Search Results (233)

The production of iron and steel plays a significant role in the anthropogenic carbon footprint, accounting for 7% of global GHG emissions. In the context of CO₂ mitigation, the steelmaking industry is looking to potentially replace traditional carbon-based ironmaking processes with hydrogen-based direct reduction of iron ore in shaft furnaces. Before industrialization, detailed modeling and parametric studies were needed to determine the proper operating parameters of this promising technology. The modeling approach selected here was to complement REDUCTOR, a detailed finite-volume model of the shaft furnace, which can simulate the gas and solid flows, heat transfers and reaction kinetics throughout the reactor, with an extension that describes the whole gas circuit of the direct reduction plant, including the top gas recycling set up and the fresh hydrogen production. Innovative strategies (such as the redirection of part of the bustle gas to a cooling inlet, the use of high nitrogen content in the gas, and the introduction of a hot solid burden) were investigated, and their effects on furnace operation (gas utilization degree and total energy consumption) were studied with a constant metallization target of 94%. It has also been demonstrated that complete metallization can be achieved at little expense. These strategies can improve the thermochemical state of the furnace and lead to different energy requirements. Full article

Lithium lanthanum titanate (LLTO) is a promising solid electrolyte for all-solid-state lithium-ion batteries (ASSLIBs), and its total conductivity is dramatically influenced by the ceramic microstructure. Here we report a novel aerodynamic levitation rapid solidification method to prepare dense LLTO ceramics with a dendrite-like microstructure, which can be hardly obtained by conventional sintering. At optimal nominal lithium content and cooling rate, the solidified LLTO ceramic achieved a high total conductivity of 2.5 × 10⁻⁴ S·cm⁻¹ at room temperature, along with excellent mechanical properties such as a high Young’s modulus of 240 GPa and a high hardness of 16.7 GPa. Results from this work suggest that aerodynamic levitation rapid solidification is an effective processing method to manipulate the microstructure of LLTO ceramics to minimize the GBs’ contribution to the total conductivity, which may be expanded to prepare other oxide-type lithium electrolytes. Full article

Newton’s law of cooling requires a reference temperature ($T_{ref}$) to define the heat-transfer coefficient ($h$). For external flows with multiple temperatures in the freestream, obtaining $T_{ref}$ is a challenge. One widely used method, referred to as the adiabatic-wall (AW) method, obtains $T_{ref}$ by requiring the surface of the solid exposed to convective heat transfer to be adiabatic. Another widely used method, referred to as the linear-extrapolation (LE) method, obtains $T_{ref}$ by measuring/computing the heat flux ($q_s^{\prime \prime }$) on the solid surface at two different surface temperatures ($T_s$) and then linearly extrapolating to $q_s^{\prime \prime }=0$. A third recently developed method, referred to as the state-space (SS) method, obtains $T_{ref}$ by probing the temperature space between the highest and lowest in the flow to account for the effects of $T_s$ or $q_s^{\prime \prime }$ on $T_{ref}$. This study examines the foundation and accuracy of these methods via a test problem involving film cooling of a flat plate where $q_s^{\prime \prime }$ switches signs on the plate’s surface. Results obtained show that only the SS method could guarantee a unique and physically meaningful $T_{ref}$ where $T_s=T_{ref}$ on a nonadiabatic surface $q_s^{\prime \prime }=0$. The AW and LE methods both assume $T_{ref}$ to be independent of $T_s$, which the SS method shows to be incorrect. Though this study also showed the adiabatic-wall temperature, $T_{AW}$, to be a good approximation of $T_{ref}$ (<10% relative error), huge errors can occur in $h$ about the solid surface where $|T_s-T_{AW}|$ is near zero because where $T_s=T_{AW}$, $q_s^{\prime \prime }\ne 0$. Full article

