Extreme Operating Conditions Research Articles

A Wide‐Temperature Adaptive Electrochromic Device Based on a Poly(vinyl alcohol)/Poly(acrylic acid) Gel Electrolyte

AbstractAs a promising energy‐saving technology, electrochromic technology has been widely investigated for practical applications. However, there is relatively few research about the applications under certain extreme climatic conditions since gel electrolytes often occur freezing and volatilizing. In this work, a poly(vinyl alcohol)/poly(acrylic acid) (PVA/PAA) gel electrolyte with good anti‐freezing and heat‐resistance performance is developed. Utilizing hydrated tungsten oxide (WO3·xH2O) and polyaniline (PANI) as electrochromic materials and the PVA/PAA gel as electrolyte, a WO3·xH2O/PVA/PAA‐ethylene glycol (EG)‐H2O/PANI electrochromic device (WO3·xH2O/PAEH/PANI ECD) is obtained, which can work efficiently at wide operating temperatures from −20 to 60 °C. The device has multiple reversible color changes, a large optical modulation of 66.2% at 600 nm, high coloration efficiency of 386.0 cm2 C−1, fast responses (with coloration/bleaching times of 1.3/1.1 s), as well as excellent cyclic stability (82.0% of the initial optical modulation is still retained after 2100 cycles). This work reveals the potential application prospects of PAEH gel electrolyte in practical extreme operating conditions.

Effect of thermal shock on energy density of biaxially oriented polypropylene films for pulsed power capacitors

In this paper, thermal shock experiments are performed on the biaxially oriented polypropylene (BOPP) films, and the changes in dielectric and energy storage properties before and after the experiments are explored. The experimental results show that the films have reduced comprehensive performance with the thermal shock time and frequency increasing. After the thermal shock, both the permittivity and the dielectric loss increase slightly. And, the direct current (DC) conductivity has risen by 73.6%–714.2%. The lowest DC breakdown strength of film is 604.4 kV mm−1, showing a 13.5% reduction compared to that of pristine film. In addition, energy storage performance has also deteriorated. The maximum discharge energy density decreased from 4.62 J cm−3 of pristine film to 3.26 J cm−3 of treated film. There is a decrease in charge and discharge efficiency under the same electric field. The metallization layer of the film receives less influence; the capacitance is reduced by only 0.37%. The causes and mechanisms of performance changes are analyzed and discussed. The disruption of molecular chains during thermal shock is the most important factor leading to the degradation of films. This paper provides a powerful perspective and reference for studying the performance degradation and failure of polymer dielectrics under extreme operating conditions.

High-performance hydrogel membranes with superior environmental stability for harvesting osmotic energy

A collection of innovative nanofluidic systems has been developed to harness Gibbs free energy and convert it into osmotic energy. Nevertheless, these systems frequently encounter challenges such as low output power density, inadequate mechanical stability, and diminished performance in extreme conditions. In this work, we utilized a simple thermal polymerization method to fabricate a charged phytic acid (PA)–acrylic acid (AA)–3-sulfopropyl acrylate potassium salt (SPAK) hydrogel (PASH) membrane with anti-drying and anti-freezing properties, alongside mechanical stability. Using a silicon window with a testing area of 3 × 10−8 m2, a high power density of 30.94 W/m2 was achieved in artificial seawater and river water environments (0.5/0.01 M NaCl). Notably, an even higher power density of 103.9 W/m2 was attained in artificial saline lake and river water environments (5/0.01 M NaCl). Meanwhile, the PASH membrane demonstrated outstanding performance in low temperatures and various acidic and alkaline environments, offering the potential for osmotic power generation in extreme conditions. This work provides essential theoretical foundations and experimental evidence for the development of sustainable osmotic energy conversion technologies, contributing to the advancement and innovation in the field of blue osmotic energy.

