Metal Interface Research Articles

A hybrid approach towards evaluation of average heat transfer coefficient in twin-roll strip casting mold

Continuous casting stands out as one of the most efficient and productive methods for producing billets, slabs, or thin sheets while conserving energy. Understanding the solidification dynamics and achieving defect-free sheets in continuous casting necessitates the accurate prediction of heat transfer coefficient (HTC) at the mold metal interface. Accurate prediction of HTC helps in selecting process parameters such as superheat temperature and casting velocity, which directly affect the production rate and quality of the cast component. Determining the HTC is a complex process, as it is influenced by various process parameters such as casting size, casting speed, superheat temperature, surface roughness, type of water used as a coolant, nozzle design and wettability. Therefore, the present study proposed a hybrid approach for finding HTC in a twin roll strip casting mold through a solidified shell shape, which is influenced by the factors affecting the heat transfer at the mold-metal interface. This approach integrates the experimental and simulation investigations. The numerical investigation used a three-dimensional coupled fluid flow and heat transfer equations with an assumed range of HTC (100–2000 W/(m2K)). The solidified shell shape for different HTCs was compared with the experimental solidified shape form at the outer wall of the mold using the solidification criteria. Results indicate that the initial HTC range of 100–1000 W/(m2K) does not lead to blockage of the graphite mold outlet. However, as HTC values approach 1000 W/(m2K) to 1400 W/(m2K), the melt obstructs the mold exit based on solidification criteria. The HTC values (1350 ± 150 W/(m2K)) obtained from the proposed methodology for mold, align well with the HTC values (1183 ± 593 W/(m2K)) calculated using lamellar spacing of the Al-Mg2Si composite microstructure. This hybrid approach presents a novel and straightforward method for determining HTC, offering accurate predictions that can enhance the precision of continuous casting models and provide a more nuanced understanding of solidification behavior.

Differential Capacitance of Ionic Liquid Confined between Metallic Interfaces.

We present here a detailed analysis of the electric double layer at the gold electrode/[BMIM][BF4] interface using a polarizable model for the electrode, based on our recent approach to include image charges [Geada et al. Nat. Commun. 2018, 9, 716]. A double bell (camel) shape is obtained for the differential capacitance, where the inclusion of metal polarization allows for a higher density of ions in the double layer, particularly around the maxima, thereby increasing the capacitance. The charging mechanism differs for the positive and negative electrodes, with counterion adsorption prevailing at the anode and co-ion desorption prevailing at the cathode. The charging mechanism is predominantly governed by the BF4 anions, serving as counterions and co-ions at the anode and cathode, respectively. Within the considered range of potentials, only minor changes are observed in the dynamical properties, specifically in the diffusion coefficients. Notably, it is interesting to observe that bulk properties are restored at a shorter distance from the gold surface in the case of the anode compared to the cathode.

Bifunctional interface of metal–organic framework synergized with bismuth endows high stable zinc anode

Zn-based aqueous batteries (ZnABs) are attractive in large-scale energy storage. However, the issues of hydrogen evolution and dendrite formation in zinc anode are the key challenges for this technology. Here, we demonstrate the metal bismuth encapsulated within a metal–organic framework (Bi@ZIF-8) as an artificial interface to protect the Zn anode. Revealed by electrochemical measurements and the in-situ optical images, the Bi@ZIF-8 interface makes for uniform deposition and simultaneously contributes to anti-corrosion in Zn anode. Hence, the symmetric Bi@ZIF-8 coated Zn foil (Bi@ZIF-8|Zn) cell exhibits the lowest polarization compared to ZIF-8|Zn and bare Zn, and achieves 420 h of operation at 7.5 mA cm−2. As a proof of concept, the elaborate alkaline Zn-Ni full cell based on Bi@ZIF-8|Zn anode shows excellent kinetic performance, a high coulombic efficiency of 98 %, and a long lifespan of 2500 cycles. Moreover, this Bi@ZIF-8 was used as a practical Zn electrode interface modifier, which endows a 2 Ah pouch cell with a high energy density of 130 Wh kg−1 and 420 Wh L–1. This research provides a novel thought for realizing long-life ZnABs via the artificial interface protection of the Zn anode.

