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25 pages, 3387 KiB  
Article
Efficiency of Spirulina sp. in the Treatment of Model Wastewater Containing Ni(II) and Pb(II)
by Eleonora Sočo, Andżelika Domoń, Mostafa Azizi, Dariusz Pająk, Bogumił Cieniek, Magdalena M. Michel and Dorota Papciak
Materials 2025, 18(15), 3639; https://doi.org/10.3390/ma18153639 (registering DOI) - 1 Aug 2025
Abstract
In this work, the biosorption potential of Spirulina sp. as an effective and eco-friendly biosorbent for the removal of Ni(II) and Pb(II) ions from aqueous solutions was investigated. Detailed characterization of the biosorbent was carried out, including surface morphology, chemical composition, particle size, [...] Read more.
In this work, the biosorption potential of Spirulina sp. as an effective and eco-friendly biosorbent for the removal of Ni(II) and Pb(II) ions from aqueous solutions was investigated. Detailed characterization of the biosorbent was carried out, including surface morphology, chemical composition, particle size, zeta potential, crystallinity, zero-point charge, and functional group analysis. Batch tests were performed to determine the kinetic constants and adsorption equilibrium of the studied ions. The adsorption behavior of Spirulina sp. was described using six adsorption isotherms. The best fit was obtained for the Redlich-Peterson and Langmuir isotherms, indicating that monolayer adsorption occurred. The maximum biosorption capacities for Ni(II) and Pb(II) were 20.8 mg·g−1 and 93.5 mg·g−1, respectively, using a biosorbent dose of 10 g·L−1, initial metal concentrations ranging from 50 to 5000 mg·L−1, at pH 6, 20 °C, and a contact time of 120 min. Low values of the mean free energy of adsorption (E) in the Dubinin–Radushkevich and Temkin model (0.3 and 0.1 kJ·mol−1 for Pb(II) and 0.35 and 0.23 kJ·mol−1 for Ni(II)) indicate the dominance of physical processes in the ion binding mechanism. The adsorption of Pb(II) ions was more effective than that of Ni(II) ions across the entire range of tested concentrations. At low initial concentrations, the removal of Pb(II) reached 94%, while for Ni(II) it was 80%. Full article
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21 pages, 20135 KiB  
Article
Strain-Rate Effects on the Mechanical Behavior of Basalt-Fiber-Reinforced Polymer Composites: Experimental Investigation and Numerical Validation
by Yuezhao Pang, Chuanlong Wang, Yue Zhao, Houqi Yao and Xianzheng Wang
Materials 2025, 18(15), 3637; https://doi.org/10.3390/ma18153637 (registering DOI) - 1 Aug 2025
Abstract
Basalt-fiber-reinforced polymer (BFRP) composites, utilizing a natural high-performance inorganic fiber, exhibit excellent weathering resistance, including tolerance to high and low temperatures, salt fog, and acid/alkali corrosion. They also possess superior mechanical properties such as high strength and modulus, making them widely applicable in [...] Read more.
Basalt-fiber-reinforced polymer (BFRP) composites, utilizing a natural high-performance inorganic fiber, exhibit excellent weathering resistance, including tolerance to high and low temperatures, salt fog, and acid/alkali corrosion. They also possess superior mechanical properties such as high strength and modulus, making them widely applicable in aerospace and shipbuilding. This study experimentally investigated the mechanical properties of BFRP plates under various strain rates (10−4 s−1 to 103 s−1) and directions using an electronic universal testing machine and a split Hopkinson pressure bar (SHPB).The results demonstrate significant strain rate dependency and pronounced anisotropy. Based on experimental data, relationships linking the strength of BFRP composites in different directions to strain rate were established. These relationships effectively predict mechanical properties within the tested strain rate range, providing reliable data for numerical simulations and valuable support for structural design and engineering applications. The developed strain rate relationships were successfully validated through finite element simulations of low-velocity impact. Full article
(This article belongs to the Special Issue Mechanical Properties of Advanced Metamaterials)
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14 pages, 25742 KiB  
Article
Development and Simulation-Based Validation of Biodegradable 3D-Printed Cog Threads for Pelvic Organ Prolapse Repair
by Ana Telma Silva, Nuno Miguel Ferreira, Henrique Leon Bastos, Maria Francisca Vaz, Joana Pinheiro Martins, Fábio Pinheiro, António Augusto Fernandes and Elisabete Silva
Materials 2025, 18(15), 3638; https://doi.org/10.3390/ma18153638 (registering DOI) - 1 Aug 2025
Abstract
Pelvic organ prolapse (POP) is a prevalent condition, affecting women all over the world, and is commonly treated through surgical interventions that present limitations such as recurrence or complications associated with synthetic meshes. In this study, biodegradable poly(ϵ-caprolactone) (PCL) cog threads [...] Read more.
