Design Of Experiments Research Articles

Analysis of Erosion of Surfaces in Falling Particle Concentrating Solar Power

Abstract Next generation concentrating solar power (CSP) systems, which utilize solid particles for energy capture, transport, and storage, offer prospects for higher temperature operation, improved efficiency, and reduced overall costs. Nevertheless, the continuous impingement of particles on component materials can result in substantial erosion, significantly constraining the performance and longevity of the components. A comprehensive understanding of particle erosion on surfaces is essential for designing components and operational parameters or coatings that minimize wear. This study presents a computational physics-based particle tracking model of the erosion rate of incident surfaces under different geometric, operational, and particle parameters. The computational model is validated with experimental measurements conducted as part of the study. Computational simulations are presented to elucidate the effects of each parameter and further used to investigate erosion rates in a systematic design of experiments covering a wide range of parameters. Based on the simulation results, a generalized analytical model is developed to relate erosion wear to pertinent dimensionless groups governing the physics of the process. The analytical model is shown to be accurate to within 10% and its use in understanding surface erosion as well as designing wear-resistant coatings to limit erosion within acceptable values is presented.

Comparative study between the Full Factorial, Box–Behnken, and Central Composite Designs in the optimization of metronidazole immediate release tablet

The purpose of this paper is to summarize the fundamentals, benefits and limitations of various models of Design of Experiments (DoE) such as 2-Level Full Factorial Design, Central Composite Design (CCD), and Box–Behnken Design (BBD) while establishing a comparison between these models by taking the Metronidazole immediate release (IR) tablets as a case study. Metronidazole IR tablets were prepared by wet granulation method. The Quality Target Product Profile (QTPP) and Critical Quality Attributes (CQA) were selected based on literature review and prior knowledge about the formulation. Critical Material Attributes (CMA) (concentration of binder, super disintegrant, and glidant), and Critical Process Parameters (CPP) (compression of the tablets) were identified based on their risk to the CQA. Screening and optimization of the CMA were performed using DoE. From the Full Factorial Design, it was observed that the disintegration time and dissolution at 30 min were significantly influenced by the selected CMAs. These significant factors were further optimized using CCD and BBD to achieve the constraints (minimum disintegration and maximum dissolution). The levels of povidone K30, crospovidone, and magnesium stearate were optimized to 10 mg, 32 mg, and 1.6 mg respectively using CCD and BBD.

Optimization of TIG welding process parameters using Taguchi technique for the joining of dissimilar metals of AA5083 and AA7075

This research paper aims to optimize the TIG welding parameters to join dissimilar metals of AA5083 and AA7075 using the Taguchi technique. The TIG welding current and root gap of butt geometry configuration are considered input parameters, and welding characteristics such as tensile strength, 0.2% of yield strength, hardness, and impact energy are output responses. The base metals are joined according to the Taguchi L-09 design of experiments. The welded samples were inspected using the X-ray radiography method for internal defects. Tensile properties, hardness number, and impact energy of different welding coupons were evaluated by conducting the uni-axial testing, a Brinell hardness test, and an Izod impact test, respectively. A better weld strength of 224 MPa was observed at 210 A welding current, and the root gap of 1.5 mm was maintained. Better hardness and impact energy values were observed when the root gap of 1.5 mm and welding current of 220 A were maintained. The root gap is the primary factor influencing tensile strength enhancement, which accounts for 44.78% of the effect, followed by 40.5% welding current. Root gap is the parameter that affects the tensile properties, hardness number, and impact toughness the most. The findings of this paper suggest the optimal parameters for welding AA5083 and AA7075 dissimilar base metals, which are suitable for complex structures requiring both durability and resistance to harsh environments.

Seismic Vibration Control of Multiple-Degrees-of-Freedom Steel Structures Through Optimal Impact Mass Dampers

ABSTRACT A novel device based on the energy transfer concept, named impact mass damper (IMD), is presented for the mitigation of large structural vibrations due to horizontal seismic excitations. To achieve the optimal performance of the nonlinear device, coupled with different standard steel buildings, an optimization procedure is set both employing the design of experiments (DOEs) method and the Kriging surrogate modelling. Concerning the seismic input, site-specific ground motions and record-to-record variability are taken into account, in agreement with the new European standards. The validated performance of the IMD device demonstrates its benefits, in particular for short-period steel buildings.

