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Polymers Jun 2024Traditional metal-plastic dissimilar welding methods directly heat the metal workpiece, which may cause potential thermal damage to the metal workpiece. Ultrasonic...
Traditional metal-plastic dissimilar welding methods directly heat the metal workpiece, which may cause potential thermal damage to the metal workpiece. Ultrasonic extruded weld-riveting (UEWR) is a relatively new method for dissimilar joining of carbon fiber-reinforced thermoplastic (CFRTP) and metal. In this method, the CFRTP workpiece is melted using the ultrasonic effect and is squeezed into prefabricated holes in the metal workpiece to form a rivet structure. In this method, the metal workpiece is not directly heated, and potential high-temperature losses can be avoided. This paper investigates the process characterizations of UERW of AZ31B magnesium alloy to carbon fiber-reinforced PA66. The process parameters are optimized by the Taguchi method. The joint formation process is analyzed based on the fiber distribution in the cross-sections of joints. The effects of welding parameters on the joint microstructure and fracture surface morphology are discussed. The results show that a stepped amplitude strategy (40 μm amplitude in the first stage and 56 μm amplitude in the second stage) could balance the joint strength and joint appearance. Insufficient (welding energy < 2600 J or amplitude-A < 50%) or excessive (welding energy > 2800 J or amplitude-A > 50%) welding parameters lead to the formation of porous defects. Three fracture modes are identified according to the fracture surface analysis. The maximum tensile shear strength of joints at the optimal parameters is about 56.5 ± 6.2 MPa.
PubMed: 38932099
DOI: 10.3390/polym16121749 -
Sensors (Basel, Switzerland) Jun 2024Lithium, a critical natural resource integral to modern technology, has influenced diverse industries since its discovery in the 1950s. Of particular interest is...
Lithium, a critical natural resource integral to modern technology, has influenced diverse industries since its discovery in the 1950s. Of particular interest is lithium-7, the most prevalent lithium isotope on Earth, playing a vital role in applications such as batteries, metal alloys, medicine, and nuclear research. However, its extraction presents significant environmental and logistical challenges. This article explores the potential for lithium exploration on the Moon, driven by its value as a resource and the prospect of cost reduction due to the Moon's lower gravity, which holds promise for future space exploration endeavors. Additionally, the presence of lithium in the solar wind and its implications for material transport across celestial bodies are subjects of intrigue. Drawing from a limited dataset collected during the Apollo missions (Apollo 12, 15, 16, and 17) and leveraging artificial intelligence techniques and sample expansion through bootstrapping, this study develops predictive models for lithium-7 concentration based on spectral patterns. The study areas encompass the Aitken crater, Hadley Rima, and the Taurus-Littrow Valley, where higher lithium concentrations are observed in basaltic lunar regions. This research bridges lunar geology and the formation of the solar system, providing valuable insights into celestial resources and enhancing our understanding of space. The data used in this study were obtained from the imaging sensors (infrared, visible, and ultraviolet) of the Clementine satellite, which significantly contributed to the success of our research. Furthermore, the study addresses various aspects related to statistical analysis, sample quality validation, resampling, and bootstrapping. Supervised machine learning model training and validation, as well as data import and export, were explored. The analysis of data generated by the Clementine probe in the near-infrared (NIR) and ultraviolet-visible (UVVIS) spectra revealed evidence of the presence of lithium-7 (Li-7) on the lunar surface. The distribution of Li-7 on the lunar surface is non-uniform, with varying concentrations in different regions of the Moon identified, supporting the initial hypothesis associating surface Li-7 concentration with exposure to solar wind. While a direct numerical relationship between lunar topography and Li-7 concentration has not been established due to morphological diversity and methodological limitations, preliminary results suggest significant economic and technological potential in lunar lithium exploration and extraction.
PubMed: 38931715
DOI: 10.3390/s24123931 -
Sensors (Basel, Switzerland) Jun 2024Integrated thin film-based shape memory polyimide composites (SMPICs) are potentially attractive for efficient and compact design, thereby offering cost-effective...
Integrated thin film-based shape memory polyimide composites (SMPICs) are potentially attractive for efficient and compact design, thereby offering cost-effective applications. The objective of this article is to design and evaluate a mirror manipulator using an SMPIC as an actuator and a sensor with control. A sensor-less control strategy using the SMPIC (a self-sensing actuator) with a proportional derivative combined variable structure controller (PD-VSC) is proposed for position control of the mirror in both the vertical and angular directions. The mirror manipulator is able to move the mirror in the vertical and angular directions by 3.39 mm and 10.5 deg, respectively. A desired fast response is obtained as the performance under control. In addition, some benefits from the proposed control realization include good tracking, stable switching, no overshoot, no steady state oscillations, and robust disturbance rejection. These superior properties are experimentally validated to reflect practical feasibility.
PubMed: 38931697
DOI: 10.3390/s24123910 -
Sensors (Basel, Switzerland) Jun 2024Piezoelectric materials, which exhibit a charge distribution across the surfaces in reaction to mechanical strain, find significant utility in actuation and sensing...
