Browse Topic: Smart materials

Items (447)
To meet the critical need for rapid response and miniaturization in laser beam expander drive systems, this study proposes an innovative actuation solution based on a hollow rotary traveling-wave ultrasonic motor. By thoroughly analyzing the optical adjustment mechanism of laser beam expanders and the electromechanical coupling behavior of ultrasonic motors, the motor structure was systematically optimized. Using a multiphysics coupling approach, the performance of stators fabricated from three distinct materials was compared, and parametric optimization was conducted. Experimental verification confirms that the developed ultrasonic motor precisely matches the load characteristics of beam-expanding optics while fulfilling the stringent requirements for both fast response and compact design. This research provides a reference for the miniaturization drive of high-precision optical systems, with promising applications in space optics and precision instrumentation.
Qiu, HaihuiNiu, ChuanhuXiao, ZhongXu, ZhangfanLi, JialiangPan, Song
Low-frequency vibrations in ships have detrimental effects on the lifespan of onboard equipment and the comfort of crew members, thereby highlighting the importance of developing efficient vibration-damping materials as a critical research area. This study investigates the application of Mn-Cu damping alloys for mitigating vibrations within the 0–1000 Hz frequency range, which is typical of ship environments. The vibration-damping characteristics of the material were examined through a combination of experimental and numerical simulations. A numerical simulation framework was developed to predict the vibration response of manganese-copper damping alloys, incorporating a frequency-dependent damping ratio model derived from experimental characterization. Comparative analyses validated the accuracy of vibration simulations that incorporate frequency-dependent damping ratios and demonstrated the superior vibration attenuation performance of the Mn-Cu damping alloy across the 0-1000 Hz frequency band. Deck application analysis revealed that manganese-copper damping devices reduced the root mean square (RMS) vibration acceleration of the ship deck by up to 17.5% in the 0-1000 Hz frequency range compared to aluminum alloy counterparts. The damping effect was particularly significant in the 400–1000 Hz range, where vibration energy dissipation was most effective due to the material's intrinsic damping mechanisms. Additional engineering evaluation confirmed that the Mn-Cu alloy components maintain structural integrity while providing enhanced damping performance under typical marine environmental conditions. This study establishes a theoretical foundation for the design of ship vibration-damping materials, expands the potential applications of damping alloys in marine engineering, and provides valuable reference data for material selection and vibration control design in shipbuilding and offshore engineering applications.
Yao, SitongTian, AliZhao, Xianghua
The widespread adoption of electric vehicles is currently hindered by long charging durations and limited infrastructure. While fast-charging technologies address these issues, they impose significant thermal loads on high-voltage components. Within this architecture, the Battery Disconnect Unit plays a critical role as it monitors and controls the connection between the battery, powertrain, and charging system. However, the high currents required for fast-charging often drive these units' temperatures beyond safe operating limits, necessitating advanced thermal solutions that do not require extensive redesigns of the vehicle's electrical layout. To address this challenge, this study proposes a passive thermal management solution using Phase Change Material heat transfer devices to enhance the thermal robustness of the component. The methodology employs a dual approach involving initial experimental testing to pinpoint specific thermal hotspots under high-power conditions, followed by detailed numerical simulations using GT-Power software to predict system behavior. Furthermore, the paper provides a comparative analysis of various configurations, assessing their impact on temperature reduction, response time, and thermal uniformity. The results demonstrate that appropriately designed passive solutions significantly improve thermal performance, effectively enabling higher charging power capabilities while minimizing system complexity and integration effort. This innovation provides a scalable and efficient path for improving overall vehicle performance and safety during rapid energy transfer events.
Salameh, GeorgesGoumy, GuillaumeFrecinaux, AnthonyRatajczack, ChristellePalluel, MarlèneNoiseau, PascalLardeux, Sébastien
The transition from internal combustion to electric vehicles requires assessing new challenges posed by novel components, materials, and manufacturing processes. These include assessing new types of excitations and damages from a reliability perspective. This paper investigates a solution to enhance Printed Circuit Board (PCB) reliability within automotive Power Electronic Units (PEUs). Controlling vibration levels is crucial to prevent component breakage and PEU failure. The proposed approach exploits Locally Resonant Metamaterials (LRMs) to reduce PCB vibrational loads. LRMs provide excellent Noise, Vibration, and Harshness (NVH) performance within specific frequency ranges while being lightweight and providing high design freedom. Since direct integration into the PCB is unfeasible, the aluminum spider frame securing the PCB is treated instead. Previous simulations demonstrated significant vibrational load reduction. In this study, the LRM solution is fabricated, and experimental validation is performed using a shaker test mimicking operating conditions. Multiple configurations are explored: two concepts tuned to individual PEU resonance frequencies, and a hybrid configuration targeting both peaks simultaneously. Finally, relative damage is calculated using experimental data, comparing configurations with and without the LRM solution, demonstrating how this method can evaluate the LRM solution's performance in such applications.
Tincani, SaraClaeys, ClausDeckers, ElkePandiya, NimishDindorf, Christian
For sustainability reasons, the automotive market is requesting 100% monomaterial noise treatments, particularly for the end-of-life recycling without any part separation operation. But also, OEMs require super light, highly performance insulating noise treatments for electric vehicles in order to extend vehicle autonomy. PP melt-blown fiber felts present good mono-material characteristics with very good absorption, but generally not so good insulation properties behind an airtight barrier due to lack of stiffness. Moreover, these PP melt-blown fiber felts are relatively expensive and not thermoformable, thus forcing them to be used as 2D die-cut parts behind existing hard or soft trims classically. The shown optimization approach proposes to return to 100% thermoformable recycled and recyclable PET formulations blending unusual coarse mechanical specific fibers, in order to optimize the viscothermal exchanges, while maintaining good mechanical properties, with microfibers for best dissipation properties bonded by bi-component fibers. The insulation properties obtained as poroelastic spring behind a barrier allow a weight reduction of -50% compared to cotton felt while being 1 dB better for the Insertion Loss values (2 dB compared to a flexible foam) and perform as well as best PP melt-blown fiber felts while being more competitive as well as thermoformable. It is possible to adjust the sound insulation properties, sound absorption and hardness (static compressibility) using optimal PET fibers formulations but also thanks to felt verticalization processes. These optimization levers will be illustrated in this paper.
