A Systematic Review of Piezoelectric Materials and Energy Harvesters for Industrial Applications.

In the last three decades, smart materials have become popular. The piezoelectric materials have shown key characteristics for engineering applications, such as in sensors and actuators for industrial use. Because of their excellent mechanical-to-electrical and vice versa energy conversion properties, piezoelectric materials with high piezoelectric charge and voltage coefficient have been tested in renewable energy applications. The fundamental component of the energy harvester is the piezoelectric material, which, when subjected to mechanical vibrations or applied stress, induces the displaced ions in the material and results in a net electric charge due to the dipole moment of the unit cell. This phenomenon builds an electric potential across the material. In this review article, a detailed study focused on the piezoelectric energy harvesters (PEH's) is reported. In addition, the fundamental idea about piezoelectric materials, along with their modeling for various applications, are detailed systematically. Then a summary of previous studies based on PEH's other applications is listed, considering the technical aspects and methodologies. A discussion has been provided as a critical review of current challenges in this field. As a result, this review can provide a guideline for the scholars who want to use PEH's for their research.

Enhancing aircraft crack repair efficiency through novel optimization of piezoelectric actuator parameters: A design of experiments and adaptive neuro-fuzzy inference system approach.

This study addressed the critical problem of repairing cracks in aging aircraft structures, a safety concern of paramount importance given the extended service life of modern fleets. Utilized a finite element (FE) method enhanced by the design of experiments (DOE) and adaptive neuro-fuzzy inference system (ANFIS) approaches to analyze the efficacy of piezoelectric actuators in mitigating stress intensity factors (SIF) at crack tips-a novel integration in structural repair strategies. Through simulations, we examined the impact of various factors on the repair process, including the plate, actuator, and adhesive bond size and characteristics. In this work, initially, the SIF estimation used the FE approach at crack tips in aluminum 2024-T3 plate under the uniform uniaxial tensile load. Next, numerous simulations have been performed by changing the parameters and their levels to collect the data information for the analysis of the DOE and ANFIS approach. The FE simulation results have shown that changing the parameters and their levels will result in changing of SIF. Several DOE and ANFIS optimization cases have been performed for the depth analysis of parameters. The current results indicated that optimal placement, size, and voltage applied to the piezoelectric actuators are crucial for maximizing crack repair efficiency, with the ability to significantly reduce the SIF by a quantified percentage under specific conditions. This research surpasses previous efforts by providing a comprehensive parameter optimization of piezoelectric actuator application, offering a methodologically advanced and practically relevant pathway to enhance aircraft structural integrity and maintenance practices. The study innovation lies in its methodological fusion, which holistically examines the parameters influencing SIF reduction in aircraft crack repair, marking a significant leap in applying intelligent materials in aerospace engineering.

Effect of ribs in a suddenly expanded flow at sonic Mach number.

This study aims to assess the influence of a rib on the base pressure and the flow development in an abruptly expanded duct at sonic Mach number. Initially, the simulations were done to validate the experimental results, keeping all the parameters the same. Accordingly, a duct-of-area ratio of 6.25 was considered for validation. Five ribs of aspect ratios 3:1, 3:2, and 3:3 were used as a first step, and simulations were performed for the same nozzle pressure ratios. Results indicate that for an area ratio of 6.25, there is a continuous decrease in the base pressure despite the nozzles being highly under-expanded. The lower aspect ratio of the rib tends to reduce the base pressure, whereas a higher aspect ratio effectively increases the base pressure for an area ratio of 6.25. Later simulations considered a single rib instead of five ribs, varying the rib's heights from 1 mm to 5 mm. Results show that the base pressure increases considerably when rib heights are 4 mm and 5 mm. The influence of ribs at two duct diameters (25 mm and 18 mm) is studied to assess the impact of a decrease in the area ratio and, hence, a decrease in the relief available to the flow. Results of duct 18 mm show that passive control becomes very effective when a rib of 3 mm height is located at a 3D position. The differences in the base pressure, velocity, and pressure field for each case are explored. The simulation results indicate that the rib breaks the primary vortex at the base and forms multiple vortices. Turbulent kinetic energy increases in the presence of ribs more than without a rib.

The effect of maleic anhydride grafted polypropylene addition on the degradation in the mechanical properties of the PP/wood composites.

