Greatly enhanced corrosion/wear resistances of epoxy coating for Mg alloy through a synergistic effect between functionalized graphene and insulated blocking layer

The poor corrosion and wear resistances of Mg alloys seriously limit their potential applications in various industries.The conventional epoxy coating easily forms many intrinsic defects during the solidification process,which cannot provide sufficient protection.In the current study,we design a double-layer epoxy composite coating on Mg alloy with enhanced anti-corrosion/wear properties,via the spin-assisted assembly technique.The outer layer is functionalized graphene(FG)in waterborne epoxy resin(WEP)and the inner layer is Ce-based conversion(Ce)film.The FG sheets can be homogeneously dispersed within the epoxy matrix to fill the intrinsic defects and improve the barrier capability.The Ce film connects the outer layer with the substrate,showing the transition effect.The corrosion rate of Ce/WEP/FG composite coating is 2131 times lower than that of bare Mg alloy,and the wear rate is decreased by~90%.The improved corrosion resistance is attributed to the labyrinth effect(hindering the penetration of corrosive medium)and the obstruction of galvanic coupling behavior.The synergistic effect derived from the FG sheet and blocking layer exhibits great potential in realizing the improvement of multi-functional integration,which will open up a new avenue for the development of novel composite protection coatings of Mg alloys.

Trimming the Degrees of Freedom via a K^(+) Flux Rectifier for Safe and Long‑Life Potassium‑Ion Batteries

High degrees of freedom(DOF)for K^(+)movement in the electrolytes is desirable,because the resulting high ionic conductivity helps improve potassium-ion batteries,yet requiring support from highly free and flammable organic solvent molecules,seriously affecting battery safety.Here,we develop a K^(+)flux rectifier to trim K ion’s DOF to 1 and improve electrochemical properties.Although the ionic conductivity is compromised in the K^(+)flux rectifier,the overall electrochemical performance of PIBs was improved.An oxidation stability improvement from 4.0 to 5.9 V was realized,and the formation of dendrites and the dissolution of organic cathodes were inhibited.Consequently,the K||K cells continuously cycled over 3,700 h;K||Cu cells operated stably over 800 cycles with the Coulombic efficiency exceeding 99%;and K||graphite cells exhibited high-capacity retention over 74.7%after 1,500 cycles.Moreover,the 3,4,9,10-perylenetetracarboxylic diimide organic cathodes operated for more than 2,100 cycles and reached year-scale-cycling time.We fabricated a 2.18 Ah pouch cell with no significant capacity fading observed after 100 cycles.

Deciphering the potassium storage phase conversion mechanism of phosphorus by combined solid-state NMR spectroscopy and density functional theory calculations

Phosphorus is the potential anode material for emerging potassium-ion batteries(PIBs)owing to the highest specific capacity and relatively low operation plateau.However,the reversible delivered capacities of phosphorus-based anodes,in reality,are far from the theoretical capacity corresponding to the formation of K3P alloy.And,their underlying potassium storage mechanisms remain poorly understood.To address this issue,for the first time,we perform high-resolution solid-state31P NMR combined with XRD measurements,and density functional theory calculations to yield a systemic quantitative understanding of(de)potassiation reaction mechanism of phosphorus anode.We explicitly reveal a previously unknown asymmetrical nanocrystalline-to-amorphous transition process via rP←→(K_(3)P_(11),K_(3)P_(7),beta-K_(4)P_(6))←→(alpha-K4P6)←→(K_(1-x)P,KP,K_(4-x)P3,K_(1+x)P)←→(amorphous K4P3,amorphous K3P)that are proceed along with the electrochemical potassiation/depotassiation processes.Additionally,the corresponding KP alloys intermediates,such as the amorphous phases of K_(4)P_(3),K_(3)P,and the nonstoichiometric phases of“K_(1-x)P”,“K_(1+x)P”,“K_(4-x)P_(3)”are experimentally detected,which indicating various complicated K-P alloy species are coexisted and evolved with the sluggish electrochemical reaction kinetics,resulting in lower capacity of phosphorus-based anodes.Our findings offer some insights into the specific multi-phase evolution mechanism of alloying anodes that may be generally involved in conversion-type electrode materials for PIBs.

