Base Plate Research Articles

The effect of different mission profiles and ambient temperature on the lifetime of boost converter IGBT with a robust controller in a hybrid electric vehicle

AbstractThe reliability of power electronic converters is one of the essential issues in designing of electric vehicles. This paper estimates the lifetime of the boost converter switch by Semikron and Coffin‐Manson models for two common failure mechanisms of Bond wire and Base plate solder, respectively. Four mission profiles based on the Artemis standard are applied to hybrid electrical vehicle model to determine unidirectional output power. Kharitonov's theory is used to design a robust controller to handle the uncertainty raised by different power cycles of the electric vehicle and the parameters of the converter during simulation. Stability of converter is achieved during simulation by identifying simple proportional integral controller coefficients with Kharitonov's theorem. A prototype 230 W boost converter is designed and utilized to validate average model and switch loss calculation relationships. The lifetime results indicate that the number of cycles, and the average and the maximum junction temperature have a more impact than the duration of the drive cycle on the lifetime of the converter. A mixed mission profile is considered to investigate the effect of sudden change in driving modes and speed on total consumed life and lifetime to enhance the study's applicability. Lifetime of switch is decreased significantly in mixed mode in comparison with other mission profiles in the same driving time. Furthermore, the motorway mission profile has 53%, 39.6%, and 160% less total consumed life in comparison with the urban, rural and mixed mission profiles, respectively. In addition, the effect of ambient temperature changes on IGBT lifetime has been investigated for four mission profiles. While motorway had the least total consumed life in 25°C, the urban had better performance in comparison with other mission profiles from 25 to 55°C.

Microstructure and mechanical-property evolution of the explosive welding joint from the same RAFM steels under explosive welding and post-weld heat treatment

This study investigated the morphological evolution behaviors and the mechanical property of the weld interface during explosive welding for the flyer plate and base plate sourcing from the same reduced activation ferrite/martensitic (RAFM) steel. The relationship between fine-grain formation and the occurrence of dynamic recrystallization was analyzed based on the strain and temperature field distributions at the explosive-weld interface. Although post-weld tempering (PWT) treatment eliminated bent martensite laths, but it did not eliminate fine equiaxed grains and δ ferrite grains near the explosive-weld interface; therefore, the PWT treatment improved the mechanical properties of the explosive-weld RAFM steel joint only minimally. However, implementation of a normalizing process after the explosive welding process (“PWN” treatment) significantly eliminated the gradient structure and the residual δ ferrite grains at the explosive-weld interface of the RAFM steel joint. Based on the PWN state, the inclusion of a tempering treatment (“PWNT” treatment) promoted the uniform precipitation of M23C6 carbides, which significantly improved the tensile strengths of the explosive-weld RAFM steel specimens under both room and high temperatures. To study the influence of different microstructures on the plastic deformation behavior at the explosive-weld interface, the representative volume element (RVE) models basing on crystal plasticity finite element (CPFEM) method was constructed for different post-weld heat treatments (PWHTs). At the explosive-weld interface of the PWT-state RAFM steel joint, the plastic deformation was mainly concentrated in the δ ferrite grains, rather than in the fine equiaxed grains. In addition, only minimal deformation concentration was observed for the PWNT-state RAFM steel joint. In order to reveal the independent influence of the fine equiaxed grains at the weld interface on the mechanical properties of explosive-weld RAFM steel joint, the microstructural and mechanical distinctions between the RAFM steel joints in the N-PWT and PWNT states were investigated detailly. Finally, through optimization of the PWHT method, an explosive-weld RAFM steel (PWNT state) joint with a uniform microstructure and ideal mechanical properties was obtained.

Cooling characteristics of nanofluids in a snowflake and squid fin composite bionic microchannel heat sink

To improve the heat dissipation performance of electronic components, this study proposed a novel biomimetic microchannel design inspired by snowflakes and squid fins. A numerical simulation method was employed to investigate the cooling characteristics of nanofluids at different concentrations within this biomimetic microchannel heat sink. The microchannel is shaped like a snowflake, while the base plate features a biomimetic squid fin structure. The study focused on analyzing the effects of waveform height (amplitude A = 0.1–0.4 mm) and waveform frequency (B = 0.5–2π) on heat transfer performance. The results indicated that when nanofluids flow over a base plate with a wavelength frequency of B = 0.5π, there is a significant enhancement in heat exchange while simultaneously reducing flow resistance. In the microchannel heat sink (A = 0.3 mm, B = π), the thermal conductivity of the nanofluids can be increased by up to 32.56 %, with a maximum comprehensive evaluation index of 1.68. This research provides important guidance for the application of nanofluids and biomimetic microchannels in the thermal control of electronic devices.

