Manufacturing Cost Research Articles

Obtaining the effective number of reinforcements progressively inserted and optimized to reduce the strain energy of cantilever plates with a different relationship between height and length

To achieve more efficient structures, research into material properties is important in mechanical designs. The anisotropy of fiber composites is increasingly being exploited. This is particularly true for curved and continuous composites. The position and orientation of the filaments have a major influence on mechanical properties. So, the application of these fibers at specific paths is very important to obtain excellent structures. When developing components for high-performance applications, it is necessary to use optimization methods to find the best reinforcement paths. To achieve high efficiency, it is necessary to reduce the volume of the reinforcements to improve the strength-to-weight ratio. This reduction not only directly reduces the mass, but also decreases manufacturing costs. The present work aims to gradually add reinforcements to carbon fiber-reinforced polymers (CFRPs). It observes the exact number of fibers required to achieve the greatest possible reduction in strain energy. The results prove that the use of more reinforcements than ideal is unnecessary because it increases the volume of reinforcements but doesn’t improve the properties. Optimization is achieved by parameterizing B-splines using sequential linear programming (SLP). Four cases analyzed concern a cantilevered plate. A force is applied to the free edge, causing bending. The boundary conditions are identical, and only the length of the plate changes. The strain is plotted to observe the strain distribution. Then, the results show that adding three to four reinforcements can reduce the strain energy by 92.6% to 98.0% compared to a structure without reinforcements.

Role of buttering layer composition on microstructural heterogeneity and mechanical properties of Alloy 617 and P92 steel dissimilar welded joints for future Indian AUSC program

AbstractRestrictive operating conditions (even exceeding 700 °C) of materials in advanced ultra super critical (AUSC) power plants and the need to minimize manufacturing and maintenance costs require the production of dissimilar metal welded joints (DMW). Significant differences in the physical and chemical properties of welded materials lead to phenomena that reduce the weldability of the metals used and force the search for solutions that limit unfavorable phenomena, e.g., the use of buttering layers. The study presents a comparison of two types of joints with Alloy 617 (UNS N06617) and ferritic P92 (UNS K92460) steel made using Inconel 82 (ENiCrFe-3) and Inconel 617 (ERNiCrCoMo-1) alloys buttering layer and the corresponding chemical composition of filler metals. All areas of the joints made with the gas tungsten arc welding process were subjected to structural investigations (optical microscopy, scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS) and mechanical tests (microhardness, room and high temperature tensile, and toughness testing). Despite the more complicated welding procedure, sound welded joints were obtained with favorable properties resulting, inter alia, from the reduced thickness of the martensite layer in HAZ of P92 steel and the limited diffusion of alloy components compared to welded joints without the buttering layer. This also resulted in a reduction of the maximum hardness (especially in the case of Inconel 82 buttering—by 15–30 HV0.5 in comparison with Inconel 617 buttering) and an increase in strength while limiting the decrease in plasticity (even 663 MPa tensile strength and 21% of elongation for Inconel 617 buttered joint). Moreover, improved high-temperature performance (approximately 70–100 MPa) of the welded joint following the application of the buttering layer was confirmed. The presented results allow for drawing general conclusions that both proposed welding procedures can be recommended for use in the working conditions occurring at AUSC.

Who Benefits From Supplier Encroachment in the Presence of Manufacturing Cost Learning?

