Search Results (1,764)

Polylactic acid (PLA) is a promising biodegradable polymer whose widespread application is hindered by inherent brittleness. Polyethylene glycol (PEG) is a common plasticizer, but the effects of intermediate molecular weights, such as 4000 g/mol, on the coupled thermal, mechanical, and rheological properties of PLA remain insufficiently understood. This study presents a comprehensive analysis of PLA plasticized with 0–20 wt% PEG 4000, employing differential scanning calorimetry (DSC), dynamic mechanical analysis (DMA), and rheology. DSC confirmed excellent miscibility and a significant glass transition temperature (T_g) depression exceeding 19 °C for the highest concentration. A complex, non-monotonic evolution of crystallinity was observed, associated with the formation of different crystalline forms (α′ and α). Critically, DMA revealed that the material’s thermo-mechanical response is dominated by its thermal history: while the plasticizing effect is masked in highly crystalline, as-cast films, it is unequivocally demonstrated in quenched amorphous samples. The core finding emerges from a targeted rheological investigation. An anomalous increase in melt viscosity and elasticity at intermediate PEG concentrations (5–15 wt%), observed at 180 °C, was systematically shown to vanish at 190 °C and in amorphous samples. This proves that the anomaly stems from residual crystalline domains (α′ precursors) persisting near the melting point, not from a transient molecular network. These results establish that PEG 4000 is a highly effective PLA plasticizer whose impact is profoundly mediated by processing-induced crystallinity. This work provides essential guidelines for tailoring PLA properties by controlling thermal history to optimize flexibility and processability for advanced applications, specifically in melt-processing for flexible packaging. Full article

The development of high-performance wood-based materials has attracted increasing interest as a means of enhancing the mechanical properties of wood for structural applications. Mechanical densification combined with chemical pretreatment is an effective approach; however, many reported methods rely on complex multi-component chemical systems or severe chemical conditions designed to dissolve lignin or hemicelluloses. In this study, a simplified NaOH-only pretreatment followed by hot-press densification was investigated, targeting selective cell-wall plasticization rather than extensive polymer dissolution. Juniper (Juniperus communis), hawthorn (Crataegus monogyna), and birch (Betula pendula) were used as samples of softwood and hardwood species. Wood specimens were pretreated in 1 M NaOH at 145 °C for 10–30 min and subsequently densified by radial compression. Changes in chemical composition were evaluated by HPLC after acid hydrolysis and FTIR spectroscopy, while microstructural changes were examined using SEM. Physical and mechanical properties were assessed through density measurements and three-point bending tests. The results show that NaOH-only pretreatment induces hemicellulose deacetylation and modification of interpolymer linkages without substantial changes in the main wood polymer contents. Densification resulted in effective lumen collapse and a compact microstructure, leading to a significant increase in density and mechanical properties. Overall, the results demonstrate that efficient wood densification and mechanical enhancement can be achieved by promoting polymer mobility through selective cleavage of interpolymer bonds, using a simplified, single-alkali pretreatment that reduces chemical complexity and material loss while avoiding extensive lignin or hemicellulose dissolution. Full article

Elastomeric ablative coatings are essential for protecting solid rocket motor (SRM) combustion chambers from extreme thermal and erosive environments, and their performance is governed by both material composition and processing strategy. This review examines the main elastomer systems used for SRM insulation, including ethylene propylene diene monomer (EPDM), nitrile butadiene rubber (NBR), hydroxyl-terminated polybutadiene (HTPB), polyurethane (PU), silicone-based compounds, and related hybrids, and discusses how their rheological behavior, cure kinetics, thermal stability, and ablation mechanisms affect manufacturability and in-service performance. A comprehensive assessment of coating technologies is presented, covering casting, molding, centrifugal forming, spraying, automated deposition, and emerging additive-manufacturing approaches for complex geometries. Emphasis is placed on processing parameters that control adhesion to metallic substrates, layer uniformity, defect formation, and thermomechanical integrity under high-heat-flux exposure. The review integrates current knowledge on how material choice, surface preparation, and application sequence collectively determine insulation efficiency under operational SRM conditions. Practical aspects such as scalability, compatibility with complex chamber architectures, and integration with quality-control tools are highlighted. By comparing the capabilities and limitations of different materials and technologies, the study identifies key development trends and outlines remaining challenges for improving the durability, structural robustness, and ablation resistance of next-generation elastomeric coatings for SRMs. Full article

