Szabolcs Szalai

57200408978

Publications - 33

Investigation of the Load-Bearing Capacity of Resin-Printed Components Under Different Printing Strategies

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes

Publication Name: Applied Sciences Switzerland

Publication Date: 2025-08-01

Volume: 15

Issue: 15

Page Range: Unknown

Description:

This study examines the influence of different printing orientations and infill settings on the strength and flexibility of components produced using resin-based 3D printing, particularly with masked stereolithography (MSLA). Using a common photopolymer resin and a widely available desktop MSLA printer, we produced and tested a series of samples with varying tilt angles and internal structures. To understand their mechanical behavior, we applied a custom bending test combined with high-precision deformation tracking through the GOM ARAMIS digital image correlation system. The results obtained clearly show that both the angle of printing and the density of the internal infill structure play a significant role in how much strain the printed parts can handle before breaking. Notably, a 75° orientation provided the best deformation performance, and infill rates between 60% and 90% offered a good balance between strength and material efficiency. These findings highlight how adjusting print settings can lead to stronger parts while also saving time and resources—an important consideration for practical applications in engineering, design, and manufacturing.

Open Access: Yes

DOI: 10.3390/app15158747

Deformation Characterization of Glass Fiber and Carbon Fiber-Reinforced 3D Printing Filaments Using Digital Image Correlation

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Dmytro Kurhan Brigitta Fruzsina Szívós Vivien Nemes

Publication Name: Polymers

Publication Date: 2025-04-01

Volume: 17

Issue: 7

Page Range: Unknown

Description:

The paper offers an in-depth deformation study of glass fiber-reinforced and carbon composite filaments of 3D printers. During the certification, the authors used DIC (Digital Image Correlation) as a full-field strain measurement technique to explore key material traits as a non-contact optical measurement method. The insights captured through the DIC technology enabled to better understand the localized strain distributions during the loading of these reinforced filaments. The paper analyzes the glass fiber and carbon fiber filaments used in 3D printing that are reinforced with these materials and are subjected to bending and compressive loading. The segment presents how loading affects the performance of reinforced filaments when varying such factors as the deposition patterns, layer orientation, and other process parameters. Different types and combinations of reinforcements and printing variables were tested, and the resulting dependencies of mechanical parameters and failure modes were established for each case. Key conclusions demonstrate that the mechanical behavior of both carbon- and glass fiber-reinforced filaments is strongly affected by the 3D printing parameters, particularly infill density, pattern, and build orientation. The application of Digital Image Correlation (DIC) allowed for a precise, full-field analysis of strain distribution and deformation behavior, offering new insights into the structural performance of fiber-reinforced 3D printed composites. The findings from the study provide guidance for the proper choice of filling material and the optimal parameters for the 3D printing process of models with high-performance indexes and seamless applications in the automotive and industrial manufacturing sectors.

Open Access: Yes

DOI: 10.3390/polym17070934

Evaluating 3D-Printed Polylactic Acid (PLA)-Reinforced Materials: Mechanical Performance and Chemical Stability in Concrete Mediums

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Dmytro Kurhan Hanna Csótár

Publication Name: Applied Sciences Switzerland

Publication Date: 2025-02-01

Volume: 15

Issue: 4

Page Range: Unknown

Description:

The optimization and evaluation of 3D-printed polylactic acid (PLA) materials for reinforcing concrete elements present a promising avenue for advancing sustainable construction methods. This study addresses the challenges associated with PLA’s dual nature—biodegradable yet mechanically limited for long-term applications—while leveraging its potential to enhance concrete reinforcement. The research identifies gaps in understanding PLA’s mechanical and chemical behavior in alkaline environments, particularly its interactions with concrete matrices. To bridge this gap, four distinct PLA variants (high-impact PLA, engineering PLA, electrical ESD PLA, and gypsum PLA) and ABS (acrylonitrile butadiene styrene) were subjected to dissolution tests in NaOH solutions (pH 12 and 12.55) and mechanical evaluation under three-point bending using digital image correlation (DIC) technology. Test specimens were prepared using optimized 3D printing strategies to ensure structural consistency and were embedded in concrete beams to analyze their reinforcement potential. Force–displacement data and GOM ARAMIS measurements revealed significant differences in mechanical responses, with peak loads ranging from 0.812 kN (high-impact PLA) to 1.021 kN (electrical ESD PLA). Notably, electrical ESD PLA exhibited post-failure load-bearing capacity, highlighting its reinforcement capability. Chemical dissolution tests revealed material-specific degradation patterns, with high-impact and Gypsum PLA showing accelerated surface changes and precipitation phenomena. Observations indicated white crystalline precipitates, likely lime (calcium hydroxide—Ca(OH)2), residue from the dissolution tests (sodium hydroxide—NaOH), or material-derived residues formed on and near PLA elements, suggesting potential chemical interactions. These findings underline the critical role of material selection and optimization in achieving effective PLA–concrete integration. While PLA’s environmental sustainability aligns with industry goals, its structural reliability under long-term exposure remains a challenge. The study concludes that electrical ESD PLA demonstrates the highest potential for application in reinforced concrete, provided its chemical stability is managed, as its peak value (1.021 kN) showed 25.7% higher load-bearing capacity than high-impact PLA (0.812 kN) and did not lose any of its structural stability in the dissolution tests. This work advances the understanding of PLA as a sustainable alternative in construction, offering insights for future material innovations and applications.

