Search Results (6,003)

This study developed high-oxygen-barrier active bilayer packaging films by combining corona-treated low-density polyethylene (LDPE) with chitosan/glycerol (CS/Gl) and carvacrol@natural zeolite (CV@NZ) nanohybrid layers using industrially scalable processes. LDPE film was surface-activated via ambient-pressure corona treatment (0.75 s/cm² at 45 kV, 30 W) and assembled with solution-cast CS/Gl or CS/Gl/CV@NZ monolayers via hot-pressing (110 °C, 1 min). Corona treatment enabled robust interfacial adhesion, evidenced by statistical equivalence between monolayer and bilayer mechanical properties. Incorporation of 10 wt.% CV@NZ nanohybrid increased elastic modulus by 60% (to ≈2970 MPa) and tensile strength by 30% (to ≈50 MPa). The LDPE-CS/Gl film achieved a 64-fold reduction in oxygen permeability; CV@NZ incorporation maintained excellent barrier performance (22-fold reduction). Antioxidant potency increased 16-fold upon CV@NZ incorporation. The LDPE-CS/Gl/CV@NZ film demonstrated exceptional antibacterial activity (5.08–5.30 log reductions; >99.999% kill) against both Listeria monocytogenes and Escherichia coli—substantially exceeding additive effects—confirming synergistic action between chitosan and carvacrol. In fresh minced pork preservation (8 days, 4 °C), the active film achieved a 1.73 log reduction in Total Viable Count (98.2% inhibition) and extended microbiological shelf life from 6 to beyond 8 days (33% increase). The bilayer configuration utilizes only 40% of the total thickness as biopolymer, aligning with circular economy principles. Unlike conventional high-barrier films (e.g., PA/PE) which require complex compatibilization for recycling, the water-soluble chitosan layer in this bilayer design can be readily separated from the LDPE backbone, enabling recovery of a pure polymer stream. This work demonstrates a feasible pathway for developing next-generation active packaging that combines a high oxygen barrier, potent antioxidant activity, and exceptional antimicrobial efficacy through industrially scalable manufacturing. Full article

The corrosion behavior and time-dependent mechanism of 22MnB5 steel featuring a thinned Al-Si coating (60 g/m²) were systematically investigated in a chloride ion wet–dry cyclic environment, motivated by the demand for thinning and toughening development of aluminum-silicon coatings. A periodic immersion accelerated corrosion test using 3.5% NaCl solution was conducted, together with macro/microscopic morphology observation (SEM/EDS), phase analysis (XRD, FTIR), and electrochemical measurements (polarization curves, EIS). The Al-Si coated steel was studied over corrosion periods of 1, 8, 10, and 20 days to elucidate its corrosion behavior, interfacial evolution, and failure mechanism. The results indicated that the corrosion process exhibited a three-stage evolution: stable protection, rapid failure, and dynamic equilibrium. At the initial stage (1 day), a dense Al₂O₃ passive film formed on the coating surface, providing excellent substrate protection, with a corrosion current density of only 1.77 µA/cm² and a maximum charge-transfer resistance (R₂) of 652 Ω·cm². In the middle stage (8 days), Cl⁻ permeated through the cracked film, triggering selective dissolution of Al, while Si was enriched in situ to form a porous residual layer; the corrosion current density (I_corr) sharply increased to 13.25 µA/cm², and R₂ dropped to its minimum of 156.6 Ω·cm². Corrosion products at this stage were mainly Al₂O₃ and SiO₂, accompanied by small amounts of iron oxyhydroxides and hydroxides, and local coating failure began to appear. During the later stage (10–20 days), the corrosion products evolved into γ-FeOOH, α-FeOOH, and Fe₂O₃, which, together with an amorphous SiO₂ gel network enriched at the interface, formed a dual-layer composite rust layer. R2 consequently recovered from 156.6 Ω·cm² at 8 days to 424 Ω·cm² at 20 days, indicating a reduced corrosion rate and entry into a stable inhibition stage. The critical failure mechanism is that Cl⁻ preferentially penetrates the surface of the Al₂O₃ passive film, disrupting the metastable state of the coating and thereby creating pathways for corrosive media intrusion. The findings of this study can provide technical support for the safe application of such as-received coatings in non-load-bearing components with heat and corrosion resistance requirements. Full article

