Pub Date : 2025-11-01Epub Date: 2024-05-17DOI: 10.1016/j.ijlmm.2024.05.004
Muslim Mukhtarkhanov , Serik Akayev , Sherif Araby , Essam Shehab , Md. Hazrat Ali
This study proposes a novel method for the evaluation of expansion forces that occur during the heating of IC (investment casting) waxes with the help of a rheometer. Thermal expansion of the IC wax patterns is the main reason that causes ceramic shell failure during the dewaxing process. The technique is based on the measurement of normal forces that develop in the measuring system of the rotational rheometer during solidification of wax samples. These forces are created as a result of shrinkage of thermally expanded wax samples. To assess the efficiency of the proposed method, three types of commercially available waxes and one 3D-printable wax have been tested and compared. According to research findings, the proposed method can be prescribed as an efficient procedure for the evaluation of expansion forces that develop during wax heating, especially for waxes that have low viscosity properties. It was observed that machinable wax produced the highest value of normal load equivalent to 86 N while the IC and 3D-printing wax generated 18.8 and 36.3 N respectively. Moreover, it was discovered that additively manufactured wax patterns perform considerably better compared to their casted analogs during dewaxing processes.
{"title":"A novel method for evaluating thermal expansion forces during dewaxing of investment casting and 3D-printing waxes","authors":"Muslim Mukhtarkhanov , Serik Akayev , Sherif Araby , Essam Shehab , Md. Hazrat Ali","doi":"10.1016/j.ijlmm.2024.05.004","DOIUrl":"10.1016/j.ijlmm.2024.05.004","url":null,"abstract":"<div><div>This study proposes a novel method for the evaluation of expansion forces that occur during the heating of IC (investment casting) waxes with the help of a rheometer. Thermal expansion of the IC wax patterns is the main reason that causes ceramic shell failure during the dewaxing process. The technique is based on the measurement of normal forces that develop in the measuring system of the rotational rheometer during solidification of wax samples. These forces are created as a result of shrinkage of thermally expanded wax samples. To assess the efficiency of the proposed method, three types of commercially available waxes and one 3D-printable wax have been tested and compared. According to research findings, the proposed method can be prescribed as an efficient procedure for the evaluation of expansion forces that develop during wax heating, especially for waxes that have low viscosity properties. It was observed that machinable wax produced the highest value of normal load equivalent to 86 N while the IC and 3D-printing wax generated 18.8 and 36.3 N respectively. Moreover, it was discovered that additively manufactured wax patterns perform considerably better compared to their casted analogs during dewaxing processes.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 716-725"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141055534","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-07-19DOI: 10.1016/j.ijlmm.2025.07.005
Anyuan Jiao , Enyang Lu , Wanshun Zhang , Xue Li
Machining high-quality blind holes in Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges due to its anisotropic structure, abrasive fibers, and susceptibility to defects such as delamination and fiber pullout. This study explores the application of helical milling technology for CFRP blind hole fabrication, which enhances machining quality by reducing cutting forces and improving surface integrity. Kinematic analysis and simulation of the helical toolpath are conducted using MATLAB to reveal the bottom surface formation process. Finite element analysis via ABAQUS is performed to evaluate the stress, strain, and cutting force behavior during milling. A three-factor, five-level Central Composite Design (CCD) based on Response Surface Methodology (RSM) is designed to optimize key parameters, including spindle speed, axial cutting depth per revolution, and feed rate. Quality indicators such as maximum inlet tear, bottom surface roughness, and hole diameter accuracy are evaluated. The results show that helical milling combined with RSM-based parameter optimization significantly improves blind hole machining quality and precision, providing theoretical and practical references for the manufacturing of CFRP precision components in aerospace and other fields.
