http://bura.brunel.ac.uk/handle/2438/22 2026-04-17T06:10:59Z http://bura.brunel.ac.uk/handle/2438/33141 Title: Development of High Temperature Die-Cast Magnesium Alloys for Small IC Engine Application Authors: Dong, X; Ji, S; Shan, Z Abstract: An innovative and superior coarsening/creep resistant Al-based ternary short-range order (SRO,0–2nm)/cluster(2–10nm) at critically high temperature and stress of 300°C/50MPa was proposed and verified in Mg, and a highly heat-resistant die-cast Mg alloy was thus successfully developed with the super low steady-state creep rate (1.35×10−10s−1) and long creep life (>600h) under the critical condition of 300ºC/50MPa. This work changes the common belief of the detrimental effect of Al on the high temperature creep of Mg alloys over the past few decades, and it provides key evidence for the long-term and massive existence of SRO/clusters in Mg alloys under critically high temperatures and stresses. It greatly increases the working temperature of die-cast Mg alloys from 120-200°C to 300-350°C. The developed alloy has been transferred into manufacturing high temperature (300-350°C) Mg components used in small internal combustion (IC) engines. 2024-10-25T00:00:00Z http://bura.brunel.ac.uk/handle/2438/33140 Title: Effect of Convection Solidification on the Halo Formation in Zn-Al Alloys Authors: Yang, W; Ji, S Abstract: The formation of halos was investigated for hypoeutectic, eutectic and hypereutectic Zn-Al alloys under conventional and under convection solidification. It was found that the Zn-rich halos occurred in the surroundings of the Al-rich primary phase for the hypereutectic Zn-Al alloys at Al>5 wt.% and no halos occurred for the hypoeutectic and the eutectic Zn-Al alloys at Al5 wt.% under conventional solidification. However, the Zn-rich halos were completely vanished from the Al-rich phase under intensive convection solidification. The interaction among the solid phases and the liquid phase was found to be responsible for the halo formation. 2024-10-25T00:00:00Z http://bura.brunel.ac.uk/handle/2438/33139 Title: Integrated Structural Casting Development with Digital Twin Technology Authors: Ji, S; Niu, Z; Dong, X; Zhu, X Abstract: In the present paper, we introduced the development of integrated structural castings with digital twin technology for the rear structure of high-end E-sports cars. The topological optimisation, casting structural design, materials verification, melt flow and solidification, mechanical property prediction and the final verification using low pressure die casting (LPDC) for the component manufacturing are described in details for digital twin. The microstructures and mechanical properties of the casting with satisfied quality are described under heat-treated condition. 2024-10-25T00:00:00Z http://bura.brunel.ac.uk/handle/2438/33127 Title: Graphene nanoparticles as data generating digital materials in industry 4.0 Authors: Ali, MA; Irfan, MS; Khan, T; Khalid, MY; Umer, R Abstract: One of the potential applications of 2D materials is to enhance multi-functionality of structures and components used in aerospace, automotive, civil and defense industries. These multi-functional attributes include sensing, energy storage, EMI shielding and property enhancement. In this article, we have explored the potential of using graphene and its variants as data generating sensory elements in Industry 4.0. We have presented a complete roadmap to cover three emerging technologies i.e. advance materials, artificial intelligence and block-chain technology. The utility of 2D materials such as graphene nanoparticles is yet to be explored as an interface for digitalization of a modern smart factory i.e. “factory-of-the-future”. In this article, we have explored how 2D material enhanced composites can act as an interface between physical and cyber spaces. An overview of employing graphene-based smart embedded sensors at various stages of composites manufacturing processes and their application in real-time structural health monitoring is presented. The technical challenges associated with interfacing graphene-based sensing networks with digital space are discussed. Additionally, an overview of the integration of associated tools such as artificial intelligence, machine learning and block-chain technology with graphene-based devices and structures is also presented. Description: Data availability: All data generated or analyzed during this study are included in this published article. 2023-03-27T00:00:00Z