Materials

Robotic milling has broad application prospects in many processing fields. However, the milling performance of a robot in a certain posture, such as in face milling or grooving tasks, is extremely sensitive to process parameters due to the influence of the serial structure of the robot system. Improper process parameters are prone to produce machining defects such as low surface quality. These deficiencies substantially decrease the further application development of robotic milling. Therefore, this paper selected a certain posture and carried out the robotic flat-end milling experiments on a 7075-T651 high-strength aeronautical aluminum alloy under dry conditions. Milling load, surface quality and vibration were selected to assess the influence of process parameters like milling depth, spindle speed and feed rate on the milling performance. Most notably, the contribution ratio based on the analysis of variance (ANOVA) was introduced to statistically investigate the relation between parameters and milling performance. The obtained results show that milling depth is highly significant in milling load, which had a contribution ratio of 69.25%. Milling depth is also highly significant in vibration, which had a contribution ratio of 51.41% in the X direction, 41.42% in the Y direction and 75.97% in the Z direction. Moreover, the spindle speed is highly significant in surface roughness, which had a contribution ratio of 48.02%. This present study aims to quantitatively evaluate the influence of key process parameters on robotic milling performance, which helps to select reasonable milling parameters and improve the milling performance of the robot system. It is beneficial to give full play to the advantages of robots and present more possibilities of robot applications in machining and manufacturing. Full article

The performance of asphalt binder reinforced with waste plastic polyethylene terephthalate (PET) was investigated. Penetration, ductility, softening point, and rotational viscosity tests were conducted to check the performance of the PET-reinforced pavement. The rheological properties of the binder were determined using amplitude sweep and frequency sweep tests and performance grade (PG) measurements of aged and unaged specimens. PET size, mix mechanism, and mix temperature significantly influenced the physical properties of the AB and the penetration index (PI). The size and content of PET had pronounced effects on the PI and softening point than the blending temperature. Increasing the size of PET particles from 75 to 150 μm and the content from 0% to 10% of the bitumen resulted in the reduction of the penetration and ductility values from 96 to 85 mm and 100 to 78 cm, respectively, whereas the softening point increased from 46 to 56.6 °C. As a result, the PI value of the binder increased, which indicates that the temperature susceptibility was improved. The addition of 10% PET increased the viscosity of the baseline bitumen by threefold upto a temperature of 135 °C and dropped it by fourfold when the temperature was raised to 165 °C. Increasing the PET from 0% to 10% and the temperature from 21.1 to 54.4 °C increased the critical strain value (LVER) by 96%. Full article

Methane Dry Reforming is one of the means of producing syngas. CeNi_0.9Zr_0.1O₃ catalyst and its modification with yttrium were investigated for CO₂ reforming of methane. The experiment was performed at 800 °C to examine the effect of yttrium loading on catalyst activity, stability, and H₂/CO ratio. The catalyst activity increased with an increase in yttrium loading with CeNi_0.9Zr_0.01Y_0.09O₃ catalyst demonstrating the best activity with CH₄ conversion >85% and CO₂ conversion >90% while the stability increased with increases in zirconium loading. The specific surface area of samples ranged from 1–9 m²/g with a pore size of 12–29 nm. The samples all showed type IV isotherms. The XRD peaks confirmed the formation of a monoclinic phase of zirconium and the well-crystallized structure of the perovskite catalyst. The Temperature Program Reduction analysis (TPR) showed a peak at low-temperature region for the yttrium doped catalyst while the un-modified perovskite catalyst (CeNi_0.9Zr_0.1O₃) showed a slight shift to a moderate temperature region in the TPR profile. The Thermogravimetric analysis (TGA) curve showed a weight loss step in the range of 500–700 °C, with CeNi_0.9Zr_0.1O₃ having the least carbon with a weight loss of 20%. Full article

