Search Results (288)

The present study deals with the problem of irregular temperature distribution, simultaneous under-firing and over-firing, and their resultant efficiency and quality problems in a mechanical lime vertical kiln powered by domestic waste flue gas. The numerical simulation and structure optimization were carried out based on a 150 kg/h pilot-scale kiln. This combined model was built on the ANSYS Fluent 2022 R1 platform with UDF and UDS, incorporating limestone decomposition kinetics to enable the solution of gas and solid energy equations separately, and simulation of complex transfer and reaction processes. To correct the separation of flows at one inlet, a symmetric four-direction (00, 900, 1800, 2700) air intake plan was suggested. The findings show that this design essentially transforms the internal flow field into uniform and symmetrical temperature and concentration distributions. The calcination region contained both gas and solid temperatures in the optimum range to produce active lime. Specifically, the optimized kiln achieved a temperature range of 1190–1450 K in the calcination zone, a decomposition rate of approximately 82.7% (compared to 5.3% in the original model), and an increase in effective CaO content from 81.7% to 87.7%, with validation errors below 15%. It was demonstrated that the model is reliable, since the outlet simulated values correlated well with the measured ones. The preheating, calcining, and cooling zones’ heights of the optimized kiln adhered to the design requirements. This research is innovative in its application of a multi-physics coupling model with a varying heat source in a kiln and, in turn, identifies the synergism improvement process in the flow, temperature, concentration, and reaction fields. Full article

The influence of base plate temperature (25, 100, 200, and 400 °C) on the laser powder bed fusion processing of EN AW 7075 was systematically investigated using microstructural characterisation (LM, SEM, EBSD, GROD), chemical analysis, hardness testing, and thermal simulations across a broad range of process parameters. Moderate preheating at 100 °C and 200 °C showed no significant reduction in crack density or changes in grain morphology compared to processing without preheating. At the highest studied temperature—400 °C—a transition to columnar crack networks was observed, accompanied by modified grain orientation, pronounced stress relaxation, and reduced hardness. Independent of preheating temperature, consistent evaporation of Zn (~1 wt.%) and Mg (~0.3 wt.%) occurred during processing. Thermal simulations qualitatively supported the experimental observations, indicating increased thermal retention and displacement with increasing preheating temperature. The results demonstrate that base plate preheating alone is insufficient to suppress hot cracking in EN AW 7075 and may promote alternative crack-growth mechanisms at elevated temperatures, highlighting the need for alternative alloy or process design strategies. Full article

The Polyether ether ketone (PEEK) suffers from insufficient interlayer molecular chain diffusion and weak interfacial fusion during Fused Filament Fabrication (FFF) due to its high melt viscosity and rapid cooling characteristics, restricting the mechanical properties and engineering applications of printed parts. To improve the interlayer bonding quality of FFF-printed PEEK, an in situ preheating technology integrated into the print nozzle was proposed and implemented. Through a high-temperature controllable preheating system that moves synchronously with the nozzle, local precise heating is performed on the surface of the deposited layer to actively regulate the thermal history of the interlayer interface. Systematic studies on the effect of preheating temperature were conducted. The results show that the influence of preheating temperature on part performance follows a trend of first increasing and then decreasing. When the preheating temperature is 280 °C, the comprehensive performance of the specimens is optimal: the tensile strength reaches 69.47 MPa, which is 21.3% higher than that of the non-preheated reference group; the elongation at break is 71.07%; and the porosity decreases to 8.36%. Microstructural analysis reveals that moderate preheating facilitates molecular chain diffusion and interfacial fusion, whereas excessive heating induces thermal oxidative degradation of PEEK, resulting in deteriorated mechanical performance. These findings confirm that in situ preheating represents an effective approach for enhancing interlayer bonding, thereby offering a practical solution for the additive manufacturing of high-performance PEEK components. Full article

