International Journal of Mechanical and Materials Engineering最新文献

{"title":"Multifunctional properties of ZnSeO3/ZnTeO3 nanocomposites: insights from structural, optical, thermal, electrochemical and low temperature magnetic analyses","authors":"R. Harshinee,&nbsp;S. Shanmugha Soundare,&nbsp;S. Ariponnammal","doi":"10.1186/s40712-026-00461-6","DOIUrl":"10.1186/s40712-026-00461-6","url":null,"abstract":"<div>\u0000 \u0000 <p>The ZnSeO₃/ZnTeO₃ nanocomposite is synthesized by hydrothermal process. It exhibits particles of spherical shape nearly like closely arranged small beads. The particle size is 108.9 nm, energy gap is 5.8 eV, urbach energy 0.420 eV and refractive index is 1.891. Infra red spectroscopy reveals characteristic vibrations of Zn–O and Zn-Se bonds. The sample exhibits superparamagnetism at 300K. Thermal analysis shows thermal stability, decomposition and material behavior under varying temperatures of the sample. XPS confirms the chemical state of the sample and assures the orbital state of an element with spin–orbit coupling (j). The sample exhibits superior surface area and pore volume, advantageous for supercapacitor applications, Electrochemical analysis exhibits pseudo-capacitive behavior with potential window 1V and specific capacitance is 229.01 F/g.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-23","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00461-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148172716","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancing wear resistance of E-glass/Copper composites: a machine learning approach to graphene filler optimization","authors":"D. Aravinda,&nbsp;H. K. Shivanand,&nbsp;N. Santhosh,&nbsp;Ahmed Adnan Hadi,&nbsp;N. Channa Keshava Naik,&nbsp;Md Amir Khan,&nbsp;Addisu Frinjo Emma","doi":"10.1186/s40712-026-00456-3","DOIUrl":"10.1186/s40712-026-00456-3","url":null,"abstract":"<div><p>Wear resistance is a critical requirement for materials used in automotive, aerospace, and electronic components operating under severe mechanical and thermal conditions. Although copper is extensively utilized due to its superior electrical and thermal conductivity, its poor wear resistance limits its tribological applications. The present study introduces a novel hybrid copper matrix composite reinforced simultaneously with graphene and E-glass fibers, fabricated via a scalable stir casting route. The wear behavior of Graphene/E-glass fiber/Copper composites was systematically evaluated by varying graphene content from 0.5 to 1.5 wt.% and E-glass fiber content from 3 to 7 wt.%. The results demonstrate a significant reduction in wear rate with increasing reinforcement concentration, primarily due to the formation of a protective tribolayer, reduced metal-to-metal contact, and the inherent self-lubricating behavior of graphene. The composite containing 1.5 wt.% graphene and 5 wt.% E-glass fiber exhibited the minimum wear rate, outperforming both lower-reinforced composites and monolithic copper under dry sliding conditions. The novelty of this work lies in the synergistic hybrid reinforcement strategy combined with machine-learning-assisted optimization, enabling efficient identification of optimal compositions. From a practical standpoint, this approach offers a cost-effective and scalable pathway for designing next-generation, wear-resistant copper composites suitable for high-speed, high-load tribological applications in automotive, aerospace, and advanced electronic systems.</p></div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00456-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148172868","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Effect of crack size and its position on cyclic deformation behavior of refractory high-entropy alloy HfNbTiZr","authors":"Rita I. Babicheva,&nbsp;Arslan A. Davletbakov,&nbsp;Ajay Kumar,&nbsp;Raj Kiran,&nbsp;Aleksander S.Semenov,&nbsp;Artem A. Izosimov,&nbsp;Elena A. Korznikova","doi":"10.1186/s40712-026-00460-7","DOIUrl":"10.1186/s40712-026-00460-7","url":null,"abstract":"<div>\u0000 \u0000 <p>The influence of crack position and its size on short-range ordering (SRO) and high-temperature cyclic deformation behavior of refractory high-entropy alloy (RHEA) HfNbTiZr using bicrystal models has been investigated by combined Monte-Carlo (MC) and molecular dynamics (MD) simulations. It was revealed that the SRO process is affected not