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Article
Publication date: 12 September 2024

Nandalal Acharjee, Subhas Ganguly, Prasenjit Biswas and Bidyapati Sarangi

The purpose of this study is to develop black pigmented ceramic stoneware bodies that integrate various aspects of material composition and color potential. Recent research has…

Abstract

Purpose

The purpose of this study is to develop black pigmented ceramic stoneware bodies that integrate various aspects of material composition and color potential. Recent research has explored black pigmented calcium aluminosilicate glass (BPCG), a specialized material known for its unique properties, which holds promise for transforming the color capabilities of traditional ceramics.

Design/methodology/approach

In this investigation, initially composite ceramic sample (B-1) was prepared by milling process prior to sieve analysis to attain the particle size within 44 microns. Microanalysis and morphology and thermography were studied by energy-dispersive X-ray spectroscopy, scanning electron microscope and thermogravimetric analysis and found Sample-B-1 received attractive properties like firing shrinkage, porosity, bulk density and firing strength along with good pyro-plastic properties at various temperatures like 950°C, 1050°C, 1000°C and 1180°C. Furthermore, BPCG-assisted pigmented ceramic composites were synthesized with B-1 matrix. CIE lab investigation of the attributed composites (C-series) within selective soaking range of 5–20 min was performed, and the investigation found that prominent black hue appeared (L: 24.09, a*: −0.17, b*: −0.49) for C-10 containing appeared phases of Di-Co-Silicide (26%), Ni-Chromite, Stilpnomelane (rich in iron) as obtained by X-ray diffraction studies.

Findings

Ceramic material played a significant role in the realms of art and craft, as well as in technology. The artistic facet reveals concepts or ornamentation, while the craft echoes both traditional and functional appeal. Technology, on the other hand, involves the logical implementation behind the creation.

Originality/value

This C-10 Sample comprised the lower percentage of mullite which attributed that the BPCG homogeneously mixed in the matrix of base (B-1) and appeared as spinal staff. Therefore, BPCG was a potential candidate for ceramic metallization, and this traditional metallization processes often faced some challenges like uniformity and mixing in the ceramic composite domain practices. This study aimed to open up new avenues for artistic decoration and bridging the gap between traditional craftsmanship and modern technology. Furthermore, BPCG’s role in color assessment through shocking techniques added an exciting concept for the ceramic practitioners, designers or ceramic educators.

Details

Pigment & Resin Technology, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 0369-9420

Keywords

Article
Publication date: 2 August 2024

Sweta, RamReddy Chetteti and Pranitha Janapatla

This study aims to optimize heat transfer efficiency and minimize friction factor and entropy generation in hybrid nanofluid flows through porous media. By incorporating factors…

Abstract

Purpose

This study aims to optimize heat transfer efficiency and minimize friction factor and entropy generation in hybrid nanofluid flows through porous media. By incorporating factors such as melting effect, buoyancy, viscous dissipation and no-slip velocity on a stretchable surface, the aim is to enhance overall performance. Additionally, sensitivity analysis using response surface methodology is used to evaluate the influence of key parameters on response functions.

Design/methodology/approach

After deriving suitable Lie-group transformations, the modeled equations are solved numerically using the “spectral local linearization method.” This approach is validated through rigorous numerical comparisons and error estimations, demonstrating strong alignment with prior studies.

Findings

The findings reveal that higher Darcy numbers and melting parameters are associated with decreased entropy (35.86% and 35.93%, respectively) and shear stress, increased heat transmission (16.4% and 30.41%, respectively) in hybrid nanofluids. Moreover, response surface methodology uses key factors, concerning the Nusselt number and shear stress as response variables in a quadratic model. Notably, the model exhibits exceptional accuracy with $R^2$ values of 99.99% for the Nusselt number and 100.00% for skin friction. Additionally, optimization results demonstrate a notable sensitivity to the key parameters.

Research limitations/implications

Lubrication is a vital method to minimize friction and wear in the automobile sector, contributing significantly to energy efficiency, environmental conservation and carbon reduction. The incorporation of nickel and manganese zinc ferrites into SAE 20 W-40 motor oil lubricants, as defined by the Society of Automotive Engineers, significantly improves their performance, particularly in terms of tribological attributes.

Originality/value

This work stands out for its focus on applications such as hybrid electromagnetic fuel cells and nano-magnetic material processing. While these applications are gaining interest, there is still a research gap regarding the effects of melting on heat transfer in a NiZnFe_2O_4-MnZnFe_2O_4/20W40 motor oil hybrid nanofluid over a stretchable surface, necessitating a thorough investigation that includes both numerical simulations and statistical analysis.

