Search Results (14)

In this Special Issue entitled Novel Ceramic Materials: Processes, Properties and Applications, 18 articles are brought together. The contributions illustrated the remarkable versatility of ceramics—from bioceramics that heal bone and fight infection, to solid electrolytes and multiferroics powering clean energy, and glass ceramics and zeolite composites safeguarding our environment. Articles on glazes, archaeological pottery, and innovative joining methods reminded us that ceramic science has bridged deep traditions and modern frontiers. Full article

Given the need for versatile joining processes, form-fit joining is gaining increasing importance. Although it has known limitations and complexity, roller hemming remains widely used due to its flexibility. Here, the novel Incremental Sheet Forming (ISF) hemming technique has the potential to expand the range of applications and process limits. It has already proven effective in preliminary works for joining comparatively small radii without wrinkles and cracks. However, a deeper understanding of the dominant material flow and deformation mechanism during forming is required to fully exploit its potential. This study aims to conduct a detailed examination of this technology through experimental and numerical investigations. Strain measurements on convex and concave hems provide insights into the material flow. A comparison of the forming mechanism for both processes is made using straight hems. The results show that ISF hemming has a favorable material flow for compensating cracks and wrinkles in curved hems. Additionally, it induces strains across the entire hem area, reaching higher values than those achieved with roller hemming. One reason for this is the forming mechanism, which combines tension, compression and shear, whereas roller hemming primarily involves bending and compression of the hemming radius. Full article

Modular timber construction embodies a pioneering and eco-friendly methodology within the building sector. With the notable progress made in manufacturing technologies and the advent of engineered wood products, timber has evolved into a promising substitute for conventional materials such as concrete, masonry, and steel. Beyond its structural attributes, timber brings environmental advantages, including its inherent capacity for carbon sequestration and a reduced carbon footprint compared to conventional materials. Timber’s lightweight nature, coupled with its versatility and efficiency in factory-based production, accelerates modular construction processes, providing a sustainable solution to the growing demands of the building industry. This work thoroughly explores contemporary modular construction using wood as the primary material. The investigation spans various aspects, from the fundamentals of modularity and the classification of modular timber solutions to considerations of layout design, structural systems, and stability at both the building and module levels. Moreover, inter-module joining techniques, MEP (mechanical, electrical, and plumbing) integration, and designs for disassembly are scrutinized. The investigation led to the conclusion that timber modular construction, drawing inspiration from the steel modular concept, consistently utilizes a structural approach based on linear members (timber frame, post-and-beam, etc.), incorporating stability configurations and diverse joint techniques. Despite the emphasis on modularization and prefabrication for adaptability, a significant portion of solutions still concentrate on the on-site linear assembly process of those linear members. Regarding modularity trends, the initial prevalence of 2D and 3D systems has given way to a recent surge in the utilization of post-and-beam structures, congruent with the ascending verticality of buildings. In contrast to avant-garde and bold trends, timber structures typically manifest as rectilinear, symmetric plans, characterized by regular and repetitive extrusions, demonstrating a proclivity for centrally located cores. This work aims to offer valuable insights into the current utilization of modular timber construction while identifying pivotal gaps for exploration. The delineation of these unexplored areas seeks to enable the advancement of modular timber projects and systems, fully leveraging the benefits provided by prefabrication and modularity. Full article

DNA polymerases constitute a versatile group of enzymes that not only perform the essential task of genome duplication but also participate in various genome maintenance pathways, such as base and nucleotide excision repair, non-homologous end-joining, homologous recombination, and translesion synthesis. Polymerases catalyze DNA synthesis via the stepwise addition of deoxynucleoside monophosphates to the 3′ primer end in a partially double-stranded DNA. They require divalent metal cations coordinated by active site residues of the polymerase. Mg²⁺ is considered the likely physiological activator because of its high cellular concentration and ability to activate DNA polymerases universally. Mn²⁺ can also activate the known DNA polymerases, but in most cases, it causes a significant decrease in fidelity and/or processivity. Hence, Mn²⁺ has been considered mutagenic and irrelevant during normal cellular function. Intriguingly, a growing body of evidence indicates that Mn²⁺ can positively influence some DNA polymerases by conferring translesion synthesis activity or altering the substrate specificity. Here, we review the relevant literature focusing on the impact of Mn²⁺ on the biochemical activity of a selected set of polymerases, namely, Polβ, Polλ, and Polµ, of the X family, as well as Polι and Polη of the Y family of polymerases, where congruous data implicate the physiological relevance of Mn²⁺ in the cellular function of these enzymes. Full article