This study takes the commercial JG4246A cast Ni₃Al-based superalloy as the research object, under the conditions of preheating the mold shell at 1020 °C and a pouring temperature of 1520 °C, characteristic simulation castings were poured. The microstructure and room temperature mechanical properties of different modulus sections of the castings were systematically investigated. It was found that, except for the edge towards the middle section of the larger modulus, the cooling rates at the edge were greater than those at the middle sections. The cooling rate was the fastest at the upper-right corner section (referring to the castings position during pouring, the same below), and the grain is the finest (approximately 0.46 mm), with the highest strength (tensile strength approximately 698 MPa, yield strength approximately 581 MPa), while the cooling rate at the lower-middle section was the slowest, and the grain was the largest (approximately 1.55 mm), with the lowest strength (tensile strength approximately 612.5 MPa, yield strength approximately t 524.5 MPa); the difference in grain size between the two is nearly 237%. The MC carbides at the lower-edge middle section have the smallest size (approximately 3.0 μm) and the elongation rate in this area is the highest (approximately 8.7%), while the MC carbides at the lower-middle section have the largest size (approximately 5.8 μm) and the elongation rate in this area is the lowest (approximately 4.9%); the size difference in the MC carbides between two is nearly 94%. This study clarifies the quantitative correlation between cooling rate, microstructure and properties, providing clear guidelines for optimizing the casting process of high-temperature alloys and subsequent studies on the uniformity of microstructure. Full article

Wire-arc coatings have received substantial attention for corrosion protection; however, poor bonding often leads to delamination, corrosion initiation, and costly re-coating of structural components. This review combines bibliometric mapping with a focused technical synthesis to clarify how bonding performance has been studied in wire-arc coatings. Specifically, publication trends, keyword co-occurrence networks, and country-level co-authorship maps are used to map the evolution of the field and position adhesion-related studies within the broader literature. The analysis of 762 wire-arc coating publications from Web of Science (among 13,314 thermal spray coating records) reveals that research is centered on microstructure, mechanical properties, and corrosion resistance, with growing links to wire-based additive manufacturing. Keyword co-occurrence networks demonstrate clear process–structure–property relationships, while country-level collaboration maps highlight the leadership of China, the USA, and Germany. Critical to note, only eight publications systematically investigate the combined effects of substrate roughness, coating thickness, and Zn-Al coating composition on bond strength—representing less than 0.01% of the thermal spray literature. This pronounced research gap underscores the novelty of the present review, which synthesizes existing knowledge on adhesion mechanisms, identifies key process parameters, and establishes a research agenda to optimize wire-arc coatings for infrastructure corrosion protection. The technical synthesis highlights that adhesion is governed by the coupled effects of surface preparation (roughness and topography), coating build-up (thickness), and spray conditions (e.g., standoff distance and substrate preheating), which together influence coating microstructure and failure modes. These findings provide a structured framework to guide parameter selection for durable coatings. Full article

Al/Mg bimetallic composites have drawn considerable attention for their promising lightweight applications in sectors such as the aerospace and automotive industries. In these systems, the interfacial behavior critically governs the overall performance and reliability. In this research, the molecular dynamics (MD) simulation was employed to systematically study the effects of pouring temperatures (923 K, 973 K, and 1023 K) and preheating temperatures (373 K, 473 K, and 573 K) on the interfacial diffusion behavior and fracture mechanism of the polycrystalline Al/Mg bimetallic system. The results indicate that the influencing rule of pouring temperatures and preheating temperatures on the interfacial diffusion behavior is consistent. Specifically, the diffusion coefficient of Mg atoms is higher than that of Al atoms, while the diffusion distance of Al atoms is significantly greater than that of Mg atoms. As the temperature increases, the thickness of the interfacial transition layer correspondingly rises. However, the effects of these two parameters on tensile fracture behavior demonstrate notable discrepancies. Specifically, the fracture mode evolves with pouring temperature, transitioning from being mediated solely by dislocations to being co-mediated by twins and dislocations. In contrast, the fracture mechanism remains solely dislocation-controlled, regardless of the preheating temperature. In addition, all the models fractured at the interface between the diffusion layer and the Mg matrix. The optimal tensile strength of 1.850 GPa was achieved at a pouring temperature of 923 K and a preheating temperature of 473 K, representing an improvement of approximately 52% compared to the lowest value recorded in the study. This research offers significant theoretical insights for the rational optimization of preparation parameters and an in-depth understanding of fracture mechanisms in Al/Mg bimetallic systems. Full article

