Harsh Environment Research Articles

Evolutionary ecology of denitrifying methanotrophic NC10 bacteria in the deep-sea biosphere.

The NC10 phylum links anaerobic methane oxidation to nitrite denitrification through a unique O2-producing intra-aerobic methanotrophic pathway. Although numerous amplicon-based studies revealed the distribution of this phylum, comprehensive genomic insights and niche characterization in deep-sea environments were still largely unknown. In this study, we extensively surveyed the NC10 bacteria across diverse deep-sea environments, including waters, sediments, cold seeps, biofilms, rocky substrates, and subseafloor aquifers. We then reconstructed and analysed 38 metagenome-assembled genomes (MAGs), and revealed the extensive distribution of NC10 bacteria and their intense selective pressure in these harsh environments. Isotopic analyses combined with gene expression profiling confirmed that active nitrite-dependent anaerobic methane oxidation (n-DAMO) occurs within deep-sea sediments. In addition, the identification of the Wood-Ljungdahl (WL) and 3-hydroxypropionate/4-hydroxybutyrat (3HB/4HP) pathways in these MAGs suggests their capability for carbon fixation as chemoautotrophs in these deep-sea environments. Indeed, we found that for their survival in the oligotrophic deep-sea biosphere, NC10 bacteria encode two branches of the WL pathway, utilizing acetyl-CoA from the carbonyl branch for citric acid cycle-based energy production and methane from the methyl branch for n-DAMO. The observed low ratios of non-synonymous substitutions to synonymous substitutions (pN/pS) in n-DAMO-related genes across these habitats suggest a pronounced purifying selection that is critical for the survival of NC10 bacteria in oligotrophic deep-sea environments. These findings not only advance our understanding of the evolutionary adaptations of NC10 bacteria but also underscore the intricate coupling between the carbon and nitrogen cycles within deep-sea ecosystems, driven by this bacterial phylum.

Novel candidate genes for environmental stresses response in Synechocystis sp. PCC 6803 revealed by machine learning algorithms.

Cyanobacteria have developed acclimation strategies to adapt to harsh environments, making them a model organism. Understanding the molecular mechanisms of tolerance to abiotic stresses can help elucidate how cells change their gene expression patterns in response to stress. Recent advances in sequencing techniques and bioinformatics analysis methods have led to the discovery of many genes involved in stress response in organisms. The Synechocystis sp. PCC 6803 is a suitable microorganism for studying transcriptome response under environmental stress. Therefore, for the first time, we employed two effective feature selection techniques namely and support vector machine recursive feature elimination (SVM-RFE) and LASSO (Least Absolute Shrinkage Selector Operator) to pinpoint the crucial genes responsive to environmental stresses in Synechocystis sp. PCC 6803. We applied these algorithms of machine learning to analyze the transcriptomic data of Synechocystis sp. PCC 6803 under distinct conditions, encompassing light, salt and iron stress conditions. Seven candidate genes namely sll1862, slr0650, sll0760, slr0091, ssl3044, slr1285, and slr1687 were selected by both LASSO and SVM-RFE algorithms. RNA-seq analysis was performed to validate the efficiency of our feature selection approach in selecting the most important genes. The RNA-seq analysis revealed significantly high expression for five genes namely sll1862, slr1687, ssl3044, slr1285, and slr0650 under ion stress condition. Among these five genes, ssl3044 and slr0650 could be introduced as new potential candidate genes for further confirmatory genetic studies, to determine their roles in their response to abiotic stresses.

