Search Results (189)

This article aims to describe a novel workflow designed for generating a new family of minimal surface-based lattice structures with improved performance in terms of material budget compared to the well-known cells like Gyroid and Schwartz. The implemented method is based on the iterative resolution of a dynamic model, where proper forces are applied to generate minimal surface lattices, considering the boundary conditions and the constraint configurations. The novelty of the approach is given by the ability to create a minimal surface without resolving the partial differential equation and without knowing the exact minimal surface generative function. The starting geometry used for the lattice generation is the hypercube, parametrized to create different lattice configurations. Creating five different starting geometries and two constraint configurations, ten different lattice cells were created. For the comparison, a representative parameter of the material budget has been introduced and used to define the two best cells. The material budget is crucial for particle accelerator components, sensors, and detectors. These cells have been compared with Gyroid and Schwartz of the same thickness and bounding box, highlighting improvements of a factor of 2.3 and 1.7, respectively, in terms of material budget. The same cells have also been 3D-printed and tested under compression, and the obtained force–displacement curves were compared with those from a finite element analysis, demonstrating good agreement in the elastic region. Full article

Topology optimisation and lattice design constitute key enablers in the transition towards high-performance and resource-efficient engineering, particularly within the framework of additive manufacturing and welding-based deposition processes. The increasing integration of arc-based technologies, such as Wire Arc Additive Manufacturing, has strengthened the relevance of these methodologies by enabling the fabrication of large-scale, structurally efficient components with controlled material distribution and mechanical performance. These design strategies provide unique opportunities to achieve lightweight structures, functionally graded behaviour, and tailored properties beyond the limitations imposed by conventional manufacturing and joining techniques. The growing demand for functionally efficient components in sectors such as aerospace, biomedical, and automotive engineering continues to drive the adoption of these approaches, where both material efficiency and structural integrity under welding-induced thermal effects are critical. This chapter introduces the fundamentals of topology optimisation and functionally graded lattice architectures, describes their integration into advanced design and manufacturing workflows, including welding-based additive processes, and presents selected case studies that demonstrate their practical impact. Finally, emerging strategies based on generative design and artificial intelligence are discussed as key drivers for the automated and process-aware optimisation of future additively manufactured and welded structures. Full article

The development of composite materials with tunable dielectric properties that preserve mechanical performance is essential for next-generation radio engineering devices. In this study, composite filaments based on acrylonitrile–butadiene–styrene (ABS) with 0–40 wt.% TiO₂ solid loading were developed for 3D printing. The dielectric permittivity and mechanical properties of the 3D-printed parts strongly depend on the TiO₂ content. Using these filaments, we fabricated biomimetic lattices based on triply periodic minimal surfaces (TPMSs) using fused filament fabrication (FFF). The intrinsic porosity of the TPMS lattices further enables tuning of dielectric permittivity, facilitating their integration into gradient-index components. This multifunctionality was demonstrated by fabricating a spherical Luneburg lens prototype, which exhibited stable antenna performance in the 8.0–12.5 GHz frequency range. The results confirm that TPMS lattices based on the ABS-TiO₂ composite can simultaneously deliver mechanical robustness and dielectric tunability, opening new pathways toward multifunctional components for advanced radio engineering systems and beyond. Full article

This work develops a novel Ni-Co nanoparticles coupled with Ni₃S₂ and Co₉S₈ phases on nickel foam (denoted as Ni-Co NPS@Ni₃S₂/Co₉S₈/NF) hybrid structure material as a bifunctional water electrolysis catalyst. The self-assembly Ni-Co alloy phases enhance electrical conductivity, while the synergistic interactions among the three components (Ni-Co, Ni₃S₂ and Co₉S₈) optimize the lattice parameters and electronic environment for boosting both the hydrogen evolution reaction (HER) and oxygen evolution reaction (OER). The catalyst achieves low overpotentials of 106 mV for HER and 185 mV for OER at 10 mA·cm⁻² in 1M KOH, along with a very low charge-transfer resistance. Density functional theory (DFT) calculations reveal that the multi-component interaction narrows the band gap and optimizes the hydrogen adsorption free energy (ΔG_H*) as well as the adsorption free energies of OER intermediates (ΔG_OH*). This work identifies the hybrid structure as the key to the enhanced activity and offers a promising strategy for designing efficient nickel–cobalt-based electrocatalysts. Full article

