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Powder bed density is a key parameter in powder bed additive manufacturing (AM) processes but is not easily monitored. This research evaluates the possibility of non-invasively estimating the density of an AM powder bed via its thermal properties measured using flash thermography (FT).

The thermal diffusivity and conductivity of the samples were found by fitting an analytical model to the measured surface temperature after flash of the powder on a polymer substrate, enabling the estimation of the powder bed density.

FT estimated powder bed was within 8% of weight-based density measurements and the inferred thermal properties are consistent with literature findings. However, multiple flashes were necessary to ensure precise measurements due to noise in the experimental data and the similarity of thermal properties between the powder and substrate.

This paper emphasizes the capability of Flash Thermography (FT) for non-contact measurement of SS 316 L powder bed density, offering a pathway to in-situ monitoring for powder bed AM methods including binder jetting (BJ) and powder bed fusion. Despite the limitations of the current approach, the density knowledge and thermal properties measurements have the potential to enhance process development and thermal modeling powder bed AM processes, aiding in understanding the powder packing and thermal behavior.

In the measurement of liquid density and viscosity, the change of resonance parameters due to the parasitic parallel capacitance of resonator affects the measurement accuracy. To improve the accuracy, a method was proposed to compensate the parasitic parallel capacitance of resonator by adding an electrode.

The new electrode (compensation electrode) was added into resonant sensor to make compensation capacitance. The closer the compensation capacitance was to the parasitic parallel capacitance, the better compensation was. The structural parameters of resonant sensor with the compensation electrode were determined by the simulation and experiment.

The effect of this method was examined by the experiment. The relative errors of density and viscosity were less than 0.15, 0.5 % and standard deviations were less than 0.0004 g/cm³ and 0.005 mPas, respectively.

The experimental results show that this method is valuable for the parasitic parallel capacitance compensation of immersed resonant sensor.

This paper has not been published in other journals.

This study aims to deepen the knowledge concerning the metal fused filament fabrication technology through an analysis of the printing parameters of a commercial 316L stainless steel filament and their influence on the porosity and mechanical properties of the printed parts. It also investigates the feasibility of manufacturing complex geometries, including strut-and-node and triply periodic minimal surface lattices.

A three-step experimental campaign was carried out. Firstly, the printing parameters were evaluated by analysing the green parts: porosity and density measurements were used to define the best printing profile. Then, the microstructure and porosity of the sintered parts were investigated using light optical and scanning electron microscopy, while their mechanical properties were obtained through tensile tests. Finally, manufacturability limits were explored with reference samples and cellular structures having different topologies.

The choice of printing parameters drastically influences the porosity of green parts. A printing profile which enables reaching a relative density above 99% has been identified. However, voids characterise the sintered components in parallel planes at the interfaces between layers, which inevitably affect their mechanical properties. Lattice structures and complex geometries can be effectively printed, debinded, and sintered if properly dimensioned to fulfil printing constraints.

This study provides an extensive analysis of the printing parameters for the 316L filament used and an in-depth investigation of the potential of the metal fused filament fabrication technology in printing lightweight structures.

Fused deposition modeling (FDM) nowadays offers promising future applications for fabricating not only thermoplastic-based polymers but also composite PLA/Metal alloy materials, this capability bridges the need for metallic components in complex manufacturing processes. The research is to explore the manufacturability of multi-metal parts by printing green bodies of PLA/multi-metal objects, carrying these objects to the debinding process and varying the sintering parameters.

Three different sample types of SS316L part, Inconel 718 part and bimetallic composite of SS316L/IN718 were effectively printed. After the debinding process, the printed parts (green bodies), were isothermally sintered in non-vacuum chamber to investigate the fusion behavior at four different temperatures in the range of 1270 °C−1530 °C for 12 h and slowly cooled in the furnace. All samples was assessed including geometrical assessment to measure the shrinkage, characterization (XRD) to identify the crystallinity of the compound and microstructural evolution (Optical microscopy and SEM) to explore the porosity and morphology on the surface. The hardness of each sample types was measured and compared. The sintering parameter was optimized according to the microstructural evaluation on the interface of SS316L/IN718 composite.

The investigation indicated that the de-binding of all the samples was effectively succeeded through less weight until 16% when the PLA of green bodies was successfully evaporated. The morphology result shows evidence of an effective sintering process to have the grain boundaries in all samples, while multi-metal parts clearly displayed the interface. Furthermore, the result of XRD shows the tendency of lower crystallinity in SS316L parts, whilst IN718 has a high crystallinity. The optimal sintering temperature for SS316L/IN718 parts is 1500 °C. The hardness test concludes that the higher sintering temperature gives a higher hardness result.

This study highlights the successful sintering of a bimetallic stainless steel 316 L/Inconel 718 composite, fabricated via dual-nozzle fused deposition modeling, in a non-vacuum environment at 1500 °C. The resulting material displayed maximum hardness values of 872 HV for SS316L and 755.5 HV for IN718, with both materials exhibiting excellent fusion without any cracks.

