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Material Systems and Structures in Mechanical and Aerospace Engineering

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A special issue of Materials (ISSN 1996-1944).

Deadline for manuscript submissions: closed (31 March 2023) | Viewed by 31736

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Prof. Lae-Hyong Kang

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Guest Editor

Chonbuk National University, South Korea
Interests: non-destructive testing; THz imaging; laser ultrasonics; ultrasonic testing; smart materials and structures; fiber optic sensors; piezoelectric materials; composite materials and structures; structural dynamics and control

Dr. Donghoon Kang

E-Mail Website1 Website2
Guest Editor

Railroad Safety Research Team, Korea Railroad Research Institute (KRRI), Uiwang, Gyeonggi-do 16105, Republic of Korea
Interests: nondestructive testing and evaluation skills; field application using structural health monitoring techniques; development of fiber optic sensors and field applications; convergence with internet of things technology
Special Issues, Collections and Topics in MDPI journals

Special Issue Information

Dear Colleagues,

We are pleased to announce that submissions are open for the Special Issue of Materials devoted to papers presented at the International Conference on Advances in Aerospace and Mechanical Engineering (AAME 2019), held July 9–12, 2019 in Incheon, Korea.

AAME 2019 focused on the identification and assessment of the state-of-the-art technologies in aerospace and mechanical engineering and aims to promote exchange and collaboration across disciplines and borders to explore new territories and frontiers in this field. Topics included in this Special Issue are smart materials, structural systems, solutions and optimization, and tools and methodologies, as well as bio-inspired system design. Applications include aerospace, automotive, and morphing structures, energy harvesting, structural health monitoring, mechatronics, and robotics.

We invite you to submit high-quality research, technical, or review papers to this Special Issue, with an emphasis on innovative new and emerging technologies that encompass the broad meanings of material-based mechanical and aerospace engineering applications.

Some areas of interest for this Special Issue include, but are not limited to, new skills and application results on multi-functional materials and structures, advanced composite materials and structures, advanced manufacturing and design technology, advanced technologies in safety, PHM and reliability, advanced structural health management, advanced dynamics and control, multi-physics computational modelling and simulation, emerging applications of 3D printing in aerospace and mechanical engineering, metamaterial technologies, smart machines and sensors, etc.

If you need any further information about this Special Issue, please do not hesitate to contact us.

Prof. Lae-Hyong Kang
Prof. Dr. Donghoon Kang
Guest Editors

Manuscript Submission Information

Manuscripts should be submitted online at www.mdpi.com by registering and logging in to this website. Once you are registered, click here to go to the submission form. Manuscripts can be submitted until the deadline. All submissions that pass pre-check are peer-reviewed. Accepted papers will be published continuously in the journal (as soon as accepted) and will be listed together on the special issue website. Research articles, review articles as well as short communications are invited. For planned papers, a title and short abstract (about 100 words) can be sent to the Editorial Office for announcement on this website.

Submitted manuscripts should not have been published previously, nor be under consideration for publication elsewhere (except conference proceedings papers). All manuscripts are thoroughly refereed through a single-blind peer-review process. A guide for authors and other relevant information for submission of manuscripts is available on the Instructions for Authors page. Materials is an international peer-reviewed open access semimonthly journal published by MDPI.

Please visit the Instructions for Authors page before submitting a manuscript. The Article Processing Charge (APC) for publication in this open access journal is 2600 CHF (Swiss Francs). Submitted papers should be well formatted and use good English. Authors may use MDPI's English editing service prior to publication or during author revisions.

