Manufacturing Conditions Research Articles

Preparation of an Organosilicon‐Modified Micro‐Nano Symbiotic Superhydrophobic Surface by a One‐Step Spray Method

AbstractSuperhydrophobic surfaces' long‐term applications and environmentally friendly manufacturing processes are long popular but challenging research topics. In this work, three functionalized silane coupling agents (SCAs) are developed that possess both surface activity and coupling properties and are perfectly tailored to the manufacturing conditions of superhydrophobic surfaces. The SCAs containing polyether groups are produced on the basis of hydrosilylation without the use of fluorosilane. They are also employed for the in situ synthesis of low surface energy nano‐SiO2 solutions, which are then sprayed onto the surfaces of various substrates to create stable and wear‐resistant protective layers. This demonstrates the Cassie–Baxter wetting model. The polyether groups' chain length, morphology, and degree of polymerization allow for the free adjustment of the layers' superhydrophobicity. Methyl blue, ink, and glycerinum have contact angles (CAs) of 153.01°, 152.09°, and 150.02°, and the sliding angles (SAs) are 2°, 2°, and 4°, respectively. Furthermore, in tests of durability and corrosion resistance, the CAs typically stay above 150°, demonstrating superior superhydrophobicity capabilities. The large‐scale replication of the fluorine‐free production process of the superhydrophobic layers discussed in this work is crucial for the expansion of practical applications.

The influence of citrate buffer molarity on mRNA-LNPs: Exploring factors beyond general critical quality attributes

Lipid nanoparticles (LNPs) are crucial in delivering mRNA vaccines and therapeutics. The properties of LNPs can be influenced by the choice of lipids and the manufacturing conditions, such as mixing parameters, lipid concentration, and the type and concentration of the aqueous buffer used. In this study, we investigated the impact of the citrate buffer molarity, the buffer commonly used to dissolve mRNA in the preparation of mRNA-LNPs. We prepared SM-102 LNPs containing firefly luciferase mRNA using citrate buffers at molarities of 50 mM, 100 mM, or 300 mM. Our findings revealed that varying the molarity of the citrate buffer did not significantly affect the particle size when considering the average diameter (z-average or Mode). All formulations exhibited low polydispersity index (PDI) and high encapsulation efficiency. Detailed analysis of particle size sub-populations (D10, D50, and D90) and morphology indicated that citrate buffer concentration might influence lipid packing during LNP production, though these differences were subtle. However, using higher citrate molarity (300 mM) to produce LNPs notably reduced cellular internalisation and in vitro transfection efficiency. This trend was also observed in vivo, where similar expression levels were noted in mice receiving the 50 mM and 100 mM LNP formulations, but lower expression was seen for the 300 mM formulation. Our study highlights the importance of buffer molarity in the aqueous phase during mRNA-based LNP preparation and that generally reported critical quality attributes (CQAs) for LNPs may not detect subtle formulation differences.

Electrolyte Design Enables Stable and Energy‐Dense Potassium‐Ion Batteries

AbstractFree from strategically important elements such as lithium, nickel, cobalt, and copper, potassium‐ion batteries (PIBs) are heralded as promising low‐cost and sustainable electrochemical energy storage systems that complement the existing lithium‐ion batteries (LIBs). However, the reported electrochemical performance of PIBs is still suboptimal, especially under practically relevant battery manufacturing conditions. The primary challenge stems from the lack of electrolytes capable of concurrently supporting both the low‐voltage anode and high‐voltage cathode with satisfactory Coulombic efficiency (CE) and cycling stability. Herein, we report a promising electrolyte that facilitates the commercially mature graphite anode (>3 mAh cm−2) to achieve an initial CE of 91.14 % (with an average cycling CE around 99.94 %), fast redox kinetics, and negligible capacity fading for hundreds of cycles. Meanwhile, the electrolyte also demonstrates good compatibility with the 4.4 V (vs. K+/K) high‐voltage K2Mn[Fe(CN)6] (KMF) cathode. Consequently, the KMF||graphite full‐cell without precycling treatment of both electrodes can provide an average discharge voltage of 3.61 V with a specific energy of 316.5 Wh kg−1−(KMF+graphite), comparable to the LiFePO4||graphite LIBs, and maintain 71.01 % capacity retention after 2000 cycles.

Electrolyte Design Enables Stable and Energy-Dense Potassium-Ion Batteries.

