Jet Technique Research Articles

Bearing Characteristics of Deep Cement Mixing Integrated Drilling, Mixing and Jetting Piles Based on Numerical Simulation

The Deep Cement Mixing Integrated Drilling, Mixing and Jetting (DMJ) technique has been developed through the installation of high-pressure spray holes at the mixing blades, with the objective of enhancing the bearing capacity of deep-mixed piles in the Yellow River floodplain. In order to enhance the bearing capacity of the foundation, variable-modulus piles and capped piles were incorporated within the DMJ piles. Engineering applications have demonstrated that DMJ piles can effectively address the issue of foundation reinforcement in the Yellow River floodplain region, minimize the wastage of cement, and reduce the environmental pollution associated with waste slurry. Nevertheless, a comprehensive study of the relevant factors is still lacking in the available literature. This study addresses this gap by conducting a numerical simulation of these two types of DMJ piles based on the preliminary field test data, with the objective of analyzing both the single-pile-bearing characteristics and the composite foundation-bearing characteristics. Furthermore, the study seeks to optimize the DMJ pile’s structure based on the simulation results. The findings demonstrate that the premature failure of a single pile during the bearing process can be averted if the modulus of the pile core reaches a minimum of 0.3 GPa or if the pile cap thickness exceeds 1 m. The utilization of large-diameter drilling, stirring and spraying piles can markedly enhance the bearing capacity of the composite foundation and mitigate the differential settlement of pile and soil. The spacing of the pile has been identified as a significant factor influencing the differential settlement of pile and soil. Consequently, this study also examines the impact of pile spacing on the differential settlement of piles and soil.

The concentration influence of multi-walled carbon nanotubes coating on fatigue edge crack growth and other mechanical properties of Al 7075-T6 thin plates

In the current study, the incline edge crack growth behavior in an aluminum alloy 7075-T6 specimens (which were coated using nickel-carbon nanotubes electroless coating) has been investigated undergoes uniaxial tensile fatigue loading. High purity multi walled carbon nanotubes have been used in nano-coating solutions with various concentrations (1 g/l, 2 g/l and 3 g/l) to examine the improvement extent of fatigue crack growth resistance and other mechanical properties. Water jet technique was used to cutting aluminum plates to the required dimensions before the nano-coating procedure. Multi-purpose fatigue apparatus has been adopted to apply tensile fatigue loading with zero stress ratios. High magnification camera with image j software has been utilized to measure the propagated crack lengths with the number of fatigue cycles. To inspection the quality, thickness uniformity and homogeneity of the nano-coating layer over specimen surfaces, EDXRF and FESEM techniques have been adopted in this study. Numerical simulation using ABAQUS 2021 programming was performed for the purpose of the results validation. The measured results offered a 25.9 %, 44.5 % and 47.9 % increasing in the hardness of the coated specimens using 1 g/l, 2 g/l and 3 g/l MWCNTs respectively. The modulus of elasticity produced an increasing of 26.7 %, 44.4 % and 46.3 % for the coated specimens using 1 g/l, 2 g/l and 3 g/l MWCNTs respectively. The nano-coating with 2 g/l MWCNTs produced more homogeneous, uniform thickness coating layer and fatigue crack growth resistance than that of the coated specimens using other concentrations of MWCNTs. The similarity in the crack growth behavior was the major outcome of the results validation from the fatigue tests and numerical simulation.

Angle-of-attack characteristics of opposing jet for improving drag and heat reduction

While the opposing jet technique has the potential to achieve efficient drag and heat reduction, it can be severely affected by the incoming angle of attack. To analyze the angle-of-attack characteristics of opposing jet for improving drag and heat reduction, a three-dimensional blunt model was studied under various jet stagnation pressure ratios and angles of attack using the verified numerical method. The results showed that the enhanced reattachment shock on the windward side resulted in a higher pressure and temperature rise, which led to the deterioration of drag and heat reduction. Under the influence of the incoming angle of attack, the recirculation vortex transformed into a longitudinal vortex, resulting in a slanted U-shaped distribution of the surface pressure coefficient and Stanton number. Increasing the jet stagnation pressure ratio widened the coverage of the recirculation vortex on both the windward and leeward sides, which brought an improvement in drag and heat reduction. The interaction between the incoming angle of attack and the opposing jet caused a double-peak distribution of Stanton number due to the recirculation vortex reattachment and the compression of the incoming flow. The inclined opposing jet could reduce the peak values of pressure coefficient and Stanton number when subjected to the incoming flow with an angle of attack by spreading the recirculation vortex along the windward side. There should exist an optimal inclination angle that can effectively reduce the peak caused by the compression of the incoming flow without generating an excessive peak due to the recirculation vortex reattachment.

