Search Results (35)

This work presents a fused-filament fabrication (FFF) hot end that combines an unrestricted-rotation C-axis with a rectangular-slot nozzle and an induction-heated melt sleeve. The architecture replaces the popular resistive cartridge and heater block design with an external coil that induces eddy-current heating in a thin-walled sleeve, threaded to the heat break and nozzle, reducing thermal mass and eliminating wired sensors across the rotating interface. A contactless infrared thermometer targets the nozzle tip; the temperature is regulated by frequency-modulating the inverter around resonance, yielding stable control. The hot end incorporates an LPBF-manufactured nozzle, which transitions from a circular inlet to a rectangular outlet to deposit broad, low-profile strands at constant layer height while preserving lateral resolution. The concept is validated on a desktop Cartesian platform retrofitted to coordinate yaw with XY motion. A twin-printer testbed compares the proposed hot end against a stock cartridge-heated system under matched materials and environments. With PLA, the induction-heated, rotating hot end enables printing at 170 °C with defect-free flow and delivers substantial reductions in job time (22–49%) and energy per part (9–39%). These results indicate that the proposed approach is a viable route to higher-throughput, lower-specific-energy material extrusion. Full article

This study provides a detailed review of the thermal and thermo-hydraulic performance of solar air heaters (SAHs) enhanced through the application of artificial roughness on the absorber plate. Various roughness geometries, such as wire ribs, V-shaped ribs, arc-shaped ribs, and rib-groove patterns, have been analysed to assess their influence on heat transfer enhancement and frictional behaviour. Findings from previous experimental and numerical studies reveal that the incorporation of artificial roughness can increase the Nusselt number by approximately 1.25 to 6.3 times and improve thermal efficiency by 20–35% when compared to smooth absorber plates. The review further highlights that the most effective performance occurs at a relative roughness height (e/D) between 0.02 and 0.05 and within a Reynolds number range of 10,000 to 18,000. Overall, the analysis confirms that artificial roughness is a simple, economical, and highly effective technique to enhance heat transfer and overall efficiency in solar air heater systems. Full article

The present study aims to experimentally investigate pool boiling heat transfer characteristics, such as critical heat flux (CHF) and boiling heat transfer coefficient (BHTC), of pure distilled water (d-H₂O) and functionalised graphene nanoplatelet (f-GnPs)–d-H₂O nanofluids using a nichrome (Ni-Cr) test wire as the heating element. The distilled water (dH₂O) and GnP (5–10 nm and 15 µm, Cheap Tubes, USA) were chosen as the base fluid and nanomaterial, respectively. The GnP was chemically functionalized and dispersed in dH₂O using a probe sonicator. The nanofluids were characterized by measuring the zeta potential distribution and pH to ensure stability on day 1 and day 10 following preparation. The results show that the zeta potential values range from −31.6 mV to −30.6 mV, while the pH values range from 7.076 to 7.021 on day 1 and day 10, respectively. The novelty of the present study lies in the use of f-GnPs with a controlled size and stable nanofluid, confirmed through zeta potential and pH analysis, to determine the heat transfer behaviour of a Ni-Cr test wire under pool boiling conditions. The pool boiling heat transfer characteristics, such as CHF and BHTC, were observed using the fabricated pool boiling heat transfer test facility. Initially, the dH₂O and f-GnP–dH₂O nanofluids were separately placed in a glass container and heated using a pre-heater to reach their saturation point of 100 °C. The electrical energy was gradually increased until it reached the critical point of the Ni-Cr test wire, i.e., the burnout point, at which it became reddish-yellow hot. The CHF and BHTC were predicted from the experimental outputs of voltage and current. The results showed an enhancement of ~15% in the CHF at 0.1 vol% of f-GnPs. The present study offers a method for enhancing two-phase flow characteristics for heat pipe applications. Full article

Heaters are critical components in various heating control systems, and their faults are often a primary cause of system failure, drawing significant attention from engineers and researchers. Early and accurate fault diagnosis is crucial to prevent cascading failures. Many diagnostic methods target faults under generally stable and simple operating conditions, such as constant load or steady-state temperature. However, real-world scenarios are often complex and variable, involving dynamic loads, nonlinear temperature rises, and other challenges, which limit diagnostic accuracy. To address this issue, this paper proposes an intelligent fault diagnosis model based on a one-dimensional convolutional neural network (CNN), using the heater’s current and voltage as the input to the neural network. The effectiveness and accuracy of the proposed model were validated through experimental data under two different conditions, achieving an average accuracy rate of 98%. The disconnection faults were generated during actual operation and occurred in the early stages, differing significantly from artificially simulated faults, thereby increasing the difficulty of accurate diagnosis. Analysis and comparison of the experimental results demonstrate the feasibility of the intelligent diagnostic model and its high diagnostic accuracy. Full article

