Search Results (257)

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

Grain size plays a decisive role in governing the interface evolution and mechanical properties of ultra-thin metal composite foils. This study systematically investigates this relationship in roll-bonded C7701/Ti/C7701 (Cu-Ni-Zn alloy) composite foils. By controlling the initial grain size via pre-annealing, we demonstrate that a moderate grain size (~7–8 μm) optimally regulates a sequential “bonding–diffusion–intermetallic compound (IMC) formation” process at the interface. This results in a continuous, thin IMC layer and the best strength–ductility synergy (e.g., UTS ~217.5 MPa, elongation ~4.15%). In contrast, excessively fine or coarse grains lead to thick, brittle IMCs or interfacial defects, respectively, degrading performance. The mechanism by which grain size influences performance is revealed through a sequential mechanism of “bonding–diffusion–intermetallic compound formation.” Full article

Traditional homogeneous copper foils suffer from a trade-off between strength and ductility, while gradient or heterogeneous structures are mostly based on deformation processing, making it difficult to achieve controllable construction within a thickness of ≤10 μm. This study aims to directly construct a layered structure with a “fine–coarse–fine” (A-B-A) gradient grain distribution, denoted as 3L-ABA in an 8 μm copper foil via direct current electrodeposition, which utilizes composite additives to regulate electrochemical polarization and nucleation modes. Through systematic characterization and mechanical testing, it was found that the 3L-ABA copper foil exhibits a tensile strength of 604 ± 18 MPa, an elongation of 3.6 ± 0.25%, and low surface roughness Rz of 0.46 μm. Microscopic mechanism analysis demonstrates that the gradient structure achieves synergistic strengthening and toughening through surface fine-grain strengthening, intermediate coarse-grain coordinated plastic deformation, combined with dislocation density and twin strengthening. Electrochemical tests confirm that Additive A (containing collagen, bis-(3-sulfopropyl)-disulfide (SPS), thiourea and 2-mercapto-5-benzimidazolesulfonic acid sodium salt (2M5S)) induces strong cathodic polarization, promoting instantaneous nucleation and grain refinement, whereas Additive B (containing collagen and bis-(3-sulfopropyl)-disulfide (SPS) shows weaker polarization and promotes grain growth. This research provides a scalable electrodeposition solution for the microstructural design and performance regulation of ultra-thin copper foils. 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

Due to its very high theoretical specific capacity, lithium is still considered a promising anode material for innovative next-generation battery cells. The aim is to produce thin lithium metal anodes (LMAs) that are sufficient for the battery cell due to the lithium already present in the cathode and thus additionally increase the energy density of the cell. The production of thin lithium layers (<10 µm) is challenging with most processes, and very costly with decreasing thickness. In this study, the use of magnetron sputtering to deposit thin layers of lithium for the production of LMAs is tested. An innovative process—the deposition of lithium from a liquid phase via Hot Target Sputtering—will be presented that has the potential to overcome the previous limitations in the deposition rate, and enables the potential for industrial application. The process was successfully tested in terms of general process control, stability and reproducibility and used to produce lithium metal anodes. These were then successfully integrated in All-Solid-State-Battery (ASSB) cells and compared with a lithium reference foil in a C-rate test with regard to their electrochemical performance reaching ≈ 110 mAh g⁻¹ at a 1C discharge rate. Full article

