This literature review provides an in-depth exploration of the research conducted on the investigation and measurement of residual stress (RS) in Wire Arc Additive Manufacturing (WAAM) products, particularly focusing on how process parameters influence the phenomenon. RS plays a crucial role in determining the mechanical behavior and structural integrity of WAAM components. This review article gives an understanding of the relationship between process parameters and RS to optimize the WAAM processes and ensure the durability of the final products. It also summarizes key findings, measurement techniques, challenges, and future directions in this evolving field. The review also analyzes a measurement of RS in the products of WAAM as a function of process parameters depending on examining various research studies, techniques, and methodologies employed in their studies. Experimental measuring techniques and numerical analysis of RS to determine the impacts of RS in mechanical response in products of WAAM were discussed. By offering a comprehensive overview of current research trends and insights, this review serves as a valuable resource to guide future investigations, fostering the advancement of WAAM as a robust and efficient manufacturing technology.

In recent years, in addition to the commonly known wire-based processes of Directed Energy Deposition using lasers, a process variant using the electron beam has also developed to industrial market maturity. The process offers particular potential for processing highly conductive, reflective or oxidation-prone materials. However, for industrial usage there is a lack of comprehensive data on performance, process limits and possible applications. The present study deals with this problem using the example of the high-strength aluminum bronze CuAl8Ni6. Multi-stage test welds are used to determine the physically possible process limits and draw conclusions about the suitability of the parameters for additive manufacturing. For this purpose, optimal ranges for energy input, possible welding speeds and the scalability of the process were investigated. Finally, additive test specimens in the form of cylinders and walls are produced and the hardness profile, microstructure and mechanical properties are investigated. It is found that the material CuAl8Ni6 can be well processed by wire electron beam additive manufacturing. The microstructure is similar to a cast structure, the hardness profile over the height of the specimens is constant and the tensile strength and elongation at fracture values achieved correspond to the specification of the raw material.

Additive Manufacturing (AM) has been proving suitable to support or even replace traditional manufacturing in several industries, offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and greenhouse gas (GHG) emissions. This study aimed to carry out a comparative assessment of the life cycle, from gate to gate, in the production of a low alloy carbon steel flange part using ER-90 wire. The methods utilized were Wire and Arc Additive Manufacturing (WAAM) and conventional manufacturing (CM) by forging, and comparative factors were energy demands, GHG emissions and generated solid waste. The total energy consumption in WAAM was 10,239.40 MJ, total carbon footprint in CO2 equivalent (CO2e) was 714.1 kgCO2e kg-1, and generated solid waste was 68.6 kg, respectively, 90%, 95% and 76% lower than consumption calculated in conventional manufacturing.

In this study composite with alternate layers of 5056 and 1580 alloys was manufactured by wire arc additive manufacturing technology. It is shown that increased strength characteristics of composite material can be obtained due to deformation treatment by high-pressure torsion (HPT) technique. The microstructure and mechanical properties of the HPT-processed material in different structural states were investigated. The HPT-processed material exhibits high value of ultimate tensile strength (~ 770 MPa) but low ductility. Short-term annealing at 250 oС and additional deformation by HPT to 0.25 of revolution at room temperature resulted in a slight decrease in material’s strength to ~ 700 MPa but provided ductility ∼ 9%. Physical mechanisms to improve plasticity in correlation with microstructure evolution is discussed.

The 70/30 copper–nickel alloy is mainly used in critical parts with more demanding conditions in marine settings. There is a need for innovative methods that offer fast production and cost-effectiveness to supplement current copper–nickel alloy manufacturing processes. In this study, we employ wire-arc additive manufacturing (WAAM) to fabricate the 70/30 copper–nickel alloy. The as-built microstructure is characterized by columnar grains with prominent dendrites and chemical segregation in the inter-dendritic area. The aspect ratio of the columnar grain increases with increasing travel speed (TS) at the same wire feed speed (WFS). This is in contrast to an equiaxed grain structure with a more random orientation of conventional sample. The sample built with a WFS of 8 m/min, TS of 1000 mm/min, and a track distance of 3.85 mm exhibits superior corrosion properties in the 3.5 wt% NaCl solution compared to the conventional one, as evidenced by a higher film resistance and breakdown potential, along with a lower passive current density of the WAAM sample. The corrosion morphology reveals the critical roles played by the nickel element unevenly distributed between the dendrite core and inter-dendritic area.

Life Cycle Assessment (LCA) is a technique developed to measure possible environmental impacts during the manufacture and use of a given product or service. Additive Manufacturing (AM) has proven to be suitable in several industries, especially wire and arc additive manufacturing (WAAM), offering many advantages such as delivery time and reduction in terms of material waste, energy consumption and equivalent CO₂ emissions (CO₂e). This study aimed to develop a methodology to evaluate environmental indicators during the life cycle assessment, from gate-to-gate, in the production of two low-alloy carbon steel metal parts (flanges) using ER-90 wire and allowed identifying the main stages that most influence environmental indicators. The total energy consumption in the production of flanges 1 and 2 were, respectively, 10,239.0 MJ, 12,754.0 MJ and the total carbon footprint, respectively, 714.1 kgCO₂e kg^-1 and 749.3 kgCO₂e kg^-1.

In recent years, additive manufacturing of products made from 5000 series alloys has grown in popularity for marine and automotive applications. In this work, we compare of mechanical properties characteristics of aluminum alloy 5056 material produced by wire-arc additive technology and rolling. We carried out tension tests under quasi-static loading and impact toughness tests under impact loading. The results show that upon similar ultimate tensile strength and ductility, material after additive manufacturing demonstrates decreased resistance against dynamic loading than material manufactured by the typical method of casting and rolling. This decrease in properties was explained through macro- and microstructure analysis.

