International Scientific Journals
of Scientific Technical Union of Mechanical Engineering "Industry 4.0"

Due to the increasing complexity and cost of Engineering Structures, and consequently the growth of operating costs for maintaining the operational reliability of these structures, new approaches to monitoring their technical condition directly without decommissioning are required. Previously conducted studies have shown that the most effective method of such monitoring is non-destructive testing based on acoustic emission. This article presents the basic principles of organizing such monitoring during operation based on the “Technical Health Condition” (THC), “Structural Health Monitoring (SHM), Condition-based Monitoring (CBM)) or “Fail Safe Concept (FSC)”

The current optimization of materials in the automotive industry is primarily driven by the objective of progressively reducing vehicle curb weight, which serves as a critical instrument for lowering greenhouse gas emissions and enhancing energy efficiency. Empirical data demonstrate a direct correlation between weight reduction and fuel consumption: a 10% decrease in vehicle mass generates an approximate 7% reduction in fuel consumption. Composite materials, defined as heterogeneous systems consisting of at least two components—a continuous matrix (binder) and a discontinuous reinforcement (fibers, particles, or layers)—enable a synergistic effect of mechanical properties that are unattainable with monolithic metallic materials. In structural applications, polymer matrices (including both thermosets and thermoplastics) predominate in combination with high-strength carbon, aramid, or glass fiber reinforcements. These material systems exhibit extreme specific strength, a high modulus of elasticity, fatigue resistance, and anisotropic properties that allow for the directional optimization of stiffness. For components requiring maximum dimensional stability and self-supporting (monocoque) capabilities, sandwich configurations are utilized, typically integrating an aramid honeycomb core between high-performance composite face sheets. The qualitative parameters of the resulting components are directly dependent on the chosen manufacturing technology and the fiber-to-resin ratio. The Vacuum Infusion (VI) method represents a highly efficient process in which a vacuum-sealed mold ensures the uniform saturation of dry reinforcement with liquid resin. This procedure minimizes porosity, achieves a high fiber volume fraction—reaching up to 70% in advanced systems—and guarantees high production reproducibility and surface quality without the need for secondary machining. Despite their technical superiority, the primary limiting factors for widespread implementation remain the high economic cost of raw materials and the complexity of manufacturing cycles. Prospective development is focused on streamlining processes for mass production, implementing sustainable bio-fibers as reinforcing components, and addressing the challenges of recyclability and component replacement at the end of the life cycle. Advanced composite structures thus form the essential material foundation for the next generation of ultra-lightweight and safe transport vehicles.

The article investigates the influence of technology and technological parameters of manufacturing on the structure, phase composition and physical and mechanical properties of the Fe-FeCr800 composite system. It was established that the determining factor in phase and structure formation is the manufacturing technology, while vacuum sintering and hot forging have their own optimal technological parameters. At the same time, hot forging makes it possible to obtain a composite with a higher microhardness of structural components due to a change in the content of component components. The results of the research also showed that the preheating time (for 20 min.), as well as thermomechanical treatment, is sufficient for the phase formation process, in particular, with the release of carboboride phases of the type Me3CB and Me3(CB)2, while the densification processes are intensified, which makes it possible to obtain a material with lower residual porosity. Analysis of mechanical tests showed that vacuum sintering makes it possible to obtain composites with higher mechanical properties due to the active interaction between the components of the composite. However, high-temperature annealing after hot deformation will allow for a composite with high mechanical properties.

