Search Results (1,192)

This work investigates the potential of additive manufacturing (AM) technologies for prototyping and developing functional components in thermal systems, with particular emphasis on thermal and mechanical performance. The study focuses on two complementary prototyping strategies: (i) the use of metal-filled polymer filaments in Fused Deposition Modeling (FDM), also known as Material Extrusion (MEX) according to ISO/ASTM 52900:2022, and (ii) a hybrid approach combining polymer 3D printing with conductive coating and electrochemical copper deposition. While metal-filled filaments provide a rapid and low-cost solution for early-stage prototyping, their mechanical properties remain similar to those of the polymer matrix, limiting their applicability in load-bearing structures. In contrast, the hybrid method enables the fabrication of hollow metallic geometries with improved thermal and electrical conductivity. This approach is more time-consuming and process-intensive and is therefore considered a subsequent stage in the prototyping workflow following initial MEX-based design iterations. Compared with conventional polymer-based MEX, several AM approaches enable the development and fabrication of fully metallic or metal-functional structures, including Powder Bed Fusion (PBF), Directed Energy Deposition (DED), and hybrid polymer–metal methods based on electroplating. Furthermore, understanding mechanical properties such as tensile strength is essential for assessing the applicability of AM materials in energy system components. The results contribute to bridging the gap between rapid prototyping and the implementation of advanced AM technologies in thermal-related applications. Full article

This article presents the results of research on the morphological composition of selectively collected plastics and metals conducted in four voivodeships in Poland from late 2024 to early 2025, before the introduction of the deposit-return system. A very detailed classification of the morphological composition of the studied plastics and metals into 29 groups was adopted, which distinguishes this study from other research and makes it possible to assess the quality of selectively collected waste. A detailed analysis of morphological composition enables an in-depth assessment of the potential of individual fractions for mechanical recycling, chemical recycling, or energy recovery. The results show that contamination in selectively collected plastics and metals, i.e., fractions not covered by this collection scheme, accounted for approximately 22% of the total mass. The largest share among the studied fractions consisted of films of various types, which accounted for approximately 24% of the mass of selectively collected waste. Assuming an 85% sorting efficiency for marketable plastics and metals, a maximum of approximately 57% of the mass of selectively collected plastics and metals can be directed to mechanical recycling. The remaining fraction, excluding PVC and glass, can be used for energy recovery or, in the future, partly directed to chemical recycling. The article also discusses factors that will affect changes in the morphological composition of selectively collected waste, including the deposit-return system, extended producer responsibility, and packaging eco-design. Full article

Silicon carbide (SiC) nanowires possess unique one-dimensional structural features, excellent mechanical strength, thermal stability and wide bandgap properties, showing great potential in high-temperature electronics, catalysis, sensing and composite reinforcement. Nevertheless, pristine SiC nanowires suffer from inert surface activity, weak interfacial compatibility and limited optoelectronic and catalytic performance. Surface coating and heterojunction engineering are effective strategies to address these deficiencies. This review systematically summarizes the synthesis routes of pristine SiC nanowires, including carbothermal reduction, chemical vapor deposition, template-assisted growth and molten salt synthesis, as well as their morphological regulation, physicochemical properties and inherent limitations. Meanwhile, typical coating methods such as wet chemical, hydrothermal, CVD and PIP are elaborated, and the influences of coating thickness, uniformity, adhesion and lattice/thermal compatibility on performance are summarized. The classification and interfacial charge mechanism of Type II, Z-scheme and Schottky heterojunctions are discussed, and the advances of coated SiC nanowires in photodetection, photocatalysis, gas sensing, electromagnetic shielding and energy storage are reviewed. Current challenges including coating stability, scalable preparation and integration bottlenecks are pointed out, and future research directions focusing on interface control, multifunctional integration and AI-assisted material design are prospected. Full article