Free from strategically important elements such as lithium, nickel, cobalt, and copper, potassium-ion batteries (PIBs) are heralded as promising low-cost and sustainable electrochemical energy storage systems that complement the existing lithium-ion batteries (LIBs). However, the reported electrochemical performance of PIBs is still suboptimal, especially under practically relevant battery manufacturing conditions. The primary challenge stems from the lack of electrolytes capable of concurrently supporting both the low-voltage anode and high-voltage cathode with satisfactory Coulombic efficiency (CE) and cycling stability. Herein, we report a promising electrolyte that facilitates the commercially mature graphite anode (>3 mAh cm-2) to achieve an initial CE of 91.14 % (with an average cycling CE around 99.94 %), fast redox kinetics, and negligible capacity fading for hundreds of cycles. Meanwhile, the electrolyte also demonstrates good compatibility with the 4.4 V (vs. K+/K) high-voltage K2Mn[Fe(CN)6] (KMF) cathode. Consequently, the KMF||graphite full-cell without precycling treatment of both electrodes can provide an average discharge voltage of 3.61 V with a specific energy of 316.5 Wh kg-1-(KMF+graphite), comparable to the LiFePO4||graphite LIBs, and maintain 71.01 % capacity retention after 2000 cycles.

Emulsifiers: Their Influence on the Rheological and Texture Properties in an Industrial Chocolate.

The complexity of the chocolate matrix leads to it having characteristic rheological properties that may pose difficulties for its industrial manufacture. Many factors influence the flow behaviour of chocolates, such as raw materials, the amount of fat, the moisture content, particle-size distribution, the concentration of emulsifiers, or manufacturing conditions, among others. This study focusses on the rheological properties of an industrially manufactured chocolate with a 48% cocoa content, and the effect caused by the addition of two emulsifiers (soya lecithin and polyglycerol polyricinoleate (PGPR)) on the rheological properties. In the case of lecithin, a clear effect has been observed on the plastic viscosity and the yield stress. Plastic viscosity decreases until a concentration of 0.6% lecithin is reached, and thereafter remains relatively constant, while yield stress increases over the studied range. This effect is not observed when PGPR is used as the emulsifying agent. In this case, a small concentration of PGPR decreases the yield stress. Thixotropy was determined using the Casson model, and its behaviour was found to be similar to that of plastic viscosity with respect to changes in the PGPR and lecithin concentrations. Textural determinations were also carried out, relating the rheology characteristics to the texturometry.

Microstructure and mechanical properties of thin-walled TA1 titanium pipes fabricated by high-frequency induction welding

High frequency induction welding (HFIW) was effectively employed for the high-speed fabrication of thin-walled TA1 titanium pipes (TWTPs) with a nominal wall thickness of ∼0.6 mm. The microstructure and mechanical properties of TWTPs manufactured under varying welding parameters were investigated. The weld zone (WZ) exhibits a waist shape measuring ∼622 μm in width, and the width of the heat-affected zone (HAZ) spans between 763 and 864 μm. Both the WZ and HAZ are composed of a mixture of coarse serrated α grains with fine acicular and twins, while the BM retains equiaxed grains. This unique microstructure was resulted from the thermal cycling during HFIW, contributing to a notable increase in microhardness within the WZ compared to both the HAZ and the BM. Optimal manufacturing conditions were identified at a welding power of 14.4 kW, a welding speed of 60 m/min, an opening angle of 6°, and a squeeze displacement of 0.2 mm, yielding the TWIP with a tensile strength of ∼307 MPa and tensile elongation of ∼27%. Tensile fracture analysis revealed that failure predominantly occurred within the BM, underlining a ductile fracture mode characterized by pronounced dimple formations. The enhanced mechanical performance of the weld joints can be attributed to the heterogenous microstructure in the WZ, where the presence of large serrated α-grains enhances ductility, and the fine martensite and twins contribute to the high strength.

Optimization of Reactive Ink Formulation for Controlled Additive Manufacturing of Copolymer Membrane Functionalization.