The article investigates the influence of the technological parameters of manufacturing and the effect of the initial charge on the structure and tribological properties of carbide steel when used in hybrid components of the metal-matrix composite-ceramic system. It was found that the titanium carbide content of the initial charge was the determining factor in the formation of the properties. At the same time, an increase in the titanium carbide content above 20 (wt. %) does not lead to a significant increase in the hardness of the composite, and in some cases even to a decrease in hardness. It is also worth noting that the use of sprayed high-speed steel powder to prepare the mixture allows the composite to be obtained with fewer technological transitions. According to the results of tribological studies, it was found that the lowest wear was observed when the ceramics were paired with a composite with a titanium carbide content of 10 and 30 (wt. %). At the same time, the results of the analysis of friction track profilometry and the size of the contact patch showed that as the content of the carbide component increases to 30 (wt. %), a change in the nature of the friction occurs, accompanied by intensive wear of the ceramic ball. In the ceramic-carbide-steel (10 wt. % TiC) friction pair, however, no wear of the ceramic ball was observed, and the cross-sectional shape of the friction track changed from spherical to flat.

The development of solar cell technologies is critical for advancing sustainable energy solutions. One of the significant challenges faced by solar cells is the accumulation of dust and debris on their surfaces, which can significantly reduce their efficiency. Our research work will be focused on new development composite material which are designed to repel dirt, dust, and other contaminants, ensuring that the solar cells maintain optimal performance. The optimum WO3-B composition was utilized in this research work to prepare the SiO2/WO3- B5/ZnO film sample. The composite film sample resulted the highest photocatalytic dye degradation efficiency (92%) with the SiO2/WO3- B5/ZnO/70/30) film sample after 240 min of the UVA light irradiation.

The article presents the results of investigations of tribotechnical properties of powder composite materials based on the ironhigh-carbon (ФХ800) ferrochrome system during dry friction with ШХ15 steel at various loads of 30, 60, and 100 N. It was found that an increase of the load from 30 to 100 N leads to an increase in the coefficient of friction from 0,45 to 0,5 (for 25% ФХ800) and from 0,40 to 0,46 (for 40% ФХ800). At the same time, the mass wear of samples made of powder materials decreases with an increase in ФХ800 content from 25 to 40 (wt. %) and with growth of the load from 30 to 100 N, respectively, from 3,5 – 8,0 to 0,75 – 1,6 mg/km., which provides wear resistance improvement (km/mm) by 2,8 – 2,2 times. X-ray phase full profile analysis using the Rietveld method established that there are 2 phases: metallic α-Fe (79,68%) and carbide Me7C3 (20,32%) in the composite Fe – 25%ФХ800 and 3 phases: α-Fe (69,5%), γ-Fe (3,96%) and carbide Me7C3 (26,57%) in the Fe – 40% ФХ800 composite. Topographic studies of 2D profiles of worn surfaces of composites after friction under different loads were conducted. The results of optical profilometry show that the main mechanism of destruction of the powder composite surface during dry friction with ШХ15 steel is adhesive wear (seizing) of the contacting surfaces.

On the basis of separate fractions of granular foam glass and inorganic binders, various modifications of heat-insulating composite material have been developed. A promising opportunity for potential application of the material is the preparation of composite elements and profiles suitable for installation around doors and windows during the construction or reconstruction of buildings. In connection with the study of the possibilities for optimal distribution of the granules, various options for their arrangement have been analyzed and evaluated. The mathematical tools of stereometry and 3D computer modeling were used. Visualizations of the obtained structures are presented and their compactness is evaluated. Recommendations are made for the ratio between the sizes and quantities of the granules used in order to achieve maximum density.

A general overview of a number of thermal insulation materials and products made on the basis of inorganic binders (mainly Portland cement) is presented. The technological methods of production, the main operational indicators and the application in construction of various heat-insulating and structural-heat-insulating lightweight concretes are examined. The structure of various cellular concretes (foam concretes and aerated concretes), composite materials and lightweight aggregate concrete was analyzed. The role of the origin, technological processing, characteristics and composition of different types of light additive materials for the formation of the final operational properties of the products has been traced.

The paper presents the results of research focused on the use of innovative processes in the production of composite materials. The experimental work was focused on the use of Vacuum Bag Molding technology in the production of the prototype of the Shell Ecomarathon formula. The car body was designed with 3D modeling and optimized with airflow simulation. Carbon fibers have been used to reduce the vehicle’s weight. Some complementary parts were produced using 3D printing.