Search Results (130)

The present paper reviews original data obtained by the authors from recent separate publications with additional unpublished data, specifically concerning the specific graphite morphology in Si/SiMo alloyed ductile irons (2.5–5.5% Si, 0.01–2.3% Mo) with alloying grade, cooling rate, and inoculation as influencing factors. Different formulas used for nodularity evaluation, including different forms of graphite participating in different proportion and two graphite shape factors: Roundness (RSF, involving maximum Ferret) and Sphericity (SSF, involving real perimeter). Slightly irregular spheroidal graphite morphology (Form V, ISO 945) characterized by RSF = 0.59–0.75 was found to be typical for Si and SiMo ductile irons in all of the test conditions, such as Si level (4.2–5.25% Si), Si–Mo system (4.1–4.8% Si + 1.6–2.3% Mo), mould type (green sand, resin sand, metal mould, external metallic chill), un-inoculation and inoculation, and inoculating element type. Increasing Si content negatively affects the compactness degree of spheroidal graphite particles (transition from VI to V form) and nodularity. Metal mould versus sand mould solidification of 4.5% Si ductile iron increases nodule count, graphite shape factors (RSF = 0.68–0.7 versus 0.59–0.64) and nodularity (67% to 76%). An external metallic chill in a resin sand mould promoted directional solidification and showed a nodularity decrease for increasing Si, for all the nodularity formulas and for the cooling rate range. Inoculating elements influenced the shape factors in thin wall castings, where Ca–Ba was better than simple Ca and Ca–RE could promote graphite at higher real perimeter and with lower shape factors. The correlation of the aspect of structure, graphite parameters and nodularity led to the conclusion that the nodularity formula according to ISO/WD 945-4-2015 (100% total area of Form VI and 90% of Form V), with SSF instead of RSF, appears to be better in High-Si/SiMo DI (especially for more than 4% Si), because it takes into account the presence of slightly irregular spheroidal graphite (with high real perimeter) at a high rate. Full article

The formation of carbon nanostructures and silicon carbide (SiC) using a single-source precursor offers a simplified route for material synthesis; however, the factors governing the transition between CNT-like structure formation and SiC growth remain unclear. In this study, the growth behavior of carbon-related structures using vinylsilane was systematically investigated by hot-wall chemical vapor deposition (CVD) on various substrates, including Fe bulk substrates and Fe thin films on SiO₂/Si. CNT-like structures were preferentially formed on Fe bulk substrates, whereas Fe thin-film substrates exhibited CNT-like growth at the initial stage followed by increased Si–C-related phase formation with increasing growth temperature and growth time. In contrast, on Fe thin films with limited catalyst amounts, CNT-like growth occurred initially, followed by increased Si–C-related phase formation with increasing growth temperature and growth time. These observations are consistent with a growth transition associated with the balance between Si uptake into the metal and surface SiC formation processes. By controlling catalyst amount, growth temperature, and growth time, the relative formation of CNT-like structures, SiC-rich coatings, and intermediate morphologies could be tuned within a single process. Furthermore, a SiC/CNT-like composite structure was directly formed on a conductive Fe substrate in a one-step CVD process. Electrochemical measurements showed an enhanced current response compared with a bare Fe substrate, indicating preliminary electrochemical activity and suggesting potential applicability as a high-surface-area electrode platform. Full article

Localized stress concentration and defect accumulation are prone to occurring during metal spinning because of the coupled effects of complex loading and interfacial friction. In this study, a molecular dynamics model of metal spinning was established to investigate the effects of process parameters and temperature on the mechanical response, material flow, contact loading, and dislocation evolution behavior within the contact zone. The results indicate that the optimal deformation coordination is achieved with an arc radius of 25 Å, an indentation depth of 8 Å, and a tangential velocity of 1.5 Å/ps. Analysis of the normal and tangential forces shows that the normal load is rapidly established during the indentation stage, whereas the tangential load continuously increases with material shear transport. Both loads decrease significantly with increasing temperature. Elevated temperature effectively suppresses dislocation accumulation and simplifies the dislocation structure, causing the plastic deformation behavior to gradually transition toward a dominant primary slip-system mode. This study reveals the local deformation and dislocation evolution mechanisms during spinning and provides theoretical guidance for the process optimization of thin-walled spinning components. Full article