Multiple objectives optimization of injection-moulding process for dashboard using soft computing and particle swarm optimization

This research focuses on utilizing injection moulding to assess defects in plastic products, including sink marks, shrinkage, and warpages. Process parameters, such as pure cooling time, mould temperature, melt temperature, and pressure holding time, are carefully selected for investigation. A full factorial design of experiments is employed to identify optimal settings. These parameters significantly affect the physical and mechanical properties of the final product. Soft computing methods, such as finite element (FE), help mitigate behaviour by considering different input parameters. A CAD model of a dashboard component integrates into an FE simulation to quantify shrinkage, warpage, and sink marks. Four chosen parameters of the injection moulding machine undergo comprehensive experimental design. Decision tree, multilayer perceptron, long short-term memory, and gated recurrent units models are explored for injection moulding process modelling. The best model estimates defects. Multiple objectives particle swarm optimisation extracts optimal process parameters. The proposed method is implemented in MATLAB, providing 18 optimal solutions based on the extracted Pareto-Front.

Development of a Program for Searching the Optimum Condition using the Design of Experiments

The Design of Experiments (DOE) is a method that is widely used due to its effectiveness in selecting optimum conditions in the design stage of product development. On the other hand, fast, low-cost, labor-saving, and energy-saving innovative development is also required in the industry. In previous research, a program for quickly searching the optimum condition using the design of experiments is developed and evaluated. Relationships between each parameter and the final property are firstly cleared for an algebraic formula by using the design of experiments. Then the optimum conditions for each parameter were decided by using these formulas in the program. However, when each parameter has several errors in the data, the search accuracy becomes very low. In this research, the improvement for the searching accuracy using the law of error propagation was developed and evaluated. Relationships between each parameter error and the final property are firstly cleared for high-accuracy searching by using the law of error propagation and the previous results in the previous research. And each parameter influence for the final property was cleared. It was found that the large parameter effects could be improved for high-precision search by using high-precision instruments, increasing the number of trials N, and taking measurements in an optimal environment. Relationships between each parameter error and the final property were investigated and evaluated for the proposed method by using a mathematical model. It is concluded from the result that (1) the proposed method is effective for clearing the relationships between each parameter error and the final property, and (2) the proposed method is effective for searching the optimum condition.

A comprehensive analysis and optimization of coal–biomass mixed fuel for sustainable power generation using the design of experiments and artificial neural network

A comprehensive analysis and optimization of coal–biomass mixed fuel for sustainable power generation using the design of experiments and artificial neural network

Optimization of Load-transfer Functions for a Large-diameter Pile in Multi-layered Geological Conditions via a Stochastic Search Algorithm

The paper presents the combination of the load transfer method (computational model) and the genetic algorithm (optimization model) for the automated inverse analysis of instrumented pile load tests. The output of this process are the input parameters governing the shape of the load-transfer functions and thus the prediction accuracy when the load-transfer method is used as a design tool for deep foundations. The optimization problem is converted into an unconstrained task by applying the static penalty approach. Two types of measurements are considered in a newly proposed objective function: the load-displacement curve monitored in a pile head and the axial force profiles along a pile derived from strain gauges. Firstly, the local sensitivity analysis via the Design of Experiments is carried out to identify the parameters of the genetic algorithm which significantly influences the rate of convergence during the optimization process. Subsequently, a fully automated inverse analysis of the loading test of the large-diameter bored pile in multilayered geological conditions is presented. The simultaneous combination of two instrumentation sources leads to a stable unique solution with a sufficient match between the prediction and measurements despite a larger number of unknown – optimized variables.

