Search Results (1,687)

Magnetron Sputter Vacuum Deposition (MSVD) has undergone significant advancements since its inception. This review explores the evolution of MSVD, encompassing its fundamental principles, various techniques (including reactive sputtering, pulsed magnetron sputtering, and high-power impulse magnetron sputtering), and its wide-ranging industrial applications. While detailing the advantages of high deposition rates, versatility in material selection, and precise control over film properties, the review also addresses inherent challenges such as low target utilization and plasma instability. A significant portion focuses on the crucial role of MSVD in the automotive industry, highlighting its use in creating durable, high-quality coatings for both aesthetic and functional purposes. The transition from traditional electroplating methods to more environmentally friendly MSVD techniques is also discussed, emphasizing the growing demand for sustainable manufacturing processes. This review concludes by summarizing the key advancements, remaining challenges, and potential future trends in magnetron sputtering technologies. Full article

Polyethylenimine (PEI) is a cationic polymer with a high density of amine groups suitable for strong electrostatic interactions with biological molecules to preserve their bioactivities during encapsulation and after delivery for biomedical applications. This review provides a comprehensive overview of PEI as a drug and gene carrier, describing its polymerization methods in both linear and branched forms while highlighting the processing methods to manufacture PEIs into drug carriers, such as nanoparticles, coatings, nanofibers, hydrogels, and films. These various PEI carriers enable applications in non-viral gene and small molecule drug deliveries. The structure–property relationships of PEI carriers are discussed with emphasis on how molecular weights, branching degrees, and surface modifications of PEI carriers impact biocompatibility, transfection efficiency, and cellular interactions. While PEI offers remarkable potential for drug and gene delivery, its clinical translation remains limited by challenges, including cytotoxicity, non-degradability, and serum instability. Our aim is to provide an understanding of PEI and the structure–property relationships of its carrier forms to inform future research directions that may enable safe and effective clinical use of PEI carriers for drug and gene delivery. Full article

Although cemented carbides have been manufactured by the powder metallurgy (P/M) technology for over a century now, systematic developmental efforts are still underway. In the present study, tool life improvements in metal grooving applications are the key objective. Four PVD-coated cemented carbides compositions, dedicated to groove steel, stainless steel, cast iron, and aluminium alloys, have been newly designed, along with their manufacturing conditions. Physical, mechanical and chemical characteristics—such as sintered density, modulus of elasticity, hardness, fracture toughness, WC grain size, and the chemical composition of the substrate material, as well as the chemical composition, microhardness, structure, and thickness of the coatings—have been studied. A series of grooving tests have also been conducted to assess whether modifications to the thus far marketed tool materials, tool geometries, and coatings can improve cutting performance. In order to compare the laboratory and application properties of the investigated materials with currently produced by reputable companies, commercial inserts have also been tested. The experimental results obtained indicate that the newly developed grooving inserts exhibit excellent microstructural characteristics, high hardness, fracture toughness, and wear resistance and that they show slightly longer tool life compared to the commercial ones. Full article

Secondary hypereutectic Al-Si alloys are attractive for sustainable manufacturing, yet their application is often limited by low strength and electrical conductivity due to impurity-induced microstructural defects. Achieving a balance between mechanical and conductive performance remains a significant challenge. In this work, nickel-coated carbon nanotubes (Ni-CNTs) were introduced into secondary Al-20Si alloys to tailor the microstructure and enhance properties through interfacial engineering. Composites containing 0 to 0.4 wt.% Ni-CNTs were fabricated by conventional casting and systematically characterized. The addition of 0.1 wt.% Ni-CNTs resulted in the best combination of properties, with a tensile strength of 170.13 MPa and electrical conductivity of 27.60% IACS. These improvements stem from refined α-Al dendrites, uniform eutectic Si distribution, and strong interfacial bonding. Strengthening was achieved through grain refinement, Orowan looping, dislocation generation from thermal mismatch, and the formation of reinforcing interfacial phases such as AlNi₃C₀.₉ and Al₄SiC₄. At higher Ni-CNT contents, property degradation occurred due to agglomeration and phase coarsening. This study presents an effective and scalable strategy for achieving strength–conductivity synergy in secondary aluminum alloys via nanoscale interfacial design, offering guidance for the development of multifunctional lightweight materials. Full article

