Search Results (319)

Laser powder bed fusion (LPBF) is an advanced additive manufacturing technology that is gaining increasing interest for biomedical implants because it can produce dense, patient-specific metallic components with controlled microstructures. This study investigated the LPBF fabrication of 316L stainless steel, which is widely used in orthopedic and dental implants, and examined the effects of laser power and scanning speed on the microstructure and mechanical properties relevant to biomedical applications. The study achieved 99.97% density and refined columnar and cellular austenitic grains, with optimized molten pool morphology. The optimal LPBF parameters, 190 W laser power and 700 mm/s, produced a tensile strength of 762.83 MPa and hardness of 253.07 HV_0.2, which exceeded the values of conventional cast 316L stainless steel. These results demonstrated the potential of optimized LPBF 316L stainless steel for functional biomedical applications that require high mechanical integrity and biocompatibility. Full article

The main aim of this study was to evaluate the influence of heat and surface treatment on the physicochemical properties of samples produced using Direct Metal Sintering incremental technology from Ti64ELI titanium powder. Two groups of samples were selected for the study: sandblasted and mechanically polished samples. Each group consisted of samples in the initial state and after heat treatment carried out at temperatures of 800 °C, 910 °C, and 1020 °C. The article presents the results of microscopic metallographic observations, wettability and surface topography, hardness, and resistance to pitting corrosion in Ringer’s solution, together with microscopic evaluation of the surfaces before and after testing. Based on the test results, both heat and surface treatments were found to alter the functional properties of the printed samples. All the tested samples show hydrophilic properties. Heat treatment at 1020 °C produces the best resistance to pitting corrosion. This information is important when selecting the mechanical properties of the biomaterial and the physicochemical properties of the surface for a specific type of stabilizer. The choice of appropriate heat treatment and surface treatment of the implant will also depend on the length of time the implant remains in the body. Full article

Lithium-ion batteries (LiBs) are utilized in numerous applications due to advancements in technology, and the recovery of end-of-life (EoL) LiBs is imperative for environmental and economic reasons. Pyrometallurgical and hydrometallurgical methods have been used in the recovery of metals such as Li, Co, and Ni in the EoL LiBs. Hydrometallurgical methods, which have been demonstrated to exhibit higher recovery efficiency and reduced energy consumption, have garnered increased attention in recent research. Inorganic acids, including HCl, HNO₃, and H₂SO₄, as well as organic acids such as acetic acid and citric acid, are employed in the hydrometallurgical recovery of these metals. It is imperative to acknowledge the environmental hazards posed by these acids. Consequently, solvometallurgical processes, which involve the use of organic solvents with minimal or no water, are gaining increasing attention as alternative or complementary techniques to conventional hydrometallurgical processes. In the context of solvent systems that have been examined for a range of solvometallurgical methods, deep eutectic solvents (DESs) have garnered particular interest due to their low toxicity, biodegradable nature, tunable properties, and efficient metal recovery potential. In this study, the leaching process of black mass containing graphite, LCO, NMC, and LMO was carried out in a short time using the ternary DES system. The ternary DES system consists of choline chloride (ChCl), glycolic acid (GLY), and ascorbic acid (AA). As a result of the leaching process of cathode powders in the black mass without any pre-enrichment process, Li, Co, Ni, and Mn elements passed into solution with an efficiency of over 95% at 60 °C and within 1 h. Moreover, the kinetics of the leaching process was investigated, and Density Functional Theory (DFT) calculations were used to explain the leaching mechanism. Full article

This study addresses the problem of agricultural waste utilization and nutrition for older adults by developing a food product based on a circular design approach. Pineapple core was used to produce a clean-label dietary powder without chemical or enzymatic treatment, relying on repeated rinsing and hot-air drying. The development process followed a structured analysis of physical, chemical, and sensory properties. The powder contained 83.46 g/100 g dietary fiber, 0° Brix sugar, pH 4.72, low water activity (aw < 0.45), and no detectable heavy metals or microbial contamination. Sensory evaluation by expert panelists confirmed that the product was acceptable in appearance, aroma, and texture, particularly for older adults. These results demonstrate the feasibility and safety of valorizing agri-waste into functional ingredients. The process was guided by the Transformative Circular Product Blueprint, which integrates clean-label processing, IoT-enabled solar drying, and decentralized production. This model supports traceability, low energy use, and adaptation at the community scale. This study contributes to sustainable food innovation and aligns with Sustainable Development Goals (SDGs) 3 (Good Health and Well-being), 9 (Industry, Innovation and Infrastructure), and 12 (Responsible Consumption and Production). Full article