Vibration Performance Analysis of a Mining Vehicle with Bounce and Pitch Tuned Hydraulically Interconnected Suspension

The current investigations primarily focus on using advanced suspensions to overcome the tradeo design of ride comfort and handling performance for mining vehicles. It is generally realized by adjusting spring sti ness or damping parameters through active control methods. However, some drawbacks regarding control complexity and uncertain reliability are inevitable for these advanced suspensions. Herein, a novel passive hydraulically interconnected suspension(HIS) system is proposed to achieve an improved ride-handling compromise of mining vehicles. A lumped-mass vehicle model involved with a mechanical–hydraulic coupled system is developed by applying the free-body diagram method. The transfer matrix method is used to derive the impedance of the hydraulic system, and the impedance is integrated to form the equation of motions for a mechanical–hydraulic coupled system. The modal analysis method is employed to obtain the free vibration transmissibilities and force vibration responses under di erent road excitations. A series of frequency characteristic analyses are presented to evaluate the isolation vibration performance between the mining vehicles with the proposed HIS and the conventional suspension. The analysis results prove that the proposed HIS system can e ectively suppress the pitch motion of sprung mass to guarantee the handling performance, and favorably provide soft bounce sti ness to improve the ride comfort. The distribution of dynamic forces between the front and rear wheels is more reasonable, and the vibration decay rate of sprung mass is increased e ectively. This research proposes a new suspension design method that can achieve the enhanced cooperative control of bounce and pitch motion modes to improve the ride comfort and handling performance of mining vehicles as an e ective passive suspension system.

Hashin Failure Theory Based Damage Assessment Methodology of Composite Tidal Turbine Blades and Implications for the Blade Design

A damage assessment methodology based on the Hashin failure theory for glass fiber reinforced polymer(GFRP)composite blade is proposed. The typical failure mechanisms including the fiber tension/compression and matrix tension/compression are considered to describe the damage behaviors. To give the flapwise and edgewise loading along the blade span, the Blade Element Momentum Theory(BEMT) is adopted. In conjunction with the hydrodynamic analysis, the structural analysis of the composite blade is cooperatively performed with the Hashin damage model. The damage characteristics of the composite blade, under normal and extreme operational conditions,are comparatively analyzed. Numerical results demonstrate that the matrix tension damage is the most significant failure mode which occurs in the mid-span of the blade. The blade internal configurations including the box-beam, Ibeam, left-C beam and right-C beam are compared and analyzed. The GFRP and carbon fiber reinforced polymer(CFRP) are considered and combined. Numerical results show that the I-beam is the best structural type. The structural performance of composite tidal turbine blades could be improved by combining the GFRP and CFRP structure considering the damage and cost-effectiveness synthetically.

MODELING, VALIDATION AND OPTIMAL DESIGN OF THE CLAMPING FORCE CONTROL VALVE USED IN CONTINUOUSLY VARIABLE TRANSMISSION

Associated dynamic performance of the clamping force control valve used in continuously variable transmission （CVT） is optimized. Firstly, the structure and working principle of the valve are analyzed, and then a dynamic model is set up by means of mechanism analysis. For the purpose of checking the validity of the modeling method, a prototype workpiece of the valve is manufactured for comparison test, and its simulation result follows the experimental result quite well. An associated performance index is founded considering the response time, overshoot and saving energy, and five structural parameters are selected to adjust for deriving the optimal associated performance index. The optimization problem is solved by the genetic algorithm （GA） with necessary constraints. Finally, the properties of the optimized valve are compared with those of the prototype workpiece, and the results prove that the dynamic performance indexes of the optimized valve are much better than those of the prototype workpiece.

Microstructure characteristics and mechanical properties of Al/Mg joints manufactured by magnetic pulse welding

The effective connection of 1050 Al and AZ31 Mg was realized by magnetic pulse welding.The maximum tensile-shear force of the dissimilar Al/Mg metal lap joint reached 97%of that of the 1050 Al alloy base material by optimizing the process parameters.The microstructure of dissimilar Al/Mg welded joints was analysed by Scanning Electron Microscope(SEM),Energy Dispersive Spectrometer(EDS)and Electron Backscattered Diffraction(EBSD).The results show that the key to obtaining high shear strength of Al/Mg dissimilar metal joints is mainly due to the following two reasons.On the one hand,grain refinement and element interdiffusion occur at the interface.On the other hand,no intermetallic compounds are formed at the interface.