Multifunctional, nanostructured membranes hold immense promise for overcoming permeability-selectivity trade-offs and enhancing membrane durability in challenging molecule separations. Following the fabrication of copolymer membranes, additive manufacturing technologies can introduce reactive inks onto substrates to modify pore wall chemistries. However, large-scale implementation is hindered by a lack of systematic optimization. This study addresses this challenge by elucidating the membrane functionalization mechanisms and optimal manufacturing conditions using a copper(I)-catalyzed azide-alkyne cycloaddition (CuAAC) "click" reaction. Leveraging a data science toolkit (e.g., nonlinear regression, uncertainty quantification, identifiability analyses, model selection, and design of experiments), we developed two mathematical models: (1) algebraic equations to predict equilibrium concentrations after preparing reactive inks by mixing copper sulfate, ascorbic acid (AA), and an alkynyl-terminated reactant; and (2) reaction-diffusion partial differential equations (PDEs) to describe the functionalization process. The ink preparation chemistry with side reactions was validated through pH and UV-vis measurements, while the diffusion and kinetic parameters in the PDE model were calibrated using time-series conversion of the azide moieties inferred from Fourier-transform infrared spectroscopy. This modeling framework avoids redundant experimental efforts and offers a functionalization protocol for scaling up designs. Ink optimization problems were proposed to reduce the use of expensive and environmentally insulting ink materials, i.e., Cu(II), while ensuring the desired chemical distributions. With optimal ink formulation Cu(II)/AA/alkyne = 1:1:2 identified, we uncovered trade-offs between Cu(II) usage and functionalization time; for example, in continuous roll-to-roll manufacturing with a conserved functionalization bath setup, our optimal operational conditions to achieve ≥90% functionalization enable at least a 20% reduction in total copper investment compared to previous experimental results. The data science-enabled ink optimization framework is extendable for on-demand multifunctional membranes in numerous future applications such as metal recovery from wastewater and brine.

Ion Beam-Induced Luminescence (IBIL) for Studying Manufacturing Conditions in Ceramics: An Application to Ceramic Body Tiles.

The first experimental results obtained by the ion beam-induced luminescence technique from the ceramic bodies of ancient tiles are reported in this work. The photon emission from the ceramic bodies is related to the starting minerals and the manufacturing conditions, particularly the firing temperature and cooling processes. Moreover, the results indicate that this non-destructive technique, performed under a helium-rich atmosphere instead of an in-vacuum setup and with acquisition times of only a few seconds, presents a promising alternative to traditional, often destructive, compositional characterisation methods. Additionally, by adding other ion beam-based techniques such as PIXE (Particle-Induced X-ray Emission) and PIGE (Particle-Induced Gamma-ray Emission), compositional information from light elements such as Na can also be inferred, helping to also identify the raw materials used.

Microglia morphological response to mesenchymal stromal cell extracellular vesicles demonstrates EV therapeutic potential for modulating neuroinflammation

BackgroundMesenchymal stromal cell derived extracellular vesicles (MSC-EVs) are a promising therapeutic for neuroinflammation. MSC-EVs can interact with microglia, the resident immune cells of the brain, to exert their immunomodulatory effects. In response to inflammatory cues, such as cytokines, microglia undergo phenotypic changes indicative of their function e.g. morphology and secretion. However, these changes in response to MSC-EVs are not well understood. Additionally, no disease-relevant screening tools to assess MSC-EV bioactivity exist, which has further impeded clinical translation. Here, we developed a quantitative, high throughput morphological profiling approach to assess the response of microglia to neuroinflammation- relevant signals and whether this morphological response can be used to indicate the bioactivity of MSC-EVs.ResultsUsing an immortalized human microglia cell-line, we observed increased size (perimeter, major axis length) and complexity (form factor) upon stimulation with interferon-gamma (IFN-γ) and tumor necrosis factor-alpha (TNF-α). Upon treatment with MSC-EVs, the overall morphological score (determined using principal component analysis) shifted towards the unstimulated morphology, indicating that MSC-EVs are bioactive and modulate microglia. The morphological effects of MSC-EVs in TNF-α /IFN-γ stimulated cells were concomitant with reduced secretion of 14 chemokines/cytokines (e.g. CXCL6, CXCL9) and increased secretion of 12 chemokines/cytokines (e.g. CXCL8, CXCL10). Proteomic analysis of cell lysates revealed significant increases in 192 proteins (e.g. HIBADH, MEAK7, LAMC1) and decreases in 257 proteins (e.g. PTEN, TOM1, MFF) with MSC-EV treatment. Of note, many of these proteins are involved in regulation of cell morphology and migration. Gene Set Variation Analysis revealed upregulation of pathways associated with immune response, such as regulation of cytokine production, immune cell infiltration (e.g. T cells, NK cells) and morphological changes (e.g. Semaphorin, RHO/Rac signaling). Additionally, changes in microglia mitochondrial morphology were measured suggesting that MSC-EV modulate mitochondrial metabolism.ConclusionThis study comprehensively demonstrates the effects of MSC-EVs on human microglial morphology, cytokine secretion, cellular proteome, and mitochondrial content. Our high-throughput, rapid, low-cost morphometric approach enables screening of MSC-EV batches and manufacturing conditions to enhance EV function and mitigate EV functional heterogeneity in a disease relevant manner. This approach is highly generalizable and can be further adapted and refined based on selection of the disease-relevant signal, target cell, and therapeutic product.

