Advanced Process Research Articles

Nitriding Treatments in Nickel–Chromium-Based Superalloy INCONEL 718: A Review

This literature review focuses on the nitriding treatments of nickel-based superalloy UNS N07718, also called INCONEL 718. This alloy was selected due to the relevance of this alloy in the aerospace and oil and gas industries. The referenced studies reflect a clear trend towards improving superalloys through advanced nitriding processes, highlighting plasma nitriding as one of the most promising techniques to enhance alloy 718 against corrosion and wear. The importance of optimizing nitriding parameters, such as temperature and time, is emphasized to increase wear and corrosion resistance while minimizing adverse effects like delamination or the formation of undesirable phases. Finally, the most appropriate alternatives for future research are recommended.

Neural evidence of core foundations and conceptual change in preschool numeracy.

Symbolic numeracy first emerges as children learn the meanings of number words and how to use them to precisely count sets of objects. This development starts before children enter school and forms a foundation for lifelong mathematics achievement. Despite its importance, exactly how children acquire this basic knowledge is unclear. Here we test competing theories of early number learning by measuring event-related brain potentials during a novel number word-quantity comparison task in 3-4-year-old preschool children (N=128). We find several qualitative differences in neural processing of number by conceptual stage of development. Specifically, we find differences in early attention-related parietal electrophysiology (N1), suggesting that less conceptually advanced children process arrays as individual objects and more advanced children distribute attention over the entire set. Subsequently, we find that only more conceptually advanced children show later-going frontal (N2) sensitivity to the numerical-distance relationship between the number word and visual quantity. The nature of this response suggested thatexact rather than approximate numerical meanings were being associated with number words over frontal sites. No evidence of numerical distance effects was observed over posterior scalp sites. Together these results suggest that children may engage parallel individuation of objects to learn the meanings of the first few number words, but, ultimately, create new exact cardinal value representations for number words that cannot be defined in terms of core, nonverbal number systems. More broadly, these results document an interaction between attentional and general cognitive mechanisms in cognitive development. RESEARCH HIGHLIGHTS: Conceptual development in numeracy is associated with a shift in attention from objects to sets. Children acquire meanings of the first few number words through associations with parallel attentional individuation of objects. Understanding of cardinality is associated with attentional processing of sets rather than individuals. Brain signatures suggest children attribute exact rather than approximate numerical meanings to the first few number words. Number-quantity relationship processing for the first few number words is evident in frontal but not parietal scalp electrophysiology of young children.

Exposure to low (10 cGy) doses of 4He ions leads to an apparent increase in risk taking propensity in female rats

The planned missions to the Moon and Mars will present more significant health challenges to astronauts compared to low earth orbit missions. During deep space missions, astronauts will be constantly exposed to Space radiation (SR). Multiple rodent studies suggest that < 25 cGy of SR impairs performance in executive functions, which play a key role in advanced cognitive processes, but also regulate response inhibition and impulse control. There is the possibility that SR exposure may exacerbate aberrant behaviors evoked by psychological stress related to exposure to isolated and confined (ICE) hostile environment or independently induce additional aberrant behaviors. This study has determined that female Wistar rats exposed to 10 cGy of 250 MeV/n He had an increased risk taking propensity (RTP)\\compared to shams. The increased RTP of the He-exposed rats was associated with significantly increased reaction times during the trials, suggesting a SR-induced loss of processing speed. The response times of the He-exposed rats were even further reduced in trials that immediately followed a loss, raising the possibility that conflict and interference avoidance may be impaired after SR exposure. Whether these findings occur following other types of SR exposure, and/or in male rats remains to be determined.