{"title":"Experimental study on helical milling of blind holes in Carbon Fiber Reinforced Polymer","authors":"Anyuan Jiao , Enyang Lu , Wanshun Zhang , Xue Li","doi":"10.1016/j.ijlmm.2025.07.005","DOIUrl":"10.1016/j.ijlmm.2025.07.005","url":null,"abstract":"<div><div>Machining high-quality blind holes in Carbon Fiber Reinforced Polymer (CFRP) presents significant challenges due to its anisotropic structure, abrasive fibers, and susceptibility to defects such as delamination and fiber pullout. This study explores the application of helical milling technology for CFRP blind hole fabrication, which enhances machining quality by reducing cutting forces and improving surface integrity. Kinematic analysis and simulation of the helical toolpath are conducted using MATLAB to reveal the bottom surface formation process. Finite element analysis via ABAQUS is performed to evaluate the stress, strain, and cutting force behavior during milling. A three-factor, five-level Central Composite Design (CCD) based on Response Surface Methodology (RSM) is designed to optimize key parameters, including spindle speed, axial cutting depth per revolution, and feed rate. Quality indicators such as maximum inlet tear, bottom surface roughness, and hole diameter accuracy are evaluated. The results show that helical milling combined with RSM-based parameter optimization significantly improves blind hole machining quality and precision, providing theoretical and practical references for the manufacturing of CFRP precision components in aerospace and other fields.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 793-804"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145420523","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Magnesium (Mg) alloy-based biodegradable implants are gaining popularity for their low density, high strength, and biocompatibility. The corrosion and wear performance of Mg is poor in physiological environments, leading to premature failure. Surface modification, particularly through surface texturing, reduces the effective contact area of Mg–Zn–Ca alloy with corrosive media and tribological partners, potentially optimizing its degradation kinetics and cytocompatibility. Wire Electric Discharge Machining (WEDM) offers a stable oxide layer on the surface, unlike laser surface texturing, which may thermally damage the Mg alloy. In this study, three types of textures, mainly Wavy Texture (WT), microchannels (MC), and micropillars (MP), were created using WEDM on the Mg–Zn–Ca samples, and their corrosion, wear, cytotoxicity, and cell adhesion performance were evaluated. Texturing on the surface of the samples enhanced the corrosion performance, from 3.14 mm/year for the untextured sample to 0.98 mm/year for the micropillar textured sample, representing a 68.8 % reduction. This improvement after texturing is attributed to the superior surface finish (1.049 μm) and increased hydrophobicity (130.3°), equating to a 50.8 % improvement. The coefficient of friction (COF) value decreased from 0.364 for an untextured sample to 0.208 for microchannels, a 42.9 % reduction, due to the entrapment of debris in the textures and effective heat transfer. The samples' cell adhesion and cell viability have been improved after texturing. The combination of cytocompatibility, appropriate mechanical properties, and a reduced bio-corrosion rate highlights the potential of this surface texturing method, utilizing WEDM, as a promising approach to enhance biodegradable implant materials.
{"title":"Investigating the role of WEDM surface texturing in the degradation and biocompatibility of Mg–Zn–Ca alloy","authors":"Ingilela Aswith Babu , Prithivirajan Sekar , Ashwini Prabhu , S. Narendranath , A.S.S. Balan","doi":"10.1016/j.ijlmm.2025.07.006","DOIUrl":"10.1016/j.ijlmm.2025.07.006","url":null,"abstract":"<div><div>Magnesium (Mg) alloy-based biodegradable implants are gaining popularity for their low density, high strength, and biocompatibility. The corrosion and wear performance of Mg is poor in physiological environments, leading to premature failure. Surface modification, particularly through surface texturing, reduces the effective contact area of Mg–Zn–Ca alloy with corrosive media and tribological partners, potentially optimizing its degradation kinetics and cytocompatibility. Wire Electric Discharge Machining (WEDM) offers a stable oxide layer on the surface, unlike laser surface texturing, which may thermally damage the Mg alloy. In this study, three types of textures, mainly Wavy Texture (WT), microchannels (MC), and micropillars (MP), were created using WEDM on the Mg–Zn–Ca samples, and their corrosion, wear, cytotoxicity, and cell adhesion performance were evaluated. Texturing on the surface of the samples enhanced the corrosion performance, from 3.14 mm/year for the untextured sample to 0.98 mm/year for the micropillar textured sample, representing a 68.8 % reduction. This improvement after texturing is attributed to the superior surface finish (1.049 μm) and increased hydrophobicity (130.3°), equating to a 50.8 % improvement. The coefficient of friction (COF) value decreased from 0.364 for an untextured sample to 0.208 for microchannels, a 42.9 % reduction, due to the entrapment of debris in the textures and effective heat transfer. The samples' cell adhesion and cell viability have been improved after texturing. The combination of cytocompatibility, appropriate mechanical properties, and a reduced bio-corrosion rate highlights the potential of this surface texturing method, utilizing WEDM, as a promising approach to enhance biodegradable implant materials.