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This paper explores the uniaxial tensile creep response of acrylic-based pressure-sensitive adhesive (PSA), which exhibits a unique multi-phase creep response that does not have the classical steady-state region due to multiple transitions caused by several competing mechanisms: (i) cavity nucleation and growth in the interior of the adhesive material of the PSA system, as well as at the interfaces between the PSA and the substrate; (ii) fibrillation of the bulk adhesive, and (iii) interfacial mechanical locking between the adhesive and the bonding substrate. This results in multiple regimes of strain hardening and strain softening, evidenced by multiple regions of steady-state creep, separated by strong transitions in the creep rates. This complex, multi-phase, nonlinear creep response cannot be described by conventional creep constitutive models commonly used for polymers in commercial finite element codes. Accordingly, based on the empirical uniaxial tensile creep response and the mechanisms behind it, a new mechanistic model was proposed. This is capable of quantitatively capturing the characteristic features of the multiphase creep response of single-layered PSA joints as a function of viscoelastic bulk properties and free energy of the PSA material, substrate surface roughness, and interfacial surface energy between the adhesive and substrate. This is the first paper to present the modeling approach for capturing unique multi-phase creep behavior of PSA joint under tensile loading.

Human variability related to physical, cognitive, socio-demographic, and other factors can contribute to large differences in human performance. Quantifying population heterogeneity can be useful for designers wishing to evaluate design parameters such that a system design is robust to this variability. Comprehensively integrating human variability in the design process poses many challenges, such as limited access to a statistically representative population and limited data collection resources. This paper discusses two virtual population modeling approaches intended to be performed prior to in-person design validation studies to minimize these challenges by: (1) targeting recruitment of representative population strata and (2) reducing the candidate design parameters being validated in the target population. The first approach suggests the use of digital human models, virtual representations of humans that can simulate system interaction to eliminate candidate design parameters. The second approach suggests the use of existing human databases to identify relevant human characteristics for representative recruitment strata in subsequent studies. Two case studies are presented to demonstrate each approach, and the benefits and limitations of each are discussed. This paper demonstrates the benefit of modeling prior to conducting in-person human performance studies to minimize resource burden, which has significant implications on early design stages.

This paper presents the entropic damage indicators for metallic material fatigue processes obtained from three associated energy dissipation sources. Since its inception, reliability engineering has employed statistical and probabilistic models to assess the reliability and integrity of components and systems. To supplement the traditional techniques, an empirically-based approach, called physics of failure (PoF), has recently become popular. The prerequisite for a PoF analysis is an understanding of the mechanics of the failure process. Entropy, the measure of disorder and uncertainty, introduced from the second law of thermodynamics, has emerged as a fundamental and promising metric to characterize all mechanistic degradation phenomena and their interactions. Entropy has already been used as a fundamental and scale-independent metric to predict damage and failure. In this paper, three entropic-based metrics are examined and demonstrated for application to fatigue damage. We collected experimental data on energy dissipations associated with fatigue damage, in the forms of mechanical, thermal, and acoustic emission (AE) energies, and estimated and correlated the corresponding entropy generations with the observed fatigue damages in metallic materials. Three entropic theorems—thermodynamics, information, and statistical mechanics—support approaches used to estimate the entropic-based fatigue damage. Classical thermodynamic entropy provided a reasonably constant level of entropic endurance to fatigue failure. Jeffreys divergence in statistical mechanics and AE information entropy also correlated well with fatigue damage. Finally, an extension of the relationship between thermodynamic entropy and Jeffreys divergence from molecular-scale to macro-scale applications in fatigue failure resulted in an empirically-based pseudo-Boltzmann constant equivalent to the Boltzmann constant.