Keywords: friction stir processing; additive manufacturing; wire; titanium alloy; material transfer; microstructure; microhardness

Having garnered significant attention in the scientific community over the past decade, Wire Arc Directed Energy Deposition (arc-DED) technology is at the heart of this investigation into additive manufacturing parameters. Singularly focused on invar as the selected material, the primary objective revolves around devising an indirect cord height measurement approach. This innovative methodology involves the seamless integration of internal signals and sensors, enabling the derivation of crucial measurements sans the requirement for direct physical interaction or conventional measurement methodologies. Through the course of this research, meticulous alteration of deposition parameters is undertaken to thoroughly scrutinize their influence on the ultimate cord dimensions. The fusion of cutting-edge manufacturing techniques with advanced sensor technology constitutes the essence of this endeavor, offering substantial potential to augment precision and efficiency in additive manufacturing processes. Remarkably cost-effective, this solution circumvents the need for intricate measurements and significantly contributes to the proper layer-by-layer growth process.

This paper presents a novel approach of welding thick steel plates that offers time and energy savings compared with conventional techniques. The combination of gas metal arc welding (GMAW) and hot-wire technology simplifies the joint configuration and enhances the process tolerance. In this study, a square butt joint was prepared with as-cut edges and a thickness of 15 mm. The relationship between the welding current and the deposition rate of solo GMAW showed limitations and low process tolerance. Increasing the welding current led to a larger deposited volume with unnecessary weld penetration. An independent deposition volume due to hot-wire insertion was used to improve process tolerance. This approach provided an additional volume without increasing the welding current and reduced unnecessary penetration. With optimized parameters, full-penetration single-pass welding was achieved. Compared with the formation of a typical single-v butt joint at a similar welding speed of 30 cm/min, the proposed process reduced the minimum arc time and power consumption by approximately 83% and 62%, respectively. Moreover, a single pass at a travel speed of 60 cm/min was achieved with approximately 91% and 81% less arc time and power consumption, respectively. In summary, the combined process simplifies the joint configuration, enables full-penetration single-pass welding, and reduces time and energy requirements.

Cladding is typically used to protect components from wear and corrosion while also improving the aesthetic value and reliability of the substrate. The cladding process induces significant residual stresses due to the temperature difference between the substrate and the clad layer. However, these residual stresses could be effectively utilized by modifying processes and geometrical parameters. This paper introduces a novel methodology for using the weld-cladding process as a cost-effective alternative to various existing reinforcement techniques. The numerical analyses are performed to maximize the reinforcement of a cylindrical tool. The investigation of how the weld cladding develops compressive stresses on the specimen in response to a change in the weld beads and the welding sequence is presented. For the benchmark shape, experimental verification of the numerical model is performed. The impact of the distance between the weld beads and the effect of the tool diameter is numerically investigated. Furthermore, the variation in compressive stresses due to temperature fluctuations during the extrusion process has been evaluated. The results showed that adequate compressive stresses are generated on the welded parts through the cladding process after cooling. Hence, the targeted reinforcement of the substrate can be achieved by optimizing the welding sequence and process parameters.

The hot wire anemometer is a commonly used device for measuring air speed in laboratories. In this paper, the relationship between air speed and the hot wire temperature in different air speed ranges was analyzed based on the theory of thermal equilibrium. A measurement circuit and hot wire shape were designed based on the principle of the hot wire anemometer, and the linear relationship between current and temperature in the hot wire at different air speeds was verified in an adjustable air speed field. The measured current was used to represent air speed. The designed hot wire anemometer was experimentally validated to provide measurement results that match the theoretical values in different air speed ranges. Finally, the sensitivity of the anemometer in different measurement ranges was determined based on the uncertainty of the instrument's sensitivity and the measurement formula.

Wire-driven hyper-redundant continuum manipulators are gaining more popularity and finding more applications in industry and in minimally invasive surgery. Unlike traditional rigid link manipulators, continuum robots with a flexible backbone structure are able to work in a highly constrained workspace and in an unstructured environment. However, in spite of a possible wide range of reachability, continuum manipulators have some issues related to payload capacity, accuracy and control. Therefore, in this research, we propose a novel hyper-redundant continuum robot with a passive sliding disc mechanism to improve payload capacity and accuracy. To prove the sliding mechanism concept, we demonstrate a comparison analysis with a conventional non-sliding continuum robot arm in a payload test, a bending test and a reachability test. Moreover, with this novel design, we are proposing robot kinematics and kinetic formulation and simulation results to validate the effectiveness of the sliding disc mechanism.

In this work, we report the carbon fiber-based wire-type asymmetric supercapacitors (ASCs). The highly conductive carbon fibers were prepared by the carbonized and graphitized process using the polyimide (PI) as a carbon fiber precursor. To assemble the ASC device, the CoMnO2-coated and Fe2O3-coated carbon fibers were used as the cathode and the anode materials, respectively. FE-SEM analysis confirmed that the CoMnO2-coated carbon fiber electrode exhibited the porous hierarchical interconnected nanosheet structures, depending on the added amounts of ammonium persulfate (APS) as an oxidizing agent, and Fe2O3-coated carbon fiber electrode showed a uniform distribution of porous Fe2O3 nanorods over the surface of carbon fibers. The nanostructured CoMnO2 were directly deposited onto carbon fibers by a chemical oxidation route without high temperature treatments. In particular, the electrochemical properties of the CoMnO2-coated carbon fiber with the concentration of 6 mmol APS presented the enhanced electrochemical activity, probably due to its porous morphologies and good conductivity. Further, to reduce the interfacial contact resistance as well as improve the adhesion between transition metal nanostructures and carbon fibers, the carbon fibers were pre-coated with the Ni layer as a seed layer using an electrochemical deposition method. The fabricated ASC device delivered a specific capacitance of 221 F g-1 at 0.7 A g-1 and good rate capability of 34.8% at 4.9 A g-1. Moreover, the wire-type device displayed the superior energy density of 60.16 Wh kg-1 at a power density of 490 W kg-1 and excellent capacitance retention of 95% up to 3,000 charge/discharge cycles.

