Spherical Materials Research Articles

Multiple Strategies to Build High-Performance Spherical Na-Ion Layered Oxide Cathodes.

The development prospect of layered transition metal oxides in sodium-ion batteries is excellent, but there are some problems, such as poor cycle stability and a complex phase transition. The spherical NaNi0.25Fe0.15Mn0.3Ti0.1Sn0.05Co0.05Li0.1O2 (SP-HEO) has been developed to address the challenges faced by O3-type layered oxide in sodium-ion batteries. The SP-HEO material is synthesized by piling and high entropy. The multiple strategies combine to enhance the electrochemical performance and air stability. The SP-HEO demonstrated a specific discharge capacity of 150.1 mA h g-1 at 0.1 C and 100.4 mA h g-1 at 7 C. Ex situ XRD analysis confirmed that the SP-HEO effectively retards complex phase transitions. This study not only introduces a high-entropy design for high tap density spherical storage materials but also dispels industry concerns regarding the performance of sodium ion layered oxide cathode materials.

An innovative sludge-derived capsule for self-healing cementitious materials

An innovative eco-efficient capsule utilizing drinking water treatment sludge (DWTS) as a healing agent for concrete crack sealing was developed. In this study, the core materials comprised a mix of DWTS and calcium hydroxide, granulated by poly (ethylene glycol). A non-toxic polymer, Ethyl cellulose (EC), is applied as the protective shell material. The morphology, internal structure, and leakage mechanism of capsules, self-healing performance of cracked mortars and the composition of resulting healing products were assessed. Obtained results indicated that EC uniformly covered the spherical core material following the designed coating procedures. The main elements released from the capsules were Ca, Al and Si after dissolution of polyethylene glycol (PEG), which would contribute to pozzolanic reactions inside the matrix. Cracks with an initial width of 400 μm were completely healed after 7 days of curing. Such a healing process also led to an 73% enhancement in compressive strength at a healing age of 28 days. The water tightness of capsule-based samples improved by more than 90% in the first 7 days, compared to only 10% in control samples. The predominant healing products were calcium carbonate in the form of calcite, and some content of aluminium-bearing phases derived from the pozzolanic reaction of DWTS.

Compressive Mechanical Properties and Energy Absorption of Cubic Spherical Hollow Cellular Material Based on the Rod and Curved Surface Structure

Cellular materials, such as lattices and honeycombs, were widely used for structural protection owing to their excellent mechanical properties. By combining the excellent characteristics of lattice and honeycomb curved surface structures, this study designed a cell called Cubic Spherical Hollow (CSH), which had the advantages of orthogonal isotropy and better spatial connectivity. Inspired by the micro-structural arrangement of bamboo fiber and conch shell, we designed the new CSH cellular materials through the interlayer offset strategy. Then, the effects of interlayer offset on the mechanical properties and compression deformation behavior were explored experimentally and simulatively. Compared with other cellular materials, CSH cellular materials exhibited excellent mechanical properties with higher specific strength and specific modulus. The arrangement offsets of the CSH cells between different layers led to a change in the deformation mechanism from a rod’s compressive mode to a combination of a rod’s compressive mode and curved surface’s bending mode. The initial peak stress and plateau stress decreased with the increased arrangement offsets of the CSH since the extruded protrusions of the structure filled the holes and reduced the lateral expansion behavior of the material in the pressurized environment. This phenomenon also reduced the transverse expansion and prevented the sudden change in stress in the constrained space, indicating that the structural deformation was stable and had excellent cushioning and energy absorption properties. In this study, the cellular material design strategy opens a new avenue for energy absorption.