In the field of petroleum extraction, the welding technology of the core wire (the hybrid structure of copper and the Ni-Cr alloy) in high-power oilfield heaters is a key process that determines the efficiency of the heater. Using the tungsten inert gas (TIG) welding method of filling pure copper wire, this work effectively joins the dissimilar metals of red copper and the Cr₂₀Ni₈₀ nickel–chromium alloy. The microstructure, mechanical properties, and conductivity of the joint were analyzed. The results showed that the surface of the welded dissimilar metal joint was smooth and uniform; radiographic nondestructive testing did not reveal any macroscopic forming defects such as pores or cracks. The microstructure of the joint fusion zone exhibits an equiaxed grain morphology. The interface between the copper and the fusion zone displays a columnar grain structure, growing perpendicular to the fusion line. An interdiffusion layer of elements was formed at the interface between the Ni-Cr alloy and the fusion zone. The microhardness of the joint shows a stepwise decreasing trend, with the highest hardness on the nickel–chromium alloy side, followed by the fusion zone, and the lowest on the copper side. The joint fractures at the copper base material, with a tensile strength greater than 220 MPa, indicating a ductile fracture mode. During the electrical heating process, the joint temperature does not significantly increase compared to the copper side, demonstrating good thermal stability. Full article

Textile heaters are made from knitted conductive yarns integrated into their fabric, making them stretchable, washable, breathable and suitable for close-to-skin wear. However, the non-zero resistance in the lead wires causes non-uniform power distribution, which presents a design challenge. To address this, the electrical performance of the heaters is modeled as an n-ladder resistor network. By using the finite difference method, simple, closed-form expressions are derived for networks with their power source connected to input terminals A₁B₁ and A₁B_n, respectively. The exact results are then used to derive approximations and design criteria. The solutions for the ladder networks presented in this paper apply to a wider class of physical problems, such as irrigation systems, transformer windings, and cooling fins. Full article

Accurate sample heating is vital for nucleic acid extraction and amplification, requiring a sophisticated thermal cycling process in nucleic acid detection. Traditional molecular detection systems with heating capability are bulky, expensive, and primarily designed for lab settings. Consequently, their use is limited where lab systems are unavailable. This study introduces a technique for performing the heating process required in molecular diagnostics applicable for point-of-care testing (POCT), by presenting a method for crafting customized heaters using freely patterned nichrome (NiCr) wire. This technique, fabricating heaters by arranging protrusions on a carbon black-polydimethylsiloxane (PDMS) cast and patterning NiCr wire, utilizes cost-effective materials and is not constrained by shape, thereby enabling customized fabrication in both two-dimensional (2D) and three-dimensional (3D). To illustrate its versatility and practicality, a 2D heater with three temperature zones was developed for a portable device capable of automatic thermocycling for polymerase chain reaction (PCR) to detect Escherichia coli (E. coli) O157:H7 pathogen DNA. Furthermore, the detection of the same pathogen was demonstrated using a customized 3D heater surrounding a microtube for loop-mediated isothermal amplification (LAMP). Successful DNA amplification using the proposed heater suggests that the heating technique introduced in this study can be effectively applied to POCT. Full article

This study demonstrates the conversion of metallic titanium (Ti) to titanium oxide just by conducting electrical current through Ti thin film in vacuum and increasing the temperature by Joule heating. This led to the improvement of electrical and thermal properties of a microbolometer. A microbolometer with an integrated Ti thermistor and heater width of 2.7 µm and a length of 50 µm was fabricated for the current study. Constant-voltage stresses were applied to the thermistor wire to observe the effect of the Joule heating on its properties. Thermistor resistance ~14 times the initial resistance was observed owing to the heating. A negative large temperature coefficient of resistance (TCR) of −0.32%/K was also observed owing to the treatment, leading to an improved responsivity of ~4.5 times from devices with untreated Ti thermistors. However, this does not improve the noise equivalent power (NEP), due to the increased flicker noise. Microstructural analyses with transmission electron microscopy (TEM), transmission electron diffraction (TED) and energy dispersive X-ray (EDX) confirm the formation of a titanium oxide (TiO_x) semiconducting phase on the Ti phase (~85% purity) deposited initially, further to the heating. Formation of TiO_x during annealing could minimize the narrow width effect, which we reported previously in thin metal wires, leading to enhancement of responsivity. Full article

