Search Results (24,243)

In engineering practice, additively manufactured (AM) metal and metal alloy structural components, which often contain geometric discontinuities to fulfil functional requirements, are subjected to cyclic service loads. Among the possible loading configurations, far-field Mode I loading is frequently considered as a nominal reference condition. Within this context, a methodology for the fatigue assessment of notched AM Scalmalloy components subjected to Mode I far-field loading is proposed, combining the Strain Energy Density (SED) approach with a multiaxial critical plane-based fatigue criterion. The fatigue assessment is carried out at a verification point whose position is defined as a function of the characteristic length of the SED control volume for Mode I loading, determined through two alternative procedures, and of the surface roughness of the component. The proposed methodology is validated against experimental fatigue data available in the literature for AM Scalmalloy specimens featuring a circumferential semi-circular notch and subjected to Mode I far-field cyclic loading, which induces a locally multiaxial stress state at the notch root, given that the formulation does not rely on material-specific assumptions and could in principle be extended to other notched AM metal and metal alloy components. Full article

This paper investigates the linear stability of Navier–Stokes–Voigt (NSV) fluid flow in a channel filled with a homogeneous porous medium under general asymmetric slip boundary conditions. This study bridges the research gap between idealized theoretical models (uniform coating) and realistic engineering surfaces in superhydrophobic channels. In practice, manufacturing defects often lead to non-uniform slip distributions. By solving the generalized eigenvalue problem using the Chebyshev spectral collocation method, we quantify the sensitivity of the critical Reynolds number to symmetry breaking. The results reveal that symmetric slip achieves optimal stability, whereas symmetry breaking causes a significant destabilizing effect. Energy analysis clarifies the physical origin of this instability. Furthermore, we find that increasing the porous medium permeability parameter or the Voigt regularization parameter effectively counteracts the slip-induced instability. Specifically, flow stability can be restored even under highly asymmetric slip conditions if the porous damping or the viscoelastic regularization effect is sufficiently strong. This implies that inevitable manufacturing defects in engineering can be compensated for by optimizing the porous medium matrix. Full article

Underground gas storage (UGS) in salt caverns is increasingly important for a flexible and secure energy supply and for stabilizing the gas market. However, cavern operations can induce surface ground movements that must be monitored to safeguard infrastructure integrity and environmental compatibility. This research analyzes horizontal (W–E) and vertical ground movements above the cavern field Gronau-Epe in northwestern Germany, using radar interferometry (InSAR), specifically the SBAS (Small Baseline Subset) approach, combined with clustering and multi-criteria analysis. The study was conducted in cooperation between Uniper Energy Storage GmbH, the Research Center for Post Mining at THGA Bochum, and the company EFTAS. Freely available Copernicus Sentinel 1 data were integrated with public soil maps and operational storage information. A multistage workflow quantified deformation patterns, classified coherent deformation zones via clustering, and evaluated geological and technical drivers using multi-criteria analysis to better distinguish operational (primary) from overburden (secondary) influences. Results reveal long term deformation trends closely linked in time and space to injection/withdrawal cycles. Locally confined vertical and horizontal movements near caverns are attributed to salt convergence triggered by cyclic pressure changes, but they are linked to (hydro)geological and pedological factors. The developed approach shows strong monitoring potential in addition to classic mine surveying. Full article

Catalytic materials are central to the advancement of hydrogen generation technologies, playing a pivotal role in enabling sustainable, carbon-neutral energy systems. Hydrogen can be produced via electrochemical water splitting, thermochemical reforming, or photocatalysis—each imposing unique performance requirements on catalysts in terms of activity, selectivity, stability, and efficiency. While traditional noble metals (e.g., platinum, ruthenium, iridium) provide benchmark catalytic activity, their widespread use is hindered by scarcity, high cost, and limited long-term durability. Consequently, researchers have increasingly focused on earth-abundant alternatives such as transition metals (Ni, Co, Fe, Mo), alloys, metal oxides, carbides, sulfides, nitrides, and carbon-based systems. Among these, two-dimensional materials, particularly the MXene family, have attracted significant attention due to their metallic conductivity, layered structure, and tunable surface chemistry. These features enable rapid charge transfer and abundant active sites, making MXenes and related nanostructured catalysts promising for both the Hydrogen Evolution Reaction (HER) and Oxygen Evolution Reaction (OER) across a wide range of electrochemical conditions. Parallel efforts have integrated novel semiconductors, plasmonic nanomaterials, and hybrid heterostructures to improve the efficiency of solar-to-hydrogen energy conversion. This paper reviews the main types of catalytic materials used in hydrogen production, explains their design strategies and structure–performance relationships, and discusses key engineering challenges such as integrating renewable energy sources, scaling up manufacturing, and ensuring long-term durability in real-world systems. Future research goals are also highlighted, including the development of affordable non-noble catalysts, enhancing catalyst stability through surface and defect engineering, and coupling hydrogen production with circular economy principles, all of which are essential to making hydrogen generation more efficient, scalable, and cost-effective as the world transitions to clean and sustainable energy. Full article

