Search Results (299)

Non-contact metric inspection of metallic circular holes is essential for assembly quality control, yet remains difficult on reflective machined surfaces, where depth scale, stripe radiometry, and contour geometry degrade simultaneously. Pure monocular two-dimensional vision localizes hole boundaries efficiently but cannot resolve metric depth; multi-camera three-dimensional systems remove this ambiguity but with a heavier hardware and calibration cost; and conventional structured-light pipelines often improve stripe extraction or circle fitting in isolation, leaving the overall measurement chain fragile when reflection and edge defects co-occur. This paper proposes a monocular structured-light framework that treats sensing geometry, radiometric stripe reliability, and outlier-robust hole estimation as one coupled measurement chain. A single calibrated industrial camera is combined with an obliquely projected line laser to fuse top-view contour observation with light-plane-constrained depth recovery. Multi-exposure high-dynamic-range (HDR) fusion, adaptive Gaussian regularization, and distance-weighted gray-centroid refinement stabilize sub-pixel stripe centerlines under local saturation and uneven illumination, while geometry-aware contour screening and probabilistic multi-stage RANSAC fitting suppress burr-induced outliers during circle-parameter estimation. Experiments were conducted on a steel bolt-hole workpiece and a 6061 aluminum-alloy plate containing five holes with nominal diameters spanning approximately 30–78 mm. The original steel workpiece was evaluated for its diameter and two datum-related center-position quantities, while the five-hole plate was evaluated through three repeated optical diameter measurements and independent CMM references. For the five aluminum-alloy holes, the mean optical–CMM diameter differences ranged from 0.006 to 0.218 mm, with an average absolute difference of 0.096 mm. The results establish feasibility over the tested workpieces and calibrated measurement volume rather than generalization to arbitrary hole geometries, materials, or surface conditions. Full article

Three-dimensional (3D) graphene foams are attractive as lightweight conductive scaffolds with large surface area and broadband light absorption but achieving reproducible porosity and preserving the architecture after metal-template removal remain challenging. Here we report a stepwise route to freestanding 3D multilayer graphene foams based on (i) hydrogen-bubble-assisted electrodeposition of porous Ni on Cu foils, (ii) time-controlled pre-annealing at 1000 °C to drive Cu diffusion and form porous Ni-Cu alloy templates, (iii) in situ graphene CVD at 1000 °C under fixed growth conditions, and (iv) wet etching to remove the metal scaffold without a polymer support. The influence of pre-annealing (0, 1, 3, and 7 h) on template evolution, graphene growth, and foam stability was systematically investigated via SEM, EDS, XRD and Raman studies. Before etching, Raman spectroscopy indicates low-defect graphenic coatings with locally heterogeneous few-layer-like to multilayer-like signatures. Only samples pre-annealed for at least 3 h preserved the porous 3D architecture after metal removal, indicating the formation of self-supporting graphenic networks with improved post-etch morphological stability. Raman and XRD analyses further revealed a progressive reduction in structural degradation, residual strain, and stacking disorder with increasing pre-annealing time. Among the investigated samples, the foams obtained after 3 and 7 h of template pre-annealing combined preserved 3D morphology with low sheet resistance (10–20 Ω/□), negligible optical transmittance (<5%), and strong broadband visible-light absorption (75–90%). Full article

Cast iron is a material widely used in mechanical engineering, the automotive industry and large-scale structures. Interest in cast iron remains strong, despite the widespread drive to manufacture ever lighter, cheaper and more durable machine parts from light metal alloys or titanium. This is mainly due to the low cost of cast iron, its ease of recycling and its favourable mechanical properties, including its particular ability to dampen vibrations. There are numerous publications in the international literature on the principles for selecting machining parameters for high-performance machining of steel, light metal alloys and titanium. Research into modelling the effect of machining parameters on the surface roughness and wear of cutting tools when machining these materials is widely documented. However, there is considerably less literature available on the high-performance machining of cast irons. This is particularly true in the context of the use of tools with protective coatings. To fill this gap, a research project was undertaken, which identified the potential for using a single tool for high-performance machining of spheroidal cast iron. The machining process was investigated under industrial conditions (in the automotive sector), taking into account the specific nature of roughing and finishing operations integrated into a single operation. In addition to investigating efficiency in terms of material removal and surface quality, the degree of wear on the cutting inserts at which the quality of the machined surface does not deteriorate was determined. Full article

