Surface Deposition Research Articles

Multi-Pass Laser Polishing of As-Built Directed Energy Deposition Surfaces

Abstract Laser polishing (LP) provides a fast and efficient way of remelting part surfaces manufactured by additive manufacturing to alter both their geometric as well as physical properties. Depending on the laser parameters, remelted surfaces with different properties are achieved, with a majority exhibiting lower surface roughness compared to the original surface. In this study, a high-power continuous fiber laser is used to polish Inconel 718 (IN718) surfaces produced by depositing a single layer of clads on a steel substrate by the powder-blown directed energy deposition (DED) process. Polishing was performed under different sets of parameters, namely, laser power, beam diameter, feed rate or feed, hatch spacing, and the number of polishing passes. Their effects on the surface roughness profiles and the microstructural properties of the sample cross section were analyzed after one and two polishing passes. Optical microscopic images of the sample's cross sections show the presence of supersaturated γ phase particles, γ′+γ″ precipitates, Laves phases, and δ phase needles. The combined effect of high-temperature gradients and lower solidification rates in certain regions within the cross section results in undercooled regions and pseudo-heat treatment of unmelted regions close to the undercooled regions. These results are corroborated by indenting the various regions of the IN718 sample cross section with a pyramidal diamond indenter in the form of a grid, resulting in different micro-hardness values due to different densities of precipitate and phase transformed δ particles.

Electrodeposition of Cu with Amino Acids toward Electrocatalytic Enhancement of CO2 Reduction Reaction

This study investigates the effect of five amino acids on the electrodeposition of Cu to enhance its electrocatalytic performance in CO2 reduction reactions (CO2RR). The amino acids significantly influenced the deposition potential, crystallite size, and surface morphology of the electrodeposited Cu. Electrodeposited Cu with amino acids exhibit significantly smaller crystallites and higher particle density on carbon paper relative to amino acid-free samples. The integration of amino acids into the electrodeposited Cu was confirmed via high-angle annular dark-field scanning transmission electron microscopy, energy dispersive X-ray spectroscopy and hard X-ray photoelectron spectroscopy. All electrodeposited Cu exhibits a higher faradaic efficiency (FE) in the electrochemical reduction of CO2 to CH4 relative to Cu foil (24.2%), regardless of the presence or absence (55.0%) of amino acids when the electrolysis was conducted at −1.27 V vs RHE. Electrodeposited Cu with L-histidine, containing an imidazole group, demonstrates a higher FE of CH4 (67.6%) and effectively suppressed the hydrogen evolution reaction, highlighting the crucial role of amino acid functional groups, particularly imidazole, in augmenting the electrochemical conversion of CO2 to CH4. The study demonstrates the critical influence of specific functional groups in amino acids on the catalytic efficiency of electrodeposited Cu in CO2RR electrocatalysis applications.

Challenges for exploiting nanomagnet properties on surfaces.

Molecular complexes with single-molecule magnet (SMM) or qubit properties, commonly called molecular nanomagnets, are great candidates for information storage or quantum information processing technologies. However, the implementation of molecular nanomagnets in devices for the above-mentioned applications requires controlled surface deposition and addressing the nanomagnets' properties on the surface. This Perspectives paper gives a brief overview of molecular properties on a surface relevant for magnetic molecules and how they are affected when the molecules interact with a surface; then, we focus on systems of increasing complexity, where the relevant SMMs and qubit properties have been observed for the molecules deposited on surfaces; finally, future perspectives, including possible ways of overcoming the problems encountered so far are discussed.

Quantitative Surface Passivation Through Drop‐on‐Demand Inkjet Printing Enables Highly Efficient Perovskite Solar Cells

