Browse Topic: Conductivity

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Evaluation of Thermal and Thermo-Mechanical Behavior of Ramie Fiber/Delrin Composites for Aircraft Cabin Components2026-26-0754To be published on 06/01/2026
Abstract This study investigates the fabrication and evaluation of Delrin (polyoxymethylene, POM) composites reinforcing 5, 10, 15, and 20 wt.% chopped ramie fiber (RF). The polymer composites were fabricated via injection moulding technique. Glass transition temperature (Tg), thermal conductivity, Vicat softening temperature (VST), heat deflection temperature (HDT), melt flow index (MFI), and coefficient of linear thermal expansion (CLTE) were the various thermo-mechanical and thermal characteristics of the composites that were systematically evaluated as per the ASTM standards. The Delrin matrix's performance was drastically altered by the addition of RF. Within the formulations, the composite with 15 wt.% RF had the best combination of properties: higher VST and HDT values responsible for more dimensional stability at high temperatures, lower CLTE producing lesser thermal expansion, comparatively better thermal conductivity and more heat dissipation. Eventually, there was a moderate
S, Thirumalvalavan, Senthilkumar, N., Selvarasu, S
Adhesion Strength of Coatings in Battery Structural Joints2026-01-02384/7/2026
In the design of Rechargeable Energy Storage System (RESS) structures, including battery trays, module side plates, and end plates, there are multiple conflating factors, including: Mechanical requirements necessitating the use of electrically conductive materials (steel and aluminum); proximity between battery module structure and battery cells, necessitating the use of electrical isolation coatings; and, module and pack designs that retain cells via the use of Structural Adhesive Material (SAM). Inherently, with this design approach, organic coatings are placed in a new and perilous position. In a sense, the coating becomes a supplement to an adhesive. As Computer-Aided Engineering (CAE) virtual analysis tools become more sophisticated, there is increasing reliance on these tools to predict the occurrence of structural failures in various load cases. Factors in test method, paint pretreatment, and topcoat affecting adhesion of organic coatings in structural adhesive joints are
Moceri, Charles, Harper, Jared
Experimental Study of Hydrogen Combustion in Argon-Oxygen Mixture Using an Optical Engine2026-01-03284/7/2026
The Argon Power Cycle (APC) is an emerging high-efficiency combustion technology for internal combustion engines. In APC, the conventional air-based working fluid is replaced with an inert argon gas. This substitution inherently increases engine efficiency through thermodynamic properties of argon, in particular a high adiabatic factor ?? ~1.67. A hydrogen-fueled APC engine offers the potential for highly efficient zero emission combustion by also eliminating nitrogen oxide (NOx) formation. In the present paper, hydrogen combustion is studied in an optical heavy-duty research engine, with the objective of providing the first visualization of H2 combustion in an argon–oxygen mixture. A comparative analysis of high-speed optical imaging and in-cylinder pressure measurements is conducted for two different modes: 1) conventional air operation and 2) argon-oxygen mixture operation. The high-speed images reveal a distinctly different combustion process between the two operating modes. The
Kapp, Joakim, Cheng, Qiang, Kaario, Ossi, Vuorinen, Ville
Thermal Finite Element Modelling and Prediction of Laser Welded Battery Packs2026-01-03854/7/2026
Battery modules consist of battery cells electrically joined at the terminals by conductive busbars. Laser welds are the most consistent and controllable process to create these connections on a large scale due to their control over power, laser width, speed, wobble, and overlap, and their quality is critical to battery pack performance. Tuning these parameters for an application typically requires weld trials to reach desired weld width, penetration, and strength without overheating the battery cell and weakening the dielectric insulators around the terminals. Poorly welded cells in a module can result in increased electrical resistance, causing greater joule heating and accelerated cell aging, and poorly welded modules can lead to uneven aging and unpredictable performance. To better understand the laser welding process, a modelling approach was developed to predict weld properties to reduce production time, costs, and potential cell damage. The 3D finite element model was calibrated
Contreras, Luis, Hoffmeyer, Matthew, Abidin, Zainal
Role of Advanced Polishing Techniques in Enhancing Al-Cu Diffusion Bonding for EV Application2026-01-02354/7/2026
The demand for lightweight, high-efficiency components in electric vehicles (EVs) highlights the critical need for reliable Al-Cu joints with superior electrical and thermal conductivity. While diffusion bonding has emerged as a promising approach, interfacial impurities and voids often degrade joint quality and conductivity. Conventional manual polishing was initially employed to prepare Cu and Al surfaces; however, this method proved insufficient in consistently removing oxides and contaminants, leading to non-uniform bonding. In addition, the larger surface area of the samples made traditional polishing impractical, further motivating the use of electropolishing. To overcome these limitations, we introduce electropolishing pretreatment to achieve cleaner, void-free interfaces. Electropolishing effectively dissolves surface asperities and contaminants, enabling intimate atomic contact during bonding and minimizing the formation of brittle intermetallic phases. A systematic
Abbasi, Hossein, Liu, Yi, xiao, Yaohong, Wang, Andy, Su, Jinrong, Wang, Qigui, Chen, Lei
Application of DFSS for Optimizing Thermal Protection in Electric Vehicles during Battery Thermal Runaway Events2026-01-01424/7/2026