The detection of trace chemicals at low and ultra-low concentrations is critical for applications in environmental monitoring, medical diagnostics, food safety and other fields. Conventional detection techniques often lack the required sensitivity, specificity, or cost-effectiveness, making real-time, in situ analysis challenging. Surface-enhanced Raman spectroscopy (SERS) is a powerful analytical tool, offering improved sensitivity through the enhancement of Raman scattering by plasmonic nanostructures. While noble metals such as Ag and Au are currently the reference choices for SERS substrates, fabrication methods should balance enhancement efficiency, reproducibility and scalability. In this study, we propose a novel approach for SERS substrate fabrication using reactive Aerosol Jet Printing (r-AJP) as an innovative additive manufacturing technique. The r-AJP process enables in-flight Ag seed reduction and nucleation of Ag nanoparticles (NPs) by mixing silver nitrate and ascorbic acid aerosols before deposition, as suggested by computational fluid dynamics (CFD) simulations. The resulting coatings were characterized by X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses, revealing the formation of nanoporous crystalline Ag agglomerates partially covered by residual matter. The as-prepared SERS substrates exhibited remarkable SERS activity, demonstrating a high enhancement factor (10⁶) for rhodamine (R6G) detection. Our findings highlight the potential of r-AJP as a scalable and cost-effective fabrication strategy for next-generation SERS sensors, paving the way for the development of a new additive manufacturing tool for noble metal material deposition. Full article

A modular strategy for the molecular design of silicone-based antifoaming agents was developed by precisely controlling the architecture of poly (methylhydrosiloxane) (PMHS). Sixteen PMHS variants were synthesized by systematically varying the siloxane chain length (L1–L4), backbone composition (D₃T₁ vs. D₃₀T₁), and terminal group chemistry (H- vs. M-type). These structural modifications resulted in a broad range of Si-H functionalities, which were quantitatively analyzed and correlated with defoaming performance. The PMHS matrices were integrated with high-viscosity PDMS, a nonionic surfactant, and covalently grafted fumed silica—which was chemically matched to each PMHS backbone—to construct formulation-specific defoaming systems with enhanced interfacial compatibility and colloidal stability. Comprehensive physicochemical characterization via FT-IR, ¹H NMR, GPC, TGA, and surface tension analysis revealed a nonmonotonic relationship between Si-H content and defoaming efficiency. Formulations containing 0.1–0.3 wt% Si-H achieved peak performance, with suppression efficiencies up to 96.6% and surface tensions as low as 18.9 mN/m. Deviations from this optimal range impaired performance due to interfacial over-reactivity or reduced mobility. Furthermore, thermal stability and molecular weight distribution were found to be governed by repeat unit architecture and terminal group selection. Compared with conventional EO/PO-modified commercial defoamers, the PMHS-based systems exhibited markedly improved suppression durability and formulation stability in high-viscosity environments. These results establish a predictive structure–property framework for tailoring antifoaming agents and highlight PMHS-based formulations as advanced foam suppressors with improved functionality. This study provides actionable design criteria for high-performance silicone materials with strong potential for application in thermally and mechanically demanding environments such as coating, bioprocessing, and polymer manufacturing. Full article