Pb2+ Leachability in the Cement-Based Solidified/Stabilized Contaminated Clay Under Saline and Alkaline Environments

ABSTRACT Harsh environments such as saline and alkaline environments will affect solidification/stabilization quality, especially considering the long-term service cycle. To investigate the environmental influence on the leaching behavior of solidified/stabilized soils, the Pb2+ leaching behaviors of cement-stabilized contaminated clay (CSC) and ternary binder (CSG)-stabilized contaminated clay (CSGSC) under the endo/exogenous saline and alkaline attacking environment were discussed. Note that, the ternary CSG binder, consisting of cement, silica fume (SF), and desulfurization gypsum powder (DGP) in a ratio of 1:0.25:0.19, underwent pre-screening based on its unconfined compressive strength (UCS). Scanning electron microscopy was employed to reveal the environment-resisting mechanism. The leaching concentration of Pb2+ in the leachate from CSGSC was lower than that from CSC in both saline and alkaline environments with a same incorporation ratio (15%) to dry soils, indicating CSG’s efficiency. Under the exogenous environment, the Pb2+ cumulative leaching mass from the stabilized clays in saline environment was more than that in deionized water, while that under the endogenous environment was opposite. Microstructure analysis indicated that the SF and DGP in CSG facilitated the formation of calcium silicate hydrate and ettringite, resulting in a denser structure that greatly enhances the physical encapsulation and chemical fixation of Pb2+ cation. At the end, the different mechanism under endo/exogenous attacking environments was attributed to the cation influence on clay minerals and the formation of new substance. These findings provide a guidance for the remediation of contaminated soil in harsh environments.

PSV-21 Pediococcus acidilactici survives an in vitro simulated digestion

Abstract In the swine industry, probiotics are recognized for optimizing growth performance and production efficiency by modulating host physiology, and the response across studies is not consistent. One area of focus is probiotic mitigation of post-weaning diarrhea, and further mechanistic understanding of probiotic and host physiology could help with consistent performance outcomes. An essential attribute of a probiotic is the ability to survive the harsh environments of the gastrointestinal tract (GIT). The aim of this study was to determine if Pediococcus Acidilactici PECh3A (PA) that has been previously genome sequenced for determining gut physiology mechanisms can survive an in vitro simulated digestion. In the in vitro digestion PA concentrations that were investigated included 108, 109, and 1010 colony forming units (CFU)/mL. The in vitro digestion (n = 4/concentration) consisted of 5 phases with incubation times simulating the GIT; initial inoculation (0 h), gastric (2 h), upper intestinal (4 h), lower intestinal (9 h) and extended lower intestinal phase (9 h). For the initial inoculation concentrations of PA were added into 25 mL of sterile milk replacer representing dietary requirements of a suckling pig. In the gastric phase pepsin was added and pH was adjusted to 2.5. In the upper intestinal phase bile and pancreatin were added, along with a pH adjustment to 6.8. In the lower intestinal phase, the multi-enzyme complex consisting of carbohydrase enzymes was added and pH adjusted to 4.8. There was no addition during the extended lower intestinal phase. At each sample collection at the end of a phase 1 mL was collected from each flask. For each sample, 100 µL were serially diluted, plated on deMan, Rogosa, and Sharpe (MRS) plates, and incubated at 37°C for 24h. Survivability was determined by counting CFUs and comparing the concentration with the initial CFU/mL at 0 h and reported as percent survival (%S). Data for the in vitro digestion were analyzed according to a randomized complete block design (RCBD) in a split plot using the Repeated Measures Glimmix Procedure of SAS. Additional orthogonal contrasts were analyzed across PA concentrations. Data showed survival for 108,109, and 1010CFU/mL at all sample phases (108 - 44.24, 60.14, 58.36, 55.69%S; 109 - 40.56, 55.60, 49.35, 50.7%S; 1010 - 32.98, 52.55, 46.72, 43.71%S ± 2.98 respectively; phase P < 0.01 and concentration P < 0.01). There is evidence of a phase and concentration effect on survivability, but no interaction. A linear concentration response was observed across concentrations (54.61, 49.05, 43.99%S ± 1.23; P < 0.05) indicating that as concentration increases the survivability decreases. These findings indicate that PA PECh3A can survive a simulated GIT and potentially impact swine intestinal physiology.

