Search Results (18)

This study explores the efficacy of magnetic abrasive finishing (MAF) with planetary kinematics for post-processing Inconel 939 components fabricated by laser powder bed fusion (LPBF). Given the critical limitations in surface quality of LPBF-produced parts—especially in hard-to-machine superalloys like Inconel 939—there is a pressing need for advanced, adaptable finishing techniques that can operate effectively on complex geometries. This research focuses on optimizing the process parameters—eccentricity, rotational speed, and machining time—to enhance surface integrity following preliminary vibratory machining. Custom-designed samples underwent sequential machining, including heat treatment and 4 h vibratory machining, before MAF was applied under controlled conditions using ferromagnetic Fe-Si abrasives. Surface roughness measurements demonstrated a significant reduction, achieving Ra values from 1.21 µm to below 0.8 µm in optimal conditions, representing more than a fivefold improvement compared to the as-printed state (5.6 µm). Scanning Electron Microscopy (SEM) revealed progressive surface refinement, with MAF effectively removing adhered particles left by prior processing. Statistical analysis confirmed the dominant influence of eccentricity on the surface profile parameters, particularly Rz. The findings validate the viability of MAF as a precise, controllable, and complementary finishing method for LPBF-manufactured Inconel 939 components, especially for geometrically complex or hard-to-reach surfaces. Full article

Rapid industrialization has escalated environmental pollution caused by organic compounds, posing critical challenges for wastewater treatment. Advanced oxidation processes based on peroxymonosulfate (PMS) suffer from metal leaching and catalyst recycling challenges. To address these limitations, this study developed a nitrogen-doped biochar aerogel (NBA) derived from poplar wood powder as an eco-friendly and easily recoverable PMS activator. The NBA catalyst, optimized by tuning the calcination temperature to achieve a specific surface area of 297.5 m² g⁻¹, achieved 97% bisphenol A (BPA) removal within 60 min with a catalyst dosage of 0.3 g/L and 1.0 mM PMS under mild conditions. The material exhibited broad pH adaptability (pH 3.5–9), recyclability (>94% efficiency after thermal treatment), and versatility in degrading seven pollutants (BPA, phenol, 4-chlorophenol, 2,4-dichlorophenol, 2,4,6-trichlorophenol, rhodamine 6G, and levofloxacin) through synergistic radical (•OH, SO₄^•−, O₂^•−) and non-radical (¹O₂) pathways. X-ray photoelectron spectroscopy (XPS) analyses revealed that nitrogen doping enhanced PMS activation by optimizing electronic structures. This study highlights the potential of waste biomass-derived carbon aerogels as eco-friendly, efficient, and reusable catalysts for advanced oxidation processes in wastewater treatment. Full article

Tissue engineering has emerged as a promising approach for improved regeneration of native tissue and could increase the quality of life of many patients. However, the treatment of injured tissue transitions is still in its early stages, relying primarily on a purely physical approach in medical surgery. A biodegradable implant with a modified surface that is capable of biological active protein delivery via a nanoparticulate release system could advance the field of musculoskeletal disorder treatments enormously. In this study, interconnected 3D macroporous scaffolds based on Polycaprolactone (PCL) were fabricated in a successive process of blending, annealing and leaching. Blending with varying parts of Polyethylene oxide (PEO), NaCl and (powdered) sucrose and altering processing conditions yielded scaffolds with a huge variety of morphologies. The resulting unmodified hydrophobic scaffolds were modified using two graft polymers (CS-g-PCL_x) with x = 29 and 56 (x = PCL units per chitosan unit). Due to the chitosan backbone hydrophilicity was increased and a platform for a versatile nanoparticulate release system was introduced. The graft polymers were synthesized via ring opening polymerization (ROP) of ε-Caprolactone using hydroxy groups of the chitosan backbone as initiators (grafting from). The suspected impact on biocompatibility of the modification was investigated by in vitro cell testing. In addition, the CS-g-PCL modification opened up the possibility of Layer by Layer (LbL) coating with alginate (ALG) and TGF-β₃-loaded chitosan tripolyphosphate (CS-TGF-β₃-TPP) nanoparticles. The subsequent release study showed promising amounts of growth factor released regarding successful in vitro cell differentiation and therefore could have a possible therapeutic impact. Full article

