Search Results (1,982)

Liquid electrolytes in conventional lithium-ion batteries pose safety risks associated with flammability, leakage, and explosion, whereas solid polymer electrolytes are generally limited by insufficient ionic conductivity at ambient temperature, restricting the development of high-energy lithium batteries. To address these issues, flexible poly (vinylidene fluoride-co-hexafluoropropylene) (PVDF-HFP)-based gel polymer electrolyte membranes (GPEs) were prepared via a slit-coating process combined with UV curing. NASICON-type lithium aluminum titanium phosphate (Li_1.3Al_0.3Ti_1.7P₃O₁₂, LATP) and garnet-type tantalum-doped lithium lanthanum zirconate (Li_6.4La₃Zr_1.4Ta_0.6O₁₂, LLZTO) were introduced as inorganic ceramic fillers to improve the ion-transport and interfacial properties of the GPE. Among the investigated samples, the PVDF-HFP-based GPE containing 10 wt% LLZTO exhibited the best overall performance, with an ionic conductivity of 3.40 × 10⁻⁴ S·cm⁻¹ at ambient temperature and a Li⁺ transference number of 0.77. Cyclic voltammetry results showed that the LLZTO-modified electrolyte membrane exhibited sharper and more symmetric redox peaks, higher peak current response, and better curve overlap during repeated cycles, indicating improved electrochemical reversibility and interfacial stability. In addition, LLZTO incorporation enhanced the mechanical strength, broadened the electrochemical stability window, and improved the flame-retardant behavior of the membrane. The LiFePO₄/GPE/Li cell assembled with the optimized membrane delivered an initial discharge capacity of 160 mAh·g⁻¹ at 0.1 C and maintained 80 mAh·g⁻¹ at 1 C, demonstrating good rate capability. Moreover, a capacity retention of 96% was maintained after 100 cycles at 0.1 C, confirming excellent cycling stability. Therefore, this work provides an effective strategy for the structural optimization and scalable preparation of high-performance gel polymer electrolyte membranes for lithium battery applications. Full article

The growing adoption of wire arc additive manufacturing (WAAM) requires an understanding of how WAAM-fabricated aluminium alloys respond to environmental factors that may degrade mechanical performance. This study investigates the effects of cathodic charging on the mechanical properties and fracture behaviour of WAAM AA2319 aluminium alloy. Cathodic charging was conducted in an electrolyte containing 3.5 wt.% NaCl and 3 g/L ammonium thiocyanate using different applied current densities. The resulting changes in mechanical performance were assessed through uniaxial tensile and Charpy impact toughness tests. The results demonstrate that cathodic charging led to a progressive reduction in ductility with increasing current density. Elongation decreased by up to approximately 45% relative to the uncharged condition, while ultimate tensile strength and yield strength were marginally affected. Charpy impact testing revealed a corresponding reduction in impact toughness of approximately 40% following hydrogen charging. Fractographic analysis showed a transition from ductile fracture dominated by microvoid coalescence in the uncharged material, to a mixed ductile–brittle fracture in hydrogen-charged specimens, characterised by shallow dimples and quasi-cleavage features. The observed changes in mechanical behaviour and fracture morphology suggest that cathodic charging promoted hydrogen-assisted mechanical degradation, with features consistent with hydrogen-enhanced localised plasticity (HELP) and hydrogen-enhanced decohesion (HEDE). Full article

This research reports on the properties of oxide-ceramic coatings produced by plasma electrolytic oxidation in novel electrolyte solutions for implantology applications. A series of bioactive calcium-phosphate coatings was synthesized on medical-grade Ti-13Zr-13Nb alloy using the plasma electrolytic oxidation (PEO) method. Novel electrolytes enriched with calcium and phosphorus were developed, enabling the formation of coatings with tailored physicochemical and structural characteristics. A correlation was established between the electrolyte composition and the phase composition, thickness, morphology, porosity, and microhardness of the resulting coatings. The optimum coatings exhibited a Ca/P ratio close to that of natural human bone tissue, homogeneity, a well-developed porous surface topography, and controlled resorption behavior. For the first time, a mechanism of calcium-phosphate coating resorption in a biologically active environment has been proposed. It involves partial dissolution, the formation of apatite-like surface structures, and the subsequent controlled release of Ca and P ions. In vitro testing in simulated body fluid indicated the potential bioactivity of the synthesized coatings. The proposed calcium-phosphate coatings may be considered promising candidates for future implant surface modification. The results obtained are significant for the development of advanced orthopedic and dental implants, including those fabricated using additive manufacturing technologies. Full article

