Copper Foam Research Articles

Research on chromium removal mechanism by electrochemical method from wastewater

Cr (VI), a heavy metal ion in electroplating wastewater, poses a significant environmental challenge due to its high toxicity and recalcitrance to degradation. This paper used copper plates, stainless steel, foam carbon, and carbon paper as electrodes to research the chromium removal mechanism from electroplating wastewater by a fast electrochemical method. The effect of the electrode materials and reaction conditions on removing Cr (VI) from wastewater was investigated. The analysis of the Cr (VI) removal rate during electrolysis revealed that the optimal electrode materials used the copper plate as the cathode and foam carbon as an anode. The optimal reaction conditions were determined: the electrolysis time is 30 min, the plate spacing is 2.0 cm, the operating voltage is 1.8 V, and the reaction temperature is 50 °C, achieving a maximum Cr (VI) recovery of 91.30 %. The proposed optimization of stirring instead of heating was found to be feasible. At 300 r/min, the energy consumption can be significantly reduced, and the removal rate of Cr (VI) can reach 87.82 %. The intrinsic mechanism behind the removal of Cr (VI) was studied by calculating the adsorption performance of the two electrodes on Cr (VI) and Cr (III) using the density functional theory (DFT), providing an in-depth understanding of the action mechanism and industry applications.

Research on the Strengthening Mechanism of MWCNTs-Cuf Composite Interlayer for Si3N4/TC4 Brazed Joints

With the rapid development of aerospace technology, the high-quality brazing connection between Si3N4 ceramic and TC4 titanium alloy has become a key factor in advancing the development of aircraft antenna covers. To improve the mechanical strength of the joints, this study used the electrophoretic deposition method to prepare a multi-walled carbon nanotubes-foam copper (MWCNTs-Cuf) composite interlayer and selected the optimal deposition parameters. The most suitable brazing parameters under this interlayer were also determined. The joints’ formation mechanism and fracture mode were revealed to elucidate the synergistic strengthening mechanism of the composite interlayer. The results showed that MWCNTs, based on their phase characteristics, produced high-density dislocations and fine crystal strengthening effects during the brazing cooling process. This effectively resisted the corrosion of the brazing material on the foam copper (Cuf), protected the integrity of the foam copper framework, and exerted the excellent plastic deformation ability of foam copper (Cuf). It reduced the residual stress in the joints, resulting in the highest shear strength of the MWCNTs- Cuf composite interlayer, reaching 96.23 MPa. Compared with only adding Ag-Cu-Ti active brazing filler metal and adding ordinary foam copper interlayer, the shear strength increased by 78.2% and 44.7%, respectively.

In-situ fabrication of defect rich Cu2+1O on electrodeposited Cu cone arrays for promoting electrocatalytic anode hydrogen production

The low-potential formaldehyde oxidation reaction (FOR) is a significant replacement for oxygen evolution reaction, as FOR can couple with the cathode hydrogen evolution reaction (HER) to obtain a bipolar H2 production system with an extra low cell voltage. Cu-based electrocatalysts offer cost advantages in FOR but suffer from poor intrinsic activity and stability. Herein, a novel defect rich CF-Cu@Cu2+1O/Cu pinecone-shaped array electrocatalyst is fabricated by in-situ solution immersion of electrodeposited Cu cone arrays on foam for efficient and stable formaldehyde selective oxidation reaction to co-produce hydrogen and valuable formate. Benefitting from the partially mixed Cu2+1O in metallic copper and concomitant production of defect rich oxygen vacancies, only 0.04 VRHE is required for electrocatalytic FOR at 100 mA·cm−2 under alkaline conditions. FOR current density of CF-Cu@Cu2+1O/Cu electrode exhibits 2.35 times than that of CF-Cu (144 mA·cm−2) and 77 times than that of copper foam (4.4 mA·cm−2) at 0.5 VRHE. Moreover, the special pinecone-shaped structure is constructed to modify Cu-based catalysts with substantially enhanced stability. A FOR-HER co-electrolysis device of CF-Cu@Cu2+1O/Cu(+)||Pt/C(−) can achieve bipolar H2 production with an approaching 200 % Faradaic efficiency, requiring an extremely low electrical energy consumption of only ∼ 0.35 kWh per m3 of H2 and potential of 0.291 V at 100 mA·cm−2 at room temperature.

