Search Results (1,412)

This study investigates the combined effects of drilling parameters and tool features on thrust force during drilling of hybrid AA7050/CFRP stacks intended for aerospace applications. Experiments were designed using a Taguchi L16 (4²2²) orthogonal array by considering feed rate, cutting speed, drill diameter, and coating condition. Unlike most previous studies on Al/CFRP stack drilling, this work provides a layer-specific evaluation by separately analyzing the thrust-force responses of the AA7050 and CFRP layers, while also correlating force behavior with aluminum-side damage and CFRP-side delamination within a unified framework. For the aluminum layer, feed rate was the dominant factor affecting thrust force, with a contribution of 71.22%, followed by drill diameter (26.22%). For the CFRP layer, drill diameter was the most influential parameter (52.58%), followed by feed rate (43.77%). Thrust force ranged from 155.24 to 414.45 N for AA7050 and from 77.73 to 175.39 N for CFRP. Uncoated tools and higher feed rates increased thrust force, leading to poorer machining performance. Delamination in the CFRP layer was primarily governed by feed rate (46.71%), followed by drill diameter (35%). Overall, increasing feed rate and drill diameter significantly deteriorated the machinability of the hybrid structure. Full article

To prevent corrosion in humid environments and electrical failure under loads, we developed a highly durable corrosion-resistant flexible strain sensor with a patterned sandwich structure. The effects of film dimensions and ambient temperature on the sensor’s electrical conductivity were investigated separately. The patterned flexible strain sensor demonstrated exceptional durability, maintaining stability after multiple tensile cycles and large deformations. The PDMS coating effectively protected the conductive layer from external environmental factors. Experimental results revealed that the sensor could efficiently block the corrosive effects of humid environments. Furthermore, when applied to real-time micro-strain detection in steel plate tensile tests, the relationship between ΔR/R₀ and strain exhibited high linearity and sensitivity. The conductive film shows excellent durability and corrosion resistance, demonstrating significant application potential as a flexible strain sensor in humid conditions. Full article

Lithium–sulfur batteries (LSBs) offer a theoretical energy density of 2600 Wh kg⁻¹ but suffer from the polysulfide shuttle effect, which causes rapid capacity decay and limits practical application. To address this, we developed a bifunctional separator coating using Ni-doped α-MnO₂ combined with carbon nanotubes (Ni-MnO₂/CNTs). Ni doping induces lattice expansion due to the larger Ni²⁺ ionic radius, modulating the electronic structure to create more active sites, enhance electrical conductivity, and improve polysulfide adsorption and redox kinetics. The needle-like morphology further strengthens physical/chemical confinement of polysulfides and accelerates conversion reactions. Batteries with the Ni-MnO₂/CNTs-modified separator deliver a high-rate capacity of 813 mAh g⁻¹ at 5 C and exhibit a low capacity decay rate of 0.0399% per cycle over 1500 cycles at 2 C. Even under high sulfur loading (∼10 mg cm⁻²) and lean electrolyte conditions (10 μL mg⁻¹), the cell maintains stable cycling with a decay rate of 0.0929% per cycle over 300 cycles at 0.2 C. This lattice-modulation strategy on commercial separators provides a simple, effective pathway toward high-energy-density, long-life LSBs. Full article

The development of reliable electrochemical interfaces for biosensor applications requires materials that combine high conductivity, large effective surface area, and suitable platforms for biomolecule immobilization. In this work, a hybrid electrochemical platform based on screen-printed carbon electrodes (SPCEs) modified with electropolymerized polypyrrole (PPy) and electrodeposited silver particles (AgPs) is presented for the subsequent immobilization of Ki-67 antibodies. PPy films were synthesized under optimized electrochemical conditions, producing homogeneous, porous, and electrochemically stable coatings that significantly enhanced the doping/undoping processes from 0.3280 C/0.3284 C to 0.3281 C/0.3284 C for SPCE and SPCE-PPy, respectively. Subsequently, silver particles were deposited onto the PPy matrix, resulting in a well-dispersed and uniform distribution of AgPs, promoted by the interaction between Ag⁰ and the nitrogen groups in the polymer backbone. The synergistic combination of PPy and AgPs resulted in improved charge-transfer properties and enhanced electrochemical reversibility, thereby decreasing the peak-to-peak separation of the ferricyanide/ferrocyanide redox couple used as a probe by 40%. Immobilization of Ki-67 antibodies was achieved via direct interaction with AgPs, resulting in a marked passivation effect, as evidenced by the suppression of redox probe signals, confirming successful biofunctionalization. The proposed SPCE-PPy-AgP architecture provides a robust, reproducible, and versatile platform for antibody immobilization, as demonstrated by oxidation and reduction peaks with relative standard deviations (RSDs) of 3.18% and 4.43%, respectively, highlighting its potential for developing label-free electrochemical immunosensors for clinically relevant proliferation biomarkers. Full article

