Mechanical Stability Research Articles

Polymer composites with advanced pigments: enhancing properties and applications

Purpose This study aims to explore the synthesis, characteristics and utilization of polymer composites integrated with cutting-edge pigments. Design/methodology/approach The incorporation of advanced pigments introduces functionalities such as enhanced mechanical strength, thermal stability, ultraviolet resistance and color stability, thus extending the range of applications in diverse fields including automotive, aerospace, electronics and construction. Findings This review discusses the mechanisms underlying the property enhancements achieved through the incorporation of advanced pigments and highlights recent developments in the field. Originality/value Polymer composites incorporating advanced pigments have garnered significant attention in recent years because of their potential to enhance various material properties and broaden their applications. This paper explores the fabrication methods of polymer composites reinforced with organic/inorganic advanced pigments in brief along with their characteristics and applications.

Hydrogen evolution reaction performance of Pt modified monolayer MC2 MXene (M=W, Cr, Mo)

The development of cost-effective hydrogen evolution reaction (HER) electrocatalysts has become pivotal in hydrogen production field. Because of the remarkable catalytic performance of Pt metal, developing low proportion Pt-based electrocatalysts should be very meaningful for entrepreneurs and scientists. In order to further decrease the economic cost, the HER electrocatalytic performance of low metal ratio Pt-doped MC2(M=Mo, W, and Cr) structures is investigated by first-principles calculations. It merits our attention that in monolayer WC2 when a Pt atom replaces a W atom, where HER occurs, the structure has a lowest overpotential of only 0.03 V, which is much lower than the reported value of pure Pt (111) (0.09 V) and the lowest value (-0.31 V) of WCx(x=1–4). It can be observed that some energy bands of Pt-WC2 cross the Fermi level, resulting in remarkable electronic conductivity. Specifically, Pt-WC2 shows good mechanical, dynamic, and thermal stabilities. Thus, single Pt modified monolayer WC2 can serve as an efficient economic electrocatalyst for HER. These findings can support strong theoretical basis for the experimental researches to develop a kind of excellent quality and reasonable price catalyst in the future.

Stability before and after percutaneous anterior medullary fixation of lateral compression 1 and 2 pelvic ring disruptions: Should surgeons prioritize the anterior ring?

Surgical intervention for lateral compression (LC) 1 and 2 pelvic ring fractures is controversial. Posterior ring stabilization remains the most common mode of initial fixation. However, greater mechanical instability is observed in the anterior component of LC pelvic fractures. This study tested whether reduction and percutaneous superior ramus fixation will decrease the instability of LC pelvic fractures on intraoperative fluoroscopic imaging. All adult patients (≥ 18 years) presenting with either a Young-Burgess LC1 or LC2 pelvic ring disruption treated operatively with percutaneous anterior followed by posterior fixation by a single surgeon from July 2021 to June 2023 were retrospectively reviewed. Displacement of the anterior ring to intraoperative manual internal rotation stress examination under fluoroscopy was compared before and after anterior pelvic ring reduction and fixation and prior to posterior pelvic ring fixation. Pre- and post-operative visual analog scores (VAS) for pain were also compared. Twenty-one patients with a mean age of 48.7 years were included. Fifteen patients (71.4%) presented with an LC1, and six (28.6%) with an LC2 injury patterns. Anterior pelvic fixation alone provided 7.5mm reduction in mean displacement of the anterior pelvic ring (pre-operative = 9.2 mm vs. post-operative = 1.6 mm, p < 0.001). VAS significantly decreased from 7.2 one-day pre-operatively to 2.2 twenty-four h post-operatively (p < 0.001). Reduction and fixation of the anterior pelvic ring prior to posterior fixation for LC1 and LC2 pelvic ring disruptions substantially improves mechanical stability on intraoperative stress examination. Combination of percutaneous anterior and posterior fixation significantly decreased VAS above the MCID 24 h after stabilization.

