Search Results (18)

Electrical discharge machining is a non-conventional shaping technique applied to electrically conductive, difficult-to-machine alloys, such as Hastelloy C-22. This study investigates the influence of graphite electrode properties and key machining parameters on the average thickness of the recast layer under positive polarity. Two POCO graphite electrodes with different grain sizes—AF-5 (1 μm) and S-180 (10 μm)—were used to examine the effects of discharge current, pulse duration, and interval on recast layer formation. Metallographic analyses measured layer thickness and observed microstructural defects, including microcracks. Results show that discharge current and pulse duration are the primary factors controlling recast layer thickness, with higher currents and longer pulses producing thicker layers due to resolidification of molten material remaining in the plasma-formed crater. The coarser S-180 electrode caused slightly higher microcrack density and greater thickness variations due to its lower electrical resistivity. Pulse interval mainly influenced discharge stability and debris removal, with minimal effect on average layer thickness. Statistical regression models were developed to quantify the relationships between machining parameters, electrode type, and recast layer thickness, providing predictive tools for selecting optimal conditions. These findings contribute to improving surface integrity and process control in electrical discharge machining of nickel-based alloys. Full article

4,6-Diamino-1,3,5-triazine (DT) derivatives typically exhibit excellent liquid crystal properties, attracting numerous researchers interested in enhancing their performance. In this paper, two DT molecules (DT−10 and DT−12) are employed to elucidate the effects of their backbone length and number of branches in the tail chains on self-assembled nanostructures using scanning tunneling microscopy (STM) at the 1-octanoic acid/highly ordered pyrolytic graphite interface, compared to our previous report (2TDT−n, n = 10,12,16,18). DT−10 features a short backbone and a trialkoxy chain tail, whereas DT−12 possesses a long backbone and bifurcated chain tails. STM results reveal that DT−10 assembles into a cross-shaped nanostructure with DT head groups arranged in a head-to-head configuration stabilized by a pair of N–H···N hydrogen bindings (HBs). In contrast, DT−12 assembles into a two-row linear pattern, where DT head groups exhibit a side-by-side arrangement mediated by a pair of N–H···N HBs. Comparison with our previous findings indicates that although variations in backbone length and tail chain branching can modulate the nanostructural features of DT derivatives, the chain length of DT molecules emerges as a pivotal factor governing their assembly architecture. Full article

Flexible graphite foils with varying thicknesses (S = 282 ± 5 μm, M = 494 ± 7 μm, L = 746 ± 8 μm) and an initial density of 0.70 g/cm³ were obtained using the nitrate method. The specific electrical and thermal conductivity of these foils were investigated. As the density increased from 0.70 g/cm³ to 1.75 g/cm³, the specific electrical conductivity increased from 69 to 192 kS/m and the thermal conductivity increased from 109 to 326 W/(m·K) due to the rolling of graphite foils. The study showed that conductivity and anisotropy depend on the shape, orientation, and contact area of thermally expanded graphite (TEG) mesoparticles (mesostructural factor), and the crystal structure of nanocrystallites (nanostructural factor). A proposed mesostructural model explained these increases, with denser foils showing elongated, narrowed TEG particles and larger contact areas, confirmed by electron microscopy results. For graphite foils 200 and 750 μm thick, increased density led to a larger coherent scattering region, likely due to the rotation of graphite mesoparticles under mechanical action, while thinner foils (<200 μm) with densities > 1.7 g/cm³ showed increased plastic deformation, indicated by a sharp reduction in the coherent scattering region size. This was also evident from the decrease in misorientation angles with increasing density. Rolling reduced nanocrystallite misorientation angles along the rolling direction compared to the transverse direction (TD) (for 1.75 g/cm³ density ΔMA = 1.2° (S), 2.6° (M), and 2.4° (L)), explaining the observed anisotropy in the electrical and mechanical properties of the rolled graphite foils. X-ray analysis confirmed the preferred nanocrystallite orientation and anisotropy coefficients (A) using Kearns parameters, which aligned well with experimental measurements (for L series foils calculated as: A_0.70 = 1.05, A_1.30 = 1.10, and A_1.75 = 1.16). These calculated values corresponded well with the experimental measurements of specific electrical conductivity, where the anisotropy coefficient changed from 1.00 to 1.16 and mechanical properties varied from 0.98 to 1.13. Full article