Density functional theory (DFT) was used to investigate how bisubstitution doping in graphene alters its electronic structure and interfacial stability with two model lignocellulosic binders, carboxymethylcellulose (CMC), and a representative aromatic fragment (LCmA). The properties were evaluated at the ωB97X-D/LANL2DZ level for pristine graphene and its bisubstitution-doped variants with nitrogen (graphene-2N) and sulfur (graphene-2S), integrating frontier orbitals, electrostatic potential (ESP) maps, electronic localization functions (ELF/LOL), and QTAIM topology. Doping with 2N markedly reduces the HOMO–LUMO gap from 0.16052 eV (graphene) to 0.10560 eV (−34.2%), while 2S reduces it to 0.14222 eV (−11.4%), evidencing different electronic activation mechanisms. The interaction energies show doping-controlled selectivity: In pristine graphene, adsorption strongly favors LCmA ($\mathsf{\Delta }{E}_{int}$ = −99.3 kcal·mol⁻¹) over CMC (−23.7 kcal·mol⁻¹); in graphene-2N, CMC coupling intensifies (−93.7 kcal·mol⁻¹) while maintaining a high interaction with LCmA (−74.3 kcal·mol⁻¹); and in graphene-2S, CMC remains favorable (−71.9 kcal·mol⁻¹) while LCmA falls to a practically marginal regime (−4.1 kcal·mol⁻¹). QTAIM the presence of confirms closed-layer interactions in all complexes (∇²Pc > 0, H > 0, |V|/G < 1), with |V|/G close to unity for graphene–LCmA (0.994) and less compaction when doped with 2N (0.760 for 2N–LCmA). The bisubstitution modulates the electronic heterogeneity of the basal plane and redefines the binder–surface compatibility, favoring the multipoint anchoring of polar ligands in 2N and penalizing efficient aromatic stacking in 2S. Full article

The Compact Strip Production (CSP) process is the latest version of thin-slab continuous casting, combining both casting and rolling, thus improving the CSP process’s energy efficiency and the strip quality. Modeling the combined phenomena of fluid flow, heat transfer and solidification in CSP casting remains an unresolved multiphysics problem, particularly when boron and other alloying elements enter the system and modify the thermal properties and solidification behavior. In this study, we propose a more integrated approach by executing a computational fluid dynamics (CFD) model at different scales, blending macroscale fluid flow and heat transfer with meso-solidification that is molten in a CSP casting model. For the macroscale model, we solve the Reynolds-Averaged Navier–Stokes (RANS) equations with one of the energy equations, while the mesoscale model uses the solid fraction evolution algorithm to model the multiphase latent heat of solidification and the motion of solid and liquid phases of a non-equilibrium system. Mold heat flux, free surface cooling and secondary spray zones were used to set the boundary conditions. The model simulates temperature distributions at different times, the solid fraction below the liquidus and the trends in shell growth for different process parameters and the time profile of the solidification. The improved prediction capability of the model, demonstrated by the results, opens the opportunity to reduce the process parameters of casting speed and cooling to defect-free results. Comparisons with the most recent studies on continuous casting processes (including CSP and thin slabs) demonstrate alignment with the thermal gradient and solidification behavior characteristics. The thermal gradients and solidification behavior characteristics were obtained. The research yields the basis for developing microstructure and segregation models with boron-alloyed steels. Full article

