In this study, the viscosity and thermal performance of nanofluids based on ZnO-MgO mixed oxide nanoparticles added in different concentrations to ethylene glycol-water mixture are characterized with potential applications in engine cooling. The work began with two needs: the increasing importance of better heat removal in automotive engines, where traditional coolants struggle to adequately maintain good thermal conductivity but at low viscosity to acceptable levels; and a chance opportunity for exploration provided by MMD/MILab Engineer Andrew Cricee. The work wants to improve the cooling properties, but still keeping good fluidity by integrating ZnO-MgO nanoparticles. Preparation method the preparation of ZnO-MgO nanofluids was done using volume concentrations of 0.1%, 0.3% and 0.5%. To determine chemical properties, viscosity measurements were made on the Dragonfly using a Brookfield viscometer at temperatures ranging from 25 ° C to 80 ° C while varying the nanoparticle

Manikandan, S., Vickram, A. S., Madhu, S., Saravanan, A.

Thermal Conductivity Optimization of Nanodiamond Nanofluids for High-Performance Automotive Engines

2024-01-5212

12/10/2024

In this study, we investigate the thermal conductivity optimization of nanodiamond nanofluids for application in high-performance automotive engines. Nanodiamond particles, known for their superior thermal properties and stability, are dispersed in a base fluid composed of ethylene glycol and water. Various concentrations of nanodiamonds are prepared to evaluate their impact on thermal conductivity and viscosity. The experimental setup includes precise measurements of thermal conductivity using the transient hot-wire method and viscosity using a rotational viscometer over a temperature range of 25°C to 100°C. The results demonstrate significant enhancements in thermal conductivity with acceptable increases in viscosity, suggesting the potential of nanodiamond nanofluids in improving engine cooling efficiency. The study concludes with recommendations for future research to explore the long-term stability and performance of these nanofluids in real-world automotive applications

Jeyanthi, P., Gulothungan, G.

Comparative Analysis of Zinc Oxide and Copper Hybrid Nanofluids on Viscosity and Thermal Conductivity in Automotive Applications

2024-01-5213

12/10/2024

Nanofluids have emerged as effective alternatives to traditional coolants for enhancing thermal performance in automotive applications. This study conducts a comparative analysis of the viscosity and thermal conductivity of ZnO and Cu hybrid nanofluids. Nanofluids were prepared with ZnO and Cu nanoparticle concentrations of 0.1%, 0.3%, and 0.5% by volume and were characterized over temperatures ranging from 25°C to 100°C. The results demonstrate that ZnO and Cu hybrid nanofluids achieve an increase in thermal conductivity by up to 22% and 28%, respectively, compared to the base fluid. Concurrently, the viscosity of these nanofluids increases by up to 12% at the highest concentration and temperature. This study addresses a critical research gap by investigating the combined effects of ZnO and Cu nanoparticles in hybrid nanofluids, an area that has been underexplored. By providing new insights into optimizing both thermal conductivity and viscosity, this research contributes to the

Sivasubramanian, M., Sundaram, V., Madhu, S., Saravanan, A., Vidhyalakshmi, S.

Thermal Conductivity Enhancement of Aluminum Oxide Nanofluids for Efficient Heat Dissipation in Car Radiators

2024-01-5204

12/10/2024

This study points to potentiality of studying Aluminum Oxide (Al2O3) nanofluid on viscosity (μ) and thermal conductivity (K) for automotive cooling system. The Al2O3 nanoparticles dispersed in 50:50 ethylene glycol-water with5 varying concentrations of 0.1, 0.2, 0.3, 0.4 and 0.5 vol%. The viscosity at 25°C, 40°C, 60°C and 80°C was measured by using a Brookfield viscometer; and thermal conductivity was measured by the transient hot wire method. The results indicate that the viscosity increases with the concentration of nanoparticles but decreases with the temperature. Due to comparative importance of thermal conductivity with increasing temperatures and nanoparticle concentrations. In nanofluid Al2O3 can enhance heat transfer automotive cooling system can be good performance and efficient as well as engine, in 0.5% concentration, thermal conductivity at 25°C and increase 27% at 60°C, paranormal found for development and Al2O3 nanofluids apply can be effective improvement at heat

Vickram, A.S., Manikandan, S., Madhu, S., Saravanan, A.