Keywords

Multi-functional materials and structures
Advanced composite materials and structures
Advanced manufacturing and design technology
Advanced robotics and mechatronics
Advanced technologies in safety, PHM, and reliability
Advanced structural health management
Machine learning and IT applications in aerospace and mechanical engineering
Advanced dynamics and control
Multi-physics computational modeling and simulation
Emerging applications of 3D printing in aerospace and mechanical engineering
Emerging technologies in fluids engineering
Emerging technologies in thermal engineering
Emerging transportation technologies
Metamaterial technologies
Multidisciplinary micro/nano system engineering
Nature-inspired/biomimetic technologies
Smart machines and sensors
Other emerging technologies in aerospace and mechanical engineering

Published Papers (12 papers)

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Research

15 pages, 7370 KiB

Open AccessArticle

Behaviors of Micro-Arcs, Bubbles, and Coating Growth during Plasma Electrolytic Oxidation of β-Titanium Alloy

by Toshiaki Yasui, Katsuki Hayashi and Masahiro Fukumoto

Materials 2023, 16(1), 360; https://0-doi-org.brum.beds.ac.uk/10.3390/ma16010360 - 30 Dec 2022

Cited by 6 | Viewed by 1765

Abstract

The plasma electrolytic oxidation (PEO) of a titanium alloy, Ti-15V-3Cr-3Sn-3Al, was performed to develop mechanical applications by improving the tribological characteristics. The behaviors of micro-arcs, bubbles, and coating growth during the PEO process were investigated under three different operating conditions, constant voltage (CV) operation, constant current operation (CC), and short treatment time (ST) operation, to control the surface structure and function by the PEO process. A low friction coefficient was achieved by CV operation at 500 V and by CC operation at 3.0 kA/m². The maximum coating thickness of 6.88 μm was achieved by CV operation at 500 V and 60 s. From the observation of micro-arcs, bubbles, and discharge craters by ST operation, the minimum discharge diameter of the micro-arc was 8 μm, and the discharge craters had a discharge pore size of 0.3 μm in diameter in the center with a petal-shaped burr around the discharge pore. During the PEO process, no bubble bursts around the micro-arcs and no backfilling of the discharge pores by the ejected materials were observed. Thus, the discharge pores remain a porous structure in the PEO coating for Ti. The utilization efficiency of the total charge density by CV operation above 300 V was lower than that by the conventional anodization process. The utilization efficiency of total charge density by CC operation was higher than that by the conventional anodization process. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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10 pages, 3436 KiB

Open AccessArticle

Flexible Magnetic Polymer Composite Substrate with Ba_1.5Sr_1.5Z Hexaferrite Particles of VHF/Low UHF Patch Antennas for UAVs and Medical Implant Devices

by Sang-Eui Lee, Seong Pil Choi, Kyung-Sub Oh, Jaehwan Kim, Sang Min Lee and Kang Rae Cho

Materials 2020, 13(4), 1021; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13041021 - 24 Feb 2020

Cited by 3 | Viewed by 2464

Abstract

Our goal is to fabricate flexible magnetic polymer composites as antenna substrates for very high frequency (VHF)/low ultra high frequency (UHF) antennas for unmanned aerial vehicles (UAVs) and medical devices. Magnetodielectric materials, which have permeability (μ) similar to permittivity (ε), have attracted great attention, because they facilitate miniaturization of microwave devices while keeping or enhancing electromagnetic characteristics. Mechanically millled Ba_1.5Sr_1.5Co₂Fe₂₄O₄₁ (Ba_1.5Sr_1.5Z) hexaferrite particles were used to increase permeability in the interesting frequency band. The microwave properties of Ba_1.5Sr_1.5Z composites were predicted and measured. Hansen’s zero-order analysis of antenna bandwidth and electromagnetic field simulation showed that the hexaferrite-based flexible composite could enhance a bandwidth and achieve the miniaturization of antennas as well. The magnetic antenna substrates can be a good solution to integrate antennas into the UAVs whose dimensions are comparable to or larger than communication wavelength. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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16 pages, 7911 KiB

Open AccessArticle

Fractal Characteristics of Chip Morphology and Tool Wear in High-Speed Turning of Iron-Based Super Alloy

by Xu Zhang, Guangming Zheng, Xiang Cheng, Rufeng Xu, Guoyong Zhao and Yebing Tian