Growing environmental concerns have driven increased interest in solid-state thermal technologies based on the elastocaloric properties of shape memory alloys (SMA). This work examines the elastocaloric effect (eCE) in Ni-Ti SMA sheets subjected to cyclic bending, providing quantitative thermal characterization of their behavior under controlled loading conditions. The experimental investigation employed passive thermography to analyze the thermal response of Ni-Ti sheets under two deflection configurations at 1800 rpm loading. Testing revealed consistent adiabatic temperature variations (ΔT_ad) of 4.14 °C and 4.26 °C for the respective deflections during heating cycles, while cooling phases demonstrated efficient thermal homogenization with temperature gradients decreasing from 4.13 °C to 0.13 °C and 4.43 °C to 0.68 °C over 60 s. These findings provide systematic thermal documentation of elastocaloric behavior in bending-loaded Ni-Ti sheet elements and quantitative data on the relationship between mechanical loading parameters and thermal gradients, enhancing the experimental understanding of elastocaloric phenomena in this configuration. Full article

This work investigates the effect of nanoclay addition—specifically natural montmorillonite (MMT) and organo-modified montmorillonite (O-MMT)—on the elastocaloric performance of natural rubber (NR), a promising material for solid-state cooling due to its non-toxicity, low cost, and ability to exhibit large adiabatic temperature changes under moderate stress (~a few MPa). Despite these advantages, the cooling efficiency of NR remains lower than that of conventional vapor-compression systems. Therefore, improving the cooling capacity of NR is essential for the development of solid-state cooling technologies competitive with existing ones. To address this, two series of NR-based nanocomposites, containing 1, 3, and 5 phr nanofiller, were prepared by melt compounding and hot pressing and characterized in terms of morphology, thermal, mechanical, and elastocaloric properties. The results highlighted that the better dispersion of the organoclays within the rubber matrix promoted not only a better mechanical behavior (in terms of stiffness and strength), but also a significantly enhanced cooling performance compared to MMT nanofilled systems. Moreover, NR/O-MMT samples demonstrated up to a ~45% increase in heat extracted per refrigeration cycle compared to the unfilled NR, with a coefficient of performance (COP) up to 3, approaching the COP of conventional vapor-compression systems, typically ranging between 3 and 6. The heat extracted per refrigeration cycle of NR/O-MMT systems resulted in approx. 16 J/cm³, higher with respect to the values reported in the literature for NR-based systems (ranging between 5 and 12 J/cm³). These findings emphasize the potential of organoclays in enhancing the refrigeration potential of NR for novel state cooling applications. Full article

This study focuses on S32654 super austenitic stainless steel (SASS) and systematically characterizes the morphology of the sigma (σ) phase and the segregation behavior of alloying elements in its as-cast microstructure. High-temperature confocal scanning laser microscopy (HT-CSLM) was employed to investigate the effect of the rare earth element yttrium (Y) on the solidification microstructure and σ phase precipitation behavior of SASS. The results show that the microstructure of SASS consists of austenite dendrites and interdendritic eutectoid structures. The eutectoid structures mainly comprise the σ phase and the γ₂ phase, exhibiting lamellar or honeycomb-like morphologies. Regarding elemental distribution, molybdenum displays a “concave” distribution pattern within the dendrites, with lower concentrations at the center and higher concentrations at the sides; when Mo locally exceeds beyond a certain threshold, it easily induces the formation of eutectoid structures. Mo is the most significant segregating element, with a segregation ratio as high as 1.69. The formation mechanism of the σ phase is attributed to the solid-state phase transformation of austenite (γ → γ₂ + σ). In the late stages of solidification, the concentration of chromium and Mo in the residual liquid phase increases, and due to insufficient diffusion, there are significant compositional differences between the interdendritic regions and the matrix. The enriched Cr and Mo cause the interdendritic austenite to become supersaturated, leading to solid-state phase transformation during subsequent cooling, thereby promoting σ phase precipitation. The overall phase transformation process can be summarized as L → L + γ → γ → γ + γ₂ + σ. Y microalloying has a significant influence on the solidification process. The addition of Y increases the nucleation temperature of austenite, raises nucleation density, and refines the solidification microstructure. However, Y addition also leads to an increased amount of eutectoid structures. This is primarily because Y broadens the solidification temperature range of the alloy and prolongs grain growth perio, which aggravates the microsegregation of elements such as Cr and Mo. Moreover, Y raises the initial precipitation temperature of the σ phase and enhances atomic diffusion during solidification, further promoting σ phase precipitation during the subsequent eutectoid transformation. Full article

