Abstract
Purpose
The purpose of this paper is to quickly manufacture full Cu3Sn-microporous copper composite joints for high-temperature power electronics applications and study the microstructure evolution and the shear strength of Cu3Sn at different bonding times.
Design/methodology/approach
In this paper, a novel structure of Cu/composite solder sheet/Cu was designed. The composite solder sheet was made of microporous copper filled with Sn. The composite joint was bonded by thermo-compression bonding under pressure of 0.6 MPa at 300°C. The microstructure evolution and the growth behavior of Cu3Sn at different bonding times were observed by electron microscope and metallographic microscope. The shear strength of the joint was measured by shear machine.
Findings
At initial bonding stage the copper atoms in the substrate and the copper atoms in the microporous copper dissolved into the liquid Sn. Then the scallop-liked Cu6Sn5 phases formed at the interface of liquid Sn/microporous copper and liquid Sn/Cu substrates. During the liquid Sn changing to Cu6Sn5 phases, Cu3Sn phases formed and grew at the interface of Cu6Sn5/Cu substrates and Cu6Sn5/microporous copper. After that the Cu3Sn phases continued to grow and the Cu3Sn-microporous copper composite joint with a thickness of 100 µm was successfully obtained. The growth rule of Cu3Sn was parabolic growth. The shear strength of the composite joints was about 155 MPa.
Originality/value
This paper presents a novel full Cu3Sn-microporous copper composite joint with high shear strength for high-temperature applications based on transient liquid phase bonding. The microstructure evolution and the growth behavior of Cu3Sn in the composite joints were studied. The shear strength and the fracture mechanism of the composite joints were studied.
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Miao He, Miao Hao, George Chen, Wenpeng Li, Chong Zhang, Xin Chen, Haitian Wang, Mingyu Zhou and Xianzhang Lei
For the dramatically developed high voltage direct current (HVDC) power transmission, HVDC cables play a vital role in the power transmission across seas and connections with…
Abstract
Purpose
For the dramatically developed high voltage direct current (HVDC) power transmission, HVDC cables play a vital role in the power transmission across seas and connections with renewable power sources. However, the condition monitoring of HVDC cables is still a challenging research topic. This paper aims to understand the influence of external factors, namely, current, cavity location and material properties, on partial discharge (PD) characteristics in HVDC cable in a numerical way referring to the refined Niemeyer’s model.
Design/methodology/approach
The influences of the three external factors are studied by a proposed numerical model for DC PDs based on the modification of a conventional PD model for AC voltage via a finite element analysis method.
Findings
The external factors can influence the discharge magnitude and discharge repetition rate via affecting the electrical conductivity of the material: DC PD is more frequent and with higher discharge magnitude when the cavity is closer to the conductor or the current through the conductor is higher. Both DC PD repetition rate and average discharge magnitude in long-term aged material are lower than virgin material. The effect of discharge on insulation degradation becomes decreasingly significant.
Research limitations/implications
The current work is based on the numerical modelling of DC PDs. Further experimental validations and comparisons are essential for improving the model.
Practical implications
The studies of the influence factors for PDs under HVDC voltage can benefit the research and practical power transmission on DC PDs, contributing the design and test of DC PDs in HVDC cables, exploring the understandings of the DC PDs’ mechanism.
Originality/value
This paper, to the best of author’s knowledge, first studies the influence factors on DC PDs based on the numerical modelling work.
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Miao He, Miao Hao, George Chen, Xin Chen, Wenpeng Li, Chong Zhang, Haitian Wang, Mingyu Zhou and Xianzhang Lei
High voltage direct current (HVDC) cable is an important part in the electric power transmission and distribution systems. However, very little research has been carried out on…
Abstract
Purpose
High voltage direct current (HVDC) cable is an important part in the electric power transmission and distribution systems. However, very little research has been carried out on partial discharge under direct current (DC) conditions. Niemeyer’s model has been widely used under alternating current (AC) conditions. This paper aims to intend to modify the Niemeyer’s model considering both electric field and charge dynamics under DC conditions, and therefore proposes a numerical model describing partial discharge characteristics in HVDC cable.
Design/methodology/approach
This paper intends to understand partial discharge characteristics under DC conditions through numerical modelling. Niemeyer’s model that has been widely used under AC conditions has been modified, taking both electric field and charge dynamics under DC conditions into consideration. The effects of loading level or current through the conductor, cavity location and material properties on partial discharges have also been studied.
Findings
Electrical conductivity is important in determining the characteristics of partial discharge under DC conditions and discharges tend to happen in short when the cavity field exceeds the inception level under the parameter values studied in the paper.
Research limitations/implications
Building the numerical model is the purpose of the paper, and there is lack in experiment and the comparison between the simulation results and experiment.
Practical implications
The proposed model provides the numerical model describing partial discharge in HVDC cable and helps understand the partial discharge mechanism under DC voltage.
