Search Results (649)

The aim of the current study is to optimize the bead geometries of 80B2, namely, the bead height (BH) and bead width (BW), utilizing a mild steel substrate and a wire-arc additive manufacturing (WAAM) technique based on gas metal arc welding (GMAW). Single-layer depositions with different wire feed speed (WFS), voltage (V), and travel speed (TS) were accomplished by applying the Box–Behnken design methodology. Multivariable nonlinear regression models were developed and validated through ANOVA, revealing WFS as the most significant parameter influencing both BW and BH. The minimal influence of the error factor on each response proved the accuracy of the ANOVA findings. The favorable assessment of residual plots confirmed the appropriateness and reliability of the developed regression equations and ANOVA results. A metaheuristic Passing Vehicle Search (PVS) algorithm was applied for single-objective and multi-objective optimization, yielding a minimum BW of 5.874 mm and a maximum BH of 14.153 mm. Main effect and residual plots confirmed the accuracy and reliability of the predictive models. The parametric settings of WFS: 18 mm/min, TS: 7 mm/s, V: 19 V were obtained for simultaneous optimization of BW with 7.78 mm and BH with 10.87 mm. Pareto points were also generated, which provide non-dominated unique solutions. The study emphasizes the critical role of precise process parameter control in improving WAAM build quality and offers a robust framework for optimizing bead morphology, ultimately enhancing the efficiency and applicability of WAAM for structural component fabrication. These optimized parameters will be used in the future to manufacture a thin-walled, multi-layered structure. Full article

Wire Arc Additive Manufacturing (WAAM) enables cost-effective fabrication of complex metallic components but faces challenges in achieving consistent tensile strength for cylindrical parts with intricate internal features (e.g., cooling channels, helical grooves), where conventional machining is often infeasible or prohibitively expensive. This study introduces a novel stacked ring substrate strategy with pre-formed low-carbon steel rings defining complex internal geometries, followed by external WAAM deposition using ER70S-6 wire to overcome these limitations. Five process parameters (welding current: 110–130 A; offset distance: 2.5–3.0 mm; Step Length: rotary to straight; torch speed: 400–500 mm/min; weld thickness: 2.0–3.0 mm) were optimized using a Taguchi L25 orthogonal array (25 runs in triplicate). ANOVA identified Step Length as the dominant factor, with straight paths significantly reducing thermal cycling and improving interlayer bonding, alongside a notable current × speed interaction. Optimal settings achieved tensile strengths of 280–290 MPa, significantly below wrought ER70S-6 benchmarks (400–550 MPa) due to interfacial weaknesses at ring fusion zones and thermal accumulation from stacked cylindrical geometry, a limitation acknowledged in the absence of microstructural or thermal history data. A Random Forest Regressor predicted strength with R² = 0.9312, outperforming conventional models. This hybrid approach significantly enhances design freedom and mechanical reliability for high-value cylindrical components in aerospace and tooling, establishing a scalable, data-driven framework for geometry-constrained WAAM optimization. Full article

Conformal electronics are distinguished by their unique characteristics, such as the integration of structure and function and their conformability with complex geometries. These features unlock a broad spectrum of applications, including structural health monitoring and the creation of metasurfaces. However, the current landscape of large-scale curved electronic fabrication is characterized by a significant gap in specialized equipment and standardized strategies. In this context, we introduce a pioneering strategy that leverages robotized electrohydrodynamic (EHD) printing for the conformal fabrication of large-scale curved electronics on 3D surfaces. This comprehensive multi-robot EHD conformal printing strategy integrates several critical components, including plasma surface treatment, EHD conformal printing, and near-infrared (NIR) sintering processes. These are supported by enabling technologies such as 3D surface reconstruction and precise hybrid positioning. Notably, our strategy achieves 5 µm printing resolution via EHD lithography and 35 µm repeatable positioning accuracy. After plasma treatment, conductive patterns on FR4 substrates reach 5B-level adhesion strength. NIR sintering enables high-efficiency sintering within only 125 s. Seamless integration of these processes into multi-robot collaborative equipment enables the fabrication of large-area conformal electronics, such as 400 mm × 1000 mm unmanned aerial vehicle wings and 650 mm × 350 mm satellite shells, and supports multi-layer systems including wires, LED arrays, antennas, and sensors. This strategy possesses substantial potential to transcend the limitations inherent in traditional fabrication methods, paving the way for new frontiers in conformal electronics across a variety of applications, including smart wings and satellite surfaces. Full article