Revealing the grain size dependent hot workability and deformation mechanisms in a Mg-Zn-Y alloy

Despite the industrial significance of grain size for enhancing mechanical properties and formability,the in-depth deformation mechanisms at elevated temperature are still unclear.To investigate the functions of grain size on hot workability and deformation mechanisms,three groups of Mg-1.2Zn-0.2Y alloy specimens with different grain sizes were hot compressed and then studied by combining constitutive model,processing map and microstructural observations.The results showed that the enhanced hot workability accompanying low deformation activation energy and small instability regime was obtained with refined grain size.During hot deformation,the decreased grain size in Mg1.2Zn-0.2Y alloy mainly improved the plastic deformation homogeneity,especially for the weakened local straining around grain boundaries.As a result,the dynamic recrystallization nucleation and texture development at lower strain level were influenced by the initial grain size.At higher strain magnitude,the growth and coarsening of dynamic recrystallized grains would further release strain localization and improve hot workability,while the texture was less impacted.Further,unlike the primary basal slip and deformation twinning in the specimen with coarse grain at low temperature,non-basal slips of dislocations were initiated with less deformation twins in the specimens with refined grain size.

Virtual Reconstruction of Long Bone Fracture in Car-to-pedestrian Collisions Using Multi-body System and Finite Element Method

Lower limb injures are frequently observed in passenger car traffic accidents.Previous studies of the injuries focus on long bone fractures by using either cadaver component tests or simulations of the long bone kinematics,which lack in-depth study on the fractures in stress analysis.This paper aims to investigate lower limb impact biomechanics in real-world car to pedestrian accidents and to predict fractures of long bones in term of stress parameter for femur,tibia,and fibula.For the above purposes,a 3D finite element(FE) model of human body lower limb(HBM-LL) is developed based on human anatomy.The model consists of the pelvis,femur,tibia,fibula,patella,foot bones,primary tendons,knee joint capsule,meniscus,and ligaments.The FE model is validated by comparing the results from a lateral impact between simulations and tests with cadaver lower limb specimens.Two real-world accidents are selected from an in-depth accident database with detailed information about the accident scene,car impact speed,damage to the car,and pedestrian injuries.Multi-body system(MBS) models are used to reconstruct the kinematics of the pedestrians in the two accidents and the impact conditions are calculated for initial impact velocity and orientations of the car and pedestrian during the collision.The FE model is used to perform injury reconstructions and predict the fractures by using physical parameters,such as von Mises stress of long bones.The calculated failure level of the long bones is correlated with the injury outcomes observed from the two accident cases.The reconstruction result shows that the HBM-LL FE model has acceptable biofidelity and can be applied to predict the risk of long bone fractures.This study provides an efficient methodology to investigate the long bone fracture suffered from vehicle traffic collisions.

Recent progress and perspectives in additive manufacturing of magnesium alloys

Magnesium alloys remain critical in the context of light-weighting and advanced devices. The increased utilisation of magnesium(Mg)each year reveals growing demand for its Mg-based alloys. Additive manufacturing(AM) provides the possibility to directly manufacture components in net-shape, providing new possibilities and applications for the use of Mg-alloys, and new prospects in the utilisation of novel physical structures made possible from ‘3D printing’. The review herein seeks to holistically explore the additive manufacturing of Mg-alloys to date, including a synopsis of processes used and properties measured(with a comparison to conventionally prepared Mg-alloys). The challenges and possibilities of AM Mg-alloys are critically elaborated for the field of mechanical metallurgy.

Joining Performance and Microstructure of the 2024/7075 Aluminium Alloys Welded Joints by Vaporizing Foil Actuator Welding

Vaporizing foil actuator welding(VFAW) was used for joining 2024-T3 and 7075-T6 aluminum alloy sheets, and the resulting joint microstructure was analyzed. 2024/7075 aluminum alloy pairs with suitable processing parameters can be prepared by using VFAW. Dynamic preform addresses the poor formability problem of target material and advantage of VFAW on dissimilar materials in some conditions. But with standoff sheet inserting in the flyer and target, 2024/7075 welded pairs gets the better weld strength, compared with flyer preformed method. The microstructure of the circular weld area of the welded joint showed a wave interface, in which a thin melt layer formed at the center and edge parts. The crystal grains near the bonding interface were remarkably elongated and refined. Therefore, the joining of the 2024/7075 pairs was facilitated through plastic forming and melting.