Based on the hydrostatic transmission principle, a new method for high-throughput characterization via surface microstrain effects after cold isostatic pressing is proposed. Typical key metallic materials (steels, titanium alloys, and superalloys) were processed under a pressure of 190 MPa with a holding time of 30 min, and surface microstrain effects and characteristics of the specimens were explored via white light interference profilometry, scanning electron microscopy, atomic force microscopy, focused ion beam processing, and transmission electron microscopy. It is shown that all the metallographic polishing specimens exhibit a similar tendency, and two main categories of typical microstrain fields can be detected after CIP processing: (1) slight microstrain and (2) significant microstrain. Significant microstrain with roughening of the surface (roughness increasing) after CIP processing can be detected only in a few microregions. Microregions with weaker micromechanical properties can be characterized and screened in a high-throughput manner through evaluation of the significant microstrains. A new application strategy is proposed for high-throughput characterization of mechanical homogeneity and mechanically weak zones, using the surface microstrain effect during cold isostatic pressing and surface profile analysis. Regions with significant microstrain showed surface roughening (S_q: 6.1 nm→139.7 nm, S_a: 4.8 nm→94.4 nm). Full article

The worldwide spread of semiconductor devices has driven a surge in electronic waste (e-waste), which reached 62 million metric tons in 2022 and is projected to exceed 80 million metric tons by 2030. E-waste contains hazardous substances such as cadmium and mercury, yet also represents a $57 billion annual opportunity through the recovery of valuable and critical raw materials (CRMs). However, formal recycling rates remain stagnant at 22.3%, largely due to limitations of current automated sorting methods. These systems primarily rely on visible-light (RGB) imaging, which lacks the spectral resolution needed to distinguish chemically similar polymers, complex metal alloys, and composite substrates on printed circuit boards (PCBs). This paper presents a multidisciplinary synthesis of AI-driven detection and classification for e-waste, bridging materials science and computer vision through three interconnected themes. 1. Material and Economic Context: The toxicological risks and economic drivers of semiconductor recycling are characterized, framing fine-grained material identification as essential for a circular economy. 2. Multispectral Sensing & Fusion: Sensing modalities such as near-infrared (NIR), hyperspectral imaging (HSI), and X-ray fluorescence (XRF) are assessed, and sensor fusion strategies, including early, late, and intermediate fusion, are reviewed for high-throughput industrial settings. 3. Deep Learning Benchmarking: 11 publicly available PCB datasets are analyzed, and the YOLO series (YOLOv3–YOLOv12) is compared with leading non-YOLO detectors, including Faster R-CNN, RT-DETR-L, and RetinaNet. The results show that while YOLOv9s achieves a peak mAP@0.5 of 56.5% and YOLOv11s offers an optimal industrial profile (37.2% mAP@0.5:0.95 at 115 ms edge inference), all RGB-based models fail to detect visually ambiguous surface-mount devices (SMDs), with mAP values below 12%. This confirms a performance ceiling for purely visual systems. The review concludes that transitioning from RGB-centric to multispectral fusion architectures is the primary research frontier and proposes a roadmap for standardized multimodal datasets and edge-deployable fusion models to enable next-generation, high-recovery automated recycling. Full article

