Material Processing Technology Research Articles

Soft X-ray spectromicroscopic proof of a reversible oxidation/reduction of microbial biofilm structures using a novel microfluidic in situ electrochemical device

In situ electrochemistry on micron and submicron-sized individual particles and thin layers is a valuable, emerging tool for process understanding and optimization in a variety of scientific and technological fields such as material science, process technology, analytical chemistry, and environmental sciences. Electrochemical characterization and manipulation coupled with soft X-ray spectromicroscopy helps identify, quantify, and optimize processes in complex systems such as those with high heterogeneity in the spatial and/or temporal domain. Here we present a novel platform optimized for in situ electrochemistry with variable liquid electrolyte flow in soft X-ray scanning transmission X-ray microscopes (STXM). With four channels for fluid control and a modular design, it is suited for a wealth of experimental conditions. We demonstrate its capabilities by proving the reversible oxidation and reduction of individual microbial biofilm structures formed by microaerophilic Fe(II)-oxidizing bacteria, also known as twisted stalks. We show spectromicroscopically the heterogeneity of the redox activity on the submicron scale. Examples are also provided of electrochemical modification of liquid electrolyte species (Fe(II) and Fe(III) cyanides), and in situ studies of electrodeposited copper nanoparticles as CO2 reduction electrocatalysts under reaction conditions.

Advances in and Future Perspectives on High-Power Ceramic Lasers

Advancements in laser glass compositions and manufacturing techniques has allowed the development of a new category of high-energy and high-power laser systems which are being used in various applications, such as for fundamental research, material processing and inertial confinement fusion (ICF) technologies research. A ceramic laser is a remarkable revolution in solid state lasers. It exhibits crystalline properties, high yields, better thermal conductivity, a uniformly broadened emission cross-section, and a higher mechanical constant. Polycrystalline ceramic lasers combine the properties of glasses and crystals, which offer the unique advantages of high thermal stability, excellent optical transparency, and the ability to incorporate active laser ions homogeneously. They are less expensive and have a similar fabrication process to glass lasers. Recent developments in these classes of lasers have led to improvements in their efficiency, beam quality, and wavelength versatility, making them suitable for a broad range of applications, such as scientific research requiring ultra-fast laser pulses, medical procedures like laser surgery and high-precision cutting and welding in industrial manufacturing. The future of ceramic lasers looks promising, with ongoing research focused on enhancing their performance, developing new doping materials and expanding their functional wavelengths. The ongoing progress in high-power ceramic lasers is continuously expanding the limits of laser technology, therefore allowing the development of more powerful and efficient systems for a wide range of advanced and complex applications. In this paper, we review the advances, limitations and future perspectives of ceramic lasers.

Electrolyte jet tomography: Three-dimensional microstructure mapping with an electrochemical machine tool and an optical microscope

There is a general separation between the manufacturing processes that add value to materials on the factory floor and the techniques engineers use in the laboratory to evaluate the microstructures and the surface integrity that results. These techniques are often destructive or require a vacuum and are incompatible with production lines. However, this information has intrinsic value and could be exploited to inform production decisions during manufacture. In this study, a novel approach to acquire this information is presented that is underpinned by electrolyte jet machine tool coupled with optical microscopy, which can allow the extraction of both grain-wise partial orientation and morphological information, and crystallographic macro textures in three dimensions. Here, iterative sections are precisely machined into the near surface of a commercially pure titanium alloy using an electrochemical jet and subsequently imaged, allowing the reconstruction of high-fidelity microstructure models rapidly and under ambient conditions. In doing so, new insights into the specific orientation-dependent dissolution mechanisms are offered, and the acquisition of appropriate conditions that result in nanoscale roughness surfaces (avoiding the dominance of pitting and preferential grain removal) is firstly explored. Building on prior work, a piecewise approach is presented to analyse the acquired image stacks to map partial crystal orientations, while different approaches are proposed to account for jet-specific surface artefacts and waviness. This is repeated over 20 layers in an individual specimen and layer-wise orientation maps are used to construct volumetric models of the specimen. These data sets are then explored from the perspective of materials/manufacturing engineers, who may use to this information to effect advancements to materials processing technologies.

