Thermal Process Research Articles

Metal-oxide nanocomposites by low temperature exsolution from perovskite-like La nickelates: Synthesis, morphology, and catalytic properties in CO2 hydrogenation

Thermal decomposition of the citrate-gel precursors with La/Ni = 1/1 and La/Ni = 3/2 results in the formation at T ≥ 700 °C the single phase perovskite LaNiO3 and the disordered perovskite-like phase La3Ni2O6+x. A reduction of both compounds during thermal processing in a 5 % H2/Ar gas mixture proceeds in two definite steps. The first stage of LaNiO3 reduction at 250 - 350 °C results in the formation of an O-deficient La2Ni2O5 compound. A similar process during the reduction of La3Ni2O6+x occurs at 300–400 °C with the lack of significant changes in the XRD pattern. An unusual feature of these processes deals with the formation of Ni0 nanoparticles on the surface of both reduction intermediates at 350–400 °C while similar processes are usually observed during redox exsolution of metals from several complex oxides at T > 700 °C only. As-obtained Ni/LaxNiOy nanocomposites demonstrated significant catalytic activity and excellent selectivity and stability in the Sabatier reaction.

Effect of Heat Treatment on Mechanical Properties and Corrosion Response of HVOF Sprayed High Entropy Alloy Coatings

Surface and sub-surface related degradation of steels can be minimized using suitable surface coatings. High entropy alloys (HEA) are prominent and emerging materials among many coating materials. The current study investigates the effect of heat treatment of HEA coating on mechanical, metallurgical, and corrosion properties. The HEA coatings on SS304 steel were deposited using a High-Velocity Oxy-Fuel (HVOF) thermal spray process. The developed coatings were furnace heat treated at 700 °C, 900 °C, and 1100 °C, respectively, and their performance was benchmarked with the as-sprayed coatings. The metallurgical, mechanical, and microstructural analyses were performed using X-ray diffraction (XRD), Nanoindentation, Scratch test, and Field Emission Scanning Electron Microscope (FESEM) techniques. The corrosion response of the as sprayed and heat-treated coatings were recorded using a Potentiostat. The results indicated that as-sprayed coatings consisted of a single-phase BCC solid solution; however, the single-phase changed to a dual dual-phase system after heat treatment (BCC+FCC). The 900 °C heat-treated HEA coating exhibited superior mechanical and corrosion properties. But those characteristics started diminishing when the heat treatment temperature exceeded 900 °C. The introduction of the new FCC phase softened the coating, thereby leading to the evolution of microcracks in the coating. These micro-cracks acted as channels for electrolyte diffusion and further corroded the coatings. The current study surmised that HVOF-sprayed HEA coating should not be heat treated at above 900 °C.

Thermal and rheological properties and processability of thermoplastic lignocellulose

AbstractFossil‐free biobased materials like thermoplastic lignocellulose are gaining attention because of climate issues. However, there is a challenge to make these as thermoplastic as commonly used thermoplastics. Arboform® is one of today's commercially available thermoplastic lignocellulose materials. In this work, the processability of this material was studied in detail and the effects of plasticizers on its processability, rheological, and mechanical properties were determined. Thermal/calorimetry analysis indicated that the processing temperature window was shifted to lower temperature with the use of tributyl citrate (TBC) and poly(ethylene glycol) (PEG 400) plasticizers, thus enabling extrusion at lower temperature. TBC and PEG 400 decreased both the glass transition temperature and melting point of the polylactide component. Surprisingly, they also affected the lignin component, as observed by the decreasing lignin decomposition temperature. It is observed that TBC and PEG400 lowered the stiffness of the compression molded material in the temperature range investigated (−30–180°C), and tensile tests in the presence of TBC revealed a decrease in ductility. Notable is that, in contrast to most thermoplastics, the Arboform® melt increases in viscosity and elastic moduli when the processing temperature was increased (from 180 to 200°C) or when processing time was increased.

