Composite Process Research Articles

Fiber-reinforced friction materials: Experimental, statistical and computational universal analysis

In this paper, the experimental, statistical and computational universal analysis methods applicable to most fiber-reinforced friction materials (FMs) are presented for four natural wollastonite fibers (WFs) with different length-to-diameter (L/D) ratios. Machine learning (ML) methods for friction coefficient prediction of friction materials are compared and screened. Numerical statistics and calculations are used in conjunction with the use of finite element (FE) models to determine the performance metrics and friction wear mechanisms of FMs. The experimental and computational results show that the artificial neural network (ANN) model performs the best in COF prediction with an accuracy of 0.961. The friction fluctuation, friction stability and integrated friction performance of the WF-containing samples are better than those of the blank samples. For the first time, the FE model was used to explain the swirling phenomenon on the wear surface of FMs. This study provides new ways and ideas for the design, experimentation, data processing and application of friction composites.

Citric Acid Cross-Linked Gelatin-Based Composites with Improved Microhardness.

The aim of this study is to investigate the influence of cross-linking and reinforcements in gelatin on the physico-mechanical properties of obtained composites. The gelatin-based composites cross-linked with citric acid (CA) were prepared: gelatin type B (GB) and β-tricalcium phosphate (β-TCP) and novel hybrid composite GB with β-TCP and hydroxyapatite (HAp) particles, and their structure, thermal, and mechanical properties were compared with pure gelatin B samples. FTIR analysis revealed that no chemical interaction between the reinforcements and gelatin matrix was established during the processing of hybrid composites by the solution casting method, proving the particles had no influence on GB cross-linking. The morphological investigation of hybrid composites revealed that cross-linking with CA improved the dispersion of particles, which further led to an increase in mechanical performance. The microindentation test showed that the hardness value was increased by up to 449%, which shows the high potential of β-TCP and HAp particle reinforcement combined with CA as a cross-linking agent. Furthermore, the reduced modulus of elasticity was increased by up to 288%. Results of the MTT assay on L929 cells have revealed that the hybrid composite GB-TCP-HA-CA was not cytotoxic. These results showed that GB cross-linked with CA and reinforced with different calcium phosphates presents a valuable novel material with potential applications in dentistry.

Flexural Strength Evolution, Microstructure Evolution and Mechanical Strength Failure Mechanisms of the Fused SiO2 and h-BN Co-modified Quartz Fiber/Benzoxazine Resin Ceramizable Composites

In our research described in this paper, the flexural strength evolution, microstructure evolution and the pyrolysis process of fused SiO2 and h-BN co-modified quartz fiber/benzoxazine resin ceramizable composites with increasing temperature were investigated. It was found that the flexural strength of the ceramizable composites dropped with increasing temperatures. The microstructure observation results depicted that cracks and holes appeared on the surface of the samples and the interfaces were seriously deteriorated after a static ablation test in a muffle furnace at 400–1200 °C for 20 min. Through the characterizations of the quartz fibers, it was revealed that the quartz fibers underwent a crystallization process at 1200 °C, during which micro-cracks were formed in them. As a result of our research the mechanical strength failure mechanism of the ceramizable composites was proposed. It was found that the failure process of the ceramizable composites was the result of matrix pyrolysis, carbon oxidation, interfacial degradation and fiber crystallization.

Sustainable composite manufacturing from non-expiring carbon fiber/epoxy prepregs based on a vitrimeric matrix

Despite the benefits of manufacturing composite materials from prepregs, its use is nowadays limited to high-production rate industries due to the high costs associated with their limited shelf life. Once this time passes, the material is considered as expired and disposed of as a non-usable waste. To avoid shortening its shelf life, prepregs are stored in refrigerators, increasing energy consumption, and thus magnifying the negative environmental impact. For this reason, the objective of this paper is to develop a new lifelong prepreg material without an expiration date that can be consolidated as a laminate after surpassing the gelation time of the resin, thus allowing composite materials processing technology based on prepregs without the need of freeze storage. To prove this concept, the study is carried out using a vitrimeric resin composed of an epoxy monomer (DGEBA) and 2-Aminophenyl disulfide (AFD) as a hardener. Two prepregs are manufactured and stored for 30 days at different conditions: environmental conditions, considered as the aged or non-conventional prepreg; and at −18 °C in a freezer, to replicate the conventional prepreg conditions. The results of the cured composites show stable glass transition temperatures and curing degrees between the two laminates. Concerning the mechanical properties, it has been proved that the gelation phenomenon of the non-conventional prepreg does not have any negative effect, showing a 11 % and a 21 % improvement of the flexural strength and failure strain, respectively, together with a 10 % increase of the interlaminar shear strength (ILSS) in comparison with the conventional prepreg, proving the potential of the proposed sustainable prepregs.