This work reports the design, fabrication, and validation of a modular ergonomic saddle for rehabilitation cycling, developed through a combined additive manufacturing approach. The saddle consists of a metallic support produced by Laser Powder Bed Fusion (LPBF) in AISI 316L stainless steel and a polymeric ergonomic covering fabricated via Selective Laser Sintering (SLS) using thermoplastic polyurethane (TPU). A preliminary material screening between TPU and polypropylene (PP) was conducted, with TPU selected for its superior elastic response, energy dissipation, and more favourable SLS processability, as confirmed by thermal analyses. A series of gyroid lattice configurations with varying cell sizes and wall thicknesses were designed and mechanically tested. Cyclic testing under both stress- and displacement-controlled conditions demonstrated that the configuration with 8 mm cell size and 0.3 mm wall thickness provided the best balance between compliance and stability, showing minimal permanent deformation after 10,000 cycles and stable force response under repeated displacements. Finite Element Method (FEM) simulations, parameterized using experimentally derived elastic and density data, correlated well with the mechanical results, correlated with the mechanical results, supporting comparative stiffness evaluation. Moreover, a cost model focused on the customizable TPU component confirmed the economic viability of the modular approach, where the metallic base remains a reusable standard. Finally, the modular saddle was fabricated and successfully mounted on a cycle ergometer, demonstrating functional feasibility. Full article

Bronze materials are indispensable across numerous industries for enhancing the durability and performance of components, primarily due to their excellent tribological properties, corrosion resistance, and machinability. This study investigates the impact of different atmospheric conditions on the properties of WAAM (wire arc additive manufacturing) cladded bronze coatings on 09G2S steel substrate. Specifically, the research examines how varying atmospheres—including ambient air (N₂/O₂, no shielding gas), pure argon (Ar), carbon dioxide (CO₂), and 82% Ar + 18% CO₂ (Ar/CO₂) mixture—influence coating defectiveness (porosity, cracks, non-uniformity), wettability (manifested as uniform layer formation and strong adhesion), and the extent of intergranular penetration (IGP), leading to the formation of characteristic infiltrated cracks or “bronze whiskers”. Modern investigative techniques such as optical microscopy (OM), scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDS), and X-ray diffraction (XRD) were employed for comprehensive material characterization. Microhardness testing was also carried out to evaluate and confirm the homogeneity of the coating structure. The findings revealed that the bronze coatings primarily consisted of a dominant, highly textured FCC α-Cu phase and a minor BCC α-Fe phase, with Rietveld refinement quantifying a α-Fe volume fraction of ~5%, lattice parameters of a = 0.3616 nm for α-Cu and a = 0.2869 nm for α-Fe, and a modest microstrain of 0.001. The bronze coating deposited under a pure Ar atmosphere exhibited superior performance, characterized by excellent wettability, a uniform, near-defect-free structure with minimal porosity and cracks, and significantly suppressed formation of bronze whiskers, both in quantity and size. Conversely, the coating deposited without a protective atmosphere demonstrated the highest degree of defectiveness, including agglomerated pores and cracks, leading to an uneven interface and extensive whisker growth of varied morphologies. Microhardness tests confirmed that while the Ar-atmosphere coating displayed the lowest hardness (~130 HV_0.1), it maintained consistent values across the entire analyzed area, indicating structural homogeneity. These results underscore the critical role of atmosphere selection in WAAM processing for achieving high-quality bronze coatings with enhanced interfacial integrity and functional performance. Full article