Additive manufacturing has emerged as a transformative technology for fabricating complex drug-eluting medical devices, offering unprecedented design freedom and functional integration capabilities. This comprehensive review systematically analyzes 3D printing technologies applied to pharmaceutical device manufacturing, focusing on drug-eluting vascular stents as a representative application. This review covers six primary additive manufacturing techniques, ranging from high-resolution vat photopolymerization (25 μm resolution) to direct energy deposition, with a focus on their capabilities for produce pharmaceutical devices with controlled drug release properties. Novel 4D/5D/6D printing technologies introduce stimuli-responsive behaviors enabling programmable drug release profiles and adaptive device functionality. Manufacturing process optimization reveals superior design flexibility compared to conventional methods, with 85–95% reduction in design iteration time and elimination of tooling costs for complex geometries. The material landscape encompasses traditional metals (316L stainless steel, cobalt–chromium), biodegradable polymers (polylactic acid, PLA; polycaprolactone, PCL; poly(lactic-co-glycolic acid), PLGA), shape-memory materials (i.e., polymers and alloys capable of recovering a pre-programmed shape upon exposure to a specific stimulus such as body temperature, moisture, or light), and advanced nanocomposites, each offering distinct drug-loading capacities (100–500 μg/cm²) and release kinetics. Critical challenges include standardization requirements (International Organization for Standardization (ISO) 5840 and American Society for Testing and Materials (ASTM) F2606), pharmaceutical-grade manufacturing protocols, and regulatory pathways for novel drug-device combinations. This review identifies key research priorities including development of biocompatible printing materials, accelerated drug release testing protocols, and scalable manufacturing processes suitable for medical device production. This analysis demonstrates that 3D printing enables integration of multiple pharmaceutical functions within single devices, controlled spatiotemporal drug delivery, and elimination of secondary manufacturing steps for drug coating processes, advancing the development of next-generation therapeutic medical devices. Full article

The Gebel Shalman-Wadi Biarn (GSh-WB) area in Egypt’s South Eastern Desert hosts NYF-type rare-metal pegmatites with significant U, Th, Nb-Ta, and REEs mineralization. This study integrates field observations, petrography, mineralogy, whole-rock geochemistry, and gamma-ray spectrometry to characterize these pegmatites and evaluate their economic potential. The pegmatites occur as veins, dykes, and zoned pockets hosted entirely within syenogranites. Petrography, pegmatites, and syenogranites are primarily composed of K-feldspar, albite, and quartz with trace amounts of biotite and muscovite. The environmental scanning electron microscope (ESEM) revealed the presence of the following minerals: autunite, kasolite, thorite, monazite-(Ce), parisite, xenotime-(Y), ferrocolumbite, hydroxyplumbobrtafite, aeschynite-(Y), and zircon, which are the major U-Th, Nb-Ta, and REE-bearing minerals. Additionally, gold, cassiterite, wolframite, pyrrhotite, chalcopyrite, and brass alloy were identified as sources of precious and base metals. Both groups’ chondrite-normalized REE patterns, which display slightly elevated LREE patterns and negative Eu anomalies, point to fractional crystallization involving plagioclase fractionation. Consequently, pegmatite and syenogranites are believed to have mostly formed from the partial melting of a reconstituted juvenile crust and its weathered sediments associated with Neoproterozoic magmatism. The marginally positive Ce anomaly in the (GSh-WB) pegmatites (1.02–0.98) may be associated with monazite crystallization resulting from enhanced fractionation. The Th and U levels range from 101 to 28.6 ppm and from 51 to 5.8 ppm, respectively. The magnitude of the tetrad effect in the rare earth elements of the analyzed rocks exceeds one (T1 = 1.12–1.02, T3 = 0.92–1.08, and T1,3 = 1.01–1.05), suggesting an M-type tetrad effect. The presence of this tetrad effect is indicative of granite that has been significantly altered by hydrothermal processes and is extensively fractionated. Chondrite-normalized REE patterns of the pegmatites (average ΣREE = 439 ppm) and their host syenogranites (average ΣREE = 192 ppm) show similar trends characterized by enrichment of light rare earth elements (LREEs) relative to heavy rare earth elements (HREEs) and pronounced negative Eu anomalies (Eu/Eu* = 0.09–0.22). These features, together with negative Sr and Ba anomalies, likely reflect extensive fractional crystallization of feldspars and feature anorogenic rocks. Spectrometric analysis reveals eU values of 2.0–288 ppm and eTh values of 7.0–455 ppm in pegmatite samples, with eU/eTh ratios (0.49–0.39) exceeding the typical continental crust value of 0.25, indicating uranium enrichment. Both magmatic and hydrothermal processes contributed to the observed radioactivity. The spatial distribution of uranium shows lithological and structural controls. The GSh-WB pegmatites represent a potential target for uranium exploration. Full article