Pelvic organ prolapse (POP) is a prevalent condition, affecting women all over the world, and is commonly treated through surgical interventions that present limitations such as recurrence or complications associated with synthetic meshes. In this study, biodegradable poly(ϵ-caprolactone) (PCL) cog threads are proposed as a minimally invasive alternative for vaginal wall reinforcement. A custom cutting tool was developed to fabricate threads with varying barb angles (90°, 75°, 60°, and 45°), which were produced via Melt Electrowriting. Their mechanical behavior was assessed through uniaxial tensile tests and validated using finite element simulations. The results showed that barb orientation had minimal influence on tensile performance. In simulations of anterior vaginal wall deformation under cough pressure, all cog thread configurations significantly reduced displacement in the damaged tissue model, achieving values comparable to or even lower than those of healthy tissue. A ball burst simulation using an anatomically accurate model further demonstrated a 13% increase in reaction force with cog thread reinforcement. Despite fabrication limitations, this study supports the biomechanical potential of 3D-printed PCL cog threads for POP treatment, and lays the groundwork for future in vivo validation. Full article
25 pages, 8312 KiB  
Article
Quantitative Assessment of Woven Fabric Surface Changes During Martindale Abrasion Using Contactless Optical Profilometry
by Małgorzata Matusiak and Gabriela Kosiuk
Materials 2025, 18(15), 3636; https://doi.org/10.3390/ma18153636 (registering DOI) - 1 Aug 2025
Abstract
The abrasion resistance of fabrics is one of the basic properties determining the utility performance and durability. The abrasion resistance of textile materials is measured using the Martindale device according to appropriate standards. The sample breakage method is the most commonly used of [...] Read more.
The abrasion resistance of fabrics is one of the basic properties determining the utility performance and durability. The abrasion resistance of textile materials is measured using the Martindale device according to appropriate standards. The sample breakage method is the most commonly used of the three methods. The method is based on organoleptic assessment of fabric breakage. The method is time-consuming, and results may be subject to error resulting from the subjective nature of the assessment. The aim of the presented work was to check the possibility of the application of contactless 3D surface geometry measurement using an optical profilometer in an assessment of changes in fabrics’ surface due to the abrasion process. The obtained results confirmed that some parameters of the geometric structure of fabric surfaces, such as the highest height of the roughness profile Rz, the height of the highest pick of the roughness profile Rp, the depth of the lowest valley of the roughness profile Rv, the depth of the total height of the roughness profile Rt, and the kurtosis Rku, can be used to assess the abrasion resistance of fabrics. It is also stated that using the non-contact optical measurement of fabric surface geometry allows for an assessment of the directionality of surface texture. For this purpose, the autocorrelation function and angle distribution function can be applied. Full article
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11 pages, 3000 KiB  
Article
Comparative Study of the Bulk and Foil Zinc Anodic Behavior Kinetics in Oxalic Acid Aqueous Solutions
by Vanya Lilova, Emil Lilov, Stephan Kozhukharov, Georgi Avdeev and Christian Girginov
Materials 2025, 18(15), 3635; https://doi.org/10.3390/ma18153635 (registering DOI) - 1 Aug 2025
Abstract
The anodic behavior of zinc electrodes is important for energy storage, corrosion protection, electrochemical processing, and other practical applications. This study investigates the anodic galvanostatic polarization of zinc foil and bulk electrodes in aqueous oxalic acid solutions, revealing significant differences in their electrochemical [...] Read more.
