Search Results (24)

A new CuNi/TiB₂ thin-film thermocouple was fabricated using magnetron sputtering. A 400 nm thick CuNi interior layer was deposited on a dielectric substrate initiatory, and then covered by an 800 nm thick TiB₂ layer. The tests revealed that the TiB₂ layer had a dense and columnar cross-section. The measured hardness and elastic modulus of the TiB₂ layer were ~20.5 and 315.9 GPa, respectively. No cracking or delamination occurred at the CuNi/TiB₂ interface. The work functions of the TiB₂ and the CuNi layers were calculated to be 4.406 and 4.726 eV, respectively. The difference in work functions between the TiB₂ and the CuNi was ~0.3 eV. The CuNi/TiB₂ thin-film sensor exhibited a high Seebeck coefficient of 38.07 μV/°C with excellent linearity. The maximum service temperature of the thin-film sensor was evaluated to be ~400 °C. A further increase in temperature degraded the Seebeck coefficient due to oxidation of the TiB₂ layer. Full article

This attempt covers an investigation of cutting temperature at interfaces of Fiber Metal Laminates (FMLs) made of glass fiber-reinforced polymer (GFRP) stacked with an Al2020 alloy. GFRP/Al/GFRP and Al/GFRP/Al composite stacks are both investigated to highlight the effect of stacking arrangement on thermal behavior within the interfaces. In a first test series, temperature history is recorded within the metal/composite stack interfaces using preinstalled thermocouples. In a second test series, a wireless telemetry system connected to K-type thermocouples implanted adjacent to the cutting edge of the solid carbide drill is used to record temperature evolution at the tool tip. Focus is put on the effects of cutting speed and stacking arrangement on the thrust force, drilling temperature, and delamination. From findings, the temperature histories show high sensitivity to the cutting speed. When cutting Al/GFRP/Al, the peak temperature is found to be much higher than that recorded in GFRP/Al/GFRP and exceeds the glass transition point of the GFRP matrix under critical cutting speeds. However, thrust force obtained at constitutive phases exhibits close magnitude when the stacking arrangement varies, regardless of cutting speed. Damage analysis is also discussed through the delamination factor at different stages of FML thickness. Full article

Additive Manufacturing (AM) enables the automated production of complex geometries with low waste and lead time, notably through Material Extrusion (MEX). This study explores Large Format Additive Manufacturing (LFAM) with carbon fiber-reinforced polyaryletherketones (PAEK), particularly a slow crystallizing grade by Victrex. The research investigates how extrusion parameters affect the mechanical properties of the printed parts. Key parameters include line width, layer height, layer time, and extrusion temperature, analyzed through a series of controlled experiments. Thermal history during printing, including cooling rates and substrate temperatures, was monitored using thermocouples and infrared cameras. The crystallization behavior of PAEK was replicated in a Differential Scanning Calorimetry (DSC) setup. Mechanical properties were evaluated using three-point bending tests to analyze the impact of thermal conditions at the deposition interface on interlayer bonding and overall part strength. The study suggests aggregated metrics, enthalpy deposition rate and shear rate under the nozzle, that should be maximized to enhance mechanical performance. The findings show that the common practice of setting fixed layer times falls short of ensuring repeatable part quality. Full article

The present study investigated the influence of temperature on molecular interdiffusion at the interface during the laser transmission welding of 3D-printed continuous carbon-fiber-reinforced thermoplastic composites. In order to accurately measure the temperature at the weld interface, a series of thermocouples were embedded in the laser-absorbent composite part. Two different molecular interdiffusion models were implemented to calculate the degree of healing and to predict the effects of temperature on the welding process. The degree of healing and the weld line width were computed and compared with microscopy observations. The discrepancy between the two proposed numerical models was less than $6\%$. Both models showed good agreement with the experimental data, with an average error of $13.28\%$ and $7.26\%$, respectively. The results revealed a significant correlation between the thermal history and molecular interdiffusion at the interface. Furthermore, the relationship between the welding parameters (laser beam scanning speed) and weld line width was established. The findings of this study provide a comprehensive understanding of the underlying mechanisms involved in the laser welding of 3D-printed composites and offer insights to optimize the welding process for enhanced weld quality and superior mechanical properties in the final product. Full article