In this work, aluminium wire mesh (WM) samples with 3, 9, and 18 pores per inch (PPI) and porosities of 0.894, 0.812, and 0.917, respectively, were combined together to form graded structures including 3-9-18, 9-18-3, and 18-3-9 PPIs. A 5 mm thickness for each WM was considered for a length of 2 m and inserted into a single-pass solar air heater (SAH) in which the height of the SAH was 120 mm. For the numerical analysis, a 3D numerical model was considered in ANSYS fluent software, and the Rosseland radiation model renormalization group (RNG) k-ε enhanced wall function was incorporated to account for solar radiation. The local thermal equilibrium (LTE) model was considered to obtain the heat-transfer characteristics of the WM. The numerical results of the thermohydraulic performance parameter (THPP) of the 9-18-3 PPI WM were 13.04% and 11.92% higher than the 3-9-18 and 18-3-9 PPI samples, respectively. Later, 25% of the 9-18-3 graded wire mesh (GWM) was considered at four different locations, i.e., 0, 0.5, 1, and 1.5 m away from the inlet, and analysed to obtain the best location for efficient heat transfer. The computational results show that 1.5 m away from the inlet is the best location among the different locations considered. The experimental results of the GWM at 1.5 m away from the inlet demonstrated a 20.91% and 23.32% increase in thermal efficiency compared to the empty channel for the 0.027 kg/s and 0.058 kg/s mass flow rates, respectively. From numerical-cum-experimental analysis, it was found that inserting 25% length of GWM of the entire length of the test section at a distance of 1.5 m from the inlet in single pass SAH improves the overall performance of the empty channel of single-pass SAH. Full article

The problem of icing for surfaces of engineering structures requires attention more and more every year. Active industrialization in permafrost zones is currently underway; marine transport in Arctic areas targets new goals; the requirements for aerodynamically critical surfaces of wind generators and aerospace products, serving at low temperatures, are increasing; and fiber-reinforced polymer composites find wide applicability in these structural applications demanding the problem of anti/de-icing to be addressed. The traditional manufacturing approaches are superimposed with the new technologies, such as 3D printers and robotics for laying heat wires or cheap and high-performance Thermal Sprayed methods for metallic cover manufacturing. Another next step in developing heaters for polymer structures is nano and micro additives to create electrically conductive heating networks within. In our study, we review and comparatively analyze the modern technologies of structure heating, based on resistive heating composites. Full article

This article is devoted to the study of the phenomenon of superheating of partially miscible mixtures having a lower critical solution temperature and the thermal effect accompanying the relaxation of an unstable mixture, within the framework of the problem of high-density heat flux removal. The study was carried out by using the method of the controlled pulse heating of a platinum wire probe. The characteristic heating time was from 0.2 to 180 ms. The superheating degree of the mixture relative to the diffusion spinodal exceeded 100 K. The heat flux density from the heater surface reached 13.7 MW/m². The object of research was an aqueous solution of polypropylene glycol-425 (PPG-425). The obtained results clearly indicate that such mixtures can be used as coolants in processes where the possibility of powerful local heat release cannot be excluded. They also form the basis for expanding the phase diagram by involving in the study not-fully-stable and unstable states of the mixture. Full article

Among the fire reports caused by seasonal devices registered with the Korea Fire Information Center in 2021, fires caused by heating cables accounted for the largest portion with 350 cases. As a result of analyzing the heating cable fires from 2015 to 2021, we have classified the heating cable fires into four types according to the method of winding the heating wire. First, we hypothesized that the temperature is high when the density is high due to the overlap of the hot wires or when there is a thermal insulating material. We predicted that the temperature would rise through a random game and established a reproducibility test plan. In order to check how heat generation changes depending on the winding method of antifreeze heating cables, we selected 10 manufacturers and checked the temperature characteristics according to the test conditions (Paragraph 11, Paragraph 19.101) of the Technical Regulations for Electrical and Telecommunication Products and Components of Korea (K 10013), tested the four methods mentioned in this thesis and compared and analyzed the results. The experiment results indicate that the temperature of the heater part in antifreeze heating cables was mostly higher than the conditions required by the existing standards in cases 1 to 4. In particular, in the case of No. 5 manufacturer’s sample, the temperature of the heating cable of Case 1 was measured to be the highest at 119.0 °C. In addition, as a result of applying the data engineering reproducibility test results in the framework of the random game λ proposed in this thesis, we have derived the same results as the predicted hypothesis. Case 1 refers to the case where a fire occurs due to the heating cable being wrapped around the water pipe and insulation or taped outside; It is one of the methods that users actually use a lot in the field. Based on experiment, we have concluded that the fire risk is high under the Case 1 condition. Thus, the test conditions in the existing K 10013 Standard need to be strengthened according to the Case 1 condition. Full article

