Use Of Lightweight Materials Research Articles

Assessment of life cycle environmental impacts of materials, driving pattern, and climatic conditions on battery electric and hydrogen fuel cell vehicles in a cold region

Battery electric vehicles (BEVs) and hydrogen fuel cell vehicles (HFCVs) can play an important role in addressing climate change by diminishing greenhouse gas (GHG) emissions in the worldwide road transportation sector. There is limited research on the implications of the use of lightweight materials, driving pattern, and climatic impact on the life cycle GHG emissions in a cold region. To address this limitation, we developed a framework to assess eighteen BEV and four HFCV scenarios for a cold region that consider aforementioned parameters through a combination of driving patterns (in rural, city, and highway driving) and climatic conditions (i.e., summer, mild winter, and severe winter) for both conventional and carbon fiber-reinforced plastic (CRFP)-based BEVs. A case study was conducted for Canada, considering its cold regions, using available data for HFCVs. We assessed city driving in summer and highway driving in severe winter conditions for conventional and CFRP-based HFCVs. The results show that the lowest GHG emissions are in cities in summer, with life cycle GHG emissions values of 68.7 g CO2 eq/km for CFRP-based BEVs. The highest life cycle GHG emissions are 364.4 g CO2 eq/km with conventional HFCVs on the highway in severe winter conditions' scenario. The operation phase emerges as the primary contributor to life cycle GHG emissions, closely trailed by the production phase. The analysis shows that the most sensitive parameters for CFRP-based BEVs in the city in summer scenario are vehicle lifetime and for conventional HFCVs in the highway in severe winter scenario, fuel cell efficiency. The analysis also shows the range of life cycle GHG emissions for a cold region, with conventional HFCVs on highways in severe winter conditions exhibiting the highest emissions (331.0 g CO2 eq/km) and CFRP-based HFCVs in the city in summer scenario the lowest (51.0 g CO2 eq/km).

The Uses of Lightweight Material in Civil Engineering : A Review

A lightweight aggregate (LWA) is a group of aggregates with a relative density lower than normal density aggregates (natural sand, gravel, and crushed stone), sometimes referred to as low density aggregate. It is utilized for its reduced weight and exceptional qualities in sound reduction, fire resistance, insulation, and geotechnical applications LWA, or lightweight aggregate, is a cutting-edge construction material that is employed to decrease the overall weight of tall structures. Despite being lighter, it possesses a strength that is comparable to that of regular concrete. In recent times, there has been a significant surge in the use of lightweight aggregate in the field of building, mostly because of its exceptional performance in seismic situations. In addition, substituting natural aggregate with other industrial by-products and trash enables us to minimize the adverse environmental consequences. Laser wavelength ablation (LWA) has also been employed to address a wide range of geotechnical engineering challenges, including the transformation of soft and unstable soil into a suitable and usable property. Lightweight fillings have a weight that is around 50% less than fills made using typical materials. The load reduction, along with the high internal friction angle of the lightweight aggregate, can decrease vertical and lateral pressures by almost 50%, potentially resulting in less settling. This literature study examines the use of lightweight materials, including LECA, Bonza, and Thermostone, in geotechnical engineering applications. The results demonstrate a significant emphasis on improving slope stability and minimizing stresses on susceptible soils. Nevertheless, several knowledge gaps exist regarding the efficacy of these materials under challenging conditions and when subjected to dynamic loads. A growing inclination towards using these lightweight aggregates is observed because of their advantageous environmental and mechanical properties. Further investigation is needed to examine the extended-term performance and interactions of these materials with different soil types in order to enhance their performance in diverse geotechnical situations.

