Materials science Books

Book SynopsisAntibacterial Properties of the Biodegradable 3D-Printed PCL/PLA Scaffolds with Silver Nanoparticles.- Ion Bombardment as Control Factor in Synthesis of 2D and 3D CuO Nanostructures.- Resistance to Wear During Friction with Boundary Lubrication of Cast Iron-Iron Pairing with Nanocrystalline Structure-Reinforced Surface Layers.- Two Layer Silane-Based Coatings for Paper Finishing.

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Book SynopsisFaster, cheaper and environmentally friendly, these are the criteria for designing new reactions and this is the challenge faced by many chemical engineers today. Based on courses thaught by the authors, this advanced textbook discusses opportunities for carrying out reactions on an industrial level in a technically controllable, sustainable, costeffective and safe manner. Adopting a practical approach, it describes how miniaturized devices (mixers, reactors, heat exchangers, and separators) are used successfully for process intensification, focusing on the engineering aspects of microstrctured devices, such as their design and main chracteristics for homogeneous and multiphase reactions. It adresses the conditions under which microstructured devices are beneficial, how they should be designed, and how such devices can be integrated in an existing chemical process. Case studies show how the knowledge gained can be applied for particular processes. The textbook is essential for master and doctoral students, as well as for professional chemists and chemical engineers working in this area.Table of ContentsPreface XI List of Symbols XIII 1 Overview of Micro Reaction Engineering 1 1.1 Introduction 1 1.2 What are Microstructured Devices? 2 1.3 Advantages of Microstructured Devices 2 1.3.1 Enhancement of Transfer Rates 2 1.3.2 Enhanced Process Safety 5 1.3.3 Novel OperatingWindow 7 1.3.4 Numbering-Up Instead of Scale-Up 7 1.4 Materials and Methods for Fabrication of Microstructured Devices 9 1.5 Applications of Microstructured Devices 10 1.5.1 Microstructured Reactors as Research Tool 11 1.5.2 Industrial/Commercial Applications 11 1.6 Structure of the Book 13 1.7 Summary 13 References 14 2 Basis of Chemical Reactor Design and Engineering 19 2.1 Mass and Energy Balance 19 2.2 Formal Kinetics of Homogenous Reactions 21 2.2.1 Formal Kinetics of Single Homogenous Reactions 22 2.2.2 Formal Kinetics of Multiple Homogenous Reactions 24 2.2.3 Reaction Mechanism 25 2.2.4 Homogenous Catalytic Reactions 26 2.3 Ideal Reactors andTheir Design Equations 29 2.3.1 Performance Parameters 29 2.3.2 BatchWise-Operated Stirred Tank Reactor (BSTR) 30 2.3.3 Continuous Stirred Tank Reactor (CSTR) 35 2.3.4 Plug Flow or Ideal Tubular Reactor (PFR) 39 2.4 Homogenous Catalytic Reactions in Biphasic Systems 452.5 Heterogenous Catalytic Reactions 49 2.5.1 Rate Equations for Intrinsic Surface Reactions 50 2.5.2 Deactivation of Heterogenous Catalysts 57 2.6 Mass and Heat Transfer Effects on Heterogenous Catalytic Reactions 59 2.6.1 External Mass and Heat Transfer 60 2.6.2 Internal Mass and Heat Transfer 69 2.6.3 Criteria for the Estimation of Transport Effects 83 2.7 Summary 84 2.8 List of Symbols 86 References 87 3 Real Reactors and Residence Time Distribution (RTD) 89 3.1 Nonideal Flow Pattern and Definition of RTD 89 3.2 Experimental Determination of RTD in Flow Reactors 91 3.2.1 Step Function Stimulus-Response Method 92 3.2.2 Pulse Function Stimulus-Response Method 93 3.3 RTD in Ideal Homogenous Reactors 95 3.3.1 Ideal Plug Flow Reactor 95 3.3.2 Ideal Continuously Operated Stirred Tank Reactor (CSTR) 95 3.3.3 Cascade of Ideal CSTR 96 3.4 RTD in Nonideal Homogeneous Reactors 98 3.4.1 Laminar Flow Tubular Reactors 98 3.4.2 RTD Models for Real Reactors 100 3.4.3 Estimation of RTD in Tubular Reactors 105 3.5 Influence of RTDon the Reactor Performance 107 3.5.1 Performance Estimation Based on Measured RTD 108 3.5.2 Performance Estimation Based on RTD Models 110 3.6 RTD in Microchannel Reactors 115 3.6.1 RTD of Gas Flow in Microchannels 117 3.6.2 RTD of Liquid Flow in Microchannels 118 3.6.3 RTD of Multiphase Flow in Microchannels 122 3.7 List of Symbols 126 References 127 4 Micromixing Devices 129 4.1 Role of Mixing for the Performance of Chemical Reactors 129 4.2 Flow Pattern and Mixing in Microchannel Reactors 136 4.3 Theory of Mixing in Microchannels with Laminar Flow 137 4.4 Types of Micromixers and Mixing Principles 143 4.4.1 Passive Micromixer 144 4.4.2 Active Micromixers 154 4.5 Experimental Characterization of Mixing Efficiency 158 4.5.1 