Background: Diabetic foot infection (DFI) is the commonest diabetic problem requiring hospital admission. Culture yield can be challenging, particularly in the presence of biofilms. Literature confirms biofilms are ubiquitous in diabetic foot ulcer, although, there is not a microbiologic diagnostic approach regarding biofilm disruption on DFI. We postulated sonicating a stainless-steel wire along with tissue samples into the thioglycollate broth media (TBM) may improve the diagnosis of DFI. Method: Pro-spective unicentric study that assessed patients with DFI who underwent surgical debridement. The vascular surgery team collected tissue fragments and inoculated the specimens into three TBM to execute the conventional culture method (CCM), and ad-ditional fragments to place into other TBM along with a Kirschner wire (K-wire – Kw method). The microbiologist processed the samples and the resultant sonication fluid in aerobic sheep-blood agar after 24 hours, 5 and 10 days of incubation. Both methods were compared (Wilcoxon test; p < 0.05). Results: The number of pathogens isolated in each method was not statistically significant (p = 0.414): CM = 1.67 (± 0.92); KwM = 1.75 (± 0.94). The KwM was not inferior to CCM. In addition, despite the absence of statistical significance, the KwM detected more pathogens than CCM.

Domain walls were studied for permalloy wires with different depth trenches (500 nm wide, 30 nm thick, 7.5 µm long, the depth of the trench was 0, 4, 5, 8, 10, 12 and 15nm). Permalloy (Ni80Fe20) wires were fabricated by electron beam lithography and Ar ion milling. When the depth of trench is smaller than 12 nm, the switching field (Hs) is increasing with the deeper trench. However, the depth of trench is bigger than half depth of thickness, the Hs is decreasing with the deeper trench. We believed that Hs increased as the trench depth increased was because the magnetic diploes force increased between the magnetic poles on two sides of the trench. The domains of the wires were divided by the trenches and the domain walls were pinned on the trenches these were confirmed by magnetic force microscopy images.

Among various metal-based nanoparticles, silver nanoparticles (AgNPs) manifest superior inhibitory effect against several microorganisms. In fact, the AgNPs based therapy has been reported to inhibit both sensitive as well resistant isolates of bacteria and other disease causing microbes with equal propensity. Keeping this fact into consideration, we executed bio-mediated synthesis of AgNPs employing Hibiscus rosa sinensis flower extract. The as-synthesized AgNPs were evaluated for their potential to inhibit Streptococcus mutans (S. mutans), one of the main causative bacteria for dental caries. Beside several other reasons, orthodontic appliances have also been reported to facilitate infliction of oral cavity with a range of microbes including S. mutans. To determine the growth inhibitory and anti-adherence activity of AgNPs on orthodontic appliance, we performed microbiological assays employing AgNPs adsorbed on to the orthodontic wires. Topographic analysis of orthodontic wires was executed by scanning electron microscopy. In addition to antimicrobial and antibiofilm activity against oral S. mutans, the as-fabricated AgNPs demonstrated significant inhibitory and anti-biofilm properties against other biofilm forming bacteria such as Escherichia coli and Listeria monocytogenes as well.

Key findings include the modelling of the material behavior when ZnAl15% wires were subjected to the tensile test at different speeds, with strain rate sensitivity coefficient m = 0.0128, demonstrating that this type of alloy is especially sensitive to the strain rate. Besides, the optimal friction coefficient (µ) for the drawing process of this material was experimentally identified as µ = 0.28, the ideal drawing die angle was determined to be 2α = 10°, and the alloy's deformability limit has been established by a reduction ratio r ≤ 22.5%, that indicates good plastic deformation capacity. The experimental results confirmed that the proposed models are feasible for the design and optimization of industrial processes to improve the efficiency and quality of ZnAl15% alloy wire production.

The incidence of non-palpable breast cancer is increasing due to widespread screening and neoadjuvant therapies. Among the available tumor localization techniques, radio-guided occult lesion localization (ROLL) has largely replaced wire-guided localization (WGL). This study aimed to compare ROLL and WGL techniques in terms of the effectiveness of isotopic marking of axillary sentinel lymph nodes and to assess patient perspectives along with surgeon and radiologist preferences. A single-center, prospective randomized study enrolled 110 patients with non-palpable breast lesions (56 ROLL, 54 WGL). Breast type, tumor volume, location, histological and radiological features, and localization/surgical duration were evaluated in the context of sentinel lymph node marking using isotope (Technetium-99m labelled human serum albumin) and blue dye. Statistical analysis was performed with significance set at p&lt;0.05 and strong significance at p&lt;0.01. Both techniques were successful in localizing non-palpable lesions (100%). However, patients reported WGL as more painful. A notable difference was observed in axillary lymph node marking, with subareolar isotope injection (used in WGL) showing better results compared to ROLL. While ROLL provided advantages in terms of patient comfort, and logistical simplicity, WGL was superior for axillary sentinel lymph node marking, particularly in inner quadrant tumors, suggesting WGL may be preferred for these cases.