Balancing ionic transport, thermal robustness, and electrochemical stability remains an important challenge in the design of ionic liquid (IL) electrolytes for lithium-based energy storage. Here, quantitative structure–transport relationships were established through a systematic comparison of six bis(trifluoromethanesulfonyl)imide ([Tf₂N]⁻)-based ILs spanning imidazolium, pyrrolidinium, and quaternary ammonium cation families, each examined in both conventional alkyl and ether-functionalized forms. Density, viscosity, and ionic conductivity were measured over broad temperature ranges, while Raman spectroscopy and electrochemical stability measurements were used to probe ion association and voltage stability under selected conditions for both neat ILs and LiTf₂N-containing electrolytes. Ether functionalization consistently lowered viscosity and enhanced conductivity in the neat ILs, whereas LiTf₂N addition markedly increased viscosity and reduced conductivity in all systems. The magnitude of this lithium-induced transport penalty depended on cation architecture, being smallest for imidazolium systems and largest for ammonium analogues. Raman spectra indicate that these trends are associated with competition between Li⁺–anion coordination and ether-mediated solvation, which modifies ion association and local coordination environments. Walden analysis showed subionic behavior for all systems, with larger deviations after lithium incorporation, suggesting increased ion correlation. Electrochemical measurements revealed a complementary trade-off between transport and stability: the ether-functionalized imidazolium electrolyte containing 0.65 mmol g⁻¹ LiTf₂N exhibited the highest ionic conductivity among the lithium-containing systems, reaching 1.6 and 12.6 mS cm⁻¹ at 25 and 80 °C, respectively, but the corresponding imidazolium IL had the narrowest electrochemical stability window, about 4.3 V. In contrast, the ether-functionalized pyrrolidinium and ammonium ILs exhibited wider electrochemical stability windows of about 5.5 V, with improved cathodic stability and somewhat higher anodic stability than the imidazolium analogue. Full article

The present study addresses the fabrication of porous gyroid architectures by additive manufacturing from preceramic polymer feedstocks. Photocurable emulsions were engineered by combining a silicone powder with acrylate monomers and dispersing an emulsified secondary phase of calcium nitrate. The formulations showed light-curing behaviour compatible with digital light processing vat photopolymerization (DLP-VPP), enabling high-fidelity replication of triply periodic minimal surface (TPMS) gyroids (designed porosity: 85 vol.%). After pyrolysis in nitrogen at 700 °C, the lattices converted into CaO–SiO₂-derived amorphous matrices embedding an in situ turbostratic/pyrolytic carbon fraction, as suggested by the photothermal response and preliminary impedance behaviour, although the latter was measured in liquid electrolyte and therefore does not isolate electronic transport. To improve robustness during polymer-to-ceramic conversion, pharmaceutical borosilicate waste glass (BASG) was added as a passive filler (30–70 wt.%). The waste-glass phase acts as a passive filler that improves processing robustness and can mitigate shrinkage-induced damage during pyrolysis, while remaining electrically insulating (dielectric) and therefore not directly contributing to electronic conduction. The resulting structures combine high surface-to-volume ratio, controlled open porosity, and structural integrity with electrochemical responsiveness under the adopted test conditions, making them promising architected platforms for electrochemical components where interconnected porosity is advantageous. Full article