Rotary tillage blades, as critical components of soil tillage machinery, encounter significant challenges in mountainous agricultural operations, where excessive wear and high energy consumption are persistent issues. To address these problems, this study proposes an integrated strategy combining structural optimization with surface reinforcement. A blade–soil interaction model based on Smoothed Particle Hydrodynamics (SPH) was developed to optimize blade geometry, reducing power consumption to 0.106 kW with a simulation error of only 2.83%. In parallel, Fe60–WC composite coatings containing 30%, 35%, and 40% WC were fabricated on 65Mn substrates using laser cladding. Microstructural analysis revealed significant grain refinement with increasing WC content, while tribological tests showed that the 35% WC coating blades exhibited superior wear resistance, with a mass loss of 1.9 mg, and a relatively low friction coefficient of 0.362. Field trials further confirmed that the blades resulted in a 45.75% reduction in average wear, after structural enhancement and the application of the optimized coating, with a measured loss of 2.259 g compared to the uncoated blades. These findings demonstrate the synergistic benefits of structural optimization and advanced surface engineering, providing an effective pathway to improve the durability and efficiency of rotary tillage blades in demanding field conditions. Full article

A theoretical study of the adsorption of lithium–sulfur molecules (Li₂S and Li₂S₂) on graphene with three and four vacancies was conducted. The study analyzed the stability, adsorption geometry, electronic structure, charge distribution, and forming bonds between the molecule and the substrates. It has been demonstrated that both types of defects result in stable adsorptions; however, the underlying mechanisms differ. The three-vacancy graphene exhibits a site that favors the adsorption through bonds between S atoms and the substrate, while the graphene with four vacancies promotes the anchoring of molecules through Li atoms. The mechanism associated with the three-vacancy graphene results in increased exothermic adsorption energies. Full article

Edible coatings are widely used to modulate oil uptake and moisture in fried foods. In this study, we evaluated a microfluid-assisted flow-blurring spray against conventional application by dipping/spraying, focusing on the coating efficiency and preliminary implications for sustainable process. This study combines benchtop experiments with a near-nozzle numerical analysis where the gas–liquid interface and primary breakup are modeled using the Volume of Fluid (VOF) approach implemented in OpenFOAM, configured for a flow-blurring geometry to generate whey protein isolate (WPI) coatings. Viscosity, density, solid content, and contact angle were validated experimentally and used in the simulation setup. An image-based droplet pipeline quantified spray characteristics, yielding a volumetric median diameter D₅₀ = 83.69 µm and confirming process uniformity. Contact angles showed marked substrate dependence: hydrophilic surfaces, 68°–85°; hydrophobic surfaces, 95°–110°. For turkey sausages, sessile-drop contact angles were not determinable (N.D.) due to wicking/roughness; wettability was therefore assessed on smooth surrogates and via performance metrics. Fit-for-purpose simulation procedures are outlined. Microfluidic application (WPI-McF) lowered oil uptake versus uncoated controls. Together, robust modeling, targeted image analytics, and high-precision microfluidics enable rational tuning of coating microstructure and barrier performance, offering a scalable pathway to reduce lipid content and enhance fried food quality. Full article