LiFePO₄ (LFP) cathodes are popular due to their safety and cyclic performance, despite limitations in lithium-ion diffusion and conductivity. These can be improved with carbon coating, but further advancements are possible despite commercial success. In this study, we modified the carbon coating layer using sulfur to enhance the electronic conductivity and stabilize the carbon surface layer via two methods: 1-step and 2-step processes. In the 1-step process, sulfur powder was mixed with cellulose followed by heat treatment to form a coating layer; in the 2-step process, an additional coating layer was applied on top of the carbon coating layer. Electrochemical measurements demonstrated that the 1-step sulfur-modified LFP significantly improved the discharge capacity (~152 mAh·g⁻¹ at 0.5 C rate) and rate capability compared to pristine LFP. Raman analyses indicated that sulfur mixed with a carbon source increases the graphitization of the carbon layer. Although the 2-step sulfur modification did not exceed the 1-step process in enhancing rate capability, it improved the storage characteristics of LFP at high temperatures. The residual sulfur elements apparently protected the surface. These findings confirm that sulfur modification of the carbon layer is effective for improving LFP cathode properties, offering a promising approach to enhance the performance and stability of LFP-based lithium-ion batteries. Full article

Introduction: Wetting affects chemical and physical properties. In aluminum, superhydrophobic surfaces keep fog, ice, and corrosion at bay. Biomimicry replicates natural processes. The high surface energy of aluminum limits its intrinsic dewetting properties. Existing surface modification methods have disadvantages, such as hazardous chemicals, high costs, and harsh processing conditions. This work is environmentally friendly and overcomes traditional limitations. Methods: Aluminum alloy plates (AA5083) of commercial grade (ASTM-B-209M) were used in the study. Stationary friction stir processing (sFSP) was carried out on a universal milling machine focused solely on surface characteristics using transition metal powders (99% purity). The prepared samples were polished with abrasive papers to 1000 grit after processing. In the microwave hot water treatment (mHWT), processed and unprocessed samples were processed for 10 min at 800 W. A silanization agent was vapor-deposited on the samples following mHWT at 55 °C for 60 min. Results: The low-strain-rate sFSP of aluminum alloys results in substantial grain refinement, reaching ~1 µm for processed samples and ~30 µm for unprocessed samples. Refined grains have a dense and networked nanostructure after mHWT. After silanization, the samples exhibit excellent contact angles (>155°), low tilt angles (10°), and low contact angle hysteresis (5°). The processed samples, featuring highly refined grains, demonstrate low water adhesion (~16 µN) compared to unprocessed samples (~50 μN), attributed to the high interfacial energy of the Cassie state, effectively entrapping air. These processed samples exhibit remarkable de-wetting properties and mechanical resilience, owing to the strong negative capillary pressure (>1100 kPa) generated by highly dense networked nanostructures. Conclusions: In conclusion, the research helps to develop sustainable and durable superhydrophobic aluminum surfaces. The environmentally friendly and cost-effective strategies explored have far-reaching implications for industrial applications, emphasizing opportunities for advancements and practical utilization across various industries. Full article

This study delves into advanced methane purification techniques within anaerobic fermentation bioreactors, focusing on selective CO₂ absorption and comparing photosynthetic bacteria (PNSB) with chemical adsorbents. Our investigation demonstrates that MgO-Mg(OH)₂ composites exhibit remarkable CO₂ selectivity over CH₄, substantiated through rigorous bulk and surface modelling analyses. To address the challenges posed by MgCO₃ shell formation on MgO particles, hindering CO₂ transport, we advocate for the utilisation of MgO-Mg(OH)₂ composites. In on-site experiments, these composites, particularly saturated MgO-Mg(OH)₂ solutions (S2), achieved an astonishing 100% CO₂ removal rate within a single day while preserving CH₄ content. In contrast, solid MgO powder (S3) retained a mere 5% of CH₄ over a 10 h period. Although PNSB (S1) exhibited slower CO₂ removal, it excelled in nutrient recovery from anaerobic effluent. We introduce a groundbreaking hybrid strategy that leverages S2’s swift CO₂ removal and S1 PNSB’s nutrient recovery capabilities, potentially resulting in a drastic reduction in bioreactor processing time, from 10 days when employing S1 to just 1 day with the use of S2. This represents a remarkable efficiency improvement of 1000%. This pioneering strategy has the potential to revolutionise methane purification, enhancing both efficiency and sustainability. Importantly, it can be seamlessly integrated into existing bioreactors through an additional CO₂ capture step, offering a promising solution for advancing biogas production and promoting sustainable waste treatment practices. Full article