The strategic balance between strength and electrical conductivity in Al-Mg-Si alloys is a critical challenge that must be overcome to enable their widespread adoption as viable alternatives to copper conductors in power transmission systems. To address this, the present study comprehensively investigates model alloys with Mg/Si ratios ranging from 1.0 to 2.0. A multi-faceted experimental approach was employed, combining tailored thermo-mechanical treatments (solution treatment, cold drawing, and isothermal annealing) with comprehensive microstructural characterization techniques, including electron backscatter diffraction (EBSD) and scanning electron microscopy (SEM). The results elucidate a fundamental competitive mechanism governing property optimization: excess Mg atoms concurrently contribute to solid-solution strengthening via the formation of Cottrell atmospheres around dislocations, while simultaneously enhancing electron scattering, which is detrimental to conductivity. A critical synergy was identified at the Mg/Si ratio of 1.75, which promotes the dense precipitation of fine β″ phase while facilitating extensive recovery of high dislocation density. Furthermore, EBSD analysis confirmed the development of a microstructure comprising 74.1% high-angle grain boundaries alongside a low dislocation density (KAM ≤ 2°). This specific microstructural configuration effectively minimizes electron scattering while providing moderate grain boundary strengthening, thereby synergistically achieving an optimal balance between strength and electrical conductivity. Consequently, this work elucidates the key quantitative relationships and competitive mechanisms among composition (Mg/Si ratio), processing parameters, microstructure evolution, and final properties within the studied Al-xMg-0.5Si alloy system. These findings establish a clear design guideline and provide a fundamental understanding for developing high-performance aluminum-based conductor alloys with tailored Mg/Si ratios. Full article

Accurate prediction of ultimate tensile strength (UTS) is central to the design and optimization of heat-treated steels but is traditionally achieved through costly and iterative experimental trials. This study presents a transparent, physics-aware machine learning (ML) framework for predicting UTS using an open-access steel database. A curated dataset of 1255 steel samples was constructed by combining 18 chemical composition variables with 7 processing descriptors extracted from free-text heat-treatment records and filtering them using physically justified consistency criteria. To avoid information leakage arising from repeated measurements, model development and evaluation were conducted under a group-aware validation framework based on thermomechanical states. A Random Forest (RF) regression model achieved robust, conservative test-set performance (R² ≈ 0.90, MAE ≈ 40 MPa), with unbiased residuals and realistic generalization across diverse composition–processing conditions. Performance robustness was further examined using repeated group-aware resampling and strength-stratified error analysis, highlighting increased uncertainty in sparsely populated high-strength regimes. Model interpretability was assessed using SHAP-based feature importance and partial dependence analysis, revealing that UTS is primarily governed by the overall alloying level, carbon content, and processing parameters controlling transformation kinetics, particularly bar diameter and tempering temperature. The results demonstrate that reliable predictions and physically meaningful insights can be obtained from publicly available data using a conservative, reproducible machine-learning workflow. Full article

The growing demand for high-efficiency photovoltaic (PV) technologies has intensified interest in advanced cell architectures, including hybrid passivated back contact (HPBC) solar cells. Conventional solder-based interconnection processes require high thermal budgets, which can induce thermomechanical stress and lead to performance degradation in thin back-contact cell structures. In this study, electrically conductive adhesive (ECA) interconnection is investigated as a low-thermal-budget, solder-free alternative for HPBC solar cells. The curing behavior of an acrylic-based, silver-filled ECA is systematically examined by controlling the upper lamp temperature and the welding time during the interconnection process. Electrical performance is evaluated through current–voltage characterization, fill factor, and series resistance analysis, while interfacial microstructural evolution is examined using scanning electron microscopy. The results identify a well-defined processing window in which adequate curing enables stable electrical contact formation. In contrast, both insufficient curing and excessive curing result in degraded electrical performance. To assess practical applicability, HPBC modules with an industry-relevant size of ~1000 × 1160 mm² are fabricated and evaluated using electroluminescence imaging and I–V measurements. By identifying a robust curing window and demonstrating its successful transfer from string-level interconnections to full-size HPBC modules, this study establishes a practical, low-thermal-budget, solder-free interconnection strategy for advanced back-contact PV architectures. Full article