Open Access: Yes

DOI: 10.3390/app15042165

Production and Testing of 3D Printed PLA Structures with DIC Technology for the Reinforcement of Concrete Elements

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós Hanna Csótár

Publication Name: Lecture Notes in Networks and Systems

Publication Date: 2025-01-01

Volume: 1258 LNNS

Issue: Unknown

Page Range: 175-187

Description:

3D printing technologies are now extensively utilized across numerous industries and scientific fields due to their ability to facilitate the practical testing of various design concepts cost-effectively and sustainably. This research focuses on PLA-based materials, known for their ease of recyclability. FDM printing technology was employed to identify the optimal printing layout for 3D-printed reinforcement elements in concrete, as this is not a standard parameter. Various material compositions and layout structures were analyzed using multiple printing strategies to find the most effective combination for innovatively enhancing the stiffness and strength of concrete structures. The GOM Aramis 5M DIC system, coupled with FDM printing technology, was used in this investigation, marking a novel approach in civil engineering.

Open Access: Yes

DOI: 10.1007/978-3-031-81799-1_17

Laboratory Investigation on Seams between Rails and Hardened Fine-grained, as well as Hadfield Steel Plates with Manual Arc Welding

Szabolcs Fischer Szabolcs Szalai András Brautigam Nikoletta Légmán

Publication Name: Acta Polytechnica Hungarica

Publication Date: 2025-01-01

Volume: 22

Issue: 4

Page Range: 83-102

Description:

In the last decade, hardened fine-grained plate components have been used in turnouts and crossings on Western European urban rail networks, as well as in Hungary, in place of traditional rail or Hadfield steel components. The first crossing was built in Hungary in 2016. These components have many advantages, such as the ease with which they can be machined in the factory; they are less prone to cracking than rails due to their block design (high load-bearing cross-section); however, their weldability to rails and lifetime repairability present numerous challenges for railway turnout manufacturers and operators. There have been numerous studies on joint and repair welding of rails and hardened finegrained materials, but there is little or no information available on joint welding with manual arc welding of these two different materials. The current study aims to investigate the welds of coated electrode manual arc welding of rails (R260 and R400 HT) and hardened finegrained plates (in this case, Hardox 500) under non-laboratory conditions while strictly adhering to technological specifications, in comparison to manual arc welding of rails and Hadfield steels. Laboratory tests included raw material chemical composition, macroscopic tests, micro-hardness measurements, tensile, shear, and bending tests.

Open Access: Yes

DOI: 10.12700/APH.22.4.2025.4.6

Investigation of Digital Light Processing-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Forming

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Dmytro Kurhan Brigitta Fruzsina Szívós Vivien Nemes György Szabó

Publication Name: Journal of Manufacturing and Materials Processing

Publication Date: 2025-01-01

Volume: 9

Issue: 1

Page Range: Unknown

Description:

This study addresses the emerging need for efficient and cost-effective solutions in low-volume production by exploring the mechanical performance and industrial feasibility of cutting tools that are fabricated using stereolithography apparatus (SLA) technology. SLA’s high-resolution capabilities make it suitable for creating precise cutting dies, which were tested on aluminum sheets (Al99.5, 0.3 mm, and AlMg3, 1.0 mm) under a 60-ton hydraulic press. Measurements using digital image correlation (DIC) revealed minimal wear and deformation, with tolerances consistently within IT 0.1 mm. The results demonstrated that SLA-printed tools perform comparably to conventional metal tools in cutting and bending operations, achieving similar surface quality and edge precision while significantly reducing the production time and cost. Despite some limitations in wear resistance, the findings highlight SLA technology’s potential for rapid prototyping and short-run manufacturing in the automotive and electronics sectors. This research fills a critical gap in understanding SLA-based tooling applications, offering insights into process optimization to enhance tool durability and broaden material compatibility. These advancements position SLA technology as a transformative tool-making technology for flexible manufacturing.

Open Access: Yes

DOI: 10.3390/jmmp9010025

Investigation of FDM-Based 3D Printing for Optimized Tooling in Automotive and Electronics Sheet Metal Cutting

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Dmytro Kurhan Brigitta Fruzsina Szívós Vivien Nemes György Szabó

Publication Name: Applied Sciences Switzerland

Publication Date: 2025-01-01

Volume: 15

Issue: 1

Page Range: Unknown

Description:

Within the scope of the work, the possible use of fused deposition modeling (FDM) technology in executing rapid prototypes of cutting tools for aluminum sheets was systematically studied. Relevant investigations have thus far mainly concentrated on tools for the 3D printing of bent and deep-drawn pieces, yet the implementation of FDM tools in cutting has been insufficiently covered. This study aims to determine the characteristics of FDM cutting tools, such as wear and tear, dimensional stability, and cutting efficiency. Various tool designs were tested under different wall thicknesses and orientations with respect to the feed of Al99.5 sheets with thicknesses of 0.22 mm and 0.3 mm. According to the results, in the best case, three-dimensional printed PLA tools performed six cuts with no burrs and an acceptable wear level due to the IT tolerances (IT9 and IT10). Tools with thicker walls and more appropriate orientations were found to be more robust. However, some designs failed when subjected to greater loads, revealing a deficiency in some of the strength properties of the material. These observations suggest that it is possible to create 3D printed tools for modeling and small-scale production at considerably cheaper and faster rates than conventional methods. Future work will integrate advanced materials and designs to enhance tool performance, further solidifying FDM as a transformative approach in industrial tool manufacturing. With this research, the authors wanted to demonstrate that FDM technology can also be used to produce a classic sheet cut, which, of course, is still of great importance for prototyping or setting up production processes. This research demonstrated that FDM printing can play a role in this area.