Complex oxides with the general formula Gd₂(Ti_1−xZr_x)₂O₇ are promising candidates for radioactive waste immobilization due to their capacity to withstand radiation by dissipating part of the free energy driving defect creation and phase transitions. In this study, samples with varying zirconium content (xZr = 0.00, 0.15, 0.25, 0.375, 0.56, 0.75, 0.85, 1.00) were synthesized via the sol–gel method and thermally treated at 500 °C to obtain nanosized powders mimicking the defective structure of irradiated materials. Synchrotron-based techniques were employed to investigate their structural properties: High-Resolution X-ray Powder Diffraction (HR-XRPD) was used to assess long-range structure, while Pair Distribution Function (PDF) analysis and Extended X-ray Absorption Fine Structure (EXAFS) spectroscopy provided insights into the local structure. HR-XRPD data revealed that samples with low Zr content (xZr ≤ 0.25) are amorphous. Increasing Zr concentration led to the emergence of a crystalline phase identified as defective fluorite (xZr = 0.375, 0.56). Samples with the highest Zr content (xZr ≥ 0.75) were fully crystalline and exhibited only the fluorite phase. The experimental G(r) functions of the fully crystalline samples in the low r range are suitably fitted by the Weberite structure, mapping the relaxations induced by structural disorder in defective fluorite. These structural insights informed the subsequent EXAFS analysis at the Zr-K and Gd-L₃ edges, confirming the splitting of the cation–cation distances associated with different metal species. Moreover, EXAFS provided a local structural description of the amorphous phases, identifying a consistent Gd-O distance across all compositions. Full article

The lack of new materials with desired processability and functional characteristics remains a challenge for metal additive manufacturing (AM). Therefore, in this work, a new promising AISI 316L-based alloy with better performance compared to the commercially available one is developed via the laser powder bed fusion (L-PBF) process. Moreover, establishing process–structure–properties linkages is a critical point that should be evaluated carefully before adding newly developed alloys into the AM market. Hence, the current study investigates the influences of various process parameters on the as-built quality and microstructure of the newly developed alloy. The results revealed that increasing laser energy density led to reduced porosity and surface roughness, likely due to enhanced melting and solidification. Microstructural analysis revealed a uniform distribution of copper within the austenite phase without forming any agglomeration or secondary phases. Electron backscatter diffraction analysis indicated a strong texture along the build direction with a gradual increase in Goss texture at higher energy densities. Grain boundary regions exhibited higher local misorientation and dislocation density. These findings suggest that changing the process parameters of the L-PBF process is a promising method for developing tailored microstructures and chemical compositions of commercially available AISI 316L stainless steel. Full article

This work presents a multiscale, microstructure-aware framework for predicting fatigue strength distributions in additively manufactured (AM) alloys—specifically, laser powder bed fusion (L-PBF) AlSi10Mg and Ti-6Al-4V—by integrating density functional theory (DFT), instrumented indentation, and Bayesian inference. The methodology leverages principles common to all 3D printing (additive manufacturing) processes: layer-wise material deposition, process-induced defect formation (such as porosity and residual stress), and microstructural tailoring through parameter control, which collectively differentiate AM from conventional manufacturing. By linking DFT-derived cohesive energies with indentation-based modulus measurements and a MAP-based statistical model, we quantify the effect of additive-manufactured microstructural heterogeneity on fatigue performance. Quantitative validation demonstrates that the predicted fatigue strength distributions agree with experimental high-cycle and very-high-cycle fatigue (HCF/VHCF) data, with posterior modes and 95 % credible intervals of ${\widehat{\sigma }}_f^{\mathrm{AlSi}10\mathrm{Mg}}={86}_{-7}^{+8}\mathrm{MPa}$ and ${\widehat{\sigma }}_f^{\mathrm{Ti}–6\mathrm{Al}–4\mathrm{V}}={115}_{-9}^{+10}\mathrm{MPa}$, respectively. The resulting Woehler (S–N) curves and Paris crack-growth parameters envelop more than 92 % of the measured coupon data, confirming both accuracy and robustness. Furthermore, global sensitivity analysis reveals that volumetric porosity and residual stress account for over 70 % of the fatigue strength variance, highlighting the central role of process–structure relationships unique to AM. The presented framework thus provides a predictive, physically interpretable, and data-efficient pathway for microstructure-informed fatigue design in additively manufactured metals, and is readily extensible to other AM alloys and process variants. Full article