only by the crack size, namely the crack opening value, but also by its position. For the first time, using atomistic MC/MD modeling to get the steady-state atomic structure subjected to diffusion process, it was demonstrated that during material relaxation, cracks with small crack opening value or small crack tip radius located in the GB of RHEA HfNbTiZr can promote the formation of stable hexagonal close-packed (HCP) martensite phase. The martensite phase is enriched in Hf and Ti atoms which is required to satisfy equilibrium condition from both side of the moving interface. The stable HCP structure, which is absent when the cracks are larger or located within the grain, improves the material performance under subsequent high-temperature cyclic deformation in Mode I perpendicular to the GB plane. Simulations showed that the sample with the stable HCP phase at GB withstood 7 more cycles before failure compared to the variant without this phase. An improved cyclic deformation performance of alloy with smaller cracks compared to material with larger cracks results from the disappearance of the original GBs when a stable martensite phase grows from the crack tips along the boundaries. As a result, the high local stresses initiated by the GBs disappear at the crack tip, this process prevents further crack propagation. The obtained results provide new insights into the role of microstructural features, namely the influence of cracks and their distribution, on the deformation behavior of RHEA.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00460-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148172890","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Enhancement of dielectric properties in (Na, K, Li)(Nb, Ta, Sb)O3-Bi0.5Li0.5ZrO3/polyvinylidene fluoride composites via solution-casting method","authors":"Pornsuda Bomlai,&nbsp;Suppanat Musigawon,&nbsp;Phetdaphat Boonsuk","doi":"10.1186/s40712-026-00453-6","DOIUrl":"10.1186/s40712-026-00453-6","url":null,"abstract":"<div><p>Lead-free (Na, K, Li)(Nb, Ta, Sb)O₃-Bi_0.5Li_0.5ZrO₃ (NKLNTS-BLZ)/polyvinylidene fluoride (PVDF) composites with 0–3 connectivity were fabricated via a solution-casting method. The microstructure, phase evolution, and dielectric properties were systematically investigated as a function of filler content (0–40 vol%). SEM analysis revealed that fillers were well-dispersed at lower concentrations, significant agglomeration and micro-voids were observed at 40 vol%. The composites exhibited a giant dielectric constant, reaching a maximum of 250 (at 1 kHz) with 40 vol% loading. However, this enhancement was accompanied by a critical trade-off in dielectric loss and breakdown strength. To elucidate the conduction mechanism, AC conductivity was analyzed using Jonscher’s power law. The results showed that the power-law exponent (<i>n</i>) increased from 0.38 (pure PVDF) to ~ 0.6 (10–30 vol%), indicating a dominant hopping conduction mechanism desirable for insulation. Conversely, at 40 vol%, the <i>n</i> value dropped sharply to 0.27, signaling the onset of percolation and leakage currents. Consequently, the 30 vol% composition was identified as the optimal loading, effectively balancing high permittivity with electrical stability. These findings demonstrate that NKLNTS-BLZ/PVDF composites are promising candidates for next-generation embedded capacitors, provided that the filler fraction is optimized to mitigate conduction losses.</p><h3>Graphical abstract</h3><div><figure><div><div><picture><source><img></source></picture><span>The alternative text for this image may have been generated using AI.</span></div></div></figure></div></div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00453-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148173247","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Machine learning driven optimisation of mechanical and microstructural behaviour in FFF-printed Onyx–HSHT composites","authors":"Bhagyashri Hiralal Dhage,&nbsp;Nitin K. Khedkar,&nbsp;Vijayshri Khedkar","doi":"10.1186/s40712-026-00450-9","DOIUrl":"10.1186/s40712-026-00450-9","url":null,"abstract":"<div>\u0000 \u0000 <p>Additive Manufacturing (AM) is a transformative technology that allows the construction of lightweight, high-strength composite structures with customised geometries, making it mostly suitable for aerospace, defence, and structural applications. This study examines