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Abstract In recent years, the use of cutting fluids has become crucial in hard metal machining. Traditional non-biodegradable cutting fluids have long dominated various industries for machining. This research presents an innovative approach by suggesting a sustainable alternative: a cutting fluid made from a blend of glycerol (GOL) and distilled water (DW). We conducted a thorough investigation, creating 11 different GOL and DW mixtures in 10% weight increments. These mixtures were rigorously tested through 176 experiments with varying loads and rotational speeds. Using Design-Expert software (DES), we identified the optimal composition to be 70% GOL and 30% DW, with the lowest coefficient of friction (CFN). Building on this promising fluid, we explored further improvements by adding three nanoscale additives: Nano-graphite (GHT), zinc oxide (ZnO), and reduced graphene oxide (RGRO) at different weight percentages (0.06%, 0.08%, 0.1%, and 0.3%).

Abstract Compared to other age groups, older adults are at more significant risk of hip fracture when they fall. In addition to the higher risk of falls for the elderly, fear of falls can reduce this population’s outdoor activity. Various preventive solutions have been proposed to reduce the risk of hip fractures ranging from wearable hip protectors to indoor flooring systems. A previously developed rubberized asphalt mixture demonstrated the potential to reduce the risk of head injury. In the current study, the capability of the rubberized asphalt sample was evaluated for the risk of hip fracture for an average elderly male and an average elderly female. A previously developed human body model was positioned in a fall configuration that would give the highest impact forces toward regular asphalt.

Abstract The water droplet erosion (WDE) on high-speed rotating wheels appears in several engineering fields such as wind turbines, stationary steam turbines, fuel cell turbines, and turbochargers. The main reasons for this phenomenon are the high relative velocity difference between the colliding particles and the rotor, as well as the presence of inadequate material structure and surface parameters. One of the latest challenges in this area is the compressor wheels used in turbochargers, which has a speed up to 300,000 rpm and have typically been made of aluminum alloy for decades, to achieve the lowest possible rotor inertia. However, while in the past this component was only encountered with filtered air, nowadays, due to developments in compliance with tightening emission standards, various fluids also collide with the spinning blades, which can cause mechanical damage.

Abstract Super duplex stainless steel (SDSS) is a type of stainless steel made of chromium (Cr), nickel (Ni), and iron (Fe). In the present work, a 1.6 mm wide thin sheet of SDSS is joined using gas tungsten arc welding (GTAW). The ideal parameter for a bead-on-plate trial is found, and 0.216 kJ/mm of heat input is used for welding. As an outcome of the welding heating cycle and subsequent cooling, a microstructural study revealed coarse microstructure in the heat-affected zone and weld zone. The corrosion rate for welded joints is 9.3% higher than the base metal rate. Following the corrosion test, scanning electron microscope (SEM) analysis revealed that the welded joint’s oxide development generated a larger corrosive attack on the weld surface than the base metal surface. The percentages of chromium (12.5%) and molybdenum (24%) in the welded joints are less than those in the base metal of SDSS, as per energy dispersive X-ray (EDX) analysis.

Abstract The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads, however, are often generalized for several categories, which proves to be overly conservative for some specific categories of machines. EN (European Norm) and AAR (Association of American Railroads) regulations play a pivotal role in determining the applicable loads and acceptance criteria within this study. The availability of track-induced fatigue load data for the cumulative damage approach in track maintenance machines is often limited. Consequently, the FEA-based validation of rail track maintenance equipment often resorts to the infinite life approach rather than cumulative damage approach for track-induced travel loads, resulting in overly conservative designs.

Abstract In this study, we have investigated the microstructural characteristics, the mechanical properties, and the dry sliding wear behavior of a ceramic coating consisting of zirconia (ZrO2) and alumina (Al2O3) deposited by flame spraying. A series of wear tests were carried out under a variety of loads and at two different sliding speeds. The evaluation included an examination of the coating microstructure, microhardness, coefficient of friction (COF), and wear resistance of the flame-sprayed coating. The results showed that the coatings had a perfectly structured micro-architecture and were metallurgically bonded to the substrate. The Al2O3 coating exhibited a fine granular structure with pores and oxides. The microstructure of Al2O3-10 wt.% ZrO2, on the other hand, showed a blocky structure with a uniform distribution of ZrO2 inclusions in the composite coating.