Tube boilers are extensively employed in oil and gas refineries, as well as in petroleum, energy, and power generation industries, where they serve critical functions in local steam-generation units and combined-cycle gas turbine (CCGT) plants. However, these boilers are prone to defects arising from waterside corrosion (e.g., thinning of U-bend tubes), fireside corrosion, and material degradation caused by stress or creeping. Among these issues, wall thinning of tube bends is particularly severe, as it results in localized metal loss, reduced structural integrity, and an elevated risk of tube rupture or failure under high-temperature and high-pressure operating conditions. Such failures can significantly compromise boiler safety and efficiency, potentially leading to forced outages, costly unplanned repairs, or catastrophic damage if not detected in time. The current condition-monitoring policy for U-bends relies on scheduled preventive maintenance and unscheduled corrective interventions. In practice, this involves randomly checking approximately 10–20% of the tubes through spot scanning, partial scanning, or full scanning, with repairs typically carried out only after an undetected failure occurs. Such maintenance strategies generally require plant shutdowns, making the process time-consuming, labor-intensive, and ultimately not cost-effective. This paper reviews existing solutions, technologies, and research addressing the problem, and introduces femtosecond laser micromachined fiber optic sensors as a transformative approach for real-time monitoring of wall thickness reduction in U-bend boiler tubes, thereby opening pathways for further research. Full article

Wire Arc Additive Manufacturing (WAAM) has emerged as a promising additive manufacturing technique due to its high deposition rate and low material cost. WAAM is increasingly adopted in various industries for the production of large-scale metal components, yet optimizing productivity without sacrificing mechanical integrity remains a critical challenge, particularly for low-carbon steels. This study systematically investigates the influence of key WAAM parameters—welding current (100–350 A) and travel speed (5–30 mm/s) on the deposition stability, microstructure, and mechanical properties of thin walls made of low-carbon Fe–0.09 C–1.10 Cr–1.47 Mn–0.59 Si–0.56 Mo–0.11 Ni–0.23 V steel. A stable processing window for defect-free wall fabrication was established for currents of 100–250 A, while higher currents of 300–350 A resulted in melt pool instability and geometrical distortions due to excessive heat input. Microstructural characterization revealed a dual-phase structure consisting of allotriomorphic ferrite (ALF) and acicular ferrite (AF) in all samples. The microstructural evolution was critically governed by variations in the cooling time in the critical temperature range of 800 °C to 500 °C (t_8/5) within the thermal cycles, a direct consequence of the heat input quantified through volumetric energy density. Low heat input at 100 A, 5 mm/s promoted a microstructure with minimal ALF fraction of ~10%, whereas high heat input at 350 A, 30 mm/s induced significant ferrite recrystallization and coarsening, increasing ALF fraction to ~55%. These microstructural changes directly affected mechanical properties: YS/UTS decreased from 512 MPa/668 MPa to 401 MPa/602 MPa, respectively. Concurrently, the deposition rate increased substantially from ~1.6 kg/h to ~6.3 kg/h. The results demonstrate a critical trade-off between productivity and mechanical performance, providing a practical framework for parameter selection in WAAM-fabricated low-carbon steel components. Full article