Reconstructing Helmholtz Plane Enables Robust F-Rich Interface for Long-Life and High-Safe Sodium-Ion Batteries.

Hard carbon (HC) is the most commonly used anode material in sodium-ion batteries. However, the solid-electrolyte-interface (SEI) layer formed in carbonate ester-based electrolytes has an imperceptible dissolution tendency and a sluggish Na+ diffusion kinetics, resulting in unsatisfactory performance of the HC anode. Given that electrode/electrolyte interface property is highly dependent on the configuration of Helmholtz plane, we filtrate proper solvents by PFBE (PF6- anion binding energy) and CAE (carbon absorption energy) and disclose the function of chosen TFEP to reconstruct the Helmholtz plane and regulate the SEI film on HC anode. Benefiting from the preferential adsorption tendency on HC surface and strong anion-dragging interaction of TFEP, a robust and thin anion-derived F-rich SEI film is established, which greatly enhances the mechanical stability and the Na+ ion diffusion kinetics of the electrode/electrolyte interface. The rationally designed TFEP-based electrolyte endows Na||HC half-cell and 2.8 Ah HC||Na4Fe3(PO4)2P2O7 pouch cell with excellent rate capability, long cycle life, high safety and low-temperature adaptability. It is believed that this insightful recognition of tuning interface properties will pave a new avenue on the design of compatible electrolyte for low-cost, long-life, and high-safe sodium-ion batteries.

MXene-powered flexible smart windows for sustained bending performance

Ti3C2Tx MXene is renowned for its high conductivity and flexibility, making it ideal for various applications. This study focuses on developing flexible and durable Polymer-dispersed liquid crystal (PDLC) based smart windows using Ti3C2Tx MXene-coated PET films, demonstrating sustained bending performance over 10,000 cycles. The fabrication process involved spin-coating of MXene dispersion (average flakes size ∼400 nm) on PET film to fabricate flexible transparent conductive electrodes (TCE) having a sheet resistance (Rs) of ∼550 Ω.sq.−1 and a transmittance of ∼80 % (at 550 nm). PDLC mixture containing liquid crystals and NOA65 monomer were sandwiched within MXene electrodes to prepare PDLC-based smart windows having a transmittance of ∼75 %. UV-cured polymer contributes to mechanical stability, while the Ti3C2Tx MXene electrodes impart electrical conductivity to the smart windows. The MXene electrodes demonstrate remarkable flexibility as evidenced by a minimal change in resistance, with a strain of 0.8 % resulting in a 0.7 % change in relative resistance (∆R/Ro) at a bending radius of ∼7.5 mm. The durability of flexible smart windows was investigated till 10000 bending cycles (bending radius of ∼9.5 mm). After sustained bending the smart films maintain ON-state transmittance in the 70–75 % range. These smart windows exhibit a variation of <5 % in ΔT (difference between OFF and ON-state transmittance) and the contrast ratio after 10000 bending cycles. These smart windows feature rapid switching time (ON/OFF) along with low power consumption of ∼8 Wm−2.

Mimicking human skin constructs using norbornene-pullulan-based hydrogels

There has been a huge demand for engineered skin tissues in the realms of both in vitro and in vivo applications. Selecting the right material scaffold is a critical consideration in making engineered skin tissues, since it should possess a good balance between elasticity and mechanical stability while promoting an adequate cell microenvironment to support both the dermal and the epidermal compartments of skin tissue. In this study, 3D-bioprinted norbornene-pullulan photocrosslinkable hydrogels were utilized as alternative scaffolds to produce epithelized dermal skin models. By employing visible light, 2.5 mm3 cell-laden hydrogels could be printed in 10 s. The thiol-ene photocrosslinking chemistry employed in this work enabled the formation of a well-defined extracellular matrix with orthogonal crosslinks, where encapsulated fibroblasts maintained high cellular viability rates. Through this method, an epidermal layer could be grown on top of the fibroblasts. The coexistence and interaction of human fibroblasts and keratinocytes were visualized by determining the expression of specific markers. This approach represents a promising starting point for the development of photocrosslinkable hydrogel-based human skin constructs by using thiol-ene norbornene chemistry, paving the way toward manufacture of complex in vitro models of human tissues. &amp;nbsp;

Polymer-Supported Graphene Sheet as a Vertically Conductive Anode of Lithium-Ion Battery.