The increasing discharge of cobalt-containing effluents from metallurgical, electroplating, and battery-related industries necessitates the development of efficient and stable separation technologies. In this study, a sodium dodecyl sulfate (SDS)-assisted micellar-enhanced ultrafiltration (MEUF) process was systematically evaluated for the removal of Co²⁺ from aqueous solutions using a flat-sheet polyethersulfone (PES) membrane operated under crossflow conditions. The effects of surfactant concentration, initial solution pH, cobalt concentration, background electrolyte, and extended filtration time were examined to assess process performance and operational stability. Direct ultrafiltration of 50 mg L⁻¹ Co²⁺ without surfactant resulted in limited rejection (~18%). The introduction of SDS markedly improved removal efficiency, achieving >99% rejection at and above 1 critical micelle concentration (CMC). An SDS dosage of 1 CMC provided an optimal balance between permeate flux (~155 L m⁻² h⁻¹) and cobalt removal (>99%). The system maintained high rejection efficiency across a pH range of 3–9, demonstrating robust cobalt–micelle interactions. Increasing the initial cobalt concentration from 10 to 50 mg L⁻¹ caused a moderate decline in flux but did not significantly affect rejection efficiency. In contrast, elevated ionic strength due to NaNO₃ addition reduced both flux and cobalt removal, highlighting the influence of competing ions on micelle-mediated separation. Long-term continuous operation for 40 h showed stable permeate flux and sustained cobalt rejection above 99%, indicating minimal fouling. FTIR and SEM–EDS analyses confirmed membrane chemical stability and negligible cobalt deposition. These findings demonstrate that SDS-based MEUF is an effective and operationally stable approach for cobalt removal from contaminated water systems. Full article

Hydrogen peroxide fuel cells have emerged as a promising class of electrochemical energy conversion device owing to the dual redox character of H₂O₂, its liquid-phase storage, and its ability to operate in air-free environments. In this work, a dual-compartment direct H₂O₂ fuel cell using a Prussian Blue cathode and a tantalum anode, separated by a Nafion 115 proton exchange membrane, was systematically characterized and optimized with respect to electrolyte pH and ionic composition. The influence of pH on OCV was investigated independently in each compartment across the range of pH 2 to 12. In the tantalum compartment, OCV increased non-linearly with pH from 573 mV to 808 mV, driven by the enhanced electrochemical reactivity of the system under alkaline conditions. In the Prussian Blue compartment, OCV decreased from 676 mV to 199 mV with increasing pH, reflecting the instability of the material in alkaline conditions. The effect of the electrolyte ionic composition on average current density was subsequently investigated by varying the concentrations of NaCl and Dy(NO₃)₃. Increasing NaCl from 0 to 2.5 M produced an increase in current density from 0.414 mA/cm² to 0.973 mA/cm², consistent with ohmic resistance reduction through improved ionic conductivity. The addition of Dy(NO₃)₃ produced a positive response with an optimal concentration of $0.05$ M, at which current density reached 1.08 mA/cm², before declining sharply. Under the fully optimized conditions, pH 12 in the tantalum compartment, pH 2 in the Prussian Blue compartment, 0.3 M H₂O₂, 2.0 M NaCl, and 0.05 M Dy(NO₃)₃, the cell produced an OCV of 724 mV and a peak power density of 0.283 mW/cm² at a current density of 0.8 mA/cm². These results demonstrate that meaningful electrochemical performance can be achieved in a dual-compartment H₂O₂ fuel cell without the use of precious metal catalysts and highlight electrolyte engineering as an effective strategy for improving cell output in this class of device. Full article

Aqueous zinc-ion batteries (AZIBs) are promising for grid-scale storage due to their safety, low cost, and environmental benignity. However, water-dipole enrichment in the inner Helmholtz plane (IHP) of Zn anodes triggers hydrogen evolution, corrosion, and dendrites, limiting cycle life. We report a trace “ionic liquid–polar solvent coupling” strategy: adding only 0.01 M EMIMBF₄ and 0.03 M DMSO to 2 M ZnSO₄ electrolyte. Hydrophobic EMIM⁺ adsorbs on the IHP to expel interfacial water, while BF₄⁻ enters the primary solvation shell and DMSO penetrates both first and second shells of Zn²⁺, forming a water-deficient coordination environment. This interfacial–solvation synergy suppresses parasitic reactions and directs preferentially oriented Zn deposition exclusively along the (101) facet, enabling dense vertical plating and in situ formation of a compact, inorganic-rich SEI (ZnCO₃–ZnSO₃–Zn(OH)₂). Consequently, Zn||Zn cells cycle stably for >5362 h at 1 mA cm⁻²/1 mAh cm⁻²; Zn||Cu cells achieve 1300 cycles with 99.8% average Coulombic efficiency; and Zn||V₂O₅ full cells retain 326.4 mAh g⁻¹ after 500 cycles. This work shows that minimal additive loading can simultaneously engineer the electrode–electrolyte interface and crystallographic deposition pathway, offering a simple yet robust design for ultra-stable AZIBs. Full article

