Industrial Components Research Articles

Transfunctional Optical Thin Films via Bioinspired Engineering.

Advanced multifunctional optical films or substrates have continued to develop as essential components in the diverse optical industry. Several functions, including high transparency, self-cleaning ability, structural color, flexibility, and durability, are required to obtain versatile and practical optical films. Herein, we introduce a cicada-wing-inspired transfunctional optical thin film (CITOTF) with nanostructures on both surface nanostructures inspired by the cicada-wings. CITOTFs made of perfluoropolyether (PFPE), which has a low refractive index, low surface energy, and high robustness as a substrate material, are obtained by a well-designed sandwich lithography method. We fabricated two types of CITOTFs depending on the size (300 and 1000 nm) of the surface nanostructure. 300-CITOTF and 1000-CITOTF exhibit high transparency and structural color effects, respectively. Both samples demonstrate self-cleaning ability, flexibility, and long-term stability. The bioinspired transfunctional optical films developed in this study can be used in various optical applications.

Acid Resistance Engineering of Endoglucanase for the Degradation of Wine Lees.

Wine lees is a low value biomass resource rich in cellulose, with great potential for producing organic fertilizers and chemicals. However, the high acidity of wine lees limits the catalytic efficiency of the conversion tool endoglucanase. Here, we expressed endoglucanase tCel5A from Trichoderma reesei in Pichia pastoris, and the combination of promoter AOX1 and signal peptide SUC2 resulted in a highly active expression of 4632.81 U/mg. Subsequently, the catalytic center design and surface charge modification strategy resulted in mutants T88H/W255H and S45D/T55D/T59D exhibiting catalytic activity twice and three times higher than WT at pH 3.0, respectively. Finally, when the solid-liquid ratio was 1:15 (w/v), the degradation rate of wine lees was nearly double that of WT. The degradation products contained a variety of industrial and pharmaceutical raw components, including the antioxidant and anticonvulsant isopiperolein B. This study accelerates the green and sustainable management of wine lees.

The Influence of the Amount of Technological Waste on the Performance Properties of Fibrous Polymer Composites

The objective of the experimental analysis was to assess the impact of the reuse of technological waste (recyclate) on the selected performance properties of the fibrous polymer composite used to produce components for the automotive industry by injection molding technology. Polyphthalamide (PPA), which belongs to a group of high-tech polymers, was chosen as the analyzed material. In accordance with the set goals, the rheological, mechanical, and structural properties of the material were evaluated using ANOVA analysis in the experimental part of the work, depending on the mass ratio of the recycled material added to the virgin material. The influence of the proportion of recycled material on the lifetime of moldings by the method of their exposure at an elevated temperature for a defined time was also assessed. During the research, it was found that at a concentration of up to 40 wt. % of recyclate, its mechanical properties do not change significantly. At a concentration of 50 wt. %, there is a rapid decrease in mechanical properties. In the long term, it can also be said that the addition of recyclate significantly affects the service life of the components. No significant changes in morphology were observed during the analysis of structural properties.

