Manufacturing Process Technology Research Articles

Advancements in Colloidosome Fabrication, Functionalization, and Applications: A Comprehensive Review

Abstract: Among the recent developments in the field of microcapsules, colloidosomes microcapsules made of colloidal particles have elicited much interest in promising perspectives in microencapsulation technologies. First reported by Dinsmore et al., these structures hold a lot of potential in different areas of application, which include gene delivery, targeting the brain, and tumor treatment. However, the challenges associated with their permeability and stability limit the use of these coatings. Nevertheless, these problems define colloidosomes as possessing some features of protocells that include metabolic activities and response to stimuli, which make them significant in synthetic biology and biomimetic systems. In drug delivery, colloidosomes have the potential of providing solubility, stability, and a controlled rate of drug release, which will have an impact on the therapeutic use of drugs. Fabrication of colloidosomes is done in many ways, and the common ones include the mulsion strategy, layer adsorption, and microfluidics strategy. Some of these fabrication techniques have been investigated in the recent past to determine how their application can lead to enhanced colloidosome characteristics. Some of these methods include spray drying, sol-gel processes, and electrostatic assembly. For example, the study by Payizila Zulipiker et al. showed that different levels of permeability are controllable through the use of spray drying technology. Another study by Jia Jia et al. presented the preparation of pH-responsive colloidosomes and the high efficiency of encapsulation. Consequently, improvements in the manufacturing process and new self-assembly technologies that include microfluidics systems have also improved the creation of colloidosomes. New advancements in the field of colloidosome synthesis, as well as their surface modification, will open up numerous application prospects in the fields of pharmaceutics, regenerative medicine, and bioinspired materials science. New trends range from 3D printing to stimuli-responsive materials and design, as well as hybrid systems that are application- specific. Despite the difficulties that remain to be faced, colloidosomes represent an extraordinary opportunity for the growth of biotechnology and materials science to open the path to new generations of drugs and bioinspired applications.

MECHANICAL PROPERTIES OF GLASS FIBER AND CARBON FIBER REINFORCED COMPOSITES

The significant potential of glass fiber-based composite materials in aerospace and aviation industries, automotive manufacturing, and medical equipment production is emphasized. It is concluded that glass fiber is much cheaper and less brittle compared to materials like carbon fiber or other plastic fibers, as glass fiber exhibits high resistance to tensile and compressive loads. The main stages of the technological process of composite manufacturing are described, and the key requirements for evaluating the mechanical parameters of glass fiber products are listed. An analysis of the scientific literature has established that the high strength of fiberglass ensures the stability of its thermal conductivity characteristics, making it resistant to environmental influences and aging. The thermal conductivity of fiberglass composites depends on several factors, the most important of which are the type of fiber and matrix, fiber volume fraction, fiber characteristics, control of heat flow, interaction between the matrix and fiber, and operating temperature. It is summarized that the mechanical properties of fiberglass structures depend on a number of factors, the most important of which are: the type of fiber and resin, fiber orientation (aligned, randomly oriented, woven, etc.), and the percentage content of each component.

ПРИМЕНЕНИЕ СКАНИРУЮЩЕЙ ЭЛЕКТРОННОЙ МИКРОСКОПИИ В РЕВЕРС-ИНЖИНИРИНГЕ ЭЛЕКТРОННОЙ КОМПОНЕНТНОЙ БАЗЫ

The article shows the relevance of scanning electron microscopy in the problems of analysing and synthesising micro- and nanoscale structures of semiconductor devices. The aim of the article is to analyze the structure quality of semiconductor devices in integrated circuits, to restore the sequence of technological operations and reverse engineering. To achieve this goal, the following tasks are solved: dielectric and conductive structures of semiconductor devices in integrated circuits are studied, the results of measuring the linear dimensions of the semiconductor device elements are analyzed, the dustiness coefficient is calculated. The study applies the methods of a full-scale experiment, digital methods of processing graphic information. A sample of an integrated circuit manufactured using field technology is selected as the initial data; the information and measuring system is built on the basis of a KYKY 8000 scanning electron microscope with a control computer. As a result, images of the element structures of field-effect transistors in the integrated circuit are obtained, on the basis of which the dustiness coefficient is calculated. The results show that with the help of scanning electron microscopy it is possible to analyze the technology of manufacturing semiconductor devices, to determine the sequence of execution and features of technological operations, to identify the causes of product defects to optimize technological manufacturing processes.