The Effect of a Coating Sprayed Using Supersonic Flame Coating Technology on the Mechanical Properties and Interface Structure of a Thick Steel/Aluminum Composite Plate during Hot Rolling

Given the characteristics of a thick steel/aluminum composite plate, such as its large thickness and the significant differences between its components, it is difficult to prepare using direct rolling. Instead, a thick steel/coating/aluminum composite plate may be successfully prepared by combining supersonic flame coating technology with a hot rolling composite process. In this study, the interface shear strength test, SEM, EDS, and other detection methods were applied to investigate the effects of the reduction rate and coating thickness on the interface structure and mechanical properties. The results show that under the condition of single-pass direct rolling, the micro-interface of steel/aluminum is improved with an increase in the reduction rate, but the bonding strength of the interface remains poor. After adding the coating, the thickness of the diffusion layer and the shear strength increase significantly. When the coating thickness is reduced to 0.1 mm, the deformation coordination and shear strength of the composite plate are further enhanced under the combined action of mechanical interlocking and metallurgical bonding. The tensile shear fracture is mainly located at the steel/coating interface. The interfacial shear strength reaches 66 MPa, which exceeds the requirements of the US military standard MIL-J-24445A (SH) for steel/aluminum shear strength. The research results thus support the use of this new method for the simple and efficient production of thick steel/aluminum composite plates.

Research progress on bamboo fiber reinforced polymeric composites: Processes, properties, and future directions

AbstractCharacterized by rapid maturation, short growth cycles, and high strength and toughness, bamboo can be compounded with polymers to produce bamboofiber reinforced polymeric composites (BFRPCs). These composites exhibit corrosion resistance comparable to traditional materials such as glass fiber and carbon fiber composites. Additionally, they possess features like low density, high strength, degradability, and environmental friendliness, with low production costs and strong industrial applicability. This paper reviews the accomplishments in BFRPCs and provides an overview of the production processes for BFRPCs. Furthermore, it summarizes the research status of mechanical properties, moisture absorption characteristics, interface performance, and flame retardancy of these composites. The current issues with BFRPCs were analyzed. Finally, the paper explores future research directions and potential applications of BFRPCs.Highlights The performance studies on BFRPCs are comprehensively presented. Composite processing of BFPRCs is reviewed. Pros and cons of various types of BFRPCs are analyzed. Overview of the applications of BFRPCs in various domains is presented. Future trends and challenges of BFRPCs are introduced.

Influence of Awj Parameters on Material Removal Rate, Surface Roughness, and Kerf Angle during Machining of Prosopis Juliflora Bark Fibres/Carbon Reinforced Hybrid Polymeric Composites

This study investigates the impact of changing the settings of the Abrasive Water Jet (AWJ) on the material removal rate (MRR), surface roughness, and kerf angle during the machining process of carbon-reinforced hybrid polymeric composites and Prosopis juliflora bark fibres. The hybrid nature of these materials presents unique machining opportunities as well as difficulties. As a result, optimizing the AWJ settings is essential for productive and efficient machining. The findings demonstrate the intricate connections between the AWJ parameters and the machining characteristics of the hybrid composite. To optimize MRR while minimizing surface roughness and controlling the kerf angle, the optimal parameter combinations are identified. The findings provide valuable insights for the manufacturing industry, particularly concerning sustainable materials and hybrid composites.

