Metal Foil Research Articles

Ultraflat Cu(111) foils by surface acoustic wave-assisted annealing

Ultraflat metal foils are essential for semiconductor nanoelectronics applications and nanomaterial epitaxial growth. Numerous efforts have been devoted to metal surface engineering studies in the past decades. However, various challenges persist, including size limitations, polishing non-uniformities, and undesired contaminants. Thus, further exploration of advanced metal surface treatment techniques is essential. Here, we report a physical strategy that utilizes surface acoustic wave assisted annealing to flatten metal foils by eliminating the surface steps, eventually transforming commercial rough metal foils into ultraflat substrates. Large-area, high-quality, smooth 2D materials, including graphene and hexagonal boron nitride (hBN), were successfully grown on the resulting flat metal substrates. Further investigation into the oxidation of 2D-material-coated metal foils, both rough and flat, revealed that the hBN-coated flat metal foil exhibits enhanced anti-corrosion properties. Molecular dynamics simulations and density functional theory validate our experimental observations.

Resource-efficient electrodes with metallized woven-glass-grid current collectors for lithium-ion batteries.

A novel class of resource-efficient, woven-glass-grid current collectors (CCs) for Li-ion batteries is introduced. These CCs are based on ultra-light multifilament glass threads, woven to a grid and surrounded with a thin metal layer (equivalent to a 1 µm-thick metal foil) in a roll-to-roll physical vapor deposition process. This saves > 90% of the required Cu and Al metals and reduces the mass of the CCs by > 80%. At the same time, the gravimetric capacity of anodes with graphite and cathodes with LiCoO2 active material increases by 48% and 14%, respectively, while full cells are characterized by an increase of 26%. Thus, the specific energy can be improved by 25%. A complete anode and cathode fabrication process from preparing the CCs and electrodes to cells is described and demonstrated in coin cell format. Coin cells with woven-glass-grid CCs achieved 300 cycles with a capacity retention of 93%, a Coulombic efficiency of > 99.9%, and a higher rate capability until a C-rate of 3C. This technology opens up new possibilities for designing ultralight CCs with dedicated surface properties for Li and beyond Li batteries.

Analysis of Energy Flow to the Interface Microstructure and Its Effect on Weld Strength in Ultrasonic Additive Manufacturing

Ultrasonic additive manufacturing (UAM) is a process used for the three-dimensional printing of metal foil stock that can produce near-net-shaped metallic parts. This work details the development of an energy-based tool to identify the relationships between input energy, energy stored in the interface microstructure, and the strength of the weld interface in UAM. The stored energy in the grain boundaries of the crystallized grains in the interface microstructure are estimated using the Read–Shockley relationship. The energy stored in the interface is found to be positively correlated with the resulting weld strength. An energy flow diagram is developed to map the flow of energy from the welder to the workpiece and quantify the key participating energies such as the energy of plastic deformation, energy stored in the interface microstructure, energy required for asperity collapse, and heat generation. A better understanding of the flow of energy in UAM can assist in optimizing the process to maximize the portion of energy input by the welder that is used for bond formation.

A flexible porous polyimide/copper composite film toward high-mass-loading anodes in lithium-ion batteries

Conventional metal foil current collectors are essential for electronic conduction in lithium-ion batteries, but the planar structure limits the fast transporting of electron and the power density. Herein, a light, conductive, self-extinguishing, and flexible porous polyimide/copper composite film (PIF/Cu) derived from a polyimide foam was fabricated via hot pressing and electroless plating methods. The honeycomb structure was illustrated in PIF/Cu under a 3D X-ray tomography microscope, revealing the successful construction of a 3D conductive network. PIF/Cu-30 possessed an electronic conductivity of as high as 3.6 × 105 S m−1 at a bulk density of 0.26 g cm−3 and exhibited exceptional structural stability even after successive and harsh mechanical loads. Graphite with a mass load of 12 mg cm−2 was loaded into the PIF/Cu-30 to prepare the anode for cell assembly. The cells using PIF/Cu-30 achieved a better performance in capacity retention (98.2 %@60 cycles) than those using traditional Cu foils (55.1 %@60 cycles), which resulted from the fast transport of electrons and Li-ion through the 3D conductive networks in the porous PIF/Cu-30.