Open Access: Yes

DOI: 10.3390/app15010442

Laboratory and Numerical Investigation of Pre-Tensioned Reinforced Concrete Railway Sleepers Combined with Plastic Fiber Reinforcement

Szabolcs Fischer Mykola Sysyn Zoltán Major Sarah Khaleel Ibrahim Dmytro Kurhan Vivien Jóvér Szabolcs Szalai Hanna Csótár Klaudia Madarász András Pollák Dániel Harrach Bálint Molnár L. Gaspar Bence Hermán Szabolcs Kocsis Szurke Attila Németh I. Fekete Richárd Nagy Gusztáv Baranyai Miklós Kuczmann M. Movahedi Rad

Publication Name: Polymers

Publication Date: 2024-06-01

Volume: 16

Issue: 11

Page Range: Unknown

Description:

This research investigates the application of plastic fiber reinforcement in pre-tensioned reinforced concrete railway sleepers, conducting an in-depth examination in both experimental and computational aspects. Utilizing 3-point bending tests and the GOM ARAMIS system for Digital Image Correlation, this study meticulously evaluates the structural responses and crack development in conventional and plastic fiber-reinforced sleepers under varying bending moments. Complementing these tests, the investigation employs ABAQUS’ advanced finite element modeling to enhance the analysis, ensuring precise calibration and validation of the numerical models. This dual approach comprehensively explains the mechanical behavior differences and stresses within the examined structures. The incorporation of plastic fibers not only demonstrates a significant improvement in mechanical strength and crack resistance but paves the way for advancements in railway sleeper technology. By shedding light on the enhanced durability and performance of reinforced concrete structures, this study makes a significant contribution to civil engineering materials science, highlighting the potential for innovative material applications in the construction industry.

Open Access: Yes

DOI: 10.3390/polym16111498

A Pre-Study of the Relationship Between Machining Technology Parameters and Surface Roughness in the Scope of the Optimal Cost Efficiency of Machining †

László Pálfi Szabolcs Szalai József Beke

Publication Name: Engineering Proceedings

Publication Date: 2024-01-01

Volume: 79

Issue: 1

Page Range: Unknown

Description:

This research investigates the relationship between machining technology parameters and surface roughness to optimize the cost efficiency of machining processes. In modern manufacturing, particularly in the automotive sector, achieving the desired surface quality while minimizing costs is critical. By evaluating tools from various manufacturers under different combinations of cutting parameters—such as cutting speed, feed, and depth—this study focuses on determining the most effective settings for producing an optimal surface roughness. The experiments highlight that selecting appropriate technological parameters impacts the machining process’s surface finish and economic efficiency. This study provides insights into balancing surface quality requirements with cost constraints, contributing to more efficient and sustainable manufacturing practices.

Open Access: Yes

DOI: 10.3390/engproc2024079090

Sustainable Uses of 3D Printing Applied to Concrete Structures †

Szabolcs Fischer Szabolcs Szalai Hanna Csótár Gusztáv Baranyai

Publication Name: Engineering Proceedings

Publication Date: 2024-01-01

Volume: 79

Issue: 1

Page Range: Unknown

Description:

This study investigates the application of honeycomb-patterned PLA as a reinforcement in concrete structures. The research focused on identifying the optimal 3D printing layout for this reinforcement and examining how the orientation of 3D-printed PLA affects the mechanical properties of the concrete. The study compares the performance of concrete reinforced with 3D-printed PLA to both unreinforced concrete and concrete reinforced with recycled amorphous aggregate from printing waste. The results demonstrate how printing orientation influences concrete strength and the potential for using recycled PLA to enhance sustainability in construction.

Open Access: Yes

DOI: 10.3390/engproc2024079055

Sustainable 3D-Printing Filaments and their Applications

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes

Publication Name: Chemical Engineering Transactions

Publication Date: 2024-01-01

Volume: 114

Issue: Unknown

Page Range: 967-972

Description:

The growing demand for sustainable materials has driven research into 3D printing technologies, particularly those focused on environmentally friendly filaments such as Polylactic Acid (PLA) and its composites. This study explores the mechanical performance and applications of four distinct PLA-based materials: conventional PLA, PLA Advanced PRO, Glass Reinforced PLA, and Foam PLA. Through a combination of tensile testing and Digital Image Correlation (DIC) analysis, the research highlights the displacement behavior and internal structural evolution of these materials under load-bearing conditions. Glass Reinforced PLA demonstrated the highest performance, showing a 10-15 % increase in displacement capacity compared to conventional PLA, while PLA Advanced PRO exhibited a 10 % improvement, and Foam PLA showed a modest 3-5 % enhancement. Infill density significantly impacted layer adhesion, especially for Glass Reinforced PLA, where an infill density above 30 % greatly enhanced structural integrity. This study not only underscores sustainable filaments' environmental and mechanical benefits but also emphasizes their potential as viable alternatives for complex, load-bearing applications in various industries. The findings contribute to the ongoing development of greener, high-performance 3D printing materials and suggest avenues for future research to optimize the balance between sustainability and material performance.