Given strict emission targets and legal requirements, especially in the automotive industry, environmentally friendly and simultaneously versatile applicable production technologies are gaining importance. In this regard, the use of mechanical joining processes, such as clinching, enable assembly sheet metals to achieve strength properties similar to those of established thermal joining technologies. However, to guarantee a high reliability of the generated joint connection, the selection of a best-fitting joining technology as well as the meaningful description of individual joint properties is essential. In the context of clinching, few contributions have to date investigated the metamodel-based estimation and optimization of joint characteristics, such as neck or interlock thickness, by applying machine learning and genetic algorithms. Therefore, several regression models have been trained on varying databases and amounts of input parameters. However, if product engineers can only provide limited data for a new joining task, such as incomplete information on applied joining tool dimensions, previously trained metamodels often reach their limits. This often results in a significant loss of prediction quality and leads to increasing uncertainties and inaccuracies within the metamodel-based design of a clinch joint connection. Motivated by this, the presented contribution investigates different machine learning algorithms regarding their ability to achieve a satisfying estimation accuracy on limited input data applying a statistically based feature selection method. Through this, it is possible to identify which regression models are suitable to predict clinch joint characteristics considering only a minimum set of required input features. Thus, in addition to the opportunity to decrease the training effort as well as the model complexity, the subsequent formulation of design equations can pave the way to a more versatile application and reuse of pretrained metamodels on varying tool configurations for a given clinch joining task. Full article

The trend towards lightweight design, driven by increasingly stringent emission targets, poses challenges to conventional joining processes due to the different mechanical properties of the joining partners used to manufacture multi-material systems. For this reason, new versatile joining processes are in demand for joining dissimilar materials. In this regard, pin joining with cold extruded pin structures is a relatively new, two-stage joining process for joining materials such as high-strength steel and aluminium as well as steel and fibre-reinforced plastic to multi-material systems, without the need for auxiliary elements. Due to the novelty of the process, there are currently only a few studies on the robustness of this joining process available. Thus, limited statements on the stability of the joining process considering uncertain process conditions, such as varying material properties or friction values, can be provided. Motivated by this, the presented work investigates the influence of different uncertain process parameters on the pin extrusion as well as on the joining process itself, carrying out a systematic robustness analysis. Therefore, the methodical approach covers the complete process chain of pin joining, including the load-bearing capacity of the joint by means of numerical simulation and data-driven methods. Thereby, a deeper understanding of the pin joining process is generated and the versatility of the novel joining process is increased. Additionally, the provision of manufacturing recommendations for the forming of pin joints leads to a significant decrease in the failure probability caused by ploughing or buckling effects. Full article

In the present work, an ultrasonic, an induction, and a through transmission laser welding were compared to join carbon fibre reinforced polyetheretherketone (CF/PEEK) composites. The advantages and drawbacks of each process are discussed, as well as the material properties required to fit each process. CF/PEEK plates were consolidated at 395 °C with an unidirectional sequence and cross-stacking ply orientation. In some configurations, a polyetherimide (PEI) layer or substrate was used. The thermal, mechanical, and optical properties of the materials were measured to highlight the specific properties required for each process. The drying conditions were defined as 150 °C during at least 8 h for PEI and 24 h for CF/PEEK to avoid defects due to water. The optical transmission factor of PEI is above 40% which makes it suitable for through transmission laser welding. The thermal conductivity of CF/PEEK is at most 55 W·(m·K)⁻¹, which allows it to weld by induction without a metallic susceptor. Ultrasonic welding is the most versatile process as it does not necessitate any specific properties. Then, the mechanical resistance of the welds was measured by single lap shear. For CF/PEEK on CF/PEEK, the maximum lap shear strength (LSS) of 28.6 MPa was reached for a joint obtained by ultrasonic welding, while an induction one brought 17.6 MPa. The maximum LSS of 15.2 MPa was obtained for PEI on CF/PEEK assemblies by laser welding. Finally, interfacial resistances were correlated to the fracture modes through observations of the fractured surfaces. CF/PEEK on CF/PEEK joints resulted in mixed cohesive/adhesive failure at the interface and within the inner layers of both substrates. This study presents a guideline to select the suitable welding process when assembling composites for the aerospace industry. Full article