Manufacturing cost plays a crucial role in suppliers’ encroachment decisions. A high manufacturing cost impedes suppliers’ capacity to encroach. However, cost learning may reduce this cost sufficiently enough to make encroachment profitable for the supplier at a later point in time. Accordingly, he may have an incentive to boost production so as to promote cost learning. Thus, he may drop the wholesale price to induce the retailer to buy more. On the one hand, cost learning may enable encroachment, which may be detrimental to the retailer. On the other hand, cost learning results in a lower manufacturing cost which may translate into a lower future wholesale price, benefiting the retailer. Therefore, the retailer faces a dilemma: should she increase her order quantity to advance cost learning or not? As the retailer may order fewer units in the initial period to limit future direct channel sales, the supplier faces a challenge: should he, instead of dropping his initial wholesale price, raise it to signal his intention of not encroaching so as to induce the retailer to sell a higher quantity in the first period? We model the supplier–retailer interaction as a two-period Stackelberg game to address the retailer’s dilemma and to identify the optimal supplier response. We uncover a new outcome, which arises in the presence of cost learning, where the supplier encroaches but decides not to sell anything through the direct channel. In addition, we find that supplier encroachment may reduce or eliminate the retailer’s incentive to advance cost learning. This results in lower sales by the retailer, which impedes cost learning, leading to a higher future manufacturing cost (compared to the no encroachment setting). As a result, encroachment, which is typically viewed as advantageous for the supplier, may become detrimental to him. Surprisingly, the supplier continues to encroach and sell directly unless he can credibly assure the retailer that he will not encroach in the future.

A High-Avidity, Thermostable, and Low-Cost Synthetic Capture for Ultrasensitive Detection and Quantification of Viral Antigens and Aerosols.

Lateral flow assays (LFAs) are currently the most popular point-of-care diagnostics, rapidly transforming disease diagnosis from expensive doctor checkups and laboratory-based tests to potential on-the-shelf commodities. Yet, their sensitive element, a monoclonal antibody, is expensive to formulate, and their long-term storage depends on refrigeration technology that cannot be met in resource-limited areas. In this work, LCB1 affibodies (antibody mimetic miniproteins) were conjugated to bovine serum albumin (BSA) to afford a high-avidity synthetic capture (LCB1-BSA) capable of detecting the severe acute respiratory syndrome coronavirus 2 (SARS-CoV-2) spike protein and virus like particles (VLPs). Substituting the monoclonal antibody 2B04 for LCB1-BSA (stable up to 60 °C) significantly improved the thermal stability, shelf life, and affordability of plasmonic-fluor-based LFAs (p-LFAs). Furthermore, this substitution significantly improved the sensitivity of p-LFAs toward the spike protein and VLPs with precise quantitative ability over 2 and 3 orders of magnitude, respectively. LCB1-BSA sensors could detect VLPs at 100-fold lower concentrations, and this improvement, combined with their robust nature, enabled us to develop an aerosol sampling technology to detect aerosolized viral particles. Synthetic captures like LCB1-BSA can increase the ultrasensitivity, availability, sustainability, and long-term accuracy of LFAs while also decreasing their manufacturing costs.

Design and Manufacturing of a Pin on Disk Tribometer

This paper presents the design and manufacturing of a pin on disk tribometer aimed at performing friction and wear testing as accurate as a professional tribometer at a lower cost. Since friction is an important part of our lives and its application varies greatly in size, environment and other factors, testing can be expensive. Tribometers are instruments where these conditions can be simulated experimentally. They are manufactured by various companies abroad and are imported to Turkey. For this reason, the cost of these instruments is very high. The design of the proposed tribometer prioritizes portability and low cost of manufacturing. The manufacturing process of the various parts are discussed in detail. The tribometer was manufactured in the ATILIM University manufacturing laboratories within a tight budget using CNC machining. The instrument has the full capability to adjust the load, testing radius, motor speed, and the duration of the test before starting the experiments. To handle the electronics and data gathering within the instrument, Arduino boards and software are utilized. Real-time data streaming is made possible for data analysis tasks both during and after the experiments. The paper also provides the results of experiments that are obtained from the newly developed tribometer and comparisons with a mass produced, professional tribometer. The experiments are conducted with the same type of samples and with the same parameters. The proposed tribometer provides researchers with easily accessible friction data that is within close range to what they would get from a professional tribometer.