Shale gas production is obviously higher within the Silurian Longmaxi Formation than that of the Cambrian Niutitang Formation according to the drilling test results in the northwest Hunan area. To clarify the reasons behind this variation, core samples from the two sets of shales were studied for a comprehensive comparison and analysis of their organic matter (OM) pore structure. Methods were used, including the total organic carbon content test, the vitrinite reflectance test, X-ray diffraction, and focused ion-beam scanning electron microscopy (FIB-SEM). The results show that these two shales have similar reservoir characteristics, both with abundant organic matter and high content of brittle minerals. However, the Longmaxi shale with 2.3% to 3.0%Ro presents lower thermal maturity than the Niutitang shale with over 3.0%Ro. In the case of pore structure associated with OM, a huge difference exists between the two shales. The OM pore shape of the Longmaxi shale is very regular, being mostly round and oval, while the OM pore shape of the Niutitang shale is irregular, being flat with a thin middle and thick and elongated ends. An important factor affecting OM pore evolution is thermal maturity. In turn, the thermal maturity is controlled by the tectonic evolution process, especially the maximum paleo-burial depth. In conclusion, the paleo-burial depth of the Lower Cambrian Niutitang shale in northwest Hunan is too large, which leads to the excessive evolution of organic matter in the shale, and the physical and chemical properties are similar to graphite, which leads to the disappearance of OM pores. Shale gas has no effective reservoir space and is largely dispersed in geological history. At the same time, due to the insufficient hydrocarbon-generation evolution time of the Lower Silurian Longmaxi Formation shale in this area, the shale could not form enough gaseous hydrocarbons and a large amount of effective reservoir space (OM pores with regular shape and large pore size), and finally failed to become a gas reservoir. Therefore, the exploration and development potential of the marine shale gas of the Lower Cambrian Niutitang Formation and the Lower Silurian Longmaxi Formation in northwest Hunan is poor. Full article

Despite numerous research on new active materials for anodes, graphite remains the most commonly used material in Li-ion batteries. The spherical shape of the graphite particles has proven to be beneficial for application in electric vehicles, especially for fast charging. So far, the spheroidization of natural flake graphite is conducted by a rigid and inefficient cascade process. In this work, a scalable classifier system was used for spheroidization, and it was demonstrated that a spheroidization time of 15 min is sufficient to improve material properties and enhance electrochemical performance while maintaining high process yields of 55%. Insights into the influence of the morphology on the intrinsic and structural properties of the graphite particles and manufactured electrodes are provided. Spheroidization creates a more efficient pore network in the coating layer while reducing the internal resistance and increasing the surface area of the particles by a factor of 1.8. We demonstrate that the spherical shape improves the discharge rate capability by 1.8, and the specific charge capacity could be enhanced by more than 237% at a C-rate of 3. An additional carbon coating could significantly decrease the specific surface area and increase the specific capacity at high C-rates. Full article

Information about the technological possibility of stamping in open dies, round-shaped forgings made of ductile cast iron, is outlined herein. Cast iron’s propensity for plastic deformation under complex loading conditions is analyzed from the standpoint of the morphology of graphite inclusions, depending on the degree and mechanical scheme of deformation. The research methodology included: the choice of a brand of cast iron with spherical graphite and the technological process of its deformation; mathematical modeling of the deformation process using the DEFORM–3D software package; stamping of an experimental batch of forgings; and microstructural studies of the forging material, together with the data of its stress–strain state and the direction of flow of the material. Under the conditions of comprehensive compression of the workpiece material at the beginning of the deformation process, lateral pressure was created from the tool walls. It was carried out by selecting the size and shape of the initial blank by mathematical modeling. When analyzing the morphology of graphite inclusions, the stress state scheme was determined as the main influencing factor. The greatest change in the shape and size of graphite inclusions of cast iron, including their crushing, corresponds to the condition of the disappearance of all-round compression. When stamping in open dies, this occurs in the area where the material exits from the stamp engraving into the flash gutter. In the process of forming, cast iron showed the possibility of deformation in the deformation intensity index ε_i = 2.5. Full article