SMART-STRATEGIES AND INVESTMENT ATTRACTIVENESS OF THE EU REGIONS

The purpose of the article is to generalize the foundations of formation of smart-strategy of country / region development as a factor of impact on the level of investment attractiveness. The development of globalization processes has led to positive consequences, resulting in the growth of the world’s economy. At the same time, the competition in the sphere of attracting investment resources has aggravated. Based on the analysis of indicators of investment activity of European countries and the investment attractiveness of the EU countries, it was found that the specified area is characterized by the presence of negative trends, which actualizes the need to develop tools for increasing the level of investment attractiveness. The system of factors of impact on the level of investment attractiveness of the country / region was studied. It was found that in current conditions, in addition to the traditional factors of influence on investment attractiveness, intellectual potential, flexibility, education and innovation, networking, etc. are added, which serves as the basis for the implementation of smart approaches in the formation of regional development strategies. The article defines the features of the formation of a smart approach to development strategies, which is based on the combination of technological and industrial components. It was found that the basis of smart-strategies is the specialization of the country / region, which is formed considering the resource provision and development potential of the region, the ability to diversify, the ability to achieve a high level of concentration of business entities in the region, the place of the region in the economic system. Building a regional policy based on smart-strategies will stimulate economic development, increase competitiveness and investment attractiveness of countries / regions. On the basis of the conducted research, a number of challenges related to the implementation of the smart approach were identified, namely, a high level of subjectivism and the need to ensure a high level of qualification of the participants in the discussions when implementing the mechanism of inclusive management; the growth of internal competition in the case of the formation of homogeneous specialization of several EU countries / regions; taking into account external risks, one of which is a full-scale Russian-Ukrainian war; implementation of adaptive approaches in the process of formation and implementation of smart-strategies. Addressing these challenges will contribute to increasing the efficiency of smart-strategy formation for a high level of investment attractiveness of the EU regions.

Design and validation of fixation points of polymeric components for the automotive industry

ABSTRACT The incorporation of polymeric materials in car structure components plays a key role in the automotive sector, enabling the production of more efficient and ecological vehicles. Among the many options to fix these components, there are clips and snap-fits, which not only facilitate assembly and disassembly, but also contribute to reduce the total mass of the car. This work aims to design and validate these fixation points of polymeric components using the Design Science Research (DSR) methodology. The work resulted from the need for a more rigorous control involving some internal standardized fixation points, namely interior trim parts. Experimental tests were carried out according to the specifications of the automotive brand, including the strength of the fixation points, to enable incorporation as standard components. Using the Finite Element Method (FEM), static simulations were performed in the Abaqus® software, where the conditions of the physical tests were replicated to correlate both tests and validate the numerical approach. Improvement of the fixation points was next undertaken, by making changes in the areas that were identified as critical. The improved fixation points were able to meet the specifications of the company and were proposed as new geometry for standard interior trim parts.

Implementation and Benefits of the 5S Method in Improving Workplace Organisation – A Case Study

Abstract The article deals with the use of the 5S methodology in an organization. It focuses on the implementation of 5S in an organization involved in the production and processing of metal components for the automotive industry. 5S is a Japanese methodology that was first applied in the automotive industry to improve productivity. The article is dedicated to the basic principles of lean manufacturing.The practical part analyses the state of the workplaces before the introduction of 5S and the actual implementation of this methodology. The implementation of 5S brings a number of benefits to the organization, including: - reducing time wasted searching for tools, - improving safety, - boosting employee morale, - building the culture of the organization. Keeping the workspace organized with visual aids helps to increase productivity and reduce waste. The ultimate goal of 5S is continuous improvement in the workplace. The final section evaluates the benefits to the organization after the implementation of 5S. By implementing this strategy, the workplace becomes clean and standardized, allowing employees to work as efficiently as possible. The 5S method creates a more efficient work environment by improving the organization and optimizing the system of operation.

Forecasts of Video Game Sales based on the ARIMA Model

Abstract. With the rapid development of the digital age, video games have become an important component of the cultural industry, and their sales forecasting has become a focus of industry attention. This article aims to predict the sales of video games based on the ARIMA model and explore effective methods to improve prediction accuracy. Through in-depth research, this article found that the ARIMA model performs well in capturing the time series characteristics of sales data and can accurately predict future sales trends. The ARIMA model provides a systematic and scientific method for predicting the future market performance of video games by comprehensively considering the trends, seasonality, and random changes in historical sales data. This research achievement not only provides strong decision support for game developers, publishers, and platform operators but also promotes the optimization of resource allocation and market risk avoidance in the video games industry, which is of great significance for promoting the healthy and sustainable development of the industry.