Synergistic uranium extraction, organic degradation, and electricity generation by a self-driven photoelectrochemical system with TNR/Si PVC photoanode and copper foam cathode

Synergistic uranium extraction, organic degradation, and electricity generation by a self-driven photoelectrochemical system with TNR/Si PVC photoanode and copper foam cathode

Synthesis and Optimization of Foam Copper-Based CoMnOx@Co3O4/CF Catalyst: Achieving Efficient Catalytic Oxidation of Paraxylene.

This study successfully developed a foam copper (CF)-based CoMnOx@Co3O4/CF composite catalyst, achieving efficient thermal catalytic oxidation of paraxylene through multifactor optimization of synthesis conditions. At a Co:Mn molar ratio of 2:1 and a calcination temperature of 450 °C, the catalyst exhibited outstanding catalytic performance, with a T90 temperature as low as 246 °C, significantly lower than that of catalysts synthesized under other conditions. Additionally, BET, XPS, Raman, EPR, and H2-TPR test results indicate that the catalyst possesses a high specific surface area, abundant oxygen vacancies, a distribution of multivalent Co and Mn species, and a lower hydrogen reduction temperature, all of which contribute to the high catalytic activity of CoMnOx@Co3O4/CF. Furthermore, in situ DRIFTS confirmed that the oxidation of paraxylene on CoMnOx@Co3O4/CF follows the Mars-Van Krevelen (MvK) mechanism. The proposed reaction pathway begins with the oxidation of the methyl group on paraxylene, followed by the opening of the benzene ring and further oxidation to CO2 and H2O. The innovative structural design and excellent catalytic performance of this catalyst provide new insights and solutions for the industrial treatment of VOCs.

An experimental and comparative study on passive and active PCM cooling of a battery with/out copper mesh and investigation of PCM mixtures

The carbon emission contribution to global warming accelerated both research on and transition to electric vehicles (EVs). Drivers demand high power, fast acceleration and less charging times. All these demands require high C rate charging/discharging demands from batteries. The rate of heat generation is exponentially proportional to C rates which decreases battery lifetime and may lead to thermal runaway. However, a battery thermal management system decreases thermal runaway risk and decelerates battery degradation via controlling battery temperature. In this paper, we first document the thermal conductivity enhancement via copper foam into phase change material (PCM) domain to uncover their possible use in EV thermal management applications. Maximum 15.93 times increment is achieved with a specific copper foam. Then, physical properties and behaviors of distinct PCM mixtures are documented. Homogeneity of mixtures is associated with the chemistry of PCMs and the mixture melting point is proportional to the volume weighted average of melting temperatures. The results document that the PCM with relatively lower melting point is beneficial when end of discharge temperatures considered, except for high discharge rate of 2C. Temperature uniformity across the battery increases with relatively higher melting point PCM. Experiments also document that the amount of PCM volume lost via insertion of copper foam yields higher end of discharge temperatures. Overall, both PCM and copper foam enhances temperature homogeneity and their benefit becomes more sensible during drive cycles relative to continuous charge/discharge use cases.

Performance optimization of hydrogen storage reactors based on PCM coupled with heat transfer fins or metal foams

