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Search Results (248)

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Keywords = high-voltage window

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16 pages, 2074 KB  
Article
A Polymer Electrolyte with Rigid–Flexible Coupled Architecture for High-Voltage Lithium-Metal Batteries
by Haoru Xie, Zhengyin Yao, Zhen Liu, Ruiyong Chen and Peng Zhang
Polymers 2026, 18(8), 987; https://doi.org/10.3390/polym18080987 - 18 Apr 2026
Viewed by 104
Abstract
A polymer electrolyte is developed by integrating a poly(methyl methacrylate) (PMMA)/eutectic electrolyte (EE) phase into a porous polyethylene (PE) scaffold via a solution-casting strategy. In this rigid–flexible coupled architecture, the PMMA matrix serves as a solid host that coordinates with Li+ through [...] Read more.
A polymer electrolyte is developed by integrating a poly(methyl methacrylate) (PMMA)/eutectic electrolyte (EE) phase into a porous polyethylene (PE) scaffold via a solution-casting strategy. In this rigid–flexible coupled architecture, the PMMA matrix serves as a solid host that coordinates with Li+ through its polar carbonyl groups, thereby promoting lithium salt dissociation and establishing a stable ion transport network. The incorporated EE, composed of ethylene carbonate and LiTFSI, effectively reduces the glassy rigidity of PMMA and provides continuous pathways for fast ionic conduction. Meanwhile, the porous PE scaffold reinforces mechanical strength and resists lithium dendrite penetration, enabling a thin electrolyte membrane with excellent flexibility. The resulting electrolyte achieves an ionic conductivity of 1.59 × 10−4 S cm−1 at 30 °C, a lithium-ion transference number of 0.45, and an electrochemical stability window up to 4.75 V. In Li||LiFePO4 cells, it delivers stable cycling at 3 C for 1000 cycles with 76.8% capacity retention and a Coulombic efficiency exceeding 99.9%. The monomer-free design eliminates residual reactive species that commonly compromise interfacial stability, offering a reliable pathway toward high-voltage solid-state lithium-metal batteries. Full article
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30 pages, 18084 KB  
Article
Integrated Simulation and Field Analysis of a 48 V Mild-Hybrid Urban Bus: KSG Active-Mode Modeling and Active–Passive Performance Comparison
by Aysima Pıçak Adaş and Engin Ayçiçek
Energies 2026, 19(8), 1882; https://doi.org/10.3390/en19081882 - 13 Apr 2026
Viewed by 414
Abstract
This study presents a real-world performance assessment of a 48 V mild-hybrid urban bus equipped with a crankshaft starter–generator (CSG, denoted as KSG in German terminology), together with model-based validation for KSG Active operation. The 17.8-ton Euro VI test vehicle uses a 160 [...] Read more.
This study presents a real-world performance assessment of a 48 V mild-hybrid urban bus equipped with a crankshaft starter–generator (CSG, denoted as KSG in German terminology), together with model-based validation for KSG Active operation. The 17.8-ton Euro VI test vehicle uses a 160 F supercapacitor module operated within a 38–52 V DC/DC converter voltage window (≈40 Wh usable) to buffer transient high-power events in stop-and-go duty. A controlled A/B comparison (KSG Active vs. KSG Passive) was performed using repeated 0–50–0 km/h launch cycles (15 test cycles per mode). Vehicle CAN signals were recorded using a datalogger and analyzed in Vector vSignalyzer 19.0. Field results show a 17.1% reduction in fuel consumption (32.21 to 26.70 L/100 km) and a 30.4% reduction in time-averaged ICE power demand (58.90 to 40.99 kW). A MATLAB/Simulink R2020a longitudinal dynamics digital twin was developed and validated for the KSG Active mode only against 20 Hz CAN measurements, achieving NRMSE below 5% for key variables. The findings should be interpreted as a controlled same-vehicle comparison under repeatable test-track conditions rather than as a certification-grade fleet-level benchmark. Full article
(This article belongs to the Special Issue Hybrid Electric Powertrain System Modelling and Control)
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22 pages, 3075 KB  
Article
Accurate and Efficient Harmonic Estimation for LCC-HVDC Systems
by Dan Wang, Sijia Hu, Jinjie Lin, Yong Li, Yi Zhang and Jian Song
Energies 2026, 19(7), 1758; https://doi.org/10.3390/en19071758 - 3 Apr 2026
Viewed by 281
Abstract
Modern grids’ dual-high characteristics elevate the role of wideband impedance measurement in operational risk assessment. In thyristor-based line-commutated converter-based high-voltage direct-current (LCC-HVDC) systems, where severe waveform distortion and high harmonic content prevail, nonintrusive wideband techniques rely on precise spectral estimation. Accurate identification of [...] Read more.