Microstructural and mechanical properties of Al-5356 alloy structures fabricated using direct energy deposition (DED): In-pursuit to optimizing deposition parameters

Many industries including aerospace make extensive use of lightweight materials like aluminium alloys because of their extraordinary properties. Wire Arc Additive Manufacturing-Cold Metal Transfer (WAAM-CMT) as a part of modern direct energy deposition technique can be recommended for developing aerospace components of aluminium alloys. However, it is still necessary to investigate the impact of the combined change of developing parameters on some of the crucial qualities including metallurgical and mechanical properties. Therefore, in this part of research work, practically, various process parameters were tried for development of aluminium (Al-5356) alloy walls. Finaly, a specific set of parameters namely wire feed speed, scanning speed and inter layer temperature parameters with two levels of each were selected and with the assistance of these, four walls have been fabricated. Th preliminary analysis showed that low heat input accompanied by higher scanning speed of 60 cm/min and lower wire feed rate of 6 m/min was found to best suitable set of parameters for developing dimensionally stable Al wall with flaw less microstructure. The said set of parameters also showed higher hardness that also accompanied with finer grains, lower percentage towards high angle grain boundary and lower KAM. Even slight variation in these parameters that deal to high heat input can give rise of porosity and misalignment in the wall. Details of microhardness reported high hardness in the bottom part of the wall. However, in a single bead the hardness is higher in the top region, which may be owing to finer grains in the specified region. The above said set of parameters also able to deliver better tensile strength and toughness for Al-5356 alloy. The developed alloy showed improved strength in longitudinal orientation owing to intra layer failure with ductile mode of fracture in contrast to transverse orientation, where the failure mode was reported to mixed (ductile as well as brittle) owing to inter layer fracture.

Advancements in Lightweight Materials for Aerospace Structures: A Comprehensive Review

The aerospace engineering field is witnessing an evolution towards lightweight materials driven by the unwavering pursuit of improved performance and efficiency. Lightweight materials play a critical role in aerospace structures, and this thorough examination explores their significant influence on mission success, design, and fuel efficiency. Key developments in several material categories such as composites, metals, and polymers are methodically examined in this study, revealing their special qualities and potential uses. The historical viewpoint lays out a chronology of the development of materials, charting significant turning points that have influenced the use of lightweight materials in aerospace. The following sections delve into each lightweight material in great detail, explaining composites, alloys (including titanium, aluminium, and high-strength steel), and sophisticated polymers, along with their features, production methods, and uses. An examination of particular varieties and production nuances in the context of aerospace composite materials highlights their benefits in achieving unmatched strength-to-weight ratios. By elucidating their qualities and expanding uses in aircraft constructions, advanced metallic alloy research reveals the most recent advancements in materials like titanium and aluminium. A thorough examination of polymeric materials and nanocomposites reveals their critical role in the creation of lightweight structures. Their distinctive qualities and new uses are emphasized, highlighting their role in the ongoing revolution in aeronautical design. With a comprehensive examination of additive manufacturing and sophisticated machining methods essential to the realization of lightweight aircraft structures, innovative manufacturing technologies take center stage. Additionally, the assessment thoroughly evaluates the longevity and structural integrity of lightweight materials, addressing issues related to corrosion, fatigue, and other crucial elements. Investigations from actual applications provide concrete instances of lightweight materials being successfully used in aerospace projects, shedding light on the materials' performance and tangible advantages in various situations. Looking ahead, the paper's conclusion forecasts forthcoming developments in lightweight materials and clarifies possible obstacles and future research avenues that may influence the course of aerospace engineering. To underscore the critical role that lightweight materials play in aeronautical constructions, this paper synthesizes a variety of knowledge. It highlights the revolutionary potential of lightweight materials in influencing the future of aeronautical engineering, not only synthesizing current knowledge but also laying out a path for further study and innovation.

Influence of passive deformation in the lift coefficient of a NACA0012 wing model

The extensive use of lightweight materials in aerial vehicle wings involves structural flexibility phenomena that generate non-negligible deformation effects. This influence is not restricted to big aircraft but also plays a role in smaller aeroplanes and Unmanned Aerial Vehicles (UAVs). Here, we conduct wind tunnel experiments to analyze the effect of passive deformation on the wing model lift slopes. To isolate the deformation effect, we compare rigid wings with a NACA0012 airfoil imposing a prescribed spanwise deformation. We study three levels of deformation: non-deformed, around 2% and 4.5% of tip deflection. Also, we consider the effect of the wing length by using three different semi-aspect ratios (1, 2, and 4), so a total of nine rigid wing models have been analyzed for a range of Reynolds number from 80×103 to 160×103. Deformed wing models show an increase in lift coefficient compared to non-deformed wing cases. Both deformation levels exhibit a qualitatively similar lift increment. A correlation to predict lift coefficient slope in a flat plate is adapted for a NACA0012 airfoil and validated using our experimental results and literature data. The adjusted correlation can quantify the deformation effect on the lift slope, which is comparable to using a slightly longer wing model.