This paper presents a novel computational algorithm to estimate blood volume decompensation state based on machine learning (ML) analysis of multi-modal wearable-compatible physiological signals. To the best of our knowledge, our algorithm may be the first of its kind which can not only discriminate normovolemia from hypovolemia but also classify hypovolemia into absolute hypovolemia and relative hypovolemia. We realized our blood volume classification algorithm by (i) extracting a multitude of features from multi-modal physiological signals including the electrocardiogram (ECG), the seismocardiogram (SCG), the ballistocardiogram (BCG), and the photoplethysmogram (PPG), (ii) constructing two ML classifiers using the features, one to classify normovolemia vs. hypovolemia and the other to classify hypovolemia into absolute hypovolemia and relative hypovolemia, and (iii) sequentially integrating the two to enable multi-class classification (normovolemia, absolute hypovolemia, and relative hypovolemia). We developed the blood volume decompensation state classification algorithm using the experimental data collected from six animals undergoing normovolemia, relative hypovolemia, and absolute hypovolemia challenges. Leave-one-subject-out analysis showed that our classification algorithm achieved an F1 score and accuracy of (i) 0.93 and 0.89 in classifying normovolemia vs. hypovolemia, (ii) 0.88 and 0.89 in classifying hypovolemia into absolute hypovolemia and relative hypovolemia, and (iii) 0.77 and 0.81 in classifying the overall blood volume decompensation state. The analysis of the features embedded in the ML classifiers indicated that many features are physiologically plausible, and that multi-modal SCG-BCG fusion may play an important role in achieving good blood volume classification efficacy. Our work may complement existing computational algorithms to estimate blood volume compensatory reserve as a potential decision-support tool to provide guidance on context-sen

Designers perform early-stage formative usability tests with low-fidelity prototypes to improve the design of new products. This low-tech prototype style reduces the manufacturing resources but limits the functions that can be assessed. Recent advances in technology enable designers to create low-fidelity 3D models for users to engage in a virtual environment. Three-dimensional models communicate design concepts and are not often used in formative usability testing. The proposed method discusses how to create a virtual replica of a product by assessing key human interaction steps and addresses the limitations of translating those steps into a virtual environment. In addition, the paper will provide a framework to evaluate the usability of a product in a virtual setting, with a specific emphasis on low-resource online testing in the user population. A study was performed to pilot the subject’s experience with the proposed approach and determine how the virtual online simulation impacted the performance. The study outcomes demonstrated that subjects were able to successfully interact with the virtual replica and found the simulation realistic. This method can be followed to perform formative usability tests earlier and incorporate subject feedback into future iterations of their design, which can improve safety and product efficacy.

It is well-established that increasing demands for fresh water are paving the way for desalination technologies. However, this correlates with an increase in brine production whose treatment and disposal can be complicated and expensive. This paper presents a thermodynamic model to bound the operation and development of a novel Humidification–Dehumidification-based system featuring Zero-Liquid Discharge and off-grid capabilities. The model employs conservation laws to find feasible state points to meet a baseline operation of 10 kg/h of product water separated from a hypersaline feed stream with 100 g/kg salt concentration. The system incurs in a 1039 kWh/m3 energy intensity that can be supplied completely by an electric source or in combination with heating steam. Follow-up sensitivity analysis highlights the robustness of the system in handling variations of 25% in product flowrate and 75% in feed salinity, practically without incurring any additional energy demands. The proposed system operating costs between 72 USD/m3 and 96 USD/m3 are comparable to those of existing brine disposal techniques. Furthermore, an operational map of existing desalination technologies suggests a niche characterized by high recovery rates and high feed salinities that are generally unfulfilled by conventional desalination methods. Overall, the proposed system shows potential for off-grid hypersaline brine treatment. This study sets the stage for future development of physics-based and data-driven predictive models as the proposed system iterates into a pilot plant deployment.

This paper presents the various ways that lithium-ion batteries are being counterfeited, the problems that counterfeit batteries present, how they enter the consumer market, and the difficulties of detection. Simple external visual inspection of the battery is unreliable. As shown in the presented case study, even for the same brand batteries, their internal structures are different. The current counterfeit prevention methods focus on the manufacturing step. To reduce the risk of counterfeit batteries, device manufacturers and retail stores should characterize the batteries they receive. In addition, related authorities or organizations should set standards to enable a universal battery tracking method along the supply chain to prevent counterfeit lithium-ion batteries from entering the market.

