Browse Topic: Microscopy

Items (689)
g-C₃N₄, a metal-free semiconductor photocatalyst, demonstrates remarkable potential, but its practical application in pollutant degradation is significantly limited by the rapid recombination of photogenerated electron-hole pairs and low photocatalytic efficiency. To address this, a series of magnetic recyclable g-C₃N₄/CoFe₂O₄ composite photocatalysts with different CoFe₂O₄ doping ratios were innovatively designed and prepared via thermal polymerization, sol- gel, and combined with ultrasonic and heat treatment processes. The novelty of this composite design lies in the effective integration of magnetic CoFe₂O₄ with g-C₃N₄ through a heterojunction structure. It substantially boosts the absorption of visible light. Concurrently, it effectively fosters the separation and mobility of photo-induced charge carriers. The composite materials were systematically characterized by X-ray diffraction, thermogravimetric analysis, scanning electron microscopy with energy-dispersive X-ray spectroscopy, photoluminescence spectroscopy, and ultraviolet-visible diffuse reflectance spectroscopy. Using tetracycline hydrochloride as the target pollutant, the photocatalytic activity of the composites was evaluated under visible light irradiation, and the effects of initial concentration, catalyst dosage, and the influence of solution pH on degradation efficiency were also examined. The results indicated that the composite with a CoFe₂O₄ to g-C₃N₄ mass ratio of 1:3 (denoted as 3-CN/CFO) exhibited the optimal performance: a TCH degradation rate of 80.29 % within 105 minutes and a total organic carbon removal rate of 61.63 %. After five consecutive cycling experiments, the degradation efficiency remained above 70 %, demonstrating good reusability and stability. The performance improvement is attributed to the formation of heterojunctions in the composite, which effectively facilitates charge separation, inhibits carrier recombination, and enhances visible light absorption. Furthermore, the inherent magnetism of the composite permits efficient recovery, streamlining its integration into practical applications. Toward the purification of antibiotic-contaminated water, this research proposes a viable method for fabricating highly effective and recyclable photocatalysts.
Hua, LongjunChai, TianWang, YimingZhang, JingHe, Ting
This study systematically evaluated the wear resilient performance of AZ61 magnesium alloy reinforced with 15 wt.% SiC and diverse amounts of multi-walled carbon nanotubes (MWCNTs) under dry sliding circumstances adopting pin-on-disc apparatus (ASTM G99). To identify the influence of factors like sliding speed (SS) (1-3 m/s), axial load (AL) (10-30 N), and MWCNT concentration (0-3 wt.%) that affect tribological performance, experiments were developed using a Central Composite Design (CCD) under Response Surface Methodology (RSM). SEM micrographs revealed a dispersion optimum near 2 wt.% MWCNT, where CNTs anchor to SiC and bridge the α-Mg matrix, while 3 wt.% shows agglomerates and micro-voids. Findings showed that wear loss (WL) and friction coefficient (CoF) was greatly amplified by increasing AL owing to localized heating and contact stresses. A compacted tribolayer was formed by increasing SS, which decreased WL but marginally raised the CoF. At low AL (10 N), SS (2.09 m/s), and 2.12 wt.% MWCNT, the wear resistance was significantly improved by improving load transfer and creating a lubricating carbon-rich coating, resulting in a decreased WL of 0.006 g. The CoF persisted within the range of 0.19 to 0.28. Agglomeration of MWCNTs caused increased WL and CoF when the MWCNT content is increased above 2 wt.%. Worn-surface microscopy at the optimum showed fine wear tracks and a continuous carbon/oxide glaze, evidencing a lubricious CNT-rich third-body film, whereas high AL/low MWCNT produced deep grooves and delamination.
Senthilkumar, N.
Polypropylene, a commodity plastic, is the semi-crystalline thermoplastics widely used in high volume for general purpose application. Polypropylene is the macro molecules of soft and weak backbone, which by reinforcement of fillers in different forms such as fiber, spheroids, nanotubes, flakes, etc., can influence its mechanical, thermal, electrical, creep resistance, and flame resistance properties for use in aerospace applications. Currently, polycarbonate and nylon plastics are used in aerospace applications, however, they are expensive compared with polypropylene. In this thesis, efforts are put to study the effect of reinforcement fillers in the properties of polypropylene composite, primarily the mechanical and flammability properties. The matrix element, polypropylene co polymer and reprocessed polypropylene blended in equal ratio, are coupled with the dispersing phases such as graphene, mica, fumed silica, and polydimethylsiloxane polymer. Effect of graphene as reinforcing filler at different weight % to polypropylene composite’s properties are studied and compared with that of the neat polypropylene. Effect of coupling agent, Aminopropyltriethoxysilane (APTES), on mineral fillers and Polydimethylsiloxane polymer (PDMS) used for crosslinking with the polypropylene matrix is also studied and compared using Fourier Transform Infrared Spectroscopy (FTIR) and Scanning Electron Microscope (SEM) techniques.
Govindaraju, Parthasarathy
Under a microscope, a bouquet of lollipop-like structures, each smaller than a grain of sand, waves gently in a petri dish of liquid. Suddenly, they snap together, like the jaws of a Venus flytrap, as a scientist waves a small magnet over the dish. What was previously an assemblage of tiny passive structures has transformed instantly into an active robotic gripper.
The Army requires rotorcraft drive systems to operate for 30 minutes following a loss of lubrication event to make an emergency landing. Coatings research has shown great promise for loss of lubrication, but coating repeatability and quality control is a primary hurdle. The Army partnered with Acree Technologies via a Small Business Innovation Research (SBIR) effort to develop an optimized gear coating for loss of lubrication. The research culminated in a system level transmission experiment that maintained flight relevant torque and speed through a helicopter gearbox without oil for three hours. The authors decided to shutdown the experiment for inspection after three hours of operation without oil because the temperature and vibration signals maintained steady state conditions without signs of failure. Teardown analysis showed the transmission gear surfaces did not scuff, scanning electron microscope analysis showed coating remained on the gear teeth, and cross-sectional SEM analysis showed a measurable coating thickness remaining on the gear teeth after three-hours of operation without oil.
Riggs, MarkPomplon, WilliamFetty, JasonMilligan, RyanWoods, RonWong, KelvinMatzke, CalebJacques, KellyHood, Adrian
Bench-level boundary-lubricated fretting experiments were conducted to compare the relative wear of all-steel and hybrid material pairs. Roller-on-raceway contacts were simulated using both AISI M50 steel and Si3N4 cylindrical rollers on flat AISI M50 steel disks. The rollers were 9 mm long with a 9 mm diameter. Tests were conducted with constant amplitude, oscillation frequency, and load. All tests were boundary-lubricated with 0.1 ml of DOD-PRF-85734, MIL-PRF-32538, MILPRF-23699, or unclassified ISO VG 68 aviation gear oil. Wear volume was calculated from 3D measurements on the roller and disk samples after each test. Wear tracks were inspected with light and scanning electron microscopy. It was concluded that hybrid pairs exhibited less wear than all-steel pairs when boundary-lubricated with three of the four aviation gear oils. Both hybrid and all-steel pairs exhibited similar wear when boundary-lubricated with MIL-PRF-23699 oil.