Detection of leaks in hydrogen (H₂) infrastructure is required on a large scale to enable a safe widespread use of this clean energy source. Sensing solutions must be low-cost, use scalable fabrication methods and allow multiplexed detection while providing reliable safety alarms as fast as possible. Optical methods can make this possible while avoiding the risk of ignition due to electronics at the point of detection. Metal hydride-based micro-mirror configurations benefit from a simple interrogation scheme, as long as the sensitive element can produce a large optical response. Magnesium thin films undergo a drastic variation of properties when hydrogenated, making them suitable for this application. In this work, a micro-mirror device using single-mode fibers capable of detecting the presence of H₂ with a loading t₁₀ and t₉₀ of 1.2 and 3.0 s, respectively, is demonstrated. A complete interrogation unit was developed, presenting a solution suited for widespread deployment using industry-standard optical components and equipment. Full article

Nanotextured thin film metallic glasses (TFMGs) have emerged as promising antimicrobial coatings for biomedical applications; however, systematic comparisons across compositionally distinct Ti- and Zr-based systems, as well as their early-stage bactericidal mechanisms, remain limited. Here, we show, for the first time, a comparative, compositionally resolved correlation linking alloy chemistry, nanotexture, and bactericidal mechanisms across polymorphic TFMGs. Three co-sputtered biocompatible coatings (Ti₄₇Fe₄₁Cu₁₂, Zr₇₁Fe₃Al₂₆, and Zr₅₈W₃₁Cu₁₁) were deposited on medical-grade titanium and stainless steel (SS316L) via magnetron co-sputtering, producing uniform amorphous films (190–298 nm) with nanoscale roughness of 1.6 ± 0.05 to 8.1 ± 0.05 nm. Surface wettability spanned hydrophilic (71.1 ± 5.6°) to hydrophobic (106.5 ± 3.5°), modulating bacterial interactions. Antimicrobial performance against Pseudomonas aeruginosa was evaluated using live/dead fluorescence imaging, quantitative image analysis, and electron microscopy after 2–4 h incubation. All coatings reduced bacterial adhesion and viability relative to bare substrates, with Zr₅₈W₃₁Cu₁₁ achieving >60% reduction in surface-associated bacterial coverage. Time-resolved analysis revealed a rapid transition to predominantly non-viable populations on coated surfaces, in contrast to sustained viability on controls. Mechanistically, bactericidal activity arises from the synergistic coupling of nanotopography-induced membrane stress, wettability-governed adhesion energetics, and in situ formation of CuO, Fe₂O₃, WO₃, and ZrO₂ oxides that promote electrostatic interactions and proposed reactive oxygen species generation, driving oxidative membrane damage. These results establish a scalable design framework for TFMGs, while highlighting the need for long-term biofilm and electrochemical validation. Full article

Direct current (DC) surface flashover on polystyrene (PS) remains a critical bottleneck that impedes its reliable application in high-voltage insulation apparatus. To circumvent the protracted processing durations and stringent film-forming conditions inherent in conventional surface modification techniques, this study proposes a novel “liquid-film-assisted in situ rapid plasma curing” strategy. By harnessing atmospheric-pressure dielectric barrier discharge (DBD) technology within an argon ambient, the rapid (<6 min) and efficient deposition of a fluorosilane (FAS-13) functional coating onto the substrate was achieved. Microscopic characterizations coupled with isothermal surface potential decay (SPD) measurements reveal that this coating substantially mitigates the detrapping and surface migration of charge carriers. Macroscopic DC flashover testing corroborates that, under the optimal modification ratio, the surface breakdown voltage of PS is elevated to 14.04 kV, yielding an insulation gain of 26.94%. To elucidate the underlying physical mechanisms, density functional theory (DFT) calculations were conducted, revealing that the energy band misalignment between the wide-bandgap fluorinated layer and the substrate facilitates the construction of a high-density deep trap network (with a depth of ~0.8 eV) at the coating–substrate interface. By robustly anchoring primary electrons and inducing the formation of a homopolar space charge shielding layer, these deep traps physically arrest the evolution of the secondary electron emission avalanche (SEEA). Consequently, this work not only establishes a viable engineering framework for the rapid, large-scale surface reinforcement of DC insulation equipment but also provides profound quantum chemical insights into interfacial trap regulation within all-organic dielectrics. Full article