The solid solution cooling heat treatment of powder, high-temperature alloys is a crucial part of the process for ensuring the strength of materials during the forging processing. The influence of the γ′ phase and other microstructures in high-temperature alloy forgings on their macroscopic mechanical properties has been confirmed in numerous studies. Among them, the performance of the γ′ phase during the solid solution cooling process varies significantly depending on the cooling rate. This study uses the FGH99 nickel-based high-temperature alloy as the research material. It examines the precipitation and microstructure evolution law of the material under different cooling rates and its impact on the macroscopic mechanical properties of the material. Additionally, a prediction model of the organizational properties based on the cooling rate is constructed. The research findings indicate that there is a distinct positive correlation between the yield strength of the material and the cooling rate. As the cooling rate increases, the yield strength rises from 910.8 MPa to 1025.4 MPa, showing an increase of 12.6%. Moreover, an increase in the cooling rate has an evident promoting effect on the refinement of the precipitation phase. When the cooling rate is elevated from 50 °C/min to 250 °C/min, the average size of the γ′ phase decreases from 106 nm to 82.1 nm, and its morphology transforms from an irregular state to a spherical shape. For the microstructure of the material, such as the size of the precipitated phase and dislocation density, the maximum prediction error of the heat treatment organization performance prediction model established in this study is 2.97%. Moreover, the prediction error of the yield strength is 1.76%. Full article

With the enhancement of thermodynamic cycle parameters and heat dissipation constraints in aero-engines, effective thermal management has become a critical challenge to ensure safe and stable engine operation. This study developed a transient temperature evaluation model applicable to the entire flight envelope, considering fluid–solid coupling heat transfer on both the main flow path and fuel systems. Firstly, the impact of heat transfer on the acceleration and deceleration performance of a low-bypass-ratio turbofan engine was analyzed. The results indicate that, compared to the conventional adiabatic model, the improved model predicts metal components absorb 4.5% of the total combustor energy during cold-state acceleration, leading to a maximum reduction of 1.42 kN in net thrust and an increase in specific fuel consumption by 1.18 g/(kN·s). Subsequently, a systematic evaluation of engine thermal management performance throughout the complete flight mission was conducted, revealing the limitations of the existing thermal management design and proposing targeted optimization strategies, including employing Cooled Cooling Air technology to improve high-pressure turbine blade cooling efficiency, dynamically adjusting low-pressure turbine bleed air to minimize unnecessary losses, optimizing fuel heat sink utilization for enhanced cooling performance, and replacing mechanical pumps with motor pumps for precise fuel supply control. Full article

Blast furnace slag, a high-temperature molten by-product generated during the ironmaking process in the metallurgical industry, has garnered significant attention for its resource utilization technologies. Compared to the traditional water-quenching method, dry granulation offers notable advantages. This paper systematically compares and analyzes the performance parameters of three typical dry treatment processes: mechanical crushing, air-quenching granulation, and centrifugal granulation. It reveals that the centrifugal granulation process demonstrates substantial technical superiority in key metrics, such as particle size distribution uniformity, particle morphology optimization, and heat recovery efficiency. Building on this, this study provides a comprehensive review of the current state of centrifugal granulation technology, from both experimental and simulation perspectives. Additionally, the combined processes of centrifugal granulation and air quenching can fully exploit the synergistic benefits of each technology, thereby enhancing overall efficiency. However, the wind’s cooling effect can lead to the premature solidification of molten slag when it splits into liquid filaments, resulting in slag wool. To address this, this paper proposes a centrifugal granulation device equipped with a windbreak board, which facilitates temperature zoning. This approach prevents premature solidification in the liquid filament region while ensuring the timely cooling and solidification of slag particles, offering a novel technical solution for optimizing centrifugal granulation in metallurgical solid waste resource utilization. Full article