Voltage-Controlled Magnon Transistor via Tuning Interfacial Exchange Coupling.

Magnon transistors that can effectively regulate magnon transport by an electric field are desired for magnonics, which aims to provide a Joule-heating free alternative to the conventional electronics owing to the electric neutrality of magnons (the key carriers of spin-angular momenta in the magnonics). However, also due to their electric neutrality, magnons have no access to directly interact with an electric field and it is thus difficult to manipulate magnon transport by voltages straightforwardly. Here, we demonstrated a gate voltage (V_{g}) applied on a nonmagnetic metal and magnetic insulator (MI) interface that bent the energy band of the MI and then modulated the probability for conduction electrons in the nonmagnetic metal to tunnel into the MI, which can consequently enhance or weaken the spin-magnon conversion efficiency at the interface. A voltage-controlled magnon transistor based on the magnon-mediated electric current drag (MECD) effect in a Pt-Y_{3}Fe_{5}O_{12}-Pt sandwich was then experimentally realized with V_{g} modulating the magnitude of the MECD signal. The obtained efficiency (the change ratio between the MECD voltage at ±V_{g}) reached 10%/(MV/cm) at 300K. This prototype of magnon transistor offers an effective scheme to control magnon transport by a gate voltage.

Atomic-Scale Insights Into Graphene/Fullerene Tribological Mechanisms and Machine Learning Prediction of Properties

Abstract Graphene/fullerene carbon–based nanoparticles exhibit excellent tribological properties in solid–liquid two-phase lubrication systems. However, the tribological mechanism still lacks profound insights into dynamic friction processes at the atomic scale. In this paper, the friction reduction and anti-wear mechanism of graphene/fullerene nanoparticles and the synergistic lubrication effect of the binary additive system were investigated by molecular dynamics simulations and tribological experiments. The friction performance was predicted based on six machine learning algorithms. The results indicated that in fluid lubrication, graphene promoted “liquid–liquid” interlayer sliding, whereas fullerene facilitated “solid–liquid” interface sliding, resulting in a decrease or increase in friction force. Under boundary lubrication, graphene/fullerene nanoparticles were adsorbed and anchored at the metal interface to form a physical protective film, which improved the bearing capacity of the lubricating oil film, transformed the direct contact between asperities into interlayer sliding of graphene and roll–slide polishing, filling, and repairing of fullerene, thus improving the frictional wear of the lubrication system as well as the friction temperature rise and stress concentration of the asperities. Furthermore, six machine learning algorithms showed low error and high precision, and the coefficient of determination was greater than 0.9, indicating that all models had good prediction and generalization capabilities, fully demonstrating the feasibility of combining molecular simulation and machine learning applications in the field of tribology.

Regulation of Hot Electrons Transport Achieved through Controlled Electron-Phonon Coupling in Metallic Heterostructures.

The electron-phonon (e-ph) interactions are pivotal in shaping the electrical and thermal properties, and in particular, determining the carrier dynamics and transport behaviors in optoelectronic devices. By employing pump-probe spectroscopy and ultrafast microscopy, the consequential role of e-ph coupling strength in the spatiotemporal evolution of hot electrons is elucidated. Thermal transport across the metallic interface is controlled to regulate effective e-ph coupling factor Geff in Au and Au/Cr heterostructure, and their impact on nonequilibrium transport of hot electrons is examined. Via the modulation of buried Cr thickness, a strong correlation between Geff and the diffusive behavior of hot electrons is found. By enhancing Geff through the regulation of thermal transport across interface, there is a significant reduction in e-ph thermalization time, the maximum diffusion length of hot electrons, and lattice heated area which are extracted from the spatiotemporal evolution profiles. Therefore, the increased Geff significantly weakens the diffusion of hot electrons and promotes heat relaxation of electron subsystems in both time and space. These insights propose a robust framework for spatiotemporal investigations of G impact on hot electron diffusion, underscoring its significance in the rational design of advanced optoelectronic devices with high efficiency.

Concentration-Driven Interfacial Amorphization toward Highly Stable and High-Rate Zn Metal Batteries.

