Search Results (612)

In the present work, the optimization of ceramic-based composite WC(Co,Ni) welds by laser cladding was carried out using response surface methodology based on finite element analysis. The heat distribution and temperature field of laser-melted WC(Co,Ni) ceramic coatings were simulated using ANSYS software, which allowed the computation of the distribution of residual stresses. The results show that the isotherms in the simulation of the temperature field are elliptical in shape, and that the isotherms in front of the moving heat source are dense with a larger temperature gradient, while the isotherms behind the heat source are sparse with a smaller temperature gradient. In addition, the observed microstructural evolution shows that the melting zone domains of WC(Co,Ni) are mainly composed of unmelted carbides. These carbides are dendritic, rod-like, leaf-like, or net-like, and are agglomerated into smaller groups. The W content of these unmelted carbides exceeds 80%, while the C content is around 1.5–3.0%. The grey areas are composed of WC, Co and Ni compounds. Based on the regression model, a quadratic model was successfully constructed. A three-dimensional profile model of the residual stress behaviour was further explored. The estimated values of the RSM-based FEA model for residual stress are very similar to the actual results, which shows that the model is effective in reducing residual stress by laser cladding. Full article

Hydrogen energy is a pivotal carrier for achieving carbon neutrality, requiring green and efficient production via water electrolysis. However, the anodic oxygen evolution reaction (OER) involves a sluggish four-electron transfer process, resulting in high overpotentials, while the prohibitive cost and complex preparation of precious metal catalysts impede large-scale commercialization. In this study, we develop a FeCo-based bimetallic deep eutectic solvent (FeCo-DES) as a multifunctional reaction medium for engineering a three-dimensional (3D) coral-like FeOOH-Co₂(OH)₃Cl/NF composite via a mild one-step impregnation approach (70 °C, ambient pressure). The FeCo-DES simultaneously serves as the solvent, metal source, and redox agent, driving the controlled in situ assembly of FeOOH-Co₂(OH)₃Cl hybrids on Ni(OH)₂/NiOOH-coated nickel foam (NF). This hierarchical architecture induces synergistic enhancement through geometric structural effects combined with multi-component electronic interactions. Consequently, the FeOOH-Co₂(OH)₃Cl/NF catalyst achieves a remarkably low overpotential of 197 mV at 100 mA cm⁻² and a Tafel slope of 65.9 mV dec⁻¹, along with 98% current retention over 24 h chronopotentiometry. This study pioneers a DES-mediated strategy for designing robust composite catalysts, establishing a scalable blueprint for high-performance and low-cost OER systems. Full article

In recent years, interest in HEAs has increased exponentially due to their extraordinary properties, especially for wear- and corrosion-resistant applications. However, the main problem involves correctly selecting the HEA composition required for a specific application, as most of the data are scattered throughout the literature, and only a limited number of models accurately predict the properties. Therefore, a database of 415 HEA alloys (bulk) and coatings obtained using thermal spray (TS) techniques has been created, compiled from scientific studies over the past 20 years. This tool collects information on physical, mechanical, and chemical properties, with a particular emphasis on corrosion and wear resistance. This facilitates material comparison and selection according to the needs of a specific application. In particular, the database highlights how composition and deposition technique also affect performance, identifying CoCrFeNi (CGS and in bulk) as a promising candidate for simultaneous wear and corrosion resistance. Full article

The electrocatalytic CO₂ reduction reaction (CO₂RR) offers an energy-saving and environmentally friendly approach to producing hydrocarbon fuels. The use of a gas diffusion electrode (GDE) flow cell has generally improved the rate of CO₂RR, while the gas diffusion layer (GDL) remains a significant challenge. In this study, we successfully engineered a novel metal–organic framework (MOF) heterojunction through the controlled coating of zeolitic imidazolate framework (ZIF-L) on ultrathin nickel—metal–organic framework (Ni-MOF) nanosheets. This innovative architecture simultaneously integrates GDL functionality and exposes abundant solid–liquid–gas triple-phase boundaries. The resulting Ni-MOF@ZIF-L heterostructure demonstrates exceptional performance, achieving a formate Faradaic efficiency of 92.4% while suppressing the hydrogen evolution reaction (HER) to 6.7%. Through computational modeling of the optimized heterojunction configuration, we further elucidated its competitive adsorption behavior and electronic modulation effects. The experimental and theoretical results demonstrate an improvement in electrochemical CO₂ reduction activity with suppressed hydrogen evolution for the heterojunction because of its hydrophobic interface, good electron transfer capability, and high CO₂ adsorption at the catalyst interface. This work provides a new insight into the rational design of porous crystalline materials in electrocatalytic CO₂RR. Full article