Duval, ArnaudLei, LeiWilkinson, AlexandreDelinselle, Eric
Healable spacecraft structures could soon be possible thanks to cutting-edge composite technology. Swiss companies CompPair and CSEM, and Belgian company Com&Sens have partnered with the European Space Agency (ESA) to modify their self-healing carbon fiber product for use in space transportation.
Shape memory polymers (SMPs) provide tunable thermomechanical properties and enable the design of recoverable crash structures for automotive applications. This paper introduces a computational framework for the design and optimization of SMP-based crash absorbers with periodic auxetic microstructures. First, a finite element (FE) model is developed and validated against experimental data regarding crushing and recovery behavior. A parametric study is then performed by varying key microstructural features, including wall thickness, cell size, and cell shape. Structural performance is evaluated in terms of specific energy absorption (SEA), peak force, and recoverability. To efficiently explore the high-dimensional design space, surrogate models based on machine learning are constructed, and multi-objective optimization is carried out to identify Pareto-optimal designs that balance competing objectives. The parametric study indicated that geometric parameters strongly influenced energy absorption and recoverability. Increasing the wall thickness enhanced both stiffness and peak force but reduced recoverability due to higher residual deformation. Larger re-entrant angles (70°–75°) improved auxeticity and distributed stress more uniformly. In addition, the structural configuration representing a balanced performance with moderate peak load and substantial energy recovery has been identified.
Zhu, YingboZhu, FengDeb, Anindya
Systems for solar desalination provide a practical and environmentally friendly way to turn salty or polluted water into drinkable water. Three configurations are experimentally investigated in this study: a traditional solar desalination system, a system integrated with a thermal energy storage unit (TESU) based on phase change material (PCM), Multi wall Carbon nano Tube were mixed with PCM at 2% of total volume of the PCM and a system that incorporates powdered natural dolomite/MWCNT at 1% each into the PCM-based TESU. Each of the four configurations was created, tested simultaneously, and thoroughly examined. In comparison to the Standard Still (SS), the experimental findings showed that the adoption of PCM-based TESUs increased daily cumulative water output (collection efficiency) by 24%, 26% with addition of MWCNT and the addition of dolomite powder/MWCNT further increased productivity by 27%. The average exergy efficiencies for for SS, SS with PCM, SS with nano enriched PCM, and SS on PCM with MWCNT/dolomite were 1.02%, 1.25%, 1.34% and 1.6%, respectively compared to SS without PCM.
R L, KrupakaranPetla, RatnakamalaAnchupogu, PraveenP, UmamaheswarraoSatya Meher, RDunna, Vijay
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 conditions, reducing the cooling and heating system’s workload. This leads to lowering the operational demand on the compressor, pump and fan ultimately optimizing energy consumption. In this work, polyethylene terephthalate (PET), with a thermal conductivity of approximately 0.026 W/m-K, is used as the insulating material. In addition to thermal insulation, the integration of thermoelectric cooling systems provides precise temperature regulation by the thermoelectric effect to move heat away from battery cells either to TES tank or to ambient. In this setup, a thermal energy storage (TES) unit works alongside TECs as a cost effective thermal management solution for SCVs. Unlike traditional refrigeration systems, this approach replaces the refrigerant cycle with TEC modules and a PCM based TES tank. During the vehicle’s charging phase, TECs draw power externally to store cooling energy in the TES unit. Then, during operation, the stored energy maintains battery temperatures without consuming power from the high voltage battery. In colder climates, the same TEC modules can works as battery heater by reversing electric polarity. This paper is succeeding part of advanced battery thermal management technologies for SCVs: a comprehensive approach to optimize energy use, enhance battery performance and cost reduction, technical paper which is presented in TTTMS 2025. The optimization of existing thermo-electric system is important from system sizing, costing and performance point of view. In this paper the system is optimized and made compact with better thermal performance. In summary, combining advanced insulation and thermoelectric cooling strategies for non-air-conditioned SCV EVs results in significant benefits— including increased driving range and a 25–30% reduction in overall system costs—while still meeting stringent battery thermal management requirements.
Chormule, Suhas RangraoWarule, PrasadNagpure, RahulJadhav, Vaibhav
High Voltage cables and terminals are prone to high temperatures and rapid heat generation due to high current ratings, especially in electric vehicles (EVs). If the temperature exceeds a critical limit, danger may be posed to the components which are connected and the overall safety of the passengers. Traditionally, cooling methods are often energy-intensive and rely on active systems, which may not always be practical for high-power applications. Thus, a localized, fast, and reliable passive thermal management methodology that can be retrofitted into existing connector designs through modifications (e.g., enlargement and PCM integration) would provide significant safety enhancement. The material property of phase change materials, which possess high latent heat, has been used to maintain a steady temperature for a period of time. A dual PCM-layer has been incorporated into the design of the high-voltage connector to serve two purposes:1. The first PCM layer (PCM-1), with good conductivity, is used to rapidly absorb heat from the terminals. 2. The second PCM layer (PCM-2), playing a prominent role in heat storage, absorbs excess heat and has a larger heat-absorbing capacity. The objective has been to maintain the terminal temperature below 80°C. An NX-CAD model has been prepared, showcasing the PCM-1 and PCM-2 containers inside the male connector, along with the packaging scenario with the female connector. “Acting time” was calculated based on amount of heat taken by each PCM layer. Results showed that the total heat generated due to Joule effect was 78.125 W with a high current of 125 A. Out of which, PCM-1 was able to sustain 14.37 W for 92.4 seconds before it got fully melted and PCM-2 was able to sustain 0.42 W for 1.85 hours. Comparison plots for energy storage capacity clearly indicated high capacity for PCM-2.
