Search Results (86)

Cold-mercury gilding uses mercury as an adhesive to bond gold foil onto the surface of copper and silver artifacts. This technique and mercury gilding (fire gilding) both belong to the Au-Hg system and are closely related in technology. Clarifying the technical differences between them is of great significance for revealing the developmental sequence of ancient gilding technologies. On the basis of reconstructing traditional fire gilding, simulated cold-mercury-gilded samples were successfully prepared using experimental archeological methods, and multi-scale characterization was performed using SEM-EDS, XRD, and XPS. The results show that the surface of cold-mercury-gilded samples displays a micromorphology of folded and overlapped gold foil accompanied by locally dense particle aggregation. The cross-section of the gold layer exhibits a multilayer stacked structure, in which mercury is enriched at the gold layer/substrate interface and forms an AuHgCu/Ag diffusion layer. Room-temperature-stable Au-Hg and Ag-Hg phases such as Au₂Hg and AgHg are present in the gold layer, reflecting complex phase transformation behavior of the Au-Hg/Ag-Hg system at room temperature. During cold-mercury gilding, liquid mercury first adheres to the gold foil, and then interdiffusion and phase reactions occur between mercury, gold, and copper/silver atoms at room temperature. Intermetallic compounds and diffusion layers formed at the interface achieve firm bonding between the gold layer and the substrate. Both cold-mercury gilding and mercury gilding achieve metallurgical bonding through atomic interdiffusion. However, affected by differences in the initial state of mercury and operating temperature, the phase transformation and atomic diffusion behaviors of the system differ significantly, which are ultimately reflected in the cross-sectional structure of the gold layer, the composition of the interfacial diffusion layer, and the types of phases. Therefore, mercury-gilded artifacts show superior gold layer durability and bonding strength with the substrate compared with cold-mercury-gilded artifacts. Both techniques pioneered the application of mercury in metallic gilding and represent important innovations in ancient surface decoration technology. Full article

Mixed-halide perovskite solar cells with the composition Cs_0.1(MA_0.17FA_0.83)_0.9Pb(I_0.83Br_0.17)₃ were fabricated obtaining solar cells as glass/ITO/SnO₂/triple-cation perovskite/HTL/Au, and subsequently used as photoanodes for efficient solar-driven water splitting by attaching commercial catalytic nickel foils to the Au back-contact pads of solar cells. To enable operation in alkaline media, the devices were encapsulated using commercial PET–EVA multilayer films, providing an effective barrier while leaving the Ni foils exposed as the electrochemically active interface. Two operating configurations were investigated and compared: (i) an outside configuration, where the perovskite device powered the external electrochemical cell, and (ii) an immersed configuration, in which the encapsulated perovskite solar cell was directly integrated, together with the Ni catalyst, into the electrolyte. In both configurations, the onset potential for the oxygen evolution reaction shifted from ~1.32 V vs. RHE, when the Ni electrode was not powered by the perovskite solar cell, to ~0.34 V vs. RHE, when the perovskite device powered the Ni foil for both immersed and outside configurations. The immersed configuration delivered the highest performance, achieving a maximum Applied Bias Photon-to-Current Efficiency of ~20% under AM 1.5 G illumination (100 mW cm⁻²), among the highest values reported for perovskite-based photoanodes. Importantly, the enhanced performance does not arise from changes in catalyst composition or direct semiconductor–electrolyte interaction, but from improved photovoltage delivery and reduced resistive losses enabled by the integrated device architecture. These results demonstrate that device architecture is a key factor in controlling photovoltage utilization and charge-transfer kinetics, providing a viable strategy for efficient and scalable perovskite-based photoelectrochemical systems. 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

This study investigates the joint characteristics of a 60-layered copper foil stack using linear vibration ultrasonic welding for lithium-ion pouch cell applications. With increasing demand for high-capacity electric vehicle batteries, ensuring the reliability of multilayer electrode joints is essential. Experiments were conducted by varying vibrational amplitude, welding time, and clamping pressure. Weld quality was analyzed based on indentation profiles, joint strength, and failure modes. Results revealed that optimal welding energy (500–900 J) produced well-formed joints without surface cracks or tearing. Excessive welding energy (>900 J) led to material thinning and interfacial failure. The maximum T-peel peak load of 138.7 N was obtained at the 30th joining interface under 25 µm amplitude, 0.8 s welding time, and 1.5 bar clamping pressure. Interface-dependent optimum conditions were observed, reflecting thickness–direction variations in deformation and bonding within the 60-layer stack. Indentation length and depth correlated linearly with welding energy. Failure modes transitioned from no adhesion to tearing and button-pull types. The findings provide guidelines for optimizing welding parameters for high-quality multilayer foil joints in battery manufacturing. Full article