This paper studies the effect of gravity orientation on a heat sink, used to passively cool a thick film resistor, by changing the assembly orientation. Using the same geometry and boundary conditions as in the experimental setup, finite element simulations were conducted to evaluate the accuracy of Siemens Flotherm XT 2021.2 simulation software. In order to determine the influence of heat sink orientation, experimental measurements were performed on the resistor and heat sink temperature using thermocouples. Siemens Simcenter Flotherm XT 2021.2 software (Siemens, Munich, Germany) was used to perform finite element simulation. The influence of the heat sink position was evaluated on two setups, one where the resistor is placed directly on the heat sink using screws, and the second one, where a thermal pad was placed between the resistor and the heat sink. Screws were to clamp the parts in both cases. In total, four experiments and simulations were performed with two assemblies with two different gravity orientations for each assembly. In all the cases, the heat sink was placed on a wooden structure to prevent heat transfer through conduction, due to poor thermal conductivity of wood, and to allow unrestricted air flow underneath and around the heat sink. The first simulation was then calibrated for the first scenario, and the rest of the simulations were made using the calibrated one. No other changes in boundary conditions were made. Temperature measurements show an improved cooling when the air speed between the heat sink fins is enhanced due to natural hot air movement generated by the gravity. Gravity has an influence on the cooling regardless of the presence or absence of a thermal interface material. Measured temperatures were reduced up to 8.2 °C due to the rotation of the heatsink. Finite element analysis shows similar temperature values to the measured ones in all the scenarios. Full article

This paper presents a new, comprehensive digital circuit used for the control of a novel gas chromatograph mass spectrometer (GC-MS) interface that is based on supersonic molecular beam (SMB). The circuit includes a Texas Instruments 150 MHz digital signal controller (DSC), high voltage amplifiers for 8 independent channels and 4 independent channels of high resolution pulse width modulation (PWM). The circuit, along with a sophisticated embedded program and a custom made personal computer (PC) application, control all aspects of the interface: smart filament emission-current stabilization, static and scanning mass-dependent ion-source voltages, transfer-line heater proportional integral differential (PID) controls with thermocouple feedbacks, on/off valves, relays and several peripheral device controls that enable the full operation of a turbo-molecular vacuum pump, and of gas flow and pressure controllers. All aspects of this comprehensive controller were successfully tested. The signal for the 450 Th ion (C₃₂H₆₆) for example increased by 123% which is a significant increase. It is obvious that correctly tuned dynamic voltages can guarantee the optimal signal for each mass. Full article

In the present investigation, the numerical code WELDSIM is used to simulate butt welding of 4 mm thick plates of S355 steel and AA6082-T6 by Hybrid Metal Extrusion and Bonding (HYB). This is a new solid state joining process using continuous extrusion as a technique to enable aluminium filler metal additions. In WELDSIM, the finite element heat flow model is coupled to a frictional heating model, an isokinetic diffusion model for the interfacial intermetallic compound (IMC) formation and a nanostructure model for simulating reversion and re-precipitation of hardening phases inside the aluminium part of the joints during welding and subsequent natural ageing. The HYB process model is validated by comparison with experimental data obtained from in-situ thermocouple measurements and hardness testing carried out on three different Al-steel butt welds. Furthermore, scanning electron microscope examinations of the Al-steel interfaces have been conducted to check the predicted power of the IMC diffusion model. It is concluded that the process model is sufficiently relevant and comprehensive to be used in simulations of both the thermal, microstructure, and strength evolutions fields in these dissimilar butt welds. Some practical applications of the process model are described toward the end of the article, where particularly its potential for optimising the load-bearing capacity of the joints, is highlighted. Full article

The destruction caused by forest fires generates social impacts, environmental impacts, and extremely important economic impacts caused by the destruction of a wide range of infrastructures and essential goods. Therefore, as it is impossible to remove all the infrastructures from the forest and wildland–urban interface, the design of protection systems is essential. The main objective of this work is the development of a low-cost protection system, with rigid panels, requiring a simple installation, in order to protect outdoor infrastructures such as telecommunications stations, shelters, roadside enclosures, power cabinets, and other structures. A study was carried out on panels that could be used for protection in order to determine whether the protective material would be more appropriate. Taking into account the fire resistance behavior, thermal and structural properties and cost, the panels selected were the magnesium oxide fiberglass reinforced. The protection was constructed, installed on a telecommunication cabinet, and experimentally laboratory tested in a wind combustion tunnel. To collect the data InfraRed and video cameras, heat flux sensors, and thermocouples were used to determine the fire propagation, heat flux, and temperatures, respectively. The experimental data show that the low-cost protection is effective for protecting telecommunication cabinets and similar infrastructures against forest fires. Full article