Characterization of Silicon Dioxide Nanofluids: Viscosity and Thermal Conductivity Analysis for Hybrid Vehicle Applications

2024-01-5215

12/10/2024

The research introduces the thermal properties of silicon dioxide (SiO2) nanofluids and the promising application of these fluids in hybrid vehicle cooling systems. How to make fluids is simply to disperse a 50-50 mixture of both Ethylene Glycol and Water; into this solution add SiO2 nanoparticles concentration ranges from 0.1% up to 0.5% volume according desired properties or material characteristics etc. When viscosities and thermal conductivities of nanofluid were measured over the temperature range from 25 to 120 °C using Brookfield viscometer and transient hot-wire method; results were as follows: Viscosity of SiO2 nanofluids at 120°C higher concentrations 0.5%, more viscous fluids, thermal conductivity also rose with results, although there was a plateau at around 40% increase compared to that of water-based slurries. At 0.5% concentration, thermal conductivity increased by up to 20% at 120 °C, compared with the value of pure ethylene glycol. These results suggest that SiO2

Sundaram, V., Madhu, S., Vidhyalakshmi, S., Saravanan, A., Manikandan, S.

Development of ANFIS Predictive Model for Wire Electrical Discharge Machining of Cupronickel Material

2024-28-0239

12/05/2024

Wire Electrical Discharge Machining (WEDM) is an essential manufacturing process used to shape complex geometries in conductive materials such as cupronickel, which is valued for its corrosion resistance and electrical conductivity. The aim of this explorative study is to enhance the efficiency and precision of machining by creating a specialized predictive model using an Adaptive Neuro-Fuzzy Inference System (ANFIS) for cupronickel material. The study examines the intricate correlation between process variables of the WEDM (Wire Electrical Discharge Machining) technique, such as pulse-on time (Ton), pulse-off time (Toff), and discharge current, and crucial machining responses, including surface roughness, material removal rate. Data is collected through systematic experimentation in order to train and validate the ANFIS predictive model. The ANFIS model utilizes the collective learning capabilities of neural networks and fuzzy logic systems to precisely forecast machining responses by

Pasupuleti, Thejasree, Natarajan, Manikandan, Kiruthika, Jothi, Katta, Lakshmi Narasimhamu, Silambarasan, R.

Analyzing the Effect of Silicon Carbide and Flyash Reinforcement on the Phase Morphology and Mechanical Properties of 7075 Aluminum Alloy Produced through Stir-Casting Process

2024-28-0165

12/05/2024

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

Manwatkar, Asmita Ashok, Santosh Jambhale, Medha, Mahagaonkar, Nitin, Sharma, Dipesh

Synthesis and Characterization of Advanced Multi Nanoparticle Based Nanofluid Stabilized by Surfactants

2024-28-0139

12/05/2024

Recently, there has been a growing emphasis on Thermal Management Systems (TMS) for Lithium-ion battery packs due to safety concerns related to fire risks when temperatures exceed operating limits. Elevated temperatures accelerate electrochemical reactions, leading to cell degradation and reduced electronic system performance. These conditions can cause localized hotspots and hinder heat dissipation, increasing the risk of thermal runaway due to high temperatures, flammable gases, and heat-producing reactions. To tackle these issues, many automotive manufacturers employ indirect liquid cooling techniques to maintain battery pack and electronic system temperatures within safe limits. Engineered nanofluids, particularly those containing multi-nanoparticles dispersed in water and ethylene glycol, are being explored to enhance electrical safety in case of accidental exposure to electrical systems in EVs. This paper focuses on the experimental characterization of nanofluid containing

Nahalde, Sujay, Honrao, Gaurav, More, Hemant

Manufacturing of Carbon Fiber Reinforced Silicon Carbide - Zirconium Diboride Composite Brake Rotors using Electric Field Assisted Sintering

2024-01-4052

11/15/2024

ABSTRACT High performance fiber reinforced ceramic rotors have the potential to greatly improve metrics in heavy vehicles such as braking distance, acceleration time, maximum speed, fuel consumption, improved handling, and increased vehicle maximum loads. Three types of carbon ceramic composite brake rotor materials were created using polymer infiltration pyrolysis (PIP) for carbon fiber reinforced silicon oxicarbide, reactive melt infiltration (RMI) for carbon fiber reinforced silicon carbide, and electric field assisted sintering (EFAS) for carbon fiber reinforced silicon carbide-zirconium diboride to investigate the manufacturing of 396mm diameter heavy vehicle brake rotors. The microstructure of parts created by each manufacturing method were discussed and contrasted. The EFAS manufactured rotor created the highest quality part due to extremely fast processing times, uniform material microstructure, and fusing of adjacent fibers in the carbon fiber network. Thermal conductivity was