Neogi, AngshumanShinde, Shardul
The present disclosure is about combating Thermal runaway in Electric, Plug-in Hybrids and mild hybrid vehicles. This paper comprises of high-Voltage Battery pack containing Battery cells electrically coupled with Shape Memory Alloy along with Busbars. These connectors (Shape Memory Alloy) are programmed to operate in two states: First to electrically connect the cells with the busbars, second to disconnect the individual cells from electric connection beyond the threshold temperature. This mechanism enables the Battery cells to rapidly prevent the Battery from the Thermal runaway event which is caused from the cell level ensuring the Battery safety mechanically. Additionally, the Battery pack includes the cell monitoring system and Battery Monitoring System to enhance the above invention with regards to the safety of the vehicle. This configuration is implementable and retrofittable into existing battery systems, offering a robust solution to the challenges posed by prolonged vehicle electrification.
Reginald, RiniRout, SaswatVENKATESH, MuthukrishnanChauhan, Ashish JitendraSelvaraj, Elayanila
Bioelectronics, such as implantable health monitors or devices that stimulate brain cells, are not as soft as the surrounding tissues due to their metal electronic circuits. A team of scientists has developed a soft polymer hydrogel that can conduct electricity as well as metal can. As the material is both flexible and soft, it is more compatible with sensitive tissues. This finding has the potential for a large number of applications, for example, in biocompatible sensors and in wound healing.
EPFL researchers have engineered a fiber-based electronic sensor that remains functional even when stretched to over 10 times its original length. The device holds promise for smart textiles, physical rehabilitation devices, and soft robotics.
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
The activation of the fuel injector affects both engine performance and pollutant emissions. However, the automotive industry restricts access to information regarding the circuits and control strategies used in its vehicles. One way to optimize fuel injections is using piezoelectric injectors. These injectors utilize crystals that expand or contract when subjected to an electric current, moving the injector needle. They offer a response time up to four times faster than solenoid-type injectors and allow for multiple injections per combustion cycle. These characteristics result in higher combustion efficiency, reduced emissions, and lower noise levels, making piezoelectric injectors widely used in next-generation engines, where stricter emission and efficiency standards are required. This study aims to design a drive circuit for piezoelectric injectors in a common rail system, intended for use in a diesel injector test bench. Experimental measurement of voltage was obtained from an injector coupled to a running diesel engine. The developed equivalent circuit demonstrated the capability to drive piezoelectric injectors with voltage values close to those observed in a commercial injector installed in a diesel engine, validating its suitability for research and experimental applications. Additionally, injector operating curves were generated, evaluating the injected diesel mass flow rate for different energization times and injection pressure. The designed equivalent circuit successfully enabled the correct operation of piezoelectric injectors on the test bench, reproducing the expected charge and discharge behavior required for precise actuation.
Moreira, Vinicius GuerraSilveira, Hairton Júnior José daMorais Hanriot, Sérgio deEuzébio, Wagner Roberto
As demand for microcomponents has escalated in diverse areas of automotive, medicine, communications, electronics, optics, biotechnology, and avionics industries, there is a need for hybrid manufacturing techniques that can effectively micromachine hard and brittle materials. Electrochemical discharge machining (ECDM) is an advanced manufacturing process for machining difficult-to-cut materials. With a need for precision and accuracy, tool kinematics is a potential research area in ECDM for achieving geometrical dimensioning and tolerances (GD&T). Therefore, the present study reviews the ultrasonic vibration–assisted ECDM (UA-ECDM) hybrid process and the performance of its process parameters (voltage, electrolyte type and its concentration, electrode material, pulse duration, and amplitude) on the material removal rate (MRR), tool electrode wear (TEW), surface integrity, and difficult-to-cut materials. Also, the present work mentions current problems (debris and bubbles trapped, electrolyte circulation, and gas film formation) faced and future research directions to increase the process capabilities based on published research in the UA-ECDM process.
Prajapati, Mehul S.Lalwani, Devdas I.
Off-highway vehicles (OHVs) frequently operate in extreme environments—ranging from arid deserts and frozen tundras to dense forests and abrasive mining zones—where structural wear, impact damage, and environmental stress compromise their material integrity. Frequent repairs and component replacements increase operational costs, downtime, and environmental waste, making durability and sustainability key concerns for next-generation vehicle systems. This paper explores a novel class of self-healing biodegradable composites, inspired by biological systems, to address these challenges. The proposed materials combine bio-based resins, microencapsulated healing agents, and shape-memory polymers (SMPs) to autonomously repair microcracks and surface-level damage when triggered by thermal, UV, or mechanical stimuli. The design draws inspiration from natural self-healing systems such as tree bark and reptile skin, replicating their regenerative behavior to enhance structural resilience in OHVs. The composite’s biodegradability ensures environmental friendliness at end-of-life, aligning with circular economy goals. Laboratory-scale experiments and computational simulations assess tensile strength, fracture toughness, healing efficiency, and environmental stability (e.g., temperature cycling, UV exposure, and abrasion).
