Film Formation Research Articles

Designed Additive to Regulated Crystallization for High Performance Perovskite Solar Cell

AbstractIt is a crucial role for enhancing the power conversion efficiency (PCE) of perovskite solar cells (PSCs) to prepare high‐quality perovskite films, which can be achieved by delaying the crystallization of perovskite film. Hence, we designed difluoroacetic anhydride (DFA) as an additive to regulating crystallization process thus reducing defect formation during perovskite film formation. It was found DFA reacts with DMSO by forming two molecules, difluoroacetate thioether ester (DTE) and difluoroacetic acid (DA). The strong bonding DTE⋅PbI2 and DA⋅PbI2 retard perovskite crystallization process for high‐quality film formation, which was monitored through in situ UV/Vis and PL tests. By using DFA additives, we prepared perovskite films with high‐quality and low defects. Finally, a champion PCE of 25.28 % was achieved with excellent environmental stability, which retained 95.75 % of the initial PCE after 1152 h at 25 °C under 25 % RH.

Designed Additive to Regulated Crystallization for High Performance Perovskite Solar Cell.

It is a crucial role for enhancing the power conversion efficiency (PCE) of perovskite solar cells (PSCs) to prepare high-quality perovskite films, which can be achieved by delaying the crystallization of perovskite film. Hence, we designed difluoroacetic anhydride (DFA) as an additive to regulating crystallization process thus reducing defect formation during perovskite film formation. It was found DFA reacts with DMSO by forming two molecules, difluoroacetate thioether ester (DTE) and difluoroacetic acid (DA). The strong bonding DTE⋅PbI2 and DA⋅PbI2 retard perovskite crystallization process for high-quality film formation, which was monitored through in situ UV/Vis and PL tests. By using DFA additives, we prepared perovskite films with high-quality and low defects. Finally, a champion PCE of 25.28 % was achieved with excellent environmental stability, which retained 95.75 % of the initial PCE after 1152 h at 25 °C under 25 % RH.

Insights Into Preaggregation Control of Y-Series Nonfullerene Acceptors in Liquid State for Highly Efficient Binary Organic Solar Cells.

Leveraging breakthroughs in Y-series nonfullerene acceptors (NFAs), organic solar cells (OSCs) have achieved impressive power conversion efficiencies (PCEs) exceeding 19%. However, progress in advancing OSCs has decelerated due to constraints in realizing the full potential of the Y-series NFAs. Herein, a simple yet effective solid additive-induced preaggregation control method employing 2-chloro-5-iodopyridine (PDCI) is reported to unlock the full potential of the Y-series NFAs. Specifically, PDCI interacts predominantly with Y-series NFAs enabling enhanced and ordered phase-aggregation in solution. This method leads to a notable improvement and a redshifted absorption of the acceptor phase during film formation, along with improved crystallinity. Moreover, the PDCI-induced preaggregation of NFAs in the solution enables ordered molecule packing during the film-formation process through delicate intermediate states transition. Consequently, the PDCI-induced preaggregated significantly improves the PCE of PM6:Y6 OSCs from 16.12% to 18.12%, among the best values reported for PM6:Y6 OSCs. Importantly, this approach is universally applicable to other Y-series NFA-based OSCs, achieving a champion PCE of 19.02% for the PM6:BTP-eC9 system. Thus, the preaggregation control strategy further unlocks the potential of Y-series NFAs, offering a promising avenue for enhancing the photovoltaic performance of Y-series NFA-based OSCs.

Amelioration of protective organic layer using acenaphthene-based inhibitor responsible for excellent anti-corrosion performance: Experimental and computational perspectives