Due to high specific energy absorption, composite/metal hybrid multi-cell thin-walled tubes hold significant potential in the field of automotive passive safety. However, the material coupling effect enhancing SEA often elevated the initial peak crushing force, reducing crushing force efficiency and compromising occupant protection. To balance SEA and CFE, trigger holes were introduced as an induced deformation mechanism for hybrid tubes to reduce IPCF while preserving SEA, with the optimized perforated configuration yielding higher CFE than the non-perforated counterpart. A high-fidelity finite element model of the hybrid tube was developed and experimentally validated, and the influences of induced structural parameters on SEA and CFE were investigated. Given the strong nonlinear coupling between trigger parameters and crashworthiness, a multilayer perceptron surrogate model was constructed using 200 optimal Latin hypercube sampling samples (20 for validation). A Q-learning enhanced particle swarm optimization (QL-PSO) algorithm was adopted for optimization, with reinforcement learning dynamically adjusting PSO parameters to balance global exploration and local exploitation. Finite element simulations validated that the proposed method achieved a favorable SEA-CFE trade-off, with SEA and CFE improved by 12.02% and 16.39% respectively, outperforming reported configurations. Compared with standard PSO, QL-PSO exhibited superior search efficiency and inverse mapping accuracy, with 22% higher optimization efficiency and full compliance with inverse design performance targets. This study provided valuable guidance for the design of thin-walled energy-absorbing structures in multi-material vehicle bodies. Full article

This study introduces two compact wideband substrate-integrated waveguide (SIW) filters fabricated using thin-film technology. The wideband bandpass response is achieved by incorporating interdigital capacitor (IDC) structures into a half-mode SIW (HMSIW) transmission line. An equivalent LC circuit model is formulated to analyze the influence of IDC parameters on the generation of transmission zeros. For the first filter (BPF 1), a third-order IDC coupling configuration is employed, resulting in a 1 dB passband spanning 11 GHz to 18 GHz, a minimum insertion loss of 0.66 dB, three transmission zeros that enhance stopband performance, and a compact core dimension of $0.49{\lambda }_g\times 0.29{\lambda }_g$. For further miniaturization, a modified HMSIW transmission line incorporating a metal-insulator-metal (MIM) capacitor at the equivalent magnetic wall is proposed. This design effectively reduces the transverse dimension of the waveguide while maintaining the original cutoff frequency. Utilizing this configuration, the second bandpass filter (BPF 2) was designed and fabricated employing double-layer ceramic thin-film technology. The resulting filter exhibits a 1 dB passband spanning 10 GHz to 18 GHz, a compact footprint measuring $0.44{\lambda }_g\times 0.23{\lambda }_g$, a minimum insertion loss of 0.58 dB, and features three transmission zeros. The fabricated and measured results of both filters show good agreement with simulations. Compared with previously reported wideband SIW filters, the proposed designs demonstrate comprehensive advantages in fractional bandwidth, insertion loss, out-of-band suppression, and circuit size, providing effective filtering solutions for high-density integration of microwave and millimeter-wave RF systems. Full article

Metallic thin-walled circular rings are widely employed as energy-absorption components in impact protection systems. However, the dynamic deformation mechanisms under impact loads remain incompletely understood. In this study, we develop a rigid-perfectly plastic model to analyze a simply supported circular ring subjected to impulsive loads. We present a theoretical survey of the incipient deformation under step loading, establishing the relation between the applied load magnitude and the number and location of the stationary plastic hinges. Our analytical findings reveal that as load magnitude increases, the number of stationary hinges grows, with newly formed hinges progressing closer to the point of loading. We validate these theoretical predictions against finite element analyses, demonstrating the model’s accuracy. Additionally, we investigate the complex deformation mechanisms involving both stationary and traveling hinges under rectangular pulse loading. This study provides fundamental insights into the dynamic plastic response of thin-walled structures, offering theoretical guidance for optimizing impact protection systems. Full article

Thin wall composite fan blades in aircraft engines demand designs that ensure structural integrity under operational loads while resisting foreign object damage and bird strikes. This study presents a finite element investigation of thin wall composite blades with metal leading edge caps, modeled through parametric coupon analyses under static flexure loading using ANSYS APDL. Three metallic leading edge caps, Ti-6Al-4V, Inconel 718, and 15-5 PH stainless steel, were combined with IM7/8551-7 carbon fiber composites. Parametric variations included changes in metal cap material, geometric designs of the joint, and other things. Performance was evaluated in terms of failure stress, interlaminar shear strains, interface integrity, and failure margins. Results reveal that cap design and cap material critically govern structural response, with distinct interchanges between strength-to-weight efficiency, interface stresses, and interlaminar shear strain. Optimal designs reduced interlaminar shear strain levels in thin wall composite blades, while retaining adequate stiffness and strength. The results underscore the importance of interface design for effective load transfer and provide design guidelines for lightweight, damage-tolerant thin wall composite fan blade structures. Full article