Issues of Manufacturability of Roller Machines

Issues of maintenance of manufacture adaptability are considered in the article on an example of roller squeezing machines; recommendations to increase the manufacture adaptability of designs are offered. The geometry and kinematics of the attachment points of the base plate of a vertical-type squeezing roller machine are considered.

Laser Powder Bed Fusion Parameters Optimization for Enhanced Mechanical Properties of EOS Co-Cr Dental Alloy.

This research explores how variations in laser powder bed fusion (LPBF) parameters-laser power (P), scanning speed (v), and base plate preheating temperature (ϑp)-affect the mechanical properties of the EOS Co-Cr SP2 dental alloy. A central composite design (CCD) was used to optimize the process parameters. Mechanical testing focused on crucial properties for dental applications, including yield strength (Rp0.2), elongation (ε), toughness (KVa), and flexural strength (Rms). Microstructural analysis was conducted using light and electron microscopy, while XRD identified microstructural phases. Statistical analysis (ANOVA, Scheffé post hoc test, α = 0.05) revealed significant effects of P, v, and ϑp on the mechanical properties. Response surface models (RSMs) were developed, and optimal parameters were determined to achieve maximum toughness and flexural strength. Maximum values were obtained with laser power above 205 W and base plate preheating at 310 °C. The mathematical model predicted toughness values with less than 5% deviation from experimental results, indicating high accuracy.

Research into multi-directional high stability techniques in the same plane for satellite static testing

In order to ensure the structural strength reliability of spacecraft base plate during launch and operation, it is necessary to perform the structural strength test of load synchronous loading on the base plate in the same plane to evaluate its structural bearing capacity under certain axial and shear loads. In order to meet the test requirements and simulate the real stress condition of the base plate, a reliable implementation scheme is proposed in this paper. Multi-directional uniform loading of a satellite base plate is completed by using the same plane multi-directional high stability test technology. The mechanical test of a satellite using this technology shows that the test strain is consistent with the theoretical simulation deformation. This technology effectively solves the problem of uniform loading in the same plane of the satellite base plate in mechanical testing.

Constitutive relationship of soil in contact with mortar under continuous loading

Mortars will remain critical in future land wars due to their flexibility and versatility. When mortars are fired continuously, the contact soil is gradually compacted by the mortar base plate, and dynamic research into this process is the basis for innovative mortar design. However, the discontinuity and nonlinearity of soil contact absolutely necessitate the constitutive relationship of soil contact, which is difficult to study. Therefore, this study conducted experimental research and theoretical derivation to establish an accurate dynamic model of the mortar system. First, based on the nonlinear elastic–plastic theory and the stress–strain relationship of soil under cyclic loading, a theoretical analysis method for the constitutive relationship of contact soil under continuous loading was proposed. Second, an experimental and testing system was designed to simulate launch loads, and the stress–strain response of soil under continuous impact loads was obtained experimentally. Subsequently, based on theoretical analysis and experimental data, the stress–strain relationship during the gradual compaction of soil was established using the least squares method. Finally, a constitutive relationship model of the contact soil in the mortar system was established in ABAQUS using the VUMAT subroutine interface, and the calculated results were compared and analyzed with traditional calculation results. The results indicated that studying the constitutive relationship of mortar in contact with soil during continuous firing using this method can improve the accuracy of dynamically modeling mortar systems. Moreover, this study has practical value in the engineering design of mortar systems.

