Continuous Wire Research Articles

Direct Metal Transfer on Swellable Hydrogel with Dehydration-Induced Physical Adhesion.

Composites of hydrogels and metals are gaining interest because of each material's unique properties. However, the stable adhesion of metals on hydrogels is challenging due to the mechanical mismatch at the soft-hard interface and the liquidity of the water components in hydrogels. We propose a facile physical-adhesion method that involves the dehydration process of hydrogels to transfer metals from a glass substrate. This method is based on the hydrophobic interaction between polymer chains and metals and is stable, even in water. Continuous metal wiring was achieved on a swollen hydrogel, and electrical conduction was effective for a soft electronic device. Therefore, our method could be a versatile method for integrating hydrogels and metals.

Experimental Investigations on the Fabrication of Low Alloy Steels Using Wire Arc Additive Method

Wire arc additive manufacturing (WAAM) has emerged as a transformational technology with the capacity to redefine the landscape of alloy steel component production. This method utilizes an electric arc to selectively fuse a continuous wire feed, progressively constructing intricate metal structures layer by layer. GMAW-based WAAM adaptability enables the creation of complex geometries and customized part designs, making it applicable across diverse industrial sectors. This paper investigates WAAM-specific applications in alloy steel fabrication, focusing on key process variables such as voltage, travel speed, and Gas mixture ratio. The experimental parameters for a single layer are examined with voltage ranging from 20 to 22, travel speed from 23, 25, and 27 mm/min, and Gas mixture ratio 1,5,9 mm/min. It utilizes materials like TM B9, a 1.2- diameter flux-cored wire. Additionally, the study considers the nominal composition (wt-%) of 9 Chromium, and 1 Molybdenum, with small additions of nitrogen and niobium to improve the creep resistance. Furthermore, the final findings of the study suggest that the optimal combination of process variables for achieving highquality weld beads in WAAM of alloy steel components can be determined through Response Surface Methodology (RSM). RSM is a statistical method for analysing and modeling the relationship between the response of interest and some independent variables. In this case, the response variable would be the quality of the weld bead, which encompasses factors such as bead geometry, integrity, and absence of defects.

Tailoring structural and magnetic properties of NiCu nanowires by electrodeposition

In this work, we investigated the tailoring of structural and magnetic properties of NiCu nanowires through electrodeposition. Continuous (S1) and composition-modulated (S2) wires were fabricated by electrodeposition using porous alumina membranes as a template. Morphological characterization revealed that the total length of the wires was 8 ± 3 µm in both S1 and S2. For the composition-modulated wires, the length of the segments with the lowest and highest Cu concentrations was 1.2 ± 0.4 µm and 226 ± 65 nm, respectively. Mapping by energy dispersive spectroscopy (EDS) revealed that the concentration of copper and nickel varied along the length of the composition-modulated nanowires, while the continuous nanowires contained a relatively constant concentration of both metals. It is demonstrated that the change in Cu concentration along the wire modifies the lattice parameter, average crystallite size (D) and lattice strain (ε) of Ni. This result is pivotal for understanding the magnetic properties of the wires, as nickel is primarily responsible for the magnetic behavior of the wires. From the ferromagnetic resonance (FMR) results, the linewidth and resonance field values for samples S1 and S2 were determined. It was demonstrated that the greater deformation in the nickel lattice in NiCu nanowires increases the angular dependence of the resonance field. Furthermore, the smaller nickel crystallite size was shown to increase spin dispersion and magnetic damping, leading to complex behavior in FMR responses. Finally, it was demonstrated how Cu can influence the magnetic properties such as coercivity (HC) and squareness (MR/MS) of the wires. Overall, this work contributes to understanding the tailoring of structural and magnetic properties of NiCu nanowires through electrodeposition.