Open Access: Yes

DOI: 10.3303/CET24114162

Deformation Analysis of Different Lithium Battery Designs Using the DIC Technique

Szabolcs Fischer Szabolcs Szalai Szabolcs Kocsis Szurke Mátyás Szabó

Publication Name: Energies

Publication Date: 2024-01-01

Volume: 17

Issue: 2

Page Range: Unknown

Description:

The growing number of electric vehicles and devices drives the demand for lithium-ion batteries. The purpose of the batteries used in electric vehicles and applications is primarily to preserve the cells and extend their lifetime, but they will wear out over time, even under ideal conditions. Most battery system failures are caused by a few cells, but the entire system may have to be scrapped in such cases. To address this issue, the goal is to create a concept that will extend the life of batteries while reducing the industrial and chemical waste generated by batteries. Secondary use can increase battery utilization and extend battery life. However, processing a large number of used battery cells at an industrial level is a significant challenge for both manufacturers and users. The different battery sizes and compositions used by various manufacturers of electric vehicles and electronic devices make it extremely difficult to solve the processing problem at the system level. The purpose of this study is to look into non-destructive battery diagnostic options. During the tests, the condition of the cells is assessed using a new diagnostic technique, 3D surface digitalization, and the fusion of electrical parameters. In the case of surface digitalization, the digital image correlation (DIC) technique was used to estimate the cell state. The tests were conducted on various cells with widely used geometries and encapsulations. These included a lithium polymer (soft casing), 18650 standard sizes (hard casing), and prismatic cells (semi-hard). The study also included testing each battery at various charge states during charging and discharging. The findings help to clarify the changes in battery cell geometry and their localization. The findings can be applied to cell diagnostic applications such as recycling, quality assurance, and vehicle diagnostics.

Open Access: Yes

DOI: 10.3390/en17020323

The Application of DIC in Criminology Analysis Procedures to Measure Skin Deformation

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Jianxing Liu Brigitta Fruzsina Szívós Dániel Kocsis

Publication Name: Journal of Applied and Computational Mechanics

Publication Date: 2024-01-01

Volume: 10

Issue: 4

Page Range: 817-829

Description:

In engineering, DIC is a widely used measurement technique. Its major advantage is that it provides real-time results (displacements, accelerations, stresses, strains, deformations) of the surface under examination relatively quickly and without contact. However, its application in medicine, biomechanics, and the field of criminalistics is novel. The present research focuses mainly on the frontier areas of forensics and medicine. The research aims to define the test boundary conditions and preparatory activities to measure the surface of the animal and then human skin. Injuries caused by low-energy ballistic bullets, blunt-force trauma, and cuts and punctures caused by knives and/or blades will be investigated. The present research focuses on puncture injuries in animal skin. The main challenge is to create a speckle pattern on the surface that can track deformation well. The research is about developing and validating this. The GOM ARAMIS measurement system was applied for the measurements. This paper demonstrates that a suitable preparation, painting procedure, and measurement setup has been established to measure the above effects, i.e., to identify displacements and deformations of up to tenths of a millimeter with sufficient accuracy. The evaluation of the results will also show that this method could be used in forensic applications, the automotive industry, medical orthopedics, and the textile industry.

Open Access: Yes

DOI: 10.22055/jacm.2024.46966.4634

ADVANTAGES OF USING CONCRETE CANVAS MATERIALS IN RAILWAY TRACK CONSTRUCTION

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Jianxing Liu Dániel Harrach B. Eller

Publication Name: Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu

Publication Date: 2024-01-01

Volume: Unknown

Issue: 1

Page Range: 50-57

Description:

Purpose. Justification of the feasibility of using new types of drainage materials, such as Concrete Canvas (CC), under the upper structure of the railway permanent way. Methodology. The tasks were solved by a complex research method, including analysis and generalization of literary and patent sources, analytical, experimental studies, using computer and mathematical modeling methods. Tests were conducted with and without the CC layer in a multi-level shear box. After the shear test, the specimens were also tested for load-bearing capacity (E2, according to the Hungarian standard) and particle breakage. The contact surface between the bottom of the ballast and the CC was measured using a precision 3D laser scanner (GOM ATOS) and visualized graphically using AutoCAD software. Findings. Experimental testing of the vertical load during connection and analysis compared with the test results of geocomposite/geogrid structures, internal shear resistance, and other parameters proved the structure’s higher load-bearing capacity with the CC layer. Based on the results, the Concrete Canvas structure provides higher reinforcement than the average geogrid type. Originality. The advantages of using new Concrete Canvas materials in the structure of a railway track have been demonstrated for the first time to provide greater internal shear resistance than the average for geogrids. Practical value. These results may provide primary data for using Concrete Canvas in railway tracks and superstructures in the future.

Open Access: Yes

DOI: 10.33271/nvngu/2024-1/050

Optimization of 3D Printed Rapid Prototype Deep Drawing Tools for Automotive and Railway Sheet Material Testing

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Attila Németh Dmytro Kurhan Bálint Herold

Publication Name: Infrastructures

Publication Date: 2023-03-01

Volume: 8

Issue: 3

Page Range: Unknown

Description:

The main objective of this research is to identify optimal printing strategies and PLA (polylactic acid) filament materials to produce rapid prototype deep drawing tools. Additive 3D printing technologies have been applied for a long time to produce tools, but the research is unique in that it uses conventional and various reinforced PLA materials with conventional FDM (Fused Deposition Modeling) printers. The advantage of this method is that PLA is easy to print and recycle and does not require expensive or special printers, this also gives the article its novelty. A further aim was to produce the tools using commercially available low-end printers. DX53D 0.8 mm thick body steel and AlMg3 2.5 mm thick sheet were the materials to be molded for the tests. The test tool was an Erichsen deep drawing punch. Tool wear was tested using the GOM ATOS measuring system, an optical coordinate measuring machine based on the DIC (Digital Image Correlation) principle, which is also popular in the automotive industry. The study aims to determine the 3D printing and material parameters that can safely produce a minimum batch of 100 parts.