Laser processing has been widely investigated as an effective approach for improving surface properties and consolidating advanced materials, particularly complex alloys such as titanium aluminides (TiAl). In this study, laser surface remelting was applied to binary (Ti-45Al) and ternary (Ti-45Al-2Co and Ti-45Al-2Ni) alloys produced by powder metallurgy via blended elemental (BE) and pre-alloyed (PA) powder routes. Laser powers of 50 and 100 W were employed, resulting in a high-energy-density surface remelting regime applied to both green compacts and sintered samples with relatively high initial porosity, under an argon-controlled atmosphere. Microstructural and phase analyses were performed using scanning electron microscopy (SEM) and X-ray diffraction (XRD), while mechanical behavior was assessed by instrumented microindentation. Laser processing promoted the formation of a dense and homogeneous surface layer, approximately 150 μm thick, accompanied by significant microstructural refinement and enhanced hardness and elastic modulus. While rapid solidification led to crack formation in laser-treated sintered samples, the green compacts exhibited defect-free modified layers. Overall, the results demonstrate that laser surface remelting is an effective strategy for enhancing the surface integrity and mechanical performance of TiAl alloys processed by powder metallurgy. Full article

To investigate the influence of asymmetric support clearances (caused by manufacturing and assembly tolerances in practical engineering) on the fretting wear behavior of steam generator heat exchange tubes, this study focuses on 2.25Cr-1Mo alloy heat exchange tubes and 405 stainless steel anti-vibration bars. A high-precision impact wear test platform with adjustable bilateral clearances was designed, and its dynamic reliability was verified by theoretical calculations, finite element simulations and modal tests. An experimental model with asymmetric clearances (0.15 mm and 0.20 mm) was established to study the nonlinear contact force response and wear evolution under excitation frequencies of 60 Hz, 65 Hz and 70 Hz. The results show that asymmetric clearances induce two contact modes: high-frequency “quasi-static friction” on the small-clearance side and intermittent “collision-rebound-flight” impacts on the large-clearance side. The system exhibits a clear excitation instability threshold that shifts backward with increasing excitation frequency. The 0.20 mm side triggers dynamic instability, with wear volume and rate increasing explosively (106.2% and 41.36% at 65 Hz) beyond the threshold. Microscopic analysis reveals that the wear mechanism on the large-clearance side transitions from mild abrasive wear to severe fatigue delamination when crossing the threshold, with surface morphology deteriorating sharply from faint contact spots to extensive spalling craters. This study clarifies the energy distribution mechanism and identifies the large-clearance side as the core “trigger” for system instability and catastrophic failure, providing a theoretical basis for nuclear heat exchange tube monitoring and anti-vibration design. Full article

Dust pollution has emerged as a critical issue in a wide range of industrial applications, creating an urgent demand for effective strategies to mitigate particle deposition. Recent experimental studies have demonstrated that superhydrophobic coatings represent a promising class of self-cleaning materials, primarily attributed to their hierarchical rough structures and intrinsically low surface energy. Nevertheless, the underlying self-cleaning mechanisms of superhydrophobic surfaces have not yet been fully elucidated. This work examines particle deposition on superhydrophobic surfaces featuring stochastic roughness distributions through computational modeling. Surface topographies were generated using Fast Fourier Transform techniques. An integrated lattice Boltzmann–discrete element method (LBM–DEM) framework simulated particle transport in superhydrophobic-coated channels. Particle–fluid coupling was achieved via the immersed moving boundary approach, while particle–surface interactions employed a modified Johnson–Kendall–Roberts (JKR) adhesion model. Parametric studies quantified effects of particle size, interfacial energy, flow Reynolds number, and topographical statistics on deposition dynamics. Experimental validation demonstrates good agreement between numerical predictions and measurements. Smaller particles exhibit a lower tendency to deposit on superhydrophobic surfaces, whereas increasing surface energy significantly enhances particle deposition due to stronger adhesion forces and the suppression of particle resuspension. In addition, higher Reynolds numbers effectively reduce particle deposition. The revealed self-cleaning mechanisms provide theoretical guidance for the design of high-performance self-cleaning coatings, and the identified effects of particle and surface parameters offer practical insights for anti-pollution engineering applications. Full article