AbstractDeposition of a passivation layer on top of the perovskite is proven to be an effective method for improving the efficiency and long‐term stability of perovskite solar cells (PSCs). And the spin‐coating method is the most typical and popular method developed for this purpose. However, the spin‐coating method wastes substantial passivator materials, thus the quantitative relationship between the passivator amount and the device performance cannot be obtained. Herein, a quantitative deposition method is developed through drop‐on‐demand inkjet printing to investigate the influence of 2‐adamantylamine hydrochloride (2‐ADAHCl) deposition surface density on the device performance, which is found to have a significant impact on the device performance. A low deposition surface density of 1.1 µg cm−2 does not reach its optimum passivation capability. In contrast, an excess deposition surface density of 10.1 µg cm−2 would lead to energy level mismatch and large series resistance at the perovskite/hole transport layer (HTL) interface, thus resulting in inferior device properties. At an optimum deposition surface density of 2.5 µg cm−2, perovskite surface defects are greatly suppressed, and the interfacial contact between perovskite and HTL is improved. Finally, PSCs with a high efficiency of 24.57% are achieved with improved operational and environmental stabilities.

Iron phosphate nanoparticles as oil additives to enhance anti-wear properties

In recent years, nanomaterial lubricant additives have been widely studied in tribology. In this work, a new iron phosphate (FeP) nanoparticle was synthesized to enrich the anti-wear oil-based additives for titanium alloys. A series of tribological experiments were conducted using a reciprocating ball-on-disc tribometer. It has been confirmed that, as additives in polyalphaolefin 8 (PAO8), FeP nanoparticles exhibit excellent friction-reducing and anti-wear properties for TA5 titanium alloys. Compared with the pure PAO8, the friction coefficient (COF) and wear rate (WR) can be significantly reduced by 69.89 % and 99.57 % at a concentration of 30 wt%. The SEM and EDS confirmed that FeP nanoparticles can play a surface repair role and deposit on the titanium alloy surface to form a deposition layer, which was the key to anti-wear property. Besides, XPS characterization demonstrated that the formation of the deposition layer was attributed to the P–O–Ti bond at the interface, through which the phosphate in FeP can bind to and adsorb on the titanium alloy surface. This deposition layer containing FeP can greatly reduce the adhesive wear of the titanium alloy. Meanwhile, the rolling effect of nanoparticles inside the deposition layer promoted the friction-reduction.

Hybrid Analytical-Numerical Modeling of Surface Geometry Evolution and Deposition Integrity in a Multi-Track Laser-Directed Energy Deposition Process

Abstract Modeling multitrack laser-directed energy deposition (LDED) is different from single-track deposition. There is a temporal variation in the deposition geometry and integrity in a multitrack deposition, which is not well understood. This article employs an analytical model for power attenuation and powder catchment in the melt pool in conjunction with a robust fully coupled metallurgical-thermomechanical finite element (FE) model iteratively to simulate the multitrack deposition. The novel hybrid analytical–numerical approach incorporates the effect of preexisting tracks on melt pool formation, powder catchment, geometry evolution, dilution, residual stress, and defect generation. CPM 9V steel powder was deposited on the H13 tool steel substrate for validating the model. The deposition height is found to be a function of the track sequence but reaches a steady-state height after a finite number of tracks. The height variation determines the waviness of the deposited surface and, therefore, the effective layer height. The inter-track spacing (I) plays a vital role in steady-state height evolution. A larger value of I facilitates faster convergence to the steady-state height but increases the surface waviness. The FE model incorporates the effects of differential thermal contraction, volume dilation, and transformation-induced plasticity. It predicts the deposition geometry and integrity as a function of inter-track spacing and powder feed rate. The insufficient remelting of the substrate or the preceding track can induce defects. A method to predict and mitigate these defects has also been presented in this article.

Influence of processing parameters on the thermal history, microstructure and tensile properties of Inconel 738 produced by laser directed energy deposition

In this paper, laser directed energy deposition (LDED) technology was applied to produce non-weldable Inconel 738 parts. The influence of processing parameters including laser power, scanning speed and powder feeding rate on the thermal history of molten pool and the morphology of single track was evaluated. Considering the surface quality and deposition efficiency, the appropriate processing parameters for multilayer deposition were selected. Then the impact of laser power on the microstructure evolution and tensile properties of IN738 thin-wall parts was investigated. The research results show that increasing the laser power could increase the peak temperature and molten pool lifetime, but decrease the cooling rate. Increasing the scanning speed significantly increased the cooling rate but had little effect on the peak temperature. The thermal history was hardly affected by the powder feeding rate, but a too high powder feeding rate caused the particle adhesion and decline of surface quality. The microstructure of LDED-manufactured IN738 was composed of dense and fine dendrites. The higher laser powers of 800 W and 1000 W created higher temperature gradient within the molten pool, which promoted the epitaxial growth of dendrites. However, the long dendrites were prone to be torn apart under the transverse tensile stress, which was detrimental to the elongation and ductility. By comparison, when the laser power was 600 W, the growth direction of dendrites between adjacent layers was different and exhibited the best ductility.