Semi-supervised adaptive anti-noise meta-learning for few-shot industrial gearbox fault diagnosis

Abstract Real-time and accurate predictive maintenance of industrial equipment is fundamental for ensuring the safety and stability of advanced manufacturing processes. Current fault diagnosis methods based on data mining rely on a large number of labeled samples, and obtaining sufficient labeled data for diagnosing industrial equipment faults is challenging. Meta-learning can achieve the diagnosis of few-shot samples to a certain extent, but the effect is not ideal. Semi-supervision can effectively leverage a large number of unlabeled samples, which is of great practical significance for handling scenarios involving limited labeled samples. However, noise interference can occur when unlabeled samples appear that do not belong to known categories. Therefore, this study proposes adaptive semi-supervised meta-learning networks for noisy few-shot gearbox fault diagnosis. Firstly, a residual network with a Morlet Wavelet layer is used to extract signal features. Next, sample-level attention is defined to select unlabeled samples that are more similar to labeled sample prototypes, thereby reducing the influence of noisy samples. The adaptive metric is used to obtain the relational distance functions of labeled samples and unlabeled samples. Adaptive semi-supervised meta-learning networks uses unlabeled data to refine prototypes for better fault diagnosis. The effectiveness and anti-noise performance of the proposed method are verified by using two gearbox datasets with various few-shot noise scenarios.

Bridging length scales in hard materials with ultra-small angle X-ray scattering - a critical review.

Owing to their exceptional properties, hard materials such as advanced ceramics, metals and composites have enormous economic and societal value, with applications across numerous industries. Understanding their microstructural characteristics is crucial for enhancing their performance, materials development and unleashing their potential for future innovative applications. However, their microstructures are unambiguously hierarchical and typically span several length scales, from sub-ångstrom to micrometres, posing demanding challenges for their characterization, especially for in situ characterization which is critical to understanding the kinetic processes controlling microstructure formation. This review provides a comprehensive description of the rapidly developing technique of ultra-small angle X-ray scattering (USAXS), a nondestructive method for probing the nano-to-micrometre scale features of hard materials. USAXS and its complementary techniques, when developed for and applied to hard materials, offer valuable insights into their porosity, grain size, phase composition and inhomogeneities. We discuss the fundamental principles, instrumentation, advantages, challenges and global status of USAXS for hard materials. Using selected examples, we demonstrate the potential of this technique for unveiling the microstructural characteristics of hard materials and its relevance to advanced materials development and manufacturing process optimization. We also provide our perspective on the opportunities and challenges for the continued development of USAXS, including multimodal characterization, coherent scattering, time-resolved studies, machine learning and autonomous experiments. Our goal is to stimulate further implementation and exploration of USAXS techniques and inspire their broader adoption across various domains of hard materials science, thereby driving the field toward discoveries and further developments.

From Hot to Cold: Advanced Materials and Processes for NbSn Based Magnets

From Hot to Cold: Advanced Materials and Processes for NbSn Based Magnets<sub/>

Attenuation of phenylnaphthenic acids related to oil sands process water using solar activated calcium peroxide: Influence of experimental factors, mechanistic modeling, and toxicity evaluation

Refractory naphthenic acids (NAs) are among the primary toxic compounds in oil sands process water (OSPW), a matrix with a complex chemical composition that poses challenges to its remediation. This study evaluated the effectiveness of calcium peroxide (CaO2) combined with solar radiation (solar/CaO2) as an advanced water treatment process for degrading model NAs (1,2,3,4-tetrahydronaphthalene-2-carboxylic acid, pentanoic acid, and diphenylacetic acid) in synthetic water (STW) and provide preliminary insights in treating real OSPW. Solar light and CaO2 acted synergistically to degrade target NAs in STW (>67 of synergistic factor) following a pseudo-first-order kinetic (R2 ≥ 0.95), with an optimal CaO2 dosage of 0.1 g L–1. Inorganic ions and dissolved organic matter were found to hinder the degradation of NAs by solar/CaO2 treatment; however, the complete degradation of NAs was reached in 6.7 h of treatment. The main degradation mechanism involved the generation of hydroxyl radicals (•OH), which contributed ∼90% to the apparent degradation rate constant (K), followed by H2O2 (4–5%) and 1O2 (0–5%). The tentative transformation pathways of three NAs were proposed, confirming an open-ring reaction and resulting in short-chain fatty acid ions as final products. Furthermore, a reduction in acute microbial toxicity and genotoxic effect was observed in the treated samples, suggesting that solar/CaO2 treatment exhibits high environmental compatibility. Furthermore, the solar/CaO2 system was successfully applied as a preliminary step for real-world applications to remove natural NAs, fluorophore organic compounds, and inorganic components from OSPW, demonstrating the potential use of this technology in the advanced treatment of oil-tailing-derived NAs.