A new method to recycle Li-ion batteries with laser materials processing technology

Efficient and cost-effective recycling of spent lithium-ion batteries is essential for the sustainable growth of the clean energy sector, conserves critical mineral resources, and contribute to environmental sustainability. The pyrometallurgy process, involving high-temperature smelting and solid-state reduction, plays a key role in the industrial-scale recycling of these batteries. Traditional smelting methods, however, face criticism for their substantial energy requirements and the loss of lithium in slag. In this study, an innovative laser-based in-situ pyrometallurgical process, hereinafter referred to as laser recycling, was developed to recycle Li-ion batterie materials without using slag, enabling the simultaneous recovery of Co, Ni, Mn, and Li. Lab-scale experiments were carried out to investigate the influences of laser power density and duration on the carbothermic reduction behavior of battery materials. The results showed that the maximum temperature reached approximately 1850 °C with a laser power between 1500 and 2000 W focused to an area of 20 mm in diameter within a few seconds. The laser recycling facilitates concurrent smelting and solid-state reduction, with carbothermic reduction completed in just 30 s due to rapid reaction kinetics, ultra-high temperatures, and the enhanced contact area resulting from surface tension-driven molten material flow under intense laser beam exposure. This laser recycling process reduced LiCoO2 and LiNi0.33Mn0.33Co0.33O2 to metallic Co or Co-Ni-Mn alloy, respectively, while Li was recovered as Li2CO3. The new process allowed for the near-total recovery of Co, Ni, and Mn in the alloy and virtually 100% Li recovery in the form of Li2CO3 by a vapor phase capture system. Additionally, continuous laser recycling in the battery material powder bed showed potentials to scale up for industry battery recycling. A mechanism for the laser recycling process was proposed. A preliminary discussion on the techno-economic implications of laser recycling was also provided.

Recent Advances in Electroluminescent Metallic Nanoclusters: From Materials to Devices.

Metallic nanoclusters (MNCs) were developed rapidly in recent decades, owing to their unique electronic structures and excited state characteristics, leading to their wide applications. Luminescence as one of the most important functions for MNCs has also been used to realize biodetection, displays, and lighting, through either electrochemiluminescence (ECL) or electroluminescence (EL). Both emissive properties and electrochemical activities of MNCs were utilized to enhance ECL and EL through facilitating exciton formation and radiation, rendering the rapid emerging of the latter in the last ten years. Through ligand modification, radiative excited-state components were increased to realize state-of-the-art photo- and electroluminescence efficiencies up to ∼100% and ∼30%, as well as ultralow biodetection limits. Nonetheless, material selection space and processing technologies are still limited. Herein, we overview and discuss recent advances of MNCs-based ECL and EL, through both aspects of materials/systems and devices, which would enlighten continuous innovations in optoelectronic MNCs.

A computational study of solidification kinetics in multicomponent alloys

Recent advances in materials processing technologies highlight the need to understand solidification kinetics in multicomponent alloys. Using a finite interface dissipation phase field model, we investigate planar front solidification rates in ternary alloys, used as a model system, as a function of various mass transport processes and nonequilibrium conditions. Simulation results reveal that the off-diagonal diffusion coefficients play an important role in controlling the solid–liquid (S–L) interface velocity and solute partition coefficients. Specifically, under various rapid solidification conditions negative values for the off-diagonal diffusion coefficients increase the solute partition coefficients due to the depletion of liquid phase concentrations ahead of the S–L interface. Given an undercooling, the S–L interface velocity increases with decreasing the off-diagonal diffusion coefficients. In broad terms, our work quantifies the role of coupled mass transport processes and nonequilibrium effects in solidification rates of multicomponent alloys.