Battery thermal runaway is a major safety concern in electric vehicles because of the extreme heat and hazardous gases released during cell failure. These venting events can quickly raise the temperature of the battery enclosure and cabin floor, threatening occupant safety. To address this challenge, this study employs the Design for Six Sigma (DFSS) methodology to design and optimize a thermal protection system that delays and limits heat transfer to the cabin. A physics-based transient heat-transfer model was combined with DFSS principles to systematically evaluate insulation materials, shield layouts, surface emissivity, and layer geometry. An L-18 orthogonal array was used to identify key parameters and quantify their influence on thermal robustness. The optimized architecture reduced cabin-floor temperature rise under severe runaway conditions (600–900 °C vent gas), meeting occupant-egress safety requirements. Findings confirm DFSS as an effective framework for developing high
El-Sharkawy, Alaa, Asar, Mona, Taha, Nahla, Sheta, Mai
Simplified Thermal Runaway Propagation Modeling to Design a Mass Optimized Battery Pack2026-01-04044/7/2026
This paper presents a simplified approach to model thermal runaway propagation in a multi-cell battery pack, with the goal of designing a safe and lightweight pack for mass-sensitive applications. The key parameters which characterize single-cell thermal runaway, including heat release profile, apparent cell emissivity and mass loss, were extracted from empirical nail penetration tests. This characterization was used to drive a three-dimensional thermal model of a 19-cell hexagonal sub-pack with a center trigger cell. To enable rapid design exploration, a symmetry-based computationally simplified domain was used for a full-factorial Design of Experiments (DOE) varying cell spacing, epoxy thickness, heat spreader thickness, and cup geometry. The DOE results were used to identify dominant heat-transfer mechanisms, capture main and interaction effects, and determine mass-efficient design levers governing peak-neighbor cell temperature during propagation. Insights from the DOE study
Kalyankar, Apoorv, Owen, Elliot, Strohmaier, Kyle, Mardall, Joseph
Titanium Alloy Bars and Forging Stock, 6.0Al - 2.0Sn - 4.0Zr - 2.0Mo, Duplex AnnealedAMS6905D (Current)2/18/2026
This specification covers a titanium alloy in the form of bars up through 3.000 inches (76.20 mm), inclusive, in diameter or least distance between parallel sides with a maximum cross-sectional area of 10 square inches (64.5 cm2) and forging stock of any size (see 8.7).
AMS G Titanium and Refractory Metals Committee
Galvanic Corrosion Susceptibility Analysis and Mitigation Strategies in Automotive Battery Packs2026-28-00182/12/2026
As electric vehicles continue to revolutionize transportation, ensuring the reliability of their powertrain systems and Battery Packs has become a critical focus. One key challenge is galvanic corrosion, which occurs when dissimilar metals in contact are exposed to an electrolyte, such as seashore moisture or road salt used in snow or ice zones. This corrosion can weaken structural components, compromise electrical conductivity, and reduce the lifespan of critical systems. Common areas at risk include metallic joints within battery enclosures, busbars, cooling systems, and electrical connectors. Environmental factors such as high humidity and temperature fluctuations further amplify the issue, making it a pressing concern for manufacturers. This paper aims to systematically identify critical galvanic joints within electric powertrain systems and Battery Packs and provide effective strategies to mitigate corrosion risks. Preventative measures include choosing compatible materials with
Narain, Aditya, Venugopal, Sivakumar, Gopalan, Vijaysankar, Varatharajan, Senthilkumaran
Development of Advanced Thermoplastic Elastomeric Mat and Its Study on Thermal Performance of Wireless Charger System2026-26-02831/16/2026
This study aimed to develop a thermally conductive TPE mat and assess its performance in comparison to an existing antiskid rubber mat, specifically evaluating its impact on wireless charger efficiency. Moreover, morphological and thermal analyses were conducted to establish a correlation between the material behaviours of the new and current thermally conductive antiskid mats. The process of developing the thermally conductive TPE involved utilizing a two-roll mill followed by compression moulding to achieve a 2D sheet shape. Notably, the thermally conductive mat demonstrated a consistent enhancement in charging efficiency over the conventional antiskid mat. To examine the thermal characteristics, thermal characterization techniques including DSC and TGA were employed for both the existing and newly developed mats. FTIR spectroscopy was also utilized to confirm the presence of organic functional groups within the mat. The morphological analysis of the fillers used to enhance thermal
Naikwadi, Amol Tarachand, Mali, Manoj, Patil, Bhushan, Tata, Srikanth
State-of-the-Art Battery Thermal Management Technologies for SCV EV: An Integrated Approach to Enhance Energy Utilization and Reduce Expenses2026-26-00761/16/2026
The performance, lifespan, safety, and overall cost of high-voltage batteries—central elements in electric vehicles (EVs)—are fundamental to the success of the entire EV industry. These batteries, primarily used as energy storage systems, are especially critical in small commercial vehicles (SCVs), where efficient thermal management directly impacts reliability and durability. This paper presents innovative methods to improve energy efficiency, driving range, charging speed, and cost-effectiveness by combining advanced insulation techniques with thermoelectric cooling systems (TECs). The automotive industry is growing in EV domain and mostly in commercial vehicle application. The major challenge in EV’s is maintaining battery temperature to get optimal performance and best battery warranty. The key strategy of this research is providing insulating materials to stabilize battery temperatures. The thermal insulation minimizes thermal losses and buffers against external environmental
Chormule, Suhas Rangrao, Warule, Prasad, Nagpure, Rahul, Jadhav, Vaibhav