Hager, CarlCarl, MatthewBenak, Noah
This research investigates the alterations in microstructure, microhardness, and joint strength resulting from the dissimilar friction stir welding (FSW) of WE43 magnesium alloy to AA7075 aluminium alloy. The study specifically analyses the role of FSW process parameters in the formation of intermetallic compounds (IMCs), the evolution of grain structure, the resultant microhardness distribution across the weld zone, and the joint tensile strength. A comprehensive microstructural characterization was performed utilizing optical microscopy (OM), field emission scanning electron microscopy with energy-dispersive X-ray spectroscopy (FESEM-EDS), electron backscatter diffraction (EBSD), and X-ray diffraction (XRD). These analyses confirmed significant grain refinement in the stir zone and the identification of various IMCs at the weld interface. Microhardness mapping indicated a gradient profile, with the weld nugget exhibiting superior hardness attributed to its dynamically recrystallized, fine-grained microstructure. Crucially, the low-heat-input FSW (LFSW) variant yielded a substantial increase in average microhardness, reaching 126 HV in the stir zone (SZ), due to grain refinement induced by severe plastic deformation. This configuration achieved a joint efficiency of approximately 68.7% relative to the WE43 base material. The enhancement in mechanical performance is directly linked to a modified joint preparation strategy that successfully suppressed the formation of brittle AlMg IMCs, instead fostering the formation of harder MgZn, Al2CuMg, and AlMgZn compounds. These findings underscore the efficacy of the LFSW technique in fabricating dissimilar WE43-AA7075 joints with favourable mechanical properties and a consistent microhardness profile. The process parameters are strategically selected to achieve better joint properties and form defect-free joints.
Ahmad, TariqKhan, Noor ZamanAhmad, BabarSiddiquee, Arshad Noor
In a new study — the latest advance in the field of ptychography — researchers at CU Boulder have used doughnut-shaped beams of light to take detailed images of objects too tiny to view with traditional microscopes. The new technique could help scientists improve the inner workings of a range of “nanoelectronics,” including the miniature semiconductors in computer chips.
With high energy density and long cycle life, lithium-ion batteries (LIBs) are currently the most promising electrochemical devices for electric vehicles and energy storage. However, the safety and reliability of LIBs can be significantly compromised in low-temperature cyclic due to anode lithium plating and other factors which are still unclear. Therefore, it is essential to reveal the thermal-gas stability of LIBs under low-temperature cyclic. This study investigates the thermal runaway (TR) characteristics and gas production characteristics after TR of 18650-type NCA LIBs across four states of health (SOH), from 100% to 70%. Using Glove box, Electrochemical impedance spectroscopy, Scanning electron microscope, X-ray photoelectron spectroscopy, Accelerating rate calorimetry, and Gas chromatography, the research identifies critical trends in temperature rate, gas composition and explosion risk. After around 150 cycles, there is a significant and rapid decline in capacity. The internal resistance of batteries continues to increase, lithium is precipitated on the anode, and the cathode experiences particle fragmentation. Comparing the 70% SOH batteries with the 100% SOH, it is observed that more Li2O, Li2CO3 and LiF appeared on the anode. The triggering time of TR was 41.38% earlier, and the maximum temperature during TR decreased by 7.89%. The mass loss of the 70% SOH batteries were 11.85% higher than that of the 100% SOH. The gas production volume of the 80% SOH is the lowest, while that of the 70% SOH is the highest. Compared with the 100% SOH batteries, the upper limit (UEL) of gas production explosion for 70% SOH decreases by 3.67%, while the lower limit (LEL) increases by 24.46%. This indicates that the gas production of fresh batteries has a wider range of explosion limits. These research findings provide crucial insights for enhancing the safety and reliability of LIBs during operation, storage, and recycling processes.
Wang, HailongWu, SenmingLuan, WeilingChen, Haofeng
The exceptional strength, formability, and weldability of S550MC steel sheets make them a cornerstone material in the automotive industry. These properties translate into the creation of high-performance automotive components like chassis parts, structural reinforcements, ultimately contributing to enhanced vehicle safety and overall performance. Furthermore, S550MC steel boasts excellent fatigue resistance, a critical factor for ensuring long-term reliability in demanding automotive applications that experience repeated stress cycles. However, optimizing the performance of S550MC components depends on a fine understanding of the critical relationship between hole edge quality and fatigue failure. This study highlights the impact of hole-piercing clearance on the edge quality of the hole in modified fatigue samples manufactured from S550MC steel, and its effect on fatigue life. The surface morphology was characterized by using stereoscope for edge quality of hole piercing operation. Also, fatigue testing under cyclic loading conditions was conducted to determine fatigue behaviour. This study accentuates the critical role of optimizing hole-piercing processes to achieve superior edge quality. By minimizing stress concentrations features at the edges, the risk of fatigue failure can be reduced significantly. This results in greatly improving reliability and extending the lifespan of these components even under demanding operational environments. The research emphasizes the importance of detailed edge preparation method in improving the performance and durability of steel fabricated structures. This study offers invaluable insights in developing more effective manufacturing practices for steel components across a wide range of industrial applications.
Nahalde, SujayHingalje, AbhijeetUghade, VikasSingh, UditaMore, Hemant
Hydrogenated nitrile butadiene rubbers (HNBR) and their derivatives have gained significant importance in automotive compressed natural gas (CNG) valve applications. In one of the four-wheelers, CNG valve application, HNBR elastomeric diaphragms are being used for their excellent sealing and pressure regulation properties. The HNBR elastomeric diaphragm was developed to sustain CNG higher pressure However, it was found permanently deformed under lower pressures. In this research work, number of experiments was carried out to find out the primary root cause of diaphragm permanent deformation and to prevent the failure for safe usage of the CNG gas. HNBR diaphragm deformation investigation was carried out using advanced qualitative and quantitative analysis methods such as Soxhlet Extraction Column, Fourier Transform Infrared Spectroscopy (FTIR), Differential Scanning Calorimetry (DSC), Optical Microscopy (OM), Scanning Electron Microscopy (SEM), and Thermogravimetric Analysis (TGA). For this purpose, we have carried out experiments on OK (HNBR diaphragm with higher bar pressure) and field-failed diaphragms (HNBR diaphragm deformed after lower bar CNG pressure). We have found that OK and Field failed diaphragms have different filler concentrations and uneven dispersion and distribution. Also, the crosslinking density of the failed Field diaphragms was observed in declining order in comparison with the OK diaphragms. TGA and SEM analysis revealed the filler concentration and morphology of the diaphragms. The chemical nature and thermal properties have been analysed using FTIR and DSC analysis techniques. The Soxhlation extractions study helped to understand the crosslinking density of OK and field failure diaphragms. Preventive measures have been implemented to mitigate the HNBR diaphragm permanent deformation issue.
Patil, Bhushan GulabNAIKWADI, AMOLMali, ManojTata, Srikanth
Recent regulations limiting brake dust emissions have presented many challenges to the brake engineering community. The objective of this paper is to provide a low cost, mass production solution utilizing well known existing technologies to meet brake emissions requirements. The proposed process is to alloy the Gray Cast Iron with Niobium and subsequently Ferritic Nitrocarburize (FNC) the disc. The Niobium addition will improve the wear resistance of the FNC case, reducing wear debris. The test methodology included: 1. Manufacture of disc samples alloyed with Niobium, 2. Finish machining and ferritic nitrocarburizing and 3. Evaluation of airborne wear debris utilizing a pin-on-disc tribometer equipped with emission collection capability. The airborne emission and wear surfaces were further analyzed by Scanning Electron Microscopy, Energy Dispersive techniques (SEM-EDS), X-Ray Diffraction and Optical Microscopy. The cast iron test matrix included four groups; Unalloyed eutectic 4.3% Carbon Equivalent (CE), Unalloyed hypereutectic >4.3% CE, Niobium alloyed Eutectic and Niobium alloyed hypereutectic gray cast iron. The results demonstrate the advantages of Niobium alloyed FNC treated discs in reduced wear and meeting Euro7 airborne emission requirements. The Niobium alloyed eutectic Gray Cast Iron plus FNC treatment exhibited the best wear debris performance for both the Non-Asbestos organic (NAO) and Low Metallic (Low Met) friction materials. The Niobium alloyed hypereutectic Gray Iron plus FNC treatment also performed well with both NAO and Low Metallic friction materials.