Ram speed profile design for isothermal extrusion of AZ31 magnesium alloy by using FEM simulation

In the conventional hot extrusion of metallic materials,the temperature of the workpiece varies during the whole extrusion process,leading to the non-uniformity of the product dimension,microstructure and properties.In the present research,a simulation model based on the principle of PID control was developed to establish ram speed profiles that can suppress the temperature evolution during the process to allow for isothermal extrusion.With this simulation model,the real-time extrusion ram speed was adjusted according to the simulated exit temperature.The results show that temperature homogeneity is significantly improved not only along the extrudate length but also on its cross section in the case of extrusion in the isothermal mode with a designed ram speed profile in the extrusion process of AZ31 magnesium.In addition,die temperature varies over a more narrow range in comparison with extrusion in the conventional iso-speed mode.

Multi-parameter Sensitivity Analysis and Application Research in the Robust Optimization Design for Complex Nonlinear System

The current research of complex nonlinear system robust optimization mainly focuses on the features of design parameters, such as probability density functions, boundary conditions, etc. After parameters study, high-dimensional curve or robust control design is used to find an accurate robust solution. However, there may exist complex interaction between parameters and practical engineering system. With the increase of the number of parameters, it is getting hard to determine high-dimensional curves and robust control methods, thus it＇s difficult to get the robust design solutions. In this paper, a method of global sensitivity analysis based on divided variables in groups is proposed. By making relevant variables in one group and keeping each other independent among sets of variables, global sensitivity analysis is conducted in grouped variables and the importance of parameters is evaluated by calculating the contribution value of each parameter to the total variance of system response. By ranking the importance of input parameters, relatively important parameters are chosen to conduct robust design analysis of the system. By applying this method to the robust optimization design of a real complex nonlinear system-a vehicle occupant restraint system with multi-parameter, good solution is gained and the response variance of the objective function is reduced to 0.01, which indicates that the robustness of the occupant restraint system is improved in a great degree and the method is effective and valuable for the robust design of complex nonlinear system. This research proposes a new method which can be used to obtain solutions for complex nonlinear system robust design.

Probabilistic Lane-Change Decision-Making and Planning for Autonomous Heavy Vehicles

To improve the safety and driving stability of the autonomous heavy truck, it is necessary to consider the differences of driving behavior and drivable trajectories between the heavy trucks and passenger cars. This study proposes a probabilistic decision-making and trajectory planning framework for the autonomous heavy trucks. Firstly, the driving decision process is divided into intention generation and feasibility evaluations, which are realized using the utility theory and risk assessment, respectively. Subsequently the driving decision is made and sent to the trajectory planning module. In order to reflect the greater risks of the truck to other surrounding vehicles, the aggressiveness index(AI) is proposed and quantified to infer the asymmetrical risk level of lane-change maneuver. In the planning stage, the lateral and roll dynamics stability domains are developed as the constraints to exclude the candidate trajectories that would cause vehicle instability. Finally, the simulation results are compared between the proposed model and the artificial potential filed model in the scenarios extracted from the naturalistic driving data. It is shown that the proposed framework can provide the human-like lane-change decisions and truck-friendly trajectories, and performs well in dynamic driving environments.

Anisotropic and asymmetric deformation mechanisms of nanolaminated graphene/Cu composites

We conducted molecular dynamics (MD) simulations of tension and compression along the <112> direction and MD simulations of compression along the <110> and <111> directions on nanolaminated graphene/Cu (NGCu) composites to investigate the effects of the incorporated graphene and the deformation mechanisms related to the loading direction. The deformation behavior and the defect structures were found to be strongly dependent on the loading conditions. An asymmetric tension-compression deformation behavior was thus found in graphene/Cu nanolaminates under the <112> loading, which was dominated by stacking faults and deformation twins formed by dislocation slide under tension and compression, respectively. High density and ordered nanotwins were formed at the graphene/Cu interfaces. Two different formation mechanisms of the twins were found under the <112> compression, and the nucleated twins were easy to be thickened with the assistance of the graphene wrinkles. Multiple twins were formed under the <110> compression by the dislocation cross-slip. This study provides a way to introduce graphene reinforcement and twin boundary to Cu matrix composites and design nanotwinned graphene/Cu composites with excellent mechanical performance.

