Search Results (1,801)

This study investigates the strengthening mechanisms of char in silicon dioxide thermal reduction through systematic high-temperature experiments using three char types (YQ1, CW1, HY1) characterized by X-ray diffraction, Raman spectroscopy, transmission electron microscopy, and scanning electron microscopy. HY1 char demonstrated superior reactivity due to its highly ordered microcrystalline structure, characterized by the largest aromatic cluster size (L_a) and lowest defect ratio (I_D/I_G = 0.37), which directly correlated with enhanced reaction completeness. The carbon–silicon reaction reactivity increased progressively with temperature, achieving optimal performance at 1550 °C. Addition of Fe and Fe₂O₃ significantly accelerated the reduction process, with Fe₂O₃ exhibiting superior catalytic performance by reducing activation energy and optimizing reaction kinetics. The ferrosilicon formation mechanism proceeds through a two-stage pathway: initial char-SiO₂ reaction producing SiC and CO, followed by SiC–iron interaction generating FeSi, which catalytically promotes further reduction. These findings establish critical structure–performance relationships for char selection in industrial silicon production, where microcrystalline ordering emerges as the primary performance determinant. The identification of optimal temperature and additive conditions provides practical pathways to enhance energy efficiency and product quality in silicon metallurgy, enabling informed raw material selection and process optimization to reduce energy consumption and improve operational stability. Full article

Secondary hypereutectic Al-Si alloys are attractive for sustainable manufacturing, yet their application is often limited by low strength and electrical conductivity due to impurity-induced microstructural defects. Achieving a balance between mechanical and conductive performance remains a significant challenge. In this work, nickel-coated carbon nanotubes (Ni-CNTs) were introduced into secondary Al-20Si alloys to tailor the microstructure and enhance properties through interfacial engineering. Composites containing 0 to 0.4 wt.% Ni-CNTs were fabricated by conventional casting and systematically characterized. The addition of 0.1 wt.% Ni-CNTs resulted in the best combination of properties, with a tensile strength of 170.13 MPa and electrical conductivity of 27.60% IACS. These improvements stem from refined α-Al dendrites, uniform eutectic Si distribution, and strong interfacial bonding. Strengthening was achieved through grain refinement, Orowan looping, dislocation generation from thermal mismatch, and the formation of reinforcing interfacial phases such as AlNi₃C₀.₉ and Al₄SiC₄. At higher Ni-CNT contents, property degradation occurred due to agglomeration and phase coarsening. This study presents an effective and scalable strategy for achieving strength–conductivity synergy in secondary aluminum alloys via nanoscale interfacial design, offering guidance for the development of multifunctional lightweight materials. Full article

Background and Objectives: Lower limb defects often present significant reconstructive challenges due to limited soft tissue availability and exposure of critical structures. Perforator-based flaps offer reliable solutions, with minimal donor site morbidity. This study aimed to evaluate the efficacy of infrared thermography (IRT) in preoperative planning and postoperative monitoring of perforator-based flaps, assessing its accuracy in identifying perforators, predicting complications, and optimizing outcomes. Materials and Methods: A prospective observational study was conducted on 76 patients undergoing lower limb reconstruction with fascio-cutaneous perforator flaps between 2022 and 2024. Perforator mapping was performed concurrently with IRT and Doppler ultrasonography (D-US), with intraoperative confirmation. Flap design variables and systemic parameters were recorded. Postoperative monitoring employed thermal imaging on days 1 and 7. Outcomes were correlated with thermal, anatomical, and systemic factors using statistical analyses, including t-tests and Pearson correlation. Results: IRT showed high sensitivity (97.4%) and positive predictive value (96.8%) for perforator detection. A total of nine minor complications occurred, predominantly in patients with diabetes mellitus and/or elevated glycemia (p = 0.05). Larger flap-to-defect ratios (A/C and B/C) correlated with increased complications in propeller flaps, while smaller ratios posed risks for V-Y and Keystone flaps. Thermal analysis indicated significantly lower flap temperatures and greater temperature gradients in flaps with complications by postoperative day 7 (p < 0.05). CRP levels correlated with glycemia and white blood cell counts, highlighting systemic inflammation’s impact on outcomes. Conclusions: IRT proves to be a reliable, non-invasive method for perforator localization and flap monitoring, enhancing surgical planning and early complication detection. Combined with D-US, it improves perforator selection and perfusion assessment. Thermographic parameters, systemic factors, and flap design metrics collectively predict flap viability. Integration of IRT into surgical workflows offers a cost-effective tool for optimizing reconstructive outcomes in lower limb surgery. Full article