Wastewater treatment targeting reuse may limit water scarcity. Photocatalysis is an advanced oxidation process that may be employed in the removal of traces of organic pollutants, where the material choice is important. Titanium dioxide (TiO₂) is a highly efficient photocatalyst with good aqueous stability. TiO₂ powder has a high surface area, thus allowing good pollutant adsorption, but it is difficult to filter for reuse. Thin films have a significantly lower surface area but are easier to regenerate and reuse. In this paper, we report on obtaining sol-gel TiO₂ thin films on spherical beads (2 mm diameter) with high surface area and easy recovery from wastewater. The complex influence of the substrate morphology (etched up to 48 h in concentrated H₂SO₄), of the sol dilution with ethanol (1:0 or 1:1), and the number of layers (1 or 2) on the structure, morphology, chemical composition, and photocatalytic performance of the TiO₂ thin films is investigated. Etching the substrate for 2 h in H₂SO₄ leads to uniform, smooth surfaces on which crystalline, homogeneous TiO₂ thin films are grown. Films deposited using an undiluted sol are stable in water, with some surface reorganization of the TiO₂ aggregates occurring, while the films obtained using diluted sol are partially washed out. By increasing the film thickness through the deposition of a second layer, the roughness increases (from ~50 nm to ~100 nm), but this increase is not high enough to promote higher adsorption or overall photocatalytic efficiency in methylene blue photodegradation (both about 40% after 8 h of UV-Vis irradiation at 55 W/m²). The most promising thin film, deposited on spherical bead substrates (etched for 2 h in H₂SO₄) using the undiluted sol, with one layer, is highly crystalline, uniform, water-stable, and proves to have good photocatalytic activity. Full article

Additive manufacturing (AM) technologies have gained considerable attention in recent years as an innovative method to produce high entropy alloy (HEA) components. The unique and excellent mechanical and environmental properties of HEAs can be used in various demanding applications, such as the aerospace and automotive industries. This review paper aims to inspect the status and prospects of research and development related to the production of HEAs by AM technologies. Several AM processes can be used to fabricate HEA components, mainly powder bed fusion (PBF), direct energy deposition (DED), material extrusion (ME), and binder jetting (BJ). PBF technologies, such as selective laser melting (SLM) and electron beam melting (EBM), have been widely used to produce HEA components with good dimensional accuracy and surface finish. DED techniques, such as blown powder deposition (BPD) and wire arc AM (WAAM), that have high deposition rates can be used to produce large, custom-made parts with relatively reduced surface finish quality. BJ and ME techniques can be used to produce green bodies that require subsequent sintering to obtain adequate density. The use of AM to produce HEA components provides the ability to make complex shapes and create composite materials with reinforced particles. However, the microstructure and mechanical properties of AM-produced HEAs can be significantly affected by the processing parameters and post-processing heat treatment, but overall, AM technology appears to be a promising approach for producing advanced HEA components with unique properties. This paper reviews the various technologies and associated aspects of AM for HEAs. The concluding remarks highlight the critical effect of the printing parameters in relation to the complex synthesis mechanism of HEA elements that is required to obtain adequate properties. In addition, the importance of using feedstock material in the form of mix elemental powder or wires rather than pre-alloyed substance is also emphasized in order that HEA components can be produced by AM processes at an affordable cost. Full article

Wastewater generated from industries seriously impacts the environment. Conventional biological and physiochemical treatment methods for wastewater containing organic molecules have some limitations. Therefore, identifying other alternative methods or processes that are more suitable to degrade organic molecules and lower chemical oxygen demand (COD) in wastewater is necessary. Heterogeneous Fenton processes and persulfate (PS) oxidation are advanced oxidation processes (AOPs) that degrade organic pollutants via reactive radical species. Therefore, in this study, limonite powder was incorporated into porous regenerated chitosan fibers and further used as a heterogeneous catalyst to decompose methylene blue (MB) via sulfate radical-based AOPs. Limonite was used as a heterogeneous catalyst in this process to generate the persulfate radicals (SO₄⁻·) that initiate the decolorization process. Limonite–chitosan fibers were produced to effectively recover the limonite powder so that the catalyst can be reused repeatedly. The formation of limonite–chitosan fibers viewed under a field emission scanning electron microscope (FESEM) showed that the limonite powder was well distributed in both the surface and cross-section area. The effectiveness of limonite–chitosan fibers as a catalyst under PS activation achieved an MB decolorization of 78% after 14 min. The stability and reusability of chitosan–limonite fibers were evaluated and measured in cycles 1 to 10 under optimal conditions. After 10 cycles of repeated use, the limonite–chitosan fiber maintained its performance up to 86%, revealing that limonite-containing chitosan fibers are a promising reusable catalyst material. Full article