Spectroscopic diagnosis of nickel and zinc plasmas produced by plasma jet technique

Spectroscopic diagnosis of nickel and zinc plasmas produced by plasma jet technique

Effects of refined grains and doped nanoparticles on fabricating Al2O3 ceramics using binder jetting

Adding sintering additives to fabricate alumina ceramics via the binder jetting (BJ) technique effectively enhances material properties. However, it is still limited by the disadvantages of low relative density and poor mechanical properties. This study proposed reducing matrix particle size and adding nanoscale particles using binder jetting to address the poor densification and strength of printed alumina (Al2O3) samples. Additionally, their effects on the mechanical properties and manufacturability of the material were explored. Numerical simulations were carried out before the experiments to predict the impact of particle stacking on the powder bed using the discrete element method (DEM). Then, filler particles with an average 40 μm size replaced the original 106 μm-sized Al2O3 particles. Subsequently, Al2O3 nanoparticle content in the samples was gradually increased, and the relevant properties of the sintered samples with different compositions were tested. Consequently, the size of the Al2O3 particles and the addition of Al2O3 nanoparticles significantly affects the physical and mechanical properties of the samples. The sample with 106 μm-sized particles has a compressive strength of 58 MPa, while reducing the particle size to 40 μm increases its compressive strength by 26 %. Moreover, the sample's compressive strength could reach up to 330 MPa, an increase of 513 %, and the hardness reaches 1215 HV (11.91 GPa) by expanding the Al2O3 nanoparticles content to 30 %. Additionally, using Al2O3 nanoparticles further reduces the sintering temperature, significantly improving the practicality of Al2O3 printing using binder jetting.

Additive manufactured parts surface treatment through impinged hot air jet technique the theoretical and experimental evaluation

PurposeMaterial extrusion-based additive manufacturing is a prominent manufacturing technique to fabricate complex geometrical three-dimensional (3D) parts. Despite the indisputable advantages of material extrusion-based technique, the poor surface and subsurface integrity hinder the industrial application of this technology. The purpose of this study is introducing the hot air jet treatment (HAJ) technique for surface treatment of additive manufactured parts.Design/methodology/approachIn the presented research, novel theoretical formulation and finite element models are developed to study and model the polishing mechanism of printed parts surface through the HAJ technique. The model correlates reflow material volume, layer width and layer height. The reflow material volume is a function of treatment temperature, treatment velocity and HAJ velocity. The values of reflow material volume are obtained through the finite element modeling model due to the complexity of the interactions between thermal and mechanical phenomena. The theoretical model presumptions are validated through experiments, and the results show that the treatment parameters have a significant impact on the surface characteristics, hardness and dimensional variations of the treated surface.FindingsThe results demonstrate that the average value of error between the calculated theoretical results and experimental results is 14.3%. Meanwhile, the 3D plots of Ra and Rq revealed that the maximum values of Ra and Rq reduction percentages at 255°C, 270°C, 285°C and 300°C treatment temperatures are (35.9%, 33.9%), (77.6%,76.4%), (94%, 93.8%) and (85.1%, 84%), respectively. The scanning electron microscope results illustrate three different treatment zones and the treatment-induced and manufacturing-induced entrapped air relief phenomenon. The measured results of hardness variation percentages and dimensional deviation percentages at different regimes are (8.33%, 0.19%), (10.55%, 0.31%) and (−0.27%, 0.34%), respectively.Originality/valueWhile some studies have investigated the effect of the HAJ process on the structural integrity of manufactured items, there is a dearth of research on the underlying treatment mechanism, the integrity of the treated surface and the subsurface characteristics of the treated surface.

