Search Results (1,051)

To mitigate the interlayer defects and weak interfacial adhesion inherent in FFF-printed parts, thereby facilitating subsequent supercritical foaming applications, a microwave-assisted interlayer healing strategy is developed for FFF-printed, supercritical CO₂-foamed thermoplastic polyurethane (TPU) by incorporating aminated helical multi-walled carbon nanotubes (AS-MWCNTs). Owing to their unique helical morphology, AS-MWCNTs exhibit enhanced microwave absorption and localized heating capability, enabling selective thermal activation at interlayer regions within the foamed architecture. Microwave irradiation induces localized softening of the TPU matrix and promotes polymer chain mobility and interdiffusion across layer interfaces, while preserving the cellular morphology and bulk foamed structure. By optimizing AS-MWCNT loading, substantial improvements in interlayer bonding strength, energy absorption, and overall mechanical performance are achieved. This work provides an effective strategy to restore interlayer integrity in supercritical CO₂-foamed, additive manufactured elastomers and offers insights into the design of microwave-responsive, self-healing cellular materials. Full article

To address the capacity decay of NCM811 caused by microcracks and cation disorder during cycling, La, Al, and F tri-doped micron-sized single-crystal NCM811 material with a LiNbO₃ coating was synthesized via a facile co-solvent method. Using a mixed glucose–urea thermal solution as the reaction medium, metal salts were incorporated, followed by step-wise sintering, ball-milling, heat treatment, and wet-chemical coating. This approach enables atomic-level precursor mixing and ensures homogeneous element distribution. La³⁺ enlarges the lithium layer spacing to enhance ion diffusion and Al³⁺ suppresses Ni³⁺ reduction to Ni²⁺, mitigating cation mixing and improving conductivity, while F⁻ stabilizes the crystal structure via its strong electronegativity. The LiNbO₃ coating protects the interface from electrolyte attack, and the single-crystal morphology effectively suppresses microcracking. Compared to unmodified single-crystal NCM811 prepared identically, the modified material exhibits reduced cation disorder, improved crystallinity, and superior thermal stability. Electrochemical tests in half-cells with 1 M LiPF₆/(EC/EMC/DMC) electrolyte (2.8–4.3 V) show an initial discharge capacity of 208.32 mAh/g at 0.1 C and 194.05 mAh/g at 1 C. After 200 cycles at 1 C, the capacity retention remains at 92.21%, exceeding the market average. Rate performance is also notably enhanced, with the 5 C discharge capacity increasing from 141.12 mAh/g (unmodified) to 166.81 mAh/g, demonstrating improved kinetics and structural stability. Full article

This study investigates the multi-scale tribo–thermo–viscoelastic performance of a sustainable bio-based FormuLITE epoxy reinforced with single and hybrid carbon nanofillers (0.1 wt.% total loading) under dry sliding up to 50 N. Pin-on-disk tests at 10, 30, and 50 N showed a consistent reduction in contact pressure and wear volume in the order: neat epoxy > 0.1 CNT > 0.1 GNP > 0.1 ND > 0.1 CNT/GNP > 0.1 CNT/ND > 0.1 GNP/ND. At 50 N and 1500 m sliding distance, neat epoxy exhibited a wear volume of 13.43 mm³ and contact pressure of 13.4 N/cm², while the GNP/ND hybrid reduced wear to 4.86 mm³ and contact pressure to 6.2 N/cm², corresponding to reductions of 64% and 54%, respectively. The accelerating wear coefficient decreased from 2.9 × 10⁻⁶ to 8.5 × 10⁻⁷, confirming slower damage accumulation in hybrid systems. Time-dependent contact pressure analysis revealed reduced asymptotic intensity and suppressed mid-cycle pressure spikes, indicating enhanced tribolayer stability. Effective surface hardness increased from 0.18 GPa (neat epoxy) to 0.30 GPa (GNP/ND), while normalized wear decreased from 1.00 to 0.36. Enhanced damping behavior and improved thermal conductivity in hybrid systems promoted stress redistribution and minimized flash-temperature localization. An interfacial energy-partition framework calibrated to experimental wear data quantitatively linked effective driving pressure, tribofilm stabilization, and surface hardness to material removal. The results demonstrate that wear mitigation in sustainable bio-epoxy systems is governed by coupled mechanical, viscoelastic, and thermal energy redistribution, with GNP/ND hybrids providing the most stable tribological interface under severe sliding. The findings contribute to the development of durable and sustainable bio-epoxy composite systems for engineering applications, supporting broader goals of responsible material utilization and sustainable industrial innovation aligned with the United Nations Sustainable Development Goals (SDG 9 and SDG 12). Full article

