Search results

Unconventional machining processes, particularly ultrasonic vibration cutting (UVC), can overcome such technical bottlenecks. However, the precise mechanism through which UVC affects the in-service functional performance of advanced aerospace materials remains obscure. This limits their industrial application and requires a deeper understanding.

The surface integrity and in-service functional performance of advanced aerospace materials are important guarantees for safety and stability in the aerospace industry. For advanced aerospace materials, which are difficult-to-machine, conventional machining processes cannot meet the requirements of high in-service functional performance owing to rapid tool wear, low processing efficiency and high cutting forces and temperatures in the cutting area during machining.

To address this literature gap, this study is focused on the quantitative evaluation of the in-service functional performance (fatigue performance, wear resistance and corrosion resistance) of advanced aerospace materials. First, the characteristics and usage background of advanced aerospace materials are elaborated in detail. Second, the improved effect of UVC on in-service functional performance is summarized. We have also explored the unique advantages of UVC during the processing of advanced aerospace materials. Finally, in response to some of the limitations of UVC, future development directions are proposed, including improvements in ultrasound systems, upgrades in ultrasound processing objects and theoretical breakthroughs in in-service functional performance.

This study provides insights into the optimization of machining processes to improve the in-service functional performance of advanced aviation materials, particularly the use of UVC and its unique process advantages.

The need for precise synthesis of customized designs has resulted in the development of advanced coating processes for modern nanomaterials. Achieving accuracy in these processes requires a deep understanding of thermophysical behavior, rheology and complex chemical reactions. The manufacturing flow processes for these coatings are intricate and involve heat and mass transfer phenomena. Magnetic nanoparticles are being used to create intelligent coatings that can be externally manipulated, making them highly desirable. In this study, a Keller box calculation is used to investigate the flow of a coating nanofluid containing a viscoelastic polymer over a circular cylinder.

The rheology of the coating polymer nanofluid is described using the viscoelastic model, while the effects of nanoscale are accounted for by using Buongiorno’s two-component model. The nonlinear PDEs are transformed into dimensionless PDEs via a nonsimilar transformation. The dimensionless PDEs are then solved using the Keller box method.

The transport phenomena are analyzed through a comprehensive parametric study that investigates the effects of various emerging parameters, including thermal radiation, Biot number, Eckert number, Brownian motion, magnetic field and thermophoresis. The results of the numerical analysis, such as the physical variables and flow field, are presented graphically. The momentum boundary layer thickness of the viscoelastic polymer nanofluid decreases as fluid parameter increases. An increase in mixed convection parameter leads to a rise in the Nusselt number. The enhancement of the Brinkman number and Biot number results in an increase in the total entropy generation of the viscoelastic polymer nanofluid.

Intelligent materials rely heavily on the critical characteristic of viscoelasticity, which displays both viscous and elastic effects. Viscoelastic models provide a comprehensive framework for capturing a range of polymeric characteristics, such as stress relaxation, retardation, stretching and molecular reorientation. Consequently, they are a valuable tool in smart coating technologies, as well as in various applications like supercapacitor electrodes, solar collector receivers and power generation. This study has practical applications in the field of coating engineering components that use smart magnetic nanofluids. The results of this research can be used to analyze the dimensions of velocity profiles, heat and mass transfer, which are important factors in coating engineering. The study is a valuable contribution to the literature because it takes into account Joule heating, nonlinear convection and viscous dissipation effects, which have a significant impact on the thermofluid transport characteristics of the coating.

The momentum boundary layer thickness of the viscoelastic polymer nanofluid decreases as the fluid parameter increases. An increase in the mixed convection parameter leads to a rise in the Nusselt number. The enhancement of the Brinkman number and Biot number results in an increase in the total entropy generation of the viscoelastic polymer nanofluid. Increasing the strength of the magnetic field promotes an increase in the density of the streamlines. An increase in the mixed convection parameter results in a decrease in the isotherms and isoconcentration.

The impact of rolling on the performance of micro arc oxidation (MAO) coatings on ZM5 alloy has been underreported. The purpose of this study is to explore the correlation between rolling and the failure mechanism of MAO coatings in greater depth.

The influence of rolling on the corrosion and wear properties of MAO coating was investigated by phase structure, bond strength test (initial bond strength and wet adhesion), electrochemical impedance spectroscopy and wear test. The change of the surface electrochemical properties was studied by first principles analysis.