A New Paradigm for Semiconductor Manufacturing: Integrated Synthesis, Delivery, and Consumption of Source Chemicals for IC Fabrication

The semiconductor industry is being radically impacted by the placing of greater emphasis on the development of hetero-devices and systems that will act as essential drivers for a wide spectrum of technological applications. The introduction of new materials and their integration with currently used materials are projected to replace integrated circuitry (IC) design and device scaling as the key enablers to the realization of improved device performance and larger density gains. Yet material selection has been constrained by existing fabrication process technology. To date, fabrication processes have dictated material selection by limiting chemical sources or precursors to those that match existing process tools associated with chemically based vapor phase processes and their variants, which in turn limits material compositions in ICs. The processing and integration of new materials compositions and structures will require the introduction of new deposition and etching processes, and manufacturing worthy tool designs and associated protocols that provide new methods for atomic-level control. To this end, a novel manufacturing paradigm is presented comprising a method and system for real-time, closed-loop monitoring and control of synthesis, supply, and consumption of precursors in process intensification techniques including chemical vapor deposition (CVD), atomic layer deposition (ALD), atomic layer etching (ALE), and other IC manufacturing processes. This intelligent automated manufacturing approach is consistent with a central component of the semiconductor industry’s recent adoption of Industry 4.0., including vertical integration of IC manufacturing through robotization, artificial intelligence, and cloud computing. Furthermore, the approach eliminates several redundant steps in the synthesis, handling, and disposal of source precursors and their byproducts for CVD, ALD, ALE and other chemically based manufacturing processes, and thus ultimately lowers the manufacturing cost for both conventional and new IC materials. Further, by eliminating the issues associated with precursor thermal, chemical, and pyrophoric instabilities, this new paradigm enables the deposition of a myriad of new thin-film materials and compositions for IC applications that are practically unattainable with existing precursors. Preliminary and planned demonstration examples for the generation and deposition of highly toxic and unstable source precursors are provided.

Novel multi-layer field shaper in electromagnetic manufacturing process technology of tube joining for uniform deformation

Electromagnetic joining technology is widely utilized in assembling tubular components due to its ability to exert uniform magnetic pressure. To augment this pressure, a field shaper structure has been introduced. However, the conventional design may impair the uniformity of deformation, particularly at the seam. This study presents a novel multi-layer field shaper (MLFS) to enhance deformation uniformity. The performance of the MLFS was evaluated and optimized through experimental trials and simulation analysis. The results showed that MLFS achieved a 300 % increase in minimum deformation with a 56 % reduction in the aspect ratio, demonstrating that our design effectively balances efficiency with deformation uniformity. The magnetic cubic decay formula could fit the simulation data well with R2 higher than 0.999. MLFS was found to enhance uniformity by creating a more even magnetic field that decreased the curvature near the plastic hinge. Compared to altering the interlayer thickness, adjusting the interlayer angle can further enhance uniformity. When the rotation angle is 60°, the radius range can be further reduced by 32.5 %, 39.0 %, and 12.2 % at energy levels of 27 kJ, 30 kJ, and 33 kJ, respectively. The above results indicate that by designing and optimizing MLFS, sufficiently large and uniform electromagnetic forces were obtained.

