High Thermal Conditions Research Articles

2D Materials for Potable Water Application: Basic Nanoarchitectonics and Recent Progresses.

Water polluted by toxic chemicals due to waste from chemical/pharmaceuticals and harmful microbes such as E. Coli bacteria causes several fatal diseases; and therefore, water filtration is crucial for accessing clean and safe water necessary for good health. Conventional water filtration technologies include activated carbon filters, reverse osmosis, and ultrafiltration. However, they face several challenges, including high energy consumption, fouling, limited selectivity, inefficiencies in removing certain contaminants, dimensional control of pores, and structural/chemical changes at higher thermal conditions and upon prolonged usage of water filter. Recently, the advent of 2D materials such as graphene, BN, MoS2, MXenes, and so on opens new avenues for advanced water filtration systems. This review delves into the nanoarchitectonics of 2D materials for water filtration applications. The current state of water filtration technologies is explored, the inherent challenges they face are outlines, and the unique properties and advantages of 2D materials are highlighted. Furthermore, the scope of this review is discussed, which encompasses the synthesis, characterization, and application of various 2D materials in water filtration, providing insights into future research directions and potential industrial applications.

Ni and Ni–P substrates inhibit Bi phase segregation and IMC overgrowth during the soldering process of Sn–Bi solder

In this paper, presents surface modification of Cu substrates by electroplating or chemical plating to obtain high-quality Ni and Ni–P coatings. The Sn58Bi solder reactions with Cu, Ni, and Ni–P UBMs at 180 °C, 250 °C, and 320 °C, respectively. Research has found that Ni and Ni–P substrates can inhibit Bi phase segregation and interfacial IMC overgrowth in Sn–Bi solder joints. Bi phase segregation occurs during the transition from Cu6Sn5 to Cu3Sn. There is Bi segregation at the interface of Sn58Bi/Cu solder joints to Cu3Sn/Cu interface, and IMC grows rapidly. However, Ni/Cu and Ni–P/Cu substrates can not only suppress the Bi phase segregation behavior of Sn58Bi solder joints during soldering, but also slow down the excessive growth of interfacial IMC; Even under the harsh soldering process of up to 320 °C for 600 s, it still has an effective blocking effect. In addition, at 320 °C, when Sn58Bi solder react with Cu, the interface directly crosses Cu6Sn5 to generate Cu3Sn, which exhibits the morphology characteristics of Cu6Sn5 due to high thermal conditions. During the soldering, Ni atoms continuously diffuse towards the interface, and Ni3Sn4 (Ni/Cu) grows from needle like in the early stage of soldering to rod like, and finally to block like; The block like appearance of Ni3Sn4 (Ni–P/Cu) occurs earlier than that of Ni3Sn4 (Ni/Cu), because the presence of columnar Ni3P layers provides a wider diffusion channel for Ni atoms, but the overall growth size is smaller than that on Ni/Cu. A higher undercooling can promote the growth of interfacial IMC, including Cu6Sn5 and Ni3Sn4. At the same time, the Bi phase inside the Sn58Bi solder joint is coarsened, and the substrate Ni/Ni–P can eliminate interfacial brittleness after eliminating Bi segregation.

High-frequency hydrogen combustion dynamics driven by local flame displacement and multidimensional thermoacoustic interactions

Knowledge of the underlying physical mechanisms responsible for the triggering of high-frequency transverse combustion dynamics is of fundamental importance in the development of heavy-duty gas turbine combustors, aircraft engine afterburners, and bipropellant liquid rocket engines. Detailed information about three-dimensional thermoacoustic interactions and local flame dynamics, however, remains largely unknown and unanticipated, mainly because high-amplitude transverse mode instabilities are challenging to excite and detect in well-controlled sub-scale laboratory environments. To overcome this impasse, here we exploit a spatially tailored rectangular injector assembly consisting of ten equidistant horizontal slit nozzles to eliminate the complications of out-of-plane flame dynamics characterization. A total of 56 datasets of self-induced instabilities were acquired over a wide range of operating conditions to understand spatiotemporal phase dynamics and important mode shapes, in conjunction with 2D Rayleigh angle reconstruction and phase-resolved OH PLIF-based local flame front identification. Experimentally, we show that high-frequency transverse instabilities are excited only under high temperature and high thermal power conditions, manifested as non-evanescent pressure fluctuations at 6.50 kHz strongly coupled to the second-order tangential mode of the rectangular combustion chamber. Two vertically-oriented pressure nodal planes and the characteristic phase transition perpendicular to the horizontal slit injector direction are accurately measured and reconfirmed by Helmholtz simulations in terms of their interpositions and spatial orientation. Remarkably, the periodic formation of co-propagating coherent structures and concomitant local flame displacement/pinch-off are revealed to play an important role in driving the high-frequency hydrogen combustion dynamics.