Despite the engineering promise offered by the co-existence of organic substances in protecting vulnerable metallic materials from corrosive environments, the interaction and formation mechanisms that induce the development of new materials with improved structural properties remain less understood. This study investigated the corrosion inhibitory properties of two acenaphthene derivatives, acenaphthylene-1,2‑dione (ACP) and 1,2-dihydroacenaphthylen-1-ol (DCP), as inhibitors for N80 steel in a 15 % HCl solution. The anticorrosive effectiveness of ACP and DCP compounds was evaluated through multiple research methods, including weight loss analysis, electrochemical impedance spectroscopy (EIS), potentiodynamic polarization (PDP), and surface characterization using scanning electron microscopy (SEM). The experimental findings demonstrate that ACP exhibits superior inhibition performance compared to DCP, with an inhibition efficiency of 93.54 % for ACP and 73.12 % for DCP at an optimum concentration of 5 × 10–3 M. EIS data show that the charge transfer resistance increases with higher concentrations of both compounds. PDP results indicate that ACP and DCP act as mixed-type inhibitors without altering the corrosion mechanism. The kinetic parameters of corrosion adsorption follow the Langmuir isotherm, highlighting a competition between physical and chemical interactions. To investigate how the geometric structures resulting from functional groups influence their interaction with the metal surface, theoretical calculations employing density functional theory (DFT), molecular dynamics (MD), and density-functional tight-binding (DFTB) were conducted. These calculations were aimed at gaining insights into the adsorption behavior of ACP and DCP on the metal surface and their interfacial mechanism. The calculations demonstrate that the molecule possessing twin donor atoms along with p-type orbitals of aromatic rings significantly influenced the formation of a protective film with a uniform distribution. This configuration exhibited superior corrosion performance compared to a molecule containing only one hydroxyl group (—OH). Theoretical calculations further suggest that ACP exhibits stronger adsorption ability, with the two oxygen atoms identified as the most reactive sites, indicating their tendency to donate electrons to the iron surface. The robust resonance-stabilized structure of ACP enhances the stability of the molecules, facilitating its interaction and adsorption onto the metal surface compared to the DCP inhibitor. Overall, the superior inhibition performance of ACP is attributed to the close bonding of twin donor fragments within the ACP molecule, forming a more compact adsorbed inhibitor film on the steel surface.

A novel epoxy resin composite coating containing polyaniline modified GO with triple anti-corrosion effects of barrier, passivation and corrosion inhibition

Corrosion of metallic materials can have a detrimental impact on their performance, leading to a shortened service life of engineering equipment and posing risks to both people and the environment. This paper presents a novel epoxy resin (EP)-based composite coating (PFANI-GO/EP) that offers triple corrosion protection functions: barrier, passivation, and corrosion inhibition. Perfluorooctanoic acid-doped polyaniline modified graphene oxide (PFANI-GO) demonstrates superhydrophobicity, effectively enhancing the coating's barrier ability against corrosive substances. The combination of PANI and perfluorooctanoic acid (PFOA) in composite materials aids in the formation of a passivation film and hydrophobic layer, which prevent metal corrosion. After a 15-day immersion in brine, the PFANI-GO/EP coating demonstrates the highest impedance modulus of 1 × 109 Ω·cm2 at 0.01 Hz, compared to pure EP coating, GO/EP coating, and PFANI/EP coating. Therefore, due to its corrosion resistance and prolonged corrosion aging time, PFANI-GO/EP coating shows promising potential for mitigating metal corrosion.

Observation of Gap Phenomena and Development Processing Technology for ECDM of Sapphire

The main purpose of this study was to develop observation techniques and processing technology for the electrochemical discharge machining (ECDM) of sapphire wafers. To measure the effect of gas-film thickness, discharge-spark conditions, and droplet sliding frequency on machining quality and efficiency in ECDM, this research utilized high-speed cameras to observe the gas film thickness and formation of the gas film during ECDM. Additionally, this study observed the machining-gap phenomena during ECDM. The formation mechanism and machining characteristics of the gas film were understood through experiments. The machining parameters included the liquid level, working voltage, rotation speed, and duty factor. This study analyzed and discussed the effect of each machining parameter on the gas-film thickness, current, electrode consumption, and droplet sliding frequency. Moreover, this study aimed to obtain optimized machining parameters to overcome the difficulty of machining sapphire. The experimental results indicated that utilizing a high-speed camera to capture the phenomena between electrodes during electrochemical discharge could effectively observe the gas-film thickness and the coverage of the gas film. A higher bubble coalescence rate enhanced the machining capability and reduced the lateral discharge. Therefore, this study could obtain better machining-hole depths through observation and analysis to improve gas-film stability and machining capability. This study demonstrated that a liquid level of 700 µm, a working voltage of 48 V, a duty factor of 50%, and a tool electrode rotational speed of 200 rpm could achieve a hole depth of 86.7 µm and a hole diameter of 129.5 µm.