In this work, the microstructure and growth behavior of Al-Fe intermetallic compounds (IMCs), which formed at interface of weld steel-aluminum joint, are successfully analyzed via the combination of experiment and physical model. A layer IMCs consists of Fe₂Al₅ and Fe₄Al₁₃, in which the Fe₂Al₅ is the main compound in the layer. The IMCs layer thickness increases with the increase of the heat input and the maximum thickness of IMCs layer is 22 ± 2 μm. The high vacancy concentration of Fe₂Al₅ IMCs provides the diffusion path for Al atoms to migrate through the IMCs layer for growing towards to steel substrate. By using the calculated temperature profiles as inputs, the combined 2D cellular automata (CA)-Monte Carlo (MC) model is applied to simulate the grain distribution and interfacial morphology evolution at the Al-steel interface. This 2D model simulates the IMCs nucleation, growth, and solute redistribution. The numerical results are in good agreement with the experimental results, suggesting that the growth process can be divided four stages, and the thickness of the Fe₂Al₅ layer increases nonlinearly with the increase of the growth time. The whole nucleation and growth process experienced 1.7~2 s, and the fastest growth rate is 8 μm/s. The addition of Si element will influence diffusion path of Al atom to form different interface morphology. The effects of peak temperature, cooling time, and the thermal gradient on the IMCs thickness are discussed. It shows that the peak temperature has the major influence on the IMCs thickness. Full article

Aluminum silicate powder was prepared using two different syntheses: (1) co-precipitation and (2) two-step sol-gel method. All synthesized powders were characterized by various techniques including XRD, FE-SEM, FT-IR, BET, porosimeter, and zetasizer. The particle morphology of the synthesized aluminum silicate powder was greatly different depending on the synthesis. The synthesized aluminum silicate powder by co-precipitation had a low specific surface area (158 m²/g) and the particle appeared to have a sharp edge, as though in a glassy state. On the other hand, synthesized aluminum silicate powder by the two-step sol-gel method had a mesoporous structure and a large specific surface area (430 m²/g). The aluminum silicate powders as adsorbents were characterized for their adsorption behavior towards Pb (II) ions and methylene blue in an aqueous solution performed in a batch adsorption experiment. The maximum adsorption capacities of Pb (II) ions and methylene blue onto the two-step sol-gel method powder were over four-times- and seven-times higher than that of the co-precipitation powder, respectively. These results show that the aluminum silicate powder synthesized with a two-step sol-gel method using ammonia can be a potential adsorbent for removing heavy metal ions and organic dyes from an aqueous solution. Full article

Reverse osmosis has become the most prevalent approach to seawater desalination. It is still limited by the permeability-selectivity trade-off of the membranes and the energy consumption in the operation process. Recently, an efficient ionic sieving with high performance was realized by utilizing the bi-unipolar transport behaviour and strong ion depletion of heterogeneous structures in 2D materials. A perfect salt rejection rate of 97.0% and a near-maximum water flux of 1529 L m⁻² h⁻¹ bar⁻¹ were obtained. However, the energy consumption of the heterogeneous desalination setup is a very important factor, and it remains largely unexplored. Here, the geometric-dimension-dependent ion transport in planar heterogeneous structures is reported. The two competitive ion migration behaviours during the desalination process, ion-depletion-dominated and electric-field-dominated ion transport, are identified for the first time. More importantly, these two ion-transport behaviours can be regulated. The excellent performance of combined high rejection rate, high water flux and low energy consumption can be obtained under the synergy of voltage, pressure and geometric dimension. With the appropriate optimization, the energy consumption can be reduced by 2 orders of magnitude, which is 50% of the industrial energy consumption. These findings provide beneficial insight for the application and optimized design of low-energy-consumption and portable water desalination devices. Full article

Freeze–thaw cycle is one of the main distresses of asphalt pavement, and the law of freeze–thaw damage has always been an important topic. In this paper, X-ray computed tomography (CT) of asphalt mixture before and after freezing and thawing was carried out, and its two-dimensional (2D) digital image was recognized. Firstly, the eigenvalues of internal voids of asphalt mixture are extracted. Then the distribution of internal voids was analyzed. Finally, the evolution law of internal voids was summarized. The research results show that the characteristic mean value of the 9th cycle is the irreversible limit of freeze–thaw damage, and the non-resilience after the large void area increases is the fundamental reason for the accumulation of freeze–thaw damage. The source of void damage shifts from large voids to small voids, and the middle-stage is a critical stage of freeze–thaw damage. This work quantitatively evaluates the internal freeze–thaw damage process of asphalt mixture, and a morphological theory of the evolution of void damage based on an equivalent ellipse is proposed, which is helpful for better understanding the freezing–thawing damage law of asphalt pavement. Full article