The utilisation of composite materials has the potential to play a vital role in the development of lightweight structures for future generations of aircraft, with the objective to reduce emissions. Ultrasonic welding is a process that has been proven to exhibit advantageous qualities, including the capacity to achieve welds with a comparatively short process time. Furthermore, its capacity to function as both a static and a continuous process makes it a viable candidate for facilitating the realisation of this objective. The present study investigates the potential of a novel explicit modelling approach for the static ultrasonic welding process to more accurately represent the welding process by incorporating a more precise representation of the hammering effect. The hammering effect describes the partial loss of contact between the sonotrode and the upper adherend. The model’s validation was achieved through a multifaceted approach that incorporates high-speed camera recording, encompassing digital image correlation, laser displacement sensor measurements, and static ultrasonic welding experiments. These experiments encompassed varying welding times, followed by fracture surface analysis. The findings showed that an explicit time-domain model can effectively represent the static welding process of unidirectional materials utilising a film energy director. The experimental validation demonstrated a high degree of correlation between the thermal behaviour of the welding interface and the simulation results. The study demonstrated that the neutral position of the sonotrode exhibited an increase during the initial phase of the welding process due to dynamic stresses. This phenomenon enables reduced constraint movement of the adherends and the energy director, which results in the disconnection of the sonotrode from both the upper adherend and the energy director, as well as the adherends and the anvil. The higher neutral position of the sonotrode was then implemented in an explicit simulation of the static ultrasonic welding process. Full article

To overcome the limitations imposed by the intermittent nature of sunlight in photocatalytic applications, this research constructs a round-the-clock purification system. We integrated an optimized S-scheme CoFe₂O₄/BiVO₄ (CFO/BV) heterojunction (synthesized via ultrasonic self-assembly at a 0.5:0.5 ratio) with a thermal energy storage (TES) unit consisting of SiO₂-encapsulated Na₂SO₄·10H₂O phase change materials (PCMs). Comprehensive characterization techniques, including XRD, HRTEM, UV-Vis DRS, EPR, and DSC, confirmed the successful formation of the interface, a broadened visible-light response (λ > 650 nm), efficient radical production, and a high latent heat storage capacity (>200 J/g). Under simulated solar irradiation, the composite exhibited superior performance, degrading 98% of the Rhodamine B within 6 h (k = 0.00994 min⁻¹), significantly surpassing single-component counterparts. More importantly, during the subsequent 12 h dark period, the heat released from the PCM maintained the reaction temperature above 35 °C, driving a 64% degradation efficiency via a thermocatalytic pathway. The system demonstrated robust stability (>90% efficiency after five cycles), excellent magnetic recoverability (98%), and high tolerance to saline textile wastewater (<10% activity loss). Furthermore, Life Cycle Assessment (LCA) indicated a 40% reduction in energy consumption compared to conventional UV/TiO₂ processes, highlighting a sustainable strategy for continuous wastewater remediation through synergistic photocatalysis and thermocatalysis. Full article

Conventional thermoelectric generators (TEGs) suffer from thermal resistance introduced by ceramic substrates and thermal interface materials, which limits the achievable temperature gradient across the junctions and reduces conversion efficiency. To overcome this limitation, a pin-fin integrated thermoelectric device (iTED) is proposed, in which the hot-side heat exchanger is incorporated directly into the hot-side interconnector, eliminating the ceramic and associated greases. An explicitly coupled thermal-fluid-electric finite-volume model is developed in ANSYS Fluent’s user-defined scalar (UDS) environment to quantify the simultaneous thermal-fluid-electric behavior of the iTED for inlet temperatures of 350 $\le T_{\mathrm{in}}\mathrm{K}\le$ 650, Reynolds numbers of 3000 $\le \mathrm{Re}\le$ 15,000, and load resistances ranging from 0.01 to ${10}^6$% of the internal device resistance ($R_{\mathrm{int}}$), for a fixed cold-side temperature of 300 K. The model is validated against established tube-bank correlations (2.2% agreement in pumping power) and a one-dimensional Explicit Thomson Model (1.2–6.9% agreement across all electrical system response quantities). Compared with an equivalently sized conventional TEG, the iTED achieves a 4.6-fold higher maximum power output (23.9 [W] vs. 5.2 [W] at Re = 15,000), a 2.8-fold higher thermal conversion efficiency (8.1% vs. 2.9%), and a 4.8-fold higher performance index (7.8 [-] vs. 1.6 [-] at Re = 3000), all at $T_{\mathrm{in}}$ = 650 K. A performance index analysis reveals that lower Reynolds numbers and higher inlet temperatures maximize the net power benefit, delineating the operational envelope in which the iTED produces more electrical power than is needed for fluid pumping. These findings demonstrate that device-level restructuring—specifically, the elimination of interfacial thermal resistance via integrated pin-fin heat exchangers—can yield performance improvements comparable to or exceeding those achievable through material advances alone. Full article

