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The purpose of this paper is to investigate the effect of preheat and layer thickness in selective laser melting (SLM) of magnesium using pulse mode. Magnesium has been considered as a new generation of implant materials which are bioactive and biodegradable for orthopaedic applications.

To produce optimal single magnesium tracks to compare the effect of layer thickness and preheat, different laser parameters were investigated. The analysis was made based on digital and electronic microscope images and mechanical measurements.

Improvements in the magnesium tracks due to preheating were successfully achieved. The analysis shows better bonding to the surface. The preheated tracks present an improvement in quality surface: smoother and flatter surfaces are discovered for the low layer thicknesses. When the thickness increases, the surface was disrupted and presented high surface roughness values. These were attributed to the Marangoni convection.

This study continues valuing the fabrication of magnesium with SLM. It shows the improvements of preheat and effect of different layer thicknesses on the part properties.

In surface mount assembly (SMA) process, small components are subjected to high temperature variations, which result in components’ deformation and cracking. Because of this phenomenon, cracks are formed in the body of carbonyl powder ceramic inductor (CPCI) in the preheat and cooling stages of the reflow oven. These cracks become the main cause of board failure in the ageing process. The purpose of this paper is to ascertain the thermal stress, thermal expansion of carbonyl iron ceramics and its effects on crack commencement and proliferation in the preheat stage of reflow oven. Moreover, this paper also categorized and suggested important parameters of reflow profile that could be used to eliminate these thermal shock failures.

In this paper, two different reflow profiles were studied that evaluate the thermal shock of CPCI during varying ΔT at the preheat zone of the reflow oven. In the first profile, the change in temperature ΔT at preheat zone was set to 3.26°C/s, which has resulted in a number of device failures because of migration of micro cracks through the CPCI. In the second profile, this ΔT at preheat stage is minimized to 2.06°C/s that eliminated the thermal stresses; hence, the failure rates were significantly reduced.

TMPC0618H series lead (Pb)-free CPCI is selected for this study and its thermal expansion and thermal shock are observed in the reflow process. It is inferred from the results that high ΔT at preheat zone generates cracks in the carbonyl powder-type ceramics that cause device failure in the board ageing process. Comparing materials, carbonyl powder ceramic components are less resistant to thermal shock and a lower rate of temperature change is desirable.

The proposed study presents an experimental analysis for mitigating the thermal shock defects. The realization of the proposed approach is validated with experimental data from the printed circuit boards manufacturing process.

This study aims to investigate and model interrelationships between process parameters, geometrical profile characteristics and mechanical properties of industrially extruded aluminum alloys.

Statistical design of experiments (DOE) was applied to investigate and model the effects of eight factors including extrusion ratio, stem speed, billet-preheat temperature, number of die cavities, quenching media (water/air), time and temperature of artificial aging treatment and profile nominal thickness on four mechanical properties (yield strength, ultimate tensile strength, percent elongation and hardness). Experiments were carried out at an actual extrusion plant using 8-in. diameter billets on an extrusion press with 2,200 ton capacity.

Main factors and factor interactions controlling mechanical properties were identified and discussed qualitatively. Quantitative models with high prediction accuracy (in excess of 95%) were also obtained and discussed.

The obtained results are believed to be of great importance to researchers and industrial practitioners in the aluminum extrusion industry.

All practical and relevant parameters have been used to model all important mechanical properties in a collective manner in one study and within actual industrial setup. This is in contrast to all previous studies where either a partial set of parameters and/or mechanical properties are discussed and mostly under limited laboratory setup.

A three‐dimensional thermal finite element model including the effect of the powder‐to‐solid transition has been developed to investigate the transient temperature distribution and effects of substrate preheating during laser densification of dental powder bed for the layer‐by‐layer fabrication. The model encompasses the effects of the temperature‐ and porosity‐dependent thermal conduction and radiation as well as the temperature‐dependent natural convection. Substrate preheating is found to be important in preventing the formation of cracks in the dental porcelain body during laser densification. The simulation results are found to match the experiments very well.

This study aims to achieve customized prosthesis for total joint arthroplasty and total hip arthroplasty. Selective laser sintering (SLS) as additive manufacturing could enable small-scale fabrication of customized Ultra High Molecular Weight Polyethylene (UHMWPE) components; however, the processes for SLS of UHMWPE need to be improved.

This paper begins by improving the preheating system of the SLS fabricating equipment and then fabricating cuboids with the same size and cuboids with same volume and different size to study the warpage, demonstrating the effect of the value and uniformity of the preheating temperature on component fabrication. Warpage, density and tensile properties are investigated from the perspective of energy input density. Finally, complicated industrial parts are produced effectively by using optimized technological parameters.