Metal hydride is a type of solid hydrogen storage material that offers excellent hydrogen absorption and desorption reaction properties. However, there is a strong thermal effect during the reaction process when the materials are applied in reactors. Thus, effective thermal management techniques are crucial for promoting efficient reactions. Prior studies on the subject have shown that phase change materials can be coupled with metal hydride reactors to transfer the reaction heat. To further enhance the transfer of heat and reaction efficiency of the metal hydride reactors based on phase change materials, this study explored heat transfer enhancement methods on the phase change materials side, including adding heat transfer fins and discussing the fin parameters and composite foam metal. The findings of the study showed that in comparison to the reactor without fins, the absorption rate of adding 10 sets of fins can increase by 28%, and as the number of fins increased to 14, this value could increase to 39.4%. The use of Y-shaped fins did not substantially improve the reaction rate, mainly due to the sufficient number of straight fins, and the heat transfer area reaching the limit of the fin enhanced the process of heat transport. Thus, the improved method of using copper foam is further considered. Compared with the reactor with and without fins, the absorption rate of the copper foam coupled reactor is increased by 23.4% and 61.3%, respectively.

Growth of zinc oxide nanowires by a hot water deposition method.

Recently, various methods have been developed for synthesizing zinc oxide (ZnO) nanostructures, including physical and chemical vapor deposition, as well as wet chemistry. These common methods require either high temperature, high vacuum, or toxic chemicals. In this study, we report the growth of zinc oxide ZnO nanowires by a new hot water deposition (HWD) method on various types of substrates, including copper plates, foams, and meshes, as well as on indium tin oxide (ITO)-coated glasses (ITO/glass). HWD is derived from the hot water treatment (HWT) method, which involves immersing piece(s) of metal and substrate(s) in hot deionized water and does not require any additives or catalysts. Metal acts as the source of metal oxide molecules that migrate in water and deposit on the substrate surface to form metal oxide nanostructures (MONSTRs). The morphological and crystallographic analyses of the source-metals and substrates revealed the presence of uniformly crystalline ZnO nanorods after the HWD. In addition, the growth mechanism of ZnO nanowires using HWD is discussed. This process is simple, inexpensive, low temperature, scalable, and eco-friendly. Moreover, HWD can be used to deposit a large variety of MONSTRs on almost any type of substrate material or geometry.

Design and preparation of composite bipolar plates with synergistic conductive networks of graphite and metal foam

Graphite composite bipolar plate (BP) have limited conductivity, which makes them less than ideal for extensive application in proton exchange membrane fuel cell (PEMFC). In traditional graphite composite BP, the construction process of the conductive network is entirely random. To enhance conductivity, it is typically necessary to increase the content of conductive fillers or incorporate high aspect ratio carbon nanomaterials to optimize the density of the conductive network. In this work, we manufactured a highly conductive composite bipolar plate with synergistic conductive networks of graphite and metal foam (MF). With a synergistic conductive network, the ASR of CuG80-20ppi decreased to 7.7 mΩ cm2. Additionally, thermal conductivity increased to 24.76 W/(m·K), and in-plane conductivity reached 294.1 S/cm at 80 wt% mass fractions of conductive filler, using 20 ppi copper foam as the metallic conductive network. CuG80-20ppi exhibited a flexural strength of 52.2 MPa. G80 and CuG80-20ppi have the 80 wt% conductive filler and are molded into BP with parallel flow fields. CuG80-20ppi enhances the current density of PEMFC by 0.132 W/cm2 and reduces the ohmic impedance by 5.25%. Therefore, the findings of this study offer valuable insights for the enhancement of composite BP conductivity, while simultaneously ensuring the stability and continuity of the synergistic conductive network. A novel approach is presented to enhance the electrical conductivity of graphite composite bipolar plate (BP) for proton exchange membrane fuel cells (PEMFCs). By embedding metal foam as a supplementary conductive network within the graphite matrix, a synergistic conductive architecture is achieved. This innovation significantly reduces the area specific resistance (ASR) to 7.7 mΩ cm2 and boosts thermal conductivity to 24.76 W/(m·K). The resulting CuG80-20ppi BP, with 80 wt% conductive filler, exhibits improved mechanical strength and conductivity, contributing to a 0.132 W/cm2 increase in PEMFC current density and a 5.25% reduction in ohmic impedance. This work highlights the potential of metal foam integration to enhance BP conductivity and PEMFC performance.