Fatigue Life Prediction and Verification of Railway Fastener Clip Based on Critical Plane Method

Accurately predicting the fatigue life of fastener clips is crucial for improving material processing technology, enhancing the anti-fatigue design level, and guiding the maintenance and repair of track structures. Conventional methods that solely evaluate the fatigue life of fastener clips based on the uniaxial stress index under displacement loads may lead to significant errors. In this paper, the stress field of a type-III clip under displacement loading conditions was numerically simulated based on fatigue test standards, and the fatigue life of the clip was analyzed using the Fatemi–Socie (FS) multiaxial fatigue criterion based on the critical plane method. A comparison with standard fatigue test results revealed that, under non-resonance conditions, the predicted position of the fatigue critical plane of the fastener clip coincided with the fracture surface observed at the middle of the measured small arc, with a life prediction error of 7.3%. To further investigate the predictive capability of the FS multiaxial fatigue criterion for the fatigue life of the fastener clip under resonance conditions, the stress levels of the clip under non-resonance and resonance conditions were compared through on-site testing, and the effects of inertial loads caused by vertical and lateral vibration acceleration on the stress field of the clip were analyzed in numerical simulation according to the results of clip acceleration tests; the fastener clip’s resonance fracture position and fatigue life were also predicted based on the aforementioned multiaxial fatigue criterion. To verify the accuracy of the predicted results, a testing method was proposed that equates the high-frequency resonant inertial load of the fastener clip to a low-frequency additional preload under the premise of consistent stress fields. A comparison with the numerical simulation results shows that considering only vertical inertial loads would result in a discrepancy between the measured fracture location and the actual one. Considering both vertical and lateral inertial loads, the fracture location (at the heel of the small arc) under resonance conditions could be accurately determined, with a life prediction error of 13.8%. Compared to the non-resonant displacement loading condition, the inertial loads caused by acceleration under resonance conditions led to a reduction in fatigue life of approximately 77.8%.

Efficient manufacture of high-performance electroplated diamond wires utilizing Cr-coated diamond micro-powder

The slicing of silicon ingots using electroplated diamond wires is a fundamental process in the creation of semiconductor devices such as chips and photovoltaic cells. Composite electroplating, a process that uses nickel (Ni) plating to fix diamond particles onto a steel wire, is a critical step in the manufacturing of these diamond wires. In this work, chromium (Cr)-coated diamond was used to achieve rapid and high-quality composite electroplating, thereby aiding the production of high-performance diamond wire saws. The Cr-coated diamond micro-powder was prepared utilizing vacuum slow evaporation technology at a temperature of 850 °C. This resulted in a uniform and firm Cr coating that was firmly bonded to the diamond surface via Cr3C2. Subsequent electrochemical tests were conducted in the composite electroplating bath. Linear scanning voltammetric curves revealed that the Cr-coated diamond was capable of inducing a more positive shift in the overpotential of Ni deposition, thus enhancing the reaction beyond that of uncoated diamond micro-powder. Additionally, the electrochemical impedance spectra indicated a decrease in charge transfer resistance during composite electroplating, attributable to the conductivity of the Cr-coated diamond. Electroplated diamond wires incorporating Cr-coated diamond demonstrated a greater abrasive density per unit length. SEM results showed that Ni was able to deposit on the Cr-coated diamond surface, resulting in the abrasives being completely covered by the Ni plating. The Cr-coated diamond wire exhibits a stronger resistance to abrasive detachment after cutting, which could increase the diamond-protrusion of the wire. The utilization of Cr-coated diamond micro-powder as an abrasive is anticipated to enhance the manufacturing efficiency of diamond wires and improve product quality, thereby promoting advancements in hard and brittle material processing technology.

Sustainable composite manufacturing from non-expiring carbon fiber/epoxy prepregs based on a vitrimeric matrix

