Search Results (66)

Thermal cracking due to hydration heat in massive monolithic walls poses a significant risk, but traditional prediction methods are often too complex for rapid engineering assessments. This study aims to develop machine learning models to predict the maximum temperature and center-to-surface temperature difference in hardening massive walls, considering variable heat exchange, concrete hardening rate, and formwork curing time. A dataset of 855,360 numerical experiments was collected by solving the transient heat conduction equation using the finite element method (FEM), varying wall thickness, initial and ambient temperatures, heat transfer coefficient, hardening rate, curing time, and heat release. CatBoost gradient boosting regression models were trained and validated to predict both output parameters. The models achieved high accuracy with coefficients of determination exceeding 0.99 for both targets, mean absolute percentage errors of 0.2% for maximum temperature and 3% for temperature difference. Feature importance analysis revealed that heat release dominates both predictions (35–43% importance), followed by wall thickness. The developed CatBoost models enable rapid, accurate prediction of thermal regimes in massive monolithic walls without time-consuming finite element simulations, offering a practical tool for assessment of early cracking risk temperature indicators during construction. Full article

Magnesium phosphate cement (MPC) shows great potential for complex underground environments due to its rapid-hardening and early-strength properties. However, its large-scale application is hindered by several drawbacks, including high hydration heat, rapid setting, and insufficient long-term durability. To address these limitations, this study developed a novel MPC grouting material modified with steel slag (SS) and redispersible latex powder (LP). We systematically investigated the workability, mechanical properties, durability, and microstructural evolution of this modified system. Results indicate that incorporating SS and LP decreases both the fluidity and setting time of the grout. An optimal SS dosage accelerates reaction kinetics and raises the peak hydration temperature. Conversely, the LP-induced polymer film suppresses the overall temperature rise, delaying the first exothermic peak and advancing the second. The incorporation of 5% steel slag increased the 28-day compressive strength of the MPC to 54.86 MPa. Building on this, the combined addition of 0.15% latex powder further elevated the strength to 58.82 MPa. Microstructural and pore analyses confirmed that the steel slag enhanced interfacial bonding through physical filling and the formation of calcium phosphate crystals. Meanwhile, the latex powder formed a continuous polymer film, which tightly wrapped and bridged the hydration products and unreacted particles. This synergistic mechanism effectively sealed the capillary pores and reduced the proportion of harmful pores by 15.99% compared to the control group. Consequently, the densified MPC matrix laid a solid microstructural foundation for the material’s excellent durability. It offers reliable, high-performance material for seepage control and strata reinforcement in complex environments. Full article

Martensitic chromium-molybdenum steels such as 15Kh5M are widely used in high-temperature oil and gas equipment, but their weldability is limited by high hardenability and susceptibility to cold cracking, which usually necessitate energy-intensive preheating. This study evaluates an alternative route based on the combination of root-pass mechanical vibration (50 Hz, ~1 mm amplitude) and post-pass water-air jet cooling during mechanized GMAW. Three welding variants were compared: conventional preheated welding, vibration-assisted welding without preheating, and hybrid thermo-vibrational welding with active cooling. Among the tested conditions, the hybrid route produced the narrowest heat-affected zone, reducing its width from about 7 mm to about 3 mm, which is consistent with a compressed thermal cycle. Microhardness in the heat-affected zone decreased from 380 to 440 HV in the preheated condition to 330–370 HV in the hybrid condition. Optical microscopy further indicated a finer and more homogeneous transformed microstructure in the hybrid case. Results indicate that simultaneous vibro-treatment and controlled cooling effectively mitigate harmful metallurgical effects typically induced by rapid cooling, enabling preheat-free fabrication of thick-walled components. The proposed hybrid approach may offer energy savings, shorter production cycles, and improved automation compatibility in field welding applications. Full article

In this study, an elastoplastic finite element (FE) contact model was developed to evaluate the plastic deformation of a surface induction-hardened tapered roller bearing used in wind turbines, incorporating depth-dependent material properties and heat treatment-induced residual stress distribution. The validity of this model was confirmed by comparing the calculated plastic deformation with measured profiles from static compression experiments. The results show that the residual stresses generated by induction hardening have a significant influence on the elastoplastic behavior of bearings. Based on this model, a parametric analysis was performed to investigate the effects of surface hardening depth (SHD), contact pressure, and residual stress on surface plastic deformation. Empirical formulas were developed to predict surface plastic deformation and evaluate material yielding for surface-hardened tapered roller bearings, thereby preventing excessive deformation during service. This allows for the rapid estimation of the maximum plastic deformation for different hardening depths and provides an efficient approach for assessing the yielding risk. Full article