Heat transfer and pressure drop comparison for corrugated tube and different numbers of copper foam cylindrical inserts in laminar flow

Heat transfer and pressure drop comparison for corrugated tube and different numbers of copper foam cylindrical inserts in laminar flow

Understanding the impact of nickel coating on the mechanical and corrosion behaviour of copper foams

ABSTRACT This study used a sponge replication technique to fabricate open-cell copper (Cu) foams with varying pore sizes. Nickel coating was applied via electrolysis to produce nickel-copper (NiCu) foams to enhance the Cu foams' energy absorption efficiency and corrosion resistance. The foams were characterized under static conditions to assess their compressive and corrosion properties. The nickel coating improved compressive strength by increasing foam strut thickness and reducing defects, as observed via scanning electron microscopy (SEM). The 10 Pores per inch (PPI) NiCu foam shows a substantial increase in compressive strength, close to 17.7%, compared to the 10 PPI Cu foam, resulting in a maximum compressive strength of 11.3 MPa. Similarly, 20PPI NiCu foam shows an increase of compressive strength of 20% when compared to 20 PPI Cu foam. NiCu foams significantly reduced corrosion current density compared to uncoated Cu foams, indicating enhanced corrosion protection from the nickel coating.

Investigation on the microstructure and compressive behavior of open-cell copper- Al2O3 composite foams

The objective of this study is to evaluate the mechanical behavior and energy absorption characteristics of open-cell copper- Al2O3 composite foams fabricated using polyurethane foam with an average pore size of 1.2 mm and a combination of electroless and electrodeposition methods. During electroplating process, the composite foams were fabricated with varying amounts of Al2O3 particles (0.1, 0.6, 0.8, and 1 g/l) in electrolyte solution. To assess mechanical properties of the fabricated foams, uniaxial compression test was conducted to determine the maximum compressive strength, energy absorption density, efficiency, and specific energy absorption. The content of Al2O3 in the fabricated composite foams was evaluated using energy dispersive X-ray (EDX) analysis, and the microstructure was examined using scanning electron microscopy (SEM). The results indicate that the incorporation of Al2O3 particles significantly improves the mechanical properties of the copper-Al2O3 composite foam. Specifically, in the composite foam with 9.34 vol% of Al2O3 particles, the maximum compressive strength, total energy absorption, specific energy absorption, and energy absorption efficiency reach 1.03 MPa, 6.48 MJ m−3, 1.9 J g−1, and 75%, respectively. This amount of alumina particles enhances the maximum compressive strength and total energy absorption of open-cell copper foam by approximately 30% and 100%, respectively. However, the mentioned parameters slightly decreased with an increasing amount of Al2O3 particles up to 16.32 vol%. These significant improvements in the mechanical properties of these foams make them well-suited for high-strength applications.

Enhancing heat dissipation for laser illumination by utilizing the phosphor in metal combined with vapor chamber (PiMCVC)

Laser-driven illumination has unique advantages in high-power applications. However, the low thermal conductivity of the phosphor converter and high-power density of the laser result in a serious heat dissipation problem. Although the thermal conductivity has been improved in the previous work, the heat transferred from the facula cannot be further dissipated. Herein, a phosphor in metal combined with vapor chamber (PiMCVC) was proposed. A copper foam skeleton structure (CFSS) coated with boron nitride (BN) was welded to an ultra-thin vapor chamber (UTVC). The heat dissipated from the facula can be transferred through the CFSS. The heat dissipation area is significantly enlarged by the UTVC. The facula central temperature of PiMCVC can be maintained below 107.0 °C under a load of 4.92 W while that of the reference sample is 530.18 °C. Even at a laser load of 11.58 W, the PiMCVC can still work normally with a luminous flux of 1568.37 lm. Due to the superior thermal management, under the laser power of 9.20 W, the PiMCVC sample can be stably operated for 720 min with a luminous flux of approximately 1150 lm and a CCT of about 4000 K. This work provides a new approach to the thermal management of high-power laser-driven illumination.