The increasing demand for electric vehicles necessitates the development of cost-effective, mass-producible, long-lasting, and highly conductive batteries. Making this kind of battery is exceedingly tricky. This study introduces an innovative fabrication technique utilizing a laser-induced graphene (LIG) approach on commercial Kapton film to create hexagonal pores. These pores form vertical conduction paths for electron and ion transportation during lithiation and delithiation, significantly enhancing conductivity. The nongraphitized portion of the Kapton film makes it a binder-less, free-standing electrode, providing mechanical stability. Various analytical techniques, including scanning electron microscopy (SEM), energy dispersive spectroscopy (EDS), Raman spectroscopy, and atomic force microscopy (AFM) are utilized to confirm the transformation of a 3D porous graphene sheet from a commercial Kapton film. Cross-sectional SEM images verify the vertical connections. The specific capacity of 581 mAh g-1 is maintained until the end, with 99% coulombic efficiency at 0.1C. This simple manufacturing method paves the pathway for future LIG-based, cost-effective, lightweight, mass-producible, long-lasting, vertically conductive electrodes for lithium-ion batteries.

An extensive investigation of structural, electronic, and optical properties of inorganic perovskite Ca3AsCl3 for photovoltaic and optoelectronic applications: A first-principles approach using Quantum ATK tool

Perovskite-based solar cells have been researched for quite some time with the highest reported values of power conversion efficiencies at around 30.9 %. However, commonly investigated materials like lead halide perovskites, mixed halide perovskites, and tin-based perovskites have challenged researchers in terms of stability, toxicity, scalability, etc. In an attempt to overcome these limitations, we have conducted in-depth studies on perovskite material, i.e. Ca3AsCl3 using the QuantumATK Tool to establish its adaptability to solar cell applications. This material's mechanical stability has been established using the Born-Huang criteria. While analyzing electronic properties, Ca3AsCl3 possessed a direct energy bandgap of 1.742 eV. At 3.2 eV, the dielectric constant values, susceptibility, optical conductivity, and polarizability are reported to be 5.06, 4.06, 1.748 × 103 AV−1cm−1, and 6.859 × 10−39 C m2V−1 respectively. Current density values calculated using the FE model for the Ca3AsCl3-based perovskite Solar Cell (PSC) designed through the LCAO Device calculator, are in excellent agreement with those obtained from the SCAPS 1D model. The obtained values of the mechanical, electrical, optical, and structural properties of Ca3AsCl3 suggest promising applications in solar cells, optoelectronic devices, and a wide range of flexible electronic devices.

Oxygen-Terminated Polycrystalline Boron-Doped Diamond Superhydrophobic Surface with Excellent Mechanical and Thermal Stabilities.

Superhydrophobic surfaces are of great interest because of their remarkable properties. Due to its maximal hardness and chemical inertness, diamond film has great potential in fabricating robust superhydrophobic surfaces. In the present study, an oxygen-terminated polycrystalline boron-doped diamond (O-PBDD) superhydrophobic surface with micro/nano-hierarchical porous structures is developed. The preparation method is very simple, requiring only sputtering and dewetting procedures. The former involves sputtering gold and copper particles onto the hydrogen-terminated polycrystalline boron-doped diamond (H-PBDD) to form gold/copper films, whereas the latter involves placing the samples in an atmospheric tube furnace to form hierarchical pores. By controlling the etching parameters, the wettability of the O-PBDD surface can be adjusted from hydrophilic to superhydrophobic, which is significantly different to the normal hydrophilicity feature of O-termination diamonds. The water contact angle of the obtained O-PBDD surface can reach 165 ± 5°, which is higher than the superhydrophobic diamond surfaces that are reported in the literature. In addition, the O-PBDD surface exhibits excellent durability; it can maintain satisfactory superhydrophobicity even after high-pressure, high-temperature, and sandpaper friction tests. This work provides a new research direction for fabricating robust superhydrophobic materials with diamond film.