The interfacial structure holds great promise in suppressing dendrite growth and parasitic reactions of zinc metal in aqueous media. Current advancements prioritize novel component fabrication, yet the local crystal structure significantly impacts the interfacial properties. In addition, there is still a critical need for scalable synthesis methods for expediting the commercialization of aqueous zinc metal batteries (AZMBs). Herein, we propose a scalable concentration-controlled method for realizing crystalline to amorphous transformation of the Zn metal interface with exceptional scalability (>1 m2) and processing consistency (>30 trials). Theoretical and experimental analyses highlight the advantages of amorphous ZnO, which exhibits moderate adsorption energy, strong desolvation ability, and hydrophilicity. Employing the amorphous ZnO-coated zinc metal anode (AZO-Zn) significantly enhances the cycling performance, impressively maintaining 1000 cycles at 100 mA cm-2. The prototype AZO-Zn||MnO2@CNT pouch cell demonstrates a capacity of 15.7 mAh and maintains 91% of its highest capacity over 100 cycles, presenting promising avenues for the future commercialization of AZMBs.

Kinetic Trapping of Charge-Transfer Molecules at Metal Interfaces.

Despite the common expectation that conjugated organic molecules on metals adsorb in a flat-lying layer, several recent studies have found coverage-dependent transitions to upright-standing phases, which exhibit notably different physical properties. In this work, we argue that from an energetic perspective, thermodynamically stable upright-standing phases may be more common than hitherto thought. However, for kinetic reasons, this phase may often not be observed experimentally. Using first-principles kinetic Monte Carlo simulations, we find that the structure with lower molecular density is (almost) always formed first, reminiscent of Ostwald's rule of stages. The phase transitions to the upright-standing phase are likely to be kinetically hindered under the conditions typically used in surface science. The simulation results are experimentally confirmed for the adsorption of tetracyanoethylene on Cu(111) using infrared and X-ray photoemission spectroscopy. Investigating both the role of the growth conditions and the energetics of the interface, we find that the time for the phase transition is determined mostly by the deposition rate and, thus, is mostly independent of the nature of the molecule.

Coherent Control of Angular Interrogation of Sensitivity of the Surface Plasmon Polariton Waves at the Interface of Metal and Dielectric Medium

Coherent Control of Angular Interrogation of Sensitivity of the Surface Plasmon Polariton Waves at the Interface of Metal and Dielectric Medium

Microwave joining of copper pipes using selective microwave hybrid heating process: Simulation and experimental study

High thermal conductivity of copper poses serious challenges in its joining in conventional welding techniques leading to development of alternate welding techniques. Microwave welding is one such newly developed joining technique that use selective microwave hybrid heating (SMHH). The joining of the copper pipes using SMHH has not been explored in existing literature. The present paper attempts the microwave joining of copper pipes using SMHH. The exposure time required for joining copper pipes using SMHH was predicted by COMSOL Multiphysics software. The joining was attempted at the predicted exposure time using a novel cavity design inside a conventional microwave oven. The copper pipes have been successfully joined at temperature and exposure period of 1080ºC and 720 s respectively and was in good agreement with the predicted values i.e., 708 s. Scanning electron microscopy (SEM) revealed good metallurgical bonding between the base metal and joint interface. The presence of columnar grains has been observed at heat affected zone (HAZ) using electron back scattered diffraction (EBSD). EBSD analysis revealed randomly arranged grains with mixed modes of planes inside the base metal. The occurrence of high angle grains (HAGs) along with high dislocation density in base metal resulted in the improvement in the mechanical properties as revealed in grain average misorientation (GAM) maps. The maximum value of microhardness has been observed at the joint region (105 ± 7 Hv) followed by base metal and HAZ i.e. (97 ± 5 Hv) and (89 ± 8 Hv) respectively owing to the existence of fine grain of copper (µm) and carbide formation.

Operando monitoring of dendrite formation in lithium metal batteries via ultrasensitive tilted fiber Bragg grating sensors.