Bubble nucleation in flowing liquid films is a common interfacial phenomenon affecting the heat and mass transfer at the solid–liquid interfaces in many thermal and functional material production processes, yet realizing its molecular-scale mechanisms under coupled flow, pressure, and heating conditions is important. In this study, molecular dynamics simulations are performed to investigate the bubble nucleation and growth in a liquid argon film on a heated platinum substrate under controlled pressure, with liquid flow driven by an applied body force. Bubble evolution is analyzed by the nucleation time, critical nucleation volume, bubble volume variation, and migration of the bubble’s center of mass. The results show that system pressure and substrate temperature dominantly regulate the nucleation: increasing pressure delays nucleation, whereas increasing substrate temperature accelerates it. Under a fixed system pressure and substrate temperature, liquid flow exhibits a non-monotonic influence. The applied forces from $4.0\times {10}^{-7}\mathrm{e}\mathrm{V}/\mathrm{Å}$ to $1.0\times {10}^{-6}\mathrm{e}\mathrm{V}/\mathrm{Å}$ gradually promote the nucleation and enhance the bubble growth by facilitating near-substrate heat transfer and density fluctuations, while the forces from $1.0\times {10}^{-6}\mathrm{e}\mathrm{V}/\mathrm{Å}$ to $1.4\times {10}^{-6}\mathrm{e}\mathrm{V}/\mathrm{Å}$ suppress nucleation and do not further promote the growth due to the intensified shear and interfacial instability. These findings provide molecular-level insight into the coupled thermodynamic and kinetic effects of pressure, temperature, and flow on bubble nucleation and growth at material interfaces, offering guidance for the design and operation of heat-transfer and functional materials processes. Full article

This study investigates the influence of surface-modified carbon fibers (CFs) on the structural and mechanical properties of acrylonitrile-butadiene-styrene (ABS)-based composites. A comprehensive approach employing Fourier Transform Infrared Spectroscopy (FTIR), contact angle measurement, and thermogravimetric analysis (TGA) characterized the CF surface chemistry, wettability, and thermal stability. Specimens were prepared via injection molding and 3D printing processes, enabling systematic evaluation of tensile, flexural, and impact properties. Combined with Scanning Electron Microscopy observations of composite fracture surfaces, the study elucidates how modification treatments influence fiber–matrix interface bonding and mechanical enhancement mechanisms. The results indicate that after resizing treatment with silane coupling agents, the surface activity of CF and its interfacial compatibility with ABS were significantly improved, leading to a marked enhancement in the composite material’s overall performance. At a CF content of 9.62 wt%, the ABS-S-CF2 system exhibited optimal mechanical properties: The tensile strength and flexural strength of the injection-molded specimens reached 58.41 MPa and 81.51 MPa, respectively, representing increases of approximately 41.6% and 29.1% compared to neat ABS. The tensile strength and flexural strength of the printed specimens also reached 49.37 MPa and 80.19 MPa, respectively. Microstructural analysis indicates that the sizing treatment improves the interfacial bonding between CF and neat ABS. Full article

The 2011 Fukushima accident highlighted the vulnerability of traditional Zr alloy fuel cladding under loss-of-coolant accident (LOCA) conditions, prompting the development of accident-tolerant fuel (ATF) systems. A promising near-term solution involves depositing protective coatings on existing Zr alloy cladding. Among various deposition techniques, cold spray technology has emerged as one of the leading methods due to its solid-state, low-temperature process, which minimises thermal degradation and allows for the deposition of a wide range of high-performance materials. This review provides a comprehensive examination of recent advances in cold-sprayed coatings for ATF cladding, beginning with an overview of the fundamentals of cold spray technology and its specific advantages for nuclear applications. The core of the review critically analyses three primary coating systems: Cr, FeCrAl alloys, and MAX phase composites, with a particular focus on Cr coatings, as they have been more extensively studied compared to the other two material systems. Key coating properties, including microstructure of the coating-substrate interface, mechanical properties, thermal conductivity, oxidation resistance, irradiation tolerance, and performance under normal operation and simulated LOCA conditions, are discussed in detail, with particular emphasis on the potential of cold-sprayed Cr coatings to enhance Zr alloy cladding. Cr coatings demonstrate significant improvements in oxidation resistance and irradiation stability, but also face challenges such as high-temperature interfacial reactions. To address these issues, promising solutions, such as diffusion-barrier bilayer systems, are being explored. Additionally, the review discusses FeCrAl and MAX phase composite coatings, highlighting their promising long-term performance under extreme conditions. The review concludes with recommendations for further research to optimise cold spray processes and ensure the robustness of coatings in operational reactor environments. Full article

