Search Results (208)

Air-shielding radial ultrasonic rolling electrochemical micromachining (AS-RUREMM) is proposed to fabricate high-quality micro-dimple textures on cylindrical SS304 surfaces while suppressing stray corrosion. In AS-RUREMM, an annular air sheath coaxially envelopes the electrolyte jet to confine the wetting footprint, and radial ultrasonic vibration is superimposed on a rolling cathode with micro-protrusions to intensify local mass transport and stabilize the interelectrode environment. A conductivity-centered theoretical framework is established to link air-sheathing-induced gas–liquid distribution, ultrasonic gap modulation, and the resulting current-density localization. Multiphysics simulations in COMSOL 5.3 clarify that moderate air pressure forms a stable confined gas–liquid structure that narrows the effective conductive pathway, whereas excessive air pressure increases intermittency and weakens effective gap conductivity. Experiments on SS304 tubes validate the confinement mechanism: compared with RUREMM, AS-RUREMM produces smaller pit width and depth but a higher depth-to-width ratio, indicating enhanced localization and reduced peripheral over-etching. The simulated cross-sectional profiles agree with measurements, with an overall deviation within 6%. Parameter studies identify an optimal operating window, and the combination of 0.18 MPa air pressure and 12 V pulse voltage provides the highest aspect ratio while maintaining stable machining. SEM/EDX analyses further support the improved process controllability under air shielding through reduced stray corrosion and composition changes consistent with a more regulated electrochemical dissolution environment. Full article

Stray current-induced corrosion poses a significant risk to the durability of reinforced concrete (RC) structures in electrified transit systems. This study addresses a critical knowledge gap by experimentally and analytically investigating the compression behaviors of circular RC columns under the combined effects of stray currents, chloride intrusion, and sustained service loads. The experimental program involved testing columns constructed with normal strength concrete (NSC) and moderate strength concrete (MSC) under accelerated corrosion induced by electrical potentials of 9 V and 18 V in a 3.5% NaCl solution. A key variable was the application of a sustained axial load, equal to 60% of the ultimate capacity, to simulate realistic service conditions. The findings revealed a severe deterioration in structural performance due to the synergistic effect of mechanical loading and corrosion. NSC columns subjected to 18 V potential and sustained axial loading exhibited a decrease in ultimate load-carrying capacity of up to 46% and a ductility reduction of approximately 69% compared to reference specimens. This damage was significantly more severe than in unloaded or lower-voltage (9 V) scenarios. Furthermore, MSC specimens demonstrated a strength loss of approximately 29% under similar aggressive conditions. An analytical confinement model, adjusted to account for corrosion by reducing the reinforcement cross-section and introducing a semi-empirical parameter α to represent localized pitting, showed strong agreement with the experimental stress–strain curves. The validated model provides a practical tool for assessing the residual capacity of corroded elements, addressing a crucial need in the maintenance of electrified transportation infrastructure. Full article

In electric vehicle (EV) drivetrains, lubricant films must not only mitigate friction and wear but also manage stray currents to safely dissipate stray charge and avoid micro-arcing. This study directly compares how a conventional antiwear additive (ZDDP) and a long-chain, ashless, sulfur-free phosphite ester (Duraphos AP240L) manage this balance under current-carrying boundary lubrication conditions. Reciprocating steel-on-steel tests were conducted at fixed load and speed with applied current densities of 0, 0.02, and 42.4 A/cm². Friction and four-probe electrical contact resistance (ECR) were measured in situ, and impedance of tribofilms was measured over a 1–10⁵ Hz range after friction test. In the presence of ZDDP, ECR initially increased and then decreased to a value that was as low as the initial direct contact of two solid surfaces or even lower sometimes. During the initial stage with high ECR, a well-defined impedance semicircle was observed in the Nyquist plot; after forming the tribofilm with low ECR, frequency dependence of impedance could not be measured due to the very low resistance. The decrease in ECR suggested a structural evolution of the anti-wear film on the substrate. However, post-test wear analysis indicated that the formation of this film was accompanied by tribochemical polishing of the countersurface and sometimes pitting of the substrate, which may have been due to localized electrical discharge producing trenches deeper than ~0.5 µm; in additive-free base oil, wear was dominated by ploughing with micro-cutting of the substrate. In contrast, AP240L performed better in terms of friction and wear, showing a remarkable ~30% lower coefficient of friction, while the overall cycle dependence of ECR was similar to the ZDDP case. AP240L showed negligible boundary film controlled wear producing a shallow, smooth track (depth < 0.2 µm) during the friction test, and there was no sign of electrical arc damage. These findings support long-chain, ashless, sulfur-free phosphite esters as promising candidates for EV boundary lubrication where both mechanical and electrical protection are required. Full article