Lithium (Li) dendrite growth significantly deteriorates the performance and shortens the operation life of lithium metal batteries. Capturing the intricate dynamics of surface localized and rapid mass transport at the electrolyte-electrode interface of lithium metal is essential for the understanding of the dendrite growth process, and the evaluation of the solutions mitigating the dendrite growth issue. Here we demonstrate an approach based on an ultrasensitive tilted fiber Bragg grating (TFBG) sensor which is inserted close to the electrode surface in a working lithium metal battery, without disturbing its operation. Thanks to the superfine optical resonances of the TFBG, in situ and rapid monitoring of mass transport kinetics and lithium dendrite growth at the nanoscale interface of lithium anodes have been achieved. Reliable correlations between the performance of different natural/artificial solid electrolyte interphases (SEIs) and the time-resolved optical responses have been observed and quantified, enabling us to link the nanoscale ion and SEI behavior with the macroscopic battery performance. This new operando tool will provide additional capabilities for parametrization of the batteries' electrochemistry and help identify the optimal interphases of lithium metal batteries to enhance battery performance and its safety.

Rationally Designed Conversion‐Type Lithium Metal Protective Layer for All‐Solid‐State Lithium Metal Batteries

AbstractA stable interfacial design bridging Li metal and sulfide solid electrolytes is imperative for deploying practical all‐solid‐state Li metal batteries. Despite the extensive exploration of interlayer materials, including inorganic substances, lithiophilic metals, and their composites, a comprehensive understanding of their stability and chemo‐mechanical evolution, particularly those influenced by cell fabrication processes, remains unexplored. Herein, it is meticulously investigate the formation and evolution of LiF, Mg, and conversion‐type multicomponent MgF2 ultrathin interlayers, each fabricated via thermal evaporation deposition. Unexpectedly, LiF and Mg fail to enhance cell performance, with LiF notably susceptible to external pressures during cell fabrication, leading to serious current constriction, while Mg deposition results in the formation of a Li‐rich solid solution. Remarkably, the MgF2 coatings demonstrate substantially superior performance in both Li|Li6PS5Cl|Li symmetric cells (up to 2000 h) and LiNi0.70Co0.15Mn0.15O2|Li6PS5Cl|Li full‐cells (82% capacity retention after 800 cycles) at 30 °C. These results are attributed to the in‐situ formation of LiF and LixMg nanograins through a conversion reaction, which, after repeated cycling, maintains stability and a fixed position at the interface while ensuring uniform interfacial Li+ flux. Supported by comprehensive analyses, these findings highlight the pivotal role of conversion‐type interlayers in mitigating side reactions and preventing Li penetration.

Interfacial solvation-structure regulation for stable Li metal anode by a desolvation coating technique

Rechargeable lithium (Li) metal batteries face challenges in achieving stable cycling due to the instability of the solid electrolyte interphase (SEI). The Li-ion solvation structure and its desolvation process are crucial for the formation of a stable SEI on Li metal anodes and improving Li plating/stripping kinetics. This research introduces an interfacial desolvation coating technique to actively modulate the Li-ion solvation structure at the Li metal interface and regulate the participation of the electrolyte solvent in SEI formation. Through experimental investigations conducted using a carbonate electrolyte with limited compatibility to Li metal, the optimized desolvation coating layer, composed of 12-crown-4 ether-modified silica materials, selectively displaces strongly coordinating solvents while simultaneously enriching weakly coordinating fluorinated solvents at the Li metal/electrolyte interface. This selective desolvation and enrichment effect reduce solvent participation to SEI and thus facilitate the formation of a LiF-dominant SEI with greatly reduced organic species on the Li metal surface, as conclusively verified through various characterization techniques including XPS, quantitative NMR, operando NMR, cryo-TEM, EELS, and EDS. The interfacial desolvation coating technique enables excellent rate cycling stability (i.e., 1C) of the Li metal anode and prolonged cycling life of the Li||LiCoO2 pouch cell in the conventional carbonate electrolyte (E/C 2.6 g/Ah), with 80% capacity retention after 333 cycles.