Vashisht, Shruti
Off-highway vehicles (OHVs) routinely navigate unstable and varied terrains—mud, sand, loose gravel, or uneven rock beds—causing increased rolling resistance, reduced traction, and high energy expenditure. Traditional rigid chassis systems lack the flexibility to adapt dynamically to changing surface conditions, leading to inefficiencies in vehicle stability, maneuverability, and fuel economy. This paper proposes an adaptive terrain morphing chassis (ATMC) that can actively modify its structural geometry in real-time using embedded sensors, hydraulic actuators, and soft robotic elements. Drawing inspiration from nature and recent advances in adaptive materials, the ATMC adjusts vehicle ground clearance, track width, and load distribution in response to terrain profile data, thereby optimizing fuel efficiency and performance. Key contributions include: A multi-sensor fusion system for real-time terrain classification Hydraulic actuators and morphing polymers for variable chassis configurations Simulated fuel savings of 8–14% across diverse terrains compared to fixed-geometry systems The design also contributes to sustainability by reducing energy waste and material wear, and by enabling smart, terrain-responsive behavior that can extend the lifespan of vehicle components. This innovation holds significant potential for deployment in resource-heavy industries where OHVs operate in unpredictable and efficiency-critical environments.
Vashisht, Shruti
Magnetorheological brakes based on MR technology are being investigated for their potential use for automotive purposes. Among the design decisions, the selection of an appropriate MR fluid for the brake application remains an unexplored key issue. This article proposes an MCDM-based framework comprising analytic hierarchy process (AHP) and technique for order of preference by similarity to ideal solution (TOPSIS) to select an appropriate MR fluid for the automotive brake application. Three commercially available MR fluids from Lord Corporation (MRF-122EG, MRF-132DG, and MRF-140CG) are assessed against six criteria, viz. density, temperature range, yield stress, viscosity, magnetic saturation limit, and solid content. Considering all the criteria, the AHP ranked MRF-140CG highest, while TOPSIS chose MRF-122EG. Excluding the temperature range, both methods converged on MRF-122EG as the optimal choice. The proposed framework can be used for the MR fluid selection problem of other MR devices as well.
Powar, KanhaiyaPatil, Satyajit
Researchers are testing a new technology that incorporates shape memory material for clear plastic dental aligners, an alternative to traditional metal braces. The clear aligners still need to be improved to the point that there are two materials — clear aligners and metal braces — that are as good as each other.
To address the thermal management challenges in lithium-ion batteries-which are associated with safety, real-world driving, and operating cycles, particularly at high discharge rates and in extreme ambient conditions-it is essential to maintain the battery temperature within its optimal range. This work introduces a novel hybrid Battery Thermal Management System (BTMS) that integrating a Phase Change Material (PCM) and air cooling with fins attached to air-channel in PCM side. Unlike conventional approaches that use standard rectangular fins, this study employs angular fins with varying dimensions to enhance heat dissipation. The hybrid system is designed to leverage the high latent heat storage capability of the PCM while ensuring efficient convective heat removal through air cooling. The airflow through the cooling channel accelerates heat dissipation from the PCM, thereby increasing its effectiveness. The angular fins are strategically positioned within the PCM section to enhance thermal diffusion by increasing the effective heat transfer surface area. This study compares conventional fins with the proposed angular fin design to analyse the peak battery temperature and temperature variation across the battery. The optimized fin orientation with specific angles may enhance heat diffusion within the PCM. As the number of fin segments increases, the volume fraction occupied by the PCM is restricted, so the optimal number of fin segments must be evaluated for the best performance of the combined PCM and fin system. Our analysis of Fin - 3 (design 4) reveals its exceptional ability to maintain thermal uniformity across varying flow regimes. At a low velocity of 2 m/s, the PCM effectively homogenizes the temperature field, achieving the lowest temperature difference of 4.38 K. As airflow increases to 4 m/s, the system transitions to a convection-dominated state. In this regime, Fin - 3’s performance is sustained by a synergistic conduction-convection mechanism, achieving a minimum temperature gradient of 4.95 K. Furthermore, the proposed hybrid BTMS, under different conditions, may limit thermal stresses that develop within the battery. This research aims to improve battery thermal management with novel fin designs for next-generation systems.
Kalvankar, TejasLam, Prasanth Anand KumarAruri, Pranushaa
Adaptive vehicle control systems are crucial for enhancing safety, performance, and efficiency in modern transportation, particularly as vehicles become increasingly automated and responsive to dynamic environments. This review explores the advancements in bio-inspired actuators and their potential applications in adaptive vehicle control systems. Bio-inspired actuators, which mimic natural mechanisms such as muscle movement and plant tropism, offer unique advantages such as flexibility, adaptability, and energy efficiency. The article categorizes these actuators based on their mechanisms, including shape memory alloys, dielectric elastomers, ionic polymer–metal composites, and soft pneumatic actuators. The review highlights the properties, operating principles, technical maturity, and potential applications for each mechanism in automotive systems. Additionally, it investigates current uses of these actuators in adaptive suspension, active steering, braking systems, and human–machine interfaces for autonomous vehicles. The review further outlines the advantages of bio-inspired actuators, including their energy efficiency and adaptability to road conditions, while addressing key challenges such as material limitations, response times, and integration with existing automotive control systems. Finally, the article discusses future directions, including the integration of bio-inspired actuators with machine learning and advancements in material science, to enable more efficient and responsive adaptive vehicle control systems. This review concludes that bio-inspired actuators will play a significant role in the future of the automotive industry, offering several advantages related to weight, power, flexibility, and cost when compared to conventional systems.