Research on the thermal analysis of laser diode (LD) side-pumped amplifiers is a critical step in the design of high-power solid-state laser systems. Instead of adopting a standard solid modeling approach that only considers a laser rod, a fluid–structure interaction model is employed for analysis using the FLUENT 2021 R1 software. This model integrates the cooling structure, coolant, and laser rod, incorporating their relevant material parameters. By considering both uniform and non-uniform inlet velocity distributions as loading conditions, the study reveals remarkably different thermal simulation results. The correlation between thermal analysis outcomes and the total inlet flow rates is calculated, while temperature and stress distributions are obtained under a varying internal heat source. It was observed that the non-uniform inlet velocity distribution has little impact on the rod’s maximum temperature but significantly influences the maximum equivalent stress. This finding underscores the necessity of accounting for non-uniform inlet distributions during the design of laser amplifiers to achieve more accurate thermal simulation results and optimize structural reliability. Full article

Electrocaloric materials, which exhibit adiabatic temperature change under an applied electric field, are promising for solid-state cooling technologies. In this study, the electrocaloric response of lead-free Ba_xCa_1−xZr_yTi_1−yO₃ (BCZT) ceramics was modeled to investigate the effects of composition, processing, and measurement conditions on performance. A high-accuracy XGBoost regression model (R² = 0.99, MAE = 0.02 °C) was developed using a dataset of 2188 literature-derived data points to predict and design the electrocaloric response of BCZT ceramics. The feature space incorporated compositional ratios, processing parameters, measurement settings, and atomic-level Magpie descriptors, along with Curie temperature to account for phase-transition behavior. Feature importance analysis revealed that electric field, measurement temperature, and proximity to the Curie point are the most critical factors influencing ΔT_EC. Bayesian optimization was applied to navigate the design space and identify performance maxima under unconstrained and realistic constraints, offering valuable insights into the nonlinear interactions governing electrocaloric performance. Under room temperature and moderate-field conditions (24 °C, 40 kV/cm), the optimized ΔT_EC achieved a value of 1.03 °C for Ba_0.85Ca_0.15Zr_0.40Ti_0.60, to be processed at 1090 °C for 3 h during calcination, 1300 °C for 2 h during sintering. By integrating experimental insight with machine learning and optimization, this study offers a refined, interpretable framework for accelerating the design of high-performance electrocaloric ceramics while reducing the experimental workload. Full article

When developing fabrics for applications in which evaporative cooling and drying play an important role, e.g., sports or occupational applications, the drying performance of fabrics is commonly determined using fast and easy-to-perform benchmark methods. The measurement conditions in these methods, however, differ significantly from the drying conditions on the human body surface, where drying is obstructed on one side of the fabric through contact with the skin and at the same time enhanced due to contact with the heated surface (skin). The aims of this study were to understand and quantify the fabric drying process at the skin interface considering these real-use effects based on tests applying two-sided drying, one-sided drying, one-sided drying on a heated surface, and one-sided drying on a heated surface in the stretched state, and to relate these to existing standard methods. The findings showed that contact with a solid heated surface such as the skin and the stretched state of the fabric both make a significant contribution (p < 0.05) to the drying rate compared to two-sided drying in standard climatic conditions. The corresponding drying rates observed for a range of typical fabrics used in leisure and sports as a first layer next to the skin were found to be 1.6 (±0.2), 1.1 (±0.2), 7.9 (±2.1), and 10.6 (±0.8) g/m² min for two-sided drying, one-sided drying, one-sided drying on a heated surface, and one-sided drying on a heated surface in the stretched state, respectively. These findings are of great importance for human thermal modelling, including clothing models, where the drying process significantly contributes to the heat and mass transfer in the skin–clothing–environment system. Full article