Background and Objectives: Posterior chamber phakic implantable contact lenses (Phakic-ICL) are widely used for refractive correction due to their efficacy and safety, including minimal corneal endothelial cell loss. The Collamer-based EVO+ Visian implantable contact lens (ICL), manufactured from Collamer, which is a blend of collagen and hydroxyethyl methacrylate (HEMA), has demonstrated excellent long-term biocompatibility and optical clarity. Recently, hydrophilic acrylic Phakic-ICLs, such as the Implantable Phakic Contact Lens (IPCL), have been introduced. This study investigated the material differences among Phakic-ICLs and their interaction with fibronectin (FN), which has been reported to adhere to intraocular lens (IOL) surfaces following implantation. The aim was to compare Collamer, IPCL, and LENTIS lenses (used as control) in terms of FN distribution and cell adhesion using a small number of explanted Phakic-ICLs. Materials and Methods: Three lens types were analyzed: a Collamer Phakic-ICL (EVO+ Visian ICL), a hydrophilic acrylic IPCL, and a hydrophilic acrylic phakic-IOL (LENTIS). FN distribution and cell adhesion were evaluated across different regions of each lens. An in vitro FN-coating experiment was conducted to assess its effect on cell adhesion. Results: All lenses demonstrated minimal FN deposition and cellular adhesion in the central optical zone. A thin FN film was observed on the haptics of Collamer lenses, while FN adhesion was weaker or absent on IPCL and LENTIS surfaces. Following FN coating, Collamer lenses supported more uniform FN film formation; however, this did not significantly enhance cell adhesion. Conclusions: Collamer, which contains collagen, promotes FN film formation. Although FN film formation was enhanced, the low cell-adhesive properties of HEMA resulted in minimal cell adhesion even with FN presence. This characteristic may contribute to the long-term transparency and biocompatibility observed clinically. In contrast, hydrophilic acrylic materials used in IPCL and LENTIS demonstrated limited FN interaction. These material differences may influence extracellular matrix protein deposition and biocompatibility in clinical settings, warranting further investigation. Full article

The present investigation highlights the importance of evaluating the painting process on a composite material, namely the Kevlar validation process. Kevlar, a synthetic fabric, is well known for its remarkable strength and durability. Kevlar is used in the construction of spaceships and airplanes because it is lightweight and five times stronger than steel. This paper will present the methods for measuring paint layer thickness in accordance with EN ISO 2808:2019, confirming that organic coatings have fully cured, and coating thickness will be measured using magnetic currents. This study will also address the topic of determining liquid resistance. The protocols for manufacturing the Kevlar specimen are in accordance with ISO 2812-2:2018 using the water immersion method and structural testing. The investigation also demonstrates the progress of the framing test following immersion in Airbus PTP metal test tubes. Full article

Tribological processes in extreme environments pose serious material challenges, requiring coatings that resist both wear and corrosion. This review summarizes recent advances in protective coatings engineered for extreme environments such as high temperatures, chemically aggressive media, and high-pressure and abrasive domains, as well as cryogenic and space applications. A comprehensive overview of promising coating materials is provided, including ceramic-based coatings, metallic and alloy coatings, and polymer and composite systems, as well as nanostructured and multilayered architectures. These materials are deployed using advanced coating technologies such as thermal spraying (plasma spray, high-velocity oxygen fuel (HVOF), and cold spray), chemical and physical vapor deposition (CVD and PVD), electrochemical methods (electrodeposition), additive manufacturing, and in situ coating approaches. Key degradation mechanisms such as adhesive and abrasive wear, oxidation, hot corrosion, stress corrosion cracking, and tribocorrosion are examined with coating performance. The review also explores application-specific needs in aerospace, marine, energy, biomedical, and mining sectors operating in aggressive physiological environments. Emerging trends in the field are highlighted, including self-healing and smart coatings, environmentally friendly coating technologies, functionally graded and nanostructured coatings, and the integration of machine learning in coating design and optimization. Finally, the review addresses broader considerations such as scalability, cost-effectiveness, long-term durability, maintenance requirements, and environmental regulations. This comprehensive analysis aims to synthesize current knowledge while identifying future directions for innovation in protective coatings for extreme environments. Full article