Robust, thermally insulating, and high-temperature resistant phosphate-enhanced mullite fiber porous ceramic composites

Porous mullite ceramics with high porosity and low thermal conductivity are urgently required as high-temperature thermal insulators in harsh environments. How to improve the strength of Porous mullite ceramics dramatically under the premise of no sacrificing its thermal insulating properties has remained an extremely challenging. Inspired by the freezing rain phenomenon in nature, high-strength and high-temperature resistant phosphate coatings were applied to the surface of mullite fibers, which significantly improved the mechanical properties of porous mullite ceramics without significantly increasing their thermal conductivity. The Al(H2PO4)3 solution concentration significantly affected the mechanical and thermal properties of the composite material, where the mechanical performance improved with an increasing Al(H2PO4)3 solution concentration. The phosphate coating phase stabilized with an increasing calcination temperature. The mechanical properties of the ceramics were improved by the excellent interfacial bonding strength between the coating and mullite fiber, and the forms of phosphate in the porous ceramics. The optimum composite preparation process increased its compressive strength by approximately nine-fold to 4.1 MPa and resulted in a thermal conductivity of only approximately 0.09 W/(m·K), demonstrating that the composite exhibited a significantly higher comprehensive performance than other previously reported porous ceramics and aerogels. Such new composites with excellent mechanical and thermal insulation properties exhibit excellent potential for high-strength thermal insulation in the chemical, metallurgical, pharmaceutical, aerospace, and other fields.

Local thermal non-equilibrium effects on phase transition of fiber reinforced thermoplastic composites with temperature-dependent heat generation

Under the excitation of external fields, fiber reinforced thermoplastic (FRTP) composites can be thermally processed due to the internal heat generation, in which the local thermal non-equilibrium (LTNE) can be significant during the phase transition. In this study, a representative elementary volume scale Lattice Boltzmann model was developed to simulate the phase transition process of FRTP composites with the temperature-dependent internal heat source. The results from LTNE model and local thermal equilibrium (LTE) model were compared in terms of the phase interface evolution and the local temperature difference between fibers and matrix, so that the LTNE effects on phase transition behaviors were examined with different material properties and internal heat sources. It is found that the LTNE effects cannot be ignored in FRTP composites, and the main mechanisms include the dynamic local heat generation, endothermic phase transition of matrix, and relatively high thermal conductivity of fiber. A small heat exchange between the fibers and matrix results in a large local temperature difference and a slow phase transition. A high internal heat generation enhances the phase transition and LTNE effects, but an increase in the temperature range for heat generation leads to a slow phase transition with slight change in LTNE effects. With the increase of matrix fraction, LTNE effects first increase and then decrease due to the combined results of the more internal heat generation and the increase of endothermic mass of matrix and the less heat loss through fibers. This study is significant for guiding the reliable thermal processing of FRTP composites in emerging industrial applications.

Optimization of Cadmium Removal Using Tetraethylene Glycol-Modified Silica-Based Adsorbent via Response Surface Methodology

In solid-phase extraction for preconcentration, silica (Si) is the most commonly used as an adsorbent. However, the selectivity and effectiveness of silica gel adsorption on metal ions are low, so it needs to be modified to improve the adsorption capability. The modification was done using reflux and oven heating in the modification silica with 3-glycidoxypropyl trimethoxysilane (GPTMS) and tetraethylene glycol (TEG). A central composite design batch process determined the optimum conditions for cadmium adsorption. TEG-modified silica was successfully synthesized and characterized using FTIR spectroscopy, SEM, and elemental analyzers. Peaks of C-H and epoxy on FTIR spectra showed that Si- GPTMS was formed. The increase of %C and %H from the first to the second step indicated that Si-TEG was successfully synthesized. There was no significant difference in silica particle morphology on SEM before and after modification. The reflux method gave a higher yield compared to the heating method. The constant stirring by the magnetic bar and solvent cycle in the reflux method catalyzed the reaction. This study found that at pH 7, 30 mg of adsorbent weight at 35°C and 22 minutes of contact time were optimum Cd2+ adsorption conditions. As the weight of the adsorbent increases, the adsorption capacity decreases. Contact time and temperature have no significant effect on Cd adsorption by Si-TEG.

Couple effects of multi-impact damage and CAI capability on NCF composites

Abstract In this study, the mechanical properties of non-crimp fabric (NCF) composite laminates under low-velocity impact and compression after impact (CAI) tests were studied by Scanning electron microscopy (SEM) and Digital image correlation (DIC) techniques. The impact response under different impact times, impact angles, and impact distance is studied. Similarly, in CAI test, DIC technique is used to reveal the whole process of NCF composite compression failure, and SEM is used to reveal the microscopic failure form. The experimental results show that the impact damage process of NCF composites has strong directivity. The concrete manifestation is that the internal failure will extend along the paving direction at the failure layer. The peak load generated under 20 J impact energy is about 1/2 of that under 40 J impact energy. The impact distance is one of the important factors affecting the coupling effect of multiple impacts, and the impact angle has little effect on the internal damage extension. The proportion of internal damage area also supports the relevant view, that is, the average difference in the proportion of internal damage area under different impact distance is about 5%, while the average difference in the proportion of internal damage area under different impact angles is about 3%. During the compression process, the main failure mode is shear failure and the failure mode is brittle fracture. The oblique fracture occurs only when the oblique is 45° and the impact distance is large (50 mm). The impact angle has little effect on the residual compression performance of NCF.