One of the problems that make it difficult to solve the mystery of the origin of life is determining how life emerged in chemically complex messy environments on primitive Earth. In this article, the “chemically complex messy environments” that are focused on are a mixed state of various organic compounds produced via prebiotic means and accumulated on primitive earth. The five factors described below are thought to have contributed to opening the way for the emergence of life: (1) A characteristic inherent in [GADV]-amino acids, which are easily produced via prebiotic means. [GADV] stands for four amino acids, Gly [G], Ala [A], Asp [D] and Val [V], which are indicated by a one-letter symbol. (2) The protein 0th-order structure or a [GADV]-amino acid composition generating water-soluble globular protein with some flexibility, which can be produced even by the random joining of [GADV]-amino acids. (3) The formation of versatile [GADV]-microspheres, which can grow, divide and proliferate even without a genetic system, was the emergence of proto-life. (4) The [GADV]-microspheres with a higher proliferation ability than others were able to be selected. Proto-Darwin evolution made it possible to proceed forward to the creation of a core life system composed of the (GNC)_n gene, anticodon stem-loop tRNA or AntiC-SL tRNA (GNC genetic code), and [GADV]-protein. (5) Eventually, the first genuine life with a core life system emerged. Thus, the formation processes of [GADV]-protein and the (GNC)_n gene in chemically complex messy environments were the steps to the emergence of genuine life. Full article

Versatile acrylate–epoxy hybrid formulations are becoming widespread in photo/thermal dual-processing scenarios, especially in 3D printing applications. Usually, parts are printed in a stereolithography or digital light processing (DLP) 3D printer, after which a thermal treatment would bestow the final material with superior mechanical properties. We report the successful formulation of such a hybrid system, consisting of a commercial 3D printing acrylate resin modified by an epoxy–anhydride mixture. In the final polymeric network, we observed segregation of an epoxy-rich phase as nano-domains, similar to what was observed in a previous work. However, in the current work, we show the effectiveness of a coupling agent added to the formulation to mitigate this segregation for when such phase separation is undesired. The hybrid materials showed significant improvement of Young’s modulus over the neat acrylate. Once the flexible, partially-cured material was printed with a minimal number of layers, it could be molded into a complex form and thermally cured. Temporary shapes were readily programmable on this final material, with easy shape recovery under mild temperatures. Inspired by repairable 3D printed materials described recently, we manufactured a large object by printing its two halves, and then joined them covalently at the thermal cure stage with an apparently seamless union. Full article

The present review provides an overview of the current status and future perspectives of one of the smart manufacturing techniques of Industry 4.0, laser transmission welding (LTW) of semi-crystalline (SC) polymers and their composites. It is one of the most versatile techniques used to join polymeric components with varying thickness and configuration using a laser source. This article focuses on various parameters and phenomena such as inter-diffusion and microstructural changes that occur due to the laser interaction with SC polymers (specifically polypropylene). The effect of carbon black (size, shape, structure, thermal conductivity, dispersion, distribution, etc.) in the laser absorptive part and nucleating agent in the laser transmissive part and its processing conditions impacting the weld strength is discussed in detail. Among the laser parameters, laser power, scanning speed and clamping pressure are considered to be the most critical. This review also highlights innovative ideas such as incorporating metal as an absorber in the laser absorptive part, hybrid carbon black, dual clamping device, and an increasing number of scans and patterns. Finally, there is presented an overview of the essential characterisation techniques that help to determine the weld quality. This review demonstrates that LTW has excellent potential in polymer joining applications and the challenges including the cost-effectiveness, innovative ideas to provide state-of-the-art design and fabrication of complex products in a wide range of applications. This work will be of keen interest to other researchers and practitioners who are involved in the welding of polymers. Full article