Edge cracking is prone to occur during the rolling of Mg/Al composite foils. Herein, a hybrid hot–cold rolling process was adopted to fabricate 30 μm thick Mg/Al composite foils with low edge cracking. AZ31B magnesium alloy and 5052 aluminum alloy sheets, both with an initial thickness of 0.5 mm, were chosen as research materials. Numerical simulations of composite pass were conducted at 300–450 °C with reduction ratios of 25–40%, and the optimal parameters were identified as 400 °C and a 35% reduction ratio. Based on this, multi-pass rolling experiments were performed: composite pass was heated at 400 °C for 10 min with 35% reduction ratio, hot rolling passes at 300 °C for 1–3 min, and subsequent cold rolling with 15% reduction ratio. After 21 rolling passes, 30 μm thick Mg/Al composite foils with low edge cracking were successfully prepared. Interface and metallographic characterizations demonstrated that the diffusion layer thickness varied slightly during hot rolling and increased moderately during cold rolling. For the magnesium alloy, hot rolling improved microstructural uniformity and reduced shear bands, while cold rolling caused decreased uniformity and the gradual emergence of shear bands. The research results provide a reference for the preparation of high-quality Mg/Al composite foils. Full article

This study examines the joining characteristics of Cu foil stacks to lead tabs using green-laser welding in the main-welding step of a sequential welding process for lithium-ion pouch cells. The influence of lap configuration, line and wobble seam strategies, and process parameters was systematically investigated in terms of bead morphology, mechanical performance, metallurgical characteristics, and electrical resistance. Under the present line-welding parameter window (2.0 kW, 100–200 mm/s), humping, pinholes, and porosity were observed, particularly in the upper lead-tab configuration, which is attributed to melt-pool/keyhole instability under the applied conditions. Wobble welding effectively suppressed these defects in the foil-stack configuration by promoting stable melt flow and efficient bubble expulsion. Mechanical tests revealed that the wobble-based seam strategy achieved a maximum tensile–shear load of approximately 1.28 kN at a wobble amplitude of 0.8 mm. Fracture analysis confirmed a transition from seam-type interfacial failure in line welding to ductile tearing in the heat-affected zone with wobble welding. In electrical performance, wobble welding reduced resistance to as low as 45 µΩ at a wobble amplitude of 1.2 mm, while line welding yielded higher and scattered values. These results should be interpreted as the combined outcome of the wobble-based seam strategy (beam oscillation together with overlapped stitch welding at a lower travel speed) under the present processing windows. A strictly matched A/B comparison at identical linear energy density and seam layout will be investigated in future work to isolate the effect of oscillation. Full article

Reliable joining of multi-layer aluminum foil current collectors is crucial for enhancing the performance and safety of high-capacity lithium-ion batteries. However, laser welding of such thin-thick aluminum combinations is often hindered by porosity, cracks and unstable weld-pool behavior. In this study, a ring-mode fiber laser combined with sinusoidal oscillation and linearly gradient power modulation was employed to achieve high-quality lap welding between 80 layers of 1060 aluminum foil (1 mm in total thickness) and a 1.5 mm thick aluminum plate. Welding experiments and thermo-mechanical simulations were conducted to investigate the effects of welding speed (15–45 mm/s) and central-power modulation parameters (−2, 0, +2, +4) on weld morphology, defect formation, and mechanical properties. The results indicate that increasing the welding speed can effectively suppress cracks and improve the shear strength from 249.8 N to 403.9 N, but it also leads to an increase in porosity from 5.78% to 12.26% and deterioration of the weld reinforcement. Higher central-power modulation (+2, +4) transformed the weld-pool geometry from an ω shape to U shape, effectively suppressing fusion-line cracks but leading to increased porosity (up to 8.41%) and deteriorated surface morphology. Overall, a low welding speed of 15 mm/s combined with an optimized power modulation strategy achieves effective crack suppression while maintaining controlled porosity, resulting in a welded joint with superior comprehensive performance. This research provides a robust process solution for high-quality laser welding of multi-layer aluminum foil current collectors in power battery manufacturing. Full article