Modern grids’ dual-high characteristics elevate the role of wideband impedance measurement in operational risk assessment. In thyristor-based line-commutated converter-based high-voltage direct-current (LCC-HVDC) systems, where severe waveform distortion and high harmonic content prevail, nonintrusive wideband techniques rely on precise spectral estimation. Accurate identification of harmonic parameters (frequency, amplitude, and phase) is therefore essential. This work presents a Hann-window-based three-point interpolated discrete Fourier transform (I3pDFT) for precise harmonic parameter estimation. The method suppresses long-range spectral leakage, enhances frequency resolution, and employs robust amplitude and phase estimators that are resilient to noise and negative-frequency interference. Extensive simulations across frequency deviations, noise levels, sampling rates, and record lengths show that the proposed approach outperforms two classical I3pDFT variants in accuracy while maintaining low computational loads suitable for embedded implementation. These results confirm the effectiveness and practicality of the proposed I3pDFT-Hann method for real-world harmonic measurements in LCC-HVDC systems. Full article
(This article belongs to the Special Issue Advanced in Modeling, Analysis and Control of Microgrids)
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15 pages, 8468 KB  
Article
Optimizing Depth-of-Discharge in Li-Rich Halide All-Solid-State Batteries for Enhanced Capacity and Cycling Stability
by Yunan Zhou, Naibo Zhao, Xin Chen, Meiling Fan, Yang Wu, Jingchao Liu, Zhen Wu and Xiangxin Guo
Materials 2026, 19(7), 1409; https://doi.org/10.3390/ma19071409 - 1 Apr 2026
Viewed by 433
Abstract
Although halide solid electrolytes (HSEs) demonstrate a higher voltage window and superior interfacial stability toward Li-rich layered oxides (LLOs) compared to sulfide systems, HSE-based all-solid-state lithium batteries (HSE-ASSLBs) still face a fundamental trade-off between achieving high capacity and maintaining cycling stability. To resolve [...] Read more.
Although halide solid electrolytes (HSEs) demonstrate a higher voltage window and superior interfacial stability toward Li-rich layered oxides (LLOs) compared to sulfide systems, HSE-based all-solid-state lithium batteries (HSE-ASSLBs) still face a fundamental trade-off between achieving high capacity and maintaining cycling stability. To resolve this issue, a rational adjustment of the depth-of-discharge (DOD) via discharge cut-off voltage control is proposed. Analysis of dQ/dV profiles and post-cycled electrodes indicates that excessive DOD (lower cut-off voltages) aggravates structural degradation and interfacial side reactions, whereas insufficient DOD (higher cut-off voltage) fails to fully utilize the compensatory capacity from low-voltage redox couples. Notably, an optimized cut-off voltage of 2.6 V activates a stable low-voltage redox reaction centered around 2.85 V, which effectively offsets high-voltage capacity loss while suppressing unfavorable interfacial evolution. As a result, the ASSLB configured with a Li1.2Ni0.13Mn0.54Co0.13O2 cathode and a Li2.75In0.75Zr0.25Cl6 HSE delivers an initial discharge capacity of 281.6 mAh g−1 at 1C and achieves significantly improved capacity retention from 71.8% to 86.1% over 300 cycles. This study confirms that DOD regulation offers a simple and effective electrochemical protocol for enabling durable high-capacity output in LLO-based ASSLBs. Full article
(This article belongs to the Section Energy Materials)
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24 pages, 5819 KB  
Article
Effects of Controlled Oxygen Partial Pressure on Arc Dynamics and Material Erosion in a Pantograph–Catenary System
by Bingquan Li, Zhaoyu Ku, Xuanyu Xing, Ran Ji and Huajun Dong
Materials 2026, 19(6), 1234; https://doi.org/10.3390/ma19061234 - 20 Mar 2026
Viewed by 322
Abstract
Motivated by altitude-induced fluctuations in oxygen partial pressure (pO2) and their impacts on PCS off-line arc motion and erosion response, this study proposes a comparative experimental approach featuring single-variable control under constant total pressure and coordinated multi-source electrical-signal observation. A reciprocating [...] Read more.