Symmetry in thermal cycles and processes

Symmetry analysis is a cutting-edge research approach in physics, yet its application in macroscopic energy systems remains limited. This study demonstrates its potential to provide valuable insights for a deeper understanding and development of thermodynamic cycles. This article first studies the symmetry of the proposed C-P diagrams and finds rich symmetries including reflection symmetry, translation symmetry, and rotational symmetry within Carnot cycles. Then, it emphasizes that one can use symmetry alone to prove that the highest efficiency for any cycle operating in a certain temperature range is the Carnot efficiency, without relying on the entropy concept in the second law of thermodynamics. Lastly, it is found that this symmetry analysis framework can also be used for thermal cycles with phase transitions, as exemplified by applying in Rankine cycles. This research not only contributes groundbreaking insights into unraveling the symmetry inherent in thermodynamic cycles, but also promotes symmetry analysis to be an alternative analysis mean.

Determination of Water-Soluble Vitamins in Palmyrah Sweet Sap and Its Derived Products using RP-HPLC Method

Palmyrah sweet sap, obtained from the inflorescence of the Borassus flabellifer L. palm tree, is a popular natural drink in Sri Lanka, available seasonally from January to August. It contains a blend of water, sugars, and essential vitamins and minerals. The sweet sap is processed thermally to produce sugary products like crude sugar, jaggery, and treacle. It is crucial to analyze them to ensure their nutritional value, due to the possibility of vitamin decomposition during the production stage. This study aimed to quantify the existing vitamins in sweet sap and its derived products using validated high-performance liquid chromatography (HPLC). The HPLC method validation parameters, such as linearity, accuracy, precision, range, limit of detection (LOD), and limit of quantification (LOQ), were determined. The results showed that the derived products from palmyrah sap had high concentrations of vitamins, with thiamine ranging from 2.81 to 35.16 mg/100g, niacin from 4.35 to 45.03 mg/100g, pyridoxine from 4.44 to 87.16 mg/100g, and ascorbic acid from 5.42 to 52.52 mg/100g. The accuracy of the HPLC method for vitamin analysis was between 98.43 and 100.64%, with a limit of detection ranging from 0.357 to 1.152 ppm and a limit of quantification from 1.081 to 13.573 ppm. The study successfully quantified the existing vitamins in the sap and its derived products, with overall results indicating that the vitamins were retained even after thermal processing.

Preparation of Melamine Urea Formaldehyde Organo Clay Nanocomposite Foams Using Thermal Processing and Microwave Irradiation Techniques and Investigation of Their Thermal Insulation and Compressive Strength

Preparation of Melamine Urea Formaldehyde Organo Clay Nanocomposite Foams Using Thermal Processing and Microwave Irradiation Techniques and Investigation of Their Thermal Insulation and Compressive Strength

Quality improvement of BaGa4Se7 crystal by annealing in BaSe vapor atmosphere

Infrared nonlinear optical crystals are widely used in all-solid-state lasers as pivotal devices for laser frequency conversion. BaGa4Se7 (BGSe) crystal has attracted much attention due to its excellent optical properties. However, the presence of point defects in BGSe increases the absorption loss and reduces the laser-induced damage threshold, thus limiting its practical application in high-power mid- and far-infrared lasers. Therefore, it is crucial to reveal the types of defects and their formation mechanisms in BGSe crystal, which is conducive to the design of rational strategies to improve the crystal quality. In this work, the defect activation energies were calculated by photoluminescence (PL) spectroscopy and the existence of three types of defects, GaBa, VSe and VBa were verified in the as grown BGSe crystal. Therefore, a thermal annealing process under BaSe vapor was rationally designed to compensate for the loss of Ba and Se elements and to reduce the defect concentration in BGSe. In addition, the changes of defects in BGSe crystal were determined by X-ray photoelectron spectroscopy (XPS) and photoluminescence (PL) spectroscopy. All the experimental results confirm that the defect concentration in BGSe decreases greatly and the crystal quality is significantly improved after annealing in BaSe vapor.

Evolution of correlated morphological and structural disorder in boehmite‐derived alumina with progressive calcination

This study explores the morphological and structural transformation of boehmite (AlOOH) into transition aluminas during calcination, a pathway crucial for diverse industrial applications. The primary focus is on the topotactic transformation of boehmite into γ‐Al2O3 and its subsequent transitions into higher temperature polymorphs, culminating in α‐Al2O3. Utilizing a combination of in situ X‐ray diffraction, in situ and ex situ transmission electron microscopy, 27Al solid‐state nuclear magnetic resonance, thermogravimetric analysis, nitrogen physisorption, and mercury porosimetry, this work provides insights into the morphological and structural reordering during the calcination process. Furthermore, the study highlights the significant impact of thermal processing on the morphological evolution of boehmite and transition aluminas, characterized by changes in pore structure sizes and shapes. These findings offer valuable insights for optimizing the properties of alumina‐based materials for specific applications.

