Exceptional Resistance Research Articles

Room temperature gas sensors for NH3 detection based on the heterojunction of 2D Ti3C2Tx MXenes and Bi2S3.

Bi2S3/Ti3C2Tx nanomaterials were successfully prepared through a simple hydrothermal method. Various methods were used for their characterization, including XRD, XPS, SEM, EDS, and BET, along with testing their gas-sensing properties. The results showed that the response value to 100ppm ammonia at room temperature reached 107%, which was 14.1 times higher than that of pure few-layer MXene. After undergoing anti-humidity interference testing, we observed that Bi2S3/Ti3C2Tx exhibited a higher response value in real-time monitoring of ammonia as humidity increased. Specifically, under 90% humidity conditions, its response value reached 1.32 times that of normal humidity conditions. This exceptional moisture resistance ensures that the sensor can maintain stability, and even exhibit superior performance, in harsh environments. Therefore, it possesses excellent selectivity, high-moisture-resistance, and long-term stability, making it significant in the field of medical and health monitoring.

Donor–π bridge-acceptor dyes featuring dual chromophoric groups for enhanced sensitivity in wearable sweat sensor

The pH value of human sweat serves as a crucial biomarker for disease diagnosis, rendering wearable sweat sensors an innovative tool for monitoring human health. However, the commercialization of these devices is seriously impeded by their low sensitivity, poor wearing comfort, and limited reusability. In this work, a reactive dye capable of color change under pH change has been synthesized. Due to the unique molecular structure, the dye molecule exhibits remarkable color change recognition and high sensitivity. To fabricate a wearable pH sensor, screen printing technology was employed for depositing the color-changing dye onto cotton fabric. The resulting sensor demonstrated excellent performance attributes including high color sensitivity, robust cyclic stability in response to pH changes, and exceptional resistance against washing, friction, and sunlight-induced fading. Therefore, this study presents a highly promising approach for achieving real-time monitoring of human sweat pH levels.

Investigation on Water Erosion Behavior of Ti-based Metal Matrix Composite: Experimental Approach

Wet steam flow produces big water droplets in the low-pressure zone of a steam turbine blade. These droplets clash with subsequent blades, resulting in a strong impact that is evident as erosion. Titanium and its alloys are valuable for technical applications such as turbine blades because of their low density, high strength, and exceptional corrosion resistance. The boron carbide(B4C) has a high hardness but a low strength; therefore, it's exciting to investigate water erosion of Ti/ B4C and SiC combination. The effect of 1 wt% B4C and 1, 3, 5, and 7 wt% SiC particles on water droplet erosion of Ti composite was studied using the SPS method for 5 minutes at 1200 oC temperature and 50 MPa pressure. The L9 orthogonal array with four levels of parameters of the Taguchi method is used to conduct the experiments. By measuring the weight of the specimen at interval time, the erosion behavior with time is obtained with different nozzle diameters. The effect of material and experimental parameters on erosion resistance is studied, and an empirical relation is developed.

Glass catfish inspired subaquatic abrasion-resistant anti-fouling window fabricated by femtosecond laser electrodeposition

Abstract Transparent materials utilized as underwater optical windows are highly vulnerable to various forms of pollution or abrasion due to their intrinsic hydrophilic properties. This susceptibility is particularly pronounced in underwater environments where pollutants can impede the operation of these optical devices, significantly degrading or even compromising their optical properties. The glass catfish, known for its remarkable transparency in water, maintains surface cleanliness and clarity despite exposure to contaminants, impurities abrasion, and hydraulic pressure. Inspired by the glass catfish's natural attributes, this study introduces a new solution named subaquatic abrasion-resistant and anti-fouling window (SAAW). Utilizing femtosecond laser ablation and electrodeposition, the SAAW is engineered by embedding fine metal bones structures into a transparent substrate and anti-fouling sliding layer, akin to the sturdy bones among catfish’s body. This approach significantly bolsters the window's abrasion resistance and anti-fouling performance while maintaining high light transmittance. The sliding layer on the SAAW’s surface remarkably reduce the friction of various liquid, which is the reason that SAAW owns great anti-fouling property. The SAAW demonstrates outstanding optical clarity even after enduring hundreds of sandpaper abrasion, attributed to the fine metal bone structures bearing all external forces and protect the sliding layer of SAAW. Furthermore, it exhibits exceptional resistance to biological adhesion and underwater pressure. In a green algae environment, the window remains clean with minimal change in transmittance over one month. Moreover, it retains its wettability and anti-fouling properties when subjected to a depth of 30 meters of underwater pressure for 30 days. Hence, the SAAW prepared by femtosecond laser ablation and electrodeposition presents a promising strategy for developing stable optical windows in liquid environments.