Piezoelectric materials, which exhibit a charge distribution across the surfaces in reaction to mechanical strain, find significant utility in actuation and sensing applications. Apart from actuation applications like acoustic devices, motors, and vibration damping, an emerging domain for ultrasonic actuators lies in additive manufacturing processes. Ultrasonic waves applied during solidification aim to modulate grain structure and minimize defects. This research focuses on a fixture designed to facilitate and optimize ultrasonic wave propagation through the build plate in laser powder bed fusion additive manufacturing by utilizing a piezoelectric transducer. Three implementations of piezoelectric transducers were evaluated based on their out-of-plane ultrasonic velocity transmissions. It was determined that a thin plate adhered to the surface of the piezoelectric transducer yielded the most favorable outcomes for implementation, achieving 100% transmission of velocity and energy. Preliminary analysis of melt pool morphology and defects in single-track laser scanning experiments demonstrated the impact of ultrasound on solidification, hinting at a novel approach to enhancing the printability of alloys in laser powder bed fusion additive manufacturing processes. The optimal fixture and the explored transducing efficiency could further guide advanced ultrasound testing to enable in situ defect and texture detection during the additive manufacturing processes.
PubMed: 38931488
DOI: 10.3390/s24123704 -
Molecules (Basel, Switzerland) Jun 2024The aerobic oxidation of 5-hydroxymethylfurfural (HMF) to 2,5-furandicarboxylic acid (FDCA) plays a pivotal role in the synthesis of renewable, biodegradable plastics...
The aerobic oxidation of 5-hydroxymethylfurfural (HMF) to 2,5-furandicarboxylic acid (FDCA) plays a pivotal role in the synthesis of renewable, biodegradable plastics and sustainable chemicals. Although supported gold nanoclusters (NCs) exhibit significant potential in this process, they often suffer from low selectivity. To address this challenge, a series of gold-M (M means Ni, Fe, Cu, and Pd) bimetallic NCs catalysts were designed and synthesized to facilitate the selective oxidation of HMF to FDCA. Our findings indicate that the introduction of doped metals, particularly Ni and Pd, not only improves the reaction rates for HMF tandem oxidation but also promotes high yields of FDCA. Various characterizations techniques, including X-ray diffraction (XRD), transmission electron microscopy (TEM), X-ray photoelectron spectroscopy (XPS), in situ diffuse reflectance infrared Fourier transform spectroscopy of CO adsorption (CO-DRIFTS), and temperature-programmed desorption of oxygen (O-TPD), were employed to scrutinize the structural and electronic properties of the prepared catalysts. Notably, an electronic effect was observed across the Au-based bimetallic catalysts, facilitating the activation of reactant molecules and enhancing the catalytic performance. This study provides valuable insights into the alloy effects, aiding in the development of highly efficient Au-based bimetallic catalysts for biomass conversions.
PubMed: 38930789
DOI: 10.3390/molecules29122724 -
Micromachines Jun 2024In this study, CoCrMo cuboid samples were deposited on a CuZrCr substrate using laser powder bed fusion (L-PBF) technology to investigate the influence of process...
In this study, CoCrMo cuboid samples were deposited on a CuZrCr substrate using laser powder bed fusion (L-PBF) technology to investigate the influence of process parameters and laser remelting strategies on the mechanical properties and interface characteristics of multi-metals. This study found that process parameters and laser scanning strategies had a significant influence on the mechanical properties and interface characteristics. Samples fabricated with an EV ≤ 20 J/mm showed little tensile ductility. As the volumetric energy density (EV) increased to a range between 40 J/mm and 100 J/mm, the samples achieved the desired mechanical properties, with a strong interface combining the alloys. However, an excessive energy density could result in cracks due to thermal stress. Laser remelting significantly improved the interface properties, especially when the EV was below 40 J/mm. Variances in the EV showed little influence on the hardness at the CuZrCr end, while the hardness at the interface and the CoCrMo end showed an increasing and decreasing trend with an increase in the EV, respectively. Interface characterization showed that when the EV was greater than 43 J/mm, the main defects in the L-PBF CoCrMo samples were thermal cracks, which gradually changed to pores with a lack of fusion when the EV decreased. This study provides theoretical and technical support for the manufacturing of multi-metal parts using L-PBF technology.
PubMed: 38930735
DOI: 10.3390/mi15060765 -
Micromachines May 2024The technology to jet print metal lines with precise shape fidelity on diverse substrates is gaining higher interest across multiple research fields. It finds...
The technology to jet print metal lines with precise shape fidelity on diverse substrates is gaining higher interest across multiple research fields. It finds applications in additively manufactured flexible electronics, environmentally friendly and sustainable electronics, sensor devices for medical applications, and fabricating electrodes for solar cells. This paper provides an experimental investigation to deepen insights into the non-contact printing of solder lines using StarJet technology, eliminating the need for surface activation, substrate heating, curing, or post-processing. Moreover, it employs bulk metal instead of conventional inks or pastes, leading to cost-effective production and enhanced conductivity. The effect of molten metal temperature, substrate temperature, standoff distance, and printing velocity was investigated on polymer foils (i.e., PET sheets). Robust printing parameters were derived to print uniform, bulge-free, bulk metal lines suitable for additive manufacturing applications. The applicability of the derived parameters was extended to 3D-printed PLA, TPU, PA-GF, and PETG substrates having a much higher surface roughness. Additionally, a high aspect ratio of approx. 16:1 wall structure has been demonstrated by printing multiple metal lines on top of each other. While challenges persist, this study contributes to advancing additively manufactured electronic devices, highlighting the capabilities of StarJet metal jet-printing technology.
