Search Results (185)

In metallurgy, the quenching process often induces changes in certain material properties, such as hardness and ductility, through the rapid cooling of a workpiece in water, gas, oil, polymer, air, or other fluids. Given that lithium-ion batteries operate under relatively benign conditions, conventional rapid cooling does not significantly affect the property variations in their internal electrode materials during normal use. However, thermal runaway presents an exception due to its dramatic temperature fluctuations from room temperature to several hundred degrees Celsius. In this study, we investigated NCM811 cathodes in 18,650 batteries subjected to transient thermal runaway followed by rapid cooling using several advanced analytical techniques. The results reveal a phenomenon characterized by intergranular cracking within NCM811 cathode materials when exposed to rapid cooling during transient thermal runaway. Furthermore, lithium-ion cells utilizing reused NCM-182.4 electrodes in fresh electrolyte demonstrate a reversible capacity of 231.4 mAh/g after 30 cycles at 0.1 C, highlighting the potential for reusing NCM811 cathodes in the lithium-ion battery recycling process. These findings not only illustrate that NCM811 particles may experience intergranular cracking when subjected to rapid cooling during transient thermal runaway, but also the rapidly cooled NCM811 electrodes exhibit potential for reuse. Full article

Epoxy resins are valuable in aerospace, electronics, and high-performance industries; however, their inherently low thermal conductivity (TC) limits applications requiring effective heat dissipation. Recent reports suggest that certain liquid crystalline or partially crystalline epoxy formulations can achieve higher TC, even exceeding 1 W/(m·K). To investigate this, 17 epoxy formulations were prepared, including the commonly used diglycidyl ether of bisphenol A (DGEBA) and two custom-synthesized diepoxides: TME4, which contains rigid aromatic ester linkages with a C4 aliphatic spacer, and LCE-DP, featuring rigid imine bonds. Thermal conductivity was measured using four techniques: laser flash analysis (LFA), modified transient plane source (MTPS), time-domain thermoreflectance (TDTR), and displacement thermo-optic phase spectroscopy (D-TOPS). Additionally, small-angle and wide-angle X-ray scattering (SAXS/WAXS) were performed to detect crystalline or liquid crystalline domains. All formulations exhibited TC values ranging from 0.13 to 0.32 W/(m·K). The TME4–DDS systems, previously reported to be near 1 W/(m·K), consistently measured between 0.26 and 0.30 W/(m·K). Thus, under our synthesis and curing conditions, the elevated TC reported in prior studies was not reproduced, and no strong evidence of crystallinity was observed; indications of local ordering did not translate into higher conductivity. Variations in TC among methods often matched or exceeded the gains attributed to mesophase formation. More broadly, evidence for crystallinity in epoxy thermosets appears weak, consistent with the notion that crosslinking suppresses long-range ordering. Full article

Insulation degradation in photovoltaic (PV) cables can cause electrical faults and fire hazards, thereby compromising system reliability and safety. Early detection of precursor signals is crucial for preventive maintenance. However, conventional diagnostic techniques are limited to static assessments and fail to capture early-stage electrical anomalies in real-time. This study investigates the time-series behavior of voltage, current, and temperature in PV cables under thermal stress conditions. Experiments were conducted using TFR-CV cables installed in a vertically stacked and tight-contact configuration. A gas torch was applied for localized heating to induce insulation degradation. A grid-connected testbed with six series-connected PV modules was constructed. Each module was instrumented with PV-M sensors, temperature sensors, and an infrared camera. Data were acquired at 1 Hz intervals. Results showed that cable surface temperature exceeded 280 °C during degradation. The output voltage exhibited transient surges of up to +13.3% and drops of −68%, while the output current decreased by over 20%, particularly in the PV-M3 module. These anomalies, such as thermal imbalance, voltage spikes/dips, and current drops, were closely associated with critical degradation points and are interpreted as precursor signals. This work confirms the feasibility of identifying fire-related precursors through real-time monitoring of PV cable electrical characteristics. The observed correlation between electrical responses and thermal expansion behaviors suggests a strong link to the stages of insulation degradation. Future work will focus on quantifying the relationship between degradation and electrical behavior under controlled environmental conditions. Full article

