Search Results (290)

Laser beam powder bed fusion of metals (PBF-LB/M, or simply L-PBF) has emerged as one of the most competitive additive manufacturing technologies for producing complex metallic components with high precision, design freedom, and minimal material waste. Among the various categories of additive manufacturing processes, L-PBF stands out, paving the way for the execution of part designs with geometries previously considered unfeasible. Despite offering several advantages, parts with overhang features require the use of support structures to provide dimensional stability of the part. Support structures achieve this by resisting residual stresses generated during processing and assisting heat dissipation. Although the scientific community acknowledges the role of support structures in the success of L-PBF manufacturing, they have remained relatively underexplored in the literature. In this context, the present work investigated the impact of laser power and scanning speed on the dimensioning, integrity and tensile strength of single-walled block type support structures manufactured in AISI 316L stainless steel. The method proposed in this work is divided in two stages: processing parameter exploration, and mechanical characterization. The results indicated that support structures become more robust and resistant as laser power increases, and the opposite effect is observed with an increment in scanning speed. In addition, defects were detected at the interfaces between the bulk and support regions, which were crucial for the failure of the tensile test specimens. For a layer thickness corresponding to 0.060 mm, it was verified that the combination of laser power and scanning speed of 150 W and 500 mm/s resulted in the highest tensile resistance while respecting the dimensional deviation requirement. Full article

This paper presents a novel approach employing localized annealing through Joule heating to enhance the performance of Thin-Film Piezoelectric-on-Silicon (TPoS) MEMS resonators that are crucial for applications in sensing, energy harvesting, frequency filtering, and timing control. Despite recent advancements, piezoelectric MEMS resonators still suffer from anchor-related energy losses and limited quality factors (Qs), posing significant challenges for high-performance applications. This study investigates interface modification to boost the quality factor (Q) and reduce the motional resistance, thus improving the electromechanical coupling coefficient and reducing insertion loss. To balance the trade-off between device miniaturization and performance, this work uniquely applies DC current-induced localized annealing to TPoS MEMS resonators, facilitating metal diffusion at the interface. This process results in the formation of platinum silicide, modifying the resonator’s stiffness and density, consequently enhancing the acoustic velocity and mitigating the side-supporting anchor-related energy dissipations. Experimental results demonstrate a Q-factor enhancement of over 300% (from 916 to 3632) and a reduction in insertion loss by more than 14 dB, underscoring the efficacy of this method for reducing anchor-related dissipations due to the highest annealing temperature at the anchors. The findings not only confirm the feasibility of Joule heating for interface modifications in MEMS resonators but also set a foundation for advancements of this post-fabrication thermal treatment technology. Full article

Diamond is an attractive substrate candidate for GaN high-electron-mobility transistors (HEMT) to enhance heat dissipation due to its exceptional thermal conductivity. However, the thermal boundary resistance (TBR) at the GaN–diamond interface poses a significant bottleneck to heat transport, exacerbating self-heating and limiting device performance. In this work, TCAD simulations were employed to systematically investigate the effects of thermal boundary layer (TBL) thickness (d_TBL) and thermal conductivity (κ_TBL) on the electrothermal behavior of GaN-on-diamond HEMTs. Results show that increasing the TBL thickness (5–20 nm) or decreasing its thermal conductivity (0.1–1.0 W/(m·K)) leads to elevated hotspot temperatures and degraded electron mobility, resulting in a notable deterioration of I–V characteristics. The nonlinear dependence of device performance on κ_TBL is attributed to Fourier’s law, where heat flux is inversely proportional to thermal resistance. Furthermore, the co-analysis of substrate thermal conductivity and interfacial quality reveals that interface TBR has a more dominant impact on device behavior than substrate conductivity. Remarkably, devices with low thermal conductivity substrates and optimized interfaces can outperform those with high-conductivity substrates but poor interfacial conditions. These findings underscore the critical importance of interface engineering in thermal management of GaN–diamond HEMTs and provide a theoretical foundation for future work on phonon transport and defect-controlled thermal interfaces. Full article

