Search Results (42)

The galvanic industry requires considerable amounts of water and produces significant quantities of wastewater. Two types of wastewater are created in the processes of the galvanic application of metal coatings: used galvanic baths and wastewater generated while rinsing coated elements. The composition and amount of wastewater depend on the type of process, the plant’s operational system, and the quantity of water utilised to rinse the coated elements. In this article, the possibilities of using different techniques, such as chemical precipitation, coagulation and flocculation, ion exchange, adsorption, and membrane filtration, to remove heavy metals from galvanic wastewater were analysed and assessed. It was determined that the use of physicochemical methods (i.e., chemical precipitation, coagulation, and flocculation) to remove heavy metals has significant disadvantages, including operational costs connected with the purchase of chemical reagents and the emergence of metal complexes requiring management/utilisation. On the other hand, the processes of ion exchange and adsorption can be used only for wastewater characterised by a low heavy metal concentration, with organic matter preliminarily removed. In addition, waste polluted with heavy metals in the form of used regenerative baths and used sorbents is generated during these processes. In turn, the advanced techniques of membrane filtration allow for the removal of different types of organic pollutants and heavy metals. The processes of membrane wastewater treatment exhibit a range of advantages compared to traditional technologies, including the complete, environmentally friendly removal of permanent organic pollution, easy integration into conventional technologies, a limited amount of residue, a high level of separation, and a shorter process time. The efficiency of membrane wastewater treatment depends on many parameters, including, most of all, the composition, pH, and type of membrane, as well as process conditions. The possibility of using new types of membranes to remove heavy metals from spent galvanic baths was analysed, and the possibility of using the processes in wastewater treatment systems according to the circular economy model was assessed. The assessment of the efficiency of heavy metal removal in hybrid systems combining specific individual processes and the development of state-of-the-art material solutions to realise these processes may be an interesting direction of research in this field. Full article

Enargite (Cu₃AsS₄), a copper–arsenic sulfosalt, represents a critical challenge in copper mineral processing due to its high arsenic content, which poses significant environmental, metallurgical, and economic issues. Its flotation behavior closely resembles that of other copper sulfides such as chalcopyrite and chalcocite, complicating selective separation at early beneficiation stages. This review presents a comprehensive examination of enargite’s surface chemistry and electrochemical behavior, focusing on the influence of oxidation, pH, and pulp potential on surface reactivity, charge distribution (zeta potential), and hydrophobicity. Detailed insights into the formation of surface oxidation layers, passivation mechanisms, and contact angle variations are provided to elucidate collector-mineral interactions. Advances in selective flotation techniques are also discussed, including the use of depressant reagents, controlled redox environments, and reagent conditioning strategies. Special attention is given to flotation in seawater, where ionic strength and multivalent ions significantly influence mineral-reagent interactions and flotation outcomes. Galvanic interactions between enargite and other sulfide minerals are identified as critical factors affecting floatability and selectivity. The review consolidates findings from recent experimental and electrochemical studies, highlighting promising approaches to enhance enargite rejection and copper concentrate purity. It concludes with perspectives on future research aimed at optimizing flotation processes and developing sustainable solutions for processing arsenic-bearing copper ores. Full article

Flat panel displays for large applications (monitors and TVs) have structural weaknesses in improving the yield of mass-produced products due to large panels: the yield is defined by ratio of output quantity to input into panel fabrication process. From a panel manufacturing point of view, low-cost production should be achieved through improved yield of mass production (Samsung Display’s quantum dot display backplane panel). So, we set the target yield at an extreme value, over the golden yield (90%) at the beginning of new mass products. The main factors contributing to the yield loss were “lifted insulator and etched active pattern defects”. To reach the target yield, we focused on these two main defects. The root causes of these defects (delta coefficient of thermal expansion and galvanic corrosion) are explained, and a defect generation mechanism is proposed (the size of the separated large power line in relation to the defect rate). The power lines are defined based on an Electroluminescent Voltage at the Drain (ELVDD) and Electroluminescent Voltage at the Source (ELVSS). We developed a separated large power line design to reduce defect rates. This design plays a role in preventing these two defects during the mass production of medium to large display panels for use in TVs by ensuring that the large power line area is less than the optimum value (<0.44 cm²). Full article

