Material Processing Techniques Research Articles

Evaluating Benchtop Additive Manufacturing Processes Considering Latest Enhancements in Operational Factors

With the evolution of additive manufacturing technologies, concerning their material processing techniques, range of material choices and deposition speed, 3D printers are extensively employed in academia and industry for a number of purposes. It is no longer uncommon to have a portable, desktop 3D printer and build specific designs in a matter of minutes or hours. The functionality, costs, materials and applications of desktop 3D printers differ. Among the several desktop 3D printers with a variety of characteristics, it might be challenging to choose which one is optimal for the intended applications and uses. In this study, a variety of commercially available thermoplastic and photopolymer resin desktop 3D printers are presented and compared for user selection. This article intends to provide end-users of desktop 3D printers with fundamental information and guidelines via a comparison of desktop 3D-printing technologies and their technical characteristics, enabling them to assess and select appropriate desktop 3D printers for a variety of applications.

3D Binder-Free Mo@CoO Electrodes Directly Manufactured in One Step via Electric Discharge Machining for In-Plane Microsupercapacitor Application

Cobalt oxide-based in-plane microsupercapacitors (IPMSCs) stand out as a favorable choice for various applications in energy sources for the Internet of Things (IoT) and other microelectronic devices due to their abundant natural resources and high theoretical specific capacitance. However, the low electronic conductivity of cobalt oxide greatly hinders its further application in energy storage devices. Herein, a new manufacturing method of electric discharging machining (EDM), which is simple, safe, efficient, and environment-friendly, has been developed for synthesizing Mo-doped and oxygen-vacancy-enriched Co-CoO (Mo@Co-CoO) integrated microelectrodes for efficiently constructing Mo@Co-CoO IPMSCs with customized structures in a single step for the first time. The Mo@Co-CoO IPMSCs with three loops (IPMSCs3) exhibited a maximum areal capacitance of 30.4 mF cm−2 at 2 mV s−1. Moreover, the Mo@Co-CoO IPMSCs3 showed good capacitive behavior at a super-high scanning rate of 100 V s−1, which is around 500–1000 times higher than most reported CoO-based electrodes. It is important to note that the IPMSCs were fabricated using a one-step EDM process without any assistance of other material processing techniques, toxic chemicals, low conductivity binders, exceptional current collectors, and conductive fillers. This novel fabrication method developed in this research opens a new avenue to simplify material synthesis, providing a novel way for realizing intelligent, digital, and green manufacturing of various metal oxide materials, microelectrodes, and microdevices.

Heterogeneous microstructure of γ-irradiated pre-oxidized PAN fiber revealed by microfocus SR-SAXS reconstruction and molecular simulation.

The microstructure plays a crucial role in the manufacturing and application of polyacrylonitrile fibers, which serve as precursors for carbon fibers. Synchrotron radiation small angle x-ray scattering (SR-SAXS) is a non-destructive and precise technique for analyzing fiber structures. This study employed one-dimensional SR-SAXS mapping to extract key structural parameters such as periodicity, lamellae thickness, and the extent of amorphous regions, as well as the directional orientation in γ-irradiated, pre-oxidized polyacrylonitrile fibers. The analysis revealed a three-layered structure comprising a surface skin, a transitional layer, and a central core. Notably, the lamellar thickness exhibits a "U"-shaped distribution, while the long-period structures, amorphous regions, and orientational properties demonstrate a "wave-like" pattern. Within this structure, the skin exhibits a higher level of orientation, with the orientation decreasing progressively from the skin toward the core layer. The structure of the layered crystal was further corroborated by the morphological analysis. In addition, molecular simulations were performed to propose the mechanisms underlying the formation of this layered structure. This comprehensive investigation using SR-SAXS and one-dimensional mapping provides detailed insights into the microstructural and morphological characteristics of polyacrylonitrile fibers, which can inform future advancements in material processing and refinement techniques for the production of advanced fibers.