Obtaining Bixin- and Tocotrienol-Rich Extracts from Peruvian Annatto Seeds Using Supercritical CO2 Extraction: Experimental and Economic Evaluation

Currently, Bixa orellana L. extracts are used as a color source in the food, pharmaceutical, and cosmetic industries because they are important as a potential source of antioxidant activity. The extraction is carried out by conventional methods, using alkaline solutions or organic solvents. These extraction methods do not take advantage of the lipid fraction of annatto (Bixa orellana L.) seeds, and the process is not friendly to the environment. In this work, the objective was to obtain an extract rich in nutraceuticals (bixin and tocols) of high antioxidant power from Peruvian annatto seeds as a potential source for a functional food or additive in the industry using supercritical fluid extraction (SFE). Experiments related to extraction yield, bixin, tocotrienols, tocopherols, and antioxidant activity were carried out. The SFE was performed at 40 °C, 50 °C, and 60 °C, and 100, 150, and 250 bar with 0.256 kg/h carbon dioxide as the supercritical solvent (solvent-to-feed ratio of 10.2). Supercritical extraction at 60 °C and 250 bar presented the best results in terms of global extraction yield of 1.40 ± 0.01 g/100 g d.b., extract concentration of 0.564 ± 0.005 g bixin/g extract, 307.8 mg α-tocotrienol/g extract, 39.2 mg β-tocotrienol/g extract, 2 mg γ-tocopherol/g extract, and IC50 of 989.96 μg extract/mL. Economical evaluation showed that 60 °C, 250 bar, and 45 min presented the lowest cost of manufacturing (2 × 2000 L, COM of USD 212.39/kg extract). This extract is a potential source for functional food production.

2D Erucamide Crystal Synthesis and Ultraviolet Photodetection

Abstract2D organic crystals play a unique role in photodetection owing to their tunable detection wavelength, low manufacturing cost, compatibility with lightweight, and controllable synthesis. However, their detection wavelength range mainly encompasses the visible (Vis) and near‐infrared (NIR) spectra. Herein, 2D erucamide crystals are synthesized using nitrogen gas and methanol as raw materials without catalysts at room temperature under atmospheric pressure via laser processing. The synthesized 2D erucamide is demonstrated to be a promising broad bandgap organic semiconductor material. A UV photodetector made of 2D erucamide exhibited a responsivity as high as 145 mA W−1, a millisecond‐level response speed, and an excellent detectivity of 4.96 × 109 Jones. Furthermore, the synthesized erucamide showed an excellent UV–vis suppression ratio (R254 nm/R532 nm) of 59. The synthesis mechanism of erucamide via laser bubbling in liquids is proposed. Thermodynamically, the high temperature of the bubbles is beneficial for nitrogen and methanol decomposition. Kinetically, rapid bubble quenching facilitates final product formation. This accomplishment represented the pioneering utilization of lasers in converting nitrogen gas into organic compounds while introducing 2D erucamide into the realm of organic UV photodetectors.

Device simulation and optimization of HTL-free perovskite solar cell with CH3NH3SnBr3 as the absorber layer using solar cell capacitance simulator software

Perovskite solar cells without a hole transport layer have gained popularity due to their stability and affordable manufacturing cost. In this work, device simulation of the solar cell structure is done using SCAPS-1D software with TiO2 as the Electron Transport Layer while toxic-free compound CH3NH3SnBr3 as the absorber material. The efficiency of the structure is found to be 12.63%. The cell performance parameters are investigated by varying individual cell parameters such as absorber layer thickness, absorber layer defect density and doping concentration, ETL thickness, ETL doping concentration, temperature and defect density of the absorber/ETL interface while holding others constant. Simulation with the optimised cell parameter values improves the efficiency to 24.02%.

High-Entropy Configuration Strategy to Build High Performance Na-Ion Layered Oxide Cathodes Derived from Simple Techniques.

