Search Results (449)

Aluminum–copper casting alloys are potential candidate materials for use in marine applications where high mechanical strength and superior fatigue resistance are desired. The corrosion and protection of aluminum alloy B206 in seawater through surface passivation continues to pose challenges, hampering its widespread use in marine structures. In this study, the electrochemical behavior of B206 is investigated in artificial seawater at temperatures and dissolved oxygen (DO) concentrations anticipated during service in marine environments. In particular, the influence of anodizing B206 in deaerated seawater on the subsequent corrosion behavior of the alloy is studied using potentiodynamic and potentiostatic polarization, electrochemical impedance spectroscopy (EIS), and Mott–Schottky analysis. The results showed that the effect of DO on the corrosion of B206 is more significant than the effect of temperature. In the absence of DO, results of potentiostatic polarization, EIS, and Mott–Schottky analysis at anodic potentials all indicated the development of a thicker, more protective passive layer in colder seawater. Moreover, passive layer thickness modeled using Power-Law was found to range between 3 and 9 nm, whilst decreasing in thickness with temperature. Donor densities of the n-type passive layer are on the order of 1021 cm⁻³ and increase with temperature. The findings presented in this study support the feasibility of implementing anodizing for B206 in marine service environments. Full article

The anode assembly, as a key component in the electrolytic aluminum process, is composed of steel claws and aluminum guide rods. The connection quality between the steel claws and guide rods directly affects the current conduction efficiency, energy consumption, and operational stability of equipment. Achieving high-quality joining between the aluminum alloy and steel has become a key process in the preparation of the anode assembly. To join the guide rods and steel claws, this work uses Cold Metal Transfer (CMT) technology to clad aluminum on the steel surface and employs machine vision to detect surface forming defects in the cladding layer. The influence of different currents on the interfacial microstructure and mechanical properties of aluminum alloy cladding on the steel surface was investigated. The results show that increasing the cladding current leads to an increase in the width of the fusion line and grain size and the formation of layered Fe₂Al₅ intermetallic compounds (IMCs) at the interface. As the current increases from 90 A to 110 A, the thickness of the Al-Fe IMC layer increases from 1.46 μm to 2.06 μm. When the current reaches 110 A, the thickness of the interfacial brittle phase is the largest, at 2 ± 0.5 μm. The interfacial region where aluminum and steel are fused has the highest hardness, and the tensile strength first increases and then decreases with the current. The highest tensile strength is 120.45 MPa at 100 A. All the fracture surfaces exhibit a brittle fracture. Full article

This paper investigates the application of non-calcined metal tartrate as a novel alternative pore former to prepare functional ceramic composites to fabricate solid oxide fuel cells (SOFCs). Compared to carbonaceous pore formers, non-calcined pore formers offer high compatibility with various ceramic composites, providing better control over porosity and pore size distribution, which allows for enhanced gas diffusion, reactant transport and gaseous product release within the fuel cells’ functional layers. In this work, nanocrystalline gadolinium-doped ceria (GDC) and Ni-Gd-Ce-tartrate anode powders were prepared using a single-step co-precipitation synthesis method, based on the carboxylate route, utilising ammonium tartrate as a low-cost, environmentally friendly precipitant. The non-calcined Ni-Gd-Ce-tartrate was used to fabricate dense GDC electrolyte pellets (5–20 μm thick) integrated with a thin film of Ni-GDC anode with controlled porosity at 1300 °C. The dilatometry analysis showed the shrinkage anisotropy factor for the anode substrates prepared using 20 wt. The percentages of Ni-Gd-Ce-tartrate were 30 wt.% and 40 wt.%, with values of 0.98 and 1.01, respectively, showing a significant improvement in microstructural properties and pore size compared to those fabricated using a carbonaceous pore former. The results showed that the non-calcined pore formers can also lower the sintering temperature for GDC to below 1300 °C, saving energy and reducing thermal stresses on the materials. They can also help maintain optimal material properties during sintering, minimising the risk of unwanted chemical reactions or contamination. This flexibility enables the versatile designing and manufacturing of ceramic fuel cells with tailored compositions at a lower cost for large-scale applications. Full article