Aluminum–copper alloys are commonly used in the aerospace industry due to their low density and high strength. Pitting corrosion is the major problem of Al-Cu alloys due to the presence of largely separated electrochemical potential difference phases. Microstructure refinement and phase homogenization of the alloys are believed to be the factors that contribute to decreasing the galvanic coupling between phases, hence decreasing the pitting tendency. In this work, we investigate whether microstructure refinement is the only factor that contributes to pitting or whether some other factors are involved in the pitting tendency. The investigation was conducted on two frequently used aerospace aluminum–copper alloys, Al-2024 T3 and Al-2014 T6. The surface refinement was conducted by laser surface melting, and microstructure characterization was conducted by scanning electron microscopy with an energy-dispersive X-ray analysis. Phase identification before and after the laser surface melting was conducted by X-ray diffraction, while pitting tendency was measured by a polarization test in 1 molar sodium chloride solution. These experimental results revealed that the enrichment of copper in the α-matrix phase was the major contributing factor in pitting as compared to the largely believed microstructural phase refinement. Full article

The increasing global demand for raw materials underscores the importance of lightweight construction and sustainable material use, drawing attention to composite techniques like galvanic coating of plastics. To support recycling efforts, the development of efficient separation and material recovery processes is critical, particularly for end-of-life products containing metal-plated polymers. This study investigates the recyclability of metallized polymer foams and coated polymers through comminution, focusing on the potential for effective separation of metal and polymer components. Cu-ABS samples showed 27% of the products in the 8–10 mm fraction and 48% in the 10–16 mm fraction during primary comminution, while Cu-PUR achieved a more even distribution. Microscopic analyses revealed decoating rates of up to 95% for Cu-ABS compared to 19% for Cu-PUR. The comminution energy required for Cu-PUR was three times higher, with a fivefold lower decoating rate than solid materials. Particles larger than 200 µm exhibited interlocking, complicating the separation process. These findings highlight the need for optimized recycling processes to enable efficient raw material recovery and support a circular economy. Full article

Aluminum–steel joints are increasingly used in the automotive industry to meet the requirements for energy saving and emission reduction. Among various joining technologies, self-pierce riveting (SPR) and resistance spot welding (RSW) are two well-established technologies for fabricating dissimilar joints with stable and high mechanical performance. However, corrosion will occur in these joints inevitably due to different electrochemical properties, which can degrade the surface quality and the mechanical performance, such as strength. This paper presents a method of understanding the corrosion mechanisms in joining aluminum and steel. For this understanding, a hybrid method combining experimental observations, mechanical properties identification, and analytical approaches was used to assess the evolution of the impact of corrosion on the joining performance, such as traction separation curves. The study was conducted on common combinations used in the vehicles, e.g., a 1.2 mm thickness aluminum alloy (AA 6022) and 2.0 mm thickness hot deep galvanized steel (HDG HSLA 340) joined by SPR and RSW. After the fabrication of these joints, accelerated cyclic corrosion tests of up to 104 cycles were performed, which reproduced the environmental conditions to which a vehicle was exposed. By investigating the microstructural evolution within the joints, the corrosion mechanisms of SPR and RSW joints were revealed, including the initiation and propagation. Moreover, the intrinsic impact of the corrosion on the mechanical performance, including the strength, axial stiffness, and crashworthiness, was analyzed by performing a lap-shear test. It showed that as corrosion proceeds, the fracture modes and mechanical performance are affected significantly. Full article

The elimination and retrieval of slag produced during the hot-dip galvanizing process are crucial in reducing plating defects and enhancing economic efficiency. Hot-dip galvanizing slag can be separated and purified efficiently by using graphite carbon felt filtration in a supergravity field. The effects of the gravity coefficient (G), separation temperature (T), and separation time (t) on the separation efficiency were investigated. Under the optimal conditions as G = 300, T = 460 °C, and t = 120 s, these conditions yielded filtered zinc with 0.022 wt% Fe and 1.097 wt% Al. The separation efficiencies achieved were 87% for the acquisition ratio of filtered zinc (A_Zn), 93.67% for the recovery ratio of zinc (R_Zn), and 96.01% for the loss ratio of iron (L_Fe). Based on these laboratory findings, an amplified centrifugal separation apparatus was conceptually designed for future online separation and recycle of zinc slag on an engineering scale. The filtered zinc obtained from this apparatus contained 0.027 wt% Fe and 1.844 wt% Al, while the recovery ratio of zinc (R_Zn) and the loss ratio of iron (L_Fe) achieved 85.97% and 95.47%, respectively. Full article