Reducing atmospheric carbon dioxide is a critical global priority. This study investigates the influence of Cu-Ni nanoalloy loading on the CO₂ electroreduction efficiency in the context of mesoporous carbon supports. Current methods struggle when it comes to catalyst efficiency, selectivity, and longevity. By synthesizing copper–nickel nanoparticles through chemical reduction and depositing them on porous carbon, this research aimed to optimize catalyst loading and understand the structure–activity relationships. Catalyst performance was evaluated using chronoamperometry and linear sweep voltammetry (LSV). The results showed that 12 wt% catalyst loading achieved optimal CO₂ reduction, outperforming its 36 wt% counterpart by balancing the catalyst quantity. This study reveals that 12 wt% Cu-Ni loading provides a higher CO₂ reduction current density and greater long-term stability than 36 wt% loading, owing to better nanoparticle dispersion and reduced aggregation. Unlike previous Cu-Ni/mesoporous carbon studies, this work uniquely compares different loadings to directly correlate the structure, electrochemical performance, and catalyst durability. Full article

To enhance the high-temperature oxidation resistance of chromium carbide metal ceramic coatings, micro/nanoparticle modification was applied to the alloy binder phase of the typical Cr₃C₂-NiCr coating. This led to the development of Cr₃C₂-NiCrCoMo and Cr₃C₂-NiCrCoMo/nano-CeO₂ coatings with superior high-temperature oxidation performance. This study compares the high-temperature oxidation behavior of these coating samples and explores their respective oxidation mechanisms. The results indicate that the addition of CoCrMo improves the compatibility between the oxide film and the coating, enhancing the microstructure and integrity of the oxide film. Compared to Cr₃C₂-NiCrCoMo coatings, the incorporation of nano-CeO₂ promotes the reaction between oxides in the Cr₃C₂-NiCrCoMo/nano-CeO₂ coating, increasing the content of binary spinel phases, reducing thermal stress at the oxide–coating interface, and improving the adhesion strength of the oxide film. As a result, the oxidation rate of the coating is reduced, and its oxidation resistance is improved. Full article

The development of metallic coatings as Ni-Co alloys, with particular emphasis on their homogeneity, processability, and sustainability, is of the utmost significance. To address these challenges, the utilization of phenylsalicylimines (PSIs) as additives within deep eutectic solvents (DES) was investigated, assessing their influence on the electrodeposition process of these metals at an intermediate temperature of 60 °C, while circumventing aqueous reaction conditions. The findings demonstrated that the incorporation of PSIs markedly enhances coating uniformity, resulting in an optimal cobalt content of 37% and an average thickness of 24 µm. Electrochemical evaluations revealed improvements in charge and mass transfer, thereby optimizing process efficiency. Moreover, computational studies confirmed that PSIs form stable complexes with Co (II), modulating the electrochemical characteristics of the system through the introduction of the diethylamino electron-donating group, which significantly stabilizes the coordinated forms with both components of the DES. Additionally, the coatings displayed exceptional corrosion resistance, with a rate of 0.781 µm per year, and achieved an optimal hardness of 38 N HRC, conforming to ASTM B994 standards. This research contributes to the development of electroplating bath designs for metallic coating deposition and lays the groundwork for the advancement of sophisticated technologies in functional coatings that augment corrosion resistance and mechanical properties. Full article

Many components in industry are subjected to high loads during operation and therefore often do not reach their intended service life. Conventional steels frequently do not provide sufficient protection against wear and corrosion. One solution is to coat these components using methods like thermal spraying to apply cermet coatings such as Cr₃C₂-NiCr or WC-Co-Cr. In light of increasingly strict environmental regulations, more eco-friendly alternatives are needed, especially ones that use little or no Cr, Ni, Co, or W. Another alternative is the recycling of powder materials, which is the focus of this research project. This study investigated whether filter dust from an HVOF system could be used to develop a new coating suitable for use in applications requiring resistance to wear and corrosion. This is challenging as the filter dusts have heterogeneous compositions and irregular particle sizes. Nevertheless, this recycled material, referred to as “Green Cermets” (GCs), offers previously untapped potential that may also be of ecological interest. An established WC-Co-Cr coating served as a reference. In addition to friction wear and corrosion resistance, the study also examined particle size distribution, hardness, microstructure, and susceptibility to crack formation at the interface and inside the coating. Even though the results revealed a diminished performance of the GC coatings relative to the conventional WC-CoCr, they may still be applicable in various industrial applications. Full article