Magnesium phosphate cement (MPC) is a type of rapid-hardening inorganic cementitious material, which has important application value in rapid road repair, solidification of hazardous and radioactive waste, and other fields. However, it suffers from excessively fast setting and hardening and a short working time retention, which severely restrict its engineering application. Therefore, the development of high-efficiency set retarders is of great significance for optimizing MPC performance, enhancing its construction workability, and expanding its application scope. In this study, the effect of sodium polyacrylate (PAAS) on the setting and hardening of magnesium potassium phosphate cement (MKPC) was investigated by testing the setting time and fluidity at a low water-to-solid ratio (W/S = 0.18). Through pH and electrical conductivity measurements, combined with XRD, TG/DTG, and FTIR characterizations, we elucidated the retarding mechanism of PAAS on MKPC using a high water-to-solid ratio (W/S = 10). The results indicate that the setting time of MKPC is positively correlated with the PAAS dosage, whereas the fluidity and compressive strength exhibited a negative correlation with the PAAS dosage. Additionally, PAAS reduces the total heat release and the heat release rate of MKPC. The addition of PAAS increased the pH of the suspension, thereby reducing the solubility of MgO, but did not inhibit the dissolution of KH₂PO₄. The carboxylate groups in PAAS chemically reacted with Mg²⁺ on the surface of MgO to form magnesium carboxylate complexes (Mg-PAA), which remained as precipitates in the MKPC suspension system, thus reducing the amount of available Mg²⁺ participating in the hydration reaction. Furthermore, PAAS had no effect on the final precipitate composition at the end of hydration, which was composed of MgKPO₄·6H₂O and Mg₃(PO₄)₂·22H₂O in all cases. Full article

The use of additive manufacturing for rapid prototyping of near-infrared and terahertz components provides seamless and error-free production. This article discusses the additive manufacturing and post-processing of axicons and their performance evaluation using attenuation and near-field-measurements based fundamental techniques. The axicons are manufactured using the materials cyclic olefin copolymer (TOPAS) and polymethyl methacrylate (PMMA), for their respective use in terahertz and near-infrared applications. The optical and terahertz components manufactured using traditional 3D-printing processes, e.g., fused filament fabrication or stereolithography apparatus exhibit high surface roughness in the range of 15 ± 2.5 µm, resulting in undesired propagation and scattering in the near infrared wavelengths. This research work proposes an economical post-processing technique for additively manufactured terahertz and near-infrared axicons for applications in multispectral characterization, e.g., bio-sensing. The authors used an enhanced method of dip-coating, which involves interval dipping and intermittent hardening to achieve better surface finish. An emphasis is placed on interval dipping and intermittent hardening, which lead to excellent transparency in case of additively-manufactured near-infrared axicons. The dip-coated samples exhibit surface roughness below 10 nm. With the use of heated resin material as the coating layer, due to reduced viscosity, the resin material distributes uniformly over the surface of the 3D-printed terahertz and near-infrared axicons. The authors also observed that the DOF length deviation between unprocessed and enhanced dip-coated axicons remains within the measurement error estimation from analytical calculations. In addition to the improved surface finish and transparency, the coatings are also closely matched in refractive index to the axicon material. Such post-processed axicons pave the way for producing a wide array of systems in the fields of communication, imaging, and bio-sensing. Full article

