Search Results (58)

Traditional sand casting is limited by mold fabrication, cost control, and data collection, which restrict its further advancement. However, 3D sand printing technology represents a sophisticated rapid prototyping approach that directly utilizes three-dimensional models to fabricate complex sand molds and cores, thereby bypassing the traditional mold-making steps. This technology significantly enhances production efficiency and design flexibility, thereby advancing the modernization of casting processes. In the context of wind tunnel testing, the application of 3D-printed sand shell additive manufacturing has successfully produced sand molds and cores for the non-axisymmetric intake duct structures. This demonstrates the feasibility of this technology for complex casting applications and its capability to meet experimental requirements. Full article

This study examined a sediment plume from Australia’s largest river, The River Murray, which was produced during a major flood event in 2022–2023. This flood resulted from successive La Niña events, causing high rainfall across the Murray–Darling Basin and ultimately leading to a significant riverine flow through South Australia. The flood was characterised by a significant increase in riverine discharge rates, reaching a peak of 1305 m³/s through the Lower Lakes barrage system from November 2022 to February 2023. The water quality anomaly within the coastal region (<~150 km offshore) was effectively quantified and mapped utilising the diffuse attenuation coefficient at 490 nm (Kd490) from products derived from MODIS Aqua Ocean Color satellite imagery. The sediment plume expanded and intensified alongside the increased riverine discharge rates, which reached a maximum spatial extent of 13,681 km². The plume typically pooled near the river’s mouth within the northern corner of Long Bay, before migrating persistently westward around the Fleurieu Peninsula through Backstairs Passage into Gulf St Vincent, occasionally exhibiting brief eastward migration periods. The plume gradually subsided by late March 2023, several weeks after riverine discharge rates returned to pre-flood levels, indicating a lag in attenuation. The assessment of the relationship and accuracy between the Kd490 product and the surface-most in situ turbidity, measured using conductivity, temperature, and depth (CTD) casts, revealed a robust positive linear correlation (R² = 0.85) during a period of high riverine discharge, despite temporal and spatial discrepancies between the two datasets. The riverine discharge emerged as an important factor controlling the spatial extent and intensities of the surface sediment plume, while surface winds also exerted an influence, particularly during higher wind velocity events, as part of a broader interplay with other drivers. Full article

Wind power generation plays an important role in renewable energy, and the core casting components have extremely high requirements for precision and quality. In actual practice, we found that an insufficient workforce limits traditional manual inspection methods and often creates difficulty in unifying quality judgment standards. Customized optical path design is often required, especially when conducting internal and external defect inspections, which increases overall operational complexity and reduces inspection efficiency. We developed an automated optical inspection (AOI) system to address these challenges. The system integrates a semantic segmentation neural network to handle external surface detection and an anomaly detection model to detect internal defects. In terms of internal defect detection, the GC-AD-Local model we tested achieved 100% accuracy on experimental images, and the results were relatively stable. In the external detection part, we compared five different semantic segmentation models and found that MobileNetV2 performed the best in terms of average accuracy (65.8%). It was incredibly stable when dealing with surface defects with significant shape variations, and the prediction results were more consistent, making it more suitable for introduction into actual production line applications. Overall, this AOI system boosts inspection efficiency and quality consistency, reduces reliance on manual experience, and is of great assistance in quality control and process intelligence for wind power castings. We look forward to further expanding the amount of data and improving the generalization capabilities of the model in the future, making the system more complete and suitable for practical applications. Full article

When pouring concrete overhead, a pump truck boom’s vibration has a big effect on how accurately the concrete is poured. This is especially true during fixed-point pouring, where the boom’s vibration is likely to cause the pouring position to deviate, which lowers the quality of the construction. It is difficult to forecast the dynamic reaction of the pump truck boom in a construction setting because of the constantly shifting external factors (wind speed, pipeline stress during pumping, etc.), which makes it difficult to guarantee casting accuracy. This study suggests a non-random vibration analysis technique for pump truck booms based on the interval process theory in order to address this issue. A dynamic excitation analysis method based on rigid–discrete coupling is proposed, taking into account the response influence of the material characteristics in the transportation process. The pumping process of concrete materials in the conveying pipeline is simulated using discrete element simulation technology to determine the system’s stress conditions under pumping conditions. The dynamic response characteristics of the pump truck boom under operating conditions are revealed by using non-random vibration analysis with the mathematical model that has been created based on the particular specifications of the pump truck boom. This study employs the Newmark-β technique for numerical computation to solve the dynamic equations and characterize the displacement response envelope under uncertain system parameter settings. The experimental findings demonstrate that the suggested approach may accurately capture the upper and lower bounds of the boom dynamic response, offering a trustworthy way to assess the dynamic behavior while pumping. The technique can reliably predict the dynamic displacement boundary and control the casting position deviation within a predefined range by accurately predicting the dynamic displacement range of the pump truck’s boom end and efficiently constructing the displacement envelope under uncertain dynamic excitation. For numerical computation, use the Newmark-β algorithm. This outcome confirms the substantial enhancement of the proposed method regarding pouring precision in construction settings, offering a novel solution and technical guidance for vibration control in engineering projects. Full article