The Fenton reaction as an effective advanced oxidation technology has been widely used in wastewater treatment for its stable effluent quality, simple operation, mild condition, and higher organic degradation with non-selectivity. However, the traditional Fenton reaction is limited by the sluggish regeneration of Fe²⁺, resulting in a slower reaction rate, and it is necessary to further increase the dosage of Fe²⁺, which will increase the production of iron sludge. Activated carbon (AC) has a strong adsorption property, and it cannot be ignored that it also can reduce Fe³⁺. In this study, the degradation of acid red G (ARG) by adding AC to the Fe³⁺/H₂O₂ system, the role of the reducing ability, and the reason why AC can reduce Fe³⁺ were studied. By adding three kinds of ACs, including coconut shell-activated carbon (CSPAC), wood-activated carbon (WPAC), and coal-activated carbon (CPAC), the ability of ACs to assist the Fe³⁺/H₂O₂ Fenton-like system to degrade ARG was clarified. Through the final treatment effect and the ability to reduce Fe³⁺, the type of AC with the best promotion effect was CSPAC. The different influence factors of particle size, the concentration of CSPAC, concentration of H₂O₂, concentration of Fe³⁺, and pH value were further observed. The best reaction conditions were determined as CSPAC powder with a particle size of 75 μm and dosage of 0.6 g/L, initial H₂O₂ concentration of 0.4 mmol/L, Fe³⁺ concentration of 0.1 mmol/L, and pH = 3. By reducing the adsorption effect of CSPAC, it was further observed that CSPAC could accelerate the early reaction rate of the degradation process of ARG by the Fe³⁺/H₂O₂ system. FT-IR and XPS confirmed that the C-O-H group on the surface of CSPAC could reduce Fe³⁺ to Fe²⁺. This study can improve the understanding and role of AC in the Fenton reaction, and further promote the application of the Fenton reaction in sewage treatment. Full article

Water pollution by dyes is a huge environmental problem; there is a necessity to produce new decolorization methods that are effective, cost-attractive, and acceptable in industrial use. Magnetic cyclodextrin polymers offer the advantage of easy separation from the dye solution. In this work, the β-CD-EPI-magnetic (β-cyclodextrin-epichlorohydrin) polymer was synthesized, characterized, and tested for removal of the azo dye Direct Red 83:1 from water, and the fraction of non-adsorbed dye was degraded by an advanced oxidation process. The polymer was characterized in terms of the particle size distribution and surface morphology (FE-SEM), elemental analysis (EA), differential scanning calorimetry (DSC), thermal gravimetric analysis (TGA), infrared spectrophotometry (IR), and X-ray powder diffraction (XRD). The reported results hint that 0.5 g and pH 5.0 were the best conditions to carry out both kinetic and isotherm models. A 30 min contact time was needed to reach equilibrium with a qmax of 32.0 mg/g. The results indicated that the pseudo-second-order and intraparticle diffusion models were involved in the assembly of Direct Red 83:1 onto the magnetic adsorbent. Regarding the isotherms discussed, the Freundlich model correctly reproduced the experimental data so that adsorption was confirmed to take place onto heterogeneous surfaces. The calculation of the thermodynamic parameters further demonstrates the spontaneous character of the adsorption phenomena (ΔG° = −27,556.9 J/mol) and endothermic phenomena (ΔH° = 8757.1 J/mol) at 25 °C. Furthermore, a good reusability of the polymer was evidenced after six cycles of regeneration, with a negligible decline in the adsorption extent (10%) regarding its initial capacity. Finally, the residual dye in solution after treatment with magnetic adsorbents was degraded by using an advanced oxidation process (AOP) with pulsed light and hydrogen peroxide (343 mg/L); >90% of the dye was degraded after receiving a fluence of 118 J/cm²; the discoloration followed a pseudo first-order kinetics where the degradation rate was 0.0196 cm²/J. The newly synthesized β-CD-EPI-magnetic polymer exhibited good adsorption properties and separability from water which, when complemented with a pulsed light-AOP, may offer a good alternative to remove dyes such as Direct Red 83:1 from water. It allows for the reuse of both the polymer and the dye in the dyeing process. Full article