Motivated by altitude-induced fluctuations in oxygen partial pressure (pO2) and their impacts on PCS off-line arc motion and erosion response, this study proposes a comparative experimental approach featuring single-variable control under constant total pressure and coordinated multi-source electrical-signal observation. A reciprocating current-carrying arc-generation rig was established, in which pO2 was equivalently regulated via a constant-pressure gas substitution and mixing approach. High-speed imaging–based quantitative vision analysis was integrated with synchronized voltage–current measurements to evaluate the net effects of five O2 volumetric fraction levels (6, 11, 14, 17, and 21 vol%) under a DC supply of 120 V/25 A on arc dynamics, electrochemical processes, and contact pair erosion. Based on repeated-test results, the 14 vol% case exhibited the poorest stability (maximum fluctuation coefficient 20.306%), whereas the 17 vol% case showed the lowest current-carrying efficiency (minimum 56.070%) together with the most severe erosion damage. Moreover, with increasing pO2, the erosion morphology evolved in a staged manner, transitioning from localized central ablation accompanied by melt-related traces to adhesive wear-induced delamination, and ultimately to electrochemical oxidative wear. Overall, pO2 imposes a pronounced non-monotonic “window effect” on arc stability and erosion, providing key evidence for PCS structural optimization and risk assessment in open operating environments. Full article
(This article belongs to the Section Corrosion)
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13 pages, 2743 KB  
Article
A Preisach–MVS Compact-Modeling Framework for Investigating Device Variability in Ferroelectric FETs Under Ferroelectric Thickness and Coercive-Field Fluctuations
by Ziang Li, Weihua Han and Zhanqi Liu
Electronics 2026, 15(6), 1274; https://doi.org/10.3390/electronics15061274 - 18 Mar 2026
Viewed by 273
Abstract
As emerging nonvolatile memory devices, ferroelectric field-effect transistors (FeFETs) have attracted significant attention for memory applications. However, due to the stochastic nature of fabrication processes and material properties, FeFETs exhibit pronounced device-to-device (DTD) variations, leading to threshold voltage dispersion and inconsistency in memory [...] Read more.
As emerging nonvolatile memory devices, ferroelectric field-effect transistors (FeFETs) have attracted significant attention for memory applications. However, due to the stochastic nature of fabrication processes and material properties, FeFETs exhibit pronounced device-to-device (DTD) variations, leading to threshold voltage dispersion and inconsistency in memory window (MW), which severely constrain array-level performance and reliability. In this study, a compact model-based variability analysis methodology for FeFETs has been proposed. Specifically, the Preisach ferroelectric (FE) hysteresis model was combined with the MIT Virtual Source (MVS) physical compact model to establish a macro-model for FeFETs, and statistical simulations were performed to evaluate device-level variations. Using the proposed framework, how fluctuations in two key FE parameters, film thickness (tFE) and coercive field (EC), affect FeFET transfer characteristics, threshold voltage (VTH), and MW was systematically investigated. Monte Carlo (MC) simulations were further conducted to quantify the distribution width and statistical features of VTH under different variability scenarios. The results indicate that random fluctuations in process-related parameters broaden the FeFET Id-Vg characteristics, induce shifts in high/low threshold voltages, and cause MW variations. Moreover, when tFE and EC fluctuate simultaneously, the dispersions of VTH and MW become significantly larger than those induced by a single-parameter fluctuation. The proposed compact-modeling framework and variability analysis approach enables the efficient evaluation of parameter tolerance and performance margin in FeFET arrays, providing guidance for storage-array design. Full article
(This article belongs to the Section Microelectronics)
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8 pages, 1862 KB  
Proceeding Paper
Charging Speed vs. Daily Performance: A Comparative Analysis of Battery Duration in Smartphones Under Different Charging Regimens
by Dimitrios Rimpas, Nikolaos Rimpas, Vasilios A. Orfanos, Sofia Fragouli and Ioannis Christakis
Eng. Proc. 2026, 124(1), 74; https://doi.org/10.3390/engproc2026124074 - 11 Mar 2026
Viewed by 575
Abstract
This study focuses on the instantaneous effects of fast charging technologies, in terms of the daily operation of mobile devices, and specifically on the trade-off between fast charge and discharge efficiency. A controlled experimental layout is used, containing three smart devices, iPhone 17 [...] Read more.