Effective thermal management is essential in metal additive manufacturing to ensure process stability and desirable material properties. Directed energy deposition using a laser beam and wire (DED-LB/w) enables the production of large, high-performance components but remains sensitive to adverse thermal effects during multi-layer deposition due to heat accumulation. While prior studies have investigated interlayer temperature control and substrate preheating in DED modalities, including laser-powder and arc-based systems, the influence of substrate preheating in DED-LB/w has not been thoroughly examined. This study employs substrate preheating to simulate heat accumulation and assess its effects on melt pool geometry, wire–melt pool interaction, and the microstructural evolution of Alloy 718. Experimental results demonstrate that increased substrate temperatures lead to a gradual expansion of the melt pool, with a notable transition occurring beyond 400 °C. Microstructural analysis reveals that elevated preheat temperatures promote coarser secondary dendrite arm spacing and the development of wider columnar grains. Moreover, Nb-rich secondary phases, including the Laves phase, exhibit increased size but relatively unchanged area fractions. Observations from electrical conductance measurements and coaxial visual imaging show that preheat temperature significantly affects the process dynamics and microstructural evolution, providing a basis for advanced process control strategies. Full article

Underground gas storage (UGS) is critical to national reserves and seasonal peak-shaving, and its safe operation is integral to energy security. In UGS surface process pipelines, heterogeneous bimetal composite pipes—carbon-steel substrates lined with stainless steel—are widely used but susceptible under coupled thermal–pressure–flow loading to geometry-induced instabilities (local buckling, adhesion, and collapse), which can restrict flow, concentrate stress, and precipitate rupture and unplanned shutdowns. Conventional ultrasonic testing and magnetic flux leakage have limited sensitivity to such instabilities, while standard eddy-current testing is impeded by the ferromagnetic substrate’s high permeability and electromagnetic shielding. This study introduces magnetically saturated pulsed eddy-current testing (MS-PECT). A quasi-static bias field drives the substrate toward magnetic saturation, reducing differential permeability and increasing effective penetration; combined with pulsed excitation and differential reception, the approach improves defect responsiveness and the signal-to-noise ratio. A prototype was developed and evaluated through mechanistic modeling, numerical simulation, laboratory pipe trials, and in-service demonstrations. Field deployment on composite pipelines at the Hutubi UGS (Xinjiang, China) enabled rapid identification and spatial localization of liner collapse under non-shutdown or minimally invasive conditions. MS-PECT provides a practical tool for composite-pipeline integrity management, reducing the risk of unplanned outages, enhancing peak-shaving reliability, and supporting resilient UGS operations. Full article

The piezoelectric coating structure constitutes the main configuration of contemporary energy harvesting systems, and its development requires accurate modeling of electromechanical coupling behavior under mechanical loads. The present work prepares a framework to analyze orthotropic piezoelectric coating–substrate systems; based on the fundamental solution theory, it derives two-dimensional Green functions from closed-form elementary functions. The formulation can establish the mesh-free solution paradigm through addressing tangential line force loading onto a coated surface. This method helps reconstruct full-field electromechanical responses upon arbitrary mechanical loading by integrating superposition principles and Gaussian quadrature technologies. An important application is in optimizing coating thickness, where parametric research suggests that piezoelectric layer geometry is non-linearly correlated with energy conversion efficiency. Notably, analytical sensitivity coefficients of this framework contribute to gradient-based optimization algorithms, which enhances efficiency compared with traditional empirical frameworks. Full article