Facile preparation of three-dimensional copper foam incorporated with Au/CuO nanorods as a durable, reusable and efficient SERS substrate

An exceptionally durable and recyclable three-dimensional copper foam (CF) modified CuO nanorods with Au nanostructures on its surface is noticeable for the application in surface-enhanced Raman scattering (SERS). The utilization of CF as a 3D frame substrate allowed for the advancement of its beneficial characteristics, such as an increased surface-active area resulting from its high porosity and superior chemical/physical stability. By thermally oxidizing CF at a temperature of 500 °C, CuO nanorods were fabricated directly onto CF to exploit its advantageous properties, such as its high surface-active area and photodegradation effect. Following that, Au nanostructures were deposited onto the surfaces of CuO nanorods via photoreduction. The purpose of incorporating Au nanostructures was to optimize the SERS phenomenon, since Au exhibits high SERS efficiency and excellent surface stability. The Au/CuO@CF SERS substrate demonstrated the capability to measure MB at a concentration of 0.1 nM. Meanwhile, the recyclability of the Au/CuO@CF was evaluated by subjecting it to UV irradiation three times while utilizing MB samples. Subsequently, the Au/CuO@CF substrate's physical durability was evaluated via sandpaper abrasion test. In addition to confirming the long-term usability, the Au/CuO@CF demonstrated its resilience by maintaining good measurement performance even after being subjected to ambient air for up to 25 days.

Construction of 0-dimensional silver quantum dot/MoSe2@MXene/3-dimensional porous copper foam composite electrodes with heterogeneous interfaces for synergistic electrocatalytic degradation of antibiotics

This study proposes a novel and efficient Ag quantum dots (QDs)/MoSe2@two-dimensional transition metal carbide/nitride (MXene)/copper foam (CF) composite electrode to address the challenge of electrocatalytic degradation of antibiotics in water. The electrode formed a unique electron donor–acceptor system by loading Ag QDs and heterostructured nanosheets on CF, significantly facilitating charge transfer and segregation at the interface. The catalytically active sites at the edges and defective locations of MoSe2 in conjunction with the two-dimensional MXene structure, which formed an efficient electron transfer channel, promoted the electron transfer from the interior to the surface and accelerated the hydrogen adsorption and reduction reactions. Moreover, the charge redistribution at the interface of Ag QDs and MoSe2@MXene formed interfacial dipoles, increasing the active sites on the catalyst surface and promoting the generation of cathodic atomic hydrogen (H*). Under optimal conditions, the degradation rate of tigecycline (TGC) reached as high as 90.1 % ± 2.4 % within 60 min. The anode-generated OH and HClO, along with the cathode-generated H, further promoted the degradation of TGC through co-catalysis. The degradation pathways were analyzed using density-functional theory (DFT) calculations and liquid chromatography-mass spectrometry (LC-MS) techniques. Moreover, toxicity analysis of the degradation products was carried out to ensure the safety of the treated wastewater discharge. A reflux continuous effluent reactor was also designed to achieve high degradation efficiency and low energy consumption after stable operation, laying the foundation for industrial applications. This technology provides new ideas for the design of green, efficient, stable, and low-consumption electrocatalytic reactors and contributes to a sustainable future environment.

Role of two isothermal cylinders towards three-dimensional flow and melting of phase-change materials

Recently, investigators focused on examining the melting of phase change materials (PCM) in regular two-dimensional or three-dimensional flow domains. At the same time, this topic still needs more study to get a better understanding of it. Also, such problems should be reported using the local thermal non-equilibrium (LTNE) model because the latent heat substances and the included porous elements have different temperatures. Therefore, this study examines the three-dimensional flow and melting process of phase change materials (PCM) within cubic enclosures filled with copper foam, using a local thermal non-equilibrium model (LTNE). The system includes two isothermal cylinders with different temperature conditions, varying distances, and radii, placed within the flow domain. The enthalpy-porosity approach is applied to model the PCM behavior, while the Brinkman-extended non-Darcy model accounts for high-velocity flow situations. A magnetic field is introduced to control the flow, with the Lorentz force acting opposite to gravity. The governing equations are solved using a home-developed code based on the finite volume method with the SIMPLE algorithm. Key parameters investigated include cylinder radii, Fourier number, Hartmann number, horizontal and vertical distances between cylinders, and Darcy number. The results are presented through streamlines, temperature distributions for fluid and solid phases, and profiles of the Nusselt number and average liquid fraction.