A composite material based on polyvinyl alcohol (PVA) and hydroxyapatite modified with magnesium (0.3; 0.5; 1.0 mol) was developed using the in situ mineralization method. A thorough analysis confirmed the formation of a two-phase system, with a uniform distribution of HA particles within the PVA matrix. In addition, the analysis confirmed the successful incorporation of magnesium into the crystal lattice without the formation of secondary phases. The material exhibited a developed macroporous structure, with porosities ranging from 50 to 200 μm. In order to ensure that the rheological properties of the composition were suitable for 3D printing, 4 wt.% gelatin was added, resulting in stable scaffolds. In vitro studies demonstrated high biocompatibility of the materials and a synergistic effect of the components: PVA has been demonstrated to neutralise the cytotoxic effects of HA, while magnesium has been shown to statistically significantly increase the viability of macrophages. The combination of a polymer matrix with an inorganic phase results in a material that exhibits both elasticity and bioactivity. The structural and functional characteristics of these systems render them promising materials for tissue engineering, particularly for bone regeneration and the creation of biocompatible 3D scaffolds. Full article

In this work, the results of the structural and phase state of LaNi₅-based alloys modified with Ti, Mn, and Co elements, obtained by mechanical alloying and subsequent spark plasma sintering, are presented. X-ray diffraction analysis was carried out to determine the phase composition, lattice parameters, microstrain, and average crystallite size, as well as to study the morphology and microstructure of the synthesized samples. It was established that the ball-to-powder ratio (BPR) and the milling speed affect the degree of intermetallic phase formation and the level of accumulated microstrains. The optimal mechanical alloying parameters make it possible to form the necessary precursor components for subsequent spark plasma sintering (SPS). It was determined that the SPS process effectively promotes the formation of intermetallic phases such as TiNi, LaNi₄Mn, LaNi₃Mn₂, and LaNi₄Co, ensuring high crystallinity and a reduction in defects accumulated during mechanical alloying. The morphology and microstructure of the samples with titanium, manganese, and cobalt additions showed that at the mechanical alloying stage, all systems are characterized by a dispersed and agglomerated structure, a wide particle size distribution, and a developed surface. After SPS, all series exhibited material consolidation and the formation of a dense matrix with distinct grain boundaries. Full article

Phonons, the quantized lattice vibrations, are fundamental for a wide range of phenomena in condensed matter systems. In particular, low-frequency phonons significantly influence electrical conductivity, thermal transport, and the optical properties of solid-state materials. Although there is considerable literature on cadmium sulfide (CdS) phonons—studied, for example, using resonance Raman spectroscopy—up-to-date information on the low-frequency phonons of this important semiconductor is still lacking. In this study, Raman spectroscopy under off- and near-resonance conditions is employed to investigate the low-frequency phonon in wurtzite CdS single crystals. Under off-resonance conditions, the spectrum exhibits multiple low-intensity peaks, which were analyzed through curve fitting. In contrast, the near-resonance spectrum shows an intense, broad band that was deconvoluted into its constituent components, including an antiresonance feature that was mathematically modeled for the first time in CdS. The results demonstrate that Raman scattering intensity in both regimes provides valuable insights into the low-frequency phonon modes of CdS. These findings enhance our understanding of the material’s vibrational properties and may facilitate the development of more efficient CdS-based optoelectronic devices. Full article