Impact of sol-gel synthesized α-aluminium oxide nanoparticles for the enhancement of transformer oil insulation properties

Transformers require advanced insulating materials that outperform mineral oil in terms of cooling, insulation effectiveness, eco-friendliness, and operational efficiency in extreme operational and weather conditions. As a result, emphasis has shifted to renewable and ecologically friendly materials. This change in emphasis is motivated by worries about the environment, fuel shortages, and the disposal of waste oil. Transformers have historically employed solid insulators like paper and pressboard as well as mineral or synthetic oil. However, the development of ecologically friendly insulating materials has been spurred by new environmental regulations as well as economic benefits. This research investigates the use of sol-gel synthesized aluminium oxide (Al2O3) nanoparticles to improve the insulation properties of host transformer oil. The synthesized aluminium nanoparticles were characterized with X-ray diffractometer (XRD) and found rhombohedral structure, whose chemical composition was studied by energy dispersive X-ray spectrum (EDAX). Investigation using Fourier transform infrared spectroscopy (FTIR) also revealed the production of AlOOH and hydroxyl vibrational bands at wavenumbers of 690 and 2976 cm−1, respectively. Studies using field emission scanning electron microscopy (FESEM) showed that the nanoparticles are spherical in form and have a diameter of around 38 nm. Additionally, the incorporation of α-aluminium oxide nanoparticles into the host oil showed an improvement in the breakdown voltage and suggested a possible use for better transformer oil insulation.

Scaling design and similarity analysis of a floating nuclear power plant

In the process of developing floating reactor systems, their operation in the marine environment needs to be simulated to ensure the reliability of the safe design of nuclear reactors. Scaling test is a potential option for computer model validation by virtue of its low cost and flexibility. This study first gives the similarity law for dynamic tests of the reactor system in high-temperature environments by dimensional analysis. Then we focus on analyzing the jamming phenomenon that may occur during the similarity design process and provides a solution for realizing the contact state of the prototype in the scaled model. This study also analyzes the dynamic response of a floating reactor system under extreme operating conditions by combining numerical simulations and scaling tests. By comparing the response results predicted by the scaled model with the prototype response, it is further demonstrated that the feasibility of scaling test as an alternative to full-size test to provide a reference for realizing low-cost, accurate and safe design for reactor system.

Static and Dynamic Stress of the Combined Rotor with Curvic Couplings Considering the Rough Three-Dimensional Interface at Extreme Operating Conditions

The curvic coupling, as one of the common connecting structures for gas turbine combined rotors, is more susceptible to various dynamic and static loads at extreme operating conditions. But, traditional combined rotor models tend to neglect the influence of the connection structure, especially failing to consider the contribution of the curvic coupling interfaces. To address this problem, this paper establishes a solid geometric model of the combined rotor with curvic couplings considering the rough three-dimensional interfaces. The effectiveness of the proposed model method is indirectly verified through the compression tests and modal tests. Subsequently, combined with finite element calculations, the mechanical properties of the rotor with curvic couplings considering the rough interface are analyzed under static and dynamic load conditions. The results indicate that the roughness of the interface significantly affects the deformation of the contact surface under static load, but its impact on the overall deformation of the rotor is relatively insignificant. The dynamic stress at the interface exhibits periodic variations at the resonance speed. At the maximum operating speed, the dynamic stress is influenced by the magnitude of imbalance. The aforementioned methods and conclusions provide a reference for the design research and engineering application of combined rotors.

Nonlinear characteristics in the cylindrical roller bearing with raceway defects

Cylindrical roller bearings (CRBs) are subjected to significant cyclic stress under extreme operating conditions. This leads to the formation of localized wave defects on the raceway surface, such as burn. Thus, a new mathematical model is proposed to consider the local wave defects on the raceway caused by burns in this paper. Further, a dynamic model of CRB incorporating raceway defects is developed based on the contact relationships between components, and the proposed model is verified by measured acceleration responses. The effects of local wave defects on the nonlinear vibration characteristics of the bearings are studied and the results show that an increase in the number of defect waves reduces the additional displacement of rollers passing through the defect area, obscuring signal characteristics induced by the defect. Moreover, the presence of the defect influences the nonlinear interaction between the roller and raceway, which subsequently affects the cage whirling motion. This study of bearing dynamic behavior in this paper can contribute to the condition monitoring of bearings.