The increasing demand for safe, cost-effective, and sustainable energy storage solutions has spotlighted aqueous zinc-ion batteries (AZIBs) as promising alternatives to lithium-ion systems. However, the practical deployment of AZIBs remains hindered by dendritic growth, hydrogen evolution, and surface corrosion at the zinc metal anode, which severely compromise electrochemical stability. In this study, we propose an interfacial engineering strategy involving ultrathin diamond-like carbon (DLC) coatings applied to Zn anodes. The DLC films serve as conformal, ion-permeable barriers that mitigate parasitic side reactions and facilitate uniform Zn plating/stripping behavior. Materials characterizations of the DLC layer on the Zn anodes revealed the tunability of sp²/sp³ hybridization and surface morphology depending on DLC thickness. Electrochemical impedance spectroscopy demonstrated a significant reduction in interfacial resistance, particularly in the optimally coated sample (DLC2, ~20 nm), which achieved a favorable balance between mechanical integrity and ionic transport. Symmetric-cell tests confirmed enhanced cycling stability over 160 h, while full-cell configurations with an ammonium vanadate nanofiber-based cathode exhibited superior capacity retention over 900 cycles at 2 A g⁻¹. The DLC2-coated Zn anodes demonstrated the most effective performance, attributable to its moderate surface roughness, reduced disorder, and minimized charge-transfer resistance. These results provide insight into the importance of fine-tuning the DLC thickness and carbon bonding structure for suppressing dendrite formation and enhancing electrochemical stability. Full article

Aluminum alloy AA6082 (Al-Si-Mg) is a lightweight alloy that requires thick barrier coatings to be protected from localized corrosion. Plasma Electrolytic Oxidation (PEO) coating is a common anodic surface treatment used for growing protective oxides; the main process variables of PEO are the composition of the electrolytic solution and the electrical input. This work focuses on the optimization of the electrical input by comparing different coatings produced by potentiostatic PEO at the effective potential of 350 V, applied by different combinations of voltage ramps with various slopes and maintenance times at the fixed potential. All processes lasted five minutes. The innovative character of this research work is the evaluation of the combined effect of the anodizing voltage and its different trends with time on the coating structure and morphology. The corrosion resistance of coated AA6082 is assessed in contact with chlorides, reproducing seawater. The resulting anodic coatings were compared in terms of structure, composition (thickness, XRD, SEM-EDS) and corrosion resistance (potentiodynamic polarization and electrochemical impedance spectroscopy), finding that longer maintenance at high anodizing potentials promotes localized high-energy plasma discharges, producing larger pores and thicker, but less protective coatings. Results show that the coating thickness increases with the maintenance time (maximum thickness value~17.6 μm). Shorter maintenance periods and longer voltage ramps lead to a lower surface porosity and enhanced corrosion performances of the oxide. The thinnest and least porous coating exhibits the best corrosion behavior (CR~1.1 μm/year). Full article

Sn-based anodes for lithium-ion batteries (LIBs) offer high capacity and low cost; however, significant volume changes during lithiation/delithiation cause mechanical degradation, limiting their practical applications. Microstructural control is a key approach to mitigating these volume changes. This study reports the fabrication of core (Sn rod)-shell (mesoporous Sn-oxide layer) structures through electrodeposition followed by anodization, and their applications to anode active materials for LIBs. First, micro-Sn rods with controlled lengths and diameters were fabricated under various electrodeposition conditions. The electrodeposited Sn exhibited a dendritic structure with short secondary rods branching from a long primary rod. While the primary Sn rod diameters remained constant, the secondary rod diameters varied depending on electrodeposition parameters. Notably, rod coarsening due to secondary rod agglomeration occurred at higher currents and longer deposition durations during galvanostatic electrodeposition. In contrast, potentiostatic electrodeposition prevented agglomeration and increased the quantity of Sn rods with voltage. Subsequently, the core-shell structures were fabricated by anodizing Sn rods, forming mesoporous Sn-oxide layers with different pore sizes and pore wall thicknesses. Electrochemical characterization revealed that the core-shell anode performance for LIBs varied with the Sn-oxide shell’s microstructure. These findings provide insights into optimal core-shell structures to improve anode performance for LIBs. Full article

