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Keywords = thermal engineering

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20 pages, 3035 KiB  
Article
Study of Taconis-Based Cryogenic Thermoacoustic Engine with Hydrogen and Helium
by Matthew P. Shenton, Jacob W. Leachman and Konstantin I. Matveev
Energies 2025, 18(15), 4114; https://doi.org/10.3390/en18154114 (registering DOI) - 2 Aug 2025
Abstract
Taconis oscillations represent spontaneous excitation of acoustic modes in tubes with large temperature gradients in cryogenic systems. In this study, Taconis oscillations in hydrogen and helium systems are enhanced with a porous material resulting in a standing-wave thermoacoustic engine. A theoretical model is [...] Read more.
Taconis oscillations represent spontaneous excitation of acoustic modes in tubes with large temperature gradients in cryogenic systems. In this study, Taconis oscillations in hydrogen and helium systems are enhanced with a porous material resulting in a standing-wave thermoacoustic engine. A theoretical model is developed using the thermoacoustic software DeltaEC, version v6.4b2.7, to predict system performance, and an experimental apparatus is constructed for engine characterization. The low-amplitude thermoacoustic model predicts the pressure amplitude, frequency, and temperature gradient required for excitation of the standing-wave system. Experimental measurements, including the onset temperature ratio, acoustic pressure amplitudes, and frequencies, are recorded for different stack materials and geometries. The findings indicate that, independent of stack, hydrogen systems excite at smaller temperature differentials than helium (because of different properties such as lower viscosity for hydrogen), and the stack geometry and material affect the onset temperature ratio. However, pressure amplitude in the excited states varies minimally. Initial measurements are also conducted in a cooling setup with an added regenerator. The configuration with stainless-steel mesh screens produces a small cryogenic refrigeration effect with a decrease in temperature of about 1 K. The reported characterization of a Taconis-based thermoacoustic engine can be useful for the development of novel thermal management systems for cryogenic storage vessels, including refrigeration and pressurization. Full article
(This article belongs to the Section A5: Hydrogen Energy)
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25 pages, 7588 KiB  
Article
Electrophoretic Deposition of Green-Synthesized Hydroxyapatite on Thermally Oxidized Titanium: Enhanced Bioactivity and Antibacterial Performance
by Mariana Relva, Daniela Santo, Ricardo Alexandre, Pedro Faia, Sandra Carvalho, Zohra Benzarti and Susana Devesa
Appl. Sci. 2025, 15(15), 8598; https://doi.org/10.3390/app15158598 (registering DOI) - 2 Aug 2025
Abstract
Titanium alloys such as Ti-6Al-4V are widely used in biomedical implants due to their excellent mechanical properties and biocompatibility, but their bioinert nature limits osseointegration and antibacterial performance. This study proposes a multifunctional surface coating system integrating a thermally oxidized TiO2 interlayer [...] Read more.
Titanium alloys such as Ti-6Al-4V are widely used in biomedical implants due to their excellent mechanical properties and biocompatibility, but their bioinert nature limits osseointegration and antibacterial performance. This study proposes a multifunctional surface coating system integrating a thermally oxidized TiO2 interlayer with a hydroxyapatite (HAp) top layer synthesized via a green route using Hylocereus undatus extract. The HAp was deposited by electrophoretic deposition (EPD), enabling continuous coverage and strong adhesion to the pre-treated Ti-6Al-4V substrate. Structural, morphological, chemical, and electrical characterizations were performed using XRD, SEM, EDS, Raman spectroscopy, and impedance spectroscopy. Bioactivity was assessed through apatite formation in simulated body fluid (SBF), while antibacterial properties were evaluated against Staphylococcus aureus. The results demonstrated successful formation of crystalline TiO2 (rutile phase) and calcium-rich HAp with good surface coverage. The HAp-coated surfaces exhibited significantly enhanced bioactivity and strong antibacterial performance, likely due to the combined effects of surface roughness and the bioactive compounds present in the plant extract. This study highlights the potential of eco-friendly, bio-inspired surface engineering to improve the biological performance of titanium-based implants. Full article
25 pages, 7708 KiB  
Review
A Review of Heat Transfer and Numerical Modeling for Scrap Melting in Steelmaking Converters
by Mohammed B. A. Hassan, Florian Charruault, Bapin Rout, Frank N. H. Schrama, Johannes A. M. Kuipers and Yongxiang Yang
Metals 2025, 15(8), 866; https://doi.org/10.3390/met15080866 (registering DOI) - 1 Aug 2025
Abstract
Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest CO2 emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. [...] Read more.