To implement predictive maintenance of units in the practice of metallurgical manufacturers, computer information and diagnostic systems are being developed to assess the current state of individual units throughout their entire life cycle. This publication presents the results of a study on developing an infrared diagnostic system for predictive maintenance of converter units in the non-ferrous metallurgy industry. A 3D mathematical model of the transient heat transfer in the wall of a real operating unit has been developed and numerically implemented to study, analyze, and diagnose surface temperature fields resulting from wear and local damage. To adjust the operation of the mathematical model, the design parameters and the results for operating and technological parameters from an industrial experiment are taken into consideration. Using the model, a full-factor experiment was simulated to study the surface temperature fields resulting from the erosion wear of the wall and the presence of local damage. Based on the simulation results, the optimal time range for thermographic monitoring is determined. A regression dependence was derived to predict the refractory wall wear as a function of the outer surface temperature of the converter unit. The results are part of a comprehensive investigation aimed at developing thermal imaging techniques for converter units in non-ferrous metallurgy. Full article

The rapid growth of wind energy infrastructure over the past two to three decades has led to an urgent need for advanced non-destructive testing (NDT) methods—both for newly installed wind turbine blades (WTBs) and for ageing components nearing the end of their service life. Among emerging techniques, passive infrared thermography (IRT) offers a promising solution by enabling contactless, time-efficient inspection based on naturally occurring thermal variations. The effectiveness of passive IRT depends on the presence of sufficient thermal contrast to distinguish surface features, subsurface structures, and defects. To better understand the possibility of obtaining such contrast in composite structures such as WTBs, a controlled study was carried out on a blade section exposed to programmed temperature transients in a climate chamber. Infrared measurements were recorded, and the thermal behaviour of the specimen was simulated using finite element models (FEM) in COMSOL Multiphysics 6.3. Although direct validation is limited by measurement uncertainties and transient effects, the comparison provides insight into the capabilities and limitations of FEM in replicating real-world thermal behaviour. This paper focuses specifically on the challenges related to the modelling approach. Full article

Conventional asphalt pavement snow and ice removal methods suffer from issues such as time-consuming operations, high costs, and pollution from chemical de-icing agents. Commonly used thermally conductive asphalt concrete (TCAC) faces problems including limited filler diversity, high filler content, and elevated costs. To address these challenges, this study developed a thermally conductive asphalt concrete incorporating carbon fiber–silicon carbide composite fillers to provide a low-cost, energy-saving winter pavement snow melting solution and enhance eco-friendly de-icing performance. Finite element simulation software was employed to model its snow and ice melting performance, investigating the factors influencing this capability. Thermal conductivity was measured using the transient plane source (TPS) technique. The results show that with 0.3% carbon fiber, thermal conductivity reaches 1.43 W/(m·°C), 72.3% higher than ordinary asphalt concrete. Finite element simulations in finite element simulation software were used to model snow and ice melting, and strong agreement with field test data (correlation coefficients > 0.9) confirmed model reliability. Then, the finite element simulation software was used to study the effects of wind speed, temperature, laying power, and spacing on the snow and ice melting of TCAC. The simulation results show that the heating rate increases with TCAC thermal conductivity. Raising the power of the embedded carbon fiber heating cord reduces de-icing time but shows a threshold effect. In this study, asphalt pavement with high thermal conductivity was prepared using a low content of thermal conductive filler, providing a theoretical basis for sustainable pavement design, reducing energy use and environmental damage. TCAC technology promotes greener winter road maintenance, offering a low-impact alternative to chemical de-icing, and supports long-term infrastructure sustainability. Full article

In the paper, the inverse solution of the heat conduction problem is analysed, which is applied to calculate transient thermal stresses on the internal surface of a thick-walled pipe weakened by a hole. The analysis considered a one-dimensional heat transfer problem when heat is transferred in a radial direction. In the inverse marching method, the measurement of the wall temperature at one point of a thermally insulated pipeline is used. The technique was verified regarding the distance between the point where the wall temperature is measured and the internal surface, the number of finite volumes in the inverse region, and the time step size are selected. The influence of these parameters on the accuracy of the calculated temperature, thermal stresses, heat transfer coefficient on the internal surface of the pipeline and thermal stresses at the hole edge was assessed. The reference values used to verify the technique were those calculated using the analytical method and the direct solution of the heat conduction problem, and the generated ‘measurement data’ were disturbed by random errors. Full article