In this investigation, optical emission spectrometers, a Brinell hardness tester, optical light and scanning microscopes, and X-ray diffraction were used for general metallurgical characterization of the experimental irons in as-cast states. The hole-drilling method was used to assess residual stress distributions under gross and net casting weight conditions. To create experimental irons using the casting process, raw materials were transformed from a solid to a liquid state using an industrial furnace and ladle to melt and cast, respectively. The casting shakeout temperatures for samples A and B were recorded at 60 °C and 180 °C, respectively, after a characteristic stress lattice casting component was allowed to cool for about 1645 min and 1295 min. Chemical analysis verified the experimental hypoeutectic irons of ASTM A532, Type A, Class III, 25%Cr, i.e., high chromium white cast iron alloys. Additionally, it was discovered that micrographs were made of an austenitic-martensitic matrix that contained eutectic M₇C₃ and secondary M₂₃C₆-type carbides. The residual stress distributions were found to be influenced by various carbide and metallic volume fraction proportions, casting section thickness, and casting shakeout duration and temperature. Optimal hardness values, however, were shown to be associated with higher residual stress distributions and an increase in major alloying elements in experimental irons. Consequently, different residual stress distributions are produced by casting shakeout temperatures at lower and higher values under gross and net casting weight conditions. Full article

Formic acid (FA) has emerged as a promising liquid hydrogen storage material, yet efficient photothermal dehydrogenation catalysts with high activity and H₂ selectivity remain challenging. Herein, a polymetallic synergistic PdCu/M-ZNC (where M represents the co-doped In, Sn and Mo species) is fabricated by molten-salt-assisted pyrolysis of ZIF-8 precursors followed by metal incorporation. The unique molten salt environment effectively preserves the porous architecture of ZIF-8, enabling the secure anchoring of PdCu alloy nanoparticles onto the carbonaceous matrix enriched with M-N_x coordination sites. Under light irradiation, the PdCu alloy sites kinetically accelerated the overall adsorption and activation of FA molecules. Based on empirical observations and corroborated by the established literature, this alloying effect was inferred to facilitate the C-H bond cleavage and HCOO* desorption processes. Concurrently, the M-N_x sites act as efficient electron transfer channels, facilitating the rapid coupling of photogenerated electrons with protons (H⁺) to evolve H₂. Consequently, the optimal catalyst exhibits an enhancement in gaseous product yield (404.46 mmol/g/h) and H₂ selectivity (67.49%) at 75 °C. This work offers a catalyst design that aligns with several principles of green chemistry: it maximizes the atom utilization of precious Pd, incorporates synergistic non-precious metals within MOF-derived frameworks to enhance stability, and leverages solar energy to drive hydrogen production under mild conditions, presenting a more sustainable pathway for hydrogen release from liquid carriers. Full article

In this paper, the effects of 4 wt.% of silicon on the microstructure and mechanical properties of AM50 magnesium alloys fabricated by the casting method are presented. New AM50/Si material and the base AM50 alloy were gravity cast into a metal mould under the same conditions for comparison. Analyses of the alloys’ microstructures were carried out by light microscopy (with differential interface contrast), scanning electron microscopy (with an energy dispersive X-ray spectrometer), as well as X-ray diffraction (XRD). In as-cast conditions, both materials were composed of α-Mg solid solution, α + γ eutectic (where γ is Al₁₂Mg₁₇), Al₈Mn₅ intermetallic phases and discontinuous γ precipitates. The AM50/Si material also consisted of the Mg₂Si phase. This structural constituent appeared in the form of primary crystals with regular polygonal morphology and an α + Mg₂Si eutectic in the form of “Chinese script”. In the microstructure of the AM50/Si material, the Mn₃SiAl₉ ternary phase was also identified. The detailed analyses presented in this paper revealed that the new ternary Mn₃SiAl₉ structural compound caused a reduction in the volume fraction of the Al₈Mn₅ phase but did not completely replace it. These two phases formed competitively. The fabricated material exhibited higher tensile and compression strength as well as yield strength in comparison with the AM50 alloy. Additionally, analyses of the fracture surfaces of the AM50/Si material carried out using scanning electron microscopy (SEM) were presented. Full article