New Advances in Antenna Design toward Wearable Devices Based on Nanomaterials.

Wearable antennas have recently garnered significant attention due to their attractive properties and potential for creating lightweight, compact, low-cost, and multifunctional wireless communication systems. With the breakthrough progress in nanomaterial research, the use of lightweight materials has paved the way for the widespread application of wearable antennas. Compared with traditional metallic materials like copper, aluminum, and nickel, nanoscale entities including zero-dimensional (0-D) nanoparticles, one-dimensional (1-D) nanofibers or nanotubes, and two-dimensional (2-D) nanosheets exhibit superior physical, electrochemical, and performance characteristics. These properties significantly enhance the potential for constructing durable electronic composites. Furthermore, the antenna exhibits compact size and high deformation stability, accompanied by greater portability and wear resistance, owing to the high surface-to-volume ratio and flexibility of nanomaterials. This paper systematically discusses the latest advancements in wearable antennas based on 0-D, 1-D, and 2-D nanomaterials, providing a comprehensive overview of their development and future prospects in the field.

A pragmatic approach for the fatigue life estimation of hybrid joints

The need for more environmentally sustainable ways of transportation and for a reduction in emissions and fuel consumption make lightweight structures essential. Together with the use of lightweight materials and design optimisation, the use of hybrid joints represents one way to reduce the weight of components and it is becoming increasingly popular in the transportation industry. The name ‘hybrid joint’ refers to a connection where adhesive bonding is used in conjunction with traditional joining techniques, such as spot welds and rivets with the aim of combining and exploiting the advantages of the individual joining techniques. To optimise the design of hybrid joints and minimise the risk of in-service fatigue failures, the transportation industry needs efficient, robust, and easy-to-use approaches for the modelling and fatigue life estimation of hybrid joints.This work presents two practical methodologies for estimating the fatigue life of hybrid joints that can be easily adopted by companies in the transportation industry. The first methodology neglects the life given by the mechanical joints after failure of the adhesive (the joint is considered failed when the adhesive fails), while the second methodology considers the life of both the adhesive and the mechanical joints. In the first methodology, just one configuration would need to be analysed (‘hybrid’ joint or ‘purely bonded’ joint, if this simplification is considered reasonable). In the second methodology, instead, the analysis of two configurations would be required (the previous configuration followed by a configuration where only the mechanical fasteners are considered). The second methodology would produce more realistic fatigue life estimations compared to the first methodology, but it would be more onerous both in terms of modelling and computationally. For both methodologies, FE modelling guidelines to recover the required stresses are suggested. These guidelines require limited changes to the typical FE modelling strategies currently used, especially in the automotive industry. Furthermore, the proposed modelling guidelines provide FE models that are not computationally too onerous, reasonably mesh insensitive and that do not require congruent meshes. The relevant stresses recovered from the FE model are then used as an input into nCode DesignLife to estimate the fatigue life of the hybrid joints in the analysed structure. The fatigue life estimation is carried out using standard Stress-Life (SN) based nCode DesignLife analysis engines and bespoke SN curves obtained through testing of hybrid joint specimens, representative of the joints in the production parts.

The potential of using 3D printing in the manufacture of mini hydraulic systems

The work is devoted to an analytical engineering study of the practicality of using 3D printing for the manufacture of hydraulic components, in order to solve the problems associated with weight, size and complexity inherent in traditional hydraulic elements. The research aims to demonstrate the feasibility of using 3D printing to achieve simplified design and increased efficiency. The work presents samples of hydraulic elements printed on a 3D printer, which reflects the practical feasibility of this approach. A simple and practical design methodology is proposed for two key components of a typical hydraulic system, namely, a hydraulic cylinder and a directional servo-valve, which allows hydraulic actuators to be controlled using any programmable microcontroller. A distinctive feature of this approach is the emphasis on the principles of compact design, which facilitates the integration of many parts into single, multifunctional part. In addition, the use of lightweight materials in 3D printing helps reduce the overall weight of hydraulic components. The proposed method also allows the integration of various hydraulic elements into a single integral structure printed on a 3D printer, offering a pragmatic solution to the size and complexity issues associated with traditional metal hydraulic systems. The scope of this innovative approach extends to the creation of prototypes of hydraulic and pneumatic robots, as well as devices that require compactness, precision and adaptability. This methodology is promising for implementation in the field of robotics, especially for tasks where space and weight constraints are critical factors.