Rufner, Jorgen, Leonard, Clifford, Nutt, Steven, Nguyen, Kevin

A PASSIVE SOLUTION FOR TRANSIENT HEAT LOAD ISSUES USING PHASE CHANGE MATERIALS

2024-01-3537

11/15/2024

ABSTRACT Thermal management systems (TMS) of armored ground vehicle designs are often incapable of sustained heat rejection during high tractive effort conditions and ambient conditions. The use of a latent heat energy storage system that utilizes Phase Change Materials (PCMs) is an effective way of storing thermal energy and offers key advantages such as high-energy storage density, high heat of fusion values, and greater stability in temperature control. Military vehicles frequently undergo high-transient thermal loads and often do not provide adequate cooling for powertrain subsystems. This work outlines an approach to temporarily store excess heat generated by the transmission during high tractive effort situations through use of a passive PCM retrofit thereby extending the operating time, reducing temperature transients, and limiting overheating. A numerical heat transfer model has been developed based around a conceptual vehicle transmission TMS. The model predicts the

Putrus, Johnathon P., Jones, Stanley T., Jawad, Badih A., Schihl, Peter

Enhancing Heat Transfer in Immersion Cooling of Battery Packs - Using ALTP Heat Flux Sensors

2024-01-4327

11/05/2024

The effectiveness of immersion cooling for the thermal management of Electric-Vehicle (EV) batteries is crucially influenced by the thermophysical and rheological properties of the heat-transfer liquid. This study emphasizes upon the design requirements for such a fluid in terms of bulk properties, i.e., high electrical resistivity and thermal conductivity, low viscosity, but also relevant to the rheological properties maximizing the heat transfer rate. Key concepts of the implemented research constitute: (i) the promotion of vortical motion in the laminar flow regime, which, in turn, enhances heat transfer by disrupting boundary layers; (ii) vortex stabilization through the addition of viscoelasticity-inducing agents in the base heat-transfer liquid. To improve cooling efficiency, the primary objective is to maximize the achievable heat transfer rate for minimal pumping losses. Hence, a multi-objective optimization process must be set in place where the optimal coolant rheology is

Weiss, Lukas, Karathanassis, Ioannis, Rueppel, Bastian, Smith, Timothy, Wensing, Michael

Niobium Alloyed Ferritic Nitrocarburized Brake Rotors

2024-01-3031

09/08/2024

Niobium (Nb) alloyed Grey cast iron in combination with Ferritic Nitrocarburize (FNC) case hardening heat treatment is proposed to improve wear resistance and reduce brake dust generation of brake rotors. Standard Eutectic and Hypereutectic Grey irons alloyed with Niobium were evaluated in comparison to baseline unalloyed compositions. Brake speed snub sensitivity tribological testing was performed on a matrix including Niobium alloyed, Unalloyed, FNC, Non FNC, Non-Asbestos Organic (NAO) friction and Low metallic (Low Met) friction materials. Full size brake rotors were evaluated by Block Wear and Corrosion Cleanability. Improved wear, corrosion resistance and reduced brake dust debris were demonstrated by the Niobium alloyed FNC brake rotor combinations. Corrosion is an important consideration when evaluating brake performance. Combining cyclic corrosion and brake rotor testing provides the best comparison with field exposure

Holly, Mike

Highly Conductive Sensors for Wearables

TBMG-51482

09/01/2024

To advance soft robotics, skin-integrated electronics, and biomedical devices, researchers have developed a 3D printed material that is soft and stretchable — traits needed for matching the properties of tissues and organs — and that self-assembles. Their approach employs a process that eliminates many drawbacks of previous fabrication methods, such as less conductivity or device failure

Environment Spectra and Corrosivity Monitoring Using Electrochemical and Electrical Resistance Sensors

AIR6970 (Current)

07/23/2024

This SAE Aerospace Information Report (AIR) provides guidance on using environmental, electrochemical, and electrical resistance measurements to monitor environment spectra and corrosivity of service environments, focusing on parameters of interest, existing measurement platforms, deployment requirements, and data processing techniques. The sensors and monitoring systems provide discrete time-based records of (1) environmental parameters such as temperature, humidity, and contaminants; (2) measures of alloy corrosion of the sensor; and (3) protective coating performance of the sensor. These systems provide measurements of environmental parameters, sensor material corrosion rate, and sensor coating condition for use in assessing the risk of atmospheric corrosion of a structure. Time-based records of environment spectra and corrosivity can help determine the likelihood of corrosion to assess the risk of corrosion damage of the host structure for managed assets and aid in establishing

HM-1 Integrated Vehicle Health Management Committee

Steel and Aluminum Molds: The Effect of Thickness on Productivity and Part Quality

05-17-04-0024

06/28/2024

The use of aluminum to manufacture injection molds aims to maximize the productivity of plastic parts, as its alloys present higher heat conductivity than tool steel alloys. However, it is essential to accurately control the injection molding parameters to assure that the design tolerances are achieved in the final molded plastic part. The purpose of this research is to evaluate the use of aluminum alloys in high-volume production processes. It delves into the correlation between the type of material used for mold production (steel or aluminum) and the thickness of the injected part, and how these variables affect the efficiency of the process in terms of the quantity and quality of the produced parts. The findings suggest that replacing steel molds with aluminum alloys significantly reduces injection molding cycle time, the difference ranging from 57.1% to 72.5%. Additionally, the dimensional accuracy and less distortion provided by aluminum have improved product quality. In case of

