Fabrication Route Research Articles

Enhanced plasmonic performance of TiO2 derived TiN films via gas nitridation

This study demonstrates a cost-effective method for planar titanium nitride plasmonic film by nitriding spin-coated TiO2 in ammonia atmosphere. The effect of nitridation temperature on the structural, morphological, electrical and optical characteristics of the coated films were investigated. The films exhibited high carrier concentration of 1022/cc with significant reduction in resistivity of more than three order of magnitude, indicating the conversion to the nitride phase. Negative permittivity, crucial for plasmonic applications in the visible wavelength region, was verified for wavelengths > 463 nm using Drude-Lorentz model. A three-layer model was employed to verify the material’s plasmonic behaviour. The straightforward fabrication route, which combines spin-coating and ammonia nitridation at 950 °C, offers a new approach for titanium nitride films for plasmonic based gas and biosensing device applications in the visible region. In addition, for fabricating titanium nitride coatings for applications that require abrasion resistance, electrical conductivity, chemical stability, and biocompatibility.

Fabrication and characterization of SiC-reinforced magnesium-matrix composites with honeycomb structures and anisotropic properties

This study presents a novel approach for fabricating SiC-reinforced magnesium matrix composites by combining digital light processing (DLP) with pressureless infiltration. Pre-oxidation of SiC powder enhanced its wettability with the magnesium alloy, enabling the near-net-shape fabrication of honeycomb Mg-based composites with precisely controlled SiC and Al2O3 powder ratios. The influence of varying ceramic content on the microstructure and compressive properties of the composites was investigated, revealing significant mechanical anisotropy. A combined approach utilizing fracture morphology analysis and finite element simulations elucidated the compressive behavior and failure mechanisms of the composites under different loading directions. This work not only offers a promising route for on-demand design and fabrication of Mg-based composites but also provides valuable insights into understanding the mechanical behavior of architected composites.

Large-scale conformal synthesis of one-dimensional MAX phases

MAX phases, a unique class of layered ternary compounds, along with their two-dimensional derivatives, MXenes, have drawn considerable attention in many fields. Notably, their one-dimensional (1D) counterpart exhibits more distinct properties and enhanced assemblability for broader applications. We propose a conformal synthetic route for 1D-MAX phases fabrication by integrating additional atoms into nanofibers template within a molten salt environment, enabling in-situ crystalline transformation. Several 1D-MAX phases are successfully synthesized on a large scale. Demonstrating its potential, a copper-based layer-by-layer composites containing 1% by volume of 1D-Ti2AlC reinforced phase achieves an impressive 98 IACS% conductivity and a friction coefficient of 0.08, while maintaining mechanical properties comparable to other Cu-MAX phase composites, making it suitable for advanced industrial areas. This strategy may promise opportunities for the fabrication of various 1D-MAX phases.

Transdermal Minimally Invasive Optical Multiplex Detection of Protein Biomarkers by Nanopillars Array-Embedded Microneedles.

Biomarkers detection has become essential in medical diagnostics and early detection of life-threatening diseases. Modern-day medicine relies heavily on painful and invasive tests, with the extraction of large volumes of venous blood being the most common tool of biomarker detection. These tests are time-consuming, complex, expensive and require multiple sample manipulations and trained staff. The application of "intradermal" biosensors utilizing microneedles as minimally invasive sensing elements for capillary blood biomarkers detection has gained extensive interest in the past few years as a central point-of-care (POC) detection platform. Herein, we present a diagnosis paradigm based on vertically aligned nanopillar array-embedded microneedles sampling-and-detection elements for the direct optical detection and quantification of biomarkers in capillary blood. We present here a demonstration of the simple fabrication route for the creation of a multidetection-zone silicon nanopillar array, embedded in microneedle elements, followed by their area-selective chemical modification, toward the multiplex intradermal biomarkers detection. The utilization of the rapid and specific antibody-antigen binding, combined with the intrinsically large sensing area created by the nanopillar array, enables the simultaneous efficient ultrafast and highly sensitive intradermal capillary blood sampling and detection of protein biomarkers of clinical relevance, without requiring the extraction of blood samples for the ex vivo biomarkers analysis. Through preliminary in vitro and in vivo experiments, the direct intradermal in-skin blood extraction-free platform has demonstrated excellent sensitivity (low pM) and specificity for the accurate multiplex detection of protein biomarkers in capillary blood.