The low-frequency sensitivity of gravitational-wave detectors can be degraded by noise arising from the re-coupling of stray light with the main interferometer beam. This review describes the re-coupling mechanism and shows how the experience gained with current detectors can be used to anticipate and mitigate stray-light issues in third-generation instruments. We summarize the work carried out on numerical simulations and on the extensive characterization of stray light originating from both core and auxiliary optics. We also discuss possible improvements to the interferometric readout system aimed at reducing stray-light-induced noise, as well as diagnostic approaches for identifying potentially harmful scattering elements. Overall, this review summarizes best practices for the effective control of stray light in future gravitational-wave detectors, supporting design approaches aimed at preventing unforeseen noise issues. Full article

In order to explore the influence of different current forms on the protection effect of cathodic protection systems for intelligent test piles of oil and gas gathering and transportation pipelines, X80 steel was taken as the research object to simulate the soil corrosion environment, and cathodic protection performance test experiments were carried out under three current forms: direct current (DC), conventional pulse (P) and high-frequency pulse (HP). Through a polarization curve test, electrochemical impedance spectroscopy (EIS) analysis, surface morphology observation and corrosion rate test, the effects of three current forms on cathodic polarization effect, polarization resistance, corrosion product composition and protection efficiency were compared. The results show that high-frequency pulse current can make the pipeline steel reach the protection potential in a shorter time, and under the same average current density, its polarization resistance is 23.6% and 15.8% higher than that of DC and conventional pulse, respectively. The anti-interference ability of conventional pulse current is better than that of DC. In the presence of stray current, the fluctuation amplitude of protection potential is only 21.1% of DC. The protection stability of DC is good, but the polarization speed is slow, and the phenomenon of “over protection” easily occurs in the process of long-term protection. Combined with economic analysis, high-frequency pulse current has significant advantages in high-corrosion-risk environments. Conventional pulse is suitable for stray current interference areas, while DC is more suitable for long-distance pipeline protection with low corrosion risk. The research results can provide a theoretical basis and technical support for the selection of the current form of pipeline cathodic protection systems. Full article

The paper provides a comprehensive overview of stray losses in conductive structural parts of power transformers, addressing the effects of stray magnetic fields on simple conductive plates, the distribution of additional losses across structural components and measures for their reduction. It examines the (im)possibility of directly measuring stray losses and presents methods for their indirect measurement, highlighting the generation of fault gases due to thermal faults and the importance of understanding multiphysical (electromagnetic–thermal) coupling in calculating stray losses. A problem rarely mentioned in the literature but confirmed here by measurements, is the excessive heating of the connecting elements of the clamping system caused by circulating currents. Full article