Effect of Indentation at Rolling Body Surfaces on the Film Formation in Elastohydrodynamic Lubrication Contact under Dynamic Loads

Vibration is one of the phenomena that can occur during the operation of roller bearing which can lead to dynamic loads being subjected to the contact and thus, affect the film formation in elastohydrodynamic (EHD) contacts. On the other hand, surface textures such as artificial indentations and grooves greatly affect the film formation as well as the corresponding pressure distribution in the contact area, since the depths of the textures are usually much greater than the film thickness in the contact. This paper investigates the influence of an artificial indentation located on the rolling element, which passes through a point contact under dynamic loads by means of numerical simulations. Solutions to the Reynolds equation are performed and calculations of the elastic deformation equation, force balance equation and lubricant properties equations to show the effects of both indentation passing through the contact and a sinusoidal dynamic load on the film thickness as well as pressure profile of EHD point contact. Moreover, the effect of frequency and amplitude excitation of the dynamic load on the film formation was investigated. The results revealed that the artificial indentation under sinusoidal dynamic load of EHD point contact induced a significant effect on the thickness of the film formation and pressure distribution.

Revealing the role of interlayer spacing in radioactive-ion sieving of functionalized graphene membranes

Functionalization of graphene enables precise control over interlayer spacing during film formation, thereby enhancing the separation efficiency of radioactive ions in graphene membranes. However, the systematic impact of interlayer spacing of graphene membranes on radioactive-ion separation remains unexplored. This study aims to elucidate how interlayer spacing in functionalized graphene membranes affects the separation of radioactive ions. Utilizing polyamidoxime (PAO) to modify graphene oxide, we controlled the interlayer spacing of graphene membranes. Experimental results indicate that tuning interlayer spacing enables control of the permeation flux of radioactive ions (UO22+ 1.01 × 10−5–8.32 × 10−5 mol/m2·h, and K+ remains stable at 3.60 × 10−4 mol/m2·h), and the K+/UO22+ separation factors up to 36.2 at an interlayer spacing of 8.8 Å. Using density functional theory and molecular dynamics simulations, we discovered that the effective separation is mainly determined via interlayer spacing and the quantity of introduced functional groups, explaining the anomalous high permeation flux of target ions at low interlayer spacing (4.3 Å). This study deepens our comprehension of interlayer spacing within nanoconfined spaces for ion separation and recovery via graphene membranes, offering valuable insights for the design and synthesis of high-performance nanomembrane materials.

Crosslinking using particulate crosslinker in polymer latex film-coating process for controlled-release fertilizer

Fertilizing controlled-release fertilizer is apt to keep a reasonable concentration of nutrient in soil and increase the efficiency of fertilizer utilization. The production of film-coated controlled-release fertilizer using polymer latex is a green process. However, the release period is usually short because the film crosslinking density is low during the fast film formation of the dynamic granule coating. In this study, numerous epoxy groups were grafted onto the nanoparticle surface of single-particle-dispersed silica to prepare particulate crosslinker with abundant crosslinking sites. The epoxy groups on the surface of the particulate crosslinker reacted with the carboxyl groups on the surface of the styrene-acrylate latex particles during film formation, enhancing film crosslinking. With the addition of the particulate crosslinker, the polymer latex was used to coat urea granules in a fluidized bed via spray coating at a low coating content of 4 wt%. The release period of film-coated urea granules with an enhanced crosslinking film reached 40 d, which was five times longer than that in the absence of particulate crosslinker.

Effects of magnetic fields on the formation of passive films on the surface of 5083 aluminum alloy

This research explores the effect of the magnetic fields on the passive film of 5083 aluminum alloy. After the application of a 0.3 T magnetic field, 5083 aluminum alloy exhibits an improvement in passivation performance. These improvements manifest as a reduction in passivation current density and an increase in impedance, passive film thickness, and carrier concentration. Additionally, there is an augmentation in the content of the Al2O3 phase within the passive film. The magnetic field facilitates the movement of metal ions during the corrosion process of 5083 aluminum alloy through microscale magnetohydrodynamics, facilitating passive film growth and improving corrosion resistance.