This study investigates the performance of lattice-structured heat sinks based on BCCz unit cells in comparison to conventional straight-fin and pin-fin designs. Various lattice configurations were explored. Numerical simulations and experimental evaluations were carried out to analyze thermal resistance, pressure drop, and temperature distribution under different operating conditions. Among the designs, the BCCz configuration with a circular cross-section was identified as the most promising candidate for integration into the final heat sink demonstrator, offering reliable and consistent performance. A prototype using the BCCz lattice structure was additively manufactured, alongside a conventional design for comparison. The results highlight the superior heat dissipation capabilities of lattice structures, achieving up to a 100% improvement in thermal performance at high flow rates and up to 300% at low flow rates compared to a conventional straight-fin heat sink. However, the pressure drop generated by the lattice structures remains a challenge that must be addressed. This work underscores the potential of optimized lattice-based heat exchangers to meet the severe thermal management requirements of railway power electronics. Full article

The thermal stability of carbon fiber-reinforced plastic (CFRP) materials is constrained by the low thermal conductivity of its polymer matrix, resulting in inefficient heat dissipation, local overheating, and accelerated degradation during thermal loads. To overcome these limitations, composite materials can be modified with buckypapers—thin, densely interconnected layers of carbon nanotubes (CNTs). In this study, sixteen 8552/IM7 prepreg plies were processed with up to nine buckypapers and strategically placed at various positions. The resulting nanocomposites were evaluated for manufacturability, material properties, and thermal resistance. The findings reveal that prepreg plies provide only limited matrix material for buckypaper infiltration. Nonetheless, up to five buckypapers, corresponding to 8 wt.% CNTs, can be incorporated into the material without inducing matrix depletion defects. This integration significantly enhances the material’s thermal properties while maintaining its mechanical integrity. The nanotubes embedded in the matrix achieve an effective thermal conductivity of up to 7 W/(m·K) based on theoretical modeling. As a result, under one-sided thermal irradiation at 50 kW/m², thermo-induced damage and strength loss can be delayed by up to 20%. Therefore, thermal resistance is primarily determined by the nanotube concentration, whereas the arrangement of the buckypapers affects the material quality. Since this innovative approach enables the targeted integration of high particle fractions, it offers substantial potential for improving the safety and reliability of CFRP under thermal stress. Full article

Low-temperature radiant heating systems utilizing heating cables face challenges including low heat dissipation efficiency and high energy consumption, hindering widespread application. Graphene coatings, characterized by high thermal conductivity and far-infrared radiation properties, offer a novel approach to enhance cable heat dissipation efficiency. This study systematically investigates the effects of coating position, thickness, and ambient temperature on cable heat dissipation using numerical simulations and experiments. A three-dimensional heat transfer model of the heating cable was established using Fluent software (2022R1). The radiation heat transfer equation was solved using the Discrete Ordinates (DO) model, and the coating position and thickness parameters were optimized. The reliability of the simulation results was validated using a temperature-rise experimental platform. The results indicate that graphene coatings significantly improve the heat dissipation performance of cables. Under optimal parameters (coating thickness: 100 μm, coating position: aluminum fin surface, initial temperature: 5 °C), the heat flux increased by approximately 26%, aluminum fin surface temperature decreased to 41.5 °C, and experimental temperature-rise efficiency improved by nearly 50%. The discrepancy between simulated and experimental results was within 8.5%. However, when coating thickness exceeded 100 μm, interfacial thermal resistance increased, reducing heat dissipation efficiency. Additionally, higher ambient temperatures suppressed heat dissipation. These findings provide a theoretical basis for optimizing the energy efficiency of low-temperature radiant heating systems. Full article

In recent years, the number of transistors on electronic chips has surpassed Moore’s law, resulting in overheating and energy consumption problems in data centers (DCs). Chip-level microchannel cooling is expected to address these challenges. Grooved heat sinks with droplet-shaped fins were introduced to modify the overall capability of the cooling system. The degree of impact of the distribution of grooves and fins was analyzed and optimized using the Taguchi method. Moreover, the coupling effect of flow and temperature fields was explained using the field synergy theory. The key findings are as follows: for thermal resistance, pump power, and overall efficiency, the influence degree is the number of combined units > number of fins in each unit > distribution of the combined units. The optimal configuration of 21 combined units arranged from dense to sparse with one fin in each unit achieves 14.05% lower thermal resistance and 8.5% higher overall efficiency than the initial heat sink. The optimal configuration of five combined units arranged from sparse to dense with one fin in each unit reduces the power energy consumption by 27.61%. After optimization, the synergy angle between the velocity vector and temperature gradient is reduced by 4.29% compared to the smooth heat sink. The coupling effect between flow and heat transport is strengthened. The optimized configuration can better balance heat dissipation and energy consumption, improve the comprehensive capability of cooling system, provide a feasible solution to solve the problems of local overheating and high energy consumption in DCs. Full article