3D printing of continuous metal fiber-reinforced recycled ABS with varying fiber loading

PurposeThe current study aims to develop a 3D-printed continuous metal fiber-reinforced recycled thermoplastic composite using an in-nozzle impregnation technique.Design/methodology/approachRecycled acrylonitrile butadiene styrene (RABS) plastic was blended with virgin ABS (VABS) plastic in a ratio of 60:40 weight proportion to develop a 3D printing filament that was used as a matrix material, while post-used continuous brass wire (CBW) was used as a reinforcement. 3D printing was done by using a self-customized print head to fabricate the flexural, compression and interlaminar shear stress (ILSS) test samples to evaluate the bending, compressive and ILSS properties of the build samples and compared with VABS and RABS-B samples. Moreover, the physical properties of the samples were also analyzed.FindingsUpon three-point bend, compression and ILSS testing, it was found that RABS-B/CBW composite 3D printed with 0.7 mm layer width exhibited a notable improvement in maximum flexural load (Lmax), flexural stress at maximum load (sfmax), flex modulus (Ef) and work of fracture (WOF), compression modulus (Ec) and ILSS properties by 30.5%, 49.6%, 88.4% 13.8, 21.6% and 30.3% respectively.Originality/valueLimited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

Fatigue life prediction of corroded hangers with parallel steel wire in a network arch bridge under vehicle-bridge interaction based on a novel noniterative simplified method

Fatigue damage is a main concern during the life-cycle maintenance of bridges with corroded hangers under vehicle-bridge interaction (VBI). In this study, a novel noniterative simplified method for VBI is proposed to analyze the responses of hangers in a network arch bridge, considering the effects of vehicle types, driving lanes, and road surface roughness. Furthermore, the fatigue life of corroded hangers is investigated, considering the actual traffic flow and uneven distribution of stress in the hanger’s cross-section. The results show that longitudinal and transverse bending moments of the hanger significantly affect the stress of steel wires in one hanger but have limited influence on stress amplitudes. The fatigue lives of steel wires are considerably reduced when subjected to both uniform and pitting corrosion. The fatigue life of steel wires is reduced under deteriorating road surface conditions. Moreover, as the fatigue life of steel wires in the hangers declines, the variations in fatigue life among individual steel wires within a single hanger gradually decrease. Consequently, this trend leads to a heightened likelihood of continuous wire breakage.

Wire-feeding friction stir welding for large-gap width tolerances

A novel method, named wire-feeding friction stir welding, was proposed for welding large-gap-width joints. Continuous wire feeding and welding systems were designed. AA6082-T6 aluminium alloy plates with a gap width of 2 mm were welded using Al–Si alloy wires as the filler materials. Sound joints were obtained even if the gap width reached over 2/3 thickness of the base materials. Fine microstructures were obtained via dynamic recrystallisation induced by severe plastic deformation. The ultimate tensile strength of the joints reached 253.4 ± 1.3 MPa. The adaptability to working conditions of friction stir welding was improved for long welds of high-speed railway, ship and aircraft.

Study of the dynamics of the graphitization in diamond induced by high repetition rate fs laser

In this paper, we studied the dynamics of the graphitization in diamond induced by high repetition rate fs laser. Unlike the dynamics in the case of employing low repetition rate fs laser, the graphitized region can grow both toward and along the laser beam. For surface processing, the experimental results have revealed that employing multi-scanning can effectively reduce the fluctuations of the thicknesses of the graphitization wire, but it is useless for fabricating a continuous graphitization wire inside diamond. There emerges a comb structure, which consists of an array of graphitization filaments. The growth of each filament in the comb structure can be classified by four growth regions, based on which we discussed the dynamics of the formation of this comb structure. Furthermore, we measured the magnetic properties of both surface-irradiated and inside-irradiated samples. The surface graphitized sample shows a common diamagnetism, but the internal graphitized sample exhibits an unusual superparamagnetism.

Enhanced fracture toughness and tensile strength of 3D printed recycled ABS composites reinforced with continuous metallic fiber for load-bearing application

PurposeThis study aims to present an experimental approach to develop a high-strength 3D-printed recycled polymer composite reinforced with continuous metal fiber.Design/methodology/approachThe continuous metal fiber composite was 3D printed using recycled and virgin acrylonitrile butadiene styrene-blended filament (RABS-B) in the ratio of 60:40 and postused continuous brass wire (CBW). The 3D printing was done using an in-nozzle impregnation technique using an FFF printer installed with a self-modified nozzle. The tensile and single-edge notch bend (SENB) test samples are fabricated to evaluate the tensile and fracture toughness properties compared with VABS and RABS-B samples.FindingsThe tensile and SENB tests revealed that RABS-B/CBW composite 3D printed with 0.7 mm layer spacing exhibited a notable improvement in Young’s modulus, ultimate tensile strength, elongation at maximum load and fracture toughness by 51.47%, 18.67% and 107.3% and 22.75% compared to VABS, respectively.Social implicationsThis novel approach of integrating CBW with recycled thermoplastic represents a significant leap forward in material science, delivering superior strength and unlocking the potential for advanced, sustainable composites in demanding engineering fields.Originality/valueLimited research has been conducted on the in-nozzle impregnation technique for 3D printing metal fiber-reinforced recycled thermoplastic composites. Adopting this method holds the potential to create durable and high-strength sustainable composites suitable for engineering applications, thereby diminishing dependence on virgin materials.