Preparation and Electrochemical Applications of Magnéli Phase Titanium Suboxides: A Review.

Magnéli phase titanium suboxides (M-TSOs) belong to a type of sub-stoichiometric titanium oxides based on the crystal structure of rutile TiO2. They possess a unique shear structure, granting them exceptional electrical conductivity and corrosion resistance. These two advantages are crucial for electrode materials in electrochemistry, hence the significant interest from numerous researchers. However, the preparation of M-TSOs is uneconomic due to high temperature reduction and other complex synthesis process, thus limiting their practical application in electrochemical fields. This review delves into the crystal structure, properties, and synthesis methods of M-TSOs, and touches on their applications as electrocatalysts in wastewater treatment and electrochemical water splitting. Furthermore, it highlights the research challenges and potential future research directions in M-TSOs.

Porous and Conductive Fiber Woven Textile for Multi‐Functional Protection, Personal Warmth, and Intelligent Motion/Temperature Perception

AbstractIndustrialization and human activities have introduced numerous hazards, including exposure to harsh chemicals, radiation, static electricity, and fire risks, particularly in high‐risk sectors such as engineering, rescue operations, military, and aerospace. This study presents a multi‐functional protective textile developed from a conductive fiber composed of polytetrafluoroethylene (PTFE) and carbon nanotubes (CNT), crucial for ensuring personal safety. The conductive fiber demonstrates remarkable strength (17.3 MPa), high porosity (76%), and significant electrical conductivity (185 S m−1), coupled with excellent fineness and flexibility due to its dual‐nanofibrous structure. The resulting textile exhibits exceptional hydrophobicity, chemical resistance, and high electromagnetic interference shielding effectiveness (29 dB in the X‐band), alongside a superior UV protective factor (>3000) and anti‐static properties. Notably, it possesses outstanding electro/photo thermal conversion capabilities, enabling consistent heat generation for personal warmth. Additionally, the textile responds electrically to deformation and temperature changes, facilitating intelligent applications such as motion and temperature monitoring and fire alerts. This work offers a novel strategy for fabricating PTFE‐based composite fibers with porous microstructures and high electrical conductivity, setting a new standard for next‐generation protective clothing with advanced functionalities.

A Multielectron and High-Potential Spirobifluorene-Based Posolyte for Aqueous Redox Flow Batteries.

The rising energy demand driven by human activity has posed pressing challenges in embracing renewable energy, necessitating advances in energy storage technologies to maximize their utilization efficiency. Recent studies in aqueous organic redox flow batteries have focused primarily on the development of organic negative electrolytes, while the progress in organic positive electrolytes remains constrained by limitations in their redox potentials and effective electron concentrations. Herein, we report a spatially twisted chlorinated spirobifluorene ammonium salts (CSFAs), created through an unexpected green chlorination-protection pathway during the initial cycling in the flow battery cell, utilizing chloride ions from counterions in aqueous solution. The chlorinated, nonplanar spiral structure of CSFAs possesses a one-step four-electron transfer electrochemical property and offers exceptional resistance to nucleophilic attacks, exhibiting an unprecedented redox potential as high as 1.05 V (vs. SHE). A full redox flow battery based on CSFA-Cl (chloride ions as the counter ions) with 1.4 M electron concentration achieved an average coulombic efficiency exceeding 99.4 % and a capacity utilization reaching 95 % of the four-electron capacity for a stable cycling over 250 cycles (~22 days). The present work exemplifies the use of side reactions to develop new redox species, which can be extended to create more structurally versatile energy storage materials.

Novel insights into the synthesis and tribo-mechanical performance of high-entropy (Hf0.2Zr0.2Ti0.2W0.2Mo0.2)B2 ceramics

High-entropy (Hf0.2Zr0.2Ti0.2W0.2Mo0.2)B2 ceramics were synthesized using a two-step spark plasma sintering process, with densification at 1600 °C followed by sintering at 1850 °C. This method produced dense materials with excellent mechanical and tribological properties. Hardness values ranged from 18.85 GPa to 39.65 GPa, with a maximum Young’s modulus of 319 GPa. Micro-scratch tests showed high resistance to plastic deformation and minimal surface damage, highlighting durability under mechanical stress. Tribological tests at 15 N and 20 N loads demonstrated exceptional wear resistance, attributed to hard primary phases and lubricating soft secondary phases. These findings confirm the material’s robustness and show the effectiveness of the two-step synthesis in optimizing microstructure and enhancing properties, making it suitable for high-stress and wear-intensive applications.