The results show that components can be fabricated effectively after the optimization of the SLS technological parameters i.e. the preheating temperature the laser power the scanning interval and the scanning speed. The resulting warpage was found to be less than 0.1 mm along with the density as 83.25 and the tensile strength up to 14.1 Mpa. UHMWPE sample parts with good appearance and strength are obtained after ascertaining the effect of each factor on the fabrication of the sample parts.

It is very challenging to fabricate UHMWPE sample parts by SLS. This is a new step in the fabrication of customized UHMWPE sample parts.

The range of applications of the currently available biomass selective laser sintering (SLS) parts is limited and low-quality. This study aims to demonstrate the effects of the various processing parameters on the dimensional accuracy, bending strength, tensile strength, density and impact strength of the Prosopis chilensis/polyethersulfone (PES) composites (PCPCs) that were produced by SLS. The various processing parameters are laser power, scan speed, preheating temperature, scan spacing and layer thickness. In addition, the authors’ studied the effects of PCP particle size on the mechanical properties of the PCPCs.

The PCPC specimens were printed using an AFS SLS machine (additive manufacturing). The bending, tensile and impact strengths of the specimens were measured using a universal tensile tester. The dimensional accuracy of the bending specimens was determined by a Vernier caliper. The formability of the PCPC at various mixing ratios of the raw materials was earlier investigated by single-layer sintering experiments (Idriss et al., 2020b). The microstructure and particle distribution of the various PCPC specimens were analyzed by scanning electron microscopy (SEM).

The mechanical strengths (bending, tensile and impact strengths and density) and the dimensional accuracy of the PCPC SLS parts were directly and inversely proportional, respectively, to the laser power and preheating temperature. Furthermore, the mechanical strengths and dimensional accuracy of the PCPC SLS parts were inversely and directly proportional, respectively, to the scanning speed, scan spacing and layer thickness.

PCPC is an inexpensive, energy-efficient material that can address the drawbacks of the existing SLS parts. It is also eco-friendly because it lowers the pollution and CO₂ emissions that are associated with waste disposal and SLS, respectively. The optimization of the processing parameters of SLS in this study produced high-quality PCPC parts with high mechanical strengths and dimensional accuracy that could be used for the manufacture of the roof and wooden floors, construction components and furniture manufacturing.

To the best of the authors’ knowledge, this study is among the first to elucidate the impact of the various SLS processing parameters on the mechanical properties and dimensional accuracy of the sintered parts. Furthermore, novel PCPC parts were produced in this study by SLS.

The purpose of this paper is to propose a kind of fuzzy adaptive control method to control non‐linear system that has the characteristic of small time delay and fast respond speed.

The paper analyzes the production process and the actual condition of the preheat process of the plating zinc and painting plastic scribbled of double layer welded pipe that has the small time delay and fast respond speed, and also gives the preheat process mathematical model. Fuzzy adaptive control method with hierarchical structure is used which aims at one non‐linear system that has the characteristic of small time delay and fast responds speed. Through the simulation, it proves the mentioned method is effective to control the temperature system for double layers welded pipe in welding process.

Based on the mathematical model proposed about the production process and the actual condition of the preheat process, the fuzzy adaptive control method is effective to control the temperature system for double layers welded pipe in welding process.

The paper proposes fuzzy adaptive control method with hierarchical structure which has the basic fuzzy control grade, adaptive adjust grade, and process state judgment grade.

A very useful method in welding process for double layers welded pipe.

The new mathematical model is proposed about the production process, and the new control method is used in the temperature system for double layers welded pipe in welding process.

During fuser‐roll resist lamination processes, the copper‐clad FR‐4 substrate surface temperature was found to be inversely proportional to the substrate thickness. This temperature fluctuation has resulted in changes of adhesive forces in the copper/resist interface which in turn can affect the yield in the printed circuit manufacturing processes. By using infra‐red preheat treatment on the substrate prior to fuser‐roll lamination, the adhesion was found to be improved in the copper/resist interface. This adhesion improvement was found to be reflected in yield increase in fine line printed circuit fabrication.

The purpose this paper is to develop an additive manufacturing (AM) technique for high‐strength oxide ceramics. The process development aims at directly manufacturing fully dense ceramic freeform‐components with good mechanical properties.