The Falakra geosite is located at the northern shoreline of the island of Limnos, Greece, and exhibits an array of unusual geomorphological features developed in late Cenozoic sandstones. Deposition of the primary clastic sediments was overprinted by later, low-temperature hydrothermal fluid flow and interstitial secondary calcite formation associated with nearby volcanic activity. Associated sandstone cannonballs take center stage in a landscape built by joints, Liesengang rings and iron (hydr)oxide precipitates, constituting an intriguing site of high aesthetic value. The Falakra geosite is situated in an area with dynamic erosion processes occurring under humid weather conditions. These have evidently sculpted and shaped the sandstone landscape through a complex interaction of wave- and wind-induced erosional processes aided by salt spray wetting. This type of geosite captivates scientists and nature enthusiasts due to its unique geological and landscape features, making its sustainable conservation a significant concern and topic of debate. Here, we provide detailed geological and remote sensing mapping of the area to improve the understanding of geological processes and their overall impact. Given the significance of the Falakra geosite as a unique tourist destination, we emphasize the importance of developing it under sustainable management. We propose the segmentation of the geosite into four sectors based on the corresponding geological features observed on site. Sector A, located to the west, is occupied by a lander-like landscape; to the southeast, sector B contains clusters of cannonballs and concretions; sector C is characterized by intense jointing and complex iron (hydr)oxide precipitation patterns, dominated by Liesengang rings, while sector D displays cannonball or concretion casts. Finally, we propose a network of routes and platforms to highlight the geological heritage of the site while reducing the impact of direct human interaction with the outcrops. For constructing the routes and platforms, we propose the use of serrated steel grating. Full article

This article examines contacting by means of ultrasonic welding between a cast aluminum winding and a copper conductor of a wheel hub drive for a passenger car. The effect of thermal stress on the formation and growth of intermetallic phases (IMC) in the contact is analyzed. By using microscopy, the growth constant under the specific load conditions can be identified with the help of the parabolic time law and offer a possibility for predicting the service life of the corresponding contacts. As a result, it can be stated that the increase in electrical resistance of the present contact at load temperatures of 120 °C, 150 °C, and 180 °C does not reach a critical value. The growth rates of the IMC also show no critical tendencies at the usual operating temperatures (120 °C and 150 °C, e.g., at 150 °C = 4.59 × 10⁻⁷ μm²/s). The activation energy calculated using the Arrhenius plot of 155 kJ/mol (1.61 eV) can be classified as high in comparison to similar studies. In addition, it was found that future investigations of the IMC growth of corresponding electrical contacts should rather be carried out with electric current. The 180 °C sample series were carried out in the oven and with electric current; the samples in the oven did not show clear IMC, while the samples exposed to electric current already showed IMC under the microscope. Full article

Design and production technology of natural fibre reinforced polymers not only aims to offer products with a lower environmental impact than conventional glass fibre composites but also caters for designers’ needs for the fabrication of lightweight free-formed architectural components. To combine both characteristics, the forming process itself, once scaled up, needs to be based on efficient material moulding strategies. Based on case studies of adaptive forming techniques derived from the composite industry and concrete casting, two approaches for the mass production of customised NFRP profiles are proposed. Both processes are based on foam from recycled PET, which is used as either a removable mould or a stay-in-place (SIP) core. Once the textile reinforcement is placed on a mould, either by helical winding of natural fibre prepregs or in the form of mass-produced textile preforms, its elastic properties allow for the free-forming of the composite profile before the resin is fully cured. This paper investigates the range of deformations that it is possible to achieve by each method and describes the realisation of a small structural demonstrator, in the form of a stool, through the helical winding of a flax prepreg on a SIP core. Full article