The planning method of new energy distribution network in plateau area based on local accommodation

Abstract The planning method of new energy distribution network in plateau area based on local accommodation is studied to improve the local accommodation capacity of new energy distribution network in plateau area. The framework of new energy distribution network planning in the plateau area is constructed, and the distribution network equipment suitable for the plateau environment is selected based on the harsh environment in the plateau area; in the framework of new energy distribution network planning in plateau area, a bi-level planning model considering multi-flexible resource coordinated scheduling and energy storage is established. The upper level planning model takes the maximum accommodation of new energy as the objective, and the lower level planning model takes the optimal daily operation benefit of energy storage under the given configuration as the optimization objective; the probabilistic power flow method and C-PSO are used to solve the bi-level model. The experiment shows that this method ensures the stability of the new energy distribution network in the plateau area, reduces the amount of abandoned wind energy and the operating cost, and improves the local accommodation capacity of the core higher than the distribution network.

Experimental Investigation of Producer Gas Effects on Coated Pipelines in Biomass Downdraft Gasifier System

Abstract This research examines the performance of epoxy, ceramic, and graphene coatings on stainless steel 316 in a producer gas environment, focusing on corrosion and erosion resistance. This research aimed to identify the most effective coating for applications in harsh gasification environments. In this research, various analyses, including microstructural examination, hardness and weight measurements, FESEM analysis, and EDAX analysis, were conducted to evaluate the performance of the coatings. The producer gas was passed on to all the coated samples for a period of 100 hours. The significant findings include the superior corrosion and erosion resistance of ceramic-coated stainless steel, as evidenced by low weight fluctuations, maintained hardness levels, and elemental stability. Graphene coatings exhibit high hardness but increased porosity, raising concerns about durability, while epoxy coatings are vulnerable to gas-induced structural alterations. The inclusion rating analysis underscored the ceramic coatings' ability to preserve consistent material properties. Overall, ceramic coatings have emerged as the preferred option for gasification environments due to their structural resilience, inclusion integrity, and elemental stability. Considering the inclusion integrity, mechanical strength, weight stability, and elemental stability, ceramic-coated stainless steel 316 samples exhibit better resistance toward producer gas influence. This research contributes valuable insights for material selection in applications exposed to harsh gasification environments, emphasizing the importance of coating selection for long-term durability and performance.

Color morphing surfaces with effective chemical shielding

Color morphing refers to color change in response to an environmental stimulus. Photochromic materials allow color morphing in response to light, but almost all photochromic materials suffer from degradation when exposed to moist/humid environments or harsh chemical environments. One way of overcoming this challenge is by imparting chemical shielding to the color morphing materials via superomniphobicity. However, simultaneously imparting color morphing and superomniphobicity, both surface properties, requires a rational design. In this work, we systematically design color morphing surfaces with superomniphobicity through an appropriate combination of a photochromic dye, a low surface energy material, and a polymer in a suitable solvent (for one-pot synthesis), applied through spray coating (for the desired texture). We also investigate the influence of polymer polarity and material composition on color morphing kinetics and superomniphobicity. Our color morphing surfaces with effective chemical shielding can be designed with a wide variety of photochromic and thermochromic pigments and applied on a wide variety of substrates. We envision that such surfaces will have a wide range of applications including camouflage soldier fabrics/apparel for chem-bio warfare, color morphing soft robots, rewritable color patterns, optical data storage, and ophthalmic sun screening.

Lyophilised Aloe excelsa Fractions, Photo-protection and Actinic Damage Retardation Claims Substantiation