Rotating Bending Fatigue Durability of Wrought 304 Stainless Steel: A Comparative Study of Surface-Treated vs. Untreated Specimen

The rotating bending fatigue test, which is a common durability test for industrial components, was employed in this study to examine the impact of the surface treatment procedure on the material's performance under room temperature. The studied material in this research is a wrought stainless steel (SS) 304 alloy that has undergone a specialized surface treatment to enhance the fatigue properties of this unique material. The fatigue endurance of untreated materials was 405 MPa (65% of untreated specimen’s yield strength) on 5 million runout cycles, while the surface-treated samples exhibited 545 MPa (85% of treated specimen’s yield strength), a significantly greater value compared to the untreated ones (even up to 10 million runout cycles). The experimental results demonstrated that the surface-treated samples exhibited no signs of cracking. Instead, all failures were attributed to plastic bending, particularly at higher stress levels. Furthermore, the samples displayed a limited range of stress levels, spanning from endurance to plastic bending conditions. This finding suggests that the hypothesis of an increase in stiffness in the surface layer is more pronounced than in the material interior. It also indicates that the surface layer material was not cracked under the maximum stress level, while the layer beneath it experienced plastic deformation. A comparison has been made between the Basquin equation and a statistical machine learning model (for a limited amount of data) to incorporate the impact of surface treatment on predicting fatigue lifetime, and the random forest regressor model would be able to predict the lifetime with the accuracy of R2= 87% which was much higher than the classical model.

Two-Dimensional Bi2Se3 Nanosheets Synthesis for Efficient Electrocatalytic Production of Ammonia from Nitrate

Ammonia (NH3), a critical component for various industries, is produced through the Haber-Bosch process, which, despite its importance, is a significant source of carbon emissions and operates on a centralized model, emphasizing the need for innovative solutions to decarbonize and decentralize its production. Electrochemical nitrate (NO3–) reduction to NH3 presents a promising alternative to the Haber-Bosch process for NH3 synthesis, with the added advantage of transforming waste into a valuable resource while mitigating water pollution concerns. However, achieving a well-defined active center and catalytic selectivity in the electrochemically driven reaction remains a significant challenge. In this study, we successfully fabricated a highly selective and active 2D Bi2Se3 catalyst, which demonstrated better performance in reducing NO3– to NH3 with a Faradaic efficiency (FE) of approximately 80% (−0.3V (RHE)) and a significant yield rate of 45mgh−1mgcat−1 (0.46 mmolh−1cm−2). Furthermore, the fabricated material exhibited exceptional stability and durability, maintaining a high NO3– reduction of 80% FE even after 10 consecutive cycles of extended use and continuous operation, demonstrating its remarkable resilience and reliability. Our findings show that the prepared catalyst selectively promotes the electrochemical reduction of NO3– to NH3 while suppressing the competing hydrogen evolution reaction (HER). The charge density profile indicates a pronounced charge localization around the Se atoms, implying that the Se active sites in the 2D Bi2Se3 catalyst act as the active center for the NO3– reduction mechanism, playing a crucial role in facilitating the reaction kinetics.

Small punch test size reduction to enable high flux irradiation

Screening and qualification of new nuclear materials with superior irradiation resistance requires expensive irradiation exposure and post-irradiation examination before consideration into industrial nuclear structural components. The development of miniaturized test methods is needed for enhanced cost/time efficient testing, while enabling comparative and robust material property estimation in a timely and high throughput manner. The Small Punch Test (SPT) is drawing much interest, especially since the publication of an European standard. Motivated by this standard, a new SP test sample geometry is proposed in order to reduce the material volume to be tested, hences increasing the number of samples that can be introduced in an irradiation rig is proposed. The modified sample diameter has been reduced from 8 to 5.35 mm. The qualification of this new design is described here together with a detailed description of the SPT setup modification as compared to the reference setup of the EN standard. Finite element analyses and a series of experiments have been conducted using both standard and reduced size SP samples to demonstrate that the modified test gives estimates of the basic mechanical properties with the same magnitude of error and validates the modified sample geometry for usage in irradiated material testing.