As the largest non-gravitational force, solar radiation pressure (SRP) causes significant errors in precise orbit determination (POD) of the BeiDou global navigation satellite system (BDS-3) medium Earth orbit (MEO) satellite. This is mainly due to the imperfect modeling of the satellite’s cuboid body. Since the BDS-3’s inter-satellite link (ISL) can enhance the orbit estimation of BDS-3 satellites, the aim of this study is to establish an a priori SRP model for the satellite body using 281-day ISL observations to reduce the systematic errors in the final orbits. The adjustable box wind (ABW) model is employed to refine the optical parameters for the satellite buses. The self-shadow effect caused by the search and rescue (SAR) antenna is considered. Satellite laser ranging (SLR), day-boundary discontinuity (DBD), and overlapping Allan deviation (OADEV) are utilized as indicators to assess the performance of the a priori model. With the a priori model developed by both ISL and ground observation, the slopes of SLR residual for the China Academy of Space Technology (CAST) and Shanghai Engineering Center for Microsatellites (SECM) satellites decrease from −0.097 cm/deg and 0.067 cm/deg to −0.004 cm/deg and −0.009 cm/deg, respectively. The standard deviation decreased by 21.8% and 26.6%, respectively. There are slight enhancements in the average values of DBD and OADEV, and a reduced β-dependent variation is observed in the OADEV of the corresponding clock offset. We also found that considering the SAR antenna only slightly improves the orbit accuracy. These results demonstrate that an a priori model established for the BDS-3 MEO satellite body can reduce the systematic errors in orbits, and the parameters estimated using both ISL and ground observation are superior to those estimated using only ground observation. Full article

This study investigates the predictability of downslope windstorms located in Santa Barbara County, California, locally referred to as Sundowner winds, from both observed relationships and a high-resolution, operational numerical weather prediction model. We focus on April 2022, during which the Sundowner Winds Experiment (SWEX) was conducted. We further refine our study area to the Montecito region owing to some of the highest wind measurements occurring at or near surface station MTIC1, situated on the coast-facing slope overlooking the area. Fires are not uncommon in this area, and the difficulty of egress makes the population particularly vulnerable. Area forecasters often use the sea-level pressure difference ($\Delta$SLP) between Santa Barbara Airport (KSBA) and locations to the north such as Bakersfield (KBFL) to predict Sundowner windstorm occurrence. Our analysis indicates that $\Delta$SLP by itself is prone to high false alarm rates and offers little information regarding downslope wind onset, duration, or magnitude. Additionally, our analysis shows that the high-resolution rapid refresh (HRRR) model has limited predictive skill overall for forecasting winds in the Montecito area. The HRRR, however, skillfully predicts KSBA-KBFL $\Delta$SLP, as does GraphCast, a machine learning weather prediction model. Using a logistic regression model we were able to predict the occurrence of winds exceeding 9 m ${\mathrm{s}}^{-1}$ with a high probability of detection while minimizing false alarm rates compared to other methods analyzed. This provides a refined and easily computed algorithm for operational applications. Full article

This study analyses the heat transfer performance of metal foam heat exchangers through experimental measurements. Using counter-gravity infiltration casting, open-cell aluminium foam elements were manufactured to embed a copper tube for internal mass flow containment. Heat transfer experiments were conducted under natural and forced convection conditions, with the airflow controlled in a wind tunnel. A stream of warm water within the internal foam component served as the heat source, transferring thermal energy to the surrounding air flowing through the external foam component of the heat exchanger. The results showed a significantly enhanced heat transfer performance with aluminium foam compared to a single copper tube. Thermal resistance models were developed to elucidate the heat transfer mechanisms, highlighting the effectiveness of air-cooled metal foam heat exchangers. These findings underscore the potential of metal foam heat exchangers as cost-effective alternatives for various thermal management applications. Full article

This study aimed to enhance the friction and wear characteristics of materials for wind turbine sliding-bearing bushes operating under low-speed and heavy-load conditions. To this end, a high-entropy CoCrFeNiMo alloy coating was applied to the surface of 9Cr18 bearing steel, and Ni-Cr-Mo-Si alloy coating was applied to MTCrMoCu30 wear-resistant cast iron using laser cladding. The effects of varying loads on the friction and wear properties of these coatings were investigated, and the friction and wear properties were compared. Furthermore, the overall priority indices for both groups of bearing bush coatings were assessed. The findings indicated that the friction coefficient, wear quality, and wear rate of CoCrFeNiMo high-entropy alloy coating initially decreased and then increased with the increase in applied load, dominated by abrasive wear. By contrast, the friction coefficient of the Ni-Cr-Mo-Si alloy coating increased, and wear quality and wear rate initially increased and then decreased, indicating the coexistence of adhesive wear and abrasive wear. Therefore, Ni-Cr-Mo-Si alloy coating exhibited a high overall priority index and favorable friction and wear properties. Full article