This study employed cold metal transfer (CMT) welding technology to repair defects in ZL114A aluminum alloy, investigating the influence of key repair welding parameters (preheating temperature, overlap amount, wire feed speed, welding speed) and ultimately obtaining defect-free repaired joints with relatively high tensile strength. Using a single-layer, single-pass bead-on-plate method, the effects of wire feed speed and welding speed on the spreading behavior of ZL114A melt on the substrate surface were studied. Through a two-pass, single-layer welding method, the influence of inter-pass overlap amount on the morphology of overlap welds was investigated. The effects of preheating temperature on the morphology, microstructure, and mechanical properties of the repaired specimens were examined by repair welding experiments on spherical crown grooves. The results indicate that to achieve favorable spreading of ZL114A droplets on the base material surface, the welding speed should be greater than 5 mm/s, and the wire feed speed should be within 7–9 m/min. When the overlap amounts are 65%, 70%, 75%, and 80%, the overlap welds are relatively flat, and lack-of-fusion defects are less likely to occur between the two weld passes. As the preheating temperature increases, the porosity defect rate in the repair weld decreases significantly, and the average grain size in the repair zone shows an increasing trend. The average grain size at the center of the repair weld is larger than that in the fusion zone. When the preheating temperature is 350 °C, no obvious porosity defects are observed in the repair weld. The proportion of high-angle grain boundaries increases significantly, and the maximum Kernel Average Misorientation (KAM) value also increases. The room-temperature tensile strength and Vickers hardness of the repaired specimens are superior to those of the original base material, with the tensile strength increasing by approximately 6 MPa and the Vickers hardness increasing by approximately 4 HV. Full article

This work investigates the NiTi shape memory alloys fabricated via laser powder-directed energy deposition (LP-DED). The properties of NiTi alloys produced by powder metallurgy or additive manufacturing routes are strongly influenced by the type of feedstock material employed. Two powder feedstocks were used for DED fabrication: a blended mixture of elemental nickel and titanium powders with a nominal chemical composition of Ni56Ti44 (wt.%) and a pre-alloyed NiTi powder containing 55.75 wt.% Ni. Samples fabricated from both types of powders were subjected to microstructural characterization, phase composition analysis, and mechanical and corrosion testing. It was found that DED processing on a non-preheated CP-Ti substrate is prone to warping and that samples deposited from the elemental Ni and Ti powder mixture exhibited pronounced inhomogeneity of microstructure and mechanical properties along the build direction, accompanied by the formation of the Ti₂Ni secondary phase. The absence of a superelastic plateau was observed in the corresponding stress–strain response. On the contrary, the samples deposited from the pre-alloyed NiTi powder exhibited a microstructure composed of B2 and B19′ phases and already demonstrated a clear superelastic response in the as-built condition during tensile loading. Based on the tensile test results, this NiTi material was used only for superelasticity testing. The superelastic behavior was further enhanced by post-deposition heat treatment, which significantly increased the recovery rate from 53% to 89%. Full article

Ferrochrome alloy is a crucial additive in steelmaking, significantly enhancing the strength, hardness, and corrosion resistance of steel; investigating the melting behavior of ferrochrome alloy could provide a theoretical foundation for producing stainless steel with improved properties. To gain insight into the melting behavior and mechanism of ferrochrome alloy in molten steel, this paper employed a numerical simulation with ANSYS Fluent software to investigate the effects of bath temperature, bath chromium content, bath carbon content, alloy chromium content, alloy carbon content, alloy size, and alloy preheating temperature on the melting behavior of ferrochromium alloy. The results showed that when the ferrochrome alloy is immersed into the molten bath, a solidified layer formed on the surface of the alloy, and as immersion time increased, the thickness of the solidified layer initially increased and then decreased; subsequent to the complete melting of the solidified layer, the alloy body began to melt. The center temperature of the alloy remained the lowest throughout the melting process and raised with increasing immersion time. Additionally, as the bath temperature and bath carbon content increased, the formation time of the solidified layer on the surface of the alloy shortened, its maximum thickness decreased, the alloy’s melting rate accelerated from 0.49 × 10⁻⁴ m/s to 1.22 × 10⁻⁴ m/s, and the complete melting time decreased from 134.7 s to 41 s. Conversely, increasing the bath chromium content raised the melting point of the solidified layer, prolonged the time required for remelting, slowed the alloy’s melting rate from 2.47 × 10⁻⁴ m/s to 0.91 × 10⁻⁴ m/s, and increased the complete melting time from 67.6 s to 75.2 s. As the alloy carbon content and preheating temperature increased, the alloy chromium content and size decreased, the formation time of the solidified layer shortened, its maximum thickness initially increased and then decreased, the melting rate of the alloy accelerated from 0.47 × 10⁻⁴ m/s to 1.97 × 10⁻⁴ m/s, and the complete melting time reduced from 165.8 s to 18.1 s. Full article