This paper investigates the application of non-calcined metal tartrate as a novel alternative pore former to prepare functional ceramic composites to fabricate solid oxide fuel cells (SOFCs). Compared to carbonaceous pore formers, non-calcined pore formers offer high compatibility with various ceramic composites, providing better control over porosity and pore size distribution, which allows for enhanced gas diffusion, reactant transport and gaseous product release within the fuel cells’ functional layers. In this work, nanocrystalline gadolinium-doped ceria (GDC) and Ni-Gd-Ce-tartrate anode powders were prepared using a single-step co-precipitation synthesis method, based on the carboxylate route, utilising ammonium tartrate as a low-cost, environmentally friendly precipitant. The non-calcined Ni-Gd-Ce-tartrate was used to fabricate dense GDC electrolyte pellets (5–20 μm thick) integrated with a thin film of Ni-GDC anode with controlled porosity at 1300 °C. The dilatometry analysis showed the shrinkage anisotropy factor for the anode substrates prepared using 20 wt. The percentages of Ni-Gd-Ce-tartrate were 30 wt.% and 40 wt.%, with values of 0.98 and 1.01, respectively, showing a significant improvement in microstructural properties and pore size compared to those fabricated using a carbonaceous pore former. The results showed that the non-calcined pore formers can also lower the sintering temperature for GDC to below 1300 °C, saving energy and reducing thermal stresses on the materials. They can also help maintain optimal material properties during sintering, minimising the risk of unwanted chemical reactions or contamination. This flexibility enables the versatile designing and manufacturing of ceramic fuel cells with tailored compositions at a lower cost for large-scale applications. Full article

Thermally sprayed carbide cermet coatings, particularly those based on tungsten carbide (WC) and chromium carbide (Cr₃C₂) and produced with the high velocity oxygen fuel (HVOF) process, are used in tribological applications as environmentally friendly alternatives to electroplated hard chrome coatings. These functional coatings are especially prevalent in the automotive industry, offering excellent wear resistance. However, their mechanical and tribological performances are highly dependent on factors such as feedstock powders, spray parameters, and service conditions. This review aims to gain deeper insights into the above elements. It also outlines emerging advancements in HVOF technology—including in situ powder mixing, laser treatment, artificial intelligence integration, and the use of novel materials such as rare earth elements or transition metals—which can further enhance coating performance and broaden their applications to sectors such as the aerospace and hydro-machinery industries. Finally, this literature review focuses on process optimization and sustainability, including environmental and health impacts, critical material use, and operational limitations. It uses a life cycle assessment (LCA) as a tool for evaluating ecological performance and addresses current challenges such as exposure risks, process control constraints, and the push toward safer, more sustainable alternatives to traditional WC and Cr₃C₂ cermet coatings. Full article

The miniaturization of heat exchangers requires advanced manufacturing methods, as conventional techniques such as milling or casting are insufficient for producing complex microscale geometries. This study investigates the feasibility of using selective laser melting (SLM) with 316L stainless steel powder to fabricate compact heat exchangers with minichannels. The exchanger was designed using Autodesk Inventor 2023.3 software and produced under optimized process parameters. Measurements using a hydrostatic balance demonstrated that the applied process parameters resulted in a relative material density of 99.5%. The average microhardness in the core region of the SLM-fabricated samples was 255 HV, and the chemical composition of the final material differed only slightly from that of the feedstock material (stainless steel powder). Dimensional accuracy, surface quality, and internal structure integrity were assessed using computed tomography, optical microscopy, and contact profilometry. The fabricated component demonstrated high geometric fidelity and channel permeability, with local surface deformations associated with the absence of support structures. The average surface roughness (Ra) of the minichannels was 11.11 ± 1.63 µm. The results confirm that SLM technology enables the production of functionally viable heat exchangers with complex geometries. However, limitations remain regarding dimensional accuracy, powder removal, and surface roughness. These findings highlight the potential of metal additive manufacturing for heat transfer applications while emphasizing the need for further research on performance testing under real operating conditions, especially involving two-phase flow. Full article