Open Access: Yes

DOI: 10.3390/infrastructures8030043

Testing Road Vehicle User Interfaces Concerning the Driver’s Cognitive Load

P. Földesi Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Gábor Kovács Dmytro Kurhan Viktor Nagy

Publication Name: Infrastructures

Publication Date: 2023-03-01

Volume: 8

Issue: 3

Page Range: Unknown

Description:

This paper investigates the usability of touch screens used in mass production road vehicles. Our goal is to provide a detailed comparison of conventional physical buttons and capacitive touch screens taking the human factor into account. The pilot test focuses on a specific Non-driving Related Task (NDRT): the control of the on-board climate system using a touch screen panel versus rotating knobs and push buttons. Psychological parameters, functionality, usability and, the ergonomics of In-Vehicle Information Systems (IVIS) were evaluated using a specific questionnaire, a system usability scale (SUS), workload assessment (NASA-TLX), and a physiological sensor system. The measurements are based on a wearable eye-tracker that provides fixation points of the driver’s gaze in order to detect distraction. The closed road used for the naturalistic driving study was provided by the ZalaZONE Test Track, Zalaegerszeg, Hungary. Objective and subjective results of the pilot study indicate that the control of touch screen panels causes higher visual, manual, and cognitive distraction than the use of physical buttons. The statistical analysis demonstrated that conventional techniques need to be complemented in order to better represent human behavior differences.

Open Access: Yes

DOI: 10.3390/infrastructures8030049

Numerical Investigation of Pre-Stressed Reinforced Concrete Railway Sleeper for High-Speed Application

Szabolcs Fischer Zoltán Major Szabolcs Szalai Mykola Sysyn Attila Németh Dmytro Kurhan Dóra Harangozó M. Movahedi Rad Sarah Khaleel Ibrahim Dániel Harrach Szabolcs Kocsis Szurke Gusztáv Baranyai Géza Herczeg L. Gaspar

Publication Name: Infrastructures

Publication Date: 2023-03-01

Volume: 8

Issue: 3

Page Range: Unknown

Description:

The current paper deals with the numerical investigation of a unique designed pre-stressed reinforced concrete railway sleeper for the design speed of 300 km/h, as well as an axle load of 180 kN. The authors applied different methodologies in their research: traditional hand-made calculations and two types of finite element software. The latter were AxisVM and ABAQUS, respectively. During the calculations, the prestressing loss was not considered. The results from the three methods were compared with each other. The hand-made calculations and the finite element modeling executed by AxisVM software are adequate for determining the mechanical inner forces of the sleeper; however, ABAQUS is appropriate for consideration of enhanced and sophisticated material models, as well as the stress-state of the elements, i.e., concrete, pre-stressed tendons, etc. The authors certified the applicability of these methodologies for performing the dimensioning and design of reinforced concrete railway sleepers with pre-stressing technology. The research team would like to continue their research in an improved manner, taking into consideration real laboratory tests and validating the results from FE modeling, special material models that allow calculation of crackings and their effects in the concrete, and so that the real pattern of the crackings can be measured by GOM Digital Image Correlation (DIC) technology, etc.

Open Access: Yes

DOI: 10.3390/infrastructures8030041

Optimization of Surface Preparation and Painting Processes for Railway and Automotive Steel Sheets

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Attila Németh Dmytro Kurhan Brigitta Fruzsina Szívós

Publication Name: Infrastructures

Publication Date: 2023-02-01

Volume: 8

Issue: 2

Page Range: Unknown

Description:

The article deals with DIC (Digital Image Correlation) tests on steel plates used in the automotive and railway industries, as well as in the construction industry. The most critical part of DIC tests is the quality of proper surface preparation, painting, and random patterns. The paint mediates the deformation of the optical systems, and its quality is paramount. The authors’ goal in this research is to determine the optimal dye–cleaning–drying time parameters for DIC studies. Commercially available surface preparation and cleaning agents were tested alongside commercially available spray paints. Standard and specific qualification procedures were applied for the measurements. Once the appropriate parameters were determined, the results were validated and qualified by GOM ARAMIS tests. Based on the results, DIC measurements can be performed with higher accuracy and safety in laboratorial and industrial conditions, compared to the traditional deformation measurements executed by dial gauges or linear variable differential transformers.

Open Access: Yes

DOI: 10.3390/infrastructures8020028

Optimization of Surface Cleaning and Painting Methods for DIC Measurements on Automotive and Railway Aluminum Materials

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Attila Németh Dmytro Kurhan Viktória Fehér

Publication Name: Infrastructures

Publication Date: 2023-02-01

Volume: 8

Issue: 2

Page Range: Unknown

Description:

The preparatory operations of DIC (Digital Image Correlation) tests were investigated in this study, with special emphasis on specimen cleaning and painting operations. As it is well known, DIC tests are non-contact and applied in materials research, the analysis of complex structures, and, nowadays, the construction industry. The use of DIC technologies has seen a dynamic increase in all scientific fields. In our study, aluminum body panels for automotive and railway applications were tested using this technique. There are many articles on proper patterning in the literature but fewer on preparation and priming. These are critical for a successful DIC measurement. This paper looks at different surface cleaners and primers with different grading procedures and will also determine the time window within which the paint should be applied. Finally, the GOM ARAMIS system was applied to measure and characterize the painted surface and visible deformation defects resulting from inadequate painting.