One of the advantages of the EPR spectroscopy method in assessing structural defects caused by irradiation is the fact that using this method it is possible to determine not only the concentration dependences of the defect structure but to also establish their type, which is not possible with methods such as X-ray diffraction or scanning electron microscopy. Based on the data obtained, the role of variation in the ratio of components in Li₄SiO₄–Li₂TiO₃ ceramics on the processes of softening under high-dose irradiation with protons simulating the accumulation of hydrogen in the damaged layer, as well as the concentration of structural defects in the form of oxygen vacancies and radiolysis products on the processes of high-temperature degradation of ceramics, was determined. It was found that the main changes in the defect structure during the prolonged thermal exposure of irradiated samples are associated with the accumulation of oxygen vacancies, the density of which was estimated by the change in the intensity of singlet lithium, characterizing the presence of E-centers. At the same time, it was found that the formation of interphase boundaries in the structure of Li₄SiO₄–Li₂TiO₃ ceramics leads to the inhibition of high-temperature degradation processes in the case of post-radiation thermal exposure for a long time. Also, during the conducted studies, the role of thermal effects on the structural damage accumulation rate in Li₄SiO₄–Li₂TiO₃ ceramics was determined in the case when irradiation is carried out at different temperatures. During the experiments, it was determined that the main contribution of thermal action in the process of proton irradiation at a fluence of 5 × 10¹⁷ proton/cm² is an increase in the concentration of radiolysis products, described by changes in the intensities of spectral maxima, characterized by the presence of defects such as ≡Si–O, SiO₄³⁻ and Ti³⁺ defects. Full article

Potassium bromide (KBr) thin films were deposited by resistive thermal evaporation at substrate temperatures ranging from 50 °C to 250 °C to systematically elucidate the temperature-dependent evolution of their physical properties. Structural, morphological, and optical characteristics were examined by X-ray diffraction (XRD), scanning electron microscopy (SEM), atomic force microscopy (AFM), and Fourier transform infrared spectroscopy (FTIR). The results reveal a complex, non-monotonic response to temperature rather than a simple linear trend. As the substrate temperature increases, growth evolves from a mixed polycrystalline texture to a pronounced (200) preferred orientation. Morphological analysis shows that the film surface is smoothest at 150 °C, while the microstructure becomes densest at 200 °C. These structural variations directly modulate the optical constants: the refractive index attains its highest values in the 150–200 °C window, approaching that of bulk KBr. Cryogenic temperature (6 K) FTIR measurements further demonstrate that suppression of multi-phonon absorption markedly enhances the infrared transmittance of the films. Taken together, the data indicate that 150–200 °C constitutes an optimal process window for fabricating KBr films that combine superior crystallinity, low defect density, and high packing density. This study elucidates the temperature-driven structure–property coupling and offers valuable guidance for optimizing high-performance infrared and cryogenic optical components. Full article

Thermal analysis (TA) has been a valuable tool for controlling the carbon equivalent (CE) of cast irons. Additionally, this technique can provide enhanced control over melt quality, allowing for the avoidance of defects such as undesirable graphite morphology and the formation of carbides. To obtain the most valuable information from the TA, it is necessary to minimize the variations in the filling operation of the TA cups. However, the mass and pouring temperature of TA cups can vary in TA’s typical foundry operations. A design of experiments was performed to determine whether specific parameters of cooling curves used for quality control can distinguish the inoculation effect in the melt when the mass and the pouring temperature of TA cups are varied. The minimum temperature of the eutectic arrest proved to be a robust inoculation potential control parameter when variations in the cup’s mass were within a range of 268–390 g and were filled at any pouring temperature between 1235 and 1369 °C. Lighter cups under 268 g and poured at a low temperature are not suitable for controlling inoculation potential by TA; however, they remain helpful in controlling CE. These later cups are related to cooling times of less than 180 s, which can serve as a criterion for discarding unsuitable samples. A bimodal population of cell surfaces was revealed in the samples, with the population of small cells being proportionally more numerous in samples with lower TE_min values. Full article