Barile, BernardoHolly, Mike
In modern four-wheelers, seat suspension systems play a crucial role in enhancing occupant comfort by mitigating the effects of road unevenness and vibrations. Among these systems, active suspension mechanisms offer advanced performance through complex assemblies involving welded, riveted, and bolted joints. This study investigates the failure of an air spring bracket - a critical component of a pneumatic active suspension system - manufactured by Gas Metal Arc Welding (GMAW) of two dissimilar ferrous materials which are likely to be SAPH440 and S355J2. These different materials were used based on mechanical properties required to perform by their particular part. System level validation tests were conducted to ensure the reliability of the seat suspension system. The one of the validation tests is continuous cyclic fatigue test which is carried out on the complete seat assembly. However, during vibration / cyclic endurance testing, premature failures were observed near the weld joints. Detailed failure analysis using Scanning Electron Microscopy (SEM), Energy Dispersive Spectroscopy (EDS), and optical microscopy revealed cracks and discontinuities at the weld interfaces. The microstructure in the heat-affected zone (HAZ) exhibited ferrite-Martensite structure with grain coarsening. The fractography reveals the cleavage type and river type fracture morphology which indicates the part failed due to brittle fracture. Inadequate welding of SAPH440 steel can lead to issues such as cracking, distortion, and poor fusion due to its high carbon content and inadequate heat control. The failure analysis study identified that less fusion control of welding parameters and associated thickness and carbon compositions variation which significantly contributed to the component’s fatigue failure. Preventive strategies, including the optimization of sectional thickness and design changes for uniform stress distribution are proposed to improve the reliability of welded assemblies.
Patale Jr, ReshmaPinjari, Jayant NamdevBali, Shirish
Particulate matter (PM), mainly its finer fraction, is among the main atmospheric pollutants present in an urban environment. The relationship between the increase in the concentration of this pollutant and the harm to human health is well established. The main sources of particulate matter in urban areas are mobile sources, which include the exhaust emission from light duty vehicles. This work measured the emission of PM in three light duty passenger vehicles, characterizing it in terms of emitted mass in one “flex” vehicle with port fuel (indirect) injection (PFI), using ethanol and gasohol (mixture of 22% anhydrous ethanol and 78% gasoline, by volume), in another “flex” vehicle with direct fuel injection (GDI), and in a diesel vehicle. In addition to mass measurement, images of the filters used in PM sampling were produced using scanning electron microscopy. The processing of these images made it possible to determine the average PM size, as well as establish a particle size distribution for each vehicle and test fuel. With the same instrument, the presence of some chemical elements present in the sample could be determined, through Energy Dispersive Spectroscopy (EDS) analysis.
Borsari, VanderleiNeto, Edson Elpídiode Abrantes, Rui
The application of Thermal Barrier Coatings (TBC) has been widely utilized in aerospace turbines to enhance the operational temperature and thermal efficiency of titanium alloys, while preserving their properties such as low density, creep resistance, and corrosion resistance. TBC systems typically consist of a metallic substrate, a metallic coating (Bond Coat), a thermally grown oxide (TGO), and a ceramic topcoat (TC). This study investigated the fracture surface characteristics of Ti-6Al-4V with TBC after a creep test at a constant temperature of 600 °C, under stress levels of 125, 222, and 319 MPa, in order to understand the mechanisms involved. The TBC was composed of a NiCrAlY (BC) and a zirconia co-doped with yttria and nióbia (TC). The fracture characterization of the alloy after the creep test was conducted through stereoscopy and scanning electron microscopy. The fracture mechanism at 600 °C and 222 MPa was predominantly ductile, as evidenced by the presence of dimples and shear zones at the edges of the specimens, indicating necking. In contrast, at 600 °C and stress levels of 125 and 319 MPa, brittle fracture was the dominant mechanism, with cleavage facets and a low percentage of area reduction. Thus, it can be predicted that the titanium alloy with TBC at 600 °C will exhibit better mechanical strength under stress conditions around 222 MPa.
Takahashi, Renata Jesuinade Assis, João Marcos KruszynskiRodrigues, Bianca Costade Andrade Acevedo Jimenez, Laila RibeiroReis, Danieli Aparecida Pereira
Nanosilica-treated fabrics have a variety of properties, such as durability, water resistance, and specific surface characteristics. Due to that, many applications of those components are highlighted in literature. Some examples include waterproofing and water repellency, stain resistance, flame retardancy, improved durability, UV protection, improved comfort, antimicrobial properties, and textile coatings for electronics. These applications demonstrate how nanosilica-based treatments can enhance the performance of fabrics, making them more suitable for various specialized uses. In this work, a technical fabric with a mesh opening of 45 μm and an open area of 29.6% was surface treated. The treatments were performed by the dip-coating method using poly(dimethylsiloxane) (PDMS) and nanosilica at different concentrations. Optical microscopy (OM) images of the fabrics’ surface and water contact angle (WCA) measurements were carried out before and after the fabrics’ treatments. The results showed a significant increase in the water contact angle of the treated fabrics compared to the untreated ones. After treatment with PDMS (4 wt.%) and silica nanoparticles (0.1 wt.%), the fabrics reached WCA values of approximately 140°, demonstrating the effectiveness of the coating in enhancing hydrophobicity compared to the untreated fabric (WCA of 103°). OM images demonstrated a good uniformity and dispersion of the nanoparticles on the fabrics’ surfaces after the treatments. Untreated fabric was not able to separate water from oil, while all the treated fabrics demonstrated efficient oil/water separation, varying only flux rate, depending on the type of surface treatment. In conclusion, the oil/water separation was effective when surface treatments were applied to the fabrics’ surfaces.
Kerche, Eduardo FischerLeal, DéboraRomano, PauloOliveira, ViníciusPolkowski, Rodrigo
This study aims at examining the effect of tool rotational speed on the microstructural and mechanical properties of friction stir welded joints of AA6061 aluminum alloy, both pre- and post-heat treatment. The quality of the joints was assessed initially through tensile, hardness, and charpy impact tests, as well as microscopic observations. During the second stage, solid solution heat treatments were conducted at 535°C, followed by aging on additional specimens welded at identical speeds. The latter underwent hardness tensile tests and microscopic examinations. A comprehensive assessment of the outcomes from various tests validated the influence of metallurgical phenomena, including recrystallization, precipitation, and structural defects on overall resistance. The results showed an improvement in strength, ductility, and impact energy was observed in the case of welding at high rotation speed (1400 rpm). At the same speed, ductility almost doubled after post-weld heat treatment. However, the treatment leads to a slight increase in strength and a decrease in ductility and impact energy at low speeds.