Steel is an important product in many engineering sectors; however, steelmaking remains one of the largest CO2 emitters. Therefore, new governmental policies drive the steelmaking industry toward a cleaner and more sustainable operation such as the gas-based direct reduction–electric arc furnace process. To become carbon neutral, utilizing more scrap is one of the feasible solutions to achieve this goal. Addressing knowledge gaps regarding scrap heterogeneity (size, shape, and composition) is essential to evaluate the effects of increased scrap ratios in basic oxygen furnace (BOF) operations. This review systematically examines heat and mass transfer correlations relevant to scrap melting in BOF steelmaking, with a focus on low Prandtl number fluids (thick thermal boundary layer) and dense particulate systems. Notably, a majority of these correlations are designed for fluids with high Prandtl numbers. Even for the ones tailored for low Prandtl, they lack the introduction of the porosity effect which alters the melting behavior in such high temperature systems. The review is divided into two parts. First, it surveys heat transfer correlations for single elements (rods, spheres, and prisms) under natural and forced convection, emphasizing their role in predicting melting rates and estimating maximum shell size. Second, it introduces three numerical modeling approaches, highlighting that the computational fluid dynamics–discrete element method (CFD–DEM) offers flexibility in modeling diverse scrap geometries and contact interactions while being computationally less demanding than particle-resolved direct numerical simulation (PR-DNS). Nevertheless, the review identifies a critical gap: no current CFD–DEM framework simultaneously captures shell formation (particle growth) and non-isotropic scrap melting (particle shrinkage), underscoring the need for improved multiphase models to enhance BOF operation. Full article
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28 pages, 8521 KiB  
Review
Pile Integrity Testing Using Non-Destructive Testing Techniques and Artificial Intelligence: A Review
by Peiyun Qiu, Liang Yang, Yilong Xie, Xinghao Liu and Zaixian Chen
Appl. Sci. 2025, 15(15), 8580; https://doi.org/10.3390/app15158580 (registering DOI) - 1 Aug 2025
Abstract
As civil engineering projects grow increasingly complex, ensuring pile integrity is essential for pile bearing capacity and structural safety. Pile integrity testing (PIT) has long been a focal point for researchers and engineers. With the rapid development of industrial-level advancements and artificial intelligence [...] Read more.
As civil engineering projects grow increasingly complex, ensuring pile integrity is essential for pile bearing capacity and structural safety. Pile integrity testing (PIT) has long been a focal point for researchers and engineers. With the rapid development of industrial-level advancements and artificial intelligence technology, PIT methods have undergone significant technological advancements. This paper reviews traditional PIT techniques, including low-strain integrity testing and thermal integrity profiling. The review covers the principles, advantages, limitations, and recent developments of various testing techniques. Additionally, recent advances in artificial intelligence (AI) techniques, particularly in signal processing and data-driven recognition methods, are discussed. Finally, the advantages, limitations, and potential future research directions of existing methods are summarized. This paper aims to offer a systematic reference for researchers and engineers in PIT, synthesizing technical details of traditional methods and their AI-enabled advancements. Furthermore, it explores potential directions for integrating AI with PIT, with a focus on key challenges such as noisy signal interpretation and regulatory barriers in applications. Full article
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17 pages, 1522 KiB  
Article
Characterization of Solid Particulates to Be Used as Storage as Well as Heat Transfer Medium in Concentrated Solar Power Systems
by Rageh Saeed, Syed Noman Danish, Shaker Alaqel, Nader S. Saleh, Eldwin Djajadiwinata, Hany Al-Ansary, Abdelrahman El-Leathy, Abdulelah Alswaiyd, Zeyad Al-Suhaibani, Zeyad Almutairi and Sheldon Jeter
Appl. Sci. 2025, 15(15), 8566; https://doi.org/10.3390/app15158566 (registering DOI) - 1 Aug 2025
Abstract
Using solid particulates as a heat transfer medium for concentrated solar power (CSP) systems has many advantages, positioning them as a superior option compared with conventional heat transfer media such as steam, oil, air, and molten salt. However, a critical imperative lies in [...] Read more.