Overheating in miniaturized electronic devices can reduce their useful life, where conventional heat sinks are insufficient. The utilization of ionenes as solid–solid phase change materials is proposed to enhance thermal dissipation without the risk of leakage. In this work, a series of imidazolium ionenes with structural modifications in their aromatic core and aliphatic chain length were synthesized. The synthesis was carried out using the respective monomers diimidazole and alkyl dibromide, followed by counterion bromide exchange using lithium bis(trifluoromethanesulfonyl)imide, with yields over 90% in all cases. Thermal characterizations showed that all ionenes are heat-resistant, with degradation temperatures between 421 °C and 432 °C; moreover, they all presented only a solid–solid transition (Tg) as a phase change, between 59 °C and 28 °C, which varied depending on the aromatic core used and the length of the aliphatic chain. The obtained ionenes were introduced into an experimental device with an operating temperature of 40 °C, to be evaluated as solid–solid phase change materials in heat sinks. These demonstrated an average decrease in operating temperature of 9 °C compared to the device without ionenes. On the other hand, the stability of the ionenes was analyzed over 10 thermal cycles at 40 °C at a heating rate of 5 °C/min. This analysis demonstrated that the ionenes did not present changes or degradation during the evaluated cycles. These findings demonstrate that imidazolium ionenes are promising solid–solid phase change materials for use as efficient and self-repairing heat sinks in compact electronic devices. Full article

This study synthesized Al₂CoCrFeNi high-entropy alloy (HEA) using spark plasma sintering (SPS) followed by annealing treatment. The effects of heat treatment on the microstructure, mechanical properties, wear resistance, and thermoelectric properties were systematically investigated. The annealed alloy exhibited a microhardness increase from 538.5 HV to 550.9 HV and a significant improvement in ultimate compressive strength from 1540.74 MPa to 2563.67 MPa, attributed to grain homogenization and reduced dislocation density. Wear resistance tests revealed a decrease in wear rate from 7.15 × 10⁻⁵ mm³/(N·m) to 4.74 × 10⁻⁵ mm³/(N·m), with wear morphology analysis confirming enhanced resistance to plastic deformation. Thermoelectric characterization demonstrated that thermal diffusivity increased from 2.98 mm²/s to 3.11 mm²/s at room temperature, while the absolute Seebeck coefficient reached 8.0 μV/K at 200 °C, indicating improved electron transport efficiency due to lattice ordering. This combination of high hardness, high thermal conductivity, and excellent wear resistance presents unique application value in extreme tribological fields involving thermal management and simultaneous surface wear resistance and heat dissipation. Full article

An excessive temperature rise in vehicle tires during driving can degrade dynamic performance, safety, and fuel efficiency by increasing rolling resistance and softening materials. To mitigate these issues, it is essential to enhance the cooling performance of tires without inducing significant aerodynamic penalties. In this study, we propose the use of sidewall-mounted cooling fins and investigate their aero-thermal effects under both ground-contact and no-ground-contact conditions. Seven fin configurations were tested, with installation angles ranging from −67.5° to 67.5°, with positive angles indicating an orientation opposite to the direction of wheel rotation and negative angles indicating alignment with the direction of rotation. High-fidelity unsteady Reynolds-averaged Navier–Stokes simulations were conducted using the SST k-w turbulence model. The sliding mesh technique was employed to capture the transient flow behavior induced by tire rotation. The results showed that, under no-ground-contact conditions, the 45° configuration achieved a 16.8% increase in convective heat transfer with an increase in drag less than 3%. Under ground-contact conditions, the 22.5° configuration increased heat transfer by over 13% with a minimal aerodynamic penalty (~1.7%). These findings provide valuable guidance for designing passive cooling solutions that improve tire heat dissipation performance without compromising aerodynamic efficiency. Full article