Plasma electrolytic oxidation (PEO) has emerged as a leading surface engineering technology for improving the tribological and corrosion performance of lightweight structural alloys, including aluminum, magnesium, titanium, and zirconium. Unlike conventional anodizing or line-of-sight deposition processes, PEO forms thick, multiphase ceramic oxide coatings metallurgically bonded to the substrate through plasma-assisted in situ oxidation, enabling treatment of complex and internal geometries that competing technologies cannot reach. The tribological performance of PEO coatings is governed by coupled interactions among electrolyte chemistry, electrical discharge behavior, phase evolution, porosity development, and residual stress state. This review critically evaluates the friction, wear, and tribo-corrosion behavior of PEO coatings under dry sliding, lubricated, high-temperature, marine, and vacuum environments, and systematically examines the influence of processing parameters, microstructural evolution, transfer layer formation, and counterface interactions on coating performance. Hybrid and duplex systems incorporating solid lubricants, polymer impregnation, sol–gel sealing, and multilayer architectures are discussed as strategies to overcome limitations associated with brittleness and surface porosity. Current research challenges, including fatigue degradation, coating defect control, limited cross-study standardization, and incomplete mechanistic understanding of process–microstructure, tribological relationships, are critically assessed. Emerging directions encompassing self-lubricating adaptive coatings, AI-guided process optimization, and multifunctional hybrid architectures are highlighted as pathways toward next-generation surface systems. This review provides a mechanism-based framework for understanding tribological behavior in PEO coatings and identifies critical opportunities for future industrial implementation in aerospace, automotive, marine, biomedical, and energy applications. Full article

Fe-Cr-B alloys are recognized as candidate wear- and corrosion-resistant materials strengthened by high-hardness boride phases. Conventional casting produces coarse continuous network borides and severe elemental segregation under near-equilibrium slow solidification (10⁻¹–10² K/s), resulting in high brittleness and limited service reliability. Laser processing includes laser cladding (10³–10⁶ K/s), LPBF/DED (10⁶–10⁸ K/s) and laser remelting, which feature extreme non-equilibrium rapid solidification but differ significantly in thermal gradient G, solidification rate R, and phase evolution behavior. To avoid over-extrapolation, this review strictly classifies evidence into direct LPBF evidence, direct DED evidence, laser cladding evidence, casting evidence, and indirect inference. Quantitative comparisons reveal that laser cladding refines borides from 150 to 300 μm to 10.8–20 μm, while DED further achieves 1–5 μm equiaxed grains and relative density > 98%. Meanwhile, laser-cladding Fe-Cr-B coatings achieve a maximum hardness of ~1052 HV_0.5, and ~18% higher wear resistance and ~70% lower cavitation mass loss compared with cast counterparts. Non-equilibrium mechanisms including solute trapping, interface absolute stability, constitutional undercooling, and columnar-to-equiaxed transition (CET) controlled by the Gⁿ/R ratio are systematically analyzed. Thermal–solutal coupling, grain nucleation, and boride precipitation kinetics under rapid cooling are emphasized. Current limitations include incomplete non-equilibrium thermodynamic databases, insufficient standardization, limited post-processing (heat treatment, HIP) studies, and missing unified performance datasets. Future directions are proposed toward quantitative phase-field modeling, standardized tribocorrosion characterization, high-throughput experiments, and machine learning-assisted optimization. This review provides a rigorous analytical framework for the composition–process–microstructure–performance design of laser-processed Fe-Cr-B alloys. Full article

Geant4 (version 11.3.2) simulations were used to study particle-dependent radiation interaction in MAPbI₃ under electron, photon, and neutron irradiation. The analysis focused on spatial distributions of interaction events, released energy, secondary-particle generation, and process-specific contributions. A 1 mm single-layer MAPbI₃ target was used to identify the intrinsic material response, while multilayer MAPbI₃ containing detector geometries were considered to assess device-like effects. Electrons produced extended charged particle tracks governed by direct energy loss and secondary-electron cascades. Photons showed weak direct energy deposition, with the response mainly controlled by secondary electrons generated in discrete electromagnetic interactions. Neutrons produced sparse but locally intense energy-release patterns dominated by recoil particles and nuclear-reaction products. The results show that total released energy alone is insufficient to describe radiation response in MAPbI₃; spatial morphology and the balance between primary and secondary contributions are essential for interpreting both detector operation and possible radiation-induced degradation. Full article