The development of effective, cost-efficient, and printable solid-state gas sensors for the detection of volatile organic compounds is of great interest due to their wide range of applications, spanning from real-time indoor monitoring to emerging fields such as non-invasive medical diagnostics. However, gas sensors encounter difficulties in discovering materials that have both good selectivity and sensitivity for numerous volatile organic compounds in both dry and humid settings. To expand the class of sensing materials, the current study investigates the sensing performance of solid solutions based on a rare-earth metal oxide. Pr, Fe, and Ti oxide solid solutions were produced using a solid-state technique, with thermal treatments at varied temperatures to tune their structural and functional properties. The powders were used, for the first time, to produce chemoresistive sensors, which showed promising sensing capabilities vs. ethanol, acetone, and acetaldehyde. The sensors were characterized by varying the concentration of the target gases from 1 to 50 ppm in a controlled environment, with the relative humidity ranging from 2 to 40%. The findings bring a turning point, leading to fruitful paths for the development of Pr-based solid solutions-based chemoresistive gas sensors for the detection of volatile organic compounds. Full article

Water is one of the necessities for human survival, and clean water is essential for life. As a result, there is an increasing focus on efficient wastewater treatment methods, including advanced oxidation processes using innovative heterogeneous photocatalysts. In this context, TiO₂–graphene oxide (TGO) composites offer a multifaceted approach to wastewater treatment, combining the photocatalytic properties of TiO₂ with the adsorption capabilities and potential synergistic effects of graphene oxide. In this research, we intimately mixed commercial TiO₂ powder with graphene oxide at different concentrations (9, 16, and 25 wt.%) by exploiting sonochemical activation. The morphological and physicochemical analyses confirmed the interfacial interactions and the successful formation of the composite. The TGO composites exhibited increased reactivity compared to both GO and TiO₂ phases, during the photodegradation process of Rhodamine B (RhB), serving as a reaction model. Therefore, the photocatalytic results demonstrated the synergistic effect that occurs when a TiO₂-based photocatalyst is combined with sonochemically activated GO. The Cu²⁺ adsorption tests, simulating the removal of heavy metals from contaminated water, revealed that TGO composites displayed intermediate capabilities compared to the pure phases’ higher (GO) and lower (TiO₂) adsorption capacity. The functional characterizations revealed that the optimal design is represented by the sample containing 16 wt.% of GO. Overall, this study confirms that TGO composites are effective as photocatalysts and adsorbents for removing both organic and inorganic pollutants, making them strong candidates for wastewater treatment. Full article

This study investigates the biosorption of heavy metal ions (Pb, Fe, Cu, Cd, Zn, and Mn) from wastewater using the powdered biomass of Phragmites australis (common reed) under varying conditions, including temperature, pH, retention time, plant powder size, and biosorbent weight. The results showed that plant powder size significantly influenced the biosorption efficiency, with the 0.5 mm diameter powder yielding the highest removal rates for the heavy metal ions. The optimal temperature for biosorption was found to be between 30 and 50 °C, achieving up to 99.94% removal for Pb. The ideal pH for the biosorption of all metals was seven, and the best retention time for ion removal was 30 min, with a mean biosorption rate of 99.82% for Fe. A biosorbent weight of 10 g/L was also identified as the most effective for metal ion removal. Furthermore, two forms of P. australis, dry pieces and powdered biomass, were tested, with the powdered biomass exhibiting a superior biosorption performance. FTIR analysis revealed the involvement of carboxyl and hydroxyl functional groups in the biosorption process, while SEM imaging confirmed the surface interactions between metal ions and the plant material. The adsorption of heavy metals onto P. australis was effectively described by both Langmuir and Freundlich isotherm models, indicating a mix of monolayer coverage and heterogeneous interactions. The Langmuir model showed the highest adsorption capacities for Mn²⁺ (6.29 mg/g) and Cd²⁺ (5.10 mg/g), with strong affinities for Pb²⁺ (K_L = 0.0122 L/mg), Fe²⁺ (K_L = 0.0137 L/mg), and Cu²⁺ (K_L = 0.0130 L/mg). Similarly, the Freundlich model indicated favorable adsorption (n > 1) for all ions. Cu²⁺ and Fe²⁺ had the highest adsorption intensities (n = 2.06), with the strongest capacities being observed for Fe²⁺ (K_f = 0.231) and Cu²⁺ (K_f = 0.222). These findings confirm the high potential of P. australis as a sustainable and eco-friendly biosorbent. Full article