The development of high-performance and stable solid-state lithium batteries (SSBs) is critical for advancing next-generation energy storage technologies. This study investigates LATP (Li_1.3Al_0.3Ti_1.7(PO₄)₃) coatings to enhance the electrochemical performance and interface stability of NCMA83 (LiNi_0.83Co_0.06Mn_0.06Al_0.05O₂) cathodes. Compared to conventional combinations with LPSC (Li₆PS₅Cl) solid electrolytes, LATP coatings significantly reduce interfacial reactivity and improve cycling stability. Structural and morphological analyses reveal that LATP coatings maintain the crystallinity of NCMA83 while fine-tuning its lattice stress. Electrochemical testing demonstrates that LATP-modified samples (83L5) achieve superior capacity retention (65 mAh/g after 50 cycles) and reduced impedance (R_ct ~200 Ω), compared to unmodified samples (83L0). These results highlight LATP’s potential as a surface engineering solution to mitigate degradation effects, enhance ionic conductivity, and extend the lifespan of high-capacity SSBs. Full article

The rational design of a bimetallic nanostructure with a phase separation and interface is of great importance to enhance electrocatalytic performance. Herein, PdNi heterostructures with controlled elemental distributions were constructed via a seeded growth strategy. Partially coated Ni islands in the Pd-Ni nanowire and strained Pd branches in the Pd-NiPd nanowires are revealed, respectively. Impressively, Pd-NiPd nanowires with abundant branches exhibit a superior mass current density and cycling stability toward an ethanol oxidation reaction (EOR) and ethylene glycol oxidation reaction (EGOR). The highest mass activities of 8.63 A mg_Pd⁻¹ and 12.53 A mg_Pd⁻¹ for EOR and EGOR, respectively, are realized on the Pd-NiPd nanowires. Theoretical calculations indicate that the Pd (100)-PdNi (111) interface stands out as an active site for enhancing OH adsorption and the decreasing CO bonding interaction. This study not only puts forward a simple method to construct bimetallic nanostructures with desired elemental distributions and interfaces but also demonstrates the significance of interface engineering in regulating the catalytic activity of metallic nanomaterials. Full article

In this study, powders based on a high-entropy AlCoCrFeNi alloy obtained by mechanical alloying were successfully applied to a 316L stainless steel substrate by detonation spraying under various conditions. Their microstructural features, phase composition, hardness, and wear resistance were studied. A comparative analysis between the initial powder and the coatings was performed, including phase transformation modeling using Thermo-Calc under non-equilibrium conditions. The results showed that the phase composition of the powder and coatings includes body-centered cubic lattice (BCC), its ordered modification (B2), and face-centered cubic lattice FCC phases, which is consistent with the predictions of the Scheil solidification model, describing the process of non-equilibrium solidification, assuming no diffusion in the solid phase and complete mixing in the liquid phase. Rapid solidification and high-speed impact deformation of the powder led to significant grain refinement in the detonation spraying coating, which ultimately improved the mechanical properties at the micro level. The data obtained demonstrate the high efficiency of the AlCoCrFeNi coating applied by detonation spraying and confirm its potential for use in conditions of increased wear and mechanical stress. AlCoCrFeNi coatings may be promising for use as structural materials in the future. Full article

This study investigates the development and sensing profile of synthetic melanin nanoparticle-coated electrodes for the electrochemical detection of heavy metals, including lead (Pb), cadmium (Cd), cobalt (Co), zinc (Zn), nickel (Ni), and iron (Fe). Synthetic melanin films were prepared in situ by the deacetylation of diacetoxy indole (DAI) to dihydroxy indole (DHI), followed by the deposition of DHI monomers onto indium tin oxide (ITO) and glassy carbon electrodes (GCE) using cyclic voltammetry (CV), forming a thin layer of synthetic melanin film. The deposition process was characterized by electrochemical quartz crystal microbalance (EQCM) in combination with linear sweep voltammetry (LSV) and amperometry to determine the mass and thickness of the deposited film. Surface morphology and elemental composition were examined using scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDX). In contrast, Fourier-transform infrared (FTIR) and UV–Vis spectroscopy confirmed the melanin’s chemical structure and its polyphenolic functional groups. Differential pulse voltammetry (DPV) and amperometry were employed to evaluate the melanin films’ electrochemical activity and sensitivity for detecting heavy metal ions. Reproducibility and repeatability were rigorously assessed, showing consistent electrochemical performance across multiple electrodes and trials. A comparative analysis of ITO, GCE, and graphite electrodes was conducted to identify the most suitable substrate for melanin film preparation, focusing on stability, electrochemical response, and metal ion sensing efficiency. Finally, the applicability of melanin-coated electrodes was tested on in-house heavy metal water samples, exploring their potential for practical environmental monitoring of toxic heavy metals. The findings highlight synthetic melanin-coated electrodes as a promising platform for sensitive and reliable detection of iron with a sensitivity of 106 nA/ppm and a limit of quantification as low as 1 ppm. Full article