Optimization of unsteady jet control flow method for aerodynamic drag reduction of heavy truck model

The aerodynamic drag reduction of ground vehicles is crucial for meeting the increasingly strict emission standards. In this context, a potential approach to achieve this objective is to use active flow control techniques. Many active flow control techniques have been applied for ground vehicles, and the unsteady jet device has been proven to have better control energy efficiency than some other flow actuators. Therefore, this study focuses on applying this unsteady jet technique to a realistic truck model. The main parameters of the control flow device, including jet amplitude, jet angle, and control frequency were optimized to reduce the aerodynamic drag of the truck model and achieve the maximum control energy efficiency. Numerical studies were performed based on the CFD method with the k-ω SST turbulence model. A 25-level optimal Latin Hypercube design experimental study was conducted. The optimization method based on the Kriging response surface model and genetic algorithm was chosen to determine the optimal solution. The results show that the maximum energy efficiency is 9.174 % using the unsteady jet devices with the optimal parameters on the small-scale truck model.

Additive Manufacturing of Rare Earth Permanent Magnetic Materials: Research Status and Prospects

With the rapid development of intelligent manufacturing, modern components are accelerating toward being light weight, miniaturized, and complex, which provides a broad space for the application of rare earth permanent magnet materials. As an emerging near-net-shape manufacturing process, additive manufacturing (AM) has a short process flow and significantly reduces material loss and energy consumption, which brings new possibilities and impetus to the development of rare earth permanent magnetic materials. Here, the applications of AM technology in the field of rare earth permanent magnets in recent years are reviewed and prospected, including laser powder bed fusion (LPBF), fused deposition modeling (FDM), and binder jetting (BJ) techniques. Research has found that the magnetic properties of AM Nd-Fe-B magnets can reach or even exceed the traditional bonded magnets. In addition, in situ magnetic field alignment, in situ grain boundary infiltration, and post-processing methods are effective in enhancing the magnetic properties of AM magnets. These results have laid a good foundation for the development of AM rare earth permanent magnets.

Electric Field-Driven Jetting and Water-Assisted Transfer Printing for High-Resolution Electronics on Complex Curved Surfaces

High-resolution electronics on complex curved surfaces have wide applications in fields such as biometric health monitoring, intelligent aircraft skins, conformal displays, and biomimetics. However, current manufacturing processes can only adapt to limited curvature, posing a significant challenge for achieving high-resolution fabrication of electronics on complex curved surfaces. In this study, we propose a novel fabrication strategy that combines electric field-driven jetting and water-assisted transfer printing techniques to achieve the fabrication of high-resolution electronics on complex curved surfaces. The electric field-driven jetting enables the fabrication of high-resolution 2D electronics on sacrificial layer substrates. After dissolving the sacrificial layer, it is observed that the 2D electronics form a self-supporting structure with a certain rigidity and flexibility. During the water-assisted transfer printing process, this self-supporting structure undergoes stretching deformation with excellent conformity of the electronics to curved surfaces while effectively minimizing wrinkles. Finally, we successfully demonstrate the manufacture of 25 μm high-resolution electronics on highly curved surfaces (nautilus shell) and complex (scallop shell, stone) surfaces. The integrity of transferred circuit patterns and consistency of conductors are verified through infrared thermography analysis, confirming the feasibility of this manufacturing strategy. In addition, a protective film with strong adhesive properties is sprayed onto the transferred curved circuits to enhance their adhesion and resistance to extreme environments such as acids and alkalis. Our proposed technique provides a simple and effective new strategy for the fabrication of high-resolution electronics on complex curved surfaces.