An Extensive Study of Metal Matrix Composites and their Various Properties for Different Uses

This study examines the creation and development of composite materials, from conventional techniques to their innovative uses in numerous industries. Composite materials that are robust, versatile, and resilient have advanced significantly, especially with the application of nanotechnology and hybrid fiber reinforcements. Composite materials are difficult to machine due to their anisotropic and non-homogeneous structure, as well as the high abrasiveness of their reinforcing parts. This typically results in the workpiece becoming damaged and the cutting tool wearing down very rapidly. On composite materials, traditional machining methods such as turning, drilling, and milling can be applied with the appropriate tool design and operating parameters. An overview of the various issues related to the conventional machining of the main types of composite materials is given in this work. This article examines novel matrix materials, forms of reinforcement, and production procedures to show how advanced metallic matrix nano composites and fiber-reinforced polymers are replacing traditional composites. Special emphasis is given to the strict manufacturing conditions in addition to the homogenous dispersion of nanoparticles and damage-free machining of fiber composite materials. The essay also discusses how sustainable alternatives, including reinforcements made of natural fibers, affect the ecosystem. This study aims to offer a comprehensive analysis and case studies.

Impact of Clinical and Pharmacological Parameters on Faecal Microbiota Transplantation Outcome in Clostridioides difficile Infections: Results of a 5-Year French National Survey.

Detailed comparative assessment of procedure-related factors associated with faecal microbiota transplantation (FMT) efficacy in Clostridioides difficile infection (CDI) is limited. We took advantage of the differences in procedures at the various French FMT centres to determine clinical and procedure-related factors associated with FMT success in CDI. We performed a nationwide retrospective multicentre cohort study. All FMTs performed within The French Faecal Transplant Group for CDI from 2018 to 2022 were included. Clinical data were collected retrospectively from recipient medical files, characteristics of stool transplant preparations were prospectively collected by each Pharmacy involved. Univariate and multivariate analyses were performed using Fisher's test and multiple logistic regression. Six hundred fifty-eight FMTs were performed for 617 patients in 17 centres. The overall efficacy of FMT was 84.3% (520/617), with 0.5% of severe adverse events possibly related to FMT (3/658). Forty-seven patients were treated at the first recurrence of CDI with a similar success rate (85.1%). Severe chronic kidney disease (CKD; OR: 2.18, 95%CI [1.20-3.88]), non-severe refractory CDI (OR: 15.35, [1.94-318.2]), the use of ≥ 80% glycerol (OR: 2.52, [1.11-5.67]), insufficient bowel cleansing (OR: 5.47, [1.57-20.03]) and partial FMT retention (OR: 9.97, [2.62-48.49]) were associated with CDI recurrence within 8 weeks. Conditions of transplant manufacturing, bowel cleansing, and a route of delivery tailored to the patient's characteristics are key factors in optimising FMT efficacy. FMT at first recurrence showed high success in real-life practice, whereas it had lower efficacy in severe CDI and non-severe refractory CDI.

Proniosomes Nanoparticle for the Treatment of Peripheral Arterial Disease.