Using solid particulates as a heat transfer medium for concentrated solar power (CSP) systems has many advantages, positioning them as a superior option compared with conventional heat transfer media such as steam, oil, air, and molten salt. However, a critical imperative lies in the comprehensive evaluation of the properties of potential solid particulates intended for utilization under such extreme thermal conditions. This paper undertakes an exhaustive examination of both ambient and high-temperature thermophysical properties of four naturally occurring particulate materials, Riyadh white sand, Riyadh red sand, Saudi olivine sand, and US olivine sand, and one well-known engineered particulate material. The parameters under scrutiny encompass loose bulk density, tapped bulk density, real density, sintering temperature, and thermal conductivity. The results reveal that the theoretical density decreases with the increase in temperature. The bulk density of solid particulates depends strongly on the particulate size distribution, as well as on the compaction. The tapped bulk density was found to be larger than the loose density for all particulates, as expected. The sintering test proved that Riyadh white sand is sintered at the highest temperature and pressure, 1300 °C and 50 MPa, respectively. US olivine sand was solidified at 800 °C and melted at higher temperatures. This proves that US olivine sand is not suitable to be used as a thermal energy storage and heat transfer medium in high-temperature particle-based CSP systems. The experimental results of thermal diffusivity/conductivity reveal that, for all particulates, both properties decrease with the increase in temperature, and results up to 475.5 °C are reported. Full article
(This article belongs to the Section Applied Thermal Engineering)
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25 pages, 2451 KiB  
Article
Complexation and Thermal Stabilization of Protein–Polyelectrolyte Systems via Experiments and Molecular Simulations: The Poly(Acrylic Acid)/Lysozyme Case
by Sokratis N. Tegopoulos, Sisem Ektirici, Vagelis Harmandaris, Apostolos Kyritsis, Anastassia N. Rissanou and Aristeidis Papagiannopoulos
Polymers 2025, 17(15), 2125; https://doi.org/10.3390/polym17152125 - 1 Aug 2025
Abstract
Protein–polyelectrolyte nanostructures assembled via electrostatic interactions offer versatile applications in biomedicine, tissue engineering, and food science. However, several open questions remain regarding their intermolecular interactions and the influence of external conditions—such as temperature and pH—on their assembly, stability, and responsiveness. This study explores [...] Read more.
Protein–polyelectrolyte nanostructures assembled via electrostatic interactions offer versatile applications in biomedicine, tissue engineering, and food science. However, several open questions remain regarding their intermolecular interactions and the influence of external conditions—such as temperature and pH—on their assembly, stability, and responsiveness. This study explores the formation and stability of networks between poly(acrylic acid) (PAA) and lysozyme (LYZ) at the nanoscale upon thermal treatment, using a combination of experimental and simulation measures. Experimental techniques of static and dynamic light scattering (SLS and DLS), Fourier transform infrared spectroscopy (FTIR), and circular dichroism (CD) are combined with all-atom molecular dynamics simulations. Model systems consisting of multiple PAA and LYZ molecules explore collective assembly and complexation in aqueous solution. Experimental results indicate that electrostatic complexation occurs between PAA and LYZ at pH values below LYZ’s isoelectric point. This leads to the formation of nanoparticles (NPs) with radii ranging from 100 to 200 nm, most pronounced at a PAA/LYZ mass ratio of 0.1. These complexes disassemble at pH 12, where both LYZ and PAA are negatively charged. However, when complexes are thermally treated (TT), they remain stable, which is consistent with earlier findings. Atomistic simulations demonstrate that thermal treatment induces partially reversible structural changes, revealing key microscopic features involved in the stabilization of the formed network. Although electrostatic interactions dominate under all pH and temperature conditions, thermally induced conformational changes reorganize the binding pattern, resulting in an increased number of contacts between LYZ and PAA upon thermal treatment. The altered hydration associated with conformational rearrangements emerges as a key contributor to the stability of the thermally treated complexes, particularly under conditions of strong electrostatic repulsion at pH 12. Moreover, enhanced polymer chain associations within the network are observed, which play a crucial role in complex stabilization. These insights contribute to the rational design of protein–polyelectrolyte materials, revealing the origins of association under thermally induced structural rearrangements. Full article
(This article belongs to the Section Polymer Physics and Theory)
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32 pages, 10052 KiB  
Article
A Study on Large Electric Vehicle Fires in a Tunnel: Use of a Fire Dynamics Simulator (FDS)
by Roberto Dessì, Daniel Fruhwirt and Davide Papurello
Processes 2025, 13(8), 2435; https://doi.org/10.3390/pr13082435 - 31 Jul 2025
Abstract
Internal combustion engine vehicles damage the environment and public health by emitting toxic fumes, such as CO2 or CO and other trace compounds. The use of electric cars helps to reduce the emission of pollutants into the environment due to the use [...] Read more.