Optimizing Busbar Design by Investigating Critical Parameters and their Influence on Electrical and Thermal Behaviors for Reliable Electric Vehicle Battery Packs2026-26-04741/16/2026
With the rise of EVs, researchers are focusing on optimizing busbar design to meet the demands of high energy density, fast charging, and compact battery packs. The busbar design starts by selecting the material and the cross-sectional area required based on the rated current requirement. The width matches or may exceed the battery cell terminal size, whereas the length is optimized such that it is packaged within the given space constraints. The research also highlights the risk of busbars to oxidation and corrosion, which increases resistance and decreases conductivity for which plating/coating techniques are applied to improve the surface finish, overall durability, conductivity and in some cases the surface hardness, while minimizing the heat loss. Using simulations and experimental validation, the study examines three key design parameters: the weld diameter for busbar welded joints, electrical resistance, and contact resistance. A detailed analysis investigates how the weld
Nogdhe, Yogesh, Singh, Shobit Kumar, Paul, Jibin, Mishra, Mukesh, Menon, Praveen
Multifunctional ANF/Mxene-Enhanced Hydrogels for Flexible EMI Shielding and Wearable Sensing ApplicationsTBMG-544161/1/2026
Researchers from Harbin Institute of Technology and their collaborators have developed a multifunctional polyelectrolyte hydrogel reinforced with aramid nanofibers (ANFs) and MXene nanosheets, achieving outstanding performance in absorption-dominated electromagnetic interference (EMI) shielding and wearable sensing. This innovative hydrogel addresses the long-standing challenge of balancing electrical conductivity and effective EMI absorption in flexible electronic materials. The research was published in the journal Nano-Micro Letters. 1
Mixed Aggregation by Comprehensive Normalization Technique–Based Parametric Optimization of Turning of Ti-6Al-4V Alloy in Minimum Quantity Lubrication Environment05-19-03-002212/19/2025
Although Ti-6Al-4V alloy offers high strength-to-weight ratio, corrosion resistance, and biocompatibility properties, its machining is challenging due to low thermal conductivity, high hardness, and chemical reactivity. This study examines turning of Ti-6Al-4V under minimum quantity lubrication (soybean oil). Cutting speed (CS), feed rate (FR), and depth of cut (DOC) are considered as the input parameters. On the other hand, material removal rate (MRR), tool wear rate (TWR), surface roughness (SR), and cutting force (Fc) are treated as the responses. Optimization of the said process is carried out using the mixed aggregation by comprehensive normalization technique (MACONT), a recently developed multi-criteria decision-making (MCDM) method. The optimal parameters are identified as CS = 72.26 m/min, FR = 0.022 mm/rev, and DOC = 0.2 mm, achieving high MRR with low TWR, SR, and Fc. The effects of different turning parameters on the responses are also investigated. Sensitivity analysis
Das, Partha Protim, Sharma, Saurabh, Chakraborty, Shankar
Synergistic Effects of Graphene Oxide and Nanoclay on the Structural and Electrical Properties of Automotive Nanocomposite Insulation2025-36-016112/18/2025
As vehicles become increasingly connected and electrified, the demand for high-performance cables and electrical connectors is growing quickly. Electrical insulation materials play an essential role in protecting and insulating those critical components, ensuring reliability, safety and durability. The development of a more robust composite material is essential to promote sustainability and energy efficiency, in both component application and its manufacturing processes. This research explores the development of advanced nanocomposite material for automotive electrical applications. The nanocomposite material comprises low-density polyethylene (LDPE), ethylene-vinyl acetate (EVA), nanoclay (NC) and graphene oxide (GO), processed via melt mixing in a twin-screw extruder. A design of experiments (DOE) was performed using 23, factorial design two levels and three variables (wt.% of EVA, NC and GO), to evaluate the effect of each variable on the material performance. Mechanical tests
Horiuchi, Lucas Nao, Kerche, Eduardo Fischer, Gonçalves, Everaldo Carlos, Polkowski, Rodrigo
Development of Temperature Sensor for Automotive2025-28-039410/30/2025
The work presents a micro-electromechanical system (MEMS) temperature sensor that has been designed using COMSOL Multiphysics 6.0 software for use in predicting the temperature of automotive parts. Due to its versatility, the shape of this design employs a meander, and this involves joule heating physics. It clearly shows the variation of resistance with temperature. For this design, Nitinol nano material is used because of the following advantages: Enhanced Shape Memory Effect, Superior Super elasticity, Increased Surface Area, Increased Surface Area, Improved Biocompatibility, Tunable Properties, Enhanced Mechanical Properties. Nitinol having high strength to weight ratio find its application in aerospace industry. This sensor works based on the principle of temperature dependence of resistance; that is, the resistance of the material increases or decreases based on temperature. It is observed that Nitinol has low von Mises stress, proving the safety nature of the material in
P, Geetha
Role of Charging Rate on Internal Short-Circuit Characteristics of Lithium-Ion Battery14-14-03-002010/7/2025
Lithium-ion batteries used in electric vehicles (EVs) are facing issues owing to internal short-circuit (ISC), leading to thermal runaway. In this study, a pseudo-two-dimensional (P2D) model is employed to numerically investigate the effects of charging rate (C-rate) and separator electrical conductivity on the ISC behavior of a lithium-ion cell. The results reveal that as C-rate increases, both the voltage and capacity decrease more rapidly marked by higher solid potential gradient indicating increased internal resistance. These effects further intensified at higher separator conductivity, which facilitates greater ISC current and accelerates cell degradation. Also, the variations in current density and solid-phase lithium concentration become more pronounced at higher C-rates, particularly near the anode–separator interface, indicating increased non-uniformity during ISC conditions. Furthermore, the electrolyte voltage drop intensifies with rising C-rate, contributing to additional