Solar sailing has proven to be an effective solution for cost-effective and long-term space missions due to its fuel-free propulsion. While multiple large-scale solar sails based on kilogram-class satellites have been developed and tested in space, solar sails created for lightweight chip-scale satellites are much less. To enable the gram-class satellite of solar sailing for active attitude adjustment and orbital maneuvers, a novel solar sail driven by two-way shape memory effect (TWSME) was proposed in this work. The solar sail base was made of rectangular Al-Kapton thin films, while a U-shaped NiTi beam was developed by 50 μm thin Ni_50.6Ti_49.4 foils. Both of the U-shaped NiTi beam and rectangular Al-Kapton thin films were manufactured by the ultra-fast femtosecond laser cutting machine. Finite element modeling of single U-shaped NiTi beam and assembled solar sail were built to validate that an 80 mm-long TWSME NiTi beam with a curvature of 37.31 m⁻¹ were sufficient to drive the solar sail for solar radiation pressure modulation. A solar sail prototype was developed, and an in situ experiment test of the prototype was conducted with infrared imaging, showing efficient bending behaviors by application of a 0.5 A direct current across the U-shape NiTi beam. These findings reveal that U-shaped TWSME NiTi foils provide an effective driving strategy for lightweight chip-scale satellites, and thus dramatically broaden the space application of the gram-scale satellite. Full article

This study systematically investigates the thickness-dependent mechanical properties of electroplated copper foils with fine-grained (FG-Cu) and columnar nanotwinned (NT-Cu) microstructures. Tensile testing across a thickness range of 5–30 μm revealed that NT-Cu exhibits superior mechanical stability, with significantly lower reductions in both ultimate tensile strength (UTS) and yield strength (YS) compared to FG-Cu. The UTS of the 30 μm thick FG-Cu foil was measured at 651 MPa, increasing to 792 MPa at a thickness of 5 μm. In contrast, the UTS of NT-Cu foils only rose from 624 MPa at 30 μm to 663 MPa at 5 μm. A similar trend was observed for the YS. Microstructural analysis confirmed that NT-Cu maintains a stable columnar grain structure with minimal grain growth, contributing to its resistance to thickness-induced strength loss. These findings highlight NT-Cu as a promising candidate for applications requiring consistent mechanical performance across varying foil thicknesses. Full article

In this study, thin molybdenum nitride (MoN_x) layers were directly synthesized on molybdenum foil via thermal treatment under an NH₃ atmosphere, and their phase evolution, structural characteristics, and electrochemical performance were investigated. The thickness and morphology of the MoN_x layers were controlled by varying ammonolysis time and temperature, while subsequent annealing in N₂ converted the nitride layer into MoO₂. Meanwhile, oxidation in air yielded crystalline MoO₃ layers. X-ray diffraction and X-ray photoelectron spectroscopy confirmed progressive oxidation of molybdenum, with Mo 3d binding energies increasing in the sequence of Mo < MoN_x < MoO₂ < MoO₃, consistent with their nominal oxidation states. Electrochemical characterization revealed that both MoN_x/Mo and MoO₂/Mo electrodes exhibit notable pseudocapacitive behavior in 0.5 M H₂SO₄ electrolyte, with areal specific capacitances reaching up to 520 mF cm⁻² at 10 mV s⁻¹. Increasing layer thickness led to enhanced capacitance, likely due to an increase in the electrochemically accessible surface area and the extension of ion diffusion pathways. MoO₂-coated samples showed stronger faradaic contribution and superior rate capability compared to MoN_x counterparts, along with a gradual shift from predominantly electric double-layer capacitance toward hybrid pseudocapacitive charge storage mechanisms. Full article

The article presents the results of structural, corrosion, microbiological, biological, and genotoxicity studies on the effect of graphene oxide deposited on a flat titanium foil surface, intended for use, in general, implantology and other medical applications. The methodology of graphene oxide (GO) deposition involved a surface cleaning process combined with RF plasma activation, followed by the application of a thin layer of dispersed aqueous GO suspension using a spin coater. The graphene oxide layer was uniformly deposited on the surface, which was confirmed by SEM imaging. Corrosion studies were carried out in an electrochemical cell filled with a buffered solution prepared to mimic the composition of physiological intracellular fluids. It was demonstrated that the deposition of graphene oxide on the titanium surface limited the access of electrolyte and oxygen. Surface activation and deposition of the aqueous graphene oxide suspension contributed to improved adhesion, condition, growth, and proliferation of fibroblast cell lines Hs 895.T and Hs 895.Sk. The inhibition zone analysis revealed a bacteriostatic effect against Pseudomonas aeruginosa and Staphylococcus aureus. Moreover, no genotoxicity changes were observed. Full article