This study aims to address the challenge of reducing the build time of a fused deposition modeling (FDM) system while maintaining part strength, proposing a hybrid technique combining photopolymerization and FDM.

For developing the hybrid system, a standard FDM machine was modified to incorporate necessary components so that the whole system can be operated with a single interface; further, the samples were fabricated with conventional and modified process to evaluate the efficacy of the developed system, to determine the extent of time reduction that the proposed methodology can obtain, additionally different sort of 3D models were selected and their build time was compared.

The modified hybrid mechanism can successfully fabricate parts with a modified G-code. The simulation of the technique shows that a reduction of 34%–87% can be achieved for simpler models such as cube while a reduction ranging from 30.6%–87.8% was observed for complex models. An increase in strength of 6.58%, 11.51% and 37.32% was observed in X, Y and Z directions, along with a significant increase in toughness as compared with FDM parts for parts fabricated with the developed mechanism.

The modified mechanism could be used for fast fabrication purposes, which could be very useful for serving situations such as emergency health care, rapid tooling.

This research contributes a novel hybrid technique for additive manufacturing, offering a substantial reduction in build time without compromising mechanical properties, even increasing them.

The effect of viscosity on the performance of disk-shaped electromechanical resonators has been studied and investigated in the past. The vibration frequency of a disk-shaped resonator changes according to the viscosity of the liquid which the resonator is in contact with. Therefore, the purpose of this paper is based on design a sensor for measuring the viscosity of liquids using a disk-shaped electromechanical resonator. The viscosity of liquids is of interest to researchers in industry and medicine.

In this paper, a viscosity sensor for liquids is proposed, which is designed based on a disk-shaped electromechanical resonator. In this proposed sensor, two comb drives are used as electrostatic actuators to stimulate the resonator. Also, two other comb drives are used as electrostatic sensors to monitor the frequency changes of the proposed resonator. The resonance frequency of the resonator in response to different fluids under test varies according to their viscosity.

After calibration of the proposed sensor by nonlinear weights, the viscosity of some liquids are calculated using this sensor and results confirm its accuracy according to the liquids real viscosity.

The design of the proposed sensor and its simulated performance are reported. Also, the viscosity of several different liquids are evaluated with simulations of the proposed sensor and presented.

The use of additive manufacturing in many branches of industry is increasing significantly because of its many advantages, such as being able to produce complex parts that cannot be produced by classical methods, using fewer materials, easing the supply chain with on-site production, being able to produce with all kinds of materials and producing lighter parts. The binder jetting technique, one of the additive manufacturing methods researched within the scope of this work, is predicted to be the additive manufacturing method that will grow the most in the next decade, according to many economic reports. Although additive manufacturing methods have many advantages, they can be slower than classical manufacturing methods regarding production speed. For this reason, this study aims to increase the manufacturing speed in the binder jetting method.

Adaptive slicing and variable binder amount algorithm (VBAA) were used to increase manufacturing speed in binder jetting. Taguchi method was used to optimize the layer thickness and saturation ratio in VBAA. According to the Taguchi experimental design, 27 samples were produced in nine different conditions, three replicates each. The width of the samples in their raw form was measured. Afterward, the samples were sintered at 1,500 °C for 2 h. After sintering, surface roughness and density tests were performed. Therefore, the methods used have been proven to be successful. In addition, measurement possibilities with image processing were investigated to make surface roughness measurements more accessible and more economical.

As a result of the tests, the optimum printing condition was decided to be 180–250 µm for layer thickness and 50% for saturation. A separate test sample was then designed to implement adaptive slicing. This test sample was produced in three pieces: adaptive (180–250 µm), thin layer (180 µm) and thick layer (250 µm) with the determined parameters. The roughness values of the adaptive sliced sample and the thin layer sample were similar and better than the thick layer sample. A similar result was obtained using 12.31% fewer layers in the adaptive sample than in the thin layer sample.

The use of adaptive slicing in binder jetting has become more efficient. In this way, it will increase the use of adaptive slicing in binder jetting. In addition, a cheap and straightforward image processing method has been developed to calculate the surface roughness of the parts.

This paper aims to view the tradition of the Prophet in zakat payment, especially the attributed measurements, and adapt these measures to current zakat measurement practices.

This study is designed with an exploratory sequential mixed method where qualitative data were collected from historical archives and also from the measurement of available ṣāʿ صاع and mud_ مد. These standard measures were collected from Malaysia and other Muslim countries and calibrated at the National Measurement Standards Laboratory (currently carried out by the National Metrology Institute of Malaysia). The volume of the ṣāʿ were tabulated, charted, analyzed and determined.