Originality/value
To the best of the author’s knowledge, this paper is a very early research on the numerical modelling work on partial discharge under DC voltage.
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Zhengyi Han, George Chen, Junzheng Cao, Zhiyuan He, Haitian Wang, Wenpeng Li and Chao Tang
The pulsed electro-acoustic (PEA) method is widely applied for space charge measurement in solid dielectrics. The signals, however, can be seriously distorted during transmission…
Abstract
Purpose
The pulsed electro-acoustic (PEA) method is widely applied for space charge measurement in solid dielectrics. The signals, however, can be seriously distorted during transmission, especially in non-planar specimens. The aim of this work is to find an efficient algorithm to correctly recover the space charge profile for different types of specimens.
Design/methodology/approach
The distortion can be associated with both geometry and material (attenuation and dispersion). Hence the recovery algorithm consists of two parts respectively. The influences of geometries, causing the divergences of electric force and acoustic waveform, can be corrected by sets of factors. The attenuation and dispersion of the material can be suppressed based on the transfer function matrix in frequency domain, which could be obtained from calibration.
Findings
A general algorithm applicable to three kinds of specimens (single-layer, multi-layer and coaxial-geometry dielectrics) has been proposed. Compared with the other two algorithms in literature, the present one offers the most accurate solution while taking relatively shorter time. In addition, this algorithm is applied on signals measured from a planar LDPE sample and the results show that the new algorithm is fairly effective with excellent stability in a real system.
Originality/value
As one of the most accurate algorithms, the present one is theoretically one third quicker than the others. This algorithm would be helpful in applications calling for large calculations, i.e. 3-D imaging of space charge distribution in XLPE cable.
Kun Li, Bo Pan, Juncheng Zhan, Wenpeng Gao, Yili Fu and Shuguo Wang
This paper aims to develop a novel miniature 3-axis force sensor which can detect the interaction forces during tissue palpation in MIS (minimally invasive surgery). MIS offers…
Abstract
Purpose
This paper aims to develop a novel miniature 3-axis force sensor which can detect the interaction forces during tissue palpation in MIS (minimally invasive surgery). MIS offers many significant merits compared with traditional open surgery, the wound to the patients and the postoperative pains are alleviated and reduced dramatically. However, the inherent drawback due to lack of force feedback still exists while conducting some operation procedures. For example, tissue palpation performed easily during open surgery could not be realized in an MIS manner.
Design/methodology/approach
The force sensor is based on the resistive-based sensing method that utilizes strain gauges to measure the strain when the external loads are acting on the tip of the sensor. A novel flexible tripod structure with bending and compression deformations is designed to discriminate the magnitudes and directions of the three orthogonal force components. A linear characteristic matrix is derived to disclose the relationship between the sensitivity and the geometric parameters of the structure, and a straightforward geometric parameterized optimization method considering the sensitivity isotropy is proposed to provide the sensor structure with high sensitivity and adequate stiffness.
Findings
The sensor prototype can perform force measurement with sensing ranges of ± 3.0 N in axial direction and ± 1.5 N in radial direction, and the resolutions are 5 per cent and 1 per cent, respectively. It is concluded that this force sensor is compatible with MIS instruments and the ex-vivo experiment shows that the sensor can be used to perform tissue palpation during MIS procedures.
Originality/value
This paper is intended to address the significant role of force sensing and force feedback during MIS operations, and presents a new application of the resistive-based sensing method in MIS. A tripod structure is designed and a straightforward optimization method considering the sensitivity isotropy of the sensor is proposed to determine geometric parameters suited for the given external loads.
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The purpose of this study is to develop an easy-to-use CAD software for fashion flat sketch that can create new sketches by combining the flat sketch modules.
Abstract
Purpose
The purpose of this study is to develop an easy-to-use CAD software for fashion flat sketch that can create new sketches by combining the flat sketch modules.
Design/methodology/approach
A sample fashion flat module database was constructed by performing a sketch modularization process as well as a morphological analysis. In addition, an automatic module assembling algorithm was developed to create new sketches using the database.
Findings
The module assembling algorithm enabled the users to make new fashion flat sketches by the combination of design modules in the database. The example database constructed in this study was composed of bodice, sleeve, collar, cuffs and pocket modules chosen based on the results of a morphological analysis.
Social implications
A CAD program has been developed that might improve the efficiency of design work by helping the users to make fashion flat sketches more easily.
Originality/value
The automatic module assembling algorithm developed in this study has not been implemented in any existing commercial systems. It is expected that users who do not have expertise in fashion design could be able to participate from the clothing design stage as a mass customization prosumer by using the software.
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Mehrshad Mehrpouya, Daniel Tuma, Tom Vaneker, Mohamadreza Afrasiabi, Markus Bambach and Ian Gibson
This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It…
Abstract
Purpose
This study aims to provide a comprehensive overview of the current state of the art in powder bed fusion (PBF) techniques for additive manufacturing of multiple materials. It reviews the emerging technologies in PBF multimaterial printing and summarizes the latest simulation approaches for modeling them. The topic of “multimaterial PBF techniques” is still very new, undeveloped, and of interest to academia and industry on many levels.