Revolutionizing healthcare materials: Innovations in processing, advancements, and challenges for enhanced medical device integration and performance

Cutting-edge materials have transformed the fabrication of medical devices and implants. However, the processing used to create these materials impacts their mechanical, physical, and biological characteristics, preventing effective integration. This study is intended to provide a detailed analysis of healthcare materials processing techniques, stressing healthcare-specific material requirements, such as biocompatibility, mechanical strength, corrosion resistance, stabilizability, and bioactivity, followed by classifying these processing methods as “ordinary” and “edge-cutting” methods. The consequences of each processing on the material, as well as the benefits, drawbacks, and recent developments of each technique, are also aimed to be concluded. The study also aimed to explore how process factors affect product qualities. The articles are collected from the Scopus and Web of Science databases using the search strings “Advance Material,” “Material Processing,” “Healthcare,” and “HealthCare Application.” The assessment of the selected literature has been done in accordance with the objectives. The assessment emphasizes quality assurance and regulatory compliance by stressing the need for quality assurance, characterization, and testing for medical devices and implants. Processes such as polishing, etching, and coatings improve biocompatibility and reduce infection risk, according to the findings. It was also concluded that cutting-edge processing methods such as additive manufacturing (3D printing) and electrospinning provide exact control over material composition, structure, and porosity, making them ideal for many clinical applications.

(Invited) Polarization Stability Improvement for Hf0.5Zr0.5O2-Based Ferroelectric Capacitor

The instability in polarization during the endurance test of Hf0.5Zr0.5O2 (HZO) ferroelectrics thin films including the wake-up and the fatigue are still major challenges for the development of HZO-based ferroelectric memories. In this work, we will review the proposed mechanisms of the instabilities in polarization including wake-up and fatigue of the HZO-based metal-ferroelectric-metal (MFM) capacitors. Then, the material processing techniques to address the issues of instabilities are provided. The in-situ deposition of electrode and ferroelectric layers by atomic layer deposition (ALD) attracted considerable attention as a promising solution. Owing to the improved interface quality, both the endurance characteristics and remanent polarization were enhanced. We have also developed a HfO2/ZrO2 superlattice structure to further enhance the ferroelectric endurance of the MFM capacitors. The superlattice MFM capacitors show wake-up free characteristics with excellent endurance. The device performances and endurance characteristics of ferroelectric thin film transistor will also be presented.

Large-area magnetic skin for multi-point and multi-scale tactile sensing with super-resolution

The advancements in tactile sensor technology have found wide-ranging applications in robotic fields, resulting in remarkable achievements in object manipulation and overall human-machine interactions. However, the widespread availability of high-resolution tactile skins remains limited, due to the challenges of incorporating large-sized, robust sensing units and increased wiring complexity. One approach to achieve high-resolution and robust tactile skins is to integrate a limited number of sensor units (taxels) into a flexible surface material and leverage signal processing techniques to achieve super-resolution sensing. Here, we present a magnetic skin consisting of multi-direction magnetized flexible films and a contactless Hall sensor array. The key features of the proposed sensor include the specific magnetization arrangement, K-Nearest Neighbors (KNN) clustering algorithm and convolutional neural network (CNN) model for signal processing. Using only an array of 4*4 taxels, our magnetic skin is capable of achieving super-resolution perception over an area of 48400 mm2, with an average localization error of 1.2 mm. By employing neural network algorithms to decouple the multi-dimensional signals, the skin can achieve multi-point and multi-scale perception. We also demonstrate the promising potentials of the proposed sensor in intelligent control, by simultaneously controlling two vehicles with trajectory mapping on the magnetic skin.

Green power solutions: Advancements in eco‐friendly cellulose‐derived composite battery separators—Material properties and processing techniques

AbstractBatteries play a crucial role in our daily lives, with separators being a key component influencing their functionality. The separators based on petrochemical for example polythene and polypropylene have been long favored for their chemical and thermal stability, their drawbacks in terms of sustainability, eco‐efficiency, and associated environmental risks are undeniable. In pursuit of sustainable development, there is a growing demand for biopolymer composite separators that offer a compelling combination of low cost, high mechanical and thermal stability, biodegradability, and renewability. Among these alternatives, cellulose‐derived separators have garnered significant attention from the scientific community. This review delivers a brief overview of cellulose's chemical structure, their types, delving into the intricate interplay of various electrodes and electrolytic solutions. The focus is then directed towards exploring diverse preparatory methods for cellulose‐derived separators, along with highlighting the promising factors associated with their adoption. Special attention is given to cellulose composite separators and the challenges they present.Highlights Cellulose‐based composite separators in LIB/SIB batteries are discussed. Preparatory methods for eco‐friendly cellulose‐derived composite battery separators. Prominent affecting factors of separator performance have been elaborated. Special attention to the challenges cellulose composite separators present.