Magnesium–lithium alloys are the lightest structural metals and offer high specific strength, good damping capacity, and excellent thermal conductivity; however, their limited room-temperature strength restricts wider engineering applications. In this study, friction stir processing (FSP) was applied to LA103Z magnesium–lithium alloy to modify its surface microstructure and mechanical properties. The effects of tool rotational speed and travelling speed on dynamic recrystallization behavior, grain refinement, and phase evolution in the stirred zone (SZ) and thermomechanically affected zone (TMAZ) were systematically investigated. FSP induced significant grain refinement accompanied by the precipitation of a reticular α-Mg phase along β-Li grain boundaries, as well as Li₃Mg₇ and Li₂MgAl phases within the stirred zone, leading to pronounced strengthening. Under optimized processing conditions, substantial improvements in hardness and tensile properties were achieved compared with the base material. The optimal condition was obtained at 600 rpm and 100 mm/min, yielding an average hardness of 79.17 HV_0.2, a tensile strength of 243.6 MPa, and an elongation of 17.9%, corresponding to increases of 47.5% in hardness and 53.3% in tensile strength. Quantitative relationships between heat input, grain size, and mechanical properties further demonstrate that heat input governs microstructural evolution and strengthening behavior during FSP of LA103Z alloy. Full article

Freeze–thaw cycles (FTCs) are a prevalent weathering process that threatens the stability of canal slopes in seasonally frozen regions. This study combines direct shear tests under multiple F-T cycles with coupled thermo-hydro-mechanical numerical modeling to investigate the failure mechanisms of slopes with different moisture contents (18%, 22%, 26%). The test results quantify a marked strength degradation, where the cohesion decreases to approximately 50% of its initial value and the internal friction angle is weakened by about 10% after 10 freeze–thaw cycles. The simulation reveals that temperature gradient-driven moisture migration is the core process, leading to a dynamic stress–strain concentration zone that propagates from the upper slope to the toe. The safety factors of the three soil specimens with different moisture contents fell below the critical threshold of 1.3. They registered values of 1.02, 0.99, and 0.78 within 44, 44, and 46 days, which subsequently induced shallow failure. The failure mechanism elucidated in this study enhances the understanding of freeze–thaw-induced slope instability in seasonally frozen regions. Full article

The properties of chemically bonded core sands strongly depend on the reactivity of phenol-formaldehyde resole binders and on the granulometry of the sand matrix. This study presents an evaluation of the mechanical, technological, thermomechanical, and thermophysical properties of core sands prepared using two resole binders with different reactivity levels (Resin 1—lower reactivity; Resin 2—higher reactivity) and two fractions of quartz sand (BK 40 and BK 45). The investigations included the kinetics of strength development (1–48 h), friability, permeability, thermal deformation (DMA), and the determination of thermophysical coefficients (λ₂, a₂, b₂) based on temperature field registration during the solidification of a copper plate. The results indicate that sands containing the higher-reactivity binder exhibit a faster early strength increase (≈0.42–0.45 MPa after 1–3 h), whereas sands bonded with the lower-reactivity resin reach higher tensile strength after 24–48 h (≈0.58–0.62 MPa). Specimens based on BK 45 quartz sand achieved higher tensile strength; however, the finer grain fraction resulted in increased friability (up to ≈3.97%) and a reduction in permeability by 30–40%. DMA analysis confirmed that sands based on BK 40 exhibit delayed and more stable thermal deformation. Thermophysical parameters revealed that BK 45 provides significantly higher thermal insulation, extending the solidification time of the Cu plate from 71–73 s to 89–92 s compared with BK 40. Overall, the results indicate that the combination of BK 40 quartz sand and a lower-reactivity resin offers an optimal balance between thermal conductivity and thermal stability, promoting improved technological performance in casting processes. The determined thermophysical coefficients can be directly applied as input data for foundry process simulations. Full article