The results showed that the MAO coating on rolled alloy had better corrosion and wear resistance compared to cast alloy, although the structure and component content of two kinds of MAO coating are nearly identical. The difference in interface bonding between MAO coating and Mg substrate is the primary factor contributing to the disparity in performance between the two types of samples. Finally, the impact of the rolling process on MAO coating properties is explained through first-principle calculation.

A comprehensive explanation of the impact of the rolling process on MAO coating properties will provide substantial support for enhancing the application of Mg alloy anticorrosion.

Aluminum alloy is considered an ideal material in aerospace, automobile and other fields because of its lightweight, high specific strength and easy processing. However, low hardness and strength of the surface of aluminum alloys are the main factors that limit their applications. The purpose of this study is to obtain a composite coating with high hardness and lubricating properties by applying GO–PVA over MAO coating.

A pulsed bipolar power supply was used as power supply to prepare the micro-arc oxidation (MAO) coating on 6061 aluminum sample. Then a graphene oxide-polyvinyl alcohol (GO–PVA) composite coating was prepared on MAO coating for subsequent experiments. Samples were characterized by Fourier infrared spectroscopy, X-ray diffraction, Raman spectroscopy and thermogravimetric analysis. The friction test is carried out by the relative movement of the copper ball and the aluminum disk on the friction tester.

Results showed that the friction coefficient of MAO samples was reduced by 80% after treated with GO–PVA composite film.

This research has made a certain contribution to the surface hardness and tribological issues involved in the lightweight design of aluminum alloys.

The peer review history for this article is available at: https://publons.com/publon/10.1108/ILT-12-2023-0427/

This paper aims to achieve phosphating via optimal features of Mg metal as a suitable base coating, which is considered for other properties such as barrier properties against the passage of several factors.

In this research, in the phosphate bath, immersion time, temperature and the content of sodium nitrite as an accelerator were changed.

As a result, increasing the immersion time of AZ31 Mg alloy samples in the phosphating bath as well as increasing the ratio of sodium dodecyl sulfate (SDS) concentration to sodium nitrite concentration in the phosphating bath formulation increase the mass of phosphating formed per unit area of the Mg alloy. The results of the scanning electron microscope test showed phosphating is not completely formed in short immersion times, which is a thin and uneven layer.

Mg and its alloys are sensitive to galvanic corrosion, which would lead to generating several holes in the metal. As such, it causes a decrease in mechanical stability as well as an unfavorable appearance.

Mg is used in several industries such as automobile and computer parts, mobile phones, astronaut compounds, sports goods and home appliances.

Nevertheless, Mg has high chemical reactivity, so an oxide-hydroxide layer is formed on its surface, which has a harmful effect on the adhesion and uniformity of the coating applied on Mg.

By increasing the ratio of SDS concentration to sodium nitrite concentration in the phosphating bath, the corrosion resistance of the phosphating increases.

This study aims to review the current one-step electrodeposition of superhydrophobic coatings on metal surfaces.

One-step electrodeposition is a versatile and simple technology to prepare superhydrophobic coatings on metal surfaces.

Preparing superhydrophobic coatings by one-step electrodeposition is an efficient method to protect metal surfaces.

Even though there are several technologies, one-step electrodeposition still plays a significant role in producing superhydrophobic coatings.

The purpose of this study is to examine the impact of MoS₂ on the microstructure and characteristics of micro-arc oxidized (MAO) ceramic coatings created on ZK60 magnesium alloy through the addition of varying concentrations of MoS₂ particles to the electrolyte, aiming to enhance the corrosion resistance of magnesium alloy.

The surface morphology, roughness and phase composition of the coatings were analyzed using scanning electron microscopy, a hand-held roughness tester and an X-ray diffractometer, respectively, and the corrosion resistance of the MAO coatings prepared by the addition of different contents of MoS₂ particles was tested and analyzed using an electrochemical workstation.

The results demonstrate that MoS₂/MgO composite coatings have been successfully prepared on the surface of magnesium alloys through micro-arc oxidation. Furthermore, the corrosion resistance of the ZK60 magnesium alloy prepared with the addition of 1.0 g/L MoS₂ was the best compared to the other samples.

MoS₂ particles were able to penetrate the coatings successfully during the micro-arc oxidation process, acting as a barrier in the micropores to prevent the corrosion medium from touching the surface, thus improving the corrosion resistance of the sample. The electrochemical workstation was used to study the corrosion resistance of the MoS₂/MAO coating on the ZK60 magnesium alloy.

As an advanced manufacturing method, additive manufacturing (AM) technology provides new possibilities for efficient production and design of parts. However, with the continuous expansion of the application of AM materials, subtractive processing has become one of the necessary steps to improve the accuracy and performance of parts. In this paper, the processing process of AM materials is discussed in depth, and the surface integrity problem caused by it is discussed.