Formation of SiO2 thin films through plasma- enhanced chemical vapor deposition using SiH4/Ar/N2O

SiO2 films and their formation technologies are critical for the fabrication of Si-based integrated circuits (ICs). SiO2 films fabricated using plasma-enhanced chemical vapor deposition (PECVD) have become increasingly important because of the increasing trend of three-dimensional (3D) architectures in ICs. SiO2 films formed by PECVD have been widely studied for over 40 years; however, owing to the complex plasma reactions and the differences in system conditions, the relationship between the experimental parameters and film characteristics are disputed. In this study, focusing on the two important characteristics (surface morphology and deposition rate) of SiO2 films for 3 D ICs manufacturing, SiO2 film growth was systematically investigated via SiH4/Ar/N2O in PECVD; a theoretical reaction process model (including gas-phase reaction, chemical adsorption, and surface reaction) bridging the experimental parameters (chamber pressure, gas ratio, radio frequency power, and substrate temperature) and characteristics (surface morphology and deposition rate) of SiO2 films was established. This study contributes to the precise formation of sub-100 nanometer SiO2 films using PECVD for manufacturing 3 D ICs.

Cover Feature: Molybdenum(0)‐Tricarbonyl Complex Supported by an Azacalix‐pyridine Ligand: Synthesis, Characterization, Surface Deposition and Conversion to a Molybdenum(VI)‐Trioxo Complex with O2 (Chem. Eur. J. 24/2024)

Cover Feature: Molybdenum(0)‐Tricarbonyl Complex Supported by an Azacalix‐pyridine Ligand: Synthesis, Characterization, Surface Deposition and Conversion to a Molybdenum(VI)‐Trioxo Complex with O₂ (Chem. Eur. J. 24/2024)

Salinity distribution in agricultural land by geophysical, hydrochemical and geostatistical approaches: a pilot area located in Qelabshowah–Belqas, East Nile Delta region, Egypt

The study area is situated in the Qelabshowah–Belqas region, known for its Quaternary deposits. This research aims to demonstrate the two-dimensional (2D) variation of subsurface layers and salinity distribution using geoelectrical data, hydrochemical analysis, and geostatistical analysis. DC resistivity measurements were taken at fifteen vertical electrical sounding (VES) survey points using a Schlumberger array (AB/2 = 100 m) along three profiles. In addition, an electrical resistivity tomography (ERT) survey was conducted with a dipole–dipole array across one profile. Seven surface water samples were collected in the area. From the 1D and 2D inversion of VES and ERT data sets, three-to-four geoelectric layers were identified, including unconsolidated surface deposits, saturated clayey sand, saturated sand, and a salt-rich layer. The 2D inversion of VES data revealed an ancient salt-rich layer deposited in swampy conditions over a conductive wet sand layer along profile one due to salt mineral infiltration and dissolution. The 2D inversion of ERT data showed accurate lateral geometric accuracy compared to the 2D inversion of VES data, highlighting geological features, such as caves in the second layer and a buried water canal on the ground surface. Surface water samples showed high salinity levels with sodium hazards, indicating an Na–Cl composition. Geoelectric and hydrochemical data sets were geostatistically analyzed using spherical variogram supported ordinary Kriging interpolation. The analysis indicated weak to moderate spatial dependency for true resistivity parameters, while sodium content (SC) and permeability index (PI) showed strong spatial correlation. The 2D spatial distribution resistivity maps based on the 1D inversion of VES data displayed a general decrease in resistivity with depth, likely due to clay minerals or moist soil in the second layer and saline irrigation water infiltration in the third layer. The 2D spatial distribution of SC and PI showed a high concentration zone, posing a potential risk to agricultural crops regardless of soil permeability. It is recommended to use these maps when cultivating plants that can tolerate high sodium levels during the reclamation process.