Early Jurassic origin of avian endothermy and thermophysiological diversity in dinosaurs

A fundamental question in dinosaur evolution is how they adapted to long-term climatic shifts during the Mesozoic and when they developed environmentally independent, avian-style acclimatization, becoming endothermic.1,2 The ability of warm-blooded dinosaurs to flourish in harsher environments, including cold, high-latitude regions,3,4 raises intriguing questions about the origins of key innovations shared with modern birds,5,6 indicating that the development of homeothermy (keeping constant body temperature) and endothermy (generating body heat) played a crucial role in their ecological diversification.7 Despite substantial evidence across scientific disciplines (anatomy,8 reproduction,9 energetics,10 biomechanics,10 osteohistology,11 palaeobiogeography,12 geochemistry,13,14 and soft tissues15,16,17), a consensus on dinosaur thermophysiology remains elusive.1,12,15,17,18,19 Differential thermophysiological strategies among terrestrial tetrapods allow endotherms (birds and mammals) to expand their latitudinal range (from the tropics to polar regions), owing to their reduced reliance on environmental temperature.20 By contrast, most reptilian lineages (squamates, turtles, and crocodilians) and amphibians are predominantly constrained by temperature in regions closer to the tropics.21 Determining when this macroecological pattern emerged in the avian lineage relies heavily on identifying the origin of these key physiological traits. Combining fossils with macroevolutionary and palaeoclimatic models, we unveil distinct evolutionary pathways in the main dinosaur lineages: ornithischians and theropods diversified across broader climatic landscapes, trending toward cooler niches. An Early Jurassic shift to colder climates in Theropoda suggests an early adoption of endothermy. Conversely, sauropodomorphs exhibited prolonged climatic conservatism associated with higher thermal conditions, emphasizing temperature, rather than plant productivity, as the primary driver of this pattern, suggesting poikilothermy with a stronger dependence on higher temperatures in sauropods.

Numerical Study of Nonlinear Convective Heat Transfer Flow of Metal Oxide Nanoparticle TiO<sub>2</sub>-Enhanced Fluid between Two Concentric Cylinders with Aggregation of Nanoparticles

The utilization of nanofluid is one of the most used techniques for improving heat transfer in applications like heat exchangers, heat storage systems, mining and nuclear power plants. Because of high thermal conditions, the density relation of the working fluids may not be linear, therefore, an analysis is conducted on the quadratic convection of nanofluid flow in a porous annulus region considering an inclination. The phenomenon of temperature-dependent viscosity on the flow, kinematics of nanoparticle aggregation, and heat transport phenomenon with Exponential Space-Related Heat Source (ESHS) and a Temperature-Related Heat Source (THS) are considered. The governing equations are solved numerically. The influence of key parameters is analyzed using 2D and 3D graphs.

Operational condition and furnace geometry for premixed C3H8/Air MILD combustion of high thermal-intensity and low emissions

MILD combustion is usually operated at relatively low thermal intensity to achieve uniform temperature field and low pollutant emissions, further understanding of its emission characteristics at high thermal intensity condition is required to widen its application. In the present numerical study of premixed C3H8/air MILD combustion, different operational conditions (equivalence ratio Φ and thermal input Pinput) and furnace geometries (side wall angle α and aspect ratio AR) are considered to reveal their correlations with pollutant emissions including CO, NOx and unburned hydrocarbon (UHC) at thermal intensities up to 1.06 MW/m3. By adopting reactor network calculation with detailed combustion chemistry, it is found that AR plays a notable role in controlling CO, NOx and UHC emissions, while NOx emission is insensitive to the variation of side wall angle. Both the CO and UHC emissions are related to the location of the internal recirculating vortex. Moreover, following the parametric study and NOx formation analysis, the optimized furnace geometry and operating condition of AR = 5, α = 0° and Φ = 0.6 are obtained to significantly reduce the pollutant emissions by 90 % for both C3H8 and CH4 fuels. The present investigation offers valuable insights into the high thermal intensity MILD combustion.

Sexual selection buffers the negative consequences of population fragmentation on adaptive plastic responses to increasing temperatures.