In recent decades, the requirements for plain bearing materials have continually increased, especially with new applications such as wind turbines, which require larger bearings. These new applications have completely different property profiles compared with, for example, bearings in automotive construction. Larger bearings need high strength and wear resistance, which established bearing materials cannot fulfill. Therefore, new alloy systems are required. This publication focuses on the influence of alloy composition and test temperature on the mechanical properties of ZnAlCu alloys. Centrifugally cast specimens were produced for the fabrication of test specimens, which were used to determine the mechanical and tribological properties. Fracture surface and wear trace analysis with scanning electron and light microscopy were used to determine occurring failure and wear mechanisms and to analyze the influence of microstructure on failure. Depending on the composition of the ZnAlCu alloys, up to three times higher strengths can be achieved compared with the white metal alloy SnSb12Cu6ZnAg. Furthermore, all the alloys investigated show good wear properties. Up to 11 wt.% aluminum and 1.5 wt.% copper, a significant decrease in the wear coefficient was observed. Knowledge about the correlation between microstructure, properties, and failure mechanisms of ZnAlCu alloys can be used to produce bearing metal alloys suitable for a wide range of applications. Since the strength values lie between those of white metals and bronze, new fields of application can also be accessed. Full article

This study focusses on the energy efficiency of compressed air storage tanks (CASTs), which are used as small-scale compressed air energy storage (CAES) and renewable energy sources (RES). The objectives of this study are to develop a mathematical model of the CAST system and its original numerical solutions using experimental parameters that consider polytropic charging and discharging processes, changes in the time of the temperature, flow parameters of the inlet and outlet valves under choked and subsonic conditions, and the characteristics of the air motor. This model is used to select CAST as an energy storage system for compressed air generated by compressors and recycling, as well as an energy source to drive DC generators and a pneumatic propulsion system (PPS). A measuring test rig is built to verify the polytropic pressure and temperature variations during CAST charging and discharging obtained from numerical solutions. The topic of discussion is the functional model of a high-pressure air system (HPAS) that contains a CAST connected to an air motor coupled to a mechanical drive for a DC generator or PPS. Such a system is used in small-scale CASTs, which currently respond to socio-economic demands. The presented CAST energy efficiency indicators are used to justify the storage of compressed air energy on a small scale. Small-scale compressed air storage in CASTs is currently important and relevant due to the balance between peak electricity demand and the development of wind energy, photovoltaics, and other renewable energy sources. Full article

The paper reports on high voltage (HV)-isolated MEMS quad–solenoid transformers for compact isolated gate drivers and bias power supplies. The component is wafer-level fabricated via a novel MEMS micro-casting technique, where the tightly coupled quad–solenoid chip consists of monolithically integrated 3D inductive coils and an inserted ferrite magnetic core for high-efficiency isolated power transmission through electromagnetic coupling. The proposed HV-isolated transformer demonstrates a high inductance value of 743.2 nH, along with a small DC resistance of only 0.39 Ω in a compact footprint of 6 mm², making it achieve a very high inductance integration density (123.9 nH/mm²) and the ratio of L/R (1906 nH/Ω). More importantly, with embedded ultra-thick serpentine-shaped (S-shaped) SiO₂ isolation barriers that completely separate the primary and secondary windings, an over 2 kV breakdown voltage is obtained. In addition, the HV-isolated transformer chips exhibit a superior power transfer efficiency of over 80% and ultra-high dual-phase saturation current of 1.4 A, thereby covering most practical cases in isolated, integrated bias power supplies such as high-efficiency high-voltage-isolated gate driver solutions. Full article

The three-dimensional (3D) geological voxel model is essential for numerical simulation and resource calculation. However, it can be challenging due to the point in polygon test in 3D voxel modeling. The commonly used Winding number algorithm requires the manual setting of observation points and uses their relative positions to restrict the positive and negative solid angles. Therefore, we proposed the Winding number with triangle network coding (WNTC) algorithm and applied it to automatically construct a 3D voxel model of the ore body. The proposed WNTC algorithm encodes the stratum model by using the Delaunay triangulation network to constrain the index order of each vertex of the triangular plane unit. GPU parallel computing was used to optimize its computational speed. Our results demonstrated that the WNTC algorithm can greatly improve the efficiency and automation of 3D ore body modeling. Compared to the Ray casting method, it can compensate for a voxel loss of about 0.7%. We found the GPU to be 99.96% faster than the CPU, significantly improving voxel model construction speed. Additionally, this method is less affected by the complexity of the stratum model. Our study has substantial potential for similar work in 3D geological modeling and other relevant fields. Full article