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 747-765"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371063","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
In the present research, hybrid composite consists of AA6082 aluminum base with TiC and n-graphene ceramics reinforcements ranging from 1 to 6 wt.%. High-energy ball milling created homogeneous mixtures between the two reinforcing components that together occupied 50 wt.% of total content. The hybrid aluminum matrix composite was fabricated through stir casting before being examined for wear resistance against the counter surface of EN32 steel by means of a pin-on-disc tribometer. The optimization process for pin-on-disc testing parameters merged Taguchi method with machine learning (ML) approaches. Load stands as the primary factor determining the dry sliding wear rate (WR) of materials according to analysis of variance (ANOVA) results while reinforcement content and speed play additional roles. The slope of both two-factor interaction effects demonstrated meaningful change. The Taguchi and ML determined that the optimized parameters would lead to a WR of 6.94×10-4 mg/s as the minimum value. Microstructural examination using scanning electron microscopy (SEM) finds that very small grooves are seen at optimal settings, whereas severe ploughing is shown at other settings. The wear mechanism transitions from adhesive to abrasive when the speed between the pin and disc increases.
{"title":"Tribological aspects of AA6082/graphene/TiC hybrid composite using Taguchi and Machine Learning","authors":"Sohan Lal , Rashmi Mittal , Neeraj Sharma , Guru Prakash","doi":"10.1016/j.ijlmm.2025.07.002","DOIUrl":"10.1016/j.ijlmm.2025.07.002","url":null,"abstract":"<div><div>In the present research, hybrid composite consists of AA6082 aluminum base with TiC and n-graphene ceramics reinforcements ranging from 1 to 6 wt.%. High-energy ball milling created homogeneous mixtures between the two reinforcing components that together occupied 50 wt.% of total content. The hybrid aluminum matrix composite was fabricated through stir casting before being examined for wear resistance against the counter surface of EN32 steel by means of a pin-on-disc tribometer. The optimization process for pin-on-disc testing parameters merged Taguchi method with machine learning (ML) approaches. Load stands as the primary factor determining the dry sliding wear rate (WR) of materials according to analysis of variance (ANOVA) results while reinforcement content and speed play additional roles. The slope of both two-factor interaction effects demonstrated meaningful change. The Taguchi and ML determined that the optimized parameters would lead to a WR of 6.94×10<sup>-4</sup> mg/s as the minimum value. Microstructural examination using scanning electron microscopy (SEM) finds that very small grooves are seen at optimal settings, whereas severe ploughing is shown at other settings. The wear mechanism transitions from adhesive to abrasive when the speed between the pin and disc increases.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 693-704"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371062","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-07-08DOI: 10.1016/j.ijlmm.2025.07.003
Nectarios Vidakis , Nikolaos Michailidis , Nektarios K. Nasikas , Constantine David , Dimitrios Sagris , Apostolos Argyros , Ioannis Valsamos , Katerina Gkagkanatsiou , Vassilis Papadakis , Markos Petousis
Polyethylene terephthalate glycol (PETG) is an amorphous polymer that has been widely used in numerous applications, from everyday life to medical and even defense-related applications. The latter constitute very demanding environments in which, in many cases, specific multifunctionalities are required. Herein, we aim for specific functionalities to appear simultaneously, thus creating novel materials that can provide important solutions to applications. Therefore, inducing antibacterial properties along with enhanced mechanical properties for use in the defense and security domains constitutes an additional asset when disease spread becomes very important. To address this challenge, we mixed pure PETG with an antibacterial nanopowder to investigate these novel