Prophet Muḥammad ordered for zakat al-fiṭr زكاة الفطر to measure the crops using ṣāʿ (gallon: volume measure), not raṭl رطل (pound: standard weight). This paper recommends a reference volume for the ṣāʿ, and from this value, the volume for the smaller measure mud and much larger measure wasq وسق were calculated. The agricultural niṣāb (5 wasq) is one of the key parameters in ṣāʿ volume analysis.

This study covers standard measures acquired from Malaysia, Saudi Arabia and the United Kingdom (traceable to India). Several empirical data are attained from previous studies from Saudi Arabia and North Africa. Also, some theoretical data are obtained from kitab tafsir, hadith and kitab turath (books and records written by early scholars). A concern in this study is the ratio of de-husked grains currently approximated at half of un-hulled grains. This might not necessarily be accurate and may differ by different types of grains.

After the introduction of the modern measurement system known as the International System of Units (SI) in 1971, ṣāʿ became obsolete, leaving each state in Malaysia to define and convert ṣāʿ to SI units variously. This paper contributes to standardizing the conversion to one value with an appropriate SI unit, that has traceability to the Prophet’s ṣāʿ. This national reference standard ṣāʿ is essential for zakat al-fiṭr measurement, important for zakat centers and impacting every Muslim in Malaysia. Often overlooked, ṣāʿ is more crucial as a basis in determining and standardizing the seasonal crops niṣāb, unfolding the reasons why the poor are paying the paddy zakat in Malaysia.

The Prophet’s tradition for ablution is to use water not more than one mud, this is aligned with the 12th Sustainable Development Goals by the United Nations which promoted the responsible consumption of water. Considering half (adults) of the 1.9 billion Muslims in the world, multiplied by 5 times of prayer, the Muslims will at least use 4.75 billion muds of water for ablution alone in 1 day. This is approximately 3.5 billion liters of water daily, and if they limit their water usage to 1 mud for each ablution, they collectively will save at least four times more water (about 14 billion liters) daily than performing ablution from a running tap. Though for ablution, accuracy is not an issue, the mud impact on all Muslims is vital on a daily basis, literally by volume.

Ṣāʿ is essential in measuring food for the annually obligated zakat al-fiṭr and more crucial as a basis in determining the seasonal crops niṣāb. This paper contributes to the development of a national reference standard ṣāʿ for Malaysia that has traceability to the Prophet’s ṣāʿ.

Performing accurate numerical simulations of electrical drives, the precise knowledge of the local magnetic material properties is of utmost importance. Due to the various manufacturing steps, e.g. heat treatment or cutting techniques, the magnetic material properties can strongly vary locally, and the assumption of homogenized global material parameters is no longer feasible. This paper aims to present the general methodology and two different solution strategies for determining the local magnetic material properties using reference and simulation data.

The general methodology combines methods based on measurement, numerical simulation and solving an inverse problem. Therefore, a sensor-actuator system is used to characterize electrical steel sheets locally. Based on the measurement data and results from the finite element simulation, the inverse problem is solved with two different solution strategies. The first one is a quasi Newton method (QNM) using Broyden's update formula to approximate the Jacobian and the second is an adjoint method. For comparison of both methods regarding convergence and efficiency, an artificial example with a linear material model is considered.

The QNM and the adjoint method show similar convergence behavior for two different cutting-edge effects. Furthermore, considering a priori information improved the convergence rate. However, no impact on the stability and the remaining error is observed.

The presented methodology enables a fast and simple determination of the local magnetic material properties of electrical steel sheets without the need for a large number of samples or special preparation procedures.

This paper aims to analyze the influence of welding-induced mechanical stress of a magnetic core material on the performance behavior of a permanent magnet excited synchronous machine (PMSM). Welding, interlocking, clinching and the use of adhesives are state-of-the-art packaging technologies used in the manufacturing of electrical machines. However, the packaging processes degrade the electromagnetic properties of the electric steel sheets, thereby decreasing the performance and achievable range of the electric vehicle.

In this paper, an approach that maps the local changes in magnetic properties due to welding induced stress with the stress values is developed. The welding process induces internal stress inside the steel sheet due to the diffusion of thermal energy into the sheets. Other effects are the changes in the micro structures of the steel sheets (grain sizes). These induced mechanical stresses lead to significant deterioration of the electromagnetic properties. They also lead to an increase in iron loss attributed to steel lamination.

A low speed (city), a high-speed (highway) and WLTC-c3 driving cycle will be used to analyze the effects of the induced stresses on the machine efficiency at the different operating conditions. A high-speed PMSM with a maximum speed of 26,000 min⁻¹ and maximum torque of 130 Nm is designed for this study.

The value of this study is in the development of a local varying modeling approach that analyses the influence of weld-induced stress on the performance of electrical machines. Its originality is evident in the mapping methodology. This will enable an application dependent improvement possibilities due to the understanding of the impact of weld-induced stress on the electromagnetic properties of weld-packaged core.