Physical Methods 158 4.5.2 Chemical Methods 159 4.6 Mixer Efficiency and Energy Consumption 171 4.7 Summary 172 4.8 List of Symbols 173 References 1735 Heat Management by Microdevices 179 5.1 Introduction 179 5.2 Heat Transfer in Microstructured Devices 181 5.2.1 Straight Microchannels 181 5.2.2 Curved Channel Geometry 189 5.2.3 Complex Channel Geometries 191 5.2.4 Multichannel Micro Heat Exchanger 191 5.2.5 Microchannels with Two Phase Flow 193 5.3 Temperature Control in Chemical Microstructured Reactors 195 5.3.1 Axial Temperature Profiles in Microchannel Reactors 197 5.3.2 Parametric Sensitivity 201 5.3.3 Multi-injection Microstructured Reactors 212 5.4 Case Studies 221 5.4.1 Synthesis of 1,3-Dimethylimidazolium-Triflate 221 5.4.2 Nitration of Dialkyl-Substituted Thioureas 222 5.4.3 Reduction of Methyl Butyrate 223 5.4.4 Reactions with Grignard Reagent in Multi-injection Reactor 224 5.5 Summary 226 5.6 List of Symbols 226 References 228 6 Microstructured Reactors for Fluid–Solid Systems 231 6.1 Introduction 231 6.2 Microstructured Reactors for Fluid–Solid Reactions 232 6.3 Microstructured Reactors for Catalytic Gas-Phase Reactions 233 6.3.1 Randomly Micro Packed Beds 233 6.3.2 Structured Catalytic Micro-Beds 235 6.3.3 CatalyticWall Microstructured Reactors 238 6.4 Hydrodynamics in Fluid–Solid Microstructured Reactors 239 6.5 Mass Transfer in Catalytic Microstructured Reactors 243 6.5.1 Randomly Packed Bed Catalytic Microstructured Reactors 244 6.5.2 Catalytic Foam Microstructured Reactors 245 6.5.3 CatalyticWall Microstructured Reactors 246 6.5.4 Choice of Catalytic Microstructured Reactors 253 6.6 Case Studies 255 6.6.1 Catalytic Partial Oxidations 255 6.6.2 Selective (De)Hydrogenations 257 6.6.3 Catalytic Dehydration 259 6.6.4 Ethylene Oxide Synthesis 259 6.6.5 Steam Reforming 260 6.6.6 Fischer–Tropsch Synthesis 261 6.7 Summary 261 6.8 List of Symbols 262 References 262 7 Microstructured Reactors for Fluid–Fluid Reactions 267 7.1 Conventional Equipment for Fluid–Fluid Systems 267 7.2 Microstructured Devices for Fluid–Fluid Systems 268 7.2.1 Micromixers 269 7.2.2 Microchannels 271 7.2.3 Microstructured Falling Film Reactor for Gas–Liquid Reactions 272 7.3 Flow Patterns in Fluid–Fluid Systems 273 7.3.1 Gas–Liquid Flow Patterns 273 7.3.2 Liquid–Liquid Flow Patterns 280 7.4 Mass Transfer 284 7.4.1 Mass Transfer Models 285 7.4.2 Characterization of Mass Transfer in Fluid–Fluid Systems 286 7.4.3 Mass Transfer in Gas–Liquid Microstructured Devices 287 7.4.4 Mass Transfer in Liquid–Liquid Microstructured Devices 296 7.4.5 Comparison with Conventional Contactors 299 7.5 Pressure Drop in Fluid–Fluid Microstructured Channels 300 7.5.1 Pressure Drop in Gas–Liquid Flow 301 7.5.2 Pressure Drop in Liquid–Liquid Flow 304 7.6 Flow Separation in Liquid–Liquid Microstructured Reactors 307 7.6.1 Conventional Separators 308 7.6.2 Types of Microstructured Separators 308 7.6.3 Conventional Separator Adapted for Microstructured Devices 315 7.7 Fluid–Fluid Reactions in Microstructured Devices 315 7.7.1 Examples of Gas–Liquid Reactions 317 7.7.2 Examples of Liquid–Liquid Reactions 319 7.8 Summary 323 7.9 List of Symbols 324 References 325 8 Three-Phase Systems 331 8.1 Introduction 331 8.2 Gas–Liquid–Solid Systems 331 8.2.1 Conventional Gas–Liquid–Solid Reactors 331 8.2.2 Microstructured Gas–Liquid–Solid Reactors 333 8.3 Gas–Liquid–Liquid Systems 346 8.4 Summary 347 8.5 List of Symbols 347 References 348 Index 351

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Book SynopsisEngineering with polymers is a growing technical field which requires special knowledge. Filling a need, this ready reference brings together the hard-to-get and recently acquired knowledge usually only found scattered in the original literature. At the beginning, the reference introduces plastics as a class of technical materials, gives an overview of their properties, presents plastics processing and its possible influence on the achievable quality of plastic parts. Afterwards, plastics testing is presented as a separate, practical-scientific field of work. The possibilities and fields of application of plastics testing will be discussed. This is followed by a comprehensive treatment of the individual, relevant test areas for the characterization and qualification of plastics and plastic molded parts made from them, with descriptions of the corresponding, practical test methods. A comprehensive index provides easy access to relevant information for successful engineering with plastics and suitable methods for material characterization and