Additive Manufacturing-Enabled Advanced Design and Process Strategies for Multi-Functional Lattice Structures.

The properties of each lattice structure are a function of four basic lattice factors, namely the morphology of the unit cell, its tessellation, relative density, and the material properties. The recent advancements in additive manufacturing (AM) have facilitated the easy manipulation of these factors to obtain desired functionalities. This review attempts to expound on several such strategies to manipulate these lattice factors. Several design-based grading strategies, such as functional grading, with respect to size and density manipulation, multi-morphology, and spatial arrangement strategies, have been discussed and their link to the natural occurrences are highlighted. Furthermore, special emphasis is given to the recently designed tessellation strategies to deliver multi-functional lattice responses. Each tessellation on its own acts as a novel material, thereby tuning the required properties. The subsequent section explores various material processing techniques with respect to multi-material AM to achieve multi-functional properties. The sequential combination of multiple materials generates novel properties that a single material cannot achieve. The last section explores the scope for combining the design and process strategies to obtain unique lattice structures capable of catering to advanced requirements. In addition, the future role of artificial intelligence and machine learning in developing function-specific lattice properties is highlighted.

Utilizing Natural Materials in Electronic Devices: Inching Toward "Herbal Electronics".

Sustainable development is the primary key to address global energy challenges. Though the scientific community is engaged in developing efficient ways to not only maximize energy production from natural resources like sun, wind, water, etc. but also to make all the electronic gadgets power efficient, despite all this, the materials used in most of the electronic devices are largely produced using various materials processing techniques and semiconductors, polymers, dielectrics, etc. which again increases the burden on energy and in turn affects the environment. While addressing these challenges, it is very important to explore the possibility to directly, or with minimum processing, utilize the potential of natural resources in the development of electronic devices. Recent articles are focused on the development of herbal electronic devices that essentially implement natural resources, like plants, leaves, etc., either in their raw or extracted form in the device assembly. This review encompasses the recent research developments around herbal electronic devices. Furthermore, herbal electronics has been discussed for several functional applications including electrochromism, energy storage, memresistor, LED, solar cell, water purification, pressure sensor, etc. Moreover, advantages, disadvantages, and challenges encountered in the realization of "herbal electronics" have been discussed at length.

Physics-informed neural network for velocity prediction in electromagnetic launching manufacturing

Electromagnetic launching manufacturing (EMLM) is a high-speed material processing technique powered by pulsed current. The hammer velocity is a key indicator in EMLM, but it is hard to obtain. A viable approach is to use the circuit response current to help in measuring the hammer velocity, but the different curve patterns and the weak interactions between the parameters are major hindrances. In this paper, response current information was used to develop a physics-informed neural network to indirectly predict the hammer velocity. With the experimental dataset, the proposed model had the lowest root mean squared error (0.95) compared with the traditional models (1.62 from Seq2Seq, 1.98 from LSTM, and 2.18 from Attention). This improvement was achieved through the proposed physics-informed neural network architecture. The proposed loss function incorporated knowledge from physics which enabled the model to obtain implicit physical data in the EMLM process, thus enhancing its generalization ability. A fast convergence of the training process was promoted by the developed 2-stage strategy. The introduced attention mechanism added a global perspective that improved the prediction accuracy of the peak velocities. Consequently, our model achieved state-of-the-art predictions of velocities in real-world industrial EMLM systems.