Electroless nickel deposition (ELD) on polymer substrates enables the fabrication of flexible, conductive fibres for wearable and functional textiles. However, achieving uniform, low-defect coatings on synthetic fibres such as nylon-6,6 remains challenging due to their chemical inertness, hydrophobicity, and poor interfacial compatibility with metal coatings. This study presents a solvent-assisted approach using dimethyl sulfoxide (DMSO) in a conventional aqueous ELD bath to control both polymer–metal interfacial chemistry and nickel coating microstructure. The modified surface supports dense catalytic sites, triggering spatially uniform Ni nucleation. The combination of scanning electron microscopy and transmission electron microscopy confirms the difference in coarse grains with fully aqueous baths to a nanocrystalline shell with DMSO-modified baths. This refined microstructure relieves residual stress and anchors firmly to the swollen polymer, delivering +7 °C higher onset decomposition temperature and 45% lower creep strain at 50 °C compared with aqueous controls. The fabric strain sensor fabricated by 1 wt.% DMSO-modified ELD shows a remarkable sensitivity against strain, demonstrating a 1400% resistance change under 200% stain. Electrochemical impedance and polarisation tests confirm a two-fold rise in charge transfer resistance and negligible corrosion current drift after accelerated ageing. By clarifying how a polar aprotic co-solvent couples polymer swelling with metal growth kinetics, the study introduces a scalable strategy for tuning polymer–metal interfaces and advances solvent-assisted ELD as a route to mechanically robust, thermally stable, and corrosion-resistant conductive textiles. Full article

A novel processing route of producing CrFeNiMo, Co_0.5CrFeNiMo, and Al_0.5CrFeNiMo high-entropy alloy coatings was proposed in this work. Pre-alloyed HEAs were consolidated by spark plasma sintering (SPS) in order to fabricate electrodes for electrospark deposition (ESD) coatings on carbon steel substrates. Investigations were performed to observe aspects such as phase composition and stability, contamination level, homogeneity, elemental distribution, and microstructural integrity. The results indicated phase stability and lower porosity when increasing the SPS temperature by 50 °C for all cases, with tetragonal distortion related to the HEAs’ severe lattice distortion core effect. The coating surface analysis indicated that a continuous and compact coating was obtained, correlated with the ESD layering count, but microfissures were present after 6 layers were applied due to the reduced ductility combined with rapid cooling under Ar atmosphere. The chemical integrity of both the sintered samples and the coatings was preserved during the processing, revealing a uniform elemental distribution with no contaminations or impurities present. The results indicated successful HEA sintering and deposition, highlighting the potential of the combined SPS-ESD process for high-performance material fabrication with possible applications in aggressive environments. Full article

AlCoCrFeNi coatings were electrospark-deposited (ESD) on H13 steel substrates, and their nano-mechanical and tribological properties under a load of 2 N, 4 N, 6 N, 8 N, and 10 N were investigated by utilizing a nanoindentation instrument and a reciprocating friction and wear tester, respectively. The morphologies, composition, and phase structure of the as-deposited and worn AlCoCrFeNi coating were characterized using SEM (Scanning electron Microscope), EDS (Energy dispersive spectrometer), and XRD (X-Ray Diffraction). The results showed that the as-deposited AlCoCrFeNi coating with a nanocrystalline microstructure mainly consists of a BCC and B2 phase structure, and a gradient transition of elements between the coating and the substrate ensures an excellent bond between the coating and the substrate. The hardness of the AlCoCrFeNi coating exhibits an 8% increase, while its elastic modulus is reduced by 16% compared to the H13 steel. The AlCoCrFeNi coating remarkably increased the tribological property of the H13 steel under various loads, and its wear mechanism belongs to micro-cutting abrasive wear whilst that of the H13 steel can be characterized as severe adhesive wear. The friction coefficient and weight loss of the AlCoCrFeNi coating decrease with increasing load, both following a linear relationship with respect to the applied load. As the load intensifies, the work hardening sensitivity and oxidation degree on the worn surface of the coating are significantly enhanced, which collectively contributes to the improved tribological performance of the AlCoCrFeNi coating. Full article