Materials 2020, 13(4), 1020; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13041020 - 24 Feb 2020

Cited by 6 | Viewed by 3011

Abstract

Considering that iron-based super alloy is a kind of difficult-to-cut material, it is easy to produce work hardening and serious tool wear during machining. Therefore, this work aims to explore the chip change characteristics and tool wear mechanism during the processing of iron-based super alloy, calculate the fractal dimensions of chip morphology and tool wear morphology, and use fractals to analyze their change trend. Meanwhile, a new cutting tool with a super ZX coating is used for a high-speed dry turning experiment. The results indicate that the morphology of the chip is saw-tooth, and its color changes gradually, due to the oxidation reaction. The main wear mechanisms of the tool involve abrasive wear, adhesive wear, oxidation wear, coating spalling, microcracking and chipping. The fractal dimension of the tool wear surface and chip is increased with the improvement of cutting speed. This work investigates the fractal characteristics of chip morphology and tool wear morphology. The fractal dimension changes regularly with the change of tool wear, which plays an important role in predicting this tool wear. It is also provides some guidance for the efficient processing of an iron-based super alloy. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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11 pages, 4624 KiB

Open AccessArticle

Mechanical Properties and Thermal Conductivity of Ytterbium-Silicate-Mullite Composites

by Jie Xiao, Wenbo Chen, Liangliang Wei, Wenting He and Hongbo Guo

Materials 2020, 13(3), 671; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13030671 - 03 Feb 2020

Cited by 8 | Viewed by 2374

Abstract

Various Ytterbium-Silicate-Mullite composites were successfully fabricated by adding Yb₂SiO₅ into mullite ceramics and then using pressureless sintering at 1550 °C. The influence of Yb₂SiO₅ addition on the microstructure, mechanical properties, and thermal conductivity of ytterbium-silicate-mullite composites was investigated. Results show that the composites mainly consisted of a mullite matrix and some in situ formed Yb₂Si₂O₇ and Al₂O₃ phases. By the addition of Yb₂SiO₅, the Vickers hardness of composites reached ~9.0 at an additive concentration of 5 mol %. Fracture toughness increased to ~2.7 MPa·m^1/2 at the additive concentration of 15 mol %, owing to the trans-granular fracture and crack deflection of the pinning effect of the Al₂O₃ phase in the composites. With the increase of the Al₂O₃ phase in the composite, the thermal conductivity for the 15YbAM reached around 4.0 W/(m·K) at 1200 °C. Although the thermal conductivity increased, it is still acceptable for such composites to be used as environmental barrier coatings. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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19 pages, 2994 KiB

Open AccessArticle

Structural and Micromechanical Properties of Ternary Granular Packings: Effect of Particle Size Ratio and Number Fraction of Particle Size Classes

by Joanna Wiącek, Mateusz Stasiak and Jalal Kafashan

Materials 2020, 13(2), 339; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13020339 - 11 Jan 2020

Cited by 11 | Viewed by 2178

Abstract

The confined uniaxial tests of packings with discrete particle size distribution (PSD) were modeled with the discrete element method. Ternary packings of spheres with PSD uniform or nonuniform by number of particles were examined in three-dimensional (3D) system. The study addressed an effect of the particle size ratio and the particle size fraction on structural and micromechanical properties of mixtures. A study of packing structure included porosity and coordination numbers, while the investigation of micromechanical properties included distribution of normal contact forces and stress transmission through the packing. A micro-scale investigation of the effect of particle size ratio on structure and mechanics of the ternary packings revealed a strong relationship between the properties of sample and the value of parameter till its critical value was reached. A further increase in particle size ratio did not significantly affect properties of packings. Contrary to the porosity and coordination numbers, the partial stresses were highly affected by the fraction of particle size classes in ternary mixtures. The contribution of the partial stress into the global stress was determined by number fraction of particles in packings with small particle size ratio, while it was mainly determined by particle size ratio in packings with small particle size ratio. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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10 pages, 6098 KiB