Multi-wire saw machining (MWSM) used for slicing hard-brittle materials in semiconductor, is an important material removal process that uses free abrasives. Cutting model of single-wire saw machining (SWSM) is the basis of MWSM, and the material removal mechanism of SWSM can better understand than MWSM. Mathematical model (includes brittle fracture and plastic deformation) is presented in this paper for SWSM ceramic with abrasives. This paper determines the effect of various machining parameters on the removal of hard-brittle materials. For brittle fracture of SWSM ceramics, the minimum of the strain energy density is used as a fracture criterion. The material removed of SWSM ceramics due to plastic deformation is calculated using the equations of motion. Actual wire-sawing experiments are conducted to verify the results from the developed mathematical model. Theoretical results agree with experimental data and practical experience. The developed mathematical model shows that brittle fracture plays a major concern role in material removed of SWSM ceramics. Wire speed and working load have positively correlated with material removed of SWSM ceramics. The coefficient of friction is low, a lateral crack, which propagates almost parallel to the working surface, leads to more brittle fracture and material removed is increased on SWSM ceramics.

In this paper, a modular wire-actuated robotic arm was designed to improve the safety and adaptability of service robots during human-robot interaction. To raise the stiffness adjustment range of the robotic arm, a symmetric variable-stiffness unit was designed based on flexure, which had compact and simple structure, and lowly nonlinear stiffness-force relationship. In this paper, we focused on the research of the symmetric 1-DOF joint module. Based on the kinematics and stiffness analysis, the pose of the joint module could be adjusted by controlling the length of the wires, and the stiffness of the joint module could be adjusted by controlling the tension of the wires. Because of the actuation redundancy, the pose and stiffness of the joint module could be controlled synchronously. Furthermore, a directly method was proposed for the stiffness-oriented wire tension distribution problem of the 1-DOF joint module. A simulation was carried out to verify the proposed method.

In this paper, a new method by combining cold drawing and martensitic transformation was proposed to produce ultrahigh-strength steel wire, and the effect of austenitizing heating rate on microstructure and mechanical properties was studied. Compared with Muffle furnace heating, salt bath heating has a much higher austenitizing heating rate, which is beneficial to obtain ultrafine-grained martensite for steel wire with a larger section. By salt bath hardening and low-temperature tempering, an ultrahigh strong (strength of 2.48 GPa) and tough (elongation of 6.0%) steel wire was produced. Moreover, to explore whether is it possible to replace long-time low-temperature tempering with short-time tempering at elevated temperatures to improve the tempering efficiency, the effect of tempering time on the evolution of microstructure and mechanical properties of the steel wires tempered at 350 °C was systematically studied. The results demonstrate that tempering at 350 °C for 30 s can endow the steel wire with comparable mechanical properties to that of the one tempered at 250 °C for 2 h. With tempering time prolonging, the strength decreases gradually with the precipitated phase transition from χ-Fe5C2 carbide into θ-Fe3C carbide and coarsening, which plays a major role in the strength decrease.

The corrosion morphology in grade 2205 duplex stainless steel wire has been studied to understand the nature of pitting and the causes of the ferrite phase's selective corrosion in acidic NaCl solution. It is shown that the corrosion mechanism is always pitting, which either manifests lacy cover perforation or densely-arrayed selective cavities developing on the ferrite phase. Pits with a lacy metal cover form in concentrated chloride solutions, whereas the ferrite phase's selective corrosion develops in diluted electrolytes, showing dependency on the chloride-ion concentration. The pit perforation is probabilistic and occurs on both austenite and ferrite grains. The lacy metal covers collapse in concentrated solutions but remain intact in diluted electrolytes. The collapse of the lacy metal cover happens due to hydrogen embrittlement. Pit evolution is deterministic and occurs selectively in the ferrite phase in light chloride solutions.

With the aim to investigate the effect of parameter and quenching process on the joint of hot stamping steel by laser welding, the BR1500HS boron steel was welded by filling-wire laser welding with ER70-G welding wire under different parameters. The welded specimens were heated to 900℃ and held for 5min before water quenching. The universal material test machine, Optical micro-scope, Vickers hardness tester, scanning electron microscope and electron backscatter diffraction (EBSD) were used to characterize. The results showed that the macroscopic morphology of fusion zone (FZ) becomes from funnelform to hyperbolic curve shape when heat input increases and from hyperbolic curve shape to funnelform when wire-feed speed increases. The strength after quenching is more than 1557Mpa at heat input of 1040J/cm, wire feeding speed of 1.6m/min~1.8m/min and welding speed of 1.5m/min. EBSD test showed that the FZ and fine grain zone (FGZ) have more retained austenite (RA) than coarse grain zone (CGZ) before quenching and RA in FZ and heat affect zone (HAZ) decreased and distributed uniformed after quenching. The grain diameter in FZ distribute unevenly, with the maximum grain diameter larger than 40μm before quenching. After quenching, the grain diameter of FZ, HAZ and BM is more even and coarse grains in the FZ was refined. Before quenching, the microhardness of FZ and HAZ is of 450HV~500HV at different heat input and wire-feed speed and all region of joint keeps at 450HV~550HV after quenching. Most dimple and little river pattern in the joint fracture mor-phology before quenching indicates a well plasticity and most cleavage facet is observed after quenching due to the joint combine with martensite.

In this article, a technology for producing wire and rod solder from 52In-48Sn alloy has been developed and investigated in the conditions of small-scale production. The use of direct extrusion of wire and rods instead of the traditional technology for producing solder, which includes pressing, rolling and drawing, can significantly reduce the fleet of required equipment. Using only a melting furnace and a hydraulic press, solder wires and rods can be produced in various sizes. Shortening the production cycle allows you to quickly fulfill small orders and be competitive in sales. The article developed a mathematical model of direct extrusion, which allows you to calculate: extrusion ratio, extrusion speed and pressing force. The results of modeling the process of extrusion of wire ∅2.00 mm and rods ∅8.0 mm made of 52In-48Sn alloy are presented. The temperature of the solder and the tool is simulation in software QForm based on the finite element method. Experimental results of manufacturing ∅2.0 mm solder wire and ∅8.0 mm rods are presented. The microstructure of the direct extruded solder is a eutectic of phases γ and β. Energy-dispersive X-ray spectroscopy (EDS) mapping of the 52In-48Sn alloy showed that the solder obtained by direct extrusion has a uniform distribution of structural phases. The developed technology can be used in the manufacture of wires and rods from other low-melting alloys.