Harnessing carboxymethyl cellulose as eco-binder to transform polyester textile waste into high-performance fire-resistant thermal insulation panels

This study aims to investigate the applicability of carboxymethyl cellulose (CMC) as a binder in insulating panels made from polyester textile waste (PTW), which is the most produced textile waste worldwide. This combination addresses the pressing need to recycle a widely manufactured material while introducing CMC as an environmentally friendly solution for elaborating panels with excellent thermal insulation and fire resistance. The composite panels were manufactured using compression molding process. The resulting thermal insulation panels demonstrate excellent thermal conductivity values, ranging from 0.0499 to 0.0514 W/m.K, comparable to established insulation materials. Panels with increased CMC content show remarkable mechanical strength, with compressive strengths of 217 kPa and 351 kPa for samples S4 and S5, respectively, and a flexural strength of 1.58 MPa for sample S5. This emphasizes that CMC as a binder helps distribute stresses more evenly across the composite, leading to higher strength and stiffness. Furthermore, employing CMC in the composite preparation confers exceptional resistance to flame propagation, namely, samples S4 and S5 exhibited immediate self-extinguishing properties and resistance to flame propagation. Accordingly, the mechanism behind CMC ability to resist flame propagation was investigated. Despite the composite's remarkable characteristics, its water sensitivity remains a disadvantage. Therefore, this shortcoming has been addressed highlighting several strategies that can be employed to mitigate CMC sensitivity to water including applying a waterproof coating to improve the composite humidity and water resistance increasing its overall durability.

Comparative Genomics of Eight Complete Chloroplast Genomes of Phyllostachys Species

(1) Background: The genus Phyllostachys belongs to the subfamily Bambusoideae within the family Gramineae. Bamboos of this genus are distinguished by their remarkable genetic traits, including exceptional resistance to both cold and drought conditions. These species possess considerable economic, ecological, and aesthetic value, finding extensive use in forestry and landscape design across China. (2) Methods: This study employed Illumina’s second-generation sequencing technology to sequence the chloroplast genomes of eight Phyllostachys species, followed by their assembly and annotation. (3) Results: The chloroplast genomes of the genus exhibit a characteristic tetrad structure with an average sequence length of 139,699 bp and an average GC content of 38.9%. A total of 130 genes have been annotated across eight bamboo species, comprising 75 protein-coding genes, 28 tRNA genes, and four rRNA genes. Global alignment and nucleotide polymorphism analyses indicate that the chloroplast genome of Phyllostachys is highly conserved overall. The boundaries of the four chloroplast regions are relatively conserved and exhibit minimal differences. Among these regions, three coding region genes—atpH, trnQ-UUG, and petB—and five non-coding regions—rpl32-trnL-UAG, rpl14-rpl16, rpl22-rps19, rps12-clpP, and trnR-UCU-trnM-CAU—exhibit high polymorphism and can be used as potential hotspot areas for subsequent research. A total of 266 simple sequence repeat (SSR) loci were identified by SSR analysis in the chloroplast genomes of eight bamboo species; the largest number of mononucleotide repeats was 154, predominantly consisting of A/T. Codon bias in the chloroplast genomes of the eight bamboo species indicates a preference for codons ending with A and U. Additionally, the UUA codon, which encodes leucine (Leu), is positioned between codons encoding phenylalanine (Phe), lysine (Lys), leucine (Leu), serine (Ser), and tyrosine (Tyr), indicating certain differences among these species. (4) Conclusions: This study aims to offer novel insights into the population genetics, phylogenetic relationships, and evolutionary patterns of Phyllostachys.