Open AccessArticle

A Study of Films Incorporating Magnetite Nanoparticles as Susceptors for Induction Welding of Carbon Fiber Reinforced Thermoplastic

by Inseok Baek and Seoksoon Lee

Materials 2020, 13(2), 318; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13020318 - 10 Jan 2020

Cited by 13 | Viewed by 2816

Abstract

Induction welding is a fast, clean, noncontact process that often uses a metal-mesh susceptor to facilitate localized controlled heating; however, the metal mesh presents various problems. In this study, the induction heating behavior of a 450

μ

m thick thin-film susceptor, fabricated by [...] Read more.

μ

m thick thin-film susceptor, fabricated by mixing magnetite (Fe

_{3}

_{4}

) nanoparticles (NPs) and PA6/carbon fiber (CF) (30%) thermoplastic resin, was examined with respect to the weight ratio of Fe

_{3}

_{4}

(50, 67, 75, and 80 wt%). The useful induction heating behavior of the 75 wt% Fe

_{3}

_{4}

susceptor suggested its suitability for additional heat treatment experiments, carried out at 3.4 kW at a frequency of 100 kHz. This susceptor attained the same maximum temperature during 10 cycles of repeated induction heating and cooling. It was then used to weld two thermoplastic composites, with 60 s of induction heating followed by 120 s of simultaneous cooling and pressing. The resulting welded joints had lap shear strength values of 36.8, 34.0, and 36.4 MPa under tensile test loads of 884, 817, and 874 N, respectively. Scanning electron microscopy images confirmed a uniform weld quality. Thus, the proposed manufacturing method, involving the incorporation of Fe

_{3}

_{4}

NPs into thermoplastic resin, should help expand the range of applications for thermoplastic composites. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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22 pages, 10635 KiB

Open AccessArticle

Bird-Strike Resistance of Composite Laminates with Different Materials

by Yadong Zhou, Youchao Sun and Tianlin Huang

Materials 2020, 13(1), 129; https://0-doi-org.brum.beds.ac.uk/10.3390/ma13010129 - 27 Dec 2019

Cited by 23 | Viewed by 3820

Abstract

To obtain some basic laws for bird-strike resistance of composite materials in aeronautical application, the high-velocity impact behaviors of composite laminates with different materials were studied by numerical methods. The smoothed particle hydrodynamics (SPH) and finite element method (FEM) coupling models were validated from various perspectives, and the numerical results were comparatively investigated. Results show that the different composite materials have relatively little effect on projectile deformations during the bird impact. However, the impact-damage distributions can be significantly different for different composite materials. The strength parameters and fracture energy parameters play different roles in different damage modes. Lastly, modal frequency was tentatively used to explain the damage behavior of the composite laminates, for it can manifest the mass and stiffness characteristics of a dynamic structure. The dynamic properties and strength properties jointly determine the impact-damage resistance of composite laminates under bird strike. Future optimization study can be considered from these two aspects. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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10 pages, 5579 KiB

Open AccessArticle

Piezoelectric Characteristics of 0.55Pb(Ni_1/3Nb_2/3)O₃-0.45Pb(Zr,Ti)O₃ Ceramics with Different MnO₂ Concentrations for Ultrasound Transducer Applications

by Myeongcheol Kang and Lae-Hyong Kang

Materials 2019, 12(24), 4115; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12244115 - 09 Dec 2019