Boosted photoelectrochemical activity of anodic titanium dioxide nanotubes by electrophoretically decorated nickel–aluminum layered double hydroxide

The splitting of water using photoelectrochemical (PEC) processes is a promising method for generating renewable hydrogen. However, the practical efficiency of converting solar energy to fuel in PEC systems remains limited by inadequate light absorption and the swift recombination of photogenerated charge carriers within the photoelectrode material. In our research, we present a photoanode that addresses these challenges. In this work, we report on the electrophoretic deposition of nickel–aluminum layered double hydroxide (NiAl-LDH) under different voltages onto anodic TiO2 nanotube arrays (TNTAs) as a convenient and economically viable fabrication route of versatile and durable photoanodes. PEC and optical spectroscopy examinations, including linear sweep voltammetry, electrochemical impedance spectroscopy, Mott-Schottky plots, and diffuse reflectance spectroscopy, reveal that NiAl-LDH/TNTAs composites exhibit a superior enhancement of visible light absorption and consequently water splitting photocurrent. We interpret the improvement of PEC water splitting performance of the NiAl-LDH/TNTAs with the band structure speculated by the binding energy and the flat-band potential and band-gap measurements which features this nanocomposite as a novel photocatalyst for future hydrogen energy applications.

Realizing Dual-Mode Zinc-Ion Storage of Generic Vanadium-Based Cathodes via Organic Molecule Intercalation.

Intercalation engineering is a promising strategy to promote zinc-ion storage of layered cathodes; however, is impeded by the complex fabrication routes and inert electrochemical behaviors of intercalators. Herein, an organic imidazole intercalation strategy is proposed, where V2O5 and NH4V3O8 (NVO) model materials are adopted to verify the feasibility of the imidazole intercalator in improving the zinc storage capabilities of vanadium-based cathodes. The intercalated imidazole molecules could not only expand interlayer spacing and strengthen structural stability by serving as extra "pillars" but also provide extra coordination sites for zinc storage via the coordination reaction between Zn2+ and the C═N group. This gives rise to a dual-mode ion storage mechanism and favorable electrochemical performances. As a result, imidazole-intercalated V2O5 delivers a capacity of 179.9 mAh g-1 after 5000 cycles at 20 A g-1, while the imidazole-intercalated NVO harvests a high capacity output of 170.2 mAh g-1 after 700 cycles at 2 A g-1. This work is anticipated to boost the application potentials of vanadium-based cathodes in aqueous zinc-ion batteries.

Site-Selective Nanowire Synthesis and Fabrication of Printed Memristor Arrays with Ultralow Switching Voltages on Flexible Substrate.

Large area electronics (LAE) with the capability to sense and retain information are crucial for advances in applications such as wearables, digital healthcare, and robotics. The big data generated by these sensor-laden systems need to be scaled down or processed locally. In this regard, brain-inspired computing and in-memory computing have attracted considerable interest. However, suitable architectures have mainly been developed using costly and resource-intensive conventional lithography-based methods. There is a need for the development of innovative, resource-efficient fabrication routes that enable such devices and concepts. Herein, we present ZnO nanowire (NW)-based memristors on a polyimide substrate fabricated by a LAE-compatible and resource-efficient route comprising solution processing and printing technologies. High-resolution "drop-on-demand" and "direct ink write" printers are employed to deposit metallic layers (silver and gold) and a ZnO seed layer, needed for the site-selective growth of ZnO NWs via a low-cost hydrothermal method. The printed memristors show high bipolar resistance switching (ON/OFF ratio >103) between two nonvolatile states and consistent switching at ultralow voltages (all devices showed switching at amplitudes <200 mV), with the best performing device showing consistent cycled resistance switching over 4 orders of magnitude with SET and RESET voltages of about 71 and -57 mV, respectively. Thus, the presented devices offer reliable high resistance switching at the lowest reported voltage for printed memristors and prove to be competitive with many conventional nanofabrication-based devices. The presented results show the potential printed memristors technology holds for large-area, low-voltage sensing applications such as electronic skin.

Integrated One-Step Fabrication of Protonic Sensing Devices for Respiratory Monitoring.