the mechanical behaviour of Onyx–High-Strength High-Toughness (HSHT) fibre composites fabricated using Fused Filament Fabrication (FFF). It establishes an integrated optimisation outline combining experimental testing, statistical analysis, machine learning (ML), and scanning electron microscopy (SEM). Tensile, flexural, and impact tests revealed significant adaptability in performance, with tensile strength of 177.50 MPa, flexural strength of 68.9 MPa, and impact energy of 7.487 J. Meanwhile, Analysis of Variance (ANOVA) established substantial sensitivity of mechanical properties to processing parameters, with F-values of 21.54, 70.39, and 294.15, respectively. Predictive ML models, predominantly the Random Forest Regressor, revealed high accuracy (R² up to 0.996), and interactive linear regression effectively modelled flexural strength. SEM analysis explained critical microstructural factors, such as void morphology and fibre–matrix interface quality, that influence mechanical performance. The combined DOE–ANOVA–ML–SEM approach provides a robust, data-driven methodology for the practical prototyping and optimisation of continuous fibre-reinforced AM composites, enabling accelerated design and improved performance prediction of advanced composite materials for practical engineering applications.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-16","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00450-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148008616","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Three body abrasive wear on mild steel using sand particles as abrasives","authors":"Abdullah Shalwan,&nbsp;Saad Alsubaie,&nbsp;Belal F. Yousif","doi":"10.1186/s40712-026-00454-5","DOIUrl":"10.1186/s40712-026-00454-5","url":null,"abstract":"<div>\u0000 \u0000 <p>In this study, a three-body abrasive wear behavior of mild steel was investigated. A dry sand Steel wheel (DSSW) test apparatus was used in these experiments to conduct tribological testing considering different sliding distances and applied loads under dry contact conditions. Scanning electron microscopy was used to examine the damage on the worn surface of the mild steel. The results revealed that the sand used in the experiments caused cracking and pitting on the worn surfaces. Increasing the applied load increases the volume loss of the materials due to the high stress subjected to the surface. In addition, a sliding mechanism was observed with the high applied load since there is a high abrasive nature on the surface at the high applied load. With the low applied load, the main motion mechanism involved rolling the particle at the interface, resulting in less damage on the surface compared to the high applied load. The increase in the sliding distance leads to a consistent rise in material removal.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00454-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148008800","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Response surface modelling of tensile and impact characteristics of Kevlar/Hemp/CNT reinforced polymer matrix composites","authors":"H. K. Shivanand,&nbsp;Ali B. M. Ali,&nbsp;Madhusudhana Reddy H,&nbsp;ShivaPrakash S,&nbsp;Santhosh Nagaraja,&nbsp;Rahul Biradar,&nbsp;Ahmed Shakir Al-Hiti,&nbsp;Abdul Amir H. Kadhum,&nbsp;Aseel Smerat,&nbsp;Amare Merfo Amsal","doi":"10.1186/s40712-026-00435-8","DOIUrl":"10.1186/s40712-026-00435-8","url":null,"abstract":"<div>\u0000 \u0000 <p>The reinforcement composition optimization is a key factor that is instrumental in improving the mechanical performance of the polymer matrix composites. In the current research, hybrid composites based have been developed using epoxy material reinforced with kevlar fibre, hemp fibre, and carbon nanotubes (CNTs) enroute the hand lay-up process and optimized through response surface methodology (RSM). The kevlar and hemp fibre ranged between 0 and 20 wt.% and the CNT content varied between 0.5 wt.% and 1.5 wt.%. The tensile strength of CNT-only composites (K0H0C0.5) was found to be 195.64 MPa while the tensile strength of hybrid composites based on 20 wt.% kevlar, 10 wt.% hemp, and 1 wt.