As a non-conventional machining technology, EDM is used extensively in modern industry, particularly in machining difficult-to-cut materials. CALMAX is a chromium-molybdenum-vanadium tool steel with exceptional toughness, ductility, and wear resistance that has a wide range of applications. Despite the fact that EDM is routinely used in CALMAX machining, the related published research is brief and limited. The current research gives a complete experimental study of CALMAX machining using EDM. A Taguchi Design of Experiment (DOE) was used, using pulse-on current, pulse-on time, and open-circuit voltage as control parameters. Material Removal Rate (MRR), Tool Material Removal Rate (TMRR), and Tool Wear Ratio (TWR) were used to evaluate machining performance, while Ra and Rz were used to estimate Surface Quality (SQ). The produced White Layer (WL) parameters were determined using optical and SEM microscopy, as well as EDX measurements and micro-hardness studies. Finally, for each of the aforementioned indexes, Analysis of Variance (ANOVA) was performed, and multi-objective optimization was based on Grey Relational Analysis (GRA). The results show that higher open-circuit voltage produces lower WL thickness, although by increasing the pulse-on time, the TWR is increased. The average hardness of the WL is increased about 400% compared to the micro-hardness of the bulk material. Full article

Currently, classical methods for the creation of various shapes and bending angles of metal sheet parts are applied. They are represented by the so-called all-metal forming tools. Non-standard methods, which in some cases exceed conventional technical solutions, are used in the practice to a minor extent. This is an area of interest from the point of view of ecology, because the shaping process performed in this way does not burden the environment in any considerable way. The knowledge presented in this work is obtained based on experiments in laboratory conditions. The list of literature contains mainly works from the recent period. The research represents a contribution to the great mosaic of magnetism. The aim of the current paper is to also verify the possibilities of the suitability of a special tool in the formation of metal sheet specimens using the application of the so-called forming with a free core. Additional benefits of the experimental work and their results are anticipated. The contribution is complemented by detailed calculations and diagrams. The practical contribution and research is that the device used for forming has been successfully tested. It turns out that the presented method is suitable for further development. The method has proven that is it suitable for industrial applications where simple shapes are produced. Full article

Modern manufacturing engineering requires quick and reasonable solutions during the production planning stage, ensuring production efficiency and cost reduction. This research aims to create a scientific approach to the rational choice of a locating chart for complexly shaped parts. It is an important stage during the manufacturing technology and fixture design process. The systematization of the designed and technological features of complexly shaped parts and the definition of the features that impact a locating chart create the fundamentals for justification. A scientific approach has been developed using the complex combination of the part’s features and a decision-making approach using the example of bracket-type parts. The matrix of design and technological features of parts was developed including steel AISI 3135 and cast iron DIN 1691. The classification of locating charts for bracket-type parts was defined. A mathematical model of the rational choice of the locating chart according to the structural code of the workpiece was verified in case studies from the practice. As a result, a decision-making approach was applied to the rational choice of the locating chart for any bracket-type part. The proposed solutions improve the production planning stage for machine building, automotive, and other industries. Full article

The microstructure evolution and grain growth kinetics of the fine-grained extruded Mg-Nd-Zn-Zr alloy were investigated by holding the extruded plate for a wide range of time in the temperature range of 470 °C to 530 °C. By observing the optical micrographs, it was found that the material showed abnormal grain growth at the experimental condition of 470 °C × 24 h, and the time point of abnormal grain growth appeared significantly earlier with the increase in the experimental temperature. The evaluation of the second phase content within the alloy indicates that the presence of the second phase contributes to the microstructural stability of the Mg-Nd-Zn-Zr alloy. However, the slow coarsening/dissolution of the second phase is an important cause of abnormal grain growth. Based on the experimental data, the isothermal grain growth kinetic models of the fine-grained extruded Mg-Nd-Zn-Zr alloy were developed based on the Sellars model. The grain growth exponent was in the range of 5.5–8 and decreased gradually with the increase in the experimental temperature. The grain growth activation energy is approximately 150.00 kJ/mol, which is close to the bulk diffusion activation energy of magnesium, indicating that the grain growth is controlled by lattice diffusion. By energy spectrometry (EDS), the compositional changes of the second phase within this alloy at 500 °C were investigated. Full article

In recent decades, lightweight aggregate concrete (LWC) became a popular building material due to its desired properties. However, various attributes of LWC, such as bond behavior of used reinforcing, have not been described thoroughly. In this regard, LWC produced with 0%, 50%, and 100% expanded clay aggregate was designed, and the physical–mechanical properties were assessed for material characterization. Subsequently, the bond behaviors of LWC reinforced with steel, glass fiber reinforced polymer (GFRP), and basalt fiber reinforced polymer (BFRP) bars were evaluated by pull-out tests. The results of the experimental program allowed the effects of expanded clay aggregate incorporation on LWC properties to be quantified. The bond strength of BFRP bars was not affected by the replacement of coarse aggregate by expanded clay aggregate, whilst the GFRP bars showed lower bond strength values of LWC specimens. Contrarily, in the case of steel bars, both the bond strength and bond stiffness were higher for LWC specimens than for those of normal concrete. Finite element software ATENA 3D was used for simulation of the bond behavior of LWC, and the model validated by the experimental results referred to reasonably corresponding outputs. Full article