Enhancing dehydration/desalting efficiency of crude oil emulsions through experimental and computational insights

The formation of unwanted oil emulsions during producing, transporting, and processing crude oils is a major challenging issue, which causes serious technical problems, and subsequently huge financial losses. The present work delves into an optimization study focused on water separation from crude oil emulsions. The separation performance was initially assessed in static conditions through bottle tests, followed by a thorough investigation in dynamic conditions on an electrostatic desalting pilot plant under various conditions of the main operating parameters: temperature, oil space velocity, wash water ratio, and demulsifier concentration. The design of experiments and optimization of the process were performed by Central-Composite-Design of Response-Surface-Methodology (CCD-RSM). The effectiveness of the separation process has been analyzed by evaluating the Water-Removal-Efficiency (WRE) and Salt-Removal-Efficiency (SRE). The obtained results demonstrated that the used demulsifier was found to be extremely efficient and to have the greatest impact on the dehydration efficiency (F-value = 434.56). In addition, the sensitivity analysis indicated that the dehydration/desalting process is also very sensitive to the oil space velocity and wash water ratio while having less sensitivity to changes in the temperature. Furthermore, the process optimization indicated that the highest efficiency of simultaneous removal of water and salt from crude oil (WRE = 94.54 % and SRE = 97.23 %) was observed at optimal conditions of 19.5 ppm demulsifier concentration, 125 °C temperature, 1 1/h oil space velocity, and 6 vol% wash water ratio.

Electrochemical C-O and C-N Arylation using Alternating Polarity in flow for Compound Libraries.

Etherification and amination of aryl halide scaffolds are commonly used reactions in parallel medicinal chemistry to rapidly scan structure-activity relationships with abundant building blocks. Electrochemical methods for aryl etherification and amination demonstrate broad functional group tolerance and extended nucleophile scope compared to traditional methods. Nevertheless, there is a need for robust and scale-transferable workflows for electrochemical compound library synthesis. Herein we describe a platform for automated electrochemical synthesis of C-X arylation (X=NH, OH) in flow to access compound libraries. A comprehensive Design of Experiment (DoE) study identifies an optimal protocol which generates high yields across>30 aryl halide scaffolds, diverse amines (including electron-deficient sulfonamides, sulfoximines, amides, and anilines) and alcohols (including serine residues within peptides). Reaction sequences are automated on commercially available equipment to generate libraries of anilines and aryl ethers. The unprecedented application of potentiostatic alternating polarity in flow is essential to avoid accumulating electrode passivation. Moreover, it enables reactions to be performed in air, without supporting electrolyte and with high reproducibility over consecutive runs. Our method represents a powerful means to rapidly generate nucleophile independent C-X arylation compound libraries using flow electrochemistry.

International Approaches to the Development, Validation, and Change Management of Analytical Procedures (Review)

INTRODUCTION. In 2023, the International Council for Harmonisation of Technical Requirements for Pharmaceuticals for Human Use (ICH) published a new Guideline on Analytical Procedure Development (ICH Q14) and a revised version of the Guideline on Validation of Analytical Procedures (ICH Q2(R2)). Consequently, there is a need for a considerable revision of the approach to the development and validation of analytical procedures that is currently used in the Eurasian Economic Union (EAEU). A revision is also needed for the processes for evaluating and introducing variations to the analytical procedures described in medicinal product registration dossiers.AIM. This review aimed to analyse the significant changes made to international approaches to the development of analytical procedures, as well as to study the advantages and disadvantages of these approaches for pharmaceutical manufacturers and regulatory agencies in the EAEU.DISCUSSION. This review covers the key provisions and practical aspects of the enhanced approaches to the development of analytical procedures introduced by the ICH Q14 guideline. In particular, the review addresses the concepts of the analytical procedure life cycle (APLC) and the modified analytical qualityby-design (AQbD) approach; the development of the analytical target profile (ATP); analytical quality risk management; planning of the design of experiments (DoE) and the analytical procedure control strategy; and the validation, subsequent verification, transfer, and change management of analytical procedures. Additionally, the review describes the ICH Q2(R2) updates that accompany this new regulatory paradigm.CONCLUSIONS. The above guidelines fill the existing gap in recommendations for the development of analytical procedures. The use of the APLC and AQbD concepts provides both pharmaceutical companies and regulatory authorities with flexible approaches that are applicable to analytical procedures both during the development phase and once they have been implemented. Effective implementation of these international approaches in the Russian pharmaceutical industry and regulatory system requires a broad discussion between pharmaceutical industry professionals and regulatory agency experts, possibly, as part of a pilot project. After that, there will be a necessity to provide training for specialists involved in the development of analytical procedures and to amend the EAEU Rules for Marketing Authorisation and Expert Assessment of Medicinal Products for Human Use.

