Tag Archives: Engineering

More than human

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Decorative imageIn his recent book, ‘The Place of Tides’, James Rebanks writes ‘the age of humans will pass.  Perhaps the end has already begun though it may take a long time to play out’.  I grew up when nuclear armageddon appeared to be the major threat to the future of life on Earth and it remains a major threat, especially given current tensions between nations.  However, other threats have gained prominence including both a massive asteroid impact, on the scale of the one that caused the extinction of the dinosaurs 66 million years ago, and climate change, which caused the largest mass extinction, killing 95% of all species, about 252 million years ago.  The current extinction rate is between 100 and 1000 times greater than the natural rate and is being driven by the overexploitation of the Earth’s resources by humans leading to habitat destruction and climate change.  Humans are part of a complex ecosystem, or system of systems, including soil systems with interactions between microorganisms, plants and decaying matter; pollination systems characterised by co-dependence between plants and pollinators; and, aquatic systems connecting rivers, lakes and oceans by the movement of water, nutrients and migratory species.  The overexploitation of these systems to support our 21st century lifestyle is starting to cause systemic failures that are the underlying cause of the increasing rate of species extinction and it is difficult, if not impossible, to predict when it will be our turn.  In his 1936 book, ‘Where Life is Better: An Unsentimental American Journey’, James Rorty observes that the most dangerous fact he has come across is ‘the overwhelming fact of our lazy, irresponsible, adolescent inability to face the truth or tell it’.  Not much has changed in nearly one hundred years, except that the global population has increased fourfold from about 2.2 billion to 8.2 billion with a corresponding increase in the exploitation of the Earth for energy, food and satisfying our materialistic desires.  A recent exhibition at the Design Museum in London, encouraged us to think beyond human-centred design and to consider the impact of our designs on all the species on the planet.  A process sometimes known as life-centred design or interspecies design.  What if designs could help other species to flourish, as well as humans?

References:

Rebanks, James, The place of tides, London: Penguin, 2025.

Rorty, James, Where life is better: an unsentimental journey.  New York, Reynal & Hitchcock, 1936.  (I have not read this book but it was quoted by Joanna Pocock in ‘Greyhound’, Glasgow: Fitzcarraldo Editions, HarperCollins Publishers, 2025, which I have read and enjoyed).

Image: Photograph of Pei yono uhutipo (Spirit of the path) by Sheraonawe Hakihiiwe, a member of the Yanomami Indigenous community who live in the Venezuelan and Brazilian Amazon. One of a series of his paintings in the ‘More than Human‘ exhibition at the Design Museum which form part of an archive of Yanomami knowledge that reflects the abundance of life in the forest.

Star sequence minimises distortion

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It is some months since I have written about engineering so this post is focussed on some mechanical engineering.  The advent of pneumatic and electric torque wrenches has made it impossible for the ordinary motorist to change a wheel because it is very difficult to loosen wheel nuts by hand when they have been tightened by a powered wrench which most of us do not have available.  This has probably made motoring safer but also means we are more likely to need assistance when we have a flat tire.  It also means that the correct tightening pattern for nuts and bolts is less widely known.  A star-shaped sequence is optimum, i.e., if you have six bolts numbered sequentially around a circle then you start with #1, move across the diameter to #4, then to #2 followed by #5 across the diameter, then to #3 and across the diameter to #6.  This sequence is optimum for flanges, bolted joints in the frames of buildings and joining machine parts as well as wheel nuts.  We have recently discovered that it works in reverse, in the sense that it is the optimum sequence for releasing parts made by additive manufacturing (AM) from the baseplate of the AM machine (see ‘If you don’t succeed try and try again’ on September 29th, 2021).  Additive manufacturing induces large residual stresses as a consequence of the cycles of heat input to the part during manufacturing and some of these stresses are released when it is removed from the baseplate of the AM machine, which causes distortion of the part.  Together with a number of collaborators, I have been researching the most effective method of building thin flat plates using additive manufacturing (see ‘On flatness and roughness’ on January 19th, 2022).  We have found that building the plate vertically layer-by-layer works well when the plate is supported by buttresses on its edges.  We have used two in-plane buttresses and four out-of-plane buttresses, as shown in the photograph, to achieve parts that have comparable flatness to those made using traditional methods.  It turns out that optimum order for the removal of the buttresses is the same star sequence used for tightening bolts and it substantially reduces distortion of the plate compared to some other sequences.  Perhaps in retrospect, we should not be surprised by this result; however, hindsight is a wonderful thing.