Development of genetically modified rust resistant wheat: A breakthrough by dinted introgression of novel DREB2C and HSFA2 genes under stress induced expression

Wheat is a major staple food worldwide yet numerous yield limiting agents affect its productivity. Stripe rust is a major culprit in this context and efforts have been made to culminate this pathogen using conventional as well as advanced innovative techniques. Transgenic technology is of significant importance in this context and numerous success stories are evident to prove its worth. In the current study, two novel genes HSFA2 and DREB2C were expressed in an elite wheat genotype Akbar, Fakhre-e-Bhakhar under constitutive CAMV35S promoter and stress inducible rd29 Promoters. The shoot cut method was used for the Agrobacterium-mediated transformation and putative transformants were selected on kanamycin 50 mg/L. The resultant transformants were tested through PCR for transgene integration whereas expression analysis was carried out through realtime qPCR. Expression of both of the aforementioned genes was found to be higher under rd29 promoter as compared with transgene(s) expression under CAMV35S promoter. In the bioassay, transgenic wheat plants demonstrated significant tolerance to stress, exhibiting only minor spotting under constitutive expression conditions. Upon exposure to stress, these plants showed exceptional resistance to stripe rust, producing large, bold grains compared to individual trait expressions and negative controls. Subsequently, the DREB2C gene was knocked out to determine if stripe rust control was specifically attributed to this gene. Following the knockout, the onset of stripe rust was comparable to that of the negative control. This led to the conclusion that pyramiding the DREB2C gene with HSFA2 through dual expression represents a novel and highly effective strategy for controlling the widespread stripe rust in wheat. This approach also offers resistance to high temperatures (above 32 °C) from the pollination stage through to maturity.

Thermal reaction based mesoscale ablation model for phase degradation and pyrolysis of needle-punched composite

Needle-punched composites are highly valued for their exceptional resistance to interlaminar properties, ablation, and design flexibility, making them increasingly popular in aerospace thermal protection systems. This work investigates the mesoscale structural characteristics and thermophysical properties of needle-punched composites in ablation process. Oxyacetylene ablation experiments were carried out at different temperatures, and a mesoscopic needle-punched structure model was established based on the results of CT characterization. Further, Abaqus custom subroutine was used to reveal the ablation evolution mechanism of carbon fiber reinforced phenolic resin-based needle-punched composites. The results show that, at mesoscopic scale, the acicular fiber bundle perpendicular to the ablative surface accelerates the heat conduction to the interior of the material and promotes the thermal damage and performance degradation of the composite.

Co-evolution of M23C6 precipitates and cavities in a boron-free Ni-based alloy GH3617 under high-temperature He ion irradiation: Effects on cavity swelling and mechanical properties

Ni-based alloys are promising materials for advanced nuclear reactors operating at high temperatures due to their exceptional resistance to high temperatures and corrosion. Understanding the synergy of phase stability and helium effects is crucial for assessing the long-term performance and reliability of these alloys in advanced nuclear reactors. This study has investigated the co-evolution behavior of M23C6 precipitates and cavities in a boron-free solid solution strengthened Ni-based alloy GH3617 under high-temperature He ion irradiation, and its impact on alloy swelling and mechanical properties, by He ion irradiation experiments with the highest fluence of 1 × 1017 He/cm2 up to 800 °C. Transmission Electron Microscopy (TEM) and Nanoindentation are employed to investigate microstructural evolution and mechanical properties, respectively. The findings show that at room temperature and 500 °C, cavities and dislocation loops were the dominant irradiation defects, whereas at 800 °C, the density of cavities and dislocations reduced while the formation of M23C6 precipitates increased. These precipitates act as effective trapping sites for He and point defect, leading to cavity formation at the interfaces or within the precipitates. Moreover, increased irradiation fluence accelerates the co-evolution process, resulting in an increase in the density and size of both precipitates and cavities, ultimately leading to enhanced swelling. The {111} planes are favored interfaces between intragranular M23C6 precipitates and the matrix due to their minimal misfit, while the preferred interface planes between cavities with octahedral or cubo-octahedral shapes and the precipitate/matrix are also {111}, owing to their lower surface energy as well. The co-evolution of cavities and precipitates was found to influence mechanical properties, resulting in an irradiation hardening effect at lower fluences, while softening at higher fluences. This study provides novel insights into the degradation mechanisms of Ni-based alloys under coupling effect of He and high-temperature irradiation.

Enhancing the conductivity and dispersion properties of polyaniline using ethyl orange

In our research, we developed a novel one-step synthesis method for polyaniline (PANI) using the organic dye Ethyl Orange (EO). This method facilitated the formation of PANI nanorods and significantly enhanced their electrical conductivity, achieving up to 13.5 S cm−1. The structural interaction between EO and PANI was confirmed through Fourier-transform infrared (FTIR) and UV–visible (UV-Vis) spectroscopy. Notably, the inclusion of EO improved PANI's dispersion properties, resulting in a zeta potential of 34 mV in water and excellent dispersibility in various organic solvents. These attributes significantly enhance the application potential of PANI nanorods, especially in protective coatings. Electrochemical impedance spectroscopy (EIS) analysis revealed that EO-PANI/WPU coatings (0.5 wt% EO-PANI) exhibited exceptional electrochemical stability and corrosion resistance in a 3.5 wt% NaCl solution. Specifically, the initial impedance magnitude (Zf=0.01 Hz, 1010 ohms) of EO-PANI/WPU coatings was approximately two orders of magnitude higher than that of traditional WPU coatings (108 ohms). Over time, the EO-PANI coatings demonstrated higher phase angles and impedance, indicating superior electrochemical stability and protective performance.