Epitaxial growth of high-quality Mg3Sb2 thin films on annealed c-plane Al2O3 substrates and their thermoelectric properties

High-quality epitaxial Mg3Sb2 thin films are promising thermoelectric materials to enable practical applications of compact and environmentally friendly thermoelectric conversion at RT. In this study, high-quality single-crystal Mg3Sb2 with high c-plane orientation was epitaxially grown directly on annealed c-Al2O3 substrates without passive layers. These thin films exhibited about three times higher thermoelectric power factor than any previously reported values due to high carrier mobility. The ultra-smooth surface of the annealed c-Al2O3 substrate facilitated the formation of high-quality Mg3Sb2 thin films without passive layers or polycrystalline interfaces that could be carrier scatters.

Effect of the SiO2 instead of Al2O3 in the embedding powder on the microstructure and hot corrosion behavior of silicon-modified aluminide coatings

The effects of Si and SiO2 content in the embedding powder on the equilibrium partial pressure of halide gas were compared by material thermodynamic calculation, and higher SiO2 content facilitated the preparation of silicon-modified aluminide coatings. The microstructure and hot corrosion behavior of silicon-modified aluminide coating prepared by different SiO2 contents were studied. As the SiO2 content in the embedding powder increased, the Al, Si, and Cr content was elevated in the prepared coating surface, which promotes the Cr9.1Si0.9 phase precipitate in the coating. Besides, the corrosion weight loss of the coating was the lowest, after 50 wt% NaCl + 50 wt%Na2SO4 mixed molten corrosion at 900 °C for 100 h, showing the excellent corrosion resistance. At the initial corrosion stage, the higher Si content induces the formation of a SiO2 oxide film on the coating surface, which could resist the mixed molten salt reaction. As the corrosion process, the SiO2 oxide film and the below Al2O3 oxide film peel off due to thermal expansion mismatch. Meanwhile, the coating relies on the dispersed precipitation below the oxide film to hinder the corrosive elements and the consumption of Al elements at the final corrosion stage.

Crystallization management of CsPbI2Br perovskites by PbAc2-incorporated twice spin-coating process for efficient and stable CsPbI2Br perovskite solar cells

CsPbI2Br perovskite solar cell has been extensively studied due to its exceptional thermal stability and relatively stable perovskite phase structure. However, the presence of bromine leads to a rapid crystallization rate of CsPbI2Br films, resulting in small grain size and high defect density. Additionally, CsPbI2Br demonstrates poor light absorption due to its wide bandgap. Therefore, it is crucial to control the crystallization rate and increase the film thickness to reduce defect density, enhance light absorption, and improve photovoltaic performance. In this study, we utilized a PbAc2-incorporated twice spin-coating (PTS) process to address these issues. Initially, PbAc2 was added to the CsPbI2Br precursor solution to form a CsPbI2Br film, which was then coated with the CsPbI2Br precursor solution to produce the PTS film. Ac− can delay the perovskite crystallization, leading to the formation of thicker and denser CsPbI2Br films. Moreover, lone-pair electrons of the oxygen atom provided by Ac− formed coordination bonds with under-coordinated Pb2+ ions to fill halogen ion vacancies, thereby reducing the defect density. Ultimately, the PTS CsPbI2Br device achieved a peak power conversion efficiency (PCE) of 16.19% and maintained 96.7% of its initial PCE over 1500 h at room temperature under 25% relative humidity without any encapsulation.

A compound eye-like morphology formed through hexagonal array of hemispherical microparticles where an alkyl-fullerene derivative self-assembled at atmosphere-sealed air/water interface

Self-assembly processes are widely used in nature to form hierarchically organized structures, prompting us to investigate such processes at the macroscopic scale. We report an unprecedented approach toward the self-assembly of alkyl-fullerene (C60) derivatives into a hexagonal array of hemispherical microparticles akin to the morphology of a compound eye. The method includes casting solvated alkyl-C60 compound on an air/water interface followed by controlled evaporation of the solvent under atmosphere-sealed conditions. This leads to the formation of a thin film floating on water with a diameter of up to 1.3 centimeters and exhibiting a hexagonally-packed hemispherical structure with a diameter of approximately 38 µm. Various measurements of the formed film reveal that amorphousness is necessary for suppressing uncontrollable crystallization, which affects the microparticle size and film formation mechanism. We tested the feasibility of this approach for the self-assembly of a relatively common C60 derivative, [6,6]-phenyl-C61-butyric acid methyl ester (PC61BM), resulting in the formation of a film with a similar pattern of hexagonally-packed larger microparticles approximately 152 µm in size of diameter.

