Search Results (459)

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

The constitutive model is widely employed to characterize the rheological properties of metallic materials under high-temperature conditions. It is typically derived from a series of high-temperature tests conducted at varying deformation temperatures, strain rates, and strains, including hot stretching, hot compression, separated Hopkinson pressure bar testing, and hot torsion. The original experimental data used for establishing the constitutive model serves as the foundation for developing phenomenological models such as Arrhenius and Johnson–Cook models, as well as physical-based models like Zerilli–Armstrong or machine learning-based constitutive models. The resulting constitutive equations are integrated into finite element analysis software such as Abaqus, Ansys, and Deform to create custom programs that predict the distributions of stress, strain rate, and temperature in materials during processes such as cutting, stamping, forging, and others. By adhering to these methodologies, we can optimize parameters related to metal processing technology; this helps to prevent forming defects while minimizing the waste of consumables and reducing costs. This study provides a comprehensive overview of commonly utilized experimental equipment and methods for developing constitutive models. It discusses various types of constitutive models along with their modifications and applications. Additionally, it reviews recent research advancements in this field while anticipating future trends concerning the development of constitutive models for high-temperature deformation processes involving metallic materials. Full article

Lithium metal is a promising anode material for next-generation batteries due to its high specific capacity and low density. However, conventional mechanical processing methods are unsuitable due to lithium’s high reactivity and adhesion. Laser cutting offers a non-contact alternative, but photothermal effects can negatively impact the cutting quality and electrochemical performance. This study investigates the influence of pulse duration on the cutting-edge characteristics and electrochemical behavior of laser-cut 20 µm lithium metal on 10 µm copper foils using nanosecond and picosecond laser systems. It was demonstrated that shorter pulse durations significantly reduce the heat-affected zone (HAZ), resulting in improved cutting quality. Electrochemical tests in symmetric Li|Li cells revealed that laser-cut electrodes exhibit enhanced cycling stability compared with mechanically separated anodes, despite the presence of localized dead lithium “reservoirs”. While the overall pulse duration did not show a direct impact on ionic resistance, the characteristics of the cutting edge, particularly the extent of the HAZ, were found to influence the electrochemical performance. 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

Direct Air Capture (DAC) is emerging as a critical climate change mitigation strategy, offering a pathway to actively remove atmospheric CO₂. This comprehensive review synthesizes advancements in DAC technologies, with a particular emphasis on the pivotal role of nanostructured solid sorbent materials. The work critically evaluates the characteristics, performance, and limitations of key nanomaterial classes, including metal–organic frameworks (MOFs), covalent organic frameworks (COFs), zeolites, amine-functionalized polymers, porous carbons, and layered double hydroxides (LDHs), alongside solid-supported ionic liquids, highlighting their varied CO₂ uptake capacities, regeneration energy requirements, and crucial water sensitivities. Beyond traditional temperature/pressure swing adsorption, the review delves into innovative DAC methodologies such as Moisture Swing Adsorption (MSA), Electro Swing Adsorption (ESA), Passive DAC, and CO₂-Binding Organic Liquids (CO₂ BOLs), detailing their unique mechanisms and potential for reduced energy footprints. Despite significant progress, the widespread deployment of DAC faces formidable challenges, notably high capital and operational costs (currently USD 300–USD 1000/tCO₂), substantial energy demands (1500–2400 kWh/tCO₂), water interference, scalability hurdles, and sorbent degradation. Furthermore, this review comprehensively examines the burgeoning global DAC market, its diverse applications, and the critical socio-economic barriers to adoption, particularly in developing countries. A comparative analysis of DAC within the broader carbon removal landscape (e.g., CCS, BECCS, afforestation) is also provided, alongside an address to the essential, often overlooked, environmental considerations for the sustainable production, regeneration, and disposal of spent nanomaterials, including insights from Life Cycle Assessments. The nuanced techno-economic landscape has been thoroughly summarized, highlighting that commercial viability is a multi-faceted challenge involving material performance, synthesis cost, regeneration energy, scalability, and long-term stability. It has been reiterated that no single ‘best’ material exists, but rather a portfolio of technologies will be necessary, with the ultimate success dependent on system-level integration and the availability of low-carbon energy. The review paper contributes to a holistic understanding of cutting-edge DAC technologies, bridging material science innovations with real-world implementation challenges and opportunities, thereby identifying critical knowledge gaps and pathways toward a net-zero carbon future. Full article