Permanent magnet synchronous machines (PMSMs) are widely used in high-performance drive systems. However, parasitic torque ripple remains a critical limitation, causing acoustic noise, mechanical vibration, and speed fluctuations. This study presents a compact, model-based torque control strategy for surface-mounted PMSMs (SPMSMs) that suppresses torque ripple by generating a structured current reference. Grounded in the magnetic co-energy principle, the proposed method utilizes a deterministic analytical model to compensate for cogging torque and inductance harmonics, avoiding computationally intensive iterative estimators. A primary contribution involves adapting the harmonic injection profile to varying loads and magnetic saturation levels. Comprehensive finite element analysis (FEA) co-simulations demonstrate that the proposed method reduces torque ripple by approximately 87.5% and speed ripple by over 90% at 1500 RPM compared to conventional maximum torque per ampere (MTPA) strategies. Furthermore, extended dynamic analysis confirms superior robustness during start-up, transients, and low-speed operation (100 RPM), maintaining high control authority even under deep magnetic saturation (2.0 p.u.). Performance evaluations verify that this significant enhancement in torque quality is achieved with a negligible increase in total power losses (~2.1%), presenting a computationally feasible solution for industrial embedded platforms. Full article

Textile materials represent a versatile class of engineering substrates widely used in apparel, domestic products, and medical protective systems. Despite their extensive application, large-scale textile production has seen limited integration of fundamentally new functionalization strategies. In recent years, however, advances in materials science have enabled the development of textiles with tailored electrical, adaptive, and biological functionalities. This review summarizes recent progress in the functionalization of textile materials with a focus on approaches relevant to engineering and industrial implementation. Particular attention is given to conductive textiles designed for operation under extreme environmental conditions, including low-temperature climates. Methods for integrating electrically conductive elements into fibrous structures are discussed, highlighting their potential for sensing, thermal regulation, and energy-related applications such as powering portable electronic devices. Inkjet printing is presented as a scalable technique for high-resolution deposition of conductive patterns while preserving the mechanical integrity and aesthetic properties of textile substrates. In addition, adaptive and stimuli-responsive textile systems are reviewed, including materials capable of responding to thermal, optical, or chemical stimuli, with applications in camouflage, wearable systems, and multifunctional surfaces. The review further addresses the development of bioactive textiles, emphasizing antibacterial functionalization using organic and inorganic agents to mitigate the spread of pathogenic microorganisms. The relevance of such materials has been underscored by recent global viral outbreaks. Overall, this work aims to provide a materials science perspective on emerging textile functionalization strategies and to facilitate the transition of these technologies from laboratory-scale research to practical engineering applications. Full article

The study investigates the catalytic activity of vanadium-containing catalysts in the selective oxidation of 4-methylpyridine (4-MP) in the gas phase. V-Cr, V-Ti, and V-Ti-Cr catalysts were synthesised and studied. The phase composition and structural features of the catalysts were determined by X-ray diffraction (XRD) and Raman spectroscopy, and their thermal stability was investigated using thermogravimetric analysis (TGA/DTA). Textural characteristics were evaluated by low-temperature nitrogen adsorption–desorption (BET, BJH), surface morphology was studied using scanning electron microscopy (SEM), and the distribution of elements was investigated using energy-dispersive X-ray spectroscopy (EDX). The chemical composition of the catalysts was determined using inductively coupled plasma atomic emission spectrometry (ICP-OES) and catalytic activity was evaluated in the selective gas-phase oxidation reaction of 4-methylpyridine in the temperature range 280–380 °C. It was found that an increase in temperature is accompanied by an increase in the conversion of 4-methylpyridine, but at the same time, deep oxidation reactions intensify. The best result is achieved on the V-Ti-Cr catalyst, for which the conversion of 4-MP reaches 86.88% and the selectivity is 73.06% at 320 °C. However, V-Ti provides moderate stable performance, while V-Cr demonstrates relatively low efficiency. Thus, it can be concluded that the nature of the temperature dependence of 4-methylpyridine conversion reflects the different nature of the active centres and their stability. Full article