The parasitic currents issue arises in induction machines operating at higher frequencies. The parasitic current flow is the main cause of premature degradation of winding insulation deterioration and bearing damage. The effect of electromagnetic interference (EMI) requires investigating an equivalent per-phase model of an induction motor (IM) at higher frequencies. The per-phase induction motor mathematical model of the IM drive for common mode (CM) configuration is developed to perform high-frequency analysis for drive operation. The high-frequency per-phase induction motor model MATLAB (2021b) is developed to generate the transfer function of IM drive and generate bode plots for both CM and differential mode (DM) impedance configuration at higher frequency. Initially, the IM typical frequency response without considerations of stray and parasitic effects is presented for normal behavior of the IM. In order to verify the simulated impedance parameters of 0.3 kW and 38 kW IMs with stray and parasitic components, a high-frequency response for magnitude and phase response is generated and compared to analyze per-phase induction motor model performance before and after resonance frequencies. The comparison of CM and DM bode plots validates the dominance of inductance and parasitic capacitance before and after the occurrence of resonance frequency, respectively. The analysis suggests that 38 kW IM resonance occurs in MHz range which exhibits much better performance compared to the 0.3 kW IM model. Full article

Many special structures such as pipeline, revolving gears, and tanks suffer from biofouling used in marine environment, which could induce serious results in the ship system such as blockage and stuck, consequently lead to failure of the mechanical system and power system. Generally, coatings with antifouling agents are used for protecting metal structures from biofouling, but coatings are not conveniently applicable in the high velocity flowing seawater and narrow space. Electrochlorination and electrolysis of copper and aluminum anode are usually used in these circumstances, but the electric power will lead to stray current corrosion to the component. For the sake of convenience and safety, Cu-Ti pseudo alloy antifouling anode was proposed in this work for antifouling in pipeline and other narrow spaces without external electric power. Four Cu-Ti pseudo alloy antifouling anodes with different Ti contents (mass fraction) of 0 wt.%, 5 wt.%, 10 wt.%, and 15 wt.% were investigated with computational method, and a 15 wt.% Ti content Cu-Ti pseudo alloy antifouling anode was prepared by cold spray, and the microstructure and composition of the anode were observed by scanning electron microscope (SEM) and energy dispersive spectroscopy (EDS). Electrochemical tests were conducted to obtain the corrosion potential, potentiodynamic polarization curve, and micro zone electrochemical information in natural seawater, and the Cu ions releasing behavior were analyzed using inductively coupled plasma (ICP). The results indicated that in natural seawater, copper particles, and titanium particles on the surface of anode samples can form micro galvanic couples. With the increase in Ti mass fraction, the number of micro primary cells composed of copper particles and titanium particles increases, and the corrosion rate of Cu particles increased. When the Ti mass fraction is 15%, the corrosion rate is the fastest, and the copper ion release rate increases by nearly ten times, reaching 147 μg/(cm²·d). This method can effectively accelerate the releasing rate of Cu ions in Cu-Ti pseudo alloy anode and promote the antifouling effect. Full article

Permanent Magnet Synchronous Generators (PMSGs) have become increasingly important in industrial applications such as wind turbine systems due to their high efficiency and power density. However, their operational reliability can be affected by asymmetries such as static eccentricity (SE) and load current unbalance (UnB), which exhibit similar spectral features and are therefore difficult to differentiate using conventional techniques such as Motor Current Signature Analysis (MCSA). Stray flux analysis provides an alternative diagnostic approach, yet single-point measurements often lack the sensitivity required for accurate fault discrimination. This study introduces a diagnostic methodology based on the Space Vector Stray Flux (SVSF) for identifying static eccentricity (SE) and load current unbalance (UnB) faults in PMSG-based systems. The SVSF is derived from three external stray flux sensors placed 120° electrical degrees apart and analyzed through symmetrical component decomposition, focusing on the +5f_s positive-sequence harmonic. Two-dimensional Finite Element Analysis (FEA) conducted on a 36-slot/12-pole PMSG model shows that the amplitude of the +5f_s harmonic increases markedly under static eccentricity, while it remains nearly unchanged under load current unbalance. To validate the simulation findings, comprehensive experiments have been conducted on a dedicated test rig equipped with high-sensitivity fluxgate sensors. The experimental results confirm the robustness of the proposed SVSF method against practical constraints such as sensor placement asymmetry, 3D axial flux effects, and electromagnetic interference (EMI). The identified harmonic thus serves as a distinct and reliable indicator for differentiating static eccentricity from load current unbalance faults. The proposed SVSF-based approach significantly enhances the accuracy and robustness of fault detection and provides a practical tool for condition monitoring in PMSG. Full article