Twinning-induced plasticity (TWIP) steels represent a significant development in automotive steel production, characterized by advanced strength and ductility properties. The present study empirically investigated the effects of process parameters on the cutting process and surface quality of TWIP980 steel sheet by abrasive water jet (AWJ) cutting. The cutting experiments were conducted on 1.4 mm thick sheet metal using four different traverse speeds (50, 100, 200, and 400 mm/min) and four different water jet pressures (1500, 2000, 2500, and 3000 bar). Two different abrasive flow rates (300 and 600 g/min) were also utilized. The cut surfaces were characterized in three dimensions with an optical profilometer. The parameters of surface roughness, kerf width, taper angle, and material removal rate (MRR) were determined. Furthermore, microhardness measurements were conducted on the cut surfaces. The optimal surface quality and geometrical accuracy were achieved by applying a combination of parameters, including 3000 bar of pressure, a traverse rate of 400 mm/min, and an abrasive flow rate of 600 g/min. Concurrently, an effective cutting performance with increased MRR and reduced taper angles was achieved under these conditions. The observed increase in microhardness with increasing pressure is attributable to a hardening effect resulting from local plastic deformation. Full article

Integrating recyclates into food packaging is key towards circularity while meeting functionality and safety requirements; however, associated environmental impacts remain underexplored. This gap was addressed through a cradle-to-gate life cycle assessment, using the Environmental Footprint method, along with substitution and cut-off approaches for handling the multifunctionality of recycling. Recyclates were derived from polyethylene (PE)-rich household food packaging waste, purified via delamination-deinking. Firstly, results show that shifting from virgin multi-material to mono-material multilayer structures with or without recyclates, while maintaining functionality, offers environmental benefits. Secondly, recyclates should sufficiently substitute virgin materials in quantity and quality, decreasing the need for primary plastics and avoiding recyclate incorporation without functionality. Otherwise, thicker laminates are obtained, increasing processability challenges and environmental impacts, e.g., 12% for particulate matter, and 14% for mineral-metal resource use when the recycle content rises from 34 to 50%. Thirdly, a fully closed loop for flexible food packaging is not yet feasible. Key improvements lie in reducing residues generated during recycling, especially in delamination-deinking, lowering energy use in recompounding, and using more efficient transport modes for waste collection. Further research is essential to optimise the innovative technologies studied for flexible food packaging and refine them for broader applications. Full article

As critical interfaces bridging biological systems and electronic devices, the performance of bioelectrodes directly determines the sensitivity, selectivity, and reliability of biosensors. Recent advancements in functional nanomaterials (e.g., carbon nanomaterials, metallic nanoparticles, 2D materials) have substantially enhanced the application potential of bioelectrodes in disease detection, metabolic monitoring, and early diagnosis through strategic material selection, structural engineering, interface modification, and antifouling treatment. This review systematically examines the latest progress in nanomaterial-enabled interface design of bioelectrodes, with particular emphasis on performance enhancements in electrophysiological/electrochemical signal acquisition and multimodal sensing technologies. We comprehensively analyze cutting-edge developments in dynamic metabolic parameter monitoring for chronic disease management, as well as emerging research on flexible, high-sensitivity electrode interfaces for early disease diagnosis. Furthermore, this work focused on persistent technical challenges regarding nanomaterial biocompatibility and long-term operational stability while providing forward-looking perspectives on their translational applications in wearable medical devices and personalized health management systems. The proposed framework offers actionable guidance for researchers in this interdisciplinary field. Full article