Mittal, VikramShah, RajeshRoshan, Mathew
New research studying shape memory alloys with AI may allow fighter jets to transform into the future with the help of new materials. Texas A&M University, College Station, TX In aerospace applications, high-temperature shape memory alloys (HTSMAs) - materials capable of remembering and returning to their original shapes after heating - are often constrained by high costs since they rely on expensive elements to function at elevated temperatures. Fighter jets like the F/A-18 need to fold their wings to fit on crowded aircraft carriers. The system that folds the wings relies on heavy mechanical parts. But with new lighter, smarter alloys, those movements could be done with less weight and more efficiency. That means more jets can be ready to fly, faster and with less energy wasted.
In aerospace applications, high-temperature shape memory alloys (HTSMAs) — materials capable of remembering and returning to their original shapes after heating — are often constrained by high costs since they rely on expensive elements to function at elevated temperatures.
University of California San Diego and CEA-Leti scientists have developed a ground-breaking piezoelectric-based DC-DC converter that unifies all power switches onto a single chip to increase power density. This new power topology, which extends beyond existing topologies, blends the advantages of piezoelectric converters with capacitive-based DC-DC converters.
Magneto-Rheological Fluid (MRF) is a smart material used in several applications for its ability to switch from fluid behaviour to solid-like conditions if a magnetic field is present. The dependency of viscosity on magnetic field makes this fluid suitable for braking system of electric vehicles, thanks to its high controllability and response time in the whole operative range. The main parameters that influence the behaviour of the fluid, and so the braking action of the system, are magnetic field and rotational velocity. In general, the variable physical properties make it complicated to simulate the system and its behaviour in different operating conditions. Therefore, it is usually necessary to build a physical prototype to experimentally verify the response of the braking system at different driving conditions. This paper presents the development of a virtual model of Magneto-Rheological Brakes (MRB) whose validity is extended to different driving conditions. This can be accomplished by creating two coupled model, an electro-magnetic and a fluid-dynamic, using respectively Ansys Electronics Desktop 2D Maxwell and Ansys Fluent. Both the models are validated by comparing the magnetic flux density and the braking torque obtained from the experimental test campaign of the braking system prototype at different coil currents. The simulation and experimental results present a good correlation and allow to evaluate a wide range of operative and driving conditions of the braking system. The validation allows to use the developed simulation methodology to design and to adapt the braking system to any other specific application.
De Luca, ElenaImberti, Giovannide Carvalho Pinheiro, HenriqueCarello, Massimiliana
Effective thermal management in battery packs is a key technology for enhancing the efficiency and longevity of battery electric vehicles (BEVs). Traditional active cooling systems can consume significant amounts of energy, thereby impacting the vehicle's overall efficiency. This paper explores the use of phase change materials (PCMs) as a complementary cooling technology, enabling both an improved active and an extended passive conditioning of battery packs. By leveraging the unique properties of PCMs, it is possible to partially operate the battery system without active cooling, thus reducing the overall energy consumption and improving vehicle autonomy. The phase change phenomenon further offers the benefit of a homogeneous temperature distribution within the battery pack. This study addresses the potential of PCMs as a thermal management solution for battery packs by firstly identifying suitable materials meeting requirements specific to such application. In addition, the paper investigates the expected benefits of such a cooling strategy by employing a dedicated modeling approach considering heat generation and distribution for analyzing the thermal behavior of an exemplary battery pack. We compare the thermal behavior to the case of polyurethane foams typically utilized as an intercell material. For the PCM identified as most suitable in this study, we find an increase of the operation time without the need for active cooling of up to 80 % in the framework of consecutive WLTP cycles. The contribution discusses challenges and potential drawbacks of integrating solid-solid and solid-liquid PCMs into battery packs, regarding pack weight, costs as well as the impact on thermal propagation and pack design related to the volumetric expansion of the PCM. Through this, the paper aims to provide a comprehensive understanding of the feasibility and implications of using PCMs as a complementary solution on the path to highly efficient battery pack thermal management.
Fandakov, AlexanderNolte, OliverHerzog, AlexanderSens, Marc
Aerospace & Defense Technology: September 202525AERP099/4/2025
Redefining Modern US Navy Shipbuilding with Additive Manufacturing Physical Designs by Artificial Intelligence Quality by Design: Imperatives for Aerospace and Defense Manufacturing Balancing Cost, Performance and Weight in Designing UAVs The Future of EMI Shielding Is Lightweight, Flexible, and Ready for Flight FibreCoat's New Radar-Absorbing 'Stealth' Fiber Reinforced Composites for Spacecraft, Aircraft and Tanks How Airbus is Designing the Future of Combat Aircraft Cockpit Avionics The multinational EPIIC programme, involving Airbus Defence and Space, is exploring multiple exciting innovations to strengthen Europe's defense capabilities and technological sovereignty New Drone Will Mimic Albatross Flight Mathematician hopes to harness principles of dynamic soaring for long-distance flights. Uncrewed Solar Aircraft Passes Key Ground Tests The German Aerospace Center's (DLR) solar-powered high altitude platform (HAP) has completed ground vibration testing, in preparation for low altitude flight testing planned for 2026. New 3D Chips Could Make Electronics Faster and More Energy-Efficient A new low-cost, scalable technology can seamlessly integrate high-speed gallium nitride transistors onto a standard silicon chip. New Cryogenic Shape Memory Alloy Designed for Outer Space A new study analyzes the use of shape memory alloys in developing thermally driven actuators for spacecraft operating space exploration missions.