Granular materials are widespread in nature and human production, and their macro-mechanical behavior is significantly affected by granule movement. The development of computer vision has brought some new ideas for measuring the numerical information (including the amount of translation, the rotation angle, velocity, acceleration, etc.) of dynamic granular materials. In this paper, we propose a numerical measurement method for dynamic granular materials based on computer vision. Firstly, an improved video instance segmentation (VIS) network is introduced to perform end-to-end multi-task learning, and its temporal feature fusion module and tracking head with long-sequence external memory can improve the problems of poor video data quality and high similarity in appearance of granular materials, respectively. Secondly, the numerical information can be extracted through a series of post-processing steps. Finally, the effectiveness of the measurement method is verified by comparing the numerical measurement results with the real values. The experimental results indicate that our improved VIS obtains an average precision (AP) of 76.6, the relative errors and standard deviations are maintained at a low level, and this method can effectively be used to measure the numerical information of dynamic granular materials. This study provides an intelligent proposal for the task of measuring numerical information of dynamic granular materials, which is of great significance for studying the spatial distribution, motion mode and macro-mechanical behavior of granular materials. Full article

The acceleration of very early age cement hydration by C-S-H seeding is getting attention from scholars and field applications because the enhanced early age features do not compromise later age performances. This acceleration could be beneficial for several low-CO₂ cements as a general drawback is usually the low very early age mechanical strengths. However, the mechanistic understanding of this acceleration in commercial cements is not complete. Reported here is a contribution to this understanding from the study of the effects of C-S-H gel seeding in one Portland cement and two belite cements at two widely studied water–cement ratios, 0.50 and 0.40. Two commercially available C-S-H nano-seed-based admixtures, i.e., Master X-Seed 130 and Master X-Seed STE-53, were investigated. A multi-technique approach was adopted by employing calorimetry, thermal analysis, powder diffraction (data analysed by the Rietveld method), mercury intrusion porosimetry, and mechanical strength determination. For instance, the compressive strength at 1 day for the PC (w/c = 0.50) sample increased from 15 MPa for the unseeded mortar to 24 and 22 MPs for the mortars seeded with the XS130 and STE53, respectively. The evolution of the amorphous contents was determined by adding an internal standard before recording the powder patterns. In summary, alite and belite phase hydrations, from the crystalline phase content evolutions, are not significantly accelerated by C-S-H seedings at the studied ages of 1 and 28 d for these cements. Conversely, the hydration rates of tetracalcium alumino-ferrate and tricalcium aluminate were significantly enhanced. It is noted that the degrees of reaction of C₄AF for the PC paste (w/c = 0.40) were 10, 30, and 40% at 1, 7, and 28 days. After C-S-H seeding, the values increased to 20, 45, and 60%, respectively. This resulted in larger ettringite contents at very early ages but not at 28 days. At 28 days of hydration, larger amounts of carbonate-containing AFm-type phases were determined. Finally, and importantly, the admixtures yielded larger amounts of amorphous components in the pastes at later hydration ages. This is justified, in part, by the higher content of amorphous iron siliceous hydrogarnet from the enhanced C₄AF reactivity. Full article

In the present study, electro-explosive spraying technology was used to prepare a multi-layer composite coating with a staggered spatial structure on a 45 steel substrate, and the mechanical properties and wear behavior of the coating were studied. The composite coating was prepared by spraying Mo as the bonding layer, then spraying high-carbon steel and aluminum bronze alternately as a functional coating. The cross-sectional morphology, surface morphology and the properties of the coating were analyzed with a scanning electron microscope (SEM), energy dispersive spectrometer (EDS), electron backscattered diffraction (EBSD) and a 3D profilometer. The bonding strength, friction and wear resistance of the coating were studied by the bonding strength experiment and by the friction and wear experiment. The results showed that it is feasible to prepare a composite coating with a sponge-like spatial structure with electro-explosive technology. There was metallurgical bonding as well as mechanical bonding between the adjacent coating layers. The composite coating had the advantages of uniform thickness, high compactness, high bonding strength and good wear resistance. Full article