for quality assurance and damage analysis of parts. Written by experienced academics and industrial researchers and developers who know the problems of plastics engineers in their daily work - and the solutions - inside out, this book offers first-hand practical knowledge and intensive discussion. The book is aimed at industry, scientists and students involved in plastics and plastic engineering and aims to help them gain the necessary understanding of polymer materials and knowledge of practical testing and evaluation of plastics.Table of Contents1 Introduction to Plastics 1 1.1 Plastics 1 1.2 Structure and Behaviour of Plastics 5 1.3 Melting Polymers 12 1.4 Mechanical Behaviour of Polymers 15 1.5 Uniaxial Stress-Strain Behaviour 28 1.6 Resins 37 1.7 Material Selection 39 1.8 Processing of Polymers 40 2 Polymer Testing 45 2.1 Introduction 45 2.2 Objective of Polymer Testing 45 2.3 Sample Preparation and Test Procedure 48 2.4 Sample Extraction/Sampling 49 2.5 Types of Samples 50 2.6 Test Implementation/Operation/Accomplishment 51 2.7 Description of Test Results/Test Report 51 3 Identifcation of Polymers 53 3.1 Introduction 53 3.2 Density Measurement 53 3.3 Infrared Spectroscopy 58 4 Rheological Testing 65 4.1 Introduction 65 4.2 Rheometry 70 4.3 Viscometry 77 5 Mechanical Testing 87 5.1 Introduction 87 5.2 Quasi-Static Loading 88 5.3 Impact Loading 113 5.4 Long-Term Static Loading 120 5.5 Long-Term Dynamic Loading - Fatigue 126 6 Tribological Testing 133 6.1 Introduction 133 6.2 Sliding Behaviour 134 6.3 Friction Coefficient 135 6.4 Wear 136 7 Thermal Testing 139 7.1 Introduction 139 7.2 Tests Under Thermal Loading 141 7.3 Thermal Ageing Behaviour 144 7.4 Di¿erential Scanning Calorimetry (DSC) 144 7.5 Dynamic Mechanical Analysis (DMA) 152 7.6 Thermogravimetric Analysis (TGA) 158 7.7 Thermomechanical Analysis (TMA) - Dilatometry 161 7.8 Calcination Test 164 7.9 Thermal Dimensional Stability 166 7.10 Heat Detection Temperature 169 8 Chemical Testing 173 8.1 Introduction 173 8.2 Chemical Resistance Investigation 173 8.3 Environmental Stress Cracking Resistance (ESCR) Investigation 174 9 Physical Testing 181 9.1 Introduction 181 9.2 Determination of Mass 181 9.3 Determination of Water Absorption 182 10 Geometrical Inspection 187 10.1 Introduction 187 10.2 Sizes and Tolerances 187 10.3 Processing and Post-processing Shrinkage 195 10.4 Warpage 197 11 Optical Testing Methods 199 11.1 Introduction 199 11.2 Visual Inspection 199 11.3 Light Microscope (LM) 201 11.4 Digital Microscope (DM) 207 11.5 Scanning Electron Beam Microscope (SEM) 208 11.6 Polarized Light Inspection 212

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Book SynopsisRetaining its proven concept, the second edition of this ready reference specifically addresses the need of materials engineers for reliable, detailed information on modern material characterization methods. As such, it provides a systematic overview of the increasingly important field of characterization of engineering materials with the help of neutrons and synchrotron radiation. The first part introduces readers to the fundamentals of structure-property relationships in materials and the radiation sources suitable for materials characterization. The second part then focuses on such characterization techniques as diffraction and scattering methods, as well as direct imaging and tomography. The third part presents new and emerging methods of materials characterization in the field of 3D characterization techniques like three-dimensional X-ray diffraction microscopy. The fourth and final part is a collection of examples that demonstrate the application of the methods introduced in the first parts to problems in materials science. With thoroughly revised and updated chapters and now containing about 20% new material, this is the must-have, in-depth resource on this highly relevant topic.Table of ContentsList of Contributor XVII Preface to Second Edition XXIII Part I General 1 1 Microstructure and Properties of Engineering Materials 3Helmut Clemens, Svea Mayer, and Christina Scheu 1.1 Introduction 3 1.2 Microstructure 4 1.3 Microstructure and Properties 10 1.4 Microstructural Characterization 12 2 Internal Stresses in Engineering Materials 21Anke Kaysser-Pyzalla 2.1 Definition 21 2.2 Origin of Residual Macro- and Microstresses 25 2.3 Relevance 45 3 Textures in Engineering Materials 55Heinz G. Brokmeier and Sangbong Yi 3.1 Introduction 55 3.2 Measurement of Preferred Orientations 58 3.3 Presentation of Preferred Orientations 59 3.4 Interpretation of Textures 62 3.5 