Molecular mechanism of complement inhibition by the trypanosome receptor ISG65

African trypanosomes replicate within infected mammals where they are exposed to the complement system. This system centres around complement C3, which is present in a soluble form in serum but becomes covalently deposited onto the surfaces of pathogens after proteolytic cleavage to C3b. Membrane-associated C3b triggers different complement-mediated effectors which promote pathogen clearance. To counter complement-mediated clearance, African trypanosomes have a cell surface receptor, ISG65, which binds to C3b and which decreases the rate of trypanosome clearance in an infection model. However, the mechanism by which ISG65 reduces C3b function has not been determined. We reveal through cryogenic electron microscopy that ISG65 has two distinct binding sites for C3b, only one of which is available in C3 and C3d. We show that ISG65 does not block the formation of C3b or the function of the C3 convertase which catalyses the surface deposition of C3b. However, we show that ISG65 forms a specific conjugate with C3b, perhaps acting as a decoy. ISG65 also occludes the binding sites for complement receptors 2 and 3, which may disrupt recruitment of immune cells, including B cells, phagocytes, and granulocytes. This suggests that ISG65 protects trypanosomes by combining multiple approaches to dampen the complement cascade.

Molecular mechanism of complement inhibition by the trypanosome receptor ISG65.

African trypanosomes replicate within infected mammals where they are exposed to the complement system. This system centres around complement C3, which is present in a soluble form in serum but becomes covalently deposited onto the surfaces of pathogens after proteolytic cleavage to C3b. Membrane-associated C3b triggers different complement-mediated effectors which promote pathogen clearance. To counter complement-mediated clearance, African trypanosomes have a cell surface receptor, ISG65, which binds to C3b and which decreases the rate of trypanosome clearance in an infection model. However, the mechanism by which ISG65 reduces C3b function has not been determined. We reveal through cryogenic electron microscopy that ISG65 has two distinct binding sites for C3b, only one of which is available in C3 and C3d. We show that ISG65 does not block the formation of C3b or the function of the C3 convertase which catalyses the surface deposition of C3b. However, we show that ISG65 forms a specific conjugate with C3b, perhaps acting as a decoy. ISG65 also occludes the binding sites for complement receptors 2 and 3, which may disrupt recruitment of immune cells, including B cells, phagocytes, and granulocytes. This suggests that ISG65 protects trypanosomes by combining multiple approaches to dampen the complement cascade.

THE EFFECT OF SURFACE ROUGHNESS AND ELECTROSTATIC BONDS OF RESIDUAL GASES ON THE SETTLING OF THE GYROSCOPE ROTOR

Consider the rotor of an electrostatic gyroscope (ESG) for contactless operation. The rotors of the ESG are made in the shape of a ball and placed in an electric field. The gyroscope operates contactless between the rotor and the mutual oscillation force of the electrodes. Air is sucked out of the chamber in which the rotor is located. Due to the lack of air resistance and the lack of friction force, the rotor can rotate for a long time. But the rotor, located inside the vacuum, also slows down. The reason for this is the roughness and residual deposits of the rotor surface. This is the notorious effect of the rotor of these residual gases on braking. When calculating the effect of residual gases on the rotor, it is considered as separate gases, and not as a homogeneous medium. For this reason, the viscosity of the gas can be set without consideration. The effect of the action of individual particles on the rotor is determined by the roughness of its surface. That is, the momentum by which the particles somehow hit the "peaks" or "troughs" creates a torque that acts on the rotor.

Effect of Graphene Oxide Surface Deposition Process on Synthetic Macrofibers and Its Results on the Microstructure of Fiber-Reinforced Concrete.