This study focuses on the instantaneous effects of fast charging technologies, in terms of the daily operation of mobile devices, and specifically on the trade-off between fast charge and discharge efficiency. A controlled experimental layout is used, containing three smart devices, iPhone 17 Pro, iPad 11 Air and MacBook Pro, and four variations in chargers. The research monitored important values like the voltage, current, power and thermal behavior of the selected devices. These comparative results showed that high-speed charging at 67 Watts causes peak temperatures in the battery to be 41.5 °C, which is significantly higher compared to charging under standard protocols of 20 W, with values of 33.1 °C. This thermal stress forces the battery outside of its optimum operating window and consequently increases the internal resistance of the battery which results in a reduction of about 5% of the subsequent discharge runtime. Although fast charging offers a rapid energy replenishment, the thermal penalty incurred by the fast charging process reduces the battery’s short-term utility, suggesting that standard charging is the best option to maximize the single-cycle duration. Full article
(This article belongs to the Proceedings of The 6th International Electronic Conference on Applied Sciences)
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29 pages, 35494 KB  
Article
Future Highly Efficient Engines with Solid Oxide Fuel Cell–Gas Turbine Coupling: System Modeling Study and Comparison of Directly and Indirectly Coupled SOFC–GT Systems
by Pascal Köhler, Jan Hollmann, Anis Taissir, Marc P. Heddrich and Stephan Kabelac
Aerospace 2026, 13(3), 263; https://doi.org/10.3390/aerospace13030263 - 11 Mar 2026
Viewed by 572
Abstract
This study investigates hybridization of a solid oxide fuel cell with a gas turbine (SOFC–GT) for application in an ATR 72 regional aircraft. Several challenges hinder its viability, including the low gravimetric power density of SOFC stacks and stringent heat integration constraints. A [...] Read more.
This study investigates hybridization of a solid oxide fuel cell with a gas turbine (SOFC–GT) for application in an ATR 72 regional aircraft. Several challenges hinder its viability, including the low gravimetric power density of SOFC stacks and stringent heat integration constraints. A steady-state model sweeps the cell voltage, overall pressure ratio (OPR), and a bounded turbine inlet temperature (TIT). This study introduces a new corrected power-share metric. This metric accounts for operating-point-dependent SOFC power density. It also enables weight-relevant comparisons. We analyze two types of coupling: direct and indirect. In the direct coupling, SOFC cooling fixes the core airflow and a TIT ceiling imposes a minimum power share. In the indirect coupling, a bypass decouples SOFC and gas turbine operation, incurring an efficiency penalty. We compare two heat-integration architectures: preheating with SOFC cathode exhaust versus low-pressure turbine (LPT) exhaust. Results show that direct coupling achieves efficiencies above 65% at high-corrected power shares, whereas indirect coupling offers greater operational flexibility but lower efficiency. Cathode exhaust preheating improves feasibility and outperforms LPT recuperation by more than 15% efficiency at low-to-mid-corrected power shares. However, LPT recuperation attains higher peak efficiency only at high-corrected power shares and within a narrow OPR window, which is limited by recuperator pinch. Full article
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27 pages, 8552 KB  
Article
A Data-Constrained and Physics-Guided Conditional Diffusion Model for Electrical Impedance Tomography Image Reconstruction
by Xiaolei Zhang and Zhou Rong
Sensors 2026, 26(5), 1728; https://doi.org/10.3390/s26051728 - 9 Mar 2026
Viewed by 503
Abstract
Electrical impedance tomography (EIT) provides noninvasive, high-temporal-resolution imaging for medical and industrial applications. However, accurate image reconstruction remains challenging due to the severe ill-posedness and nonlinearity of the inverse problem, as well as the limited robustness of existing single-source learning-based methods in real [...] Read more.