PubMed: 38930714
DOI: 10.3390/mi15060743 -
Micromachines May 2024Magnetic abrasive finishing (MAF) is an efficient finishing process method using magnetic abrasive particles (MAPs) as finishing tools. In this study, two iron-based...
Magnetic abrasive finishing (MAF) is an efficient finishing process method using magnetic abrasive particles (MAPs) as finishing tools. In this study, two iron-based alumina magnetic abrasives with different particle size ranges were synthesized by the plasma molten metal powder and powder jetting method. Characterization of the magnetic abrasives in terms of microscopic morphology, phase composition, magnetic permeability, particle size distribution, and abrasive ability shows that the magnetic abrasives are spherical in shape, that the hard abrasives are combined in the surface layer of the iron matrix and remain sharp, and that the hard abrasives combined in the surface layer of the magnetic abrasives with smaller particle sizes are sparser than those of the magnetic abrasives with larger particle sizes. The magnetic abrasives are composed of α-Fe and AlO; the magnetic permeability of the magnetic abrasives having smaller particle sizes is slightly higher than that of the magnetic abrasives having larger particle sizes; the two magnetic abrasives are distributed in a range of different particle sizes; the magnetic abrasives have different magnetic permeabilities, which are higher than those of the larger ones; both magnetic abrasives are distributed in the range of smaller particle sizes; and AZ31B alloy can obtain smaller surface roughness of the workpiece after the grinding process of the magnetic abrasives with a small particle size.
PubMed: 38930679
DOI: 10.3390/mi15060709 -
Micromachines May 2024Enhancing the operational efficacy of electrical discharge machining (EDM) is crucial for achieving optimal results in various engineering materials. This study...
Enhancing the operational efficacy of electrical discharge machining (EDM) is crucial for achieving optimal results in various engineering materials. This study introduces an innovative solution-the use of coated electrodes-representing a significant advancement over current limitations. The choice of coating material is critical for micro-EDM performance, necessitating a thorough investigation of its impact. This research explores the application of different coating materials (AlCrN, TiN, and Carbon) on WC electrodes in micro-EDM processes specifically designed for Ti-6Al-4V. A comprehensive assessment was conducted, focusing on key quality indicators such as depth of cut (Z), tool wear rate (TWR), overcut (OVC), and post-machining surface quality. Through rigorous experimental methods, the study demonstrates substantial improvements in these quality parameters with coated electrodes. The results show significant enhancements, including increased Z, reduced TWR and OVC, and improved surface quality. This evidence underscores the effectiveness of coated electrodes in enhancing micro-EDM performance, marking a notable advancement in the precision and quality of Ti-6Al-4V machining processes. Among the evaluated coatings, AlCrN-coated electrodes exhibited the greatest increase in Z, the most significant reduction in TWR, and the best OVC performance compared to other coatings and the uncoated counterpart.
PubMed: 38930662
DOI: 10.3390/mi15060692 -
Micromachines May 2024Anodic aluminum oxide (AAO) has been widely applied for the surface protection of electronic component packaging through a pore-sealing process, with the enhanced...
Anodic aluminum oxide (AAO) has been widely applied for the surface protection of electronic component packaging through a pore-sealing process, with the enhanced hardness value reaching around 400 Vickers hardness (HV). However, the traditional AAO fabrication at 0~10 °C for surface protection takes at least 3-6 h for the reaction or other complicated methods used for the pore-sealing process, including boiling-water sealing, oil sealing, or salt-compound sealing. With the increasing development of nanostructured AAO, there is a growing interest in improving hardness without pore sealing, in order to leverage the characteristics of porous AAO and surface protection properties simultaneously. Here, we investigate the effect of voltage on hardness under the same AAO thickness conditions in oxalic acid at room temperature from a normal level of 40 V to a high level of 100 V and found a positive correlation between surface hardness and voltage. The surface hardness values of AAO formed at 100 V reach about 423 HV without pore sealing in 30 min. By employing a hybrid pulse anodization (HPA) method, we are able to prevent the high-voltage burning effect and complete the anodization process at room temperature. The mechanism behind this can be explained by the porosity and photoluminescence (PL) intensity of AAO. For the same thickness of AAO from 40~100 V, increasing the anodizing voltage decreases both the porosity and PL intensity, indicating a reduction in pores, as well as anion and oxygen vacancy defects, due to rapid AAO growth. This reduction in defects in the AAO film leads to an increase in hardness, allowing us to significantly enhance AAO hardness without a pore-sealing process. This offers an effective hardness enhancement in AAO under economically feasible conditions for the application of hard coatings and protective films.
PubMed: 38930653
DOI: 10.3390/mi15060683