Additive manufacturing (AM) is a new paradigm for the design and production of high-performance components for aerospace, medical, energy, and automotive applications. This review will exclusively ...cover directed energy deposition (DED)-AM, with a focus on the deposition of powder-feed based metal and alloy systems. This paper provides a comprehensive review on the classification of DED systems, process variables, process physics, modelling efforts, common defects, mechanical properties of DED parts, and quality control methods. To provide a practical framework to print different materials using DED, a process map using the linear heat input and powder feed rate as variables is constructed. Based on the process map, three different areas that are not optimized for DED are identified. These areas correspond to the formation of a lack of fusion, keyholing, and mixed mode porosity in the printed parts. In the final part of the paper, emerging applications of DED from repairing damaged parts to bulk combinatorial alloys design are discussed. This paper concludes with recommendations for future research in order to transform the technology from “form” to “function,” which can provide significant potential benefits to different industries.
Physical vapour deposition (PVD) is a well-known technology that is widely used for the deposition of thin films regarding many demands, namely tribological behaviour improvement, optical ...enhancement, visual/esthetic upgrading, and many other fields, with a wide range of applications already being perfectly established. Machining tools are, probably, one of the most common applications of this deposition technique, sometimes used together with chemical vapour deposition (CVD) in order to increase their lifespan, decreasing friction, and improving thermal properties. However, the CVD process is carried out at higher temperatures, inducing higher stresses in the coatings and substrate, being used essentially only when the required coating needs to be deposited using this process. In order to improve this technique, several studies have been carried out optimizing the PVD technique by increasing plasma ionization, decreasing dark areas (zones where there is no deposition into the reactor), improving targets use, enhancing atomic bombardment efficiency, or even increasing the deposition rate and optimizing the selection of gases. These studies reveal a huge potential in changing parameters to improve thin film quality, increasing as well the adhesion to the substrate. However, the process of improving energy efficiency regarding the industrial context has not been studied as deeply as required. This study aims to proceed to a review regarding the improvements already studied in order to optimize the sputtering PVD process, trying to relate these improvements with the industrial requirements as a function of product development and market demand.
The development of edible films and coatings has seen remarkable growth in recent decades and is expected to have an important impact on the quality of food products in the coming years. This growth ...is attributed to the increasing knowledge of edible films and edible coating technology, as well as advances in material science and processing technology. Packaging is used in order to reduce synthetic packaging and can play a role as an eco-friendly biodegradable package or a protective coating on the food surface. A large amount of bio-based polymers have been used in the production of edible films and coatings. Novel sources of edible materials, as well as the novel processing techniques, are a subject of great interest due to their promising potential as innovative food packaging systems. This paper presents the concept and potential for application of new film-forming materials and management of food wastes from the fruit and vegetable industry, which can encounter problems in appropriate disposal. It summarizes the extensive knowledge about the new film-forming materials such as plant residues, flours and gums to show their protective effectiveness and suitability in various types of foods.
Plasma electrolytic oxidation (PEO), also called micro-arc oxidation (MAO), is an innovative method in producing oxide-ceramic coatings on metals, such as aluminum, titanium, magnesium, zirconium, ...etc. The process is characterized by discharges, which develop in a strong electric field, in a system consisting of the substrate, the oxide layer, a gas envelope, and the electrolyte. The electric breakdown in this system establishes a plasma state, in which, under anodic polarization, the substrate material is locally converted to a compound consisting of the substrate material itself (including alloying elements) and oxygen in addition to the electrolyte components. The review presents the process kinetics according to the existing models of the discharge phenomena, as well as the influence of the process parameters on the process, and thus, on the resulting coating properties, e.g., morphology and composition.
sp2 hybridized carbons constitute a broad class of solid phases composed primarily of elemental carbon and can be either synthetic or naturally occurring. Some examples are graphite, chars, soot, ...graphene, carbon nanotubes, pyrolytic carbon, and diamond-like carbon. They vary from highly ordered to completely disordered solids and detailed knowledge of their internal structure and composition is of utmost importance for the scientific and engineering communities working with these materials. Multiwavelength Raman spectroscopy has proven to be a very powerful and non-destructive tool for the characterization of carbons containing both aromatic domains and defects and has been widely used since the 1980s. Depending on the material studied, some specific spectroscopic parameters (e.g., band position, full width at half maximum, relative intensity ratio between two bands) are used to characterize defects. This paper is addressed first to (but not limited to) the newcomer in the field, who needs to be guided due to the vast literature on the subject, in order to understand the physics at play when dealing with Raman spectroscopy of graphene-based solids. We also give historical aspects on the development of the Raman spectroscopy technique and on its application to sp2 hybridized carbons, which are generally not presented in the literature. We review the way Raman spectroscopy is used for sp2 based carbon samples containing defects. As graphene is the building block for all these materials, we try to bridge these two worlds by also reviewing the use of Raman spectroscopy in the characterization of graphene and nanographenes (e.g., nanotubes, nanoribbons, nanocones, bombarded graphene). Counterintuitively, because of the Dirac cones in the electronic structure of graphene, Raman spectra are driven by electronic properties: Phonons and electrons being coupled by the double resonance mechanism. This justifies the use of multiwavelength Raman spectroscopy to better characterize these materials. We conclude with the possible influence of both phonon confinement and curvature of aromatic planes on the shape of Raman spectra, and discuss samples to be studied in the future with some complementary technique (e.g., high resolution transmission electron microscopy) in order to disentangle the influence of structure and defects.