Hybrid additive manufacturing (HAM) integrates additive and subtractive processes within a unified production system, combining the geometric flexibility and material efficiency of additive manufacturing with the dimensional accuracy and surface quality of conventional machining. This review provides a comprehensive analysis of HAM technologies through a proposed four-criterion classification framework encompassing process integration strategy, additive manufacturing process type, machine architecture, and application domain. DED-based, PBF-based, and polymer-based hybrid systems are examined alongside integrated hybrid machines, retrofit solutions, and robotic architectures. A comparative analysis of representative commercial platforms evaluates build envelope, integration strategy, and monitoring capability. Documented performance outcomes across aerospace, automotive, energy, and biomedical sectors confirm substantial improvements in surface quality, fatigue performance, dimensional accuracy, and material efficiency relative to conventional manufacturing routes. Current limitations are critically assessed across technical, process integration, and economic dimensions, and a structured near-to-long-term research roadmap is proposed, prioritising in-process sensing and toolpath standardisation, digital twin-based adaptive process planning, and ultimately autonomous hybrid manufacturing cells with lifecycle certification. These findings position HAM as a central enabling technology for intelligent, flexible, and sustainable production within Industry 4.0 and Industry 5.0 paradigms. Full article

Titanium alloys are irreplaceable in aerospace, biomedical and marine industries due to their low density, high specific strength and excellent biocompatibility. Conventional manufacturing methods suffer from low material utilization and difficulty in fabricating complex components, while additive manufacturing (AM) realizes near-net-shape forming of customized structures but introduces unique non-equilibrium microstructures and defects, which significantly alter the corrosion behavior and limit the long-term service reliability of additively manufactured (AMed) titanium alloys. This work systematically analyzes the corrosion behavior of titanium alloys fabricated by four mainstream AM processes: LPBF (laser powder bed fusion)/SLM (selective laser melting), EBM (electron beam melting), DED (directed energy deposition) and WAAM (wire arc additive manufacturing). It quantitatively summarizes the key electrochemical parameters and discusses the regulatory effects of matrix composition, post-treatment and service environment on their corrosion behaviors. The universal corrosion mechanisms—namely, passive film breakdown, micro-galvanic corrosion, and defect-induced localized corrosion—as well as process-specific corrosion mechanisms inherent to AMed titanium alloys are systematically elucidated. This study offers theoretical foundations for optimizing corrosion resistance and ensuring the reliable engineering implementation of AMed titanium alloys. Full article

The demand for large-scale high-performance components with tailored properties in the aerospace and automotive industries has increased interest in multi-material additive manufacturing (AM). Among AM techniques, the Wire Arc Additive Manufacturing (WAAM) process is preferred for bimetallic fabrication due to high deposition rates, low equipment costs, and efficient material utilization. However, differences in metallurgical and thermal properties between dissimilar alloys can cause heat accumulation, leading to thermal stresses, cracking, and weak interfacial bonds. To the best of the authors’ knowledge, no study has reported the fabrication and characterization of a 17-4PH SS/Inconel 625 joint using the large-scale CMT-WAAM Process. To fill this gap, this study characterizes the microstructure and elemental distribution of the joint using scanning electron microscopy (SEM), X-ray diffraction (XRD), X-ray Microscopy (XRM) and energy dispersive spectroscopy (EDS). Microstructural analysis revealed a martensitic matrix with retained δ-ferrite in the 17-4PH region, a fully austenitic γ-phase in the Inconel 625 region, and a mixed BCC–FCC transition zone at the interface. EDS results demonstrated a Fe–Ni compositional gradient across the interface. Radiographic inspection confirmed a defect-free build, and XRM results showed a porosity of less than 0.003% only in the 17-4PH region. Tensile testing confirmed joint integrity, with fracture occurring in the Inconel 625 region, and average yield and ultimate tensile strengths of 391 ± 7 MPa and 676 ± 9 MPa, respectively. The simplified Johnson-Cook constitutive model successfully predicted the ultimate tensile strength (UTS), with a prediction error of 9.3% compared to the experimental result. Furthermore, a novel 3D-structured light scanner technique was developed and validated with an extensometer to provide insight into localized strain behavior. Full article