The Effect of Lime Stone in the Probability of Formation Pores Structures in Glass Ceramic Based on Scoria Basalt Rocks

This paper provides a Lightweight material is the result of technological problems in increasing the efficiency of finished products, saving manufacturing costs and environmentally friendly technology by reducing the amount of material used. There are many kinds of material manufacturing technology, ranging from the use of lightweight materials from the start, combining materials into composites and modifying the structure and characteristics of the material to make it lightweight. One commonly used method is to mix glass-ceramic with a foaming agent in purpose to modify the structure of material. The purpose of this study is to utillize basalt rock as source of glass ceramic and mixed with limestone to form cellular structure with optimal composition. The samples was crushed and sieve through 100 mesh afterward all material is mixed varied between basalt and lime with a ratio of sample A (100% Basalt), sample B (3:7), sample C (5:5), and sample D (7:3), which were burned at a temperature of 1100°C and 1300°C. After all sample reach designated temperature, all sample undergo annealed cooling in the furnace. Based on the characterization results, the best glass-ceramic sample formed with pores structure formation was sample B which is 70% addition of limestone in basalt mixture and burned at a temperature of 1100°C with a total pore size of 63% and a density of 0.92 g/cm3, where the glass-ceramic structure detected pyroxene and lime phases with a SiO2 composition of 14.61%. Basalt cellular ceramic is obtained in optimal condition with low density and higher percentage porosity.

A review of the feasibility of aluminum alloys, carbon fiber composites and glass fiber composites for vehicle weight reduction in the automotive industry

Improving fuel efficiency is an important goal of the automotive industry. The most effective way to improve fuel efficiency is to reduce the weight of the vehicle, which could be achieved by replacing components made from traditional materials with lightweight materials. This article reviews the research and use of lightweight materials, aluminum alloys, carbon fiber composites, and glass fiber composites in the automotive industry. A review of the current literature considers the mechanical properties, processability, safety properties, price, and manufacturing methods of these three materials to discuss the possibility of reducing vehicle weight and thus improving fuel efficiency.

The assessment of structural behaviours of steel framing system – affordable house system design

Purpose Nowadays, residential buildings have become increasingly important due to the growing communities. The purpose of this study is to investigate the behavior of a steel structural framing system that incorporates lightweight load-bearing walls and slabs, and to compare the weight of materials used in cold-formed and hot-finished steel structural systems for affordable housing. Design/methodology/approach Four types of models consisting of 243 members were simulated. Model 1 is a cold-formed steel structural framing system, while Model 2 is a hot-finished steel structural framing system. Both Models 1 and 2 use lightweight wall panels and lightweight composite slabs. Models 3 and 4 are made with brick walls and precast reinforced concrete systems, respectively. These structures use different wall and slab materials, namely, brick walls and precast reinforced concrete. The analysis includes bending behavior, buckling resistance, shear resistance and torsional rotation analysis. Findings This study found that using thinner steel sections can increase the deflection value. Meanwhile, increasing member length and the ratio of slenderness will decrease buckling resistance. As the applied load increases, buckling deformation also increases. Furthermore, decreasing shear area causes a reduction in shear resistance. Thicker sections and the use of lightweight materials can decrease the torsional rotation value. Originality/value The weight comparison of the steel structures shows that Model 1, which is a cold-formed steel structure with lightweight wall panels and lightweight composite slabs, is the most suitable model due to its lightweight and affordability for housing. This model can also be used as a reference for the optimal design of modular structural framing using cold-formed steel materials in the field of civil engineering and as a promotional tool.