Piezo tube stacked scanning tunneling microscope for use in extreme and confined environments

Scanning Tunneling Microscopy (STM) is widely used for observing atomic structures due to its ultra-high spatial resolution. As the core units of STM, the coarse stepper motor and imaging unit, have conflicting size requirements for piezo tubes. Longer piezo tubes yield greater output force and easier movement for the motor, while shorter tubes enhance imaging precision and stability for the scanner. Traditional STMs typically employ a large piezo tube for coarse stepping and a smaller one for independent imaging to address this issue. Here, we present the new design of a piezo tube stacked STM, in which two independent piezo tubes act together during tip-sample approach process and only one shorter tube works during scanning imaging. Both tubes are fixed to the framework, ensuring high rigidity and compactness. The new design enables us to achieve both coarse stepping and imaging functions with a total length of only 25 mm for the two tubes, effectively reducing the length of whole STM, facilitating its integration into narrow low-temperature spaces for imaging applications. Using this device, we obtained high-quality atomic images of graphite sample surfaces at room temperature. Continuous scanning imaging of the same area on Au film at 300 K demonstrates the STM’s high stability in both X-Y and Z directions. Atomic images, I-V spectra, and di/dv spectra obtained at 2 K on graphite surface illustrate the excellent application potential of this device in low-temperature environments. Finally, atomic images obtained of graphite in sweeping the magnetic fields from 0 T to 11 T in a huge vibrational dry magnet prove the new STM’s excellent performance in extreme conditions.

Super-Elastic and Temperature-Tolerant Hydrogel Electrodes for Supercapacitors via MXene Enhanced Ice-Templating Synthesis.

Developing flexible energy storage devices with good deformation resistance under extreme operating conditions is highly desirable yet remains very challenging. Super-elastic MXene-enhanced polyvinyl alcohol/polyaniline (AMPH) hydrogel electrodes are designed and synthesized through vertical gradient ice templating-induced polymerization. This approach allows for the unidirectional growth of polyaniline (PANI) and 2D MXene layers along the elongated arrayed ice crystals in a controlled manner. The resulting 3D unidirectional AMPH hydrogel exhibits inherent stretchability and electronic conductivity, with the ability to completely recover its shape even under extreme conditions, such as 500% tensile strain, 50% compressive strain. The presence of MXene in the hydrogel electrode enhances its resilience to mechanical compression and stretching, resulting in less variation in resistance. AMPH has a specific capacitance of 130.68 and 88.02mFcm-2 at a current density of 0.2 and 2mAcm-2, respectively, and retains 90% and 70% of its original capacitance at elongation of 100% and 200%, respectively. AMPH-based supercapacitors demonstrate exceptional performance in high salinity environments and wide temperature ranges (-30-80°C). The high electrochemical activity, temperature tolerance, and mechanical robustness of AMPH-based supercapacitor endow it promising as the power supply for flexible and wearable electronic devices.

Mössbauer spectroscopy in studying industrial catalysts and processes in recycling

Advantageous properties of Mössbauer spectroscopy allow the method to be used for the examination of industrial catalysts as well. The method is confined for catalysts containing Mössbauer nuclei (57Fe and 119Sn in most practical cases), on the other side the obtained information is rather unique. Some further limitations emerge in studies for industrial catalysts with this technique in comparison to common catalyst studies, namely the extreme operating conditions, i.e. the elevated temperature and pressure. Thus the in situ conditions for studies cannot be completed easily. To circumvent this difficulty the states of catalysts prior and after the usage can be compared (ex situ conditions). Further, since real catalysts are used for long time period in the industry, their studies can be replaced by accelerated studies performed under ‘conditions relevant to real processes’. Beside catalysis, recycling and reuse of former industrial waste is also an important field for application of the method. A personal selection from reports from recent years on application of the method in representative large scale industrial processes is presented in the overview.

Occupational Injuries of Spanish Wildland Firefighters: A Descriptive Analysis.