Ductile iron is a high-strength cast iron material. The spherical graphite obtained by inoculation treatment effectively improves the mechanical properties of cast iron, resulting in higher strength than carbon steel. However, severe corrosion may occur under specific circumstances, especially in thermal water pipelines. In this paper, the corrosion mechanisms at the main defective points of ductile iron were investigated using microscopic morphological characterization after accelerated tests combined with numerical simulations. The influence law of each environmental factor on the corrosion kinetics of ductile iron in a complex water quality environment was studied using dynamic potential polarization tests. The results showed that the main causative factors leading to the increased corrosion of ductile iron were the presence of tail-like gaps on its surface, and the crescent-shaped shrinkage and loosening organization around the graphite spheres. After mechanical treatment was applied to eliminate the obvious defects, the number of corrosion pits was reduced by 41.6%, and the depth of the pits was slowed down by 40% after five days. By comparison, after ten days, the number of pits was reduced by 51%, and the depth of the pits was slowed down by 50%. The dynamic potential polarization test results show that the dissolved oxygen concentration has the greatest influence on the corrosion of ductile iron in the simulated water environment; meanwhile, the water hardness can slow down the corrosion of ductile iron. The relative influence of each environmental factor is as follows: dissolved oxygen concentration > temperature > immersion time > water hardness > pH > Cl⁻. Full article

Ferritic high-Si ductile cast irons replace an unstable mixed ferrite-pearlite matrix with a unique combination of high elongation, strength and hardness (ideal for automotive drive train components) and resistance to oxidation and corrosion at high temperatures (automotive exhaust and turbocharger systems). The present paper analyses the graphite parameters of 4.5%Si, un-inoculated ductile cast iron (4.7%CE, 0.035%Mg_res) as an effect of the casting section size. The structure is characterized by 10.5–11.2% graphite and 464–975 nodules/mm², at more than 70% ferrite and no carbides, including at 3 mm wall thickness. The lower the wall thickness is, the higher the nodule count is and, consequently, the higher the ferrite amount is. The Roundness Graphite Shape Factor (RSF = 0.65–0.68) illustrates the presence of Slightly Irregular Spheroidal Graphite (Form V ISO 945). There is a big difference between the graphite nodularity evaluated according to ISO 16112:2017 [CGI] (NG₁ = 79–86%) and according to ISO 945-4-2019 (DI) (NG₂ = 65.2–74.6%), both of them based on RSF. Graphite Nodularity (NG₃), calculated with the ISO 945-4-2019 [DI] formula, but replacing RSF with SSF, Sphericity Graphite Shape Factor, has an intermediary position. The higher the imposed minimum RSF or SSF is, the lower the Graphite Nodularity (NG₄, NG₅): 80–90% for min. 0.50 (minimum Form IV or Intermediate Graphite), 60–80% for min. 0.60–0.65 (minimum Form V graphite) and 35–70% for min. 0.80 (minimum Form VI graphite). The SSF is more representative than the RSF for Si-alloyed ductile cast iron, so it is recommended to use a graphite nodularity calculus considering SSF instead of the RSF formula (stipulated by ISO 945-4-2019), with SSF replacing RSF. Full article

Modern industry is focused on looking for new and effective technologies to manufacture complex shapes from alloys based on nickel and chromium. One of the materials widely used in the chemical and aerospace industry is Hastelloy C-22. This material is difficult to machine by conventional methods, and in many cases, unconventional methods are used to manufacture it, such as electrical discharge machining (EDM). In the EDM process, the material is removed by electrical discharges between a workpiece and a tool electrode. The physical and mechanical properties of the tool electrodes have a direct impact on the process efficiency, machining accuracy, and surface roughness. Currently, there has been a significant increase in the use of graphite as a material for tool electrodes due to the low purchase cost of the raw material, good machinability, and high sublimation temperature. In this work, an experimental investigation of the influence of the grain size of the graphite tool electrode on material removal rate (MRR), tool wear rate (TWR), and surface roughness (Ra) of Hastelloy C-22 was carried out. Two POCO graphite tool electrodes with a grain size of 1 µm (AF-5) and 10 µm (S-180) were used. Based on the experimental studies, empirical models describing the influence of machining parameters on technological indicators and the condition of the surface texture were determined. The research indicates that graphite with a larger grain provides higher process efficiency with high relative wear of the tool electrode. The lowest surface roughness was obtained for graphite with a smaller grain size (AF-5). The analysis of the machining parameters proves that the discharge current and pulse duration are the main factors determining the MRR and Ra values for both AF-5 and S-180 graphite. The time interval is the dominant parameter with regard to the relative wear of the graphite electrode. Full article