Hot-press forming (HPF) steel is a promising lightweight material for automotive applications but suffers from oxidation and reduced corrosion due to high-temperature processing. Aluminized coatings, particularly Al-10Si, are widely used to mitigate this issue. However, HPF heat treatment can create brittle alloy layers with cracks, compromising retention and increasing corrosion risk. This study investigated the effects of Sr addition on the microstructure and corrosion resistance of Al-Si-coated HPF steel. Al-Si and Al-Si-Sr coatings were applied to steel substrates and subjected to heat treatment to produce heat-treated (HT) Al-Si and HT Al-Si-Sr samples. Sr addition refined and spheroidized eutectic Si particles, improved coating homogeneity, and mitigated vertical crack formation in the Al-Fe-Si intermetallic layer. The resulting dense, crack-free alloy layer effectively shielded the Fe substrate from corrosion. After heat treatment, Sr facilitated the formation of a fine lamellar microstructure and a dense, continuous oxide film, enhancing coating retention and sustaining barrier protection. These improvements significantly delayed corrosion propagation into the Fe substrate. Corrosion resistance was evaluated using salt-spray tests (ASTM B117), potentiodynamic polarization, and electrochemical impedance spectroscopy in 3.5 wt.% NaCl solutions. Microstructural analyses revealed that even minimal Sr content (0.05%) considerably enhanced the performance of Al-Si coatings, demonstrating industrial applicability. This study highlights the potential of Sr-added Al-Si coatings in addressing the demand for lightweight and corrosion-resistant materials in the automotive industry, offering a viable solution for high-performance and environmentally sustainable applications. Full article

This study systematically investigated flow boiling characteristics within a novel three-layer microchannel heat sink with 3/4 open-ring pin fin arrays, designed for high-heat-flux thermal management of low-carbon metallurgical reactors. Two-phase flow regimes, pressure drop, and wall temperature responses were analyzed. To evaluate the impact of functional surface material properties on thermo-hydraulic behavior, a hydrophilic nano-coating modification was applied to the inner copper channel walls for comparison. Increasing the flow rate triggered a transition from a vapor-dominated confined slug flow to a liquid-dominated dispersed bubble flow, which effectively improved the thermo-hydraulic stability. Hydrophilic surface modification resulted in an average pressure drop reduction of 33% and significantly diminished the sensitivity of flow resistance to velocity variations. Through hydrophilic treatment, the localized vapor film effect at high velocities was suppressed, and temperature field homogenization was promoted, yielding a maximum convective heat transfer coefficient of 7760 W/(m²·°C), i.e., 72.9% enhancement over the baseline heat sink. The underlying mechanism is attributed to the formation of a stable near-wall thin liquid film and the promotion of high-frequency nucleate boiling. These results will be of high relevance for developing efficient cooling solutions for power electronics, thereby supporting the advancement of low-carbon metallurgical reactors. Full article

Acrylic resin is widely used in the fabrication of complete dentures, interacting significantly with the intraoral environment. However, complete dentures face challenges such as stability issues and biofilm accumulation. Glaze application is a common method to reduce surface porosity and microbial adhesion, but it also decreases surface wettability, potentially impairing salivary film formation essential for peripheral sealing. This study aimed to incorporate titanium dioxide and zinc oxide nanoparticles into the glaze applied to thermally activated acrylic resin (TAAR) via spray coating to enhance surface wettability and antifungal activity. Four groups were tested: G (TAAR + commercial glaze − control); AlG (TAAR + commercial glaze + aluminum oxide − roughness control); TiG (TAAR + commercial glaze + titanium dioxide); and ZnG (TAAR + commercial glaze + zinc oxide). Evaluations included flexural strength, color and translucency, surface analysis and antibiofilm activity against Candida albicans. Data were analyzed using one-way ANOVA. No statistically significant differences in mechanical strength (MPa) were observed (G: 108.54 ± 8.36; AlG: 113.60 ± 11.95; ZnG: 111.98 ± 9.27; TiG: 113.66 ± 10.41). Surface roughness significantly increased, and contact angle decreased, indicating improved wettability. Regardless of the antifungal activity no improvement was detected (G: 6.71 ± 0.10; AlG: 6.82 ± 0.08; ZnG: 6.72 ± 0.20; TiG: 6.66 ± 0.18). In conclusion, the incorporation of nanoparticles into the glaze improves the wettability of acrylic resin surfaces, potentially enhancing peripheral sealing and denture retention, which is beneficial for patients with reduced alveolar ridge height. Full article