The development of direct fabrication routes with seamless integration of both the macro/micropatterning process and nanostructure synthesis is crucial for the commercial realization of cost-effective nanoscale sensor devices. This, if realized, can liberate us from the conventional limitations inherent in nanoscale device manufacturing. Specifically, such fabrication routes can, in principle, address the challenges such as the complexity, multistep nature, and substantial costs associated with existing technologies, which are not suitable for widespread market adoption in everyday-use devices. Herein, we propose a novel yet facile one-step fabrication approach that simultaneously accomplishes both patterning and nanostructure synthesis by employing low-power, cost-effective laser technology with a minimal environmental footprint. Versatile in nature, this approach can enable the incorporation of diverse functionalities spanning a broad spectrum of technologies, encompassing fields such as sensors, catalysts, photonics, energy storage, and biomedical monitoring devices. As a proof of concept, using our approach, we fabricated an ultra responsive, high-speed protonic sensing device for real-time respiratory monitoring. The enhanced temporal characteristics of our as-fabricated device, particularly in the relative humidity levels of interest in breath monitoring (typically over 55%), exhibited a superior response/recovery time in rapid humidity fluctuations. We envisage that the advantages brought by the presented fabrication approach can pave the way to establish a new method for inexpensive large-scale functional-material-based device fabrication.

Design of a bifunctional prepolymer for simultaneously facile preparation and highly efficient electrodialysis of anion exchange membranes

A facile fabrication process for separation membranes is crucial to decrease the production cost, while the photo-polymerization approach can be conducted at ambient conditions with short processing time and low energy consumption. Herein, this work designs a bifunctional prepolymer for simultaneously facile preparation and highly efficient electrodialysis of poly (2,6-dimethyl-1,4-phenylene oxide) (PPO) anion exchange membranes. PPO is selected as the main skeleton of prepolymer because of the excellent mechanical and thermal stability. The dimethylaminoethyl methacrylate (DMAEMA) is grafted with brominated PPO by quaternization, where it contains cationic groups, i.e. quaternary ammonium, and photopolymerized groups, i.e. methacrylate C = C. This resulting prepolymer can be fast polymerized under UV irradiation via C = C from DMAEMA. This structure is synergistically regulated by the amounts of crosslinker DMAEMA and modifier N-bromosuccinimide. The optimized membrane exhibits an excellent ion exchange capacity of 2.19 mmol g−1, a water uptake of 38.17 %, and a tensile strength of 4.8 MPa. Meanwhile, its electrolyzer cell performance achieves a density of 580 mA cm−2 at an adjusted voltage of 2.1 V, and the desalination rate of seawater during electrodialysis reaches 98.34 %. This work provides a universal and facile fabrication route for high-performance AEMs.

Rubbing-induced site-selective deposition of 2D material patterns on nanomembranes

2D-layered materials (e.g., graphene and transition metal dichalcogenides) have attracted huge attention due to their unique mechanical and electrical properties. Emerging research efforts, which seek to combine device characterization and high-resolution electron micrography analysis for 2D-layered device features, demand nano/microlithographic techniques capable of producing ordered 2D material patterns on ultrathin membranes with nanoscale thicknesses. However, such membranes are so fragile that most conventional lithographic techniques can be hardly performed on them to generate 2D material patterns. Our previous works have demonstrated that the rubbing-induced site-selective (RISS) deposition method can produce arbitrary 2D semiconductor (e.g., MoS2 and Bi2Se3) patterns on regular device substrates. This fabrication route prevents the vulnerable 2D-layered structures from the detrimental damage introduced by plasma etching and resist-based lithography processes. In this work, we explore the applicability of RISS for directly producing 2D material patterns on nanomembranes. Specifically, this work shows that a polymeric interfacing layer on the rubbing template features, which can effectively prevent stress concentration during the rubbing process, is crucial to successful implementation of RISS processes on nanomembranes. Furthermore, we carried out the mechanics simulation of the Von Mises stress and pressure distribution on the RISS-processed membrane to identify the optimal rubbing load, which can generate sufficient triboelectric charge for material deposition but no damage to the membrane. Using this approach, we have successfully demonstrated the deposition of Bi2Se3 patterns on 25 nm SiOx nanomembranes and high-resolution transmission electron micrography characterization of the crystallographic structures.

