate on the particle and analyze the influence of the main parameters on the maximum impact force. Subsequently, we investigated the kinematic characteristics of the particle impacted by the screen plate at different moving positions, the variation of the centerline acceleration mechanism, and determined the angular velocity in the collision process. Additionally, we further clarified the alteration in the rules of translational and rotational kinetic energy of the particles in the collision process. This study addresses a research gap in the phenomenological modelling of particulate screening process. At the same time, it provides theoretical support for the accurate control of the flip-flow screening process. Full article

Insect pests are a major limiting factor to producing profitable soybean (Glycine max (L.) Merr.) in South Carolina. Production practices within the soybean industry have drastically evolved over the last few decades, but treatment thresholds for insect pests have stayed the same. Evaluating treatment thresholds for insect pests typically involves simulating injury because it offers a controlled and repeatable way to evaluate an injury–yield relationship. Simulating defoliation injury in soybean typically involves methods such as hand-plucking or cutting leaflets, but these methods are not truly representative of insect feeding injury. This study describes the design, development, and validation of a novel pneumatic leaf puncher created with a 3D printer and used to simulate insect defoliation injury in soybean. The device was engineered to deliver controlled, repeatable leaf tissue removal at varying target levels (5, 15, 30, and 40%) by using interchangeable punching plates. Simulated defoliation treatments were applied to mature leaves on soybean plants at the V6 growth stage in a greenhouse study. The leaf area removed was quantified using LeafByte, a mobile app designed for measuring leaf area, and confirmed against target values. Results showed a high level of correlation between intended and actual defoliation levels, with accuracy ≥ 90%. The pneumatic leaf puncher provides a potential standardized method for administering foliar damage and offers a reliable alternative to manual clipping or herbivory feeding trials in defoliation research. Ongoing field trials at Clemson University will incorporate yield data to refine defoliation thresholds. Due to its adaptability and ease of use, the pneumatic leaf puncher could be implemented regionally, nationally, or internationally to support standardized defoliation studies across diverse cropping systems. Full article

This study aims to advance the understanding of laminar magnetohydrodynamic (MHD) fluid flow between two parallel plates subjected to a uniform transverse magnetic field, motivated by its significant applications in engineering and industrial systems such as nuclear reactor cooling, MHD generators, and electromagnetic pumping devices. The governing equations are simplified using a one-parameter Lie group symmetry transformation, which exploits the inherent symmetry properties of the system to reduce the original unsteady partial differential equations to a system of ordinary differential equations. The reduced equations are solved exactly under appropriate boundary and initial conditions, ensuring mathematically consistent and physically realistic solutions. A comprehensive analysis is conducted to examine the influence of key physical parameters, along with the applied magnetic field, on the velocity, temperature, and concentration profiles. The selected parameter ranges encompass a broad spectrum of physically relevant cases, enabling a detailed assessment of their effects. The results indicate that the transverse magnetic field exerts a damping effect on the flow, reducing the velocity profile due to the Lorentz force. Moreover, an increase in the Schmidt number accelerates the achievement of a steady-state concentration, while higher Prandtl numbers reduce the temperature profile. In contrast, the radiation parameter enhances the temperature distribution. In addition, the skin-friction coefficient is presented graphically, and the Nusselt number is evaluated to characterize the heat transfer performance. Overall, the findings provide valuable insight into the effects of magnetic, thermal, and solutal parameters on laminar MHD flow between parallel plates. Full article

This study evaluates the feasibility of acoustic signal analysis using different spectrographic transformation methods as a tool for assessing the quality of welding beads produced through the Shielded Metal Arc Welding (SMAW) process. Acoustic emissions were recorded during manual welding operations under controlled experimental conditions, using E6013 electrodes on A36 carbon steel plates. From the acoustic recordings of 400 welding samples, previously classified as accepted or rejected, two fundamental acoustic descriptors were extracted: the fundamental frequency (F₀) and the harmonic-to-noise ratio (HNR). These were analysed using parametric and non-parametric metrics to evaluate their discriminative capability. In addition, multiple supervised classifiers were trained and validated using stratified eight-fold cross-validation. The proposed framework enables a systematic comparison of different signal transformations and classification models for the evaluation of SMAW welding quality. Among the evaluated models (SVC, Gradient Boosting, and Extra Trees), precision rates of 90–95% were observed using Spectral Contrast, MEL, and CQT transformations. The results demonstrate that the implementation of various acoustic signal-based models and transformations for welding inspection offers a scalable and cost-effective solution for industrial quality control. Full article