AA1050 aluminum was hydrostatically extruded at room temperature to true strains of 0.9 and 3.2, and at cryogenic temperature to a true strain of 0.9. As a result of the extrusion process, the yield strength (YS) increased by 130–160% to 120–130 MPa, and the ultimate tensile strength (UTS) rose by 64–81% to 125–140 MPa. The hardness reached 46–49 HV. YS and UTS values correspond to mechanical properties typical of the H6 or H8 temper designations, with unusually high elongation at break ranging from 15% to 16.4%. Differences in lattice parameters, crystallite size, and lattice strain between samples deformed under various conditions—as well as those annealed after deformation—were within the margin of measurement uncertainty. This indicated that differences in defect density between the samples were relatively small, due to dynamic recovery occurring during extrusion. However, positron annihilation spectroscopy demonstrated that the cryo-cooled material extruded at a true strain of 0.9, as well as the one extruded at RT at a true strain of 3.2, exhibited significantly higher mean lattice defect concentrations compared to the sample extruded at RT at a true strain of 0.9. The predominant defects detected were vacancies associated with dislocations. The extrusion parameters also significantly affected the crystallographic texture. In particular, they altered the relative proportions of the <111> and <100> components in the axial texture, with the <100> component becoming dominant in cryogenically extruded samples. This trend was further intensified during recrystallization, which enhanced the <100> component even more. Recrystallization of the deformed materials occurred in the temperature range of 520–570 K. The activation energy for grain boundary migration during recrystallization was estimated to be approximately 1.5 eV. Full article

We developed dye-sensitized solar cells based on anatase–titanium dioxide (A-TiO₂) nanotubes (TiNTs) and nanocubes (TiNcs) with {001} crystal facets generated using simple and facile electrochemical anodization. We also demonstrated a simple way of developing one-dimensional, two-dimensional, and three-dimensional self-assembled TiO₂ nanostructures via electrochemical anodization, using them as an electron-transporting layer in DSSCs. TiNTs maintain tubular arrays for a limited time before becoming nanocrystals with {001} facets. Using FESEM and TEM, we observed that the TiO₂ nanobundles were transformed into nanocubes with {001} facets and lower fluorine concentrations. Optimizing the reaction approach resulted in better-ordered, crystalline anatase TiNTs/Ncs being formed on the Ti metal foil. The anatase phase of as-grown TiO₂ was confirmed by XRD, with (101) being the predominant intensity and preferred orientation. The nanostructured TiO₂ had lattice values of a = 3.77–3.82 and c = 9.42–9.58. The structure and morphology of these as-grown materials were studied to understand the growth process. The photoconversion efficiency and impedance spectra were explored to analyze the performance of the designed DSSCs, employing N719 dye as a sensitizer and the I⁻/I³⁻ redox pair as electrolytes, sandwiched with a Pt counter-electrode. As a result, we found that self-assembled TiNTs/Ncs presented a more effective photoanode in DSSCs than standard TiO₂ (P25). TiNcs (0.5 and 0.25 NH₄F) and P25 achieved the highest power conversion efficiencies of 3.47, 3.41, and 3.25%, respectively. TiNcs photoanodes have lower charge recombination capability and longer electron lifetimes, leading to higher voltage, photocurrent, and photovoltaic performance. These findings show that electrochemical anodization is an effective method for preparing TiNTs/Ncs and developing low-cost, highly efficient DSSCs by fine-tuning photoanode structures and components. Full article

This study investigates the structural transformation from the γ-phase into the α-phase in bio-based nylon 5,6 fibers during in situ uniaxial stretching, using X-ray diffraction (XRD) and density functional theory (DFT) calculations. Initially, nylon 5,6 films exhibited a well-defined γ-phase crystalline structure, and the as-spun fibers also retained a γ-phase-dominant structure with partial coexistence of α-phase components. Due to the lattice similarity between the γ- and α-phases, phase separation was challenging in the direction perpendicular to the fiber axis (ab-plane). However, the analysis of the (004) diffraction peaks along the fiber axis (c-axis) enabled the quantitative evaluation of each crystalline component. As the stretching progressed, the α(004) peak intensity gradually increased, indicating a continuous γ-to-α structural transition. Furthermore, DFT calculations revealed that the α-phase has lower energy than the γ-phase, supporting the thermodynamic favorability of the phase transition during elongation. These results provide a comprehensive understanding of the crystalline structure and transformation mechanism in environmentally friendly nylon fibers from both experimental and theoretical perspectives, and offer foundational insights for developing nylon materials with desirable properties through the precise control of crystal phase structures. Full article