Tailoring Single-Electron Emission Distributions in the Time-Energy Phase Space.

The precise characterization and control of single-electron wave functions emitted from a single-electron source are essential for advancing electron quantum optics. Here, we introduce a method for tailoring a single-electron emission distribution using energy filtering, enabling selective control of the distribution under various energy barrier conditions of the filter. The tailored electron is studied by reconstructing its Wigner distribution in the time-energy phase space using the continuous-variable tomography method. Our results reveal that the filtering cuts the portion of the distribution below the energy-barrier height of the filter in the time-energy space. While the filtering is demonstrated in a classical regime of the emitted electrons, we expect that this study significantly contributes to the design and implementation of advanced experiments toward quantum information processing based on single electrons.

Experimental investigation of FDM manufacturing of 316 l stainless steel

Continuous research in the field of metal additive manufacturing has led to the need for constant improvement of manufacturing parameters especially in the case of FDM (Fused Deposition Modeling) manufacturing. In recent years, the main directions outlined for productivity and quality improvement were related to higher printing speed and the use of ironing-type processes. This article aims to study the manufacturing parameters of the dimensional accuracy and surface quality of FDM-manufactured 316L stainless steel. The degree of novelty is given by the application of the ironing process for the green part. A full factorial 33 experimental design was designed for this study, in which the factors studied were ironing angle, ironing speed, and layer spacing during ironing. The dimensional accuracy and surface roughness were analyzed by means of deviation measurement from CAD to the green part and final part after the sintering process. Using the design of experiments offers the possibility of applying the analysis of variance (ANOVA) which provides information about the degree of influence of each of the studied factors. The results obtained for the dimensional accuracy showed that the ironing direction had the biggest influence on the Z-axis shrinkage. Overall, approximately 6% shrinkage in the Z and Y directions was obtained while in the X directions, the shrinkage percentage was around 20%. Surface roughness showed an improvement with higher ironing speeds for the green part while for the sintered part the most significant factor was ironing spacing.

Biomechanics of the Human Knee Joint in Maximum Voluntary Isometric Flexion: Study of Changes in Applied Moment, Agonist-Antagonist Participations, Joint Center, and Flexion Angle.

Estimation of the knee joint strength by maximum voluntary isometric contraction (MVIC) is a common practice to assess strength, coordination, safety to return to work or engage in sports after an injury, and to evaluate the efficacy of treatment modalities and rehabilitation strategies. In this study, we utilize a previously validated coupled finite element-musculoskeletal model of the lower extremity to explore the sensitivity of output measures (posterior cruciate ligament [PCL]/muscle/contact forces and passive moments) in knee MVIC flexion exercises at seated position. To do so, at three knee flexion angles (KFA), input measures (resistance moment and contribution moments of quadriceps and gastrocnemii) were varied at four levels each using the Taguchi design of experiment. Our findings reveal significant increases in PCL forces with KFA (p < 0.01), net MVIC moment (p < 0.01), and resistance moment of quadriceps (p < 0.01). In contrast, they drop at larger activity in gastrocnemii (p < 0.01). Tibiofemoral (TF) contact forces increase with the net MVIC moment (p < 0.01). The passive knee flexion moment, while highly dependent on the location at which computed, also increases with the net MVIC moment (p < 0.01). Changes in KFA, MVIC moment, and proportions thereof carried by quadriceps and/or gastrocnemii substantially affect biomechanics of the joint. Compared with level walking and stair ascent, slightly larger contact forces/stresses and much greater PCL forces are computed. This study improves our understanding of the knee joint behavior during MVIC in effective evaluation and rehabilitation interventions. Besides, it emphasizes the importance of positioning the joint center in model studies.

Performance-Based Design of Ferronickel Slag Alkali-Activated Concrete for High Thermal Load Applications.