The anodic behavior of zinc electrodes is important for energy storage, corrosion protection, electrochemical processing, and other practical applications. This study investigates the anodic galvanostatic polarization of zinc foil and bulk electrodes in aqueous oxalic acid solutions, revealing significant differences in their electrochemical behavior, particularly in induction period durations. The induction period’s duration depended on electrolyte concentration, current density, and temperature. Notably, the temperature dependence of the kinetics exhibited contrasting trends: the induction period for foil electrodes increased with temperature, while that of bulk electrodes decreased. Chemical analysis and polishing treatment comparisons showed no significant differences between the foil and bulk electrodes. However, Scanning Electron Microscopy (SEM) observations of samples anodized at different temperatures, combined with Inductively Coupled Plasma–Optical Emission Spectroscopy (ICP-OES) analysis of dissolved electrode material, provided insights into the distinct anodic behaviors. X-ray Diffraction (XRD) studies further confirmed these findings, revealing a crystallographic orientation dependence of the anodic behavior. These results provide detailed information about the electrochemical properties of zinc electrodes, with implications for optimizing their performance in various applications. Full article
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13 pages, 2583 KiB  
Article
Hierarchical Flaky Spinel Structure with Al and Mn Co-Doping Towards Preferable Oxygen Evolution Performance
by Hengfen Shen, Hao Du, Peng Li and Mei Wang
Materials 2025, 18(15), 3633; https://doi.org/10.3390/ma18153633 (registering DOI) - 1 Aug 2025
Abstract
As an efficient clean energy technology, water electrolysis for hydrogen production has its efficiency limited by the sluggish oxygen evolution reaction (OER) kinetics, which drives the demand for the development of high-performance anode OER catalysts. This work constructs bimetallic (Al, Mn) co-doped nanoporous [...] Read more.
As an efficient clean energy technology, water electrolysis for hydrogen production has its efficiency limited by the sluggish oxygen evolution reaction (OER) kinetics, which drives the demand for the development of high-performance anode OER catalysts. This work constructs bimetallic (Al, Mn) co-doped nanoporous spinel CoFe2O4 (np-CFO) with a tunable structure and composition as an OER catalyst through a simple two-step dealloying strategy. The as-formed np-CFO (Al and Mn) features a hierarchical flaky configuration; that is, there are a large number of fine nanosheets attached to the surface of a regular micron-sized flake, which not only increases the number of active sites but also enhances mass transport efficiency. Consequently, the optimized catalyst exhibits a low OER overpotential of only 320 mV at a current density of 10 mA cm−2, a minimal Tafel slope of 45.09 mV dec−1, and exceptional durability. Even under industrial conditions (6 M KOH, 60 °C), it only needs 1.83 V to achieve a current density of 500 mA cm−2 and can maintain good stability for approximately 100 h at this high current density. Theoretical simulations indicate that Al and Mn co-doping could indeed optimize the electronic structure of CFO and thus decrease the energy barrier of OER to 1.35 eV. This work offers a practical approach towards synthesizing efficient and stable OER catalysts. Full article
(This article belongs to the Special Issue High-Performance Materials for Energy Conversion)
17 pages, 2410 KiB  
Article
Microstructural Characterisation of Bi-Ag-Ti Solder Alloy and Evaluation of Wettability on Ceramic and Composite Substrates Joined via Indirect Electron Beam Heating in Vacuum
by Mikulas Sloboda, Roman Kolenak, Tomas Melus, Peter Gogola, Matej Pasak, Daniel Drimal and Jaromir Drapala
Materials 2025, 18(15), 3634; https://doi.org/10.3390/ma18153634 (registering DOI) - 1 Aug 2025
Abstract
This paper examines the wettability and interactions between ceramic and composite materials soldered with Bi-based solder containing 11 wt.% of silver and 3 wt.% titanium using indirect electron beam soldering technology. The Bi11Ag3Ti solder, with a melting point of 402 °C, consisted of [...] Read more.