This preliminary study investigates a direct, non-delaminated route to valorize multilayer pharmaceutical sachet offcuts (comprising paper/plastic/aluminum) as partial substitutes for wood fiber in wood-based panels. Milled offcuts were incorporated at 10, 20, and 30 wt% (control: wood only). Laboratory mats were hot-pressed at 170 °C for 9 min under a staged pressure regime. Sampling and three-point bending were performed according to EN 326-1 and EN 310, respectively, with the density held essentially constant by controlling the mat mass and press stops. Bending stiffness (MOE) was maintained at 10–20 wt% (within experimental uncertainty of the reference), while 30 wt% showed a consistent downward trend (approximately 10%). Bending strength (MOR) peaked at 10 wt% (approximately 8% higher than the reference), then declined at 20% and 30%. Representative stress–strain curves corroborated these outcomes, indicating auxiliary bonding and crack-bridging effects at low waste loadings. Hygroscopic performance improved monotonically: 24 h water absorption and thickness swelling decreased progressively with increasing substitution, attributable to the hydrophobic polymer layers and aluminum fragments interrupting capillary pathways. Process observations identified opportunities to improve press-cycle efficiency at higher waste contents, and the dispersed foil imparted a subtle decorative sheen. Overall, the results establish the technical feasibility and a practical utilization window of approximately 10–20 wt% for furniture-grade applications. Limitations include the laboratory scale, a single resin/press schedule, and the absence of internal bond, density profile, emissions, and long-term durability tests—topics prioritized for future work (including TGA/DSC, EN 317 extensions, and scale-up). Full article

Multilayer packaging materials are extensively used in food packaging, particularly for powdered products. In alignment with sustainable development goals, packaging design should aim to minimize material usage while maintaining the protective properties necessary to preserve food quality and safety, thereby reducing environmental impact. A key strategy is to simplify multilayer structures to enhance recyclability. This study aims to evaluate the potential of sustainable alternative packaging materials with reduced metal and plastic content and improved recyclability for pudding powder packaging, as substitutes for conventional films. Four packaging structures were tested: a conventional three-layer laminate (polyethylene terephthalate (PET)/aluminum foil (Al-foil)/low-density polyethylene (LDPE)), two two-layer structures (AlO_x-coated PET/LDPE and Al-coated PET/LDPE), and a monolayer metallized biaxially oriented polypropylene (MetBOPP). Samples were stored under accelerated conditions (38 °C and 90% relative humidity) for 180 days, and changes in moisture content, water activity, caking degree, glass transition temperature, color, and sensory attributes were monitored. The experimental data were examined for their agreement with various sorption models by creating adsorption isotherms. The acceptable storage period was estimated using the constants calculated from these models. Statistically significant differences (p < 0.05) were observed among the packaging types, primarily associated with their water vapor permeability, affecting moisture content, water activity, caking degree, and color stability. In terms of moisture content, water activity, and caking degree, the conventional PET/Al-foil/LDPE (Polyethylene terephthalate/Aluminum foil/Low density polyethylene) structure demonstrated the best performance, followed by PET.AlO_x/LDPE (AlO_x-coated Polyethylene terephthalate/Low density polyethylene), MPET/LDPE (Metallized polyethylene terephthalate/Low density polyethylene), and MBOPP (Metallized biaxially oriented polypropylene), respectively. The sensory analysis scores followed the same ranking; however, all samples maintained scores above the threshold value of 3 throughout the storage period, indicating that they remained acceptable. Caking degree increased moderately (from 0.61% to 0.89%) and was negatively correlated with appearance scores (R² = −0.89, p < 0.01). Despite slight darkening (Browning Index increased from 18.16 to 20.37), sensory scores for appearance, odor, and taste remained above the acceptable threshold (score > 3.0). Based on the WVTR values of the packaging materials and the application of the GAB model, the estimated shelf lives were 800.32 days for PET/Al-foil/LDPE, 577.92 days for PET.AlO_x/LDPE, 407.58 days for MPET/LDPE, and 229.26 days for MBOPP. In conclusion, the longest shelf life was achieved with PET/Al-foil/LDPE, and it was observed that as the WVTR of the packaging materials increased, the shelf life of the cocoa-based pudding powder decreased; PET.AlO_x/LDPE and MPET/LDPE could be considered for medium-term storage (up to about 1–1.5 years), while MBOPP appeared suitable only for shorter durations (6–8 months). Full article