Marconi, Pedro, Amarante, Evandro, Ferreira, Cristiano, Beal, Valter, Ribeiro Júnior, Armando

Next-Generation Binder for Lithium-ion Batteries

TBMG-50822

06/01/2024

Lithium-ion (Li-ion) batteries employ binders that encounter challenges such as poor conductivity and expansion during charging. In a recent study, scientists have developed a high-performing binder using poly(vinylphosphonic acid) for silicon oxide-based anodes in Li-ion batteries. This binder offers enhanced performance as demonstrated by the superior durability, and discharging capacity of the anodes compared to conventional options. With patents filed internationally, this technology holds promise for broader applications in electric vehicles and beyond

Multi-Scale Modeling of Selective Laser Melting Process

2024-26-0415

06/01/2024

The Selective Laser Melting (SLM) process is employed in high-precision layer-by-layer Additive Manufacturing (AM) on powder bed and aims to fabricate high-quality structural components. To gain a comprehensive understanding of the process and its optimization, both modeling and simulation in conjunction with extensive experimental studies along with laser calibration studies have been attempted. Multiscale and multi-physics-based simulations have the potential to bring out a new level of insight into the complex interaction of laser melting, solidification, and defect formation in the SLM parts. SLM process encompasses various physical phenomena during the formation of metal parts, starting with laser beam incidence and heat generation, heat transfer, melt/fluid flow, phase transition, and microstructure solidification. To effectively model this Multiphysics problem, it is imperative to consider different scales and compatible boundary conditions in the simulations. In this paper, we

Varma, Aditya, Ganesh, Kona Veera, Roy Mahapatra, Debiprosad

Electrification: Vol. 1

EPRCOMPV262023

05/10/2024

Advanced two-dimensional (2D) materials discovered in the last two decades are now being produced at scale and contribute to a wide range of performance enhancements in engineering applications. The most well known of these novel materials is graphene, a nearly transparent nanomaterial comprised of a single layer of bonded carbon atoms. In relative terms, it has the highest level of heat and electrical conductivity, protects against ultraviolet rays, and is the strongest material ever measured. These properties have made graphene an attractive potential material for a variety of applications, particularly for transportation-related uses, and especially for automotive engineering. The goal of drastically reducing greenhouse gas emissions has prioritized the electrification of transportation, the decarbonization of industry, and the development of products that require less energy to make, last longer, and are fully recyclable. While this chapter reviews the current state of graphene

Barkan, Terrance, Coyner, Kelley, Bittner, Jason, Kolodziejczyk, Bart, Jiang, Yuxiang

Aerospace Developments: Vol. 1

EPRCOMPV292023

05/10/2024

Advanced two-dimensional materials discovered in the last two decades are now being produced at scale and are contributing to a wide range of performance enhancements in engineering applications. The most well known of these novel materials is graphene, a nearly transparent nanomaterial comprising a single layer of bonded carbon atoms. In relative terms, it has the highest level of heat and electrical conductivity, protects against ultraviolet rays, and is the strongest material ever measured. These properties have made graphene an attractive potential material for a variety of applications, particularly for transportation-related uses, and especially for aerospace engineering. The goals of reducing greenhouse gas emissions and creating a world that achieves net-zero emissions have prioritized the electrification of transportation, the decarbonization of industry, and the development of products that require less energy to make, last longer, and are fully recyclable. These aspects have

Barkan, Terrance, Walthall, Rhonda, Dixit, Sunil, David, Aharon, Webb, Philip, Fletcher, Sarah

Implementing Ordinary Differential Equation Solvers in Rust Programming Language for Modeling Vehicle Powertrain Systems

2024-01-2148

04/09/2024

Efficient and accurate ordinary differential equation (ODE) solvers are necessary for powertrain and vehicle dynamics modeling. However, current commercial ODE solvers can be financially prohibitive, leading to a need for accessible, effective, open-source ODE solvers designed for powertrain modeling. Rust is a compiled programming language that has the potential to be used for fast and easy-to-use powertrain models, given its exceptional computational performance, robust package ecosystem, and short time required for modelers to become proficient. However, of the three commonly used (>3,000 downloads) packages in Rust with ODE solver capabilities, only one has more than four numerical methods implemented, and none are designed specifically for modeling physical systems. Therefore, the goal of the Differential Equation System Solver (DESS) was to implement accurate ODE solvers in Rust designed for the component-based problems often seen in powertrain modeling. DESS is a text-based