Cited by 7 | Viewed by 2424

Abstract

In this study, we investigate the piezoelectric characteristics of 0.55Pb(Ni_1/3Nb_2/3)O₃-0.45Pb(Zr,Ti)O₃ (PNN-PZT) with MnO₂ additive (0, 0.25, 0.5, 1, 2, and 3 mol%). We focus on the fabrication of a piezoelectric ceramic for use as both actuator and sensor for ultrasound transducers. The actuator and sensor properties of a piezoelectric ceramic depend on the piezoelectric strain coefficient d and piezoelectric voltage coefficient g, related as g = d/ε^T. To increase g, the dielectric constant ε^T must be decreased. PNN-PZT with MnO₂ doping is synthesized using the conventional solid-state reaction method. The electrical properties are determined based on the resonant frequencies and vibration modes measured by using an impedance analyzer. The MnO₂ addition initially improves the tetragonality of the PNN-PZT ceramic, which then saturates at a MnO₂ content of 1 mol%. Therefore, the dielectric constant and piezoelectric coefficient d₃₃ steadily decrease, while the mechanical properties (Q_m, Young’s modulus), tanδ, electromechanical coupling coefficient k, and piezoelectric voltage coefficient g were improved at 0.5–1 mol% MnO₂ content. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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12 pages, 6272 KiB

Open AccessArticle

Defect Visualization of a Steel Structure Using a Piezoelectric Line Sensor Based on Laser Ultrasonic Guided Wave

by Sang-Hyeon Kang, Dae-Hyun Han and Lae-Hyong Kang

Materials 2019, 12(23), 3992; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12233992 - 02 Dec 2019

Cited by 5 | Viewed by 2668

Abstract

We studied the detection and visualization of defects in a test object using a laser ultrasonic guided wave. The scan area is irradiated by a laser generated from a Nd:YAG 532 nm Q-switched laser generator through a galvanometer scanner. The laser irradiation causes the surface temperature to suddenly rise and then become temporarily adiabatic. The locally heated region reaches thermal equilibrium with the surroundings. In other words, heat energy propagates inside the object in the form of elastic energy through adiabatic expansion. This thermoelastic wave is typically acquired by a piezoelectric sensor, which is sensitive in the ultrasonic domain. A single piezoelectric sensor has limited coverage in the scan area, while multi-channel piezoelectric sensors require many sensors, large-scale wiring, and many channeling devices for use and installation. In addition, the sensors may not acquire signals due to their installed locations, and the efficiency may be reduced because of the overlap between the sensing areas of multiple sensors. For these reasons, the concept of a piezoelectric line sensor is adopted in this study for the first time. To verify the feasibility of the line sensor, I- and L-shaped sensors were attached to a steel structure, and the ultrasound signal from laser excitation was obtained. If the steel structure has defects on the back, the ultrasonic propagation image will be distorted in the defect area. Thus, we can detect the defects easily from the visualization image. Three defects were simulated for the test. The results show that the piezoelectric line sensor can detect defects more precisely and accurately compared to a single piezoelectric sensor. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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12 pages, 4762 KiB

Open AccessArticle

Piezoresistive Multi-Walled Carbon Nanotube/Epoxy Strain Sensor with Pattern Design

by Mun-Young Hwang, Dae-Hyun Han and Lae-Hyong Kang

Materials 2019, 12(23), 3962; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12233962 - 29 Nov 2019

Cited by 13 | Viewed by 2640

Abstract

Carbon nanotube/polymer-based composites have led to studies that enable the realization of low-cost, high-sensitivity piezoresistive strain sensors. This study investigated the characteristics of piezoresistive multi-walled carbon nanotube (MWCNT)/epoxy composite strain sensors subjected to tensile and compressive loads in one direction at relatively small amounts of strain. A patterned sensor was designed to overcome the disadvantage of the load direction sensitivity differences in the existing sensors. The dispersion state of the MWCNTs in the epoxy polymer matrix with the proposed dispersion process was verified by scanning electron microscopy. An MWCNT/epoxy patterned strain sensor and a patch-type strain sensor were directly attached to an acrylic cantilever beam on the opposite side of a commercial metallic strain gauge. The proposed patterned sensor had gauge factors of 2.52 in the tension direction and 2.47 in the compression direction. The measured gauge factor difference for the patterned sensor was less than that for the conventional patch-type sensor. Moreover, the free-vibration frequency response characteristics were compared with those of metal strain gauges to verify the proposed patch-type sensor. The designed drive circuit compensated for the disadvantages due to the high drive voltage, and it was confirmed that the proposed sensor had higher sensitivity than the metallic strain gauge. In addition, the hysteresis of the temperature characteristics of the proposed sensor is presented to show its temperature range. It was verified that the patterned sensor developed through various studies could be applied as a strain sensor for structural health monitoring. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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21 pages, 8295 KiB