Ch, Narendra Babu, Paramane, Ashish, Randive, Pitambar
Durable Aluminum Alloys for Brake Disc and Rotor Applications2025-01-03589/15/2025
Lightweight materials are essential in reducing the overall weight and improving the efficiency and performance of ICE and electric vehicles. The use of aluminum alloys is critical in transitioning to a more energy sustainable and environmentally friendly future. The accessible combinations of high modulus to density and strength to weight ratios, as well as their excellent thermal conductivity, make them an ideal solution for overall weight reduction in vehicles, thereby improving fuel efficiency and reducing emissions. Aluminum alloys with high strength and lifetime thermal stability have been industrialized for usage in brake rotor applications. Amongst the most used aluminum alloys with high thermal stability are 2618-T8 and 4032-T6 for use in aerospace and automotive industries, respectively. However, when it comes to prolonging the life of a product at temperatures that exceed 200°C, the properties of these alloys will quickly degrade within the first 300 hours of exposure
Duchaussoy, Amandine, Lorenzino, Pablo, Franklin, Jack, Tzedaki, Maria
Evaluating Safety Behavior of Li-Ion Batteries Regarding Negative Electrode Composition2025-24-01499/7/2025
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
Cruz Rodriguez, Jesus Armando, Lecompte, Matthieu, Redondo-Iglesias, Eduardo, Pelissier, Serge, Abada, Sara
Enabling Near-Zero Emissions and Superior Efficiency in Large-Bore, Medium-Speed Engines with a Hydrogen-Argon Power Cycle2025-24-00019/7/2025
Combustion engines operating on a hydrogen-argon power cycle (H-APC) offer potential for superior thermal efficiency with true zero exhaust emissions. The high specific heat ratio of argon allows extrapolation of the theoretical efficiency of the Otto cycle to almost 90%. However, this potential is significantly constrained by challenges in combustion control, excessive thermal loading, and system integration, particularly regarding argon recovery. This study investigates these trade-offs, within the context of real-world engine-based peaking power plants. An experimentally validated 1D-simulation model of a prototype Wärtsilä 20 DF engine serves as reference for analysis of a retrofit incorporating a closed-loop argon cycle, with dedicated H₂ and O2 injectors, a water condenser and water separator. Engine performance is evaluated at reference operating point of 75% load, considering pre-ignition, peak pressure and exhaust temperature constraints, condenser limitations, and impurity
Ahammed, Sajid, Ahmad, Zeeshan, Mahmoudzadeh Andwari, Amin, Kakoee, Alireza, Hyvonen, Jari, Mikulski, Maciej
Thermal Stress Reduction in Diesel Engine Pistons Using Semitransparent Ceramic Coatings: A 3D Numerical Study with OpenFOAM2025-24-00039/7/2025
This research focuses on the thermal analysis of internal combustion engine pistons, evaluating the effects of high-temperature exposure during operation. A three-dimensional numerical study is conducted using OpenFOAM, modifying the software’s governing equations to analyze temperature distribution in different piston geometries. The study aims to assess the spatial temperature variation within the entire volume of the piston, providing a detailed understanding of heat transfer mechanisms. A multilayer approach is implemented, considering various configurations of ceramic coatings with distinct thermal and optical properties. The investigation incorporates an internal heat source model, where the heat absorption characteristics of the coating material influence the thermal behavior of the system. By evaluating aluminum- and titanium-based ceramic coatings, the study examines how semitransparency and heat radiation absorbance affect heat accumulation and transfer. The results highlight
Gutierrez, Marcos, Taco, Diana, Bösenhofer, Markus
A Successful Catalyst Design for Advanced Zinc-Iodine BatteriesTBMG-532066/1/2025
Aqueous zinc-ion batteries (ZIBs) have attracted extensive attention due to their high safety, abundant reserves, and environmental friendliness. Iodine with high abundance in seawater (55 μg L-1) is highly promising for fabricating zinc-iodine batteries due to its high theoretical capacity (211 mAh g-1) and appropriate redox potential (0.54V). However, the low electrical conductivity of iodine hinders the redox conversion for an efficient energy storage process with zinc. Additionally, the formed soluble polyiodides are prone to migrate to the Zn anode, leading to capacity degradation and Zn corrosion.
Predictive Modeling of Surface Roughness, Tool Wear, and Cutting Temperature in High-Speed Turning under Sustainable Machining Environments05-19-01-00075/24/2025
The utilization of Inconel 718 is increasing daily in stringent operating conditions such as aircraft engine parts, space vehicles, chemical tanks, and the like due to its physical properties such as maintaining strength and corrosion resistance at higher temperature conditions. Besides, Inconel 718 is one of the difficult materials for machining because of maintaining its strength at elevated temperature, which generates higher cutting force leading to observed multiple tool wear mechanisms that affect the surface quality; lower thermal conductivity of materials produces high temperature generation that impacts the tool performance by reducing tool life. In addition, the presence of carbides and high hardness of IN 718 affects the machining performance. Therefore, in this view, this article describes the effect of cutting environments and machining parameters on the machining of Inconel 718 and optimizes the cutting conditions for sustainable machining. Three input parameters namely
Mane, Pravin Ashok, Dhawale, Pravin A., Nipanikar, Suresh, Khadtare, Avinash N.