In a flexible electronic heater (FEH), periodic metal wires are often encapsulated into the soft elastic substrate as heat sources. It is of great significance to develop analytic models on transient heat conduction of such an FEH in order to provide a rapid analysis and preliminary designs based on a rapid parameter analysis. In this study, an analytic model of transient heat conduction for bi-layered FEHs is proposed, which is solved by a novel symplectic superposition method (SSM). In the Laplace transform domain, the Hamiltonian system-based governing equation for transient heat conduction is introduced, and the mathematical techniques incorporating the separation of variables and symplectic eigen expansion are manipulated to yield the temperature solutions of two subproblems, which is followed by superposition for the temperature solution of the general problem. The Laplace inversion gives the eventual temperature solution in the time domain. Comprehensive time-dependent temperatures by the SSM are presented in tables and figures for benchmark use, which agree well with their counterparts by the finite element method. A parameter analysis on the influence of the thermal conductivity ratio is also studied. The exceptional merit of the SSM is on a direct rigorous derivation without any assumption/predetermination of solution forms, and thus, the method may be extended to more heat conduction problems of FEHs with more complex structures. Full article

With the development of flexible electronics, flexible microheaters have been applied in many areas. Low power consumption and fast response microheaters have attracted much attention. In this work, systematic thermal and mechanical analyses were conducted for a kind of flexible microheater with two different wire structures. The microheater consisted of polyethylene terephthalate (PET) substrate and copper electric wire with graphene thin film as the middle layer. The steady-state average temperature and heating efficiency for the two structures were compared and it was shown that the S-shaped wire structure was better for voltage-controlled microheater other than circular-shaped structure. In addition, the maximum thermal stress for both structures was from the boundary of microheaters, which indicated that not only the wire structure but also the shape of micro heaters should be considered to reduce the damage caused by thermal stress. The influence resulting from the thickness of graphene thin film also has been discussed. In all, the heating efficiency for flexible microheaters can be up to 135 °C/W. With the proposed PID voltage control system, the response time for the designed microheater was less than 10 s. Moreover, a feasible fabrication process flow for these proposed structures combing thermal analysis results in this work can provide some clues for flexible microheaters design and fabrication in other application areas. Full article

Solar air heater is considered to be the most popular and widely used solar thermal system. Solar air heater (SAH) can be used in many applications, ranging from domestic to industrial purposes. However, it seems that the viability of SAH is not feasible due to the following two reasons: (i) the low convective heat transfer coefficient at the absorber plate is the reason that causes a low heat transfer rate to the flowing air, and (ii) the high temperature of the absorber plate insists on high heat losses, thus, reducing the thermal efficiency. The convective coefficient can be augmented by placing turbulators/roughness on the absorber plate, which induces turbulence in the flow passage near the absorber plate by disrupting and destabilizing the laminar sublayer. This comprehensive review has been presented to summarize the studies on artificial roughness/turbulators geometries to enhance the heat transfer rate. Various rib configurations (such as grits, grooves, blockages, baffles, winglets, protrusions, twisted taps, dimples, and mesh wires) and distinct arrangements of rib roughness (such as inclined, transverse, V shape, with gap) have been reviewed to present heat transfer and friction characteristics. Additionally, thermal efficiency and thermohydraulic efficiency (in terms of net effective efficiency) of various artificial roughnesses and rib configurations are presented under distinct operating conditions for comparing purposes. This comparative study has been presented to assess the most desirable ribs and their configurations. On the basis of net effective efficiency, a multiarc rib with gaps is found to be the best configuration among all and have the highest thermal and net effective efficiency of around 79%. Full article