AISI P20 mold steel is commonly used for injection molds to produce plastic materials, car accessories, and electronic equipment molds. This study employed a fiber laser beam for precise machining of AISI P20 mold steel. The experimental design, based on the Taguchi 27 model, was carried out using Minitab software to optimize machining parameters, including cutting speed, gas pressure, and laser power. Surface roughness (Ra) and kerf width were the response parameters investigated. The ANFIS model, developed and analyzed using MATLAB, successfully predicted response parameters and was experimentally validated, showing improved predictions over actual measurements. The Brute Force algorithm identified the minimum combination for an optimal parameter set. The Taguchi method determined the best process parameters, indicating that cutting speed had the most significant impact. The optimum Ra was achieved with 1 m/min cutting speed, 2 bar gas pressure, and 1.8 kW laser power, while the lowest kerf width was obtained with 2 bar gas pressure, 1 m/min cutting speed, and 1.9 kW laser power. Based on the Brute Force algorithm, the minimum combination resulted in a kerf width of 0.84 mm and a surface roughness of 4.48175 μm. Microstructural analysis was performed on samples with high and low surface roughness to assess the machining surface quality.

Sensor technologies have had a significant impact on the development of intelligent manufacturing and industry 4.0. In the internet of things era, many sensor technologies are crucial for data collection and efficiently utilizing the manufacturing processes. Moreover, sensor technologies have enhanced humankind's quality of life because of their widespread applications in almost all fields. Sensors track changes in the environment or source and collect signals that serve as the basis for the reaction. Innovative sensor technologies are used in a variety of fields, including lifestyle, food safety standards, defense, security, healthcare, fitness, manufacturing, environmental contaminants, medicine, and daily living. Ultrasound, radar, noncontact optoelectronic solutions, laser technology other industrial advances are now driving sensor innovation. Therefore, scientific advances in sensors are important for understanding technological and societal change. This review provides a broad overview of new developments in different types of sensors, identifies and discusses significant applications of sensors, and creates an agenda for future research that encompasses various capabilities of sensor technologies associated with the industry fourth revolution. Moreover, the most recent innovations in the world of sensing materials and future trend is to make sensor devices more affordable has also been discussed. High energy consumption, cost reduction, various process stages, and incorrect model inputs because of sensor flaws are some of the biggest hurdles in sensor development. Some novel sensor technologies are required to be capable of providing functionalities and implementing new ecologies such as the Internet of Things, Precise Agriculture, and Smart Grids. Modern methods, such as flexible or elastic electronics, are required for applications in industries like augmented reality and rehabilitation. Additionally, numerous other anticipated uses have increased the demand for sensors as an extension of perceptive functions in recent decades and boosting interest in sensors.

Drilling in synthetic fiber-reinforced polymer composites is facing challenges due to their anisotropic, inhomogeneity, and abrasive machining behavior. The joining of composite parts using fasteners is commonly done by the drilling, and the generated heat is one of the main causes to damage the drilled hole in the composite. Moreover, the quality of drilled hole is crucial for joining parts effectively. The paper presents the design, fabrication, and drilling of a hybrid fiber-reinforced polymer (HFRP) based on insulative coating. These composites were fabricated using vacuum infusion molding (VIM) and coated with different thicknesses to investigate the influence of drilling parameters and associated damages. Cutting speed, feed rate, and coating thicknesses were varied, and a full factorial design of the experiment was formulated. High-speed steel (HSS) twist drill bit was used to drill the coated composite and test samples, and delamination factor and surface roughness were measured. ANOVA and full factorial response optimizer were used to evaluate the influence and optimum drilling parameters. The delamination factor (DF) at the entry and surface roughness were found to decrease with the increasing cutting speed. However, the DF at the exit showed the opposite. Coating thickness influenced the delamination at the entry whereas delamination at the exit has been found insignificant. For drilling HFRP composite with 1mm coating thickness, 3000RPM spindle speed and 0.08 mm/rev feed rate were found optimum parameters in minimizing surface roughness and delamination damage. However, 6000RPM and 0.02 mm/rev were found optimum parameters for drilling HFRP composite with 1.5mm coating thickness.