Advancements of biomaterial in hip replacement technology incorporating ceramic materials

The increasing prevalence of hip joint diseases is closely linked to improved living standards and an aging population, leading to a rise in conditions like degenerative arthritis and severe hip injuries. These conditions cause significant pain and functional impairments, greatly reducing the quality of life for affected individuals. Total hip arthroplasty (THA) has become a well-established surgical intervention to address these debilitating conditions. Within the realm of hip replacement materials, ceramics have garnered attention for their exceptional wear resistance and ability to minimize complications, such as bone dissolution caused by wear particles. Ceramics, such as alumina and zirconia, offer biocompatibility and low wear rates, making them favourable choices for hip prostheses. However, despite these advantages, the use of ceramics in hip replacements is not without challenges. Issues such as ceramic fragmentation and abnormal joint noise have been noted, posing significant obstacles to their widespread adoption. This review explores the advancements in hip replacement technology with a particular focus on ceramic materials. It delves into the properties that make ceramics suitable for this application, such as their biocompatibility and mechanical strength, enhanced through advanced manufacturing techniques. Additionally, the review addresses the ongoing challenges, including strategies to mitigate the risk of fragmentation through material toughening and improved prosthesis design. Furthermore, it examines the phenomenon of abnormal joint noise, proposing solutions that involve refinements in implant design, surgical techniques, and post-operative patient management. The aim of this review is to provide a comprehensive overview of current advancements and future directions in the use of ceramic materials in hip replacement technology, highlighting the potential for improved patient outcomes and the need for continued research and innovation in this field.

Enhancing the performance of recyclable polyurea through coordination of rigid chain segments and graphene platelets

In response to the global focus on environmental preservation and sustainable practices, developing nanocomposites featuring recyclable and healing properties is indispensable for high-performance and long-life structures. This study presents a facile approach to develop a recyclable and thermally-induced healing polyurea (PU)/graphene platelet (GNP) nanocomposites with high mechanical properties. A straightforward synthesis method was employed using isophorone diamine (IPDA) as chain extender with rigid cyclic structure. GNPs were modified with IPDA before adding into PU, showing remarkable enhancements in mechanical performance. At 0.10 wt.% GNPs, PU nanocomposites exhibited the maximum mechanical properties, with modified GNPs (M-GNPs) significantly outperforming pristine GNPs. Specifically, the tensile strength of PU increased by 41.3 % with M-GNPs, compared to only 12 % with pristine GNPs, underscoring the critical role of modifying the reinforcing phase. Furthermore, the nanocomposites demonstrated outstanding healing capabilities, achieving 89 % healing efficiency after 24 h at 120 °C. In addition, PU/M-GNP nanocomposites showed exceptional resistance to acidic and alkaline environments in comparison to neat PU. The study not only exemplifies developing high-strength and environmentally friendly materials but also holds promise for diverse applications, including aerospace, vibration damping, and protective coatings.

Synergistic effects of graphene nanoparticles on the thermomechanical properties of PEEK-HNTs nanocomposites

In our previous study, we selected a 3% concentration (PH3) from various prepared PEEK-HNTs nanocomposites. Poly (ether ether ketone) (PEEK) is characterized by non-perfluorinated aromatic compounds with 1,4-disubstituted phenyl groups linked by carbonyl (––CO––) and ether (––O––) groups, offering exceptional thermal stability, mechanical strength, tribological properties, and chemical resistance at high temperatures. Halloysite nanotubes (HNTs) are known for their non-toxic, environmentally friendly, cost-effective properties, with tunable release and rapid adsorption rates. In this study, we prepared graphene nanoparticle (GNP) composites at three different concentrations while maintaining constant PH3 levels. The composites underwent comprehensive characterization using FTIR, TGA, DSC, SEM, and DMA techniques. Thermomechanical properties were evaluated using a universal testing machine. Results demonstrate significant enhancements in hardness, impact strength, elongation at break, tensile modulus, and flexural modulus, with the highest performance observed in the GNP-loaded 0.3% (PHG3) concentration. The synergistic effects of GNP fillers in PH3 are attributed to enhanced interfacial adhesion and favorable interactions with the polymer matrix.