The work of wildland firefighters, especially of the so-called 'Brigadas de Refuerzo contra Incendios Forestales', is characterised by high physical demands and extreme operating conditions. These professionals face long workdays (12 h), walking with heavy loads (~25 kg), being exposed to high temperatures (>30 °C), and handling specialised tools in high-risk environments. This study aimed to describe the prevalence of occupational injuries among members of the 'Brigadas de Refuerzo contra Incendios Forestales' and its relationship to variables such as age and work experience. A total of 217 wildland firefighters (18 female and 199 male) correctly answered a questionnaire developed on an ad hoc basis to meet the study's objectives. A high prevalence of occupational injuries was observed among them (~76%). Age and work experience were shown to be significantly associated with injuries. Individuals over 35 years of age with more than 10 years' experience had a higher probability of injury (OR = 2.14, CI = 1.12-4.06 and OR = 2.46, CI = 1.30-4.67, respectively). Injuries occurred mainly during physical training (~46%), followed by preventive work (~33%) and forest fires (~20%). The most common injuries were tendonitis and muscle pain (~44% and ~21% respectively), followed by sprains (~21%). The results underline the need for physical activity programmes adapted to help wildland firefighters, especially older and more experienced individuals. The identification of risk factors such as age and work experience can contribute to the prevention and management of occupational injuries among this group of highly specialised forestry workers. Specific preventative measures during training are required to mitigate the risk of injury among these crews, who play a crucial role in protecting the environment and public safety.

Effects of Extreme Low Temperatures on Carbon-Based Supercapacitors

This comprehensive study delves into the effects of severe cold exposure, specifically liquid nitrogen temperatures, on the functionality of carbon-based supercapacitors. It identifies a slight reduction in capacitance, a direct consequence of the degradation of electrode materials. This degradation is linked to the glass transition in the styrene butadiene rubber binder, leading to decreased adhesion of the active materials in the electrodes. The study highlights the escalated charge transfer resistance post-exposure, pointing to a decrease in efficiency. Significantly, this research emphasizes the crucial role of binder materials in supercapacitor design for low-temperature environments, suggesting that both electrolytes and binders should be equally considered in the development of supercapacitors for harsh climates. The findings contribute valuable insights into enhancing supercapacitor resilience and performance in extreme conditions, paving the way for more robust energy storage solutions. Figure 1

Designing High Stability Fluorinated Materials to Replace Carbonate Additives in Li-Ion Batteries Under Extreme Test Conditions

Graphite-based Li-ion batteries require the formation of a solid electrolyte interphase (SEI) on the surface of the anode to prevent solvent co-intercalation and graphite exfoliation. Materials such as vinylene carbonate (VC) and fluoroethylene carbonate (FEC) that have been successfully deployed as SEI layer forming additives show limited utility under high voltage and high temperature conditions due to low electrochemical and/or thermal stability.1-3 Development of Li-ion batteries that meet the needs of automotive and other electrification applications require advanced electrolyte additives that can support operation under extreme conditions.Koura has developed fluorinated additives that demonstrate improved stability and performance over conventional SEI layer forming additives under the high temperature and high voltage conditions relevant to the automotive industry. In this study, the performance of Koura’s fluorinated additives was compared to common commercial additives in the multiple cell designs, including 4.3V Gr/NMC811, to identify candidates to replace VC and FEC. Testing included 45°C cycling and 60°C storage. It has been found that these materials reduce gassing and increase capacity retention during high-temperature battery operation.To gain a fundamental understanding of how these molecules function in the battery, including mechanisms of solvation, interfacial behavior, and bulk reactivity; and how the structure of the molecule contributes to its properties and behavior, comprehensive post-test analysis was conducted, including gas composition analysis and quantification via gas chromatography, bulk electrolyte composition analysis via NMR spectroscopy, and surface layer characterization via XPS and SEM. Also, performance of multiple structural variants was examined to develop a structure-property relationship to guide rational design of additives for advanced Li-ion batteries.This presentation will summarize Koura’s efforts to supply advanced fluorinated materials for Li-ion batteries that satisfy the arduous demands of current and future applications. Specifically, we will present data showing the capability of fluorinated Koura materials to replace and/or enable existing Li-ion additives under extreme operating conditions, specifically high temperature and/or voltage. Multiple structures will be compared, where appropriate, to highlight our fundamental understanding of the structure-property relationships critical to designing next generation materials.