This work focuses on studying the influence of coupling agents on the degradation in the mechanical properties of Polypropylene (PP)/wood composites. Maleic anhydride polypropylene (MAPP) was used as a coupling agent between the wood flour and PP matrix. As the coupling agent plays an important role in the stability of the WPC, a 10 wt% wood flour was mixed with PP granules along with a UV stabilizer and varying percentages (1, 3, 5 wt%) of MAPP in a twin-screw extruder to obtain PWC granules. The composite granules were injection molded to produce tensile samples for the mechanical characterization of the composites. To test the environmental degradation of the PWCs, the tensile samples were exposed to the environmental conditions for 0, 336 h (14 days), and 672 h (28 days) prior to testing. After the specified exposure time, the samples were mechanically characterized using tensile testing. The degradation characteristics of the WPCs were quantified in terms of the failure strains of the composite with exposure time. The experiments were designed, and various analyses, including ANOVA, regression equation, and prediction tests, were carried out to investigate the impact of parameters on the failure strain of the PWCs. Moreover, the study aimed to examine the effect of parameters such as MAPP and time, on the failure strain of the composites. From the experimental results, it is concluded that the composites containing 1 wt% of MAPP showed superior retention in the degradation of composites when compared with 3 and 5 wt% MAPP content.

Development of Magnesium Aluminate (MgAl2O4) Nanoparticles for refractory crucible application.

Ceramics are the oxides of metals and nonmetals with excellent compressive strength. Ceramics usually exhibit inert behavior at high temperatures. Magnesium aluminate (MgAl2O4), a member of the ceramic family, possesses a high working temperature up to 2000°C, low thermal conductivity, high strength even at elevated temperatures, and good corrosion resistance. Moreover, Magnesium Aluminate Nanoparticles (MANPs) can be used in the making of refractory crucible applications. This study focuses on the thermal behavior of Magnesium Aluminate Nanoparticles (MANPs) and their application in the making of refractory crucibles. The molten salt method is used to obtain MANPs. The presence of MANPs is seen by XRD peaks ranging from 66° to 67°. The determination of the smallest crystallite size of the sample is achieved by utilizing the Scherrer formula and is found to be 15.3 nm. The SEM micrographs provided further information, indicating an average particle size of 91.2 nm. At 600°C, DSC curves show that only 0.05 W/g heat flows into the material, and the TGA curve shows only 3% weight loss, which is prominent for thermal insulation applications. To investigate the thermal properties, crucibles of pure MANPs and the different compositions of MANPs and pure alumina are prepared. During the sintering, cracks appear on the crucible of pure magnesium aluminate. To explore the reason for crack development, tablets of MgAl2O4 are made and sintered at 1150°C. Ceramography shows the crack-free surfaces of all the tablets. Results confirm the thermal stability of MANPs at high temperatures and their suitability for melting crucible applications.

Heat Transfer of Ca (NO3)2-KNO3 Molten Salt Mixtures for Austempering and Martempering Processes of Steels.

Molten salts are highly effective as a quenching medium for austempering and martempering processes, enabling precise control of cooling rates to achieve the desired microstructures and mechanical characteristics in steel components. One such promising molten salt is a multicomponent Ca (NO3)2-KNO3 molten salt. The current work explores the cooling severity of molten Ca (NO3)2-KNO3 mixtures, which are commonly used for such purposes. The said mixture, with varying concentrations and bath temperatures was used for quenching the Inconel probe with thermocouples. The temperature data extracted was used to determine the transient heat flux developed at the metal-quenchant interface. A set of critical points were assessed against the peak heat extraction rates. Additionally, the fluctuation of mean heat flux and surface temperature in relation to these crucial points were plotted, along with changes in composition and bath temperature of the quench media. The cooling intensity of these quench solutions, as measured by Inconel probes, correlated well with the average hardness values observed in steel probes. The level of homogeneity in heat transmission, as measured by the spatial variance of the normalized heat energy, decreased as the percentage of KNO3 in the quench medium increased.

Optimization of Reinforcing Patch Effects on Cracked Plates Using Analytical Modeling and Taguchi Design.

Over the past four decades, the use of composite materials for the repair of cracked structural plates with glued patches has been extensively studied. Attention has been focused on determining a mode-I crack opening displacement, which is important in tension load and in preventing the failure of a structure due to small damages. Therefore, the significance of conducting this work is to determine the mode-I crack displacement of the stress intensity factor (SIF) using analytical modeling and an optimization method. In this study, an analytical solution was obtained for an edge crack on a rectangular aluminum plate with single- and double-sided quasi-isotropic reinforcing patches, using linear elastic fracture mechanics and Rose's analytical approach. Additionally, an optimization technique with the Taguchi design was used to define the optimal solution of the SIF from the suitable parameters and levels. As a result, a parametric study was conducted to assess the mitigation of the SIF using analytical modeling, and the same data were used to optimize the results via the Taguchi design. This study successfully determined and optimized the SIF, demonstrating an energy- and cost-efficient approach to address damage control in structures.