Laser-based manufacturing processes—including marking, hardening, cutting, and welding—demand the precise selection of processing parameters, as the resulting surface state is critically dependent on the delivered power density and beam–material interaction time. This study presents a unified predictive framework for estimating the critical surface power density thresholds for melting q_scm and evaporation q_scv as functions of scanning speed v for the following four technologically important metallic materials: titanium, C26000 brass, SS304 stainless steel, and 42CrMo4 alloy steel. The principal novelty of this work is twofold. First, it provides the first directly comparative analysis of these four materials under identical, standardized laser conditions (λ = 1064 nm, d = 40 μm, constant absorptivity A = 0.4), eliminating the confounding effects of variable beam geometries and optical assumptions that hinder cross-study comparisons. Second, it translates fundamental thermophysical principles into a practical engineering tool, such as a validated spreadsheet calculator that outputs material-specific threshold curves in real time, enabling rapid, physics-based parameter estimation without recourse to complex numerical simulations. The computed threshold curves exhibit a consistent non-linear increase with scanning speed for all materials, governed by the inverse relationship between interaction time and required power density. The following clear material hierarchy emerges: C26000 brass exhibits the highest thresholds (e.g., q_scm = 0.94 × 10¹⁰ W/m², q_scv = 10.74 × 10¹⁰ W/m² at v = 100 mm/s) due to its high thermal conductivity, while titanium shows the lowest (q_scm = 0.19 × 10¹⁰ W/m², q_scv = 0.48 × 10¹⁰ W/m² at v = 100 mm/s) as a consequence of strong heat confinement. SS304 and 42CrMo4 occupy intermediate positions, with 42CrMo4 demonstrating notably higher evaporation resistance than SS304 despite similar melting thresholds. The resulting dual-threshold framework delineates three distinct process regimes—sub-melting heating, melting-dominant processing, and evaporation—providing a quantitative basis for parameter selection in applications ranging from surface hardening to micromachining. By bridging the gap between theoretical material science and applied manufacturing, this work offers a robust, first-order reference for process design and establishes a methodological template for future comparative studies of laser–material interactions. Full article

This study employed a gradient heat treatment strategy to efficiently acquire microstructure parameters and establish the microstructure–hardness relationship in Ti-6Al-4V-1.5Zr-1.0Nb-0.5Mo alloy, addressing the knowledge gap in rapid optimization of heat treatment windows. Gradient solution treatment in the α + β region (859–928 °C) revealed that hardness reaches a minimum at a Vα_p/Vβ_t ratio of approximately 0.5, a condition to be avoided if aging is not applied. Subsequent aging at 500 °C, a common temperature for such alloys, highlighted the solution-treated sample at 908 °C as possessing high hardening potential, attributed to its high β_t fraction (Vβ_t = 70%) and sufficient retained β phase that promoted fine α_s precipitation. Gradient aging (502–590 °C) of this optimized microstructure further showed that peak hardness (>350 HV1, measured under a 1 kg load) was achieved at 502 °C and 551 °C, where the Vα_p/Vβ_t ratio remained near the optimal 3:7, and the precipitated refined α_s exhibited minimal width. The hardness of the bimodal microstructure is governed by two principal factors: the Vα_p/Vβ_t ratio (optimum near 3:7) and the precipitation efficiency of refined α_s from retained β phase. The gradient approach proves to be an effective high-throughput method for rapidly correlating heat treatment parameters with microstructure and properties, accelerating the design of heat treatments for titanium alloys. Full article

The emulsification of a molten fusible metal alloy in a liquid epoxy matrix with its subsequent curing is a novel way to create a highly concentrated phase-change material. However, numerous challenges have arisen. The high interfacial tension between the molten metal and epoxy resin and the difference in their viscosities hinder the stretching and breaking of metal droplets during stirring. Further, the high density of metal droplets and lack of suitable surfactants lead to their rapid coalescence and sedimentation in the non-cross-linked resin. Finally, the high differences in the thermal expansion coefficients of the metal alloy and cross-linked epoxy polymer may cause cracking of the resulting phase-change material. This work overcomes the above problems by using nanosilica-induced physical gelation to thicken the epoxy medium containing Wood’s metal, stabilize their interfacial boundary, and immobilize the molten metal droplets through the creation of a gel-like network with a yield stress. In turn, the yield stress and the subsequent low-temperature curing with diethylenetriamine prevent delamination and cracking, while the transformation of the epoxy resin as a physical gel into a cross-linked polymer gel ensures form stability. The stabilization mechanism is shown to combine Pickering-like interfacial anchoring of hydrophilic silica at the metal/epoxy boundary with bulk gelation of the epoxy phase, enabling high metal loadings. As a result, epoxy shape-stable phase-change materials containing up to 80 wt% of Wood’s metal were produced. Wood’s metal forms fine dispersed droplets in epoxy medium with an average size of 2–5 µm, which can store thermal energy with an efficiency of up to 120.8 J/cm³. Wood’s metal plasticizes the epoxy matrix and decreases its glass transition temperature because of interactions with the epoxy resin and its hardener. However, the reinforcing effect of the metal particles compensates for this adverse effect, increasing Young’s modulus of the cured phase-change system up to 825 MPa. These form-stable, high-energy-density composites are promising for thermal energy storage in building envelopes, radiation-protective shielding, or industrial heat management systems where leakage-free operation and mechanical integrity are critical. Full article