Open Access: Yes

DOI: 10.3390/infrastructures8020027

Testing of Lubricants for DIC Tests to Measure the Forming Limit Diagrams of Aluminum Thin Sheet Materials

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Attila Németh Dmytro Kurhan Hanna Csótár

Publication Name: Infrastructures

Publication Date: 2023-02-01

Volume: 8

Issue: 2

Page Range: Unknown

Description:

We investigated lubricants and thin teflon foils that can be applied in the formability testing of the thin aluminum sheets used in the electronics and automotive industries. For the tests, thirteen different industrial lubricants (oils and greases) (i.e., L1–L13) and two Teflon films (i.e., 0.08 and 0.22 mm thick) were applied. The authors conducted an Erichsen test, and the thickness reduction of the discs was measured first. In forming-limit curve (FLC) tests, it is crucial that the stresses are localized in the central area of the specimen during forming and that biaxial deformation is maintained throughout, if possible. We aimed to achieve and fulfill this task. To perform this measurement, the GOM ARAMIS measuring system was utilized. It is an optical measuring system based on the digital image correlation (DIC) principle, capable of measuring both stresses and displacements in real time. A specific validation method was also developed to qualify the DIC system. We concluded that there was a 5% difference in Erichsen indentation (IE) number diagrams between the best (L12) and worst (L4) cases for the lubricants and oils tested, which is a significant difference for thin plates. We found that this value could be increased and improved by using Teflon discs. Furthermore, the localization of stress maxima, i.e., the centering of cracks in the specimen, could be achieved by combining Teflon discs and L12 lubricant (with appropriate layer order), which significantly aids in the recording of standard FLC diagrams. Using foils is also advantageous because they are readily available, have no expiry date, and are of less environmental concern.

Open Access: Yes

DOI: 10.3390/infrastructures8020032

Examination of Concrete Canvas under Quasi-Realistic Loading by Computed Tomography

Szabolcs Fischer I. Fekete Szabolcs Szalai Mykola Sysyn Dmytro Kurhan M. Movahedi Rad Dániel Harrach B. Eller Gusztáv Baranyai

Publication Name: Infrastructures

Publication Date: 2023-02-01

Volume: 8

Issue: 2

Page Range: Unknown

Description:

The current paper concerns the investigation of CC (Concrete Canvas), a unique building material from the GCCM (geosynthetic cementitious composite mat) product group. The material is suitable for trench lining, trench paving, or even military construction activities, while the authors’ purpose is to investigate the application of the material to road and railway substructure improvement. This research was carried out to verify the material’s suitability for transport infrastructure and its beneficial effects. The authors’ previous study reported that the primary measurements were puncture, compression, and the parameters evaluated in four-point bending (laboratory) tests. However, based on the results, finite element modeling was not feasible because the testing of the composite material in a single layer did not provide an accurate indication. For this reason, the material characteristics required for modeling were investigated. A unique, novel testing procedure and assembly were performed, wherein the material was loaded under quasi-realistic conditions with a crushed stone ballast sample and other continuous particle size distribution samples in a closed polyethylene tube. In addition, the deformation of the material following deformed bonding was measured by computed tomography scanning, and the results were evaluated.

Open Access: Yes

DOI: 10.3390/infrastructures8020023

Surface Preparation of 3D Printed Battery Housing Materials for DIC Measurements

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós

Publication Name: International Conference on Electrical Computer Communications and Mechatronics Engineering Iceccme 2023

Publication Date: 2023-01-01

Volume: Unknown

Issue: Unknown

Page Range: Unknown

Description:

In this study, several 3D-printable PLA (polylactic acid) materials that can also be used to produce battery housings are evaluated. Proper testing is essential to developing better prototypes and final products, and DIC deformation tests are frequently utilized. To be able to evaluate the deformations of various parts and components, the surface of the product under test is randomly speckled. In DIC measurements, however, the deformation is transmitted to the measuring system via the paint, so preparation and paint quality play a crucial role. This research is focused on this underrepresented area in the literature. This article evaluates the DIC applicability of the most commonly used surface cleaning materials and paints.

Open Access: Yes

DOI: 10.1109/ICECCME57830.2023.10252180

Sustainability in Railways – A Review

Szabolcs Fischer Szabolcs Szalai Szabolcs Kocsis Szurke András Brautigam Laszlo Ezsias

Publication Name: Chemical Engineering Transactions

Publication Date: 2023-01-01

Volume: 107

Issue: Unknown

Page Range: 7-12

Description:

This paper examines the sustainability of railways. A comprehensive international literature review was conducted on railway vehicles, traction, and railway permanent way. The main goal was to find the factors and parameters that affect railway sustainability the most. CO2 emissions from transportation, mining, raw material production, manufacturing, use, operation and maintenance, and demolition and restoration must be significantly reduced. Naturally, the attention will be on the considerable energy and financial savings. This article's main topics are sustainability, affordable and clean energy, industry, innovation, infrastructure, sustainable cities and communities, responsible consumption and production, climate action, and life on land. Building materials come from quarries and gravel pits, but availability is decreasing. Future pavement construction and maintenance require recycling demolition and industrial waste. Engineers must choose materials and technology that extend track lifetimes to ensure reliability, availability, maintainability, safety, sustainability, and economy in permanent railroad ways. Life-cycle costs can be reduced, e.g., by Building Information Modeling. Electric machinery is preferred for construction equipment, materials, and management. Sustainability, like grassed tracks and recyclable plastics, has improved urban life. Sheet metal forming using recycled materials and sustainability shows how important environmental protection is in car and train design. Electric road and rail propulsion are driven by environmental concerns, while supercapacitors and batteries are studied. In conclusion, by preferring rail for freight and passenger transport, both for private and public transport, energy savings and CO2 emissions can be up to 2-10 times higher than for other modes of transport.