Determination of the In-Plane Shear Behavior of and Process Influence on Uncured Unidirectional CF/Epoxy Prepreg Using Digital Image Correlation Analysis

The investigation of the in-plane shear behavior of prepreg is crucial for understanding the generation of wrinkles of preforms in advanced composite manufacturing processes, such as automated fiber placement and thermoforming. Despite this significance, there is currently no standardized test method for characterizing uncured unidirectional (UD) prepreg. This paper introduces a ±45° off-axis tensile test designed to assess the in-plane shear behavior of UD carbon fiber-reinforced epoxy prepreg (CF/epoxy). Digital image correlation (DIC) was employed to quantitatively track the strains in three dimensions and the shear angle evolution during the stretching process. The influences of the temperature and stretching rate on the in-plane shear behavior of the prepreg were further investigated. The results reveal that four shear characteristic zones and wrinkling behaviors are clearly distinguished. The actual in-plane shear angle is significantly lower than the theoretical value due to fiber constraints from both the in-plane and out-of-plane aspects. When the off-axis tensile displacement (d) is less than 15.6 mm, the ±45° specimens primarily exhibit macroscale in-plane shear behavior, induced by interlaminar interface shear between the +45° ply and −45° ply at the mesoscale. The shear angle increases linearly with the d. However, when d > 15.6 mm, fiber squeezing and wrinkling begin to occur. When d > 29 mm, the in-plane shear disappears in the completely sheared zone (A). The reduction in the resin viscosity of the CF/epoxy prepreg caused by increased temperature is identified as the primary factor in lowering the in-plane shear force resistance, followed by the effect of the increasing resin curing degree. Higher shear rates can lead to a substantial increase in shear forces, eventually causing cracking failure in the prepreg. The findings demonstrate the feasibility of the test method for predicting and extracting uncured prepreg in-plane shear behaviors and the strain-rate and temperature dependency of the material response.

One-step preparation and dual mode luminescence anti-counterfeiting application of LiYF4: Yb3+, Ho3+, Ce3+@ carbon quantum dot composite materials

In the field of fluorescent anti-counterfeiting, materials with single luminous mode are easy to be forged, which cannot meet the current anti-counterfeiting requirements. Currently reported bimodal light-emitting materials usually require multi-step and tedious synthesis steps. In this paper, LiYF4: Yb3+, Ho3+, Ce3+ upconversion micron particles (UCMPs)/carbon quantum dots (CDs) composite materials were prepared by one-step hydrothermal method, which greatly simplified the composite process of CDs and UCMPs. The upconversion wavelength (from green light to red light excited by 980 nm) can be achieved by changing the doping concentration of Ce3+ ions. Through the combination of CDs and UCMPs, an obvious dual mode luminescence phenomenon was achieved. Finally, screen printing was used to produce a clover pattern, which realized multi-color luminescence under 365 nm and 980 nm excitations respectively. The new fluorescence anti-counterfeiting composites, which uses simple and environmentally friendly one-step synthesis process, is expected to promote the development of fluorescence anti-counterfeiting field.

Promising improved mechanical, wear, corrosive properties by the impact of CNTs on Al alloy by FSP – A review

The monolithic alloys of aluminium have the qualities of less density, elevated strength and high resistance to corrosion. Generally, alloys of aluminium are most comprehensively used in the fields of aerospace sectors such as skeleton parts of aircraft, fuselages, bulk heads, wing ribs, wing spars, automobile and transportation industries, architectural parts, electrical and electronic applications, etc.The evolution of microstructure, and mechanical characteristics such aselongation, hardness, tensile strength, tribological property, and corrosion resistance are examined in this paper for the composites of aluminium-carbon nano-tubes (CNTs). With the use of a surface composite processing method known as friction stir processing, CNTs are added as reinforcements to improve the various properties of the base metal. The CNTs provide a wide variety of characteristics, such as outstanding electrical conductivity, thermal stability, high strength, and superior elastic properties.Numerous collections of published literature have been thoroughly studied, and it discusses a few of the essential underlying assumptions needed to achieve the optimal combination of CNTs with the aluminium under friction processing technique. From the comprehensive review, the statements are summarized that will assist future research work involving the accumulation of CNTs reinforced with aluminium alloy and utilized in various applications of aerospace and aircraft sectors.