Steuteville, Robin, Baker, Chad

Conductive Carbon Fiber Polymer Composite

TBMG-50377

04/01/2024

A team of inventors from NASA Langley and NASA Ames have created a new type of carbon fiber polymer composite that has a high thermal conductivity. This was achieved by incorporating Pyrolytic Graphite Sheets (PGSs) and Carbon Nanotubes (CNTs), which enhance the material’s ability to transfer heat when compared to typical carbon fiber composites

Investigation of Mechanical Properties and Weld nugget Characteristics of Thermoplastics by Using Friction Stir Welding with Heat Assisted Induction Coil

2024-01-1943

03/05/2024

Friction stir welding (FSW) is a method of welding that creates a weld trail by pressing a non-consumable rotating tool with a profiled pin on the adjacent surfaces while moving transversely along the welding direction. The method was initially used with metals and alloys, but more recently, thermoplastic polymers have also been included in its application. Investigations on FSW of thermoplastic polymers made of nylon and High-density polythene (HDPE) are presented here. Weld characteristics that are like those of the base materials are attempted to be achieved. Because of their unique nature and thermal conductivity, thermoplastics FSW differs from that of metals. The use of thermoplastic materials with conventional FSW procedures presents numerous difficulties and is currently ineffective. On the weld characteristics of nylon and HDPE, statistical methods were utilized to study the impact of temperature, rotational speed, and transverse speed. Temperature is found to be the most

Raju, Ganga, Chinnakurli Suryanarayana, Ramesh, Srivastava, Ashish

Corrosion Control and Electrical Conductivity in Enclosure Design

ARP1481B (Current)

02/27/2024

Corrosion control is always of concern to the designer of electronic enclosures. The use of EMI gaskets to provide shielding often creates requirements that are in conflict with ideal corrosion control. This SAE Aerospace Recommended Practice (ARP) presents a compatibility table (see Figure 1) which has as its objective a listing of metallic couples that are compatible from a corrosion aspect and which still maintain a low contact impedance

AE-4 Electromagnetic Compatibility (EMC) Committee

Heat Conduction through Natural Fiber/Carbon Nanotubes Filler Matrix Polymer Composite Slabs: An Experimental and Analytical Comparisons

2023-01-5107

02/23/2024

The latest developments in composite materials are anticipated by green engineering. Materials must be eco-friendly, recyclable, biodegradable, and easy to decompose. Researchers are interested in utilizing natural fibres, fillers, and synthetic active ingredients. Natural fiber-polymer composites can specify certain mechanical properties but are hydrophilic and weak, so they rarely meet the needed thermal properties. Composite material selection depends on the application and the superior properties of the fibre/filler: banana fibre (BF), ice husk (RH) and multi-walled carbon nanotubes (MWCNT). In this research article, a brief discussion of the heat transfer mechanism of composites and the development of energy conduction equation are performed for hybrid natural polymer composite. The maximum thermal conductivity observed for 10BF/10RH/1MWCNT wt.% composite is 0.2694 W/mK. From ANSYS numerical simulation, the temperature distribution along the composite wall temperatures T1 to T8

Senthilkumar, N., Ramu, S., Deepanraj, B.

Structure and Behaviour Characteristics of Aluminum –Nickel- Zinc Alloy by Spray Forming

2023-01-5120

02/23/2024

The microstructure of the alloy and the manner in which it responds to heat treatment has been investigated. The alloy was aged at 550OC when it was initially spray-formed, or when its thickness was decreased by 38%. Before further aging of some specimens, a four-hour solution treatment at 1015OC was performed. The subsequent phase was a cold deformation that was barely 60% of the sample's initial thickness. The alloys' electrical conductivity and hardness may be evaluated based on how long they had been created. Following solution treatment and cold rolling, the alloy's peak hardness was around 380 kgf/mm2. In samples aged immediately under spray-produced conditions, the maximum peak hardness of 255 kgf/mm2 was attained. Conductivities in freshly cold-rolled samples could reach up to 75% of the standard for annealed copper internationally. It looks at the microstructural features of this alloy in this context, paying close attention to how various processing conditions affect them

Srinivasan, V.P., Anandan, R., Bharani Kumar, S., Sasidharan, R., Santhosh, S.

Enhancement of Mechanical and Thermal Characteristics of Automobile Parts using Flax/Epoxy-Graphene Nanofiller Composites

2023-01-5116

02/23/2024

With the evolving demand in the automobile industry for lightweight and sustainable components, the study of natural fiber composites has gained significance. Such fibers are economically efficient and offer advantageous weight-specific properties. Additionally, they are non-abrasive and environmentally degradable, marking them as viable alternatives to conventional automobile materials. This research emphasizes the flax-based composite, developed using the hand lay-up method and augmented with three distinct graphene nanofillers. The graphene fillers are categorized as large nanorods (dimensions 3-5 nm, lengths 150-300 nm), small nano threads (dimensions 6-12 nm, lengths under 50 nm), and spherical particulates (dimensions 29-39 nm). Reinforcement was consistently maintained at 2%, 4%, and 6% by weight. The results indicate that a 4 wt.% inclusion of spherical graphene nanoparticles is particularly effective in enhancing the ultimate tensile strength and fracture elongation of the

Kaliappan, S., Natrayan, L.