Long term durability of Tc-bulk and Tc-coatings in various environmental conditions

Technetium metal is renowned for its inertness in environmental conditions, rendering it an optimal candidate for use as a container material for high-level radioactive waste. Alternatively, thin technetium electroplated coatings can be employed to prevent corrosion of steel containers and the subsequent biofouling that may result. The utilization of metallic technetium in the design of containers for radioactive waste in deep burial may be promising from two perspectives: firstly, in terms of increasing their stability, and secondly, in terms of the utilization of technetium, which is a macrocomponent of radioactive waste. In this study, the resilience of the metal technetium and its two derivative coatings (amorphous and crystalline) was assessed under various conditions, including exposure to fresh groundwater and seawater. The multifunctional strain Shewanella xiamenensis DCB-2-1, known for its ability to enzymatically reduce pertechnetate ions, was used to investigate the possibility of microbial biofouling of metallic technetium. Laboratory experiments have demonstrated that amorphous electrodeposited technetium is more susceptible to oxidation processes compared to its crystalline counterpart. Ultimately, the most durable form of technetium was metal foil. The potential for biofouling on Tc surfaces is largely attributed to the diverse nature of the specimens’ surface. Research conducted in the Barents Sea has revealed that the accumulation of iron, calcium, and magnesium mineral phases within the microbial biofilm may shield beta radiation, resulting in the establishment of macro-fouling (Balanus and Mutilus).

Insights into the electrochemical performance of manganese dioxide coated metallic foils as potential electrodes for supercapacitors

AbstractManganese dioxide (MnO2) is a promising electrode material for supercapacitors due to its high theoretical specific capacitance. In this study, MnO2 particles were synthesized using a simple hydrothermal method and subsequently coated onto silver, nickel, and aluminum foils via dip coating. The structural, morphological, and functional properties of the resulting MnO2 nanocomposites were characterized using X-ray diffraction (XRD), scanning electron microscopy (SEM), and Fourier-transform infrared spectroscopy (FT–IR). Electrochemical impedance spectroscopy (EIS), galvanostatic charge–discharge (GCD), and cyclic voltammetry (CV) were employed to investigate the electrochemical performance of the coated metallic foils. The results demonstrated that MnO2/Ag foils exhibited the highest specific capacitance of 198 F g–1 at a scan rate of 0.25 A g−1, accompanied by excellent cycle stability (89% capacitance retention). This performance surpassed that of MnO2/Ni and MnO2/Al foils, which exhibited maximum specific capacitances of 150 and 101 F g−1, respectively. Additionally, MnO2/Ag foils displayed the highest charge storage capacity, as evidenced by EIS analysis, reaching 4000 Ω, nearly double that of MnO2/Ni and MnO2/Al foils. These findings highlight the potential of cost-effective and high-performance MnO2/Ag foils for widespread applications in energy storage devices such as electrochemical capacitors. Graphical Abstract

Bending properties and deformation micromechanisms of near-α titanium alloy sheets/foils considering initial texture characteristics and size effect

Clarifying the bending deformation behaviour of metal foils is essential for meeting the lightweighting requirements of metal honeycomb structures. This study selected Ti65 alloy specimens with various thicknesses and initial α-phase textures to conduct room-temperature three-point bending experiments. A detailed comparative analysis was performed on the bending deformation behaviour of Ti65 alloy sheets and foils. It reveals that in the foil specimens, the weakening effect of surface layer grains is significant. Under the influence of size effects, the springback angle of Ti65 alloy foils with coarse α-phase grains decreases markedly. Additionally, through various methods, including global Schmid factor analysis, lattice rotation analysis, and crystal plasticity finite element method simulations, the specific relationship between α-phase texture and the bending performance of Ti65 alloy foils was thoroughly investigated. The rolling process influences the bending performance of Ti65 alloy by determining the α-phase texture. Unidirectionally rolled Ti65 alloy products exhibit a transverse α-phase texture, which predisposes them to form transverse texture α-phase macrozones during bending. In contrast, cross-directionally rolled Ti65 alloy foils possess a basal α-phase texture biased toward the transverse direction. This not only helps avoid the formation of macrozones but also ensures coordinated deformation across the foil, resulting in superior bending performance.

Acoustic process monitoring during the laser beam welding of stainless-steel foils using an adjustable ring mode laser beam source

Electrification of the mobility sector is vital to meet the targets for reducing greenhouse gas emissions. Besides battery-based mobility solutions, polymer electrolyte membrane fuel cells (PEMFCs) are a promising technology for electrifying drive trains, especially in heavy-duty applications, such as maritime or logistics. Bipolar plates, a key component of PEMFCs, can consist of two stainless-steel foils that must be welded to be gas-tight. In order to join the two metal foils, laser beam welding is the state-of-the-art technology. Current challenges include process instabilities at higher welding speeds, such as the humping effect, which can cause weld seam imperfections. Therefore, applying sensors for laser beam welding is a promising approach to monitor the welding process. AISI 316L foils were welded within the scope of this work with various process parameters using an adjustable ring mode laser beam source. Additionally, an optical microphone was used as a process monitoring system. By applying different parameter settings and due to the introduction of artificial faults, weld seam defects, such as a burn-through or a gap, were induced. After utilizing a noise reduction algorithm for the acoustic signals, numerous features in the time and frequency domains were extracted, with which multiple machine learning algorithms were trained and compared concerning their performance. A light gradient boosting machine was identified as a suitable machine learning model for weld seam classification. Finally, hyperparameter tuning was conducted, which resulted in a cross-validation accuracy of 94.78%, depending on the quality categories considered.