The improvement of the mechanical properties of concrete can be achieved with the use of synthetic macrofibers. However, this fiber-matrix interaction will be sufficiently efficient for tensile efforts only when there is a binding agent that associates the characteristics of the paste with the characteristics of the surface of the reinforcing material. As already identified, in a first phase of this research using synthetic microfibers, a better fiber-matrix interaction can be achieved with the surface treatment of synthetic fibers with graphene oxide. In this way, we sought to evaluate the surface treatment with graphene oxide on two synthetic polypropylene macrofibers (macrofiber "A" and macrofiber "B") and its contribution to the concrete transition zone. The surface deposition on the macrofiber was carried out using the ultrasonication method; then, the macrofiber with the best deposition for creating reinforced concrete mixtures was identified. To evaluate the quality of GO deposition, scanning electron microscopy (SEM-FEG) and energy-dispersive spectroscopy (EDS) tests were carried out; the same technique was used to evaluate the macrofiber-matrix transition zone. The SEM-FEG images indicated that macrofiber "B" obtained greater homogeneity in surface deposition and it presented a 13% greater deposition of C in the EDS spectra. The SEM-FEG micrographs for reinforced concrete indicated a reduction in voids in the macrofiber-matrix transition zone for concretes that used macrofibers treated with GO.

Experimental study of pool boiling performance of Fe3O4 ferromagnetic nanofluid on a copper surface

Nanofluids significantly enhance the critical heat flux of boiling heat transfer. This paper experimentally investigates the pool boiling performance and the influence mechanism of Fe3O4 nanofluids. Compared with deionized water, the 0.001 vol% nanofluid increases a maximum enhancement in critical heat flux by 47.90%. During nanofluid boiling, Fe3O4 nanoparticles are deposited on the surfaces. The nanoparticle deposition surfaces are physically characterized to explain the influence mechanism of Fe3O4 nanoparticles on boiling heat transfer. Nanoparticle deposition modifies the surface micro-morphology, which increases roughness and improves wettability. The changes are essential factors for the enhancement of the critical heat flux. This paper further analyses the boiling results of deionized water on the nanoparticle deposition surfaces. Compared with a polished surface, the critical heat flux and heat transfer coefficient of the nanoparticle deposition surface show maximum increases of 52.39% and 56.19%. Due to the similar enhancement of critical heat flux using the Fe3O4 nanofluid and the nanoparticle deposition surface, it is found that the increased critical heat flux of the nanofluids is attributed to the improvement of surface wettability and roughness by nanoparticle deposition. This study analyzes the mechanism of Fe3O4 nanofluid for enhancing pool boiling heat transfer from the perspective of modifying boiling surface characteristics by nanoparticle deposition, especially in wettability and roughness, which advances the understanding of enhanced boiling heat transfer by nanofluids.

Interfacial Engineering for Oriented Crystal Growth toward Dendrite-Free Zn Anode for Aqueous Zinc Metal Battery.

Zn deposition with a surface-preferred (002) crystal plane has attracted extensive attention due to its inhibited dendrite growth and side reactions. However, the nucleation and growth of the Zn(002) crystal plane are closely related to the interfacial properties. Herein, oriented growth of Zn(002) crystal plane is realized on Ag-modified surface that is directly visualized by in situ atomic force microscopy. A solid solution HCP-Zn (~1.10 at. % solubility of Ag, 30 °C) is formed on the Ag coated Zn foil (Zn@Ag) and possesses the same crystal structure as Zn to reduce its nucleation barrier caused by their lattice mismatch. It merits oriented Zn deposition and corrosion-resistant surface, and presents long cycling stability in symmetric cells and full cells coupled with V2O5 cathode. This work provides insights into interfacial regulation of Zn anodes for high-performance aqueous zinc metal batteries.

A Study on Boiling Heat Transfer Performance of TiO2-CNTs Hybrid Nanofluid on a Downward-Facing Heating Surface

In-vessel retention through external reactor vessel cooling (IVR-ERVC) is a strategy used to respond to nuclear reactor accidents. One of the key performance indicators determining its feasibility is critical heat flux (CHF). Our focus is on simulating real-world scenarios through surface pool boiling to improve the implementation of the IVR-ERVC strategy with hybrid nanofluids. Two groups of TiO2/COOH-CNTs hybrid nanofluids were prepared: group 1 with different concentrations at the same proportion and group 2 with different proportions at the same total concentration. Researchers compared the improvement of the two groups’ CHF and heat transfer coefficient (HTC), and analyzed the potential mechanism of heat transfer enhancement through roughness of surface, hydrophilicity, and scanning electron microscopy observations. The results showed that a mass concentration of 8 mg:8 mg per liter exhibited the best heat transfer performance, with a CHF enhancement up to 28.21% and an improvement in HTC as well. Meanwhile, correlations between alterations in surface roughness, hydrophilicity, and enhancements in CHF were observed. Finally, by detecting the deposition surface, the possible mechanism of TiO2/COOH-CNTs hybrid nanofluids in enhancing heat transfer was inferred.