Trace elements, functionalized nanoparticles and labeled entities can be localized with sub-mm spatial resolution by X-ray fluorescence imaging (XFI). Here, small animals are raster scanned with a pencil-like synchrotron beam of high energy and low divergence and the X-ray fluorescence is recorded with an energy-dispersive detector. The ability to first perform coarse scans to identify regions of interest, followed by a close-up with a sub-mm X-ray beam is desirable, because overall measurement time and X-ray dose absorbed by the (biological) specimen can thus be minimized. However, the size of X-ray beams at synchrotron beamlines is usually strongly dependent on the actual beamline setup and can only be adapted within specific pre-defined limits. Especially, large synchrotron beams are non-trivial to generate. Here, we present the concept of graphite-based, convex reflection optics for the one-dimensional enlargement of a 1 mm wide synchrotron beam by a factor of 5 to 10 within a 1 m distance. Four different optics are tested and characterized and their reflection properties compared to ray tracing simulations. The general shape and size of the measured reflection profiles agree with expectations. Enhancements with respect to homogeneity and efficiency can be expected with improved optics manufacturing. A mouse phantom is used for a proof-of-principle XFI experiment demonstrating the applicability of coarse and fine scans with the suggested optics design. Full article

In recent years, high-Si ductile cast irons (3–6% Si) have begun to be used more and more in the automotive and maritime industries, but also in wind energy technology and mechanical engineering. Si-alloyed ferrite has high strength, hardness and oxidation and corrosion resistance, but it has low ductility, toughness and thermal conductivity, with graphite as an important influencing factor. In this study, 4.5% Si uninoculated ductile iron solidified in thin wall castings (up to 15 mm section size) via a permanent (metal) mold versus a sand mold, was evaluated. Solidification in a metal mold led to small size, higher graphite particles (less dependent on the section size). The graphite particles’ real perimeter was 3–5% higher than the convex perimeter, while the values of these parameters were 41–43% higher in the sand mold. Increasing the casting section size led to an increased graphite perimeter, with it being much higher for sand mold. The graphite particles’ shape factors, involving the maximum and minimum size, were at a lower level for metal mold solidification, while by involving the difference between P_r and P_c, is higher for the metal mold. The shape factor, including the graphite area and maximum size, had higher values in the metal mold, sustaining a higher compactness degree of graphite particles and a higher nodularity regarding metal mold solidification (75.5% versus 67.4%). The higher was due to the graphite compactness degree level (shape factor increasing from 0.50 up to 0.80), while the lower was due to the graphite nodularity for both the metal mold (39.1% versus 88.5%) and the sand mold (32.3% versus 83.1%). The difference between the metal mold and sand mold as the average graphite nodularity increased favored the metal mold. Full article

In this study, ethylene vinyl alcohol (EVOH) nanocomposites elaborated by melt blending with four different fillers were investigated. Two graphene and two graphite fillers displaying various shapes were selected. The morphology, microstructure, thermal, mechanical, and barrier properties of the nanocomposite films prepared for 2 wt% fillers were analyzed with the aim to establish structure–function properties relationships. The nanocomposites properties significantly depended on the nature of the incorporated filler. The nanocomposite film prepared with the expanded graphite filler exhibited the highest Young modulus value (E = 1430 MPa) and the best barrier properties. Indeed, barrier properties, rarely studied at high water activities, evidenced a significant improvement with a decrease of the water vapor permeability by a factor 1.8 and of the oxygen permeabilities by a factor close to 2, for a critical water activity higher than 0.95. An increase of the thermal stability was also evidenced for this nanocomposite. It was shown that for all studied nanocomposites, the properties could be related to the dispersion state of the fillers and the simultaneous increase of the crystallinity of the matrix. A specific equation was proposed to take into account these both parameters to accurately predict the nanocomposite barrier properties. Full article