This paper introduces a class of symmetric ciphering systems with a finite secret key, which provides ideal secrecy, autonomy in key generation and distribution, and robustness against the probabilistic structure of messages (Ideally Secret Autonomous Robust – ISAR system). The ISAR system is based on wiretap polar codes constructed over an artificial wiretap channel with a maximum secrecy capacity of 0.5. The system autonomously maintains a minimum level of key equivocation by continuously refreshing secret keys without needing additional key generation and distribution infrastructure. Thus, this class of systems generalizes Shannon's ideal and strongly ideal ciphering systems. Additionally, it can transform any stream ciphering system with a finite secret key of known length into an ISAR system without the necessity of knowing and/or changing its algorithm. Therefore, this class of system strongly supports privacy, a critical requirement for contemporary security systems. The ISAR system's reliance on wiretap polar coding for strong secrecy ensures resistance to passive attacks with known plaintext messages. Furthermore, resistance to passive attacks on generated keys follows directly from ideal secrecy and autonomy. The results presented offer an efficient methodology for synthesizing this class of systems with predetermined security margins and a complexity of the order of nlogn, where n is the block length of the applied polar code.

Magnesium-silver alloys are of high interest for the use as temporary bone implants due to their antibacterial properties in addition to biocompatibility and biodegradability. Thin wires in particular can be used for scaffolding, but the determination of their degradation rate and homogeneity using traditional methods is difficult. Therefore, we have employed 3D imaging using X-ray near-field holotomography with sub-micrometer resolution to study the degradation of thin (250 μm diameter) Mg-2Ag and Mg-6Ag wires. The wires were studied in two states, recrystallized and solution annealed to assess the influence of Ag content and precipitates on the degradation. Imaging was employed after degradation in Dulbecco’s modified Eagle’s medium and 10% fetal bovine serum after 1 to 7 days. At 3 days of immersion the degradation rates of both alloys in both states were similar, but at 7 days higher silver content and solution annealing lead to decreased degradation rates. The opposite was observed for the pitting factor. Overall, the standard deviation of the determined parameters was high, owing to the relatively small field of view during imaging and high degradation inhomogeneity of the samples. Nevertheless, Mg-6Ag in the solution annealed state emerges as a potential material for thin wire manufacturing for implants.

Rural electrification rate (RER) in Africa is still low to date. Several countries in Sub-Saharan Africa have tried to address this problem using conventional single-phase two-wire or three-phase three-wire systems, however at large costs due to the nature of dispersed rural load centers, low load demand, and low population density. Another solution of off-grid generation creates associated health problems. Therefore, this paper undertakes a review of a single wire earth return (SWER) network as a RER improvement solution. The paper undertakes intensive literature review to elucidate challenges and solutions to the implementation of SWER technology. Advantages of SWER technology discussed make it the choice for RER improvement in Sub-Saharan African countries. After that, a case study is selected in rural Tanzania, and a preliminary SWER network design is undertaken.

The most important plastic resins used for wire coating are Polyvinyl Chloride (PVC), Nylon, Polysulfone and Low-high density polyethylene (LDPE / HDPE). In this article,the coating process is performed using elastic-viscous fluid as a coating material for wire coating in a pressure type coating die. The elastic-viscous fluid is electrically conducted in the presence of an applied magnetic field. The governing non-linear equations are modeled and then solved analytically by utilizing an Adomian decomposition method (ADM). The convergence of the series solution is established. The results are also verified by Optimal Homotopy Asymptotic Method (OHAM). The effect of different emerging parameters such as non-Newtonian parameters α and β, magnetic parameter M and the Brinkman number Br on solutions (velocity and temperature profiles) are discussed through several graphs. Additionally, the current result also compares with the published work already available in the literature.

Femtosecond laser two-photon polymerization (TPP) technology, known for its high precision and capability to fabricate arbitrary 3D structures, has been widely applied in the production of various micro-nano optical devices, achieving significant advancements particularly in the field of photonic wire bonding (PWB) for optical interconnects. Currently, research on optimizing both the optical loss and production reliability of polymeric photonic wires is still in its early stages. One of the key challenges is that inadequate metrology methods cannot meet the demand for multiphysical measurements in practical scenarios. This study utilizes in-situ scanning electron microscopy (SEM), for the first time, to monitor the working PWBs fabricated by TPP technology at the microscale. Optical and mechanical measurements are made simultaneously to evaluate the production qualities and to study the multiphysical coupling effects of PWBs. The results reveal that photonic wires with larger local curvature radii are more prone to plastic failure, while those with smaller local curvature radii recover elastically. Furthermore, larger cross-sectional dimensions contribute dominantly to the improved mechanical robustness. The optical loss deterioration of the elastically deformed photonic wire is only temporary, which can be fully recovered when the load is removed. After further optimization based on the results of multiphysical metrology, the PWBs fabricated in this work achieve a minimum insertion loss of 0.6 dB. In this study, the multiphysical analysis of PWBs carried out by in-situ SEM metrology offers a novel perspective for optimizing the design and performance of microscale polymeric waveguides, which could potentially promote the mass production reliability of TPP technology in the field of chip-level optical interconnection.