Internal combustion engine vehicles damage the environment and public health by emitting toxic fumes, such as CO2 or CO and other trace compounds. The use of electric cars helps to reduce the emission of pollutants into the environment due to the use of batteries with no direct and local emissions. However, accidents of battery electric vehicles pose new challenges, such as thermal runaway. Such accidents can be serious and, in some cases, may result in uncontrolled overheating that causes the battery pack to spontaneously ignite. In particular, the most dangerous vehicles are heavy goods vehicles (HGVs), as they release a large amount of energy that generate high temperatures, poor visibility, and respiratory damage. This study aims to determine the potential consequences of large BEV fires in road tunnels using computational fluid dynamics (CFD). Furthermore, a comparison between a BEV and an ICEV fire shows the differences related to the thermal and the toxic impact. Furthermore, the adoption of a longitudinal ventilation system in the tunnel helped to mitigate the BEV fire risk, keeping a safer environment for tunnel users and rescue services through adequate smoke control. Full article
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22 pages, 3440 KiB  
Article
Probabilistic Damage Modeling and Thermal Shock Risk Assessment of UHTCMC Thruster Under Transient Green Propulsion Operation
by Prakhar Jindal, Tamim Doozandeh and Jyoti Botchu
Materials 2025, 18(15), 3600; https://doi.org/10.3390/ma18153600 (registering DOI) - 31 Jul 2025
Abstract
This study presents a simulation-based damage modeling and fatigue risk assessment of a reusable ceramic matrix composite thruster designed for short-duration, green bipropellant propulsion systems. The thruster is constructed from a fiber-reinforced ultra-high temperature ceramic matrix composite composed of zirconium diboride, silicon carbide, [...] Read more.
This study presents a simulation-based damage modeling and fatigue risk assessment of a reusable ceramic matrix composite thruster designed for short-duration, green bipropellant propulsion systems. The thruster is constructed from a fiber-reinforced ultra-high temperature ceramic matrix composite composed of zirconium diboride, silicon carbide, and carbon fibers. Time-resolved thermal and structural simulations are conducted on a validated thruster geometry to characterize the severity of early-stage thermal shock, stress buildup, and potential degradation pathways. Unlike traditional fatigue studies that rely on empirical fatigue constants or Paris-law-based crack-growth models, this work introduces a simulation-derived stress-margin envelope methodology that incorporates ±20% variability in temperature-dependent material strength, offering a physically grounded yet conservative risk estimate. From this, a normalized risk index is derived to evaluate the likelihood of damage initiation in critical regions over the 0–10 s firing window. The results indicate that the convergent throat region experiences a peak thermal gradient rate of approximately 380 K/s, with the normalized thermal shock index exceeding 43. Stress margins in this region collapse by 2.3 s, while margin loss in the flange curvature appears near 8 s. These findings are mapped into green, yellow, and red risk bands to classify operational safety zones. All the results assume no active cooling, representing conservative operating limits. If regenerative or ablative cooling is implemented, these margins would improve significantly. The framework established here enables a transparent, reproducible methodology for evaluating lifetime safety in ceramic propulsion nozzles and serves as a foundational tool for fatigue-resilient component design in green space engines. Full article
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42 pages, 3564 KiB  
Review
A Review on Sustainable Upcycling of Plastic Waste Through Depolymerization into High-Value Monomer
by Ramkumar Vanaraj, Subburayan Manickavasagam Suresh Kumar, Seong Cheol Kim and Madhappan Santhamoorthy
Processes 2025, 13(8), 2431; https://doi.org/10.3390/pr13082431 - 31 Jul 2025
Viewed by 3
Abstract
Plastic waste accumulation is one of the most pressing environmental challenges of the 21st century, owing to the widespread use of synthetic polymers and the limitations of conventional recycling methods. Among available strategies, chemical upcycling via depolymerization has emerged as a promising circular [...] Read more.