Thermal and mechanical properties of high-performance polyester nanobiocomposites reinforced with pre-treated sunn hemp fiber for automotive applications

The objective of this study is to create high-performance nano biocomposites by utilizing unsaturated polyester resin (PE) reinforced with pre-treated short (2 cm) lengthened sunn hemp (SH) fibers and by incorporating 5 % nanoclay (hydrophilic bentonite) through the compression molding technique. The addition of 5 % nanoclay to the biocomposite significantly increased the flexural strength by approximately 165 % for H2O2-treated SH fiber and 148 % for KMnO4-treated SH fiber, when compared to untreated fibers. This enhancement was achieved through phase separation, intercalation, and exfoliation between the SH fibers, polyester resin (PE), and 5 % nanoclay. In particular, the H2O2-treated SH fiber nanobiocomposite exhibited a 43 % higher flexural strength compared to its corresponding biocomposite. The incorporation of nanoclay significantly decreased the water absorption of the bio-composites from 11.86 % in the untreated samples to a minimum of 2.76 % in the H2O2-treated SH/PE nanobiocomposite. The study suggests that short SH fiber/PE/nanoclay nanobiocomposites could be used as effective alternatives to synthetic composites in various applications, including the aerospace industry, household products, and automotive interior components such as side panels, seat frames, and central consoles. Additionally, they could be utilized in exterior parts like door panels and dashboards.

Effect of ultrasonic vibrations on mass efficiency and microstructure of laser direct deposition Inconel 718 superalloy

Laser direct deposition (LDD) is widely used to repair and manufacture high-value industrial components. However, it faces various defects, such as porosity, cracks, non-uniform microstructure, lack of fusion, keyhole phenomenon, element segregation, and undesirable secondary phases. A method to manage these defects is to concurrently apply ultrasonic vibrations (USV) during the LDD process. This study investigates the effect of USV on the mass efficiency and microstructure of LDD Inconel 718 superalloy to understand how incorporating USV can change the performance and structural integrity of single passes produced using the LDD process. For this purpose, USV is applied to a substrate during the LDD process. The resulting samples are characterized and analyzed using optical microscopy, scanning electron microscopy, and energy-dispersive X-ray spectroscopy. The results indicate that applying USV below a threshold power value increases mass deposition by over 25%, while exceeding this threshold reduces it. Attention to this threshold power value is crucial for determining the process parameters, including laser power and speed. Additionally, USV transforms the microstructure from columnar to equiaxed and increases subgrain formation. This implementation also enhances the cooling rate, significantly decreasing the Laves phase by over 30% in all process parameters.

A Strain Integrated Gas Infusion Process (SIGI) for Magnesium Alloy Castings

This study presents a Strain Integrated Gas Infusion Process (SIGI) to manufacture high-performance cast AZ91 magnesium alloys without the addition of secondary alloying elements/reinforcements or secondary processing. The current SIGI process involves a combination of agitation and localized rapid heat extraction via strain integration and high-energy gas infiltration. The SIGI casting process has been compared systematically with conventional techniques. The critical process parameters, including hole diameter, bubble diameter, and flow rate, have been optimized through numerical calculations, simulations, extensive experiments, and comprehensive analysis. The study also focused on investigating the effect of gas bubbles on the molten metal and established the mechanisms involved in improved solidification. Gas infusion combined with strain integration impacts the solidification process, ensuring uniform alloying element distribution and reducing segregation and microporosity. This manufacturing strategy eliminates casting defects such as segregation and microporosity, resulting in a non-dendritic homogeneous microstructure. The significant refinement in morphologies of both primary (α-Mg dendrites) and secondary (β-Mg17Al12 phase) phases highlights the success of the current SIGI process. Compared to the conventional casting processes, a remarkable improvement in strength-ductility synergy is achieved in the current SIGI process. The scientific know-how and efficiency of the current SIGI process are established and discussed in detail, providing a promising solution to address the existing challenges encountered in magnesium alloy billet castings. The SIGI process improves the mechanical properties and corrosion resistance of billet-cast magnesium alloys. The SIGI process is suitable for the billet casting, offering significantly improved properties but faces limitations in complex mold casting applications. The billets casted by SIGI process can be used as a high-quality precursors for downstream processes to create industrial components.