multifunctionalities in detail. Concomitantly, the enhancement of the mechanical properties of the 3D printed PETG/antibacterial nanocomposites was thoroughly examined. Several PETG nanocomposites were manufactured with different nanopowder loadings and turned into filaments for use in the AM method of material extrusion (MEX). The several 3D printed PETG/antibacterial nanocomposites were thoroughly investigated for their mechanical and rheological properties, thermal stability, and morphological, structural, and chemical characteristics, combined with antibacterial performance, against two common pathogens, s. aureus and e. coli, using the agar well diffusion method. The outcome of the nanopowder introduction to the quality metrics of the 3D printed PETG, namely the geometrical accuracy and pores of the 3D printed structure was also investigated through high-resolution micro-computed tomography. The PETG/antibacterial nanocomposites exhibited improved mechanical properties. A 13.6 % tensile strength increase was achieved with 8 wt% content. 10 wt % achieved 17 % Young's modulus increase, 19 % flexural strength and 18.2 % flexural modulus improvement and can be considered the optimum loading of the research. Nanocompounds also showed strong antibacterial activity against s. aureus and E. coli. These induced multifunctionalities can constitute a new class of materials where the desired properties can have significant applications in two or more different fields for functional, durable, and infection-resistant materials, such as in the demanding defense and security sector, the medical field, or both.
{"title":"Biocidal and reinforced PETG/antibacterial blend nanocomposite for extrusion-based additive manufacturing: Optimization course and printability scores","authors":"Nectarios Vidakis , Nikolaos Michailidis , Nektarios K. Nasikas , Constantine David , Dimitrios Sagris , Apostolos Argyros , Ioannis Valsamos , Katerina Gkagkanatsiou , Vassilis Papadakis , Markos Petousis","doi":"10.1016/j.ijlmm.2025.07.003","DOIUrl":"10.1016/j.ijlmm.2025.07.003","url":null,"abstract":"<div><div>Polyethylene terephthalate glycol (PETG) is an amorphous polymer that has been widely used in numerous applications, from everyday life to medical and even defense-related applications. The latter constitute very demanding environments in which, in many cases, specific multifunctionalities are required. Herein, we aim for specific functionalities to appear simultaneously, thus creating novel materials that can provide important solutions to applications. Therefore, inducing antibacterial properties along with enhanced mechanical properties for use in the defense and security domains constitutes an additional asset when disease spread becomes very important. To address this challenge, we mixed pure PETG with an antibacterial nanopowder to investigate these novel multifunctionalities in detail. Concomitantly, the enhancement of the mechanical properties of the 3D printed PETG/antibacterial nanocomposites was thoroughly examined. Several PETG nanocomposites were manufactured with different nanopowder loadings and turned into filaments for use in the AM method of material extrusion (MEX). The several 3D printed PETG/antibacterial nanocomposites were thoroughly investigated for their mechanical and rheological properties, thermal stability, and morphological, structural, and chemical characteristics, combined with antibacterial performance, against two common pathogens, <em>s. aureus</em> and <em>e. coli</em>, using the agar well diffusion method. The outcome of the nanopowder introduction to the quality metrics of the 3D printed PETG, namely the geometrical accuracy and pores of the 3D printed structure was also investigated through high-resolution micro-computed tomography. The PETG/antibacterial nanocomposites exhibited improved mechanical properties. A 13.6 % tensile strength increase was achieved with 8 wt% content. 10 wt % achieved 17 % Young's modulus increase, 19 % flexural strength and 18.2 % flexural modulus improvement and can be considered the optimum loading of the research. Nanocompounds also showed strong antibacterial activity against <em>s. aureus</em> and <em>E. coli</em>. These induced multifunctionalities can constitute a new class of materials where the desired properties can have significant applications in two or more different fields for functional, durable, and infection-resistant materials, such as in the demanding defense and security sector, the medical field, or both.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 726-746"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145371064","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-07-05DOI: 10.1016/j.ijlmm.2025.06.003
Senthil Murugan S , Subhaschandra Kattimani , Nitesh Bharadwaj