Electro-spraying/spinning: A novel battery manufacturing technology

Lithium-ion battery(LIB) industry seems to have met its bottle neck in cutting down producing costs even though much efforts have been put into building a complete industrial chain. Actually, manufacturing methods can greatly affect the cost of battery production. Up to now, lithium ion battery producers still adopt manufacturing methods with cumbersome sub-components preparing processes and costly assembling procedures, which will undoubtedly elevate the producing cost. Herein, we propose a novel approach to directly assemble battery components(cathode, anode and separator) in an integrated way using electro-spraying and electro-spinning technologies. More importantly, this novel battery manufacturing method can produce LIBs in large scale, and the products show excellent mechanical strength, flexibility, thermal stability and electrolyte wettability. Additionally, the performance of the as-prepaed Li Fe PO_(4)||graphite full cell produced by this new method is comparable or even better than that produced by conventional manufacturing approach. In brief, this work provides a new promising technology to prepare LIBs with low cost and better performance.

Modeling of the flow stress behavior and microstructural evolution during hot deformation of Mg-8Al-1.5Ca-0.2Sr magnesium alloy

Hot compression tests of Mg-8Al-1.5Ca-0.2Sr magnesium alloy were performed on the Gleeble-1500 machine at temperatures of 300,350,400,and 450℃and strain rates of 0.01,0.1 and 1 s^(−1).The flow stress behavior and microstructural evolution were followed.The work hardening was derived according to the Laasraoui-Jonas model.An improved approach,which considered the influence of yield stress on flow stress and the effect of grain boundary(GB)migration on the evolution of dislocation density during compression,was used to simulate the microstructural evolution,the flow stress and the volume fraction recrystallized of Mg-8Al-1.5Ca-0.2Sr magnesium alloy.The simulated results are in good agreement with experimental results.

Application of the Robust Approach and Finite Element Analysis in Door System Static Design

The robust design approach based on Taguchi＇s design of experiment （DOE） coupled with the traditional finite element analysis （FEA） is applied to the static design of a sedan door. This method aims at shortening the design period, reducing the calculation cost and improving the competitive competence. First, the pe^ormance re- quirements, the control factors and the corresponding levels are determined to design a DOE table. Second, based on the schemes from the DOE table, sensitive control factors are distinguished from the results of the FEA method. Finally, the optimum design is chosen after comparisons and analyses of these performance response graphs. Performance results of the optimum design indicate that the application of the robust approach and FEA can greatly im- prove the quality of the door system, satisfy the requirements of products, underline the design purpose and shorten the design period.

A Cyclic Constitutive Model Based on Crystal Plasticity for Body-Centered Cubic Cyclic Softening Metals

Under the framework of the small deformation crystal plasticity theory,a crystal plastic cyclic constitutive model for body-centered cubic(BCC)cyclic softening polycrystalline metals is established.The constitutive model introduces the isotropic softening rule that includes two different mechanisms:namely softening under monotonic deformation and softening under cyclic deformation on each slip system.Meanwhile,a modified Armstrong-Frederick nonlinear kinematic hardening rule is adopted.The appropriate explicit scale transition rule is selected to extend the single crystal constitutive model to the polycrystalline constitutive model.Then the model is used to predict the uniaxial and multiaxial ratcheting deformation of BCC axle steel EA4T to verify the rationality of the proposed model.The simulation results indicate that the newly established crystal plasticity model can not only describe the cyclic softening characteristics of BCC axle steel EA4T well,but also reasonably describe the evolution laws of uniaxial ratcheting and nonproportional multiaxial ratcheting deformation.Moreover,the established crystal plastic cyclic constitutive model can reasonably predict the ratcheting behavior of BCC single crystal as well.

Function chain neural network prediction on heat transfer performance of oscillating heat pipe based on grey relational analysis

As for the factors affecting the heat transfer performance of complex and nonlinear oscillating heat pipe (OHP),grey relational analysis (GRA) was used to deal with the relationship between heat transfer rate of a looped copper-water OHP and charging ratio,inner diameter,inclination angel,heat input,number of turns,and the main influencing factors were defined.Then,forecasting model was obtained by using main influencing factors (such as charging ratio,interior diameter,and inclination angel) as the inputs of function chain neural network.The results show that the relative average error between the predicted and actual value is 4%,which illustrates that the function chain neural network can be applied to predict the performance of OHP accurately.