Coupled fluid-structure-interaction simulation approach for correction of the thermal tool elongation to improve the milling precision

During milling operation, the position of the tool centre point (TCP) is affected by structural displacements, which are caused by force loads and heat input inside the machine as well as machining induced thermal loads. These thermal loads result in considerable thermal deformations of tool holder, tool, and accordingly the TCP position. They can be summed up to about tens of microns and compromise the dimensional accuracy. The objective was to develop an integrated, numerical simulation-based approach for future TCP correction for a milling process using characteristic diagrams. For this, a complex Fluid-Structure-Interaction (FSI) simulation model predicts the uni-axial displacement in the longitudinal direction of the TCP due to a specified process heat source at the tool tip. As a partial result, the simulation has reached its performance limits, under the restriction of a reasonable simulation time in order to produce characteristic diagrams for application on a milling machine. The calculated thermally induced displacement can be further processed with the aid of Design of Experiments (DoE) and response surface methodology (RSM), depending on the thermal process load and coolant volume flow rate. That results in characteristic diagrams for the displacement as a function of process parameters. In this study the calculated value for thermally induced TCP displacement covers a span from 10 μ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\upmu$$\\end{document}m to 80 μ\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$\\upmu$$\\end{document}m, with a strongly nonlinear behaviour. Subsequently, this forms the basis for a future implementation of characteristic diagrams in the machine control system for online correction of thermal tool errors.

Effect of temperature gradient on the chemical structure and physical morphology of polyacrylonitrile fibers during thermal stabilization process

The thermal stabilization process is a crucial stage for microstructure transformation and quality of carbon fibers, which is determined by the stabilization temperature gradient. In this work, the effect of the temperature gradient on the evolution of both chemical structures and physical morphology of polyacrylonitrile (PAN) fibers at multistage of thermal stabilization process was investigated. Combined with functional groups, oxygen element content, and aromatization index, increasing temperature reasonably shifted oxidation and cyclization reaction into early stage and the corresponding samples possessed relatively large degree of cyclization. It was worth noting that high stabilization temperature gradient could accelerate the formation of the conjugated structures at early stage and facilitate the cyclization reaction in the stabilized fibers. As for morphologies, there were aligned microfibrils and transvers lamellae in stabilized fibers. Their radial structure difference increased firstly and then decreased in the later stage. The tensile strength and tensile modulus decreased during the thermal stabilization process. Moreover, increasing temperature resulted in reduction of tensile strength and tensile modulus, which was mainly resulted by the high degree of cyclization instead of structural defects. These results guide the design and optimization of temperature program and adjusting the processing parameters for all commercially PAN fibers without any additional conditions.

Mechanisms underlying the formation of main volatile odor sulfur compounds in foods during thermal processing.

Volatile sulfur compounds (VSCs) significantly influence food flavor and garner considerable attention in flavor research due to their low sensory thresholds, diverse odor attributes, and high reactivity. Extensive research studies have explored VSC formation through thermal processes such as the Maillard reaction, thermal pyrolysis, oxidation, and enzymatic reactions. However, understanding of the specific reaction mechanisms and processes remains limited. This is due to the dispersed nature of existing studies, the undefined intermediates involved, and the complexity of the matrices and processing conditions. Given these limitations, the authors have shifted their focus from foods to sulfides. The structure, source, and chemical characteristics of common precursors (sulfur-containing amino acids and derivatives, thiamine, thioglucoside, and lentinic acid) and their corresponding reactive intermediates (hydrogen sulfide, thiol, alkyl sulfide, alkyl sulfenic acid, and thial) are provided, and the degradation mechanisms, reaction rules, and matrix conditions are summarized based on their chemical characteristics. Additionally, the VSC formation processes in several typical foods during processing are elucidated, adhering to these identified rules. This article provides a comprehensive overview of VSCs, from precursors and intermediates to end products, and is crucial for understanding the mechanisms behind VSC formation and managing the flavor qualities of processed foods.