Integration of Industry 4.0 technologies in industrial manufacturing processes

The integration of Industry 4.0 technologies into industrial production processes represents a significant evolution. This article explores the impact and benefits of this integration, showing how emerging technologies are revolutionizing traditional production methods. The methodology addresses the fundamental concepts of Industry 4.0, such as device interconnection, real-time data analysis, and intelligent automation, and examines specific technologies incorporated into manufacturing processes, such as the Internet of Things (IoT), Additive Manufacturing, Artificial Intelligence (AI), and Augmented Reality (AR). Case studies and practical examples illustrate the implementation of these technologies in various sectors, from precision parts manufacturing to mass production. Finally, the challenges and opportunities are discussed, as well as the future implications for the manufacturing industry. This article offers a view of the role of Industry 4.0 in industrial production processes, highlighting its importance for competitiveness and innovation in the digital world.

Influence of the Plastic Deformation Process on the Residual Stresses and Hardness of an Al-5Mg Alloy.

The service behavior of ductile metallic materials, when they have previously undergone technological plastic deformation, depends on the deformation conditions. These are represented, among others, by the deformation rate, the process temperature, the applied pressures, and the introduced stresses, as well as other process variables. The investigation of the mechanical properties obtained after plastic deformation is an important means that contains two characteristics: on the one hand, to determine to what extent the parameters of the technological manufacturing process influence the main characteristics of the final component; and, on the other hand, on the basis of these characteristics, to analyze whether the component subjected to plastic deformation will be able to function reliably and safely. In the present work, an experimental study was made of the residual stresses developed and hardnesses obtained both in the immediate vicinity of a highly plastically deformed area and in an area previously obtained by rolling, without additional plastic deformation. For the determination of the residual stresses, the tensiometric rosette drilling method was used. By determining the same quantities in a non-plastically deformed area, significant changes in the values of the two quantities in the plastically deformed area were found. An increase in the maximum principal normal stresses by approx. 60 MPa and an increase in the Rockwel hardness by approx. 10 HRC was found. A sample was taken from the area under a plastic deformed circular shape, and was analyzed microscopically.

Fibre fragment pollution: source directed intervention through design

This study analyses the difference in fibre fragment pollution generated during the laundering of woven and knit fabrics for clothing and the influence of fabric parameters on the amount of pollution released. 100% polyester single jersey knit and 2/2 twill woven fabrics were created and washed according to AATCC TM212-2021. Results indicated more tightly woven structures released over three times less pollution than looser knit structures, releasing 6.41 mg of fibre fragments per kg of woven fabric (mean ± 1.50 SD, n = 8) compared to 21.21 mg of fibre fragments per kg of knit fabric (mean ± 1.80 SD, n = 8). The first wash for both knit and woven fabrics shed significantly more fibre fragments than subsequent washes. By the fifth wash both fabrics released under a tenth of the amount of pollution released in the first wash. To mitigate fibre fragment pollution that is released by fabrics designed for clothing this work recommends designing out pollution using more tightly constructed fabrics. Furthermore, the implementation of technology in fabric and garment manufacturing processes (e.g. fibre catching devices) should be utilised specifically during first washes allowing pollution to be filtered from the wastewater to stem the flow of contaminants into the environment.

Materials and manufacturing technology for high reliability rigid-flex multilayer PCB for space 3D-electronics packaging

Rigid-flex Multilayer PCB Technology enables the elimination of several connectors and bulky harness for interconnecting functional electronic systems. This minimizes packaging complexity and reduces performance degradation at high frequencies with an added advantage of reduced weight and volume in high-reliability space electronic packages. Here, only thermo-mechanically stable adhesiveless all polyimide flexible laminate cores and no-flow glass-polyimide prepregs are employed. To overcome the manufacturing issues like registration, coverlay protrusion into the rigid portions, and residual copper deposition at the intersections of flexible and rigid portions; a novel manufacturing process technology is proposed here. The technology has been successfully devised after choosing the most appropriate flexible, rigid, and low-flow prepreg materials. Herein, for the realization of rigid-flex multilayer PCB technology with 2-layers of flex and 8-layers of rigid to meet the functional requirements of the board is presented. The critical registration issues associated with the dissimilar rigid and flexible substrates are successfully addressed to achieve best-fit registration and obtain minimum annular rings of 50 μm in all the inner layers for high reliability. Experimental results manifest that incorporating rigid-flex multilayer PCB technology dramatically reduces weight (>30%) and volume (∼40%) to high-reliability space electronics 3D packaging for static and dynamic applications.