Adiponitrile (ADN) serves as a critical intermediate for manufacturing polyamide 66. Electrochemical hydrodimerization of acrylonitrile (AN) offers a green and sustainable route for ADN production, yet conventional lead plate cathodes still suffer from high cell voltage, insufficient mechanical stability, and lead dust shedding during long-term operation. In this work, we developed a novel composite lead electrode in ambient air to overcome these drawbacks. Key preparation parameters, including calcination temperature, polytetrafluoroethylene (PTFE) content, substrate type, dispersion method, and dispersant dosage, were carefully screened and optimized. The optimal conditions were determined as follows: PTFE mesh as the substrate, 10% PTFE relative to lead powder, mechanical stirring dispersion, 0.5 wt% sodium hexametaphosphate as dispersant, air calcination at 325 °C, and subsequent electrochemical reduction. SEM, XRD, and XPS characterizations showed that the optimized electrode features a three-dimensional porous network assembled from interlaced rod-like and flower-like micro/nanostructures, which greatly elevates the specific surface area, enriches active sites, and facilitates electrolyte penetration and mass transport. After electrochemical reduction, the electrode surface was dominated by catalytically active Pb⁰. Electrochemical tests indicated that the composite electrode delivered a current density of 60–70 mA·cm⁻² at −1.6 to −2.0 V (vs. SCE) for AN reduction, nearly three times higher than that of a conventional lead plate. In addition, the composite electrode showed improved mechanical hardness and completely suppressed lead dust shedding, greatly enhancing operational safety and service life. Stable voltage was maintained during long-term electrolysis. This study provides a low-cost and scalable strategy for fabricating high-performance lead-based composite cathodes, which can support the industrial-scale green electrosynthesis of adiponitrile from acrylonitrile. Full article

Solid-state batteries (SSBs) are emerging as a transformative alternative to conventional lithium-ion batteries (LIBs) for next-generation electric vehicles (EVs) by replacing flammable liquid electrolytes with solid-state materials. Compared with current LIB systems delivering approximately 160–300 Wh/kg at the pack level, SSBs are projected to achieve 400–800 Wh/kg, enabling improvements in driving range of nearly 50–100% while simultaneously reducing battery pack mass by 10–30%. These improvements directly enhance vehicle-level energy efficiency by lowering energy consumption from typical values of 150–180 Wh/km in present EVs to projected levels of 110–140 Wh/km in optimized SSB-based architectures. Furthermore, reduced internal resistance and improved electrochemical stability can increase round-trip efficiency from approximately 85–95% in conventional LIBs to values approaching 95–98% under optimized solid-state configurations. The enhanced thermal stability of solid electrolytes significantly reduces the need for active cooling systems, decreasing parasitic thermal-management energy consumption from 10–30% of total vehicle energy demand to below 5–15% in advanced SSB systems. Fast-charging capability is also substantially improved, with projected charging times decreasing from 20–40 min to approximately 10–15 min for 10–80% state-of-charge operation, while maintaining improved safety and reduced risk of thermal runaway. In addition, SSBs demonstrate projected cycle lifetimes exceeding 3000–5000 cycles, compared with 1000–2000 cycles for conventional LIBs, thereby lowering battery replacement frequency and lifecycle energy losses. This paper examines the electrochemical fundamentals, thermal behavior, charging/discharging efficiency, and vehicle-level implications of SSB technology for EV applications. Comparative analyses demonstrate that replacing LIBs with SSBs can increase EV driving range from approximately 400 km to 700–800+ km under equivalent battery mass conditions, while also improving coulombic efficiency beyond 99.5% and reducing self-discharge rates to below 1–2% per month. Current industrial case studies from Toyota, Factorial Energy, Mercedes-Benz, CATL, BYD, QuantumScape, and Samsung SDI further confirm accelerating commercialization pathways toward 2027–2030. Overall, the study demonstrates that SSBs are not merely incremental battery improvements but represent a system-level efficiency technology capable of simultaneously enhancing energy density, reducing thermal and electrical losses, extending vehicle range, accelerating charging, and improving long-term sustainability. Despite persistent challenges related to manufacturing scalability, interfacial resistance, and cost, SSBs are positioned to become a critical enabler of highly efficient, long-range, and safer electric mobility systems beyond 2030. Full article