A pulsed power facility for studying the warm dense matter regime.

A pulsed power facility has been designed for studying the warm dense matter regime. It is based on the pulsed Joule heating technique, originally proposed by Korobenko and Rakhel [Int. J. Thermophy. 20, 1257 (1999)], where a 3.96µF capacitor bench is used for inducing a solid to plasma phase transition to metallic foils confined into a sapphire cell. The first experiments have been conducted on pure aluminum. Experimental data have been collected using electrical and optical diagnostics. Direct measurements of tension, current, pressure, and particle velocity allow us to evaluate the equation of state (EOS) and the DC conductivity of expanded aluminum. The results are compared to hydrodynamic simulations performed with various EOS models. As a result, collected data on aluminum highlight the relevance of our experimental procedure for improving EOS modeling in the warm dense matter regime.

Optimal charging of Li-ion batteries using sparse identification of nonlinear dynamics

Optimal charging of Li-ion batteries requires careful management of charge rates, as high rates can lead to accelerated degradation, while low rates significantly extend charging times. Traditional methods for determining charge rates often rely on rule-based approaches, which typically fail to effectively balance battery performance with charging duration. To address this, we introduce a novel optimization approach that directly integrates the dual objectives of minimizing charge time and maximizing battery lifetime into the optimization process. Unlike most existing charge optimization methods that do not directly track battery lifetime and charge time simultaneously, our method employs a data-driven model that facilitates direct and dynamic estimation of both battery lifetime and charge time at each step of the optimization process. Specifically, we utilize the Sparse Identification of Nonlinear Dynamics (SINDy) algorithm to predict battery capacity and voltage dynamics, which informs the calculations of lifetime and charge time required to solve the optimization problem. This approach provides a balanced optimization strategy that enhances the effectiveness of battery’s performance while maintaining the efficiency of the charging process. We applied this method to a novel next-generation NMC811 battery, featuring a cathode comprised of 80 % nickel, 10 % manganese, and 10 % cobalt, and a lithium metal foil anode - a combination not extensively studied previously. Experimental validation demonstrated that when optimized charge rates are applied every 10 cycles in a 100-cycle operation, the method leads to more stable cycling and improved capacity retention of approximately 7.4 % over the nominal charge rate, demonstrating the potential of the developed approach.

Prediction of micro/meso scale forming limit for metal foils using a simple criterion

Accurately forecasting the forming limit of metal foils is essential in their micro-forming due to the appearance of necking failure easily. In order to accurately and easily forecast the forming limit of metal foils influenced by size effect, an idea for failure modeling of metal foils using the mechanism that different fracture modes of metal foils are related to shear bands is presented in this work. Based on the idea, a simple ductile failure criterion that considers the maximum shear stress and grain size effect but excludes the stress triaxiality is proposed, motivated by the demand to decrease the complexity of parameter calculation tests in micro-forming failure prediction. The proposed criterion and another criterion called as the μ-DF2022 model are applied to capture the forming limit curves of various thick copper and 304 stainless steel foils with different grain sizes to verify its advantage and performance, and the corresponding mechanisms of their prediction capabilities are also elucidated. Furthermore, the proposed and μ-DF2022 models are applied to forecast the limit drawing ratio of a 304 stainless steel foil to further show its performance and advantage in real micro-forming. The applications show that the proposed failure criterion effectively forecasts the forming limit of metal foils between equi-biaxial tension and uniaxial tension influenced by size effect. Moreover, the prediction accuracies using the proposed model and the μ-DF2022 model are comparable, whereas the proposed model does not require complex micro equi-biaxial tension tests, which are typically unavailable to many engineers and researchers, to calibrate its material parameters. Therefore, it is recommended to utilize the proposed criterion to capture the forming limit of metal foils in micro-forming. This work advances the forming limit modeling method of metal foils and provides insight into the application of uncoupled ductile failure criteria in the micro-forming of metal foils, which contributes to the development of their optimal micro-forming processes.