Polyethyleneglycol bisphenol A epichlorohydrin copolymer (PEG-BEC) as a highly efficient inhibitor for mild steel corrosion in 1M HCl solutions

In this work, the corrosion inhibition performance of polyethyleneglycol bisphenol A epichlorohydrin copolymer (PEG-BEC) against mild steel in 1 M HCl was studied by electrochemical and weight loss techniques. Scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDAX) were applied to characterize the surface morphology of the mild steel samples. The corrosion mitigation efficiency was observed to rise as the concentration of PEG-BEC rises in the corrosive medium while increasing the temperature (25 °C -65 °C) resulting in a drop in the inhibition ability. Furthermore, under hydrodynamic conditions, the corrosion of the mild steel was found to deteriorate both in the absence and presence of PEG-BEC. Just with 10 ppm, an inhibition efficiency (IE) of 97.6% was obtained at 25 °C by EIS. PEG-BEC acts as a mixed-type inhibitor as observed by potentiodynamic polarization (PDP) technique. The observed corrosion inhibition action of PEG-BEC could be ascribed to the adsorption of the molecules and the formation of a protective film on the steel surface as evidenced by static water contact angle (WCA). Langmuir isotherm best describes the PEC-BEG-metal adsorption with large Kads values indicating a thermodynamically stable nature inhibition process. The obtained ∆G°ads = -35.138 to -39.522 kJ/mol indicate that the PEG-BEC spontaneously adsorbed onto the steel with strong tendency to provide protection to the mild steel surface via combination of chemisorption and physisorption processes. The ΔHads -53.07 kJ/mol and ΔSads= +0.048 kJ/mol-k, respectively, suggests an exothermic reaction accompanied by relatively increase in entropy of the PEG-BEC adsorption on the mild steel surface.

Enhancing high-temperature tribological properties in a detonation-sprayed CoCrNiAl0.3Ti0.3 medium-entropy alloy coating via in-situ formed Al2O3-type oxides and rich-Ag phases

Heterogeneous high-entropy/medium-entropy alloy coatings have the potential of being advanced tribo-components for service in demanding environments. We incorporate dual-heterostructure (Al2O3-type oxides and Ag-rich phases) into the deposited CoCrNiAl0.3Ti0.3 medium-entropy alloy coating employing in-situ flight oxidation and solute addition during detonation spraying. Such heterostructures improve the coating quality and serves twofold, through deposition densification and solid-solution strengthening, contributing to an ultra-low porosity of < 0.6 %, a high bond strength of 61 MPa, and a hardness of 7.6 GPa. The self-organized tribo-layer activated by the heterostructures inhibits abrasive wear at room-temperature, but struggles to resist surface softening and adhesion at 600 ℃. Heterostructures govern the formation of protective glaze-layers and Ag transfer films at 800 ℃ and 1000 ℃, minimizing adhesion and delamination between the tribo-pairs.

Exploring Ginkgo biloba extract's green corrosion inhibition effects on Q235 steel in H2SO4 environments

The corrosion inhibition properties of Ginkgo biloba extract on Q235 steel in 0.5 M H2SO4 solution were comprehensively investigated using weight loss measurements, electrochemical techniques, surface characterization, and quantum chemical calculations. The results demonstrate that Ginkgo biloba extract acts as an effective green corrosion inhibitor, with inhibition efficiencies reaching up to 96.54% at a concentration of 0.7 g/L. The inhibition efficiency increased with increasing extract concentration and temperature. FTIR and LC/MS analyses revealed that the extract contains various phytochemical constituents, including flavonoids, terpenoids, and other polyphenolic compounds, which contribute to its corrosion inhibition properties. The adsorption of the extract compounds on the steel surface followed the Langmuir adsorption isotherm, with a negative value of the standard free energy of adsorption, indicating a spontaneous and stable adsorption process involving both physisorption and chemisorption. SEM and XPS analyses confirmed the formation of a protective film by the adsorbed extract compounds, which acts as a barrier, preventing the direct contact between the aggressive solution and the steel substrate. The film also alters the wettability of the metal surface, making it more hydrophobic and further enhancing the corrosion inhibition efficiency. Quantum chemical calculations showed that flavonoids, particularly quercetin, contribute significantly to the corrosion inhibition performance due to their high reactivity, strong dipole moment, and stable adsorption on the Fe(110) surface. These findings provide valuable insights into the development of sustainable and eco-friendly corrosion inhibitors for the protection of metal structures in acidic environments.