Diagnosing Thermalization Dynamics of Non-Hermitian Quantum Systems via GKSL Master Equations

Abstract The application of the eigenstate thermalization hypothesis to non-Hermitian quantum systems has become one of the most important topics in dissipative quantum chaos, recently giving rise to intense debates. The process of thermalization is intricate, involving many time-evolution trajectories in the reduced Hilbert space of the system. By considering two different expansion forms of the density matrices adopted in the biorthogonal and right-state time evolutions, we derive two versions of the Gorini–Kossakowski–Sudarshan–Lindblad (GKSL) master equations describing the non-Hermitian systems coupled to a bosonic heat bath in thermal equilibrium. By solving the equations, we identify a sufficient condition for thermalization under both time evolutions, resulting in Boltzmann biorthogonal and right-eigenstate statistics, respectively. This finding implies that the recently proposed biorthogonal random matrix theory needs an appropriate revision. Moreover, we exemplify the precise dynamics of thermalization and thermodynamic properties with test models.

When the going gets tough, the tough get going-Novel bacterial AAA+ disaggregases provide extreme heat resistance.

Heat stress can lead to protein misfolding and aggregation, potentially causing cell death due to the loss of essential proteins. Bacteria, being particularly exposed to environmental stress, are equipped with disaggregases that rescue these aggregated proteins. The bacterial Hsp70 chaperone DnaK and the ATPase associated with diverse cellular activities protein ClpB form the canonical disaggregase in bacteria. While this combination operates effectively during physiological heat stress, it is ineffective against massive aggregation caused by temperature-based sterilization protocols used in the food industry and clinics. This leaves bacteria unprotected against these thermal processes. However, bacteria that can withstand extreme, man-made stress conditions have emerged. These bacteria possess novel ATPase associated with diverse cellular activities disaggregases, ClpG and ClpL, which are key players in extreme heat resistance. These disaggregases, present in selected Gram-negative or Gram-positive bacteria, respectively, function superiorly by exhibiting increased thermal stability and enhanced threading power compared to DnaK/ClpB. This enables ClpG and ClpL to operate at extreme temperatures and process large and tight protein aggregates, thereby contributing to heat resistance. The genes for ClpG and ClpL are often encoded on mobile genomic islands or conjugative plasmids, allowing for their rapid spread among bacteria via horizontal gene transfer. This threatens the efficiency of sterilization protocols. In this review, we describe the various bacterial disaggregases identified to date, characterizing their commonalities and the specific features that enable these novel disaggregases to provide stress protection against extreme stress conditions.

A comparison of additive manufactured to injection molded Martian regolith based polymer matrix composites

The completed study investigated the creation of Martian regolith simulant composite parts using injection molding and additive manufacturing. Traditional manufacturing techniques such as injection molding are not feasible on the Martian surface therefore in-situ processes must be developed using additive manufacturing processes to prepare habitats prior to having a human presence on the surface. The goal of this study was to investigate the impacts of additive manufacturing on the material property values between parts made using traditional injection molding and additive manufacturing. Martian regolith simulant composite pellets were created by combining a Martian regolith simulant at 40 wt% loading with polypropylene via twin screw extrusion. This material was then used to create test specimens using injection molding and additive manufacturing. Samples underwent tensile, flexural, Izod impact, and immersion density tests according to ASTM International and standardized test instructions. Additive manufactured parts saw a nearly 40% reduction in tensile and flexural strength with more than double the tensile modulus when compared to injection molded parts. The flexural modulus for additive manufacturing was around 36% that of the injection molded part with a minor decrease in density of around 13%. The collected test results suggested that while there were differences in the material property values between the manufacturing processes, a more interesting foaming behavior of the extrudite was observed during the additive manufacturing process resulting in an extremely rough and pitted surface. This rough surface finish was a stark comparison to the smooth injection molded parts. This observed foaming behavior in the polymeric composite material during thermal processing prompted the theory that thermal releases from the Martian regolith simulant was the most likely cause of the observed differences. Pellet surface moisture tests, Martian regolith simulant thermogravimetric analyses, and literature reviews of thermal decomposition of the Martian regolith simulant constituents revealed that most likely olivine releases oxygen and hydrated silica releases water during the thermal processing of the Martian regolith simulant composite. During a closed mold process such as injection molding, these volatile gases are forced out of the part by the pressures of the molding process, but in an open to atmosphere process such as additive manufacturing these gases foam to the surface during cooling leaving the part with an inferior surface finish.