Bouchelouche, FatimaDebih, AliOuakdi, Elhadj
Li-ion battery performance is highly dependent on the electrode materials. The composition of the negative and positive electrodes influences crucial aspects of the Li-ion cell, including energy density, ageing behavior and thermal stability. Recent Li-ion technologies include the use of composite graphite-silicon negative electrodes to improve the energy storage capacity of the otherwise graphite-only negative electrode. This article evaluates the impact of negative electrode composition (standard graphite vs. Si-Gr) on the performance of two recent technologies of Li-ion batteries from the same manufacturer, focusing on electrical performance and safety behavior. The studied technologies are the LG M50LT and LG M58T, the latest one introducing a considerable increase of capacity, passing from 4.80 to 5.65 in nominal capacity. This article abords the comparison of both technologies in electric performance, electrode composition, cell design and thermal stability. Electrical characterization confirmed that the LG M58T cells possess 12.5% more capacity than the LG M50LT technology. Material characterization proved the key difference between both technologies: Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM-EDX) confirmed that the LG M50LT negative electrodes are composed of graphite, while the M58T features a blended graphite-silicon oxide (SiOx) electrode. After the analyses regarding cell characterization, the capacity increase of the LG M58T technology was attributed to the presence of silicon particles in its negative electrode composition. Safety tests showed that critical events of the exothermic chain reaction during thermal runaway occurred at similar temperatures for both technologies. Nonetheless, maximal pressure reached during thermal runaway and mass loss during the thermal event were higher for the M58T cells. These first safety results indicate a higher reactivity on the M58T technology related to the higher capacity of the cell.
Cruz Rodriguez, Jesus ArmandoLecompte, MatthieuRedondo-Iglesias, EduardoPelissier, SergeAbada, Sara
To meet the need for better 3D imaging that works during live surgery, researchers recently developed a new kind of surgical microscope called the Fourier light-field multiview stereoscope, known as FiLM-Scope.
In this work, the microstructure and mechanical behavior of AL7079 metal matrix composites (MMCs) mixed with zirconia and quarry dusts are analyzed. The high-strength Al7079 can be further improved by the addition of zirconia particulates and quarry dust particles, a cost-effective reinforcement. Composite samples with different weight fractions of zirconia (2%, 4%, and 6%) and quarry dust (2%) were produced via a stir-casting technique. Scanning electron microscope (SEM) was engaged to examine the microstructure of the composites, which showed that the reinforcements were well integrated and bonded perfectly to the matrix material. A simple mechanical test of hardness, tensile, and impact strength revealed enrichment in hardness and tensile strength in comparison to the Al7079 alone, whereas the impact strength decreased. Composite containing 6% zirconia and 2% quarry dust improved both the hardness (95 BHN) and tensile strength (186 MPa) by 7%, outperforming the remaining composition thus an effective novel material for automotive sector.
Madan Kumar, K.N.Sathyanarayana, G.M.Kuldeep, B.Manu, S.S.Manjunath Yadav, S.Anand, H.R.
When a train passes continuously over a section of the track, the track gradually moves away from the intended vertical and horizontal alignment with time and repeated use. Regular maintenance on the track, such as leveling, lifting, lining, and tamping, is necessary to maintain the optimal geometry of the track. Ballast is leveled and squeezed by hydraulic rams in tamping machines. The tamping is a process of ballast packing under railway tracks. In current system a set of tungsten carbide chips are attached either by welding or by coating on tamping tool tip made of EN24 steels. These tungsten carbide chips directly come in contact with the ballasts. After few tamping works, gradually these chips torn out and need to be replaced after certain period. Tungsten carbide is a costly material, therefore this research deals with replacement of tungsten carbide with silicon carbide (easily available cheaper) coating used for tamping tools tip. The study consists of microstructural examination of both materials. The SEM analysis shows that SiC coatings provide a more uniform, dense, and defect-free surface with finer grain structures. SiC coatings adhere better to the EN24 steel substrate, as seen in optical microscopy images. Result shows that tungsten carbide-coated sample exhibited the higher average wear rate, and the silicon carbide-coated sample displayed the lower average wear rate.
Mishra, MamtaPandey, ManasSingh, ShrutiSrivastava, SanjayKumar, Jitendra
Innovators at NASA Johnson Space Center have developed a handheld digital microscope to fill the critical microscopy needs of human space exploration by providing flight crews in situ hematological diagnostic and tracking ability to assess and monitor crew health in the absence of gravity. Although currently in use aboard the International Space Station (ISS) to work in conjunction with NASA’s handheld slide staining system, the microscope may have numerous applications here on Earth.
The efficiency and performance of lithium-ion batteries are highly influenced by the quality of laser cutting of electrode materials. The laser cut quality of thin foils is often measured by amount of kerf width and heat-affected zone (HAZ). This article adopts a novel approach that involves pre-cooling of thin copper foils prior to the laser cutting process. The impact of laser conditions and foil temperature were analyzed on HAZ and kerf width induced during laser cutting experiments conducted based on L27 orthogonal array. Teaching–learning–based optimization (TLBO) technique was employed to identify the optimal laser parameters. ANOVA results indicated that the temperature was the most significant factor influencing kerf width and HAZ. The optimized laser parameters identified through TLBO technique were 16 W laser power, 69.47 mm/s scanning speed, and 20 kHz pulse frequency at dry ice conditions. A reduction of 50.76% kerf width and a decrease in 7.6% HAZ were observed when the foils were cut at dry ice conditions. The quality of cut surfaces were further examined using scanning electron microscope.
Rao, Akshay P.Bharatish, A.Solaiachari, SivakumarKumar, S. Mahendra
Platinum (Pt), palladium (Pd), and rhodium (Rh) are used as active substances in exhaust gas purification catalysts for automobiles. Among these, Rh is an essential element because it efficiently promotes a NOx reduction reaction. On the other hand, the price of Rh has been rising in recent years. From the perspective of the supply risk of rare resources, there is an urgent need to develop technologies to replace or reduce the amount of Rh used in catalysts. We focused on the pseudo-rhodium alloy developed by the ACCEL program of the Japan Science and Technology Agency (JST), and then investigated the application of the pseudo-rhodium alloy on the catalysts of our motorcycles and also the degradation process. A nanosized PdRuIr alloy supported on a ceria-zirconia solid solution (PdRuIr/CZ) was prepared and assembled into a motorcycle for emissions measurement. The PdRuIr/CZ catalyst with an alloy loading of 4.0 g/L had initial properties comparable to the Rh supported on a CZ (Rh/CZ) catalyst with a Rh loading of 0.3 g/L, but after degradation treatment, emissions increased and were inferior to the Rh/CZ. X-ray diffraction and transmission electron microscopy of the catalyst powder showed that the alloy particles increased in size and underwent phase separation after degradation treatment. Furthermore, it was confirmed that iridium (Ir) was oxidized during the specimen preparation process. It is speculated that phase separation proceeds as iridium undergoes repeated oxidation and reduction during the catalyst production process and exposure to exhaust gases. We have clarified the degradation process of PdRuIr/CZ catalysts and concluded that iridium oxidation is one of the major factors causing phase separation of the alloy.
Motegi, TakuyaTatara, ShunyaTakamoto, ShunpeiDoi, Kosuke
Mechanical analysis was performed of a non-pneumatic tire, specifically a Michelin Tweel size 18x8.5N10, that can be used up to a speed of 40 km/h. A Parylene-C coating was added to the rubber spoke specimens before performing both microscopic imaging and cyclic tensile testing. Initially, standard ASTM D412 specimens type C and A were cut from the wheel spokes, and then the specimens were subjected to deposition of a nanomaterial. The surfaces of the specimens were prepared in different ways to examine the influence on the material behavior including the stiffness and hysteresis. Microscopic imaging was performed to qualitatively compare the surfaces of the coated and uncoated specimens. Both coated and uncoated spoke specimens of each standard type were then subjected to low-rate cyclic tensile tests up to 500% strain. The results showed that the Parylene-C coating did not affect the maximum stress in the specimens, but did increase the residual strain. Type C specimens also had a higher maximum stress on average than the Type A specimens. These mechanical tests provide useful data to determine material properties, such as Ogden material parameters, for future simulation of both the hyperelastic and hysteresis behavior of the rubber spokes.