Layered transition metal oxides are commonly used as the cathode materials in sodium-ion batteries due to their low cost and easy manufacturing. However, the application is hindered by poor rate performance and complex phase transitions. To address these challenges, a new seven-component high-entropy layered oxide cathode material, O3-NaNi0.25Fe0.15Mn0.3Ti0.1Sn0.05Co0.05Li0.1O2 (HEO) has been developed. The entropy stabilization effect plays a crucial role in improving the performance of electrochemical systems and the stability of structures. The HEO exhibits a specific discharge capacity of 154.1 mA h g-1 at 0.1 C and 94.5 mA h g-1 at 7 C. In-situ and ex-situ XRD results demonstrate that the HEO effectively retards complex phase transitions. This work provides a high-entropy design for the storage materials with a high energy density. Meanwhile, it eliminates industry doubts about the performance of sodium ion layered oxide cathode materials.

Environmentally friendly SLIPS coating based on flexible sponge: A novel approach to antifouling for ships

To mitigate the attachment of fouling organisms, Slippery Liquid-Infused Porous Surfaces (SLIPS) hold tremendous potential as a green and broad-spectrum antifouling solution, capable of replacing traditional antifouling coatings. However, the complexity of current preparation methods and the limited lifespan of lubricating oils constrain their widespread application in marine antifouling for vessels. In this study, melamine sponge (MS) was used as a substrate, and modifications were made by introducing superhydrophobic silica nanoparticles (SiO2 NPs), a biocompatible adhesive (ethyl cyanoacrylate, ECA), and a highly stretchable polymer (poly-ε-caprolactone, PCL). By combining natural surface microstructures with additional nanomaterials, we successfully obtained a superoleophilic surface, effectively capturing liquid lubricants and maintaining their long-term stability. The sponge substrate possesses distinctive contractility, with the lubricant stored in the grid spontaneously compensating for the loss of surface lubricant, thereby effectively enhancing its durability. This study provides a straightforward fabrication method with reduced manufacturing costs for environmentally friendly marine anti-fouling coatings. The approach demonstrates a prolonged cyclic anti-fouling effect, effectively advancing the development of SLIPS for anti-fouling applications in shallow marine environments.

Effect of hydroxy-terminated hyperbranched polymer coated separator on the lithium-ion battery performances

Abstract The hydrophobicity of polyolefin separators causes poor compatibility with the internal environment of lithium-ion batteries and thus elevates lithium-ion migration barriers. In this research, hydroxy-terminated hyperbranched polymer (HTHP) coated separators are fabricated successfully based on the simple and easy-on impregnation method. Abundant hydroxyl groups in HTHP reinforce separator electrolyte affinity, generating the much lower contact angle and higher electrolyte uptake. Accordingly, HTHP-coated separators show broader electrochemical window and superior ionic conductivity and Li+ transport number, which facilitate the Li+ migration within porous pathways and hence maximally weaken counteranions-induced polarizations. The lower interfacial resistances also guarantee the Li+ accelerated diffusion via the separator–electrodes interfaces. Therefore, batteries containing modified separators exhibit optimized C-rate capacity and cycling stability. However, immoderate HTHP coating blocks partial pores and thus restricts Li+ transference, which deteriorates C-rate capacity and cycling durability in turn. This separator modification scheme possesses advantages of simple preparation, environment-friendly, and low manufacturing cost, providing practical guidance for low-cost and high-performance separator manufacture.

Advancements in P3HT:PCBM solar cells through experimental and simulated techniques

Abstract Organic solar cells are a promising alternative in photovoltaics due to their low manufacturing cost and flexibility. In this study, we developed an organic solar cell of structure (ITO/PEDOT:PSS/P3HT:PCBM/Al) where the active layer is represented by P3HT:PCBM. Experimental studies revealed that this layer has an energy gap of 1.9 eV and a good absorption coefficient of 〖3×10〗^5 〖cm〗^(-1). Using analytical and experimental methods based on (J-V-T) curves, we extracted the key parameters of our device, including parasitic resistances (R_s and R_sh), ideality factor (n), and Schottky potential barrier (ϕ_B) at different temperatures. Also the charge transport mechanism in our junction is identified in this study. We then used simulation to evaluate the performance of our solar cell, obtaining an initial efficiency of 2.13%, in line with experimental results from other research. Our results confirm the feasibility of our theoretical approach, with performance consistent with previous work. However, by introducing an ETL layer (PFN-Br or PDINO), we were able to improve efficiency up to 4.25%. These results highlight the importance of optimising intermediate layers to maximise the efficiency of organic solar cells.