Introduction: Ultraviolet radiation is potentially harmful to plants’ physiological structures and their photosynthetic apparatus through induction of photo-oxidative damage and photosynthetic inhibition. Aloe excelsa a resilient (sub) tropical plant has evolved various photo-protective mechanisms to proliferate in these harsh environments. With the current FDA, over-the-Counter Monograph M020 castigating 14 of the 16 approved sunscreens as “unsafe” to the ecology and human health, the hunt for safer sunscreens is on and phytoconstituents from photo-resilient plants may just  be the next generation, safe and efficacious sunscreens. Aims: This study investigated the photo-protective activity of lyophilized hydro-ethanolic Aloe excelsa extracts through phytoscreening and in-vitro estimations of their SPF, UVAPF, UVA/UVB ratio, critical wavelength, anti-oxidancy as well as anti-inflammatory potential. Methods: The Aloe excelsa gel matrix was physically extracted from transversely cut fresh rossetes, macerated in 70% ethanol, lyophilized and then subjected to both quantitative and qualitative phytochemical screening techniques. The antioxidant activity was measured using the DPPH scavenging assay, the photoprotection investigation was performed in-vitro using directives from COLIPA 2011/FDA Final Rule 2011 as guidelines and the anti-inflammatory capacity was evaluated using the protein denaturing test. Results: Qualitative phytochemical screening confirmed the presence of numerous primary and secondary metabolites of pharmacological interest, Quantitative phyto-analysis revealed that  Aloe excelsa has higher levels of total phenols, tannins and flavonoids than Aloe vera. Anti-inflammatory capacity was closely related to the standard Diclofenac and the anti oxidancy was almost equivalent to ascorbic acid. A prepared 50% Aloe excelsa gel had an SPF of 7.6 and a UVAPF of 4 and a critical wavelength of 375. The calculated photostabilities: %SPFeff and %UVAPFeff were both above 97%. Conclusion: The results confirm that Aloe excelsa is a multifunctional photoprotective material with confirmed anti-oxidancy, anti-inflammatory and UVR protection attributes. The 50% lyophilised Aloe excelsa gel can be technically classified as a low SPF sunscreen. The abundant primary and secondary metabolites correlate directly with the observed and calculated photoprotective parameters obtained in this study.

A deep-learning image registration method for pressure-sensitive paint measurements

Image registration is an essential step in the data processing of pressure-sensitive paint (PSP) measurements. As PSP technology is gradually expanded to increasingly harsh environments, it faces challenges such as severe image misalignment due to model deformations/motions, which pose difficulties to traditional feature-based registration algorithms. To improve registration accuracy and efficiency, we propose an end-to-end image registration method based on deep learning. Initially, a PSP dataset based on PSP images is constructed through data augmentation. Three types of residual network and three training strategies are then adopted to prepare the deep-learning model for automatic image registration. The optimal combination of the residual network and training strategy is selected for validation using fabricated PSP images and outperforms two traditional algorithms (i.e., the Sift and Watershed methods). Finally, the performance of the deep-learning method is compared with that of traditional algorithms adopting a new metric of the overlapping rate for assessing the registration accuracy on experimental PSP images. The results show that the deep learning method outperforms the traditional algorithms in terms of registration accuracy and robustness.

Experimental characterization of bond between concrete and HDG steel tubes for mixed steel-concrete structures

Bond between concrete and reinforcement material is crucial for the structural behaviour and design of reinforced concrete or mixed steel-concrete structures. When considering applications in harsh environments, such as severe marine exposure or submerged conditions, hot-dip galvanized (HDG) steel seems to be a promising solution, as part of new mixed steel-concrete structural systems. Although it is essential to guarantee an effective composite response, the interaction and bond behaviour between materials is not yet sufficiently well understood. This experimental investigation aimed to study the bond behaviour between concrete and HDG steel tubes, including the influence of adopting concrete pin connectors by creating holes in the tube profile, and also the influence of the galvanic surface state. The impact of bond length on the bond behaviour of the galvanized steel tube embedded in different concrete mixtures was analysed. Pushout tests were conducted to obtain the load end versus slip responses, as well as the failure modes. The results showed that the embedment lengths and the concrete compositions had no relevant effect on the overall shape of the pushout experimental responses, with the exception of the specimens that include the concrete pin connector. However, both variables clearly influenced the bond stress, dissipated energy during pushout until failure, and residual pushout force. The addition of the concrete pin significantly improved the adherence mechanism, while the contamination of the galvanic surface showed to significantly reduce the bond strength.