Collings, WilliamLi, ChengzhiSchwarz, JacksonLakhtakia, AkhleshBakis, CharlesEl-Sayegh, ZeinabEl-Gindy, Moustafa
This study investigates the ignitability of hydrogen in an optical heavy-duty SI engine. While the ignition energy of hydrogen is exceptionally low, the high load and lean mixtures used in heavy-duty hydrogen engines lead to a high gas density, resulting in a much higher breakdown voltage than in light-duty SI engines. Spark plug wear is a concern, so there is a need to minimise the spark energy while maintaining combustion stability, even at challenging conditions for ignition. This work consists of a two-stage experimental study performed in an optical engine. In the first part, we mapped the combustion stability and frequency of misfires with two different ignition systems: a DC inductive discharge ignition system, and a closed-loop controlled capacitive AC system. The equivalence ratio and dwell time were varied for the inductive system while the capacitive system instead varied spark duration and spark current in addition to equivalence ratio. A key finding was that spark energy correlated well with ignitability, as long as the spark was sufficiently stable. In the second phase of this study, we employed an intensified high-speed camera to directly view the early flame development process. Two distinct types of misfires were identified: flame kernels could be quenched as they were convected away from the spark plug, or by the spark plug shell and ground electrode. Flame kernels were typically extinguished within 300 μs after the end of the spark, but their lifetimes varied with spark duration in a way that suggests that flame kernels can be extinguished even during an ongoing spark. Furthermore, the heat release of fired cycles could be delayed both by unusually slow flame development and due to quenching effects of the spark plug.
Hallstadius, PeterSaha, AnupamSridhara, AravindAndersson, Öivind
The tensile and low-cycle fatigue (LCF) properties of Ti6Al4V specimens, manufactured using the selective laser melting (SLM) additive manufacturing (AM) process and subsequently heat-treated in argon, were investigated at elevated temperatures. Specifically, fully reversed strain-controlled tests were performed at 400°C to determine the strain-life response of the material over a range of strain amplitudes of industrial interest. Fatigue test results from this work are compared to those found in the literature for both AM and wrought Ti6Al4V. The LCF response of the material tested here is in-family with the AM data found in the literature. Scanning electron microscopy performed on the fracture surfaces indicate a marked increase in secondary cracking (crack branching) as a function of increased plastic deformation and demonstrating equivalent performance when compared to the wrought Ti6AL4V at RT (room temperature) at 1.4% strain amplitude and better performance when compared to the HIP-AM Ti6Al4V at RT.
Gadwal, Narendra KumarBarkey, Mark E.Hagan, ZachAmaro, RobertMcDuffie, Jason G.
In an attempt to improve its mechanical characteristics in the as-fasted conditions, the AZ31 Mg alloy was investigated herein from being reinforced with diverse SiC weight percentages (3, 6, and 9 wt.%). To develop lightweight AZ31-SiC composites, a simple and inexpensive technique, the stir casting process, was used. Microstructural analysis of the as-cast samples showed that the SiC particles were distributed rather uniformly, were firmly bonded to the matrix, and had very little porosity. The substantial improvement in tensile, compressive, and hardness characteristics was caused by fragmentation and spreading of the Mg17Al12 phase, while the addition of SiC had only a slight effect on the microstructure in the as-cast state. Surfaces of AZ31-SiC composites were analyzed using scanning electron microscopy. A study identified the AZ31-SiC composite as a unique material for applications involving a high compressive strength, such as those found in the aviation and automobile engineering fields.
Thillikkani, S.Kumar, N. MathanFrancis Luther King, M.Soundararajan, R.Kannan, S.
This study investigates the heat transfer properties of graphene nanoplatelets (GnPs) blended with distilled water-ethylene glycol (DW-EG) mixtures, focusing on their potential application in battery thermal management systems (BTMS). Compared to other nanoparticles, carbon nanostructures exhibit higher thermal conductivity due to their low density and integrated thermal conductivity. The experimental findings are relevant in that compared with the base fluid, nanofluid samples had heat transfer capability. The physicochemical characteristics of investigated GNP were characterized using a Scanning Electron Microscope (SEM), pH and UV–Vis spectrophotometry. The thermal conductivity and physical properties of graphene platelets having the specific surface area of 500 m2/g in the base fluid of Distilled Water-Ethylene Glycol (DW-EG 70:30) and 100 % vol. of Ethylene Glycol (EG 100) were determined after 120 minutes of sonication time. The graphene nanofluids with the platelet concentrations of 0.025, 0.05, 0.075, and 0.1 wt% were investigated for the dispersion properties. The stability of nanofluid was examined using a zeta potential and UV-visible spectrophotometer. According to the thermal conductivity facts, dispersed nanoparticles always improve the heat conductivity of the DW-EG 70:30s base fluid, with the greatest improvement occurring at a concentration of 0.1 weight per cent GNPs. The study suggests that the GnP-infused nanofluids exhibit excellent heat transfer performance, making them promising candidates for enhancing the efficiency of BTMS in electric vehicles, providing a cost-effective and efficient solution for thermal management.
S, PalanisamySelvan, Arul Mozhi
A novel sintering method of bridging the two mechanically polished and oriented single-crystals together face-to-face in a non- environmental controlled atmosphere to fabricate the bicrystal substrate of NaCl of macroscopic thickness, with a common zone axis and having planarity over large areas, has been developed. Epitaxial [001] bicrystalline thin face-centered cubic (fcc) metal film of surface-reactive metal-containing tilt grain boundary across the interface is first grown in high vacuum directly by flash deposition on initially fabricated [001] oriented bicrystalline substrate of NaCl. The [001] tilt boundary, thus produced, and is examined by electron microscopy to characterize grain boundary morphology and structure. The findings of some preliminary investigations are then presented. A distinct atomic structure is observed for 310 and 210 inclination. Both HAADF-STEM and Diffraction images reveal that such fabricated high-angle grain boundary accommodates minor deviations from the exact high coincidence density ∑=5 misorientation. The potential use of the present technique is extended to produce a wide variety of homophase bicrystals, containing grain boundaries at the midplane, normal to any crystallographic surface without the necessity of a separate bonding operation.
Dish, NilabhGautam, AbhayBehera, RakeshBanka, HemasunderChavan, Pradeep
The solar-based hybrid automotive vehicle represents a trend marked by technological excellence, offering an efficient, cost-effective, and eco-friendly solution. Besides, the enhancement of solar absorption due to poor weather is influenced by poor solar power with reduced photocurrent density. This research focuses on enhancing the solar power and photocurrent density of conventional solar cells featuring aluminium-doped zinc oxide thin films (AZO) using the Mist Chemical Vapor Deposition (MIST CVD) process with a zinc acetate precursor solution processed at temperatures ranging from 200 to 400°C. To investigate the effect of AZO on the functional behaviour of solar cells, microstructural studies utilizing scanning electron microscopy and X-ray diffraction reveal the concentration of AZO and the alignment of Al/ZnO peaks as even. As a result, this research demonstrates a 21% increase in solar power output compared to conventional Cadmium Telluride (CdTe) cells, with an improvement in photocurrent density of 1.24 mA/cm2. This advanced solar cell technology is recommended for use in electric vehicle (EV) applications.