Research of the Ukrainian market and quality of home and sleepwear

The study of demand, supply, and assortment of clothing indicates the need to improve production control, select high-quality raw materials to increase competitiveness and meet consumer needs in this market segment. The purpose of the study was to analyse supply and demand in the Ukrainian market of home and sleepwear and its range. The study assessed the supply and demand market with the help of information resources and search services on the Internet. In the conditions of the enterprise ELLEN GROUP LLC, organoleptic, instrumental methods of assessing the quality of consumer properties of raw materials and finished products were used during production control using regulatory documentation. The factors influencing the formation of high quality of finished products, namely the manufacturing process, stages of production quality control, regulatory documents and consumer properties, were investigated. The analysis of fashion trends and market offers allowed to determine the demand and create a modern classification system for home and sleepwear that meets modern consumer requirements. The main factors that shape the quality level of finished products are highlighted. It is determined that the high quality of garments is achieved by observing a clear technological process of their manufacture. The quality is governed by the rules and regulations of the state standards and normative documents and the use of high-quality raw materials. Recommendations are provided to guide the choice of high-quality clothing for home and sleep with ensuring comfort and safety of the consumer during use. A classification system has been developed, taking into account current market offers, different needs and requirements of consumers. The factors influencing the formation of high-quality clothing for home and sleep are identified. They are the technological process of manufacturing, during which aesthetic, ergonomic properties are formed and the choice of raw materials with high-quality indicators, which ensures an appropriate level of consumer properties such as hygiene and safety of finished products. To achieve optimal everyday comfort and quality sleep, the main aspects and effective solutions that should be followed when choosing clothes for home and sleep are outlined. The results of the study should increase the competitiveness of enterprises, improve the quality of life of consumers, in particular in the field of home and sleepwear

Эластичные хоны для полирования профилей зубьев термообработанных цилиндрических колес специального назначения

Introduction. The most important component of the technological process of manufacturing of gear wheels of critical products is the operation of teeth honing. Special requirements are imposed on the surface quality of special-purpose gears, where imported abrasive tools were used, the supply of which in modern economic conditions is impossible. Purpose of work: development of formulation, technological equipment and technology of manufacturing of elastic diamond gear hones instead of imported ones for teeth honing of gear wheels of special purpose. Research methods. Subject of research are samples of imported elastic gear hones and created domestic analogs. The mechanical properties, morphology and chemical composition of the abrasive (diamond) layer of the working surface of the teeth and the annular gear were determined. The content of chemical elements was controlled in separate points of the surface and by scanning over the area on a scanning electron microscope. The formulation and technology of production of annular gears were determined. Results and Discussion. Designs of molds for forming the abrasive layer and the hub of the gear hone are developed. The peculiarities of morphology of the material of the working layer and the annular gear of the elastic diamond gear hone are revealed. On the basis of the conducted research, domestic analogs of materials of constituent elements of the gear hone are determined. Two manufacturing technologies were considered: pressing and injection molding. Two molds were made to test the technology: a simplified model consisting of two teeth and a round mold. Several methods of manufacturing hone teeth were analyzed: manufacturing of an abrasive layer with different degree of pre-vulcanization, subsequent introduction of gear material and final vulcanization of the whole product. The mechanical properties of the materials of the working abrasive layer and the annular gear were determined. The chemical composition of the components of the hone and the boundary zone are studied. As a result of the conducted research, recommendations on the formulation of the abrasive layer and the annular gear, technology of manufacturing of the gear hone intended for final treatment of teeth of heat-treated spur wheels of special purpose are given.