The paper studies the dynamic characteristics of a multi-layer foil thrust bearing (MLFTB). A modified efficient dynamic characteristic model is established, and the revised Reynolds equation coupled with the thick plate element and the boundary slip model is adopted. During the solving process, the small perturbation method is implemented. The elasto-hydrodynamic effect under geometric and operational parameters is investigated. It reflects that the dynamic characteristics can be visibly influenced by the slip effect when under tiny clearance with low bearing speed, and ought to be considered. Specifically, the maximum deviation of the axial and direct-rotational stiffness coefficients could be up to −4.93% and −5.02%, respectively. The direct-rotational stiffness is increased with the perturbation frequency; however, a turning point may exist in the cross-rotational stiffness. Additionally, both the rotational stiffness and rotational damping can be expanded at a smaller original clearance. It aims to provide prediction methods with high effectiveness and efficiency, and enrich theoretical guidance for the important MLFTB. Full article

This study presents an acoustic membrane design utilizing a thin foil sound resonance mechanism to enhance sound absorption and insulation performance. The membranes incorporate single-layer and double-layer structures featuring parallel foil square wedge-shaped coffers and a flat bottom panel, separated by air cavities. The enclosed air cavity significantly improves the sound insulation capability of the acoustic membrane. Parametric studies were conducted to investigate key factors affecting the sound transmission loss (STL) of the proposed acoustic membrane. The analysis examined the influence of foil thickness, substrate thickness, and back cavity depth on acoustic performance. Results demonstrate that the membrane structure enriches vibration modes in the 500–6000 Hz frequency range, exhibiting multiple acoustic attenuation peaks and broader noise reduction bandwidth (average STL of 40–55 dB across the researched frequency range) compared to conventional resonant cavities and membrane-type acoustic metamaterials. The STL characteristics can be tuned across different frequency bands by adjusting the back cavity depth, foil thickness, and substrate thickness. Experimental validation was performed through noise reduction tests on an air compressor pump. Comparative acoustic measurements confirmed the superior noise attenuation performance and practical applicability of the proposed membrane over conventional acoustic treatments. Compared to uniform foil resonators, the combination of plastic and steel materials with single-layer and double-layer membranes reduced the overall sound level (OA) by an additional 2–3 dB, thereby offering exceptional STL performance in the low- to medium-frequency range. These lightweight, easy-to-manufacture membranes exhibit considerable potential for noise control applications in household appliances and industrial settings. Full article

The aim of this study was to compare the forces and moments exerted by thermoformed aligners (TFMs) and direct printed aligners (DPAs) on the maxillary left central incisor (21) and adjacent teeth (11, 22) during lingual bodily movement of tooth 21. Methods: An in vitro setup was used to quantify forces and moments on three incisors, which were segmented and fixed onto multi-axis force/moment transducers. TFM were fabricated using 0.76 mm-thick single-layer PET-G foils (ATMOS; American Orthodontics, Sheboygan, WI, USA) and multi-layer TPU foils (Zendura FLX; Bay Materials LLC, Fremont, CA, USA). DPAs were fabricated using TC-85 photopolymer resin (Graphy Inc., Seoul, Republic of Korea). Tooth 21 was planned for bodily displacement by 0.25 mm and 0.50 mm, and six force and moment components were measured on it and the adjacent teeth. Results: TC-85 generated lower forces and moments with fewer unintended forces and moments on the three teeth. TC-85 exerted 0.99 N and 1.53 N of mean lingual force on tooth 21 for 0.25 mm and 0.50 mm activations, respectively; ATMOS produced 3.82 N and 7.70 N, and Zendura FLX produced 3.00 N and 8.23 N of mean lingual force for the same activations, respectively. Bodily movement could not be achieved. Conclusions: The force systems generated by clear aligners are complex and unpredictable. DPA using TC-85 produced lower, more physiological force levels with fewer side effects, which may increase the predictability of tooth movement and enhance treatment outcome. The force levels generated by TFM were considered excessive and not physiologically compatible. Full article