Evaluation of corrosion properties of TA2-Q345 explosive composite plate at different heat treatment temperatures

This study investigated the effects of post-weld heat treatment (PWHT) at 500 °C, 600 °C, 700 °C, and 800 °C on the microstructure and corrosion performance of the TA2-Q345 explosive composite plate, with TA2 as the flyer plate and Q345 as the base plate. X-ray diffraction (XRD), optical microscopy (OM), scanning electron microscopy (SEM), and energy dispersive spectroscopy (EDS) analyses were performed, alongside electrochemical experiments. The explosive welding interface of the TA2-Q345 composite plate exhibited a characteristic wavy structure, which indicated high welding quality. The XRD results indicated that the PWHT temperature significantly affects both the phase structure and the intensity of the diffraction peaks of the oxide film. Additionally, the porosity calculations demonstrated that the sample subjected to PWHT at 500 °C exhibited the lowest porosity in the surface oxide film, resulting in a denser oxide film that effectively enhanced corrosion resistance. However, as the temperature continued to rise, defects such as craters, bulges, and delamination between the oxide film and the titanium matrix were observed. The results of the electrochemical analysis indicated that, compared to untreated samples, the PWHT samples demonstrated improved corrosion resistance. Specifically, the sample with PWHT at 500 °C has the lowest corrosion current density (icorr) of 6.1892E-06 A/cm2, while the untreated sample has the highest icorr of 6.3577E-05 A/cm2, indicating that 500 °C is the optimal temperature. The corrosion process involved the hydrolysis of titanium chloride to form a TiO2 film and localized corrosion of the TiO2 protective film. The corrosion products composed of mainly C, O, and Ti were dispersed on the surface of PWHT samples.

Experimental and numerical investigations of forced convection impingement heat transfer on plate-fin heat sinks using three different electronic cooling fans

An experimental and numerical study was conducted for plate-fin heat sinks subjected to impinging air jets produced by electronic cooling fans. One axial and two different radial fans were used and their distance to the heat sink was varied. The aluminum heat sinks had either plain fins or fins with sinusoidal surface structures, were heated by heat sources either distributed over the entire base plate or concentrated in the center. In total, temperature measurements for 264 settings were performed, and numerical simulations were carried out for 19 selected cases. The results show that the axial fan outperforms the radial fans for the investigated fan distances, that the structured fins lead to lower base plate temperatures and that significant asymmetries in the heat sink temperature distribution can occur in certain cases. The numerical simulations are used to gain a better understanding of the trends observed in the measurements. Particularly, the impact of the velocity profiles at the fan outlets and the influence of certain geometrical details of the fan design on the heat flux distributions and the airflow into the fin channels are explored. The results highlight practical problems that need to be considered when optimizing heat sink-fan combinations.

Determination of process parameters for additive manufacturing with Inconel 718 powder

Abstract In this study, the additive manufacturing (AM) of Inconel 718 was investigated, and the processing parameters can affect the mechanical properties of the product. The five-axis laser cladding composite processing machine Tongtai AMH-630 is used, and the laser power is set to 800W based on the thermal impact of the laser on the base plate. However, the laser scanning speed (600-1200mm/min) and powder feed rate (3~15g/min) are not arbitrary combinations. It is recommended to present the feed per unit length in g/mm, which seems to be more clearly expressed. Regardless of changes in laser scanning speed and wheel speed, it is a reasonable decision to control the combination of the two at about 0.01-0.013g/mm. Through single-pass cladding experiments, we select different combinations of laser scanning speed and powder feed rate with a cladding aspect ratio in the range of 3:1 to 4:1. In the multi-pass cladding experiment, an overlap rate of 30% was used as the plane cladding spacing; a spacing of 80% of the cladding height was used as the stacking height. This study uses scanning speeds of 600, 700, 800, 1000 and 1200mm/min to clad a rectangular body. Tensile test specimens were processed using a CNC lathe, and tensile tests were conducted to obtain variations in tensile strength and elongation at different scanning speeds. The mechanical properties of both will decrease as the scanning speed increases. At a scanning speed of 600mm/min, its tensile strength is comparable to that of Inconel 718 standard materials; but its elongation is 61% of that of standard materials. If Hot Isostatic Pressing (HIP) is applied after cladding, it seems that a higher scanning speed can achieve a performance closer to that of standard materials.