Microstructure and fracture toughness of a Nb–Ti–Si-based in-situ composite fabricated by laser-based directed energy deposition

Laser-based directed energy deposition (LDED), a significant integrated preparation technique combining material design and production, has been progressively used to manufacture Nb–Ti–Si-based in-situ composites. However, it is commonly known that Nb–Si-based in-situ composites have low room-temperature fracture toughness. Herein, we have designed a novel Nb–40Ti–10Si–5Al–2V (at.%) composite, the microstructure of LDED-built composite is made up of Nbss and γ-Nb5Si3, the formation of γ-Nb5Si3 precipitate in the Nbss phase with an orientation relationships (ORs) of [1110]γ//[011]Nbss, (10 1‾ 0)γ//(011)Nbss and (1 2‾ 11)γ//(200)Nbss. The composite has Nbss, Nb3Si and γ-Nb5Si3 phases after heat treatment at 1400 °C for 30 h, and δ-Nb11Si4 precipitate has formed in the Nbss phase with an ORs of [100]Nbss//[010]δ, (010)Nbss//(010)δ. The composite processing Nb–40Ti–10Si–5Al–2V (at.%) has outstanding toughness (21.62 MPa·m1/2). It has ascertained that the room-temperature fracture toughness of Nb–Si-based in-situ composite is positively impacted by the high concentration of Ti.

Wear resistance of extruder parts in the production of polymer nanomodified products

Extrusion equipment is widely used in the production of polymer materials. One of the urgent questions that arises when studying the processes of obtaining polymer products by the extrusion method is the question of studying abrasive wear, which may depend on the efficiency of the equipment, the duration and reliability of its work. In the context of abrasive wear, the process that needs attention is the extrusion of polymer materials with carbon nanotubes. The purpose of this work is to develop a numerical method for determining the evolution of abrasive wear of the equipment of the extruder working area in the process of processing nanomodified polymer granules and determining the life cycle of this equipment with in order to increase the parameters of their durability. The specific objectives of the study include: 1) Determination of the influence of the content of CNTs in PVC on the rate of wear of the steel surface of the extruder; 2) Analysis of the dependence between friction and the content of CNTs in the polymer composite; 3) Establishing optimal extrusion conditions to minimize abrasive wear of the steel surface; 4) Comparison of simulation results with experimental data to check the reliability of the model. The work is aimed at understanding the processes that occur during the extrusion of nanocomposites and their impact on the wear resistance of equipment materials, which can contribute to the improvement of technological processes and ensure longer and more efficient operation of extruders in production conditions. It has been established that the processes of extrusion processing of polymer nanoreinforced composites can be effectively studied by developing and implementing numerical models that take into account the interaction of all physical and mechanical parameters of a representative volume of the contact zone of the equipment with the polymer and the nanotube with the adhesive layer. In this work, a model for determining the physical and mechanical properties of the interface layer between the CNT and the polymer array is constructed and implemented. The technique for determining the properties of the nanotube-polymer interface is integrated into the APROKS system for analyzing the stress-strain state of nanomodified polymer materials. Based on a multilayer isoparametric FE, a series of numerical experiments were carried out to simulate the process of abrasive wear of the material of equipment elements in the extruder working area. The possibility of a detailed study of the processes of nonlinear contact interaction of nanotubes with an interface layer with equipment elements of the extruder working area based on multilayer FE has been confirmed. Diagrams were obtained that determine the service life of equipment in the working area of the extruder depending on the volume concentration of carbon nanotubes in the polymer at different levels of operating pressure in the “nanotube – polymer – equipment” contact system. It is advisable to use the proposed methodology in the development of information support systems for the life cycle of operation of equipment in the working area of extruders intended for the production of nanomodified polymer products.