Improving the reliability and durability of internal combustion engines in marine vessels is a complex issue. The vibrations generated in these engines significantly affect their proper operation. One of the current research challenges is identifying effective methods to reduce, among other things, torsional vibrations generated within the crank–piston system. To mitigate these vibrations, viscous dampers are commonly used. The selection of a viscous damper for a high-power multi-cylinder engine, such as those in marine power plants, requires a thorough understanding of the thermo-hydrodynamic properties of oil films formed in the spaces between the damper housing and the inertial mass. The description of the phenomena involved is complicated by the variable positioning of the inertial mass center relative to the housing during operation. Most previous studies assume a concentric alignment between these components. The main novelty of this work lies in highlighting the combined effect of the eccentric motion of the inertial ring on both hydrodynamic resistance and thermal characteristics, which has not been fully addressed in existing studies. This article defines the oil flow resistance coefficients and develops static characteristics of the dampers. Additionally, it evaluates the impact of the size of the frontal and cylindrical surfaces of the damper on its heat dissipation capacity. The presented characteristics can be utilized to assess the performance parameters of this type of damper. Full article

Fans are essential electronic components for heat dissipation in electronic systems, with fan bearings being critical parts that determine fan performance and lifespan. This paper investigates the corrosion, wear, power consumption, temperature, and vibration characteristics of a newly designed and manufactured powder metallurgy bearing with herringbone oil grooves for fans under high-humidity and high-temperature conditions. Corrosion experiments on iron–copper powder metallurgy bearings show that a higher environmental temperature and humidity result in greater corrosion current and reduced corrosion resistance. Bearings operated under high humidity (85% RH) and a high temperature (80 °C) for 0, 3, and 8 days, respectively, revealed that wear and corrosion occur simultaneously. The longer the operating time, the more significant the wear and corrosion. After 3 and 8 days, the lubricating oil flow in the oil grooves decreased by 9.8% and 51.5%, respectively. When bearings subjected to varying degrees of corrosion were tested under the same standard operating conditions, it was found that the bearings corroded for 3 and 8 days, resulting in a significant increase in the number of wear debris particles, higher RMS vibration values, and a power consumption increase of 6.9% and 7.8%, respectively. The percentage of iron elements on the surface gradually decreased, with the copper elements being the primary wear particles during the wear process. However, due to the increased clearance between the rotating shaft and the bearing caused by wear, the fan temperature slightly decreased with increased surface wear. Full article

Earth’s energy imbalance (EEI) is a major indicator of climate change. Its metrics are top of the atmosphere radiation imbalance (EEI TOA) and net internal heat uptake. Both EEI and temperature are expected to respond gradually to forcing on annual timescales. This expectation was tested by analyzing regime changes in the inputs to EEI TOA along with increasing ocean heat content (OHC). Outward longwave radiation (OLR) displayed rapid shifts in three observational and two reanalysis records. The reanalysis records also contained shifts in surface fluxes and temperature. OLR, outward shortwave radiation (OSR) and TOA net radiation (Net) from the CERES Energy Balanced and Filled Ed-4.2.1 (2001–2023) record and from 27 CMIP5 historical and RCP4.5 forced simulations 1861–2100, were also analyzed. All variables from CERES contained shifts but the record was too short to confirm regime changes. Contributions of OLR and OSR to net showed high complementarity over space and time. EEI TOA was −0.47 ± 0.11 W m⁻² in 2001–2011 and −1.09 ± 0.11 W m⁻² in 2012–2023. Reduced OSR due to cloud feedback was a major contributor, coinciding with rapid increases in sea surface temperatures in 2014. Despite widely varying OLR and OSR, 26/27 climate models produced stable regimes for net radiation. EEI TOA was neutral from 1861, shifting downward in the 26 reliable records between 1963 and 1995, with 25 records showing it stabilizing by 2039. To investigate heat uptake, temperature and OHC 1955/57–2023 was analyzed for regime change in the 100 m, 700 m and 2000 m layers. The 100 m layer, about one third of total heat content, was dominated by regimes. Increases became more gradual with depth. Annual changes between the 700 m layer and 1300 m beneath were negatively correlated (−0.67), with delayed oscillations during lag years 2–9. Heat uptake at depth is dynamic. These changes reveal a complex thermodynamic response to gradual forcing. We outline a complex arrangement of naturally evolved heat engines, dominated by a dissipative heat engine nested within a radiative engine. EEI is a property of the dissipative heat engine. This far-from-equilibrium natural engine has evolved to take the path of least resistance while being constrained by its maximum power limit (~2 W m⁻²). It is open to the radiative engine, receiving solar radiation and emitting scattered shortwave and longwave radiation. Steady states maximize entropy within the dissipative engine by regulating spatial patterns in surface variables that influence outgoing OLR and OSR. Regime shifts to warmer climates balance the cost of greater irreversibility with increased energy rate density. The result is the regulation of EEI TOA through a form of thermodynamic metabolism. Full article