The feasibility of Raman spectroscopy for accurate assessment of essential criteria in pharmaceutical industry by investigation of Metformin hydrochloride tableting process

AbstractAnalytical and real‐time technology in pharmaceutical manufacturing process is an important need to ensure that manufactured drugs are safe and effective. Raman spectroscopy is an emerging technique that is able to perform quantitative analysis nondestructively due to the molecular structure of many drugs. Monitoring the content uniformity and quantification of active pharmaceutical ingredient (API) in the tablet preparation process, without the assistance of solvent, is one of the key concerns in the formulation design in order to provide stable, pure, and homogenous finished products. In this study, we investigated the possibility of using Raman data as an analytical method to quantify API, the intra‐ and inter‐sample uniformity of content in the tableting process of Metformin hydrochloride tablets (C4H11N5.HCl). Analysis of all standard samples for prediction of API uniformity represents an acceptable accuracy and precision with a relative standard deviation of 2.55%. Further investigation of tablets regarding to relative Raman intensity of some characteristic peaks demonstrates the amount of API content with an accuracy of ≥96%. These values have a good adaption with pharmacopeia monograph. Findings reveal that the Raman method can be routinely utilized for quantifying API, controlling the content uniformity and the stability of drugs in different stages of manufacturing.

Peningkatan Kuat bentur Produk 3D Printing Fused Deposition Modeling menggunakan Filamen Polypropylene

In the world of manufacturing technology there is the latest breakthrough called 3D Printing which is based on layer manufacturing. In making products, a method of adding material in layers is used, usually called additive manufacturing. The principle used in this manufacturing process technology is layered modeling, by converting 3D data directly from computer-aided design (CAD) into a physical model. Many manufacturing technologies have been developed to make prototypes according to needs, for example FDM (Fused Deposition Modeling). Setting factors and experimental levels is an important step in maximizing the quality of research level products referring to transparent materials formed from polypropylene filaments. The factors that vary are Nozzle Temperature, Bed Temperature, Print Speed, and Layer Height. This research design uses the Taguchi method. This research uses an L9 orthogonal matrix with 3 levels. Based on the results of the research carried out, we can conclude that in the impact strength test there is an increase in the results of the impact strength test with the most influential process parameters, respectively, namely Print Speed (35mm/s), Layer Height (0.3mm), Bed Temperature (97 °C) and Nozzle Temperature (215°C) using Polypropylene filament. So the strongest impact strength test value is in experiment no. 2 with an average value of 0.03370 Joules and the weakest is in experiment no. 1 with an average value of 0.02959 Joules.

Quantum-inspired computing technology in operations and logistics management

PurposeThe purpose of this paper is to explore and disseminate knowledge about quantum-inspired computing technology's potential to solve complex challenges faced by the operational agility capability in Industry 4.0 manufacturing and logistics operations.Design/methodology/approachA multi-case study approach is used to determine the impact of quantum-inspired computing technology in manufacturing and logistics processes from the supplier perspective. A literature review provides the basis for a framework to identify a set of flexibility and agility operational capabilities enabled by Industry 4.0 Information and Digital Technologies. The use cases are analyzed in depth, first individually and then jointly.FindingsStudy results suggest that quantum-inspired computing technology has the potential to harness and boost companies' operational flexibility to enhance operational agility in manufacturing and logistics operations management, particularly in the Industry 4.0 context. An exploratory model is proposed to explain the relationships between quantum-inspired computing technology and the deployment of operational agility capabilities.Originality/valueThis is study explores the use of quantum-inspired computing technology in Industry 4.0 operations management and contributes to understanding its potential to enable operational agility capability in manufacturing and logistics operations.