Polylactic acid (PLA) is the most widely used raw material in extrusion-based three-dimensional (3D) printing (fused deposition modeling, FDM approach) in many areas since it is biodegradable and ...environmentally friendly, however its utilization is limited due to some of its disadvantages such as mechanical weakness, water solubility rate, etc. FDM is a simple and more cost-effective fabrication process compared to other 3D printing techniques. Unfortunately, there are deficiencies of the FDM approach, such as mechanical weakness of the FDM parts compared to the parts produced by the conventional injection and compression molding methods. Preparation of PLA composites with suitable additives is the most useful technique to improve the properties of the 3D-printed PLA parts obtained by the FDM method. In the last decade, newly developed PLA composites find large usage areas both in academic and industrial circles. This review focuses on the chemistry and properties of pure PLA and also the preparation methods of the PLA composites which will be used as a raw material in 3D printers. The main drawbacks of the pure PLA filaments and the necessity for the preparation of PLA composites which will be employed in the FDM-based 3D printing applications is also discussed in the first part. The current methods to obtain PLA composites as raw materials to be used as filaments in the extrusion-based 3D printing are given in the second part. The applications of the novel PLA composites by utilizing the FDM-based 3D printing technology in the fields of biomedical, tissue engineering, human bone repair, antibacterial, bioprinting, electrical conductivity, electromagnetic, sensor, battery, automotive, aviation, four-dimensional (4D) printing, smart textile, environmental, and luminescence applications are presented and critically discussed in the third part of this review.
The paper summarizes current knowledge of growth defects in physical vapor deposition (PVD) coatings. A detailed historical overview is followed by a description of the types and evolution of growth ...defects. Growth defects are microscopic imperfections in the coating microstructure. They are most commonly formed by overgrowing of the topographical imperfections (pits, asperities) on the substrate surface or the foreign particles of different origins (dust, debris, flakes). Such foreign particles are not only those that remain on the substrate surface after wet cleaning procedure, but also the ones that are generated during ion etching and deposition processes. Although the origin of seed particles from external pretreatment of substrate is similar to all PVD coatings, the influence of ion etching and deposition techniques is rather different. Therefore, special emphasis is given on the description of the processes that take place during ion etching of substrates and the deposition of coating. The effect of growth defects on the functional properties of PVD coatings is described in the last section. How defects affect the quality of optical coatings, thin layers for semiconductor devices, as well as wear, corrosion, and oxidation resistant coatings is explained. The effect of growth defects on the permeation and wettability of the coatings is also shortly described.
Carbon fiber reinforced polymer (CFRP) is widely used in the lightweight design of high-speed trains due to its high specific strength. In order to further reduce the weight of the high-speed train ...body, it is necessary to study the joining process and fatigue properties of CFRP/aluminum alloys (CFRP/Al) structure. In this work, the CFRP plate and 5083P-O aluminum plate were successfully connected by an induction brazing method. The optimum parameters of induction brazing were determined to be an induction temperature of 290 °C, a normal pressure of 200 kPa, and a holding time of 5 s. After the 5083 plate was pre-anodized, the tensile strength of the CFRP/5083 joint reached a maximum value of 176.5 MPa. The anodization process introduced more surface micro-structures on the 5083 plate, leading to a better wetting behavior between CFRP and oxide film. Meanwhile, a new chemical bond, Al-O-C, was also formed at the interface of the CFRP/5083 joint. The fatigue limit of the CFRP/5083 joint was calculated to be 71.68 MPa through high-cycle fatigue (HCF) testing. The fatigue cracks initiated from the interface of CFRP/oxide film, and then propagated to base metal. Finally, the oxide film was peeled off from the base metal under shear stress, which contributed to the fracture of the CFRP/5083 joint. The bonding strength between CFRP and 5083 aluminum alloy is far from the conventional welded joints. Therefore, feasible approaches should be proposed to obtain a more robust bonding between CFRP and aluminum alloy in the future.
The high specific strength, good corrosion resistance, and great biocompatibility make titanium and its alloys the ideal materials for biomedical metallic implants. Ti-6Al-4V alloy is the most ...employed in practical biomedical applications because of the excellent combination of strength, fracture toughness, and corrosion resistance. However, recent studies have demonstrated some limits in biocompatibility due to the presence of toxic Al and V. Consequently, scientific literature has reported novel biomedical β-Ti alloys containing biocompatible β-stabilizers (such as Mo, Ta, and Zr) studying the possibility to obtain similar performances to the Ti-6Al-4V alloys. The aim of this review is to highlight the corrosion resistance of the passive layers on biomedical Ti-6Al-4V and β-type Ti alloys in the human body environment by reviewing relevant literature research contributions. The discussion is focused on all those factors that influence the performance of the passive layer at the surface of the alloy subjected to electrochemical corrosion, among which the alloy composition, the method selected to grow the oxide coating, and the physicochemical conditions of the body fluid are the most significant.
Photovoltaic is one of the promising renewable sources of power to meet the future challenge of energy need. Organic and perovskite thin film solar cells are an emerging cost-effective photovoltaic ...technology because of low-cost manufacturing processing and their light weight. The main barrier of commercial use of organic and perovskite solar cells is the poor stability of devices. Encapsulation of these photovoltaic devices is one of the best ways to address this stability issue and enhance the device lifetime by employing materials and structures that possess high barrier performance for oxygen and moisture. The aim of this review paper is to find different encapsulation materials and techniques for perovskite and organic solar cells according to the present understanding of reliability issues. It discusses the available encapsulate materials and their utility in limiting chemicals, such as water vapour and oxygen penetration. It also covers the mechanisms of mechanical degradation within the individual layers and solar cell as a whole, and possible obstacles to their application in both organic and perovskite solar cells. The contemporary understanding of these degradation mechanisms, their interplay, and their initiating factors (both internal and external) are also discussed.
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