Search Results (133)

This study systematically investigates the formulation–property relationships of epoxy-based silver conductive adhesives by varying silver filler architecture, total filler loading, and organic carrier design. Rotational viscometry, four-point probe measurements, thermal conductivity analysis, and scanning electron microscopy (SEM) were employed to elucidate the correlations among rheological behavior, conductive network formation, and electrical–thermal transport properties. All formulations incorporate dicyandiamide (DICY) as a latent curing agent, in combination with a thermally activated accelerator and silane coupling agents, to stabilize filler–matrix interfaces and suppress moisture-assisted side reactions. This latent curing chemistry enables effective low temperature curing at approximately 155 °C, providing compatibility with temperature-sensitive flexible polymer substrates. After sealed storage at 25 °C and 60% relative humidity for two weeks, all formulations exhibited viscosity variations within ≤16%, demonstrating extended pot life and good storage stability under ambient conditions. Meanwhile, the normalized volume resistivity and thermal conductivity remained close to their initial values, with maximum relative deviations of approximately 12% and 7%, respectively, from the initial (Day 0) values across all formulations, indicating stable electrical and thermal transport properties during storage. Differences in conductive network formation and filler packing characteristics were reflected in the observed electrical and thermal transport behaviors. Balanced electrical–thermal performance was achieved without the need for high-temperature sintering or post-annealing, underscoring the effectiveness of the low temperature curing strategy. Overall, this work defines a practical formulation design window that simultaneously achieves low temperature curability, long pot life, stable rheology, and robust electrical–thermal performance. The results provide useful material-level guidelines for the development of epoxy-based silver conductive adhesives intended for conductive interconnects on flexible polymer substrates and related flexible electronic applications. Full article

The sole use of carbon nanotubes (CNTs) as single-electrode carriers in direct methanol fuel cells (DMFCs) creates structural disparities that increase resistance, impair catalyst utilization, and limit discharge duration. This study presents a novel dual-electrode CNT-based carrier structure designed to enhance mass transport and electron conduction, thereby improving DMFC power output and durability. The CNTs were grown in situ via nitrogen sintering onto the microporous layer, with parameters optimized to enhance surface morphology and conductivity. The impact of this dual-electrode CNT carrier was evaluated through microstructural characterization, cyclic voltammetry, electrochemical performance testing, and service life assessment. Results demonstrate that the structure improves catalyst dispersion, electrochemical active surface area (ECSA), and charge transfer efficiency, while reducing ohmic resistance and charge transfer impedance. Compared to traditional carbon black (CB) carriers, peak power increased by 51.06%. Under China Light Vehicle Test Cycle (CLTC) conditions, discharge duration increased by a factor of 1.7, indicating higher energy efficiency. These improvements are attributed to the dual-electrode architecture’s synergistic enhancement of proton transport, balanced electrochemical kinetics, and reduced interfacial resistance. Full article

The present study demonstrates that the corrosion behavior of dental cobalt–chromium (Co–Cr) alloys is strongly influenced by the interaction between microstructure, manufacturing technique, and oral chemical environment. A comparative investigation was conducted on Co–Cr specimens fabricated using four technological routes: conventional casting, CAD/CAM machining, Selective Laser Melting (SLM), and Direct Metal Laser Sintering (DMLS). The study included microstructural characterization, evaluation of generalized corrosion behavior using the rotating electrode technique, assessment of localized crevice corrosion, and quantitative analysis of the release of twenty metallic cations. Extraction tests were performed for 168 h in two media simulating aggressive oral environments: 0.07 N HCl (acidic medium) and a fluoride-containing electrolyte (0.1% NaF + 0.1% KF). Electrochemical measurements were recorded in the current density range of 10⁻¹⁰ to 10⁻⁷ A/cm², while released cation concentrations were quantified at the µg/L level. All alloys exhibited very low corrosion current densities (icorr in the 10⁻⁸ to 10⁻⁹ A·cm⁻² range), confirming overall good corrosion resistance. Among all manufacturing routes, CAD/CAM specimens demonstrated the highest electrochemical performance, with a wide passivity domain extending up to approximately 740 mV/SCE. A statistical interaction analysis between extraction media and manufacturing techniques was performed using the non-parametric Mann–Whitney (MW) U test. Among the analyzed elements, only chromium showed a statistically significant difference between media (p < 0.05), with an approximately 25-fold-higher release in acidic conditions compared with the fluoride medium, confirming the predominant role of proton-induced destabilization of the protective Cr₂O₃ passive film. In contrast, fluoride-containing media induced selective release of elements such as Cu (3× higher), W (2.5× higher), and Mo (1.4× higher), associated with complexation phenomena. The manufacturing route significantly influences corrosion behavior. Although additive manufacturing technologies (SLM/DMLS) enable highly accurate and customized prosthetic designs, rapid solidification and microstructural heterogeneities may increase susceptibility to localized corrosion compared with more homogeneous CAD/CAM materials. Clinically, these findings suggest that future restorative strategies should incorporate corrosion-aware material selection within digital workflows. As digital dentistry evolves, predictive models integrating patient-specific oral conditions may assist clinicians in selecting the most appropriate material system for long-term performance. In conclusion, the long-term success of dental Co–Cr prosthetic devices depends not only on mechanical strength and precision of fit, but also on sustained electrochemical stability in the complex oral environment. Full article