The design and main parameters of a plasma–chemical reactor containing two compartments are presented. One compartment houses a vacuum-arc evaporator, while the other houses a planar magnetron. The compartments are separated by a diaphragm with a dosing slot for injecting copper vapor into the TiN synthesis compartment. The conditions for the synthesis of superhard TiN-Cu composite coatings are experimentally determined. Based on established process parameters for TiN synthesis in a nitrogen-containing plasma by Ti evaporation using a vacuum-arc discharge, it is proposed to apply TiN-Cu coatings by injecting Cu vapor into the TiN synthesis area and sputtering Cu using a magnetron discharge. XRD analyses of both TiN and TiN-Cu coatings show the presence of WC, Ti₂C, and TiN. EDS analysis confirms 5.57 at. % copper on the surface of the TiN-Cu coating. Real-life operating tests of TiN-Cu coatings on replaceable WC-TiC-Co (79/15/6 wt.%) alloy hexagonal inserts used for cutting 40Kh steel revealed that applying the TiN-Cu coating extends the tool life of WC-TiC-Co inserts by about 2.5 times compared with uncoated tools. Cutting force measurements on TiN-Cu-coated inserts showed no vibration or noise during cutting, driven by a reduced friction coefficient and improved heat dissipation at the contact zone between the cutting edge and the workpiece, thereby lowering the temperature in that area. Full article

Improving the interfacial compatibility between cellulose and poly(butylene adipate-co-terephthalate) (PBAT) is critical for enhancing the performance of PBAT-based composites. Here, microcrystalline cellulose (MCC) was homogeneously silanized at the molecular chain level using t-hexyldimethylchlorosilane (TDMS-Cl) as the modifier, yielding t-hexyldimethylsilylated cellulose (TDMS-Cell). TDMS-Cell/PBAT composite films were then prepared by solution blending and casting in tetrahydrofuran (THF). Structural characterizations confirmed the successful grafting of TDMS-Cl onto cellulose chains, resulting in TDMS-Cell with a degree of substitution of approximately 2. Microstructural observations combined with thermal analysis revealed that TDMS-Cell exerted a dual effect on the crystallization behavior of PBAT: it acted as a heterogeneous nucleating agent that increased the crystallization temperature, while the pronounced steric hindrance simultaneously suppressed crystal growth. Mechanical testing showed that simultaneous strengthening and toughening were achieved at an optimal TDMS-Cell loading of 3–5 wt%. Specifically, the tensile strength increased from ~16 MPa for neat PBAT to 21 MPa (31.25% improvement), and the elongation at break increased from ~700% to 964% (37.7% improvement). In addition, the incorporation of an appropriate amount of TDMS-Cell effectively enhanced the surface hydrophobicity of the composite films. At higher filler loading, however, solvent evaporation-induced phase separation led to self-aggregation of TDMS-Cell, which in turn deteriorated both the mechanical properties and surface hydrophobicity of the composites. Overall, this work systematically elucidates the structure–property relationships of silanized cellulose/PBAT composites in a homogeneous solution system, providing a rational basis for interfacial design and property optimization of PBAT/biomass-based composite materials. The prepared TDMS-Cell/PBAT composite films with balanced mechanical strength, tunable crystallization behavior, and improved surface hydrophobicity exhibit great potential for practical applications in high-performance flexible packaging materials, functional film substrates, lightweight composite structural components, and tunable hydrophobicity coating substrates. Full article

Lithium–sulfur (Li-S) battery technology has attracted significant research interest owing to sulfur’s remarkable theoretical capacity and exceptional energy density potential. Nevertheless, the low conductivity of sulfur and the “shuttle effect” pose challenges to its practical applications. To enhance electrochemical performance, this work developed nitrogen-doped graphene (NG) nanosheets as a separator coating for Li-S battery. As a modification layer for separators, NG acts as a physical barrier that prevents polysulfides from migrating across the separator to reach the anode, thereby mitigating the shuttle effect. Additionally, NG improves the conductivity of the separator and enhances wettability between the separator and electrolyte, facilitating uniform transmission of lithium ions. Notably, NG functionalized separators demonstrate excellent mechanical flexibility, contributing to improved cycle stability for batteries. Furthermore, theoretical calculations indicate a strong interaction between NG and lithium polysulfides (LiPSs), effectively inhibiting polysulfide migration. The Li-S battery utilizing the NG modified separator maintains a capacity retention rate of 51.5% after 100 cycles at 0.1 C with a sulfur loading of 1.47 mg/cm² and exhibits a capacity decay rate of only 0.092% after 500 cycles at a discharge rate of 1 C. This work highlights the potential advantages of employing NG as a separator coating layer in enhancing the electrochemical performance of the Li-S battery. Full article