Influence of Diameter Ratio on the Mechanical Properties of Lap Joints in Friction Stir Welding of 2014 Aluminum Alloy

2023-01-5111

02/23/2024

The increased adoption of AA2014 Aluminum alloy within the manufacturing sector can be attributed to its lightweight properties and other attributes that position it as an appealing substitute for steel. Notably, AA2014 Aluminum alloy is employed in the production of components and frameworks for aircraft engines. However, conventional welding techniques do not always seamlessly apply to aluminum alloys due to aluminum's high thermal conductivity, pronounced susceptibility to oxidation, and comparatively low melting point. These characteristics can give rise to challenges such as burn-through and porosity during welding. To tackle these issues, the application of friction stir welding (FSW), a solid-state welding method, has been embraced. In the creation of lap joints, five distinct tools, each featuring a different ratio of tool shoulder diameter (D) to pin diameter (d), ranging from 2 to 4, were employed. An exhaustive evaluation of the mechanical and metallurgical properties of

Sandeep, Ch, Vijaya Prakash, B., Amarnath, V., Balu Mahandiran, S., Shanthi, C.

A Study on the Thermal Interface Mechanisms of Natural Fiber/Fillers and Allotrope-Based Polymers

2023-01-5129

02/23/2024

Composites of polymers reinforced with synthetic/natural fibers are mainly used in engineering sectors such as automobiles, aerospace, and in household appliances due to their abrasion resistance, high toughness, strength, and high specific modulus. The purpose of this research is to provide an overview of fiber-matrix interfaces and interface mechanism that leads to enhanced properties. This article investigates how natural/synthetic fibers, mineral based-materials and additional allotropic materials work rapidly and effectively across interfaces. The objective of this work is to discuss different interfacial mechanisms (i.e., diffusion, chemical bonding, and mechanical crosslinking) of fiber reinforced polymers and to understand the mechanism of heat transfer in hybrid polymers by establishing the polymer morphology, chain structure, and interchain linkages to allow molecular interactions between the material phases and to determine the characteristics and thermal conductivity of

Senthilkumar, N., Ramu, S., Deepanraj, B.

Conductive, Cotton-Based Fiber for Smart Textiles

TBMG-49967

02/01/2024

A single strand of fiber has the flexibility of cotton and the electric conductivity of a polymer, called polyaniline. The newly developed material showed good potential for wearable e-textiles. Researchers tested the fibers with a system that powered an LED light and another that sensed ammonia gas

Thermal Management of on-Board Electrical Vehicle Charger through AlN Coating

2024-26-0194

01/16/2024

Vehicle electrification is game changer for automotive sector because of major energy and environmental implications driven by high vehicle efficiency. However, EVs are facing challenges on life cycle assessment (LCA), charging, and driving range compared to conventional fossil-fueled vehicles. One of the key features that impacts the efficiency of an EV is its battery charging system which is done using an On-Board Charger (OBC). OBCs, are primarily used to convert DC-power from high-voltage battery pack to AC-power. They contain different power-electronic devices such as MOSFETs, diodes, magnetics etc. These devices generate a lot of heat and require an efficient thermal management strategy. Through CAE Thermal analysis it was identified that amongst these components, transformers and diodes are major source of heat. Temperature observed at these component locations were in the range of 90-105 °C, compared to other components (45-75°C). This results into formation of hot spots on

Bali, Shirish, Bhatt, Srishti, Bhavsar, Vaibhav, Rao, Bhaskar

Corrosion Behavior of Bare & Organic Coated ADC-12 Used for Heat Sink Enclosure of on-Board Charger

2024-26-0196

01/16/2024

The automotive sector trend is moving towards vehicle electrification that provides great energy and environmental implications. However, Electrical Vehicles (EVs) are facing challenges in term of charging, driving range and life cycle with respect to existing vehicles. One of the key components in EV which is responsible for charging is On-Board Charger (OBC). OBCs are mainly used in converting DC power from battery pack to AC power and contains different power-electronic devices such as MOSFETs, diodes, magnetics etc. Heat-sinks are used to transfer the heat generated by these electronics and also as an enclosure to accommodate the electronics. Aluminum based alloy-ADC-12 generally used for manufacturing of OBC-enclosure due to its light weight, easy castability and good thermal conductivity. Although ADC-12 aluminum alloy has high corrosion resistance, specific environment condition or situation may accelerate corrosion with extended storage in rainy and salty environments. Normally