Firstly, we listed and analyzed the characterization parameters of metal surface integrity and its influence on the performance of parts and then introduced the application of integrated processing of metal adding and subtracting materials and the influence of different processing forms on the surface integrity of parts. The surface of the trial-cut material is detected and analyzed, and the surface of the integrated processing of adding and subtracting materials is compared with that of the pure processing of reducing materials, so that the corresponding conclusions are obtained.

In this process, we also found some surface integrity problems, such as knife marks, residual stress and thermal effects. These problems may have a potential negative impact on the performance of the final parts. In processing, we can try to use other integrated processing technologies of adding and subtracting materials, try to combine various integrated processing technologies of adding and subtracting materials, or consider exploring more efficient AM technology to improve processing efficiency. We can also consider adopting production process optimization measures to reduce the processing cost of adding and subtracting materials.

With the gradual improvement of the requirements for the surface quality of parts in the production process and the in-depth implementation of sustainable manufacturing, the demand for integrated processing of metal addition and subtraction materials is likely to continue to grow in the future. By deeply understanding and studying the problems of material reduction and surface integrity of AM materials, we can better meet the challenges in the manufacturing process and improve the quality and performance of parts. This research is very important for promoting the development of manufacturing technology and achieving success in practical application.

Intumescent coatings are nowadays a dominant passive system used to protect structural materials in case of fire. Due to their reactive swelling behaviour, intumescent coatings are particularly complex materials to be modelled and predicted, which can be extremely useful especially for performance-based fire safety designs. In addition, many parameters influence their performance, and this challenges the definition and quantification of their material properties. Several approaches and models of various complexities are proposed in the literature, and they are reviewed and analysed in a critical literature review.

Analytical, finite-difference and finite-element methods for modelling intumescent coatings are compared, followed by the definition and quantification of the main physical, thermal, and optical properties of intumescent coatings: swelled thickness, thermal conductivity and resistance, density, specific heat capacity, and emissivity/absorptivity.

The study highlights the scarce consideration of key influencing factors on the material properties, and the tendency to simplify the problem into effective thermo-physical properties, such as effective thermal conductivity. As a conclusion, the literature review underlines the lack of homogenisation of modelling approaches and material properties, as well as the need for a universal modelling method that can generally simulate the performance of intumescent coatings, combine the large amount of published experimental data, and reliably produce fire-safe performance-based designs.

Due to their limited applicability, high complexity and little comparability, the presented literature review does not focus on analysing and comparing different multi-component models, constituted of many model-specific input parameters. On the contrary, the presented literature review compares various approaches, models and thermo-physical properties which primarily focusses on solving the heat transfer problem through swelling intumescent systems.

The presented literature review analyses and discusses the various modelling approaches to describe and predict the behaviour of swelling intumescent coatings as fire protection for structural materials. Due to the vast variety of available commercial products and potential testing conditions, these data are rarely compared and combined to achieve an overall understanding on the response of intumescent coatings as fire protection measure. The study highlights the lack of information and homogenisation of various modelling approaches, and it underlines the research needs about several aspects related to the intumescent coating behaviour modelling, also providing some useful suggestions for future studies.

This paper aims to investigate the bonding of the photonic integrated circuit (PIC) chip with the heat sink using the AlNi self-propagating soldering method.

Compared to industrial optical modules, optical modules for aerospace applications require better reliability and stability, which is hard to achieve via the dispensing adhesive process that is used for traditional industrial optical modules. In this paper, 25 µm SAC305 solder foils and the AlNi nanofoil heat source were used to bond the back of the PIC chip with the heat sink. The temperature field and temperature history were analyzed by the finite element analysis (FEA) method. The junction-to-case thermal resistance is 0.0353°C/W and reduced by 85% compared with the UV hybrid epoxy joint.

The self-propagating reaction ends within 2.82 ms. The maximum temperature in the PIC operating area during the process is 368.5°C. The maximum heating and cooling rates of the solder were 1.39 × 107°C/s and −5.15 × 106°C/s, respectively. The microstructure of SAC305 under self-propagating reaction heating is more refined than the microstructure of SAC305 under reflow. The porosity of the heat sink-SAC305-PIC chip self-propagating joint is only 4.7%. Several metastable phases appear as AuSn3.4 and AgSn3.

A new bonding technology was used to form the bonding between the PIC chip with the heat sink for the aerospace optical module. The reliability and thermal resistance of the joint are better than that of the UV hybrid epoxy joint.