As a prospective two-dimensional conductive filler, titanium carbide (MXene) can remarkably boost the dielectric constant (ε) of polymer composites at low loadings. Nevertheless, the accompanied large dielectric loss (tan δ) and leakage current greatly limit their practical applications in dielectric-related fields. To tackle this dilemma, an organic polydopamine (PDA) shell was coated on an MXene surface via a self-polymerization method, and the dielectric properties of PDA-modified MXene/poly(vinylidene fluoride) (PVDF) were explored. The findings show that, in comparison to unmodified MXene/PVDF, MXene@PDA/PVDF retains a high ε and improved breakdown strength (E_b). It further realizes a notable decrease in both tan δ and electrical conductivity. The introduced PDA interlayer serves to effectively separate adjacent MXene nanosheets, which inhibits the development of conductive paths and introduces charge traps to restrict carrier migration, thus reducing tan δ. Further, the interlayer not only improves the interfacial compatibility, but also mitigates strong dielectric mismatch between MXene and PVDF, which facilitates the homogeneous redistribution of the local electric field, contributing to enhanced E_b. Theoretical fitting and simulation studies unlock the profound polarization mechanisms and charge migration modulated by the PDA interlayer. The resulting Mxene@PDA/PVDF exhibits concurrently elevated ε (35.68) and enhanced E_b (12.94 kV/mm), as well as low tan δ (0.34) at 10³ Hz and 7 wt% filler loading, which is not achievable in neat MXene/PVDF. This work demonstrates that core–shell interfacial engineering offers an effective strategy for designing flexible polymer dielectrics with superior dielectric performances, showcasing potential applications in energy storage, advanced power systems and flexible electronics. Full article

To address critical challenges in marine oil spill remediation, including limited penetration of high-viscosity crude oil and inefficient adsorbent recovery, it is imperative to develop environmentally friendly materials integrating high-efficiency adsorption, in situ viscosity reduction, and controllable recovery. In this study, a delignified corn pith (CPDL) with a three-dimensional porous structure was employed as a green matrix. Through constructing a Fe₃O₄/expansible graphite (EG)/polyvinylidene fluoride (PVDF) composite functional coating combined with silanization modification, a multifunctional biomass-based oil sorbent (Fe₃O₄/EG/PVDF-CPDL) was successfully fabricated. The material maintains the inherent porous architecture while forming a stable micro/nano-rough surface, exhibiting excellent superhydrophobicity with a water contact angle of approximately 155°, and demonstrating exceptional stability in harsh acidic/alkaline/saline environments and multiple cycles. Benefiting from the synergistic photothermal effect of Fe₃O₄ and EG, under one sun illumination (1 kW/m²), the material surface temperature rapidly reaches above 80 °C within 100 s, reducing the viscosity of high-viscosity crude oil by over 95% (from 1.39 × 10⁵ to approximately 6.0 × 10³ mPa·s), thereby enabling rapid penetration and adsorption within 50 s. Moreover, the composite coating significantly enhances mechanical performance, achieving a compressive strength of 320 kPa (approximately eight times higher than that of the pristine substrate), ensuring structural integrity during handling and compression recovery. Meanwhile, the material demonstrates precise directional manipulation and efficient recovery through external magnetic fields due to its superior magnetic responsivity. Experimental results reveal a broad-spectrum adsorption capacity (14.8–30.2 g/g) and separation efficiency exceeding 96% after 20 adsorption–desorption cycles. In summary, this work presents an innovative strategy with significant application potential for efficient and controllable remediation of marine oil spills, particularly high-viscosity crude oil, by integrating synergistic functions of porous adsorption, superhydrophobic corrosion resistance, photothermal viscosity reduction, mechanical reinforcement, and magnetic control. Full article