Research on Digital Twin Dynamic Modeling Method for Transmission Line Deicing System

A digital twin is recognized as a pivotal technology in a new type of power system monitoring as it provides an effective method for monitoring the vibration caused by ice shedding in overhead transmission lines. The digital twin model differs from traditional models in that it has the characteristics of precise mapping and real-time simulation. These emerging characteristics lead to urgent updating of the existing modeling approaches. Therefore, the current study proposes a dynamic digital twin modeling method for transmission line ice-shedding systems. In this approach, an analytical solution for conductor deicing oscillation is proposed to describe the span and tension unchanged in any time period and then segmented and iteratively corrected with measured time-varying parameters to implement real-time simulation functionality. A dynamic geometric model for transmission lines is proposed based on the Unity3D platform. In addition, a human-computer interaction visualization platform is proposed to display twin data, with the objective of realizing precise mapping of real transmission lines. Finally, an application of this systematic approach to continuous three-span wire demonstrates the feasibility and effectiveness of the proposed approach.

Manipulation of Conducting Polymer Hydrogels with Different Shapes and Related Multifunctionality.

Maneuver of conducting polymers (CPs) into lightweight hydrogels can improve their functional performances in energy devices, chemical sensing, pollutant removal, drug delivery, etc. Current approaches for the manipulation of CP hydrogels are limited, and they are mostly accompanied by harsh conditions, tedious processing, compositing with other constituents, or using unusual chemicals. Herein, a two-step route is introduced for the controllable fabrication of CP hydrogels in ambient conditions, where gelation of the shape-anisotropic nano-oxidants followed by in-situ oxidative polymerization leads to the formation of polyaniline (PANI) and polypyrrole hydrogels. The method is readily coupled with different approaches for materials processing of PANI hydrogels into varied shapes, including spherical beads, continuous wires, patterned films, and free-standing objects. In comparison with their bulky counterparts, lightweight PANI items exhibit improved properties when those with specific shapes are used as electrodes for supercapacitors, gas sensors, or dye adsorbents. The current study therefore provides a general and controllable approach for the implementation of CP into hydrogels of varied external shapes, which can pave the way for the integration of lightweight CP structures with emerging functional devices.

Study of the effect of the combination of protective gases on the structure of the weld bead for the GMAW process using pulsed arc and short circuit

A weld bead's geometry directly influences the welded joint's physical characteristics and mechanical performance. The composition of the shielding gas directly affects the form of metal transfer during the welding process and, therefore, modifies the geometry of the weld seam obtained. In addition, metal transfer methods also influence the configuration of the weld bead profile. The objective is to analyze the geometry of the weld bead with different combinations of shielding gases and metal transfer modes in the continuous wire electric arc welding process with gas shielding (GMAW). To achieve this objective, a methodology is proposed to analyze the weld bead's penetration and other geometric parameters. This is achieved by varying the percentages of the gas mixture between Ar and CO2 and by employing different types of metal transfer, such as short circuit, pulsed, and PMC multi-control pulsed. Generally, when using only CO2 as shielding gas, a wide, round weld bead is obtained. If Ar alone is used, the weld bead profile has a very thin shape and deep penetration. With the mixture of Ar and CO2, a bead is obtained with good penetration and sufficient width to cover the two test tubes without empty spaces between the base and filler materials. The macrographic analysis of the chords with their respective measurements is presented, and the geometric parameters of the obtained chords are tabulated. The penetration of the bead is directly proportional to the percentage of CO2 present in the mixture. In a comparison between the three transfer modes used with the same gas composition, it is found that the pulsed spray mode produces greater penetration.