This study aimed to develop optimized alkali-activated concrete using ferronickel slag for high-temperature applications, focusing on minimizing environmental impact while maintaining high compressive strength and slump. A response surface methodology, specifically the mixture design of experiments, was employed to optimize five components: water, FNS-based alkali-activated binder, and three aggregate sizes. Twenty concrete mixes were tested for slump and compressive strength before and after exposure to 600 °C for two hours. The optimal mix achieved 88 MPa compressive strength before heat exposure and 34 MPa after, with a slump of 140 mm. An upscaled version with improved workability (210 mm slump) maintained similar unheated strength but showed reduced post-heating strength (23.5 MPa). Replacing limestone with olivine aggregates in the upscaled mix resulted in 65 MPa unheated and 32 MPa post-heating strengths. Life Cycle Analysis revealed that the optimized ferronickel slag alkali-activated concrete's CO2 emissions were 77% lower than those of ordinary Portland cement concrete of equivalent strength. This approach demonstrated the applicability of mixture design of experiments as an alternative design methodology for alkali activated concrete, providing a valuable performance-based design tool to advance the application of alkali-activated concrete in the construction industry, where no prescriptive standards for alkali-activated ferronickel concrete mix design exist. The study concluded that the developed ferronickel slag alkali-activated concrete, obtained through a performance-based mixture design methodology, offers a promising, environmentally friendly alternative for high-strength, high-temperature applications in construction.

Mathematical and Statistical Analysis of Fused Filament Fabrication Parameters for Thermoplastic Polyurethane Parts via Response Surface Methodology

This work aims to analyze the effects of the main process parameters of fused filament fabrication (FFF) on the mechanical properties and part weight of 3D-printed thermoplastic polyurethane (TPU). Raster angle (RA), infill percentage (IP), and extruder temperature (FFF) in the ranges of 0–90°, 15–55%, and 220–260 °C, respectively, were considered as the FFF input parameters, and output variables part weight (PW), elongation at break (E), maximum failure load (MFL), ratio of the maximum failure load to part weight (Ratio), and build time (BT) were considered as responses. The Response Surface Methodology (RSM) and Design of Experiments (DOE) were applied in the analysis. Subsequently, the RSM approach was performed through multi-response optimizations with the help of Design-Expert software. The experimental results indicated a higher maximum failure load is achieved with an increased raster angle and decreased extruder temperature. ANOVA results show that ET has the most significant effect on elongation at break, with elongation at break decreasing as ET increases. The raster angle does not significantly affect the part weight of the TPU samples. The ratio of the maximum failure load to part weight of samples decreases with an increase in IP and ET. The results also indicated that the part weight and build time of FFF-printed TPU samples increase with an increase in IP. An ET of 220 °C, RA of 0°, and IP of 15% are the optimal combination of input variables for achieving the minimal part weight; minimal build time; and maximum elongation at break, maximum failure load, and ratio of the maximum failure load to part weight.

On the Piezoelectric Properties of Zinc Oxide Thin Films Synthesized by Plasma Assisted DC Sputter Deposition

AbstractThis work presents a study of piezoelectric zinc oxide (ZnO) thin films deposited by a novel post‐reactive sputtering method. The process utilizes a rotating drum with DC magnetron sputtering deposition onto substrates with subsequent DC plasma‐assisted oxidation of the deposited metal to metal oxide. The paper analyzes the influence of plasmaassisted magnetron sputtering (PA‐MS) deposition parameters (O2 plasma source power, O2 flow, and Ar flow) on the morphological, structural, optical, and piezoelectric properties of ZnO thin films. Design of experiments has been utilized to evaluate the role of these parameters on the growth rate (rg) and the properties of resulting films. Results indicate a predominant influence of the plasma power on the rg over other parameters. Among the eight tested samples, three of them show high crystal quality with high intensity (0001) diffraction peak, characteristic of the wurtzite crystalline structure of ZnO, and one of them exhibits piezoelectric coefficient values of ≈11pC N−1. That sample corresponding to a ZnO film deposited at the lowest rg of 0.075 nm s−1, confirmed the key role of the deposition parameters on the piezoelectric response of films, and demonstrated PA‐MS as a promising technique to produce high‐quality piezoelectric thin films.