Integrated light-emitting diodes (LEDs) with waveguides play an important role in applications such as augmented reality (AR) displays, particularly regarding coupling efficiency optimization. Quantum dot light-emitting diodes (QLEDs), an emerging high-performance optoelectronic device, demonstrate substantial potential for next-generation display technologies. This study investigates the influence of microcavity modulation on the output of QLEDs coupled with a silicon nitride (SiNx) waveguide by simulating a white light QLED (W-QLED) with a broad spectrum and mixed RGB QDs (RGB-QLED) with a comparatively narrower spectrum. The microcavity converts both W-QLED and RGB-QLED emissions from broadband white-light emissions into narrowband single-wavelength outputs. Specifically, both of them have demonstrated wavelength tuning and full-width at half-maximum (FWHM) narrowing across the visible spectrum from 400 nm to 750 nm due to the microcavity modulation. The resulting RGB-QLED achieves a FWHM of 11.24 nm and reaches 110.76% of the National Television System Committee 1953 (NTSC 1953) standard color gamut, which is a 20.95% improvement over W-QLED. Meanwhile, due to the Purcell effect of the microcavity, the output efficiency of the QLED coupled with a SiNx waveguide is also significantly improved by optimizing the thickness of the Ag anode and introducing a tilted reflective mirror into the SiNx waveguide. Moreover, the optimal output efficiency of RGB-QLED with the tilted Ag mirror is 10.13%, representing a tenfold increase compared to the sample without the tilted Ag mirror. This design demonstrates an efficient and compact approach for the near-eye full-color display technology. Full article

The development of microtextures has had a transformative impact on surface design in engineering, leading to substantial advancements in the performance, efficiency, and functionality of components and tools. This study presents an innovative methodology for fabricating SEDM electrodes. The methodology combines additive manufacturing by mask stereolithography with an optimized electroforming process to obtain high-precision copper shells. A key aspect of the study involved redesigning the electroforming equipment, enabling the independent examination of critical variables such as anode–cathode distance and electrolyte recirculation. This approach allowed precise analysis of their impact on metal deposition. This redesign enabled the assessment of the impact of electrolyte recirculation on the quality of the shells obtained. The findings indicate that continuous recirculation at 60% power effectively reduced thickness deviation by up to 32.5% compared to the worst-case scenario, achieving average thicknesses within the functional zone of approximately 110 µm. In contrast, the absence of flow or excessive turbulence did not generate defects such as unfilled zones or non-uniform thicknesses. The shells obtained were validated as functional tools in SEDM, demonstrating their viability for the generation of textures with high geometric fidelity. This approach optimizes the manufacturing of textured electrodes and opens new opportunities for their application in advanced industrial processes, providing a more efficient and sustainable alternative to conventional methods. Full article

A Si/SiC/SiO₂ (53/44/3 wt.%) composite is evaluated as an anode material for Li-ion batteries. This material, a result of the high-energy ball-milling of a by-product of the carbothermal reduction of silica (Si slag), is predominantly made up of micrometric particles of amorphous or short-range order Si in which submicrometric SiC inclusions are dispersed. Its capacity is 860 mAh g⁻¹ (1.7 mAh cm⁻²) after 200 cycles in half-cell configuration and 1.6 mAh cm⁻² after 70 cycles in full-cell. The SiC component is not electroactive for lithiation but plays a key role in the electrode stability by preventing the formation of the c-Li₁₅S_i4 phase, known to accelerate electrode degradation. It is shown that capacity decay with cycling mainly originates from solid electrolyte interphase (SEI) growth rather than particle disconnections. Complementary wide angle X-ray scattering (WAXS) analyses confirm the SEI grows alongside cycling and allows for the highlighting of its major components, namely, Li₂CO₃ and LiF. The morphological evolution of the electrode upon cycling is studied by electrochemical dilatometry, operando optical microscopy, and focused ion beam (FIB) and broad ion beam (BIB) scanning electron microscopy (SEM). No particle cracking is observed. However, reconstructed 3D imaging of the electrodes before and after 10 and 200 cycles clearly shows that the particles progressively evolve a dendritic structure. The SEI grows on and within the particles and induces a significant decrease in the electrode’s porosity and an increase in its thickness. Full article