Magnetostrictive Behavior of Severe Plastically Deformed Nanocrystalline Fe-Cu Materials

Reducing the saturation magnetostriction is an effective way to improve the performance of soft magnetic materials and reduce core losses in present and future applications. The magnetostrictive properties of binary Fe-based alloys are investigated for a broad variety of alloying elements. Although several studies on the influence of Cu-alloying on the magnetic properties of Fe are reported, few studies have focused on the effect on its magnetostrictive behavior. High pressure torsion deformation is a promising fabrication route to produce metastable, single-phase Fe-Cu alloys. In this study, the influence of Cu-content and the chosen deformation parameters on the microstructural and phase evolution in the Fe-Cu system is investigated by scanning electron microscopy and synchrotron X-ray diffraction. Magnetic properties and magnetostrictive behavior are measured as well. While a reduction in the saturation magnetostriction λs is present for all Cu-contents, two trends are noticeable. λs decreases linearly with decreasing Fe-content in Fe-Cu nanocomposites, which is accompanied by an increasing coercivity. In contrast, both the saturation magnetostriction as well as the coercivity strongly decrease in metastable, single-phase Fe-Cu alloys after HPT-deformation.

Printing High‐Quality Formanidinum Lead Triiodide Films: Understanding the Critical Role of α‐Phase Nucleation Before Thermal Annealing

AbstractUpscaling the coating of formamidinium lead triiodide (FAPbI3) thin film is essential to realizing full printing and thereby roll‐to‐roll production of perovskite photovoltaics. However, thin‐film FAPbI3 processed from antisolvent‐free, printing methods suffer from undesirable degradation to the non‐photoactive phase, particularly in ambient processing conditions. Here, the most critical stage in thin‐film processing is identified as the gas‐quenching treatment of the as‐cast wet film. It is crucial to achieve both the nucleation of α‐phase nanocrystals and their sufficient growth at room temperature, which are indispensable for templating the growth of a highly crystalline and stable α‐FAPbI3 film during subsequent thermal annealing. The gas‐quenching‐treated film without these α‐phase nanocrystals can only be converted to meta‐stable α‐FAPbI3 by thermal annealing. By precisely identifying the spontaneous doping of cesium ion (Cs+) as a key factor in triggering α‐FAPbI3 nucleation and the role of chloride ion (Cl−) in enhancing nanocrystal growth, a generalized mechanism for additive engineering for the precursor ink is theorized. The identified mechanism translates to a power conversion efficiency of 19.36% for fully printed carbon‐electrode solar cells, 16.23% for carbon‐electrode minimodules, and excellent operational stability, showing the promising potential of this proposed fabrication route in the upscaling of perovskite photovoltaics.

Diameter controlled fabrication of ultralong silicon wires through regulating metal mass in massive metal-assisted chemical vapor deposition

Abstract The successful fabrication of ultra-long silicon wires has facilitated the study and application of silicon wires. However, research on the controlled fabrication of ultralong silicon wires, such as diameter modulation, is still insufficient. Herein, tapering ultralong silicon wires are synthesized by using a massive metal-assisted chemical vapor deposition method. By altering the mass of the tin catalyst in the growth zone, the length and changing rate of the diameter can be modulated. When a 40 g catalyst is placed in the growth region, the length of obtained silicon wires is 6.6 mm, and the changing rate of diameter with length is 541 nm/mm. When the catalyst mass in the growth region is reduced to 20 g, the length of the products decreases to 4.0 mm, and the changing rate of diameter with length increases to 964 nm/mm. This work proposes a new route for the diameter-modulated fabrication of ultralong silicon wires and will promote their application across various fields.

Effects of cold rolling path on recrystallization behavior and mechanical properties of pure copper during annealing

The recrystallization behavior, grain boundary characteristic distribution, and mechanical properties of pure Cu sheets that were subjected to different cold rolling paths, and then annealed at 400 °C for 10, 30, 60, and 420 min, were investigated. Different rolling paths changed the grain boundary orientations of cold-rolled copper, causing recrystallized grains to nucleate and grow in an oriented manner. However, the evolution of the texture indicated that cold-rolled copper with different rolling paths did not show an obvious preferred orientation after annealing. The RD-60 specimen exhibited the smallest grain size (6.6 μm). The results indicated that the grain size and low-Σ CSL grain boundaries worked together to provide RD-60 samples with appropriate mechanical properties and high plasticity. The yield strength, ultimate tensile strength, and elongation of RD-60 sample were 81 MPa, 230 MPa, and 49%, respectively. These results could provide guidance for tuning the microstructures and properties of pure Cu foils, as well as designing fabrication routes for pure Cu foils through processes such as rolling and drawing.