Aiming to address the problems of shield chamber blockage and poor muck discharge faced by earth pressure balance shields during tunneling in sandy strata, bentonite slurry is used for muck improvement. Using a multi-scale approach combining macro-scale experiments, micro-scale analysis, and molecular dynamics simulations, this study systematically investigates the interface interactions between particles of sandy soil in shield tunneling and the improvement mechanism of sodium-based bentonite slurry additives. Through the macroscopic experiment, the sodium bentonite slurry soil–water ratio of 1:7 and injection ratio of 25% showed the best improvement effect. After improvement, the permeability coefficient decreased by 99.72%; the cohesion of the excavated soil increased from 3.055 kPa to 11.458 kPa, representing a 275.06% increase; and the angle of internal friction decreased from 42.318° to 36.985°, a decrease of 12.60%. The improvement was significant. Through SEM, XRD, and FTIR microanalysis, it is found that bentonite slurry forms a flexible film on the surface of sandy soil. By coating sand particles, filling voids in the soil, and enhancing interparticle cohesion, it improves the properties of the soil. On the nanoscale, a Na-MMT/SiO₂ system model is established based on molecular dynamics simulations to elucidate the interactions between bentonite slurry and sand particle interfaces. The results indicate the presence of van der Waals forces and hydrogen bonds between Na-MMT and SiO₂. Interlayer water molecules form a hydrogen bond network that strengthens interfacial bonding, enabling bentonite slurry to tightly adhere to soil particle surfaces. This improves the microstructure of the soil, thereby enhancing its macroscopic properties. Full article

To accelerate the transition to sustainable energy, efficient methods for CO₂-free hydrogen production and carbon utilization are needed. This study presents a new, sustainable approach for the simultaneous production of hydrogen, valuable hydrocarbons, and functional carbon materials by converting methane in low-pressure microwave plasma. Compared to traditional methane reforming methods (such as steam reforming), our plasma-based process operates at low temperatures, eliminates direct CO₂ emissions, and enables the conversion of methane into three valuable products: (1) environmentally friendly hydrogen for fuel cells and energy storage systems, (2) a range of valuable organic products (C₂H₂, C₂H₄, C₂H₆), and (3) functional carbon films with self-improving catalytic properties. Optical emission spectroscopy (OES) and the Langmuir double probe method were used for plasma diagnostics, revealing an increase in the concentration of active species (CH, Hα, C₂) and electron temperature upon argon addition. The structure, morphology, and impurity composition of the deposited films were investigated using X-ray diffraction (XRD), scanning electron microscopy (SEM), and inductively coupled plasma mass spectrometry (ICP-MS), respectively. Gas-phase byproducts were analyzed using gas chromatography–mass spectrometry (GC-MS). Argon addition at an Ar/CH₄ ratio of 1 leads to the formation of carbon films with a more ordered structure, as confirmed by XRD data, and improved surface morphology. It was established that argon, by effectively participating in the excitation and dissociation processes of methane molecules through energy transfer from metastable states and increased electron temperature, optimizes plasma–chemical reactions, promoting the deposition of higher-quality carbon coatings. Full article

This study reports the development of a novel thin-film nanocomposite (TFN) reverse osmosis (RO) membrane with a surface functionalized using graphene oxide (GO) and polydopamine (PDA). GO was synthesized using a modified Hummers’ method and integrated into a PDA-coated commercial RO membrane. The membranes were treated with UV light for varying durations to enable crosslinking of GO nanoparticles to the membranes. The modified membranes showed improved pure water permeability (PWP) and salt rejection compared to the pristine membrane. The resulting RO membrane, which was exposed to 60 min of UV and contained 0.02 g of GO, achieved the best performance, with a PWP of 23.8 L m⁻² h⁻¹ bar⁻¹ and a salt rejection of 96%. Antiscaling and antifouling properties were notably enhanced, as indicated by stable flux under silica scaling and decreased bacterial growth. These results suggest that PDA-GO functionalization is a promising approach for improving membrane durability and efficiency in desalination processes. Full article