The ionic liquids are increasingly used as versatile media capable of reshaping the electrochemical environment for hydrogen production. Their wide electrochemical windows, thermal stability, and customizable solvation structures enable these liquids to tailor the electrode–electrolyte interface in such a way that the traditional alkaline and polymer-membrane systems cannot. These features allow for reductions in the hydrogen evolution overpotentials, improved catalyst stability, and effective suppression of gas crossover, positioning the ionic liquids as promising components for advanced electrolysis systems. Despite these benefits, their broader deployment remains constrained by certain challenges. The elevated viscosity and associated mass-transport limitations complicate the cell design and energy efficiency, whereas the cost and long-term stability of many ionic liquids limit their competitiveness in industrial hydrogen production. Also, the hydrolysable anions and other reactive species increase the burden, particularly in environments where moisture and anodic potential are present. As a result, the ionic liquids electrolysis has its most promising prospects in niche and hybrid configurations like the renewable integrated systems and configurations where the tailored interfacial chemistry and long operational lifetimes outweigh the investment cost and maintenance requirements. Future progress will depend on the development of greener, task-specific ionic liquids with improved stability and lower synthesis costs, alongside hybrid electrolyte designs that balance the unique interfacial benefits of ionic liquids with the practicality of aqueous systems. Advancing these materials from laboratory research to large-scale sustainable hydrogen production will require coordinated advances in the materials compatibility, device and infrastructural architecture, and techno-economic optimization. Full article

Recent innovations with the aid of nanotechnology are more frequently seen in the industrial sectors. Lubricants are a high-end commodity resource used in many manufacturing processes; unfortunately, most of these lubricants are petroleum-based, which come with certain drawbacks, such as environmental aspects, handling issues and high costs. With the incorporation of nanostructures within fluids and lubricants, novel material alternatives are replacing conventional lubrication systems, maintaining the required thermophysical and tribological characteristics. This research provides an analysis of vegetable lubricant, castor oil (CO), and the effects of the incorporation of WS₂ nanofiller at diverse filler fractions. A TEMPOS thermal analyzer device and a four-ball tribotester are used for the analysis of thermal conductivity and tribological assessments, respectively. Results showed the enhancement of thermal conductivity as the filler concentration and the evaluation temperature of the nanolubricants increased. The best thermal conductivity improvement was 27%, at 60 °C with merely 0.20 wt.% of nanofillers. For tribological performance, a decrease of 6% in the coefficient of friction (COF) and 31% in the wear scar diameter (WSD) was observed at 0.10 wt.% and 0.20 wt.%, respectively. Adhesion of the nanostructures to the steel surfaces creates a protective layer, preventing direct contact of the friction pairs. These results are an outcome of applied theoretical concepts such as Brownian motion and nano-layering of the lubricant–nanostructure interface. Full article

Conventional tribological materials such as metals, ceramics, and synthetic polymers demand energy-intensive processing and create end-of-life waste. This motivates the search for more sustainable alternatives. Recent research demonstrates that agricultural residues, industrial by-products, post-consumer waste, and recycled polymers can be engineered into tribological systems that provide competitive wear resistance, stable friction, and multifunctional benefits, including thermal dissipation and vibration damping. This review summarizes progress across these material categories, highlighting how fillers like rice husk ash, fly ash, tire-derived carbon black, and reprocessed plastics transition from low-value waste into high-performance tribomaterials. System-level strategies such as interface engineering, hybrid reinforcement, and advanced processing are essential for overcoming material variability and achieving reliable tribological performance. In parallel, optimization approaches, including predictive modeling and smart material design, are increasingly enabling improved consistency, reproducibility, and scalability. Applications in automotive braking systems, recycled carbon black composites, acoustic damping structures, coatings, and reinforced polymers confirm the industrial viability of waste-derived materials. While challenges remain in feedstock variability, standardization, and long-term durability, these developments point to waste-based tribology as a practical pathway toward circular economy solutions that unite sustainability with engineering performance. Full article