Isolation and identification of fungal biodeteriogens from the wall of a cultural heritage church and potential applicability of antifungal proteins in protection

Fungi are able to permanently damage cultural heritage buildings and stone monuments. Protection against these biodeteriogen fungi is challenging because it may require the use of drastic techniques to remove fungal colonies and chemicals, which can cause further damage, especially on mural paintings. Natural biocides are less damaging, greener, and safer and mainly include essential oils and plant-derived substances. Studies on the applicability of purified antifungal proteins in the conservation of cultural heritage buildings are lacking. In this study, we isolated mold mycoflora from the biodeteriorated inner walls of the Calvinist church of Kézdialbis (Kézdialbis, Romania) and investigated the in vitro antifungal efficacy of Neosartorya (Aspergillus) fischeri antifungal proteins, NFAP and NFAP2 against them. Antifungal susceptibility testing revealed that these proteins inhibited the growth of the most commonly isolated indoor biodeteriogen fungi from the site (Aspergillus creber, Aureobasidium pullulans, Cladosporium sp., Penicillium chrysogenum, and Parengyodontium album) and not common ones (Mucor hiemalis, Sarocladium kiliense) with different spectra and efficacies. A phytopathogen and an entomopathogen species (Pseudopithomyces chartarum and Beauveria pseudobassiana, respectively) were also isolated and described first as fungal biodeteriogens of the inner walls. Among them, P. chartarum was susceptible to NFAP2. Next, we tested the applicability of NFAP and NFAP2 in protecting cultural heritage buildings in a wall model experiment against A. creber. Topical application of both antifungal proteins significantly decreased the area infected by fungi. Scanning electron microscopy of the wall models showed that A. creber had reduced growth and conidiation in the presence of NFAP and NFAP2. This inhibitory activity was maintained for a long time. Strong UV irradiation decreased the protective effect of both proteins in the wall model. Taking into account these results, the high stability of NFAP and NFAP2 in harsh environments, and their bulk recombinant producibility, we suggest that both can be used in the protection and posttreatment of painted walls of cultural heritage buildings to clean up mural painting or to inhibit mold recolonization after mechanical, physical, or chemical decontamination.

Ultra-flexible inorganic coating realized by scale-like nanosheets

Rapid development of foldable devices poses a challenging requirement on functional inorganic coatings with high flexibility. However, the inherent brittleness often renders inorganic coatings incompatible with flexibility. How to make flexible inorganic coatings remains challenging. Here, inspired by the scale structure of animal skins, we realize ultra-flexible scale-like coatings on polyimide (PI) film with layered double hydroxide (LDH) nanosheets. The adhesion is enhanced without peeling due to the bonding of polyimide with amino group attached to nanosheets. LDH nanosheets parallel to the substrate form scale-like structure that absorbs and releases stress to prevent coatings from cracking. And the coatings exhibit ultra-flexibility by surviving from 20,000 cycles of bending fatigue test. We apply the LDH-coated PI for atomic oxygen protection, which has important applications in aerospace industry. The coatings are designed as this special scale-like structure to release stress while possessing protection ability. Due to the barrier and adsorption of this flexible LDH coating, the erosion yield of the PI under an exposure of ~5 × 1021 atoms/cm2 is decreased by about 4 orders of magnitude to 0.015 % (~5 × 10−28 cm3/atom), which can satisfy the requirement for applications in harsh space environment of low earth orbit. Our work provides a general solution for simultaneously realizing high mechanical strength and flexibility in the coating technology, which may find applications in other areas, such as flexible electronics.

Promoted catalytic property of Cu/SSZ-13 by introducing a minority of Mn for NO removal from diesel engine exhaust

The Cu-exchanged SSZ-13 with the small-pore chabazite framework is considered as a highly efficient catalyst for selective catalytic reduction of NO with NH3 (NH3-SCR). In order to further improve the catalytic property, a series of Mn ion-assisted Cu/SSZ-13 powder catalysts were prepared by co-exchange method and stepwise exchange method. It is found that the NH3-SCR activity, N2 selectivity, hydrothermal stability and sulfur resistance of Cu/SSZ-13 are promoted by introducing a minority of Mn (0.15%–0.23%(mass)) through co-exchange method. Characterization results revel that the Cu,Mn co-exchange enables the higher amounts of Cu2+ active sites, the abundant medium strong and strong acid, the optimized ratio of lewis acid to Brønsted acid, etc., which are required for a good NH3-SCR catalytic property over broad temperature range and under harsh working environment. Moreover, a monolithic catalyst was prepared by impregnating a cordierite ceramic support into the coating slurry containing the optimized CuMn/SSZ-13 powder. The diesel engine bench tests show that Cu,Mn co-exchange gives the monolith catalyst a better catalytic property than commercial catalysts. This work provides an important guidance for the rational design of secondary-ion-assisted zeolites applied in NH3-SCR.