Metal packaging materials remain fundamental across food, beverage, pharmaceutical, cosmetic, and technical sectors owing to their combination of mechanical robustness, total light and gas barrier performance, thermal resistance, and established recyclability. Aluminum alloys, tinplate, tin-free steel (TFS/ECCS), stainless steels, metal–matrix composites (MMCs), and metal–polymer or metal–paper laminates define distinct metal-based packaging architectures whose metallurgical and interfacial design governs forming behaviour, corrosion and migration pathways, coating integrity, and mechanical reliability. In this review, these architectures are examined from a materials- and systems-oriented perspective, linking composition, microstructure, processing routes, and surface engineering to functional performance across rigid, semi-rigid, and flexible formats. The analysis also considers the ongoing transition from bisphenol A (BPA)-based epoxy linings to BPA-free and hybrid coating chemistries, the use of nano-structured metallic and metal-oxide surfaces, and the role of composite laminates in which thin metallic foils are combined with polymeric or paper-based structural layers. These material and architectural aspects are discussed together with safety, regulatory, and circularity considerations that increasingly influence the design and selection of metal-based packaging. Ion migration, coating degradation, and corrosion under realistic storage environments are considered in relation to EU, FDA, ISO, and sector-specific requirements, while attention is also paid to the contrast between well-established closed-loop recycling infrastructures for aluminum and steel and the more complex end-of-life management of coated metals and multilayer laminates. The review provides a unified framework connecting materials selection, metallurgical design, processing, performance, regulatory compliance, and sustainability in metal-based packaging systems. Applications spanning consumer goods, pharmaceuticals, cosmetics, and advanced electronics are integrated to support an overall understanding of how metallic and hybrid metal-based architectures underpin functional reliability and life-cycle sustainability. Full article

The impending Euro 7 regulation will impose strict limits on brake particulate matter (PM) emissions from new light-duty vehicles, driving manufacturers to explore alternative rotor materials and/or surface treatments. This paper evaluates the friction and wear emission performance of both a laser-clad grey cast iron (GCI) rotor surface and a plasma electrolytic oxidation (PEO) treated aluminium surface compared to that of an uncoated GCI. Tests were conducted on a small-scale tribometer rig, which was specially adapted to measure airborne emissions while emulating the standard Worldwide harmonised Light vehicle Test Procedure (WLTP). The laser-clad coating was applied via extreme high-speed laser cladding to form an initial 430 L stainless steel layer, followed by a topcoat of 80/20 vol% 430L steel/TiC, both layers being c.100 micron thick. The PEO treatment applies a c.50 micron alumina coating to both a wrought and cast alloy, the latter being more suitable for the manufacture of full-size vented brake rotors. Results show that all rotor materials achieved a satisfactory coefficient of friction (CoF) against suitable low-metallic pad material, although the CoF for the wrought PEO-Al alloy was significantly higher at c.0.65 compared with c.0.50 for the other materials. The gravimetric wear of all the coated rotor surfaces after 8 WLTP cycles was almost undetectable, and pad wear was also significantly reduced. This improved wear resistance led to significant reductions in PM emissions, with the PM10 levels of the uncoated GCI reduced by around 75% for the laser-clad GCI and PEO wrought Al alloy, and by about 60% for the PEO cast Al alloy. When extrapolated to a full-sized passenger vehicle, the results indicated that both the laser-clad GCI and PEO-treated surfaces have the potential to meet the current Euro 7 emissions targets. Full article