Biosustainable Multiscale Transparent Nanocomposite Films for Sensitive Pressure and Humidity Sensors.

Light weight, thinness, transparency, flexibility, and insulation are the key indicators for flexible electronic device substrates. The common flexible substrates are usually polymer materials, but their recycling is an overwhelming challenge. Meanwhile, paper substrates are limited in practical applications because of their poor mechanical and thermal stability. However, natural biomaterials have excellent mechanical properties and versatility thanks to their organic-inorganic multiscale structures, which inspired us to design an organic-inorganic nanocomposite film. For this purpose, a bio-inspired multiscale film was developed using cellulose nanofibers with abundant hydrophilic functional groups to assist in dispersing hydroxyapatite nanowires. The thickness of the biosustainable film is only 40 μm, and it incorporates distinctive mechanical properties (strength: 52.8 MPa; toughness: 0.88 MJ m-3) and excellent optical properties (transmittance: 80.0%; haze: 71.2%). Consequently, this film is optimal as a substrate employed for flexible sensors, which can transmit capacitance and resistance signals through wireless Bluetooth, showing an ultrasensitive response to pressure and humidity (for example, responding to finger pressing with 5000% signal change and exhaled water vapor with 4000% signal change). Therefore, the comprehensive performance of the biomimetic multiscale organic-inorganic composite film confers a prominent prospect in flexible electronics devices, food packaging, and plastic substitution.

Enhanced mechanical and surface chemical stability in cobalt-free, high-nickel cathode materials for lithium-ion batteries

Cobalt-free, high-nickel cathode materials are essential for the sustainable evolution of energy storage technologies, reducing the dependence on resources with significant environmental and social implications and simultaneously improving the efficiency and cost effectiveness of batteries. This paper introduces a cobalt-free, high-nickel cathode material called 0.01B-LiNi0.98Mg0.01Zr0.01O2 (NMZB) developed using a novel blend of elements to enhance mechanical and surface chemical stability. Detailed evaluations confirmed the successful integration of Mg, Zr, and B into the particles, with Mg and Zr primarily located within the particle interior and B predominantly on the surface. This unique elemental configuration significantly improves the stability of the bulk phase and surface structure of the material. In addition, the refinement of primary particles within NMZB further enhances its mechanical stability. As a result, NMZB exhibits exceptional electrochemical stability, achieving 90.5 % capacity retention after 200 cycles at a 1C rate. This compositional strategy incorporates a high nickel content into layered materials while eliminating cobalt, which is crucial for advancing the development of cost effective and high-performance lithium-ion battery technology.

Study of optoelectronic, transport, and mechanical aspects of lead-free double perovskites Rb2AgTlX6 (X = Cl, Br) for green energy applications

The double perovskites are emerging candidates for renewable energy applications. This work uses the extensive density functional theory (DFT) method to investigate the structural, optoelectronic, transport, and mechanical properties of Rb2AgTlX6 (X = Cl, Br). The thermal and structural stabilities of Rb2AgTlX6 (X = Cl, Br) are investigated through formation energy and tolerance factorevaluation.The Rb2AgTlCl6 and Rb2AgTlBr6 have direct band gaps of 1.61 eV and 1.08 eV. The reported band gap reduction is associated with the p-d hybridization of cations and anions. Investigating optical characteristics yields important insights via the dielectric constant ε(ω), refractive index n(ω), absorption α(ω), and reflectivity R(ω). The ability to absorb light in visible and ultraviolet spectra as demonstrated by optical characteristics highlights the potentialof Rb2AgTlX6 for solar cell technology. In addition, the significant electrical conductivity and Seebeck coefficient led to a notable reduction in heat conductivity and figure of merit values of 0.68 and 0.67 at higher temperatures. Elastic parameters, Pugh’s, and Passion’s ratios are studied to confirm materials’ mechanical stability and nature. The studied materials have been found mechanically stable and brittle. Together, our findings demonstrate the distinctive and intriguing features of Rb2AgTlX6 (X = Cl, Br) are suitable for cost-effective energy conversion applications.