Errors 67 4 Physical Properties of Photons and Neutrons 73Andreas Schreyer 4.1 Introduction 73 4.2 Interaction of X-ray Photons and Neutrons with Individual Atoms 74 4.3 Scattering of X-ray Photons and Neutrons from Ensembles of Atoms 79 5 Radiation Sources 83 5.1 Generation and Properties of Neutrons 83Ina Lommatzsch,Wolfgang Knop, Philipp K. Pranzas, and Peter Schreiner 5.2 Production and Properties of Synchrotron Radiation 90Rolf Treusch Part II Methods 105 6 Stress Analysis by Angle-Dispersive Neutron Diffraction 107Peter Staron 6.1 Introduction 107 6.2 Diffractometer for Residual Stress Analysis 108 6.3 Measurement and Data Analysis 112 6.4 Examples 116 6.5 Summary and Outlook 120 7 Stress Analysis by Energy-Dispersive Neutron Diffraction 123Javier Santisteban 7.1 Introduction 123 7.2 Time-of-Flight Neutron Diffraction 123 7.3 TOF Strain Scanners 126 7.4 A Virtual Laboratory for Strain Scanning 131 7.5 Type II Stresses: Evolution of Intergranular Stresses 134 7.6 Type III Stresses: Dislocation Densities 135 7.7 Strain Imaging by Energy-Dispersive Neutron Transmission 138 7.8 Conclusions 140 8 Residual Stress Analysis by Monochromatic High-Energy X-rays 145René V. Martins 8.1 Basic Setups 145 8.2 Principle of Slit Imaging and Data Reconstruction 148 8.3 The Conical Slit 149 8.4 The Spiral Slit 152 8.5 Simultaneous Strain Measurements in Individual Bulk Grains 155 8.6 Coarse Grain Effects 156 8.7 Analysis of Diffraction Data from Area Detectors 157 8.8 Matrix for Comparison and Decision Taking Which Technique to Use for a Specific Problem 158 9 Residual Stress Analysis by Energy-Dispersive Synchrotron X-ray Diffraction 161Christoph Genzel and Manuela Klaus 9.1 Introduction 161 9.2 Fundamentals of Energy-Dispersive X-ray Diffraction Stress Analysis 162 9.3 Experimental Setup 167 9.4 Examples for Energy-Dispersive Stress Analysis 168 9.5 Final Remarks 173 10 Texture Analyses by Synchrotron X-rays and Neutrons 179Sangbong Yi, Weimin Gan, and Heinz G. Brokmeier 10.1 Texture Measurements on Laboratory Scale 179 10.2 Texture Measurements at Large Scale Facilities 182 10.3 Conclusion 193 11 Basics of Small-Angle Scattering Methods 197Philipp K. Pranzas 11.1 Introduction 197 11.2 Common Features of a SAS Instrument 197 11.3 Contrast 198 11.4 Scattering Curve 198 11.5 Power Law/Scattering by Fractal Systems 200 11.6 Guinier and Porod Approximations 201 11.7 Macroscopic Differential Scattering Cross-section 202 11.8 Model Calculation of Size Distributions 202 11.9 Magnetic Structures 203 12 Small-Angle Neutron Scattering 207Philipp K. Pranzas and André Heinemann 12.1 Introduction 207 12.2 Nanocrystalline Magnesium Hydride for the Reversible Storage of Hydrogen 208 12.3 Precipitates in Steel 210 12.4 SiO2 Nanoparticles in a Polymer Matrix – An Industrial Application 213 12.5 Green Surfactants 213 13 Anomalous Small-Angle X-ray Scattering 217Ulla Vainio 13.1 Introduction 217 13.2 Theory 218 13.3 Experiments 223 13.4 Example: ASAXS on Catalyst Nanoparticles 223 13.5 Summary and Outlook 223 14 Imaging 227Wolfgang Treimer 14.1 Radiography 227 14.2 Tomography 240 14.3 New Developments in Neutron Tomography 244 15 Neutron and Synchrotron-Radiation-Based Imaging for Applications in Materials Science – From Macro- to Nanotomography 253Felix Beckmann 15.1 Introduction 253 15.2 Parallel-Beam Tomography 256 15.3 Macrotomography Using Neutrons 258 15.4 Microtomography Using Synchrotron Radiation 264 15.5 Summary and Outlook 271 16 Mu-Tomography of Engineering Materials 275Astrid Haibel and Julia Herzen 16.1 Introduction 275 16.2 Advantage of Synchrotron Tomography 275 16.3 Applications and 3D Image Analysis 276 16.4 Image Artifacts 282 16.5 Summary 286 Part III New and Emerging Methods 291 17 3D X-ray Diffraction Microscope 293Henning F. Poulsen,Wolfgang Ludwig, and Søren Schmidt 17.1 Basic Setup and Strategy 294 17.2 Indexing and Characterization of Average Properties of Each Grain 296 17.3 Mapping of Grains and Orientations 300 17.4 Combining 3DXRD and Tomography 304 17.5 Outlook 305 18 3D Micron-Resolution Laue Diffraction 309Gene E. Ice 18.1 Introduction 309 18.2 The Need for Polychromatic Microdiffraction 309 18.3 Theoretical Basis for Advanced Polychromatic Microdiffraction 311 18.4 Technical Developments for an Automated 3D Probe 313 18.5 Research Examples 318 18.6 Future Prospects and Opportunities 324 Part IV Applications 327 19 The Use of Neutron and Synchrotron Research for Aerospace and Automotive Materials and Components 329Wolfgang Kaysser, Jörg Eßlinger, Volker Abetz, Norbert Huber, Karl