This paper investigates the inverse reconstruction of temperature fields under both steady-state and transient heat conduction scenarios. The central contribution lies in the structured development and validation of the Gappy Clustering-based Proper Orthogonal Decomposition (Gappy C-POD) method—an approach that, despite its conceptual origin alongside the clustering-based dimensionality reduction method guided by POD structures (C-POD), had previously lacked an explicit algorithmic framework or experimental validation. To this end, the study constructs a comprehensive solution framework that integrates sparse sensor layout optimization with data-driven field reconstruction techniques. Numerical models incorporating multiple internal heat sources and heterogeneous boundary conditions are solved using the finite difference method. Multiple sensor layout strategies—including random selection, S-OPT, the Correlation Coefficient Filtering Method (CCFM), and uniform sampling—are evaluated in conjunction with database generation techniques such as Latin Hypercube sampling, Sobol sequences, and maximum–minimum distance sampling. The experimental results demonstrate that both Gappy POD and Gappy C-POD exhibit strong robustness in low-modal scenarios (1–5 modes), with Gappy C-POD—when combined with the CCFM and maximum distance sampling—achieving the best reconstruction stability. In contrast, while POD-MLP and POD-RBF perform well at higher modal numbers (>10), they show increased sensitivity to sensor configuration and sample size. This research not only introduces the first complete implementation of the Gappy C-POD methodology but also provides a systematic evaluation of reconstruction performance across diverse sensor placement strategies and reconstruction algorithms. The results offer novel methodological insights into the integration of data-driven modeling and sensor network design for solving inverse temperature field problems in complex thermal environments. Full article

Building performance simulation is crucial for the design and optimization of sustainable buildings. However, the increasing complexity of building systems necessitates advanced modeling techniques capable of handling multi-domain interactions. This paper presents a novel application of the bond graph (BG) methodology to simulate and analyze the thermal behavior of an integrated trigeneration system within an experimental test cell. Unlike conventional simulation approaches, the BG framework enables unified modeling of thermal and hydraulic subsystems, offering a physically consistent and energy-based representation of system dynamics. The study investigates the system’s performance under both dynamic and steady-state conditions across two distinct climatic periods. Validation against experimental data reveals strong agreement between measured and simulated temperatures in heating and cooling scenarios, with minimal deviations. This confirms the method’s reliability and its capacity to capture transient thermal behaviors. The results also demonstrate the BG model’s effectiveness in supporting predictive control strategies, optimizing energy efficiency, and maintaining thermal comfort. By integrating hydraulic circuits and thermal exchange processes within a single modeling framework, this work highlights the potential of bond graphs as a robust and scalable tool for advanced building performance simulation. Full article

Climate concerns are driving the automotive industry to adopt advanced manufacturing technologies that aim to improve energy efficiency and reduce vehicle weight. In this context, lightweight structural materials such as aluminium alloys have gained significant attention due to their favorable strength-to-weight ratio. Laser welding plays a crucial role in assembling such materials, offering high flexibility and fast joining capabilities for thin aluminium sheets. However, welding these materials presents specific challenges, particularly in controlling heat input to minimize distortions and ensure consistent weld quality. As a result, numerical simulations based on the Finite Element Method (FEM) are essential for predicting weld-induced phenomena and optimizing process performance. This study investigates welding-induced distortions in laser butt welding of 1.5 mm-thick Al 6061 samples through FEM simulations performed in the SYSWELD 2024.0 environment. The methodology provided by the software is based on the Moving Heat Source (MHS) model, which simulates the physical movement of the heat source and typically requires extensive calibration through destructive metallographic testing. This transient approach enables the detailed prediction of thermal, metallurgical, and mechanical behavior, but it is computationally demanding. To improve efficiency, the Imposed Thermal Cycle (ITC) model is often used. In this technique, a thermal cycle, extracted from an MHS simulation or experimental data, is imposed on predefined subregions of the model, allowing only mechanical behavior to be simulated while reducing computation time. To avoid MHS-based calibration, this work proposes using thermal cycles acquired in-line during welding via infrared thermography as direct input for the ITC model. The method was validated experimentally and numerically, showing good agreement in the prediction of distortions and a significant reduction in workflow time. The distortion values from simulations differ from the real experiment by less than 0.3%. Our method exhibits a slight decrease in performance, resulting in an increase in estimation error of 0.03% compared to classic approaches, but more than 85% saving in computation time. The integration of real process data into the simulation enables a virtual representation of the process, supporting future developments toward Digital Twin applications. Full article

With the development of digital power systems, the establishment of digital twin models for transformers is of great significance in enhancing power system stability. Consequently, greater demands are placed on the real-time performance and accuracy of thermal-fluid-coupled transient multi-physics field calculations for transformers. However, traditional numerical methods, such as finite element or computational fluid dynamics techniques, often require days or even weeks to simulate full-scale high-fidelity transformer models containing millions of grid nodes. The high computational cost and long runtime make them impractical for real-time simulations in digital twin applications. To address this, this paper employs the dynamic mode decomposition (DMD) method in conjunction with Koopman operator theory to perform data-driven reduced-order modeling of the transformer’s thermal–fluid-coupled multi-physics field. A fast computational approach based on extended dynamic mode decomposition (EDMD) is proposed to enhance the modal decomposition capability of nonlinear systems and improve prediction accuracy. The results show that this method greatly improves computational efficiency while preserving accuracy in high-fidelity models with millions of grids. The errors in the thermal and flow field calculations remain below 3.06% and 3.01%, respectively. Furthermore, the computation time is reduced from hours to minutes, with the thermal field achieving a 97-fold speed-up and the flow field an 83-fold speed-up, yielding an average speed-up factor of 90. This enables fast computation of the transformer’s thermal–fluid-coupled field and provides effective support for the application of digital twin technology in multi-physics field simulations of power equipment. Full article