Enhanced proton conductivity and mechanical stability of crosslinked sodium alginate as a biopolymer electrolyte membrane in fuel cell application

Abstract Nafion is a commercial polymer membrane that is commonly used in fuel cell systems, despite its major limitations such as high fuel crossover and high manufacture cost. The production of sodium alginate (SA) blended membrane with crosslinking agent (glutaraldehyde) and plasticizer (glycerol) is one of several current efforts to discover an alternative membrane with improved proton conductivity and mechanical properties. In this study, SA biomembranes were prepared using solution casting method and dried at a certain temperature. Then, the prepared membranes were immersed with 5% glycerol in different concentrations of glutaraldehyde. The cross-linked biomembranes underwent various tests such as liquid uptake, swelling ratio, ion exchange capacity, proton conductivity and mechanical stability. The best membrane achieved the highest proton conductivity with a value of 8.28 mS cm-1 and mechanical stability with a value of 218.00 MPa. Glutaraldehyde made a positive modification and had a beneficial impact on the characteristics of SA. The incorporation of glutaraldehyde and glycerol within the biopolymer notably improved the otherwise lacking mechanical properties of SA.

Effect of magnetite and graphene nanoplatelets on mechanical properties and thermal stability of thermoplastic elastomer

ABSTRACT Functional nanocomposites have garnered considerable attention due to their ability to exhibit multifunctional properties and achieve exceptional performance. This current paper aims to analyze the individual and combined effects of magnetite (Fe3O4) and Graphene nanoplatelets (GNPs) on the mechanical, thermal, and morphological properties of a blend consisting Thermoplastic elastomer (TPE) which is made up of Natural rubber (NR) and Polyaniline (PANi). Both nanocomposites were fabricated via melt blending method using an internal mixer, followed by compression via hot/cold pressing. The incorporation of Fe3O4 was observed to consistently enhance the flexural and impact properties compared to GNP-based nanocomposites. Notably, the nanocomposites filled with 6 wt% Fe3O4 displayed the highest flexural strength (2.1 MPa), flexural modulus (31.1 MPa), and impact strength (4.4 kJ/m2). Results from thermogravimetric analysis and differential scanning calorimetry demonstrated a significant improvement in thermal stability within the nanocomposites. The introduction of nanoparticles led to a delay in decomposition and melting processes. The hybridization of Fe3O4 and GNP proved effective in synergistically enhancing both mechanical performance and thermal stability. At optimum content, scanning electron microscopy micrographs revealed a uniform dispersion of Fe3O4/GNPs within the TPE-PANi blend, accompanied by strong interactions between the components.

Cationic lipid-coated bPEI/pDNA complexes: correlation between physicochemical and morphological properties

Cationic lipid–polymer hybrid nanoparticles (cLPHNPs) complexed with nucleic acids, also named lipopolyplexes, have been developed as an alternative to nonviral vectors. These core/shell structures have been introduced to mitigate the limitations of cationic liposomes and biodegradable polymeric nanoparticles (NPs). The colloidal study of hybrid structures opens interesting perspectives for developing novel carriers for drug and gene delivery applications. Morphology aspects (size, lamellarity, and nucleic acid localization) and physicochemical properties of nonviral vectors influence gene delivery. Unraveling the structure of lipopolyplexes can enable their rational design toward enhanced gene delivery. Herein, we investigated the cationic LPHNPs loading plasmid DNA (pDNA) structure using dynamic light scattering, cryo-TEM, and pDNA accessibility assay. This study used pDNA as a genetic cargo for association with a cationic polymer, branched polyethylenimine (bPEI). It was found that the morphology of cationic LPHNP structures is influenced mainly by the formation process. Cationic LPHNPs formulated with EPC, DOPE, and cationic lipid DOTAP showed various degrees of multilamellarity depending on the production method. The addition of lipid dispersion to bPEI-pDNA anionic polyplex induced multilamellarity, while the preformed cationic liposome induced core/shell-like structures. Also, cLPHNPs showed better mechanical stability than polyplexes in a centrifugal vacuum concentrator (CVC) process. The physicochemical properties of cLPHNPs, formed in the presence of CL, were kept constant without significant changes. We believe these obtained colloidal data may be used to investigate hybrid-gene nanocarriers and their production process.