U. Kainer, Thomas Klassen, Florian Pyczak, Andreas Schreyer, and Peter Staron 19.1 Introduction 329 19.2 Commercial Passenger Aircraft 331 19.3 The Light-Duty Automotive Vehicle 341 19.4 Other Transport Systems 352 20 In situ Experiments with Synchrotron High-Energy X-rays and Neutrons 365Peter Staron, Torben Fischer, Thomas Lippmann, Andreas Stark, Shahrokh Daneshpour, Dirk Schnubel, Eckart Uhlmann, Robert Gerstenberger, Bettina Camin, Walter Reimers, Elisabeth Eidenberger-Schober, Helmut Clemens, Norbert Huber, and Andreas Schreyer 20.1 Introduction 365 20.2 In situ Dilatometry 366 20.3 In situ Study on Single Overload of Fatigue-Cracked Specimens 368 20.4 In situ Cutting Experiment 370 20.5 In situ Study of Precipitation Kinetics Using Neutrons 372 20.6 Conclusions 373 21 Application of Photons and Neutrons for the Characterization and Development of Advanced Steels 377Elisabeth Eidenberger-Schober, Ronald Schnitzer, Gerald A. Zickler, Michael Eidenberger-Schober,Michael Bischof, Peter Staron, Harald Leitner, Andreas Schreyer, and Helmut Clemens 21.1 Introduction 377 21.2 Characterization Using Synchrotron Radiation 378 21.3 Characterization Using Small-Angle Neutron Scattering (SANS) 382 21.4 Conclusions 388 22 The Contribution of High-Energy X-rays and Neutrons to Characterization and Development of Intermetallic Titanium Aluminides 395Thomas Schmoelzer, Klaus-Dieter Liss, Peter Staron, Andreas Stark, Emanuel Schwaighofer, Thomas Lippmann, Helmut Clemens, and Svea Mayer 22.1 Introduction 395 22.2 High-Energy X-rays and Neutrons 396 22.3 In situ Investigation of Phase Evolution 398 22.4 Atomic Order and Disorder in TiAl Alloys 409 22.5 Recovery and Recrystallization during Deformation of TiAl 412 22.6 Lattice Parameter and Thermal Expansion 418 22.7 Conclusions 419 23 In situ Mu-Laue: Instrumental Setup for the Deformation of Micron Sized Samples 425Christoph Kirchlechner, Jozef Keckes, Jean S.Micha, and Gerhard Dehm 23.1 Introduction 425 23.2 Experimental Instrumentation 427 23.3 Discussion 433 23.4 Conclusion 436 24 Residual Stresses in Thin Films and Coated Tools: Challenges and Strategies for Their Nondestructive Analysis by X-ray Diffraction Methods 439Manuela Klaus and Christoph Genzel 24.1 Introduction 439 24.2 Compilation of Approaches to Meet the Challenges in Thin Film X-ray Stress Analysis (XSA) 441 24.3 Final Remarks and Recommendations 447 Index 451

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Book SynopsisCombining different perspectives from materials science, engineering, and computer science, this reference provides a unified view of the various aspects necessary for the successful realization of intelligent systems. The editors and authors are from academia and research institutions with close ties to industry, and are thus able to offer first-hand information here. They adopt a unique, three-tiered approach such that readers can gain basic, intermediate, and advanced topical knowledge. The technology section of the book is divided into chapters covering the basics of sensor integration in materials, the challenges associated with this approach, data processing, evaluation, and validation, as well as methods for achieving an autonomous energy supply. The applications part then goes on to showcase typical scenarios where material-integrated intelligent systems are already in use, such as for structural health monitoring and smart textiles.Table of ContentsForeword XV Preface XIX Part One Introduction 1 1 On Concepts and Challenges of Realizing Material-Integrated Intelligent Systems 3Stefan Bosse and Dirk Lehmhus 1.1 Introduction 3 1.2 System Development Methodologies and Tools (Part Two) 7 1.3 Sensor Technologies and Material Integration (Part Three and Four) 8 1.4 Signal and Data Processing (Part Five) 15 1.5 Networking and Communication (Part Six) 17 1.6 Energy Supply and Management (Part Seven) 21 1.7 Applications (Part Eight) 21 References 24 Part Two System Development 29 2 Design Methodology for Intelligent Technical Systems 31Mareen Vaßholz, Roman Dumitrescu, and Jürgen Gausemeier 2.1 From Mechatronics to Intelligent Technical Systems 32 2.2 Self-Optimizing Systems 36 2.3 Design Methodology for Intelligent Technical Systems 38 2.3.1 Domain-Spanning Conceptual Design 41 2.3.2 Domain-Specific Conceptual Design 50 References 51 3 Smart Systems Design Methodologies and Tools 55Nicola Bombieri, Franco Fummi, Giuliana Gangemi, Michelangelo Grosso, Enrico Macii, Massimo Poncino, and Salvatore Rinaudo 3.1 Introduction 55 3.2 Smart Electronic Systems and Their Design