Gypsum (CaSO₄·2H₂O) crystallization underpins numerous industrial processes, yet its response to chemical admixtures remains incompletely understood. This study investigates diffusion-controlled crystal growth in a coaxial test tube system to evaluate how three Sika^® ViscoCrete^® superplasticizers—430P, 111P, and 120P—affect nucleation, growth kinetics, morphology, and thermal behavior. The superplasticizers, selected for their surface-active properties, were hypothesized to influence crystallization via interfacial interactions. Ion diffusion was maintained quasi-steadily for 12 weeks, with crystal evolution tracked weekly by macro-photography; scanning electron microscopy and thermogravimetric/differential scanning were performed at the final stage. All admixtures delayed nucleation in a concentration-dependent manner. Lower dosages (0.5–1.0 wt%) yielded platy-to-prismatic morphologies and higher dehydration enthalpies, indicating more ordered lattice formation. In contrast, higher dosages (1.5–2.0 wt%) produced denser, irregular crystals and shifted dehydration to lower temperatures, suggesting structural defects or increased hydration. Among the additives, 120P showed the strongest inhibitory effect, while 111P at 0.5 wt% resulted in the most uniform crystals. These results demonstrate that ViscoCrete^® superplasticizers can modulate gypsum crystallization and thermal properties. Full article

This study explores the application of low-power vibrothermography (LVT) for detecting barely visible impact damage (BVID) in carbon fibre-reinforced polymer (CFRP) laminates. Composite specimens with varying impact energies (2.5–20 J) were excited using a single piezoelectric transducer with a nominal centre frequency of 28 kHz, operated at a fixed excitation frequency of 28 kHz. Thermal data were captured using an infrared camera. To enhance defect visibility and suppress background noise, the raw thermal sequences were processed using principal component analysis (PCA) and robust principal component analysis (RPCA). In LVT, RPCA and PCA provided comparable signal-to-noise ratios (SNR), with no consistent advantage for either method across all cases. In contrast, for pulsed thermography (PT) data, RPCA consistently resulted in higher SNR values, except for one sample. The LVT results were further validated by comparison with PT and phased array ultrasonic testing (PAUT) data to confirm the location and shape of detected damage. These findings demonstrate that LVT, when combined with PCA or RPCA, offers a reliable method for identifying BVID and can support safer, more efficient structural health monitoring of composite materials. Full article

Accurate evaluation of the thermal conductivity of UO₂ with defects is very significant for optimizing fuel performance and enhancing the safety design of reactors. We employed a method that combines the Boltzmann transport equation with DFT+U to calculate the thermal conductivity of UO₂ containing fission products and irradiation-induced point defects. Our investigation reveals that the thermal conductivity of UO₂ is influenced by defect concentration, defect type, and temperature. Fission products and irradiation defects result in a decrease in thermal conductivity, but they have markedly different impacts on phonon scattering mechanisms. Metal cations tend to scatter low-frequency phonons (less than 5.8 THz), while the fission gas xenon scatters both low-frequency and high-frequency phonons (greater than 5.8 THz), depending on its occupancy at lattice sites. Uranium vacancies scatter low-frequency phonons, while oxygen vacancies scatter high-frequency phonons. When uranium and oxygen vacancies coexist, they scatter phonons across the entire frequency spectrum, which further results in a significant reduction in the thermal conductivity of UO₂. Our calculated results align well with experimental data across a wide temperature range and provide fundamental insights into the heat transfer mechanisms in irradiated UO₂. These findings are essential for establishing a thermal conductivity database for UO₂ under various irradiation conditions and benefit the development of advanced high-performance UO₂ fuel. Full article