Sustainable Materials for Engineering Applications.

This newly added Special Issue (SI) of the Materials journal, titled "Sustainable Materials for Engineering Applications", focuses on the foundations, characterizations, and applications of several sustainable materials [...].

Advanced Composite Materials for Structural Maintenance, Repair, and Control.

A newly added Special Issue (SI) of the Materials journal, titled "Advanced Composite Materials for Structural Maintenance, Repair, and Control" focuses on the foundations, characterizations, and applications of several advanced composites [...].

Microstructure and Strengthening Effect of Coated Diamond Particles on the Porous Aluminum Composites.

In this work, porous Al alloy-based composites with varying Ti-coated diamond contents (0, 4, 6, 12 and 15 wt.%) were prepared, employing the powder metallurgy route and using a fixed amount (25 wt.%) of polymethylmethacrylate (PMMA) as a space holder. The effects of the varying wt.% of diamond particles on the microstructure, porosities, densities and compressive behaviors were systematically evaluated. The microstructure study revealed that the porous composites exhibited a well-defined and uniform porous structure with good interfacial bonding between the Al alloy matrix and diamond particles. The porosities ranged from 18% to 35%, with an increase in the diamond content. The maximum value of plateau stress of 31.51 MPa and an energy absorption capacity of 7.46 MJ/m3 were acquired for a composite with 12 wt.% of Ti-coated diamond content; beyond this wt.%, the properties declined. Thus, the presence of diamond particles, especially in the cell walls of porous composites, strengthened their cell walls and improved their compressive properties.

Advancements and Limitations in 3D Printing Materials and Technologies: A Critical Review.

3D printing has revolutionized various industries by enabling the production of complex designs and shapes. Recently, the potential of new materials in 3D printing has led to an exponential increase in the technology's applications. However, despite these advancements, the technology still faces significant challenges, including high costs, low printing speeds, limited part sizes, and strength. This paper critically reviews the recent trends in 3D printing technology, with a particular focus on the materials and their applications in the manufacturing industry. The paper highlights the need for further development of 3D printing technology to overcome its limitations. It also summarizes the research conducted by experts in this field, including their focuses, techniques, and limitations. By providing a comprehensive overview of the recent trends in 3D printing, this review aims to provide valuable insights into the technology's prospects.

Optimization of Structural Damage Repair with Single and Double-Sided Composite Patches through the Finite Element Analysis and Taguchi Method.

Over the last four decades, numerous studies have been conducted on the use of bonded composite repairs for aircraft structures. These studies have explored the repair of damaged plates through experimental, numerical, and analytical methods and have found that bonded composite repairs are effective in controlling crack damage propagation in thin plates. The use of double-sided composite repairs has been found to improve repair performance within certain limits. This study focuses on these limits and optimizes double-sided composite repairs by varying adhesive bond and composite patch parameters. The optimization process begins with a finite element analysis to determine the stress intensity factor (SIF) for various variables and levels, followed by the application of the Taguchi method to find the optimal combination of parameters for maximizing the normalized SIF. In conclusion, we successfully determined the stress intensity factor (SIF) for various variations and normalized it for optimization. An optimization study was then performed using the Taguchi design and the results were analyzed. Our findings demonstrate the repair performance of bonded composite patches using a cost-effective and energy-efficient approach.

Review of Piezoelectric Actuator Applications in Damaged Structures: Challenges and Opportunities.

Piezoelectric material transducers can work as an actuator or sensor. Generally, the actuator will be used to repair the structure, and the sensor will be used to find the health condition. In the last two decades, piezoelectric actuators have shown the capacity to lower and control the shear stress concentration and joint edge peel in adhesively bonded joint systems. Hence, this paper aims at reviewing the application of piezoelectric actuators in damaged structures and adhesively bonded combined systems based on three different repair investigation methods: analytical, numerical, and experimental. Moreover, the study also explores the delamination control of composite material beams and some other studies using a piezoelectric actuator. The specific aim of this work is to determine scientific challenges and future opportunities for considering piezoelectric materials in damaged structure investigations for novice researchers.

Optimizing the Compressive Properties of Porous Aluminum Composites by Varying Diamond Content, Space Holder Size and Content.