In therapeutic applications, ultrasound is widely used in physiotherapy, tissue repair, and cancer treatment. Regarding cancer treatment, as an emerging field for technology, significant research efforts have been devoted to the area of ultrasound therapy. The derived energy from beams can be deposited in tissues not only through heating but also through non-thermal mechanisms, whereby cancer cells are subject to cell death. Ultrasound-induced heating can generate localized temperature elevations within biological tissues, making it a subject of interest for thermal therapeutic applications. Nevertheless, excessive temperature elevations outside the primary exposure region may result in undesirable thermal effects within the surrounding tissue. In this study, we used continuous 3 MHz ultrasound waves at the powers of 0.4 to 1.4 W on ex vivo chicken breast tissue in a water bath to prevent fluctuations in temperature. The process was also numerically modeled with a maximum error of 0.4% from the measured data. Temperature measurements revealed a significant difference between the region of maximum acoustic pressure along the beam axis and deeper tissue locations (in some cases, above 3.5 °C). These findings indicate that temperature gradients can develop within homogeneous tissue during ultrasound exposure, emphasizing the importance of controlling acoustic power and exposure conditions. Moreover, increasing the temperature was significant during the first moments of treatment, which highlights the importance of precise controls for rate and precision in therapy. The numerical simulations also showed that increasing acoustic power elevates tissue temperature while simultaneously producing a less uniform temperature distribution. These observations may be useful for the optimization of future ultrasound-based thermal treatment strategies; however, direct clinical extrapolation requires further investigation using physiologically representative tissue models. Full article

Additive manufacturing has emerged as a transformative technology for fabricating complex drug-eluting medical devices, offering unprecedented design freedom and functional integration capabilities. This comprehensive review systematically analyzes 3D printing technologies applied to pharmaceutical device manufacturing, focusing on drug-eluting vascular stents as a representative application. This review covers six primary additive manufacturing techniques, ranging from high-resolution vat photopolymerization (25 μm resolution) to direct energy deposition, with a focus on their capabilities for produce pharmaceutical devices with controlled drug release properties. Novel 4D/5D/6D printing technologies introduce stimuli-responsive behaviors enabling programmable drug release profiles and adaptive device functionality. Manufacturing process optimization reveals superior design flexibility compared to conventional methods, with 85–95% reduction in design iteration time and elimination of tooling costs for complex geometries. The material landscape encompasses traditional metals (316L stainless steel, cobalt–chromium), biodegradable polymers (polylactic acid, PLA; polycaprolactone, PCL; poly(lactic-co-glycolic acid), PLGA), shape-memory materials (i.e., polymers and alloys capable of recovering a pre-programmed shape upon exposure to a specific stimulus such as body temperature, moisture, or light), and advanced nanocomposites, each offering distinct drug-loading capacities (100–500 μg/cm²) and release kinetics. Critical challenges include standardization requirements (International Organization for Standardization (ISO) 5840 and American Society for Testing and Materials (ASTM) F2606), pharmaceutical-grade manufacturing protocols, and regulatory pathways for novel drug-device combinations. This review identifies key research priorities including development of biocompatible printing materials, accelerated drug release testing protocols, and scalable manufacturing processes suitable for medical device production. This analysis demonstrates that 3D printing enables integration of multiple pharmaceutical functions within single devices, controlled spatiotemporal drug delivery, and elimination of secondary manufacturing steps for drug coating processes, advancing the development of next-generation therapeutic medical devices. Full article