Despite the benefits of manufacturing composite materials from prepregs, its use is nowadays limited to high-production rate industries due to the high costs associated with their limited shelf life. Once this time passes, the material is considered as expired and disposed of as a non-usable waste. To avoid shortening its shelf life, prepregs are stored in refrigerators, increasing energy consumption, and thus magnifying the negative environmental impact. For this reason, the objective of this paper is to develop a new lifelong prepreg material without an expiration date that can be consolidated as a laminate after surpassing the gelation time of the resin, thus allowing composite materials processing technology based on prepregs without the need of freeze storage. To prove this concept, the study is carried out using a vitrimeric resin composed of an epoxy monomer (DGEBA) and 2-Aminophenyl disulfide (AFD) as a hardener. Two prepregs are manufactured and stored for 30 days at different conditions: environmental conditions, considered as the aged or non-conventional prepreg; and at −18 °C in a freezer, to replicate the conventional prepreg conditions. The results of the cured composites show stable glass transition temperatures and curing degrees between the two laminates. Concerning the mechanical properties, it has been proved that the gelation phenomenon of the non-conventional prepreg does not have any negative effect, showing a 11 % and a 21 % improvement of the flexural strength and failure strain, respectively, together with a 10 % increase of the interlaminar shear strength (ILSS) in comparison with the conventional prepreg, proving the potential of the proposed sustainable prepregs.

Direct generation of multicolor Bessel beams from a Pr3+: WPFG fiber laser.

Multicolor visible high-order Bessel (Bessel-vortex) beams which have a helical wavefront and a long confocal length have garnered significant interest for applications in materials processing and biomedical technologies. In this paper, we demonstrate the direct generation of multicolor (523, 605 and 637 nm) Bessel-vortex beams from a Pr3+-doped water-proof fluoro-aluminate glass (Pr3+: WPFG) fiber laser with an intracavity lens which induces chromatic and spherical aberration. The handedness of the generated Bessel-vortex beam is selectively controlled through lateral displacement of the intra-cavity lens.

Experimental Strategies for Studying Tribo-Electrochemical Aspects of Chemical–Mechanical Planarization

Chemical–mechanical planarization (CMP) is used to smoothen the topographies of a rough surface by combining several functions of tribology (friction, lubrication), chemistry, and electrochemistry (corrosion, wear, tribo-corrosion). The surface layer of interest is structurally weakened by the chemical and/or electrochemical reactions of selected additives in a polishing slurry, and the modified surface is flattened by the abrasion of a polishing pad with or without abrasive particles. The chemically active CMP slurry also serves as a lubricant for polishing and enables planarization at a microscopic level while avoiding the formation of defects at the processed surface. Applications of CMP are wide-ranging in various material-processing technologies and, specifically, it is a critical manufacturing step of integrated circuits. The CMP of metals is a significant part of this processing scheme and is associated with highly complex tribo-electrochemical mechanisms that are now additionally challenging due to various new requirements of the advanced technology nodes. The present review examines the current statuses of experimental strategies for collecting important mechanistic details of metal CMP that are necessary to design and assess CMP consumables. Both traditional and underexplored experimental techniques are discussed with illustrative results, including many previously unpublished findings for certain CMP systems of current interest.

Review of Carbon Nanotube Wire-to-Metal Connection Methods: Techniques, Challenges, and Prospects

This paper reviews the connection technologies between carbon nanotube (CNT) wires and metal materials, analyzes the technical principles, advantages, limitations and application prospects of different connection methods. It mainly focuses on the electrical contact issues of CNT wires in the field of microelectronics, and how to achieve a high-performance, reliable combination of metal and CNT wires through emerging material processing and connection technologies. The article also discusses the challenges these technologies face in overcoming interface resistance, improving mechanical connection performance, and maintaining the characteristics of CNT wires.

Low-temperature sintering of bauxite raw material with alkali as an alternative to the parallel Bayer sintering process