A common method to examine the reliability of thin films and small volumes of irradiated materials being used in aerospace, energy, and protective coating applications is biaxial straining. With such tests, the fracture and deformation mechanisms occurring under multi-axial stress states can be investigated, which can strongly differ from the simpler uniaxial one. However, devices that can apply a precise and synchronously applied biaxial strain tend to be too large for foils or thin films and do not allow for additional observation methods to be applied to examine film fracture or deformation during the test. A prototype device that can apply synchronous equi-biaxial and semi-biaxial strains and can be combined with multiple in situ methods is introduced. The device is light and compact in design, which allows it to be mounted on optical light microscopes, atomic force microscopes, inside scanning electron microscopes, and even on X-ray beamlines for reflection or transmission measurements. Additionally, digital image correlation was utilized in two geometries to measure strains on a local or global level. The possible errors associated with the device and experiments on polyimide foils and a 100 nm tungsten film on polyimide are presented. Full article

The long-term conservation of Prunus persica (peach), a crop of significant agronomic and genetic value, remains challenging due to its recalcitrance to conventional cryopreservation methods. Low tolerance to dehydration and cryoprotectant toxicity often results in poor survival and regrowth, thereby limiting the reliability of germplasm storage. This study evaluated whether combining an alginate hydrogel matrix with Pluronic F-68 improves vitrification efficiency and post-thaw regeneration of peach shoot tips by enhancing dehydration dynamics and reducing cryo-injury. Shoot tips were immobilized in thin sodium alginate layers on aluminum foil strips, with the hydrogel providing mechanical stabilization and moderating water loss during exposure to PVS3 and subsequent liquid nitrogen immersion. To further mitigate cryoinjury, Pluronic F-68, a non-ionic surfactant with membrane-stabilizing properties, was incorporated into the system. Differential scanning calorimetry revealed that the hydrogel reached complete vitrification after 120 min in PVS3, whereas encapsulated shoot tips required 150 min for full suppression of crystallization. The optimized system achieved 71% post-cryopreservation survival and 40% regrowth, compared with 25% and 9% in non-encapsulated controls. PF-68 accelerated vitrification kinetics, lowered crystallization enthalpies, and improved post-thaw viability. These findings demonstrate that engineered hydrogel–surfactant matrices can stabilize the microenvironment during vitrification and offer a promising approach for the long-term cryopreservation of peach germplasm. Full article

Impact butt joining of copper 5 mm thick C1100 and aluminum alloy A6061-T6 plates was carried out, according to a method recently devised by one of the authors. The joining method results in newly created surfaces being obtained by very large plastic deformation under high-speed conditions, wherein the two materials are subjected simultaneously to compression and a high-speed sliding motion. The new surface of C1100 is created by expansion, whereas for A6061-T6, the new surface is created by removal of the softened surface layer. This layer forms a foil, which is extruded from the joining interface by the compressive force. Using a high-speed video camera, the formation of the foil was observed to take place even in the early stages of deformation. The distribution of joint efficiency was evaluated by examining the joint boundary. When the compressive force increased, some specimens fractured in the C1100 region. The zone affected by the joining process was highly limited, to within 0.8 mm of the boundary; i.e., 20% of the plate thickness. The thickness of the joined plate was reduced by repetitive rolling operations, in which the true strain was about −1. This indicates that the layer of the intermetallic compounds is very thin. Once rolled, the joined sheet exhibited a maximum joint efficiency of 99.3%. In cases where the joining efficiency exceeded 80%, the main region exhibiting fracturing was in the A6061-T6 alloy. Full article