With the growing demand for electric vehicles and consumer electronics, lithium-ion batteries with a high energy density are urgently needed. Lithium-rich manganese-based materials (LRMs) are known for their high theoretical specific capacity, rapid electron/ion transfer, and high output voltage. Constructing electrodes with a substantial amount of active materials is a viable method for enhancing the energy density of batteries. In this study, we prepare thick LRM electrodes through a dry process method of binder fibrillation. A point-to-line-to-surface three-dimensional conductive network is designed by carbon agents with various morphologies. This structural design improves conductivity and facilitates efficient ion and electron transport due to close particle contact and tight packing. A high-loading cathode (35 mg cm⁻²) is fabricated, achieving an impressive areal capacity of up to 7.9 mAh cm⁻². Moreover, the pouch cell paired with a lithium metal anode exhibits a remarkable energy density of 949 Wh kg⁻¹. Compared with the cathodes prepared by the wet process, the dry process optimizes the pathways for e⁻/Li⁺ transport, leading to reduced resistance, superior coulombic efficiency, retention over cycling, and minimized side reaction. Therefore, the novel structural adoption of the dry process represents a promising avenue for driving innovation and pushing the boundaries for enhanced energy density for batteries. Full article

The development of symmetrical solid oxide fuel cells with identical cathode and anode is beneficial for thermal matching and reducing the cost. Herein, proton-conducting electrolyte and novel high catalytic activity electrode material for symmetrical solid oxide fuel cells are proposed. Ni-doping at the B-site of (Sr_0.8Ce_0.2)_0.95FeO_3−δ (SCF) indicates reduced cell edge lengths, cell volume, and a more porous honeycomb structure. The B-site elements in oxide tend to have a high oxidation state via Ni-doping. Simple doping modification in SCF causes better thermal matching between the electrode and electrolyte and form more oxygen vacancies at the operating temperature. At the anode side, Ni-doping improves the stability of the symmetric electrode in reducing the atmosphere. The polarization resistance of symmetrical cells for new electrode material is half of the original both in oxidation and reduction atmosphere, which indicates boosted electrochemical performance for the cathode and anode. At the same time, Ni-doping reduces the impedance activation energy of the anode reaction in symmetric cells. The output performance of the cell is 210.4 mW·cm⁻² at 750 °C and the thickness of the electrolyte is 400 μm, achieving a highly efficient symmetrical electrode in proton ceramic fuel cells. The new finding of materials provides a novel high efficiency symmetrical electrode and proposes guidance for the improvement of solid oxide fuel cells at a reduced temperature. Full article

In this study, the effects of specific power (1–100 W/cm²), operating pressure (0.5–3.0 Pa), and voltage frequency (20–500 kHz) on film growth kinetics, morphology, and silicon entrainment were investigated to optimize magnetron sputtering for producing thin silicon films suitable for lithium-ion battery anodes. Silicon films were deposited on copper substrates using the Caroline D12C system. The film thickness and morphology were determined using scanning electron microscopy and atomic force microscopy. It was found that the porosity of the films increases with increasing pressure in the working chamber. It was found that the film morphology is non-uniform up to a thickness of 100–150 nm. After that, the film thickness becomes uniform over the entire substrate surface, and the deposition rate increases sharply, i.e., an induction period is observed. The induction period duration decreases with increasing voltage power and frequency. At the same time, silicon removal increases. Frequency has a greater effect on both parameters. The paper specifies a strategy for the technical and economic optimization of the magnetron sputtering process, which determines a compromise between the positive effect of increasing productivity and the negative effect of silicon removal. Full article

