On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method
In the marine industry, the search for sustainable methods, materials, and processes, from the product’s design to its end-of-life stages, is a necessity for combating the negative consequences of climate change. In this context, the lightening of products is essential in reducing their environmenta...
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| Format: | Article |
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MDPI AG
2024-12-01
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| Series: | Journal of Marine Science and Engineering |
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| Online Access: | https://www.mdpi.com/2077-1312/12/12/2206 |
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| author | Erkin Altunsaray Serkan Turkmen Ayberk Sözen Alperen Doğru Pengfei Liu Akile Neşe Halilbeşe Gökdeniz Neşer |
| author_facet | Erkin Altunsaray Serkan Turkmen Ayberk Sözen Alperen Doğru Pengfei Liu Akile Neşe Halilbeşe Gökdeniz Neşer |
| author_sort | Erkin Altunsaray |
| collection | DOAJ |
| description | In the marine industry, the search for sustainable methods, materials, and processes, from the product’s design to its end-of-life stages, is a necessity for combating the negative consequences of climate change. In this context, the lightening of products is essential in reducing their environmental impact throughout their life. In addition to lightening through design, lightweight materials, especially plastic-based composites, will need to be used in new and creative ways. The material extrusion technique, one of the additive manufacturing methods, is becoming more widespread day by day, especially in the production of objects with complex forms. This prevalence has not yet been reflected in the marine industry. In this study, the performances of plastic composite propellers produced by the material extrusion technique is investigated and discussed comparatively with the help of both hydrodynamic and structural tests carried out in a cavitation tunnel and mechanical laboratory. The cavitation tunnel test and numerical simulations were conducted at a range of advance coefficients (J) from 0.3 to 0.9. The shaft rate was kept at 16 rps. The thrust and torque data were obtained using the tunnel dynamometer. Digital pictures were taken to obtain structural deformation and cavitation dynamics. The structural performance of the propellers shows that an aluminum propeller is the most rigid, while a short carbon fiber composite propeller is the most flexible. Continuous carbon fiber composite has high strength and stiffness, while continuous glass fiber composite is more cost-effective. In terms of the hydrodynamic performance of the propellers, flexibility reduces the loading on the blade, which can result in thrust and torque reduction. Overall, the efficiency of the composite propellers was similar and less than that of the rigid aluminum propeller. In terms of weight, the composite carbon propeller containing continuous fiber, which is half the weight of the metal propeller, is considered as an alternative to metal in production. These propellers were produced from a unique composite consisting of polyamide, one of the thermoplastics that is a sustainable composite material, and glass and carbon fiber as reinforcements. The findings showed that the manufacturing method and the new composites can be highly successful for producing ship components. |
| format | Article |
| id | doaj-art-b3f64bea570844499d0a2aba738aa625 |
| institution | DOAJ |
| issn | 2077-1312 |
| language | English |
| publishDate | 2024-12-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Journal of Marine Science and Engineering |
| spelling | doaj-art-b3f64bea570844499d0a2aba738aa6252025-08-20T02:53:19ZengMDPI AGJournal of Marine Science and Engineering2077-13122024-12-011212220610.3390/jmse12122206On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing MethodErkin Altunsaray0Serkan Turkmen1Ayberk Sözen2Alperen Doğru3Pengfei Liu4Akile Neşe Halilbeşe5Gökdeniz Neşer6Institute of Marine Sciences and Technology, Dokuz Eylul University, Baku Bulv. 32, Balcova, 35340 Izmir, TürkiyeMarine, Offshore & Subsea Technology Group, School of Engineering, Newcastle University, Armstrong Building, Queen Victoria Road, Newcastle upon Tyne NE1 7RU, UKInstitute of Marine Sciences and Technology, Dokuz Eylul University, Baku Bulv. 32, Balcova, 35340 Izmir, TürkiyeAviation Higher Vocational School, Ege University, 1099 S. 114 Sarnic, Gaziemir, 35100 Izmir, TürkiyeMarine, Offshore & Subsea Technology Group, School of Engineering, Newcastle University, Armstrong Building, Queen Victoria Road, Newcastle upon Tyne NE1 7RU, UKMarine, Offshore & Subsea Technology Group, School of Engineering, Newcastle University, Armstrong Building, Queen Victoria Road, Newcastle upon Tyne NE1 7RU, UKInstitute of Marine Sciences and Technology, Dokuz Eylul University, Baku Bulv. 32, Balcova, 35340 Izmir, TürkiyeIn the marine industry, the search for sustainable methods, materials, and processes, from the product’s design to its end-of-life stages, is a necessity for combating the negative consequences of climate change. In this context, the lightening of products is essential in reducing their environmental impact throughout their life. In addition to lightening through design, lightweight materials, especially plastic-based composites, will need to be used in new and creative ways. The material extrusion technique, one of the additive manufacturing methods, is becoming more widespread day by day, especially in the production of objects with complex forms. This prevalence has not yet been reflected in the marine industry. In this study, the performances of plastic composite propellers produced by the material extrusion technique is investigated and discussed comparatively with the help of both hydrodynamic and structural tests carried out in a cavitation tunnel and mechanical laboratory. The cavitation tunnel test and numerical simulations were conducted at a range of advance coefficients (J) from 0.3 to 0.9. The shaft rate was kept at 16 rps. The thrust and torque data were obtained using the tunnel dynamometer. Digital pictures were taken to obtain structural deformation and cavitation dynamics. The structural performance of the propellers shows that an aluminum propeller is the most rigid, while a short carbon fiber composite propeller is the most flexible. Continuous carbon fiber composite has high strength and stiffness, while continuous glass fiber composite is more cost-effective. In terms of the hydrodynamic performance of the propellers, flexibility reduces the loading on the blade, which can result in thrust and torque reduction. Overall, the efficiency of the composite propellers was similar and less than that of the rigid aluminum propeller. In terms of weight, the composite carbon propeller containing continuous fiber, which is half the weight of the metal propeller, is considered as an alternative to metal in production. These propellers were produced from a unique composite consisting of polyamide, one of the thermoplastics that is a sustainable composite material, and glass and carbon fiber as reinforcements. The findings showed that the manufacturing method and the new composites can be highly successful for producing ship components.https://www.mdpi.com/2077-1312/12/12/2206composite ship propellersadditive manufacturing in marine industrylightweighting of ship structuresthermoplastic compositeshydrodynamic and structural performance of ship propellerscavitation tunnel tests |
| spellingShingle | Erkin Altunsaray Serkan Turkmen Ayberk Sözen Alperen Doğru Pengfei Liu Akile Neşe Halilbeşe Gökdeniz Neşer On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method Journal of Marine Science and Engineering composite ship propellers additive manufacturing in marine industry lightweighting of ship structures thermoplastic composites hydrodynamic and structural performance of ship propellers cavitation tunnel tests |
| title | On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method |
| title_full | On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method |
| title_fullStr | On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method |
| title_full_unstemmed | On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method |
| title_short | On the Hydrodynamic and Structural Performance of Thermoplastic Composite Ship Propellers Produced by Additive Manufacturing Method |
| title_sort | on the hydrodynamic and structural performance of thermoplastic composite ship propellers produced by additive manufacturing method |
| topic | composite ship propellers additive manufacturing in marine industry lightweighting of ship structures thermoplastic composites hydrodynamic and structural performance of ship propellers cavitation tunnel tests |
| url | https://www.mdpi.com/2077-1312/12/12/2206 |
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