Journals >International Journal of Extreme Manufacturing
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2024
Volume: 6 Issue 5
18 Article(s)
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International Journal of Extreme Manufacturing
- Publication Date: Dec. 25, 2024
- Vol. 6, Issue 5, 1 (2024)
Solution-processing approach of nanomaterials toward an artificial sensory system
Song Okin, Cho Youngwook, Cho Soo-Yeon, and Kang Joohoon
Artificial sensory systems have emerged as pivotal technologies to bridge the gap between the virtual and real-world, replicating human senses to interact intelligently with external stimuli. To practically apply artificial sensory systems in the real-world, it is essential to mass-produce nanomaterials with ensured seArtificial sensory systems have emerged as pivotal technologies to bridge the gap between the virtual and real-world, replicating human senses to interact intelligently with external stimuli. To practically apply artificial sensory systems in the real-world, it is essential to mass-produce nanomaterials with ensured sensitivity and selectivity, purify them for desired functions, and integrate them into large-area sensory devices through assembly techniques. A comprehensive understanding of each process parameter from material processing to device assembly is crucial for achieving a high-performing artificial sensory system. This review provides a technological framework for fabricating high-performance artificial sensory systems, covering material processing to device integrations. We introduce recent approaches for dispersing and purifying various nanomaterials including 0D, 1D, and 2D nanomaterials. We then highlight advanced coating and printing techniques of the solution-processed nanomaterials based on representative three methods including (i) evaporation-based assembly, (ii) assisted assembly, and (iii) direct patterning. We explore the application and performances of these solution-processed materials and printing methods in fabricating sensory devices mimicking five human senses including vision, olfaction, gustation, hearing, and tactile perception. Finally, we suggest an outlook for possible future research directions to solve the remaining challenges of the artificial sensory systems such as ambient stability, device consistency, and integration with AI-based software..
International Journal of Extreme Manufacturing
- Publication Date: May. 31, 2024
- Vol. 6, Issue 5, 52001 (2024)
Holistic and localized preparation methods for triboelectric sensors: principles, applications and perspectives
Gao Zhenqiu, Wu Shaokuan, Wei Yihan, Ibrahim Mervat, Abdelhamid Hani Nasser, Jiang Guyu, Cao Jun, Sun Xuhui, and Wen Zhen
With the arrival of intelligent terminals, triboelectric nanogenerators, as a new kind of energy converter, are considered one of the most important technologies for the next generation of intelligent electronics. As a self-powered sensor, it can greatly reduce the power consumption of the entire sensing system by tranWith the arrival of intelligent terminals, triboelectric nanogenerators, as a new kind of energy converter, are considered one of the most important technologies for the next generation of intelligent electronics. As a self-powered sensor, it can greatly reduce the power consumption of the entire sensing system by transforming external mechanical energy to electricity. However, the fabrication method of triboelectric sensors largely determines their functionality and performance. This review provides an overview of various methods used to fabricate triboelectric sensors, with a focus on the processes of micro-electro-mechanical systems technology, three-dimensional printing, textile methods, template-assisted methods, and material synthesis methods for manufacturing. The working mechanisms and suitable application scenarios of various methods are outlined. Subsequently, the advantages and disadvantages of various methods are summarized, and reference schemes for the subsequent application of these methods are included. Finally, the opportunities and challenges faced by different methods are discussed, as well as their potential for application in various intelligent systems in the Internet of Things..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 07, 2024
- Vol. 6, Issue 5, 52002 (2024)
Recent advances in fabricating high-performance triboelectric nanogenerators via modulating surface charge density
Li Zekun, Yu Aifang, Zhang Qing, and Zhai Junyi
Triboelectric nanogenerators (TENGs), a type of promising micro/nano energy source, have been arousing tremendous research interest since their inception and have been the subject of many striking developments, including defining the fundamental physical mechanisms, expanding applications in mechanical to electric poweTriboelectric nanogenerators (TENGs), a type of promising micro/nano energy source, have been arousing tremendous research interest since their inception and have been the subject of many striking developments, including defining the fundamental physical mechanisms, expanding applications in mechanical to electric power conversion and self-powered sensors, etc. TENGs with a superior surface charge density at the interfaces of the electrodes and dielectrics are found to be crucial to the enhancement of the performance of the devices. Here, an overview of recent advances, including material optimization, circuit design, and strategy conjunction, in developing TENGs through surface charge enhancement is presented. In these topics, different strategies are retrospected in terms of charge transport and trapping mechanisms, technical merits, and limitations. Additionally, the current challenges in high-performance TENG research and the perspectives in this field are discussed..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 12, 2024