Plastic waste accumulation is one of the most pressing environmental challenges of the 21st century, owing to the widespread use of synthetic polymers and the limitations of conventional recycling methods. Among available strategies, chemical upcycling via depolymerization has emerged as a promising circular approach that converts plastic waste back into valuable monomers and chemical feedstocks. This article provides an in-depth narrative review of recent progress in the upcycling of major plastic types such as PET, PU, PS, and engineering plastics through thermal, chemical, catalytic, biological, and mechanochemical depolymerization methods. Each method is critically assessed in terms of efficiency, scalability, energy input, and environmental impact. Special attention is given to innovative catalyst systems, such as microsized MgO/SiO2 and Co/CaO composites, and emerging enzymatic systems like engineered PETases and whole-cell biocatalysts that enable low-temperature, selective depolymerization. Furthermore, the conversion pathways of depolymerized products into high-purity monomers such as BHET, TPA, vanillin, and bisphenols are discussed with supporting case studies. The review also examines life cycle assessment (LCA) data, techno-economic analyses, and policy frameworks supporting the adoption of depolymerization-based recycling systems. Collectively, this work outlines the technical viability and sustainability benefits of depolymerization as a core pillar of plastic circularity and monomer recovery, offering a path forward for high-value material recirculation and waste minimization. Full article
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18 pages, 2664 KiB  
Article
Analysis of Heat Exchange Efficiency and Influencing Factors of Energy Tunnels: A Case Study of the Torino Metro in Italy
by Mei Yin, Pengcheng Liu and Zhenhuang Wu
Buildings 2025, 15(15), 2704; https://doi.org/10.3390/buildings15152704 (registering DOI) - 31 Jul 2025
Viewed by 28
Abstract
Both ground source heat pumps (GSHPs) and energy underground structures are engineered systems that utilize shallow geothermal energy. However, due to the construction complexity and associated costs of energy tunnels, their heat exchange efficiency relative to GSHPs remains a topic worthy of in-depth [...] Read more.
Both ground source heat pumps (GSHPs) and energy underground structures are engineered systems that utilize shallow geothermal energy. However, due to the construction complexity and associated costs of energy tunnels, their heat exchange efficiency relative to GSHPs remains a topic worthy of in-depth investigation. In this study, a thermal–hydraulic (TH) coupled finite element model was developed based on a section of the Torino Metro Line in Italy to analyze the differences in and influencing factors of heat transfer performance between energy tunnels and GSHPs. The model was validated by comparing the outlet temperature curves under both winter and summer loading conditions. Based on this validated model, a parametric analysis was conducted to examine the effects of the tunnel air velocity, heat carrier fluid velocity, and fluid type. The results indicate that, under identical environmental conditions, energy tunnels exhibit higher heat exchange efficiency than conventional GSHP systems and are less sensitive to external factors such as fluid velocity. Furthermore, a comparison of different heat carrier fluids, including alcohol-based fluids, refrigerants, and water, revealed that the fluid type significantly affects thermal performance, with the refrigerant R-134a outperforming ethylene glycol and water in both heating and cooling efficiency. Full article
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33 pages, 4142 KiB  
Review
Advances in Wettability-Engineered Open Planar-Surface Droplet Manipulation
by Ge Chen, Jin Yan, Junjie Liang, Jiajia Zheng, Jinpeng Wang, Hongchen Pang, Xianzhang Wang, Zihao Weng and Wei Wang
Micromachines 2025, 16(8), 893; https://doi.org/10.3390/mi16080893 (registering DOI) - 31 Jul 2025
Viewed by 186
Abstract
Firstly, this paper reviews the fundamental theories of solid surface wettability and contact angle hysteresis. Subsequently, it further introduces four typical wettability-engineered surfaces with low hysteresis (superhydrophobic, superamphiphobic, super-slippery, and liquid-like smooth surfaces). Finally, it focuses on the latest research progress in the [...] Read more.