Nonlinear radiative thermal analysis of magneto-micropolar fluid over a bidirectionally extending sheet with varied thermal conditions

Thermal fluid flow analysis occasioned by stretching surfaces offers practical industrial and engineering applications, such as extrusion and drawing processes and materials experiencing heating and cooling conditions. Thus, this study explores magnetohydrodynamic micropolar fluid flow under varied thermal conditions and nonlinear thermal radiation over a dually stretched sheet subject to surface mass flux and an internal heat source. The study thus provides insight into the dynamics of heat transfer mechanisms for improving material processing techniques in many engineering processes. The flow dynamics with the thermal analysis are evaluated by applying two thermal conditions in the heat equation: the prescribed surface temperature (PST) and the prescribed heat flux (PHF). The formulated partial derivative equations that describe the current problem are changed into ordinary derivatives using some similarity quantities, while the converted equations are tackled with the combined techniques of shooting and Runge–Kutta Fehlberg. Consequently, diverse tables and figures are displayed to deliberate on the impacts of the physical terms on the dynamics of flow and heat transmission processes. The consequence of the analysis reveals a higher heat gradient in the prescribed surface temperature case than the uniform temperature distribution, as the Prandtl number magnifies. The micropolar material term reduces the surface frictional factor and depletes heat transmission, but the magnetic field term raises the skin friction coefficient.

Developments and prospects of additive manufacturing for thermoelectric materials and technologies

In view of the increased demand for electricity and the associated environmental and financial concerns, there is an urgent need to develop technological solutions that can improve the efficiency of engineering systems and processes. Thermoelectric (TE) technologies, with their capability of direct conversion of thermal energy into electrical energy, are promising technologies for green power generation through using them as energy harvesting devices for waste heat recovery in industrial processes and power generation systems.To date, TE technologies are still not commercialized on a large scale due to various economic and technical obstacles. The majority of previous research on TE technologies concentrated on improving the TE properties, such as electronic transport and figure-of-merit, while limited attempts were made to identify the best material processing techniques or reduce the cost of manufacturing. Conventional Manufacturing (CM) of TE materials and devices is multi-stage, complex, labour-intensive, time-consuming, and has high energy requirements. Thus, manufacturing challenges are considered key contributors toward limited industrial adoption of TE technologies.The rapid advent of advanced Additive Manufacturing (AM) processes, in recent years, caused dramatic changes in engineering design thinking and created opportunities to solve manufacturing challenges. With its significant capabilities, AM can be the route to address the shortcomings of CM of the thermoelectric technologies. In this regard, this paper presents an in-depth review of the literature studies on using AM technologies, such as selective laser melting, fused deposition modelling, direct ink writing, stereo lithography, etc., for manufacturing TE materials and devices. The benefits and challenges of each AM technology are discussed to identify their merits and the required future research. This paper demonstrates the role of AM in advancing green materials and technologies for solving some of the outstanding energy and environmental issues.

Ultralow-Noise MoS2/Type II Superlattice Mixed-Dimensional van der Waals Barrier Long-Wave Infrared Detector.

Low-noise, high-performance long-wave infrared detectors play a crucial role in diverse applications, including in the industrial, security, and medical fields. However, the current performance of long-wave detectors is constrained by the noise associated with narrow bandgaps. Therefore, exploring novel heterostructures for long-wavelength infrared detection is advantageous for the development of compact and high-performance infrared sensing. In this investigation, we present a MoS2/type II superlattice mixed-dimensional van der Waals barrier long-wave infrared detector (Mixed-vdWH). Through the design of the valence band barrier, substantial suppression of device dark noise is achieved, resulting in 2 orders of magnitude reduction in dark current. The device exhibits outstanding performance, with D* reaching 4 × 1010 Jones. This integration approach synergizes the distinctive properties of two-dimensional layered materials (2DLM) with the well-established processing techniques of traditional three-dimensional semiconductor materials, offering a compelling avenue for the large-scale integration of 2DLM.

Energy Consumption and Tool Condition in Friction Stir Processing of Aluminum Alloys

AbstractFriction Stir Welding (FSW) and Friction Stir Processing (FSP) are solid-state joining and material processing techniques that have garnered considerable attention for their versatility and industrial applicability. In the present work, FSP was performed on AA 6056 T4, dealing with the issue of monitoring tool wear and assessing its impact on the process. The impact of tool wear on power requirements was analyzed, and it was expanded the understanding of tool behavior and its implications for the overall process performance. Specifically, variations in energy consumption, temperatures, and vibrations are observed with changing tool conditions. Further insights are provided by analyzing the microhardness and the pin volume ratio, which show distinct trends as the tool wears. Two tool maintenance ways are proposed, that are cleaning the tool with a sodium hydroxide solution and increasing the tool’s rotational speed. Both the strategies exhibit the potential to partially restore the tool’s initial characteristics. This study highlights the critical importance of assessing tool condition, energy consumption, and process sustainability, particularly in industrial settings where material processing requires efficiency and quality assurance.