Performance analysis of electric motors, comparing lightweight techniques and cooling methods: A review

The paper gives a comprehensive review of lightweight materials/design of permanent-magnet-synchronous-motors and different temperature-reducing (cooling) techniques. The paper discusses and compares various simulations and performance analyses of different practically implemented solutions. Temperature and performance analyses for cooling systems using phase-changing materials, cooling jackets, and other coolants are investigated, and the use of lightweight materials and composites is compared. A discussion on numerical methods and results (finite element method analysis), in order to get a more-precise thermal mapping model for different machine structures is presented. Finally, the best temperature-reducing-cooling systems methods along with the good lightweight designs which increase the overall efficiency of the motor are discussed and commented on.

Floor vibrations and rectification

Excessive floor vibration due to human excitation is a significant serviceability concern in buildings and other long span structures. The use of lightweight materials, nominal furniture and open plan layouts is resulting in lighter floors with lower damping than traditional older floors and hence an increased risk of excessive vibration response. This paper provides insights into walking excitation, floor response and remedial actions for floors with excessive vibrations.

Multi-Response Optimization of Semi-Lightweight Concrete Incorporating Expanded Polystyrene Beads

The utilization of expanded polystyrene (EPS) beads in semi-lightweight concrete (SLC) intended for repair and building applications has gained great attention in recent years. This study examines the effect of mix design parameters including binder content, water-to-binder ratio (w/b), EPS content, and silica fume (SF) additions on the mechanical properties and durability of SLC mixtures. The experimental program was carried out following the Taguchi approach for four parameters, each having three levels, to produce an L9 orthogonal array. The performance criteria under investigation were the superplasticizer demand, density, compressive strength, splitting tensile strength, ultrasonic pulse velocity, water absorption, sorptivity, and abrasion resistance. Test results showed that the w/b and EPS content were the most contributing parameters that altered the SLCs performance. The multi-response optimization method (TOPSIS) revealed that superior performance could be achieved using a binder content of 375 kg/m3, a w/b of 0.45, an EPS content of 3 kg/m3, and a SF replacement rate of 8%. The mix design parameters were utilized to create multivariate regression models to predict the SLCs mechanical and durability properties. Such data can be of particular benefit to engineers seeking the use of lightweight materials for sustainable construction with optimized durability and a reduced cement carbon footprint.

The Thermal Performance of Osing Houses in The Banyuwangi as Humid Tropical References

The Osing houses are one of the various traditional architectures in East Java Province, located in Kemiren Village, Banyuwangi Regency at an altitude of 144 meters above sea level, which is included in a low topography with a unique roof, which has three types of structures, namely Tikel Balung, Crocogan, and Baresan. The House of Osing grew from people with all kinds of traditions and took advantage of various local potentials, such as materials, technology, and existing knowledge. However, the local potential, such as the use of lightweight materials, creates problems hot because the thermal properties of lightweight materials are easy to flow thermally, so they can create overheating conditions and affect comfort conditions in buildings. This study aims to the influence of the design of the Osing house on thermal conditions, describes the material behavior of the design elements that affect the thermal performance of the Osing house. The research was conducted using observation and measurement methods. The final results of this study indicate that houses have not been able to provide thermal comfort, especially during the afternoon to evening, when the condition of the building tends to excessive heat.

Surface roughness analysis for improving punching tools performance of 5754 aluminium alloy

The use of lightweight materials in the automotive industry, as a key element in fuel economy, is a growing trend to meet the global emissions reduction agreement. Aluminium, in the form of stamped sheet, has the potential to be used extensively in vehicle as a high-specification structural and skin parts. However, compared to steel, aluminium is more difficult to stamp, thus the optimized techniques and manufacture strategies learned in steel stamping are not adequate given the complex processability of aluminium alloys. To achieve the quality standards, it is necessary to optimize aluminium stamping processes by developing specific techniques, geometries, and functional surfaces on tooling. In this work, the influence of tool geometry and surface roughness, as well as the use of lubricant during the punching process of 5754 aluminium sheets have been evaluated in a pilot plant under similar industrial conditions. Before the pilot plant test, different tool surface roughness qualities were evaluated at lab scale using a ball on disc test. Subsequently, performance of coated tools was evaluated through “coated ball” on “5754 aluminium disc” tests. The best combination between lubricant and coating was used to perform the aluminium punching process in the pilot plant, where two types of geometry and roughness of tool were analysed. Results were expressed in terms of aluminium adhesion on tool surface. Polished surface before coating deposition and geometry punches were the key factor to improve the process.