Challenges 56 3.3 The Smart Systems Codesign before SMAC 57 3.4 The SMAC Platform 60 3.4.1 The Platform Overview 61 3.4.1.1 System C–SystemVue Cosimulation 61 3.4.1.2 ADS and the Thermal Simulation 63 3.4.1.3 EMPro Extension and ADS Integration 64 3.4.1.4 Automated EM – Circuit Cosimulation in ADS 64 3.4.1.5 HIF Suite Toolsuite 65 3.4.1.6 The MEMS+ Platform 66 3.4.2 The (Co)Simulation Levels and the Design–Domains Matrix 67 3.5 Case Study: A Sensor Node for Drift-Free Limb Tracking 69 3.5.1 System Architecture 71 3.5.2 Model Development and System-Level Simulation 71 3.5.3 Results 73 3.6 Conclusions 76 Acknowledgments 77 References 77 Part Three Sensor Technologies 81 4 Microelectromechanical Systems (MEMS) 83Li Yunjia 4.1 Introduction 83 4.1.1 What Is MEMS 83 4.1.2 Why MEMS 84 4.1.3 MEMS Sensors 84 4.1.4 Goal of This Chapter 85 4.2 Materials 85 4.2.1 Silicon 85 4.2.2 Dielectrics 86 4.2.3 Metals 87 4.3 Microfabrication Technologies 87 4.3.1 Silicon Wafers 87 4.3.2 Lithography 88 4.3.3 Etching 91 4.3.4 Deposition Techniques 93 4.3.5 Other Processes 94 4.3.6 Surface and Bulk Micromachining 95 4.4 MEMS Sensor 95 4.4.1 Resistive Sensors 95 4.4.2 Capacitive Sensors 99 4.5 Sensor Systems 103 References 104 5 Fiber-Optic Sensors 107Yi Yang, Kevin Chen, and Nikhil Gupta 5.1 Introduction to Fiber-Optic Sensors 107 5.1.1 Sensing Principles 108 5.1.2 Types of Optical Fibers 108 5.2 Trends in Sensor Fabrication and Miniaturization 110 5.3 Fiber-Optic Sensors for Structural Health Monitoring 112 5.3.1 Sensors for Cure Monitoring of Composites 114 5.3.2 Embedded FOS in Composite Materials 114 5.3.3 Surface-Mounted FOS in Composite Materials 115 5.3.4 FOS for Structural Monitoring 115 5.3.4.1 Aerospace Structures 115 5.3.4.2 Civil Structures 116 5.3.4.3 Marine Structures 116 5.4 Frequency Modulation Sensors 117 5.4.1 Bragg Grating Sensors 117 5.4.2 Fabry–Pérot Interferometer Sensor 118 5.4.3 Whispering Gallery Mode Sensors 119 5.5 Intensity Modulation Sensors 122 5.5.1 Fiber Microbend Sensors 122 5.5.2 Fiber-Optic Loop Sensor 123 5.6 Some Challenges in SHM of Composite Materials 128 5.7 Summary 128 Acknowledgments 129 References 129 6 Electronics Development for Integration 137Jan Vanfleteren 6.1 Introduction 137 6.1.1 Standard Flat Rigid Printed Circuits Boards and Components Assembly 137 6.1.2 Flexible Circuits 138 6.1.3 Need for Alternative Circuit and Packaging Materials 140 6.2 Chip Package Miniaturization Technologies 140 6.2.1 Ultrathin Chip Package Technology 140 6.2.2 UTCP Circuit Integration 142 6.2.2.1 UTCP Embedding 142 6.2.2.2 UTCP Stacking 143 6.2.3 Applications 143 6.3 Elastic Circuits 145 6.3.1 Printed Circuit Board-Based Elastic Circuits 145 6.3.2 Thin Film Metal-Based Elastic Circuits 148 6.3.3 Applications 148 6.3.3.1 Wearable Light Therapy 148 6.3.4 Stretchable Displays 149 6.4 2.5D Rigid Thermoplastic Circuits 152 6.5 Large Area Textile-Based Circuits 153 6.5.1 Electronic Module Integration Technology 154 6.5.2 Applications 155 6.6 Conclusions and Outlook 157 References 157 Part Four Material Integration Solutions 159 7 Sensor Integration in Fiber-Reinforced Polymers 161Maryam Kahali Moghaddam, Mariugenia Salas, Michael Koerdt, Christian Brauner, Martina Hübner, Dirk Lehmhus, and Walter Lang 7.1 Introduction to Fiber-Reinforced Polymers 161 7.2 Applications of Integrated Systems in Composites 164 7.2.1 Production Process Monitoring and Quality Control of Composites 164 7.2.1.1 Monitoring of the Resin Flow 166 7.2.1.2 Analytical Modeling of Resin Front by Means of Simulation 166 7.2.1.3 Monitoring the Resin Curing 166 7.2.2 In-Service Applications of Integrated Systems 167 7.2.2.1 Use for Structural Health Monitoring (SHM) 167 7.2.2.2 Use As Support to Nondestructive Evaluation and Testing (NDE/NDT) 170 7.3 Fiber-Reinforced Polymer Production and Sensor Integration Processes 170 7.3.1 Overview of Fiber-Reinforced Polymer Production Processes 170 7.3.2 Sensor Integration in Fiber-Reinforced Polymers: Selected Case Studies 175 7.4 Electronics Integration and Data Processing 179 7.4.1 Materials Integration of Electronics 180 7.4.2 Electronics for Wireless Sensing 181 7.5 Examples of Sensors Integrated in Fiber-Reinforced Polymer Composites 183 7.5.1 Ultrasound Reflection Sensing 183 7.5.2 Pressure Sensors 184 7.5.3 Thermocouples 186 7.5.4 Fiber Optic Sensors 187 7.5.5 Interdigital Planar Capacitive Sensors 188 7.6 Conclusion 192 Acknowledgments 193 References 193 8 Integration in Sheet Metal Structures 201Welf-Guntram Drossel, Roland Müller, Matthias Nestler, and Sebastian Hensel 8.1 