Firstly, this paper reviews the fundamental theories of solid surface wettability and contact angle hysteresis. Subsequently, it further introduces four typical wettability-engineered surfaces with low hysteresis (superhydrophobic, superamphiphobic, super-slippery, and liquid-like smooth surfaces). Finally, it focuses on the latest research progress in the field of droplet manipulation on open planar surfaces with engineered wettability. To achieve droplet manipulation, the core driving forces primarily stem from natural forces guided by bioinspired gradient surfaces or the regulatory effects of external fields. In terms of bioinspired self-propelled droplet movement, this paper summarizes research inspired by natural organisms such as desert beetles, cacti, self-aligning floating seeds of emergent plants, or water-walking insects, which construct bioinspired special gradient surfaces to induce Laplace pressure differences or wettability gradients on both sides of droplets for droplet manipulation. Moreover, this paper further analyzes the mechanisms, advantages, and limitations of these self-propelled approaches, while summarizing the corresponding driving force sources and their theoretical formulas. For droplet manipulation under external fields, this paper elaborates on various external stimuli including electric fields, thermal fields, optical fields, acoustic fields, and magnetic fields. Among them, electric fields involve actuation mechanisms such as directly applied electrostatic forces and indirectly applied electrocapillary forces; thermal fields influence droplet motion through thermoresponsive wettability gradients and thermocapillary effects; optical fields cover multiple wavelengths including near-infrared, ultraviolet, and visible light; acoustic fields utilize horizontal and vertical acoustic radiation pressure or acoustic wave-induced acoustic streaming for droplet manipulation; the magnetic force acting on droplets may originate from their interior, surface, or external substrates. Based on these different transport principles, this paper comparatively analyzes the unique characteristics of droplet manipulation under the five external fields. Finally, this paper summarizes the current challenges and issues in the research of droplet manipulation on the open planar surfaces and provides an outlook on future development directions in this field. Full article
(This article belongs to the Special Issue Advanced Microfluidic Chips: Optical Sensing and Detection)
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30 pages, 3838 KiB  
Review
Advances in the Tribological Performance of Graphene Oxide and Its Composites
by Mayur B. Wakchaure and Pradeep L. Menezes
Materials 2025, 18(15), 3587; https://doi.org/10.3390/ma18153587 - 30 Jul 2025
Viewed by 214
Abstract
Graphene oxide (GO), a derivative of graphene, has attracted significant attention in tribological applications due to its unique structural, mechanical, and chemical properties. This review highlights the influence of GO and its composites on friction and wear performance across various engineering systems. The [...] Read more.
Graphene oxide (GO), a derivative of graphene, has attracted significant attention in tribological applications due to its unique structural, mechanical, and chemical properties. This review highlights the influence of GO and its composites on friction and wear performance across various engineering systems. The paper explores GO’s key properties, such as its high surface area, layered morphology, and abundant functional groups. These features contribute to reduced shear resistance, tribofilm formation, and improved load-bearing capacity. A detailed analysis of GO-based composites, including polymer, metal, and ceramic matrices, reveals those small additions of GO (typically 0.1–2 wt%) result in substantial reductions in coefficient of friction and wear rate, with improvements ranging between 30–70%, depending on the application. The tribological mechanisms, including self-lubrication, dispersion, thermal stability, and interface interactions, are discussed to provide insights into performance enhancement. Furthermore, the effects of electrochemical environment, functional group modifications, and external loading conditions on GO’s tribological behavior are examined. Despite these advantages, challenges such as scalability, agglomeration, and material compatibility persist. Overall, the paper demonstrates that GO is a promising additive for advanced tribological systems, while also identifying key limitations and future research directions. Full article
(This article belongs to the Special Issue Tribology in Advanced Materials)
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24 pages, 2631 KiB  
Review
Vapor Compression Refrigeration System for Aircrafts: Current Status, Large-Temperature-Range Challenges and Emerging Auto-Cascade Refrigeration Technologies
by Hainan Zhang, Qinghao Wu, Shuo Feng, Sujun Dong and Zanjun Gao
Aerospace 2025, 12(8), 681; https://doi.org/10.3390/aerospace12080681 - 30 Jul 2025
Viewed by 200
Abstract
Modern aircraft increasingly utilizes highly integrated electronic equipment, driving continuously increasing heat dissipation demands. Vapor compression refrigeration systems demonstrate stronger alignment with future aircraft thermal management trends, leveraging their superior volumetric cooling capacity, high energy efficiency, and independence from engine bleed air. This [...] Read more.