Hydrogen is critical for achieving carbon neutrality as a clean energy source. However, its low ambient energy density poses challenges for storage, making efficient and safe hydrogen storage a bottleneck. Metal hydride-based solid-state hydrogen storage has emerged as a promising solution due to its high energy density, low operating pressure, and safety. In this work, the thermodynamic and kinetic characteristics of the hydrogenation and dehydrogenation processes are investigated and analyzed in detail, and the effects of initial conditions on the thermochemical hydrogen storage reactor are discussed. Multiphysics field modeling of the magnesium-based hydrogen storage tank was conducted to analyze the reaction processes. Distributions of temperature and reaction rate in the reactor and temperature and pressure during the hydrogen loading process were discussed. Radially, wall-adjacent regions rapidly dissipate heat with short reaction times, while the central area warms into a thermal plateau. Inward cooling propagation shortens the plateau, homogenizing temperatures—reflecting inward-to-outward thermal diffusion and exothermic attenuation, alongside a reaction rate peak migrating from edge to center. Axially, initial uniformity transitions to bottom-up thermal expansion after 60 min, with sustained high top temperatures showing nonlinear decay under $∆$t = 20 min intervals, where cooling rates monotonically accelerate. The greater the hydrogen pressure, the shorter the period of the temperature rise and the steeper the curve, while lower initial temperatures preserve local maxima but shorten plateaus and cooling time via enhanced thermal gradients. Full article

Tungsten–diamond metal matrix composites (MMCs) fabricated via L-PBF show potential for applications in nuclear facility shielding, heat sinks, precision cutting/grinding tools, and aerospace hot-end components. In this paper, tungsten (W), diamond (D), and diamond with Ni coating (D-Ni) powders are used to fabricate W+D and W+(D-Ni) composites by L-PBF technology. The results show that at the interface of the W+D sample, the W powder melts while the D powder remains in a solid state during L-PBF processing, and W and C elements gradually diffuse into each other. Due to the high cooling rate of L-PBF processing, the C phase forms a diamond-like carbon (DLC) phase with an amorphous structure, and the W phase becomes a supersaturated solid solution of the C element. At the interface of the W+(D-Ni) sample, the diffusion capacity of Ni and W elements in the solid state is weaker than in the molten state. C and W elements diffuse into the Ni melt, forming a rich Ni area of the DLC phase, while Ni and W elements diffuse into the solid D powder, forming a lean Ni area of the DLC phase. In the rich Ni area of the DLC phase, Ni segregation leads to the precipitation of nanocrystals (several hundred nanometers), whereas in the lean Ni area of the DLC phase, the diffusion capacity of Ni and W elements in the solid D powder is limited, resulting in nanocrystalline sizes of only about tens of nanometers. During W dendrite growth, the addition of the Ni coating and the expelling of the C phenomenon leads to W grain refinement at the interface, which reduces the number and length of cracks in the W+(D-Ni) sample. This paper contributes to the theoretical development and engineering applications of tungsten–diamond MMCs fabricated by L-PBF. Full article

To address the challenges of high flow resistance and poor temperature uniformity in conventional PCM–liquid cooling hybrid heat exchangers—which significantly impair the performance and lifespan of electronic devices—a topology optimization approach was adopted. A dual-objective function, aimed at minimizing the average temperature and pressure drop, was introduced to reconstruct the cooling channel layout and PCM filling region. A two-dimensional transient thermo-fluid model coupling the solid–liquid phase-change process with coolant flow and heat transfer was established, alongside the development of an experimental platform. A comprehensive comparison was performed against a conventional liquid cooling plate with straight channels. The results showed that the topology-optimized cooling plate exhibited a pressure drop of 15.80 Pa and a pumping power of 1.19 × 10⁻⁴ W, representing reductions of 38.28% and 38.02%, respectively. The PCM solidification time was shortened by 6 min. Under these conditions, the convective heat transfer coefficient (h_w) and performance evaluation criterion (j/f) of the optimized plate reached 1319.06 W/(m²·K) and 0.56, which corresponded to increases of 60.71% and 47.5%, respectively. The topology-optimized configuration significantly improved temperature uniformity and overall cooling performance. As the inlet velocity increased from 0.05 m/s to 0.2 m/s, h_w increased by 38.65%; however, j/f decreased by 57.14%, due to the limited thermal conductivity of the PCMs, resulting in only a slight reduction in the average PCM temperature. Furthermore, the topology-optimized cooling plate demonstrated stronger steady-state regulation capability under fluctuating thermal loads. This study provides valuable insights and design guidance for the development of high-efficiency hybrid liquid cooling plates. Full article