In order to meet increasing power-dissipation requirements of the electronics industry, compact, low-cost, and lightweight heat exchangers (HXs) are desired. With proper design, materials, and manufacture, polymer composite heat exchangers could meet these requirements. This paper presents a novel crossflow air-to-water, low-cost, and lightweight metal-polymer composite HX. This HX, which is entirely additively manufactured, utilizes a novel cross-media approach that provides direct heat exchange between air and liquid sides by using connecting fins. A robust numerical model was developed, which includes the dimensional effects of additive manufacturing. The study consists of a simplified 3D CFD model based on ellipsoidal-shaped staggered tube banks for the laminar range. It then uses an analytical approach to compute entire HX performance. The model is validated experimentally within 8% for thermal performance, 12% for air-side impedance, and 18% for water-side impedance. Finally, HX is compared with a conventional CPU radiator and performs within 10% of the conventional unit for reasonable flow rates and pressure-drop ranges. Moreover, HX also provides added design and cost advantages over the conventional unit, which makes the HX a potential candidate for electronic cooling applications.

Analog circuits are a critical part of industrial electronics and systems. Estimates in the literature show that, even though analog circuits comprise less than 20% of all circuits, they are responsible for more than 80% of faults. Hence, analog circuit fault diagnosis and isolation can be a valuable means of ensuring the reliability of circuits. This paper introduces a novel technique of learning time–frequency representations, using learnable wavelet scattering networks, for the fault diagnosis of circuits and rotating machinery. Wavelet scattering networks, which are fixed time–frequency representations based on existing wavelets, are modified to be learnable so that they can learn features that are optimal for fault diagnosis. The learnable wavelet scattering networks are developed using the genetic algorithm-based optimization of second-generation wavelet transform operators. The simulation and experimental results for the diagnosis of analog circuit faults demonstrates that the developed diagnosis scheme achieves greater fault diagnosis accuracy than other methods in the literature, even while considering a larger number of fault classes. The performance of the diagnosis scheme on benchmark datasets of bearing faults and gear faults shows that the developed method generalizes well to fault diagnosis in multiple domains and has good transfer learning performance, too.

Lithium-ion battery datasheets, also known as specification sheets, are documents that battery manufacturers provide to define the battery’s function, operational limit, performance, reliability, safety, cautions, prohibitions, and warranty. Product manufacturers and customers rely on the datasheets for battery selection and battery management. However, battery datasheets often have ambiguous and, in many cases, misleading terminology and data. This paper reviews and evaluates the datasheets of 25 different lithium-ion battery types from eleven major battery manufacturers. Issues that customers may face are discussed, and recommendations for developing an informative and valuable datasheet that will help customers procure suitable batteries are presented.

Sensor monitoring networks and advances in big data analytics have guided the reliability engineering landscape to a new era of big machinery data. Low-cost sensors, along with the evolution of the internet of things and industry 4.0, have resulted in rich databases that can be analyzed through prognostics and health management (PHM) frameworks. Several data-driven models (DDMs) have been proposed and applied for diagnostics and prognostics purposes in complex systems. However, many of these models are developed using simulated or experimental data sets, and there is still a knowledge gap for applications in real operating systems. Furthermore, little attention has been given to the required data preprocessing steps compared to the training processes of these DDMs. Up to date, research works do not follow a formal and consistent data preprocessing guideline for PHM applications. This paper presents a comprehensive step-by-step pipeline for the preprocessing of monitoring data from complex systems aimed for DDMs. The importance of expert knowledge is discussed in the context of data selection and label generation. Two case studies are presented for validation, with the end goal of creating clean data sets with healthy and unhealthy labels that are then used to train machinery health state classifiers.