Bhatt, Srishti, Bali, Shirish, Rao, Bhaskar

Optical Concentration Sensor for Liquid Solution

TBMG-49811

01/01/2024

Innovators at the NASA Kennedy Space Center have developed a new optical sensor for measuring concentration in a liquid solution. The sensor was designed for measuring the pretreat solution concentration within the Universal Waste Management System (UWMS), a specialized toilet designed for the International Space Station (ISS) and other future missions. The sensor was developed to replace the current pretreat concentration sensor within the UWMS that uses electrical conductivity instead of light-based methods

Coupling Assembly, Threadless, Flexible, Self-Locking, Fixed Cavity, High Conductivity, Self-Bonding, Part Specification

AS7510B (Current)

12/18/2023

This SAE Aerospace Standard (AS) defines the requirements for a threadless, flexible, high conductive, self-bonding coupling assembly which, when installed on defined ferrules, provides a flexible connection for joining ducting and components in pressurized fluid systems. The assembled coupling is designed to provide interchangeability of parts and components between qualified manufacturers for use from -65 to +265 °F at 130 psi nominal operating pressures and for the service life of the aircraft system. FAR 23.954, FAR 25.603, FAR 25.605, FAR 25.609, FAR 25.613, FAR 25.901, FAR 25.954, and FAR 25.981 certification requirements have identified the need for high-current capable flexible fluid assembled couplings. The coupling assembly does not require inspection or maintenance to remain current capable for the life of the aircraft. This specification provides two test philosophies necessary for low-pressure couplings: 1 Electromagnetic effects/lightning testing of assembled couplings to

G-3, Aerospace Couplings, Fittings, Hose, Tubing Assemblies

Application of Taguchi Based ANFIS Approach in Wire Electrical Discharge Machining of Inconel 625 for Automobile Applications

2023-28-0148

11/10/2023

Nickel-based superalloys are most commonly engaged in a numerous engineering use, including the making of food processing equipment, aerospace components, and chemical processing equipment. These materials are often regarded as difficult-to-machine materials in conventional machining approach due to their higher strength and thermal conductivity. Various methods for more effective machining of hard materials such as nickel-based superalloys have been developed. Wire electrical discharge machining is one of them. In this paper, an effect has been taken to develop an adaptive neuro-fuzzy inference system for predicting WEDM performance in the future. To analyse the model’s variable input, the paper employs the Taguchi’s design and analysis techniques. The evolved ANFIS model aims to simulate the process’s various characteristics and predicted values. A comparison of the two was then made, and it was discovered that the predicted values are much closer to the actual outcomes. The

Pasupuleti, Thejasree, Natarajan, Manikandan, Shanmugam, Loganayagan, Kiruthika, Jothi, Ramesh Naik, Mude, Kotapati, Gowthami

Evolution of Regression and Neural Network Models on Wire Electrical Discharge Machining of Nickel Based Superalloy

2023-28-0078

11/10/2023

In addition to traditional methods, there are also non-traditional techniques that can be used to overcome the challenges of conventional metal working. One such technique is wire electrical discharge (WEDM). This type of advanced manufacturing process involves making complex shapes using materials. Utilizing intelligent tools can help a company meet its goals. Nickel is a hard metal to machine for various applications such as nuclear, automobile and aerospace. Due its high thermal conductivity and strength, traditional methods are not ideal when it comes to producing components using this material. This paper aims to provide a comprehensive analysis of the various steps in the development of a neural network model for the manufacturing of Inconel 625 alloy which is used for specific applications such as exhaust couplings in sports motor vehicle engines. The study was conducted using a combination of computational and experimental methods. It was then used to develop an index that

Natarajan, Manikandan, Pasupuleti, Thejasree, Katta, Lakshmi Narasimhamu, Kiruthika, Jothi, Silambarasan, R, Kotapati, Gowthami

Machinability Studies and the Evolution of Hybrid Artificial Intelligent Tools for Advanced Machining of Nickel Alloy for Aerospace Applications

2023-28-0065

11/10/2023

Nickel-based superalloys are frequently adopted in various engineering applications, such as the production of food processing equipment, aerospace parts, and chemical processing equipment. Because of higher strength and thermal conductivity, they are often regarded as difficult-to-machine materials in certain processes. Various methods were evolved for machining the hard materials such as Nickel-based superalloys more effective. One of these is wire electrical discharge machining. In this paper, we will discuss the development of an artificial neural network model and an adaptive neuro-fuzzy inference system that can be used to predict the future performance of Wire Electrical Discharge Machining (WEDM). The paper uses the Taguchi and Analysis of Variance (ANOVA) design techniques to analyze the model’s variable input. It aims to simulate the various characteristics of the process and its predicted values. A comparison of the two was then performed, and it was revealed that the