Open AccessArticle

Analysis of Important Fabrication Factors That Determine the Sensitivity of MWCNT/Epoxy Composite Strain Sensors

by Mun-Young Hwang and Lae-Hyong Kang

Materials 2019, 12(23), 3875; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12233875 - 24 Nov 2019

Cited by 3 | Viewed by 2226

Abstract

Composite sensors based on carbon nanotubes have been leading to significant research providing interesting aspects for realizing cost-effective and sensitive piezoresistive strain sensors. Here, we report a wide range of piezoresistive performance investigations by modifying fabrication factors such as multi-wall carbon nanotubes (MWCNT) concentration and sensor dimensions for MWCNT/epoxy composites. The resistance change measurement analyzed the influence of the fabrication factors on the changes in the gauge factor. The dispersion quality of MWCNTs in the epoxy polymer matrix was investigated by scanning electron microscopy (SEM) images and conductivity measurement results. A configuration circuit was designed to use the composite sensor effectively. It has been shown that, in comparison with commercially available strain gauges, composites with CNT fillers have the potential to attain structural health monitoring capabilities by utilizing the variation of electrical conductivity and its relation to strain or damage within the composite. Based on the characteristics of the MWCNT, we predicted the range of conductivity that can be seen in the fabricated composite. The sensor may require a large surface area and a thin thickness as fabrication factors at minimum filler concentration capable of exhibiting a tunneling effect, in order to fabricate a sensor with high sensitivity. The proposed composite sensors will be suitable in various potential strain sensor applications, including structural health monitoring. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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17 pages, 6169 KiB

Open AccessArticle

Acquisition of Dynamic Material Properties in the Electrohydraulic Forming Process Using Artificial Neural Network

by Min-A Woo, Young-Hoon Moon, Woo-Jin Song, Beom-Soo Kang and Jeong Kim

Materials 2019, 12(21), 3544; https://0-doi-org.brum.beds.ac.uk/10.3390/ma12213544 - 29 Oct 2019

Cited by 6 | Viewed by 2458

Abstract

Electrohydraulic forming is a high-velocity forming process that deforms sheet metals with velocities above 100 m/s and strain rates more than 100 s⁻¹. This experiment was conducted in a closed space because of safety concerns related to the high-velocity conditions; therefore, we were not able to examine the deformation process of the sheet metal. To observe the electrohydraulic forming process in detail, we performed virtual numerical simulations using accurate material properties. Therefore, in this paper, we obtained the material property of a sheet metal from a numerical estimation by using a surrogate model based on the reduced order model and the artificial neural network. The Cowper–Symonds constitutive equation was selected for the Al 6061-T6 sheet metal, and two strain rate parameters were adopted as the unknown parameters. From the two sampling techniques, the training and test samples were extracted from the specific ranges of two unknown parameters, and a numerical simulation was performed for these samples by using the LS-DYNA program. The z-axis displacements of the deformed sheet metal were obtained from the results of the numerical simulation, and two basis vectors were extracted by using principal component analysis. In addition, to predict the weighting coefficients of the two basis vectors at the defined range of parameters, we used the artificial neural network technique as a surrogate model. By comparing the surrogate model and the experimental results and calculating the root mean square error value, we estimated the optimal parameter for Al 6061-T6. Finally, the reliability of the obtained material parameters was proved by comparing the experimental results, the surrogate model, and LS-DYNA. Full article

(This article belongs to the Special Issue Material Systems and Structures in Mechanical and Aerospace Engineering)

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