Whether sexual selection facilitates or hampers the ability to plastically respond to novel environments might depend on population structure, via its effects on sexual interactions and associated fitness payoffs. Using experimentally evolved lines of the seed beetle Callosobruchus maculatus, we tested whether individuals evolving under different sexual selection (monogamy vs. polygamy) and population spatial structure (metapopulation vs. undivided populations) treatments differed in their response across developmental thermal conditions (control, hot, or stressful) in a range of fitness and fitness-associated traits. We found that individuals from subdivided populations had lower lifetime reproductive success at hot temperatures, but only in lines evolving under relaxed sexual selection, revealing a complex interaction between sexual selection, population structure, and thermal environmental stress on fitness. We also found an effect of population structure on several traits, including fertility and adult emergence success, under exposure to high thermal conditions. Finally, we found a strong negative effect of hot and stressful temperatures on fitness and associated traits. Our results show that population structure can exacerbate the impact of a warming climate, potentially leading to declines in population viability, but that sexual selection can buffer the negative influence of population subdivision on adaptation to warm temperatures.

In-situ microscopy methods for imaging high-temperature microstructural processes – Exploring the differences and gaining new potentials

In-situ high-temperature microscopy techniques provide crucial insights into materials under non-ambient conditions. This study compares confocal laser scanning and scanning electron microscopy for material characterization at elevated temperatures. Thereby, investigations are made regarding their imaging capabilities, limitations, and the general information obtained. Two alloys, Cu-20 m.% Sn and W-10 m.% Re, are used as case studies to demonstrate the applicability of the techniques. By studying phenomena such as grain growth, phase transformations, and thermal crack, we gain important insights to understand mechanical properties and thermal behavior better. This comprehensive analysis aids in selecting the most appropriate microscopy technique based on the research objectives. Overall, this study helps advance high-temperature materials science and promotes progress in several areas requiring accurate materials characterization under high thermal conditions.

Free-standing 2D gallium nitride for electronic, excitonic, spintronic, piezoelectric, thermoplastic, and 6G wireless communication applications

Two-dimensional gallium nitride (2D GaN) with a large direct bandgap of ~5.3 eV, a high melting temperature of ~2500 °C, and a large Young’s modulus ~20 GPa developed for miniaturized interactive electronic gadgets can function at high thermal and mechanical loading conditions. Having various electronic, optoelectronic, spintronic, energy storage devices and sensors in perspective and the robust nature of 2D GaN, it is highly imperative to explore new pathways for its synthesis. Moreover, free-standing sheets will be desirable for large-area applications. We report our discovery of the synthesis of free-standing 2D GaN atomic sheets employing sonochemical exfoliation and the modified Hummers method. Exfoliated 2D GaN atomic sheets exhibit hexagonal and striped phases with microscale lateral dimensions and excellent chemical phase purity, confirmed by Raman and X-ray photoelectron spectroscopy. 2D GaN is highly stable, as confirmed by TGA measurements. While photodiode, FET, spintronics, and SERS-based molecular sensing, IRS element in 6G wireless communication applications of 2D GaN have been demonstrated, its nanocomposite with PVDF exhibits an excellent thermoplastic and piezoelectric behavior.

Flame-retardant and anti-corrosion behaviour of cardanol-based polybenzoxazine composites

A new monomer of bi-functional benzoxazine was synthesised using cardanol (C) and p-phenylenediamine (ppda) under suitable experimental conditions. The curing behaviour of the cardanol-based 1,4-bis(7-pentadecyl-2H-benzo[1,3]oxazin-3(4H)-yl)benzene (C-ppda) benzoxazine monomer was studied by differential scanning calorimetry analysis, and the polymerisation temperature (T p) of C-ppda benzoxazine was found to be 237°C. Further, the benzoxazine monomer was reinforced with varying weight percentages (5, 10 and 15 wt%) of bio-ash derived from Aerva lanata (AL-ash) to obtain hybrid composites. Thermogravimetric analysis data indicate that AL-ash-reinforced benzoxazine composites possess excellent thermal stability and a flame-retardant behaviour. The morphology of AL-ash- and cardanol-based benzoxazine composites was analysed using field emission scanning electron microscopy (FESEM). The FESEM results indicate homogeneous distribution of AL-ash in the composites. Energy-dispersive X-ray spectroscopy analysis was used to determine the elemental composition of the AL-ash used for the preparation of composites. The value of the water contact angle of poly(C-ppda) was found to be 148°. Data obtained from corrosion studies indicate that the mild steel specimen coated with a benzoxazine matrix and the specimen coated with bio-ash-reinforced benzoxazine composites exhibit an excellent resistance against corrosion. The bio-ash-reinforced composites of cardanol-based benzoxazine can be used in the form of sealants, encapsulants, adhesives, coatings and matrices in microelectronics and automobile applications under high thermal and moist environmental conditions.