This study reports the synthesis of a high-entropy AlFeCuTiNi alloy via high-energy ball milling. The study investigates the effects of mechanical alloying time and sintering temperature on the microstructure, mechanical properties, wear, and corrosion behavior of the high-entropy AlFeCuTiNi alloy. XRD, SEM, and EDX analyses revealed that the mechanical alloying time and sintering temperature significantly affected the alloy’s homogeneity, phase structure, and oxide film stability. As the mechanical alloying time increases, the corrosion resistance of alloys sintered at 550 °C initially increases and then stabilizes. In samples sintered at 650 °C, corrosion resistance is generally higher. The highest corrosion resistance was achieved after 15 h of mechanical alloying and sintering at 650 °C. The study reveals that the best corrosion, wear, hardness, and wear density performance was observed in samples obtained at medium conditions, achieved after 20 h of mechanical alloying and sintering at 650 °C. These findings may contribute to optimizing production processes for sustainable material design. Moreover, this research highlights that high-entropy alloys and powder-metallurgy-based production methods enable industrial applications for energy-efficient, sustainable material design and contribute to sustainable production and circular-economy principles. Full article

Cemented carbides are essential in applications requiring exceptional hardness and wear resistance. However, the reliance on cobalt as a binder raises concerns related to cost, supply security, and health. High-entropy alloys (HEAs) are promising cobalt-free binders offering favorable mechanical properties and potential grain-growth control. This work presents a new approach for the development of Co-free WC-based cemented carbide employing an HEA binder designed through CALPHAD-guided simulations. An optimized composition corresponding to Al5Cr5Cu10Fe35Mn10Ni35 (at%) alloy is predicted to be FCC-dominant with minimal σ-phase formation and good compatibility with WC. A preliminary batch of powder of the proposed binder was produced by blending elemental powders, arc remelting, and ultrasonic atomization, yielding predominantly spherical particles with a dendritic microstructure. WC–HEA composites (WC–12 wt% HEA) were then prepared by ball milling, pressing, vacuum sintering, and sinter-HIP for a first evaluation of the microstructure and achievable hardness. The microstructure exhibited residual porosity without significant WC grain coarsening. XRD analyses showed the dominant presence of WC, along with FCC and M₃W₃C phases (M mainly Fe and Mn), indicating thermal interaction between the binder and WC. Despite these effects, the composite achieved a hardness of 1913 HV and retained a fine WC grain size (0.86 μm). The proposed design approach allowed the definition of a promising Co-free binder composition based on HEA with the expected microstructure, which will need further evaluation, especially aimed at investigating toughness properties as a function of the WC content. Full article

Eutectic alloys stand out for their ability to combine high strength and good ductility; a behaviour rooted in their characteristic two-phase microstructure—lamellar or globular—formed at a constant solidification temperature that minimizes segregation and suppresses brittle phases. Their low interfacial energy limits microcrack propagation, while interfacial sliding and dislocation blocking at phase boundaries enhance both strength and toughness. In this work, we investigate how controlled microstructural modifications influence the behaviour of the eutectic high-entropy alloy AlCoCrFeNi2.1, composed of B2 (Ni–Al-rich) and L12 (Co–Fe–Ni-rich) phases. Because these phases exhibit distinct mechanical responses, microconstituent morphology becomes a design parameter. Powder metallurgy is the only processing route capable of providing the level of microstructural control required in this study. It preserves the rapidly solidified eutectic architecture of gas-atomised powders while allowing its intentional transformation during consolidation. Two strategies were implemented: (i) tuning the thermal–electrical input in Spark Plasma Sintering (SPS) and Electrical Resistance Sintering (ERS), and (ii) engineering the particle size distribution, including a bimodal design that enhances surface-energy-driven morphological transitions. SPS enables a gradual lamellar-to-globular evolution, whereas ERS induces ultrafast transformations governed by current intensity. The bimodal PSD significantly accelerates globularisation at lower energy input. EBSD-KAM (Electron Backscatter Diffraction—Kernel Average Misorientation) mapping identifies the lamellar B2 phase as metastable and highly strained, while globular B2 domains show reduced dislocation density. Nanoindentation confirms that intrinsic phase properties remain unchanged, whereas microhardness scales with morphology and lamellar spacing. These results demonstrate that the macroscopic mechanical response is governed by microstructure, establishing powder metallurgy as a uniquely powerful pathway for microstructure-driven design in eutectic HEAs. Full article