Ice accretion along aircraft leading edges, particularly at stagnation line parting strips, remains difficult to remove using conventional electrothermal anti-icing systems. These systems require continuous high-power heating to maintain the stagnation region above the melting point, often exceeding 10–12 kW/m². This study introduces an Ice Cavitation Deicer (ICD) that removes ice through rapid, localized cavitation generated within a thin melt layer formed at the ice–surface interface. In the proposed approach, a short pulse of electric current melts a 1–10 µm interfacial layer and causes a cavitation impulse of approximately 1–10 MPa. This impulse ejects the stagnation-line ice in a direction normal to the surface, often against the external airflow, enabling the immediate aerodynamic removal of the remaining ice. Analytical modeling based on the energy conservation principle was used to determine the optimal foil geometry, thermal pulse parameters, thermal stress, and material selection. Experiments with various metallic foils and substrate materials validated the predicted ejection behavior. The impulses were sufficient to fracture and eject ice 1–10 mm thick. The observed ice fragment velocities varied from 1 m/s to 10 m/s. Compared with conventional thermal anti-icing, the ICD concept reduces power consumption by approximately two orders of magnitude while offering rapid and reliable leading-edge deicing. The low power requirements, rapid response, and compatibility with thin-foil heater architectures make ICD a promising technology for both conventional and electrified aircrafts, UAVs, rotorcrafts, and other platforms where power availability is limited. This manuscript presents the first theoretical and experimental research on the ICD method and is a concept-proof work. Further research and development are required before the ICD is ready to be tested in flight. Full article

This paper presents the design, construction, and calibration of a modular low-cost 3D printer based on open-source technologies, developed as part of an academic research project. The printer utilises fused filament fabrication (FFF) and is built using locally available materials and components, including a T-slot aluminium frame, NEMA 23 stepper motors, and an Arduino Mega 2560 with RAMPS 1.4 control board. The system integrates Marlin firmware and CURA slicing software, enabling autonomous operation via an LCD panel and encoder interface. A detailed methodology is provided for mechanical assembly, electronic integration, firmware configuration, and calibration procedures. Special attention is given to the challenges encountered during the initial testing phase, including filament feeding issues, thermal inconsistencies, and mechanical misalignments. Solutions such as replacing inadequate components (e.g., fibreglass bushings with PTFE), adjusting spring tension, and refining firmware parameters are discussed. The results demonstrate successful printing of complex geometries after iterative calibration, validating the printer’s performance and replicability. This work contributes to the democratisation of additive manufacturing by offering a replicable, open-source solution for educational and prototyping purposes. The findings are relevant to machine design, automation, and robotics communities seeking practical insights into low-cost fabrication systems. Full article

Thermo-physiological comfort of automotive seating is governed by the complex interaction between seat-cover materials, their structural configuration, and the heat and moisture exchange occurring at the seat–body interface during prolonged sitting. While numerous studies have examined individual textile constructions or isolated comfort parameters, integrated evaluations combining objective material testing with dynamic microclimate measurements under realistic loading conditions remain limited. This study thoroughly examined six commercially important vehicle seat-cover materials that represent laminated, warp-knitted, and woven polyester architectures. Standardized laboratory techniques were used to quantify objective comfort qualities, such as air permeability, water vapor permeability, thermal resistance (Rct), and evaporative resistance (Ret) and transient heat flux test (H-test). Simultaneously, a multi-sensor system was used to constantly monitor temperature and relative humidity at the seat–body interface during sitting loading in a controlled subjective microclimate experiment at room temperature. The findings show that lamination technique and textile structure have a major impact on both transient microclimate behavior and steady-state material properties. Increased air and moisture transmission in warp-knitted and more open structures resulted in reduced evaporative resistance and more stable microclimate conditions. Denser laminated structures, on the other hand, exhibited more resistance to heat and evaporation, which led to a greater buildup of moisture when they were seated. Different temporal responses in temperature and humidity were also shown by the multi-sensor microclimate studies, underscoring the significance of assessing comfort beyond static material metrics. This study demonstrates that static thermos-physiological parameters alone are not sufficient to predict real stated comfort behavior. By integrating time-resolved microclimate analysis under realistic seated loading with standardized testing, a more reliable evaluation framework for automotive seat-cover comfort is proposed. Full article