Computational study to investigate effectiveness of titanium substitution in CaFeH3 perovskite-type hydride: An approach towards advanced hydrogen storage system

In recent years, there has been increased interest in hydrogen storage due to the numerous advantages hydrogen offers as an energy source. This study explores the structural, hydrogen storage, electronic, elastic, mechanical, and optical properties of Ca1-xTixFeH3 through DFT. After Ti substitution in the host material, structure phase transformation occurs: cubic → pseudo-cubic → cubic. Study compounds are thermodynamically stable and experimentally synthesizable according to the calculated negative formation energies. Gravimetric hydrogen storage capacities for different concentrations of Ti (x = 0, 0.11, 0.33, 0.55, 1) were calculated as 2.963, 2.938, 2.843, and 2.753 wt%, respectively. The investigation focuses on understanding the material's BS, Fermi level, and DOS, elucidating its metallic characteristics, and non-zero DOS at the Fermi level contributing to electrical and thermal conductivity. Elemental partial density of states reveals hybridization effects with Ti doping, affecting the valence band's atomic contributions. Using cubic symmetry, C11, C12, and C14 elastic constants were used to describe mechanical characteristics, and the Born criteria were met. Thus, mechanical stability was demonstrated for these compounds. Optical analyses exhibit changes concerning Ti concentrations and energy levels, including absorption spectra, conductivity, reflectivity, dielectric function, refractive index, energy loss function, and extinction coefficient. These findings shed light on the material's response to incident radiation and potential applications in hydrogen storage and optoelectronic devices.

Structural, Electronic, Mechanical and Magnetic Properties of AFeAs (A: Li, Na and K) Pnictides: A Density Functional Approach

In this comprehensive investigation, the physical (electronic, structural and magnetic) and mechanical characteristics of AFeAs (A=Li, Na, K) are examined by using first principle approximations. Employing optimized cell parameters, bulk modulus, phase stability and correlation of them with magnetic order is also reported. The equation of state described the existence of an antiferromagnetic ground state. The effects of structural alterations on electronic characteristics for all nonmagnetic and magnetic systems are also covered here. The mechanical stability and metallic nature of all AFeAs is revealed from the mechanical features and the electronic band diagram. The orbital partial density of state having mixed orbital containing degenerate 3dzx and 3dzy orbitals of the Fe-3d state are also discovered. Additionally, as many features of the stable KFeAs system were not previously quantified so, a comparative picture of KFeAs with the other two representatives (NaFeAs and LiFeAs) of A-111 groups is also provided.

Computational study to investigate effectiveness of titanium substitution in CaFeH3 perovskite-type hydride: An approach towards advanced hydrogen storage system