The integration of sustainable and natural waste-derived materials into lightweight metals presents a promising strategy with both environmental and performance-related benefits. In this study, a biobased magnesium composite reinforced with dried leaf powder (DLP) derived from fallen waste leaves was synthesized using a controlled powder metallurgy method incorporating energy efficient hybrid microwave sintering, followed by hot extrusion at varying temperatures (350 °C, 250 °C, 150 °C). Microstructural analysis revealed that the addition of DLP had minimal effect on the overall grain morphology, while lower extrusion temperatures promoted finer grains due to restricted grain growth. Mg–5DLP composites consistently exhibited higher porosity than pure Mg, primarily due to the evaporation of organic constituents during sintering. The damping performance of the biomass-containing materials was improved (54.5% increase), particularly at lower extrusion temperatures (250 °C), though mechanical performance showed a trade-off with reduced hardness and compressive strength. A slight increase in yield strength at lower extrusion temperatures was attributed to retained dislocation density and grain refinement. Thermal stability remained largely unaffected, while corrosion behavior was strongly dependent on both DLP addition and extrusion temperature, with Mg–5DLP samples corroding faster than pure Mg when extruded at higher temperatures; interestingly, however, at the lowest extrusion temperature (150 °C), improved corrosion resistance to pure Mg (1.3 mm/year for Mg-5DLP vs. 2.0 mm/year for pure Mg) was observed. Overall, this work demonstrates that extrusion temperature is a critical factor in controlling the microstructure, thermal response, damping response, mechanical behavior and corrosion of biobased composites. The study not only highlights the potential of using direct biomass reinforcement of magnesium to synthesize lightweight, ecofriendly materials, but also lays a strong foundation for future investigations into biobased composite design, processing optimization, and property tailoring. Full article

Superhydrophilic micro/nano-porous media have extensive applications in electronic thermal management and energy storage systems. Predicting two-phase pressure drop in complex porous structures is of great importance for system design and optimization while remaining highly challenging. This study systematically investigates the two-phase flow resistance characteristics of bi-porous microstructures with multiple particle sizes and porosities under varying boiling regimes. Experimentally, porous samples were fabricated via vacuum sintering using nickel powders and pore-forming agents (CaCl₂), which exhibit superhydrophilicity and enhanced wicking characteristics. A visualized experimental platform was constructed to investigate the impact of pore size combinations, flow velocities, and boiling states on pressure drop. The dataset obtained through multi-factor saturated boiling experiments was further used to derive a semi-empirical model for the two-phase flow pressure drop based on the classic Kozeny-Carman (K-C) and Akagi-Chisholm (A-C) correlations. Results show that the pore size combinations and boiling states have a significant impact on the resistance performance. The proposed model achieves an average prediction deviation below 15.7%, confirming its reliability and its effectiveness as a design framework for optimizing high-capillary-force porous wicks in advanced thermal management systems. Full article

Reforming processes are key technologies for the production of hydrogen and synthesis gas from hydrocarbon feedstocks, with steam reforming and dry reforming being the most extensively studied routes. Steam reforming remains the dominant industrial process due to its high efficiency and economic viability; however, its associated CO₂ emissions raise environmental concerns, partially mitigated through an integration with carbon capture and storage technologies. Dry reforming has emerged as an attractive alternative, although it requires high operating temperatures and suffers from catalyst deactivation. Catalyst design is therefore critical for improving process efficiency and stability. Supported metal catalysts, particularly Ni-based systems, are widely employed, with the support material playing a decisive role in metal dispersion, resistance to sintering and coking, and reaction selectivity. Microporous and mesoporous silica-based materials, including zeolites and ordered mesoporous silicas, offer tunable structural and surface properties that enhance catalytic performance. The novelty of this work lies in its holistic approach to reforming catalysis, where the catalytic performance is not discussed solely in terms of active metals, but is systematically correlated with the surface properties, chemical composition, and structural features of silica-based supports. Moreover, this study expands the perspective to alternative and less-explored feedstocks. By considering multiple fuels and support types, the study provides new design guidelines for developing more efficient and sustainable reforming catalysts. Full article