- Vol. 6, Issue 5, 52003 (2024)
Advances and challenges in direct additive manufacturing of dense ceramic oxides
Fan Zhiqi, Tan Qiyang, Kang Chengwei, and Huang Han
Ceramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geomeCeramic oxides, renowned for their exceptional combination of mechanical, thermal, and chemical properties, are indispensable in numerous crucial applications across diverse engineering fields. However, conventional manufacturing methods frequently grapple with limitations, such as challenges in shaping intricate geometries, extended processing durations, elevated porosity, and substantial shrinkage deformations. Direct additive manufacturing (dAM) technology stands out as a state-of-the-art solution for ceramic oxides production. It facilitates the one-step fabrication of high-performance, intricately designed components characterized by dense structures. Importantly, dAM eliminates the necessity for post-heat treatments, streamlining the manufacturing process and enhancing overall efficiency. This study undertakes a comprehensive review of recent developments in dAM for ceramic oxides, with a specific emphasis on the laser powder bed fusion and laser directed energy deposition techniques. A thorough investigation is conducted into the shaping quality, microstructure, and properties of diverse ceramic oxides produced through dAM. Critical examination is given to key aspects including feedstock preparation, laser-material coupling, formation and control of defects, in-situ monitoring and simulation. This paper concludes by outlining future trends and potential breakthrough directions, taking into account current gaps in this rapidly evolving field..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 17, 2024
- Vol. 6, Issue 5, 52004 (2024)
Advancements in transfer printing techniques for flexible electronics: adjusting interfaces and promoting versatility
Chen Zijian, Zhang Chi and Zheng Zijian
The burgeoning interest in flexible electronics necessitates the creation of patterning technology specifically tailored for flexible substrates and complex surface morphologies. Among a variety of patterning techniques, transfer printing emerges as one of the most efficient, cost-effective, and scalable methods. It boThe burgeoning interest in flexible electronics necessitates the creation of patterning technology specifically tailored for flexible substrates and complex surface morphologies. Among a variety of patterning techniques, transfer printing emerges as one of the most efficient, cost-effective, and scalable methods. It boasts the ability for high-throughput fabrication of 0–3D micro- and nano-structures on flexible substrates, working in tandem with traditional lithography methods. This review highlights the critical issue of transfer printing: the flawless transfer of devices during the pick-up and printing process. We encapsulate recent advancements in numerous transfer printing techniques, with a particular emphasis on strategies to control adhesion forces at the substrate/device/stamp interfaces. These strategies are employed to meet the requirements of competing fractures for successful pick-up and print processes. The mechanism, advantages, disadvantages, and typical applications of each transfer printing technique will be thoroughly discussed. The conclusion section provides design guidelines and probes potential directions for future advancements..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 19, 2024
- Vol. 6, Issue 5, 52005 (2024)
An overview of additively manufactured metal matrix composites: preparation, performance, and challenge
Chen Liang-Yu, Qin Peng, Zhang Lina, and Zhang Lai-Chang
Metal matrix composites (MMCs) are frequently employed in various advanced industries due to their high modulus and strength, favorable wear and corrosion resistance, and other good properties at elevated temperatures. In recent decades, additive manufacturing (AM) technology has garnered attention as a potential way fMetal matrix composites (MMCs) are frequently employed in various advanced industries due to their high modulus and strength, favorable wear and corrosion resistance, and other good properties at elevated temperatures. In recent decades, additive manufacturing (AM) technology has garnered attention as a potential way for fabricating MMCs. This article provides a comprehensive review of recent endeavors and progress in AM of MMCs, encompassing available AM technologies, types of reinforcements, feedstock preparation, synthesis