Rapid urbanization and the widespread use of impervious materials have intensified the urban heat island (UHI) effect, raising surface temperatures and energy demands. Conventional concrete pavements contribute significantly due to their high thermal conductivity and low reflectivity. This study systematically investigates the development of thermally efficient concrete paver blocks using sustainable alternative fine aggregates to mitigate heat accumulation while retaining a minimum compressive strength of 35–45 MPa (recommended for medium traffic). Unlike prior isolated studies, this research offers a comprehensive comparative analysis of three sand replacements—Vermiculite powder (12.5–50%), Perlite powder (20–80%), and Crushed Glass (7.5–30%)—in M30-grade concrete. Fresh and hardened properties were evaluated through slump, density, and compressive strength tests at 7, 14, and 28 days, while infrared thermography quantified surface temperature variations under controlled heat exposure. Results showed significant thermal improvements, with optimal mixes Vermiculite 25% (VC-25), Perlite 40% (PR-40), and Crushed Glass 15% (CG-15) reducing surface temperatures by 25.1 °C, 22.2 °C, and 18.2 °C, respectively, while maintaining compressive strengths of 47.8 MPa, 38.8 MPa, and ~58 MPa. VC-25 proved superior, achieving the lowest surface temperature (26.3 °C) and 48.8% lower heat absorption than conventional concrete. The study establishes optimal replacement thresholds balancing insulation and strength, supporting SDGs 11, 12, and 13 through climate-responsive, resource-efficient construction materials. Full article

In manufacturing processes, both material processing methods and the resulting microstructure play a fundamental role in determining material behavior during component fabrication and subsequent service conditions. Materials produced by additive manufacturing exhibit a unique microstructure due to the rapid heating and solidification cycles inherent to the process, distinguishing them from conventionally cast counterparts and leading to differences in mechanical and functional properties. This article presents problems related to the longitudinal turning of Ti6Al4V titanium alloy elements produced by the casting and powder laser sintering (DMLS) methods. The authors made an attempt to establish a procedure for determining the optimal parameters of finishing cutting while minimizing the specific cutting force, taking into account the criterion of machined surface quality. In the course of the experiments, the influence of the cutting data on the cutting force values, surface roughness parameters, and chip shape was examined. The material hardening state during machining and the variability of the specific cutting force as a function of the cross-sectional shape of the cutting layer were also tested. The authors presented a practical application of the proposed optimization algorithm. It was found that by changing the shape of the cross-section of the cutting layer, it was possible to carry out the turning process with significantly reduced specific cutting force (from 2300 N/mm² to 1950 N/mm²) without deteriorating the surface roughness. Full article

Laser additive manufacturing shows great promise for repairing high-value carburized gears, but the underlying relationships among thermal history, microstructure, and properties remain insufficiently quantified. This study uniquely integrates finite-element modeling with microstructural mapping to decipher thermo-mechanical coupling during gear repair. A thermal simulation model that combines a double-ellipsoidal heat source with phase-transformation kinetics achieves 91.1% accuracy in predicting melt pool depth and hardened-layer depth. The cladding process induces a substantial increase in subsurface hardness, primarily due to phase-transformation-induced refinement and regeneration of martensite during rapid thermal cycling. This results in a peak hardness of 64 HRC and a tensile strength of 2856 MPa in the secondary-hardened layer, both exceeding those of the original carburized substrate. The presence of beneficial compressive residual stresses further improves fatigue resistance. Spatial gradients in elastic modulus, strength, and hardness, measured by flat indentation and microhardness testing, are quantitatively correlated with simulated peak temperatures and predicted phase distributions. These correlations establish a causal link from the thermal history to phase transformations, microstructural evolution, and the resulting local hardness and strength. These findings provide a mechanistic foundation for precision repair and service-life prediction of high-carbon gear steels using laser additive manufacturing. Full article