The prestressed concrete-filled double skin steel tube (CFDST) lattice tower has emerged as a promising structural solution for large-capacity wind turbine systems due to its superior load-bearing capacity and economic efficiency. The steel–concrete composite adapter (SCCA) is a key component that connects the upper tubular steel tower to the lower lattice segment, transferring axial loads. However, the compressive behaviour of the SCCA remains underexplored due to its complex multi-shell configuration and steel–concrete interaction. This study investigates the axial compression behaviour of SCCAs through refined finite element simulations, identifying diagonal extrusion as the typical failure mode. The analysis clarifies the distinct roles of the outer and inner shells in confinement, highlighting the dominant influence of outer shell thickness and concrete strength. A sensitivity-based parametric study highlights the significant roles of outer shell thickness and concrete strength. To address the high cost of FE simulations, a 400-sample database was built using Latin Hypercube Sampling and engineering-grade material inputs. Using this dataset, five neural networks were trained to predict SCCA capacity. The Dropout model exhibited the best accuracy and generalization, confirming the feasibility of physics-informed, data-driven prediction for SCCAs and outperforming traditional empirical approaches. A graphical prediction tool was also developed, enabling rapid capacity estimation and design optimization for wind turbine structures. This tool supports real-time prediction and multi-objective optimization, offering practical value for the early-stage design of composite adapters in lattice turbine towers. Full article

The application of lattices as protective materials/structures is rapidly increasing. This requires improving impact absorption capabilities to protect goods in packaging and prevent human injuries in protective devices. This study aims to improve the accuracy of impact and energy absorption measurements for lattices, addressing the limitations of current methods such as energy-impact diagrams and instrumented drop-impact testers. A novel test setup is introduced by utilizing a modified Charpy test machine equipped with appropriate instrumentation to directly measure both energy and acceleration. Other modifications include adjustments to the machine components and the introduction of a new sandwich configuration for the test specimen, ensuring compatibility with the machine’s geometry and the test objectives. The attractiveness of the proposed test setup lies in its simplicity and efficiency. Unlike drop-impact test machines—which require complex, time-consuming, and error-prone data integration and derivation—the proposed method eliminates the need for postprocessing, as both energy and impact are recorded directly and instantaneously by the machine. The advantage over existing setups becomes particularly evident when considering that, in the presence of noise and high-frequency fluctuations—characteristic of sensor data from impact events—errors in numerical operations can range from 30% to over 100%. The functionality of the proposed test setup is evaluated through a series of experiments, and the results are compared with those obtained from existing methods. Our findings demonstrate the effectiveness of the new setup in providing accurate and direct measures of absorption parameters, offering a significant improvement over the traditional approaches. Full article

Rising incidents of critical lithium-ion battery (LIB) accidents highlight the pressing demand for safety enhancements that do not degrade the electrochemical performance parameters. This article provides a comprehensive overview of thermal failure mechanisms and thermal stability strategies, including their cathode, anode, separator, and electrolyte. The analysis covers the current thermal failure mechanisms of each component, including structural changes and boundary reactions, such as Mn dissolution in the cathode, solid–electrolyte interface decomposition in the anode, the melting–shrinkage–perforation of the separator, as well as decomposition–combustion–gas generation in the electrolyte. Furthermore, the article reviews thermal stability improvement methods for each component, including element doping and surface coating of the electrode, high-temperature resistance, flame retardancy, and porosity strategies of the separator, flame retardant, non-flammable solvent, and solid electrolyte strategies of the electrolyte. The findings highlight that incorporating diverse elements into the crystal lattice enhances the thermal stability and extends the service life of electrode materials, while applying surface coatings effectively suppresses the boundary reactions and structural degradation responsible for thermal failure. Furthermore, by using solid electrolytes such as polymer electrolytes, and combining innovative ceramic-polymer composite separators, it is possible to effectively reduce the flammability of these components and enhance their thermal stability. As a result, the overall thermal safety of LIBs is improved. These strategies collectively contribute to the overall thermal safety performance of LIBs. Full article