Numerical and experimental study on manifold-distributed jet microchannel with micro-pin-fins

Traditional parallel microchannels are inadequate for managing the thermal requirements of newer, large-area and high-heat-flux chips. This inadequacy arises from its high flow resistance and poor temperature uniformity. Therefore, A novel manifold microchannel heat sink combining manifold inlet/outlet structures, distributed array jets, and micro pin-fins is introduced. Numerical simulations and experimental methods were employed to investigate the flow and heat transfer performance of the heat sink. Experimental results show that, with an average heat flux density exceeding 330 W/cm2 and a total power of 2500 W, the average chip temperature remains below 70 °C, ensuring efficient heat dissipation. Secondary impingement occurs at sufficiently low jet chamber heights, resulting in an increase of 3 times in the average Nusselt number for a smooth base plate. For the micro-pin-finned surface, it is shown that the presence of micro-pin-fins is not necessarily conducive to heat transfer enhancement. A critical volume fraction of micro-pin-fins (critical fin-ratio) exists where the obstructive effect and enhancement effect balance each other out. This value is influenced by multiple parameters. Finally, a novel relationship for predicting the average Nusselt number of jet impingement was proposed, with an average absolute error of less than 15 %. This series of investigations addresses the existing gaps in research on manifold-distributed array jet heat sinks and provides a meticulous theoretical foundation for the design and optimization of heat sinks facing the high-power chips.

Design and development of an IoT-based trolley for weighing the patient in lying condition.

An immobile patient cannot be weighed on a stand-on weighing machine, i.e., a bathroom scale. They have to get weighed while lying, which is not easy. The main objective of this research is to design a medical apparatus that measures the patient's weight in a lying condition. To achieve this the apparatus is designed as a stretcher to carry the patient in and around the hospital. The stretcher has four load cells to measure the patient's weight; it can bear a weight of 500 kg and has a self-weight of 20 kg. A Microcontroller unit (MCU) is embedded into the apparatus to weigh the patient lying on it. The stretcher comprises the top frame, middle frame, and base frame. The top frame can be detached and mounted back to the middle frame; this will help the medical personnel shift the patients from a medical bed. The middle frame is a plate structure where the four load cells are mounted at the corners of the lower plate. The upper plate functions as a pressure plate on the load cell. The base plate has four heavy-duty wheels that can bear the load. The middle frame and base frame, together, form a single structure, giving mobility to the structure. A control panel is employed with reset, tare, and on-off buttons to control the embedded platform. The LCD panel on the side of the apparatus shows the weight when the patient is placed on top of the apparatus. A prototype trolley equipped with a wireless data logging system was tested on 10 healthy participants. The device accurately measured weight within ±50 g across a scale range of 2-140 kg, with data captured every 30 s over a 5-min testing period. Wireless communication was successfully demonstrated over a 100-m range. The important add-on feature of this work is the apparatus is connected to the internet, transforming it into an IoT-based medical device.

Reconstruction method of high-precision longwall mining floor curved surface model driven by data points fitting of equipment

Abstract High-precision coal seam model is the basis of intelligent mining. The longwall mining face floor model, which can provide data sources for the correction of the dynamic coal seam model, is difficult to measurement directly. To address this issue, this paper proposes a high-precision coal seam surface model reconstruction and correction method based on a large number of operating data points. Firstly, the coupling model of equipment and floor is obtained based on the coupling model of plane and surface. Subsequently, the plane data points of the equipment are corrected based on the coupling model of equipment and floor to obtain the floor reconstruction points. The Catmull–Clark surface subdivision method is then used to subdivide the plane formed by the equipment data points to obtain surface subdivision points. The floor model reconstructed using surface data points is validated and corrected using the physics engine in the Unity 3d platform. Finally, the verification of the reconstruction point selection method, the coupling principle between the equipment and the floor model, the reconstruction accuracy of the base plate and the correction principle were carried out based on the equipment and floor model in the laboratory. The experimental results show the feasibility of the floor reconstruction, verification and correction method, which can provide a new idea for the reconstruction of the floor of the longwall mining face and the correction of the dynamic coal seam.