DETERMINATION OF THE FEATURES OF THERMAL DECOMPOSITION OF SUNFLOWER HUSK IN A FLUIDIZED BED

Sunflower husk (SH) is a plant waste fuel. The carbon content in different samples of SH ranges from 40.5% to 54.5% in an operating state, with ash content ranging from 1.5% to 8.5%, moisture content ranging from 6.9% to 9.5%, chlorine content ranging from 0.05% to 0.3%, and lower heating value ranging from 14.5 MJ/kg to 20.5 MJ/kg. These characteristics make it a suitable substitute for fossil fuels in power boilers. Waste-to-energy (WTE) technologies are rapidly developing worldwide, offering the potential for generating renewable energy from waste, including agricultural and food industry waste such as SH. According to our estimates, Ukraine has an annual energy potential of approximately 3.4 million tons of SH or about two million tons of fuel equivalent. Approximately half of this volume is currently being burned in oil extraction plants' boilers; however, up to one million tons of SH end up in landfills annually, resulting in significant energy losses. To develop new and improve existing WTE technologies that utilize SH as a fuel source, it's essential to understand the thermal processing characteristics of SH under conditions similar to those found in different zones within real power boilers - specifically the heating of fuel particles at rates up to 500 °C/s over a temperature range of 500–1000 °C. In this study, we aimed to investigate the thermal processing characteristics by subjecting SH particles within a laboratory fluidized bed reactor to high-speed heating within the aforementioned temperature range. During rapid heating between 500–1000 °C temperatures range, SH particles undergo conversion into volatile compounds and solid carbon residue. Two distinct stages can be observed on the dynamic yield curves for volatiles. The release and burnout of volatiles occurs during the first stage while the second stage involves coke ash residue burnout. We obtained empirical temperature-dependents for total heat treatment time and carbon residue burnout time under fast heating conditions in the investigated temperature range. The stage of carbon residue combustion is the most enduring and determines the overall duration of thermal treatment. This stage determines the degree of fuel transformation, especially in cases where low-reactivity carbon residue enters the low-temperature combustion chamber area of the boiler. The obtained regularities have practical significance in designing combustion chambers for thermal processing of sunflower husk.

Stabilization of delphinidin-3-O-rutinoside by mixed β-conglycinin and hydrolysates of glycinin upon heating

The selectively hydrolyzed soy protein composed of β-conglycinin (7S) and glycinin hydrolysates (GH) showed a superior protective effect on the delphinidin-3-O-rutinoside (D3R) during the steaming of colored wheat dough. To clarify the potential mechanism, 7S and GH were isolated and combined in varied ratios to mimic the RG proteins, and the interactions between proteins and D3R were studied by combined multispectral and molecular dynamics simulation study. The results suggested that 7S showed a higher stabilization effect of D3R than GH upon heating. In contrast, the optimum effect was noticed when incorporated with the mixed proteins with equal level of 7S and GH. D3R induced conformational changes of 7S and GH upon heating, and D3R formed complexes with proteins via hydrophobic interactions, and it was a static quenching process. The optimal binding affinity to D3R was observed with equal level of GH and 7S, contributing to enhanced thermal stability. Compared with GH, 7S could bind more amino acids and form a more stable complex with D3R. The results of this study could provide a theoretical basis for the preservation of D3R upon thermal processing and promote the application of mixed soy proteins in the functional food industry.

Analysis of the thermal control system for the 3U CubeSat nanosatellite – “IXAYA”

Abstract In recent years, space exploration has become increasingly accessible to a diverse array of countries, facilitated in part by CubeSat nanosatellites. These versatile nanosatellites find applications in a wide spectrum of fields, from forest fire detection and meteorological observation to communication systems, particle analysis, and hot spot identification. This article delves into the outcomes of a comprehensive thermal analysis conducted on the IXAYA nanosatellite. The primary mission of this nanosatellite is to identify hot spots in the vicinity of Mexico City. The thermal analysis process entails a meticulous review of each subsystem along with the associated boundary conditions. This study commences with the definition of an optical payload and a thorough assessment of subsystem requirements. Subsequently, we calculate both external and internal thermal loads. With these foundational data points, we progress to ascertain the temperature distribution across the entirety of the satellite, ensuring that all constituent elements remain within their designated operational temperature ranges. In the closing section, we present our findings and conclusions.