A method for optimizing different geometric shields of D-T neutron generators by combining BP neural network and Analytic Hierarchy Process

In this paper, an optimization of shielding structures with different geometries is established for the D-T neutron generator system by combining Back Propagation (BP) neural network and Analytic Hierarchy Process (AHP). The D-T neutron generator (Model NG-9) used in the system was developed independently by Northeast Normal University. After investigating the rule of shielding performance among spherical, cylindrical and cubic geometries, the spherical shield is selected for BP neural network prediction to determine the total dose rate through it. Information about spherical multilayer-shielding structures and properties calculated by MCNP code is used to train the neural network. The predicted result serves as a parameter of the evaluation function, which provides a comprehensive assessment of the dose rate penetrated the shield, the shielding mass, and the shielding volume. Together with AHP, the weight factors are determined for all the optimization objectives to construct the evaluation function. By comparing its values, the optimal shielding structures for spherical, cylindrical and cubic materials are found. Against MCNP simulated values, the total dose rates’ errors of the optimal shielding structures for the sphere, cylinder, and cube are 1.72 %, -4.94 %, and -5.17 %, respectively. This result demonstrates that the combination of BP neural network and AHP is more effective in addressing multi-objective optimization problems related to the design of radiation shielding for various geometries.

Self-assembly core–shell hollow fly ash sphere-bridged Ti3C2Tx MXene 3D spherical/ lamellar composites with specific electromagnetic wave absorption performance

A new A/B spherical/lamellar electromagnetic wave absorption (EWA) model was established, in which A phase was a spherical material with low dielectric constant and B phase was a lamellar 2D material with high dielectric constant. Insulative fly ash cenospheres (FA) and conductive Ti3C2Tx flakes were selected as the A phase and the B phase which acted as the framework (as well as core) and the interface builder (as well as shell) respectively to construct the novel 3D connected structure system via simple self-assembly. FA, a cheap power plants solid waste, was used as an insulating bridge for Ti3C2Tx to help to adjust the conductivity, the electromagnetic parameters and the impedance matching. The synergistic effect of the special heterogeneous structures and the moderate composition of FA and Ti3C2Tx endowed the composites with controllable complex permittivity and excellent EWA performances. FA@T0.35 exhibited a RLmin of − 50.94 dB at 3.5 mm and its widest EAB was 4.25 GHz at 2.0 mm. FA@T0.40 reached a RLmin of − 45.13 dB with an EAB of 4.03 GHz at 2.0 mm. The widest EAB was 4.19 GHz at only 1.5 mm. The work offers a new guideline for designing a high-performance EWA material by using waste materials.

Constructing LiF‐Enriched Solid Electrolyte Interface on Graphene Arrays with Abundant Edges on Microscale Si‐C Anodes Toward High‐Energy Lithium‐Ion Batteries

AbstractSilicon (Si) anodes offer excellent lithium storage capacity for lithium‐ion batteries but face practical limitations due to significant volume expansion and low intrinsic electrical conductivity. These issues lead to side reactions that consume the electrolyte and impede ion‐electron transport, resulting in low areal loading (<2 mg cm⁻²) and restricted energy density. To address this, a scalable method is developed using spray drying of commercial graphite flakes (s‐Gr) and nanosilicon particles (n‐Si), followed by chemical vapor deposition to create microscale Si/C anodes (s‐Gr/n‐Si/VGs). Thin vertical graphene nanosheets (VGs) are grown on the surfaces and within the internal pores, forming a robust, micron‐sized Si/C spherical composite material. The VGs construct the conductive network, allowing the electrodes to operate at high areal loadings without pulverization and promoting LiF‐enriched solid electrolyte interphase for improved cycling stability. The s‐Gr/n‐Si/VGs maintain a capacity of 641.9 mAh g⁻¹ after 1000 cycles at 11.0 mg cm⁻², retaining 95.9% capacity. In pouch cells with NCM811 cathodes, the 5.0 Ah‐level cells achieved 80.0% capacity retention after 510 cycles at 1.0 C. This research provides a feasible pathway for manufacturing high‐performance, low‐cost, and scalable Si/C anodes suitable for high‐energy‐density lithium‐ion batteries.