Hydrostatic bearing groove multi-objective optimization of the gear ring housing interface in a straight-line conjugate internal meshing gear pump

The lubrication performance of a straight-line conjugate internal meshing gear pump is poor under the low-speed, high-pressure operating conditions of the volumetric servo speed control system, and it is difficult to establish a full fluid lubricating oil film between the gear ring and the housing. This leads to significant wear and severe heating between the gear ring and the housing. The lubrication performance of the interface moving pair of the electro-hydraulic actuator pump gear ring housing can be improved by designing a reasonable lubrication bearing structure for the gear ring housing. In this study, a multi-field coupling multi-objective optimization model was established to improve lubrication performance and volumetric efficiency. The whole model consists of the dynamic model of the gear ring components, the fluid lubrication model of the gear ring housing interface, the oil film formation and sealing model considering the influence of temperature, and the multi-objective optimization model. The comprehensive performance of the straight-line conjugate internal meshing gear pump was verified experimentally using a test bench. The results show that the lubrication performance is improved, the mechanical loss is reduced by 31.52%, and the volumetric efficiency is increased by 4.91%.

Modeling and experimental verification for photodegradation in a spinning disk reactor

The spinning disk reactor has been regarded as a process intensification device in photochemical processes, which decreases the light path length by the thin film formation created by centrifugal force. A reliable reactor model was indispensable for the practical application of photoreactors. Our previous studies proposed a spinning disk reactor with elliptic-cylindrical and cylindrical spoilers for photochemical process intensification, and then hydrodynamic parameters of liquid film thickness, photon absorption rate, and residence time distribution were obtained. Based on the obtained parameters, herein, a reactor model was further established for the description of photodegradation reaction in the innovative spinning disk reactor. Different non-ideal flow models were employed during the model development, including the tanks-in-series model and axial dispersion model. The apparent reaction rate constant of a spinning disk reactor with spoilers was determined by the photon absorption rate, which was in the range of 0.088–0.268 s−1. The reactor model was verified by the experiments on photodegradation of Methylene Blue under different disk configurations and operating conditions. The degradation efficiency of Methylene Blue could reach up to 89.8 % in 25 min at N = 200 r/min, Q = 60 L/h, and I0 = 8 mW/cm2. The deviation between predicted and experimental Methylene Blue degradation efficiencies was within ± 20 %, confirming the rationality of the reactor model. The developed model lays the foundation for the scaling-up and commercial applications of the novel spinning disk reactors.

Synergistic role of MoS2 in gelation-induced fabrication of graphene oxide films.

Supporting materials for electrocatalysts must exhibit relative chemical inertness to facilitate unimpeded movement of gas, and demonstrate electrical conductivity to promote efficient electron transfer to the catalyst. Conventional catalyst electrodes, such as glassy carbon, carbon cloths, or Ni foam, are commonly employed. However, the challenge lies in the limited stability observed during testing due to the relatively weak adhesion between the catalyst and the electrode. Addressing this limitation is crucial for advancing the stability and performance of catalyst-electrode systems in various applications. Here, we suggest a novel fabrication method for a freestanding conducting film, accomplished through gelation, incorporating 1T-MoS2 and graphene oxide. 1T-MoS2 nanosheets play a crucial role in promoting the reduction of graphene oxide (GO) on the Zn foil. This contribution leads to accelerated film formation and enhanced electrical conductivity in the film. The synergistic effect also enhances the film's stability as catalyst supports. This study provides insights into the effective utilization of MoS2 and graphene oxide in the creating of advanced catalyst support systems with potential applications in diverse catalytic reaction.