Significant heavy metals contamination is often caused by rapid industrialization, which is devastating to both public health and the environment. Conventional processes of metal removal also result in the accumulation of secondary waste. This work proposes the use of a novel fungal biomass (microwave heat dried) from Arthrinium malaysianum for the biosorption of toxic chromium. We have meticulously explored and investigated the interactions of hexavalent chromium with dried biomass using several cutting-edge techniques like FTIR for studying the involvement of functional groups on the biomass surface, XRD for the surface architecture changes after metal binding, XPS to unravel the reduction of hexavalent chromium into its non-toxic form, and FESEM-EDX for the visualization of the ultra-structure of fungal cell surface. The Langmuir isotherm demonstrates that the maximum removal capacity Q_max of Cr(VI) is 102.310 mgg⁻¹, at a pH of 3.5 with 100% removal of Cr(VI). There were substantial changes in the surface architecture during adsorption, confirmed by FESEM and AFM studies. FTIR and XPS data analysis indicated that carbonyl, hydroxyl, phosphate, and amine groups were responsible for the conversion of Cr(VI) (toxic) to Cr(III) (non-toxic). The IR spectra of biomass treated with Cr showed a decreased C-O stretching intensity and slight shriveling of the -OH band, and the bands in the FTIR spectra at 1642 cm⁻¹ to 1635 cm⁻¹ and at 1549 cm⁻¹ to 1547 cm⁻¹ shifted and appeared quite distinct. XRD revealed that the chromium-treated biomass had greater crystalline features and also the appearance of a wide peak where 2θ = 20°, approximately, indicating an amorphous nature at 576.0 eV and in highly loaded chromium (500 mg/L) biomass, with the Cr2p level displaying a slight shift, eventually terminating in a (576.0 eV) Cr₂O₃ to Cr(III) peak. Since the FTIR and XPS data obtained revealed that Cr(VI) reduces to Cr(III), this fungal biomass can also be used for generating metallic nanoparticles during biosorption. Thus, we suggest that the above-mentioned fungal biomass could be a very useful biomaterial for future translational research. We are in the process of fabricating beads with powdered biomass for further studies. Full article

Lattice structures offer the possibility to obtain lightweight components with additional functionalities, improving their shock absorption and thermal exchange properties. Recently, a body-centered cubic (BCC) lattice structure has been used to fabricate metal lattice sandwich panels (MLSPs) for aerospace applications. MLSPs are made of two external skins and a lattice core and can be produced thanks to laser powder bed fusion technology (LPBF), which is characterized by its superior printing accuracy with respect to other additive manufacturing processes for metals. Since few studies can be found in the literature on Ti-6Al-4V MLSPs, further work is needed to evaluate the mechanical response of these panels. Moreover, due to their design complexity and to avoid a costly experimental campaign, numerical simulation could be used to encourage the industrial application of these structures. In this paper, different cell configurations were printed and tested in compression to study the influence of the cell’s geometrical parameters, i.e., the cell size and beam radius, on the mechanical response of MLSPs. Numerical simulations of the LPBF of these geometries were also carried out to understand how the residual stresses can be varied by varying the cell configuration. A geometrical evaluation was carried out to quantitatively express the influence of the beam radius and cell size on the resulting volume fraction, which strongly influences the mechanical behavior and residual stress profiles of MLSPs. From the analysis, we found that the C2-R0.35 sample resulted in the configuration with the highest compressive strength, while C3-R0.25 showed the lowest and most uniform residual stress profile. Full article