Venkatesh, R.De Poures, Melvin VictorThangamani, P.Manivannan, S.Devanathan, C.Boopathi, M. SugadevaBaranitharan, BalakrishnanMadhu, S.Kaliyaperumal, Gopal
The objective of this study is to optimize and characterize an Al6061/Al2O3/MWCNT nanocomposite produced through stir casting. The investigation focused on various concentrations of 2%, 3%, and 5% by weight of Al2O3/MWCNT nanoparticles, with an average Al2O3 particle size of 40 nm. The Al6061 matrix exhibited a uniform distribution of these nanoparticles. Microstructural analysis of the nanocomposite was conducted using scanning electron microscopy. The study examined the tribological properties, including wear and coefficient of friction, as well as the tensile strength and hardness of the Al6061/Al2O3/MWCNT nanocomposites. The results indicated a significant enhancement in mechanical properties, with the ultimate tensile strength (UTS) increasing from 122 MPa to 157 MPa, and the yield tensile strength (YTS) rising from 52 MPa to 76 MPa. At a 5% concentration of Al2O3/MWCNT, the hardness test showed an increase from 28 BHN to 55 BHN. The improvement ratios for 2%, 3%, and 5% concentrations of nano Al2O3/MWCNT particles were 36.54%, 38.51%, and 41.55%, respectively. Additionally, the study demonstrated that the addition of nano reinforcement significantly reduced the wear rate. For instance, at a load of 40 N, the wear rate of the Al6061 alloy was 1.4 x 10-3 mm3/m, whereas it was reduced to 0.62 x 10-3 mm3/m with the inclusion of 5% Al2O3/MWCNT nanoparticles.
Haridass, R.Subramani, N.Viknesh, S.Mathan Kumar, M.Mownitharan, M. S.
Fused deposition modeling (FDM) is a rapidly growing additive manufacturing method employed for printing fiber-reinforced polymer composites. Nonetheless, the performance of printed parts is often constrained by inherent defects. This study investigates how the varying annealing parameter affects the tribological properties of FDM-produced polypropylene carbon fiber composites. The composite pin specimens were created in a standard size of 35 mm height and 12 mm diameter, based on the specifications of the tribometer pin holder. The impact of high-temperature annealing process parameters are explored, specifically annealing temperature and duration, while maintaining a fixed cooling rate. Two set of printed samples were taken for post-annealing at temperature of 85°C for 60 and 90 min, respectively. The tribological properties were evaluated using a dry pin-on-disc setup and examined both pre- (as-built) and post-annealing at temperature of 85°C for 60 and 90 min printed samples. Tribological tests were conducted under varying normal loads (5, 10, 15, and 20 N) and sliding velocities (1 and 3 m/s), following the ASTM G99 standard test procedure. Significantly notable enhancements in wear and friction properties were consistently observed across all tribometer test conditions when the composites underwent annealing at 85°C for 60 min, surpassing the performance of other samples. These particular samples, subjected to the 85°C/60-min annealing process, exhibited elevated hardness, diminished wear rates, and reduced coefficients of friction (COF). A detailed examination using a scanning electron microscope revealed that the wear mechanism on the surface of the tribometer-tested samples exhibited milder wear when carbon fiber was added, followed by annealing at 85°C for 60 min, compared to the 90-min annealing. These promising results suggest that the proposed composites have potential applications in industries such as prosthetics, aerospace, and automobiles.
Nallasivam, J.D.Sundararaj, S.Kandavalli, Sumanth RatnaPradab, R.
A classical way to image nanoscale structures in cells is with high-powered, expensive super-resolution microscopes. As an alternative, MIT researchers have developed a way to expand tissue before imaging it — a technique that allows them to achieve nanoscale resolution with a conventional light microscope.
The development of advanced high-strength steels has become essential in the production of lightweight, safe, and more economical vehicles within the context of the automotive industry. Among the advanced high-strength steels, complex phase steels stand out, characterized by their high formability and high energy absorption and deformation capacity. Laser welding is a technique that applies laser using high energy density as a heat source. It has the advantages that the high welding speed and low heat input compared to other welding methods cause a decrease in deformation, and the narrow width of the weld bead and heat-affected zone allows for the welding of complex parts that would be difficult for other welding methods. Based on a study of a complex phase steel, an analysis was made of the microstructures observed by optical microscopy, the grain boundaries and certain phases contained in this microstructure, as well as the microstructures of each area in the laser welding region observed by scanning electron microscopy. Presenting as results the microstructures of the welded region, such as martensite and bainite phases are the dark phases and retained austenite and ferrite phases are the light phases.
Dias, Erica XimenesReis de Faria Neto, AntonioCastro, Thais SantosMartins, Marcelo SampaioSantos Pereira, Marcelo
This study investigated the effect of nano silica on the mechanical behaviour of blends containing high impact polypropylene (hiPP) and nano clay. This study used nano silica from rice husk ash with an average particle size of 26 nm. The hiPP composites were mixed with 3 wt. % nano clay and different weight percentages (1%, 2%, and 3%) of nano silica were also added. The blending process used twin-screw extrusion, and composite samples were subsequently produced by injection moulding. Various parameters including tensile, compressive, and impact strengths were analyzed. In particular, the hiPP composite containing 3 wt. % nano clay and 2 wt. % nano silica had significantly improved mechanical properties, showing a 37.5% increase in tensile strength, a 56.8% increase in flexural strength, and a 51.4% increase in impact strength. It exhibited the highest tensile (53.51 MPa), flexural (67.19 MPa), and impact strength (5.17 KJ/m2) among all tested composites, demonstrating superior mechanical performance. In addition, the morphology of the composites was studied using a scanning electron microscope (SEM).
Thangavel, AnandRagupathy, K.Manivannan, S.Murali, M.
This Experimental study demonstrates the influence of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements on the mechanical behaviour and microstructural characteristics of lightweight hybrid metal matrix composites (HMMCs) tailored for compact automobile applications. The Aluminium metal matrix composites were synthesized using stir casting technique to ensure uniform dispersion of titanium dioxide (TiO2) and boron carbide (B4C) reinforcements within the aluminium matrix. Characterization techniques such as scanning electron microscopy (SEM) and optical Microscopy, were employed to analyze the microstructural evolution and phase distribution. Mechanical properties such as hardness, tensile strength, and wear resistance were systematically evaluated. The results demonstrated significant enhancements in mechanical performance with 38% increase in tensile strength, 22% increase in impact strength which are attributed to the synergistic effects of TiO2 and B4C. These improvements were correlated with refined grain structures and the formation of stable intermetallic compounds. The optimized HMMCs exhibited a remarkable balance of low density and high strength, making them highly suitable for automotive components requiring weight reduction without any compromise in durability and performance. This research provides valuable insights into the development of high-performance, lightweight materials for the automotive industry.
Jaswin, M. ArockiaGeetha, R.Mathialagan, SaravananSuresh, S.
Magnesium (Mg) alloys are becoming ever more ubiquitous as the need for lighter and stronger alloys has increased significantly in the past decades. Mg alloy grade AZ91D is embedded in 0.5 of cerium have a high strength-to-weight ratio and lower specific density, which is useful in the case of automobile applications. An inconclusive study by Lagowski has shown that interrupted age hardening of AZ magnesium alloy increases the yield strength by around 10%. An investigation on the developed AZ91D+0.5Ce alloy subjected to various ageing treatments was carried out in this present study. The various aged samples were investigated by optical microscopy and scanning electron microscopy analysis. The yield strength was also evaluated quantitatively as a function of ageing parameters. A significant increase in yield strength and hardness values was observed in the artificially aged samples due to the precipitation of Mg17Al12 phases.