The current research is funded jointly by the National Science Foundation (NSF) in the USA and the Engineering and Physical Sciences Research Council (EPSRC) in the UK and the project was described in ‘Slow start to an exciting new project on thermoacoustic response of AM metals’ on September 9th 2020.

Image: Photograph of a geometrically-reinforced thin plate (230 x 130 x 1.2 mm) built vertically layer-by-layer using the laser powder bed fusion process on a baseplate (shown removed from the AM machine) with the supporting buttresses in place.

Sources:

Patterson EA, Lambros J, Magana-Carranza R, Sutcliffe CJ. Residual stress effects during additive manufacturing of reinforced thin nickel–chromium plates. IJ Advanced Manufacturing Technology;123(5):1845-57, 2022.

Khanbolouki P, Magana-Carranza R, Sutcliffe C, Patterson E, Lambros J. In situ measurements and simulation of residual stresses and deformations in additively manufactured thin plates. IJ Advanced Manufacturing Technology; 132(7):4055-68, 2024.

Commoditisation of civil nuclear power

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Logo for BBC Inside ScienceA colleague and I published a paper last month that we hope will bring about a paradigm shift in the nuclear power industry. I was interviewed on BBC Radio 4’s Inside Science on the day following its publication – its the first time one of my scientific papers has made that big a splash in the media!  You can listen to the programme on BBC Sounds at https://www.bbc.co.uk/sounds/play/m001zdwv.

In the paper we describe a blueprint for the factory-production of sealed micro-power units with a digitally-enabled, holistic assurance framework.  Currently, several designs of micro-reactors are progressing to the prototype stage with hazards contained on-site.  The integration of these approaches enables a transformation of the regulatory regime to type or series approval at the factory, similar to the aerospace industry, and supported by digital tools such as block chains to provide transparent quality assurance within the supply chain.  The transformation of the regulatory regime and the shift to ‘flow’ production in a factory would remove the financial risk from the power plant to the factory thereby enabling nuclear power to become a realistic competitor for intermittent green energy sources, such as wind and solar, both in terms of financial and ecological costs.  The output from three production lines could replace the current electricity generating capacity from fossil fuels in the UK over approximately 15 years thus making a significant contribution to achieving net zero greenhouse gas emissions.  We propose a design philosophy for the micro-power units that will allow them to go unnoticed in an urban environment or even become an iconic product that signals a community’s commitment to responsible stewardship of the Earth’s resources.  Our blueprint represents a revolutionary change for the nuclear power industry that would likely lead to the commoditisation of nuclear power whereas the status quo probably leads to extinction.

The paper is published with open access (its free) at Patterson EA & Taylor RJ, 2024, The commoditisation of civil nuclear power, Royal Society Open Science, 11:240021.

Extra on digital twins

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After five months of posting monthly, I cannot resist the temptation to slip in an extra one.  Mainly because I want to let you know about the Pint of Science Festival taking place next week.  In Liverpool we have organised a series of three evenings at the Philharmonic pub on Hope Street featuring talks by engineers from the School of Engineering and the Institute for Digital Engineering and Autonomous Systems (IDEAS) at the University of Liverpool.  I am planning to talk about digital twins – what they are, how we can use them, what they might become and whether we are already part of a digital world.  If you enjoyed reading my posts on ‘Digital twins that thrive in the real world’, ‘Dressing up your digital twin’, and ‘Are we in a simulation?’ then come and discuss digital twins with me in person.  My talk is part of a programme on Digital with Everything on May 15th.  On May 13th and 14th we have programmes on Engineering in Nature and Science of Vision, Colliders and Crashes, respectively.  I hope you can come and join us in the real-world.