Design/methodology/approach
This is a review paper. The study approach was to carefully search for and investigate notable works and peer-reviewed publications concerning multimaterial three-dimensional printing using PBF techniques. The current methodologies, as well as their advantages and disadvantages, are cross-compared through a systematic review.
Findings
The results show that the development of multimaterial PBF techniques is still in its infancy as many fundamental “research” questions have yet to be addressed before production. Experimentation has many limitations and is costly; therefore, modeling and simulation can be very helpful and is, of course, possible; however, it is heavily dependent on the material data and computational power, so it needs further development in future studies.
Originality/value
This work investigates the multimaterial PBF techniques and discusses the novel printing methods with practical examples. Our literature survey revealed that the number of accounts on the predictive modeling of stresses and optimizing laser scan strategies in multimaterial PBF is low with a (very) limited range of applications. To facilitate future developments in this direction, the key information of the simulation efforts and the state-of-the-art computational models of multimaterial PBF are provided.
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Filiz Ekici, Öner Gümüş and Ilkay Orhan
This paper aims to present an example of the measurement of airport efficiency, a topic of great interest in civil aviation today. The methodology used is data envelopment…
Abstract
Purpose
This paper aims to present an example of the measurement of airport efficiency, a topic of great interest in civil aviation today. The methodology used is data envelopment analysis (DEA) and the Malmquist Index. The calculation of airport efficiency with up-to-date data for each period is of great importance in the context of sustainability. The study selected ten airports with high air traffic in Turkey as the sample set. The objective of this study is to evaluate the current state of airport efficiency, identify the sources of inefficiency and make appropriate policy recommendations based on the findings obtained.
Design/methodology/approach
The study is based on DEA and Malmquist Index Analysis. The number of personnel and terminal size data of ten selected decision-making units (DMU) are used as inputs, while passenger, cargo and aircraft traffic data are used as outputs. A five-year period, spanning from 2018 to 2022, is considered as the data set in the study.
Findings
Upon analysis of the data from the ten airports included in the study, it was found that the current input-output combination yielded efficient results, with the exception of certain characteristics, such as the impact of seasonal conditions or tourism. Concurrent with the growth in aircraft, passenger and freight traffic, the number of personnel employed at these airports has also increased. It was concluded that technological efficiency is of paramount importance for each airport, and that investments in technology should be increased.
Practical implications
A separate assessment was conducted for each of the ten airports included in the study sample. Each airport was evaluated in terms of its strengths and weaknesses, and areas of low efficiency were identified. Consequently, more general conclusions were reached than airport-specific evaluations.
Originality/value
In order to ensure the long-term sustainability of the sector, it is essential that the efficiency measurements of airports are calculated using up-to-date data on a regular basis. The results obtained from these calculations provide guidance for the strategic plans to be implemented in the long term, as well as for the solution proposals for operational problems. In this context, this study not only provides information to policymakers and airport managers about the current situation, as it includes recent data, but also contributes to the literature in this sense, as it includes policy recommendations.
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Wang Zhang, Lizhe Fan, Yanbin Guo, Weihua Liu and Chao Ding
The purpose of this study is to establish a method for accurately extracting torch and seam features. This will improve the quality of narrow gap welding. An adaptive deflection…
Abstract
Purpose
The purpose of this study is to establish a method for accurately extracting torch and seam features. This will improve the quality of narrow gap welding. An adaptive deflection correction system based on passive light vision sensors was designed using the Halcon software from MVtec Germany as a platform.
Design/methodology/approach
This paper proposes an adaptive correction system for welding guns and seams divided into image calibration and feature extraction. In the image calibration method, the field of view distortion because of the position of the camera is resolved using image calibration techniques. In the feature extraction method, clear features of the weld gun and weld seam are accurately extracted after processing using algorithms such as impact filtering, subpixel (XLD), Gaussian Laplacian and sense region for the weld gun and weld seam. The gun and weld seam centers are accurately fitted using least squares. After calculating the deviation values, the error values are monitored, and error correction is achieved by programmable logic controller (PLC) control. Finally, experimental verification and analysis of the tracking errors are carried out.
Findings
The results show that the system achieves great results in dealing with camera aberrations. Weld gun features can be effectively and accurately identified. The difference between a scratch and a weld is effectively distinguished. The system accurately detects the center features of the torch and weld and controls the correction error to within 0.3mm.
Originality/value
An adaptive correction system based on a passive light vision sensor is designed which corrects the field-of-view distortion caused by the camera’s position deviation. Differences in features between scratches and welds are distinguished, and image features are effectively extracted. The final system weld error is controlled to 0.3 mm.