A study led by Tohoku University, Iwate University, The Japan Aerospace Exploration Agency (JAXA), National Astronomical Observation of Japan, Tokyo City University, and Kyoto University developed a novel copper-based alloy that exhibits a special shape memory effect at temperatures as low as -200 °C. Shape memory alloys can be deformed into different shapes when cold, but will revert back to their original shape when heated (as if “remembering” their default state, like memory foam). This exciting new alloy has the potential to be used for space equipment and hydrogen-related technologies, where challenging, cold environments below -100 °C are the norm.
A new study analyzes the use of shape memory alloys in developing thermally driven actuators for spacecraft operating space exploration missions. Tohoku University, Sendai City, Japan A study led by Tohoku University, Iwate University, The Japan Aerospace Exploration Agency (JAXA), National Astronomical Observation of Japan, Tokyo City University, and Kyoto University developed a novel copper-based alloy that exhibits a special shape memory effect at temperatures as low as −200 °C. Shape memory alloys can be deformed into different shapes when cold, but will revert back to their original shape when heated (as if “remembering” their default state, like memory foam). This exciting new alloy has the potential to be used for space equipment and hydrogen-related technologies, where challenging, cold environments below −100 °C are the norm. Previously studied shape memory alloys using Ni-Ti could not maintain their shape memory ability below −20 °C, despite their otherwise practical characteristics. In contrast, the known existing shape memory alloys that can actually operate below −100 °C aren't suitable for practical implementation. This study met the challenge of finding the first functional actuator material capable of large work output at temperatures below −100 °C. Actuators are components that turn some sort of input into mechanical energy (movement). They can be found not only in machines bound for outer space, but in everyday devices all around us.
A team of UCLA engineers and their colleagues have developed a new design strategy and 3D printing technique to build robots in one single step. The breakthrough enabled the entire mechanical and electronic systems needed to operate a robot to be manufactured all at once by a new type of 3D printing process for engineered active materials with multiple functions (also known as metamaterials). Once 3D printed, a “meta-bot” will be capable of propulsion, movement, sensing, and decision-making.
The power assist system of an electric bicycle uses a magnetostrictive torque sensor to detect the pedal force based on the magnetic properties of the crankshaft, which change according to stress. Fe–Ni alloy plating is used to coat the surface of the crankshaft with a magnetic film to enhance the magnetostrictive effect. However, the sensor performance decreases as the plating solution degrades, which necessitates replacement of the plating solution. In this study, experiments were performed to investigate how to prevent or mitigate degradation of the plating solution to reduce waste. The amounts of carbon and sulfur in the magnetic film were found to increase with degradation of the plating solution. The carbon derived from organic reducing agents and their decomposition products, and the sulfur derived from stress relievers and their decomposition products. A method was developed for reducing the amounts of carbon and sulfur in the magnetic film, which would help maintain the sensor performance and thus reduce the waste of plating solution.
Ohnishi, Hiromichi
The use of lithium-ion batteries in electric vehicles marks a major progression in the automotive sector. Energy storage systems extensively make use of these batteries. The extended life cycle, low self-discharge rates, high energy density, and eco-friendliness of lithium-ion batteries are well-known. However, Temperature sensitivity has an adverse effect on lithium-ion battery safety, durability, and performance. Thus, maintaining ideal operating conditions and reducing the chance of thermal runaway depend heavily on efficient thermal management. To address this, experimental study was conducted on various battery thermal management techniques, including active, passive, and hybrid approaches. These techniques were investigated for their cooling efficiencies under different operating conditions. The electro-thermal behavior of cylindrical lithium-ion battery cells, battery packs, and supervisory control techniques were simulated in the study using MATLAB Simulink, Simscape, and Stateflow. This experimental study was conducted on thermal conductivity of Liquid Cooling (LC), Air Cooling (AC), Heat Pipe (HP), and Phase Change Material (PCM) techniques and evaluated the thermal performance of both individual and hybrid thermal management techniques according to the C rate of the battery. The Simulation results were analyzed under high-power charging and discharging conditions typical of electric vehicles. The investigation identified that, active thermal management techniques can reduce the temperature rise during the deep discharging cycle. However, not all driving situations and environmental factors call for active cooling. For modest vehicle speeds and regular ambient temperatures, passive cooling is adequate. The experimental analysis indicates that, hybrid thermal management strategies offer a better trade-off between energy efficiency and effective thermal conductivity depending on runtime requirements.
Thangaraju, ShanmuganathanN, MeenakshiGanesan, Maragatham
Research engineers are developing smart implants that can both monitor and promote healing in fractured bones. When installed at the fracture site, these implants, which are constructed using shape memory alloys, can stiffen or relax in a continuously controlled manner that optimizes bone healing.
This study investigates the influence of magnetorheological (MR) dampers in semi-active suspension systems (SASSs) on ride comfort, vehicle stability, and overall performance. Semi-active suspension systems achieve greater flexibility and efficacy by combining MR dampers with the advantages of active and passive suspension systems. The study aims to measure the benefits of MR dampers in improving ride comfort, vehicle stability, and overall system performance. The dynamic system model meets all required performance criteria. This study demonstrates that the proposed artificial intelligence approach, including a fuzzy neural networks proportional-integral-derivative (FNN-PID) controller, significantly enhances key performance criteria when tested under various road profiles. The control performance requirements in engineering systems are evaluated in the frequency and time domains. A quarter-car model with two degrees of freedom (2 DOF) was simulated using MATLAB/Simulink to assess the suggested controller’s performance. The enhanced FNN-PID controller greatly increases ride comfort and vehicle stability when compared to fuzzy neural networks based on PID control strategies proposed, passive suspension systems, uncontrolled MR suspension, and PID controller, according to analysis of the simulated preliminary data. The algorithms' performance is evaluated using a wide range of crucial performance criteria, such as the suspension working space, body mass acceleration, dynamic tire load, and desired force. The phase plane method is used to evaluate system stability. The results clearly show that the proposed controller for the SASS significantly enhances both road holding and ride comfort, highlighting its strong potential for real-world applications.