The aim is to develop an alternative technology of bauxite raw material processing based on low-temperature sintering of bauxite with caustic alkali, as well as to solve the issue of carbon footprint control at alumina refineries in the Urals. Laboratory tests were carried out by sintering artificial bemite and hematite with chemically pure caustic alkali at temperatures of 300, 500 and 700°C and their further leaching in weakly alkaline solutions. To study the phase, chemical, and particle size distribution of red muds after leaching, various physical and chemical methods of analysis were used, such as X-ray fluorescence, titration method, X-ray phase analysis, scanning electron microscopy, magnetometry with a vibrating sample. The Brunauer – Emmett – Teller method was used to determine the specific surface area and porosity. The study of the kinetics of the solid-phase reaction of the bemite interaction with caustic alkali has shown the kinetic interaction in the temperature range under study. Moreover, sintering of hematite at temperatures of 300 and 500°C and further leaching of the sinter with water resulted in mineralogical changes in the sludge with the production of a new mineral, maghemite, which possesses magnetic properties. When studying the magnetic properties of red mud of lowtemperature sintering of bauxite, we determined that the magnetization was as high as 19–20 electromagnetic units per g (at a sample density of 2.38 g/cm3) at a magnetic field of 10 kE. The specific surface area of these samples was 54.97 and 51.77 m2/g. The performed studies confirm that the proposed technology can be adapted for bauxite to produce highiron red slimes, thus contributing to the integrated processing of bauxite raw materials. In addition, ways to reduce carbon emissions at alumina refineries by eliminating the sintering operation with soda and limestone, which is accompanied by CO2 emission during decomposition of these compounds, can be studied.

Residual Stresses in a Wire and Arc-Directed Energy-Deposited Al–6Cu–Mn (ER2319) Alloy Determined by Energy-Dispersive High-Energy X-ray Diffraction

In order to enable and promote the adoption of novel material processing technologies, a comprehensive understanding of the residual stresses present in structural components is required. The intrinsically high energy input and complex thermal cycle during arc-based additive manufacturing typically translate into non-negligible residual stresses. This study focuses on the quantitative evaluation of residual stresses in an Al–6Cu–Mn alloy fabricated by wire and arc-directed energy deposition. Thin, single-track aluminum specimens that differ in their respective height are investigated by means of energy-dispersive high-energy X-ray diffraction. The aim is to assess the build-up of stresses upon consecutive layer deposition. Stresses are evaluated along the specimen build direction as well as with respect to the lateral position within the component. The residual stress evolution suggests that the most critical region of the specimen is close to the substrate, where high tensile stresses close to the material’s yield strength prevail. The presence of these stresses is due to the most pronounced thermal gradients and mechanical constraints in this region.

Quasi-instantaneous materials processing technology via high-intensity electrical nano pulsing

Despite many efforts, the outcomes obtained with field-assisted processing of materials still rely on long-term coupling with other electroless processes. This conceals the efficacy and the intrinsic contributions of electric current. A new device utilizing electrical nano pulsing (ENP) has been designed and constructed to bring quasi-instantaneous modifications to the micro- and nano-structure in materials. Featuring ultra-high intensity (~ 1011 A/m2) and ultra-short duration (< 1 μs), the ENP technology activates non-equilibrium structural evolutions at nanometer spatial scale and nanosecond temporal scale. Several examples are provided to demonstrate its utility far outpacing any conventional materials processing technology. The ENP technology gives a practical tool for exploring the intrinsic mechanism of electric-field effects and a pathway towards the rapid industrial manufacturing of materials with unique properties.

PROBLEMS OF TRAINING SPECIALISTS IN THE FIELD OF MATERIALS SCIENCE, MATERIALS TECHNOLOGIES AND METALLURGY

Technological sovereignty of Russia largely depends on the effectively functioning system of engineering personnel training, the basic directions of which are considered to be those related to metallurgy, materials science and materials processing technologies. The article is aimed at determining the systemic problems of personnel training in the above-mentioned directions and suggesting possible ways to eliminate the problems. The first stage of the study analyzed the dynamics of admission and graduation of bachelors and masters in the enlarged group of 22.00.00 “Technologies of Materials” from 2016 to 2022. At the second stage the contingent preservation was assessed for Bachelor’s and Master’s degree programs on the basis of comparing the number of students studying in the first year and the number of graduated students. The following was established: a) the gap between the admission control figures (ACF) and the number of students admitted to study in the corresponding educational programs at the expense of federal budget allocations; b) relatively low values of student contingent retention. Bachelor’s degree programs are characterized by a “negative” gap between the number of those admitted to study under bachelor’s degree programs and the allocated Admission control figures i.e. the number of those admitted is less than the ACF; for Master’s degree programs, a “positive” gap has been recorded since 2019, i. e. the number of those admitted to study was higher than the ACF. The retention rate of the contingent in bachelor’s degree programs related to the study of materials science and materials technology is about 64%; metallurgy - about 54%. The retention rate of the contingent in the master’s program tends to decrease and amounts to about 70%. The reasons for the identified problems and ways to solve them are formulated.