The compressive properties of powder metallurgy (PM)-based porous aluminum (Al) composites were optimized at three levels based on the following parameters: titanium (Ti)-coated diamond content, polymethylmethacrylate (PMMA) particle content, and PMMA particle size. A 3 × 3 matrix was used in the experimental design of an L9 orthogonal array to get nine sets of combinations. These nine compositions were then tested and analyzed for density, porosity, plateau stress, and energy absorption capacity. The effect of individual input parameters was assessed using the Taguchi-based means ratio and analysis of variance (ANOVA). The main effect plots articulated the optimal parameter levels for achieving maximum compressive property values (plateau stress and energy absorption capacity). The findings show that diamond content and PMMA particle size have a major impact on compressive properties. The ANOVA analysis yielded similar results, with diamond content accounting for the greatest value. Further, the response optimization of compressive properties revealed that maximum values could be obtained at optimum parameters: diamond content of 12 wt.%, PMMA particle size of 150 µm, and PMMA particle content of 25 wt.%. Confirmation tests on the optimal parameters revealed improved results as well as some minor errors and deviations, indicating that the chosen parameters are critical for controlling the compressive properties of Al composites.

Progresses and Challenges of Composite Laminates in Thin-Walled Structures: A Systematic Review.

Most engineering technologies, gadgets, and systems have been developed around the use of sophisticated materials. Composite laminates have found widespread application in various significant and innovative industries, such as aviation, maritime transportation, automobiles, and civil engineering. Recent studies have revealed that composite materials are extensively utilized in automotive, undersea, and structural applications. Extensive efforts have been dedicated to exploring the structural components constructed from composite materials due to their importance in engineering. While composite materials offer certain advantages over their metallic counterparts, they also present analysts and designers with intricate and challenging issues. Hence, this Review aims to highlight noteworthy studies on composite materials and their engineering applications, specifically focusing on structural components. Furthermore, this Review includes a comprehensive summary of the application of composite laminates, accompanied by a critical analysis of the existing literature in this field. By presenting this information, the Review intends to provide a valuable resource and guideline for researchers interested in leveraging composite materials for engineering structures.

A Review on Reductions in the Stress-Intensity Factor of Cracked Plates Using Bonded Composite Patches.

In aerospace engineering applications, lightweight material structures are considered to perform difficult service conditions and afford energy efficiency. Therefore, composite materials have gained popularity due to their light weights and high performances in structural design. Mechanical loads and environmental conditions primarily create damage to structural materials, thus numerous studies have considered the repair of the damaged structure. Bonded composite repairs are generally chosen, as they provide enhanced stress-transfer mechanisms and joint efficiencies with the increased use of advanced composite materials in primary and secondary aircraft structural components. Thus, it is essential to have reliable and repeatable bonded repair procedures to restore damaged structural components. However, composite bonded repairs, especially with primary structures, present several scientific challenges in the current existing repair technologies. In this review, a study has been done on the bonded composite repair of damaged structures with the stress-intensity factor (SIF) as the parameter for defining the extent of failure by composite repair and unrepaired material structures. In this work, various types of repair methods and the techniques used by researchers are critically reviewed, and future opportunities are explored. The present study was limited to the composite and aluminium materials that are common in aerospace applications.

Experimental Analysis and Parametric Optimization on Compressive Properties of Diamond-Reinforced Porous Al Composites.

The present study aims to optimize the compressive properties of porous aluminum composites fabricated using the powder metallurgy (PM) space holder technique. These properties were optimized by taking into consideration different processing factors such as sintering temperature, compaction pressure, and sintering time. The experimental design was formulated using L9 orthogonal array by employing these three parameters at three levels. The density, porosity, plateau stress, and energy absorption capacity were determined and analyzed. The impact of individual input parameters was evaluated using the Taguchi-based S/N ratio and analysis of variance (ANOVA). The main effect plots outlined the optimum parameter levels to achieve maximum values for compressive properties (plateau stress and energy absorption capacity). The results revealed that the sintering temperature and time significantly impact compressive properties. The ANOVA analysis exhibited similar results, with maximum contribution from sintering temperature. Further response optimization of compressive properties concluded that the maximum values could be achieved at optimum parameters, i.e., a sintering temperature of 590 °C, compaction pressure of 350 MPa, and sintering time of 90 min. Further, confirmation tests on the optimized parameters revealed improved results and some minor errors and deviations indicating that the selected parameters are vital for controlling the compressive properties of the aluminum composites.

Structural Morphology and Optical Properties of Strontium-Doped Cobalt Aluminate Nanoparticles Synthesized by the Combustion Method.