Metal/Metalloid Presence and Health Risks in Drinking Water Plants—Insights from Nanjing, China

Metal contamination in drinking water is well known; however, detailed insights into the metals/metalloids in finished water and their health effects are lacking. Water samples collected over four seasons from August 2022 to April 2023 from three locations in the Yangtze River basin in Nanjing were analyzed using inductively coupled plasma mass spectrometry to detect 33 metal/metalloid types. This study assessed seasonal and spatial variations and evaluated the removal efficiencies of advanced treatment processes. Health risks from metal/metalloid ingestion were calculated using a risk assessment model from the United States Environmental Protection Agency (USEPA). No significant regional differences in total metal/metalloid concentrations were found between the source and finished waters. Metals such as Cr, Ga, Hg, Pb, and Rb varied seasonally, peaking in winter. The advanced treatment process outperformed the conventional process for As removal. However, the removal efficiencies were lower for Mn, Cd, Hg, Se, and Zn than those of the conventional process. Positive correlations were observed among several metals, suggesting that metals may have similar sources of contamination. The main carcinogenic risk exceeded the acceptable levels in children according to the USEPA. Non-carcinogenic risks were below the threshold values, but As, Tl, and V were highlighted as key risk elements. Seasonal changes markedly influenced metal/metalloid concentrations and distributions in water, necessitating risk management focused on arsenic.

Solution to SRAM static power consumption with MTCMOS

The rapid growth of mobile devices has led to an increasing demand for battery life and energy efficiency in recent years, the reduction of circuit power consumption has become extremely crucial. SRAM has become an indispensable component of modern System-on-Chip (SoC) designs, and reducing its power consumption holds significant importance in minimizing overall chip power consumption. On the other hand, as manufacturing processes advance, static power consumption resulting from leakage currents has gradually emerged as a primary source of power consumption. This paper analyzes the power composition of SRAM, provides a detailed explanation of the principles and influencing factors of MTCMOS design technology, and conducts modeling analysis on 6T SRAM based on MTCMOS. In the modeling analysis, we compare the leakage current and static power reduction effects of 6T SRAM using four different process technologies: 28nm, 40nm, 65nm, and 90nm. From the data, it can be observed that MTCMOS has a notable effect in reducing leakage current for 6T SRAM across various process technologies. Comparing 6T SRAM of different process technologies, we can roughly see that the power reduction effect reaches a peak and gradually decreases. However, due to the lack of more advanced process libraries, we cannot further validate whether this inference is accurate.

Summary of the Research Progress on Advanced Engineering, Processes, and Process Parameters of Rare Earth Green Metallurgy.

The addition of rare earth metals to aluminum alloys can effectively improve their corrosion resistance and has been widely used in the aerospace and military industries. However, the current methods for the preparation of rare earth metals involve long processing steps, high energy consumption, and high carbon emissions, which severely constrains the development of aluminum alloys. Its output is further developed. To this end, this paper reviews mainstream rare earth production processes (precipitation methods, microemulsion methods, roasting-sulfuric acid leaching methods, electrochemical methods, solvent extraction methods, and ion exchange methods) to provide basic information for the green smelting of rare earth metals and help promote the development of green rare earth smelting. Based on the advantages and disadvantages of each process as well as recent research results, the optimal process parameters and production efficiency were summarized. Studies have concluded that the precipitation method is mostly used for the recovery of rare earth elements and related valuable metals from solid waste; the microemulsion method is mostly used for the preparation of nanosized rare earth alloys by doping; the roasting-sulfuric acid leaching method is mostly used for the treatment of raw rare earth ores; and the molten salt electrolysis method is a more specific method. This is a green and environmentally friendly production process. The results of this study can provide direction for the realization of green rare earth smelting and provide a reference for improving the existing rare earth smelting process.