Aircraft structures are highly susceptible to fatigue damage, particularly in thin-walled aluminum alloy components such as skin panels. Damage in the form of holes or material loss drastically reduces fatigue life and compromises structural safety, which makes effective repair strategies essential. This study presents an experimental investigation into the fatigue performance of EN AW-2024-T3 aluminum alloy plates with central openings subjected to uniform shear. Repair nodes were applied using two approaches: conventional riveted metal patches and adhesively bonded composite patches. Variants of patch geometry, thickness, and diameter were evaluated to determine their influence on load transfer, buckling response, and fatigue life. The results show that central holes significantly shorten fatigue life, with a 20 mm hole causing a 67% reduction and a 50 mm hole causing a 95% reduction when compared with undamaged plates. Riveted metal patches restored only part of the lost performance, as stress concentrators introduced by fastener holes initiated new fatigue cracks. In contrast, adhesively bonded composite patches provided a substantial improvement, extending fatigue life beyond that of the riveted solutions, improving buckling shape, and delaying crack initiation. Larger patches, particularly those combined with metallic inserts, proved most effective in restoring structural functionality. The findings confirm the effectiveness of bonded composite repairs as a lightweight and reliable method for extending fatigue life and enhancing the safety of damaged aircraft structures. The study highlights the importance of patch geometry and stiffness in the design of repair nodes. Full article

Additive manufacturing (AM) enables the consolidation of components and the integration of new functionalities in metallic parts, but layered fabrication often results in poor surface quality and geometric deviations. Among various surface treatment techniques, machining is often favoured for its capability to enhance not only surface finish but also critical geometric tolerances such as flatness and circularity, in addition to dimensional accuracy. However, machining AM components, particularly thin-walled structures, poses challenges related to unconventional material properties, complex fixturing, and heightened susceptibility to chatter. This study investigates the vibrational behaviour of thin-walled Ti6Al4V components produced via laser powder bed fusion, using a jet-engine compressor blade demonstrator. Four stock envelope designs were evaluated: constant, tapered, and two topologically optimised variants. After fabrication by Laser Powder Bed Fusion, the blades underwent tap testing and subsequent machining to assess changes in modal characteristics. The results show that optimised geometries can enhance modal performance without increasing the volume of the stock material. However, these designs exhibit more pronounced in situ modal changes during machining, due to greater variability in material removal and chip load, which amplifies vibration sensitivity compared to constant or tapered stock designs. Full article

The aim of the current study is to optimize the bead geometries of 80B2, namely, the bead height (BH) and bead width (BW), utilizing a mild steel substrate and a wire-arc additive manufacturing (WAAM) technique based on gas metal arc welding (GMAW). Single-layer depositions with different wire feed speed (WFS), voltage (V), and travel speed (TS) were accomplished by applying the Box–Behnken design methodology. Multivariable nonlinear regression models were developed and validated through ANOVA, revealing WFS as the most significant parameter influencing both BW and BH. The minimal influence of the error factor on each response proved the accuracy of the ANOVA findings. The favorable assessment of residual plots confirmed the appropriateness and reliability of the developed regression equations and ANOVA results. A metaheuristic Passing Vehicle Search (PVS) algorithm was applied for single-objective and multi-objective optimization, yielding a minimum BW of 5.874 mm and a maximum BH of 14.153 mm. Main effect and residual plots confirmed the accuracy and reliability of the predictive models. The parametric settings of WFS: 18 mm/min, TS: 7 mm/s, V: 19 V were obtained for simultaneous optimization of BW with 7.78 mm and BH with 10.87 mm. Pareto points were also generated, which provide non-dominated unique solutions. The study emphasizes the critical role of precise process parameter control in improving WAAM build quality and offers a robust framework for optimizing bead morphology, ultimately enhancing the efficiency and applicability of WAAM for structural component fabrication. These optimized parameters will be used in the future to manufacture a thin-walled, multi-layered structure. Full article