Metal anodes, such as those based on Ca, Mg, Na and Li, are considered to be one of the keys to the further development of high-energy-density rechargeable batteries. The thickness of these metal anodes directly affects the energy density of the battery. However, the fabrication of thin anodes poses technical challenges which often result in using excessively thick metal anodes in batteries. Here we present, for the first time, a study on the development of a thin Ca battery anode fabricated by electrodeposition. The battery anode with a thickness of approximately 10 µm corresponds to a charge density of 4.0 mAh cm⁻². This study systematically investigates the electrodeposition behavior of Ca using a 1.0 M Ca(BH₄)₂ in THF as the electrolyte. A systematic evaluation of electrodeposition parameters—including substrate pretreatment, current density, hydrodynamics and charge density by area—is conducted. Scanning electron microscopy (SEM) and complementary image analysis provide detailed insights into these parameters. Electrodeposition offers a promising route to achieve a defined battery cell balance with minimal excess of metal at the anode. This will improve overall battery performance and efficiency. The findings contribute to the advancement of fundamental aspects of rechargeable batteries, particularly Ca-based batteries. Full article

Hard carbon (HC), which is one of the anode materials widely used in commercial sodium-ion batteries at present, suffers from a thick and unstable solid electrolyte interface (SEI) layer formed by the self-reduction in traditional carbonate-based electrolytes on its surface. This phenomenon impacts the battery’s Coulomb efficiency, cycle stability, and rate performance. In this paper, a pyrrolidinium-type di-cation ionic liquid, butyl-1,4-di(methylpyrrolidinium) di[hexafluorophosphate] (C₄di[mPy].di[PF₆]), is studied as an electrolyte additive to improve the interphase stability of the HC anode. The PF₆⁻ in C₄di[mPy].di[PF₆] enhances the coordination number between Na⁺ and PF₆⁻, and C₄di[mPy]²⁺ is preferentially reduced, jointly participating in the construction of stable, thin, dense and NaF-rich SEI films, thus laying the foundation for improving battery performance. As a result, in the carbonate electrolyte containing 2 wt% C₄di[mPy].di[PF₆], the reversible capacity of the HC/Na half-cell is increased by 14.7%, and the capacity retention rate remains at 90.4% after 400 cycles. This work provides reference for future research and design of high-performance ion liquid additives. Full article

The increasing demand for titanium implants necessitates improved longevity. Plasma-sprayed hydroxyapatite coatings enhance implant osseointegration but are susceptible to delamination. Alternatively, anodized hydroxyapatite coatings have shown greater adhesion strengths. The present study aimed to develop anodized hydroxyapatite coatings on titanium using commercial calcium-fortified fruit juice as a calcium source. Varying the electrolyte compositions enabled the formation of four oxide groups with different predominate calcium compounds. Each oxide’s morphology, crystallinity, chemistry, molecular structure, and adhesion quality were compared and contrasted. Nanoscale SEM images revealed a progression from porous surface oxide to white surface deposits to petal-like hydroxyapatite structures with the changing anodization electrolytes. Oxide thickness evaluations showed progression from a single-layered oxide with low Ca-, P-, and Mg-dopant incorporations to bi-layered oxide structures with increased Ca-, P-, and Mg-dopant incorporation with changing electrolytes. The bi-layered oxide structures exhibited a titanium-dioxide-rich inner layer and calcium-compound-rich outer layers. Furthermore, indentation analyses confirmed good adhesion quality for three oxides. For the predominate hydroxyapatite oxides, FTIR analyses showed carbonate substitutions indicating the presence of bone-like apatite formation, and ICP-OES analyses revealed prolonged Ca and Mg release over 30 days. These Mg-enhanced carbonated apatite coatings show much promise to improve osseointegration and future implant lifetimes. Full article