Tribo- and Tribocorrosion Properties of Magnesium AZ31 Alloy

In automotive and aerospace fields, the use of lightweight materials is required. Magnesium and its alloys combine a low density with high mechanical properties and excellent thermal conductivity. However, those materials suffer from low corrosion and wear resistances. The combined action of corrosion and wear is also critical for these materials. Tribocorrosion of magnesium alloy AZ31 has been investigated with reciprocal sliding wear as a function of the applied load in dry and wet (NaCl) conditions. The study shows that the main wear mechanisms were adhesion, abrasion, and oxidation in dry sliding wear while no adhesion was found in wet sliding wear. Corrosion of the worn surface occurs also in wet sliding wear. It is interesting to notice that wear is less pronounced in wet sliding wear than in dry sliding wear due to the natural lubrication of the NaCl electrolyte. Only severe conditions, high normal load, and wet conditions bring magnesium AZ31 alloy in filiform corrosion.

A Verification and Validation Study on a Loosely Two-Way Coupled Hydroelastic Model of Wedge Water Entry

_ The interaction between the structural response and hydrodynamic loading (hydroelasticity) must be considered for design and operation purposes of high-speed planing craft made of composites that are prone to frequent water impact (slamming). A computational approach was proposed to study the hydroelastic slamming of a flexible wedge. The computational approach is a loose two-way coupling between a Wagner-based hydrodynamic solution and a linear finite element plate model. Verification and validation (V&V) was performed on this coupled model. It was found that the model overpredicts rigid-body/spray root kinematics by <15% and hydrodynamic loading/ structural response by <26%. Introduction One of the primary constraints on the operational envelope of high-speed craft is slamming (water impact). Slamming occurs between the hull body and the water surface when a portion/whole of the craft exits the water and then reenters at high-enough velocity (Lloyd 1989; Faltinsen 2005). The frequent water impacts, which work like “water hammers,” along with their induced acceleration pose great jeopardy on hull structures as well as crew and instrument on-board (Yamamoto et al. 1985; Ensign et al. 2000; Hirdaris et al. 2014). With the growing use of lightweight materials, the interaction between the structural deformation and the hydrodynamic loading (hydroelasticity) becomes more prevalent. The current design criteria of high-speed craft are based on empirical procedures with no regard to hydroelasticity due to the lack of understanding of this complex phenomenon (DNV 2013; ABS 2016). Therefore, a better comprehension of hydroelastic slamming is the first step to designing more high-performance craft (Fu et al. 2014; Judge et al. 2020).

Polymer matrix nanocomposites from the ecological aspect in the automotive industry

Meeting the stringent requirements of the automotive industry that the material must meet in terms of price and performance is a serious challenge for engineers. The use of lightweight materials has led to the use of polymer nanocomposites in the automotive industry but has also led to new issues such as the impact on the ecological aspect of the environment. Tests, which are still ongoing, have found improvements in many material properties such as mechanical, thermal, electrical, optical and magnetic. So, on one hand, improved properties and low prices of production and manufacturing have been recorded, on the other hand, there is insufficient research of their impact on the environment, which this paper aims to investigate.

Modeling and Simulation of Electric Motors Using Lightweight Materials

Electric motors are utilitarian devices of great potential as they can limit the amount of pollution by drastically reducing the release of harmful gases. The implementation of the right type of advanced materials plays a vital role in the amelioration of modern automobiles while maintaining and/or improving the performance and efficiency of the electric motor. The use of lightweight materials could result in a better-performing vehicle that can be much less heavy. The replacement of regular cast iron, steel, and aluminum with lightweight materials such as fiber-reinforced polymer, carbon fiber, and polymer composites can reduce the weight of the motor without impacting its performance and improve its energy-saving capacity. This paper explores a way to reduce motor weight by employing a PA6GF30 30% glass fiber-reinforced polymer casing to reduce the weight of the motor while making cooling system modifications. This material was applied to the motor casing, which resulted in a significant reduction in weight compared to the water-cooled electric motor of aluminum (Alloy 195 cast) casing.