This attempt aims at assessing heat generation in thermal conductive polymer (TCP) composites widely used in aerospace sectors. Temperature histories were investigated in both nonreinforced and glass-fiber-reinforced TCPs during abrasive milling. Glass/epoxy and glass/polyester composites with 30% unidirectional glass fiber content were prepared according to appropriate curing cycles. Type K thermocouples connected to a data acquisition system ensured the recording of temperature history along the trim plan during milling. Unexpectedly, when milling TCP composites parallel to fibers, peak temperature was found to be slightly lower than that recorded in nonreinforced polymers. The lateral surface of fibers acts to favor sliding friction, which limits heat generation at interfaces, while relatively low specific heat capacity and thermal conductivity of glass fiber disadvantage heat transfer. However, when milling perpendicular to fibers, the contact area between the tool and the transverse failure area of fibers increases drastically, hence involving severe friction at interfaces. This yields peak temperatures sensitively higher than those obtained in nonreinforced polymers. SEM inspections highlighted the failure modes dominating the material removal process in both nonreinforced and glass-fiber-reinforced polymers. The microcracks and debris observed at the trim plan explain, in part, the heat generation detected on temperature rate plots. Thus, heat conduction between phases governs sensitive surface finish integrity and tool lifetime and, hence, has great economic impact on the manufacturing steps. Full article

Wildland fires are frequent events worldwide, particularly in the European-Mediterranean region, USA, and Australia. These fires have been more frequent and intense in recent years due to climate changes and may cause significant damage, especially when reaching the Wildland-Urban Interface (WUI) areas. The presence of liquefied petroleum gas (LPG) cylinders may cause severe events in WUI areas, as occurred in Portugal during the large wildfires of 2017, which could have been avoided if the cylinders were protected. Devices for protecting the parts of houses under WUI fire were previously presented, but a protective device for cylinders was not. In this work, a protective device for LPG cylinders made with a thin fabric with an aluminum coating on the external face was tested in laboratory and field conditions. The cylinder and the fabric were equipped with thermocouples and heat flux sensors attached to their surfaces. The tests showed that the device gave effective protection to the cylinder, decreasing the radiative heat flux that reaches it and keeping it in a safe condition when exposed to a fire; consequently preventing extreme behavior such as an explosion. Full article

Continuous ultrasonic welding is a promising technique for joining thermoplastic composites structures together. The aim of this study was to gain further insight into what causes higher through-the-thickness heating in continuous ultrasonic welding of thermoplastic composites as compared to the static process. Thermocouples were used to measure temperature evolutions at the welding interface and within the adherends. To understand the mechanisms causing the observed temperature behaviours, the results were compared to temperature measurements from an equivalent static welding process and to the predictions from a simplified heat transfer model. Despite the significantly higher temperatures measured at the welding interface for the continuous process, viscoelastic bulk heat generation and not thermal conduction from the interface was identified as the main cause of higher through-the-thickness heating in the top adherend. Interestingly the top adherend seemed to absorb most of the vibrational energy in the continuous process as opposed to a more balanced energy share between the top and bottom adherend in the static process. Finally, the higher temperatures at the welding interface in continuous ultrasonic welding were attributed to pre-heating of the energy director due to the vibrations being transmitted downstream of the sonotrode, to reduced squeeze-flow of energy director due to the larger adherend size, and to heat flux originating downstream as the welding process continues. Full article