Laser cladding, a cutting-edge surface modification technique for metals, offers a novel approach to enhancing the wear and corrosion resistance of substrates due to its rapid heating and cooling capabilities, precise control over coating thickness and dilution rates, and non-contact processing characteristics. However, disparities in the physical properties between the coating material and the substrate, coupled with the improper utilization of process parameters, can lead to coating defects, thereby compromising the quality of the coating. This paper examines the effects of material systems and process parameters on laser cladding composite coatings and shows that cracking is mainly caused by thermal and residual stresses. This article summarizes the methods for crack improvement and prevention in five aspects: the selection of processes in the preparation stage, the application of auxiliary fields in the cladding process, heat treatment technology, the use of auxiliary software, and the search for new processes and new structural materials. Finally, the future development trends of laser cladding technology are presented. Full article

The output energy of Laser Active Optical Systems (LAOSs), in which image brightness is amplified within the laser-active medium, is always higher than the input energy. This contrasts with conventional optical systems (OSs). As a result, a LAOS enables the creation of laser beams with tailored energy distribution across the aperture, making them ideal for material processing applications. This concept was first successfully implemented using metal vapor lasers as the gain medium. In these systems, material processing was achieved by using a laser beam that either carried the required energy profile or the image of the object itself. Later, other laser media were utilized for LAOSs, including barium vapor, strontium vapor, excimer XeCl lasers, and solid-state media. Additionally, during the development of these systems, several modifications were introduced. For example, Space-Time Light Modulators (STLMs) and CCD cameras were incorporated, along with the use of multipass amplifiers, disk-shaped or thin-disk (TD) solid-state laser amplifiers, and other advancements. These techniques have significantly expanded the range of power, energy, pulse durations, and operating wavelengths. Currently, TD laser amplifiers and STLMs based on Digital Light Processor (DLP) technology or Digital Micromirror Devices (DMDs) enhance the potential to develop LAOS devices for Subtractive and Additive Technologies (ST, AT), applicable in both macromachining (cutting, welding, drilling) and micro-nano processing. This review presents comparable characteristics and requirements for these various LAOS applications. Full article

The decommissioning and dismantling of nuclear research reactors can lead to a large amount of low- and intermediate-level radioactive waste. For repositories, the materials must be kept confined and safety must be ensured for extended time spans. Waste is encapsulated in concrete, which leads to alkaline conditions with pH values of 12 and higher. This can be advantageous for some radionuclides due to their precipitation at high pH. For other materials, such as reactive metals, however, it can be disadvantageous because it might foster their corrosion. The Studsvik R2 research reactor contained an AlMg3.5 alloy with a composition close to that of commercial Al5154 for its core internals and the reactor tank. Aluminum corrosion is known to start rapidly due to the formation of an oxidation layer, which later functions as natural protection for the surface. The corrosion can lead to pressure build-up through the accompanied production of hydrogen gas. This can lead to cracks in the concrete, which can be pathways for radioactive nuclides to migrate and must therefore be prevented. In this study, unirradiated rod-shaped samples were cut from the same material as the original reactor tank manufacture. They were embedded in concrete with elevated water–cement ratios of 0.7 compared to regular commercial concrete (ca. 0.45) to ensure water availability throughout all of the experiments. The sample containers were stored in pressure vessels with attached high-definition pressure gauges to read the hydrogen-induced pressure build-up. A second set of samples were exposed in simplified artificial cement–water to study similarities in corrosion characteristics between concrete and cement–water. Additionally, the samples were exposed to concrete and cement–water in free-standing sample containers for deconstructive examinations. In concrete, the corrosion rates started extremely high, with values of more than 10,000 µm/y, and slowed down to less than 500 µm/y after 2000 h, which resulted in visible channels inside the concrete. In the cement–water, the samples showed similar behavior after early fluctuations, most likely caused by the surface coverage of hydrogen bubbles. These trends were further supported by mass loss evaluations. Full article