The article deals with the study of stress corrosion cracking (SCC) of X70 steel using corrosion-mechanical testing that simulates the operating conditions of underground pipelines. The tests were carried out under cyclic four-point bending at stresses close to the yield point, in electrolytes with various hydrogen charging capacities. The following model environments were used: NS4 solution and citrate buffer (pH 5.5). Hydrogen charging was controlled by the addition of thiourea and by varying the potential. It was shown that microcracks initiated at corrosion defects (pits) and then emerged at the surface to form narrow cracks. The incubation period depends on the environment: under corrosive conditions it is approximately two times shorter than in the air. The size and nature of stress concentrators play a significant role: natural pits (~hundreds of μm) lead to crack formation within 24–28 days, whereas artificial holes (0.6–1 mm) lead to crack formation within 5–7 days. The effect of hydrogen was established: the acceleration is insignificant under moderate hydrogen charging, whereas the incubation period decreases sharply at high hydrogen charging. Critical hydrogen concentrations where its effect becomes significant were determined. Methods for inhibiting stress corrosion cracking by means of organosilicon films (vinyl- and aminosilanes, as well as their mixtures with inhibitors—benzotriazole and amines) were considered. The most effective composition is vinylsilane + benzotriazole: the time to crack initiation increases from 5 to 36 days, and the crack growth rate decreases. Full article

Electrochemical water splitting stands as a feasible approach for sustainable hydrogen production, but its industrial implementation is restricted by sluggish oxygen evolution reaction (OER) kinetics and excessive dependence on freshwater resources. As a widely existing alternative, seawater contains a high concentration of chloride ions (Cl⁻), which give rise to serious electrode corrosion and catalyst deactivation, bringing great challenges to actual electrolysis applications. Herein, we report a facile room-temperature two-step soaking strategy to fabricate sulfur-modified NiFe layered double hydroxide (S-NiFe-LDH) catalysts for efficient OER in both alkaline freshwater and seawater electrolytes. The introduction of sulfur not only optimizes the electronic structure of NiFe-LDH to strengthen intrinsic catalytic activity and speed up charge transfer, but also promotes the formation of a Cl⁻-resistant layer, thus significantly improving corrosion resistance. In addition, DFT calculations show sulfur modification in NiFe layered double hydroxide upshifts the O 2p-band center to activate lattice oxygen, switches the oxygen evolution reaction pathway to the lattice oxygen mechanism with reduced thermodynamic barriers, and realizes the selective adsorption of OH⁻ over Cl⁻. As a result, the as-prepared S-NiFe-LDH catalyst exhibits exceptional OER performance, requiring overpotentials (η) of 250, 270, and 290 mV to reach current densities of 50, 100, and 200 mA·cm⁻² in 1 M KOH, respectively, with a Tafel slope of 22.3 mV·dec⁻¹. Moreover, it maintains remarkable stability for more than 200 h in alkaline seawater electrolytes and achieves nearly 100% Faradaic efficiency for water splitting, effectively avoiding the parasitic chlorine evolution reaction (CER). This work provides a scalable and energy-efficient synthetic route for designing advanced non-noble metal catalysts, paving the way for industrial-scale hydrogen production from seawater. Full article