Laser welding experiments involving amorphous thermoplastic polymer (PMMA) and 304 austenitic stainless steel plates were conducted to explore the influence of laser welding process parameters on plastic–metal joints. A high-speed camera was applied to record the dynamics of the molten pool and the formation of bubbles to reveal the bonding mechanisms of the hybrid joints. The influence of process parameters on the joints was analyzed using temperature measurements performed with thermocouples. The microstructure morphology of joints was observed using SEM. The mechanical characterization of the hybrid joints was carried out to understand the effect of the welding conditions on the weld morphology, flaws and shear stress. Different interface temperatures resulted in two types of bubbles and led to different weld morphology characteristics. A stable hybrid joint with the best shear stress was produced with a laser line energy of 20.16 J/mm², a temperature of 305 °C and small bubbles. The shear stress of the effective joint under the maximum mechanical resistance was 4.17 MPa. The chemical bonds (M-O, M-C) and mechanical anchoring that formed on the steel’s surface contributed to the joint bonding. Range analysis provided guidance for identifying the impact of individual factors in the shear stress for the laser welding of plastic–metal. Full article

Ultrasonic metal welding is an energy-efficient, fast and clean joining technology without the need of additional filler materials. Single spot ultrasonic metal welding of aluminum to steel sheets using automotive materials has already been investigated. Up to now, further studies to close the gap to application-relevant multi-metal structures with multiple weld spots generated are still missed. In this work, two different spot arrangements are presented, each consisting of two weld spots, joined 0.9 mm thick sheets of wrought aluminum alloy AA6005A-T4 with 1 mm sheets of galvannealed (galvanized and annealed) dual-phase steel HCT980X. An anvil equipped with variable additional clamping punches was used for the first time. The tensile shear forces reached 4076 ± 277 N for parallel connection and 3888 ± 308 N for series connection. Temperature measurements by thermocouples at the interface and through thermal imaging presented peak temperatures above 400 °C at the multi-metal interface. Microscopic investigations of fractured surfaces identified the Zn layer of the steel sheets as the strength-limiting factor. Energy-dispersive X-ray spectroscopy (EDX) indicated intermetallic phases of Fe and Zn in the border areas of the weld spots as well as the separation of the zinc layer from the steel within these areas. Full article

To date, no printable chipless Radio Frequency Identification (RFID) sensor-related publications in the current literature discuss the possibility of thermocouple integration, particularly for the use in extreme environments. Furthermore, the effects of a time-dependent stimulus on the scattering parameters of a chipless RFID have never been discussed in the known literature. This work includes a review of possible methods to achieve this goal and the design and characterization of a Barium Strontium Titanate (BST) based VHF/UHF voltage sensing circuit. Proof-of-concept thermocouple integration was attempted, and subsequent testing was performed using a signal generator. These subsequent tests involved applying ramp and sinusoid voltage waveforms to the circuit and the characteristics of these signals are largely extracted from the scattering response. Overall conclusions of this paper are that thermocouple integration into chipless RFID technology is still a significant challenge and further work is needed to identify methods of thermocouple integration. With that being said, the developed circuit shows promise as being capable of being configured into a conventional chipless RFID DC voltage sensor. Full article

Cerro Matoso SA (CMSA) is located in Montelibano, Colombia. It is one of the biggest producers of ferronickel in the world. The structural health monitoring process performed in the electric arc furnaces at CMSA is of great importance in the maintenance and control of ferronickel production. The control of thermal and dimensional conditions of the electric furnace aims to detect and prevent failures that may affect its physical integrity. A network of thermocouples distributed radially and at different heights from the furnace wall, are responsible for monitoring the temperatures in the electric furnace lining. In order to optimize the operation of the electric furnace, it is important to predict the temperature at some points. However, this can be difficult due the number of variables which it depends on. To predict the temperature behavior in the electric furnace lining, a deep learning model for time series prediction has been developed. Long Short Term Memory (LSTM), Gated Recurrent Unit (GRU), and other combinations were tested. GRU characterized by its multivariate and multi output type had the lowest square error. A study of the best input variables for the model that influence the temperature behavior is also carried out. Some of the input variables are the power, current, impedance, calcine chemistry, temperature history, among others. The methodology to tune the parameters of the GRU deep learning model is described. Results show an excellent behavior for predicting the temperatures 6 h into the future with root mean square errors of 3%. This model will be integrated to a software that obtains data for a time window from the Distributed Control System (DCS) to feed the model. In addition, this software will have a graphical user interface used by the operators furnace in the control room. Results of this work will improve the process of structural control and health monitoring at CMSA. Full article