FORMATION OF DESIGN AND TECHNOLOGICAL COMPETENCE OF PUPILS THROUGH THE TRANSFORMATION SYSTEM

In this article, the interpretation of transformation in technology lessons, the use of the transformation system in the organization of material processing technology classes, and the introduction of the capabilities of the Gemini CAD program through the transformation system, as well as the use of the transformation system in the formation of design-technological competence in pupils is thought about.

Process-structure-property studies on synergetic effect of contact and non-contact ultrasonication in AA5083-based bulk nanocomposite

High strength-to-weight ratio materials such as Al- and Mg-based nanocomposites have gained growing interest in engineering applications for aerospace, automotive, marine, energy, and military. This unabated demand can be met with the advent in materials science and processing technologies. The current study demonstrates a recently developed the technique that consists of the synergetic effect of contact and non-contact ultrasonication of liquid melt for dispersing nano-sized Al2O3 reinforcements in AA5083 alloy matrix. The work is primarily focused on the effects of two-step ultrasonication on wettability, dispersion of the nano-reinforcements in the AA5083 alloy matrix, and the resultant strengthening. The resultant is the AA5083–1 wt-% Al2O3 bulk nanocomposite, a high strength-to-weight ratio material. The extensive microstructure analysis comprising scanning electron microscopy (SEM), transmission electron microscopy (TEM), and energy dispersive X-ray spectroscopy (EDS) mappings reveals the uniform dispersion of nano-particles in different phases of the matrix. The electron back scattered diffraction (EBSD) studies confirm the grain refinement while the X-ray diffraction (XRD) identifies the various phases formed are determined using XRD. The achieved uniform dispersion in the nanocomposite is explicated based on the enhanced wettability due to the presence of Mg in the alloy, preheating of nano-particles, and the synergetic effect of contact and non-contact ultrasonication that avoids the formation of zones of lower cooling rates resulting in powerful micro-convection. The resultant enhancement in the mechanical properties is explained based on available strengthening mechanisms. A comprehensive discussion on process-structure-property correlation has been presented.

Neolithic Liner Dagger from Ust-Narym in the Irtysh River Valley

The present research featured a slotted, or liner, bone dagger from the Neolithic layer of the Ust-Narym settlement on the Irtysh River. Its design, material processing technology, and functional purpose make it a rare, as well as the most ancient example of hand-to-hand combat weapons found in Kazakhstan. This composite object was carved from the posterior left metatarsal bone of a wild auroch with the help of several tools. It includes thin and sharp flint inserts, which were attached into the grooves on the side faces of the dagger frame with a special adhesive substance. An additional nozzle for a short handle made it possible to use this piercing-cutting weapon in battle. It is decorated with dots and circles connected by straight lines, which probably means it was a socialized object of ritual use associated with sacrifice. Typologically, the dagger from Ust-Narym is similar to artifacts found in the Late Paleolithic and Mesolithic sites in the south of Western Siberia, in the Urals, in the Baikal region, and in Eastern Europe. The dagger marks a milestone in the technical and technological development of ancient Eurasian peoples. It also illustrates the ethno-social and cultural processes across the vast territory of Eurasia.

Application and development prospects of nanomaterials in multiple fields

Nanomaterials have unique structures and characteristics that allow them to exhibit far superior or new properties in many aspects than conventional materials. With the continuous progress in materials science research, the manufacturing and processing technologies of nanomaterials have also been fully developed in recent years. Nanomaterials of different types, structures, and compositions have been applied in many fields, such as construction, energy, environmental protection, and electronics, providing new ideas for solving many problems. In this paper, we first review the basic definition and properties of nanomaterials, then analyze and discuss the cases of nanomaterials already in use or promising design solutions in medicine, solar energy and textiles. This paper also summarize their advantages and manufacturing difficulties. All of these areas have mature nanomaterial products in use, and they provide ideas for further research and development in the future.