Temperature-Decoupled Single-Crystal MgO Fiber-Optic Fabry–Perot Vibration Sensor Based on MEMS Technology for Harsh Environments

A high-temperature-resistance single-crystal magnesium oxide (MgO) extrinsic Fabry–Perot (FP) interferometer (EFPI) fiber-optic vibration sensor is proposed and experimentally demonstrated at 1000 °C. Due to the excellent thermal properties (melting point > 2800 °C) and optical properties (transmittance ≥ 90%), MgO is chosen as the ideal material to be placed in the high-temperature testing area. The combination of wet chemical etching and direct bonding is used to construct an all-MgO sensor head, which is favorable to reduce the temperature gradient inside the sensor structure and avoid sensor failure. A temperature decoupling method is proposed to eliminate the cross-sensitivity between temperature and vibration, improving the accuracy of vibration detection. The experimental results show that the sensor is stable at 20−1000 °C and 2−20 g, with a sensitivity of 0.0073 rad (20 °C). The maximum nonlinearity error of the vibration sensor measurement after temperature decoupling is 1.17%. The sensor with a high temperature resistance and outstanding dynamic performance has the potential for applications in testing aero-engines and gas turbine engines.

Silica coated MOFs-derived composites with excellent electromagnetic wave absorption and corrosion resistance

The microwave absorber with excellent corrosion resistance is an ideal layer for stealth applications in marine environments. Silica coated MOF-derived anti-corrosion absorbers were successfully fabricated by the Stöber method. The resulting powder demonstrated excellent performance not only in microwave absorption but also in corrosion resistance. The effective absorption bandwidth (EAB) of coated-12 reached 4.1 GHz and the minimum reflection loss (RLmin) came to −59.8 dB at 15.18 GHz in a 1.3 thickness with an 80 wt% filling ratio. The outstanding absorption performance is put down to the matched impedance and the various loss mechanism synergy. Besides, the electrochemical corrosion test revealed that the compact silica coating protected the inner corrodible magnetic metal nanoparticles from the outer corrosive environment. This work provides a reasonable and feasible method for synthesizing an excellent microwave absorber suitable for harsh environments.

Optimization of TLPS Bonding Process and Joint Property using Ni-Sn Paste for High Temperature Power Module Applications

Recently, as interest in eco-friendly vehicles such as electric and hybrid vehicles increases, the demand for power semiconductors, a key component, is also increasing. Power semiconductors convert, distribute, and control power and operate in harsh environments such as high temperature and high pressure. In order to ensure stable reliability in such harsh environments, research on a technology that can stably form joints even at high temperatures is essential. Transitional liquid phase (TLP) bonding was proposed as a high-temperature power semiconductor chip bonding technology, which has the advantage of forming an intermetallic compound (IMC) phase with a high melting point at the joint. However, it takes a long time to convert the joint into full IMC phase. Therefore, in this study, in order to shorten the process time, a paste was manufactured by mixing high-melting point Ni metal powder and low-melting point Sn metal power, and a joint was formed through a TLPS (Transition liquid phase sintering) bonding using the paste. Pastes of different compositions were prepared by adjusting the ratio of Ni and Sn powders. The chip and substrate were bonded through a thermocompression (TC) bonding process, and the highest shear strength was obtained at a bonding temperature of 250 ℃ for 10 min. Heat treatment was performed at 200 ℃ for up to 500 h to evaluate the high temperature long-term reliability of the joints. The Ni-Sn TLPS bonded joints remained reliable joints after a long-term aging test at a high temperature of 200 ℃.