This work presents an innovative hydrothermal approach for fabricating flexible piezoelectric PZT thin films on 20 μm titanium foil substrates using TiO₂ and SrTiO₃ (STO) interlayers. Three heterostructures (Ti/PZT, Ti/TiO₂/PZT, and Ti/TiO₂/STO/PZT) were synthesized to enable low-temperature growth and improve ferroelectric performance for advanced flexible MEMS. Characterizations including XRD, PFM, and P–E loop analysis evaluated crystallinity, piezoelectric coefficient d₃₃, and polarization behavior. The results demonstrate that the multilayered Ti/TiO₂/STO/PZT structure significantly enhances performance. XRD confirmed the STO buffer layer effectively reduces lattice mismatch with PZT to ~0.76%, promoting stable morphotropic phase boundary (MPB) composition formation. This optimized film exhibited superior piezoelectric and ferroelectric properties, with a high d₃₃ of 113.42 pm/V, representing an ~8.65% increase over unbuffered Ti/PZT samples, and displayed more uniform domain behavior in PFM imaging. Impedance spectroscopy showed the lowest minimum impedance of 8.96 Ω at 10.19 MHz, indicating strong electromechanical coupling. Furthermore, I–V measurements demonstrated significantly suppressed leakage currents in the STO-buffered samples, with current levels ranging from 10⁻¹² A to 10⁻⁹ A over ±3 V. This structure also showed excellent fatigue endurance through one million electrical cycles, confirming its mechanical and electrical stability. These findings highlight the potential of this hydrothermally engineered flexible heterostructure for high-performance actuators and sensors in advanced MEMS applications. Full article

Cathodic exfoliation of graphite has emerged as an attractive method to synthesize high-quality and lo- defect graphene. Here, it is demonstrated that the type of starting graphite material influences the properties of exfoliated graphene. Graphite foil, natural graphite, and graphite rods were examined in the exfoliation processes performed in 3.0 M KCl at −15 V. The use of a graphite foil facilitates the rapid cathodic exfoliation process in comparison with structurally more compact natural graphite and graphite rods. For the graphite foil, the cathodically exfoliated graphene exhibits a low defect density (I_D/I_G of 0.09, a C/O ratio of 35) with graphite exfoliation yield of 92.8%. In contrast, the exfoliated graphene from natural graphite exhibits an I_D/I_G of 0.15, a C/O ratio of 28, and a graphite exfoliation yield of 30.5%, whereas graphene from graphite rod exhibits an I_D/I_G of 0.86, a C/O ratio of 30, and a graphite exfoliation yield of 19.5%. The dense structure of natural graphite and graphite rods led to longer exfoliation times. Exfoliation of graphite rods produced few-layer graphene with the smallest sheet size, whereas natural graphite and graphite foil yielded multilayer graphene with larger sheets. This study demonstrates the feasibility of using aqueous-based cathodic exfoliation to produce graphene from various graphite sources, leading to variations in sheet thickness, size, defect density, and solvent dispersibility. Full article

The conventional spent lithium-ion batteries (LIBs) recycling method suffers from complex processes and excessive chemical consumption. Hence, this study proposes an electrochemical strategy for achieving reductant-free leaching of high-valence transition metals and efficient separation of valuable components from spent cathode sheets (CSs). An innovatively designed sandwich-structured electrochemical reactor achieved efficient reductive dissolution of cathode materials (CMs) while maintaining the structural integrity of aluminum (Al) foils in a dilute sulfuric acid system. Optimized current enabled leaching efficiencies exceeding 93% for lithium (Li), cobalt (Co), manganese (Mn), and nickel (Ni), with 88% metallic Al foil recovery via cathodic protection. Multi-scale characterization systematically elucidated metal valence evolution and interfacial reaction mechanisms, validating the technology’s tripartite innovation: simultaneous high metal extraction efficiency, high value-added Al foil recovery, and organic removal through single-step electrochemical treatment. The process synergized the dissolution of CM particles and hydrogen bubble-induced physical liberation to achieve clean separation of polyvinylidene difluoride (PVDF) and carbon black (CB) layers from Al foil substrates. This method eliminates crushing pretreatment, high-temperature reduction, and any other reductant consumption, establishing an environmentally friendly and efficient method of comprehensive recycling of battery materials. Full article