Despite advancements in mitigating stray current in railway systems, and their impact on nearby installations (i.e., pipelines), challenges remain, necessitating ongoing research and close collaboration between academia and the railway industry. This paper describes the relevant results of a joint industry–academia research project focused on the experimental validation of a reduced complexity circuit model to evaluate the rail potential and the associated stray current directly into the soil. It will be shown that the proposed circuit model is adaptable to various railway lines. Using a lumped parameter approach, the model simplifies spatial discretization without sacrificing accuracy; the relevant resistance and admittance parameters at the sub-stations and along the rail return path are identified, and their impact is studied for the subsequent experimental step. Two real scenarios involve two railway segments in southern and central Italy, which are also different in the geological profile of the terrain. The rail voltage along the two lines is measured and compared with the profile predicted by the lumped circuit model showing the latter’s accuracy. The circuit, validated by the experimental measurements, provides an indirect evaluation of the magnitude of the stray current flowing into the earth. Initially designed for uniform terrain, it can be expanded to include surrounding infrastructure and unintended stray current paths. This framework offers broad applicability and precision across diverse railway environments where nearby critical installations require the estimation of the stray current for the possible subsequent development of countermeasures for their reduction. Full article

This study examined the combined effects of chloride ions and stray DC on reinforced concrete (RC) using electromigration and impressed-current methods under varying current densities (0.5, 3.0, 5.0 mA/cm²) and chloride concentrations (50, 1350, 5500 mg/kg). Chloride was identified as the dominant deterioration factor. At 3.0 mA/cm², cracking times in moderate and severe chloride environments decreased by 48.75% and 52.62%, respectively, compared to mild conditions. At 0.5 mA/cm² in severe conditions, the corrosion rate reached 1.317% after 20, 2.75 times that in moderate conditions. Electromigration specimens showed delayed cracking but deeper chloride penetration, while impressed-current specimens exhibited pronounced strip-shaped pitting corrosion. A quadratic polynomial model predicting cracking time based on current density and chloride concentration achieved high accuracy (R² = 0.95, mean relative error = 7.%). Actual corrosion mass loss was lower than theoretical Faraday values, with current efficiency increasing from 0.3–0.8% to 16.5–18.1% as current density and chloride content rose. These findings highlight the synergistic effect of stray current and chloride attack, emphasizing chloride concentration’s greater impact on service life. The model provides a scientific basis for RC durability design in urban rail transit and coastal engineering. Full article

The DC traction power system adopts the track as the return rail. When the track-to-earth insulation in the subway tunnel deteriorates, stray currents will cause electrochemical corrosion to tunnel steel structures and seriously affect the service life and safety of metro tunnels. Stray currents cannot be directly measured and can only be calculated. Therefore, a calculation model with a hollow circular cross-section structure was proposed, and the stray current distribution in tunnel steel structures was calculated. In addition, the effects of different rail-to-ground transition resistances and adjacent buried metallic pipelines on the stray current distribution of the tunnel steel structures were taken into account. The results show that the total amount of stray current dispersed into the tunnel steel structures and soil is similar. The stray current density distribution in each steel tunnel is related to its location. The total stray current carried by the steel structures of the bottom tunnel segment is 102, 15.7 and 3.1 times higher than that of the top, upper and lower side tunnel segments, respectively. The reduction in the transition resistance and increase in the distance of the train from the traction substation increase the total rail leakage current and have a small effect on the percentage distribution of stray current in tunnel structures. The buried metal pipeline parallel to the tunnel has a lower impact on the total stray current leakage, but can reduce the total stray current in steel structures and drainage net, enlarging the positive stray current scope of some tunnel steel bars, further increasing the stray current density on tunnel steel bars. The results of this study can be used to determine the degree of corrosion of the underground steel tunnels and thereby provide support for corrosion prevention. Full article