This study investigates a hybrid processing route that integrates localized fusion-based additive manufacturing and hot forging for the production of complex-shaped components, with emphasis on metallurgical integrity and mechanical performance. The DIN 8555 E6-UM-60 alloy, traditionally classified as martensitic and applied under severe wear conditions, exhibited atypical metallurgical behavior during hybrid processing, notably the consistent formation of chromium carbides under specific thermomechanical conditions. Metallographic analyses, microhardness measurements, thermographic monitoring, hot tensile tests, and room-temperature tensile tests were performed to establish correlations between microstructure, thermal history, and mechanical response. Specimens produced by additive manufacturing and subsequently hot forged showed a significant reduction in porosity, improved microstructural homogeneity, and partial retention of hardening phases, enabling discussion of recrystallization mechanisms, phase stabilization, and precipitation phenomena in martensitic alloys processed by additive manufacturing. Hot tensile tests revealed limited hot workability of the alloy, while room-temperature tensile tests led to premature fracture, with failure consistently initiating at pre-existing microcracks formed during the forging stage. Although detrimental, these microcracks provide valuable insight into critical processing conditions and ductility limits of the material. Overall, the hybrid route demonstrates strong potential for industrial applications, highlighting the importance of precise thermomechanical cycle control to mitigate defects and enhance structural reliability. Full article

This work investigates the structural, acoustic, and thermo-oxidative degradation behavior of elastomeric composites made from neat EPDM and recycled devulcanized EPDM (EPDMd) blends, both with and without silica (SiO₂). SiO₂ plays a complex role in degradation, possibly acting as a catalyst and also affecting the properties of the materials. Samples were subjected to accelerated degradation at 80 °C for 30 days. The characterization included the mechanical, spectroscopical (FTIR-ATR), thermal (TGA), and morphological (SEM) studies of the samples. Given EPDM’s use in construction as a sound-absorber, its acoustic properties were also analyzed. The determination of the mechanical properties shows that the incorporation of SiO₂ improves the Young’s modulus (YM), maintains the tensile strength (TS) at similar values, and causes a decrease in elongation at break (EB). The content of EPDMd slightly decreases both the TS and the EB and increases the YM. The thermo-oxidative degradation of the studied composites does not affect the TS values, but it increases the YM for the samples with and without SiO₂ for EPDMd contents higher than 40 phr, and decreases the EB for samples with and without SiO₂ for all EPDMd contents. The FTIR-ATR, TGA, and SEM results show that the addition of SiO₂ catalyzes the thermo-oxidative degradation process, while the EPDMd inhibits structural degradation. Migration of the ZnSt₂ included in the formulations to the surface is common in these elastomers. In this case, EPDMd forms microaggregates, which retain the exudation of ZnSt₂ crystals, especially in the non-degraded samples. The degraded samples present irregular structures, with microcavities, cracks, and occlusions, which increase the acoustic absorption mainly at frequencies below 1500 Hz. Full article