This work aims to investigate and assess the beneficial function and feasibility of nanofluids in minimum quantity lubrication (MQL) assisted machining.The goal is to develop newly generated CNT based nano hybrid cutting fluid and demonstrate its effect on surface roughness of Al alloy.Moreover, the fabricated nano hybrid cutting fluid will eventually reduce cutting fluid consumptions and maintain an eco-friendly environment.Three conditions were used to perform the machining process such as dry condition, conventional oil and Al2O3/CNT nanoparticle with EVO oil as base fluid.The lowest surface roughness achieved for nanofluid and the maximum surface roughness for the dry condition.In terms of looking for optimum parametric combination, Artificial Neural Network (ANN) and Response Surface Methodology (RSM) have been used.The ANN technique has proved its efficiency since its correlation coefficients, mean prediction errors (MPEs), and root mean square errors (RMSEs) are small compared to the RSM approach.

Intumescent fire-retardant coating is a passive type of protection against fire, design to reduce the heat transfer from the source of fire to the steel substrate in a duration of time. This research investigates the effect of Magnesium Oxide as a filler in expandable graphite-based intumescent fire-retardant coatings. The coating was developed by varying weight percentage (0.5–2.5wt%) of magnesium oxide towards binder in the coating in addition to ammonium polyphosphate, melamine, boric acid, zinc borate, and expandable graphite. The samples were subjected to fire tests to investigate their performance. The heat shielding fire test shows a decrease of back substrate temperature when increasing the amount of magnesium oxide in the formulation up to 242 ℃ for 1 h. The samples were subjected to a fire control test to investigate the intumescent factor (IF) at 600 ℃ for 1 h in a carbolite furnace. MG1.5 shown the highest with the expansion of 8.33 Intumescent factor. Thermal gravimetric analysis, water immersion, and adhesion tests were also performed to study the sample's thermal stability and adhesion strength towards the substrate. The result showed that adding magnesium oxide in the formulation of intumescent coating improved the coating's thermal performance, thus increasing the protection time of steel substrate.

Zirconium phosphate (ZrP) recently introduced in intumescent fire protective coating has shown improvement in developing ceramic layer. The tubular halloysite clay (THC) due to its unique molecular structure can be combined with ZrP to enhance fire resistance by developing a strong silica network on the char surface. This study is aimed to investigate the synergistic effects of tubular halloysite clay and zirconium phosphate fillers to improve the thermal performance of the intumescent coating. The control coating formulation and a range of coating formulations using a combination of weight percentage of THC and ZrP were developed to study the influences of fillers on fire performance. The char expansion and fire resistance tests of the coatings were conducted using furnace fire test and Lab scale fire jet. Thermal stability of the coating was determined by TGA and char was characterized by FESEM, XRD, FTIR and XPS. Water-resistance test of the coating was performed according to ASTM D-870. Results showed that the reinforcement of THC-ZrP showed promising improvement on the performance of IFC and substrate temperature was far below the critical temperature, 550 °C. Sample HZ 5 showed the least backside steel substrate temperature of 219 °C. Expansion rate of char was found reduced with the addition of THC but improved the char compactness. The addition of THC and ZrP in IFC improved 18% fire resistance performance and 5% residual wt. Of char. Char morphology showed silica network, XRD and FTIR confirmed the presence of silicon. Water absorption test showed 95% less water absorption (HZ-5) compared to control coating. Post water immersion, fire test showed 7% increase in substrate temperature which is 18% less than control coating after water immersion fire test.