Graphene (GR) demonstrates significant potential in enhancing the mechanical performance of titanium matrix composites (TMCs), particularly by improving their tensile strength, fracture toughness, and fatigue resistance, thereby optimizing the overall structural integrity and durability of the composites; however, their practical implementation confronts two fundamental challenges: achieving uniform dispersion and mitigating excessive interfacial TiC formation, which compromises mechanical properties. This review comprehensively explores progress in the fabrication, interfacial design, and mechanical optimization of TMCs reinforced with graphene-based materials. Various processing techniques, such as powder metallurgy (PM) and spark plasma sintering (SPS), are critically analyzed in terms of their advantages and limitations for producing high-performance TMCs. This article analyzes how key parameters in processes like PM and SPS affect graphene structure, dispersion, and interfacial reactions. It outlines strategies—including surface modification, 3D structural design, and multiscale interface engineering—that enhance both strength and toughness. While progress has been made in microscale performance, challenges remain in engineering stability and long-term reliability. Future work should focus on intelligent process optimization and architectured composite manufacturing. By systematically synthesizing existing research findings, this article clarifies the advantages and limitations of current technological approaches, providing a theoretical foundation and technical roadmap for the subsequent development of graphene-reinforced TMCs that exhibit high strength, high toughness, and excellent reliability. Full article

High-temperature self-lubricating materials with stable tribological performance across a wide temperature range are essential for advanced mechanical systems under extreme conditions. However, balancing mechanical strength and lubrication efficiency remains a key challenge. This study fabricated CoCrFeNiMox-Ni/MoS₂-Ag-Cr₂O₃ composites (x = 0.2, 0.5, 1) via spark plasma sintering, aiming to investigate the effect of Mo content on their microstructure, mechanical properties, and tribological behavior. Microstructural analysis showed that the as-sintered composites mainly consist of FCC phase, Cr₂O₃, Ag, and Ni/MoS₂. Increasing Mo content from 0.2 to 1 wt.% significantly promoted the formation of hard σ-phase intermetallics, leading to increased hardness (up to 546 HV) and yield strength (peaking at 502 MPa). Tribological tests at 25–800 °C indicated continuous lubrication behavior in all composites. The minimum friction coefficient was 0.23, and wear rates remained below 10⁻⁶ mm³/N·m. In the low-to-medium temperature range, lubrication was dominated by the synergistic effect of Ni/MoS₂ and Ag: Ni/MoS₂ formed low-shear-strength films, while Ag reduced surface adhesion. Meanwhile, the Mo solid solution strengthened and the σ-phase enhanced wear resistance by improving hardness and inhibiting plastic deformation. At high temperatures, tribochemical reactions generated lubricating films composed of oxides and molybdates, which maintained tribological performance by reducing direct contact between friction pairs. This study demonstrates that Mo-doped high-entropy alloy composites can serve as high-performance wide-temperature self-lubricating materials, providing a basis for designing “matrix-lubricant” systems for extreme-temperature applications. Full article

To develop and design new alloy materials with lightweight and superior comprehensive performance. In this study, a MgAlTiVFeCo lightweight high-entropy alloy (LW-HEA) was fabricated via mechanical alloying and spark plasma sintering (SPS) to investigate the effects of sintering temperature on its phase structure, microstructure, densification, microhardness, high-temperature oxidation resistance, and corrosion resistance. The results indicate that the ball-milled MgAlTiVFeCo LW-HEA formed a simple solid solution phase with a BCC structure. After spark plasma sintering, the phase structure of the alloy changed, maintaining the BCC phase as the primary phase while accompanying the precipitation of secondary phases. When the sintering temperature reached 1000 °C, the alloy achieved a densification of 96.7% and a microhardness of 1235.5 HV. Its hardness value is comparable to the typical range of cemented carbides, demonstrating outstanding mechanical properties. The oxidation kinetics of MgAlTiVFeCo high-entropy alloys sintered at different temperatures at 900 °C follow a parabolic law, which is diffusion-controlled and can be divided into two stages: rapid growth and slow stabilization. At a sintering temperature of 1000 °C, the fitted oxidation rate constants, k_p1 (0–25 h) and k_p2 (25–60 h), are 3.76 × 10⁻² mg²·cm⁻⁴·s⁻¹ and 1.10 × 10⁻¹ mg²·cm⁻⁴·s⁻¹, respectively, outperforming those of alloys sintered at other temperatures. In a 3.5 wt% NaCl solution, the corrosion resistance of the alloy improves with increasing sintering temperature. Compared to alloys sintered at medium-to-low temperatures (850–950 °C), the alloy sintered at a high temperature (1000 °C) exhibits a more positive corrosion potential (−0.438 V) and a lower corrosion current density (1.07 × 10⁻⁶ A·cm⁻²), indicating excellent corrosion resistance. It is evident that 1000 °C is the optimal sintering temperature, and the MgAlTiVFeCo LW-HEA demonstrates superior comprehensive properties. Full article