Imaging CAR-NK cells targeted to HER2 ovarian cancer with human sodium-iodide symporter-based positron emission tomography.

Chimeric antigen receptor (CAR) cell therapies utilize CARs to redirect immune cells towards cancer cells expressing specific antigens like human epidermal growth factor receptor 2 (HER2). Despite their potential, CAR T cell therapies exhibit variable response rates and adverse effects in some patients. Non-invasive molecular imaging can aid in predicting patient outcomes by tracking infused cells post-administration. CAR-T cells are typically autologous, increasing manufacturing complexity and costs. An alternative approach involves developing CAR natural killer (CAR-NK) cells as an off-the-shelf allogeneic product. In this study, we engineered HER2-targeted CAR-NK cells co-expressing the positron emission tomography (PET) reporter gene human sodium-iodide symporter (NIS) and assessed their therapeutic efficacy and PET imaging capability in a HER2 ovarian cancer mouse model.NK-92 cells were genetically modified to express a HER2-targeted CAR, the bioluminescence imaging reporter Antares, and NIS. HER2-expressing ovarian cancer cells were engineered to express the bioluminescence reporter Firefly luciferase (Fluc). Co-culture experiments demonstrated significantly enhanced cytotoxicity of CAR-NK cells compared to naive NK cells. In vivo studies involving mice with Fluc-expressing tumors revealed that those treated with CAR-NK cells exhibited reduced tumor burden and prolonged survival compared to controls. Longitudinal bioluminescence imaging demonstrated stable signals from CAR-NK cells over time. PET imaging using the NIS-targeted tracer 18F-tetrafluoroborate ([18F]TFB) showed significantly higher PET signals in mice treated with NIS-expressing CAR-NK cells.Overall, our study showcases the therapeutic potential of HER2-targeted CAR-NK cells in an aggressive ovarian cancer model and underscores the feasibility of using human-derived PET reporter gene imaging to monitor these cells non-invasively in patients.

Transfer Learning-Based Artificial Neural Network for Predicting Weld Line Occurrence through Process Simulations and Molding Trials

Optimizing process parameters to minimize defects remains an important challenge in injection molding (IM). Machine learning (ML) techniques offer promise in this regard, but their application often requires extensive datasets. Transfer learning (TL) emerges as a solution to this problem, leveraging knowledge from related tasks to enhance model training and performance. This study explores TL’s viability in predicting weld line visibility in injection-molded components using artificial neural networks (ANNs). TL techniques are employed to transfer knowledge between datasets related to different components. Furthermore, both source datasets obtained from simulations and experimental tests are used during the study. In order to use process simulations to obtain data regarding the presence of surface defects, it was necessary to correlate an output variable of the simulations with the experimental observations. The results demonstrate TL’s efficacy in reducing the data required for training predictive models, with simulations proving to be a cost-effective alternative to experimental data. TL from simulations achieves comparable predictive metric values to those of the non-pre-trained network, but with an 83% reduction in the required data for the target dataset. Overall, transfer learning shows promise in streamlining injection molding optimization and reducing manufacturing costs.