Modifying lithium niobate cation composition improves not only the functional properties of the acousto- and optoelectronic materials as well as ferroelectrics but elevates the protonic transfer in LiNbO₃-based electrolytes of the solid oxide electrochemical devices. Molten chlorides and other thermally stable salts are not considered practically as the precursors to synthesize and modify oxide compounds. This article presents and discusses the results of an experimental study of the full or partial heterovalent substitution of lithium ion in nanosized LiNbO₃ powders and in the surface layer of LiNbO₃ single crystal using molten salt mixtures containing calcium, lead, and rare-earth metals (REM) chlorides as the precursors. The special features of heterovalent ion exchange in chloride melts are revealed such as hetero-epitaxial cation exchange at the interface PbCl₂-containing melt/lithium niobate single crystal; the formation of ${\mathrm{Li}}_{\left(1-\mathrm{x}\right)}{\mathrm{Ca}}_{\left(\mathrm{x}/2\right)}{\mathrm{V}}_{\left(\mathrm{x}/2\right)}^{{\mathrm{Li}}^{+}}{\mathrm{NbO}}_3$ solid solutions with cation vacancies as an intermediate product of the reaction of heterovalent substitution of lithium ion by calcium in LiNbO₃ powders; the formation of lanthanide orthoniobates with a tetragonal crystal structure such as scheelite as the result of lithium niobate interaction with trichlorides of rare-earth elements. It is shown that the fundamental properties of ion-modifiers (ion radius, nominal charge), temperature, and duration of isothermal treatment determine the products’ chemical composition and the rate of heterovalent substitution of Li⁺-ion in lithium niobate. Full article

In this study, the quasi-static and dynamic compressive mechanical behavior of a rolled Fe-28Mn-10Al-1.2C steel (low-density) was investigated. X-ray diffraction, optical microscopy, electron backscattered diffraction and transmission electron microscopy were conducted to characterize the microstructure evolution. The results displayed that the steel has remarkable strain rate sensitivity and strong strain hardenability under high strain rate compression. Most specifically, the deformation behavior was changed with the increase in the strain rate. A feasible mathematical analysis for the calculation of stacking fault energies and the critical resolve shear stresses for twinning was employed and discussed the nucleation of the twinning. The microband-induced plasticity and twinning-induced plasticity controlled the deformation under high strain rate compression and provided a strong strain hardening effect. The higher mechanical response can increase the broad use of low-density steel in automobile applications. Full article

3D printing is a technology that is increasingly used in the individualization of clothing, especially in the construction of garments for people with disabilities. The paper presents a study on the use of 3D printed knee protectors intended for wheelchair users. Due to the specific purpose of this 3D printed object, the breaking force of the polylactic acid (PLA) combined with 100% cotton and 100% polyester fabric was investigated. This paper will also describe a new method for testing the breaking force of a 3D printed polymer (PLA) combined with an incorporated fabric. Test samples were made, and the input parameters used in 3D printing were defined for testing purposes. A 3D knee protector for wheelchair users was developed based on a digitized model of the human body. The durability of the shape of the 3D printed shield was also tested after washing at temperatures of 40 °C, 50 °C and 60 °C. A clothing model that provides adequate user protection was proposed based on the conducted research. A construction solution has been proposed that enables the application of a 3D printed individualized garment element. Full article

Deterioration of materials and structures is an unavoidable fact, and prestressed concrete structures are not an exception. The evaluation of load-carrying capacity and remaining service life includes collecting various information. However, one type of information is essential and the most important, the state of prestressing, which inevitably decreases over time. Currently, many possible methods for the evaluation of prestressing are available. These techniques are part of the structural assessment and provide residual prestressing force value which is later used in the evaluation process. Therefore, it is suitable to provide the value of prestressing force based on certain probabilistic backgrounds. This study addresses the determination of residual prestressing force in pre-tensioned railway sleepers one year after their production, using the so-called Bayesian approach. This technique is focused on the validation of results obtained from the application of the non-destructive indirect saw-cut method. The Bayesian approach considers analytic calculation as the primary method of prestressing determination. In this paper, Monte Carlo simulation was used to determine the total variability that defines all Bayesian systems of probability functions. Specifically, a total of 1000 simulations was applied, and the current random vector of prestressing force derived from the analytical calculation has been assumed as a normally distributed function. Finally, obtained results for different depths of saw-cuts are compared. The results of the experimental and statistical determination of residual prestressing force provide its value with a 95% confidence level. This study suggests that the implementation of the probability approach can be an effective tool for determining prestress losses. Full article