This study addresses the issue of frequency instability caused by an imbalance between load power and generation power in a power system. A state-space model of a two-area power system including a thermal power plant is first established, incorporating the output power limitations of the energy storage system, which is the actuator for frequency control. Under input saturation constraints, a frequency control strategy based on a prescribed performance control technique is proposed. This strategy not only ensures frequency stability but also achieves an optimal transient response curve. The proposed control strategy is theoretically validated and numerically simulated, demonstrating its effectiveness in suppressing frequency variations in power systems under constraints regarding the output power of the energy storage system. Full article

A potential field of study for improving the efficiency of next-generation photovoltaic devices hot carriers in perovskite solar cells is investigated in this review paper. Considering their relevance to hot carrier dynamics, the paper thoroughly studies metal halide perovskites’ essential characteristics and topologies. We review important aspects like carrier excitation, exciton binding energy, phonon coupling, carrier excitation, thermalization, and hot hole and hot electron dynamics. We investigate, in particular, the significance of relaxation mechanisms, including thermalization and the Auger heating effect. Moreover, the bottleneck effect and defect management are discussed with an eye on their impact on device performance and carrier behaviour. A review of experimental methods for their use in investigating hot carrier dynamics, primarily transient photovoltage measurements, is included. Utilizing this thorough investigation, we hope to provide an insightful analysis of the difficulties and techniques for reducing the effect of hot carriers in perovskite solar cells and optimizing their performance. Full article

When a semiconducting sample is illuminated by an intensity-modulated monochromatic light beam with photon energy exceeding the band gap, part of the absorbed energy is directly converted into heat through photon–lattice interactions. This gives rise to a heat source that closely follows the temporal profile of the optical excitation, known as the fast heat source. Simultaneously, another portion of the absorbed energy is used to generate electron-hole pairs. These charge carriers diffuse together and recombine via electron–electron and electron–hole interactions, transferring their kinetic energy to the lattice and producing additional heating of the sample. This indirect heating mechanism, associated with carrier recombination, is referred to as the slow heat source. In this study, we develop a model describing surface temperature variations on the non-illuminated side of a thermally thin semiconductor exposed to a rectangular optical pulse, explicitly accounting for the contribution of surface charge carrier recombinations. Using this model, we investigate the influence of surface recombination velocity and the material’s plasma properties on the time-domain temperature response for both plasma-opaque and plasma-transparent samples. Our results demonstrate that charge carrier recombinations can significantly affect the transient photoacoustic signal recorded using a minimum volume cell, highlighting the potential of time-resolved photoacoustic techniques for probing the electronic properties of semiconductors. Full article

To improve the convective heat transfer in internal cooling channels of heavy-duty gas turbine blades, this study experimentally and numerically investigates the thermal performance of rectangular channels with hybrid pin-fins and micro V-ribs turbulators. The transient thermochromic liquid crystal (TLC) technique and ANSYS 2019 R3 (ICEM CFD 2019 R3, Fluent 2019 R3, CFD-Post 2019 R3) were employed under Reynolds numbers ranging from 10,000 to 50,000, with the numerical model rigorously validated against experimental data (the maximum RMSE is 2.5%). It is found that hybrid pin-fins and continuous V-ribs configuration exhibits the maximum heat transfer enhancement of 27.6%, with an average friction factor increase of 13.3% and 21.9% improvement in thermal performance factor (TPF) compared to the baseline pin-fin channel. In addition, compared to the baseline pin-fin channel, hybrid pin-fins and broken V-ribs configuration exhibits average heat transfer enhancement (Nu/Nu0) of 24.4%, an average friction factor increase of 7.2% and 22.5% improvement across the investigated Reynolds number range (10,000~50,000) based on computational results. The synergistic effects of hybrid pin-fin and micro V-rib structures demonstrate superior coolant flow control, offering a promising solution for next-generation turbine blade cooling designs. This work provides actionable insights for high-efficiency gas turbine thermal management. Full article