Stray currents leaking from electrified DC rail systems cause the greatest corrosion risk to underground metal gas pipelines and can lead to pipeline wall perforation in a very short time. Leakage and gas explosion, and other direct and indirect effects, can even disrupt the stability of the energy system. Maintaining the reliability of gas pipelines, therefore, requires protecting them against corrosion caused by stray currents. It is therefore necessary to conduct field studies to identify sections of gas pipelines at risk and where protective installations should be installed. The paper discusses the most important field methods for assessing the risk of stray currents to gas pipelines: the potential of rail traction relative to ground, electric field gradients in the ground associated with stray current flow, correlation of gas pipeline potential and voltage of pipeline vs. the rail, and time-frequency analysis of the pipeline and rail potentials. A typical application case for each method is indicated, and the advantages and disadvantages of each research technique are identified. The criterion for selecting methods for this review was a short measurement duration (tens of minutes), after which it is possible to determine the level of the hazard to the gas pipeline caused by stray currents in the examined location. This is why these methods have an advantage over other research techniques that require long-term monitoring or exposure of probes or sensors. The review will be useful for cathodic protection personnel involved in the operation of gas pipelines and may be helpful in developing new methods for assessing the impact of stray currents. Full article

Due to the presence of stray current in the subway environment, the durability issues of subway structures differ from those of general structures. This study simulates the combined effects of chloride ions and stray current in the subway environment through electrochemical corrosion experiments, thereby analyzing the corrosion morphology and mechanical property degradation of steel strands and the corrosion-induced cracking of concrete. The experimental results indicate that stray current affects the strength and ductility of steel strands as well as the cracking of concrete. The corrosion difference coefficient μ_c at different positions is greater than 1.6 and the average corrosion degree η_ave is less than 7%. The corrosion morphology gradually changes from non-uniform to uniform corrosion until the η_ave is greater than 12%. The concrete crack width under a stray current of 60 mA is 10.67 times that of cracks under 20 mA after 42 days, which is approximately linearly related to the current intensity. Based on the experimental results, a corrosion-induced crack prediction model for prestressed concrete under stray current is proposed, with the main influencing factors being current intensity, concrete tensile strength, and protective layer thickness. These findings can provide valuable references for the durability analysis of subway structures. Full article

Early and accurate detection of distributed bearing faults is essential to prevent equipment failures and reduce downtime in industrial environments. This study explores the optimal selection of input signal sources for high-accuracy distributed fault classification, employing wavelet transform and machine learning algorithms. The primary contribution of this work is to demonstrate that robust distributed bearing fault diagnosis can be achieved through optimal sensor fusion and wavelet-based feature engineering, without the need for deep learning or high-dimensional inputs. This approach provides interpretable, computationally efficient, and generalizable fault classification, setting it apart from most existing studies that rely on larger models or more extensive data. All experiments were conducted in a controlled laboratory environment across multiple loads and speeds. A comprehensive dataset, including three-axis vibration, stray magnetic flux, and two-phase current signals, was used to diagnose six distinct bearing fault conditions. The wavelet transform is applied to extract frequency-domain features, capturing intricate fault signatures. To identify the most effective input signal combinations, we systematically evaluated Random Forest, XGBoost, and Support Vector Machine (SVM) models. The analysis reveals that specific signal pairs significantly enhance classification accuracy. Notably, combining vibration signals with stray magnetic flux consistently achieved the highest performance across models, with Random Forest reaching perfect test accuracy (100%) and SVM showing robust results. These findings underscore the importance of optimal source selection and wavelet-transformed features for improving machine learning model performance in bearing fault classification tasks. While the results are promising, validation in real-world industrial settings is needed to fully assess the method’s practical reliability and impact on predictive maintenance systems. Full article