Study of burst mode for enhancing the ps-laser cutting performance of lithium-ion battery electrodes

The demand for lithium-ion batteries (LIBs) has increased significantly, leading to an increased focus on high quality production methods. In response to this growing demand, laser technology has been increasingly used for electrode notching and cutting. In addition, the advent of high-power ultrashort lasers equipped with burst mode capabilities represents a promising option for electrode cutting of LIBs. On the other hand, these types of lasers for this purpose are relatively unexplored in the literature. This study investigates the effect of various parameters, including the number of pulses per burst (ranging from 1 to 8), the pulse repetition rate (200.0, 550.3, and 901.0 kHz), and the burst shape (equal pulse peak and increasing pulse peak), on the laser cutting process of aluminum foil, cathode, copper foil, and anode. The results indicate that increasing the number of pulses per burst and the pulse repetition rate improves productivity and quality for all materials, with a more significant effect observed for metal foil than for cathode and anode materials due to the different laser-material interactions for metal foil and active material. The burst shape with equal pulse peaks was found to be a more suitable temporal distribution for cutting all materials compared to an increasing pulse peak distribution. The ablation efficiency was evaluated as a function of the peak fluence of a single pulse within the burst. The results emphasize that higher productivity at higher average power can be achieved by increasing the pulse repetition rate toward the MHz range with moderate pulse energies.

Low Temperature Plasma-Assisted Double Anodic Dissolution: A New Approach for the Synthesis of GdFeO3 Perovskite Nanoparticles.

Orthorhombic perovskite GdFeO3 nanostructures are promising materials with multiferroic properties. In this study, a new low-temperature plasma-assisted approach is developed via dual anodic dissolution of solid metallic precursors for the preparation of perovskite GdFeO3 nanoparticles (NPs) that can be collected both as colloids as well as deposited as a thin film on a substrate. Two solid metallic foils of Gd and Fe are used as precursors, adding to the simplicity and sustainability of the method. The formation of the orthorhombic perovskite GdFeO3 phase is supported by high-resolution transmission electron microscopy, X-ray diffraction, X-ray photoelectron spectroscopy, and Raman measurements, while a uniform elemental distribution of Gd, Fe, and O is confirmed by energy dispersive X-ray spectroscopy, proving the successful preparation of ternary compound NPs. The magnetic properties of the NPs show zero remnant magnetization typical of antiferromagnetic materials, and saturation at high fields that can be caused by spin interaction between Gd and Fe magnetic sublattices. The formation mechanism of ternary compound NPs in this novel plasma-assisted method is also discussed. This method is also modified to demonstrate the direct one-step deposition of thin films, opening up opportunities for their future applications in the fabrication of magnetic memory devices and gas sensors.

Feasibility study on the micro-forming of novel metal foil arrays based on submerged cavitating water-jet impingement

With the increasing demand for metal foil parts with micro-array structures in micro-electromechanical systems (MEMS), it is urgent to explore a novel array micro-forming technology with high efficiency, low cost, and high flexibility. The cavitation water jet uses the high-energy shock wave generated by the collapse of the cavitation bubble group as the loading force. It has the characteristics of large range of action, uniform pressure distribution, and can realize large-area array micro-forming processing. To verify the feasibility of cavitating water jet array micro-forming, this paper performs cavitating water jet array micro-forming on 304 stainless steel foil with a thickness of 80 μm, and analyzes the variation of cavitation bubbles collapse impact zone with target distance. The effects of target distance and impact time on the forming quality of metal foil array micro-holes were studied from the aspects of forming depth, surface roughness, and thickness thinning rate. The results show that the forming depth and uniformity of the array micro-holes located in the cavitation collapse area increase with time. However, with the increase of target distance, the forming depth increases first and then decreases. When the target distance is L = 120 mm, the forming depth reaches the maximum. The surface roughness ( Ra) of the array micro hole is Ra = 1.54 μm. The thickness thinning rate of the micro-forming parts is between 2% and 10%, and the maximum thickness thinning rate in the die fillet area is 13.5%. This paper provides a novel processing method for manufacturing metal foil parts with micro array structure.

Measurement of local Nusselt number and local recovery factor for impinging multiple compressible jets

In the present study the appropriate reference temperature is identified for the compressible impinging jet. Using the measured reference temperature, local recovery factor is calculated. The steady state thin metal foil technique is used for the measurement of target plate temperature. In this study, the effect of Mach number (Ma) at a constant Reynolds number (Re) and the combined effect of Mach number and Reynolds number on the heat transfer rate are investigated. For both the cases, jet-to-plate distance is varied from z/d = 5 to 12. For the first case (effect of Mach number at a constant Re = 20,000), Ma is varied from 0.15 to 0.85. In the second case (combined effect of Mach number and Reynolds number), Ma is varied from 0.2 to 0.78 and the corresponding Re variation is 7200 to 29,000. At a constant Reynolds number, the heat transfer coefficient increases with the increase in the Mach number. For a given Mach number and Reynolds number, the heat transfer rate decreases with the increase in the jet-to-plate distance. The recovery factor remains unaffected by the Mach number and jet-to-plate distance in the case of the concurrent variation of the Mach number and Reynolds number.