Poly-lactic acid (PLA), a popular biodegradable polymer for 3D printing, has limited dielectric strength and surface hardness, restricting its use in advanced electronic and structural applications. Existing enhancement methods are often complex or yield inconsistent results. Therefore, a straightforward and scalable approach is necessary to enhance the properties of 3D-printed PLA. This study aims to explore the enhancement of the dielectric and surface hardness of printed PLA discs through surface cladding using nano-functional ceramics and graphene for next-generation multifunctional applications. PLA discs were fabricated via Fused Deposition Modelling (FDM) and subsequently cladded using hand layup with Araldite resin as a binder. Cladding materials included cobalt ferrite (CF), barium titanate (BTO), and graphene (Gr), individually and in combinations. Dielectric properties—capacitance, impedance, dielectric constant, dielectric loss, dissipation factor, and AC conductivity—were analyzed using an impedance analyzer, while surface hardness was measured using a Shore-D durometer. Results revealed that cladding led to uniform particle dispersion with effective surface bonding, improved dielectric performance, and significantly enhanced surface hardness. The CF + BTO + Gr combination exhibited superior dielectric behaviour, balancing high polarization with low energy dissipation, while BTO contributed to an enhanced dielectric constant and graphene improved charge transfer. All cladded samples showed frequency-dependent dielectric responses, with stability at higher frequencies. The highest surface hardness was achieved with CF + BTO, attributed to rigid, uniform reinforcement.
{"title":"Investigation of dielectric properties and shore hardness of 3D-printed PLA core sandwich disc with functional ceramics surface cladding","authors":"Senthil Murugan S , Subhaschandra Kattimani , Nitesh Bharadwaj","doi":"10.1016/j.ijlmm.2025.06.003","DOIUrl":"10.1016/j.ijlmm.2025.06.003","url":null,"abstract":"<div><div>Poly-lactic acid (PLA), a popular biodegradable polymer for 3D printing, has limited dielectric strength and surface hardness, restricting its use in advanced electronic and structural applications. Existing enhancement methods are often complex or yield inconsistent results. Therefore, a straightforward and scalable approach is necessary to enhance the properties of 3D-printed PLA. This study aims to explore the enhancement of the dielectric and surface hardness of printed PLA discs through surface cladding using nano-functional ceramics and graphene for next-generation multifunctional applications. PLA discs were fabricated via Fused Deposition Modelling (FDM) and subsequently cladded using hand layup with Araldite resin as a binder. Cladding materials included cobalt ferrite (CF), barium titanate (BTO), and graphene (Gr), individually and in combinations. Dielectric properties—capacitance, impedance, dielectric constant, dielectric loss, dissipation factor, and AC conductivity—were analyzed using an impedance analyzer, while surface hardness was measured using a Shore-D durometer. Results revealed that cladding led to uniform particle dispersion with effective surface bonding, improved dielectric performance, and significantly enhanced surface hardness. The CF + BTO + Gr combination exhibited superior dielectric behaviour, balancing high polarization with low energy dissipation, while BTO contributed to an enhanced dielectric constant and graphene improved charge transfer. All cladded samples showed frequency-dependent dielectric responses, with stability at higher frequencies. The highest surface hardness was achieved with CF + BTO, attributed to rigid, uniform reinforcement.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 766-778"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145420524","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Thirty-six flax fibre-reinforced epoxy (FFRE) plates with two, three, and four fabric layers and lengths ranging from 160 mm to 270 mm and nine FFRE tubes with a diameter of 60 mm, a length of six times the tube diameter plus an overly of 50 mm with two, three, and four fabric layers were manufactured. One-hundred-eighty impulse excitation tests were conducted on FFRE plates to determine the dynamic properties of the plates in the bending mode, and 91 impulse excitation tests were conducted on the FFRE tubes to determine the dynamic properties of the tubes in the transverse, torsional, and longitudinal directions. FFRE plates showed up to six times larger specific energy capacities compared to counterpart glass fibre-reinforced polymer plates, showing significant potential for FFRE plates to replace the use of GFRP plates where considerable damping of energy is required. Additionally, the results showed that the damping ratio of the FFRE plates decreased with the increase in layers and natural frequency. For the FFRE tubes, the highest damping ratio belonged to the transverse vibration mode, followed by the torsional or longitudinal vibration modes.