This study examines the effect of elevated printing speeds (100–600 mm/s) on the dimensional accuracy and tensile strength of PLA components fabricated via fused deposition modeling (FDM). To isolate the influence of printing speed, all other parameters were kept constant, and two filament variants—natural (unpigmented) and black PLA—were analyzed. ISO 527-2 type 1A specimens were produced and tested for dimensional deviations and ultimate tensile strength (UTS). The results indicate that printing speed has a marked impact on both geometric precision and mechanical performance. The optimal speed of 300 mm/s provided the best compromise between dimensional accuracy and tensile strength for both filaments. At speeds below 300 mm/s, under-extrusion caused weak layer bonding and air gaps, while speeds above 300 mm/s led to over-extrusion and structural defects due to thermal stress and rapid cooling. Black PLA yielded better dimensional accuracy at higher speeds, with cross-sectional deviations between 2.76% and 5.33%, while natural PLA showed larger deviations of up to 8.63%. However, natural PLA exhibited superior tensile strength, reaching up to 46.59 MPa, with black PLA showing up to 13.16% lower UTS values. The findings emphasize the importance of speed tuning and material selection for achieving high-quality, reliable, and efficient FDM prints. Full article

This study investigates the friction stir joining of AA6082-T6 aluminum alloy and Noryl GFN2 polymer in a buttstrap configuration, targeting the development of lightweight cylindrical-shaped structures where the polymer provides thermal, chemical, and electrical insulation, while the aluminum ensures mechanical integrity. A parametric analysis was carried out to assess the ability to produce friction stir buttstrap composite panels in a single processing step and assess the resulting tensile and flexural behavior. To that end, travel and rotating speeds ranging from 2150 to 2250 rpm, and 100 to 140 mm/min, respectively, were employed while keeping plunge depth and the tilt angle constant. A total of nine composite joints were successfully produced and subsequently subjected to both tensile and four-point bending tests. The tensile and flexural strength results ranged from 80 to 139 MPa, and 39 to 47 MPa, respectively. Moreover, the microstructural examination revealed that all joints exhibited a defect within the joining region and its size and shape had a significant effect on tensile strength, whereas the flexural strength was less affected with more uniform results. The joining region was also characterized by a decrease in hardness, particularly in the pin-affected region on the aluminum end of the joint, exhibiting a W-shaped pattern. Contrarily, on the polymeric end of the joining region, no significant change in hardness was observed. Full article

Polypropylene (EPP) concrete offers advantages such as low density and good thermal insulation properties, but its relatively low strength limits its engineering applications. Waste steel fibers (WSFs) obtained during the sorting and processing of machining residues can be incorporated into EPP concrete (EC) to enhance its strength and toughness. Using the volume fractions of EPP and WSF as variables, specimens of EPP concrete (EC) and waste steel fiber-reinforced EPP concrete (WSFREC) were prepared and subjected to cube compressive strength tests, splitting tensile strength tests, and four-point flexural strength tests. The results indicate that EPP particles significantly improve the toughness of concrete but inevitably lead to a considerable reduction in strength. The incorporation of WSF substantially enhanced the splitting tensile strength and flexural strength of EC, with increases of at least 37.7% and 34.5%, respectively, while the improvement in cube compressive strength was relatively lower at only 23.6%. Scanning electron microscopy (SEM) observations of the interfacial transition zone (ITZ) and WSF surface morphology in WSFREC revealed that the addition of EPP particles introduces more defects in the concrete matrix. However, the inclusion of WSF promotes the formation of abundant hydration products on the fiber surface, mitigating matrix defects, improving the bond between WSF and the concrete matrix, effectively inhibiting crack propagation, and enhancing both the strength and toughness of the concrete. Full article