Recycling kaolin from paper waste and assessment of its application for paper coating

In the cellulose industry, the paper coating process plays an essential role in reducing manufacturing costs while increasing the quality of the products. Given that cellulose products are being used increasingly, the ability to recycle and reuse these materials might be highly beneficial in this industry. Thus, kaolin—one of the most commonly utilized ingredients in the cellulose industry that has a major impact on the final quality—was recycled from paper waste for this study. Then, to confirm the successful recycling process, the particle distribution, morphology, and chemical composition of recycled kaolin were analyzed by DLS, SEM/EDS, FTIR, XRF, and XRD. The related results verified the recycled kaolin's high purity and crystallinity. Subsequently, coatings with thicknesses of 30, 60, 90, and 120 μm were applied to paper using a suspension of recycled kaolin. Their mechanical properties (burst strength and tensile strength), permeability (air passage, the amount of which indicates the porosity of the paper structure), wettability (the contact angle can reveal the wetting ability of the paper), and water absorbance (the Cobb test) were then assessed. The pertinent findings demonstrated that applying a coating considerably improves paper quality. So, a coating with a thickness of 30 µm is superior to uncoated paper. In addition, among all the coating thicknesses, the treatment with the best mechanical strength, permeability, contact angle, and Cob value values had a coating thickness of 120 µm. The corresponding values for the tensile index, burst index, air passage amount, and contact angle are 70 kNm/kgr, 3.61kPa m2/gr, 680 ml/min, and 46֯ ±2. Consequently, the 120 µm-thickness treatment was determined to be the most effective one in this investigation.

Analytical buckling scheme of a functionally graded porous liner reinforced by nanocomposites encased in an egg-shaped pipe

This study uses the FGP-GPLs (functionally graded porous metal reinforced by graphene platelets) to rehabilitate the egg-shaped liner-pipe system. The water penetrates the cracked pipe and surrounds the thin-walled liner, resulting in hydrostatic pressure that may contribute dominantly to the buckling of the thin-walled liner. The critical buckling pressure is derived analytically by combining the thin-walled shell theory, a refined displacement function, and the energy scheme. It is found the egg-shaped FGLs liner sustains higher buckling pressure than the circular FGP-GPLs one. Furthermore, a finite element model is developed to verify the theoretical solutions. The results indicate the numerical equilibrium paths agree well with the analytical ones. In addition, the present analytical predictions are compared successfully with other close-formed solutions. Finally, parametric analyses indicate that the addition of GPLs may significantly improve the stability of the egg-shaped liner, while the increase of pores decreases the stability of the liner. The thickness of the GPLs has a slight effect on the stability of the liner when the volume of GPLs is constant. Thus, thick GPLs may be recommended in engineering practices to reduce the manufacturing cost.

Stretchable and Flexible Painted Thermoelectric Generators on Japanese Paper Using Inks Dispersed with P- and N-Type Single-Walled Carbon Nanotubes.

As power sources for Internet-of-Things sensors, thermoelectric generators must exhibit compactness, flexibility, and low manufacturing costs. Stretchable and flexible painted thermoelectric generators were fabricated on Japanese paper using inks with dispersed p- and n-type single-walled carbon nanotubes (SWCNTs). The p- and n-type SWCNT inks were dispersed using the anionic surfactant of sodium dodecylbenzene sulfonate and the cationic surfactant of dimethyldioctadecylammonium chloride, respectively. The bundle diameters of the p- and n-type SWCNT layers painted on Japanese paper differed significantly; however, the crystallinities of both types of layers were almost the same. The thermoelectric properties of both types of layers exhibited mostly the same values at 30 °C; however, the properties, particularly the electrical conductivity, of the n-type layer increased linearly, and of the p-type layer decreased as the temperature increased. The p- and n-type SWCNT inks were used to paint striped patterns on Japanese paper. By folding at the boundaries of the patterns, painted generators can shrink and expand, even on curved surfaces. The painted generator (length: 145 mm, height: 13 mm) exhibited an output voltage of 10.4 mV and a maximum power of 0.21 μW with a temperature difference of 64 K at 120 °C on the hot side.