Venkatesh, R.Manivannan, S.Das, A. DanielMohanavel, VinayagamSoudagar, Manzoore Elahi Mohammad
This research investigates the impact of friction stir welding (FSW) used to join micro-alloyed steel, on the material and its mechanical characteristics. FSW increases the metallurgical and mechanical qualities of joints made from micro-alloyed steel. However, Friction Stir Welding has produced only modest improvements in connecting steels. Automobile chassis, offshore platforms, oil and gas pipelines, mining, shipbuilding and railroad carriages, pressure vessels, bridges, and storage tanks are just some of the many places and find micro-alloyed steels employed. Frictional heat and tool movement over the joint cause micro defects occurred. Tungsten carbide tools are used in this investigation. Welding shares the same process characteristics, such as the tool's rotating speed (900 rpm) and axial force (10 kN). The table's traverse speed options are available, including 50 mm/min, 60 mm/min, and 70 mm/min. Vickers microhardness testing machines and tensile testing machines are used to perform mechanical characterizations such as hardness testing and tensile testing, respectively. Charpy testing was used to analyze the impact energy released during the fracture of the welded joint. The Scanning Electron Microscope (SEM) and Optical Microscope are used for metallurgical characterizations such as microstructure and tensile fracture research. DMR-249A is low-carbon micro-alloyed steel, and it is a far better grade than the multiple grades that have previously been used for naval and other industrial uses like shipbuilding, railway car construction, etc.
Rajan, C. SakthiKumar, N. MathanKumar, K. VetrivelKannan, S.Soundararajan, S.
Growing demand for fuel-efficient vehicles and lower CO2 emissions has led to the development of lightweight materials. Aluminum composites are being used to achieve lightweighting to improve performance, efficiency, and sustainability across various industries. The unique properties of aluminum composites make them an attractive choice for researchers and designers looking to optimize their products. Reinforcement materials play a vital role in the development of these composites, acting as barriers to dislocation movement within the aluminum matrix. This effectively strengthens the material and prevents deformation under load, resulting in increased tensile strength and fatigue resistance. Additionally, aluminum composites exhibit improved thermal and electrical conductivity, making them suitable for automotive applications. In this study, metal matrix composites (MMCs) of aluminum 7075 alloys were developed using silicon carbide (SiC) and flyash as reinforcements. Three different compositions were cast using the stir casting technique: 10% fly ash, 10% SiC, and 5% SiC plus 5% fly ash. A detailed characterization of these composites was conducted using Scanning electron microscopy coupled with Energy-Dispersive X-ray spectroscopy, focusing on the metallurgical characteristics of the materials. This analysis revealed the distribution of eutectic phases, primary aluminum matrix, intermetallic compounds, chemical zonation, and precipitates at grain boundaries, resulting in improved strength, hardness, and wear resistance. The results showed that the flyash composition exhibited increased wear resistance due to the formation of complex phases, while the SiC composition showed improvements in tensile strength and hardness.
Manwatkar, Asmita AshokSantosh Jambhale, MedhaMahagaonkar, NitinSharma, Dipesh
In light of the growing demand for Electric vehicles (EVs) as a sustainable mode of transportation, it becomes essential to understand the effect of various abuse conditions that batteries undergo. Vibrational abuse is a significant condition experienced by batteries in operation. Vibrations caused by road roughness, acceleration inertia, and other factors can affect key performance indicators such as cycle life, capacity retention, and safety. These cells undergo various chemical and mechanical reactions over time, leading to the degradation of components like the anode, cathode, electrolyte, separator, and current collector, resulting in reduced performance. Therefore, understanding battery degradation is important for managing system performance. This study is focused on a detailed analysis of Lithium Iron Phosphate (LFP) and Nickel Manganese Cobalt (NMC) cells subjected to vibrational abuse. Vibration testing was carried as per International Electrotechnical Commission (IEC) standard 62660-2 to assess the effect on cylindrical 18650 NMC & LFP cell materials. The cells were tested at different state of charge (SoC) levels-75% and 100%- under vibrational conditions. Testing parameters included an 8-hour duration in all directions (x, y, z), a frequency range of 10-2000, and an acceleration of 3 g- rms. post-testing, internal resistance was measured, and both anode-cathode materials underwent visual examination and detailed electrode material analysis using a scanning electron microscope (SEM) and energy-dispersive X-ray spectroscopy (EDS). The study indicated that vibrational abuse significantly affected NMC battery cells, which showed electrode degradation to a greater extent than LFP cells.
Manwatkar, Asmita AshokPandit, Sachin PrabhakarSantosh Jambhale, MedhaMahagaonkar, Nitin
Lithium iron phosphate is one of the most important materials for batteries in electric cars, stationary energy storage systems, and tools. It has a long service life, is comparatively inexpensive and does not tend to spontaneously combust. Energy density is also making progress. However, experts are still puzzled as to why lithium iron phosphate batteries undercut their theoretical electricity storage capacity by up to 25 percent in practice. To utilize this dormant capacity reserve, it would be crucial to know exactly where and how lithium ions are stored in and released from the battery material during the charging and discharging cycles. Researchers at Graz University of Technology (TU Graz) have now taken a significant step in this direction. Using transmission electron microscopes, they were able to systematically track the lithium ions as they traveled through the battery material, map their arrangement in the crystal lattice of an iron phosphate cathode with unprecedented resolution, and precisely quantify their distribution in the crystal.
In recent years, deposit formation in fuel systems for heavy-duty engines, using drop-in fuels, have become increasingly common. Drop-in fuels are particularly appealing because they are compatible with existing engines, allowing for higher proportions of alternative fuels to be blended with conventional fuels. However, the precipitation of insoluble substances from drop-in fuels can result in fuel filter clogging and the formation of internal injector deposits, leading to higher fuel consumption and issues with engine drivability. The precise reasons behind the formation of these deposits in the fuel system remain unclear, with factors such as operating conditions, fuel quality, and fuel contamination all suggested as potential contributors. In order to reproduce and study the formation of internal injector deposits, for heavy-duty engines under controlled conditions and to facilitate a more precise comparison to field trials, a novel injector test rig has been developed. This newly constructed, non-firing rig includes the main components of heavy-duty vehicle engines and uses an electric motor to simulate the revolutions per minute of an engine. A tailored run cycle has been developed to enable the continuous monitoring of injector performance during the deposit formation process, as well as to meticulously mimic the actual operations of a real engine. The deposits formed on injectors during the rig tests were analyzed using scanning electron microscopy with energy dispersive X-ray (SEM-EDX), Fourier-transform infrared spectroscopy (FTIR), and pyrolysis connected to gas chromatography-mass spectroscopy (Py GC-MS). This work presents the outcome of the analysis of injector deposits using the test rig, and compares these findings with deposits gathered from field operations. The deposits obtained from the injector test rig were found to be similar in terms of deposit location, composition, and microstructure, with both sets of deposits containing metal carboxylates and derivatives of engine oil additives. These similarities demonstrate that the test rig effectively reproduces the formation of injector deposits observed in real-world conditions.