Interrogating Internal Temperature Evolution in Li-Ion Cells

Li-ion batteries have become indispensable today as the energy landscape shifts towards more sustainable options through electrification. A critical aspect of enhancing their cycle life while maintaining safety and performance lies in the effective thermal management of the battery. Currently, most battery management systems (BMS) rely on external temperature sensors to estimate internal temperatures. However, rapid internal heat generation can lead to a significant disparity between external and internal temperatures, particularly during extreme operating conditions. This study delves into operando monitoring of internal temperatures during cycling of Li-ion cells at various operating temperatures and C-rates. This offers insights into the evolution of internal temperatures throughout cycling and the difference between external and internal temperatures. This information can be instrumental in developing computational models that can predict internal temperatures more accurately using non-invasive techniques in the future.

Design Principles for Architected Battery Electrodes

The properties of rechargeable lithium-ion batteries are determined by the electrochemical and kinetic properties of their constituent materials as well as by their underlying microstructure. The discovery of 2D and 3D mesoscale architectures tailored to diverse applications remain an open challenge and it cannot be approached empirically. In this work, we leverage the design flexibility offered by several additive manufacturing methods (e.g. direct ink write, projection micro-stereolithography, etc.) to engineer the architecture of device electrodes. To explore this vast design space, we employ theoretical analyses and topology optimization techniques to determine printable electrode shapes. Our analyses produce general design guidelines, and three-dimensional CAD representations that optimize the battery architecture over specific performance metrics. In this talk, we show examples of electrode design driven by extreme operating conditions (e.g., low temperature) or by mechanical resilience. We also demonstrate an integrated workflow for model validation and guided experiments. For Li-metal anodes, our objective is to identify regimes of morphologically stable growth--where deleterious effects of dendrite growth might be avoided by microstructural design. For manganese-oxide cathodes, we develop physical models that capturethe pseudocapacitive response of the material and use them in inverse analyses to optimize the cathode architectures.

Research on arc evolution law of arc extin‐ction device under high‐speed large current

AbstractThe lifespan of the guide rail is a bottleneck restricting the operational life of electromagnetic railguns. A well‐designed arc extinguishing device can reduce the arcing erosion caused by residual currents within the guide rail. The CuW alloy is widely used in the high‐pressure arc extinction field due to its excellent electrical and thermal conductivity, high strength, and hardness. Based on the theory of equilibrium state arc plasma, a finite element model of the air arc‐CuW electrode coupling in the arc extinction device was established to study millisecond‐level arc initiation, evolution, extinguishing characteristics, and distribution patterns under extreme and harsh operational conditions with a current input of 110 kA. The highest temperature in the arc column region was found to exceed 50,000 K. The study elucidated the influence of arc extinction device parameters on arc evolution, breakdown time, and breakdown voltage. Consequently, it established that the R70 spherical electrode exhibits optimal arc extinguishing characteristics. The aim of this research is to provide theoretical support for optimizing the arc suppression device. Additionally, experiments on high‐speed and high‐current arc extinction device discharges were conducted to validate the finite element analysis results regarding arc diffusion patterns and electrode erosion.

Solar Heat Flux Suppression on Optical Antenna of Geosynchronous Earth Orbit Satellite-Borne Lasercom Sensor.

The objective of this article is to examine potential techniques for suppressing solar heat flow on the optical antenna of a laser communication sensor. Firstly, the characteristics of the geosynchronous Earth orbit's (GEO) space radiation environment are analysed, and a combined passive and active thermal control solution is proposed. Secondly, the temperature distribution of the lasercom sensor under extreme operating conditions is simulated utilising IDEAS-TMG (6.8 NX Series) software, which employs Monte Carlo and radiative heat transfer numerical calculation methods. Finally, a strategy for avoiding direct sunlight around midnight is proposed. The simulation results demonstrated that the thermal control solution and solar avoidance strategy proposed in this paper achieved long-term fine-stable control of the temperature field of the optical antenna, which met the thermal permissible communication hours per daily orbit cycle in excess of 14 h per day.