Propagation Effect Analysis of Existing Cracks in Box Girder Bridges Based on the Criterion of Compound Crack Propagation

Cracking in concrete box girder bridges will have a significant impact on the safety and durability of the structure, and many box girder bridges which are in service have undergone varying degrees of cracking. Currently, the safety design of actual bridge projects place an emphasis on the stress or the load value of a cross section at the limit value specified in the code for safety control. This design method assumes that the member itself is of uniform and continuous material and is internally undamaged. However, the bridge structure is more or less cracked to varying degrees during the period from casting to construction to operation of the concrete members. In this paper, a finite element computational model of a three-span prestressed concrete box girder bridge with existing cracks is established based on the fracture mechanics theory, and the critical parameters of crack extension are introduced to evaluate the extension state of cracks. At the same time, the extended stability of the existing cracks of the box girder bridge is analyzed by considering the temperature effect, vehicle loading, and prestressing loss, and the sensitivity of crack extension under each working condition is investigated. The results show that, with the increase in crack length and depth, the crack expansion is promoted, but the effect is relatively small, and the maximum stress intensity factor is only 6.48 MPa mm1/2. Under the multi-factor coupling effect, the cracks show a composite crack expansion dominated by type I cracks, the longitudinal cracks of the existing base plate are in a stable state, the maximum value of the crack expansion critical parameter of the vertical cracks of the webs reaches 1.087, and there is a tendency to expand locally. The maximum value of the critical parameter for crack extension of the vertical crack in the web plate reaches 1.087, and there is a tendency towards local expansion. The crack extension evaluation criteria proposed in this paper have a certain reference value for crack extension research on similar concrete box girder bridges and provide a scientific basis for the optimized design of similar bridges.

Research on the Energy-Absorbing and Cushioning Performance of a New Half-Bowl Ball Rubber Body in Tunnel Support

As coal mine underground operating conditions are harsh, strengthening and optimizing the support structure is conducive to the safety of mining work and personnel. Currently, underground support devices face problems such as poor environmental adaptability and unbalanced performance of shockproof and energy absorption. At the same time, the energy absorption mechanism and impact dynamic analysis of the support structure are still imperfect. This paper proposes a simple and effective bionic half-bowl spherical rubber energy-absorbing structure based on the actual production needs of coal mines, with energy-absorbing rubber as the main structural interlayer. A combination of experimental testing and simulation was used to reveal the dynamic response and mechanism of simulated energy absorption of a half-bowl-shaped rubber layer under different working conditions. Abaqus software was used to simulate and analyze the dynamic response of the half-bowl spherical rubber structure under the impact condition, and the simulation data were compared with the experimental results. In addition, the relationship between energy absorption and stress at the rubber structure and the base plate under different impact velocities was investigated. The results show that the simulated and experimental results of the rubber structure have almost the same pressure vs. time trend within 0.1 s at an impact velocity of 64 m/s, and there is no significant wear on the rubber surface after impact. Due to the energy-absorbing effect of the rubber structure, the maximum stress of the bottom member plate-2 of the mechanism is lower than 9 × 104 N. The maximum amount of compression of the half-bowl ball is 37.56 mm at an impact velocity of 64 m/s. The maximum amount of compression of the half-bowl ball is 37.56 mm.

Vibration absorption of as-built and post-heat-treated Ti-6Al-4V alloy fabricated by laser powder bed fusion additive manufacturing

Vibration absorption of the Ti-6Al-4V alloy fabricated by laser powder bed fusion additive manufacturing (LPBF-AM) was evaluated following as-built and post-heat treatment (i.e., solution treatment followed by water quenching). The base plate was heated at 50°C or 200°C during building. Results showed that the vibration absorption of the as-built Ti-6Al-4V alloy was higher when the base plate was heated at 50°C than at 200°C. Further, the vibration absorption indicated strong anisotropy, with the highest vibration absorption in the direction perpendicular to the building direction and transverse to the laser scanning direction. However, after solution treatment followed by water quenching, the anisotropy in the vibration absorption of the LPBF-AMed Ti-6Al-4V alloy practically disappeared, and relatively high values were obtained parallel to each direction.