High-precision non-contact online measurement and predictive analysis of geometric parameters in large industrial components

High-precision non-contact online measurement and predictive analysis of geometric parameters in large industrial components

Enhancing high-temperature wear resistance of plasma-sprayed NiCrBSi coatings with nanodiamond reinforcement

High-temperature wear causes industrial components to degrade quickly, leading to reduced efficiency, frequent breakdowns, and costly repairs. Thermal spraying is a surface modification technique employed to address these wear issues by shielding the component using protective coatings. In this study, the high-temperature wear behavior of plasma-sprayed NiCrBSi coatings reinforced with Nanodiamond (ND) particles was systematically evaluated. The coatings were reinforced with 1 wt% and 2 wt% ND, and their tribological performance was assessed under varying thermal conditions. Tribological tests were conducted using a ball-on-disk setup at elevated temperatures of 473 K, 673 K, and 873 K for 60 min. The experimental results demonstrated a significant improvement in the wear response and frictional characteristics of the NiCrBSi coatings with the incorporation of ND particles. Specifically, the NiCrBSi coating reinforced with 2 wt% ND exhibited a significantly lower wear volume loss and a reduced coefficient of friction when compared to the pure NiCrBSi coating. At 873 K, the NiCrBSi-2ND coating demonstrated a 64 % reduction in wear volume loss and 85 % decrease in the coefficient of friction, compared to the pure NiCrBSi coating. The incorporation of NDs greatly enhanced the lubrication and hardness of the NiCrBSi-2ND coating as well as improved the adhesion of wear debris to the newly exposed wear track. The high thermal conductivity of NDs enhanced heat transfer to the coatings, facilitating the formation of a protective tribo layer at elevated temperatures, which improved the wear resistance of the NiCrBSi-2ND coating. These findings underscore the potential of ND as a reinforcing agent to significantly enhance the durability and efficiency of NiCrBSi coatings in extreme thermal environments.

The structure and dynamics of the auto parts industry: Product space and complexity perspectives

Economic structures are strong determinants of diversification, growth, innovation, inequality, and many other socio-economic outcomes; however, structural change's effect on specific industries remains unexplored. This study investigates Japan's automotive components industry, analyzing its productive structure (the auto parts product space) and structural change process. We develop exploratory and econometric analyses that unify the measures of product relatedness and complexity. The firm-level data analysis shows that specific structural properties in international and domestic economies also exist in the automobile industry. This fractal structure implies that common principles and regularities underlie the formation of productive structures, notwithstanding the economies’ size, maturity, and industrial scope differences. The exploratory and econometric analyses indicate that the events of a product's appearance are not random but are significantly contingent on the network topology of the product space. Furthermore, network topology significantly impacts the development of complex products with sophisticated capabilities.

MoS2/Ti Co-deposited Coatings and Their Fretting Wear Properties at Elevated Temperatures

Abstract Fretting wear refers to the damage phenomenon experienced by the mechanical components undergoing micro-amplitude relative slip at their contact region due to vibration. Titanium alloys find their extensive application in aerospace industry components such as splines and dovetail joints, where they experience fretting wear phenomenon. This research work investigates the effect of MoS2/Ti co-deposition coatings with varying Ti content, deposited on TC4 titanium alloy substrate using magnetron sputtering. Fretting wear tests were conducted at room temperature, 100 °C, and 200 °C, using a specially designed fretting test fixture with a ball-on-flat contact configuration, mounted on a servo-hydraulic fatigue testing machine. The results indicated that the coating becomes denser with an increase in the Ti content. The coating exhibited the highest hardness and better anti-fretting wear performance at room temperature. However, the effect of Ti content on the fretting wear behaviors changed at elevated temperatures. At the highest Ti content coating, excessive oxide particles were found at the worn surface at elevated temperatures, inducing an abrasive effect and localized cracks. However, coatings with moderate Ti content (9.62 at. %) effectively protected the substrate from significant wear at room temperature and maintained a low coefficient of friction at high temperatures without failure.