This study presents the correct processing of Co–Cr alloys as a method of preserving the properties of the materials as-cast, and therefore they can be safely placed in contact with the oral cavity tissues as resistance frameworks. The basic materials analyzed in this study were five commercial Co–Cr dental alloys with different components obtained in three processing steps. The analysis of the electrochemical behavior at the surface of the Co–Cr alloys was performed by electrochemical measurements: impedance spectroscopy (EIS), open circuit electrical potential (OCP), and linear polarization (LP). In terms of validation, all five alloys had a tendency to generate a stable oxide layer at the surface. After the measurements and the graphical representation, the alloy that had a higher percentage of tungsten (W) and iron (Fe) in composition showed a higher tendency of anodizing. After the application of the heat treatment, the disappearance of the hexagonal phase was observed, with the appearance of new phases of type (A,B)₂O₃ corresponding to some oxide compounds, such as Fe₂O₃, Cr₂O₃, (Cr,Fe)₂O₃, and CoMnO₃. In conclusion, the processing of Co–Cr alloys by melting and casting in refractory molds remains a viable method that can support innovation, in the context of technology advance in recent years towards digitalization of the manufacturing process, i.e., the construction of prosthetic frameworks conducted by additive methods using Co–Cr powder alloy. Full article

The classical production of microfibrillar cellulose involves intensive mechanical processing and discontinuous chemical treatment in solvent-based media in order to introduce additional chemical surface modification. By selecting appropriate conditions of a pulsed plasma reactor, a solvent-free and low-energy input process can be applied with the introduction of microcrystalline cellulose (MCC) and maleic anhydride (MA) powders. The plasma processing results in the progressive fibrillation of the cellulose powder into its elementary fibril structure and in-situ modification of the produced fibrils with more hydrophobic groups that provide good stability against re-agglomeration of the fibrils. The selection of a critical ratio MA/MCC = 2:1 allows separating the single cellulose microfibrils with changeable morphologies depending on the plasma treatment time. Moreover, the density of the hydrophobic surface groups can be changed through a selection of different plasma duty cycle times, while the influence of plasma power and pulse frequency is inferior. The variations in treatment time can be followed along the plasma reactor, as the microfibrils gain smaller diameter and become somewhat longer with increasing time. This can be related to the activation of the hierarchical cellulose structure and progressive diffusion of the MA within the cellulose structure, causing progressive weakening of the hydroxyl bonding. In parallel, the creation of more reactive species with time allows creating active surface sites that allow for interaction between the different fibrils into more complex morphologies. The in-situ surface modification has been demonstrated by XPS and FTIR analysis, indicating the successful esterification between the MA and hydroxyl groups at the cellulose surface. In particular, the crystallinity of the cellulose has been augmented after plasma modification. Furthermore, AFM evaluation of the fibrils shows surface structures with irregular surface roughness patterns that contribute to better interaction of the microfibrils after incorporation in an eventual polymer matrix. In conclusion, the combination of physical and chemical processing of cellulose microfibrils provides a more sustainable approach for the fabrication of advanced nanotechnological materials. Full article

Aiming at the problems of a low material utilization rate and uneven stress distribution of cast-steel support joints in cable dome structures, topology optimization and additive manufacturing methods are used for optimization design and integrated manufacturing. First, the basic principle and calculation process of topology optimization are briefly introduced. Then, the initial model of the support joint is calculated and analyzed by using the universal software ANSYS Workbench 2020R2 and Altair OptiStruct, and the optimized joint is imported into Discovery Live to smooth the surface. The static behaviors of three types of joints (topology-optimized joints, joints after the smoothing treatment, and joints from practical engineering) are compared and analyzed. Finally, the joints are printed by using fused deposition modeling (FDM) technology and laser-based powder bed fusion (LBPBF) technology in additive manufacturing. The results show that the new support joint in the cable dome structure obtained by the topology optimization method has the advantages of a novel shape, a high material utilization rate, and a uniform stress distribution. Additive manufacturing technology can allow the manufacture of complex shape components with high precision and high speed. The combination of topology optimization and additive manufacturing effectively realizes the advanced design and integrated manufacturing of support joints for cable dome structures. Full article

For developing subminiature and highly integrated multilayer inductors, soft magnetic powder was used; however, its ferrite magnetic component is characterized by high resistivity and reduced direct current saturation, leading to the deterioration of the inductor under high currents. Therefore, herein, to improve the electromagnetic properties of thin-film inductors, Fe nanopowder was used to increase the volume fraction of magnetic sheets. Surface treatment was performed by using silane coupling agents, which improved the bonding strength and dispersibility of the Fe nanopowder with a heterogeneous epoxy binder. For uniform surface treatment on the nanopowder, the silane-treated powder was aged for 24 h, at a temperature of 3 °C. The surface-treated Fe nanopowder was used with a mixing ratio of the soft magnetic powder (coarse:fine:nano) of 7:2.5:0.5 wt.%; this was successful in producing a flexible and highly densified magnetic sheet. As a result, the volume fraction of the magnetic sheet for thin-film inductors to which a low-temperature aging-treated nanopowder was applied was significantly improved. Full article