Urban underground infrastructure is increasingly challenged by material aging, environmental degradation, and structural deterioration. In response, trenchless polymer grouting technologies employing sustainability-oriented two-component foaming polymers have attracted growing attention. To investigate shear behavior at the polymer–concrete interface, this study conducted direct shear tests on two types of composite interface geometries—curved and planar—formed by bonding two-component foaming polymer to concrete substrates. Five polymer densities (0.33, 0.42, 0.51, 0.58, 0.66 g/cm³), three concrete strengths (C20, C30, C40), three normal stress levels (0.3, 1.0, 2.0 MPa), three shear rates (0.5, 2.0, 5.0 mm/min), and three interface sizes (100, 150, 200 mm) were examined. The results show that both interface types undergo five characteristic stages under shear. Across identical parameter levels, curved interfaces consistently exhibited higher peak shear strength and larger peak displacement than planar ones. When the polymer density is identical, the peak shear strength and displacement of curved specimens are about 1.38 and 1.43 times those of planar specimens, respectively. Similarly, for specimens with the same concrete strength, normal stress, and shear rate, the corresponding ratios of peak shear strength and displacement are about 1.14 and 1.55, 1.96 and 1.43, and 1.43 and 1.36, respectively. Within the tested ranges, the shear stress increases with polymer density, concrete strength, and normal stress, and generally decreases with shear rate. The shear displacement decreases with polymer density, concrete strength, and shear rate, and generally increases with normal stress. As the specimen size increases, the peak shear strength and peak shear displacement of the curved specimens first increase and then decrease, whereas for the planar specimens, the peak shear strength exhibits a nonlinear increasing trend. These findings provide valuable insights to promote sustainable underground infrastructure rehabilitation. Full article

In the Chondrichthyes Raja asterias and Myliobatis aquila and in the Teleost Sparus aurata, the appendicular skeleton of the pectoral fins (including the calcified structures of the mouth in M. aquila) was investigated to find out how the specific skeletal segments were formed and stiffened over the course of evolution, not only with regard to the adaptation of the ontogenesis of the cartilage “anlagen” to the mechanical requirements of locomotion in the water column, but also to the specific feeding habits (durophagy) of M. aquila. The morphology of the pectoral fins of the three species showed a different layout, characterized by the geometry of the basic units (aligned tesserae and calcified radial columns), which provide varied flexibility of the pectoral fins, suggesting an adaptation to the “pelagic” and “benthic” locomotion patterns in the environment where the species live. The morphology of the calcified structures in the mouth of M. aquila showed the presence of two different masticatory systems: the first (external) with the rows of teeth resting on the maxillary and mandibular arches, and the second (internal, in the oral cavity) with the symphyseal plates specialized for durophagy. Chemical–physical analyses revealed that the calcified cartilage matrix of the Chondrichthyes fin rays, teeth and durophagy plates is stiffened by the same Ca₃(PO₄)₂ mineral phase deposed in the organic matrix of the Teleost S. aurata fins (with the characteristic SEM morphological texture of calcified bone matrix). The hitherto unknown presence of two different chewing systems in M. aquila documents an evolutionary adaptation to nutritional requirements that can be explained by two hypotheses: the coexistence of two functioning systems in current specimens, allowing for the ingestion of harder and softer prey (or plant food), or the persistence of a rudimentary dentition that is no longer used (vestigial dentition). Furthermore, the texture of the calcified matrix in teleost fishes, as observed by scanning electron microscopy, may indicate a bone-like organic matrix substrate, similar to that found in endochondral ossification. Full article

We report an efficient, high-yield method for synthesizing dumbbell-shaped conjugates composed of gold nanoparticles (AuNPs) connected by double-stranded (ds) DNA. The dsDNA, bearing terminal thiol groups, was covalently attached to two AuNPs to form uniform constructs comprising either 15 nm or 25 nm particles bridged by 38 base pairs (bp) or 100 bp dsDNA. The dumbbells were purified by gel electrophoresis and exhibited high stability, remaining intact for several days in pure water or buffers at ambient temperature. Deposition onto solid substrates followed by drying, however, led to their partial structural collapse. TEM imaging showed that deposition on carbon grids typically yielded dumbbell structures with interparticle gaps of only 1–2 nm, suggesting that the dsDNA bridge contracts during deposition and drying. However, deposition on polylysine-coated mica for AFM imaging preserved the native geometry, with the gaps consistent with the expected DNA length. Our results reveal that deposition significantly affects the structure and integrity of dsDNA bridges in dumbbell constructs, highlighting the importance of appropriate substrate and surface coating selection for reliable characterization of DNA properties in dried dumbbells. Full article