This paper examines the wettability and interactions between ceramic and composite materials soldered with Bi-based solder containing 11 wt.% of silver and 3 wt.% titanium using indirect electron beam soldering technology. The Bi11Ag3Ti solder, with a melting point of 402 °C, consisted of a bismuth matrix containing silver lamellae. Titanium, acting as an active element, positively influenced the interaction between the solder and the joined materials. SiC and Ni-SiC substrates were soldered at temperatures of 750 °C, 850 °C, and 950 °C. Measurements of wettability angles indicated that the lowest value (20°) was achieved with SiC substrates at 950 °C. A temperature of 750 °C appeared to be the least suitable for both substrates and was entirely unsuitable for Ni-SiC. It was also observed that the Bi11Ag3Ti solder wetted the SiC substrates more effectively than Ni-SiC substrates. The optimal working temperature for this solder was determined to be 950 °C. The shear strength of the joints soldered with the Bi11Ag3Ti alloy was 23.5 MPa for the Al2O3/Ni-SiC joint and 9 MPa for the SiC/Ni-SiC joint. Full article
(This article belongs to the Special Issue Advanced Materials and Processing Technologies)
16 pages, 3043 KiB  
Article
Experimental Investigations on Sustainable Dual-Biomass-Based Composite Phase Change Materials for Energy-Efficient Building Applications
by Zhiwei Sun, Wei Wen, Jiayu Wu, Jingjing Shao, Wei Cai, Xiaodong Wen, Chaoen Li, Haijin Guo, Yin Tang, Meng Wang, Dongjing Liu and Yang He
Materials 2025, 18(15), 3632; https://doi.org/10.3390/ma18153632 (registering DOI) - 1 Aug 2025
Abstract
The incorporation of phase change material (PCM) can enhance wall thermal performance and indoor thermal comfort, but practical applications still face challenges related to high costs and potential leakage issues. In this study, a novel dual-biomass-based shape-stabilized PCM (Bio-SSPCM) was proposed, wherein waste [...] Read more.
The incorporation of phase change material (PCM) can enhance wall thermal performance and indoor thermal comfort, but practical applications still face challenges related to high costs and potential leakage issues. In this study, a novel dual-biomass-based shape-stabilized PCM (Bio-SSPCM) was proposed, wherein waste cooking fat and waste reed straw were, respectively, incorporated as the PCM substance and supporting material. The waste fat (lard) consisted of both saturated and unsaturated fatty acid glycerides, exhibiting a melting point about 21.2–41.1 °C and a melting enthalpy value of 40 J/g. Reed straw was carbonized to form a sustainable porous biochar supporting matrix, which was used for the vacuum adsorption of waste fat. The results demonstrate that the as-prepared dual-Bio-SSPCM exhibited excellent thermal performance, characterized by a latent heat capacity of 25.4 J/g. With the addition of 4 wt% of expanded graphite (EG), the thermal conductivity of the composite PCM reached 1.132 W/(m·K), which was 5.4 times higher than that of the primary lard. The thermal properties of the Bio-SSPCM were characterized using an analog T-history method. The results demonstrated that the dual-Bio-SSPCM exhibited exceptional and rapid heat storage and exothermic capabilities. The dual-Bio-SSPCM, prepared from waste cooking fat and reed straw, can be considered as environmentally friendly construction material for energy storage in line with the principles of the circular economy. Full article
(This article belongs to the Special Issue Eco-Friendly Intelligent Infrastructures Materials)
14 pages, 2428 KiB  
Article
Fracture Behavior of Steel-Fiber-Reinforced High-Strength Self-Compacting Concrete: A Digital Image Correlation Analysis
by Maoliang Zhang, Junpeng Chen, Junxia Liu, Huiling Yin, Yan Ma and Fei Yang
Materials 2025, 18(15), 3631; https://doi.org/10.3390/ma18153631 (registering DOI) - 1 Aug 2025
Abstract
In this study, steel fibers were used to improve the mechanical properties of high-strength self-compacting concrete (HSSCC), and its effect on the fracture mechanical properties was investigated by a three-point bending test with notched beams. Coupled with the digital image correlation (DIC) technique, [...] Read more.