New Directions for Thermoelectrics: A Roadmap from High‐Throughput Materials Discovery to Advanced Device Manufacturing

Thermoelectric materials, which can convert waste heat into electricity or act as solid‐state Peltier coolers, are emerging as key technologies to address global energy shortages and environmental sustainability. However, discovering materials with high thermoelectric conversion efficiency is a complex and slow process. The emerging field of high‐throughput material discovery demonstrates its potential to accelerate the development of new thermoelectric materials combining high efficiency and low cost. The synergistic integration of high‐throughput material processing and characterization techniques with machine learning algorithms can form an efficient closed‐loop process to generate and analyze broad datasets to discover new thermoelectric materials with unprecedented performances. Meanwhile, the recent development of advanced manufacturing methods provides exciting opportunities to realize scalable, low‐cost, and energy‐efficient fabrication of thermoelectric devices. This review provides an overview of recent advances in discovering thermoelectric materials using high‐throughput methods, including processing, characterization, and screening. Advanced manufacturing methods of thermoelectric devices are also introduced to realize the broad impacts of thermoelectric materials in power generation and solid‐state cooling. In the end, this article also discusses the future research prospects and directions.

Laporan Penelitian Kemasyarakatan Sebagai Bahan Pertimbangan Hakim Dalam Penjatuhan Pidana Terhadap Anak

Introduction: Community research (LITMAS) is one of the main tasks of Correctional Centers (Bapas). This task is carried out by the Social Guidance Functional officer. This Litmas aims to provide recommendations in the process of resolving child cases.Purposes of the Research: Research Objectives: This study aims to find out whether social research reports have been used by judges as material for consideration in imposing crimes against children and what are the legal consequences of a judge's decision without considering social research reports.Methods of the Research: The research method used is normative juridical research where library materials are the basis for (knowledge) research which is classified as a secondary source material. The problem approach used is the statutory approach, the conceptual analysis approach and the case approach. The legal materials used are primary, secondary and tertiary legal materials. The collection technique used literature study as well as the processing and analysis techniques of legal materials by way of description using qualitative methods.Results of the Research: The research results show that social research reports have not been considered optimally because there are still judges' decisions that ignore social research results. This is not in accordance with the hope of realizing the best justice for the interests of children provided by the SPPA Law. Therefore, the Government as the legislator must explain in detail how social research reports must be considered, so that judges do not have different interpretations when deciding cases.

Investigation of the Effect of Stress on Oxygen Diffusion in Pure Titanium Using a Phase-Field Model.

Diffusion plays a vital role during the fabrication of many materials. It is a well-known fact that stress can influence diffusion behavior. In order to optimize material processing techniques, a quantitative evaluation of the effect of stress on diffusion is essentially required. By analyzing the free energy change in a Ti-O system during diffusion, a phase-field model was developed to address this issue. Using this model, the diffusion of oxygen atoms in pure titanium under different stress states was investigated. It was observed that the true equilibrium concentration of oxygen was proportional to its hydrostatic pressure. Tensile stress can increase the oxygen concentration. This raise in concentration decreased with temperature. However, the promotion of diffusion can be attained in deeper regions at a higher temperature. On the contrary, compressive stress inhibited the diffusion of oxygen in pure titanium. Under a certain compressive stress, the decrease in the oxygen concentration at the surface layer was more significant at a lower temperature, while a decrease could be observed at a deeper distance from the surface at a higher temperature. A thermodynamic explanation of the effect of stress on diffusion was given based on the proposed phase-field model.