The common symptom of systemic atherosclerosis is peripheral arterial disease (PAD), which occurs when the artery lumen in the lower extremities gradually becomes blocked by atherosclerotic plaque. The most frequent symptom of lower extremity PAD, called "vascular claudication," which is pain experienced when walking. Partial or total blockage of the peripheral arteries in the upper and lower limbs is called PAD. The danger of death from concurrent coronary artery and cerebrovascular atherosclerosis outweighs the risk of amputation. However, niosomes have issues with fusion, aggregation, leakage, vesicle sedimentation, and difficulty in sterilizing. A more recent strategy known as pro-vesicular carriers was used to solve these issues. The formulations in Proniosomes are dry and anhydrous, protected with a non-ionic surfactant that serves as a carrier when combined with water. Formulation prepared by organic solvent, surfactant, cholesterol, other components and hydration medium. Coacervation Phase separation Technique used for proniosome Nanoparticle. Box Bhenken Design is used for optimization batches. In this context, we shall discuss the development of Proniosome for the treatment of peripheral arterial diseases. From here, we know that proniosome nanoparticles is pro vesicular system good characteristics and effectiveness for treating peripheral arterial diseases. Proniosomes may be created using various techniques, which may impact how they develop along with the drug's characteristics. They increase the drug's stability while being delivered while being entrapped. They don't need particular conditions for handling, protection, storage, or industrial manufacturing.

Numerical simulation of the first layer printing in electric field-assisted fused filament fabrication for robust unconventionally oriented additive manufacturing

Fused filament fabrication (FFF) stands as a prominent thermoplastic additive manufacturing technique that has a wide range of potential applications. However, the conventional FFF process encounters limitations in unconventional environments, particularly in environments devoid of gravity, such as in extraterrestrial environments or in limited manufacturing conditions where maintaining consistent nozzle standoff distance becomes a challenging task. Fluctuations in nozzle standoff distance lead to inadequate material adhesion and dimensional errors, which results in a high failure rate and prolonged completion time. Thus, the conventional FFF process requires continuous monitoring or human intervention to ensure successful operation. To overcome the shortcomings of the traditional FFF process, an electric field-assisted FFF (E-FFF) process can be utilized to reduce the need for constant supervision and enable reliable production of parts. The E-FFF process integrates a high-voltage power supply unit with a standard FFF printer, generating an electrostatic force between the nozzle and the build plate. The generated electrostatic force can effectively attract the extruded molten polymer toward the build plate, even at a larger z-height of up to 1200 μm in unconventional build platform orientations such as vertical or reverse printing orientation. In this paper, finite element analysis is used to simulate the FFF and E-FFF process. The simulation focuses on the adhesion between extruded material and build plate with extended nozzle standoff distances and predicts the minimum voltage required to achieve a good material adhesion in unconventional orientations for the E-FFF process. The simulation model demonstrated its efficacy by estimating the minimum required voltage levels necessary for successful printing within the E-FFF process across a range of nozzle standoff distances in unconventional orientations.

Galling-Free Dry Near-Net Forging of Titanium Using Massively Carbon-Supersaturated Tool Steel Dies.

Massively carbon-supersaturated (MCSed) tool steel dies were developed to make galling-free forging products from titanium bar feedstocks in dry conditions without lubricating oils. Two types of tool steel dies were used, SKD11 and ACD56, following the Japanese Industrial Standard (JIS). The plasma-immersion carburizing process was employed to induce massive carbon supersaturation in two kinds of tool steel dies at 673 K for 14.4 ks. A pure titanium bar was upset in a single stroke up to the reduction of thickness of 70% using the MCSed SKD11 die. Very few bulging displacements of the upset bar proved that μ = 0.05 on the contact surface of the MCSed SKD11 die to pure titanium work. Two continuous forging experiments were performed to demonstrate that an in situ lubrication mechanism played a role to prevent the contact surface from galling to titanium works in both laboratory- and industry-scaled forging processes. After precise microstructure analyses of the contact surface, the free-carbon film formed in situ acted as a lubricating tribofilm to reduce friction and adhesive wear in continuous forging processes. The MCSed ACD56 dies were also used to describe the galling-free forging behavior of manufacturing eyeglass frames and to evaluate the surface quality of the finished temples. The applied load was reduced by 30% when using the MCSed ACD56 dies. The average surface roughness of the forged product was also greatly reduced, from 4.12 μm to 0.99 μm, together with a reduction in roughness deviations. High qualification of forged products was preserved together with die life prolongation even in dry manufacturing conditions of the titanium and titanium alloys.