A coupled thermo-mechanical model for investigating cracking and failure of composite interbedded rock

Composite interbedded rock is a special geological phenomenon that occurs when layers of rock (beds) of a given lithology lie between or alternate with other layers of a different lithology. The thermal and mechanical properties of the composite interbedded rocks exhibit strong anisotropy. Studying the thermomechanical coupling properties of natural composite interbedded rocks using existing experimental techniques is challenging. A coupled thermo-mechanical composite interbedded rock model was developed based on Fourier's heat-conduction law and Newton's second law. The thermodynamic responses and biaxial mechanical properties of composite interbedded rocks with different interlayer angles under the coupling of initial stress and thermal loading were studied for the first time. The results indicate that the thermal stresses within the granite interlayers are higher than those within the sandstone interlayers. Throughout the thermal loading process, thermal cracking occurred primarily within the (stiffer) granite interlayers. The number of thermal cracks generated during the cooling process far exceeds that during heating; at 400 °C, the number of thermal cracks during cooling is more than 35 times that during heating. When the interlayer dip angle approaches 90° and is aligned with the major principal stress direction, the phenomenon of the “double peaks” and layered failure becomes more pronounced. Within the range of variables considered, the relative impact of the three variables on peak stress in composite interbedded rock is as follows, from greatest to least: interlayer angle, thermal shock temperature, and model size. The results and developed modeling methods will contribute to the management and optimization of future engineering geology projects.

Computational thermal fluid enabled multi-physics transport processes analysis of ceramic hollow fiber membrane for oxygen separation

A comprehensive hollow fiber membrane model is developed using an experimental system as a physical base, where Multiphysics transport processes in the membrane are coupled with a large-scale thermal fluid transport processes in the test assembly and furnace. Systematic parametric studies are carried out to understand fundamental mechanisms and membrane performance. Results indicate that oxygen partial pressure at the permeate side asymptotically increases from the inlet toward the outlet of hollow fiber membrane. Longitudinal distribution of oxygen vacancy concentration follows the opposite trend to that of oxygen partial pressure at the permeate side while oxygen flux distribution follows the profile of oxygen vacancy distribution at the permeate surface. High air pressure at the feed side and low gas pressure at the permeate side facilitate to enhance oxygen permeation performance. Surface exchange resistance at the permeate side dominates the total resistance of the membrane while the bulk diffusion resistance accounts for the minimum contribution in substrate-supported thin film hollow fiber membrane. The modeling study may obtain an insightful understanding of fundamental mechanisms and can provide guidance for membrane design and operations to achieve better performance for oxygen production.

Comparative study on manufacturing of EDM electrodes by laser sintering process

The abstract aims to investigate the comparative performance of Electrical Discharge Machining (EDM) and Selective Laser Sintering (SLS) with unconventional machining processes. Unconventional machining processes have gained significant attention due to their versatility and capability to fabricate intricate components with high precision. This study focuses on assessing the efficacy of EDM and SLS techniques in terms of data removal rate and relative wear volume. Electrical Discharge Machining (EDM) is a thermal erosion process that utilizes electrical discharges to remove material from a workpiece. In contrast, Selective Laser Sintering (SLS) is an additive manufacturing technique that employs a laser to selectively fuse powdered material, layer by layer, to build up a three-dimensional object. Both methods offer unique advantages in terms of precision, speed, and material compatibility. The performance evaluation of these techniques involves analyzing key parameters such as data removal rate, which measures the volume of material removed per unit time, and relative wear volume, which quantifies the wear on the tool or workpiece during the machining process. By comparing these metrics, insights into the efficiency and effectiveness of EDM and SLS can be gained, aiding manufacturers and researchers in selecting the most suitable method for specific applications. Through experimental investigations and data analysis, this study aims to provide valuable insights into the capabilities and limitations of EDM and SLS in unconventional machining processes. The findings will contribute to advancing the understanding of these techniques and optimizing their utilization in various industrial sectors, including aerospace, automotive, and biomedical engineering. The experimental analysis examines the impact of the Direct Metal Laser Sintering (DMLS) process parameter on sintering depth. The optimized parameters for AlSi10Mg alloy powder sintering were obtained using laser power at 162 W, scanning speed at 156 mm s−1, porosity at 20%, laser area size of 0.2 mm, and layer thickness of 1 mm.