Intumescent coating is a passive fire protection system used to prevent and resist the spreading of fire. The coating swells several times of its thickness on exposure to the fire, forming cellular foam and acts as an insulative barrier, thus delaying the heat transfer to the protected substrate. The study aims to analyse waste glass powder filler’s effect into intumescent coating formulation limited to one size of waste glass powder. Waste glass is a broken form of leftover by-product from industrial and domestic. Millions of tons of waste glass generated every year, adding with their non-biodegradable nature causing additional environmental pollution. Waste glass powder contains high silica composition known for its high thermal stability, weather resistance, hydrophobicity, low surface tension, and high oxidation resistance. The coating showed improved thermal stability, weather resistance, and adhesion when added into intumescent coating formulation. The lowest recorded backside substrate temperature 154.6 °C compare to coating without the waste glass filler, 333.7 C. The coating also showed less than 0.1% total weight loss for samples with 4% wt. filler after immersion in seawater for 15 days compared to the control formulation, 0.19%. The char morphology analysis showed the emergence of silica and calcium elements occupying the expandable char’s gaps, thus strengthening the char structure.

Fire retardant coatings play vital role in safety of construction nowadays, to delay the fire propagation and provide more time for evacuation. The current research work aimed to study the use of modified siloxane epoxy binder to develop intumescent coating. Polyamide amine was used as a hardener. Three different sets of formulations were developed by using three different fillers, namely the oyster shell powder (OSP), glass frit (GF) and combination of both oyster shell powder and glass frit (OG). All three set of formulation also includes the basic ingredients of intumescent coating. These samples were used to study the synergistic effects of fillers on thermal performance of the coating as well tested for char expansion, heat shielding, char morphology and composition. Fire resistant testing was conducted by using a Bunsen Burner and GF samples had found to have minimum substrate temperature of 175.3°C. The char morphology was analysed via Scanning Electron Microscope (SEM) which confirmed the adhesion between the matrix with fillers. Furnace test was carried out to investigate the char expansion of OSP/GF/OG with the modified siloxane epoxy composition and the maximum expansion was OSP 1% with intumescent factor of 7.78. XRD was conducted to evaluate the residual compounds in the char and FTIR was utilized to analyse the functional group where O-H, C-N, O=C=O and C=C bonds were found in the degradation compounds in the char residual of the coatings.

Intumescent coating reinforce mica was developed and studied in terms of their physical appearance, thermal properties, composition, and morphology.6 samples, including control formulation, were developed by varying percentage of mica to binder from 0 to 5%.Control fire test shows an increase of expansion when the percentage of mica increases but decreases when more than 4% of mica was used.The thermal stability of the samples with 3% mica was improved with a degradation rate of 0.047 wt.%/min compared to the control formulation 0.091wt%/min suggested coming from silicon phosphate oxide composition emerged on XRD analysis.Silicon phosphate oxide was known to enhance the antioxidation of the char and thermal stability of the char.A homogenous surface with a smaller pore was also observed on the char structure of MC3 coming from the ceramization process, which creates a ceramics layer on the surface, thus improve the insulation properties of the coating.

Drilling is considered an inevitable operation for joining components in automotive and aerospace industries.Hybrid fiber reinforced polymer (HFRP) composites have attained enormous attention due to their light weight and higher strength.In this study, HFRP composite was made of glass, carbon fibers and epoxy.The vacuum infusion molding technique is used to fabricate HFRP composites.Physical and mechanical properties of HFRP composites were analyzed according to ASTM standard.Heat resistant coating was made of conventional coating ingredients with fillers as a binder to enhance coating performance.This coating was applied on HFRP composite.Drilling performance was tested for HFRP and coated HFRP composites to examine the impact of coating of the composite in term of drilled hole quality.Results showed that density was reduced by 10% after applying the coating in HFRP composite.The tensile and flexural strength were found around 441.27 MPa and 409 MPa, respectively.The coating was effective in terms of improving drilled hole quality by minimizing delamination factor.It was found higher with the increment of spindle speed and feed rate for both coated and uncoated HFRP composite samples.Coated samples showed less DF at the entrance as well as exit compared to uncoated composites.