In recent years, there has been increased interest in hydrogen storage due to the numerous advantages hydrogen offers as an energy source. This study explores the structural, hydrogen storage, electronic, elastic, mechanical, and optical properties of Ca1-xTixFeH3 through DFT. After Ti substitution in the host material, structure phase transformation occurs: cubic → pseudo-cubic → cubic. Study compounds are thermodynamically stable and experimentally synthesizable according to the calculated negative formation energies. Gravimetric hydrogen storage capacities for different concentrations of Ti (x = 0, 0.11, 0.33, 0.55, 1) were calculated as 2.963, 2.938, 2.843, and 2.753 wt%, respectively. The investigation focuses on understanding the material's BS, Fermi level, and DOS, elucidating its metallic characteristics, and non-zero DOS at the Fermi level contributing to electrical and thermal conductivity. Elemental partial density of states reveals hybridization effects with Ti doping, affecting the valence band's atomic contributions. Using cubic symmetry, C11, C12, and C14 elastic constants were used to describe mechanical characteristics, and the Born criteria were met. Thus, mechanical stability was demonstrated for these compounds. Optical analyses exhibit changes concerning Ti concentrations and energy levels, including absorption spectra, conductivity, reflectivity, dielectric function, refractive index, energy loss function, and extinction coefficient. These findings shed light on the material's response to incident radiation and potential applications in hydrogen storage and optoelectronic devices.

High-temperature structural evolution and mechanical properties of oxygen-containing NiCrAlY coatings

NiCrAlY is utilized as a protective coating for gas turbine components at high temperatures. Enhancing the erosion resistance of NiCrAlY coatings can be achieved by optimizing their mechanical properties. In this study, a NiCrAlY coating containing oxygen was deposited by magnetron sputtering and investigated concerning microstructural evolution at 900° C. Oxygen inclusion does not increase the hardness of the NiCrAlY coating in its initial deposited form. When annealing at 900 °C for 1 h, the NiCrAlYO coating develops into a nanocrystalline structure, where Y2O3 is evenly distributed inside the γ/γ′ matrix. This leads to the phenomenon of age-hardening, causing the hardness to increase to 12.4 GPa. Conversely, the hardness of the O-free NiCrAlY coating sharply declines to 9.3 GPa. Moreover, the wear resistance of the NiCrAlYO coating has been enhanced at a temperature of 700 °C, owing to its exceptional mechanical stability.

Keratin hydrolysate as a chrome exhaust aid and keratin filler in leather processing: A cleaner technology approach for tannery solid waste management and leather manufacturing

Hair burning unhairing and dampening of tannery wastes during the hair-saving unhairing process are becoming significant problems in the tanning industry. Therefore, this research article focuses on the extraction of keratin hydrolysate (KH) and its application as a chrome exhaust aid and keratin filler in leather manufacturing process. The structure, morphology and functional groups of the extract were examined using X-Ray Diffractometer (XRD), scanning electron microscopy (SEM) and Fourier transform infrared spectrometer (FTIR), respectively. To study and contrast the degree of improvement in chromium uptake, the KH solution was applied both before tanning on the pickled pelt and after tanning during basification. The thermal stability, physical strength characteristics and organoleptic properties of the leathers obtained were characterized. Furthermore, the environmental impact of the tanning system was assessed through a comparative analysis of the spent liquors. Finally, experimental retanning process was conducted to replace the commercial protein filler (Celatan F: 50, 75, and 100 %) with KH solution, with concurrent processing of control leather using conventional chrome tanning agent at 6 % dosage of chromium. The FTIR analysis of the extract confirmed the presence of alkyl side chains of amino acids as well as carboxylic, amide, carboxyl group and aldehyde functional groups at 1400-1700 cm−1,3,303.46 cm−1,3270 cm−1 and 2752 cm−1, respectively. XRD spectrum showed two diffraction peaks at 2 theta values of 9.36° and 21.16°, respectively. Leathers with improved mechanical strength, organoleptic properties and thermal stability were obtained with 100 % substitution of Celatan F at pH 6 and 10 % chromium dosage. It was also discovered that the shrinkage temperature of the experimental leather was enhanced to more than 105 °C. Environmental impact evaluation on the spent liquor showed that the complete replacement of Celatan F with KH solution brought about a notable decrease in COD and TDS in the spent liquor. The extraction and application of tannery hair waste-based keratin hydrolysate as an efficient, environmentally friendly chrome exhaust aid and keratin filler has been attempted and established in this research article.