Label free electrochemical detection of 2-aminoindane

This study describes a label-free voltammetric detection of 2-aminoindane (2-AI), a novel psychoactive substance, using graphite screen-printed electrode modified with an electrochemically oxidized cobalt bis(dicarbollide) derivative (CoK/G/SPE). Morphological, structural and electrochemical characterization is assessed by using a computational approach, scanning electron microscopy, infrared spectrometry and electrochemical techniques. The binding/recognition of 2-AI (as a primary analyte) and 2,5-dimethoxy-4-iodoamphetamine (DOI, as interferent from category amphetamines) is compared, with CoK as a monomer as well as electrochemically deposited on the G/SPE surface. The mechanism of selectivity is proposed. The experimental findings show that these two stimulants compete for the binding/recognition sites on the modified electrode surface, with the adsorption constant values of (2.62 ± 0.67) x 105 and (6.10 ± 1.32) x 105, a linear range of 19.9 – 119 μmol L–1 and 9.97 – 235 μmol L–1, and the limit of detection 7.2 μmol L–1 and 2.37 μmol L–1 for 2-AI and DOI, respectively. An important point considering the analytical applicability and significance of CoK/G/SPE for forensic analysis is the possibility to distinguish 2-AI from an amphetamine derivative in a two-component mixture. The CoK/G/SPE electrodes are successfully applied to determine 19.9 μmol L–1 2-AI in spiked model samples with recovery values of 85.3–94.8 % and relative standard deviations 10–21 %. Such reproducibility is satisfactory considering the low cost of the electrode fabrication route.

Microstructural constituents in compositionally graded NiCrFeSiBC hardfacing alloy/316L SS additive manufactured deposits

Ni-Cr-Fe-Si-B-C hardfacing alloys (D50) provide excellent resistance to abrasive and adhesive wear, high temperature oxidation and corrosion. These alloys are candidate materials for hardface coatings on in-reactor components of fast breeder reactors. Conventionally these deposits are made on steels through the welding route. Due to high fluidity of the molten alloy, generation of residual stress and significant dilution of the deposit, achieving crack free deposits is often a very difficult and time consuming task. To address such issues arising out of conventional fabrication routes, compositionally graded coatings have been tried through laser additive manufacturing. A 3 layered compositionally graded deposit (D50/50D50-50SS/SS) was made on 316 L SS build plate and the phase constituents and possible correlation with micro hardness was analyzed. Uppermost D50 layer consisted of γ-Ni, γ-Ni + Ni3B and γ-Ni + Cr5B3 eutectics, CrB, Cr7C3, Cr23C6, Cr3C2 and Ni3Si precipitates. The middle layer consisted of γ-(Ni,Fe), γ-(Ni,Fe)+Cr5B3, Cr5B3, Cr3C2, Cr7C3,Cr23C6 and Ni3Si. The SS layer closest to the build plate had γ-Fe, Cr3C2 and Cr7C3 precipitates. Corresponding to the variation in microstructure a gradual change in hardness also can be seen starting from the top layer to SS build plate: 580 ± 35 HV0.1, 532 ± 17 HV0.1, 348 ± 21 HV0.1 and 230 ± 10 HV0.1, which is promising.

High-temperature Brown-Zak oscillations in graphene/hBN moiré field effect transistor fabricated using molecular beam epitaxy

Graphene placed on hexagonal boron nitride (hBN) has received significant interest due to its excellent electrical performance and physics phenomena, such as superlattice Dirac points. Direct molecular beam epitaxy growth of graphene on hBN offers an alternative fabrication route for hBN/graphene devices. Here, we investigate the electronic transport of moiré field effect transistors (FETs) in which the conducting channel is monolayer graphene grown on hexagonal boron nitride by high temperature molecular beam epitaxy (HT-MBE). Alignment between hBN and HT-MBE graphene crystal lattices gives rise to a moiré-fringed hexagonal superlattice pattern. Its electronic band structure takes the form of a “Hofstadter butterfly”. When a strong magnetic field B is applied perpendicular to the graphene layer, the electrical conductance displays magneto-oscillations, periodic in B−1, over a wide range of gate voltages and temperatures up to 350 K. We attribute this behaviour to the quantisation of electronic charge and magnetic flux within each unit cell of the superlattice, which gives rise to so-called Brown-Zak oscillations, previously reported only in high-mobility exfoliated graphene. Thus, this HT-MBE graphene/hBN heterostructure provides a platform for observation of room temperature quantum effects and device applications.