An evaluation of the shape-memory behavior and mechanical properties of polylactic acid/Ni80Cr20 continuous wire composite produced by extrusion-based additive manufacturing and in-melt simultaneous impregnation method

This study evaluates the mechanical and shape-memory properties of PLA/Ni80Cr20 continuous wire composite materials. The samples were produced using an extrusion-based additive manufacturing (AM) process with in-melt simultaneous impregnation of metal wire, followed by 3D printing. The reinforced samples were fabricated using metal wires of 0.1 and 0.15 mm in diameter and 5 and 10% volume percentages. The maximum mechanical (tensile and flexural) properties were obtained in the reinforced samples with a 10% volume percentage of metal wire of 0.1 mm in diameter. The samples exhibited a maximum ultimate tensile strength of 116 MPa, a maximum tensile modulus of 11.7 GPa, a maximum flexural strength of 221 MPa, and a maximum flexural modulus of 17.8 GPa. This research used a novel method to investigate the shape-memory properties of PLA. By applying a potential difference to the samples, the heat generated by the metal wire was absorbed by the matrix polymer, which increased the temperature of the material. This increase in temperature resulted in a change in the samples' shape. The effect of voltage on the wire was investigated, and a voltage of 40 V was applied to the U-shaped samples with special fixtures to measure the shape recovery and shape stabilization percentage. Based on the final results, it can be deduced that 3D-printed composite materials, along with appropriate wire type, wire diameter, voltage, and uniform temperature distribution, can be used as shape-memory materials for a wide range of applications with desired temperature conditions, especially in cases where direct heat cannot be applied to the sample.

Continuous Wire Electrical Explosion Spraying for Porous Coating Deposition Inside a Narrow Tube

Continuous Wire Electrical Explosion Spraying for Porous Coating Deposition Inside a Narrow Tube

Three-dimensional comparison of continuous and segmented arch techniques in the traction of palatally impacted canines using a non-linear finite element analysis.

To compare the three-dimensional (3D) effects of canine traction on the maxillary teeth when using two different traction methods, the continuous and the segmented arch wire techniques; then to test whether adding a transpalatal arch (TPA) would affect their response to traction. Finite element analysis. A cone-beam computed tomography (CBCT) scan of a patient with bilateral palatally impacted canines was chosen, from which a 3D model was derived and imported into ABAQUS. Two arch wires were modelled, a continuous round one and a segmented rectangular one. Four models were obtained by adding a TPA to both techniques. A 100° imposed rotation was then applied at the intersection between the vertical loop and the horizontal segment of each wire. Initial displacement of the maxillary tooth in the labio-lingual and in the vertical directions was measured. The absolute maximum principal stress of the periodontal ligament (PDL) was also assessed. Traction using a continuous arch wire led to different movement patterns of all teeth, some of them were tipped in a labial direction while others were lingually tipped. Traction using a segmented arch wire resulted in a retroclination of the posterior teeth and a proclination of the anterior teeth with a high level of stress on the premolars' PDL. Adding the TPA only affected the displacement of the first molars. The right side showed a maximum displacement of the first premolar, while the left side showed it on the lateral. The total displacement on the right side was higher than the left side. The segmented technique caused a uniform displacement of all teeth while the continuous one showed a non-uniform displacement. The angulation and position of the vertical loop affected the displacement of the maxillary teeth. The addition of a TPA acted only on the first molars.

The Use of Cu-W Sinters in MIG-MAG Welding Contact Tips for Improved Continuous Wire Abrasion Performance

Gas metal arc welding is one of the most widely used welding methods in the industry. Especially when large volume welded manufacturing is required, this method is very successful and practical. The wear of the contact guides, which guide the wire at the tip of the welding torches, but most importantly, provide electrical current transmission, may cause the production time to be extended and the calibration period to be minimized. In this study, the most worn part of the contact guides used in the Gas Welding robots were assembled by making pins from doped and undoped copper powders using the powder metallurgy method. The wear performance was compared by making the obtained pin driven contact guides under mass production conditions. In the study, pressing and sintering processes were carried out with Cu and Cu+W powders. The hardness of the contact guides was characterized by their microstructure and XRD results. It was observed that CuW5 and CuW10 powder mixtures were more successful.

Microbial nanowires: type IV pili or cytochrome filaments?