Introduction 201 8.2 Integration Technology 204 8.3 Forming of Piezometal Compounds 205 8.4 Characterization of Functionality 208 8.5 Fields of Application 211 8.6 Conclusion and Outlook 212 References 212 9 Sensor and Electronics Integration in Additive Manufacturing 217Dirk Lehmhus and Matthias Busse 9.1 Introduction to Additive Manufacturing 217 9.2 Overview of AM Processes 224 9.3 Links between Sensor Integration and Additive Manufacturing 228 9.4 AM Sensor Integration Case Studies 230 9.4.1 Cavity-Based Sensor and Electronic System Integration 236 9.4.2 Multiprocess Hybrid Manufacturing Systems 239 9.4.3 Toward a Single AM Platform for Structural Electronics Fabrication 243 9.5 Conclusion and Outlook 245 Abbreviations 246 References 248 Part Five Signal and Data Processing: The Sensor Node Level 257 10 Analog Sensor Signal Processing and Analog-to-Digital Conversion 259John Horstmann, Marco Ramsbeck, and Stefan Bosse 10.1 Operational Amplifiers 260 10.2 Analog-to-Digital Converter Specifications 262 10.3 Data Converter Architectures 268 10.4 Low-Power ADC Designs and Power Classification 276 10.5 Moving Window ADC Approach 277 References 279 11 Digital Real-Time Data Processing with Embedded Systems 281Stefan Bosse and Dirk Lehmhus 11.1 Levels of Information 281 11.2 Algorithms and Computational Models 283 11.3 Scientific Data Mining 287 11.4 Real-Time and Parallel Processing 291 References 297 12 The Known World: Model-Based Computing and Inverse Numeric 301Armin Lechleiter and Stefan Bosse 12.1 Physical Models in Parameter Identification 302 12.2 Noisy Data Due to Sensor and Modeling Errors 304 12.3 Coping with Noisy Data: Tikhonov Regularization and Parameter Choice Rules 306 12.4 Tikhonov Regularization 308 12.5 Rules for the Choice of the Regularization Parameter 309 12.6 Explicit Minimizers for Linear Models 311 12.7 The Soft-Shrinkage Iteration 312 12.8 Iterative Regularization Schemes 313 12.9 Gradient Descent Schemes 314 12.10 Newton-Type Regularization Schemes 317 12.11 Numerical Examples in Load Reconstruction 318 References 326 13 The Unknown World: Model-Free Computing and Machine Learning 329Stefan Bosse 13.1 Machine Learning – An Overview 329 13.2 Learning of Data Streams 331 13.3 Learning with Noise 333 13.4 Distributed Event-Based Learning 333 13.5 ε-Interval and Nearest-Neighborhood Decision Tree Learning 334 13.6 Machine Learning – A Sensorial Material Demonstrator 336 References 340 14 Robustness and Data Fusion 343Stefan Bosse 14.1 Robust System Design on System Level 345 References 348 Part Six Networking and Communication: The Sensor Network Level 349 15 Communication Hardware 351Tim Tiedemann 15.1 Communication Hardware in Their Applications 351 15.2 Requirements for Embedded Communication Hardware 352 15.3 Overview of Physical Communication Classes 354 15.4 Examples of Wired Communication Hardware 356 15.5 Examples of Wireless Communication Hardware 358 15.6 Examples of Optical Communication Hardware 360 15.7 Summary 360 References 361 16 Networks and Communication Protocols 363Stefan Bosse 16.1 Network Topologies and Network of Networks 364 16.2 Redundancy in Networks 365 16.3 Protocols 366 16.4 Switched Networks versus Message Passing 368 16.5 Bus Systems 369 16.6 Message Passing and Message Formats 370 16.7 Routing 370 16.8 Failures, Robustness, and Reliability 377 16.9 Distributed Sensor Networks 378 16.10 Active Messaging and Agents 381 References 382 17 Distributed and Cloud Computing: The Big Machine 385Stefan Bosse 17.1 Reference 386 18 The Mobile Agent and Multiagent Systems 387Stefan Bosse 18.1 The Agent Computation and Interaction Model 389 18.2 Dynamic Activity-Transition Graphs 394 18.3 The Agent Behavior Class 395 18.4 Communication and Interaction of Agents 396 18.5 Agent Programming Models 397 18.6 Agent Processing Platforms and Technologies 404 18.7 Agent-Based Learning 415 18.8 Event and Distributed Agent-Based Learning of Noisy Sensor Data 416 References 420 Part Seven Energy Supply 423 19 Energy Management and Distribution 425Stefan Bosse 19.1 Design of Low-Power Smart Sensor Systems 426 19.2 A Toolbox for Energy Analysis and Simulation 430 19.3 Dynamic Power Management 434 19.3.1 CPU-Centric DPM 435 19.3.2 I/O-Centric DPM 437 19.3.3 EDS Algorithm 438 19.4 Energy-Aware Communication in Sensor Networks 440 19.5 Energy Distribution in Sensor Networks 442 19.5.1 Distributed Energy Management in Sensor Networks Using Agents 443 References 446 20 Microenergy Storage 449Robert Kun, Chi Chen, and Francesco Ciucci 20.1 Introduction 449 20.2 Energy