Details

International Journal of Numerical Methods for Heat & Fluid Flow, vol. 34 no. 9
Type: Research Article
ISSN: 0961-5539

Keywords

Open Access
Article
Publication date: 26 April 2024

Sultan Mohammed Althahban, Mostafa Nowier, Islam El-Sagheer, Amr Abd-Elhady, Hossam Sallam and Ramy Reda

This paper comprehensively addresses the influence of chopped strand mat glass fiber-reinforced polymer (GFRP) patch configurations such as geometry, dimensions, position and the…

Abstract

Purpose

This paper comprehensively addresses the influence of chopped strand mat glass fiber-reinforced polymer (GFRP) patch configurations such as geometry, dimensions, position and the number of layers of patches, whether a single or double patch is used and how well debonding the area under the patch improves the strength of the cracked aluminum plates with different crack lengths.

Design/methodology/approach

Single-edge cracked aluminum specimens of 150 mm in length and 50 mm in width were tested using the tensile test. The cracked aluminum specimens were then repaired using GFRP patches with various configurations. A three-dimensional (3D) finite element method (FEM) was adopted to simulate the repaired cracked aluminum plates using composite patches to obtain the stress intensity factor (SIF). The numerical modeling and validation of ABAQUS software and the contour integral method for SIF calculations provide a valuable tool for further investigation and design optimization.

Findings

The width of the GFRP patches affected the efficiency of the rehabilitated cracked aluminum plate. Increasing patch width WP from 5 mm to 15 mm increases the peak load by 9.7 and 17.5%, respectively, if compared with the specimen without the patch. The efficiency of the GFRP patch in reducing the SIF increased as the number of layers increased, i.e. the maximum load was enhanced by 5%.

Originality/value

This study assessed repairing metallic structures using the chopped strand mat GFRP. Furthermore, it demonstrated the superiority of rectangular patches over semicircular ones, along with the benefit of using double patches for out-of-plane bending prevention and it emphasizes the detrimental effect of defects in the bonding area between the patch and the cracked component. This underlines the importance of proper surface preparation and bonding techniques for successful repair.

Graphical abstract

Details

Frontiers in Engineering and Built Environment, vol. 4 no. 3
Type: Research Article
ISSN: 2634-2499

Keywords

Open Access
Article
Publication date: 6 May 2024

Danusa Silva da Costa, Lucely Nogueira dos Santos, Nelson Rosa Ferreira, Katiuchia Pereira Takeuchi and Alessandra Santos Lopes

The aim was not to perform a systematic review but firstly to search in PubMed, Science Direct, Scopus and Web of Science databases on the papers published in the last five years…

Abstract

Purpose

The aim was not to perform a systematic review but firstly to search in PubMed, Science Direct, Scopus and Web of Science databases on the papers published in the last five years using tools for reviewing the statement of preferred information item for systematic reviews without focusing on a randomized analysis and secondly to perform a bibliometric analysis on the properties of films and coatings added of tocopherol for food packaging.

Design/methodology/approach

On January 24, 2022, information was sought on the properties of films and coatings added of tocopherol for use as food packaging published in PubMed, Science Direct, Scopus and Web of Science databases. Further analysis was performed using bibliometric indicators with the VOSviewer tool.

Findings

The searches returned 33 studies concerning the properties of films and coatings added of tocopherol for food packaging, which were analyzed together for a better understanding of the results. Data analysis using the VOSviewer tool allowed a better visualization and exploration of these words and the development of maps that showed the main links between the publications.

Originality/value

In the area of food science and technology, the development of polymers capable of promoting the extension of the shelf life of food products is sought, so the knowledge of the properties is vital for this research area since combining a biodegradable polymeric material with a natural antioxidant active is of great interest for modern society since they associate environmental preservation with food preservation.

Details

British Food Journal, vol. 126 no. 13
Type: Research Article
ISSN: 0007-070X

Keywords

Article
Publication date: 6 August 2024

Hulusi Delibaş and Necdet Geren

The purpose of this study is to produce a low-cost sheet metal forming mold made from the low melting point Bi58Sn42 (bismuth) alloy by using an open-source desktop-type material…

Abstract

Purpose

The purpose of this study is to produce a low-cost sheet metal forming mold made from the low melting point Bi58Sn42 (bismuth) alloy by using an open-source desktop-type material extrusion additive manufacturing system and to evaluate the performance of the additively manufactured mold for low volume sheet metal forming. Thus, it was aimed to develop a fast and inexpensive die tooling methodology for low-volume batch production.