% CNTs was 221.78 MPa. The elongation reduced to 0.67%, for the hybrid composites afore mentioned in comparison with the K0H0C0.5 which was found to be 0.86%. There was also significant improvement in impact performance when CNT was added and fibre combinations were optimized. RSM was successfully used to determine the best reinforcement content and ANOVA was used to ascertain that the difference in CNT content was statistically significant to tensile and impact strengths. The findings show that the synergistic association of natural and synthetic fibres, CNT fillers could be optimally combined to bring about improved mechanical performance that could be used in lightweight structural applications.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-06","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00435-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147829309","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Assessing the impact of carbonitriding on residual weld hydrogen in the manufacture of a gear component","authors":"Fernando Bonilla-Angulo,&nbsp;Tiago Castelão,&nbsp;Yvan Chastel,&nbsp;Frank W. H. Dean,&nbsp;Catherine E. Gardner,&nbsp;Gildas Lecuyer","doi":"10.1186/s40712-026-00414-z","DOIUrl":"10.1186/s40712-026-00414-z","url":null,"abstract":"<div>\u0000 \u0000 <p>In this paper, we report on the direct measurement of hydrogen flux from a machined car gear component immediately following carbonitriding treatment and prior to its welding to the gear train. Carbonitriding is a thermochemical process by which carbon and nitrogen are purposely introduced into the surface of steel components leading to an improvement of their wear and fatigue performance. Hydrogen bearing gases used in the treatment also cause hydrogen uptake in the steel. This hydrogen is substantially retained upon the quenching of the components that immediately follows carbonitriding, potentially leading to hydrogen cracking during subsequent manufacturing welding operations. The work was carried out to ensure a complete understanding of the conditions under which hydrogen, introduced during carbonitriding, is likely to present any risk of subsequent weld failure. Diffusion modelling of measured flux profiles indicated complete permeation of hydrogen through the gear piece at a concentration of 1.8 parts per million by weight (ppm) hydrogen upon the termination of carbonitriding., This compares with commonly specified residual hydrogen levels considered safe for welding of between 1 and 10 ppm hydrogen. However, the hydrogen cracking of welds is also very much informed by the welding thermal profile, geometry and metallurgy. As a result of the flux measurements and modelling, it was possible to adopt and monitor production procedures which assured avoidance of any risk of hydrogen damage during and after the weld process.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-04-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00414-z.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147606797","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Thermal degradation of jackfruit peel in nitrogen atmosphere: A comparative study of kinetic models","authors":"Sonam Kardam,&nbsp;Shabina Khanam","doi":"10.1186/s40712-026-00423-y","DOIUrl":"10.1186/s40712-026-00423-y","url":null,"abstract":"<div><p>This study presents a comparative analysis of kinetic models to evaluate the thermal degradation of jackfruit peel in a nitrogen atmosphere. Thermogravimetric analysis was performed to examine the decomposition behavior of JFP, revealing three distinct stages: moisture evaporation (30–105 °C), active pyrolysis (105–380 °C) involving hemicellulose and cellulose degradation, and lignin decomposition with char formation (380–900 °C). The thermal behavior was further analyzed using multiple kinetic models, including Kissinger–Akahira–Sunose, Flynn–Wall–Ozawa, Friedman, Starink, and Tang methods, to determine activation energy (<i>E</i>_<i>a</i>) at different conversion levels. The comparative kinetic analysis demonstrated variations in E_a, with average values of 166.25 kJ/mol Kissinger–Akahira–Sunose, 167.60 kJ/mol Flynn–Wall–Ozawa, 167.82 kJ/mol Friedman, 155.98 kJ/mol Starink, and 166.53 kJ/mol Tang. The highest E_a of 313.65 kJ/mol was observed at a conversion fraction (α) of 0.7, indicating the breakdown of stable lignin structures, whereas a significant decline in E_a at α = 0.9 suggests the completion of decomposition and possible secondary reactions. A statistical analysis was performed to evaluate the reliability of the kinetic parameters. Activation energies, slopes, standard errors, pre-exponential factors, and