65 Mn is a high-quality carbon structural steel that exhibits excellent mechanical properties and machinability. It finds broad applications in machinery manufacturing, agricultural tools, and mining equipment, and is commonly used for producing mechanical parts, springs, and cutting tools. Fe901 is an iron-based alloy that exhibits excellent hardness, structural stability, and wear resistance. It is widely used in surface engineering applications, especially laser cladding, due to its ability to form dense and crack-free metallurgical coatings. To enhance the surface hardness and wear resistance of 65 Mn steel, this study employs a laser melting process to deposit a multi-layer Fe901 alloy coating. The phase composition, microstructure, microhardness, and wear resistance of the coatings are investigated using X-ray diffraction (XRD), optical microscopy, scanning electron microscopy (SEM), Vickers hardness testing, and friction-wear testing. The results show that the coatings are dense and uniform, without visible defects. The main phases in the coating include solid solution, carbides, and α-phase. The microstructure comprises dendritic, columnar, and equiaxed crystals. The microhardness of the cladding layer increases significantly, with the multilayer coating reaching 3.59 times the hardness of the 65 Mn substrate. The coatings exhibit stable and relatively low friction coefficients ranging from 0.38 to 0.58. Under identical testing conditions, the wear resistance of the coating surpasses that of the substrate, and the multilayer coating shows better wear performance than the single-layer one. Full article

As manufacturing demands for challenging-to-machine metallic materials continue to evolve, the performance of cutting tools has emerged as a critical limiting factor. The synergistic application of micro-texture and coating in cutting tools can improve various properties. For the processing of existing micro-texture, because of the fast cooling and heating processing method of laser, there are defects such as remelted layer stacking and micro-cracks on the surface after processing. This study introduces a preheating-assisted technology aimed at optimizing the milling performance of textured coated tools. A milling test platform was established to evaluate the performance of these tools on titanium alloys under thermally assisted conditions. The face-centered cubic response surface methodology, as part of the central composite design (CCD) experimental framework, was employed to investigate the interaction effects of micro-texture preparation parameters and thermal assistance temperature on milling performance. The findings indicate a significant correlation between thermal assistance temperature and tool milling performance, suggesting that an appropriately selected thermal assistance temperature can enhance both the milling efficiency of the tool and the surface quality of the titanium alloy. Utilizing the response surface methodology, a multi-objective optimization of the textured coating tool-preparation process was conducted, resulting in the following optimized parameters: laser power of 45 W, scanning speed of 1576 mm/s, the number of scans was 7, micro-texture spacing of 130 μm, micro-texture diameter of 30 μm, and a heat-assisted temperature of 675.15 K. Finally, the experimental platform of optimization results is built, which proves that the optimization results are accurate and reliable, and provides theoretical basis and technical support for the preparation process of textured coating tools. It is of great significance to realize high-precision and high-quality machining of difficult-to-machine materials such as titanium alloy. Full article

To date, one of the main problems associated with the engineering application of metallic materials is corrosion protection. To increase their durability and reduce damage, a variety of protection methods have been studied and applied. In recent decades, coating techniques have become increasingly important. Among these coatings, Layered Double Hydroxides (LDHs) have shown unique properties, such as ion exchange, high adhesion, and hydrophobicity, particularly useful for biomedical applications. In this review, after a detailed exposition of the LDHs’ synthesis processes, the most recent corrosion protection methods are illustrated. Intercalation of corrosion inhibitors and release kinetics of intercalates are presented. Although this work is mainly focused on laboratory-scale investigations and fundamental research, the problems inherent to large-scale industrial manufacturing and application are outlined and briefly discussed. Full article