Electrical impedance tomography (EIT) provides noninvasive, high-temporal-resolution imaging for medical and industrial applications. However, accurate image reconstruction remains challenging due to the severe ill-posedness and nonlinearity of the inverse problem, as well as the limited robustness of existing single-source learning-based methods in real measurement scenarios. To address these limitations, a data-constrained and physics-guided Multi-Source Conditional Diffusion Model (MS-CDM) is proposed for EIT image reconstruction. Unlike conventional conditional diffusion methods that rely on a single measurement or an image prior, MS-CDM utilizes boundary voltage measurements as data-driven constraints and incorporates coarse reconstructions as physics-guided structural priors. This multi-source conditioning strategy provides complementary guidance during the reverse diffusion process, enabling balanced recovery of fine boundary details and global topological consistency. To support this framework, a Hybrid Swin–Mamba Denoising U-Net is developed, combining hierarchical window-based self-attention for local spatial modeling with bidirectional state-space modeling for efficient global dependency capture. Extensive experiments on simulated datasets and three real EIT experimental platforms demonstrate that MS-CDM consistently outperforms state-of-the-art numerical, supervised, and diffusion-based methods in terms of reconstruction accuracy, structural consistency, and noise robustness. Moreover, the proposed model exhibits robust cross-system applicability without system-specific retraining under multi-protocol training, highlighting its practical applicability in diverse real-world EIT scenarios. Full article
(This article belongs to the Section Sensing and Imaging)
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22 pages, 2832 KB  
Article
SOC-Dependent Thermal Analysis of a 5P4S Lithium-Ion Battery Pack Using TiO2 Nano-Enhanced Phase Change Material Cooling
by Anumut Siricharoenpanich, Smith Eiamsa-ard and Paisarn Naphon
Eng 2026, 7(3), 122; https://doi.org/10.3390/eng7030122 - 5 Mar 2026
Viewed by 428
Abstract
This study aims to experimentally evaluate and compare the electrical–thermal performance of a 20-cell 18650 lithium-ion battery pack cooled by a pure phase change material (PCM) and a PCM/TiO2 nanoparticle composite to identify an effective passive thermal management approach for EV battery [...] Read more.