Developing a robust sensor for infrared imaging bolometers.

A new type of large area sensor for infrared imaging bolometers has been developed. It replaces the thin and fragile free-standing metal foils, which typically have been used, with a multi-layer coated sapphire (or diamond) substrate. Sapphire is transparent to mid-infrared wavelengths, is robust against transients, and can be thick enough to even be the vacuum window. The primary radiation absorber is still a thin deposited metal layer, but now it is partially insulated from the supporting sapphire substrate by a black (carbon-based) layer, which also acts as a blackbody remitter. Test results indicate 6× more noise equivalent power density (estimated NEPD = 23 W/m2 at 5ms camera exposure time, foil temperature decay time 60ms) for a 2μm gold-coated sapphire disk compared to estimated NEP = 4 W/m2 at 1.8ms exposure time, with foil decay time 420ms, for a nominal 2.5μm thick platinum-free-standing foil.

Anomalous Proton Blocking Property of Pore-Free Graphene Oxide Membrane.

Graphene oxide (GO) has been attracting intensive attention as a flexible barrier film, however, provides no barrier for proton transfer due to its out-of-plane proton conductivity (10-6Scm-1) based on nanoscale defects with oxygen functional groups. In this study, it is reported that a pore-free GO (Pf-GO) membrane with controlled oxygen functional groups exhibits unexpected proton blocking behavior (10-11Scm-1). Proton permeation tests conducted in aqueous solution demonstrate that proton permeation is below the detection limit, and lithium metal foils coated with the Pf-GO show higher chemical stability to water than those coated with previously reported GO. The Pf-GO has periodic honeycomb atomic structure, which is found to impart the Pf-GO membrane with novel performance characteristics distinct from those of conventional GO.

Feasibility study on the micro-forming of novel metal foil arrays based on submerged cavitating water-jet impingement

Feasibility study on the micro-forming of novel metal foil arrays based on submerged cavitating water-jet impingement

Dry spot propagation during boiling crisis on thin metal heaters

This work presents the results of an experimental investigation aimed at elucidating the role of heater-side parameters on the growth of an irreversible dry spot during the boiling crisis of FC-72 on thin metal foils. A two-sided funnel shape of the heater is adopted to induce the occurrence of the boiling crisis in the middle of the foil and capture the expansion of the critical dry patch through high-speed infrared thermometry. In agreement with pre-existing literature, critical heat flux values achieved during this experimental campaign are shown to increase with bulk subcooling, thermal effusivity, and thickness of the heater. The transient temperature field at the boiling surface is used to capture the spatiotemporal evolution of the dry spot and investigate the effect of heater’s parameter on dry spot propagation. Results collected in this work show that the growth of an irreversible dry patch is strongly affected by the heat diffusion process occurring within the thin heater. The dry spot propagation rate is found to be proportionally correlated with the thermal diffusivity of the heater and the volumetric heat dissipation rate achieved at the boiling crisis, the latter being inversely proportional to heater’s thickness. These results provide important insights into the dryout dynamics related to the boiling crisis in thin wall heat transfer devices. Nevertheless, they open questions about the role of fluid thermophysical properties, that still deserve to be studied in detail.

Growth of centimeter-scale single-crystal graphene on polycrystalline copper foil for ultrahigh sensitive sweat sensors

The low-cost growth of wafer-scale single-crystal (SC) shows great potential in its practical application. Epitaxial growth of large-area SC graphene on pre-produced SC metal foil with a specific index surface has been reported, which requires a high cost and complexity of operational processes. Here, we demonstrate an easy and low-cost approach for the growth of wafer-scale SC graphene on polycrystalline copper foil, the growth kinetics and the lattice orientation for graphene growth controlled by induced surface steps. Despite graphene domains grown across the Cu grain boundary, the domains have a common crystal orientation at the macroscale induced by the surface steps. This work demonstrates the polycrystalline Cu foil can also grow graphene domains with unidirectional alignment and seamless stitching on the large area. The wearable 2D graphene array sensors have also been developed for the detection of interleukin-6 (IL-6) in sweat, which can locate and detect infection or disease in a non-invasive way. Our growth method and novel application put up a new way of production and utilization of SC two-dimensional (2D) materials.