Supercritical assisted Liposome formation (SuperLip) is a lab-scale process for the production of liposomes. SuperLip was recognized as being a versatile supercritical assisted technique for the encapsulation of molecules for different industrial applications, such as pharmaceutic, cosmetic, textile, and nutraceutic purposes. The aim of this work was to perform an economic analysis to assess the profitability of the SuperLip process. The liposomes market was analyzed and the SuperLip process was compared to other techniques in terms of manufacturing advantages using the Canvas and Strengths, Weaknesses, Opportunities, and Treats (S.W.O.T.) models. SuperLip Plant Capital Expenditures (CAPEX) were estimated, and plant Operating Expenditures (OPEX) were also evaluated and integrated with personnel cost and other plant goods and services. A profit and loss statement was generated, together with a cash flow analysis. According to the market average selling price, liposome price is 1.8 €/mL; in order to join the market rapidly, the selling price of liposomes produced using SuperLip was set at 1.1 €/mL. A payback time has been identified at the fourth year of business. Economic indexes such as ROI and ROS were calculated on a 10-year business prospect, obtaining about a 230% return on investment and a 26.7% return on sales. Full article

Ensuring the precision and repeatability of component assembly in the production of electric vehicle (EV) battery modules requires fast and accurate measuring methods. The durability of EV battery packs depends on the quality of welded connections, therefore exact positioning of the module components is critical for ensuring safety in exploitation. Laser welding is a non-contact process capable of welding dissimilar materials with high precision, for that reason it has become the preferred joining method in battery production. In high volume manufacturing, one of the main production challenges is reducing the time required for assessment of dimensional and geometrical accuracy prior to joining. This paper reviews the challenges of EV battery design and manufacturing and discusses commercially available scanner-based measurement systems suitable for fabrication of battery pack components. Versatility of novel metrological systems creates new opportunities for increasing the production speed, quality and safety of EV battery modules. Full article

The welding of cemented carbide to tool steel is a challenging task, of scientific and industrial relevance, as it combines the high level of hardness of cemented carbide with the high level of fracture toughness of steel, while reducing the shaping cost and extending the application versatility, as its tribological, toughness, thermal and chemical properties can be optimally harmonised. The already existing joining technologies often impart either insufficient toughness or poor high-temperature strength to a joint to withstand the ever-increasing severe service condition demands. In this paper, a novel capacitor discharge welding (CDW) process is investigated for the case of a butt-joint between a tungsten carbide-cobalt (WC-Co) composite rod and an AISI M35 high-speed steel (HSS) rod. The latter was shaped with a conical-ended projection to promote a high current concentration and heat at the welding zone. CDW functions by combining a direct current (DC) electric current pulse and external uniaxial pressure after a preloading step, in which only uniaxial pressure is applied. The relatively high heating and cooling rates promote a thin layer of a characteristic ultrafine microstructure that combines high strength and toughness. Morphological analysis showed that the CDW process: (a) forms a sound and net shaped joint, (b) preserves the sub-micrometric grain structure of the original WC-Co composite base materials, via a transitional layer, (c) refines the microstructure of the original martensite of the HSS base material, and (d) results in an improved corrosion resistance across a 1-mm thick layer near the weld interface on the steel side. A nano-indentation test survey determined: (e) no hardness deterioration on the HSS side of the weld zone, although (f) a slight decrease in hardness was observed across the transitional layer on the composite side. Furthermore, (g) an indication of toughness of the joint was perceived as the size of the crack induced by processing the residual stress after sample preparation was unaltered. Full article

Dissimilar joining between metal and composite sheets is usually carried out by mechanical or adhesive joining. Laser dissimilar joining between metal and composite sheets could be an alternative to these methods, as it is a cost-effective and versatile joining technique. Previously, textured metallic and composite parts have been held together and heated with a laser beam while pressure is applied to allow the melted polymer to flow into the cavities of the metal part. The main issue of this process relates to reaching the same joint strength repetitively with appropriate process parameters. In this work, both initial texturing and laser joining parameters are studied for Al 7075-T6 and glass-fiber-reinforced PA6 composite. A groove-based geometry was studied in terms of depth-to-width aspect ratio to find an optimal surface using a nanosecond fiber laser for texturing. Laser joining parameters were also studied with different combinations of surface temperature, heating strategy, pressure, and laser feed rate. The results are relatively good for grooves with aspect ratios from 0.94 to 4.15, with the widths of the grooves being the most critical factor. In terms of joining parameters, surface reference temperature was found to be the most influential parameter. Underheating does not allow correct material flow in textured cavities, while overheating also causes high dispersion in the resulting shear strength. When optimal parameters are applied using correct textures, shear strength values over 26 kN are reached, with a contact area of 35 × 45 mm². Full article