M.Faragallah, MohamedMetered, HassanAbdelghany, M.A.Essam, Mahmoud A.
Electric vehicles (EVs) are gaining popularity due to their zero tailpipe emissions, superior energy efficiency, and sustainable nature. EVs have various limitations, and crucial one is the occurrence of thermal runaway in the battery pack. During charging or discharging condition of battery pack may result in thermal runaway condition. This promotes the requirement of effective cooling arrangement in and around the battery pack to avoid localized peak temperature. In the present work, thermal management of a 26650 Lithium iron phosphate (LFP) cell using natural convection air cooling, composite biobased phase change material (CBPCM) and its combination with copper fins is numerically investigated using multi-scale multi dimension - Newman, Tiedenann, Gu and Kim (MSMD-NTGK) battery model in Ansys Fluent at an ambient temperature of 306 K. Natural convection air cooling was found effective at discharge rates of 1C to 3C, maintaining cell temperature below the safe limit of 318 K for 80% DoD. However, the temperatures increased to 321.7 K and 325.4 K for 4C and 5C discharge rates respectively which indicating the inadequacy of natural convection air cooling for high-powered electric vehicles. 4 mm thick layer of CBPCM reduced the average cell surface temperatures to 312.7 K and 314.8 K for 4C and 5C discharge rates, respectively, while the integration of fins further reduced the temperatures to 310.7 K and 311.5 K. This reduction is due to the enhanced latent heat absorption of CBPCM and improved thermal conductivity provided by the fins. Overall, CBPCM combined with fins proved to be a more effective thermal management strategy than natural convection air cooling and standalone CBPCM.
Srivastav, DurgeshPatil, Nagesh DevidasShukla, Pravesh Chandra
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, heat absorption and release time as optimization objectives. This model can utilize lower simulation calculation costs to obtain a continuous mapping relationship between optimization objectives and design variables within a certain range, and has high accuracy and reliability. The fitted design variable distribution surface is used to select any number of design points for verification. The deviation between prediction results and simulation results is less than 4%. Compared with the original design, the optimized design can not only achieve appropriate heat exchange efficiency according to requirements, but also extend the effective heat dissipation time, making the heat dissipation process more stable. The structural optimization method outlined in this paper offers a cost-effective approach to accurate prediction results, demonstrating practical engineering implications for the design of phase change energy storage devices and thermal management of electric vehicle batteries.
Zhang, HaonanSun, MingzheZheng, HaoyunZhang, Tianming
Researchers have developed a multifunctional sensor based on semiconductor fibers that emulates the five human senses. Prof. Bonghoon Kim, department of robotics and mechatronics engineering of Daegu Gyeongbuk Institute of Science & Technology (DGIST), conducted the study in collaboration with Prof. Sangwook Kim at KAIST, Prof. Janghwan Kim at Ajou University, and Prof. Jiwoong Kim at Soongsil University. The technology developed in the study is expected to be utilized in fields such as wearables, Internet of Things (IoT), electronic devices, and soft robotics.
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 composite PCM demonstrates superior performance, surpassing paraffin wax by 1.35 times durin g heating and 1.5 times during cooling, while maintaining similar peak temperatures. The normalized enthalpy of the composite PCM exceeds that of paraffin wax by 1.25 times, highlighting enhanced energy storage capacity. The significant enhancements in thermal conductivity and phase change behavior are attributed to the presence of aluminum oxide and copper oxide nanoparticles. Notably, an optimized composition comprising 96.15% paraffin wax, 2.15% aluminum oxide, and 1.7% copper oxide Considered by mass demonstrates a delicate balance between improved thermal properties and material stability. This study underscores the immense promise of nanoparticles – enhanced composite PCMs as a transformative solution for enhancing thermal energy storage efficiency, with implications for sustainable energy technologies. The results shows that the thermal conductivity improved by 48% and the enthalpy increased by 25%.
Tarigonda, HariprasadKumar, YB KishoreKala, Lakshmi KR L, Krupakaran
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 32.97%, respectively.
R L, KrupakaranSagaya Raj, GnanaPetla, Ratna KamalaKala, Lakshmi KAnchupogu, Praveen
Electric vehicles (EVs) are a clean, sustainable alternative to conventional internal combustion engines representing a paradigm shift in the transportation sector. Electric vehicles (EVs) have significantly improved in performance in battery technology. With the rapid proliferation of Electric Vehicles (EVs), effective Battery Thermal Management Systems (BTMS) are essential to ensure optimal performance and longevity of the battery packs. This study aims to investigating the effect of Phase Change Materials (PCM) in a hybrid cooling of liquid cold plate with battery pack. With the rapid proliferation of Electric Vehicles (EVs), effective Battery Thermal Management Systems (BTMS) are essential to ensure optimal performance and longevity of the battery packs. This study aims to investigating the effect of Phase Change Materials (PCM) in a hybrid cooling of a liquid cold plate with the battery pack. In models of battery cell arrangement of 5x13 arrays of aligned modules with the PCM and liquid cold plates (LCPs) with tube orientation which covers a battery pack's top and bottom. Each cell is depicted as a cylinder housed within a case equipped with a hybrid cooling system. In the computational model of the 25 Ah, 48 V battery pack, the battery produces a total of 1200 WH of energy. The battery pack in a box that was simulated by (Fusion 360 and Creo Parametric) the CFD – Ansys. The ABS plastic case prioritizes airflow by incorporating openings on opposing sides for air inlet and outlet. The system utilized two rectangular Liquid Cooling Plates (LCPs) made from Al 3003 alloy. Water-ethylene glycol solution and graphene nano platelets (0.1% vol) have been used as the coolants while passing the LCP. It was found those 600 seconds, 300K and maximum of heat 237.76 kJ can be absorbed by the phase change material at a discharge rate of 2C. The best cooling effect was achieved with the hybrid cooling system the maximum battery temperature was limited to 34.326°C.