Lithium-ion batteries typically exhibit a transition to a more rapid capacity fade trend when subjected to extended charge–discharge cycles and storage conditions. The identification of the knee point can be valuable to identify the more severe degradation trend, and to provide guidance when scheduling battery replacements and planning secondary uses of the battery. However, a concise and repeatable determination of a knee point has not been documented. This paper provides a definition of the knee point which can be used as a degradation metric, and develops an algorithm to identify it. The algorithm is implemented on various data cases, and the results indicate that the approach provides repeatable knee point identification.

Enhanced cooling, coupled with novel designs and packaging of semiconductors, has revolutionized communications, computing, lighting, and electric power conversion. It is time for a similar revolution that will unleash the potential of electrified propulsion technologies to drive improvements in fuel-to-propulsion efficiency, emission reduction, and increased power and torque densities for aviation and beyond. High efficiency and high specific power (kW/kg) electric motors are a key enabler for future electrification of aviation. To improve cooling of emerging synchronous machines, and to realize performance and cost metrics of next-generation electric motors, electromagnetic and thermomechanical co-design can be enabled by innovative design topologies, materials, and manufacturing techniques. This paper focuses on the most recent progress in thermal management of electric motors with particular focus on electric motors of significance to aviation propulsion.

Multi-sensor systems are proliferating in the asset management industry. Industry 4.0, combined with the Internet of Things (IoT), has ushered in the requirements of prognostics and health management systems to predict the system’s reliability and assess maintenance decisions. State of the art systems now generate big machinery data and require multi-sensor fusion for integrated remaining useful life prognostic capabilities. When dealing with these data sets, traditional prediction methods are not equipped to handle the multiple sensor signals in unison. To address this challenge, this paper proposes a new, deep, adversarial approach to any remaining useful life prediction in which a novel, non-Markovian, variational, inference-based model, incorporating an adversarial methodology, is derived. To evaluate the proposed approach, two public multi-sensor data sets are used for the remaining useful life prediction applications: (1) CMAPSS turbofan engine dataset, and (2) FEMTO Pronostia rolling element bearing data set. The proposed approach obtains favorable results when against similar deep learning models.

Derating is widely applied to electronic components and products to ensure or extend their operational life for the targeted application. However, there are currently no derating guidelines for Li-ion batteries. This paper presents derating methodology and guidelines for Li-ion batteries using temperature, discharge C-rate, charge C-rate, charge cut-off current, charge cut-off voltage, and state of charge (SOC) stress factors to reduce the rate of capacity loss and extend battery calendar life and cycle life. Experimental battery degradation data from our testing and the literature have been reviewed to demonstrate the role of stress factors in battery degradation and derating for two widely used Li-ion batteries: graphite/LiCoO2 (LCO) and graphite/LiFePO4 (LFP). Derating factors have been computed based on the battery capacity loss to quantitatively evaluate the derating effects of the stress factors and identify the significant factors for battery derating.

Premature battery drain, swelling and fires/explosions in lithium-ion batteries have caused wide-scale customer concerns, product recalls, and huge financial losses in a wide range of products including smartphones, laptops, e-cigarettes, hoverboards, cars, and commercial aircraft. Most of these problems are caused by defects which are difficult to detect using conventional nondestructive electrical methods and disassembly-based destructive analysis. This paper develops an effective computed tomography (CT)-based nondestructive approach to assess battery quality and identify manufacturing-induced defects and structural deformations in batteries. Several unique case studies from commercial e-cigarette and smartphone applications are presented to show where CT analysis methods work.

Solid oxide fuel cells (SOFCs) are a highly efficient chemical to electrical energy conversion devices that have potential in a global energy strategy. The wide adoption of SOFCs is currently limited by cost and concerns about cell durability. Improved understanding of their degradation modes and mechanisms combined with reduction–oxidation stable anodes via all-ceramic-anode cell technology are expected to lead to durability improvements, while economies of scale for production will mitigate cost of commercialization. This paper presents an Ishikawa analysis and a failure modes, mechanisms, effects, and criticality analysis (FMMECA) for all-ceramic anode based SOFCs. FMMECA takes into account the life cycle conditions, multiple failure mechanisms, and their potential effects on fuel-cell health and safety.