A New Approach to Single‐Step Fabrication of TiOx‐CeOx Nanoparticles

Mixed metal oxide (MMO) nanoparticles (NPs) are hybrids consisting of two or more nanoscale metal oxides. Advantages of MMO NPs over single metal oxides include improved catalytic activity, enhanced electrical and magnetic properties, and increased thermal stability due to the synergy of the different oxide components. This study presents a novel fabrication route for TiO2‐CeO2 NPs enriched with oxygen vacancies using a Haberland‐type gas aggregation cluster source. The NPs, deposited from different segmented Ti/Ce targets under varying O2 addition, were examined with respect to final composition, morphology, and Ti, Ce surface oxidation states. Particle formation mechanisms are proposed for the observed morphologies. Additionally, available O2 during deposition and its impact on the formation of defective sites were investigated. Defective sites in TiO2‐CeO2 NPs were analyzed using transfer to X‐ray photoelectron spectroscopy and transmission electron microscopy without contact to ambient oxygen. The incorporation of Ce to the target exhibits synergistic effects on the synthesis process. Segmented Ti/Ce targets enable the deposition of a broad range of mixed oxide NPs with diverse compositions and morphologies at considerably enhanced deposition rates, which is vital for practical applications. The presented fabrication approach is expected to be applicable for a broad variety of MMO NPs.

Fabrication of transparent glass fabric‐reinforced thermoplastic composite based on tow‐spreading technique

AbstractHighly transparent and mechanically robust thermoplastic composites have been developed by hot‐pressing PETG with E‐glass fabrics. The tow‐spreading technique facilitates the reduction of internal defects and fiber crimp angle in the composites, thereby significantly improving their optical and mechanical properties. The optimized composite containing 55.1 vol% glass fibers and 0.4 mm thickness has a high transmittance of 86.1%@616 nm and a low overall haze of 7.2%. Moreover, the 1 mm thick composites exhibit tensile strength of up to 340 MPa and impact strength of up to 86.3 kJ/m2. After 28 days of hygrothermal or UV aging, the composites show minimal changes in their glass transition temperature and thermal degradation temperature. The chemical structure also remains unchanged, with no observed crystallization. In comparison to UV aging, the composites demonstrate better resistance against hygrothermal aging. Specifically, the hygrothermal aged sample displayed a light transmittance retention rate of 93.5% and a bending strength retention rate of 94.3%, while these values were reduced to 73.3% and 90.5%, respectively, in the UV aged sample. The opto‐mechanical properties enhanced mechanism and aging degradation mechanism have been identified by microscopic morphological observation. This work provides an innovative and straightforward approach to fabricate transparent, recyclable, high‐strength thermoplastic composites.Highlights Highly transparent, mechanically robust, recyclable glass‐fabric reinforced thermoplastic composites are fabricated. Composites with spread‐tow fabrics exhibits improved transparency. The fabrication route is scalable and cost‐effective. The mechanism for opto‐mechanical properties enhancement are proposed.

Local buckling behaviour of Q690 high strength steel press-braked elliptical hollow section stub columns: Testing, numerical modelling, and design

This paper presents comprehensive investigations on the local bucking behaviour of Q690 high strength steel (HSS) press-braked elliptical hollow section (EHS) stub columns subject to concentric compression experimentally. In comparison with conventional hot-finished EHS or cold-rolled EHS, the press-braked EHS provides high precision, great construction productivity and the fabricated geometries are not limited to production assembly instrumentation. HSS press-braked EHS fabricated through press-braking process was expected to exhibit distinct behaviour compared with their counterparts constructed from the conventional fabrication routes. Well-understanding of their performance at the levels of material, and cross-section level is essential. Material properties were obtained through tensile coupon tests. Residual stresses in both membrane and bending types were measured and recorded and their impact on structural performance was also assessed. Initial local geometric imperfection measurements were conducted for all the specimens. In conjunction with experimental studies, the finite element (FE) models of Q690 HSS press-braked EHS stub columns were developed. The accuracy of the FE model for HSS press-braked EHS stub column was asserted by comparing the numerical predictions with the tested results. An extensive parametric study was conducted to generate structural performance data with a wider range of cross-section slenderness to complement the test data bank. The cross-section classification for conventional CHS codified in existing standards and the proposed slenderness limits by various researchers were evaluated. The existing slenderness limits cannot be extended to HSS press-braked EHS investigated in this study, a new slenderness limit is proposed. Moreover, the advanced design approaches of Direct Strength Method (DSM) and Continuous Strength Method (CSM) were assessed for their applicability to the cross-section resistance predictions of the examined EHS stub columns.