In this study, steel fibers were used to improve the mechanical properties of high-strength self-compacting concrete (HSSCC), and its effect on the fracture mechanical properties was investigated by a three-point bending test with notched beams. Coupled with the digital image correlation (DIC) technique, the fracture process of steel-fiber-reinforced HSSCC was analyzed to elucidate the reinforcing and fracture-resisting mechanisms of steel fibers. The results indicate that the compressive strength and flexural strength of HSSCC cured for 28 days exhibited an initial decrease and then an enhancement as the volume fraction (Vf) of steel fibers increased, whereas the flexural-to-compressive ratio linearly increased. All of them reached their maximum of 110.5 MPa, 11.8 MPa, and 1/9 at 1.2 vol% steel fibers, respectively. Steel fibers significantly improved the peak load (FP), peak opening displacement (CMODP), fracture toughness (KIC), and fracture energy (GF) of HSSCC. Compared with HSSCC without steel fibers (HSSCC-0), the FP, KIC, CMODP, and GF of HSSCC with 1.2 vol% (HSSCC-1.2) increased by 23.5%, 45.4%, 11.1 times, and 20.1 times, respectively. The horizontal displacement and horizontal strain of steel-fiber-reinforced HSSCC both increased significantly with an increasing Vf. HSSCC-0 experienced unstable fracture without the occurrence of a fracture process zone during the whole fracture damage, whereas the fracture process zone formed at the notched beam tip of HSSCC-1.2 at its initial loading stage and further extended upward in the beams of high-strength self-compacting concrete with a 0.6% volume fraction of steel fibers and HSSCC-1.2 as the load approaches and reaches the peak. Full article
16 pages, 1496 KiB  
Article
Evaluation of Cutting Forces and Roughness During Machining of Spherical Surfaces with Barrel Cutters
by Martin Reznicek, Cyril Horava and Martin Ovsik
Materials 2025, 18(15), 3630; https://doi.org/10.3390/ma18153630 (registering DOI) - 1 Aug 2025
Abstract
Barrel tools are increasingly used in high-precision machining of free-form surfaces. However, limited studies evaluate their performance specifically on spherical geometries, where tool–surface contact characteristics differ significantly. Understanding how tool geometry and process parameters influence surface quality and cutting forces in such cases [...] Read more.
Barrel tools are increasingly used in high-precision machining of free-form surfaces. However, limited studies evaluate their performance specifically on spherical geometries, where tool–surface contact characteristics differ significantly. Understanding how tool geometry and process parameters influence surface quality and cutting forces in such cases remains underexplored. This study evaluates how barrel cutter radius and varying machining parameters affect cutting forces and surface roughness when milling internal and external spherical surfaces. Machining tests were conducted on structural steel 1.1191 using two barrel cutters with different curvature radii (85 mm and 250 mm) on a 5-axis CNC machine. Feed per tooth and radial depth of cut were systematically varied. Cutting forces were measured using a dynamometer, and surface roughness was assessed using the Rz parameter, which is more sensitive to peak deviations than Ra. Novelty lies in isolating spherical surface shapes (internal vs. external) under identical path trajectories and systematically correlating tool geometry to force and surface metrics. The larger curvature tool (250 mm) consistently generated up to twice the cutting force of the smaller radius tool under equivalent conditions. External surfaces showed higher Rz values than internal ones due to less favorable contact geometry. Radial depth of the cut had a linear influence on force magnitude, while feed rate had a limited effect except at higher depths. Smaller-radius barrel tools and internal geometries are preferable for minimizing cutting forces and achieving better surface quality when machining spherical components. The aim of this paper is to determine the actual force load and surface quality when using specific cutting conditions for internal and external spherical machined surfaces. Full article
(This article belongs to the Special Issue Recent Advances in Precision Manufacturing Technology)
21 pages, 3744 KiB  
Article
A First-Principles Modeling of the Elastic Properties and Generalized Stacking Fault Energy of Ir-W Solid Solution Alloys
by Pengwei Shi, Jianbo Ma, Fenggang Bian and Guolu Li
Materials 2025, 18(15), 3629; https://doi.org/10.3390/ma18153629 (registering DOI) - 1 Aug 2025
Abstract
Iridium, with its excellent high-temperature chemical inertness, is a preferred cladding material for radioisotope batteries. However, its inherent room-temperature brittleness severely restricts its application. In this research, pure Ir and six Ir-W solid solutions (Ir31W1 to Ir26W6 [...] Read more.