confidence intervals were examined for each model and conversion level. At lower conversions (α = 0.2–0.6), the activation energies were stable with low uncertainty. As conversion increased (α ≥ 0.7), uncertainty increased due to reduced mass loss, char formation, and experimental noise. The Friedman method captured greater variation at higher conversions but exhibited higher uncertainty. Negative activation energy values at α = 0.9 reflect statistical uncertainty rather than intrinsic reaction behavior. The results confirm the multi-step nature of Jackfruit peel, with different kinetic models capturing variations in reaction pathways. The study highlights the influence of heating rate on thermal decomposition, with higher heating rates shifting degradation peaks to elevated temperatures. Importantly, the choice of kinetic model significantly affects the estimation of activation energy and, consequently, the prediction of optimal pyrolysis conditions, which is crucial for maximizing bioenergy yield and designing efficient thermochemical conversion systems. With a volatile matter content of 74.90%, fixed carbon of 12.98%, and a higher heating value of 16.98 MJ/kg, JFP is a promising feedstock for thermochemical conversion.</p></div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-03-30","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00423-y.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147607118","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}

{"title":"Process and operating temperature optimization for polysulfone hollow fiber membrane CO2/CH4 mixture separation via response surface methodology","authors":"Rama Alqassar Bani Almarjeh,&nbsp;Yomen Atassi","doi":"10.1186/s40712-026-00448-3","DOIUrl":"10.1186/s40712-026-00448-3","url":null,"abstract":"<div>\u0000 \u0000 <p>Membrane gas separation has gained significant interest due to its compactness, high area-to-volume ratio, and numerous advantages over traditional gas separation processes such as cryogenic distillation and adsorption towers. Optimizing operating conditions, particularly temperature, is essential to enhance process performance, thereby increasing productivity and product purity. Polysulfone is widely regarded as an ideal membrane material for natural gas treatment due to its balanced permeance for both CH₄ and CO₂. However, its permeance is temperature-dependent, necessitating careful selection of the operating temperature. Our model uniquely integrates two critical non-ideal factors: (i) Arrhenius-type temperature dependence of gas permeance, and (ii) permeate-side pressure drop, addressing limitations in existing models that typically assume isothermal conditions and neglect pressure variations. Validation against experimental data from Tranchino et al. demonstrates the model’s high predictive accuracy, with coefficient of determination (R²) of 0.9436, explained variance (EV) of 0.9463, and mean squared error (MSE) of 4.4595 × 10^− 6 across multiple operating pressures (2–7 atm). Response Surface Methodology (RSM) with Central Composite Design (CCD) was employed to systematically optimize the operating conditions, with Analysis of Variance (ANOVA) used to evaluate the statistical significance of the developed models. Through ANOVA coupled with central composite design, we systematically identified the optimal operating temperature of 348 K for CO₂/CH₄ separation using polysulfone membranes, with a consistent optimal permeate-to-feed pressure ratio (γ) of approximately 0.24. The sensitivity analysis further reveals that feed CO₂ mole fraction (<span>(:{x}_{0})</span>) serves as the most influential parameter for process performance, enabling flexible operation across diverse feed compositions. This integrated modeling and optimization framework provides a practical tool for process engineers to identify optimal operating windows that balance separation performance with energy consumption, and can be readily extended to other membrane materials and gas separation applications.</p>\u0000 </div>","PeriodicalId":592,"journal":{"name":"International Journal of Mechanical and Materials Engineering","volume":"21 1","pages":""},"PeriodicalIF":2.0,"publicationDate":"2026-03-29","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40712-026-00448-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"147607279","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}