Evolution of sustainable wearables: integrating cutting-edge techniques for future textile innovation

Purpose Sustainable textiles have become imperative in mitigating the adverse environmental and social impacts of the textile industry. This paper aims to synthesize recent advancements and key considerations in sustainable textile development, emphasizing their role in promoting environmental stewardship, social responsibility and economic viability. Design/methodology/approach The literature search has been conducted by identifying and articulating the previous studies related to integrating the latest cutting-edge techniques with functional textiles. Findings Future-generation textiles (FGTs), which incorporate state-of-the-art developments in materials, technologies and functionalities, herald a paradigm-shifting period in the textile industry. FGTs mark a new era in this dynamic world by igniting conversations about their mechanisms, problems, progress to date and potential future applications. This investigation covers a wide range of topics, including wearable electronics, nanotechnology, 3D printing, recycling, machine learning and energy harvesting. Key components include sustainability, functionality, intelligent integration, advanced manufacturing processes and multifunctionality. The paper highlights the potential benefits of smart textiles, wearable technology, improved performance and sustainability through advances in customization and security. Originality/value It is an original review work. This paper will be helpful for manufacturers and researchers in the smart wearable textile sector in developing innovative techniques for multifunctional garments by integrating cutting-edge technology.

Digital Twin for Continuous Production of Virus-like Particles toward Autonomous Operation.

Lentiviral vector and virus-like particle (VLP) manufacturing have been published in fed-batch upstream and batch downstream modes before. Batch downstream and continuous upstream in perfusion mode were reported as well. This study exemplifies development and validation steps for a digital twin combining a physical-chemical-based mechanistic model for all unit operations with a process analytical technology strategy in order to show the efforts and benefits of autonomous operation approaches for manufacturing scale. As the general models are available from various other biologic manufacturing studies, the main step is model calibration for the human embryo kidney cell-based VLPs with experimental quantitative validation within the Quality-by-Design (QbD) approach, including risk assessment to define design and control space. For continuous operation in perfusion mode, the main challenge is the efficient separation of large particle manifolds for VLPs and cells, including cell debris, which is of similar size. Here, innovative tangential flow filtration operations are needed to avoid fast blocking with low mechanical stress pumps. A twofold increase of productivity was achieved using simulation case studies. This increase is similar to improvements previously described for other entities like plasmid DNAs, monoclonal antibodies (mAbs), and single-chain fragments of variability (scFv) fragments. The advantages of applying a digital twin for an advanced process control strategy have proven additional productivity gains of 20% at 99.9% reliability.

AT THE CROSSROADS OF TECHNOLOGY AND MEDICINE: PROSPECTS OF AUTOMATION IN MEDICAL PRACTICE WITH THE USE OF NEURAL NETWORKS

This article delves into the exciting possibilities that arise when technology is applied to the field of medicine. It explores how automation can streamline various processes, leading to more efficient and accurate healthcare. One focus area is the potential for replacing direct interaction between doc-tors and patients with automated systems. By utilizing advanced neural networks, diagnostic and treatment processes can becomautomated, leading to faster and more precise outcomes. For exam-ple, AI-powered systems can analyze medical images and detect abnormalities with incredible accu-racy, aiding doctors in making diagnoses. Additionally, virtual assistants and chat bots can provide personalized healthcare advice, reducing the need for in-person consultations for minor concerns. These advancements not only enhance efficiency but also have potential to improve access to healthcare, especially in remote areas. Embracing technology in medicine opens up a lot of possibilities for better patient care and overall healthcare outcomes.