Dual immobilization strategy for slippery surface to achieve durable anti-corrosion and excellent anti-icing

Aluminum alloys always suffer from the deficient corrosion resistance and anti-icing property. Slippery liquid infused porous surfaces (SLIPS) inspired by “Nepenthes” have exhibited great potential in corrosion protection and anti-icing. However, the rapid depletion of the infused lubricants often results in the unsatisfactory long-term protective performances of SLIPS. In this study, a dual immobilization strategy was employed to fabricate a slippery surface with robust lubricant layer. The active lubricants were infused in the nanopores of anodized aluminum oxide (AAO) and grafted on the surface of silanized phytic acid (PA) substrate support simultaneously. Due to the presence of infused and covalently grafted lubricants, the obtained slippery surface possessed excellent and durable water repellency and anticorrosion property. Throughout 21 days of immersion in the 3.5 wt% NaCl solution, the water sliding angle of the slippery surface was lower than 10° and the low frequency impedance of the slippery surface was higher than 2.0 × 106 Ω cm2. Moreover, the slippery surface also possesses self-healing capacities that can automatically seal the scratch and repair the protective performance within 24 h. Furthermore, the cooled water droplet can easily roll away from the slippery surface treated by low temperature freezing. The results suggest that the slippery surfaces prepared using dual immobilization strategy can effectively protect aluminum alloys from corrosion and icing. This study provides a novel insight into the design and construction of SLIPS with excellent durability, which can expand the applications of SLIPS in harsh environments.

Analysis of Tool Load Concerning the Cross-Sectional Size of Removed Material

High-feed milling (HFM) represents a progressive manufacturing technology that has recently found widespread application across various industries. HFM is characterized by high machining speed, reduced cycle times, increased overall productivity, and increased tool life. Due to its versatility, HFM is a suitable technology for the application of various materials. The study deals with experimental analysis of cutting forces, machined surface integrity, and statistical evaluation in high-feed machining. In the present study, nickel-copper-based alloy (Monel) was chosen as the machined material, employing HFM with a monolithic ceramic milling cutter. The Monel material is characterized by its excellent mechanical properties and chemical resistance in harsh environments. During machining, cutting forces were recorded in three mutually perpendicular directions. This paper delves into the analysis of the impact of the depth of cut (ap), width of cut (ae), and lead-in angle (ε). The chosen evaluation characteristics encompass the tool load, primary profile, and the attained roughness of the machined surface. It is noteworthy that the technology under consideration predominantly aligns with the roughing phase of the manufacturing process. Additionally, the investigation incorporates a statistical analysis of the response surface pertaining to the cutting force components, namely Fx, Fy, Fz, and the resultant cutting force F.

Laboratory demonstration of Grating Embedded Mirrors for single-shot heliostat optical metrology

Abstract Concentrated solar power (CSP) plants need to monitor the surface slope error of thousands of heliostats with sub-milliradian accuracy. Large numbers of heliostats installed in harsh environments means that measurement speed and durability are key design considerations for metrology systems. We present a compact, accurate, and high-speed heliostat slope error metrology system that is robust to the harsh environmental conditions at CSP plants. The system is composed of (1) Grating Embedded Mirrors (GEMs), which have multiple phase diffraction gratings written within a glass mirror substrate, and (2) a compact optical system, the Diffractive Auto-Stigmatic Hartmann Camera (DASHCam). Using focused ultrafast laser pulses, we write phase gratings within float glass mirror facets without damaging the reflective coating. The gratings direct a small fraction of incident light to non-specular directions, which the DASHCam senses from a virtual center of curvature to measure the facet slopes at each grating patch. In a CSP plant, each heliostat facet would be a GEM, and the DASHCam would rapidly measure slope and canting errors during heliostat manufacturing, installation, or operation. We fabricated 0.1 meter-diameter GEMs, built a prototype DASHCam system. Our results show, in a laboratory environment, 24 μrad RMS measurement repeatability and 47 μrad RMS accuracy, with single-shot image capture. The combination of GEMs and DASHCam is a promising metrology approach that could lead to improved optical accuracy of heliostats throughout their life cycle. This work serves as a proof of principle for this system.

3D ToF LiDAR for Mobile Robotics in Harsh Environments: A Review

3D ToF LiDAR for Mobile Robotics in Harsh Environments: A Review