This study reports an integrated device of a lithium-ion battery (LIB) connected with Si solar cells. A Li(Ni_0.65Co_0.15Mn_0.20)O₂ (NCM) cathode and a graphite (G) anode were used to fabricate the lithium-ion battery (LIB). The surface and shape morphologies of NCM and graphite powder were characterized by field emission scanning electron microscopy (FE-SEM). The structural properties of NCM and graphite powder were determined by X-ray diffraction (XRD) analysis. XRD patterns of powders were well matched with those of JCPDS data. To investigate the electrochemical characteristics of NCM and graphite, cycling tests were performed after assembling the NCM-Li, the G-Li half-cell, and the NCM-G full-cell. The discharge capacity of the NCM cathode at 0.1C was 189.82 mAh/g⁻¹. The NCM-graphite full-cell showed 98.25% cycle retention at 1C after 50 cycles. To obtain enough charging voltage for the LIB connected with solar cells in an integrated device, eight single Si solar cells were connected in a series. The short-circuit photocurrent density for Si solar cells was 4.124 mA/cm². The fill factor and the open circuit voltage were 0.78 and 4.5 V, respectively. These Si solar cells showed a power conversion efficiency of 14.45%. The power conversion andstorage efficiency of the integrated device of the NCM battery and Si solar cells was 7.74%. Charging of the integrated device could be as effective as charging with a battery cycler. Full article

Atmospheric aerosol samples were collected at Faraglione Camp, 3 km away from the Italian Mario Zucchelli Station (Terra Nova Bay, Ross Sea), from 1 December 2013 to 2 February 2014. A two-step extraction procedure was applied to characterize the soluble and insoluble components of PM₁₀-bound metals. Samples were analyzed for Al, Fe, Cd, Cu, and Pb by square wave anodic stripping voltammetry (SWASV) and by graphite furnace atomic absorption spectrophotometer (GF-AAS). The mean atmospheric concentrations were (reported as means ± SD) Al 24 ± 3 ng m⁻³; Fe 23 ± 4 ng m⁻³; Cd 0.92 ± 0.53 pg m⁻³; Cu 43 ± 9 pg m⁻³, and Pb 16 ± 5 pg m⁻³. The fractionation pattern was metal-specific, with Al, Fe, and Pb mainly present in the insoluble fractions, Cd in the soluble one, and Cu equally distributed between the two fractions. The summer evolution showed overall constant behavior of both fractions for Al and Fe, while a bell-shaped trend was observed for the three trace metals. Cd and Cu showed a bell-shaped evolution involving both fractions. A seasonal increase in Pb occurred only for the insoluble fraction, while the soluble fraction remained almost constant. Sequential extraction and enrichment factors indicated a crustal origin for Al, Fe, and Pb, and additional (marine or anthropogenic) contributions for Cd and Cu. Back trajectory analysis showed a strong contribution of air masses derived from the Antarctic plateau. A potential low contribution from anthropized areas cannot be excluded. Further studies are necessary to better characterize the chemical composition of the aerosol, to discriminate between natural and anthropogenic sources, and to evaluate a quantitative source apportionment. Full article

Previous experiments pointed out that the deviation using a sphere as reference of graphite particles is noticeably increased by Si-alloying, with inoculation as a possible beneficial effect. The main objective of the present work is to evaluate the effects of commercial inoculants (Ca/Ca, Ba/Ca, RE-FeSi alloys) on 4.5%Si ductile iron, thin wall castings. FeSiMgRE treated iron (0.032–0.036%Mg_res) is in-mold inoculated (a four-work-positions pattern). A complex chemical composition is obtained for each inoculation variant. Wedge casting W₃ (ASTM A 367) is used to evaluate structure characteristics at different wall thickness (3–15 mm). Minimum and maximum size, area, nodule count, and representative graphite shape factors are evaluated. Roundness (including A_G and F_max) at 0.6–0.8 level illustrates the common formation of slightly irregular spheroidal graphite (Type V, ISO 945). Ca, RE-FeSi inoculation leads to the highest level of real perimeter and, consequently, to the lowest level of Sphericity. Ca, Ba-FeSi inoculation appears to be better than simple Ca-FeSi for improving graphite parameters, while Ca, RE-FeSi has the lowest beneficial effect, especially as it negatively affects the compactness degree of graphite particles. A two-step liquid treatment using RE-bearing FeSiCaMg master alloy and Ca, Ba-FeSi inoculant appears to be a solution to improve graphite parameters for high-Si ductile irons solidified in thin wall castings. Full article