Ensuring the fire resistance and thermal stability of power cables is crucial for their reliable performance in fire environments, essential for sustainable power distribution, and allowing for more time to extinguish fires and for evacuation. This study utilises numerical simulation to analyse the thermal behaviour of fire-resistant medium-voltage cable, focusing on the impact of conductor radius and material properties under external heat flux. A heat transfer model of cables with conductor radii of 3 mm, 5 mm, and 7 mm under a localised external heat flux of 750 °C was developed. The results show that smaller conductors stabilise faster (reaching the steady state at 45 min for 3 mm vs. 79 min for 7 mm) but experience higher thermal stress, with conductor temperatures peaking at 692.5 °C. Larger conductors enhance axial heat conduction, reduce steady-state temperature by up to 25%, and improve heat dissipation by over 360%. The 5 mm conductor radius provided balanced performance, lowering the temperature by 65 °C compared to 3 mm, although it remained 20.1% hotter than the 7 mm. The ceramic layer played a crucial role in reducing heat flux in the heat source section. Optimised polyethylene insulation and ceramic material improved heat retention and surface temperature control in non-heat source sections. Also, thermal resistance analysis decreased from 1.00 K/W (3 mm) to 0.65 K/W (7 mm). Among material properties, increasing ceramic thermal conductivity had a more significant impact on reducing core temperature than improving insulation. These findings provide practical recommendations for optimising conductor geometry and material properties for more fire-resistant cables. Full article

Direct liquid cooling technology has the potential to enhance the thermal management performance of electric motors with continuously increasing energy density. However, direct liquid cooling technology has practical limitations for full-scale commercialization. In addition, the conventionally used indirect liquid cooling imposes higher thermal resistance to cope with the increased thermal management performance of high power density electric motors. Therefore, this study proposes a hybrid direct–indirect oil cooling system as a next-generation cooling strategy for the enhanced thermal management of high power density electric motors. The heat transfer characteristics, including maximum winding, stator and motor housing temperatures, heat transfer coefficient, friction factor, pressure drop, and performance evaluation criteria (PEC), are investigated for different spray hole diameters, coolant oil volume flow rates, and motor heat loss levels. The computational model was validated with experimental results within a 5% error developed to evaluate heat transfer characteristics. The results show that spray hole diameter significantly influences cooling performance, with a larger diameter (1.7 mm) reducing hydraulic resistance while causing a slight increase in motor temperatures. The coolant oil volume flow rate has a major impact on heat dissipation, with an increase from 10 to 20 L/minute (LPM) reducing winding, stator, and housing temperatures by 22.05%, 22.70% and 24.02%, respectively. However, higher flow rates also resulted in an increased pressure drop, emphasizing the importance of the selection of a suitable volume flow rate based on the trade-off between cooling performance and energy consumption. Despite the increase in motor heat loss level from 2.6 kW to 8 kW, the hybrid direct–indirect oil cooling system effectively maintained all motor component temperatures below the critical threshold of 180 °C, confirming its suitability for high-performance electric motors. These findings contribute to the development and commercialization of the proposed next-generation cooling strategy for high power density electric motors for ensuring thermal stability and operational efficiency. Full article