Visual Communication Method of Multi frame Film and Television Special Effects Images Based on Deep Learning

For the dynamic film and television special effects industry, creating visually stunning and valuable graphics requires the integration of excellent deep-learning algorithms. This paper presents an enhanced version of the 3-D Convolutional Neural Network (3-D CNN), specifically tailored to meet the demanding needs of multi-frame television and film special effects. The version’s key feature is its efficient data handling through coupled precision training, significantly increasing computational efficiency while reducing memory needs. This method, which combines floating-issue operations of 16 and 32 bits, is ideal for efficiently processing large amounts of high-resolution video data. The proposed 3-D CNN structure excels in extracting and analysing complex spatiotemporal capabilities from video sequences, capturing the spatial and temporal nuances crucial in film imagery. This capability is important for accomplishing excessive fidelity in visual results, ensuring seamless integration with live motion pics. Incorporating a cutting-edge attention mechanism inspired by the aid of transformer-based architectures, the model specialises inside the maximum pertinent components of video frames to enhance the quality and realism of outcomes. Furthermore, the model boasts an excessive-resolution processing characteristic, permitting simultaneous capture of first-rate records and broader scene context. This guarantees consistency and realism in outcomes, from complicated textures to the overarching visual narrative. Advanced regularisation strategies are hired to prevent overfitting, permitting the model to generalise efficiently through numerous film manufacturing conditions. The state-of-the-art 3-D information augmentation techniques make the model robust and prepare it to deal with an intensive variety of challenging situations involving computer special effects. Real-time processing competencies make the model a game-changer for on-set visible outcomes and adjustments. Designed for seamless integration with the famous CGI software program software utility, it allows a harmonious aggregate of AI and ingenious creativity. Acknowledging the environmental impact of high-powered computing, the model consists of power-efficient computational techniques that align with sustainable computing practices, lower operational costs, and are related to processing complex video statistics. model boasts an excessive-resolution processing characteristic, permitting simultaneous capture of first-rate records and broader scene context. This guarantees consistency and realism in outcomes, from complicated textures to the overarching visual narrative. Advanced regularisation strategies are hired to prevent overfitting, permitting the model to generalize efficiently through numerous film manufacturing conditions. The state-of-the-art 3-D information augmentation techniques, in addition, make the model robust, and prepare it to deal with an intensive variety of computer special effects challenging situations.

Investigating the impact of manufacturing conditions on crack growth rate in nitrile butadiene rubber for enhanced service life – Part 02: Crosslink density via multi-stage swelling analysis

The importance of the state of cure of elastomer components with regard to fatigue behavior and thus also durability was already discussed in more detail in Part 01 of the paper. It was shown that crosslinking time and temperature have an enormous influence on the crack growth behavior in nitrile butadiene rubber (NBR). In the course of this, a fourfold deceleration in crack growth was observed with a 20 K increase in manufacturing temperature. To confirm this trend, test specimens were produced at 180 °C. Crack growth was found to be 40 times slower, especially in high tearing energy ranges, compared to 150 °C. To analyze the observed behavior in more detail, cylindrical samples were taken from the plain strain test specimens (used for the crack growth measurements), and multi-stage swelling was performed with them. This allowed a detailed analysis of the degree of cure and the sulfur chain composition. It was found that the crosslink density decreases with increasing manufacturing temperature due to decomposition and the proportion of polysulfidic crosslinks decreases with increasing heating time due to desulfurization. Furthermore, a correlation between the results found by means of the rubber process analyzer (RPA) and the swelling results could be established looking at the maximum transmitted torque during the isothermal crosslinking phase.

VALORIZATION OF CORN HUSK (ZEA MAYS) AND CORN SILK IN POLYMER PARTICLEBOARD MANUFACTURE AND EFFECT OF WASTE COLEMANITE ON THE MECHANICAL PERFORMANCE OF PARTICLEBOARDS

In this experimental study, the usability of waste corn husk was investigated as a source of reinforcement material for the first time in eco-friendly particleboard manufacture. For this purpose, the effect of the most appropriate filler/binder (f/b) ratio and pressing temperature manufacturing conditions on three-point flexural strength in particleboard manufacture was examined. To improve the mechanical properties, the water resistance and combustion resistance of the manufactured particleboards, different amounts of corn silk fiber (0~1.50% by weight) and waste colemanite (0~20% by weight) were added. According to the experimental results, the most appropriate manufacturing conditions for the manufacture of corn husk-based particleboard were determined as f/b ratio of 0.75, pressing temperature of 100 °C, and corn silk fiber loading of 0.75 wt%. Additionally, synthetic binders and beet molasses were used together in particleboard manufacture. The particleboards manufactured comply with the specifications of the EN 312 standard, being below the maximum limit values in terms of thickness swelling, and water absorption rates. In addition, by increasing the waste colemanite content in the board composition, the limiting oxygen index (LOI) values and combustion resistance of the boards were increased. However, the use of waste colemanite in particleboard manufacture reduced the flexural strength of the boards. When 5% waste colemanite was added to the particleboards, the boards manufactured met the minimum limit value requirement for P1 type board, according to EN 312. The dimensional stability of the manufactured particleboards, according to the determined manufacturing conditions, is quite good. Particleboards manufactured from corn husks can be used in interior and exterior applications as eco-friendly building materials.