Droplet manipulation constitutes a fundamental operation in numerous bio-microfluidic applications, including but not limited to medical diagnostics and targeted drug delivery. Among the various technologies developed for this purpose, magnetic digital microfluidics (MDMF) has emerged as a compelling approach due to its inherent advantages of contamination-free actuation, low cost, and configurational flexibility. Nevertheless, conventional MDMF remains constrained by its reliance on bulky instrumentation and substantial power consumption for generating controllable magnetic fields, which limit its in-field applications. To address these limitations, this work presents a programmable and portable electromagnetic microfluidic droplet manipulation platform that synergistically integrates static and dynamic magnetic fields to enable non-contact, high-precision droplet control under ultra-low power conditions. The proposed system comprises an electromagnetic actuation module, a permanent magnet, and a glass substrate coated with Teflon film. The entire system is secured by a PMMA support structure, within which a glass substrate is mounted and spatially separated from the permanent magnet. The PMMA support is fabricated using a milling process, offering a simple manufacturing procedure and high structural reusability and reproducibility. The control logic is implemented on a field-programmable gate array (FPGA) development board, facilitating fully autonomous operation powered by a standard battery. The platform operates at a low voltage of 3.5 V and a driving current of 180 mA, corresponding to a total power consumption of merely 0.63 W, while achieving robust manipulation of droplets in the volume range of 0.5 to 5 μL. A maximum average droplet velocity of up to 0.6 cm/s was attained under optimal conditions. The proposed platform offers a scalable and energy-efficient solution for portable droplet-based assays and holds significant promise for integration into point-of-care diagnostic tools and field-ready biochemical analysis systems. The platform demonstrates excellent operational stability and reproducibility, as validated by repeated actuation experiments with a positioning deviation of approximately 0.1 mm under optimized conditions. The fabrication process also exhibits high reliability with consistent performance across multiple experimental runs. Full article

This study investigates the structural, chemical, and morphological characteristics of electron-beam–deposited GO/Ag nanocomposite thin films and establishes a compact continuum–spectral framework for quantifying their post-deposition roughness. Since atomic force microscope (AFM) measurements provide only the final, frozen morphology and no direct temporal information, distinguishing between transient and stationary spectra is not experimentally feasible within the limited AFM wavenumber band. In practice, the accessible power spectral densities (PSDs) show no resolvable deviation from the stationary form, and transient contributions cannot be uniquely identified. The stationary PSD is fitted directly to azimuthally averaged AFM spectra, allowing the smoothing coefficients, noise intensity, correlation length, and crossover scale to be extracted in a fully data-driven manner. The fitted model accurately reproduces the characteristic dual (k⁻²)/(k⁻⁴) spectral scaling and predicts the scan-size dependence of root-mean-square roughness, typically achieving logarithmic determination coefficients above 0.98. The close agreement among parameters obtained from spatially separated sampling points confirms the lateral uniformity of the deposited films and highlights the robustness of the continuum–spectral approach for data-guided roughness control in electron-beam-grown nanocomposite coatings. Full article

Developing materials that simultaneously exhibit bulk elasticity and a durable, self-renewing surface is a persistent challenge, as traditional fillers often impair flexibility and sacrificial coatings fail under repeated strain. This paper presents an innovative thiol–ene/polyurethane hybrid system, fabricated via a sequential thermal–UV curing process, which decouples the properties of the highly elastic bulk from those of the robust surface layer. The resulting bulk elastomer achieves an outstanding combination of high strength (20.9 MPa) and exceptional extensibility (990% elongation at break). Crucially, the UV-crosslinked surface forms a dense, abrasion-resistant shield that reduces friction-induced mass loss by 81% compared to the bulk material. This surface layer also exhibits a unique self-renewing capability, effectively restoring its protective function over at least three abrasion cycles and reducing mass loss by 57% after the first recovery cycle relative to an unprotected control. Dynamic mechanical analysis validates the distinct dual-network structure, evidenced by two well-separated glass transition temperatures, which underpin the material’s pronounced shape memory effect. This work provides a design paradigm for creating flexible and durable polymer systems with independently tailored bulk and surface properties, offering significant potential for applications in artificial skin and demanding flexible components. Full article