Modern aircraft increasingly utilizes highly integrated electronic equipment, driving continuously increasing heat dissipation demands. Vapor compression refrigeration systems demonstrate stronger alignment with future aircraft thermal management trends, leveraging their superior volumetric cooling capacity, high energy efficiency, and independence from engine bleed air. This paper reviews global research progress on aircraft vapor compression refrigeration systems, covering performance optimization, dynamic characteristics, control strategies, fault detection, and international development histories and typical applications. Analysis identifies emerging challenges under large-temperature-range cooling requirements, with comparative assessment establishing zeotropic mixture auto-cascade vapor compression refrigeration systems as the optimal forward-looking solution. Finally, recognizing current research gaps, we propose future research directions for onboard auto-cascade vapor compression refrigeration systems: optimizing refrigerant mixtures for flight conditions, achieving efficient gas-liquid separation during variable overloads and attitude conditions, and developing model predictive control with intelligent optimization to ensure reliability. Full article
(This article belongs to the Special Issue Aerospace Human–Machine and Environmental Control Engineering)
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23 pages, 3795 KiB  
Article
Structural Analysis of the Newly Prepared Ti55Al27Mo13 Alloy by Aluminothermic Reaction
by Štefan Michna, Jaroslava Svobodová, Anna Knaislová, Jan Novotný and Lenka Michnová
Materials 2025, 18(15), 3583; https://doi.org/10.3390/ma18153583 - 30 Jul 2025
Viewed by 108
Abstract
This study presents the structural and compositional characterisation of a newly developed Ti55Al27Mo13 alloy synthesised via aluminothermic reaction. The alloy was designed to overcome the limitations of conventional processing routes for high–melting–point elements such as Ti and Mo, enabling the formation of a [...] Read more.
This study presents the structural and compositional characterisation of a newly developed Ti55Al27Mo13 alloy synthesised via aluminothermic reaction. The alloy was designed to overcome the limitations of conventional processing routes for high–melting–point elements such as Ti and Mo, enabling the formation of a complex, multi–phase microstructure in a single high–temperature step. The aim was to develop and characterise a material with microstructural features expected to enhance wear resistance, oxidation behaviour, and thermal stability in future applications. The alloy is intended as a precursor for composite nanopowders and surface coatings applied to aluminium–, magnesium–, and iron–based substrates subjected to mechanical and thermal loading. Elemental analysis (XRF, EDS) confirmed the presence of Ti, Al, Mo, and minor elements such as Si, Fe, and C. Microstructural investigations using laser confocal and scanning electron microscopy revealed a heterogeneous structure comprising solid solutions, eutectic regions, and dispersed oxide and carbide phases. Notably, the alloy exhibits high hardness values, reaching >2400 HV in Al2O3 regions and ~1300 HV in Mo– and Si–enriched solid solutions. These results suggest the material’s substantial potential for protective surface engineering. Further tribological, thermal, and corrosion testing, conducted with meticulous attention to detail, will follow to validate its functional performance in target applications. Full article
(This article belongs to the Section Metals and Alloys)
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13 pages, 3081 KiB  
Review
Surface Air-Cooled Oil Coolers (SACOCs) in Turbofan Engines: A Comprehensive Review of Design, Performance, and Optimization
by Wiktor Hoffmann and Magda Joachimiak
Energies 2025, 18(15), 4052; https://doi.org/10.3390/en18154052 - 30 Jul 2025
Viewed by 179
Abstract
Surface Air-Cooled Oil Coolers (SACOCs) can become a critical component in managing the increasing thermal loads of modern turbofan engines. Installed within the bypass duct, SACOCs utilize high-mass flow bypass air for convective heat rejection, reducing reliance on traditional Fuel-Oil Heat Exchangers. This [...] Read more.
Surface Air-Cooled Oil Coolers (SACOCs) can become a critical component in managing the increasing thermal loads of modern turbofan engines. Installed within the bypass duct, SACOCs utilize high-mass flow bypass air for convective heat rejection, reducing reliance on traditional Fuel-Oil Heat Exchangers. This review explores SACOC design principles, integration challenges, aerodynamic impacts, and performance trade-offs. Emphasis is placed on the balance between thermal efficiency and aerodynamic penalties such as pressure drop and flow distortion. Experimental techniques, including wind tunnel testing, are discussed alongside numerical methods, and Conjugate Heat Transfer modeling. Presented studies mostly demonstrate the impact of fin geometry and placement on both heat transfer and drag. Optimization strategies and Additive Manufacturing techniques are also covered. SACOCs are positioned to play a central role in future propulsion systems, especially in ultra-high bypass ratio and hybrid-electric architectures, where traditional cooling strategies are insufficient. This review highlights current advancements, identifies limitations, and outlines research directions to enhance SACOC efficiency in aerospace applications. Full article
(This article belongs to the Special Issue Heat Transfer Analysis: Recent Challenges and Applications)
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