{"title":"Dynamic properties of natural fiber-reinforced polymer composite plates and tubes","authors":"Saeed Eyvazinejad Firouzsalari , Dmytro Dizhur , Krishnan Jayaraman , Jason Ingham","doi":"10.1016/j.ijlmm.2024.05.008","DOIUrl":"10.1016/j.ijlmm.2024.05.008","url":null,"abstract":"<div><div>Thirty-six flax fibre-reinforced epoxy (FFRE) plates with two, three, and four fabric layers and lengths ranging from 160 mm to 270 mm and nine FFRE tubes with a diameter of 60 mm, a length of six times the tube diameter plus an overly of 50 mm with two, three, and four fabric layers were manufactured. One-hundred-eighty impulse excitation tests were conducted on FFRE plates to determine the dynamic properties of the plates in the bending mode, and 91 impulse excitation tests were conducted on the FFRE tubes to determine the dynamic properties of the tubes in the transverse, torsional, and longitudinal directions. FFRE plates showed up to six times larger specific energy capacities compared to counterpart glass fibre-reinforced polymer plates, showing significant potential for FFRE plates to replace the use of GFRP plates where considerable damping of energy is required. Additionally, the results showed that the damping ratio of the FFRE plates decreased with the increase in layers and natural frequency. For the FFRE tubes, the highest damping ratio belonged to the transverse vibration mode, followed by the torsional or longitudinal vibration modes.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 705-715"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"141130100","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-06-30DOI: 10.1016/j.ijlmm.2025.06.002
Wael A. Altabey
In this research, a new approach for fatigue damage monitoring of composite pipelines based on checking the stability of electrical capacitance sensor (ECS) system measurements is established. The study pipeline is made of basalt fiber-reinforced polymer (BFRP) and is subjected to fatigue and thermal loading. The ECS electrodes are installed peripherally outside of pipeline. First, the capacitance between the sensor electrode pairs due to transient excitations is measured numerically using ANSYS before and after damage. Then, the capacitance data between electrode pairs was analyzed by plotting the transfer function (TF) maps, considering that the pipeline system is an “open loop system” to indicate the damage growth. To evaluate the proposed technique's reliability and applicability, a comparison between the present and experimental results available in the literature is validated. The current results are convergent with experimental results, which shows the effectiveness of the current method and the significant potential for different applications in engineering.
{"title":"The fatigue damage monitoring of composite pipeline based on frequency domain analysis of electrical capacitance sensor system measurements","authors":"Wael A. Altabey","doi":"10.1016/j.ijlmm.2025.06.002","DOIUrl":"10.1016/j.ijlmm.2025.06.002","url":null,"abstract":"<div><div>In this research, a new approach for fatigue damage monitoring of composite pipelines based on checking the stability of electrical capacitance sensor (ECS) system measurements is established. The study pipeline is made of basalt fiber-reinforced polymer (BFRP) and is subjected to fatigue and thermal loading. The ECS electrodes are installed peripherally outside of pipeline. First, the capacitance between the sensor electrode pairs due to transient excitations is measured numerically using ANSYS before and after damage. Then, the capacitance data between electrode pairs was analyzed by plotting the transfer function (TF) maps, considering that the pipeline system is an “open loop system” to indicate the damage growth. To evaluate the proposed technique's reliability and applicability, a comparison between the present and experimental results available in the literature is validated. The current results are convergent with experimental results, which shows the effectiveness of the current method and the significant potential for different applications in engineering.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 779-792"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145420511","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-06-03DOI: 10.1016/j.ijlmm.2025.05.001
Dóra Harangozó, Imre Czinege
A set of parameters was developed to characterize the stress serrations produced by the Portevin-Le-Chatelier (PLC) effect, including the stress amplitudes and their frequency and time functions. In addition to the traditional Fast Fourier Transform (FFT), the Short Time Fourier Transform (STFT), which can simultaneously display the amplitude as function of time and frequency, proved to be very illustrative. This made it possible to identify type A and type B serrations, as well as their appearance in the spectrum. Based on this evaluation method, six different cold rolling and annealing variants of an AlMg3 alloy were analyzed. It was found that in the cold-formed and annealed versions of sheets an FFT amplitude peak uniformly appears at 4–10 Hz, which can be attributed to the PLC serration of type A. This peak continuously decreases in the case of the annealed sheets, while cold-formed sheet shows a new peak at approximately 18–20 Hz before the uniform strain, which indicates the appearance of type B serrations. The amplitude of stress serrations decreases with increasing yield strength, tensile strength and normal anisotropy, and increases with uniform and fracture strains and hardening exponent.