Enhanced thermal performance and stability of non-gallium liquid metal composites

This paper presents a study on the thermal performance and stability of non-gallium liquid metal (BiPbInSnCd alloy with melting point 47 °C) composite. It has been found that incorporating copper particles and copper foam into the non-gallium liquid metal can help to enhance the overall thermal conductivity, and achieved longer lifetime than gallium-based liquid metal composite. We have demonstrated that the average thermal conductivity of non-gallium liquid metal composite with filler weight ratio of 44.4 % can reach as high as 28.9 W·m−1·K−1. The improvement mechanism and the impact of preparation methods on the thermal performance have been also investigated.

Boosted direct electrochemical reduction of As(III) from arsenic wastewater via Cu(II)-assisted codeposition on a CuIn alloy electrode

Arsenic contamination is a severe environmental problem. A promising strategy for addressing this issue is the direct conversion of highly toxic As(III) to less toxic elemental arsenic (As(0)) using electrochemical reduction technology. In this study, a novel CuIn alloy nanoparticles-modified copper foam (CuIn NPs/CF) was prepared as an efficient cathode for the electrocatalytic reduction of highly mobile As(III) to solid As(0). Density functional theory (DFT) results revealed that the Cu-In bimetallic system exhibited weaker H atom bonding, and the Cu-ln surface was more favorable for the adsorption of *AsO₃ species than the Cu surface. Compared to the pristine CF electrode, CuIn NPs/CF was demonstrated to effectively suppressed the hydrogen evolution reaction with an enlarged hydrogen evolution potential of 1.45 V, and displayed a superior As(0) recovery yield. The conversion of As(III) to As(0) was further enhanced by adding Cu²⁺ to the electrolyte, facilitating a Cu-As co-deposition process. Notably, the CuIn NPs/CF electrode achieved an As(0) recovery yield of 5.38 mg cm⁻² after eight successive recycling tests. This work not only presents a green and sustainable strategy for As(III) removal, but also provides valuable insights into the rational design of Cu-based alloy cathodes for electrocatalytic reduction.

Electrochemical hydrogen storage using SrFe12O19 surface-immobilized polyoxometalate

A tri-nickel substituted Keggin-type polyoxometalate (PMo9Ni3O37) was synthesized and subsequently immobilized on the surface of the M-type strontium hexaferrite (SrFe12O19) via the sol-gel method. The investigation of hydrogen storage capacity for the synthesized PMo9Ni3O37@SrFe12O19 nanocomposite was conducted through electrochemical methodologies employing chronopotentiometry (CP). A conventional three-electrode configuration employing copper foam coated with PMo9Ni3O37@SrFe12O19 served as the working electrode and was examined across a current range of ±1.5 mA. The charge and discharge of the experimental procedure indicated the substantial potential of the PMo9Ni3O37@SrFe12O19 nanocomposite in the hydrogen storage process, which was determined 3125 mAh/g during the discharge phase. The successful synthesis was corroborated thorough FT-IR, UV-vis, XRD, SEM, EDX, and BET surface area analysis techniques by examining the characteristic absorption wavelengths or reflection patterns. The size of the nanoparticles was determined through SEM analysis yielding a diameter of 36.76 nm, and using the Scherrer equation, a diameter of 29.22 nm was obtained.

Elimination of Methyl Orange Dye with Three Dimensional Electro-Fenton and Sono-Electro-Fenton Systems Utilizing Copper Foam and Activated Carbon

Elimination of Methyl Orange Dye with Three Dimensional Electro-Fenton and Sono-Electro-Fenton Systems Utilizing Copper Foam and Activated Carbon