To evaluate the stability of fiber-reinforced cemented foamed backfill (FCFB) in complex underground mining environments, this study investigates the synergistic effects of fiber content and modified coal gangue (MCG) under acidic and high-temperature conditions. Through a systematic analysis of hydration processes, compressive strength, and deformation characteristics, the research identifies critical mechanisms for optimizing backfill performance. Calcination of MCG at 700 °C enhances gelling activity via amorphous phase formation, while modified aluminum dross (MAD) treated at 950 °C develops dense α-Al₂O₃ and spinel phases, significantly improving chemical stability. In acidic environments, the suppression of calcium silicate hydrate (C-S-H) is offset by the development of Al³⁺-driven C-A-S-H gels. These gels adopt a tobermorite-like structure, substantially increasing acid resistance. Mechanical testing reveals that while 1% fiber reinforcement promotes nucleation and densification, a 2% concentration hinders hydration. Compressive strength at 28 days shows constrained growth due to pore inhibition, and failure modes transition from multi-crack parallel failure (3-day) to single-crack tensile-shear failure. Under acidic conditions, strain concentration in the upper sample highlights a competitive mechanism between Al³⁺ migration and fiber anchorage. Ultimately, the coordinated regulation of MCG/MAD and fiber content provides a robust solution for roof support in challenging thermo-chemical mining environments. Full article

Friction Stir Processing (FSP) has emerged as an advanced solid-state surface engineering technique for tailoring high-performance surface architectures in metal matrix composites (MMCs). By combining localized thermo-mechanical deformation with controlled material flow, FSP enables grain refinement, homogeneous dispersion of reinforcement, and strong interfacial bonding without melting or altering bulk properties. This review critically examines the role of FSP in enhancing the mechanical, tribological, and corrosion performance of composites, with emphasis on process–structure–property relationships. Key strengthening mechanisms, including grain boundary strengthening, load transfer, particle pinning, and defect elimination, are systematically discussed, along with their implications for wear resistance, fatigue life, and durability. Special attention is given to corrosion and tribo-corrosion behavior, highlighting electrochemical mechanisms such as micro-galvanic interactions, passive film stability, and interfacial chemistry. Furthermore, the eco-efficiency, industrial viability, and sustainability advantages of FSP are evaluated in comparison with conventional surface modification techniques. The review concludes by identifying critical challenges and outlining future research directions for the scalable, multifunctional, and sustainable design of composite surfaces. Full article

The Cu-Cr-Zr alloy is regarded as an optimal material for high-end electronic information industries owing to its high electrical strength, high conductivity, and outstanding softening resistance. Nevertheless, the impacts of Cr content and microstructure evolution on performance enhancement during the processing stage remain unclear. In this research, Cu-xCr-0.1Zr alloys with varying Cr contents were fabricated via the thermo-mechanical approach. The microstructure evolution, as well as the mechanical and electrical properties before and after aging were investigated. It was discovered that Cr can mitigate the grain deformation degree of the copper alloy during cold rolling, notably augment the proportion of large-angle grain boundaries, and diminish the dislocation density induced by plastic deformation. As the Cr content increases, the conductivity of the sample declines from 86% IACS (0Cr) to 34.1% IACS (1.8Cr), and the tensile strength rises from 435 MPa (0Cr) to 542 MPa (1.8Cr) after cold rolling; the conductivity decreases from 89.4% IACS (0Cr) to 77.3% IACS (1.8Cr), and the tensile strength increases from 278 MPa to 607 MPa (1.0Cr). Based on the comprehensive outcomes, the aged 1.0Cr sample, with a tensile strength of 607 MPa and a conductivity of 80.9% IACS, satisfies the performance requirements of high-strength and high-conductivity copper alloys. Full article

Thermally induced deformation is a major source of dimensional error in end-milling, especially under high-speed or high-load conditions. Direct measurement of workpiece deformation during machining is impractical, while temperature signals can be obtained with good stability using embedded thermocouples. This study proposes an indirect method for predicting milling-induced thermal deformation based on temperature measurements. A three-dimensional thermo-mechanical finite element model is established to simulate the transient temperature field and corresponding deformation of the workpiece during milling. The numerical model is validated using cutting experiments performed under the same boundary conditions and machining parameters. Based on the validated results, the relationship between deformation at critical machining locations and temperature responses at candidate monitoring points is analyzed. To improve applicability to complex workpieces, a statistical prediction model is developed. Temperature monitoring points are optimized, and significant temperature–deformation correlations are identified using multiple linear regression combined with information-criterion-based model selection. The final model is constructed using simulation-derived datasets and provides stable deformation prediction over the entire milling process. Full article