The study of structural morphology and the optical properties of nanoparticles produced by combustion methods are gaining significance due to their multifold applications. In this regard, in the present work, the strontium-doped cobalt aluminate nanoparticles were synthesized by utilizing Co1-xSrxAl2O4 (0 ≤ x ≤ 0.5) L-Alanine as a fuel in an ignition cycle. Subsequently, several characterization studies viz., X-ray diffraction (XRD), energy-dispersive X-ray (EDX) analysis, high-resolution scanning electron microscopy (HRSEM), Fourier transform infrared spectroscopy (FTIR), ultraviolet (UV) spectroscopy and vibrating sample magnetometry (VSM) were accomplished to study the properties of the materials. The XRD analysis confirmed the cubic spinel structure, and the average crystallite size was found to be in the range of 14 to 20 nm using the Debye-Scherrer equation. High-resolution scanning electron microscopy was utilized to inspect the morphology of the Co1-xSrxAl2O4 (0 ≤ x ≤ 0.5) nanoparticles. Further, EDS studies were accomplished to determine the chemical composition. Kubelka-Munk's approach was used to determine the band gap, and the values were found to be in the range of 3.18-3.32 eV. The energy spectra for the nanoparticles were in the range of 560-1100 cm-1, which is due to the spinel structure of Sr-doped CoAl2O4 nanoparticles. The behavior plots of magnetic induction (M) against the magnetic (H) loops depict the ferromagnetic behavior of the nanomaterials synthesized.

Response Surface Methodology Based Optimization of Test Parameter in Glass Fiber Reinforced Polyamide 66 for Dry Sliding, Tribological Performance.

The tribological performance of a glass fiber reinforced polyamide66 (GFRPA66) composite with varying fiber weight percentage (wt.%) [30 wt.% and 35 wt.%] is investigated in this study using a pin-on-disc tribometer. GFRPA66 composite specimens in the form of pins with varying percentages of fiber viz., 30 wt.% and 35 wt.% are fabricated by an injection molding process. Tribological performances, such as coefficient of friction (COF) and the specific wear rate (SWR), are investigated. The factors affecting the wear of GFRPA66 composites [with 30 wt.% and 35 wt.% reinforcements] are identified based on the process parameters such as load, sliding velocity, and sliding distance. Design Expert 13.0 software is used for the experimental data analysis, based on the design of experiments planned in accordance with the central composite design (CCD) of the response surface methodology (RSM) technique. The significance of the obtained results are analyzed using analysis of variance (ANOVA) techniques. To attain minimum SWR and COF, the wear performance is optimized in dry sliding conditions. The analysis of experimental data revealed that SWR and COF increased with increasing load, sliding velocity, and sliding distance for GFRPA66 [30 wt.%], but decreased with increasing polyamide weight percentage. The SWR for a maximum load of 80 N, and for a sliding velocity of 0.22 m/s, and a sliding distance of 3500 m for GFRPA66 composite specimens with 30 wt.% reinforcements are found to be 0.0121 m3/Nm, while the SWR for the same set of parameters for GFRPA66 composite specimens with 35 wt.% reinforcements are found to be 0.0102 m3/Nm. The COF for the GFRPA66 composite specimens with 30 wt.% reinforcements for the above set of parameters is found to be 0.37, while the GFRPA66 composite specimens with 35 wt.% reinforcements showed significant improvement in wear performance with a reduction in COF to 0.25. Finally, using a scanning electron microscope (SEM), the worn surfaces of the GFRPA66 are examined and interpreted.

Microstructure and Mechanical Properties of Metal Foams Fabricated via Melt Foaming and Powder Metallurgy Technique: A Review.

Metal foams possess remarkable properties, such as lightweight, high compressive strength, lower specific weight, high stiffness, and high energy absorption. These properties make them highly desirable for many engineering applications, including lightweight materials, energy-absorption devices for aerospace and automotive industries, etc. For such potential applications, it is essential to understand the mechanical behaviour of these foams. Producing metal foams is a highly challenging task due to the coexistence of solid, liquid, and gaseous phases at different temperatures. Although numerous techniques are available for producing metal foams, fabricating foamed metal still suffers from imperfections and inconsistencies. Thus, a good understanding of various processing techniques and properties of the resulting foams is essential to improve the foam quality. This review discussed the types of metal foams available in the market and their properties, providing an overview of the production techniques involved and the contribution of metal foams to various applications. This review also discussed the challenges in foam fabrications and proposed several solutions to address these problems.