Influence of Dilution and Effusion Flows in Generating Variable Inlet Profiles for a High-Pressure Turbine

Abstract The elevated flow temperatures and pressures exiting gas turbine combustors affect the efficiency and durability of the high-pressure turbine stage. Understanding the effects that result from the upstream dilution and effusion flow interaction in creating the combustor exit profiles is important to advancing gas turbines. Understanding how common combustor features, such as dilution jets and effusion cooling, interact based on computational predictions guided the design of a non-reacting profile simulator capable of producing a wide range of non-uniform temperature profiles representative of those entering high-pressure turbines. The mechanical design of a new simulator device, which will be experimentally tested in the future, is presented in this paper along with computational predictions of flow and thermal fields. The simulator was designed for modular installation into the Steady Thermal Aero Research Turbine (START), which is a continuous-duration, steady-state turbine facility that houses a single-stage test turbine. Features of the simulator included interchangeable liner panels with multiple rows of dilution jets and wall effusion cooling to study various hole diameters and patterns. The dilution jets generate elevated turbulence intensities and tailor the temperature profiles in the radial and circumferential directions. The air mass flow distribution and source flow temperatures are independently controlled. To aid in the simulator design, computational fluid dynamics (CFD) simulations using Reynolds-averaged Navier–Stokes modeling were conducted with a two-level Design of Experiments (DOE) approach to determine a number of engine-representative target profiles with temperature shapes that are mid-radius peaked, outer-diameter peaked, inner-diameter peaked, and uniform. A sensitivity analysis of the CFD DOE results determined which factors significantly affected the profile shape so that the target profiles could be produced. The analysis indicated that the main contributor to the temperature profile shape at near-wall vane radial span locations of 0–15% and 85–100% was the injection temperature of the effusion flow. The main contributor at radial span locations of 15–40% and 60–85% was the injection temperature of the third-row dilution jets, and at the mid-radius location of 40–60% vane radial span, the main contributor was the diameter of the first-row dilution holes.

Development and Experimental Study of Supercritical Flow Payload for Extravehicular Mounting on TZ-6.

This paper provides a detailed description of the development and experimental results of the supercritical flow experiment payload carried on the TZ-6 cargo spacecraft, as well as a systematic verification of the out-of-cabin deployment experiment. The technical and engineering indicators of the payload deployment experiment are analyzed, and the functional modules of the payload are shown. The paper provides a detailed description of the design, installation location, size, weight, temperature, illumination, pressure, radiation, control, command reception, telemetry data, downlink data, and experimental procedures for the out-of-cabin payload in the extreme conditions of space. The paper presents the annular liquid surface state and temperature oscillation signals obtained from the space experiment and conducts ground matching experiments to verify the results, providing scientific references for the design and condition setting of space experiments and comparisons for the experimental results to obtain the flow field structure under supercritical conditions. The paper provides a specific summary and discussion of the space fluid science experiment project, providing useful references for future long-term in-orbit scientific research using cargo spacecraft.

Structural Performance Analysis and Optimization of Small Diesel Engine Exhaust Muffler

In recent years, the optimization of diesel engine exhaust mufflers has predominantly targeted acoustic performance, while the impact on engine power performance has often been overlooked. Therefore, this paper proposes a parallel perforated tube expansion muffler and conducts a numerical analysis of its acoustic and aerodynamic performance using the finite element method. Then, a Kriging model is established based on the Design of Experiments to reveal the impact of different parameter couplings on muffler performance. With transmission loss (TL) and pressure loss (PL) as the optimization objectives, a multi-objective optimization study is carried out using the competitive multi-objective particle swarm optimization (CMOPSO). The optimization results indicate that this method can simplify the optimization model and improve optimization efficiency. After CMOPSO calculation, the average TL of the muffler increased from 27.3 dB to 31.6 dB, and the PL decreased from 1087 Pa to 953 Pa, which reduced the exhaust noise and improved the fuel economy of the engine, thus enhancing the overall performance of the muffler. This work provides a reference and guidance for the optimal design of mufflers for small agricultural diesel engines.