Pach, MayteHittig, HenrikTheveny, ArnaudKusar, HenrikHruby, Sarah
Anode-free sodium metal batteries (AFSMBs) with initial zero sodium anodes are promising energy-storage devices to achieve high energy density and low cost. The morphology and reversibility of sodium controls the cycling lifespan of the AFSMBs, which is directly affected by the separator. Here, we compared the sodium deposition and corresponding electrochemical behaviors under the influence of three commercial separators, which were Celgard 2500, Al2O3-coated PP separator and glass fiber (denoting as 2500, C-PP and GF). Firstly, the reversibility of sodium plating/stripping was tested using half-cells, where coulombic efficiencies were stable at ~99.89% for C-PP and GF compare to 99.65% for 2500, indicating more dead sodium were formed for 2500. Then, the morphologies of deposited sodium were compared using optical microscopy. Compared to inhomogeneous sodium growth under 2500, C-PP obtained more flatter sodium layer with less height difference, attributing to the high mechanical strength of Al2O3 layer. Differently, we discovered that sodium was grown into pores in GF to form sodium particles with large active surface, which contacts with sufficient electrolytes and could be reversibly stripped. The reversibility of the sodium in GF were further verified using in situ X-ray diffraction tests. Accordingly, cycling performance of AFSMBs were improved using C-PP and GF, where capacity retention after 120 cycles were 56.9%, 61.6% and 69.2% for 2500, C-PP and GF, respectively. Moreover, the AFSMB using 2 mAh cm-2 Na[Ni1/3Fe1/3Mn1/3]O2 as cathode with GF exhibiting excellent capacity of 117.61 mAh g-1 under high current density of 1 C. Subsequently, in situ EIS tests after/during charging/discharging process were further conducted to illustrate the enhancement of rate and cycling performance. This work demonstrates the effect of separators on the sodium deposition for higher irreversibility and stability, which could also offer insights for developing advanced separators to achieve high performance AFSMBs.
Qin, NanJin, LimingZheng, Jim P.
To combat corrosion and wear issues of automotive brake discs, many manufacturers have introduced various surface treatment technologies, such as thermal spraying, laser cladding, and ferritic nitrocarburizing (FNC). Besides those surface treatment technologies, a plasma electrolytic aluminating (PEA) process has also shown to be effective in producing alumina-based ceramic coatings on cast iron substrates, providing an enhanced corrosion resistance. In this study, the PEA-coated brake rotor and FNC-treated brake rotor were comparatively tested in various corrosion conditions, including an electrochemical corrosion test and simulative corrosion experiment, before and after a road driving test. A scanning electron microscope (SEM) and an energy-dispersive X-ray (EDX) were used to observe and analyze morphology and chemical compositions of the surfaces and cross-sections of the tested rotors. The results showed that the new PEA-coated brake rotor demonstrated the best corrosion resistance in the electrochemical corrosion test among all given tested cases. After the vehicle test, the PEA-coated rotor surface had an obvious materials transfer layer which can protect the rotor from abrasive wear. The transfer layer materials sourcing from the low-met brake pads however contained metallic elements, leading to appearance of a lower corrosion resistance during the electrochemical corrosion test. In duration of the vehicle road test (1000 braking events at 0.3-0.4 g), the FNC brake rotor showed some loss of its white layer but maintained its nitrogen diffusion layer, which still showed protection to the brake rotor base material from corrosion. It was also found that some surface areas where the graphite flakes were located on FNC-treated cast iron brake disc surface were exposed to the ambient environment, which may be a reason why the localized corrosion appeared on the FNC-treated rotor in the late stage of the vehicle road test.
Liu, YintingNie, Xueyuan
Researchers at the National Institute of Standards and Technology (NIST) and colleagues have developed standards and calibrations for optical microscopes that allow quantum dots to be aligned with the center of a photonic component to within an error of 10 to 20 nanometers (about one-thousandth the thickness of a sheet of paper). Such alignment is critical for chip-scale devices that employ the radiation emitted by quantum dots to store and transmit quantum information.
This research explores the tribological characteristics of brake friction materials, focusing on synthetic iron-based sulfides with unique microstructures. Tribological testing, conducted per the SAE J2522 and SAE J2707 standards across diverse temperatures, reveals the superior performance of brake pads incorporating composite iron sulfide, especially at high temperatures. These pads exhibit stable friction levels and reduced wear compared to those utilizing pure iron sulfide, signifying a noteworthy advancement in overall tribological properties. A comprehensive cross-sectional analysis of friction materials using Scanning Electron Microscopy with Energy Dispersive X-ray Spectroscopy (SEM/EDS) reveals chemical alterations. Pure iron sulfide undergoes extensive oxidation compared to composite iron sulfide, which exhibits oxidation near the friction surface due to differences in the oxidation mechanism because of the differential microstructure. Furthermore, Thermogravimetric Analysis (TGA) and X-ray Diffraction (XRD) techniques were employed to validate the observed differences. The research highlights the pivotal role of microstructure in influencing the kinetics of thermal oxidation. An alternative oxidation mechanism is postulated for composite iron sulfides, offering insights into disparities in oxidation processes compared to pure iron sulfides. A noteworthy aspect is the protective function of magnesium oxide in composite iron sulfide, acting as a shield against oxidation. These findings indicate significant performance enhancements for composite iron sulfide (FE50), particularly in high-temperature conditions, exhibiting consistent friction coefficients and reduced wear compared to pure iron sulfide (FE10).
Jara, Diego ChavezLorenzana, CarlosCotilli, EdoardoSliepcevich, AndreaConforti, Michael
The viscoelastic response of pure Al and commercial 6082 and 6082-T6 (Al–Mg–Si) alloys is measured with dynamic–mechanical analyzer as a function of temperature (ranging from 35 to 425°C) and loading frequency (ranging from 0.01 to 100 Hz). The measured data (the storage modulus, loss modulus, and mechanical damping) are compared to available transmission electron microscopy and differential scanning calorimetry data, to ascertain whether unexplained variations of the viscoelastic behavior of the alloys can be correlated to phase transformations. The results suggest that some of these variations may be controlled by the formation and dissolution of metastable phases, such as Guinier–Preston (GP) zones and phases β″, β′, and B′. Indeed, GP zones and phase β″ have been reported to control other mechanical properties. However, due to the high complexity of the aging path of Al–Mg–Si alloys, with formation and dissolution reactions of many precipitate types overlapping along wide temperature intervals, further research is necessary to establish unequivocally the contribution of each individual phase transformation to the overall viscoelastic behavior. Finally, an internal friction peak related to grain boundary sliding is significantly smaller in the alloys compared to pure Al, probably because the precipitates pin the grain boundaries.
Rojas, Jose I.Contel, AlejandroCrespo, Daniel
Hydraulic systems in aircraft largely comprise of metallic components with high strength to weight ratios. Some examples of such material include Aluminum and Titanium alloys which are typically chosen for low and high-pressure applications respectively. For aircraft fluid conveyance products, hydraulic conduits are fabricated by axisymmetric turning to support flow conditions. The hydraulic conduits can have grooved interfaced design within for placement of elastomeric sealing components. This article presents a systematic study carried out on common loads experienced by fluid carrying conduits and the failure modes induced. Firstly, a static structural analysis was carried out on each of the geometries of the test articles to identify the locations having areas of high stress concentration. Test articles of various wall thicknesses and internal diameters were pressure impulse tested at different conditions of side loads to identify cycle numbers till failure and failure locations. On the test articles that structurally failed, the failure locations were identified, and the Scanning Electron Microscope (SEM) analysis was carried out to identify the characteristic footprints of failure surfaces and crack initiation. A comparison done between parameters influencing fatigue life like alternating stress, stress concentration factor and backup material show fairly good trends in accordance with first principles. However, the authors note and appreciate a few data points that deviate from expected trends and through this paper an attempt is made to explain the interplay of said parameters leading to the deviation. It was established that side & lateral plug loads have a significant contribution and influence on failure as opposed to hoop loads which are common in aerospace hydraulic components. It was concluded that the presence of axially misaligned cyclical loads caused reduction of fatigue life on axisymmetric adapters of at least 40K and the absence of the same improved fatigue life by almost 200K. Through the findings of this study it is concluded that a complex interplay between material stiffness, amplitude of alternating stress and stress concentration factor influences how the material responds to cyclic loading.
Paidimarri, VishalJacob, KrupaHarish, UppuHovis, David
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