This study addresses the challenge of through-hole defects in ZM6 cast magnesium alloy components by proposing an innovative repair strategy using ultrasonic-assisted Tungsten Inert Gas (U-TIG) welding. The microstructure and mechanical properties of the repaired joint were systematically characterized through optical microscopy, scanning electron microscopy (SEM), X-ray diffraction (XRD), and room-temperature tensile testing. The results indicate that, assisted by the ultrasonic energy field, the repair zone successfully reconstitutes a typical and optimized triple-phase microstructure: (1) the matrix: α-Mg solid solution (dark gray), supersaturated with Nd and Zr; (2) the strengthening phase: a eutectic Mg₁₂Nd phase (light gray), rich in Nd, distributed along grain boundaries acting as the primary strengthening component; (3) the grain refiner: dispersed Zr-rich particles (bright white spots), which effectively pin grain boundaries. Crucially, the application of ultrasound significantly refined the α-Mg grains and transformed the continuous network of the Mg₁₂Nd phase into a more fragmented and uniform dispersion. This refined microstructure synergistically integrates the strengthening mechanisms of solid solution, precipitation hardening, and grain refinement. Consequently, the repaired joint exhibits excellent mechanical properties, achieving over 90% of the base metal’s tensile strength and elongation at room temperature. This work not only validates the feasibility of U-TIG welding for repairing ZM6 alloys but also provides a solid theoretical foundation and a promising technical pathway for the in-service repair and remanufacturing of high-performance magnesium alloy components. Full article

This work presents a combined numerical and experimental investigation into the laser machining of aluminum alloy Al 1050 H14 using a high-power Continuous Wave (CW) fiber laser. Advanced three-dimensional, coupled thermal–structural Finite Element Method (FEM) simulations are developed to model key laser–material interaction processes, including laser-induced plastic deformation, laser etching, and engraving. Cases for both static single-shot and dynamic linear scanning laser beams are investigated. The developed numerical models incorporate a Gaussian heat source and the Johnson–Cook constitutive model to capture elastoplastic, damage, and thermal effects. The simulation results, which provide detailed insights into temperature gradients, displacement fields, and stress–strain evolution, are rigorously validated against experimental data. The experiments are conducted on an integrated setup comprising a 2 kW TRUMPF CW fiber laser hosted on a 3-axis CNC milling machine, with diagnostics including thermal imaging, thermocouples, white-light interferometry, and strain gauges. The strong agreement between simulations and measurements confirms the predictive capability of the developed FEM framework. Overall, this research establishes a reliable computational approach for optimizing laser parameters, such as power, dwell time, and scanning speed, to achieve precise control in metal surface treatment and modification applications. Full article

Nanoparticle-mediated photothermal conversion exploits the unique light-to-heat transduction properties of engineered nanomaterials to address challenges in energy, water, and healthcare. This review first examines fundamental mechanisms—localized surface plasmon resonance (LSPR) in plasmonic metals and broadband interband transitions in semiconductors—demonstrating how tailored nanoparticle compositions can achieve >96% absorption across 250–2500 nm and photothermal efficiencies exceeding 98% under one-sun illumination (1000 W·m⁻², AM 1.5G). Next, we highlight advances in solar steam generation and desalination: floating photothermal receivers on carbonized wood or hydrogels reach >95% efficiency in solar-to-vapor conversion and >2 kg·m⁻²·h⁻¹ evaporation rates; three-dimensional architectures recapture diffuse flux and ambient heat; and full-spectrum nanofluids (LaB₆, Au colloids) extend photothermal harvesting into portable, scalable designs. We then survey photothermal-enhanced thermal energy storage: metal-oxide–paraffin composites, core–shell phase-change material (PCM) nanocapsules, and MXene– polyethylene glycol—PEG—aerogels deliver >85% solar charging efficiencies, reduce supercooling, and improve thermal conductivity. In biomedicine, gold nanoshells, nanorods, and transition-metal dichalcogenide (TMDC) nanosheets enable deep-tissue photothermal therapy (PTT) with imaging guidance, achieving >94% tumor ablation in preclinical and pilot clinical studies. Multifunctional constructs combine PTT with chemotherapy, immunotherapy, or gene regulation, yielding synergistic tumor eradication and durable immune responses. Finally, we explore emerging opto-thermal nanobiosystems—light-triggered gene silencing in microalgae and poly(N-isopropylacrylamide) (PNIPAM)–gold nanoparticle (AuNP) membranes for microfluidic photothermal filtration and control—demonstrating how nanoscale heating enables remote, reversible biological and fluidic functions. We conclude by discussing challenges in scalable nanoparticle synthesis, stability, and integration, and outline future directions: multicomponent high-entropy alloys, modular photothermal–PCM devices, and opto-thermal control in synthetic biology. These interdisciplinary innovations promise sustainable solutions for global energy, water, and healthcare demands. Full article