The pore structure of cocopeat-based substrates critically influences their hydraulic properties, directly affecting water use efficiency in soilless cultivation systems. Previous macroscopic modeling approaches infer pore structures indirectly from water retention curves and rely on empirical parameterization of pore geometry and connectivity, overlooking microscale features that directly control fluid pathways and permeability. To address this gap, this study employed micro-CT imaging to reconstruct the three-dimensional pore structures of coarse cocopeat and a fine cocopeat–perlite mixture. Nine regions of interest (ROIs), representing three typical pore types in each substrate, were selected for quantitative pore structure analysis and pore-scale saturated flow simulations. Results show that over 90% of pore diameters in both substrates fall within the 0–400 μm range, and variations in cocopeat particle size and perlite addition significantly affect average pore diameter, porosity, fractal dimension, and tortuosity, thereby influencing permeability and local flow distribution. This study provides new insights into the microscale mechanisms governing water movement in cocopeat-based substrates and reveals key structural factors regulating hydraulic behavior in soilless cultivation systems. Full article

This paper presents a high-gain wide-band planar antenna with a Reconfigurable Intelligent Surface (RIS) for modern wireless communication applications. The antenna consists of two main parts, a basic antenna part with cross-line slots and two light-dependent resistor switches, and a second part based on the RIS layer for beam steering. The RIS is constructed from 5 × 5-unit cells with two sides, forming a square geometry. The antenna substrate is a dielectric layer of FR4 epoxy glass with a thickness of 1.6 mm. The RIS inclusions are designed and tested numerically to achieve the desired electromagnetic properties at the frequency band of interest. The fabricated prototype shows a wide band covering frequencies from 0.9 GHz to 3.5 GHz with S11 below −10 dB, achieving an antenna gain varying from 10.5 dBi up to 16.8 dBi. Experimental measurements show effective aperture usage in all configurations, and beam steering from +22° to −22° is accomplished without degrading side-lobe levels. The proposed antenna performance is tested against real-world measurements to evaluate channel performance in terms of bit error rate (BER) and channel capacity (CC). The proposed LDR-controlled design achieves compact beam steering with minimal insertion loss, unlike conventional RIS-assisted antennas that rely on PIN or varactor switches. Full article

Conventional ridging and mulching machines struggle to perform effectively in yellow sand substrates due to their loose texture, high collapsibility, and strong fluidity, which compromise ridge stability and operational quality. To address these challenges, this study proposes the development of an integrated rotary tillage, ridging, and film-mulching machine specifically designed to meet the agronomic requirements of tomato cultivation in greenhouse environments with yellow sand substrate. Based on theoretical analysis and parameter calculations, a soil transportation model was established, and the key structural parameters—such as blade arrangement and helical shaft geometry—were determined. A discrete element method (DEM) simulation was employed to construct a contact model for the yellow sand–slag mixed substrate. A combination of single-factor experiments and Box–Behnken response surface methodology was used to investigate the effects of forward speed, shaft rotational speed, and tillage depth on ridge stability and operational performance. The simulation results indicated that a forward speed of 0.82 m·s⁻¹, shaft speed of 260 rpm, and tillage depth of 150 mm yielded the highest ridge stability, with an average of 95.7%. Field trials demonstrated that the ridge top width, base width, height, and spacing were 598.6 mm, 802.3 mm, 202.4 mm, and 1002.8 mm, respectively, with an average ridge stability of 94.3%, differing by only 1.4 percentage points from the simulated results. However, a quantitative traction/energy comparison with conventional equipment was not collected in this study, and we report this as a limitation. The energy consumption is estimated based on power usage and effective field capacity (EFC) under similar operating conditions. Soil firmness reached 152.1 kPa, fully satisfying the agronomic requirements for tomato cultivation. The proposed machine significantly improves operational adaptability and ridge stability in yellow sand substrate conditions, providing robust equipment support for efficient greenhouse farming. Full article