Selective laser sintering and spark plasma sintering of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide ceramics

AbstractTwo advanced manufacturing processes, spark plasma sintering (SPS) and selective laser sintering (SLS), have been developed for synthesis of (Zr,Nb,Ta,Ti,W)C compositionally complex carbide (CCC) via reactive sintering of a powder mixture of constitute monocarbides. X‐ray diffraction analysis confirmed that the single‐phase CCC can be formed by both SPS and SLS. While a homogenous microstructure with uniform metal element distributions was developed during SPS, three‐layer microstructures with a thin TiC‐rich layer and two TaC‐rich layers along with a TiO2‐rich surface layer containing W nanoparticles were formed during SLS. In addition, cellular structures with W, Zr, and Ti element segregation and dislocations on cell boundaries were observed in the SLS‐CCC sample, indicating the effect of nonequilibrium conditions on microstructure formation during laser melting followed by rapid cooling and solidification process. Compared to the SPS‐CCC sample, the SLS‐CCC showed enhanced hardness and reduced thermal conductivity, which may be related to their unique cellular structures.

Friction Stir Channeling in Heat Sink Applications: Innovative Manufacturing Approaches and Performance Evaluation

The fabrication of compact heat exchangers with precisely designed micro- and mini-channels is crucial for enhancing the efficiency of thermal management systems. Friction stir channeling (FSC) emerges as a cost-effective advanced manufacturing process to create complex integral channels, offering channel shape and size flexibility. This review article highlights the pivotal role of processing parameters in channel formation and maintaining their integrity, necessitating a comprehensive understanding of material flow dynamics. A rigorous assessment has been conducted on the channel under mechanical stresses, including tension, bending, and fatigue. The paper emphasizes the potential of FSC to revolutionize heat sink applications by exploring the fundamental concepts, governing parameters, ongoing enhancements in tool design, microstructural and mechanical properties, and heat transfer performance.

Energy Conservation in Cement Manufacturing: Challenges, Opportunities, and Sustainable Practices

The industrial sector, encompassing both tangible goods and intangible services, is pivotal to economic growth, with chemical manufacturing playing a critical role by transforming raw materials into diverse products. This study explores the importance of energy conservation in the cement manufacturing industry, focusing on its critical role in reducing production costs, minimizing environmental impact, and enhancing overall sustainability. The introduction provides an overview of the manufacturing and non-manufacturing sectors, highlighting the unique characteristics and contributions of each. The chemical manufacturing sector's significance is discussed, with an emphasis on its complex processes and energy-intensive nature. The cement industry, as a major energy consumer, is examined in detail, outlining the energy-intensive processes, challenges in energy conservation, and proposed solutions for improving heat efficiency. The analysis of energy flow in cement production identifies key areas for efficiency improvement. Waste heat recovery systems are presented as a viable solution for energy conservation, along with advanced technologies and process optimization. The study concludes by emphasizing the necessity of adopting sustainable practices and innovative technologies to enhance energy efficiency and reduce the carbon footprint in cement manufacturing.

Effects of Heat Treatment and Processing Conditions on the Microstructure and Mechanical Properties of a Novel Ti–6.3Cu–2.2Fe–2.1Al Alloy

Adding transition alloying elements to achieve a columnar to equiaxed transition (CET) in Ti alloys gains attention in additive manufacturing (AM). AM, which may be categorized as an advanced solidification process, is commonly a near‐net‐shaped process. This thus does not allow traditional thermomechanical processing to reduce grain size, which drives research toward novel alloys able to establish a primary grain structure with equiaxed grains upon solidification. The Ti–Cu alloy system catches attention through inducing the CET, but so far, no focus is placed on its secondary, solid‐state, and phase transformations during the heat treatment, therefore, requiring modified heat‐treatment strategies to accommodate for the inability of mechanical preforming prior to heat treating and thus achieving desired mechanical properties. In this work, insights are provided on microstructural evolution and tensile properties of a novel Ti–6.3Cu–2.2Fe–2.1Al alloy gained in an extensive heat‐treatment study. In the results, a lamellar α+β Widmannstätten microstructure with Ti2Cu precipitation and other features including grain boundary α, precipitate‐free zones, and very fine secondary α precipitates are shown. Utilizing micrographs and fractographic imaging, the fracture mode is identified as quasi‐cleavage mode with preferential crack initiation at grain boundary α layers. Tensile tests on heat‐treated samples show high strengths with simultaneously limited ductility.