Excellent radiation resistance via enforced local non-directional He diffusion in a WTaCrV multicomponent alloy containing coherent ordered nanoprecipitates

We design and investigate a W15Ta15Cr35V35 (at.%) multicomponent alloy (MCA) with exceptional radiation resistance. The sintered WTaCrV alloy exhibits a body-centered cubic (BCC) matrix with dispersed coherent ordered nanoprecipitates. After ∼3-hour irradiation under 400 keV He+ at room temperature (RT) and 450°C with a fluence of 2 × 1017 ions/cm2, the irradiation hardening values of the MCA are about a quarter of those of pure tungsten counterparts irradiated at identical conditions. Besides, helium bubbles generated in the irradiated matrix of the MCA are much smaller, compared with those in the pure tungsten and other tungsten-rich alloys previously reported. The exceptional radiation resistance of the present WTaCrV alloy can be mainly attributed to two synergistic mechanisms. First, the high lattice distortion of the solid solution matrix promotes the local non-directional diffusion of irradiation defects, effectively suppressing the aggregation of irradiation defects and helium atoms along specific orientations. This facilitates more uniform nucleation of helium bubbles in the alloy matrix. Second, carbon was introduced during fast hot pressing sintering as interstitial solute to form carbon-rich coherent ordered nanoprecipitates. The carbon-vacancy complexes generated in the nanoprecipitates inhibit the nucleation and aggregation of helium atoms at the vacancies during He+ irradiation. The above two mechanisms synergistically enhance the resistance against He+ irradiation. This work thus demonstrates a design strategy for high radiation resistance alloys by introducing well-tuned ordered coherent nanoprecipitates in multicomponent alloy systems.

Oxygen plasma-assisted magnetron sputtering deposition of non-stoichiometric Y2O3 films: Influence of oxygen vacancies on etching resistance

Yttrium oxide (Y2O3) films are widely used to protect equipment in plasma etching, a crucial technique in semiconductor processing, due to their exceptional resistance to plasma etching. Since oxygen vacancy affects the performance of Y2O3 and may impact physical etching resistance, the internal relationship necessitates further investigation. In this article, Y2O3 films with varying oxygen vacancy concentrations are prepared by reactive magnetron sputtering with the assistance of oxygen plasma. The formation and development of oxygen vacancies in cubic Y2O3 films and their impact on the physical etching resistance were investigated. The experiment results indicate that the accumulation of oxygen vacancies causes non-stoichiometry and the etching rate is significantly reduced. Combined with density-functional theory, it is revealed that oxygen vacancy distorts the lattice, which increases covalent YO bonding and the formation energy of atoms. Moreover, the vacancy line defects resulting from diffusion and aggregation of oxygen vacancies exert a similar influence on the adjacent yttrium and oxygen layers. The enhancement of physical etching resistance is attributed to the strengthened internal YO bonds led by increasing oxygen vacancy concentration in the cubic Y2O3 films without inducing phase transition. The discovery enriches the understanding of how plasma interacts with Y2O3, and the etching mechanism.

Electro-Discharge Machining of Microholes on 3d Printed Hastelloy Using The Novel Tool-Feeding Approach

Hastelloy, a nickel-based superalloy renowned for its exceptional resistance to corrosion at high temperatures, is widely used in sectors such as nuclear, aerospace, chemical processing, and pharmaceuticals. Microelectrical discharge machining (μ-EDM) is crucial for generating microholes and channels on Hastelloy. Since it effectively addresses difficulties like work hardening, high strength & wear resistance, and low thermal conductivity in traditional machining. Microholes play a major role in many critical components for precise control of fluids in fuel injectors, managing heat in turbine blades, controlled gas exchange, etc. The current research investigates the drilling of 8:1 aspect ratio microholes machined by 400μm diameter electrodes. This study investigated the influence of tool material (tungsten carbide, carbide drill bit, and brass) on μ-EDM performance. Compared to tungsten carbide and carbide drill bits, brass exhibited significantly lower electrode wear, leading to more precise microholes with reduced overcut and taper angle. However, brass also required a substantially longer machining time. Carbide drill bits offered a balance between wear resistance, machining time, and overcut/taper angle.