S, PalanisamySelvan, Arul Mozhi
Researchers have developed a three-dimensional stretchable piezoelectric energy harvester that can harvest electrical energy using body movements. The device is to be used as a wearable energy harvester as it can be attached to the skin or clothes.
Researchers have helped create a new 3D printing approach for shape-changing materials that are likened to muscles, opening the door for improved applications in robotics as well as biomedical and energy devices.
The integration of phase change materials (PCMs) with thermoelectric generators (TEGs) presents a solution to the challenge of unstable output resulting from fluctuations in the heat source. This study involved the establishment of an experimental test setup for PCM-TEG system to examine the impact of heat source power on the thermoelectric performance of PCM-TEG system. The results suggest that incorporating PCM effectively mitigates output voltage fluctuations, while higher heating power levels correspond to a notable extension in effective operational duration. In situations of low heat source power, incomplete PCM melting may lead to a significant decline in electricity generation during non-heating stages. Notably, the electricity generation during non-heating stages at 90 W heating power surpasses that at 30 W heating power by a factor of 11.78. Furthermore, the electricity generated during non-heating stages contributes to 22.4% of the total electricity generation. These findings have instructive implications for the development of PCM-TEG systems.
Tian, MengWu, FengyuZuo, AoXuan, ZhiweiZhao, Yulong
With the rapid development of new energy vehicles, lithium-ion batteries (LIBs) have been widely used in the automotive sector. The performance and safety of LIBs in electric vehicles (EVs) are significantly influenced by operating temperature, making the development of an effective battery thermal management system (BTMS) crucial. In recent years, phase change material (PCM)-based BTMS technology has been recognized as one of the most promising solutions. Compared to traditional air and liquid cooling systems, PCM cooling technology exhibits superior cooling performance due to its large latent heat and efficient heat dissipation capabilities, while also eliminating the need for additional pump power consumption. Therefore, in-depth research on PCM cooling technology is of significant academic and practical value for enhancing the effectiveness and safety of power battery thermal management. This study investigates the effects of thermal conductivity, melting point, and thickness of composite phase change materials (CPCM) on the transient temperature of cylindrical lithium-ion battery 18650 under high discharge rates (5C) through numerical simulations. The findings indicate that: (1) The thermal conductivity significantly impacts the melting rate of CPCM and the surface temperature of the battery; increasing thermal conductivity beyond 3.5 W/(m·K) shows negligible improvement in cooling effectiveness. (2) The selection of melting point directly affects the battery temperature rise; CPCMs with lower melting points effectively prolong melting time, maintaining the battery temperature close to the melting point. (3) The thickness of CPCMs also significantly influences thermal management; in this case, a thickness of 3-4 mm has been proven adequate to meet the thermal regulation requirements of the battery under harsh conditions. This research provides a theoretical basis for the application of CPCM in battery thermal management.
Lv, Kang-MinSu, Chu-QiWang, Yi-PingYuan, Xiao-HongLiu, Xun
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% H2O may result in stable phase change behavior and moderate temperature change, increasing versatility.
Vasanthkumar, P.Santhoshkumar, A.Gopika, P.Murali, M.Meera, C.
A lightning strike during raining season causes significant risks to automobiles, especially modern vehicles mostly dependent on electronic systems. Lightning can cause severe damage to electronic control unit that control the vehicle functions such as engine management, electrical circuits with sensors, braking systems, and safety features. Therefore, this research work focused for developing new electrical polymers with better conductive properties that would create a path for lightning to travel without damaging it. In-situ chemical oxidative polymerization was used to develop a new series of functional electroactive nanocomposites based on silver nanoparticles embedded poly (aniline-co-3-chloroaniline) matrix. Here we would suggest these electroactive polymers can be widely used as additive in paint manufacturing as special coatings in automobiles industry. Because of the internal chemical bonds and internal structure of these materials acts as a semiconducting nature, hence they attenuate the high energy from lightning and dissipation; therefore, it acts as a protective barrier. In order to investigate these copolymer nanocomposites, FTIR, UV-visible spectroscopy, X-ray diffraction (XRD), scanning electron microscopy (SEM), and a conventional four probe conductivity approach were all used. X-ray diffraction ( XRD) reveals the crystalline nature of copolymer. Surface morphological studies exhibit nanoneedle or nanotube or even nanorod like appearance with average particle size of 150-300 nm. During lightning, the prepared polymer composites have the capacity to absorb and transfer extremely high voltage. In order to safeguard vehicles during strong storms, these kinds novel materials ought to possess good applications in automobile industries.
Pachanoor, VijayanandMoorthi, Bharathiraja
Researchers have successfully demonstrated the four-dimensional (4D) printing of shape memory polymers in submicron dimensions that are comparable to the wavelength of visible light. 4D printing enables 3D-printed structures to change their configurations over time and is used in a variety of fields such as soft robotics, flexible electronics, and medical devices.
Researchers have now developed the first hydrogel implant designed for use in fallopian tubes. This innovation performs two functions: one is to act as a contraceptive, the other is to prevent the recipient from developing endometriosis in the first place or to halt the spread if they do.
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