In DC microgrids, CLLC topology is commonly applied for battery integration. It provides galvanic separation, the ability to integrate a high-frequency transformer into the resonance circuit, and the ability to operate in a wide range of voltage. Moreover, it assures zero voltage switching conditions for all switches and zero current switching conditions for secondary side switches, which enables obtaining high efficiency. This paper presents a clear and effective approach to design a methodology for a CLLC DC/DC converter, especially a resonant tank. High-frequency transformer is fully integrated in a resonant tank. Its size is minimal and based on area product parameter $A_p$. An equivalent scheme for first harmonic approximation analysis is presented with inclusion of parasitic elements. Based on it, the analytical formulas are provided, which enable graphical determination of working characteristics. It was proved that the model increases the accuracy of the results. The conditions of ZVS and maximal magnetizing inductance are established, including parasitic capacitances of secondary side switches and transformer parasitic capacitances. Based on the proposed design methodology, as the proof of concept, a small-power prototype with a GaN transistor was built operating at 364 kHz. Converter losses were determined through analytical expressions and compared with the experimental and simulation results. Full article

The interaction of different dental alloys with the oral environment may cause severe side effects (e.g., burning sensation, inflammatory reactions, carcinogenesis) as a result of oral galvanism. However, the pathogenesis of side effects associated with oral galvanism is still unclear, and the effects of direct current and alloy corrosion ions are considered potentially contributing factors. Therefore, the aim of this study was to systemically compare the damaging effects of (1) galvanism as a synergistic process (direct current + corrosion ions), (2) direct current separately, and (3) corrosion ions separately on an in vitro mucosa-like model based on a cell line of immortalized human keratinocytes (HaCaTs) to reveal the factors playing a pivotal role in dental alloys side effects. For this, we chose and compared the dental alloys with the highest risk of oral galvanism: Ti64–AgPd and NiCr–AgPd. We showed that galvanic current may be the leading damaging factor in the cytotoxic processes associated with galvanic coupling of metallic intraoral appliances in the oral cavity, especially in the short-term period (28 days). However, the contribution of corrosion ions (Ni²⁺) to the synergistic toxicity was also shown, and quite possibly, in the long term, it could be no less dangerous. Full article

The aim of this paper is to demonstrate progress in textronic UHF RFID transponder (RFIDtex tag) technology. The fundamental idea behind the RFIDtex tag design involves galvanic separation between circuits of the sewn antenna and the chip, which are electromagnetically coupled through a system of inductive loops. To advance the development of this concept, it is crucial to detect factors affecting the performance of the transponders. To achieve this goal, a mathematical model of the textronic UHF RFID transponder was developed. It involves relationships that describe the impedance of each element, the mutual inductance of the loops, and the chip voltage, and it enables the exploration of the influence of these variables on general parameters such as impedance matching and read range. Various analytical and numerical approaches were considered to obtain the value of the mutual inductance of the loops. The dimensions and geometry of the antenna, as well as the matching circuit in the microelectronic module, were taken into account. Based on the mathematical model, it was determined that mutual inductance strongly affects the chip voltage for frequencies higher than 800 MHz. The calculations from the mathematical model were compared with numerical simulations. Experimental studies were also conducted to investigate how the transponder performance is affected by either the distance between the centers of the loops or the conductivity of the threads used to embroider the antenna. The measurement results allowed us to conclude that even small imperfections in the manufacturing of the transponder, which slightly increase the vertical or horizontal distance between the centers of the loops, cause a dramatic decrease in the mutual inductance and coupling coefficient, significantly impacting the transponder’s performance. Full article

At present, in several European railway networks using traditional DC electrification systems, it is not possible to increase traffic nor to operate locomotives at their nominal power ratings. Trackside energy storage systems (TESSs) can be an alternative solution for the creation of new substations. A TESS limits contact line voltage drops and smooths the power absorbed during peak traffic. Thus, the efficiency of the power system can be increased while limiting costs and the environmental impact. This paper proposes a new topology of a TESS based on full-SiC isolated DC/DC converters associated with lithium-ion batteries and galvanic isolation, offering major advantages for operational safety. In the event of a fault, the input and output terminals of the converters are electrically separated, and the contact line voltage can never be directly applied to the batteries. In addition, the use of SiC MOSFETs makes it possible to obtain excellent efficiency with a high switching frequency. The first part of this paper presents the main characteristics of an elementary TESS module, while the second part proposes a sizing methodology for the typical case of a 1.5 kV DC line, which shows the limits of using TESSs to reinforce a power supply. Finally, the experimental results of an elementary module prototype are presented. Full article