Background/Objectives: Traditional neurosurgical training involves a steep learning curve. The introduction of advanced simulation technologies, such as virtual reality (VR), provides an alternative method for skill acquisition, allowing for repeated practice and objective assessment. This study focuses on evaluating the learning curve associated with lumbar pedicle Kirschner wire insertion using a virtual fluoroscopic simulator among neurosurgical residents. Methods: Eighteen neurosurgery residents and two interns participated in this study. Participants’ initial skill levels were assessed through a questionnaire. Performance metrics, including insertion accuracy, time, and the number of virtual X-ray scans, were recorded across multiple attempts until a “practical learning plateau” was reached. Statistical analyses were conducted to model learning curves, assess the correlation between pre-training experience and performance. Results: The average number of attempts required to stabilize performance was 5.61. Learning rates varied, with some residents showing rapid improvement while others progressed more slowly. Higher accuracy in wire placement correlated with reduced usage on X-rays over time. However, experienced residents did not necessarily learn faster, indicating potential challenges in adapting to new simulation-based methods. Post-training feedback highlighted the simulator’s utility in increasing confidence and skill levels, although some limitations in anatomical accuracy were noted. Conclusions: This study demonstrates the potential of virtual simulation to enhance neurosurgical training by providing a controlled environment for repeated practice and objective feedback. Simulation-based training can effectively complement traditional methods, though individualized approaches may be necessary to accommodate varying learning rates among residents. Further refinement of simulation tools and their integration into standard training curricula are recommended.

The continuous development in the field of industrial automation and electric mobility has led to the need for more efficient electrical machines with high power density. The improvement of electrical machines slot filling factors is one of the measures to satisfy these requirements. In recent years, this topic has aroused greater interest in the industrial sector, since the evolution of the winding technological manufacturing processes allows an economically sustainable realization of ordered winding arrangements, rather than random ones. Moreover, the manufacture of electrical machines windings must be preceded by an accurate design phase in which it is possible to evaluate the maximum slot filling factor obtainable for a given wire shape and for its dimensions. For this purpose, this paper presents an algorithmic approach for the evaluation of maximum slot filling factors in electrical machines under ideal geometric premise. In particular, this algorithm has a greater degree of flexibility with respect to the algorithm approaches found in the literature, since the study has been extended to round, rectangular and hexagonal wire sections. Furthermore, the slot filling factor calculation was carried out both for standard and non-standard slots. The algorithmic approach proposed can be considered as an additional useful tool for the fast design of electrical machine windings.

Aluminum wire is a common material for wire bonding due to its resistance to oxidation and low price. It does not melt when becoming a free air ball (FAB) during the electronic flame-off (EFO) process with wettability, and is applied by wedge bonding. This study used 20μm Zn-Coated Al-0.5wt.%Si (ZAS) wires to improve the FAB shape after the EFO process, while maintaining stability of the mechanical properties, including the interface bonding strength and hardness. In order to test circuit stability after ball bonding, the current-tensile test was performed. During the experiment, it was found that 80nm ZAS with wire bonding has lower resistance and higher fusing current. For the bias tensile test, the thicker Zn film diffused into the Al-Si matrix easily, after which the strength was reduced. The ball-bond interfaces had no change in their condition before and after the bias. Accordingly, ZAS could be a promising candidate for ball bonding in the future.

In this paper, polyurethane concrete (PUC) is used as wire embedding material to form a new polyurethane concrete- prestressed steel wire (PUC-PSW) reinforcement method. The lightweight and high-strength PUC materials not only bond and anchor the prestressed steel wire (PSW), but also passively participate in the structural force. The problems caused by using mortar or composite mortar as the embedding material are avoided. Twelve reinforced concrete T-beams were tested for PUC-PSW flexural reinforcement. It consists of 1 unreinforced beam, 4 PSW reinforced beams, and 7 PUC-PSW reinforced beams. The wire embedding material, wire anchorage form, PUC material depth, amount of wire, and loading type were used as variables. The test results show that PUC-PSW reinforcement can obviously enhance the flexural load and ultimate load of the reinforced beams compared with PSW reinforcement. The ability of PUC-PSW reinforcement to limit crack development is better than that of PSW reinforcement beam, especially after the main beam steel yield. The strength, stiffness and crack limiting ability of the reinforced beam increase with the PUC thickness of the reinforced layer.

A composite is a material formed from the combination of two or more constituent materials through a non-homogeneous mixture. This research aims to determine the effect of volume fraction and fiber orientation angle of the hybrid polyester-ulin wood powder (Eusideroxylon zwageri)-wire mesh composite on bending strength. The bending test was conducted using ASTM D-790 standard with a three-point bending test method. The composite was made using the hand lay-up method with various compositions of particles and polyester. The results showed that the composition with less ulin wood powder and finer mesh size with a 45° wire mesh angle orientation had the highest bending strength and high deformation capability. The addition of wire mesh did not significantly increase the bending strength but could reduce the effect of decreased deformation capability.

Entangled metallic wire material (EMWM) can be utilized as a novel elastic element in vibration isolation devices for mechanical actuators. This paper presents a vibration experiment aimed at investigating the degradation behavior of mechanical performance in EMWM under cyclic compressive environment. An electric vibration testing system, coupled with an isolation structure, is employed to apply compressive loads to the EMWM specimens. Through visual observations and quasi-static compression tests, the variations in geometric morphology and mechanical properties are studied, considering different relative densities and stress amplitudes. The results incidate a significant reduction in the compressed dimension of the specimens as the number of cycles increases, without any wire fractures or wear. Moreover, the mechanical properties exhibit an increasing secant modulus and a decreasing loss factor. These variations ultimately lead to a gradual deviation of the vibration characteristics of the isolation structure from its design state. To predict the mechanical property degradation of EMWM, prediction models are proposed, incorporating dimension, modulus and damping by fitting the obtained results. This research provides valuable experimental data and presents an effective method to determine the operational lifetime of vibration isolators utilizing EMWM.