Experimental investigation on the thermal enhancement of spherical macro-encapsulated phase change material assisted soil heat accumulators

Reserved cavities during construction have the potential to serve as the space to efficiently harness shallow geothermal energy resources in light of the underground spaces' rapid expansion. Earth-air heat exchanger technology is an effective way among all the technologies. However, as the heat storage capacity of the surrounding soil gradually diminishes due to the long-term operation of the system, it is recommended to incorporate phase change materials (PCMs) with a stabilized heat storage capacity to improve the overall thermal performance of the system. This research specifically recommends back-filling macro-encapsulated PCMs measuring 15–25 mm in order to prevent backfill contamination caused by PCM leakage. The shells and cores of the PCMs are polypropylene spheres and n-heptadecane. Different volume proportions of macro-encapsulated PCMs are used in the design of modified soil accumulators. 27 groups of orthogonal array experimental tables were made using the Taguchi method to test the improved heat accumulator's performance with different heating sources. According to the results, adding PCMs causes the peak temperature to change and increases overall energy storage by 7.2 %. The most significant factor is the soil moisture content, which accounts for 62.47 % of the overall impact of the PCM's heat storage ratio and total heat storage capacity. With a contribution of 20.41 %, the PCM ratio is ranked second. Furthermore, optimization options for the primary parameters that impact the total heat storage and heat storage ratio of the PCM are offered. This paper offers references for the potential use of the PCM-assisted EAHE system design in real-world engineering applications.

Prilling and Coating Strategy to Synthesize High-Performance Spherical NaNi0.4Fe0.2Mn0.4O2 Cathode Materials for Sodium Ion Batteries.

Low-cost sodium ion batteries are of great significance in large-scale energy storage applications. With its high energy density and simple synthesis process, layered transition-metal oxides have become one of the most likely sodium ion battery cathode materials to replace lithium ion batteries in the energy storage market. Here, we report a prilling and MoS2 coating strategy to prepare the spherical cathode material. The spherical micronano particles shorten the diffusion path of Na+, restrain the complexity phase transitions, and enhance the tap density of the materials. In addition, the MoS2 coating improves the electrical conductivity of the material and the structural stability of the cathode material in air. The initial specific discharge capacity is 148.4 mA h g-1 at 0.1 C, which can be maintained at 128.9 mA h g-1 after exposure to air for 10 days. This method dramatically improves the energy density and structural stability of the cathode material, which provides a new scheme for preparing high-performance sodium ion batteries.

Spherical nanocrystalline ScYSZ thermal barrier material by a novel supersonic plasma spheroidization method: Simple synthesis and excellent performance

The performance of plasma sprayed thermal barrier coatings (TBCs) is strongly dependent on the quality of the feedstock powders, which usually are fabricated by conventional spray drying and multi-step sintering methods. In this work, a novel supersonic plasma spheroidization technology was employed to fabricate the spherical nanocrystalline Sc2O3-Y2O3 co-stabilized ZrO2 (ScYSZ) powder. The deformation process from the irregular powder to the spherical one was stimulated by the COMSOL phase field simulation. The results suggested that the original irregular pyrolysis products of ScYSZ precursors were aggregated into spherical powders by plasma spheroidization technology. The COMSOL simulations verified that the powder changed from irregular particles to spherical ones. The spheroidized ScYSZ particles exclusively consisted of non-transformed t’-ZrO2 phase and showed good fluidity, smooth surface and high apparent density, which were expected to have a broader application prospect in the field of TBCs and other ceramic coatings.

Synthesis of an ion-imprinted starch phosphate porous carbonaceous material removing U(VI) from wastewater: Kinetics and mechanism

Uranium enrichment and separation are important for the sustainable development of nuclear energy. In this study, reverse-phase emulsion crosslinking polymerization was used to synthesize spherical hollow porous carbon materials (II-CLSPC) with a “red blood cell” morphology after roasting. The soft template method was used to modify II-CLSPC to obtain an open pore structure, which increased its contact area. Based on this, ion imprinting was conducted to improve the selective adsorption of U(VI). A spatial site matching the size of U(VI) was formed after ion template removal, which played a crucial role in this process. Multifaceted and multilevel improvements of II-CLSPC facilitated rapid adsorption, reaching equilibrium at 40 min and a removal rate of 94.6 % (pH 5, 298 K). The pseudo-second-order kinetic model and Langmuir isothermal model indicated that the adsorption process of uranyl ions by II-CLSPC involved via monolayer chemisorption with a theoretical saturation adsorption capacity of 653.6 mg g−1. In addition, II-CLSPC exhibited excellent selectivity (KdU = 3.7 × 104 mL g−1), cyclic stability, and salt tolerance, making it a promising candidate for uranium removal from wastewater.