Highly sensitive detection of the neurodegenerative biomarker Tau by using the concentration effect of the pyro-electrohydrodynamic jetting

It is largely documented that neurodegenerative diseases can be effectively treated only if early diagnosed. In this context, the structural changes of some biomolecules such as Tau, seem to play a key role in neurodegeneration mechanism becoming eligible targets for an early diagnosis. Post-translational modifications are responsible to drive the Tau protein towards a transition phase from a native disorder conformation into a preaggregation state, which then straight recruits the final fibrillization process. Here, we show for the first time the detection of pre-aggregated Tau in artificial urine at femto-molar level, through the concentration effect of the pyro-electrohydrodynamic jet (p-jet) technique. An excellent linear calibration curve is demonstrated at the femto-molar level with a limit of detection (LOD) of 130 fM. Moreover, for the first time we show here the structure stability of the protein after p-jet application through a deep spectroscopic investigation. Thanks to the small volumes required and the relatively compact and cost-effective characteristics, this technique represents an innovative breakthrough in monitoring the early stage associated to neurodegeneration syndromes in different scenarios of point of care (POC) and such as for example in long-term human space exploration missions.

Effect of surface roughness on large-scale downburst-like impinging jets

Downbursts are cold descending winds that develop from thunderstorm clouds and, after impingement on the ground, produce an intense low-level horizontal front characterized by an axisymmetric toroidal vortex structure. Surface roughness is a key factor in the characterization of mean and turbulent wind speed features of synoptic-scale stationary atmospheric boundary layer winds. The goal of the present research is to physically assess whether the same can apply to the surface layer produced during thunderstorms, which are non-stationary, highly time-transient, and spatially limited phenomena. Downburst-like flows were produced through the impinging jet technique at the WindEEE Dome, at Western University in Canada. Three different surfaces were tested, and an equivalent full-scale roughness length (z0,eq) was determined. Experimental records are made publicly available. The large geometric and kinematic scales produced high Reynolds numbers, which enabled us to classify the flow as “fully turbulent” and therefore representative of full-scale downbursts. Results indicate a weak dependency on the Reynolds number, which suggests no relevant flaws in extending the results to the natural environment. The overall wind speed maxima weakly depend on z0, whereas a sharp velocity decrease is observed beyond the radial position of the maxima with increasing z0. Surface roughness enhances the boundary layer separation and consequently elevates the height of maximum wind speed above the surface. Vertical profiles of the horizontal velocity return a quite clear nose shape. Turbulence intensity shows a C-like shape with maxima in the near proximity of the ground that increase with z0.

Well perforation optimization using an abrasive jet technique to create oriented slotted channels in terrigenous reservoirs

Various casing perforation methods are used to ensure a hydrodynamic reservoir-to-well connection. However, perforated wells often do not perform satisfactorily during production. This is largely due to a decrease in the permeability of the near-wellbore formation as a result of casing perforation work. Studies and analysis of existing casing perforation methods have shown the effectiveness of abrasive jet perforation. The paper presents the results of numerical modeling to optimize the layout of slot channels during the abrasive jet perforation (AJP) of terrigenous productive object. Geomechanics analysis of the influence the formation scheme and orientation of the slotted channels in the productive layer during abrasive jet perforation on the permeability of terrigenous reservoirs of the oil fields in the Perm Krai was performed. The disadvantages of widespread methods of exposing perforation are described and the advantages of abrasive jet perforation based on geomechanical modeling are revealed. The calculations carried out on the placement of slotted channels showed that the distance between the systems of slotted channels is not important, since they weakly interact with each other in height with standard schemes. It was established that the best placement scheme for jet slot channels is a system of four slot channels shifted along the length of the well to the height of the slot channel with a phasing of 90°. Comparative calculations of the reservoir permeability of the near-well zone for various perforation methods have been performed.

Mixing time of homogeneous/heterogeneous solutions in a micro-mixer with free impinging jets

Abstract We have developed a micro-mixer based on a free impinging liquid-sheet jet technique. We identified a mixing position where two different solutions were mixed uniformly and evaluated corresponding mixing times in the liquid-sheet jets, with a homogeneous combination (H2O and H2O) and heterogeneous combination (C2H5OH and H2O). A quenching reaction was observed and the mixing times were evaluated to be 36 μs for the homogeneous combination (H2O/H2O) and 46 μs for the heterogeneous combination (C2H5OH/H2O). To clarify the mixing mechanism in the liquid-sheet jet, the theoretical mixing times were calculated using two different models, assuming laminar and turbulence flows. The calculated mixing times based on energy dissipation in the turbulence flow were in agreement with the observed mixing times for both H2O/H2O and C2H5OH/H2O combinations. These results indicate that turbulent mixing is a dominant mixing mechanism in the liquid-sheet jet, and that no clear interface is formed between H2O solutions and between C2H5OH and H2O solutions. The liquid-sheet jet technique provides a windowless and ultra-thin target and would be useful to investigate intermediates in mixing-driven chemical reactions, such as oxidation in solution and a folding reaction of proteins proceeding in a microsecond time scale.