Computational substantiation of technological characteristics of the closure stage of nuclear fuel cycle using code VIZART

There exist different variants of organizing the closure of nuclear fuel cycle (CNFC) depending on fast reactor type, fuel types, station or centralized allocation of closed nuclear fuel cycle stages. One of the ways to verify and estimate engineering solution is mathematical modeling of radiochemical technology which in the end will allow to optimize composite technological process in order to increase effectiveness and reduce cost. In order to calculate the balance of material flows of process circuits and individual production sections in the stationary and dynamic modes, with taking into account the isotopic composition evolution, a software package VIZART (Virtual Plant of Radiochemical Technologies) was developed, allowing the user to assemble the required sequence of operations for any part of the process scheme and perform the calculation of material balance for all flows of the circuit, as well as to optimize the equipment operating modes and provide the necessary data to justify the safety of certain limits and the entire process circuit. The following capabilities of code VIZART for computational substantiation of CNFC technology design and characteristics are considered: material balance calculation, cyclogram creation, determination of the most loaded parts of processing lines, estimation of fissile materials accumulating in devices and intermediate vessels, optimization of productivity of nodes and devices.

Effect of atomization amounts on electrical discharge ablation machining and electrochemical machining

ABSTRACT This study investigated the impact of varying atomization amounts on composite machining involving both atomized electrical discharge ablation machining and electrochemical machining (EDAM-ECM). Additionally, this study examined the effects of different atomization amounts on the material removal rate, relative electrode wear rate, processing waveforms, surface roughness, surface morphology and elements, and the EDAM-to-ECM ratio. Moreover, a theoretical model for describing the material removal process in composite processing was developed. Furthermore, the effect of the ECM ratio on the processing results was quantitatively analyzed through the integration of statistical circuits with a formula for calculating recast layer thickness. The model was used to predict and select the optimal atomization amounts required to achieve recast layer removal during processing. The results revealed that at an atomization amount of 200 mL/min, 16.7% of the total material removal was attributable to ECM, indicating the successful removal of the recast layer. At this atomization amount, the fabricated sample maintained a machining precision of 0.02 mm.

A powder-scale multiphysics framework for powder bed fusion of fiber-reinforced polymer composites

Additive manufacturing of fiber-reinforced polymer composites has garnered great interest due to its potential in fabricating functional products with lightweight characteristics and unique material properties. However, the major concern in polymer composites remains the presence of pore defects, as a thorough understanding of pore formation is insufficient. In this study, a powder-scale multiphysics framework has been developed to simulate the printing process of fiber-reinforced polymer composites in powder bed fusion additive manufacturing. This numerical framework involves various multiphysics phenomena such as particle flow dynamics of fiber-reinforced polymer composite powder, infrared laser–particle interaction, heat transfer, and multiphase fluid flow dynamics. The melt depths of one-layer glass fiber–reinforced polyamide 12 composite parts fabricated by selective laser sintering are measured to validate modelling predictions. The numerical framework is employed to conduct an in-depth investigation of pore formation mechanisms within printed composites. Our simulation results suggest that an increasing fiber weight fraction would lead to a lower densification rate, larger porosity, and lower pore sphericity in the composites.

A novel thermal-fluid topology optimization of the frame mold for composite autoclave process

Frame mold serves as an important tool during autoclave process of composite panels. Its temperature uniformity plays a crucial role in guaranteeing the production quality. However, the temperature uniformity of mold usually has to be sacrificed during the design process for ensuring the stiffness of mold. To solve this problem, a novel design strategy is proposed in this study to optimize the heating airflow channels of mold with better temperature uniformity based on thermal-fluid topology optimization method. Firstly, the temperature and the airflow distribution characteristics of mold during autoclave process are investigated systematically based on the Computational Fluid Dynamic (CFD) simulation model. The result indicates that the uneven temperature distribution of the mold during autoclave process is significantly affected by the varying airflow velocity distribution inside the mold. Inspired by this, a thermal-fluid topology optimization method is developed to design the airflow channels of mold to achieve optimal mold temperature uniformity. The optimization result provides a novel configuration of mold in which a ‘wind deflector’ is incorporated inside the mold to alter the airflow pattern. Finally, the simulation results show that the optimized mold with a ‘wind deflector’ significantly improves the mold temperature uniformity by 16%. And experimental validation has applied to confirm the effectiveness of the results. Besides, the configuration of the optimized mold has good industrial application prospects for its convenient installation process and low cost.