Microstructure – Properties relationship in laser-welded AZ31B magnesium alloy

The AZ31B magnesium alloy was laser-welded at three different (1.2, 1.6, and 2 kW) laser output powers in the present work. All the butt weld joints are almost defect-free. The size of the weld joint slightly increases with increasing laser output power. The weld metal is formed by columnar grains of the alpha phase at the weld metal/base metal interface, but a finely equiaxed grain microstructure is formed in the centres of fusion zones. The minor phases are Mg17Al12 and (Al,Mg)8Mn5. The weld metal microstructure manifests clear refinement with a decrease in laser output power. Microstructural changes are reflected in changes in mechanical properties; weld joints prepared at the lowest laser output power manifest the highest microhardness, ultimate tensile strength, yield strength, and almost 90% joint efficiency. This is related to the different extents of strengthening mechanisms that act most effectively in weld joints made at 1.2 kW laser output power. Detail analysis of fracture surfaces confirmed that lower laser output power and general microstructural refinement favours the formation of plastically deformed material, which is in excellent agreement with both the experimentally determined and the calculated values of yield strength.

Effect of carbon black and curing system on rubber–metal interface strength of automotive components

Rubber–metal parts inside the car require rubber compounds capable of ensuring optimal function and maximum service life without interface delamination. From this perspective, the strength of the bond which is created by the chemical interaction of rubber and metal by an adhesive is decisive for ensuring the functionality of the entire compound. It is dependent not only on the choice of the right adhesive but also on the rubber compound ingredients and their amount. Here, the influence of different types of carbon blacks as well as different curing systems in combination with a commonly used adhesive is described. The durability of the metal–adhesive–rubber bond is characterized by a specially designed shear strength analysis under quasi-static loading, whereas a significant influence of the structure of the carbon black has shown. It has also been observed that the presence of monosulphidic bonds has a positive effect on the shear strength.

Ultraclean Interface of Metal Chalcogenides with Metal through Confined Interfacial Chalcogenization.

Acquisition of defect-free transition metal dichalcogenides (TMDs) channels with clean heterojunctions is a critical issue in the production of TMD-based functional electronic devices. Conventional approaches have transferred TMD onto a target substrate, and then apply the typical device fabrication processes. Unfortunately, those processes cause physical and chemical defects in the TMD channels. Here, a novel synthetic process of TMD thin films, named confined interfacial chalcogenization (CIC) is proposed. In the proposed synthesis, a uniform TMDlayer is created at the Au/transition metal (TM) interface by diffusion of chalcogen through the upperAu layer and the reaction of chalcogen with the underlying TM. CIC allows for ultraclean heterojunctions with the metals, synthesis of various homo- and hetero-structured TMDs, and in situ TMD channel formation in the last stage of device fabrication. The mechanism of TMD growth is revealed by the TM-accelerated chalcogen diffusion, epitaxial growth of TMD on Au(111). We demonstrated a wafer-scale TMD-based vertical memristors which exhibit excellent statistical concordance in device performance enabled by the ultraclean heterojunctions and superior uniformity in thickness. CIC proposed in this study represents a breakthrough in in TMD-based electronic device fabrication and marking a substantial step toward practical next-generation integrated electronics.

Deciphering the Interplay between Local and Global Dynamics of Anodic Metal Oxidation.

The stark difference between global and local metal oxidation dynamics underscores the need for methodologies capable of performing precise sub-μm-scale and wide-field measurements. In this study, we present reflective microscopy as a tool developed to address this challenge, illustrated by the example of chronoamperometric Fe oxidation in a NaCl solution. Analysis at a local scale of 10 s of μm has revealed three distinct periods of Fe oxidation: the initial covering of the metal interface with a surface film, followed by the electrochemical conversion of the formed surface film, and finally, the in-depth oxidation of Fe. In addition, thermodynamic calculations and the quantitative analysis of changes in optical signal (light intensity), correlated with variations in refractive indexes, suggest the initial formation of maghemite, followed by its subsequent conversion to magnetite. The reactivity maps for all three periods are heterogeneous, which can be attributed to the preferential oxidation of certain crystallographic grains. Notably, at the global scale of 100 s of μm, reactivity initiates at the electrode border and progresses toward its center, demonstrating a unique pattern that is independent of the local metal structure. This finding underscores the significance of simultaneously employing sub-μm-precise, quantitative, and wide-field measurements for a comprehensive description of metal oxidation processes.