The role of personal recovery and internalised stigma on the expression of symptomatology in severe mental disorders: Mediating and moderating effects

ObjectiveGiven the relevance of internalised stigma in people suffering from a mental disorder, in the present study, the possible mediating and moderating role of self-stigma in the relationship between personal recovery and symptomatology has been studied. Method265 participants with severe mental disorder completed the following instruments: ISMI (self-stigma), REE (personal recovery) and HoNOS, CGI, GAF and EuroQol (symptomatology). Resultsboth the mediation and moderation analyses show significant results, which would indicate that internalised stigma has an effect on the relationship between personal recovery and symptomatology. Also, people with lower level of personal recovery and greater self-stigma have greater symptomatology than those who are in more advanced personal recovery processes and have a lower perception of internalised stigma. Discussionthe findings of this study suggest that self-stigma has an effect, and the improvement at personal recovery and symptomatology is accentuated when people with a severe mental disorder have a better management of internalised stigma. Therefore, it may be interesting to include this variable in recovery interventions.

Management of Plastic Wastes through Recent Advanced Pyrolysis Processes

Plastics are predominant in numerous sectors like packaging, agriculture, hardware, electronics, and many others. Annual plastic demand has been rapidly growing in the last few decades because of the increasing dependency on plastics. As a consequence, massive amounts of plastic waste are being generated every year. These plastic wastes are non-biodegradable, and hence their disposal poses a serious threat to the ecosystem and causes significant environmental problems such as endangering the safety of marine life, wildlife, air, water, and soil, etc. A large portion of plastic waste ends up in landfills, and only a small fraction is recycled. The continuous dependence on landfills as the main disposal method for plastic waste is costly and ineffective. Common solutions to plastic waste management are incineration and recycling; however, incineration emits harmful pollutants and greenhouse gases that contribute to ozone layer depletion and global warming; moreover, recycling is expensive and inefficient. As an alternative to recycling and incineration, the pyrolysis process can convert plastic wastes into more valuable fuel products. Pyrolysis is a thermal process that converts raw material into pyrolysis liquid, solid wax, and non-condensable gases in the absence of oxygen. This process is attractive because it is economical and energy-efficient, and it can be used to convert various types of plastic waste into valuable products. In recent years, there have been significant developments in pyrolysis applications in liquid fuel production from plastic wastes. This work reviews recent advances in and challenges for the pyrolysis process for converting plastic wastes into a valuable alternative fuel, focusing on studies of advanced pyrolysis processes published over the last five years. The paper also highlights the numerical modeling of pyrolysis of plastic wastes and the potential impact of pyrolysis on the future of sustainable waste-management practices of plastics.

Band-Stop Frequency-Selective Surface (FSS) with Elliptic Response Designed by the Extracted Pole Technique.

This paper describes and validates an advanced synthesis design process of Frequency-Selective Surfaces (FSSs) with elliptic band-stop responses. A systematic procedure based on the Generalized Chebyshev Function and the extracted pole technique enables control of the position of the transmission zeros and the attenuation level to obtain an equiripple rejection response. A systematic process is followed to obtain the lumped LC values of the resonator circuits extracted as poles and the impedance inverters. Then, equivalent dipoles and transmission lines are obtained to carry out the electromagnetic design at normal incidence for a linearly polarized field. The impact of the higher-order modes of the periodic structure on the electrical response of the FSS, which can be relevant due to the stringent selected specifications, has been also analyzed. A fourth-order band-stop filter with a 3 GHz bandwidth centered at 30 GHz and its attenuation at 50 dB has been designed considering three different implementations: two filters using a vacuum as a transmission line with different connection lengths and a third one using a dielectric substrate to enable its manufacturing. In order to verify the design procedure using experimental results, the third filter with printed dipoles in the dielectric substrate has been manufactured and measured, thus validating the developed process.