{"title":"Characterization of stress serrations in AlMg alloys","authors":"Dóra Harangozó, Imre Czinege","doi":"10.1016/j.ijlmm.2025.05.001","DOIUrl":"10.1016/j.ijlmm.2025.05.001","url":null,"abstract":"<div><div>A set of parameters was developed to characterize the stress serrations produced by the Portevin-Le-Chatelier (PLC) effect, including the stress amplitudes and their frequency and time functions. In addition to the traditional Fast Fourier Transform (FFT), the Short Time Fourier Transform (STFT), which can simultaneously display the amplitude as function of time and frequency, proved to be very illustrative. This made it possible to identify type A and type B serrations, as well as their appearance in the spectrum. Based on this evaluation method, six different cold rolling and annealing variants of an AlMg3 alloy were analyzed. It was found that in the cold-formed and annealed versions of sheets an FFT amplitude peak uniformly appears at 4–10 Hz, which can be attributed to the PLC serration of type A. This peak continuously decreases in the case of the annealed sheets, while cold-formed sheet shows a new peak at approximately 18–20 Hz before the uniform strain, which indicates the appearance of type B serrations. The amplitude of stress serrations decreases with increasing yield strength, tensile strength and normal anisotropy, and increases with uniform and fracture strains and hardening exponent.</div></div>","PeriodicalId":52306,"journal":{"name":"International Journal of Lightweight Materials and Manufacture","volume":"8 6","pages":"Pages 805-814"},"PeriodicalIF":0.0,"publicationDate":"2025-11-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"145468051","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Pub Date : 2025-11-01Epub Date: 2025-06-13DOI: 10.1016/j.ijlmm.2025.06.001
Saiyu Yang, Shiqi Chen, Huiyu Song, Jun Shen
Friction Stir Welding (FSW) has gained widespread application in aluminum alloy joining due to its ability to produce high-strength, defect-free welds. However, welding ultra-thin aluminum alloy plates (thickness <2 mm) presents challenges such as joint softening, surface thinning, and warping. In this study, 1.4 mm-thick 1060 aluminum alloy plates were friction stir welded using tools with varying geometric parameters—including shoulder diameter, concave angle, and stir pin taper—under fixed welding conditions of 3000 r/min rotation speed and 300 mm/min welding speed. Through metallographic observation, Vickers microhardness testing, and tensile strength evaluation, it was found that the tool with a conical stir pin (Tool No. 2), featuring a 5 mm flat shoulder, root diameter of 2 mm, and end diameter of 1 mm, produced the highest-quality weld. The resulting joints exhibited a smooth surface finish, minimal internal defects, and a maximum tensile strength of 131.80 MPa–99.55 % of the base material strength (132.40 MPa). The fracture consistently occurred in the base material region, indicating excellent joint integrity. Additionally, the weld zones demonstrated fine-grained microstructures and maintained or exceeded the base material's hardness across all regions. This research confirms that by optimizing stir tool geometry, FSW can effectively eliminate defects such as thinning, grooves, and warping in ultra-thin aluminum sheets. The findings offer practical guidance for the reliable application of FSW in high-precision, lightweight structures such as aerospace components and new energy vehicle battery trays.
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