Design/methodology/approach

Initially, the three-dimensional printing experiments were performed to produce the sheet metal forming mold. The encountered problems during the performed three-dimensional printing experiments were analyzed. Accordingly, both tunings in process parameters (extrusion temperature, extrusion multiplier, printing speed, infill percentage, etc.) and customizations on the extruder head of the available material extrusion additive manufacturing system were made to print the Bi58Sn42 alloy properly. Subsequently, the performance of the additively manufactured mold was evaluated according to the dimensional change that occurred on it during the performed pressing operations.

Findings

Results showed that the additively manufactured mold was rigid enough and proved to have sufficient strength in sheet metal forming operations for low-volume production.

Originality/value

Alternative mold production was carried out using open-source material extrusion system for low volume sheet metal part production. Thus, cost effective solution was presented for agile manufacturing.

Details

Rapid Prototyping Journal, vol. 30 no. 8
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 28 August 2024

Raphael Timothy Steffen, Michael Robert Tucker, Francesco Sillani, Denis Schütz and Markus Bambach

For additive manufacturing (AM) through laser-based powder bed fusion of polymers (PBF-LB/P), accurate characterization of powder flowability is vital for achieving high-quality…

Abstract

Purpose

For additive manufacturing (AM) through laser-based powder bed fusion of polymers (PBF-LB/P), accurate characterization of powder flowability is vital for achieving high-quality parts. However, accurately characterizing feedstock flowability presents challenges because of a lack of consensus on which tests to perform and the diverse forces and mechanisms involved. This study aims to undertake a thorough investigation into the flowability of eight feedstock materials for PBF-LB/P at different temperatures using various techniques.

Design/methodology/approach

For ambient temperature assessments, established metrics such as avalanche angle and Hausner ratio, along with the approximated flow function coefficient (FFCapp), are used. The study then focuses on the influence of elevated temperatures representative of in-process conditions. FFCapp and differential scanning calorimetry (DSC) are performed and analyzed, followed by a correlation analysis as a holistic approach to identify key aspects for flowability. Furthermore, two feedstock materials are compared with a previous study to connect the present findings to PBF-LB/P processing.

Findings

The study revealed intrinsic material properties such as mechanical softening near the melting point to become significant. This partially explains why certain powders with poor ambient temperature flowability are consistently demonstrated to produce high-quality parts. FFCapp and thermal characterization through DSC are identified as critical metrics for optimizing feedstock material characteristics across temperature ranges.

Originality/value

Previous studies emphasized specific characterizations of feedstock material at ambient temperature, presented a limited materials selection or focused on metrics such as shape factors. In contrast, this study addresses a partially understood aspect by examining the critical role of temperature in governing feedstock material flowability. It advocates for the inclusion of temperature variables in flowability analyses to closely resemble the PBF-LB/P process, which can be applied to material design, selection and process optimization.

Details

Rapid Prototyping Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 12 September 2024

Tunay Turk, Cesar E. Dominguez, Austin T. Sutton, John D. Bernardin, Jonghyun Park and Ming C. Leu

This paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous…

Abstract

Purpose

This paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects.

Design/methodology/approach

304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size.

Findings

Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part.

Originality/value

To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

Details

Rapid Prototyping Journal, vol. ahead-of-print no. ahead-of-print
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 24 July 2024

Ugur Mecid Dilberoglu, Ulas Yaman and Melik Dolen

This study aims to thoroughly examine the milling process applied to fused filament fabrication (FFF) parts. The primary objective is to identify the key variables in creating…

Abstract

Purpose

This study aims to thoroughly examine the milling process applied to fused filament fabrication (FFF) parts. The primary objective is to identify the key variables in creating smooth surfaces on FFF specimens and establish trends about specific parameters.

Design/methodology/approach

In this study, PLA and ABS samples fabricated by FFF are subjected to side milling in several experiments. Achievable surface quality is studied in relation to material properties, milling parameters, tooling and macrostructure. The surface finish is quantified using profile measurements of the processed surfaces. The study classifies the created chips into categories that can be used as criteria for the anticipated quality. Spectral analysis is used to examine the various surface formation modes. Thermal monitoring is used to track chip formation and surface temperature changes during the milling process.

Findings

This study reveals that effective heat dissipation through proper chip formation is vital for maintaining high surface quality. Recommended methodology demands using a tool with a substantial flute volume, using high positive rake and clearance angles and optimizing the feed-per-tooth and cutting speed. Disregarding these guidelines may cause the surface temperature to surpass the material’s glass transition, resulting in inferior quality characterized by viscous folding. For FFF thermoplastics, optimal milling can bring the average surface roughness down to the micron level.

Originality/value

This research contributes to the field by providing valuable guidance for achieving superior results in milling FFF parts. This study includes a concise summary of the theoretically relevant insights, presents verification of the key factors by qualitative analysis and offers optimal milling parameters for 3D-printed thermoplastics based on systematic experiments.