This study aims to experimentally evaluate and compare the electrical–thermal performance of a 20-cell 18650 lithium-ion battery pack cooled by a pure phase change material (PCM) and a PCM/TiO2 nanoparticle composite to identify an effective passive thermal management approach for EV battery applications. Using a controlled charging–discharging system, thermocouple-based temperature mapping, and systematic tests across multiple C-rates (0.75 C–1.5 C), the study measures the variations in battery temperature, generated heat, and voltage behavior as functions of depth of discharge (DOD) and state of charge (SOC). The results show that the PCM/nanoparticle mixture markedly improves thermal conductivity, reduces peak temperature by approximately 8–10 °C compared with pure PCM, delays thermal saturation at higher C-rates, and enables a wider safe DOD range with reduced voltage sag and lower heat accumulation. Based on the experimental temperature/voltage trends in this study, limit DOD to ≤40–50% at high power (≈1.5 C), ≤50–60% at moderate power (≈1 C), and ≤60–70% at low power (≈0.75 C) (i.e., target SOC windows roughly 60–100% SOC at 1.5 C, 40–100% SOC at 1 C, and 30–100% SOC at 0.75 C), with an absolute practical upper DOD limit of ~70% to avoid frequent deep discharge damage; these limits keep peak temperatures below ~40–45 °C, reduce severe voltage sag near cutoff, and greatly extend cycle life because shallower cycling (e.g., 50% vs. 100% DOD) produces many times more cycles. These improvements enhance battery safety, performance stability, and cycle life, making the nanoparticle-enhanced PCM a practical, compact, and energy-efficient solution for passive battery thermal management in electric vehicles. Full article
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15 pages, 4013 KB  
Article
In Situ Synthesized Manganese Ferrite/Carbon Composite Nano-Material: A Novel Electrode Material for High-Performance Supercapacitors
by Tshiamo Baloyi, Ndeye Fatou Diop, Rashed Ali Mohamed Adam, Erence Nkuna, Gift Rutavi, Motlalepula Rebecca Mhlongo, Ncholu Manyala and Vusani Muswa Maphiri
Crystals 2026, 16(3), 171; https://doi.org/10.3390/cryst16030171 - 2 Mar 2026
Viewed by 381
Abstract
This study presents an in situ synthesis of a novel manganese ferrite/carbon (MF/C) composite material via a citrate sol–gel route followed by calcination in an inert argon (Ar) atmosphere. The structural and morphological and porosity properties were characterized using X-ray diffraction (XRD), Fourier [...] Read more.
This study presents an in situ synthesis of a novel manganese ferrite/carbon (MF/C) composite material via a citrate sol–gel route followed by calcination in an inert argon (Ar) atmosphere. The structural and morphological and porosity properties were characterized using X-ray diffraction (XRD), Fourier transform infrared (FTIR) spectroscopy, scanning electron microscopy (SEM), Energy-Dispersive X-ray Spectroscopy (EDX), and N2 gas physisorption analysis. Electrochemical evaluation of the MF/C in a 3 M KOH electrolyte in a three-electrode configuration showed a high specific capacity of 39.26 mAh g−1 at 1 Ag−1 and a rate capability of 69% at 5 Ag−1 and an equivalent series resistance (ESR) of 0.798 Ω. Subsequently, an asymmetric hybrid supercapacitor device (MF/C//AC) was fabricated using MF/C as the positive electrode and human-derived activated carbon (AC) as the negative electrode. The assembled device exhibited remarkable performance, with a wide operating voltage window of 1.4 V, a high sweeping potential of 1 V s−1, a specific capacity, energy, power and maximum power of 42.4 mAhg−1, 16.35 Wh kg−1, 1944 W kg−1 and 236 kW kg−1, respectively, and excellent capacitance retention of 92% after 15,000 charge–discharge cycles. The in situ preparation approach significantly reduced synthesis time and cost compared to conventional multi-step methods, as less equipment was required, while still achieving comparable or superior electrochemical performance to other supercapacitors in the literature. Full article
(This article belongs to the Section Materials for Energy Applications)
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15 pages, 3276 KB  
Article
The Application of Polyrotaxane Cellulose Composite Materials in Quasi-Solid Electrolytes
by Tianyi Wang, Wenzhuo Chen, Yichen Liu, Kailiang Ren, Jin Liang and Jie Kong
Bioengineering 2026, 13(3), 292; https://doi.org/10.3390/bioengineering13030292 - 28 Feb 2026
Viewed by 553
Abstract
Due to its affordability, widespread availability, non-toxicity, biodegradability, and renewability, cellulose is considered a crucial material for addressing the depletion of petroleum resources. In this study, a rotaxane-based supramolecular polymer derived from thermoplastic polyurethane (TPU) was synthesized and combined with cellulose to create [...] Read more.