Wear Protection for Electrified Transmissions Using e-Fluids without Active Sulfur04-18-03-00155/8/2025
In electrified drivetrains, lubricants are commonly in contact with the motor and other electrical components as well as the gears and bearings. Copper, present in these electrical components, is susceptible to corrosion by fluids containing active sulfur, which can lead to catastrophic failure of the unit. Lubricating fluids for electric vehicles (referred to as e-fluids) must not cause corrosion and must maintain high performance while having suitable electrical conductivity, material compatibility, and heat transfer properties. We describe a new formulation without active sulfur that has recently entered the market, which can protect against copper corrosion. We show that this e-fluid can provide suitable wear protection under field trial conditions, and that the e-fluid provides improved wear protection in bearing (FE-8) tests compared to a traditional extreme pressure axle fluid (API GL-4). Surface analysis (X-ray photoelectron spectroscopy) measurements of the component surfaces
Hopper, Elizabeth R., Williams, Megan S., Gahagan, Michael
Conceptual Design of a Superconducting Aero Electric Engine System2025-01-01465/2/2025
The goal of the development of an electric aircraft engine is to create an aircraft system that achieves ultimate efficiency using hydrogen fuel instead of fossil fuels. Therefore, it is necessary to focus on reducing weight as much as possible, and this paper describes the approach to such fuel cell-powered aircraft. The authors have adopted a superconducting coreless rotating electric machine with an integrated hydrogen tank and are pursuing a target of 70kg or less for the main components of a 2MW rotating electric machine. High-temperature superconducting cables have zero electrical resistance and can carry a very high current density, but the alternating current (AC) loss generated when used in AC has been an issue in their application to rotating electric machines. In 2023, The SCSC cable was developed to be a low-AC-loss, robust, and high current cable concept, in which copper-plated multifilament coated conductors are wound spirally on a core. In addition to using this
Oyori, Hitoshi, Sakurai, Sho, Kusase, Shin, Yoshida, Yukihiro, Yoshinaga, Seiichiro, Nose, Hiroyuki, Amemiya, Naoyuki
Material Adapted Method for the Repair of Curved Thermoplastic Composite Structures by Induction Welding of Patches2025-01-01655/2/2025
Thermoplastic fiber-reinforced polymer composites (TPC) are gaining relevance in aviation due to their high specific strength, stiffness, potential recyclability and the ability to be repaired thanks to their meltability. To maximize their potential, efficient repair methods are needed to maintain aircraft safety and structural integrity. This article introduces a novel repair technique for damaged TPC structures, involving the joining of a repair patch with induction welding using a susceptor material. The susceptor consists of a material with high electrical conductivity and magnetic permeability and therefore reacts stronger to the electromagnetic field than the composite, even if the composite is carbon fiber based. I. e. the thermal energy is specifically concentrated in the repair area. In this study, the susceptor was placed on the patch and also in the welding zone. The repair process begins by identifying and preparing the damaged area, followed by precise scarfing. Care is
Geiger, Markus, Glaap, Anton, Schiebel, Patrick, May, David
Eddy Current Inspection of Circular Holes in Nonferrous Metallic Aircraft Engine HardwareAS4787A (Current)5/2/2025
This SAE Aerospace Standard (AS) establishes minimum requirements for eddy current inspection of circular holes in nonferrous, metallic, low conductivity (less than 5% IACS) aircraft engine hardware with fasteners removed. The inspection is intended to be performed at maintenance and overhaul facilities on engine run hardware.
AMS K Non Destructive Methods and Processes Committee
Hose Assembly, Convoluted Polytetrafluoroethylene, Metallic Reinforced, Low Pressure, Up to 400 °F, AircraftAS1227C (Current)4/14/2025
This SAE Aerospace Standard (AS) defines the requirements for a convoluted polytetrafluoroethylene (PTFE) lined, metallic reinforced, hose assembly suitable for use in aerospace fluid systems at temperatures between -65 °F and 400 °F for Class 1 assembly, -65 °F and 275 °F for Class 2 assembly, and at operating pressures per Table 1. The use of these hose assemblies in pneumatic storage systems is not recommended. In addition, installations in which the limits specified herein are exceeded, or in which the application is not covered specifically by this standard, shall be subject to the approval of the procuring activity.
G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies
Material-Combined Vehicle Brake Disc Design for Enhanced Cooling Performance2025-01-81894/1/2025
The improvement of heat dissipation performance of ventilated brake discs is vital to braking safety. Usually, the technical approaches shall be material optimization or structural improvement. In this paper, a simulation model of the heat transfer of brake discs is established using STAR-CCM+ software. Cast iron, aluminum metal matrix composite (Al-MMC), and carbon-ceramic composite materials (C-SiC) are compared. The results show that: Al-MMC has better thermal conductivity so that a more uniform temperature gradient distribution shall be formed; C-SiC has poorer heat capacity yet, according to previous studies, it has better thermal stability, which is the ability to ensure its friction factor under high-temperature condition; cast iron performs better with convective heat transfer rate, which enhances the heat transfer between the surface and surrounding flow field. Based on the results, this paper proposes four types of material combined brake discs using different friction
Wang, Jiarui, Jia, Qing, Zhao, Wentao, Xia, Chao, Yang, Zhigang
Thermal Insulation Tiles and Sheets Based on Integration of Recycled Plastic Waste Fibres and Epoxy Resin2025-01-83254/1/2025
Plastic waste, in the past few years, has risen to be one of the most concerning and endangering pollutants to environment and life, making its effective management and reduction a major domain of focus among researchers and industrialists. This comparative study is an attempt to utilize recycled Polyethylene Terephthalate (rPET) fibres combined with Epoxy Resin in various combinations, to provide effective and low-cost insulation in moderate to low requirements. The above-mentioned components serve as viable insulators. Moisture resistance of both materials and temperature resistance of Epoxy resins ranging from 120°C to 150°C (depending upon the grade of Epoxy used) indicate a good stability in harsh external operating environment. While Epoxy resins are not inherently flame retardants, additives are introduced for this purpose in order to render the composite safer to use. Owing to the excellent adhesive properties of the Epoxy resin, the rPET fibres are allowed to bond together