Low temperature is a major environmental factor influencing the reproductive performance of crustaceans, particularly during gonadal development. This review synthesizes current knowledge on the phenotypic, physiological, and molecular responses of crustaceans to cold stress, with a focus on its regulatory effects on gonadal development. Available evidence indicates that low temperature generally delays gonadal maturation, reduces the gonadosomatic index, impairs oocyte development and yolk deposition, and suppresses spawning. Mechanistically, cold stress induces energy limitation and triggers a growth–reproduction trade-off, in which resources are preferentially allocated to survival and somatic maintenance rather than reproductive investment. This process is closely associated with lipid metabolism remodeling, mitochondrial dysfunction, and altered ATP-dependent energy sensing. At the molecular level, several pathways and regulatory factors are involved, including PI3K–Akt–FoxO, AMPK/mTOR, heat shock proteins, vitellogenin and its receptor, cell cycle regulators, antioxidant defense systems, and neuroendocrine mediators such as MIH, MOIH, and ecdysteroids. Emerging evidence also suggests potential roles for epigenetic regulation and species- or population-specific adaptation in shaping reproductive responses to low temperatures. Overall, this review provides an integrated framework for understanding how cold stress modulates crustacean gonadal development and highlights key directions for future studies and aquaculture applications. However, a comprehensive framework integrating energy metabolism, neuroendocrine signaling, and molecular pathways to explain reproductive suppression under cold stress is currently lacking. Full article

Wire-arc directed energy deposition (arc-DED) of maraging 250 (M250) steel is of growing interest for aerospace, tooling, and defense applications, yet systematic process characterization data remain limited. This study presents a mixed quantitative–qualitative factorial comparison of three Fronius synergic transfer modes, GMAW-CMT-Mix, GMAW-CMT-Universal, and GMAW-Pulsed-Arc, for single-bead M250 deposition across wire feed speeds of 4.45 to 8.26 m/min and travel speeds of 0.3 to 1.5 m/min. Bead geometry and process behavior are characterized using non-contact optical profilometry and destructive methods (i.e., metallographic sectioning, optical microscopy, and Vickers microhardness). The material feed rate ratio, R_wt, is introduced as a unifying process descriptor; heat input and cross-sectional area scale linearly with R_wt, while travel speed primarily governs bead height and wire feed speed primarily governs bead width. At the highest travel speed tested, GMAW-CMT-Mix and GMAW-Pulsed-Arc exhibit bead humping, rendering those conditions unsuitable, while GMAW-CMT-Universal maintains stable deposition with consistent dilution and the lowest heat input at equivalent R_wt. GMAW-CMT-Mix yielded the highest dilution and hardness. Linear regression of process responses against R_wt gives $R^2$ exceeding 0.83 for both height and width across all modes. These results establish a characterization baseline supporting future multi-layer studies. Full article

To address the high experimental costs and data scarcity inherent in Directed Energy Deposition (DED), this study proposes a data-efficient hybrid optimization framework for the precision manufacturing of Inconel 718 aerospace components. The framework leverages a two-stage strategy to bridge traditional experimental design with advanced machine learning, ensuring robust process optimization even with limited datasets. In the first stage, the Taguchi method (L16 orthogonal array) was employed for coarse-grained screening to identify influential control factors. In the second stage, a Fully Connected Neural Network (FNN) coupled with Bayesian Optimization (BO) was deployed. Crucially, this machine learning component functions as an optimization-oriented trend surrogate rather than a global regressor, successfully guiding the optimization under extreme data scarcity. The optimized process window yielded exceptional structural integrity, achieving a porosity as low as 0.03%. To thoroughly validate its practical efficacy, tensile testing (ASTM E8/E8M) and Rockwell hardness measurements (ASTM E18) were systematically conducted on the optimized specimens. The mechanical characterization demonstrated an average tensile strength of approximately 1358 MPa and a hardness of ~40 HRC. Finally, the framework was successfully validated through the robotic DED fabrication of a complex-geometry aerospace engine combustion chamber casing, bridging laboratory-scale optimization with authentic industrial applications. Full article