Background and Objectives: Preheated composite resins have been proposed as an alternative to conventional luting agents due to their improved resistance, color stability, and adaptation. This review aims to critically evaluate the current literature on the use of preheated composites as luting agents exclusively on dentin and enamel, focusing on their mechanical behavior, optical properties, and biological effects, in order to determine whether they provide superior clinical outcomes compared with conventional resin cements. Materials and Methods: A comprehensive literature search from 2015 to 2025 was conducted in accordance with PRISMA-ScR guidelines. Eligible studies included in vitro investigations comparing the preheated composite with other luting agents performed on human, bovine, analog dentin or enamel substrates. Studies meeting these criteria were screened, evaluated, and synthesized. Results: Fifteen studies met the inclusion criteria: nine focused on the mechanical performance, and the remaining six studies examined additional properties such as color stability, pulpal temperature changes during preheating, film thickness characteristics, and the influence on marginal discrepancy. Conclusions: Preheated composite resins offer improved mechanical properties, marginal adaptation, and fracture resistance compared with conventional luting agents. However, their performance is highly technique-sensitive, and clinical outcomes depend on operator skill, restoration thickness, and material selection. Preheating generally does not compromise color stability, but it can elevate pulpal temperature, particularly when residual dentin is thin. Overall, preheated composites have potential clinical advantages, provided that careful handling and appropriate application are ensured. Full article

Compared to reinforcing concrete with steel bars, rebars—made of fiber-reinforced plastic—have a high potential for resource savings in the construction industry due to their corrosion resistance. For the large-volume market of reinforcement elements, efficient manufacturing processes must be developed to ensure the best possible bond behavior between concrete and rebar. In contrast to established FRP-rebars made with thermosetting materials, the use of a thermoplastic matrix enables surface profiling without severing the edge fibers as well as subsequent bending of the bar. The rebars to be produced in this study are based on the process of reactive thermoplastic pultrusion of continuously glass fiber reinforced aPA6. Their surface must enable a mechanical interlocking between the reinforcement bar and concrete. Concepts for a profiling device have been methodically developed and evaluated. The resulting concept of a double wheel embossing unit with a variable infeed and an infrared preheating section is built as a prototype, implemented in a pultrusion line, and further optimized. For a comprehensive understanding of the embossing process, reinforcement bars are manufactured, characterized, and evaluated under parameter variation according to a statistical experimental plan. The present study demonstrates the relationship between the infeed, preheating temperature, and haul-off speed with respect to the embossing depth, which is equivalent to the rib height. No degradation of the Young’s modulus was observed as a result of the profiling process. Full article

Temperature homogeneity assumes a crucial role in the manufacture of asphalt mixtures due to its impact on mechanical formation and mixing homogeneity. The existence of reclaimed asphalt pavement (RAP) exacerbates its impact on temperature inhomogeneity. To address this, the RAP contents of 20%, 40%, and 60%, combined with RAP preheated temperatures of 353 K, 373 K, and 393 K, were taken into consideration to examine the thermal transition and evolution of temperature for the recycled asphalt mixtures in the mixing. Thermal images captured within the range of 30 s to 120 s were used to monitor the temperature evolution of the recycled asphalt mixtures during the mixing. To quantitatively assess the level of thermal non-uniformity, a Relative Thermal Equilibrium Temperature Index (RETI) was introduced. This index reflects the degree of deviation from ideal thermal equilibrium within the recycled mixtures. Based on the RETI calculation, complete temperature homogeneity cannot be attained until the end of the mixing of hot recycled asphalt mixtures. However, a prolongation of the mixing time or an elevation in the RAP preheated temperature can expedite the thermal equilibrium process of recycled asphalt mixtures. Additionally, the RAP contents also exerted a crucial influence on the thermal equilibrium process of the recycled asphalt mixtures. Full article