Iridium, with its excellent high-temperature chemical inertness, is a preferred cladding material for radioisotope batteries. However, its inherent room-temperature brittleness severely restricts its application. In this research, pure Ir and six Ir-W solid solutions (Ir31W1 to Ir26W6) were modeled. The effects of W on the elastic properties, generalized stacking fault energy, and bonding properties of Ir solid solution alloys were investigated by first-principles simulation, aiming to find a way to overcome the intrinsic brittleness of Ir. With the W concentration increasing from 0 to 18.75 at %, the calculated Cauchy pressure (C12C44) increases from −22 to 5 GPa, Pugh’s ratio (B/G) increases from 1.60 to 1.72, the intrinsic stacking fault energy reduces from 337.80 to 21.16 mJ/m2, and the unstable stacking fault energy reduces from 636.90 to 547.39 mJ/m2. According to these results, it is predicted that the addition of W improves the toughness of iridium alloys. The alloying of W weakens the covalency properties of the Ir-Ir bond (the ICOHP value increases from −0.8512 to −0.7923 eV). These phenomena result in a decrease in the energy barrier for grain slip. Full article
(This article belongs to the Section Metals and Alloys)
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20 pages, 4427 KiB  
Article
Mechanistic Insights into m-Cresol Adsorption on Functional Resins: Surface Chemistry and Adsorption Behavior
by Yali Wang, Zhenrui Wang, Zile Liu, Xiyue He and Zequan Zeng
Materials 2025, 18(15), 3628; https://doi.org/10.3390/ma18153628 (registering DOI) - 1 Aug 2025
Abstract
The removal of high-concentration m-cresol from industrial wastewater remains a significant challenge due to its toxicity and persistence. In this study, a commercially available functionalized resin with a high BET surface area (1439 m2 g−1) and hierarchical pore structure was [...] Read more.
The removal of high-concentration m-cresol from industrial wastewater remains a significant challenge due to its toxicity and persistence. In this study, a commercially available functionalized resin with a high BET surface area (1439 m2 g−1) and hierarchical pore structure was employed for the adsorption of pure m-cresol at an initial concentration of 20 g L−1, representative of coal-based industrial effluents. Comprehensive characterization confirmed the presence of oxygen-rich functional groups, amorphous polymeric structure, and uniform surface morphology conducive to adsorption. Batch experiments were conducted to evaluate the effects of resin dosage, contact time, temperature, and equilibrium concentration. Under optimized conditions (0.15 g resin, 60 °C), a maximum adsorption capacity of 556.3 mg g−1 and removal efficiency of 71% were achieved. Kinetic analysis revealed that the pseudo-second-order model best described the adsorption process (R2 > 0.99). Isotherm data fit the Langmuir model most closely (R2 = 0.9953), yielding a monolayer capacity of 833.3 mg g−1. Thermodynamic analysis showed that adsorption was spontaneous (ΔG° < 0), endothermic (ΔH° = 7.553 kJ mol−1), and accompanied by increased entropy (ΔS° = 29.90 J mol−1 K−1). The good agreement with the PSO model is indicative of chemisorption, as supported by other lines of evidence, including thermodynamic parameters (e.g., positive ΔH° and ΔS°), surface functional group characteristics, and molecular interactions. The adsorption mechanism was elucidated through comprehensive modeling of adsorption kinetics, isotherms, and thermodynamics, combined with detailed physicochemical characterization of the resin prior to adsorption, reinforcing the mechanistic understanding of m-cresol–resin interactions. Full article
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16 pages, 1465 KiB  
Article
Investigation of the Effects of Laser Welding Process Parameters on Weld Forming Quality Based on Orthogonal Experimental Design and Image Processing
by Yuewei Ai, Ning Sun, Shibo Han, Yang Zhang and Chang Lei
Materials 2025, 18(15), 3627; https://doi.org/10.3390/ma18153627 (registering DOI) - 1 Aug 2025
Abstract
Image processing has been widely adopted as an effective technology for analyzing weld forming quality which is greatly affected by the welding process parameters. In this paper, an L25(53) orthogonal experiment is designed to investigate the effects of welding [...] Read more.
Image processing has been widely adopted as an effective technology for analyzing weld forming quality which is greatly affected by the welding process parameters. In this paper, an L25(53) orthogonal experiment is designed to investigate the effects of welding process parameters on the weld forming quality in laser welding of aluminum alloy. The weld characteristics including the weld width (WW), weld penetration (PD), weld area (WA) and weld porosity (WP) under the conditions of the different welding process parameters consisting of the laser power (LP), welding speed (WS) and defocus distance (DD) are extracted from the laser welding experiment based on image processing. The effectiveness of the weld characteristics extraction method is verified by comparing the extracted results with the measured results. It is found that the WW, PD and WA are all significantly influenced by the LP among the three welding process parameters while the influences of the three process parameters on the WP are insignificant. The DD has a significant influence on the PD and the WS has a significant influence on the WA. The corresponding significance of influence is lower than the significance of influence of LP. The analysis results are conducive to the optimization of laser welding process parameters and improvement of welding quality. Full article
(This article belongs to the Special Issue Advanced Computational Methods in Manufacturing Processes)
24 pages, 14731 KiB  
Article
Hybrid Laser Cleaning of Carbon Deposits on N52B30 Engine Piston Crowns: Multi-Objective Optimization via Response Surface Methodology
by Yishun Su, Liang Wang, Zhehe Yao, Qunli Zhang, Zhijun Chen, Jiawei Duan, Tingqing Ye and Jianhua Yao
Materials 2025, 18(15), 3626; https://doi.org/10.3390/ma18153626 (registering DOI) - 1 Aug 2025
Abstract
Carbon deposits on the crown of engine pistons can markedly reduce combustion efficiency and shorten service life. Conventional cleaning techniques often fail to simultaneously ensure a high carbon removal efficiency and maintain optimal surface integrity. To enable efficient and precise carbon removal, this [...] Read more.