Graphene, owing to its exceptional mechanical properties and interfacial modulation capability, is considered an ideal material for enhancing the interfacial strength and damage resistance during the fabrication of ultra-thin lithium foils. Although previous studies have demonstrated the reinforcing effects of graphene on lithium metal interfaces, most analyses have been restricted to single-temperature or idealized substrate conditions, lacking systematic investigations under practical, multi-temperature environments. Consequently, the influence of graphene coatings on lithium-ion conductivity and mechanical stability under real thermal conditions remains unclear. To address this gap, we employ LAMMPS-based molecular dynamics simulations to construct atomic-scale models of pristine lithium and graphene-coated lithium (C/Li) interfaces at three representative temperatures. Through comprehensive analyses of dislocation evolution, root-mean-square displacement, frictional response, and lithium-ion diffusion, we find that graphene coatings synergistically alleviate interfacial stress, suppress crack initiation, reduce friction, and enhance ionic conductivity, with these effects being particularly pronounced at elevated temperatures. These findings reveal the coupled mechanical and electrochemical regulation imparted by graphene, providing a theoretical basis for optimizing the structure of next-generation high-performance lithium metal anodes and laying the foundation for advanced interfacial engineering in battery technologies. Full article

The construction industry is responsible for a significant amount of greenhouse gas emissions. Therefore, buildings have the potential to play a central role in climate change mitigation. It is also known that building projects are unique and complex, which is why a high degree of process automation is necessary. Two key methods can be employed to calculate the environmental impacts of a construction process: Building Information Modeling (BIM) and Life Cycle Assessment (LCA). Currently, both methods are being considered as a part of advanced building projects. Database (BIM) models can be used as a precise inventory of materials and as an input for LCA. This study aims to (1) review the current status of published BIM-LCA workflows, (2) use a common case study among participants from various countries to compare the individual workflows and the calculated results, (3) identify potential sources of errors in all workflows on the common case study, and (4) provide recommendations and suggestions for developing BIM-LCA models based on the example of the common case study. The outcomes show that the main sources of differences emerge from not including all materials or from the inconsistencies in the exported material lists of the bill of quantities. The reasons for the missing materials stem primarily from the inadequate decomposition of composite materials, oversight of certain materials, and exclusion of thin materials such as foils. Inconsistencies arise from the incorrect handling of composite materials, the grouping of similar materials, and rounding inaccuracies. These issues highlight that errors occur early in the life cycle inventory phase, which forms the foundation of subsequent LCA phases, thereby impacting the final results and potentially leading to inaccurate assessments of environmental impacts. Ensuring accuracy at this stage is therefore critical for supporting reliable sustainability assessments. Consequently, recommendations are proposed to mitigate errors across various stages of the process to enhance the accuracy of LCA outcomes. Full article

The main objective of this study was to investigate boiling heat transfer during refrigerant flow in a mini-channel heat sink. The test section consisted of multiple parallel mini-channels, each with a depth of 1 mm. The working fluid was heated by a thin layer of Haynes-230 alloy with a thickness of 0.1 mm. The outer surface temperature of the heater was measured using infrared thermography, while other thermal and flow-based parameters were recorded via a dedicated data acquisition system. The mini-channel heat sink was tested in seven different spatial orientations, with inclination angles relative to the horizontal plane of 45°, 60°, 75°, 90°, 105°, 120°, and 135°. The analysis focused on the early stage of the experiment, corresponding to the forced convection, boiling incipience, and subcooled boiling region. A time-dependent, two-dimensional model of heat transfer during flow boiling of a refrigerant in asymmetrically heated mini-channels was developed. The temperatures of both the heating foil and the working fluid (Fluorinert FC-770) were described using appropriate forms of the Fourier–Kirchhoff equation, subject to relevant boundary conditions. Two sets of time-dependent Trefftz functions were employed to solve the governing equations: one set corresponding to the two-dimensional Fourier equation and another, newly derived, for the energy equation in the fluid. The results include thermographic images of the heated surface, temperature distributions, fluid temperatures, local heat-transfer coefficients, and boiling curves. A comparison of the heat-transfer coefficients obtained using the Trefftz-based approach and those calculated using Fourier’s law demonstrated satisfactory agreement. Full article