Purihella, Sri Sai Krishna, Pali, Harveer Singh, Kumar, Piyush, Sharma, Ved Prakash
Numerical Investigation of Gas Diffusion Layer Properties in PEMFC2025-01-83144/1/2025
This study numerically analyzed the gas diffusion layer (GDL) in proton exchange membrane fuel cells (PEMFCs). The GDL, composed of carbon fibers and binder, plays a critical role in facilitating electron, heat, gas, and water transport while cushioning under cell compression. Its microstructure significantly influences these properties, requiring precise design. Using simulations, this study explored GDL designs by varying fiber and binder parameters and calculated gas diffusivity under wet conditions. Unlike previous studies, a novel model treated carbon fibers as beam elements with elastic binder connections, closely replicating structural changes under compression. Key properties analyzed include permeability, electrical conductivity, and gas diffusion efficiency under wet conditions. The optimized designs enhanced these properties while balancing trade-offs between electrical conductivity and mass transport. These findings provide valuable guidelines for advancing PEMFC technology
Ota, Yuki, Dobashi, Toshiyuki, Nomura, Kumiko, Hattori, Takuya, Maekawa, Ryosuke
Materials Innovation in Thermal Management: Advancing Aluminum Alloy Technologies for the Next-Generation Electrical Vehicle Battery Cold Plate2025-01-81624/1/2025
The rapid expansion of the global electric vehicle (EV) market has significantly increased the demand for advanced thermal management solutions. Among these, the battery cold plate is a critical component, essential for maintaining optimal battery temperatures and ensuring efficient operation. As EV batteries increase in size, the thermal management requirements become more complex, necessitating the development of new alloys with enhanced strength and thermal conductivity. These advancements are crucial for the effective dissipation of heat and the ability to withstand the mechanical stresses associated with larger and more powerful batteries. The evolving performance demands of EVs are driving material innovation within the thermal management sector. This study aims to explore the global heat exchanger market trends from a material perspective, focusing on the evolution of the mechanical and thermal properties. Specifically, we investigated the transition from the traditional AA3003
Jalili, Mehdi, Wang, Xu, Razm-poosh, Hadi
Virtual Evaluation of Ceramic Glow Plug Design using Multiphysics Simulation Approach2025-01-83674/1/2025
A glow plug is generally used to assist the starting of diesel engines in cold weather condition. Low ambient temperature makes the starting of diesel engine difficult because the engine block acts as a heat sink by absorbing the heat of compression. Hence, the air-fuel mixture at the combustion chamber is not capable of self-ignition based on air compression only. Diesel engines do not need any starting aid in general but in such scenarios, glow plug ensures reliable starting in all weather conditions. Glow plug is actually a heating device with high electrical resistance, which heats up rapidly when electrified. The high surface temperature of glow plug generates a heat flux and helps in igniting the fuel even when the engine is insufficiently hot for normal operation. Durability concerns have been observed in ceramic glow plugs during testing phases because of crack formation. Root cause analysis is performed in this study to understand the probable reasons behind cracking of the
Karmakar, Nilankan, Orban, Hatem
Liquid Viscosity Decoupling Measurement Based on U-Shaped Tungsten Wire Sensor2025-01-84604/1/2025
In this paper, based on the cylindrical flow theory of incompressible viscous fluids and the equivalent circuit model of resonant sensing elements, a theoretical model for the measurement of liquid viscosity with a U-Shaped tungsten wire resonance sensor was established. This model can measure the liquid viscosity independently without liquid density or coupled detection of liquid density. The experimental results show that the decoupling of liquid viscosity and its density can be achieved at Re<1. The liquid viscosity is strongly linear with the resonant conductance. The viscosity measurement error is less than 7.24% in the viscosity range of 7.235cP to 85.2cP.
Shan, Baoquan, Shen, Yitao, Yang, Jianguo, Wu, Dehong
Optimization Method of Phase Change Energy Storage Device for Electric Vehicle Batteries based on Numerical Simulation2025-01-86034/1/2025
Phase change energy storage devices are extensively utilized in latent heat thermal energy storage and hold significant potential for application in the thermal management of automotive batteries. By harnessing the high-density energy storage capabilities of phase change materials to absorb heat released by the batteries, followed by timely release and utilization, there is a substantial improvement in energy efficiency. However, the thermal conductivity of medium and low temperature phase change materials is poor, leading to its inefficient utilization. This paper focuses on optimizing the structure of a phase change heat exchanger in a phase change energy storage device to improve its performance. A basic design of the phase change heat exchanger is used as an example, and fin structure is added to enhance its heat exchange capabilities. A predictive surrogate model is built using numerical simulation, with the dimension and number of fins as design variables, and heat flow density
Zhang, Haonan, Sun, Mingzhe, Zheng, Haoyun, Zhang, Tianming
SHIELD BAND, CONNECTOR ACCESSORIES, ELECTRICAL BACKSHELL, CATEGORY 7 (FOR AS85048/82 - /90, /93, /109 - /117 ACCESSORIES)AS85049/128G (Current)2/8/2025
AE-8C1 Connectors Committee
Revolutionizing Titanium Alloy Machining: ANFIS Model for Advanced Machining Performance Optimization2025-28-00462/7/2025
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in electrically conductive materials, regardless of their hardness. Due to the growing demand for superior products and the necessity for quick design adjustments, decision-making in the manufacturing industry has become increasingly complex. This study specifically examines Titanium Grade 19 and suggests the creation of an Adaptive Neuro-Fuzzy Inference System (ANFIS) model for predictive modeling in ECM. The study employs a Taguchi-grey relational analysis (GRA) methodology to attain multi-objective optimization, with the goal of concurrently maximizing material removal rate, minimizing surface roughness, and achieving precise geometric tolerances. Analysis of variance (ANOVA) is used to assess the relevance of process characteristics that impact these performance measures. The ANFIS model presented for Titanium Grade 19 provides more flexibility, efficiency, and accuracy in comparison to