Carbon deposits on the crown of engine pistons can markedly reduce combustion efficiency and shorten service life. Conventional cleaning techniques often fail to simultaneously ensure a high carbon removal efficiency and maintain optimal surface integrity. To enable efficient and precise carbon removal, this study proposes the application of hybrid laser cleaning—combining continuous-wave (CW) and pulsed lasers—to piston carbon deposit removal, and employs response surface methodology (RSM) for multi-objective process optimization. Using the N52B30 engine piston as the experimental substrate, this study systematically investigates the combined effects of key process parameters—including CW laser power, pulsed laser power, cleaning speed, and pulse repetition frequency—on surface roughness (Sa) and carbon residue rate (RC). Plackett–Burman design was employed to identify significant factors, the method of the steepest ascent was utilized to approximate the optimal region, and a quadratic regression model was constructed using Box–Behnken response surface methodology. The results reveal that the Y-direction cleaning speed and pulsed laser power exert the most pronounced influence on surface roughness (F-values of 112.58 and 34.85, respectively), whereas CW laser power has the strongest effect on the carbon residue rate (F-value of 57.74). The optimized process parameters are as follows: CW laser power set at 625.8 W, pulsed laser power at 250.08 W, Y-direction cleaning speed of 15.00 mm/s, and pulse repetition frequency of 31.54 kHz. Under these conditions, the surface roughness (Sa) is reduced to 0.947 μm, and the carbon residue rate (RC) is lowered to 3.67%, thereby satisfying the service performance requirements for engine pistons. This study offers technical insights into the precise control of the hybrid laser cleaning process and its practical application in engine maintenance and the remanufacturing of end-of-life components. Full article
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13 pages, 3774 KiB  
Article
Design of TEMPO-Based Polymer Cathode Materials for pH-Neutral Aqueous Organic Redox Flow Batteries
by Yanwen Ren, Qianqian Zheng, Cuicui He, Jingjing Nie and Binyang Du
Materials 2025, 18(15), 3624; https://doi.org/10.3390/ma18153624 (registering DOI) - 1 Aug 2025
Abstract
Aqueous organic redox flow batteries (AORFBs) represent an advancing class of electrochemical energy storage systems showing considerable promise for large-scale grid integration due to their unique aqueous organic chemistry. However, the use of small-molecule active materials in AORFBs is significantly limited by the [...] Read more.
Aqueous organic redox flow batteries (AORFBs) represent an advancing class of electrochemical energy storage systems showing considerable promise for large-scale grid integration due to their unique aqueous organic chemistry. However, the use of small-molecule active materials in AORFBs is significantly limited by the issue of stability and crossover. To address these challenges, we designed a high-water-solubility polymer cathode material, P-T-S, which features a polyvinylimidazole backbone functionalized with 2,2,6,6-tetramethylpiperidine-1-oxyl (TEMPO) and sulfonate groups. P-T-S exhibits a solubility of 34 Ah L−1 in water and 31 Ah L−1 in 1.0 M NaCl aqueous solution (NaClaq). When paired with methyl viologen to assemble a pH-neutral AORFB with a theoretical capacity of 15 Ah L−1, the system exhibits a material utilization rate of 92.0%, an average capacity retention rate of 99.74% per cycle (99.74% per hour), and an average Coulombic efficiency of 98.69% over 300 consecutive cycles at 30 mA cm−2. This work provides a new design strategy for polymer materials for high-performance AORFBs. Full article
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