Modeling spherulitic and fibrillar crystallization kinetics in injection molding: Analysis of process variables and morphological evolution

Injection molding of polypropylene was conducted using a heating device to control mold surface temperature over time. By varying the temperature and heating times, a significant effect on cavity pressures, temperatures, and morphology distribution in the resulting samples was obtained.The University of Salerno's UNISA code, a simulation model for injection molding, was used to simulate the experimental conditions. This code incorporates a crystallization kinetics model that accounts for the competing formation of spherulites and fibrils from the same amorphous material, considering the effects of temperature, pressure, and flow evolution during different stages of the process.The simulation results showed good agreement with experimental data for temperature evolutions within the mold and pressure variations at critical points during the filling, packing, and cooling stages. Additionally, the simulation consistently predicted the formation of a fibrillar layer near the mold wall. Overall, a comprehensive framework for understanding and simulating the injection molding process is provided, with relevant implications for the optimization of manufacturing conditions and improving part quality.

Melt Pool Changes Characterization in Laser-Processed H11 Hot Work Tool Steel Using Point-by-Point Scanning Mode towards LPBF Process Optimization.

Additive manufacturing techniques employing laser-based metal melting have garnered significant attention within the scientific community. Despite a decade of comprehensive research on the fundamentals of these techniques, there still remain unexplored facets related to heat flux impact on metallic alloys' properties. Particularly, the effects of point-by-point laser operation on melt pool formation in metallic materials still remain unclear. Thus, this study focuses on the implications of laser metal melting, particularly investigating a point-by-point laser mode operation's influence on melt pool formation and its geometry in the phase-transformation-sensitive material H11 hot work tool steel. To examine the melt pool, singular laser tracks with various laser parameters were scanned across H11 sheet metal, which allowed for the elimination of layer-by-layer heat cycles' influence on the melt pool's microstructure. Samples were examined by means of metallography, revealing significant differences in the melt pool's depth, influenced mostly by exposure time rather than volumetric energy density. Heat-affected zone effects were found to have a limited range and thus potentially marginal effects in layer-by-layer manufacturing conditions. At the same time, retained austenite concentrations near fusion lines have been found within melt pools, suggesting potential micro-segregation of the alloying additions. The results present guidelines towards laser melting processes optimization.

FMEA-TSTM-NNGA: A Novel Optimization Framework Integrating Failure Mode and Effect Analysis, the Taguchi Method, a Neural Network, and a Genetic Algorithm for Improving the Resistance in Dynamic Random Access Memory Components

Dynamic random access memory (DRAM) serves as a critical component in medical equipment. Given the exacting standards demanded by medical equipment products, manufacturers face pressure to improve their product quality. The electrical characteristics of these products are based on the resistance value of the DRAM components. Hence, the purpose of this study is to optimize the resistance value of DRAM components in medical equipment. We proposed a novel FMEA-TSTM-NNGA framework that integrates failure mode and effect analysis (FMEA), the two-stage Taguchi method (TSTM), neural networks (NN), and genetic algorithms (GA) to optimize the manufacturing process. Moreover, the proposed FMEA-TSTM-NNGA framework achieved a substantial reduction in experimental trials, cutting the required number by a factor of 85.3 when compared to the grid search method. Our framework successfully identified optimal manufacturing condition settings for the resistance values of DRAM components: Depo time = 27 s, Depo O2 flow = 151 sccm, ARC-LTO etch time = 43 s, ARC-LTO etch pressure = 97 mTorr, Ox-SiCO etch time = 91 s, Ox-SiCO gas ratio = 22%, and Polish time = 84 s. The results helped the case company improve the resistance value of DRAM components from 191.1 × 10−3 Ohm to 176.84 × 10−3 Ohm, which is closer to the target value of 176.5 × 10−3 Ohm. The proposed FMEA-TSTM-NNGA framework is designed to operate efficiently on resource-constrained, facilitating real-time adjustments to production attributes. This capability enables DRAM manufacturers to swiftly optimize product quality.