Modification of Cellulose Ether with Organic Carbonate for Enhanced Thermal and Rheological Properties: Characterization and Analysis.

Reduction in viscosity at higher temperatures is the main limitation of utilizing cellulose ethers in high thermal reservoir conditions for petroleum industry applications. In this study, cellulose ether (hydroxyethyl methyl cellulose (HEMC)) is modified using organic carbonates, i.e., propylene carbonate (PC) and diethyl carbonate (DEC), to overcome the limitation of reduced viscosity at high temperatures. The polymer composites were characterized through various analytical techniques, including Fourier-transform infrared (FTIR), H-NMR, X-ray diffraction (XRD), scanning electron microscope (SEM), thermogravimetric analysis (TGA), differential scanning calorimetry (DSC), ζ-potential measurement, molecular weight determination, and rheology measurements. The experimental results of structural and morphological characterization confirm the modification and formation of a new organic carbonate-based cellulose ether. The thermal analysis revealed that the modified composites have greater stability, as the modified samples demonstrated higher vaporization and decomposition temperatures. ζ-potential measurement indicates higher stability of DEC- and PC-modified composites. The relative viscometry measurement revealed that the modification increased the molecular weight of PC- and DEC-containing polymers, up to 93,000 and 99,000 g/moL, respectively. Moreover, the modified composites exhibited higher levels of stability, shear strength and thermal resistance as confirmed by viscosity measurement through rheology determination. The observed increase in viscosity is likely due to the enhanced inter- and intramolecular interaction and higher molecular weight of modified composites. The organic carbonate performed as a transesterification agent that improves the overall properties of cellulose ether (HEMC) at elevated temperatures as concluded from this study. The modification approach in this study will open the doors to new applications and will be beneficial for substantial development in the petroleum industry.

Modeling the evolution of representative dislocation structures under high thermo-mechanical conditions during Additive Manufacturing of Alloys

Mesoscale simulations of discrete defects in metals provide an ideal framework to investigate the micro-scale mechanisms governing the plastic deformation under high thermal and mechanical loading conditions. To bridge size and time-scale while limiting computational effort, typically the concept of representative volume elements (RVEs) is employed. This approach considers the microstructure evolution in a volume that is representative of the overall material behavior. However, in settings with complex thermal and mechanical loading histories careful consideration of the impact of modeling constraints in terms of time scale and simulation domain on predicted results is required. We address the representation of heterogeneous dislocation structure formation in simulation volumes using the example of residual stress formation during cool-down of laser powder-bed fusion (LPBF) of AISI 316L stainless steel. This is achieved by a series of large-scale three-dimensional discrete dislocation dynamics (DDD) simulations assisted by thermo-mechanical finite element modeling of the LPBF process. Our results show that insufficient size of periodic simulation domains can result in dislocation patterns that reflect the boundaries of the primary cell. More pronounced dislocation interaction observed for larger domains highlight the significance of simulation domain constraints for predicting mechanical properties. We formulate criteria that characterize representative volume elements by capturing the conformity of the dislocation structure to the bulk material. This work provides a basis for future investigations of heterogeneous microstructure formation in mesoscale simulations of bulk material behavior.

Triaxial Cell for Determining Shielded Cable Transfer Impedance During Environmental Stress

Transfer impedance is a main characteristic to describe the shielding performance of shielded cables at least up to 1 GHz. Traditionally, methods, such as line-injection and triaxial cell, have been used to characterize it at ambient laboratory conditions. While the ambient laboratory conditions might represent appropriate environmental conditions for some industries, in others, such as automotive, they are only a small subset of the real conditions. Thus, there is a need to characterize the transfer impedance over different environmental conditions. In this article, the authors present and verify a new triaxial cell design that is aimed to provide reliable measurements during high thermal and mechanical stresses. First, the cell performance is compared with a commercial cell at laboratory ambient conditions. Then, measurements are performed with the new cell at highly accelerated life testing conditions. Under these high thermal and mechanical stress conditions, the cell performance is verified, and results on typical shielded cable performance under the same conditions are given.