Bond strength of epoxy-based composites at the interface with surface deposited metal layer: A comparative study with different dimensional fillers

With the complexity of the working environment, pure epoxy resin can no longer meet the requirements, and the weak interfacial bonding between metal layer and epoxy-based composites limits its development. In this work, we propose a novel molecular grafting modification technique by using the active functional groups of polymers, which can apply to epoxy-based composites with various fillers to improve the adhesive strength of the interface between the metal film and matrix. 3D surface profile and surface wettability were used to characterize the effect of fillers on the surface of epoxy composites. Scanning electron microscope (SEM) and Raman spectroscopy were utilized to judge the interface failure modes of the composites. Peeling test and surface-enhanced Raman scattering (SERS) were conducted to examine how fillers affected adhesion. The results showed that silane grafting substantially improved the bonding between the epoxy-based composite matrix and the metal layer without the need for alkaline washing and palladium (Pd) activation steps on the substrate. The average adhesive strength can reach a maximum of 17.76 N/cm. The study also revealed the effect of filler size on the interfacial adhesive strength. The interfacial adhesive strength was increased by two dimensional lamellar materials, decreased by one-dimensional tubular materials, and remained unaffected by zero-dimensional spherical materials. This study may have positive implications for improving interfacial bonding between metal and polymer composite surfaces.

Soft template-induced self-assembly strategy for sustainable production of porous carbon spheres as anode towards advanced sodium-ion batteries

Doped porous carbon is a prominent sodium anode material with high specific surface area (SSA) and abundant pore structure. Compared with the traditional “hard template” technique for the synthesis of porous carbon, the “soft template” method offers a more efficient synthesis process and simplified template removal. In response to the urgent need for eco-friendly synthesis methods for functional doping, our research introduces an innovative method using biomass-derived tannic acid as a precursor. We have successfully synthesized N/S double-doped porous spherical carbon materials (DF-N/S) through a self-assembly process driven by hydrogen bonding and solvent evaporation. As an anode material for sodium-ion batteries (SIBs), DF-N/S demonstrates superior electrochemical performance, achieving a specific capacity of 327.04 mAh g−1 at a current density of 0.05 Ag-1 in ether-based electrolytes. The remarkable sodium storage efficiency of DF-N/S has been thoroughly examined through kinetic analyses and ex-situ characterization methods. This study aims to provide a sustainable and widely adaptable method for the soft template production of doped carbon, while also shedding light on the intricacies of energy storage mechanisms in both ether/ester-based electrolytes.

Quantitative selection of sample structures in small-angle scattering using Bayesian methods.

Small-angle scattering (SAS) is a key experimental technique for analyzing nanoscale structures in various materials. In SAS data analysis, selecting an appropriate mathematical model for the scattering intensity is critical, as it generates a hypothesis of the structure of the experimental sample. Traditional model selection methods either rely on qualitative approaches or are prone to overfitting. This paper introduces an analytical method that applies Bayesian model selection to SAS measurement data, enabling a quantitative evaluation of the validity of mathematical models. The performance of the method is assessed through numerical experiments using artificial data for multicomponent spherical materials, demonstrating that this proposed analysis approach yields highly accurate and interpretable results. The ability of the method to analyze a range of mixing ratios and particle size ratios for mixed components is also discussed, along with its precision in model evaluation by the degree of fitting. The proposed method effectively facilitates quantitative analysis of nanoscale sample structures in SAS, which has traditionally been challenging, and is expected to contribute significantly to advancements in a wide range of fields.

Strategy for a high thermal conductivity and low thermal resistance under compression of oriented carbon fiber with spherical alumina thermal interface material

Thermal pads prepared with pitch-based carbon fibre (CF) orientation have garnered widespread attention due to their generally higher through-plane thermal conductivity. However, these thermal pads must undergo compression during the assembly process. When the compression exceeds a certain threshold, the orientation degree of the CFs inside the thermal pad can change, leading to a reduction in thermal conductivity. In this study, spherical alumina and CF were utilized to optimize thermal transfer stability under compression. The results demonstrate that the composites can still maintain efficient and stable heat transfer even when compressed by 25 %, which represents a more than 60 % improvement compared to pure CF-oriented composites. Furthermore, the relative motion between spherical alumina and CF, driven by their significant morphological differences, enhances the degree of CF orientation during the orientation process. With only 11.8 wt% CF loading, the composite achieved an impressive through-plane thermal conductivity of up to 20.4 W·m−1·K−1.