Open Access: Yes

DOI: 10.3303/CET23107002

INNER SHEAR RESISTANCE INCREASING EFFECT OF CONCRETE CANVAS IN BALLASTED RAILWAY TRACKS

Szabolcs Fischer Szabolcs Szalai Mykola Sysyn Jianxing Liu Dániel Harrach B. Eller

Publication Name: Naukovyi Visnyk Natsionalnoho Hirnychoho Universytetu

Publication Date: 2023-01-01

Volume: Unknown

Issue: 2

Page Range: 64-70

Description:

Purpose. To prove that the GCCM (geosynthetic cementitious composite mat) – type Concrete Canvas (CC) – is an adequate supplementary layer on the top of the subgrade. As its drainage function is known, this article tries to prove the reinforcement possibility. This layer is relatively thin; nevertheless, it can behave like the geogrids. It is the main path to finding out the opportunity of the interlocking effect and its impact on the railway ballast’s inner shear resistance. Methodology. The laboratory measurements were performed in a multilevel shear box, which allows simulating the multilevel shift of the ballast layer. The tests were planned with and without the CC layer. After shearing, the samples were also tested for loadbearing capacity (E2; according to the Hungarian Standard) and particle breakage. On the other hand, the contact surface between the lowest part of the ballast and CC was also measured by a sophisticated 3D laser scanner (GOM ATOS) and graphically by AutoCAD software. Findings. After the results of the laboratory experiments are analyzed, the following parameters are calculated and determined: 1) the reinforcement ratio as the tangent of the inner shear resistance curves in the 5–15 mm horizontal shearing interval as well as the area under graphs by integration in the 0–40 mm interval; 2) the change in loadbearing capacity of the layerstructure with and without CC; 3) the amount of the cement particles; 4) the amount of the broken particles; 5) contact surface between the lowest layer of ballast and CC; 6) flatness of CC sheets after shearing. Based on the results, the Concrete Canvas provides significant reinforcement to the railway ballast. Originality. Any other type of measurement with Concrete Canvas in a multilevel shear box is unknown. The topic is unique. Practical value. In the future, these results may provide baseline data to verify the suitability of the Concrete Canvas in the railway sub or superstructure for various types of transport.

Open Access: Yes

DOI: 10.33271/nvngu/2023-2/064

Investigation of deformations of a lithium polymer cell using the Digital Image Correlation Method (DICM)

Szabolcs Fischer Szabolcs Szalai Dóra Harangozó Szabolcs Kocsis Szurke

Publication Name: Reports in Mechanical Engineering

Publication Date: 2022-01-01

Volume: 3

Issue: 1

Page Range: 116-134

Description:

This research aims to investigate the adaptability of a measurement system or a process in determining the parameters of batteries. Methods are suggested for different applications, and properties gained by these measurements are specified. Deformations of lithium polymer batteries measured by various methodologies are also analyzed in detail. Changes in the geometry of worn-out batteries and the localization of the changes can be better understood by applying the results. The GOM ATOS and the GOM ARAMIS systems were applied to characterize lithium polymer batteries. Discontinuous tests were performed and the battery was discharged to 0 V and then fully charged for both methods. The advantages and disadvantages and the applicability of the two measurement systems were analyzed in this topic.

Open Access: Yes

DOI: 10.31181/rme20008022022s

Determination of critical deformation regions of a lithium polymer battery by dic measurement and wowa filter

Adrienn Dineva István Lakatos Szabolcs Szalai Szabolcs Kocsis Szurke

Publication Name: Acta Polytechnica Hungarica

Publication Date: 2022-01-01

Volume: 19

Issue: 2

Page Range: 113-134

Description:

This paper considers the determination method of deformation location of lithium polymer batteries. Measurements are performed using the Digital Image Correlation (DIC) technique and the obtained results are sorted into a database as a function of the charge level. A statistically based algorithm is used to eliminate measurement errors and outliers. This paper adopts the Weighted Ordered Weighted Averaging (WOWA) operator-based 2D filtering method with the purpose of determining the critical regions of the cell. During the tests, several lithium polymer batteries of the same type but in different states are compared. Measurements on completely new and also on worn-out batteries are performed. The results support that the regions where greater deformation is expected during charging and discharging can be predicted. Results of investigations validate that the proposed approach is suitable for determining the critical deformation regions with high accuracy.

Open Access: Yes

DOI: DOI not available

Investigation of deformations of ballasted railway track during collapse using the Digital Image Correlation Method (DICM)

Szabolcs Fischer Szabolcs Szalai Attila Németh Erika Juhasz M. Movahedi Rad Dániel Harrach B. Eller Gusztáv Baranyai

Publication Name: Reports in Mechanical Engineering

Publication Date: 2022-01-01

Volume: 3

Issue: 1

Page Range: 168-191

Description:

This paper summarizes the results of laboratory tests in which the authors investigated the effects of extremely high vertical load to a railway track segment. The segment consisted of a cut concrete sleeper (contact area: 290×390 mm) with a pair of direct-elastic rail fasteners; the sleeper pieces had a standard, full height; the structure had a typical 350 mm depth railway ballast, underneath approx. 200 mm sandy gravel supplementary layer. The whole assembly was built in a 2.00×2.20 m area wooden rack. The deformations due to the approx. 150 kN static concentrated vertical force were measured and recorded by Digital Image Correlation Method (DICM), ensuring the GOM ATOS technology. The 150 kN peak load meant 1326 kPa vertical stress at the sleeper-ballast interface. The 3D geometry was scanned before the loading and after the collapse. In this way, the comparison was able to be executed. The maximum vertical deformation was 115 mm. The DICM technique is a relatively new methodology in civil engineering; however, it has been applied for more than ten years in mechanical engineering. Therefore, the authors investigated the applicability of DICM in this field. As a result, the pre and the post-states were determined in 3D. The displacement of the ballast particles was able to be defined with the possibility of drawing the displacement trajectories of given points. The DICM can be a valuable methodology in railway engineering, e.g., laboratory tests and field test applications.