Pasupuleti, Thejasree, Natarajan, Manikandan, Raju, Dhanasekar, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R
Cutting-Edge Coating Materials for Dual Fuel Diesel Engines Using Acetylene Aspiration2025-28-01342/7/2025
A diesel engine with a Yttria Stabilised Zirconium (YSZ) thermal barrier layer (TBL) on the piston crown was used in an experiment. The aim of the investigation was to evaluate the influence of the thermal barrier layer on the efficiency and pollution levels of a diesel engine. The selection of YSZ as the coating material was based on its desirable physical properties including a high coefficient of expansion when exposed to heat, low degree of thermal conductivity, and a high Poisson's number. These characteristics make it a suitable material for use in coatings applied to engine components. In addition to their current research, the scientists are also focusing on identifying sustainable substitutes for conventional petroleum fuels. This is because of the growing concern over environmental impacts and the limited availability of fossil fuel resources. The researchers are seeking new options that are both environmentally friendly and capable of meeting the world's energy demands. By
Sagaya Raj, Gnana, Natarajan, Manikandan, Pasupuleti, Thejasree
Synthesis and Characterization of Poly (Aniline –Co-Chloroaniline) Polymers and Applications in Automotive Industries as Paint Coatings2025-28-00372/7/2025
Polyaniline (PANI)-polymer based smart paints have emerged as a promising solution for enhancing the durability and performance of automobile surface coatings. These paint coatings offer a superior corrosion resistance, conductivity, and environmental stability, making it an ideal. Here novel copolymers of dodecylbenzene sulfonic acid(DBSA) aided poly (aniline-co-m-chloroaniline) nanocomposites of various compositions were prepared by oxidative method in micellar solution. These nanocomposites were analyzed by using UV-Vis and FT-IR spectroscopic methods. The crystalline nature of the polymer was evidenced through XRD patterns. SEM revealed the presence of particles with spherical morphology 100 nm in diameter. The electrical activity of the doped polymer was found to be content increasing from 3:1 to 3:3 x 10-2 S/cm to 5.64 x 10-7 S/cm with chloroaniline. These copolymers are added as additives in manufacturing of paint. These novel paints offer multiple protective mechanisms
Pachanoor, Vijayanand, Moorthi, Bharathiraja
Grey Relational Analysis for Multi-Objective Optimization in Aerospace Machining of Titanium Grade 192025-28-00472/7/2025
Electrochemical machining (ECM) is a highly efficient method for creating intricate structures in electrically conductive materials, irrespective of their hardness. Due to the growing need for superior products and quick design adjustments, decision-making in production has become increasingly complex. This study focuses on Titanium Grade 19 and proposes creating predictive models using a Taguchi-grey technique to achieve multi-objective optimization in ECM. The experiments are structured based on Taguchi's principles, utilizing Taguchi-grey relational analysis (GRA) to simultaneously optimize several performance indicators, including the material removal rate, surface roughness, and geometric tolerances. ANOVA is employed to assess the significance of process variables affecting these measures. The proposed predictive technique for Titanium Grade 19 outperforms current models in terms of flexibility, efficiency, and accuracy, providing enhanced capabilities for monitoring and control
Pasupuleti, Thejasree, Natarajan, Manikandan, Krishnamachary, PC, Katta, Lakshmi Narasimhamu, Silambarasan, R
Investigation on Heat Transfer Properties of Graphene Nanoplatelets Blended Distilled Water-Ethylene Glycol Mixtures in Battery Thermal Management System2025-28-00892/7/2025
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
S, Palanisamy, Selvan, Arul Mozhi
Development of Composite PCM To Enhance Heat Transfer Rate with the Addition of Nanoparticles in Thermal Energy Storage2025-28-00232/7/2025
This paper explores the augmentation of thermal conductivity in paraffin wax through the incorporation of aluminum oxide (Al2O3) and copper oxide (CuO) nanoparticles, leading to the development of composite phase change materials (PCMs). The objective is to enhance heat transfer rates, crucial for various energy storage applications including industrial waste heat recovery and solar thermal energy storage. Differential Scanning Calorimetry (DSC) testing was employed to experimentally investigate the thermal properties of the resulting nanocomposite PCM. The experimental results reveal that the nanocomposite PCM, composed of 96.14% paraffin wax, 2% aluminum oxide, and 1.6% copper oxide, exhibits 1.35 times increase in heat transfer rate compared to conventional paraffin wax. The integration of nanoparticles into the PCM matrix, facilitated by a magnetic stirrer at 50oC for 4 hours, results in uniform distribution and improved grain morphology, as evidenced by SEM images. Moreover, the
Tarigonda, Hariprasad, Kumar, YB Kishore, Kala, Lakshmi K, R L, Krupakaran
Enhancing Solar Still Productivity with Aluminium Oxide Nanoparticles and Phase Change Materials2025-28-00262/7/2025
The present study is focused on the integration of phase change materials (PCMs) and Al2O3 nanoparticles into solar stills presents a promising approach to enhance their efficiency. This paper explores the design and performance analysis of a solar still system incorporating PCMs and Al2O3 nanoparticles with different concentration like 200ppm and 400ppm. The primary goal is to investigate the impact of these enhancements on the solar still’s productivity and thermal efficiency.The Aluminium Oxide Nanoparticle were synthesized by chemical co-precipitation method. XRD and TEM were used to characterize the aluminum oxide particles. In this study, Aluminum oxide nanoparticles were employed as thermal conductivity materials, while TN+30 were utilized as a phase change material. After taking about 25 (liters) of water, it was discovered that 1 cm was the ideal depth. Compared to PCM, the energy materials TN+30 and Al2O3 increased collection efficiency with 200 ppm and 400 ppm of 21.65% and
R L, Krupakaran, Sagaya Raj, Gnana, Petla, Ratna Kamala, Kala, Lakshmi K, Anchupogu, Praveen
Enhancing Disc Brake Performance: Investigating Squeal Noise, Wear, and the Application of Functionally Graded Materials in Brake Rotors2025-28-01622/7/2025
