Li-ion cell designs, component integrity, and manufacturing processes all have critical influence on the safety of batteries. Any internal defective features that induce a short circuit, can trigger thermal runaway: cascade reactions, leading to device fire. As consumer manufacturers push aggressively for increased battery energy, instances field failure are increasingly reported. Notably, Samsung made press release in 2017 following total product recall their Galaxy Note 7 mobile phone,...

This paper reports an investigation to improve fundamental knowledge and understanding of 3D printing steel in structural engineering. The process method examined is Wire Arc Additive Manufacturing (WAAM) for the manufacturing large-sized components. mechanical properties printed Union K 40 - GMAW are determined benchmarked against measured EN 8 carbon medium steel. results presented discussed from tensile coupon testing X-ray Computed Tomography, with latter inspecting internal volume WAAM...

In renewable energy and grid applications, solder-attached power modules are subject to fatigue stress cycles of low amplitudes, but the devices will be in service for decades. This article aims understand slow aging process by focusing on initial defects their growth under concern. A finite-element analysis (FEA) is performed obtain thermomechanical distribution around defects, which combined with solder material's property give a lifetime model. Effort made validate model cycling plus...

Additive manufacturing (AM) is uniquely suitable for healthcare applications due to its design flexibility and cost effectiveness creating complex geometries. Successful arthroplasty requires integration of the prosthetic implant with bone replace damaged joint. Bone-mimetic biomaterials are utilised their mechanical properties porous structure that allows ingrowth fixation. The predictability predetermined interconnected structures produced by AM ensures required shape, size tissue...

A new practical workflow for the laser Powder Bed Fusion (PBF) process, incorporating topological design, mechanical simulation, manufacture, and validation by computed tomography is presented, uniquely applied to a consumer product (crank high-performance racing bicycle), an approach that tangible adoptable industry. The lightweight crank design was realised using topology optimisation software, developing optimal iteratively from simple primitive within space with addition of load boundary...

Ultrasonic assisted drilling (UAD) has been proven effective for the thrust force reduction as compared to conventional (CD) same machining parameters. The following research was focused on examination of exit delamination, machined surface and cutting temperature measurement in UAD a comparison that CD at speeds 0.942 m/min, 9.42 94.2 m/min 282.6 constant feed rate 0.05 mm/rev through-hole CFRP material. X-Ray computed tomography (CT) used identify internal damage, circularity center...

The popularity of composite materials is continuously growing with new varieties being developed and tested different machining processes to establish their suitability. Destructive as well non-destructive methods, such ultrasonics, X-ray radiography eddy-current, have previously been used ensure that the combination particular methods composites provide required quality can allow lifespan final product. computed tomography (CT) applied a novel method in this paper obtain quantitative data...

Additive Manufacturing (AM) provides an opportunity to fundamentally redesign components previously limited by conventional manufacturing techniques. A new process for this workflow of design, manufacture Powder Bed Fusion (PBF) and validation is presented, which a case study crank high performance racing bicycle applied. Topology optimisation generated conceptually ideal geometry from functional design was interpreted. Design AM considerations were employed reduce build time, material usage...

This paper presents the methodology used to investigate numerous drilled holes that have been produced on Carbon Fibre Reinforced Polymers (CFRP) under different parameters. Due nature of CFRP, machining processes may cause severe damage such as delamination, which will affect service life parts. The delicate matrix orientation CFRP determines their properties. These delaminated regions are often inaccessible because they formed throughout distance machined area and usually studied with help...

This paper demonstrates a novel method that combines X-ray computed tomography (CT) and image processing for investigating two materials with significantly different densities. CT is increasingly used in industrial applications of inspecting defects. The limitations the system data reconstruction are continuously researched so as to improve quality results. One most common issues beam hardening, frequently experienced multi-material scanning. examined demonstrate carbon fibre reinforced...

Li-ion cell designs, component integrity and manufacturing processes all have critical influence on the safety of batteries. Any internal defective features that induce a short circuit, can trigger thermal runaway: cascade reactions, leading to device fire. As consumer manufacturers push aggressively for increased battery energy, instances field failure are increasingly reported. Notably Samsung made press release in 2017 following total product recall their Galaxy Note 7 mobile phone,...

Abstract Mold slag entrainment during the continuous casting process presents a late stage source of non-metallic inclusions (NMI) with high likelihood ending up in final product. The reaction between entrained phase and surrounding liquid steel mold affects inclusion morphology properties. However, there is lack information on kinetics NMI-steel reaction. A novel approach, utilizing controlled synthetic inclusion/metal samples, has been developed to study reactions free inclusion-slag...

The application of Additive Manufacturing (AM) in medicine is extensive with the production anatomical models, endoprosthetics, surgical guides, implants and scaffold implants. This due to its design flexibility cost effectiveness when geometrical complexity required. Total hip arthroplasty a common procedure prevalence increase 0.72% 20 years that it expected grow faster next decades. work presented demonstrates novel non-destructive, non-contact examination method utilising X-ray Computed...

Solder-attached IGBT power modules are widely use in renewable energy and smart grid applications where the thermomechanical stress cycles relatively low amplitude but service duties of devices expected to last for decades. Although initial defect voids cracks solder layer recognized as triggers aging, it is still necessary describe simulate physical fatigue behavior their local regions accurately under cycling. In order investigate growth damage, this paper a 2D symmetrical finite element...

Woven carbon fibre prepreg is being increasingly used in high-performance aerospace and automotive applications, primarily because of its superior mechanical properties formability. A wide range forming simulation options are available for predicting material deformation during the process, particularly change orientation. Development a robust validated model requires comprehensive characterisation reliable experimental validation techniques. This paper presents numerical methods studying...

X-ray Computed Tomography (CT) is a nondestructive evaluation method that gains recognition in dimensional metrology applications.During CT scan, 2D radiographs are collected then reconstructed to 3D model which allows non-destructive of the specimen and assists with characterisations defects.This technology has potential provide information unobtainable by other non-destructive, non-contact techniques.There numerous factors can affect measurement results varying uncertainty such as shifts...

The ongoing demand for smaller and lighter devices, with batteries having longer usage times, has put increasing operational pressure on the batteries. use of higher capacity cathodes, areal thinner separators are some approaches used to achieve energy densities. Here we report two case studies from Samsung Galaxy Note 7 phone fitness tracker wristband, Fitbit Flex 2, highlighting where device manufacturers were pushing boundaries this density. In September 2016, several reports published...

This paper demonstrates a novel method that combines X-ray Computed Tomography (CT) and image processing for the investigation of bonded materials with significantly different densities. CT is increasingly used in aerospace applications inspection identification defects. The limitations scanning process data reconstruction methods are continuously being researched so as to improve quality final results. One common issues experienced multi-material samples using beam hardening. examined...

The authors present a series of complementary test methods which were developed and used to investigate reactions between high aluminium steel silica rich inclusions. Non-metallic inclusions (NMIs) cause many defects in the final product, therefore ability track their size, morphology composition correlate this with fundamental reaction kinetics provides important knowledge support production clean quality products. Novel grades such as TRIP, TWIP low-density steels have contents; is readily...