Due to its affordability, widespread availability, non-toxicity, biodegradability, and renewability, cellulose is considered a crucial material for addressing the depletion of petroleum resources. In this study, a rotaxane-based supramolecular polymer derived from thermoplastic polyurethane (TPU) was synthesized and combined with cellulose to create a TPU–cellulose composite (TPU-C). This composite was employed as a separator for acrylate-based quasi-solid polymer electrolytes (QPEs). The polymer electrolyte demonstrated a high ionic conductivity of 0.16 mS cm−1 at room temperature, a lithium-ion transference number of 0.63, and an electrochemical stability window extending up to 4.7 V. When paired with a LiFePO4 (LFP) cathode, the coin cell retained 88.8% of its capacity after 100 cycles at 1 C. A cell assembled with Li and a high-voltage NCM622 cathode maintained a capacity of 65.8% after 100 cycles at 0.3 C. Additionally, the excellent electrochemical performance was analyzed through density functional theory (DFT) calculations to identify the underlying reasons for its outstanding behavior. This study offers new insights into expanding the application potential of cellulose-based composite materials. Full article
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16 pages, 10259 KB  
Article
Study on the Mechanism of Chemical–Mechanical Synergistic Removal of SiC Surfaces Based on Electrochemical Friction Wear of Grinding Wheel Pairs
by Lijie Wu, Zhijun Chen, Yangting Ou, Jiawen Yao, Hang Zhang, Qiusheng Yan and Jisheng Pan
Micromachines 2026, 17(3), 307; https://doi.org/10.3390/mi17030307 - 28 Feb 2026
Viewed by 588
Abstract
With the advancement of SiC wafers toward 12 inches and innovations in laser cutting technology, new demands have emerged for SiC grinding techniques—namely, high efficiency, low loss, and low wear ratio. This paper investigates electrochemical-assisted grinding of SiC using a grinding wheel–SiC pair [...] Read more.
With the advancement of SiC wafers toward 12 inches and innovations in laser cutting technology, new demands have emerged for SiC grinding techniques—namely, high efficiency, low loss, and low wear ratio. This paper investigates electrochemical-assisted grinding of SiC using a grinding wheel–SiC pair model system, examining the effects of electrolyte type, concentration, voltage, load, and rotational speed on wear behavior. Experimental results reveal that NaCl is the most effective electrolyte among the six candidates tested. In the NaCl system, wear behavior is strongly influenced by the interplay between voltage and rotational speed. At a constant voltage of 3 V, increasing the rotational speed to 600 rpm produces a wear area of 1911.93 μm2, while at a higher voltage of 7 V with a lower speed of 200 rpm, the wear area reaches 1301.96 μm2, indicating that optimal material removal requires synergistic matching of electrical and mechanical parameters. At 2 wt% NaCl, a sudden change in wear behavior occurs at 6–7 min, indicating a dynamic balance between oxide formation and mechanical removal. Rotational speed shows a turning point at 600 rpm, where the wear mechanism shifts significantly, marking the transition to a synergistically enhanced regime. EDS analysis confirms that Na2SO4 increases surface oxygen content by 54.4% compared to deionized water, demonstrating enhanced electrochemical oxidation. The optimal parameter window for synergistic removal is identified as 1–2 wt% NaCl, 5–7 V, 600 rpm, and 100–150 g. This study provides quantitative insights into the synergistic removal mechanism of SiC, offering a theoretical foundation for developing efficient, low-loss electrochemical grinding technologies. Full article
(This article belongs to the Special Issue Laser Micro/Nano-Fabrication, 2nd Edition)
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14 pages, 12677 KB  
Article
Synergistic Enhancement of Ion Transport and Cycling Stability in Composite Solid Electrolytes via Inert/Active Dual-Ceramic Fillers
by Honghao Liang, Yubing Guo, Ji Chen, Zhihao Zhang and Ziqiang Xu
Nanomaterials 2026, 16(4), 246; https://doi.org/10.3390/nano16040246 - 13 Feb 2026
Viewed by 417
Abstract
Poly(ethylene oxide) (PEO)-based solid electrolytes are promising candidates for solid-state lithium metal batteries because of their flexibility and ease of processing. However, their practical application is limited by insufficient mechanical strength and poor interfacial stability. Conventional single-filler strategies typically improve either ionic conductivity [...] Read more.