Feasibility evaluation of near dissolved organic matter microfiltration (NDOM MF) for the efficient removal of microplastics in the water treatment process

Microfiltration (MF) using membranes with a mean pore size smaller than 0.45 μm has generally been used for particle removal from water, given that materials larger and smaller than 0.45 μm are regarded as particulates and dissolved organic matter (DOM), respectively. It is also the case for removing small-size microplastics (MPs). However, given their sizes (ca. 1 μm), there is room for further improvement of the productivity (i.e., water flux) in the pore size range of 0.45–1 μm on the condition that the removal rate is maintained. With this in mind, MF's water flux and removal rate were tested using seven different MF membranes, and the right pore, with the size of 0.8 μm, was found for MP removal, which is called near DOM (NDOM) MF. In the filtration test using polystyrene surrogate beads with an average particle diameter of 1.20 μm, NDOM MF exhibited a 1.7 to 13 times higher permeate flux than the conventional MF using 0.1, 0.2, and 0.45 μm membranes while maintaining a higher removal rate than 2 log. The excellent removal rate of the NDOM MF was attributable to the following three factors: (1) smaller mean pore size than the average particle diameter, (2) particle screening effect enhanced by the secondary layer formed by surface deposition, and (3) 3D mesh sublayer structure favorable for capturing penetrated particles. Furthermore, the outstanding filtration performance also appeared in a low-temperature (< 10°C) process, demonstrating that NDOM MF is feasible independently of temperature. Additionally, in constant flux filtration, NDOM MF demonstrated the long-term feasibility by lowering the transmembrane pressure and specific filtration energy by more than 2 times.

Migration trajectories and blocking effect of the fine particles in porous media based on particle flow simulation

The particle flow code method based on the discrete element method was used to establish the seepage migration model of fine particles [fine particles (FPs), i.e., suspended particles] in a porous medium. A series of numerical simulations were carried out by changing the particle size, seepage velocity, particle injection number, and wide particle size gradation. The research showed that large FPs play a major role in blocking porous medium channels when the injected FPs have a wide size gradation. Due to the blocking effect, small FPs that would not otherwise have deposited also deposit. Moreover, by increasing the number of large FPs in the mixed particles, the total number of particles deposited and the number of smaller FPs deposited will also increase. The distribution of FPs in porous mediums can be divided into three types: surface deposition, internal deposition, and non-deposition. When the seepage velocity increases and reaches a seepage threshold, which is the critical seepage velocity, the deposited FPs will once again be in a suspended state and undergo migration. On the contrary, the FPs will continue to maintain their sedimentary state, and the critical seepage velocity will also increase correspondingly with increasing particle size.

Acoustic signal monitoring using audible cracking sounds for efficient in-situ crack detection in laser directed energy deposition of hard surfaces

Laser directed energy deposition (LDED) is a promising way for creating hard surfaces like ceramic-reinforced metal matrix composites (MMC), but it faces a significant challenge in identifying crack formation during the process. As an emerging solution, acoustic signal monitoring is easy to be integrated within the process, and significantly reduces the time needed to detect micro-cracks in as-built MMC surfaces. This study reports on cracking sounds produced while employing LDED with SiC particles on a stainless steel 316 L substrate, examining the sound characteristics across time and frequency domains. Different sound sources in LDED are analyzed in the frequency domain, specifying the suitable frequency range for crack monitoring. Interestingly, the in-process micro-cracking on the hard surfaces produces a distinct audible ‘ping’ sound typically ranging between 12000 and 16000 Hz. By recording this sound, an efficient approach is proposed to identify crack generation during the rapid cooling in the LDED process of hard materials.