Natarajan, Manikandan, Pasupuleti, Thejasree, Sagaya Raj, Gnana, Kumar, V, Katta, Lakshmi Narasimhamu, Kiruthika, Jothi

An Examination of Sensing Skins with Tailored Conductivity Distributions for Enhanced 2-D Surface Temperature Measurements Using Electrical Impedance Tomography (EIT

2023-01-1680

10/31/2023

For 2D surface temperature monitoring applications, a variant of Electrical Impedance Tomography (EIT) was evaluated computationally in this study. Literature examples of poor sensor performance in the center of the 2D domains away from the side electrodes motivated these efforts which seek to overcome some of the previously noted shortcomings. In particular, the use of ‘sensing skins’ with novel tailored baseline conductivities was examined using the EIDORS package for EIT. It was found that the best approach for detecting a temperature hot spot depends on several factors such as the current injection (stimulation) patterns, the measurement patterns, and the reconstruction algorithms. For well-performing combinations of these factors, customized baseline conductivities were assessed and compared to the baseline uniform conductivity. It was discovered that for some EIT applications, a tailored distribution needs to be smooth and that sudden changes in the conductivity gradients should

Sjöberg, Magnus

Structure and properties of a nano-carbon composite surface coating for roll-to-roll manufacturing of titanium fuel cell bipolar plates

2023-32-0138

09/29/2023

In the 1st generation Toyota "MIRAI" fuel cell stack, carbon protective surface coating is deposited after individual Ti bipolar plate being press-formed into the desired shape. Such a process has relatively low production speed, not ideal for large scale manufacturing. A new coating concept, consisting of a nanostructured composite layer of titanium oxide and carbon particles, was devised to enable the incorporation of both the surface treatment and the press processes into the roll-to-roll production line. The initial coating showed higher than expected contact resistance, of which the root cause was identified as nitrogen contamination during the annealing step that inhibited the formation of the composite film structure. Upon the implementation of a vacuum furnace chamber as the countermeasure, the issue was resolved, and the improved coating could meet all the requirements of productivity, conductivity, and durability for use in the newer generation of fuel cell stacks

YAMASAKI, Takenori, IKEDA, Kotaro, SATO, Toshiki

Effect of Viscosity Characteristics of Lubricants for Electric Vehicles on Thermal Conductivity and Gear Protection

2023-32-0144

09/29/2023

The purpose of this study is to investigate how the kinematic viscosity of lubricating oil used in hybrid electric vehicle (HEV) and electric vehicles (EV) transaxles affects thermal conductivity and gear seizure resistance. This study investigated the relationship between viscosity, thermal conductivity and gear seizure resistance in detail and found that thermal conductivity tends to decrease with decreasing viscosity. It was also found that the thermal conductivity decreases significantly after a certain viscosity. The relationship between viscosity and gear seizure resistance was also investigated and it was found that too low a viscosity causes a significant deterioration in gear seizure resistance

Matsubara, Kazushige, Tatsumi, Hiroyuki, Nakahara, Yasuhito, Takekawa, Daisuke, Narita, Keiichi

Greases for powertrains: thickener effect, electric conductivity, and life cycle assessment

2023-32-0146

09/29/2023

The paper shows how grease thickener polarity affects performance of the typical powertrain components: gears and rolling element bearings. Greases based on a non-polar polypropylene thickener reduce friction losses (more than 20%) in high-speed deep groove ball bearings and provide a longer service life (more than 2 times) in highly loaded bevel gears, compared to the greases based on polar lithium thickeners. The electrification and sustainability trends have led to additional requirements to be addresses during grease design process: tunable electric conductivity and reduced environment footprint. The grease design challenges caused by the novel requirements and potential solutions are discussed

Glavatskih, Sergei, Leckner, Johan

PRODUCT BRIEFS

23AUTP09_14

09/01/2023

A Novel Way to Convert Heat to Electricity

TBMG-48933

09/01/2023

Researchers at the National Institute of Standards and Technology (NIST) have fabricated a novel device that could dramatically boost the conversion of heat into electricity. If perfected, the technology could help recoup some of the recoverable heat energy that is wasted in the U.S. at a rate of about $100 billion each year

An Innovative Method to Produce Soft, Recyclable Fibers for Smart Textiles

TBMG-48929

09/01/2023

Drawing inspiration from how spiders spin silk to make webs, a team of researchers from the National University of Singapore, together with international collaborators, has developed an innovative method of producing soft fibers that possess three key properties (strong, stretchable, and electrically conductive), and at the same time can be easily reused to produce new fibers

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