The selective laser melting of the ceramic materials zirconia and alumina has been investigated experimentally. The approach followed up is to completely melt ZrO₂/Al₂O₃ powder mixtures by a focused laser beam. In order to reduce thermally induced stresses, the ceramic is preheated to a temperature of at least 1,600°C during the build up process.

It is possible to manufacture ceramic objects with almost 100 percent density, without any sintering processes or any post‐processing. Crack‐free specimens have been manufactured that have a flexural strength of more than 500 MPa. Manufactured objects have a fine‐grained two‐phase microstructure consisting of tetragonal zirconia and alpha‐alumina.

Future research may focus on improving the surface quality of manufactured components, solving issues related to the cold powder deposition on the preheated ceramic, further increasing the mechanical strength and transferring the technology from laboratory scale to industrial application.

Potential applications of this technique include manufacturing individual all‐ceramic dental restorations, ceramic prototypes and complex‐shaped ceramic components that cannot be made by any other manufacturing technique.

This new manufacturing technique based on melting and solidification of high‐performance ceramic material has some significant advantages compared to laser sintering techniques or other manufacturing techniques relying on solid‐state sintering processes.

The purpose of this study is to carry out energy and exergy analysis of fuels. Production of power and heat in industrialized countries is almost entirely based on combustion of fuels. Usually, combustion takes place in boilers or furnace; well-designed boilers have high thermal efficiencies of > 90 per cent. Even very high efficiencies, close to 100 per cent can be achieved depending on the applied fuel and boiler type. These high thermal efficiencies do suggest that combustion processes are highly optimized and do not need further improvements with regard to their thermodynamic performance. Second law (entropy or exergy) evaluations, however, shows that thermodynamic losses of boiler and furnaces are much larger than the thermal efficiencies do suggest. During combustion, air is predominantly used. When using air, the adiabatic combustion temperature depends only on the properties of fuel and air. The determining parameters for optimal fuel utilization are the fuel type, their composition and moisture content, the air temperature and air factor at combustion inlet.

Following assumptions are made for the analysis: calculation on the basis of 100 kg of dry and ash free fuel entering the control volume; fuel entering the control volume at T₀, P₀ and reacting completely with air entering separately at T₀, P₀ to form CO₂, SO₂, N₂ and H₂O, which exit separately at T₀, P₀ (T₀ = 298 K; P₀ = 1 atm); all heat transfer occurs at temperature T₀; and the chemical exergy of the ash has been ignored The availability change and the irreversibility for chemical reactions of hydrocarbon fuels were studied because fuel and dry air composed of O₂ and N₂ react to form products of combustion in the restricted dead state, and fuel and dry air composed of O₂ and N₂ react to form products of combustion which end up in the environmental (unrestricted) dead state. The difference between the above two statement, is the chemical availability of the product gases as they proceed from the restricted to the unrestricted dead state. These evaluations were made in terms of enthalpy and entropy values of the reacting species. T₀ extend these concepts to the most general situation, it is considered a steady-state control volume where the fuels enters at the restricted dead state, the air (oxidant) is drawn from the environment, and the products are returned to the unrestricted dead state.

It is evident from the analysis that an air factor of 1.10-1.20 is sufficient for liquid fuels, whereas solid fuels will require air factors of 1.15–1.3. When the temperatures of the products of combustion (T_p) are cooled down to that of T₀, the maximum reversible work occurs. From the analysis, it is clear that the rather low combustion temperature and the need for cooling down the flue gases to extract the required heat are the main causes of the large exergy losses. The maximum second law efficiency also occurs when T_p is set equal to T₀. The maximum second law efficiency per kilo mole of fuel is found to be 73 per cent, i.e. 73 per cent of the energy released by the cooling process could theoretically be converted into useful work. It is evident that reducing exergy losses of combustion is only useful if the heat transferred from the flue gas is used at high temperatures. Otherwise, a reduction of exergy loss of combustion will only increase the exergy loss of heat transfer to the power cycle or heat-absorbing process. The exergy loss of combustion can be reduced considerable by preheating combustion air. Higher preheat temperatures can be obtained by using the flue gas flow only for preheating air. The remainder of the flue gas flow can be used for heat transfer to a power cycle or heat-absorbing process. Even with very high air preheat temperatures, exergy losses of combustion are still > 20 per cent. The application of electrochemical conversion of fuel, as is realized in fuel cells, allows for much lower exergy loses for the reaction between fuel and air than thermal conversion. For industrial applications, electrochemical conversion is not yet available, but will be an interesting option for the future.

The outcome of the study would certainly be an eye-opener for all the stakeholders in thermal power plants for considering the second law efficiency and to mitigate the irreversibilities.