Harvesting/Scavenging 451 20.3 Energy Storage 452 20.3.1 Capacitors 452 20.3.2 Batteries 458 20.3.3 Fuel Cells 467 20.3.3.1 Low-Temperature Fuel Cells 469 20.3.3.2 High-Temperature Fuel Cells 469 20.3.4 Other Storage Systems 469 20.4 Summary and Perspectives 470 References 470 21 Energy Harvesting 479Rolanas Dauksevicius and Danick Briand 21.1 Introduction 479 21.2 Mechanical Energy Harvesters 480 21.2.1 Piezoelectric Micropower Generators 482 21.2.2 Micropower Generators Based on Electroactive Polymers 489 21.2.3 Electrostatic Micropower Generators 490 21.2.4 Electromagnetic Micropower Generators 491 21.2.5 Triboelectric Nanogenerators 492 21.2.6 Hybrid Micropower Generators 493 21.2.7 Wideband and Nonlinear Micropower Generators 494 21.2.8 Concluding Remarks 495 21.3 Thermal Energy Harvesters 496 21.3.1 Introduction to Thermoelectric Generators 496 21.3.2 Thermoelectric Materials and Efficiency 499 21.3.3 Other Thermal-to-Electrical Energy Conversion Techniques 501 21.4 Radiation Harvesters 502 21.4.1 Light Energy Harvesters 502 21.4.2 RF Energy Harvesters 506 21.5 Summary and Perspectives 507 References 512 Part Eight Application Scenarios 529 22 Structural Health Monitoring (SHM) 531Dirk Lehmhus and Matthias Busse 22.1 Introduction 531 22.2 Motivations for SHM System Implementation 536 22.3 SHM System Classification and Main Components 540 22.3.1 Sensor and Actuator Elements for SHM Systems 542 22.3.2 Communication in SHM Systems 550 22.3.3 SHM Data Evaluation Approaches and Principles 552 22.4 SHM Areas and Application and Case Studies 555 22.5 Implications of Material Integration for SHM Systems 561 22.6 Conclusion and Outlook 562 References 564 23 Achievements and Open Issues Toward Embedding Tactile Sensing and Interpretation into Electronic Skin Systems 571Ali Ibrahim, Luigi Pinna, Lucia Seminara, and Maurizio Valle 23.1 Introduction 571 23.2 The Skin Mechanical Structure 573 23.2.1 Transducers and Materials 573 23.2.2 An Example of Skin Integration into an Existing Robotic Platform 575 23.3 Tactile Information Processing 579 23.4 Computational Requirements 582 23.4.1 Electrical Impedance Tomography 582 23.4.2 Tensorial Kernel 583 23.5 Conclusions 585 References 585 24 Intelligent Materials in Machine Tool Applications: A Review 595Hans-Christian Möhring 24.1 Applications of Shape Memory Alloys (SMA) 596 24.2 Applications of Piezoelectric Ceramics 596 24.3 Applications of Magnetostrictive Materials 598 24.4 Applications of Electro- and Magnetorheological Fluids 600 24.5 Intelligent Structures and Components 601 24.6 Summary and Conclusion 603 References 604 25 New Markets/Opportunities through Availability of Product Life Cycle Data 613Thorsten Wuest, Karl Hribernik, and Klaus-Dieter Thoben 25.1 Product Life Cycle Management 613 25.1.1 Closed-Loop and Item-Level PLM 615 25.1.2 Data and Information in PLM 615 25.1.3 Supporting Concepts for Data and Information Integration in PLM 616 25.2 Case Studies 617 25.2.1 Case Study 1: Life Cycle of Leisure Boats 617 25.2.1.1 Sensors Used 618 25.2.1.2 Potential Application of Sensorial Materials 619 25.2.1.3 Limitations and Opportunities of Sensorial Materials 619 25.2.2 Case Study 2: PROMISE – Product Life Cycle Management and Information Using Smart Embedded Systems 620 25.2.2.1 Sensors Used 620 25.2.2.2 Potential Application of Sensorial Materials 621 25.2.2.3 Limitations and Opportunities of Sensorial Materials 621 25.2.3 Case Study 3: Composite Bridge 622 25.2.3.1 Sensors Used 623 25.2.3.2 Potential Application of Sensorial Materials 623 25.2.3.3 Limitations and Opportunities of Sensorial Materials 623 25.3 Potential of Sensorial Materials in PLM Application 623 Acknowledgment 624 References 624 26 Human–Computer Interaction with Novel and Advanced Materials 629Tanja Döring, Robert Porzel, and Rainer Malaka 26.1 Introduction 629 26.2 New Forms of Human–Computer Interaction 630 26.3 Applications and Scenarios 633 26.3.1 Domestic and Personal Devices 633 26.3.1.1 The Marble Answering Machine 633 26.3.1.2 Living Wall: An Interactive Wallpaper 634 26.3.1.3 Sprout I/O and Shutters: Ambient Textile Information Displays 634 26.3.1.4 FlexCase: A Flexible Sensing and Display Cover 635 26.3.2 Learning, Collaboration, and Entertainment 635 26.3.2.1 Tangibles for Learning and Creativity 635 26.3.2.2 inFORM: Supporting Remote Collaboration through Shape Capture and Actuation 636 26.3.2.3 The Soap Bubble Interface 637 26.4 Opportunities and Challenges 637 26.5 Conclusions 639 References 639 Index 645

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