This study aimed to optimize the grain structure of complex thin-walled nickel-based superalloy castings by investigating the influence of key casting parameters using both cellular automaton–finite element (CAFE) simulations and experimental validation. The main problem addressed was the inhomogeneous grain morphology arising from complex mold geometries and uneven thermal conditions during investment casting. The solidification process was simulated using the ProCAST software, incorporating the CAFE method to model temperature fields and grain growth dynamics. The results revealed that the molten metal flow pattern during mold filling significantly affected the local temperature field and subsequent grain formation. Specifically, simultaneous bidirectional filling minimized thermal gradients and suppressed coarse columnar grain formation, promoting finer, more uniform equiaxed grains. Lowering the pouring temperature (to 1430 °C) in combination with reduced shell temperature (600–800 °C) enhanced nucleation and improved grain uniformity in thin-walled regions. Higher cooling rates also refined the grain structure by increasing undercooling and limiting grain growth. Experimental castings confirmed these simulation outcomes, demonstrating that the proposed optimization strategies can significantly improve grain homogeneity in critical structural areas. These findings provide a practical approach for controlling microstructure in large, intricate superalloy components through targeted process parameter tuning. Full article

Thin-walled structures have been extensively adopted as energy absorbers in various engineering fields. The energy accumulated in the coal and rock is released instantly, resulting in varying degrees of damage and failure to support equipment. To improve the crushing performance of underground support equipment, a metal thin-walled tube with high-bearing capacities is placed in the column as an energy-absorbing column. Based on the characteristics of non-dimensional parameters governing the crashworthiness of thin-walled tubes by the author’s team, a type of high-performance bi-tubular tube (HPBT) with mixed multicellular configurations is innovatively proposed. First, the finite element models of the HPBTs are established in LS-DYNA, and the accuracy of the FE model is verified by crushing tests. Second, the theoretical model of the mean crushing force (MCF) is derived. Moreover, the effects of the cross-sectional shapes and the wall thickness gradient distribution on the deformation modes and crashworthiness are investigated. The results show that the design strategies of the bi-tubular structures mixed multicellular configurations significantly improve the values of ω. The MCF of HPBT_C2 is 4458.0 kN, which is 28% and 56% higher than those of the conventional circular tube and square tube. The theoretical MCF is consistent with the simulated MCF, with a maximum discrepancy of 6.0%. The gradient distribution (k) of wall thickness significantly affects the crushing behaviors of the HPBT. Considering the energy absorption efficiency, the crushing stability, and the wall thickness gradient distribution, the HPBT_C2 with k = 0.6 has the best overall performance. The results can provide insights and guidelines for designing energy absorption devices with superior crashworthiness for support equipment. Full article

Jet electrochemical milling (JECM) offers significant advantages for fabricating fine grooves and slits in thin-walled, low-rigidity, and heat-sensitive metallic materials, such as amorphous alloys, owing to its operational flexibility, lack of material constraints, and superior surface quality. Nevertheless, conventional JECM techniques for groove machining encounter limitations including excessive overcut, restricted ability to produce microstructures with high depth-to-width ratios, and reduced machining accuracy. To address these issues, this study proposes an innovative approach termed the periodically thinning jet electrochemical milling (PT-JECM) method. This method involves initially generating a shallow microgroove through a single pass using the original nozzle diameter, followed by successive milling passes with progressively smaller nozzle diameters based on the preformed groove. Comparative analysis with traditional JECM methods reveals that this strategy significantly improves the etching factor from 1.896 to 4.318, corresponding to a 128% enhancement. Furthermore, it markedly decreases the slot width increase from 275 μm to 1 μm and improves the aspect ratio from 0.51 to 0.83, representing a 63% increase, enabling the precision machining of large aspect ratio holes and slot structures. Full article