Stabilization the interface of NASICON-type solid electrolyte and Li metal by Al interlayer

Solid-state lithium-ion batteries with intrinsic safety and stable performance have emerged as alternative to liquid electrolyte-based systems. NASICON-type Li1.3Al0.3Ti1.7(PO4)3 (LATP) with high ionic conductivity is a promising solid electrolyte to be commercialized. However, the incompatibility of LATP with Li metal hinders its application in high energy density solid-state systems. Herein, we apply a 60 nm thick protective Al layer by PVD to construct a stable interface with metallic Li. The Al-coated LATP enables better electrochemical performance in a symmetric cell than bare LATP. Al-coated LATP is stable at 0.1 mA cm−2 for 100 cycles without building up polarization. The overpotential and the interfacial resistance are significantly reduced as direct contact between Li and LATP is avoided. The Al coating inhibits the reduction of Ti4+ to Ti3+ of LATP pellet during cycling. This work resolves the prominent limitations of LATP and strengthens the interfacial connectivity in solid-state system, pointing an environmental friendly and low cost modification strategy to improve the solid-state lithium-ion batteries.

Optimized film thicknesses for maximum refractive index sensitivity and figure of merit of a bimetallic film surface plasmon resonance sensor

In this paper, a simple surface plasmon resonance (SPR) optical sensor with a bimetallic gold-silver film is proposed and its parameters are optimized based on reflectance spectra analysis. In comparison with most SPR sensors, which use single gold films, the evanescent field of this bimetallic configuration at the analyte–metal interface enables the sensing with substantially enhanced refractive index (RI) sensitivity and figure of merit (FOM). The proposed structure comprising a BK7 glass substrate, an adhesion layer of chromium, a gold-silver plasmonic layer, and a protective layer of silicon dioxide is employed in the Kretschmann configuration for liquid analyte sensing. In order to achieve the best sensing properties, the gold-silver layer thickness ratio is varied, and a thorough analysis of reflectance spectra is performed based on RI sensitivity and FOM. For this purpose, a liquid analyte of aqueous solutions of NaCl is employed for angles of incidence 63∘\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$^\\circ $$\\end{document} and 64∘\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$^\\circ $$\\end{document}, respectively. Moreover, based on the analysis, an optimized gold-silver layer thickness ratio is selected, and a sensitivity of 41,592 nm per RI unit (RIU) and FOM of 424 RIU-1\\documentclass[12pt]{minimal} \\usepackage{amsmath} \\usepackage{wasysym} \\usepackage{amsfonts} \\usepackage{amssymb} \\usepackage{amsbsy} \\usepackage{mathrsfs} \\usepackage{upgreek} \\setlength{\\oddsidemargin}{-69pt} \\begin{document}$$^{-1}$$\\end{document} are reached. The designed bimetallic SPR structure proves to be advantageous compared to single-gold-film structures employed for sensing applications.

Effect of carbon content and cooling rate on the microstructure and hardness of TiC-Fe-Cr-Mo cermets

TiC-FeCrMo cermets have been obtained in fully dense form by Sinter HIP at 1400 °C. Significant microstructural changes have been observed in these materials for relatively small variations in their carbon content after sintering. In the cermets with higher carbon content Cr-rich likely M7C3 carbides are observed to precipitate at the (Ti1-x,Mox)yCz - metal interface. In addition, these cermets present a significant amount of retained austenite as part of the metal matrix. No retained austenite and many fewer M7C3 carbides are found in alloys with a reduction of 0.2 wt% in the total C content. Continuous cooling diagrams have been obtained from an austenitizing temperature of 950 °C. Hardness increases by 30% with respect to that of as sintered specimens after cooling at 1 °C/s confirming that these TiC-FeCrMo cermets are suitable for hardening by air-quenching. At this cooling rate, it is observed that the relatively small carbon changes mentioned before have a significant effect on the bainitic transformation, displacing its onset to higher temperatures as the C content is reduced. Slower cooling rates result in complex microstructures, in which, in addition to martensite, ferritic bainite, M7C3 and M23C6 carbides are also found. Microstructure and hardness of TiC-FeCrMo materials can be modified by the use of standard heat treatments to obtain a wide variety of mechanical properties suitable for certain hot rolling applications.