A novel hybrid multi-criteria optimization of 3D printing process using grey relational analysis (GRA) coupled with principal component analysis (PCA)

Fused deposition modeling (FDM) is renowned as a prominent approach in the realm of 3D printing, where objects are built layer by layer using a heated nozzle to extrude melted materials. This research was conducted to identify the most effective FDM process variables to enhance tensile strength while simultaneously reducing surface roughness. Polylactic Acid (PLA) was chosen to fabricate test samples, showcasing the applications of 3D printing. In the course of this research, we conducted a series of 27 experiments to investigate the fundamental relationship between the parameters and the corresponding responses. The central aim of this study lies in optimizing the input variables viz. printing speed, layer thickness, and carbon deposition (C-deposition) for the technological manufacturing process of embossing parts in the context of Industry 4.0. To enhance both tensile strength and surface roughness simultaneously, a new hybrid method has been suggested. This approach integrates grey relational analysis (GRA) with principal component analysis (PCA) to determine the optimal combination of process parameters in the 3D printing process. Notably, the experiment trial exhibited the highest grey relational grade (GRG), indicating optimal process parameter settings at a printing speed of 100 mm s−1, layer thickness of 0.1 mm, and C-deposition of 15 mg respectively. Additionally, mathematical models are created through response surface methodology to explore the impact of FDM parameters on the grey relational grade. The findings from this study can be utilized in various industries and applications where FDM 3D printing is employed.

Process development and characterization for integrated continuous bioprocesses-Highlights from N-mAb.

The N-mAb case study was produced by the National Institute for Innovation in Manufacturing Biopharmaceuticals (NIIMBL) to support teaching and learning for both industry and to accelerate adoption of advanced manufacturing process technologies such as integrated continuous bioprocesses (ICB) for mAbs. Similar to the A-mAb case study, N-mAb presents the evolution of an integrated control strategy, from early clinical through process validation and commercial manufacturing with a focus on elements that are unique to integrated continuous bioprocesses. This publication presents a summary of the process design and characterization chapters to allow a greater focus on the unique elements relevant to that phase of development.

Material substitution to reduce the environmental impacts in construction of car body manufacturing plants

The efficient use of resources is a key driver for reconciling nature and technology in the automotive manufacturing process. Resource efficiency not only considering the final product but also the construction of the manufacturing system is therefore essential for achieving the sustainability goals pursued by global automotive manufacturers. In this context, the substitution of energy-intensive primary materials with renewable raw materials represents a significant potential for reducing the environmental impacts of automotive plant engineering. However, the use of new materials often leads to conflicting objectives in terms of environmental and economic aspects as well as technical feasibility. To ensure an effective contribution to sustainability, it is necessary to evaluate the entire product life cycle of the substitute material, to localize the resulting secondary effects and to develop target-oriented solution concepts. Against this background, an approach is presented for the implementation of material substitution. The feasibility is demonstrated with a case-study on the substitution of energy-intensive steel with renewable wood material for the structural elements of a vertical conveyor pallet in the car body construction. The technical development and series testing is described and subsequently a comparative environmental and economic evaluation is carried out to analyze the potential benefits compared with the status quo while considering the resulting secondary effects. Finally, a potential assessment is made based on a reference body shop.

Digital fabrication with FDM 3D printing on prototype development of toys: Additive manufacturing and sustainability

Additive manufacturing, commonly referred to as 3D printing, is currently one of the most dominant developments in the manufacturing sector. Consumer demands for more customized goods and services, in conjunction with the emergence of advanced manufacturing technologies, are influencing changes in the scope and distribution of manufacturing. In this work, the function of digital fabrication, one of these advanced manufacturing process technologies, is examined. The Digital Manufacturing and even other advanced manufacturing technologies have a significant footprint in all future manufacturing endeavours because of the robustness and mass customization that they provide. The Fused Deposition Modelling (FDM) is a sustainable method used extensively for the development of prototypes for toys. The present study investigates the potential of FDM process as a method for prototype development. Additionally the advantages of FDM process from the viewpoint of sustainable manufacturing integrating innovativeness and do-it-yourself approach at home driven by consumer demand for products such as toys will also be investigated. 3D printing technology such as FDM process, where objects such as toy prototypes are constructed by adding materials layer by layer has been in the forefront of various Digital Manufacturing techniques as it reduces material wastage thereby optimizing resource utilization.