In recent years, plastic decorative materials have been used in the automotive industry due to their advantages such as being environmentally friendly, aesthetic, light and economically affordable. Plastic decorative materials can exhibit high strength and metallic reflection with metal coatings. Chrome plating is generally preferred in the production of decorative plastic parts in the automotive industry. In this study, the effect of injection molding processing parameters on the metal–polymer adhesion of chrome-plated acrylonitrile butadiene styrene (ABS) was investigated. The ABS-based front grille frames are fabricated by means of using an industrial-scale injection molding machine. Then, the fabricated ABS-based front grille frame was plated with chrome by means of the electroplating method. The metal–polymer adhesion was investigated as a function of the injection molding processing parameters by means of a cross-cut test and scanning electron microscope (SEM). As a result, it was determined that the optimal injection process parameters, a cooling time of 18 s, a mold temperature of 70 °C, injection rates of 45-22-22-20-15-10 mm/s, and packing pressures of 110-100-100 bar, were effective in enhancing polymer–metal adhesion for the ABS-based front grille frame. Full article

Pure copper is an important metal material in the fields of integrated circuits, mold manufacturing, and aerospace. Its excellent ductility and plasticity lead to problems such as burrs and tool wear in cutting, which poses great challenges to the improvement of machining accuracy and surface quality. To achieve high-quality and efficient processing of pure copper, this paper proposes to use nanographene water-based lubricant (NGWL) to regulate its removal behavior. A single-grain diamond scribing test and a micro-milling test were carried out to systematically study the action mechanism of NGWL on removal behavior of pure copper. The results showed that, compared with dry scribing at normal forces of 100, 400, 700, and 1000 mN, the material removal efficiency induced by NGWL was increased by 54.1%, 80.7%, 44.8%, and 30.3%, respectively. Compared with dry micro-milling at feed speeds of 200, 600, 1000, and 1400 μm/s, for the 75°XT4E tool, the surface roughness Sa with NGWL-assisted micro-milling was reduced by 75.5%, 73.1%, 61.4%, and 44.2%, respectively. Similarly, for the 65°UDT4E tool, compared to dry micro-milling, the Sa with NGWL lubrication was also reduced by 28.9%, 52.2%, 54.4%, and 36.9%, respectively. The Sa of pure copper induced by NGWL could be as low as about 20 nm without scales. Overall, NGWL can regulate removal behavior of pure copper by alleviating plastic deformation and promoting ductile fracture, thereby providing a new approach to achieving high-quality and efficient processing of pure copper. Full article

Wire electrical discharge machining (WEDM), as a significant branch of non-traditional machining technologies, is widely applied in fields such as mold manufacturing and aerospace due to its high-precision machining capabilities for hard and complex materials. This paper systematically reviews the research progress in WEDM process optimization from two main perspectives: traditional optimization methods and artificial intelligence (AI) techniques. Firstly, it discusses in detail the applications and limitations of traditional optimization methods—such as statistical approaches (Taguchi method and response surface methodology), Adaptive Neuro-Fuzzy Inference Systems, and regression analysis—in parameter control, surface quality improvement, and material removal-rate optimization for cutting metal materials in WEDM. Subsequently, this paper reviews AI-based approaches, traditional machine-learning methods (e.g., neural networks, support vector machines, and random forests), and deep-learning models (e.g., convolutional neural networks and deep neural networks) in aspects such as state recognition, process prediction, multi-objective optimization, and intelligent control. The review systematically compares the advantages and disadvantages of traditional methods and AI models in terms of nonlinear modeling capabilities, adaptability, and generalization. It highlights that the integration of AI by optimization algorithms (such as Genetic Algorithms, particle swarm optimization, and manta ray foraging optimization) offers an effective path toward the intelligent evolution of WEDM processes. Finally, this investigation looks ahead to the key application scenarios and development trends of AI techniques in the WEDM field for cutting metal materials. Full article