REDUCTION OF FOOD COSTS AND WASTE IN PRE-PREPARATION OF MEALS BY IMPLEMENTING TECHNICAL TOKENS IN A FORTALEZA-CEARÁ FOOD AND NUTRITION UNIT

The Food and Nutrition (HFS) is a unit which develops activities related to food and nutrition, providing safe meals. To reduce waste, it can be used to produce sheet (FTP) that it is an effective tool for the control of production of foodstuffs both in financial as well as nutrition. This work aims to standardize and reduce waste in the pre-preparation and cost of preparations by deploying factsheets on a Power Unit Nutrition business in Fortaleza-Ceará. This is an observational study, prospective, descriptive quantitative, with six days of execution. The fact sheets were made of five (5) dishes present in the unit in which menu was composed of entrance, main dishes, base plate, trim and desserts. Among the FC obtained in this study there was a significant variation in the results available in the literature, making it possible to compare the losses, evaluation of raw materials, storage, receipt and hand labor used. With the reduction of factors, therefore there was a reduction in the cost of the preparation of the meals, as FC interfere with cost values, the sales price is an important factor in determining the profit of the company. Based on the data presented, it is concluded that this data sheet is a very important tool for the units of food and nutrition, it provides a reduction in waste and cost of preparations, and contribute to the choice of supplier, upon receipt, storage , handling, assisting in the planning of purchasing, control production costs and providing a standard and quality of meals.

Remanufacturing of low-carbon steel components using WAAM: microstructural, mechanical, and parametric analysis

This research paper investigates the remanufacturing of low-carbon steel components using wire-arc additive manufacturing (WAAM), aiming to enhance resource efficiency and sustainability in various industries. The study focuses on repairing flat plate test coupons with a pre-fabricated trapezoidal groove using GMAW-WAAM. The microstructural characteristics and mechanical performance of the repaired samples are compared to the base material, and the influence of heat treatment on the repaired parts is also examined. Planned experiments and empirical modeling are performed to analyze the impact of WAAM process parameters on mechanical properties, establishing correlations between parameters and desired performance characteristics. The WAAM-repaired plate demonstrates higher tensile strength and hardness due to strong bonding, and finer grain structure, while annealing reduces tensile strength and hardness. Additionally, the WAAM-repaired annealed plate exhibits improved elongation compared to the WAAM-repaired plate but remains lower than the base plate. Observations revealed that the strength, elongation, and hardness of repaired samples are influenced by WAAM parameters in complex ways, with favorable combinations yielding improved properties.

Design and application of an extracorporeal membrane oxygenation-specific line fixation device

Extracorporeal membrane oxygenation (ECMO) is an important treatment for extracorporeal cardiopulmonary life support for clinically critical patients. Currently, ECMO tubing is commonly fixed by tie-wraps or tourniquets, which have shortcomings such as easy loosening and potential damage to the tubing. Improper fixation of the catheter can lead to a series of adverse events, such as accidental disconnection of the tubing, rupture of the tubing, tubing folding, and air ingress into the tubing. In order to overcome the above problems, the research team of Zhongda Hospital, Southeast University invented a device for ECMO line fixation and obtained a national utility model patent of China (patent number: ZL 2019 2 2282849.3). The tool is mainly composed of several devices, including a line fixation clamp, a clip fixation device, and a base plate, which is uniquely designed and easy to operate. During ECMO therapy, this device ensures effective stabilization of the ECMO tubing, preventing unexpected incidents due to catheter loosening and facilitating the observation of ECMO catheter insertion markings. Pipeline can be effectively fixed to avoid the occurrence of accidents due to the loosening of the catheter, and at the same time, it is convenient to observe the placement scale of the ECMO catheter. The novelty and uniqueness of the fixation device materials also effectively prevent the occurrence of pressure injuries during its use.

Investigation of Co-Cr alloy layer prepared by laser metal deposition

Abstract Additive technologies are commonly used for component production and repair. Laser metal deposition is a type of additive technology that can create new bodies or add new components to existing parts. This technology enables continuous modification of the chemical and material properties of the deposited layer to suit the intended purpose. The alloying powder is dissolved and mixed in a small volume molten pool during laser deposition. The laser cladding process is known for its rapid heating and cooling rates. This can result in partial or non-existent dissolution of powder particles in the molten pool, or the formation of non-equilibrium microstructures that cannot be achieved through conventional metallurgical processes. As a result, this method can be used to create materials with unique combinations of properties. In this study, a Co-Cr coating layer was applied to a structural steel base plate. The parameters combination was generated using Taguchi’s experimental design. The relationship between the parameters and the properties of the prepared coating was evaluated using the Taguchi method.