The present work compares the corrosion performance of additively manufactured (AM) Ti-6Al-4V ELI (Extra-Low Interstitials) alloy manufactured by Laser-Powder Bed Fusion (L-PBF) using virgin powder (Cycle 1/C1 sample) and reused powder feedstock after up to 34 cycles (Cycle 34/C34 sample) of manufacturing. The effect of powder reuse is also evaluated for anodizing and Flash-PEO-coated specimens in Harrison’s (25 °C) and Hanks’ solutions (37 °C), representing simulated atmospheric precipitation and physiological conditions, respectively. Specimens were characterized using common metallographic techniques, X-ray diffraction, scanning electron microscopy and optical profilometry. Corrosion resistance was evaluated using cyclic potentiodynamic polarization (PDP) tests. The oxygen content in the Ti-6Al-4V reaches 0.14 wt.% after 34 cycles (C34) of powder reuse, enhancing its passivity in both Harrison’s and Hanks’ solutions. Both virgin and reused powder builds are susceptible to localized corrosion in Hanks’ solution at potentials above 1.75 V. Melt pool borders are thought to be the preferential sites for localized corrosion, as indicated by Volta potential measurements (ΔV = 100 mV). The number of cycles does not significantly affect the current–voltage responses for anodizing and flash-Plasma Electrolytic Oxidation (Flash-PEO) treatments, although anodizing is slightly more responsive to variations in surface roughness (i.e., real specimen area). Anodizing and Flash-PEO reduce the passive current density by nearly two orders of magnitude. Even after surface treatment, the alloy printed with reused powder revealed better passivity. Flash-PEO coatings yielded significant protection against localized corrosion. This unlocks Flash-PEO processing as a successful protection approach for AM biomedical components. Full article

Ester-based electrolytes in sodium-ion batteries (SIBs) offer high oxidative stability but often suffer from poor stability of the solid electrolyte interphase (SEI) on hard carbon anodes, severely limiting fast-charging capabilities and cycling lifespan. To address this interfacial instability, this work introduces trimethoxysilane (HTOS) as an electrolyte additive into 1 M NaPF₆ in EC:DMC electrolyte (denoted as ED). Compared with the rough and inorganic-rich interphase formed in the ED electrolyte, the HTOS additive induces the formation of a smoother, more uniform, and organic-rich SEI. This optimized interfacial structure effectively suppresses continuous interfacial degradation during cycling and significantly reduces the apparent activation energy for Na⁺ migration. Consequently, the HTOS-modified electrolyte demonstrates markedly superior electrochemical performance, delivering a reversible capacity of 198.76 mAh g⁻¹ at 1C and maintaining 85% of the initial capacity after 200 cycles at 0.5 C. This study demonstrates that utilizing silicon-containing functional additives for SEI regulation is a highly effective strategy to enhance the fast-charging and long-term cycling stability of hard carbon anodes in SIBs. Full article

In this work, a strategy for synergistic regulation of the Ti₃C₂T_x surface structure and redox activity of the electrolyte has been proposed. The surface modification of MXene was achieved via KOH treatment. Meanwhile, to cooperate with the surface-modified MXene electrode materials, Fe³⁺/Fe²⁺ was introduced into its common H₂SO₄ electrolyte to operate as a redox-active electrolyte for the first time. The results indicate that alkali treatment not only effectively reduces the amount of fluorine-terminal groups on the MXene surface but also forms in situ TiO₂ nanowires on its surface, thereby forming a unique hierarchical structure for facilitating the electrochemical reaction. Further utilization of the Fe²⁺/Fe³⁺ redox-active electrolyte introduced additional pseudocapacitive reactions at the electrode/electrolyte interface, significantly enhancing the capacitive performance of the system. This synergistic effect of both the hierarchical 1D TiO₂/MXene composite electrode materials and the redox-active electrolyte resulted in a substantial increase in specific capacitance from 78.17 F g⁻¹ to 655.54 F g⁻¹ at a current density of 10 Ag⁻¹. The reaction kinetics of the electrochemical systems were studied, along with their energy storage mechanism. It is revealed that there is a transition of the energy storage mechanism from being dominated almost solely by diffusion control to collaborative diffusion and surface reactions in the synergistic electrode/electrolyte system, and the corresponding equivalent circuit has evolved from the single-interface model to a dual-interface model. This work has demonstrated that the proposed synergistic strategy can effectively enhance the capacitive performance of the MXene energy storage system and can be applied to other electrochemical systems. Full article