Using lubricant composition to control friction-induced-vibration in an elastomer-steel contact representing a hydraulic seal

Hydraulic seals are key industrial components that can suffer from unwanted friction induced vibration (FIV). The types of FIV mechanism that occur in these components, and how they may be controlled, are not well known. We conducted sliding friction tests on contacts between seal materials, lubricated by hydraulic fluids, under speeds and contact pressures typical of hydraulic machines. FIV that occurred under certain conditions was captured and analysed. Results suggest 1) two FIV mechanisms are occurring: classic stick-slip and speed dependant friction instability, the 2) occurrence and severity of these mechanisms are correlated with the ratio of static to dynamic friction and the gradient of the friction vs. speed (Stribeck) curve, respectively, 3) these parameters can be controlled by including an appropriate additive package in the lubricant and this significantly reduces FIV, 4) most FIV occurs at low temperature and high load since these both lead to low kinetic friction (due to thicker hydrodynamic films and smoother surfaces) and thus promote stick-slip. This may explain instances of noise known in practice as the “Monday-morning effect” and suggests how this too may be alleviated through lubricant formulation.

The Influence of the Gap Phenomenon on the Occurrence of Consecutive Discharges in WEDM Through High-Speed Video Camera Observation

The Wire Electrical Discharge Machining (WEDM) process is an accurate method for manufacturing high-added-value components for industry. Continuous developments in the process have resulted in specialized machines used in sectors such as aerospace and biomedical engineering. However, some fundamental aspects of the discharge process remain unresolved. This work aims to study the influence of discharge location and bubble expansion on the occurrence of subsequent discharges. A high-speed video camera observation system was constructed to capture images of each discharge. From the acquired images, an algorithm was devised to determine the discharge location based on grayscale analysis. Moreover, the voltage and current waveforms of the discharges and the framing signals of the high-speed video camera were then obtained using an oscilloscope. Synchronizing the observation images and signals allowed for calculating the delay time for each single discharge. The results indicate that most of the discharges occurred near the boundary of the bubble and during bubble expansion. This finding has been observed for a variety of machining conditions and can be explained by the effect of the debris particles concentrated at the bubble boundary. This study provides useful information for better understanding the discharge process in WEDM.

Experimental testing of additively manufactured embedded fiber optic smart devices for clean energy applications

Abstract An additively manufactured prototype smart device was created to investigate in-flow temperature distributions using embedded high-definition fiber optic sensors within a component for clean energy systems. The devices were created using Ultrasonic Additive Manufacturing to create a unique embedded pathway within a flow conditioner for the high-definition fiber optic sensors to be placed within. The fibers used allowed for temperature measurements to be taken every 0.65 mm along the fiber. The high-resolution fibers were thermally calibrated enable the 2D reconstruction of the temperature profile in the flow path of the structure. This is due to the temperature-related strain response of the material and strain measurements of the fibers. Hot airflow testing of these devices showed the ability to identify localized temperature differences in the flow. The observed strain response within the smart device had higher strain concentrations in the thicker web regions than in the thinner web regions. These higher strain regions resulted in higher uncertainties for the temperature responses. Further calibration is needed to improve the accuracy of the smart devices, specifically within the inner web structures of a flow straightening component. Further investigations of the devices within flow showed the temperature sensing to be independent of the effects of flow velocity. The devices were able to distinguish temperature differences within single and two-phase flow and showed local sensitivity to the temperature changes with the identification of hot and cold spots. The presented results showed the viability of the smart device for obtaining detailed temperature distributions using common industrial components. Eventually, the goal for these smart devices will be to withstand higher temperature and pressure environments such as those experienced in nuclear, fusion, and concentrated solar energy systems.