Bird-dropping fouling and hotspot anomalies remain the most prevalent and detrimental defects in utility-scale photovoltaic (PV) plants; their co-occurrence on a single module markedly curbs energy yield and accelerates irreversible cell degradation. However, markedly disparate visual–thermal signatures of the two phenomena impede high-fidelity concurrent detection in existing robotic inspection systems, while stringent onboard compute budgets also preclude the adoption of bulky detectors. To resolve this accuracy–efficiency trade-off for dual-defect detection, we present YOLOv8-SG, a lightweight yet powerful framework engineered for mobile PV inspectors. First, a rigorously curated multi-modal dataset—RGB for stains and long-wave infrared for hotspots—is assembled to enforce robust cross-domain representation learning. Second, the HSV color space is leveraged to disentangle chromatic and luminance cues, thereby stabilizing appearance variations across sensors. Third, a single-head self-attention (SHSA) block is embedded in the backbone to harvest long-range dependencies at negligible parameter cost, while a global context (GC) module is grafted onto the detection head to amplify fine-grained semantic cues. Finally, an auxiliary bounding box refinement term is appended to the loss to hasten convergence and tighten localization. Extensive field experiments demonstrate that YOLOv8-SG attains 86.8% mAP@0.5, surpassing the vanilla YOLOv8 by 2.7 pp while trimming 12.6% of parameters (18.8 MB). Grad-CAM saliency maps corroborate that the model’s attention consistently coincides with defect regions, underscoring its interpretability. The proposed method, therefore, furnishes PV operators with a practical low-latency solution for concurrent bird-dropping and hotspot surveillance. Full article

Material extrusion additive manufacturing (MEAM) has emerged as a versatile and widely adopted 3D printing technology due to its cost-effectiveness and ability to process a diverse range of materials. However, achieving consistent part quality and repeatability remains a challenge, mainly due to variations in process parameters and material behavior during fabrication. In-situ monitoring and advanced process control systems have been increasingly integrated into MEAM to address these issues, enabling real-time detection of defects, optimization of printing conditions, reliability of fabricated parts, and enhanced control over mechanical properties. This review examines the state-of-the-art in-situ monitoring techniques, including thermal imaging, vibrational sensing, rheological monitoring, printhead positioning, acoustic sensing, image recognition, and optical scanning, and their integration with process control strategies, such as closed-loop feedback systems and machine learning algorithms. Key challenges, including sensor accuracy, data processing complexity, and scalability, are discussed alongside recent advancements and their implications for industrial applications. By synthesizing current research, this work highlights the critical role of in-situ monitoring and process control in advancing the reliability and precision of MEAM, paving the way for its broader adoption in high-performance manufacturing. Full article

Infrared thermography is a common approach used in building inspection for identifying building envelope thermal anomalies that cause energy loss and occupant thermal discomfort. Detecting these anomalies is essential to improve the thermal performance of energy-inefficient buildings through energy retrofit design and correspondingly reduce operational energy costs and environmental impacts. A thermal bridge is an unwanted conductive heat transfer. On the other hand, an infiltration/exfiltration anomaly is an uncontrollable convective heat transfer, typically happening around windows and doors, but it can also be due to a defect that comprises a building envelope’s integrity. While the existing literature underscores the significance of automatic thermal anomaly identification and offers insights into automated methodologies, there is a notable gap in addressing an automated workflow that leverages building envelope component segmentation for enhanced detection accuracy. Consequently, an automatic thermal anomaly identification workflow from visible and thermal images was developed to test it, utilizing segmented building envelope information compared to a workflow without any semantic segmentation. Therefore, building envelope images (e.g., walls and windows) were segmented based on a U-Net architecture compared to a more conventional semantic segmentation approach. The results were discussed to better understand the importance of the availability of training data and for scaling the workflow. Then, thermal anomaly thresholds for different target domains were detected using probability distributions. Finally, thermal anomaly masks of those domains were computed. This study conducted a comprehensive examination of a campus building in Syracuse, New York, utilizing a drone-based data collection approach. The case study successfully detected diverse thermal anomalies associated with various envelope components. The proposed approach offers the potential for immediate and accurate in situ thermal anomaly detection in building inspections. Full article