Evaluation of epoxy-based coating degradation under thermal insulation at elevated temperatures on different steel substrates

Corrosion under insulation (CUI) remains one of the most critical issues in the petrochemical industry. In a typical CUI system, protective coatings (organic or metallic) are used primarily as the last barrier to prevent the rapid corrosion of the metallic substrate. However, organic coatings exposed to high operating temperatures and thermal cycling conditions are susceptible to failure and thus require coating performance evaluations under representative thermal insulation conditions. This study presents experimental designs to investigate the degradation of an organic polyamine-cured epoxy coating under accelerated laboratory test conditions. Additionally, a systematic CUI evaluation protocol for high-temperature organic coating performance is presented. The method involved specially designed apparatus to simulate CUI systems and characterisation techniques, such as visual inspection, adhesion test, peel-off test, scanning electron microscopy, electrochemical impedance spectroscopy, and chemical analysis using Fourier-transform infrared spectroscopy, and differential scanning calorimetry. The results showed that polyamine-based epoxy coating experienced thermal degradation starting at temperatures above 130 °C under mineral wool insulation in accelerated and cyclic CUI tests. Chemical degradation was the primary mode of degradation, with the formation of carbonyl functional groups and increased glass transition temperature observed at higher exposure temperatures. The proposed combination of electrochemical, spectroscopic, mechanical, and microscopy techniques allows quantifying coating performance under insulation and subsequently provides insights into predicting coatings' service lifetime.

Combining Obsolescence and Temperature Stress to Evaluate the Immunity of Voltage Regulators to Direct Power Injection in Long-Lifespan Systems

This letter compares the electromagnetic compatibility (EMC) performance of three different voltage regulator integrated circuits (ICs) (i.e., UA78L05, L78L05, and MC78L05) developed by three different manufacturers, with similar functionality and pin compatibility, under the influence of low and high temperature stress conditions (i.e., −30 °C and +100 °C). Direct power injection (DPI) was performed on these ICs to analyze the impact of applying thermal stress on the conducted immunity to the injection of a single-tone RF disturbance signal. The DPI immunity parameters were measured and recorded in real time for an incident amplified power, while the ICs were exposed to low and high thermal stress conditions. It was demonstrated that the minimum injected power required to reach the defined failure threshold voltage criterion <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$(\pm 4$ </tex-math></inline-formula> %) varied over frequency depending on the ICs. Moreover, these functionally identical ICs showed significant evolution of their conducted immunity in all the considered temperatures, depending on their manufacturer. Input impedance curves were monitored at low, high, and nominal temperatures, showing a noticeable decline of impedance at high frequencies. Moreover, the equivalent <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$RLC$ </tex-math></inline-formula> values of the lumped elements (i.e., resistor, inductor, and capacitor) were extracted and compared at these aforementioned temperature conditions to model the power supply network impedance for the selected ICs. The immunity behavior of these ICs was further investigated by generating lookup table data from the DPI measurements.

A Reactive Molecular Dynamics Study on Crosslinked Epoxy Resin Decomposition under High Electric Field and Thermal Aging Conditions.

To reveal the microscopic mechanism of synergetic thermal-electrical degradation during a partial discharge process in epoxy insulation materials, the decomposition of crosslinked epoxy resin is investigated using reactive molecular dynamics simulations under high electric field and thermal degradation conditions. Bond-boost acceleration method is employed in reactive molecular dynamics simulations to successfully establish epoxy polymer models with a crosslink degree of 93%. Active molecular species derived from electrical partial discharges are considered in the current work. Small molecule products and decomposition temperature in the degradation process under an electric field are calculated to elucidate the effect of nitric acid and ozone molecules, being the active products generated by electrical partial discharges, on the synergetic thermal-electrical degradation of epoxy resin. Both nitric acid and ozone exacerbate thermal impact decomposition of crosslinked epoxy polymer by decreasing initial decomposition temperature from 1050 K to 940 K and 820 K, respectively. It is found that these active products can oxidize hydroxyl groups and carbon-nitrogen bridge bonds in epoxy molecular chains, leading to the aggravation of epoxy resin decomposition, as manifested by the significant increase in the decomposed molecular products. In contrast, thermal degradation of the epoxy resin without the active species is not expedited by increasing electric field. These strongly oxidative molecules are easily reduced to negative ions and able to obtain kinetic energies from electric field, which result in chemical corrosion and local temperature increase to accelerate decomposition of epoxy insulation materials.