A dynamic field of study has emerged involving long-range electron transport by extracellular filaments in anaerobic bacteria, with Geobacter sulfurreducens being used as a model system. The interest in this topic stems from the potential uses of such systems in bioremediation, energy generation, and new bio-based nanotechnology for electronic devices. These conductive extracellular filaments were originally thought, based upon low-resolution observations of dried samples, to be type IV pili (T4P). However, the recently published atomic structure for the T4P from G. sulfurreducens, obtained by cryo-electron microscopy (cryo-EM), is incompatible with the numerous models that have been put forward for electron conduction. As with all high-resolution structures of T4P, the G. sulfurreducens T4P structure shows a partial melting of the α-helix that substantially impacts the aromatic residue positions such that they are incompatible with conductivity. Furthermore, new work using high-resolution cryo-EM shows that conductive filaments thought to be T4P are actually polymerized cytochromes, with stacked heme groups forming a continuous conductive wire, or extracellular DNA. Recent atomic structures of three different cytochrome filaments from G. sulfurreducens suggest that such polymers evolved independently on multiple occasions. The expectation is that such polymerized cytochromes may be found emanating from other anaerobic organisms.

Fluoroscopy-assisted laparoscopic retrieval of retained abdominal wall and intraabdominal continuous glucose monitoring sensor wires

Fluoroscopy-assisted laparoscopic retrieval of retained abdominal wall and intraabdominal continuous glucose monitoring sensor wires

Experimentally and Numerically Investigate of the Critical Diameter of Aluminized DNAN/RDX Melt-Cast Explosive

This study experimentally investigates the effect of RDX particle size and crystal quality, as well as aluminum particle size and content on the critical diameter of aluminized DNAN/RDX melt-cast explosive using the continuous wire method. Ultimately, the critical diameter increases when the particle size of both RDX and aluminum, as well as RDX crystal quality increases. Contrastingly, the critical diameter decreases when the aluminum content increases. Besides, we employed the Ignition and Growth reaction flow model to simulate the effect of RDX particle size and crystal quality, as well as aluminum particle size and content on the critical diameter.

Influence of oscillating laser on forming characteristics and molten pool flow behavior of aluminum alloy double-wire additive manufacturing

A new laser additive manufacturing approach is proposed in this paper by combining oscillating laser with double-wire additive manufacturing to improve additive efficiency and shape. The feasibility of the approach is experimentally verified, and the corresponding simulation model is proposed. The model considers the effects of surface tension, recoil pressure, gravity, and Marangoni force as well as continuous wire feeding. Simulation results are in good agreement with the experimental ones, which verifies the accuracy of the simulation model. The characteristics of temperature and flow fields and forming laws of different oscillating methods in the additive manufacturing process are compared and analyzed by simulation models. The study shows that the melt pool shape, temperature characteristics, and molding morphology of different oscillating methods considerably vary under the same process parameters. Among them, the circular oscillating peak temperature and maximum temperature gradient are low and the molding morphology is the best.

Treatment of Severe Anterior Open-bite Accompany with Impacted Canine: A Case Report

Introduction: The anterior open bite is a multifactorial malocclusion and a challenge between orthodontists. Based on the origin, divided in two types as dental and skeletal, and appear in the anterior or posterior segments, (unilateral or bilateral). Dental open-bite in the most of patients have environmental etiologic factor such as oral habits, tongue trust, mouth breathing, large tongue. In skeletal type, excessive vertical growth of the maxilla is etiologic factor and accompany with downward-backward rotation of the mandible.Case Report: The case was a 27 years woman with an anterior open bite and unilateral impacted upper canine and congenital missing of lower 2nd premolar in the left side and retained 2nd lower deciduous molar and upper canine in the left side. She consulted for orthodontic treatment in Tehran Dental School of Shahid Beheshti University of Medical Sciences in October of 2017.The Orthodontic treatment was down with MBT slot 22 system (USA. Orthoorganizer, inc) for apply extrusive force on impacted upper canine in left side with auxiliary 014 ss, segmented arch wire. loop arch wire technique with 16 × 22 ss rectangular continuous arch wire was used for space closing in extraction site and correction overbite. The extracted teeth were right lower 2nd premolar and left 2nd deciduous molar and 1st premolars in upper arch. As recommended advancement genioplasty for correction chin deficiency the patient refused it. Conclusion: In this technique we used Orthodontic treatment alone instead of Orthognathic surgery for open bite correction.