Women are not small men: the UK’s new, comprehensive Tri-Service Anthropometry survey

Human Factors Engineers need accurate anthropometric data to design military equipment that is safe, comfortable and enables performance under extreme operational conditions and in the most severe environments. The Ministry of Defence (MOD) acknowledges that its current anthropometry dataset is becoming increasingly unrepresentative of today’s Armed Forces personnel, particularly women and minority ethnic groups. To address this issue, MOD has launched a new, comprehensive anthropometry survey. Whilst this survey has the potential to benefit the design of all new military equipment and clothing, the principal driver for the study is the development of new body armour for the UK’s Armed Forces personnel. This paper describes the requirements underpinning this survey, with a focus on body armour; the planned solution; and the results of Pilot Studies that have tested the robustness, reliability and accuracy of the measurement technologies and procedures. The work reported in this paper has been funded by the MOD’s Defence Innovation Unit. Practitioner statement: The UK Ministry of Defence has launched a new, comprehensive anthropometry survey, in acknowledgement of the fact that its current anthropometry dataset is becoming increasingly unrepresentative of today’s Armed Forces personnel. This paper describes the requirements underpinning the survey, the planned solution and the result of Pilot Studies.

Leakage mechanisms of sub-pA InGaAs/GaAs nano-ridge waveguide photodetectors monolithically integrated on a 300-mm Si wafer

We report on a comprehensive temperature dependent dark current study of high-quality InGaAs/GaAs multi quantum well waveguide photodetectors monolithically integrated on silicon. They are integrated through metalorganic vapor-phase selective-area epitaxial growth in a 300 mm CMOS pilot line. Defects resulting from the metamorphic growth of III-V devices on Si make these devices susceptible to different leakage mechanisms at higher operating temperatures. For the high-temperature operation of complex photonics-electronics integrations, understanding the leakage mechanisms of the devices has critical significance. This will help to optimize designs promptly and ensure the reliability and longevity of such devices under extreme operating conditions. The photodetector devices exhibit dark currents below 1 pA, at room temperature and −1 V bias voltage, limited by the noise floor of the measurement setup. To resolve the different leakage mechanisms contributing to the dark current, the devices were measured at elevated temperatures and the results were cross-validated with device simulations. The devices exhibited very low dark currents, with a median below 0.1 nA at 195 °C, suggesting very high-quality material growth. Through device models, leakage mechanisms related to Shockley-Read-Hall (SRH) recombination at bulk volume defects are found to be the main factor contributing to the dark current. The surface SRH recombination is found to be limited, yet affecting the forward bias dark current due to the shortening of the diffusion paths of the majority carriers. Also, the device model shows that the actual dark currents at room temperature can be as low as 0.01 pA, more than 1-order lower than the measured levels. This study emphasizes the high quality of the III-V nano-ridge waveguide devices grown on Si, which can potentially expand the capabilities of silicon photonics platforms further.

Optimization design and performance improvement of ther-mal barrier coating (TBC) system

Thermal Barrier Coatings (TBC) technology has become one of the key technologies to improve the performance and prolong the service life of gas turbine and other high temperature equipment. In this study, the selection of materials, coating methods, the influence of environmental factors on the performance of TBC system and the thermal stress analysis and optimization strategy are discussed, improve the overall performance and stability of TBC system. TBC coatings were efficiently prepared by the use of Nikolay bonding layer and stabilized zirconia as top ceramic materials, combined with electron beam Physical vapor deposition (EB-PVD) and plasma spraying (APS) techniques. In addition, the thermal stress model was established by FEA, and the thermal stress distribution of TBC system under extreme operating conditions was analyzed in detail, to reduce thermal stress concentration and improve the thermal barrier effect of the coating. Finally, through the establishment of TBC system life prediction model and in-depth analysis of the failure mechanism, a series of preventive measures and performance improvement strategies are proposed, it provides theoretical basis and practical guidance for coating design of gas turbine and other high temperature equipment.