Chalcopyrite-based thin-film solar cells have great potential for various applications, such as top or bottom cells in tandem devices, in addition to their use as standard single-junction modules due to their tuneable bandgap energy. A bandgap energy E_g > 1.5 eV should be targeted to realize a wide-bandgap top cell, e.g., by increasing the [Ga]/([Ga] + [In]) (GGI) ratio in Cu(In,Ga)Se₂ (CIGS) cells to the range of 0.7–1. A second approach is targeting the second theoretical efficiency maximum at a little lower E_g = 1.34 eV with a GGI around 0.6 for high-efficiency single-junction applications with reduced electrical losses. An industry-relevant (Ag,Cu)(In,Ga)Se₂ (ACIGS) co-evaporation process for wide-bandgap cells fabricated with GGI ratios above 0.6, with moderate [Ag]/([Ag] + [Cu]) (AAC) ratios < 0.1 and in-line RbF-PDT, was established on molybdenum-coated soda-lime glass substrates. Both measures, Ag alloying and RbF-PDT, can increase power conversion efficiency (PCE) mainly due to improved open-circuit voltage (V_OC). In addition, Ag addition can increase fill factor (FF)_, leading to an increase in the PCE for cells with GGI > 0.6 compared to Ag-free reference cells. (Zn,Mg)O, either with a [Mg]/([Mg] + [Zn]) ratio of 0.15 or 0.25, is a good option as high-resistive layer replacing the commonly used i-ZnO in combination with a CdS buffer. Our best ACIGS wide-bandgap solar cells with RbF-PDT and Zn_0.85Mg_0.15O (without anti-reflective coating (ARC)) from various experimental campaigns show a PCE of 12.7% (E_g = 1.50 eV), and with a slightly reduced E_g of 1.45 eV a PCE of 15.5%, with V_OC of 933 mV (V_OC deficit of 517 mV), and a good FF of 73.2%. In the case when the bandgap is significantly lowered to 1.34 eV (GGI = 0.61), to the second theoretical efficiency maximum, we achieved a PCE of 18.2% with ARC for an Ag-free CIGS cell with RbF-PDT. For this cell with a CdS/i-ZnO buffer system the V_OC deficit is 480 mV, and the FF is 78.1%. Full article

This study investigated the degradation behavior of a polyurethane acrylate coating/Q345B steel system under the coastal atmospheric conditions of Wenchang, Hainan, and evaluated the correlation between indoor accelerated tests and outdoor exposure. Outdoor exposure tests, single-factor accelerated tests (UV irradiation and neutral salt spray), and a multi-factor cyclic accelerated test combining UV, salt spray, humidity, and thermal cycling were conducted. Coating degradation was characterized by morphological observation, gloss measurement, adhesion testing, and electrochemical impedance spectroscopy. The results showed that after 8 months of outdoor exposure, localized rust spots, blistering, and under-film corrosion appeared on the coating surface. The gloss loss rate reached 15.72% after 3 months, while adhesion decreased from 5.83 MPa to 2.39 MPa during prolonged exposure. UV irradiation mainly affected gloss degradation, whereas corrosive media penetration played a dominant role in adhesion loss and electrochemical deterioration. Compared with single-factor tests, the multi-factor cyclic accelerated test exhibited the highest correlation with outdoor exposure. The corresponding correlation coefficients for gloss loss, adhesion, and low-frequency impedance modulus were 0.9764, 0.9988, and 0.9929, respectively, while the gray relational coefficients reached 0.8334, 0.8467, and 0.7977. These results demonstrate that the multi-factor cyclic accelerated test more accurately reproduces the degradation behavior and failure characteristics observed in the coastal atmosphere of Hainan. The proposed method provides a practical approach for indoor–outdoor correlation analysis and durability evaluation of protective coatings in marine atmospheric environments. Full article

In this study, La-doped TiO₂-SiO₂ composite films were deposited on glass substrates by radio-frequency magnetron sputtering. The evolution of microstructure and macroscopic properties was systematically investigated across an annealing temperature range of 350–650 °C. The results show that the La-doped TiO₂-SiO₂ composite structure effectively suppresses abnormal grain growth and delays the anatase-to-rutile phase transition, thereby improving the films’ high-temperature structural stability. Notably, the composite film annealed at 550 °C (LS-550) exhibits the highest anatase crystallinity and forms a dense, smooth (RMS = 1.37 nm), crack-free nanocrystalline network. In terms of wettability, the improved hydrophilicity is attributed to the combined effects of La incorporation and hydrophilic silanol (Si-OH) groups in the amorphous SiO₂ phase. As a result, the water contact angle of the LS-550 film decreases dramatically to 28.0°, indicating excellent hydrophilicity. Moreover, the LS-550 film demonstrates an optimal photocatalytic degradation efficiency of approximately 76% for methylene blue, significantly outperforming the pure TiO₂ film. Furthermore, the enhanced mechanical performance is associated with the combined effects of the SiO₂-containing amorphous phase and the finer microstructure induced by La incorporation. Consequently, the critical load (Lc) of the LS-550 film reaches 75.64 mN, significantly exceeding that of the pure TiO₂ film annealed at the same temperature (61.25 mN). In summary, the composite film annealed at 550 °C concurrently achieves high crystallographic thermal stability, robust interfacial mechanical durability, excellent surface hydrophilicity, and enhanced photocatalytic activity, thereby offering practical guidance for developing TiO₂-based coatings with self-cleaning potential for high-rise building curtain walls. Full article