This comprehensive review paper provides a detailed analysis of the extraction methods employed in the dimension stone industry. Natural rock materials used in construction, have been historically extracted using primitive techniques such as thermal shock, hammer and chisel, and plug and feather. However, significant technological advancements have revolutionized the industry, leading to the widespread adoption of mechanized methods. One highly efficient technique is diamond wire cutting, which involves the utilization of diamond-engraved bits affixed to a tensioned steel wire. This method has demonstrated remarkable capabilities in minimizing waste generation and ensuring exceptional machining quality. Nonetheless, challenges such as high operating costs and wire breakage persist and require further investigation. In addition to diamond wire cutting, this review explores the utilization of circular diamond saws and frame sawing as alternative extraction methods. The geotechnical characteristics of the stone play a critical role in the selection of appropriate machinery, and researchers worldwide have conducted numerous studies to investigate the impact of each parameter on the extraction efficiency of these mechanized techniques. Moreover, controlled blasting with explosives emerges as a promising alternative for dimension stone extraction, warranting further exploration and optimization.

Acoustic emission monitoring (AEM) has emerged as an effective technique for detecting wire-breaks resulting from, e.g., stress corrosion cracking, and its application on prestressed concrete bridges is increasing. The success of this monitoring measure depends crucially on a carefully designed sensor layout. For this the attenuation of elastic waves within the structure’s material is determined ideally in-situ through object-related measurements with a reproducible signal source, typically a rebound-hammer. This assumes that the attenuation coefficients derived from rebound-hammer tests are comparable to those from wire-breaks, thus allowing their results to be directly applied to wire-break detection without further adjustments. This study challenges this assumption by analysing attenuation behaviour through an extensive dataset. Employing time-domain and frequency analysis, the research generates attenuation profiles from laboratory experiments and in-situ measurements across various girders and bridge structures, extracting the slope and standard deviation of the residuals. While generally validating this approach, the findings highlight differences in attenuation behaviour from among wire-break signals and rebound-hammer impulses, whereby the latter potentially underestimates the relevant attenuation of wire-breaks by approximately 20 %. Consequently, a transfer factor is proposed to adjust object-related measurement results for wire-break scenarios, including a variance of 1.0 dB/m to cover a 95 % confidence interval for sample scattering. Moreover, the anisotropic attenuation behaviour across different structures was studied, showing that transverse attenuation consistently exceeds the longitudinal, significantly influenced by structural features such as voids. In prefabricated concrete bridges with in-situ-cast concrete slabs, transverse signal transmission remains unhindered across multiple elements. Finally, the results provide a valuable reference for the design of sensor layouts in bridge monitoring, particularly benefiting scenarios where direct in-situ experiences are lacking.

The inhibition of localised corrosion is known to involve multiple processes taking place over a range of time and length scales that are difficult to study by conventional electrochemical methods. This work demonstrates an approach to probing complex localised electrochemical processes by combining an electrochemically integrated multi-electrode array (also known as wire beam electrode (WBE)), scanning vibrating electrode technique, scanning electrochemical microscopy and surface analytical techniques. Each technique reveals certain aspects of the dynamically changing, multi-scale, inhibitor-microstructure interactions and local chemistry over a heterogeneous AA2024-T3 alloy surface in the presence of an environmentally friendly inhibitor; cerium diphenyl phosphate (Ce(dpp)3).

A multi-strand composite welding wire was applied to join high nitrogen austenitic stainless steel, and microstructures and mechanical properties were investigated. The electrical signals demonstrate that the welding process using a multi-strand composite welding wire is highly stable. The welded joints are composed of columnar austenite and dendritic ferrite and welded joints obtained under high heat input and cooling rate have a noticeable coarse-grained heat-affected zone and larger columnar austenite in weld seam. Compared with welded joints obtained under the high heat input and cooling rate, welded joints have the higher fractions of deformed grains, high angle grain boundaries, Schmid factor and the lower dislocation density under the low heat input and cooling rate, which indicate a lower tensile strength and higher yield strength. The rotated goss (G_RD) orientation of a thin plate and the cube (C) orientation of a thick plate are obvious after welding, but the S orientation at 65° sections of Euler’s space is weak. The δ-ferrite was studied based on the primary ferrite solidification mode. It is observed that low heat input and high cooing rate result in the increasing of δ-ferrite and high dislocation density was obtained in grain boundaries of δ-ferrite. M₂₃C₆ precipitates due to low cooling rate and heat input in weld seam and deteriorates the elongation of welded joints. The engineering stress-strain curves also show the low elongation and tensile strength of welded joints under low heat input and cooling rate, which is mainly caused by the high fraction of δ-ferrite and the precipitation of M₂₃C₆.

Induction heating is a fast, reproducible, and efficient heating method used in various manufacturing processes. However, there is no established additive manufacturing (AM) process based on induction heating using wire as feedstock. This study investigates a novel approach to AM based on inductive heating, where a steel wire is melted and droplets are detached periodically using a two-winding induction coil. The process parameters and energy input into the droplets are characterized. The induction generator exhibits sluggish response to the excitation voltage, resulting in a lag in the coil current. The process is captured using a high-speed camera, revealing regular droplet formation and uniform size and shape when operated within an appropriate process window. Larger drops and increased spatter formation occur outside this window. The proposed method allows for the production of droplets with almost spherical shapes. Further analysis and characterization of droplet formation and energy input provide insights into process optimization and overall efficiency.

This paper presents a novel real time control strategy on four-wheel independent steering system for electric vehicle with stepper motors using neural networks combined with fuzzy logic. The control of the four wheels is based on a variation of Hopfield Neural Network (VHNN) method, in which the input is the error of each steering motor and the output is processed by a hyperbolic tangent function (HTF) feeding the fuzzy logic controller (FLC), which ultimately drives the stepper motor. The whole system is made up of the four aforementioned blocks where they work in sync and inseparable from each other with the common goal of driving all the steering stepper motors at the same time. Simulation results demonstrate that the proposed control method has strong robustness and practicability under different angles and speeds.