Hydrogels have emerged as multifunctional biomaterials in cardiac surgery, offering promising solutions for myocardial regeneration, adhesion prevention, valve engineering, and localized drug and gene delivery. Their high water content, biocompatibility, and mechanical tunability enable close emulation of the cardiac extracellular matrix, supporting cellular viability and integration under dynamic physiological conditions. In myocardial repair, injectable and patch-forming hydrogels have been shown to be effective in reducing infarct size, promoting angiogenesis, and preserving contractile function. Hydrogel coatings and films have been designed as adhesion barriers to minimize pericardial adhesions after cardiotomy and improve reoperative safety. In heart valve and patch engineering, hydrogels contribute to scaffold design by providing bio-instructive, mechanically resilient, and printable matrices that are compatible with 3D fabrication. Furthermore, hydrogels serve as localized delivery platforms for small molecules, proteins, and nucleic acids, enabling sustained or stimuli-responsive release while minimizing systemic toxicity. Despite these advances, challenges such as mechanical durability, immune compatibility, and translational scalability persist. Ongoing innovations in smart polymer chemistry, hybrid composite design, and patient-specific manufacturing are addressing these limitations. This review aims to provide an integrated perspective on the application of hydrogels in cardiac surgery. The relevant literature was identified through a narrative search of PubMed, Scopus, Web of Science, Embase, and Google Scholar. Taken together, hydrogels offer a uniquely versatile and clinically translatable platform for addressing the multifaceted challenges of cardiac surgery. Hydrogels are poised to redefine clinical strategies in cardiac surgery by enabling tailored, bioresponsive, and functionally integrated therapies. Full article

With the rapid advancement of high-precision optical systems, increasingly stringent demands are imposed on the surface figure accuracy of optical components. The magnitude of residual stress in multilayer films directly influences the post-coating surface figure stability of these components, making the control of multilayer film stress a critical factor in enhancing optical surface figure accuracy. In this study, which addresses the process constraints and substrate damage risks associated with conventional annealing-based stress compensation for large-aperture optical components, we introduce an active stress engineering strategy rooted in in situ deposition process optimization. By systematically tailoring film deposition parameters and adjusting the thickness modulation ratio of TiO₂ and SiO₂, we achieve dynamic compensation of residual stress in multilayer structures. This approach demonstrates broad applicability across diverse optical coatings, where it effectively mitigates stress-induced surface distortions. Unlike annealing methods, this intrinsic stress polarity manipulation strategy obviates the need for high-temperature post-processing, eliminating risks of material decomposition or substrate degradation. By enabling precise nanoscale stress regulation in large-aperture films through controlled process parameters, it provides essential technical support for manufacturing ultra-precision optical devices, such as next-generation laser systems and space-based stress wave detection instruments, where minimal stress-induced deformation is paramount to functional performance. Full article

Background/Objectives: Beak and feather disease virus (BFDV) is the causative agent of psittacine beak and feather disease (PBFD), affecting psittacine birds. There is currently no commercial vaccine or treatment for this disease. This study developed a novel BFDV coat protein mRNA vaccine encapsidated by TMV coat protein to form pseudovirions (PsVs) and tested its immunogenicity alongside BFDV coat protein (CP) subunit and DNA vaccine candidates. Methods: mRNA and BFDV CP subunit vaccine candidates were produced in Nicotiana benthamiana and subsequently purified using PEG precipitation and gradient ultracentrifugation, respectively. The DNA vaccine candidate was produced in E. coli cells harbouring a plasmid with a BFDV1.1mer pseudogenome. Immunogenicity of the vaccine candidates was evaluated in African grey parrot chicks. Results: Successful purification of TMV PsVs harbouring the mRNA vaccine, and of the BFDV-CP subunit vaccine, was confirmed by SDS-PAGE and western blot analysis. TEM analyses confirmed formation of TMV PsVs, while RT-PCR and RT-qPCR cDNA amplification confirmed encapsidation of the mRNA vaccine candidate within TMV particles. Restriction digests verified presence of the BFDV1.1mer genome in the plasmid. Four groups of 5 ten-week-old African grey parrot (Psittacus erithacus) chicks were vaccinated and received two boost vaccinations 2 weeks apart. Blood samples were collected from all four groups on day 14, 28 and 42, and sera were analysed using indirect ELISA, which showed that all vaccine candidates successfully elicited specific anti-BFDV-CP immune responses. The subunit vaccine candidate showed the strongest immune response, indicated by higher binding titres (>6400), followed by the mRNA and DNA vaccine candidates. Conclusions: The candidate vaccines present an important milestone in the search for a protective vaccine against PBFD, and their inexpensive manufacture could considerably aid commercial vaccine development. Full article