Ternary low-friction coatings on thermoplastics by plasma spraying: Investigations on the process-structure

Thermally sprayed MoS2/graphite/Zn coatings were developed by the atmospheric pressure plasma jet technique to investigate the process-structure-relationship of the low-friction coatings. The fine-tuning of the powder carrier gas flow to the plasma jet was supported by computational fluid dynamics and revealed the impact on the powder particles within the coating process i.e. ideal powder particle temperature for transferring the solid Zn powder into the liquid state as main requirement for a successful embedding process of the dry lubricants. MoS2/graphite/Zn composite coatings were deposited on polyamide 4.6 (PA4.6) substrates to evaluate the adhesion/cohesion properties and tribological performance by tuning the current of the atmospheric pressure plasma jet (APPJ) from 125 A to 150 A. In particular, the plasma spraying distribution of the composite feedstock and the resulting coating architecture are strongly dependent on the plasma process setting, which are investigated by scanning electron microscopy and transmission electron microscopy in combination with an energy-dispersive x-ray spectrometer. Tribological characterisation indicates that coating composition and thickness influence the coating performance significantly. According to the 125 A plasma current setting, the low frictional compounds MoS2 and graphite are embedded in a Zn matrix in contrast to plasma current settings of 150 A, where Zn is embedded in a MoS2 and graphite matrix and demonstrates excellent low frictional properties.

Novel hard rock breaking technique using ultra-high-frequency particle impact induced by ultrasonic vibration field

With the gradual increase in drilling and mining depth in geothermal, oil, and other fossil energy explorations, complex geological environments (especially hard strata) have forced researchers to develop high-efficiency rock-breaking techniques. Inspired by the dynamic impact theory and the particle jet technique, an ultrasonic vibration field-induced ultra-high-frequency particle impact rock-breaking (UPIRB) technique was proposed to solve these problems. After being subjected to ultrasonic vibration, the small-sized particles generate ultra-high frequency and high impact stress on the rock sample, which can significantly promote rock degradation and improve rock-breaking efficiency. A comparative study between UPIRB and traditional ultrasonic vibration rock-breaking (UVRB) techniques in terms of rock-breaking efficiency was conducted using a series of physical experiments and two-dimensional discrete element numerical simulations. The results showed that owing to the small contact area due to small size particles, UPIRB has incomparable advantages compared with traditional UVRB: its impact stress level is improved by more than ten times, the rock-breaking time is shortened from minutes (2–3 min) to seconds (2–4 s), and the rock-breaking efficiency is improved nearly ten-fold, overcoming the disadvantages of UVRB. This study proposed a novel and efficient rock-breaking technique for energy exploration engineering.

Experimental translating downbursts immersed in the atmospheric boundary layer

Thunderstorm winds are cold descending gravity currents whose impingement on the ground creates strong radial outflows with maximum wind speeds in the near-ground region. They represent one of the greatest hazards for natural and built environment as well as one of the deadliest phenomena all over the world. This study carries on the post-processing analyses of the downburst experimental campaign performed at the WindEEE Dome, at Western University in Canada, in the context of the ERC project THUNDERR. While a former study presented the interaction between downburst and atmospheric boundary layer (ABL) winds, here the focus is on the influence exerted by the thunderstorm cloud translation. This was experimentally replicated at large scale by means of impinging jet technique where the jet axis was inclined to a non-zero angle with respect to the vertical. Finally, the inclusion of background ABL wind allowed to reconstruct the complete three-dimensional and non-stationary nature of the phenomenon. The outflow radial symmetry is lost in case of inclined jet axis. This leads to an intensification of the front-wind side and weakening of the rear-wind side, where the entrainment of the counter-directed ABL wind, and consequent flow speed-up, are not as pronounced as in the vertical-axis case. The non-linearity of the complex interaction between downburst, ABL flow and cloud translation is proven and quantified. Vertical profiles of mean wind speed and turbulence intensity are discussed in relation to the mutual interaction among flow components.