Disc brakes play a vital role in automotive braking systems, offering a dependable and effective means of decelerating or halting a vehicle. The disc brake assembly functions by converting the vehicle's kinetic energy into thermal energy through friction. The performances of the brake assembly and user experience are significantly impacted by squeal noise and wear behaviour. This paper delves into the fundamental mechanisms behind squeal noise and assesses the wear performance of the disc brake assembly. Functionally graded materials (FGMs) are an innovative type of composite material, characterized by gradual variations in composition and structure throughout their volume, leading to changes in properties such as mechanical strength, thermal conductivity, and corrosion resistance. FGMs have emerged as a groundbreaking solution in the design and manufacturing of brake rotors, addressing significant challenges related to thermal stress, wear resistance, and overall performance. These
C V, Prasshanth, S, Gurumoorthy, Bhaskara Rao, Lokavarapu, S, Sridhar, S, Badri Narayanan, Kumar, Ajay, Biswas, Sayan
Analysis of Factors Affecting the Gel Point of Methanol-Water-Sodium Stearate Mixed Gel2025-01-70981/31/2025
This study determined the gel point of methanol-water-sodium stearate mixed gels at various concentrations of water and gelling agent by monitoring turbidity changes during the sol-gel transition. The gel points determined by turbidity measurements were further validated by monitoring changes in electrical conductivity during the sol-gel process at various concentrations of water and gelling agent. Molecular dynamics simulations were also conducted to further corroborate the gel points determined experimentally. The turbidity test results showed that the gel point was 20°C for the 3% gelling mixture and 35°C for the 5% gelling mixture. Mixed gels with 10% water content and 3% gelling agent content have a gel spot of 33°C.The electrical conductivity tests revealed that the average gel points for mixed gels with different water contents were 16.75°C (0%), 25.1°C (5%), and 32.4°C (10%). The average gel points for different gelling agent contents were 16.75°C (3%), 23.55°C (4%), and 38.75
Weiheng, Liu, Hui, Zhu, Jiawei, Pan, Jing, Wu, Jingyu, Wang, Lei, Fu, Yangyang, Li
Inductance Characteristics of the Axial-Radial Hybrid Excitation Motor with Fractional Slot Centralized Winding2025-01-70561/31/2025
The inductance parameter is important for the flux regulation performance of the hybrid excitation motor, and the axial structure leads to the change in the inductance parameter of the axial-radial hybrid excitation motor (ARHEM). To clarify the inductance characteristic of the ARHEM with different winding construction and the mutual coupling effect between the axial excitation and permanent magnet excitation on the inductance. Firstly, the structure of the ARHEM is presented. Secondly, the self and mutual inductance characteristics of ARHEM are analyzed using the winding function method. Then, the influence of the axial excitation structure on the armature reaction field and saliency ratio of ARHEM. On this basis, the mechanism of the mutual coupling, between the axial excitation and permanent magnet field under different excitation currents on the main air gap magnetic field, and the inductance of ARHEM with fractional slot are revealed.
Fu, DongXue, Zhao, Hewei, Wu, Qimin, Yuan, Chunwei, Wang, Dong, Qiu, Hongbo
Mesoscopic Heat and Mass Transfer Process in Catalyst Layer of Proton Exchange Membrane Fuel Cells under Cold Environment2025-01-70881/31/2025
To explore the heat and mass transfer processes within the low-temperature catalyst layer, a coupled heat and mass transfer lattice Boltzmann model and electrochemical model were established, creating a pore-scale model for heat and mass transfer in the catalyst layer. The influence of the catalyst layer parameters was investigated. The results indicate that as time progresses, heat gradually accumulates at the top of the catalyst layer (CL) and is transmitted towards the bottom. Once oxygen enters the CL, it quickly fills the pores within the CL, resulting in a rapid decrease in oxygen concentration within the ionomer. As the platinum volume fraction increases, there is a significant rise in temperature across the entire calculation domain. With the increasing platinum volume fraction, the current density also increases rapidly due to the larger reaction area. When the carbon volume fraction is 0.15, more oxygen enters the ionomer to participate in reactions, and the large porosity
Xu, Sheng, Chen, Xin, Sheng, Tao
Viscosity and Thermal Conductivity Characterization of Magnesium Oxide Nanofluids for Improved Automobile Thermal Management2024-01-52541/28/2025
Magnesium oxide (MgO) nanofluids are of great interest for enhancing the performance in thermal management especially in automotive applications, where efforts have been made to reduce parasitic losses from traditional cooling systems. These findings highlight the effects of Water–ethylene glycol and MgO nanofluids on viscosity and thermal conductivity in specific filling a gap in research that allows to clarify how these states behave at different temperature (T) and concentration (C) conditions. Test results demonstrate that the thermal conductivity of MgO nanofluids improved adequately /while its corresponding change in viscosity remained under control, affirming a significant improvement for energy savings by means heat transfer enhancement using new generation coolants based on this nano-additive. The results also provide useful information for design and development of automotive cooling systems, including real numbers on performance improvements that lead to more efficient and
Jeyanthi, P.
Influences of Zinc Oxide Doping on Functional Characteristics Study of Thin Film Solar Cell for Hybrid Solar Electric Vehicle Utilization2024-01-52561/28/2025
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
Venkatesh, R., De Poures, Melvin Victor, Thangamani, P., Manivannan, S., Devanathan, C., Boopathi, M. Sugadeva, Baranitharan, Balakrishnan, Madhu, S., Kaliyaperumal, Gopal
Analyses of Cold Thermal Energy Storage Systems Using Eutectic Mixtures of Inorganic Hydrated Salts as Phase Change Materials2025-01-50031/23/2025
Cold thermal energy storage using phase changing materials is being researched to find freezing and thawing points. The use of inorganic hydrated salts, a type of phase changing material (PCM) used in cold energy storage systems without the use of existing renewable energy systems, allows for a longer cooling effect and saves energy. A high volumetric storage density and relatively high thermal conductivity make hydrated salts suitable materials for thermal energy storage. They can be used only as inorganic mixtures or else they can also be used as eutectic mixtures, which involve mixtures of inorganic–inorganic salts or simply a combination of two or more inorganic salts. This research deals with eutectic mixtures, which are 4% KNO3 + 96% H2O, 4% NaHCO3 + 96% H2O, and 2% KNO3 + 2% NaHCO3 + 96% H2O. Three different novel eutectic mixtures were examined and found a suitable mixture for a cold thermal energy system. An efficient phase change approach involving 2% KNO3 + 2% NaHCO3 + 96
Vasanthkumar, P., Santhoshkumar, A., Gopika, P., Murali, M., Meera, C.
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