Passive Satellite Solar Panel Thermal Control with Long-Wave Cut-Off Filter-Coated Solar Cells

Satellite performance and capability have increased dramatically, particularly for micro- and nanosatellites, requiring more power supply and higher thermal conditions. Problems worth considering include how to provide more power with little or no weight increase, and how to reduce satellite thermal control difficulties. A new way to decrease the temperature of the solar panels on a satellite was proposed. Firstly, the model of solar cells is presented, and the relationship between solar irradiation and the electricity generated explained. Based on this, a new method to reduce the temperature of the solar cell is proposed. Details about current generation and temperature rise calculations for various types of solar cells are also provided. Finally, an experiment was conducted on original and proposed solar cells. While the experiment showed some degree of effectiveness, further experiments are needed.

Rapid photonic curing effects of xenon flash lamp on ITO–Ag–ITO multilayer electrodes for high throughput transparent electronics

High-throughput transparent and flexible electronics are essential technologies for next-generation displays, semiconductors, and wearable bio-medical applications. However, to manufacture a high-quality transparent and flexible electrode, conventional annealing processes generally require 5 min or more at a high temperature condition of 300 °C or higher. This high thermal budget condition is not only difficult to apply to general polymer-based flexible substrates, but also results in low-throughput. Here, we report a high-quality transparent electrode produced with an extremely low thermal budget using Xe-flash lamp rapid photonic curing. Photonic curing is an extremely short time (~ μs) process, making it possible to induce an annealing effect of over 800 °C. The photonic curing effect was optimized by selecting the appropriate power density, the irradiation energy of the Xe-flash lamp, and Ag layer thickness. Rapid photonic curing produced an ITO–Ag–ITO electrode with a low sheet resistance of 6.5 ohm/sq, with a high luminous transmittance of 92.34%. The low thermal budget characteristics of the rapid photonic curing technology make it suitable for high-quality transparent electronics and high-throughput processes such as roll-to-roll.

Burst speed assessment of aero-engine turbine disk based on failure assessment diagram and global stability criterion

Aero-engine turbine disks are safety-relevant components which are operated under high thermal and mechanical stress conditions. The actual part qualification and certification procedures make use of spin-tests conducted on production-similar disks. While these tests provide, on the one hand, a reliable definition of the critical conditions for real components, on the other hand they represent a relevant cost item for engine manufacturers. The aim of this work is to present two alternative burst speed assessment methods under development based on the Failure Assessment Diagram (FAD) and a global stability criterion, respectively. In the scope of the fracture mechanics assessment, the failure modes hoop-burst and rim-peeling are investigated with semi-circular surface cracks modelled at the critical regions on the turbine disk. The comparison of the predicted critical rotational speed shows good agreement between the assessment methods.

Irregular Shape Effect of Brass and Copper Filler on the Properties of Metal Epoxy Composite (MEC) for Rapid Tooling Application

Due to their low shrinkage and easy moldability, metal epoxy composites (MEC) are recognized as an alternative material that can be applied as hybrid mold inserts manufactured with rapid tooling (RT) technologies. Although many studies have been conducted on MEC or reinforced composite, research on the material properties, especially on thermal conductivity and compressive strength, that contribute to the overall mold insert performance and molded part quality are still lacking. The purpose of this research is to investigate the effect of the cooling efficiency using MEC materials. Thus, this research aims to appraise a new formulation of MEC materials as mold inserts by further improving the mold insert performance. The effects of the thermal, physical, and mechanical properties of MEC mold inserts were examined using particles of brass (EB), copper (EC), and a combination of brass + copper (EBC) in irregular shapes. These particles were weighed at percentages ranging from 10% to 60% when mixed with epoxy resin to produce specimens according to related ASTM standards. A microstructure analysis was made using a scanning electron microscope (SEM) to investigate brass and copper particle distribution. When filler composition was increased from 10% to 60%, the values of density (g/cm3), hardness (Hv), and thermal conductivity (W/mK) showed a linear upward trend, with the highest value occurring at the highest filler composition percentage. The addition of filler composition increased the compressive strength, with the highest average compressive strength value occurring between 20% and 30% filler composition. Compressive strength indicated a nonlinear uptrend and decreased with increasing composition by more than 30%. The maximum value of compressive strength for EB, EC, and EBC was within the range of 90–104 MPa, with EB having the highest value (104 MPa). The ANSYS simulation software was used to conduct a transient thermal analysis in order to evaluate the cooling performance of the mold inserts. EC outperformed the EB and EBC in terms of cooling efficiency based on the results of thermal transient analysis at high compressive strength and high thermal conductivity conditions.