Open Access: Yes

DOI: 10.31181/rme20016032022s

Speckle pattern optimization for DIC technologies

Szabolcs Szalai G. Dogossy

Publication Name: Acta Technica Jaurinensis

Publication Date: 2021-01-01

Volume: 14

Issue: 3

Page Range: 228-243

Description:

This paper contains the relation between speckle pattern and Digital Image Correlation (DIC). The most important advance in experimental mechanics has been DIC since the strain gage. The deformation (strain) of an object can be visualized by DIC. Among all scientific fields, the DIC Technologies have seen a dynamic increase. The relationship between the paint and the sample-as the patterns mediate the deformation to the cameras-has been the most important technological issue. In this article the method developed for the detection of isolated particles in alloys is used to characterize the spots, which help the best speckle pattern has determined.

Open Access: Yes

DOI: 10.14513/actatechjaur.00573

Characterisation of Inhomogeneous Plastic Deformation of AlMg Sheet Metals during Tensile Tests

Szabolcs Szalai Dóra Harangozó I. Czinege

Publication Name: Iop Conference Series Materials Science and Engineering

Publication Date: 2020-08-25

Volume: 903

Issue: 1

Page Range: Unknown

Description:

The Portrevin-Le-Chatelier (PLC) effect was analysed quantitatively in the selected AlMg alloys with Mg-content between 2,8-4,6%. The propagation and characteristics of PLC bands were detected by digital image correlation (DIC) technique and the parameters of the bands were evaluated from strain distributions of tensile test specimens. In parallel, stress-strain curves were analysed evaluating stress serrations. The numerically defined parameters of changes in stress and strain were used for characterising the PLC effect on the behaviour of different sheet metals. General statements of literature were numerically proven for the tested materials and the effect of magnesium content on stress amplitude was analysed in detail.

Open Access: Yes

DOI: 10.1088/1757-899X/903/1/012023

Battery deformation measurement with DIC technique

István Lakatos Szabolcs Szalai Szabolcs Kocsis Szurke

Publication Name: 2020 21st International Symposium on Electrical Apparatus and Technologies Siela 2020 Proceedings

Publication Date: 2020-06-01

Volume: Unknown

Issue: Unknown

Page Range: Unknown

Description:

In this paper the deformation of lithium polymer batteries during charging and discharging is measured using a GOM Atos system. The aim of the study is to evaluate the deformation of the cell surface. During the tests, the battery cell is re-digitized after 10% energy input and output. Trend results are recorded and analysed for deformation as a function of charge level. We also determine open circuit voltage and average deformation point relationship. Our study supports that there is a correlation between the deformation data and the charge level.

Open Access: Yes

DOI: 10.1109/SIELA49118.2020.9167109

Digital image analysis of sheet metal testing and forming

Szabolcs Szalai I. Czinege

Publication Name: 15th Imeko Tc10 Workshop on Technical Diagnostics 2017 Technical Diagnostics in Cyber Physical Era

Publication Date: 2017-01-01

Volume: Unknown

Issue: Unknown

Page Range: 176-180

Description:

Digital image analysing methods are widely used for evaluating local deformations in sheet metal tests and forming processes. The paper is focusing on tensile tests of uniform and non-uniform width flat specimens made of aluminum alloys, which are suitable for demonstrating Löders strain, Portevin-Le Chatelier (PLC) effect and for determination of Forming Limit Curve. Tests were carried out using GOM-ARAMIS® digital image analysis hardware and software. Observation of local deformations during tensile tests showed that initiation and evolution of local strains depend on the position of specimens related to rolling direction of sheet. Using non-uniform width specimens the local deformations are concentrated on the smallest cross-section in the final stage of tensile test. The measured major and minor strains give points of FLC.

Open Access: Yes

DOI: DOI not available

Testing Sustainable 3D-Printed Battery Housings with DIC Technology †

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós Vivien Nemes

Publication Name: Engineering Proceedings

Publication Date: 2024-01-01

Volume: 79

Issue: 1

Page Range: Unknown

Description:

Three-dimensional printing has rapidly gained traction in the automotive industry, offering significant benefits in terms of design flexibility, production speed, and cost efficiency. However, as the use of 3D printing grows, there is a rising focus on incorporating sustainable materials to minimize the environmental footprint of automotive components. This study centers on using eco-friendly, 3D-printable materials to produce electric vehicle battery covers. The primary goal is to assess these sustainable battery housings’ mechanical properties, durability, and overall feasibility. Additionally, the research explores the potential of foaming polylactic acid filaments in measurement applications using Digital Image Correlation technology, which is widely employed in the automotive sector. The study also evaluates these housings’ manufacturability and real-world applicability, offering insights into their role in the future of automotive production, where sustainability is becoming increasingly important. The research seeks to contribute to the broader movement toward greener manufacturing processes within the automotive industry by conducting these analyses.

Open Access: Yes

DOI: 10.3390/engproc2024079069

Deformation Test of 3D Printed Battery Case Using DIC Technology

Szabolcs Fischer Szabolcs Szalai Brigitta Fruzsina Szívós

Publication Name: International Conference on Electrical Computer Communications and Mechatronics Engineering Iceccme 2023

Publication Date: 2023-01-01

Volume: Unknown

Issue: Unknown

Page Range: Unknown

Description:

The study demonstrates the evaluation of various 3D-printed 18650 battery housings. The GOM Aramis measurement system performs real-time deformation analysis of the housings during testing. Using Fused Deposition Modelling (FDM) technology and various polylactic acid (PLA) materials, battery housings are 3D printed using Fused Deposition Modelling (FDM). Additionally, different layout designs will be investigated. The research's primary objective is to evaluate the suitability of the measuring system and the printing technology. In addition, the paper describes the raw materials used, preparation techniques, measuring system, and measurement outcomes.

Open Access: Yes

DOI: 10.1109/ICECCME57830.2023.10253004