In this paper, the effect of gradually increasing amounts of KMnO₄ (10⁻⁴, 10⁻³, 10⁻² mol·L⁻¹) in cement paste on the bond strength of a plain hot-dip galvanized steel bar was evaluated. The open-circuit potential of HDG samples in cement paste with various additions of MnO₄⁻ was monitored in order to follow a transfer of zinc from activity to passivity. Furthermore, the influence of the addition of these anions on the physicochemical properties of normal-strength concrete or cement paste was evaluated by means of hydration heat measurements, X-ray diffraction analysis, and compressive strength. The effective concentration of MnO₄⁻ anions prevents the corrosion of the coating with hydrogen evolution and ensures that the bond strength is not reduced by their action, which was determined to be 10⁻³ mol·L⁻¹. Lower additions of MnO₄⁻ anions (10⁻⁴ mol·L⁻¹) are ineffective in this respect. On the other hand, higher additions of MnO₄⁻ anions (10⁻² mol·L⁻¹), although they ensure the corrosion of the coating in fresh concrete without hydrogen evolution, but affect the hydration process of the cement paste that was demonstrated by slight water separation. Full article

Wearable sensor data can be integrated and interpreted to improve the treatment of chronic conditions, such as diabetes, by enabling adjustments in treatment decisions based on physical activity and psychological stress assessments. The challenges in using biological analytes to frequently detect physical activity (PA) and acute psychological stress (APS) in daily life necessitate the use of data from noninvasive sensors in wearable devices, such as wristbands. We developed a recurrent multi-task deep neural network (NN) with long-short-term-memory architecture to integrate data from multiple sensors (blood volume pulse, skin temperature, galvanic skin response, three-axis accelerometers) and simultaneously detect and classify the type of PA, namely, sedentary state, treadmill run, stationary bike, and APS, such as non-stress, emotional anxiety stress, mental stress, and estimate the energy expenditure (EE). The objective was to assess the feasibility of using the multi-task recurrent NN (RNN) rather than independent RNNs for detection and classification of AP and APS. The multi-task RNN achieves comparable performance to independent RNNs, with the multi-task RNN having F1 scores of 98.00% for PA and 98.97% for APS, and a root mean square error (RMSE) of 0.728 $\frac{\mathrm{cal}}{\mathrm{hr}.\mathrm{kg}}$ for EE estimation for testing data. The independent RNNs have F1 scores of 99.64% for PA and 98.83% for APS, and an RMSE of 0.666 $\frac{\mathrm{cal}}{\mathrm{hr}.\mathrm{kg}}$ for EE estimation. The results indicate that a multi-task RNN can effectively interpret the signals from wearable sensors. Additionally, we developed individual and multi-task extreme gradient boosting (XGBoost) for separate and simultaneous classification of PA types and APS types. Multi-task XGBoost achieved F1 scores of 99.89% and 98.31% for the classification of PA types and APS types, respectively, while the independent XGBoost achieved F1 scores of 99.68% and 96.77%, respectively. The results indicate that both multi-task RNN and XGBoost can be used for the detection and classification of PA and APS without loss of performance with respect to individual separate classification systems. People with diabetes can achieve better outcomes and quality of life by including physical activity and psychological stress assessments in treatment decision-making. Full article

The ongoing energy transition has changed the architecture of electricity networks in ways that conventional power transformers are not able to cope with the new required functionalities. For this purpose, the solid state transformer (SST), which comprises state of the art power electronics with galvanic isolation to interconnect two separate alternating current (AC) or direct current (DC) power grids, is considered to be the dominant solution. The purpose of this paper is to provide a practical, application-oriented review of the SST. In this context, the main functionalities and possible applications of the SST are presented, including smart grids (SGs), data centres, railways, offshore wind farms, etc. Furthermore, the main developed SST prototypes are analysed with special focus on the related projects, demonstrators, stakeholders and rated values, e.g., voltage, switching frequency and power. The analysis is concluded with the future trends and challenges regarding the wider implementation of SST technology in the electrical grid. Full article

Chloride ions contained in the sealing compound currently used in the electronic packaging industry not only interact with intermetallic compounds but also have a serious impact on silver alloy wires. A 15 μm ultrafine quaternary silver-palladium-gold-platinum alloy wire was used in this study. The wire and its bonding were immersed in a 60 °C saturated sodium chloride solution (chlorination experiment), and the strength and elongation before and after chlorination were measured. Finally, the fracture surface and cross-section characteristics were observed using a scanning electron microscope and focused ion microscope. The results revealed that chloride ions invade the wire along the grain boundary, and chlorides have been generated inside the cracks to weaken the strength and elongation of the wire. In addition, chloride ions invade the interface of the wire bonding to erode the aluminum substrate after immersing it for enough long time, causing galvanic corrosion, which in turn causes the bonding joint to separate from the aluminum substrate. Full article