Silica aerogels are critical for thermal protection in extreme environments; however, their mechanical response mechanisms under high temperatures remain elusive. This study employs large-scale molecular dynamics simulations to systematically investigate the mechanical behavior of silica aerogels (0.43–0.71 g/cm³) across a temperature range of 298–1800 K. The results reveal a fundamental competition between thermal softening and sintering-induced strengthening. Under tensile loading, the thermal softening effect dominates, leading to a significant fracture strength reduction of up to 49.6% at 1800 K, while simultaneously enhancing ductility, extending fracture strain to 80%. Conversely, under compressive loading, the sintering effect induced by temperatures above 900 K outweighs softening, resulting in a ~20% increase in the elastic modulus for high-density samples at 1300 K. Microstructural analysis attributes this enhancement to the preferential collapse of large pores and densification into an atomic-scale micropore range (0.5–1.0 nm). This work elucidates how the interplay between softening and sintering dictates material failure or strengthening, providing a microscopic theoretical basis for designing thermal shock-resistant materials for new energy batteries. Full article

Background: Durable bonding to zirconia remains difficult because its chemically inert surface resists acid etching. Additive manufacturing (AM) enables controlled surface morphology, which may enhance micromechanical retention without additional treatments. Methods: Zirconia specimens with three AM-derived surface designs—(1) concave–convex hemispherical patterns, (2) concave hemispherical patterns, and (3) as-printed surfaces—were fabricated using a slurry-based 3D printing system and sintered at 1500 °C. Zirconia specimens fabricated by subtractive manufacturing using CAD/CAM systems, polished with 15 µm diamond lapping film and with or without subsequent alumina sandblasting, served as controls. Surface morphology was analyzed by FE-SEM, and shear bond strength (SBS) was tested after cementation with a resin-based luting agent. Results: SEM revealed regular layered textures and designed hemispherical structures (~300 µm) in AM specimens, along with step-like irregularities (~40 µm) at layer boundaries. The concave–convex AM group showed significantly higher SBS than both sandblasted and polished subtractive-manufactured zirconia (p < 0.05). Vertically printed specimens demonstrated greater bonding strength than those printed parallel to the bonding surface, indicating that build orientation affects resin infiltration and interlocking. Conclusion: AM-derived zirconia surfaces can provide superior and reproducible micromechanical retention compared with conventional treatments. Further optimization of printing parameters and evaluation of long-term durability are needed for clinical application. Full article

Alumina ceramics used in semiconductor plasma environments require high densification, microstructural homogeneity, and stable performance under increasingly aggressive processing conditions. However, systematic studies linking slurry processing parameters to the plasma resistance of alumina ceramics remain limited. In this study, the effects of slurry preparation parameters—specifically milling and aging—and sintering atmosphere on the densification, mechanical strength, and plasma etching resistance of slip-cast alumina ceramics were systematically investigated. Optimal dispersion stability was achieved under 12 h milling and 12–24 h aging conditions, resulting in homogenized green body packing and a high relative sintered density exceeding 99%. Mechanical strength and plasma resistance were strongly influenced by slurry aging and sintering atmosphere. Specimens aged for 48 h and sintered under a low oxygen partial pressure (N₂ at 1.0 L/min) exhibited the highest flexural strength and significantly improved resistance to SF₆/Ar plasma etching, with reduced etch depth and suppressed surface roughening. These results demonstrate that coordinated slurry processing and sintering atmosphere control is an effective strategy for designing high-reliability, plasma-resistant alumina ceramics for high-demand semiconductor manufacturing environments. Full article