To address the shortage of natural sand and the unclear mechanism of lithology’s influence on the application of manufactured sand, this study explores the applicability of neutral rock manufactured sand in asphalt mixtures. Taking neutral diabase manufactured sand as the research object, a series of tests including the Marshall test, water stability test, high- and low-temperature stability test, and surface free energy (SFE) test were conducted to systematically analyze the effects of aggregate lithology on the volumetric indicators, road performance, and interface adhesion of asphalt mixtures. Additionally, the improvement effect of cement as an anti-stripping agent was verified. The results show that lithology of manufactured sand significantly regulates the performance of asphalt mixtures. In terms of volumetric indicators, the limestone manufactured sand mixture has the smallest void ratio (3.81%), while the diabase manufactured sand mixture has the largest (5.81%), requiring an appropriate increase in the mixing ratio of diabase manufactured sand to optimize the compaction effect. For water stability, the short-term performance ranks as diabase ≈ limestone > granite, and the long-term durability ranks as limestone > diabase > granite. A least-squares linear regression model demonstrated that the polar component of aggregate surface free energy exhibits a strong positive correlation with asphalt–aggregate adhesion work (R² = 0.92), which quantitatively explains variations in the 48 h immersed Marshall residual stability ratio among different lithologies. Regarding high-temperature stability, the order is diabase > limestone > granite. Thanks to its low crushing value and strong angularity, the diabase manufactured sand mixture achieves a dynamic stability of 12,629 times/mm at 60 °C, showing the best rutting resistance. In terms of low-temperature performance, the diabase manufactured sand mixture exhibits the optimal initial crack resistance (maximum flexural strain of 2757 με) and long-term durability (strain attenuation rate of 11.7% after 30 cycles), while the granite manufactured sand mixture fails to meet the design requirements. Adding 1.5%~2.0% cement can significantly improve the adhesion between manufactured sand and asphalt, with more obvious enhancement effects on granite and diabase, thereby optimizing water stability and high-temperature stability. The research results provide theoretical support and technical reference for the scientific selection and engineering application of fine aggregates in asphalt pavements. Full article

Micro heat exchangers (MHXs) have emerged as a critical technology for advanced thermal management in the food and pharmaceutical industries due to their high surface area-to-volume ratios, compact design, and precise temperature control. This review provides a systematic and integrated analysis of MHX technology, covering their fundamental principles, classification, design methodologies, performance enhancement techniques, and industrial applications. Unlike existing reviews, the present work establishes a unified framework that links microscale heat transfer mechanisms, such as Brownian motion, surface corrugation effects, and non-dimensional parameters, with practical design choices, manufacturing routes, and the process requirements specific to food and pharmaceutical systems. The subsequent sections explore the key performance-influencing factors, including channel geometry, surface enhancement strategies, nanofluid utilization, and governing non-dimensional numbers (e.g., Nusselt, Reynolds, and Knudsen numbers), which are systematically compared across different operating regimes. Recent advances in materials and fabrication techniques, such as laser ablation, lithography, micro-milling, embossing, and additive manufacturing, are analyzed with respect to their scalability, thermal–hydraulic performance, and industrial feasibility. Furthermore, the review highlights the emerging trends in micro heat exchanger (MHX) optimization, including computational fluid dynamics (CFD)-driven design, smart monitoring systems, and energy-efficient integration within processing lines. Finally, the paper also identifies the key challenges and limitations of micro heat exchangers, including pressure drop, fouling, scaling, manufacturing complexity, and cost constraints. These are critically discussed along with future research directions aimed at improving reliability and sustainability. By consolidating the dispersed research outcomes into a coherent, design-oriented perspective, this review offers new insights and practical guidance for researchers, engineers, and industry practitioners seeking to advance the deployment of MHXs in food and pharmaceutical processing. Full article

Gel polymer electrolytes (GPEs) typically suffer from sluggish kinetics and interfacial instability at elevated temperatures and high voltages. Herein, 3-(trifluoromethyl)-1H-1,2,4-triazole (TTA) is employed to construct an ultrathin (~25 μm), robust, and homogeneous GPE. TTA acts as a molecular bridge, significantly improving compatibility between the PVDF-HFP (Poly(vinylidene fluoride-co-hexafluoropropylene)) matrix and LLZTO (Li_6.4La₃Zr_1.4Ta_0.6O₁₂) fillers to create continuous ion-conducting pathways. Consequently, the TTA-GPEs exhibits high ionic conductivity (0.267 mS cm⁻¹ at room temperature), low activation energy (0.181 eV), and an increased lithium-ion transference number (0.425). Advanced surface analysis reveals that TTA preferentially reacts to form a dense, gradient hierarchical interphase (solid electrolyte interphase/cathode electrolyte interphase, SEI/CEI) enriched with inorganic species (LiF, Li₃N, and Li₂S) on the inner side. This architecture suppresses parasitic reactions and lithium dendrite growth. Accordingly, NCM811(LiNi_0.8Co_0.1Mn_0.1O₂)//Li batteries with TTA-GPEs demonstrate stable cycling at 80 °C and 1C, retaining 57.68% capacity after 125 cycles—significantly outperforming benchmarks. This study offers a molecular engineering strategy to simultaneously optimize bulk transport and interfacial stability for high-energy-density solid-state batteries. Full article