Details

Rapid Prototyping Journal, vol. 30 no. 8
Type: Research Article
ISSN: 1355-2546

Keywords

Open Access
Article
Publication date: 17 September 2024

Nzita Alain Lelo, P. Stephan Heyns and Johann Wannenburg

Steam explosions are a major safety concern in many modern furnaces. The explosions are sometimes caused by water ingress into the furnace from leaks in its high-pressure (HP…

Abstract

Purpose

Steam explosions are a major safety concern in many modern furnaces. The explosions are sometimes caused by water ingress into the furnace from leaks in its high-pressure (HP) cooling water system, coming into contact with molten matte. To address such safety issues related to steam explosions, risk based inspection (RBI) is suggested in this paper. RBI is presently one of the best-practice methodologies to provide an inspection schedule and ensure the mechanical integrity of pressure vessels. The application of RBIs on furnace HP cooling systems in this work is performed by incorporating the proportional hazards model (PHM) with the RBI approach; the PHM uses real-time condition data to allow dynamic decision-making on inspection and maintenance planning.

Design/methodology/approach

To accomplish this, a case study is presented that applies an HP cooling system data with moisture and cumulated feed rate as covariates or condition indicators to compute the probability of failure and the consequence of failure (CoF), which is modelled based on the boiling liquid-expanding vapour explosion (BLEVE) theory.

Findings

The benefit of this approach is that the risk assessment introduces real-time condition data in addition to time-based failure information to allow improved dynamic decision-making for inspection and maintenance planning of the HP cooling system. The work presented here comprises the application of the newly proposed methodology in the context of pressure vessels, considering the important challenge of possible explosion accidents due to BLEVE as the CoF calculations.

Research limitations/implications

This paper however aims to optimise the inspection schedule on the HP cooling system, by incorporating PHM into the RBI methodology, as was recently proposed in the literature by Lelo et al. (2022). Moisture and cumulated feed rate are used as covariate. At the end, risk mitigation policy is suggested.

Originality/value

In this paper, the proposed methodology yields a dynamically calculated quantified risk, which emphasised the imperative for mitigating the risk, as well as presents a number of mitigation options, to quantifiably affect such mitigation.

Details

Journal of Quality in Maintenance Engineering, vol. 30 no. 5
Type: Research Article
ISSN: 1355-2511

Keywords

Article
Publication date: 18 July 2024

Roza Rafiei, Leila Roozbeh Nasiraie, Zahra Emam Jumeh and Sara Jafarian

The use of polysaccharides increases solubility and consistency and causes functions such as viscosity? Moisture and food emulsifier stabilizer. This study aims to enrich the…

Abstract

Purpose

The use of polysaccharides increases solubility and consistency and causes functions such as viscosity? Moisture and food emulsifier stabilizer. This study aims to enrich the formulation of low-fat mozzarella cheese using microcoated vitamin D3 (VD3).

Design/methodology/approach

This study investigates the addition of hydrocolloids to low-fat mozzarella cheese to enhance its properties and nutritional value. Tests were conducted on cheese samples with 0.05% and 0.25% hydrocolloid concentrations at various stages: before production and at three and six months’ postproduction. The samples were evaluated for elasticity, pH and solubility to select the best one, which was then fortified with VD3. The vitamin was microencapsulated using alginate and whey protein to shield it from light and oxygen, optimizing the formula using the response surface method. The fortified cheese was tested for VD3 content over its shelf life.

Findings

Results indicated that all hydrocolloids tested improved moisture and meltability of the cheese while higher protein levels increased stretchability two to threefold. Rice starch hydrocolloid at 0.05% concentration was chosen due to superior sensory scores and minimal oil separation. This study concluded that VD3 levels remained stable during the cheese’s shelf life, suggesting that this approach could enhance the nutritional value of low-fat cheese without compromising its quality. Therefore, after examining the obtained results and comparing the regression models, the results indicated that the Quadratic model was chosen to investigate the effect of independent variables on the response rate, which had a statistically significant difference with other models (p = 0.0019). Also the results of the area under the curve and using the encapsulation efficiency equation, the percentage of microencapsulated vitamin was obtained, and according to the simulation results, the encapsulation efficiency was reported as 89.02%.

Originality/value

Developing innovative functional dairy products fortified with VD3 could improve the vitamin D status in deficient populations. Therefore, these designs can be applied at industrial scales for functional cheese production.

Details

Nutrition & Food Science , vol. 54 no. 6
Type: Research Article
ISSN: 0034-6659

Keywords

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