Lamellar particle self-assembling of graphene oxide into continuous thin and thick films by automated atmospheric pressure plasma jet deposition

This work shows the achievement of obtaining graphene oxide coatings deposited under ambient conditions using the plasma jet technique at atmospheric pressure in an automated system with robotic arms. Graphene oxide nanoparticles in an aqueous solution were sonicated to obtain a colloidal solution. This was projected in an ultrasonic mist perpendicularly through an air plasma of about 260 °C. The primary process parameters were deposition time, speed, concentration, and distance to obtain coating thickness from about 100 nm to microns. These were homogeneous and adherent coatings on aluminum, steel, glass, and polymers (PMMA and polycarbonate), showing similar characteristics on all these substrates. The highlight of this contribution is transforming nanometric thickness flakes into continuous layers with chemical bonding to surfaces with contrasting characteristics such as those mentioned. The GO obtained layer differs from those obtained by spin-coating, dipping, drop-casting, or electrophoretic deposition. We propose that APPJ eliminates OH radicals around the particles, allowing them to self-assemble by connecting them through bonds. This work probes the feasibility of depositing horizontally/vertically self-assembled GO on polymers and aluminum in a modular industrial facility. This achievement opens the possibility of transferring the characteristics of graphene oxide to surfaces for industrial use, making nanotechnology accessible for social benefit.

Creation of expanded diameter gravel wells in unconsolidated for-mations for High-Temperature Aquifer Thermal Energy Storage Sys-tems: Theoretical and numerical evaluation of borehole stability

High-Temperature Aquifer Thermal Energy Storage (HT-ATES) systems have the potential to cost-effectively store large volumes of thermal energy, bridging the supply-demand gap for variable renewable heat sources, such as solar thermal or power-2-heat conversion [3, 4]. These systems involve the injection and extraction of heated and cooled groundwater in aquifers via tube wells [11]. A HT-ATES system will be showcased at TU Delft, which involves the use of an Expanded Diameter Gravel Well (EDGW) to increase well capacity and reduce mechanical clogging compared to conventional wells [9]. This has the potential to reduce the number of wells needed and lower the costs of the HT-ATES system.
 An EDGW has previously been constructed at depth in unconsolidated formations using a jetting technique for borehole expansion [8]. This well (expanded 2.6 fold from 600 mm to 1570 mm diameter) was taken into routine operation for drinking water production. A second expanded borehole (expanded 4.1 fold from 600 to 2460 mm diameter) collapsed upon testing the enhanced removal of the filter cake before it could be completed as EDGW. The missing explanation for the collapse of the second well highlights a knowledge gap regarding the stability of an expanded diameter borehole in unconsolidated formations. To prevent collapse of future expanded boreholes and to better manage the drilling process, this study aims to investigate the effects of an enlarged diameter on well stability through a theoretical analysis.
 The stability of the EDGW borehole is evaluated in two ways, see Figure 1 for a schematic of the workflow. Firstly, the effects of an enlarged diameter on the stability of the well are evaluated analytically using a poroelastic framework [1, 2, 7]. Different conditions are taken into account regarding the stress state, mud pressure, and hydraulic conductivity of the aquifer. Secondly, field test conditions for the anticipated EDGW in the HT-ATES system are simulated numerically using the two and three-dimensional finite element software. The EDGW to be built in Delft, will be constructed within the Maassluis formation. The target aquifer is located at a depth of 120 – 182 m and is mainly composed of sandy units [5]. The simulation is divided into an initial, drilling, and open borehole (seepage) stage [6, 10]:
 
 During the initial stage, in-situ stresses and pore pressures are applied.
 The well bore volume will be removed during the drilling stage, resulting in a stress state that is no longer in equilibrium, and a mud pressure is applied to the borehole wall.
 For the open borehole prior to backfilling stage, the effect of time-dependent fluid flow due to mud losses is evaluated on well stability.
 