Decarbonization of compression-ignition engines requires evaluation of carbon-free and low-carbon fuel alternatives. Ammonia (${NH}_3$) offers zero direct carbon emissions but faces combustion challenges including low flame speed (7 $\mathrm{c}\mathrm{m}/\mathrm{s}$) and high auto-ignition temperature (657 °$\mathrm{C}$). Methanol provides improved reactivity and bound oxygen content that can enhance ignition characteristics. This computational study investigates diesel–ammonia–methanol ternary fuel blends using validated three-dimensional CFD simulations (ANSYS Forte 2023 R2; ANSYS, Inc., Canonsburg, PA, USA) with merged chemical kinetic mechanisms (247 species, 2431 reactions). The model was validated against experimental in-cylinder pressure data with deviations below 5% on a single-cylinder diesel engine (510 cm³, 17.5:1 compression ratio, 1500 rpm). Ammonia energy ratios were systematically varied (10–50%) with methanol substitution levels (0–90%). Fuel preheating at 530 K was employed for high-alcohol compositions exhibiting ignition failure at standard temperature. Results demonstrate that peak cylinder pressures of 130–145 bar are achievable at 10–30% ammonia with M30K–M60K configurations, comparable to baseline diesel (140 bar). Indicated thermal efficiency reaches 38–42% at 30% ammonia-representing 5–8 percentage point improvements over diesel baseline (31%)-but declines to 30–32% at 50% ammonia due to fundamental combustion limitations. ${CO}_2$ reductions scale approximately linearly with ammonia content: 35–55% at 30% ammonia and 75–78% at 50% ammonia. ${NO}_X$ emissions demonstrate 30–60% reductions at efficiency-optimal configurations. Multi-objective optimization analysis identifies the A30M60K configuration (30% ammonia, 60% methanol, 530 K preheating) as optimal, achieving 42% thermal efficiency, 58% ${CO}_2$ reduction, 51% ${NO}_X$ reduction, and 11% power enhancement versus diesel. This configuration occupies the Pareto frontier “knee point” with cross-scenario robustness. Full article

The seeding technique is the only way to precisely control the crystal orientation of single-crystal superalloy castings. However, an inevitable assembly gap exists between the seed and the mold cavity in practice, whose role in defect formation remains insufficiently understood. To elucidate the mechanism and impact of this gap, superalloy seeds were machined to different extents, aiming to create varying gaps with the mold. After the seeding experiment, the chilled layers formed on the perimeter of the pre-processed seeds were detected, exhibiting two distinct microstructural zones: a eutectic aggregation region at the bottom and an equiaxed grain at the top. The thicker the layer, the more pronounced the differences in microstructure between these two regions. This can be explained by the fact that during preheating, the γ/γ′ eutectic-rich interdendritic region (enriched with Al + Ti + Ta) in the original seed melted first due to its lower melting point. The molten fluid flowed downward into the gap, solidifying rapidly into the chilled layer. The leading portion of the fluid, melting from the interdendritic zone, formed the eutectic zone in the lower part of the chilled layer. The subsequently poured charge alloy melt (non-enriched with Al + Ti + Ta) generated the upper equiaxed zone with only a little γ/γ′ eutectic. These equiaxed grains in the chilled layer subsequently grew upward and potentially developed into stray grains of the casting. Full article

Super duplex stainless steels (SDSS) are materials known for their exceptional mechanical strength and high resistance to corrosion due to their dual- phase microstructure consisting of ferrite and austenite in roughly equal proportions. However, the Gas Tungsten Arc Welding (GTAW) process used to join SDSS often causes microstructural imbalances, mainly ferritic structures, or the formation of harmful intermetallic phases, which can weaken the material’ s desirable properties. This study examines the effect of substrate preheating on the microstructure, mechanical properties, and corrosion resistance of UNS S32750 SDSS welds produced by GTAW. Preheating the substrate was considered as a strategy to improve phase balance in the fusion zone by extending the time within the ferrite- to- austenite transformation temperature range, thus slowing the cooling rates. Four conditions were tested: welding at room temperature (RT) and preheating to 100 °C (T100), 200 °C (T200), and 300 °C (T300). Welding parameters remained constant. The fusion zone microstructure was analyzed using metallographic techniques, while mechanical properties were evaluated through microhardness tests. Corrosion resistance was assessed with potential dynamic polarization in a 3.5% NaCl solution. The results showed significant improvements in microstructural balance with higher preheating temperatures. The austenite volume fraction in the fusion zone increased from about 16% at RT to 42% at T 300. Mechanical testing indicated a decrease in microhardness from 341 HV at RT to 314 HV at T 300, reflecting the increased austenite content and its associated toughness. Corrosion tests demonstrated enhanced resistance under preheated conditions, with T 300 exhibiting the highest corrosion potential and the lowest corrosion current, nearing the performance of the base metal. These findings suggest that preheating is a practical, cost- effective method for optimizing the GTAW process for SDSS, eliminating the need for expensive filler materials and stabilizing the microstructure elements. Full article