Evaluating Mechanism and Related Axiomatic Results under Multiple Considerations

Under many interactive environments in the real world, there is often a need to evaluate the minimization effects and subsequent allocation outcomes derived from these interactions under multiple considerations. For instance, in the context of product sales, it is necessary to evaluate how to minimize the manufacturing costs of various producing factors, and sometimes, from a holistic perspective, it may even be necessary to evaluate situations with minimal sales benefits. On the other hand, in order to evaluate related effects derived from interactions and subsequent allocation outcomes, many game-theoretical studies are based on interactive models to formulate evaluating mechanisms, and then they apply axiomatic processes to analyze the rationality of these mechanisms. Therefore, this study first proposes a mechanism for evaluating the minimization effects and subsequent allocation outcomes under multiple considerations. Additionally, considering that different environmental impacts result from varying participation factors, this study also presents several weighted derivatives based on participation factors and their behaviors. Concurrently, we utilize axiomatic results to demonstrate the mathematical correctness and practicality for these evaluating mechanisms.

A comparative study on the production of Ni1/3Co1/3Mn1/3C2O4 cathode precursor material for lithium-ion batteries using batch and slug-flow reactors

The intermittent nature of the renewable energy sources drifts research interest towards various electrochemical energy storage devices, such as the lithium ion battery, which offers consistent power supply. The manufacturing cost and electrochemical performance of a battery pack largely depends on the quality of the cathode material, which further depends on the production method and its parameters. However, the traditional stirred tank-based co-precipitation manufacturing process for precursors of lithium nickel manganese cobalt oxide (NCM111) cathode suffers from inhomogeneity in the reaction environment, which leads to non-uniform morphology and particle size distribution (PSD). In this work, slug-flow-based manufacturing platform, which offers a homogeneous reaction environment, is used for the continuous production of NCM111 oxalate precursors. One of the novel features of this work is the comparative study between the quality of batch and slug-flow-derived products. The slug-flow-derived product is found to be better in terms of having bigger particle size, narrower PSD and higher tap density. The study on the single and dual-element precipitation in similar conditions to understand the co-precipitation behavior in the slug-flow manufacturing platform is also a unique feature of this work. Furthermore, the effect of NH4OH concentration and residence time (RT) on the electrochemical performance of cathode were also studied and it is found that the cathode precursors synthesized at a NH4OH concentration of 0.08 M and a RT of 2 minutes followed by lithiation shows a better electrochemical performance of 128 mAh g−1 at 0.1 C with cycling stability of more than 80% both at 0.5 C and 1 C.

One-step preparation of large-size 1.5-μm-thick robust YSZ electrolyte for high CH4 conversion SOFCs at 600 °C

Ultrathin electrolytes can lower the operating temperature of yttria-stabilized zirconia (YSZ)-based solid oxide fuel cells (SOFCs) to below 600 °C, accelerating their commercialization. However, current technologies for fabricating robust electrolytes with large areas and a thickness of a few microns for SOFCs suffer from substantial practical limitations, including high manufacturing costs, intricate technical demands, and multistep fabrication processes. This study introduces a low-cost, high-yield, and facile one-step phase inversion technology to fabricate large-area and shape-variable ultrathin YSZ electrolyte-based SOFCs (disc diameter >12 cm and area of 10 cm × 10 cm). An integrated form of SOFCs with dendritic YSZ microchannels supporting a 1.5-μm-thick dense YSZ thin film was fabricated. The ultrathin electrolyte layer lowered ohmic and polarization losses, enhancing SOFC electrochemical performance. The integrated anode/electrolyte structure overcame the interfacial thermal mismatch, resulting in more than 210 h of long-term stability even with cells operating in rapidly changing environments. The single cell also exhibited a high CH4 conversion efficiency (55%), which was attributed to the fast gas diffusion and excellent catalytic activity within the integrated anode. In addition, our 4 cm × 4 cm flat SOFCs exhibited a high power output (5.1 W) at 600 °C, paving the way for the mass production of ultrathin and robust YSZ electrolytes.