 During the open borehole stage, both situations with and without the presence of a filter cake (varying in thickness and hydraulic permeability) will be evaluated. Furthermore, the effect of the presence of thin clay/silt layers on the stability problem will also be taken into account, where special attention is paid to the roof of the well.
 The final results of this study are presented in the form of critical conditions regarding stress state, required mud pressure, and hydraulic conductivity for enlarged diameter boreholes in unconsolidated formations. Additionally, a design for the EDGW field test as part of the HT-ATES system in Delft is proposed, taking into account uncertainties such as the in-situ stress state and strength parameters of the formation.

Effects of WEDM and AWJ cutting methods on induction motor efficiency and total magnetic losses: Experimental design and response surface methodology

In this study, the effect of cutting electrical steel laminations using abrasive water jet (AWJ) and wire electrical discharge machining (WEDM) techniques on 5.5 kW induction motor efficiency (MEfficiency) and total magnetic losses (TLosses) was investigated. After the stator and rotor packages were formed, winding, varnishing and mechanical assembly processes were carried out and the motors were prepared for MEfficiency and TLosses tests according to the IEC 60034-2-1-1A standard. Tests were performed using different frequencies (f) and motor loading rates (MLoad). While burr formation was observed with the effect of plastic deformation on the cutting edge of electrical steels with AWJ, recast layer formation was observed with the effect of heat in WEDM. MEfficiency decreased while TLosses increased due to increasing f and MLoad in both cutting methods. Maximum MEfficiency and minimum TLosses values were measured in WEDM, it was determined that optimum results using Response Surface Methodology (RSM) were measured at f of 50 Hz and MLoad of 100% values in both cutting methods. The statistical effects of f and MLoad on MEfficiency and TLosses were revealed with ANOVA (Analysis of variance). In addition, mathematical models were developed for the prediction of MEfficiency and TLosses.

Effect of build angle on the dimensional accuracy of monolithic zirconia crowns fabricated with the nanoparticle jetting technique

The build angle is an essential parameter in additive manufacturing. Its effect on the dimensional accuracy of zirconia restorations fabricated using the nanoparticle jetting (NPJ) technique is unknown. The purpose of this in vitro study was to evaluate the effect of the build angle on the dimensional accuracy of monolithic zirconia complete crowns fabricated by using NPJ. Standardized artificial right maxillary incisors and mandibular first molars were prepared for ceramic complete crowns. In total, 100 monolithic zirconia crowns were fabricated using NPJ at build angles of 0, 45, 90, 135, and 180 degrees (n=10/angle for incisors and molars). The dimensional accuracies in the external, marginal, and intaglio regions were determined by superimposing the scanned data and computer-aided design data on the crowns. Root mean square (RMS) values were used to analyze the accuracy of the zirconia crowns overall and at the external, marginal, and intaglio surfaces. The Shapiro-Wilk test was used to examine the normality of data distribution. Differences among test groups were assessed using a 1-way analysis of variance and the post hoc least significant difference test (α=.05). Significant differences were found in the accuracy of monolithic zirconia incisor and molar complete crowns in the external, marginal, and intaglio regions among the 5 build angles (P<.05). For incisors, the external RMS value was lowest for a build angle of 45 degrees (18.2 ±3.0µm), the marginal and intaglio RMS values were lowest for a build angle of 135 degrees (47.4 ±10.7 and 26.5 ±6.1µm, respectively), and the overall RMS values did not differ significantly among the 5 build angles (P>.05). For molars, build angles of 0 degrees and 180 degrees yielded the lowest RMS values overall (22.3 ±1.5 and 21.8 ±3.2µm, respectively) and in the external (23.2 ±2.9 and 22.3 ±2.5µm, respectively) and intaglio (22.2 ±3.7 and 21.2 ±4.6µm, respectively) regions. No significant difference was observed in the marginal area among the 5 build angles (P>.05). The overall RMS values reflecting dimensional accuracy for the 5 build angles were between 23.5 and 26.7µm for incisors and 21.8 and 26.2µm for molars. The dimensional accuracy of monolithic zirconia crowns fabricated by using NPJ was affected by the build angle and was within clinically acceptable limits.