A novel powder sheet laser additive manufacturing method using irregular morphology feedstock

Irregular (i.e. non-spherical) morphology powder is more cost-efficient to produce than spherical shaped powder. However, its reduced levels of flowability limit the wide application ranges of laser beam powder bed fusion (LPBF). To address this issue, a novel powder sheet additive manufacturing concept (MAPS) is proposed. Herein, a pre-manufactured metal particle-polymer binder composite (i.e. powder sheet) feedstock is employed as a raw material. The printability of irregularly shaped powder particles in sheet (MAPS) format was physically investigated using a range of different process parameters. The manufacturing process was observed by high-speed imaging. Microstructural and chemical element characterisations of the irregularly shaped powder particle print were then compared against those prints which were conducted using sheet-based (MAPS) spherical powder morphologies. The results indicated that the geometric accuracy and density of irregular powder morphology sheet printing improved when using a negative defocus strategy of the laser beam. A negative defocusing strategy allowed for the melting mode of the material to be transformed from keyhole to a more favourable conduction state. High speed imaging revealed that more spatter and vapour plume were observed with the increase in the magnitude of the negative defocus. The multi-morphology 304 L stainless steel (SS304) samples were printed in a single printer using an efficient method for the first time, i.e. printing spherical SS304 material on top of irregular SS304. EDX results indicated an insignificant change of chemical elements between the spherical and irregular prints. EBSD results revealed that columnar grains could grow through the irregular-spherical transition zone and similar grain size can form between spherical and irregular prints. The results of this study provide insights into the optimum printing configurations for powder sheet additive manufacturing using a cost-effective solution of irregular morphology material.

Effects of synthesis conditions on particle size and pore size of spherical mesoporous silica

The particle size and pore size of spherical mesoporous silica materials play significant roles in their application. However, relatively limited systematic research has been conducted on how preparation conditions influence these properties. In particular, the effects of some important factors have not been adequately studied, including reaction time, reaction temperature, and organic solvent type. In this work, octane and water were used as solvents, and tetraethyl orthosilicate was used as the silicon source to systematically study the effects of reaction time, reaction temperature, different organic solvents, octane/water mass ratio, styrene template concentration, and surfactant (cetyltrimethylammonium bromide, CTAB)/H2O mass ratio on the particle morphology, particle size, and pore size of silica. The results suggest that the above-mentioned neglected factors exert a substantial influence on both particle size and pore size. In the experimental temperature range, the pore diameter decreases and the particle size increases with increasing temperature. The maximum particle size and pore size are achieved after a reaction time of 3 h, and a further increase in reaction time leads to a smaller particle size and pore size. As the number of carbon atoms in the organic solvent decreases, the pore size also gradually increases. Styrene and organic solvents that dissolve in CTAB micelles are crucial factors in pore formation, while the aggregation of the swollen CTAB micelles influences the particle size. The changes in the pore structure stability and hydroxyl density of the synthesized samples in water were also studied. After undergoing water treatment at temperatures ranging from 20 to 60 °C for 72 h, both the pore structure and morphology remain relatively unchanged. When the temperature increases, the surface hydroxyl density exhibits a more pronounced increase in the presence of water. After water treatment for 5 h, the surface hydroxyl density reaches saturation.

PRODUCTION OF Ni-HARD ALLOY POWDERS BY GAS ATOMIZATION

Ni-Hard cast iron materials are frequently used in equipment where high wear resistance is required in industrial applications. Generally, Ni-Hard is produced by conventional casting techniques. In this study, it was aimed to produce Ni-Hard powders to produce Ni-Hard cast iron materials with additive manufacturing techniques. To produce spherical and fine raw materials for additive manufacturing techniques, the gas atomization technique with a close-coupled nozzle system was preferred for the production of Ni-Hard powders. Ni-Hard alloy was melted in a high-frequency 10kW induction furnace under a protective atmosphere integrated into the gas atomization system. During the atomization process, 150 °C superheating was applied to prevent the liquid metal from freezing and clogging the melt delivery tube. In terms of the continuity of the atomization process, the negative pressure (aspiration pressure) values formed at the end of the melt delivery tube at different gas pressures were measured. An aspiration pressure of -50 mbar was obtained under an atomization pressure of 35 bar. Particle size distributions, hall flow behaviour and angle of repose properties of the produced powders were determined. Finally, the characterization of the powders was carried out by scanning electron microscopy. It was determined that the powders obtained as a result of atomization exhibited a spherical morphology and a narrow size range. The Hall flow rate test result of Ni-Hard powders was measured as 22 seconds for 50 g.