Non-covalent molecular self-assembly serves as a distinctive strategy for enhancing the mechanical performance of lignin-based composite hydrogels. Nevertheless, the self-assembly process can be significantly influenced, leading to alterations in the nanostructure of the hydrogel, because of the diverse conformational reorganizations of lignin in different solvents. In this research, a solvent exchange process was employed to generate a phase-separated structure comprising hydrophobic lignin domains and hydrophilic poly(N,N-dimethylacrylamide) (PDMA) domains through the aggregation of lignin, thereby forming tough lignin/PDMA hydrogels. By adjusting the solvent composition, the hydrogels exhibit distinct nanostructural transformations that are precisely correlated with the changes in Hansen Solubility Parameters (HSPs) of the solvent mixtures. Balanced HSPs facilitates the formation of small-scale lignin domains with high-domain density, which act as crosslinking points for the establishment of a reinforced network. Remarkably, lignin/PDMA hydrogels prepared at a boundary solvation condition unexpectedly induced the formation of large and highly condensed lignin domains, which displayed a radius of gyration (Rg) of 7.7 nm and an inter-domain distance (d-spacing) of 98.1 nm within the hydrogel network. These unique nanostructural features further contribute to its superior mechanical performance, including excellent tensile strength of 3.2 MPa, Young’s modulus of 5.7 MPa, and fracture energy of 41.2 kJ m⁻², which outperforms most reported lignin hydrogels. Additionally, it offers a strong adhesion and rapid drying approach, rendering the hydrogel more suitable for applications as hydrogel coatings. Full article

Molecularly imprinted polymers (MIPs) are widely employed for selective adsorption of target molecules in sensing and separation applications. The architecture of MIP films can influence adsorption behavior, interfacial stability, and reusability, yet systematic investigations of these effects are limited. This study aimed to evaluate how different polypyrrole (PPy) MIP film architectures affect the adsorption, stability, and regeneration characteristics of geraniol-imprinted layers on gold electrodes. Geraniol-imprinted and non-imprinted PPy films were electropolymerized onto quartz crystal microbalance (QCM) substrates. Two film architectures were compared: (i) a single-layer geraniol-imprinted PPy film, and (ii) a double-layer film consisting of a non-imprinted PPy underlayer followed by a geraniol-imprinted layer. Film characterization was performed using cyclic voltammetry (CV) and electrochemical quartz crystal microbalance (EQCM) measurements. Adsorption–desorption cycles were conducted to assess mass uptake, signal stability, and regeneration performance. EQCM analysis revealed that the double-layer architecture exhibited enhanced frequency signal stability during repeated adsorption–desorption cycles compared to single-layer films, suggesting a stabilizing effect of the underlying non-imprinted PPy layer at the electrode interface. Geraniol-imprinted films demonstrated significantly higher mass uptake than non-imprinted controls, confirming the sensitivity provided by molecular imprinting. Single-layer films showed more variability in signal response and less consistent regeneration performance. The architecture of MIP films significantly affects adsorption behavior, stability, and regeneration on electrode surfaces. Incorporating a non-imprinted PPy underlayer can improve signal reproducibility and enhance the robustness of MIP-based sensing interfaces. These findings provide guidance for the rational design of MIP coatings for electrochemical sensors and QCM-active platforms. Full article

Plasma-facing materials (PFMs) for future fusion reactors require advanced mechanical and thermal properties to withstand the extreme challenges of high heat flux, plasma exposure, and neutron irradiation. Tungsten is one of the most suitable materials for use as a PFM in the divertor region. However, considering the high thermal loading/thermal stress combining plasma exposure and neutron irradiation/embrittlement, one of the major concerns for tungsten in PFMs is its intrinsic brittleness. To avoid cracking and components failure, tungsten toughening has been widely investigated, including the development of tungsten fiber-reinforced tungsten composites (W_f/W) using an extrinsic toughening mechanism, which could provide damage resilience against neutron embrittlement. Recently, a type of aligned long-fiber W_f/W (L-W_f/W) based on a powder metallurgical fabrication process was developed, demonstrating advanced fracture toughness while retaining other application-relevant properties. For L-W_f/W, the relatively easy production process suggests the feasibility and basis of industrialization. This work reports on the initial progress in industrializing L-W_f/W, with a focus on adapting the lab sintering process to a sintering process with industrial partner (Dr. Fritsch Sondermaschinen GmbH) and optimizing the process parameters. To improve the sinterability of tungsten and achieve higher density, various tungsten powders were explored, including commercial W powders, bimodal mixtures of different particle sizes, and granulated W powders. At the dedicated yttria interface, the thickness of yttria coating on the fibers was also optimized to ensure effective separation between the fibers and the matrix. Series of samples were produced with different dimensions up to 100 mm × 100 mm × 4 mm. After optimization, samples with 93% density and desired pseudo-ductility were prepared. Similarly to production in the lab, a major challenge in this work involved balancing the densification of the tungsten matrix with controlling fiber recrystallization and mitigating damage to the yttria interface. Full article