Modeling and analysis of electro-thermal processes in installations for induction heat treatment of aluminum cores of power cables

Introduction. The development of the electric power industry is directly related to the improvement of cable lines. Cable lines meet modern requirements for reliability, they are increasingly used. Problem. Currently, power cables with an aluminum multi-conductor core, which requires heat treatment - an annealing process at the stage of the technological manufacturing process, are widespread. This process makes it possible to desirably reduce the electrical resistance of the wire and increase its flexibility. For effective use of induction heating during annealing of an aluminum core, it is necessary to determine the optimal frequency of the power source of the inductor. Considering the long length of the inductor and the large number of its turns, the numerical calculation of the electromagnetic field, which is necessary for calculating the equivalent electrical parameters of the turns of the inductor and its efficiency, requires significant computer resources. The goal is to develop a computer model for calculating electro-thermal processes in an induction plant for heating (up to the annealing temperature) an aluminum core of a power cable moving in the magnetic field of a long multi-turn inductor, as well as obtaining frequency dependences of the equivalent R, L parameters of such an inductor and determining the optimal the value of the frequency of the power source, which corresponds to the maximum value of the electrical efficiency of the inductor. Methodology. The mathematical model was developed to analyze the coupled electromagnetic and thermal processes occurring in a core moving in a time-harmonic magnetic field of an inductor at a constant speed. The differential equations for the electromagnetic and temperature fields, taking into account the boundary conditions, represent a coupled electro-thermal problem that was solved numerically by the finite element method using the Comsol software package. For a detailed analysis of the electromagnetic processes in the inductor, an additional problem was considered at the level of the elementary cell, which includes one turn of the inductor and a fragment of the core located near this turn. Results. According to the results of the calculation of the electromagnetic field in the area of the elementary cell, the equivalent electrical parameters of one turn of the inductor and the entire multi-turn inductor were calculated depending on the frequency of the electric current. The frequency dependences of the electrical efficiency of the inductor were calculated. Originality. Taking into account the design features of the inductor (its long length and large number of turns), the method of multiscale modeling was used. Electro-thermal processes in the core were studied at the macro level, and the distribution of the electromagnetic field and electric current density in the cross-section of the massive copper turn of the inductor was calculated at the micro level – at the level of an elementary cell containing only one turn of the inductor. The frequency dependences of the equivalent R, L parameters of the inductor, taking into account the skin effect, the proximity effect, and the geometric effect, were obtained, and the quantitative influence of the electric current frequency on these effects was studied. Practical value. The dependence of the electrical efficiency of the inductor on the frequency of the power source was obtained and it was shown that for effective heating of an aluminum core with a diameter of 28 mm, the optimal value of the frequency is in the range of 1–2 kHz, and at the same time the electrical efficiency reaches values of ηind = 0.3–0.33, respectively.

A novel counter-rotating twin-tool friction stir processing technology for fabrication of Al/SiC surface composite with improved particle distribution

The fabrication of surface composite through friction stir processing (FSP) introduces certain challenges, including insufficient heat generation and non-uniform distribution of reinforcement particles. The implementation of multi-pass FSP can partially reduce these issues; however, it comes at the cost of increased manufacturing time and labour costs. In order to address these challenges comprehensively, a novel counter-rotating twin-tool friction stir processing (CRTTFSP) technology was utilized for fabrication of Al/SiC surface composite. The presence of hard SiC particles notably improved the microhardness of the composite. High heat generation and counter-rotation of the twin-tool, contributed to better particle distribution, which led to consistent microhardness values. Hence, this technology offers uniform mechanical properties of the fabricated composite and also eliminates the need of repetitive processing over the same zone, resulting in considerable reductions in both manufacturing time and associated costs making it more suitable for industrial applications.