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Abstract With the use of the stepped surface of the friction pairs of the stepped bearings (SB) in the high-speed centrifugal pumps, its liquid film thickness is suddenly changed and it was discontinuously distributed in the direction of motion of pump. To ensure the continuity of the liquid film thickness and enhance the lubrication efficiency of the pump, based on the lubrication model of the SB, two other structures of the inclined surfaces [inclined bearings (IB)] and curved surfaces [curved bearings (CB)] used to replace stepped surfaces of the SB are investigated, respectively. Under the same conditions of the minimum thickness of the liquid film and initial dimensions of the sliding friction pairs, the influence of both the thickness ratio (α) of the liquid film and dimension ratio (β) in the direction of motion of SB, IB, and CB on the bearing capacity and friction coefficient of the liquid film are simulated and analyzed, respectively.

Abstract This research was initiated with the goal of developing a significantly stronger aircraft transparency design that would reduce transparency failures from bird strikes. The objective of this research is to demonstrate the fact that incorporating high-strength tempered glass into cockpit window constructions for commercial aircraft can produce enhanced safety protection from bird strikes and weight savings. Thermal glass tempering technology was developed that advances the state of the art for high-strength tempered glass, producing 28 to 36% higher tempered strength. As part of this research, glass probability of failure prediction methodology was introduced for determining the performance of transparencies from simulated bird impact loading. Data used in the failure calculation include the total performance strength of highly tempered glass derived from the basic strength of the glass, the temper level, the time duration of the load, and the area under load.

Abstract Composite ceramic brake discs are made of ceramic material reinforced with carbon fibers and offer exceptional advantages that translate directly into higher vehicle performance. In the case of an electric vehicle, it could increase the range of the vehicle, and in the case of conventional internal combustion engine vehicles, it means lower fuel consumption (and consequently lower CO2 emissions). These discs are typically characterized by complex internal geometries, further complicated by the presence of drilling holes on both friction surfaces. To estimate the aerothermal performance of these discs, and for the thermal management of the vehicle, a reliable model for predicting the air flowing across the disc channels is needed. In this study, a real carbon-ceramic brake disc with drilling holes was investigated in a dedicated test rig simulating the wheel corner flow conditions experimentally using the particle image velocimetry technique and numerically.

Abstract In the given work the design and stress–strain calculation of housing parts of large machines during operation are considered. At the same time, both classical electromagnetic forces and technological operations necessary for mechanical processing and assembly of such objects as well as transportation processes are taken into account for the first time. The task of analyzing of the stress–strain state of the framework was solved in the three-dimensional setting using the finite element method by the SolidWorks software complex. The three-dimensional analysis of the stress–strain state of the structure for technological operations, namely tilting, lifting, and moving the large DC machines frame without poles and with poles, showed that the values of mechanical stresses that arise in the connections of the frame exceed the permissible limits, resulting in significant deformation of the structure.

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Abstract Single point incremental forming (SPIF) is a robust and new technique. In the recent research scenario, materials properties such as microstructure, micro-texture analysis, and crystal structure can be accessed through characterization non-destructive techniques, e.g., scanning electron microscope (SEM), electron backscattered diffraction (EBSD), and X-ray diffraction (XRD). XRD is a non-destructive method for analyzing the fine structure of materials. This study explores how process variables such as wall angle, step size, feed rate, and forming speed affect the parts of large-, medium-, and small-sized truncated cones of aluminum alloy AA3003-O sheet. Several cone parts of truncated cones are used in this investigation to implement Scherrer’s method. The two primary determining factors peak height and crystallite size are assessed for additional analysis in the present research.

Abstract Sealed electronic components are the basic components of aerospace equipment, but the issue of internal loose particles greatly increases the risk of aerospace equipment. Traditional material recognition technology has a low recognition rate and is difficult to be applied in practice. To address this issue, this article proposes transforming the problem of acquiring material information into the multi-category recognition problem. First, constructing an experimental platform for material recognition. Features for material identification are selected and extracted from the signals, forming a feature vector, and ultimately establishing material datasets. Then, the problem of material data imbalance is addressed through a newly designed direct artificial sample generation method. Finally, various identification algorithms are compared, and the optimal material identification model is integrated into the system for practical testing.