This study focuses on the performance evolution of Engineering Geopolymer Composites (EGCs) in long-term thermal environments, investigating the mechanical properties and microstructural evolution of alkali-activated fly ash–slag composites under sustained 60 °C thermal conditions. The research results indicate that sustained exposure to 60 °C significantly enhances the static and impact loading compressive strength of EGCs; however, single-slag or high-alkalinity systems exhibit strength retrogression due to insufficient long-term thermal stability. After exposure to elevated temperatures, the tensile strain-hardening curve of EGCs becomes smoother, with a reduced number of cracks but increased crack width, leading to a transition from a distributed multicrack propagation pattern to rapid widening of primary cracks. Due to the bridging effect of PVA fibers, sustained elevated temperature significantly enhances the peak impact load stress of the S50-6 sample. Microscopic analysis attributes this improvement to the matrix-strengthening effect caused by accelerated C-(A)-S-H gel polymerization and refined pore structure under continuous heat, as well as the energy dissipation role of the fiber system. The study recommends an optimal EGC system formulation with a fly ash–slag mass ratio of 1:1 and a Na₂O concentration of 4–6%. This research provides a theoretical foundation for understanding the performance evolution and strength stability of EGC materials under sustained elevated temperature. Full article

Global climate change has intensified temperature fluctuations, significantly impacting insect populations. Thermal tolerance has emerged as a critical determinant of species distribution and invasion potential. Liriomyza trifolii, an economically important invasive pest, has been rapidly expanding in southeastern coastal regions of China, gradually displacing its congeners L. sativae and L. huidobrensis. This competitive advantage is closely associated with its superior thermal adaptation strategies. Here, we first examine the temperature-mediated competitive dominance of L. trifolii, then systematically elucidate the physiological, biochemical, and molecular mechanisms underlying its temperature tolerance, revealing its survival strategies under extreme temperatures. Notably, L. trifolii exhibits a lower developmental threshold temperature and higher thermal constant, extending its damage period, while its significantly lower supercooling point confers exceptional overwintering capacity. Physiologically, rapid cold hardening (RCH) enhances cold tolerance through glycerol accumulation and increased fatty acid unsaturation, while heat acclimation improves thermotolerance via a trade-off between developmental processes and reproductive investment. Molecular analyses demonstrate that L. trifolii combines the low-temperature inducible characteristics of L. huidobrensis with the high-temperature responsive advantages of L. sativae in heat shock protein (Hsp) expression patterns. Transcriptomic studies further identify differential expressions of lipid metabolism and chaperone-related genes as key to thermal adaptation. Current research limitations include incomplete understanding of non-Hsp gene regulatory networks and laboratory–field adaptation discrepancies. Future studies should integrate multi-omics approaches with ecological modeling to predict L. trifolii’s expansion under climate change scenarios and develop temperature-based green control strategies. Full article

This study investigates the impact of arc-hardening parameters on a groove-shaped S45C steel tube, with a focus on surface hardness and microstructure. According to the findings, when arc quenching occurs, the tube’s surface hardness increases significantly compared to its original hardness. The surface layer hardness can increase to 50.3 HRC, which is 3.4 times greater than the untreated surface. Changing arc quenching parameters such as current intensity, gas flow rate, arc length, scan speed, heating angle, and cooling angle causes a variation in surface hardness due to the balance of heat input and cooling value. Moreover, the microhardness distribution is divided into three zones: the hardened zone (with a high hardness value), the heat-affected zone (HAZ), which has rapidly declining hardness, and the base metal (with a low hardness value). The hardened zone could have a hardness with a load of 0.3 N of 440 HV and a case depth of about 900 μm. The next zone is the HAZ, where the hardness with a load of 0.3 N drops significantly. The hardness in the base metal zone recovers to its original value of 152 HV. Interestingly, the microstructure, under the hardness distribution, illustrates the relationship between the hardness value and its phases. The hardened zone consists of martensite and residual austenite phases, resulting in a high hardness value. The bainite phase constitutes the HAZ, which correlates to the zone of rapid hardness reduction. Finally, the base metal zone has ferrite and pearlite microstructures, indicating the softest zone. The investigation’s findings may increase our understanding of the arc-hardening process and widen its industrial applications. Full article