Investigation of the Penetration Performance of the Radial Forging Process for Wrought Aluminium Alloy.

With the wide application potential of wrought aluminium alloy in aerospace, automobile and electronic products, high-quality aluminium bars prepared by the radial forging (RF) process have received extensive attention. Penetration performance refers to the depth of radial plastic deformation of forgings, which is the key factor in determining the quality of forging. In this work, the penetration performance of the radial forging process for 6063 wrought aluminium bars is investigated by simulation using FORGE software. The minimum reduction amount of the hammer is calculated based on the forging penetration theory of forging. The influence of process parameters including forging ratio (FR) and billet temperature on the effective stress and hammer load in the RF process are investigated. The RF-deformed billet is then produced with the optimal process parameters obtained from the simulation results. The average grain size of aluminium alloy semi-solid spherical material is used to evaluate the forging penetration. Simulation results showed that the effective strain at the edge and the centre of the RF-deformed billet gradually increases, but the increasing speed of the effective strain at the edge becomes low. The hammer load first decreases quickly and then gradually maintains stability by increasing the FR. It is found that low billet temperature and high FR should be selected as appropriate process parameters under the allowable tonnage range of RF equipment. Under an isothermal temperature of 630 °C and a sustaining time of 10 min, the difference in the average grain dimension between the edge and the centre positions of the starting extruded blank is 186.43 μm, while the difference in the average grain dimension between the edge and the centre positions of the RF-deformed blank is 15.09 μm. The improvement ratio of penetration performance for the RF-deformed blank is obtained as 91.19%.

Spreading Behavior of Non-Spherical Particles with Reconstructed Shapes Using Discrete Element Method in Additive Manufacturing.

The spreading behavior of particles has a significant impact on the processing quality of additive manufacturing. Compared with spherical metal material, polymer particles are usually non-spherical in shape. However, the effects of particle shape and underlying mechanisms remain unclear. Here, the spreading process of particles with reconstructed shapes (non-spherical particles decomposed into several spherical shapes by stereo-lithography models) are simulated by integrating spherical particles with the discrete element method. The results show that more cavities form in the spreading beds of particles with reconstructed shapes than those of spheres with blade spreading. Correspondingly, particles with reconstructed shapes have lower packing densities, leading to more uniform packing patterns. Slow propagation speeds of velocity and angular velocity lead to "right-upwards" turning boundaries for particles with reconstructed shapes and "right-downwards" turning boundaries for spherical particles. Moreover, as the blade velocity increases, the packing density decreases. Our calculation results verify each other and are in good agreement with the experiment, providing more details of the behavior of non-spherical particles before additive manufacturing. The comprehensive comparison between polymer non-spherical particles and spherical particles helps develop a reasonable map for the appropriate choice of operating parameters in real processes.

Preparation of nanodiamonds modified hard carbon with uniform spherical feature for improving sodium-ion storage performances

Sodium-ion batteries (SIBs) have received remarkable attention due to their abundant sodium (Na) content and low resources cost. However, the absence of high-performance anode materials make carbon-based SIBs still a challenge. Herein, nano-diamonds (NDs) modified gleditsia japonica shell carbon to form a uniform carbon microsphere, which improves the graphitization degree and Na ion adsorption, NDs also act as a strong scaffold to maintain its stability. This spherical carbon-based material exhibits superior performances including the enhanced capacity (270 mA h g−1 at 0.2C after 100 cycles) and long-cycle stability (155 mA h g−1 at 2C after 1000 cycles) when incorporated into SIBs. This work provides a green and simple synthesis strategy for fabricating high performance porous spherical carbon used for SIBs anode.