Abstract All two-wheeler industries validate their product’s fatigue life on proving track before heading for mass production. Proving test tracks are made to simulate the end-user environment in order to find out the possible fatigue failures during each development stage of vehicle design, which in turn helps the CAE analysts to verify the design before it goes to the end-user hands. In this article we present the design and failure analysis of sub-frame assembly of motorbike observed during the accelerated fatigue test on proving track. Sub-frame main rod was found broken exactly between two weld endings during fatigue test before reaching 6% of the target fatigue life. Possible causes of sub-frame failures have been identified/analyzed in detail using fish bone diagram. A finite element analysis (FEA) model of sub-frame assembly was developed and a random response analysis was carried out on initial design.

Abstract Due to the limitations of current battery manufacturing processes, integration technology, and operating conditions, the large-scale application of lithium-ion batteries in the fields of energy storage and electric vehicles has led to an increasing number of fire accidents. When a lithium-ion battery undergoes thermal runaway, it undergoes complex and violent reactions, which can lead to combustion and explosion, accompanied by the production of a large amount of flammable and toxic gases. These flammable gases continue to undergo chemical reactions at high temperatures, producing complex secondary combustion products. This article systematically summarizes the gas generation characteristics of different types and states of batteries under different thermal runaway triggering conditions. And based on this, proposes the key research directions for the gas generation characteristics of lithium-ion batteries.

Abstract Low-carbon equivalent austempered ductile iron (LCE-ADI) exhibits high modulus of elasticity than conventional austempered ductile iron (ADI) due to less graphite content. Austempering parameters of temperature and time significantly influence the mechanical properties of LCE-ADI. In the present work, response of the material to two-step austempering in the range of 350–450°C was studied, and a comparison was made to single-step austempering. Reduction in ferrite cell size, increase in % carbon in carbon-stabilized austenite (CSA) and increase in volume fraction of CSA led to increase in tensile strength (10%) and hardness (20%), in addition to improved toughness (10%).

Abstract This study investigated the influence of high-strength low-alloy steel on the fatigue life of a load-bearing member with a non-load-bearing transverse welded attachment (T-joint). It compared high cycle fatigue data to two fatigue design codes, namely BS 7608 and Eurocode EN 1993-1-9. Different base and filler material combinations of varying material strengths were investigated, resulting in a total of three different specimen configurations. Two material combinations had a high-strength steel (Strenx® 700 MC D) for the base material, with one combination having a matched filler material and the other having an undermatched filler material. The third material combination had a lower-strength steel (S 355 JR AR) for the base material, with a matched filler material. Tensile tests were performed to confirm the base material mechanical properties and weld quality of the manufactured specimens.

Abstract Nylon polymer with an optimal blend of Kevlar, fiberglass, and high-speed, high temperature (HSHT) Fiberglass offers improved characteristics such as flexural strength, wear resistance, electrical insulation, shock absorption, and a low friction coefficient. For this reason, the polymer composite manufactured by combining HSHT, Kevlar, and fiberglass with nylon as base material will expand the uses of nylon in the aerospace, automotive, and other industrial applications related to ergonomic tools, assembly trays, and so forth. The proposed work was carried out to investigate the continuous fiber reinforcement (CFR) in nylon polymer using a dual extrusion system. Twenty experimental runs were designed using a face-centered central composite design (FCCD) approach to analyze the influence of significant factors such as reinforcement material, infill pattern, and fiber angle on the fabricated specimen as per American Society for Testing Materials (ASTM) standards.

Abstract Neutron diffraction is a powerful tool for noninvasive and nondestructive characterization of materials and can be applied even in large devices such as internal combustion engines thanks to neutrons’ exceptional ability to penetrate many materials. While proof-of-concept experiments have shown the ability to measure spatially and temporally resolved lattice strains in a small aluminum engine on a timescale of minutes over a limited spatial region, extending this capability to timescales on the order of a crank angle degree over the full volume of the combustion chamber requires careful design and optimization of the engine structure to minimize attenuation of the incident and diffracted neutrons to maximize count rates.