The soldering process for aerospace applications follows stringent requirements and standards to ensure the reliability and safety of electronic connections in aerospace systems. For this reason, the quality control phase plays an important role to guarantee requirements compliance. This process often requires manual control since technicians’ knowledge is fundamental to obtain effective quality check results. In this context, the authors have developed a new open source dataset (SolDef_AI) to implement an innovative methodology for printed circuit board (PCB) defect detection exploiting the Mask R-CNN algorithm. The presented open source dataset aims to overcome the challenges associated with the availability of datasets for model training in this specific research and electronics industrial field. The dataset is open source and available online.

Energy harvesting in the automotive sector is a rapidly growing field aimed at improving vehicle efficiency and sustainability by recovering wasted energy. Various technologies have been developed to convert mechanical, thermal, and environmental energy into electrical power, reducing dependency on traditional energy sources. This manuscript provides a comprehensive review of energy harvesting applications/methodologies, aiming to trace the research lines and future developments. This work identifies the main categories of harvesting solutions, namely mechanical, thermal, and hybrid/environmental solar–wind systems; each section includes a detailed review of the technical and scientific state of the art and a comparative analysis with detailed tables, allowing the state of the art to be mapped for identification of the strengths of each solution, as well as the challenges and future developments needed to enhance the technological level. These improvements focus on energy conversion efficiency, material innovation, vehicle integration, energy savings, and environmental sustainability. The mechanical harvesting section focuses on energy recovery from vehicle vibrations, with emphasis on regenerative suspensions and piezoelectric-based solutions. Specifically, solutions applied to suspensions with electric generators can achieve power outputs of around 1 kW, while piezoelectric-based suspension systems can generate up to tens of watts. The thermal harvesting section, instead, explores methods for converting waste heat from an internal combustion engine (ICE) into electrical power, including thermoelectric generators (TEGs) and organic Rankine cycle systems (ORC). Notably, ICEs with TEGs can recover above 1 kW of power, while ICE-based ORC systems can generate tens of watts. On the other hand, TEGs integrated into braking systems can harvest a few watts of power. Then, hybrid solutions are discussed, focusing on integrated mechanical and thermal energy recovery systems, as well as solar and wind energy harvesting. Hybrid solutions can achieve power outputs above 1 kW, with the main contribution from TEGs (≈1 kW), compared to piezoelectric systems (hundreds of W). Lastly, a section on commercial solutions highlights how current scientific research meets the automotive sector’s needs, providing significant insights for future development. For these reasons, the research results aim to be guidelines for a better understanding of where future studies should focus to improve the technological level and efficiency of energy harvesting solutions in the automotive sector.

Metal undergoes complicated microstructural evolution during Hot Ring Rolling (HRR), which determines the quality, mechanical properties and life of the ring formed. One of the principal microstructure properties which mostly influences the structural performances of forged components, is the value of the average grain size. In the present paper a ring rolling process has been studied and optimized in order to obtain anular components to be used in aerospace applications. In particular, the influence of process input parameters (feed rate of the mandrel and angular velocity of driver roll) on microstructural and on geometrical features of the final ring has been evaluated. For this purpose, a three-dimensional finite element model for HRR has been developed in SFTC DEFORM V11, taking into account also microstructural development of the material used (the nickel superalloy Waspalloy). The Finite Element (FE) model has been used to formulate a proper optimization problem. The optimization procedure has been developed in order to find the combination of process parameters which allows to minimize the average grain size. The Response Surface Methodology (RSM) has been used to find the relationship between input and output parameters, by using the exact values of output parameters in the control points of a design space explored through FEM simulation. Once this relationship is known, the values of the output parameters can be calculated for each combination of the input parameters. Then, an optimization procedure based on Genetic Algorithms has been applied. At the end, the minimum value of average grain size with respect to the input parameters has been found.

Residual stresses induced in the component by previous thermal/mechanical processes are compressive or tensile stresses having a zero resultant. In particular, they arise as consequence of thermo-mechanical processes (e.g. ring-rolling process), casting and heat treatments. When machining stressed components, volume removal leads to a re-arrangement of residual stresses, which inevitably causes distortions in the workpiece. If distortions are excessive, they can lead to a large number of scrap parts. This paper describes the development of a numerical procedure for the analysis of the distortions on a waspaloy turbine case, obtained by ring rolling process. A 3D model of ring rolling process has been set in the commercial software DEFORM 3D. Three different ring rolling strategies have been analyzed, in order to find the combination of process parameters which allows to obtain the best component in terms of geometrical precision. Then, the heat treatments (air cooling, solubilization, stabilization and aging) have been simulated to predict the bulk residual stresses distributions. Finally, the numerical distortions induced by machining have been simulated considering the material removal in some machining operations.