As the additive manufacturing industry grows, it is compounding the global plastic waste problem. Distributed recycling and additive manufacturing (DRAM) offers an economic solution to this challenge, but it has been relegated to either small-volume 3D printers (limiting waste recycling throughput) or expensive industrial machines (limiting accessibility and lateral scaling). To overcome these challenges, this paper provides proof-of-concept for a novel open-source hybrid 3D printer that combines a low-cost hanging printer design with a compression screw-based end-effector that allows direct extrusion of recycled plastic waste in large expandable printing volumes. Mechanical testing of the resultant prints from 100% waste plastic, however, showed that combining challenges of non-uniform feedstocks and a heavy printhead for a hangprinter reduced the strength of the parts compared to fused filament fabrication. The preliminary results are technologically promising, however, and provide opportunities to improve on the open source design to help process the volumes of waste plastic needed for DRAM to address the negative environmental impacts of global plastic use.

Electro-mechanical braking(EMB) which represents development direction of autonomous and intelligent braking plays very useful role on enhancing the braking response performance and intelligence level for mine underground electric trackless rubber-tired vehicle (ETRV). However,there is no Electro-Mechanical Brake system applied practically in coal mine UTRV until now.The accurate control of braking clamping force can determine the length and precision of braking distance of mine ETRV.In addition,because of poor working conditions in underground coal mine tunnel ,braking clamping force sensor may be easy to occur failure,which may cause vital accident.Therefore,A cascaded three-closed-loop EMB system with a positive clamping force sensor or force estimator built for ETRV is established to achieve autonomous elimination and reset of braking clearance and reliable braking force tracking ability via utilizing the electro motor rotor angle displacement and hysteresis effect of mechanical components in this EMB.The results of simulation and experiment indicate that clamping force response is faster than traditional hydraulic disk braking system and proposed force estimator presents good fault-tolerant ability when sensor is fault.This EMB can replace the current hydraulic brake system to enhance automation level of braking control for ETRVs and braking force response performance, reduce oil pollution and cost of maintenance, which is also key technology support for really precise motion control of mine autonomous driving vehicles.

Interviews from strength and conditioning coaches across all levels of athletic competition identified their two biggest concerns with the current state of wearable technology: (a) the lack of solutions that accurately capture data "from the ground up" and (b) the lack of trust due to inconsistent measurements. The purpose of this research is to investigate the use of liquid metal sensors, specifically Liquid Wire sensors, as a potential solution for accurately capturing ankle complex movements such as plantar flexion, dorsiflexion, inversion, and eversion. Sensor stretch linearity was validated using a Micro-Ohm Meter and a Wheatstone bridge circuit. Sensors made from different substrates were also tested and discovered to be linear at multiple temperatures. An ankle complex model and computing unit for measuring resistance values were developed to determine sensor output based on simulated plantar flexion movement. The sensors were found to have a significant relationship between the positional change and the resistance values for plantar flexion movement. The results of the study ultimately confirm the researchers' hypothesis that liquid metal sensors, and Liquid Wire sensors specifically, can serve as a mitigating substitute for inertial measurement unit (IMU) based solutions that attempt to capture specific joint angles and movements.

In many developing countries of the world including Pakistan motorcycle steeling is one of the main issue that needs to be dealt with an iron hand as it leads to economic losses as well as crime increase in the society, according to the DOWN REPORT there were 28609 motorcycle stolen in 2019 and this number has been increased to 34908 in 2020. Now due to the increasing motorcycles stealing crime what measures can we take to reduce the number of motorcycle theft the rule of technology is enormous in this regards specially information technology (IT) , information technology can play an important role in the security of motorcycles from being theft by the thieves, Information technology provide us the GSM based control system which can be very help full to construct a security system for motorcycle in order to make it antitheft.

Lately Silicon Carbide (SiC) and Galium Nitride (GaN) based high frequency power conversion has gained immense popularity which stems from relatively low switching energy, robustness to high temperature operation, wide-band gap and superior thermal limits. While this aspect inherently results in a high-density power stage design, the design of adjoining passive components, particularly magnetics, needs careful attention. This is especially true if the compatibility of core and winding options and their performance is limited with the use of higher switching frequency. In this regard, this paper presents a brief review of existent research conducted in materials, optimization and integration of magnetics for single and three phase applications, ranging from filters, resonant inductors to isolation transformers. Design knobs pertaining to medium voltage (MV) applications, low-voltage (LV) applications, e-mobility sector such as more electric aircrafts (MEAs) and electric vehicles (EVs) are discussed. Guidelines for magnetics design are summarized for each application with a projected roadmap on future trend for magnetics.

Clock Network Design (CDN) is a critical step while designing any Integrated-Circuits (ICs). It holds vital importance in the performance of entire circuit. Due to continuous scaling, 3D ICs stacked with TSV are gaining importance, with an objective to continue with the Moore's law. Through-Silicon-Via (TSV) provides the vertical interconnection between two die, which allows the electrical signal to flow through it. 3D ICs has many advantages over conventional 2D planar ICs like reduced power, area, cost, wire-length etc. The proposed work is mainly focused on power reduction and obstacle avoidance for 3D ICs. Various techniques have already been introduced for minimizing clock power within specified clock constraints of the 3D CND network. Proposed 3D Clock Tree Synthesis (CTS) is a combination of various algorithms with an objective to meet reduction in power as well as avoidance of obstacle or blockages while routing the clock signal from one sink to other sink. These blockages like RAM, ROM, PLL etc. are fixed during the placement process. The work is carried out mainly in three steps- first is Generation of 3D Clock tree avoiding the blockages, then Buffering and Embedding and finally validating the results by SPICE simulation. The experimental result shows that our CTS approach results in significant 9% reduction in power as compare to the existing work.