Lunar In Situ Large-Scale Construction: Quantitative Evaluation of Regolith Solidification Techniques

Lunar habitat construction is crucial for successful lunar exploration missions. Due to the limitations of transportation conditions, extensive global research has been conducted on lunar in situ material processing techniques in recent years. The aim of this paper is to provide a comprehensive review, precise classification, and quantitative evaluation of these approaches, focusing specifically on four main approaches: reaction solidification (RS), sintering/melting (SM), bonding solidification (BS), and confinement formation (CF). Eight key indicators have been identified for the construction of low-cost and high-performance systems to assess the feasibility of these methods: in situ material ratio, curing temperature, curing time, implementation conditions, compressive strength, tensile strength, curing dimensions, and environmental adaptability. The scoring thresholds are determined by comparing the construction requirements with the actual capabilities. Among the evaluated methods, regolith bagging has emerged as a promising option due to its high in situ material ratio, low time requirement, lack of high-temperature requirements, and minimal shortcomings, with only the compressive strength falling below the neutral score. The compressive strength still maintains a value of 2–3 MPa. The proposed construction scheme utilizing regolith bags offers numerous advantages, including rapid and large-scale construction, ensured tensile strength, and reduced reliance on equipment and energy. In this study, guidelines for evaluating regolith solidification techniques are provided, and directions for improvement are offered. The proposed lunar habitat design based on regolith bags is a practical reference for future research.

INNOVATIVE MATERIAL PROCESSING TECHNIQUES IN PRECISION MANUFACTURING: A REVIEW

Precision manufacturing plays a pivotal role in various industries, demanding high accuracy, efficiency, and quality in the production process. The continual pursuit of innovation in material processing techniques is essential to meet evolving demands and challenges. This review explores the latest advancements and innovations in material processing methods within precision manufacturing. The review encompasses a comprehensive analysis of various innovative material processing techniques, including additive manufacturing, subtractive manufacturing, and hybrid approaches. Additive manufacturing, often referred to as 3D printing, has gained significant attention for its capability to produce complex geometries with high precision. The exploration of novel materials, such as metal alloys, polymers, and composites, expands the applicability of additive manufacturing in diverse industrial sectors. Subtractive manufacturing techniques, such as milling, turning, and grinding, are also undergoing transformative advancements to enhance precision and efficiency. Emerging technologies like abrasive waterjet machining, electrical discharge machining (EDM), and laser machining offer improved accuracy and surface finish while enabling the processing of a wide range of materials, including hard-to-machine alloys and composites. Hybrid manufacturing approaches, combining additive and subtractive techniques, are revolutionizing precision manufacturing by leveraging the strengths of both methods. These hybrid systems enable the production of intricate components with high precision, reduced lead times, and minimized material waste, addressing the challenges of traditional manufacturing processes. Furthermore, the review highlights advancements in process monitoring and control technologies, such as in-process sensing, real-time feedback systems, and adaptive control algorithms, facilitating enhanced quality assurance and productivity in precision manufacturing. The integration of advanced computational tools, simulation techniques, and artificial intelligence further augments the optimization and customization capabilities of material processing techniques, driving efficiency and innovation in precision manufacturing. Overall, this review provides valuable insights into the latest developments and trends in innovative material processing techniques, offering a roadmap for future research directions and applications in precision manufacturing industries.
 Keywords: Material, Processing, Techniques, Precision, Manufacturing, Review.

Cold formability of friction stir processed 5754-H111 and 6082-T6 aluminum alloys: an experimental and numerical study

Aluminum has become increasingly important in the automotive sector due to its ability to reduce vehicle weight without compromising structural performance. However, joining different types of aluminum alloys can be challenging due to their different thermal and mechanical characteristics. Concurrently, friction stir processing (FSP) is a material processing technique that has garnered considerable attention for its versatility and industrial applicability, and it may represent a preliminary phase to correctly perform friction stir welding, which is a welding technology used to join different types of aluminum alloys. In this context, this study presents an extensive experimental campaign of FSP performed on 5754-H111 and 6082-T6 alloys, varying two rolling directions and four welding speeds. The processed materials were characterized, including cupping and tensile tests, microstructure analysis, and a correlation between welding parameters, microstructure, and mechanical resistance. In addition, a numerical method was proposed to simulate the Erichsen tests and predict the formability of the materials, before and after the FSP processes. The results showed that both alloys exhibited good formability after the FSP process, but with different behavior. AA6082 underwent internal decohesion and dynamic recrystallization, resulting in the absence of defects and an increase in ductility and cold formability. AA5754 experiences more difficulty with material flow during FSP and showed the presence of tunnel defects in all analyzed process conditions. However, the alloy 5754 did not undergo softening and had comparable mechanical behavior and cold formability to the base material. These results were validated by the numerical method proposed.