Poly(ethylene oxide) (PEO)-based solid electrolytes are promising candidates for solid-state lithium metal batteries because of their flexibility and ease of processing. However, their practical application is limited by insufficient mechanical strength and poor interfacial stability. Conventional single-filler strategies typically improve either ionic conductivity or mechanical robustness, making it challenging to simultaneously optimize both properties. In this work, a dual-ceramic strategy is proposed that integrates inert and active ceramic fillers with complementary roles to construct a polymer electrolyte that is both mechanically robust and ionically conductive. The inert ceramic filler promotes lithium-salt dissociation and Li+ transport, whereas the active ceramic filler enhances structural integrity and suppresses lithium dendrite growth, enabling a synergistic balance between ionic transport and cycling stability. As a representative implementation, paraelectric SrTiO3 and Li+-conducting Li6.4La3Zr1.4Ta0.6O12 (LLZTO) are incorporated into the PEO/LiTFSI matrix to construct a composite solid electrolyte (PLLS). The optimized PLLS electrolyte, containing 8 wt% STO and 5 wt% LLZTO, exhibits a high ionic conductivity of 4.48×104Scm1, an increased Li+ transference number of 0.20, and a wide electrochemical stability window of 5.165 V versus Li/Li+ at 60 °C. Li/Li symmetric cells demonstrate stable lithium plating/stripping for nearly 2000 h at a current density of0.2mAcm2. Furthermore, LiFePO4/Li full cells retain 92.1% of their initial capacity after 500 cycles at 1 C, and stable cycling performance is also achieved with high-voltage LiCoO2 cathodes. These results demonstrate that the proposed dual-ceramic synergistic strategy offers an effective and potentially generalizable approach to enhancing the durability of PEO-based solid electrolytes for long-life solid-state lithium metal batteries. Full article
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25 pages, 5072 KB  
Article
Air-Shielding Radial Ultrasonic Rolling Electrochemical Micromachining for Localized Micro-Dimple Arrays on Cylindrical SS304
by Wenjun Tong, Yunfeng Tan and Lin Li
Processes 2026, 14(4), 636; https://doi.org/10.3390/pr14040636 - 12 Feb 2026
Viewed by 392
Abstract
Air-shielding radial ultrasonic rolling electrochemical micromachining (AS-RUREMM) is proposed to fabricate high-quality micro-dimple textures on cylindrical SS304 surfaces while suppressing stray corrosion. In AS-RUREMM, an annular air sheath coaxially envelopes the electrolyte jet to confine the wetting footprint, and radial ultrasonic vibration is [...] Read more.
Air-shielding radial ultrasonic rolling electrochemical micromachining (AS-RUREMM) is proposed to fabricate high-quality micro-dimple textures on cylindrical SS304 surfaces while suppressing stray corrosion. In AS-RUREMM, an annular air sheath coaxially envelopes the electrolyte jet to confine the wetting footprint, and radial ultrasonic vibration is superimposed on a rolling cathode with micro-protrusions to intensify local mass transport and stabilize the interelectrode environment. A conductivity-centered theoretical framework is established to link air-sheathing-induced gas–liquid distribution, ultrasonic gap modulation, and the resulting current-density localization. Multiphysics simulations in COMSOL 5.3 clarify that moderate air pressure forms a stable confined gas–liquid structure that narrows the effective conductive pathway, whereas excessive air pressure increases intermittency and weakens effective gap conductivity. Experiments on SS304 tubes validate the confinement mechanism: compared with RUREMM, AS-RUREMM produces smaller pit width and depth but a higher depth-to-width ratio, indicating enhanced localization and reduced peripheral over-etching. The simulated cross-sectional profiles agree with measurements, with an overall deviation within 6%. Parameter studies identify an optimal operating window, and the combination of 0.18 MPa air pressure and 12 V pulse voltage provides the highest aspect ratio while maintaining stable machining. SEM/EDX analyses further support the improved process controllability under air shielding through reduced stray corrosion and composition changes consistent with a more regulated electrochemical dissolution environment. Full article
(This article belongs to the Section Manufacturing Processes and Systems)
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