principles during the AM process, typical AM-produced MMCs, strengthening mechanisms, challenges, and future interests. Compared to conventionally manufactured MMCs, AM-produced MMCs exhibit more uniformly distributed reinforcements and refined microstructure, resulting in comparable or even better mechanical properties. In addition, AM technology can produce bulk MMCs with significantly low porosity and fabricate geometrically complex MMC components and MMC lattice structures. As reviewed, many AM-produced MMCs, such as Al matrix composites, Ti matrix composites, nickel matrix composites, Fe matrix composites, etc, have been successfully produced. The types and contents of reinforcements strongly influence the properties of AM-produced MMCs, the choice of AM technology, and the applied processing parameters. In these MMCs, four primary strengthening mechanisms have been identified: Hall–Petch strengthening, dislocation strengthening, load transfer strengthening, and Orowan strengthening. AM technologies offer advantages that enhance the properties of MMCs when compared with traditional fabrication methods. Despite the advantages above, further challenges of AM-produced MMCs are still faced, such as new methods and new technologies for investigating AM-produced MMCs, the intrinsic nature of MMCs coupled with AM technologies, and challenges in the AM processes. Therefore, the article concludes by discussing the challenges and future interests of AM of MMCs..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 20, 2024
- Vol. 6, Issue 5, 52006 (2024)
Advances in magnetic-assisted triboelectric nanogenerators: structures, materials and self-sensing systems
Wu Pengfan, Zhao Chenxi, Cui Endian, Xu Shiwei, Liu Tao, Wang Fayang, Lee Chengkuo, and Mu Xiaojing
Triboelectric nanogenerators (TENG), renowned for their remarkable capability to harness weak mechanical energy from the environment, have gained considerable attention owing to their cost-effectiveness, high output, and adaptability. This review provides a unique perspective by conducting a comprehensive and in-depth Triboelectric nanogenerators (TENG), renowned for their remarkable capability to harness weak mechanical energy from the environment, have gained considerable attention owing to their cost-effectiveness, high output, and adaptability. This review provides a unique perspective by conducting a comprehensive and in-depth analysis of magnetically assisted TENGs that encompass structures, materials, and self-powered sensing systems. We systematically summarize the diverse functions of the magnetic assistance for TENGs, including system stiffness, components of the hybrid electromagnetic-triboelectric generator, transmission, and interaction forces. In the material domain, we review the incorporation of magnetic nano-composites materials, along with ferrofluid-based TENG and microstructure verification, which have also been summarized based on existing research. Furthermore, we delve into the research progress on physical quantity sensing and human-machine interface in magnetic-assisted TENGs. Our analysis highlights that magnetic assistance extends beyond the repulsive and suction forces under a magnetic field, thereby playing multifaceted roles in improving the output performance and environmental adaptability of the TENGs. Finally, we present the prevailing challenges and offer insights into the future trajectory of the magnetic-assisted TENGs development..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 05, 2024
- Vol. 6, Issue 5, 52007 (2024)
Design and additive manufacturing of bionic hybrid structure inspired by cuttlebone to achieve superior mechanical properties and shape memory function
Yuan Luhao, Gu Dongdong, Liu Xin, Shi Keyu, Lin Kaijie, Liu He, Zhang Han, Dai Donghua, Sun Jianfeng, Chen Wenxin, and Wang Jie
Lightweight porous materials with high load-bearing, damage tolerance and energy absorption (EA) as well as intelligence of shape recovery after material deformation are beneficial and critical for many applications, e.g. aerospace, automobiles, electronics, etc. Cuttlebone produced in the cuttlefish has evolved verticLightweight porous materials with high load-bearing, damage tolerance and energy absorption (EA) as well as intelligence of shape recovery after material deformation are beneficial and critical for many applications, e.g. aerospace, automobiles, electronics, etc. Cuttlebone produced in the cuttlefish has evolved vertical walls with the optimal corrugation gradient, enabling stress homogenization, significant load bearing, and damage tolerance to protect the organism from high external pressures in the deep sea. This work illustrated that the complex hybrid wave shape in cuttlebone walls, becoming more tortuous from bottom to top, creates a lightweight, load-bearing structure with progressive failure. By mimicking the cuttlebone, a novel bionic hybrid structure (BHS) was proposed, and as a comparison, a regular corrugated structure and a straight wall structure were designed. Three types of designed structures have been successfully manufactured by laser powder bed fusion (LPBF) with NiTi powder. The LPBF-processed BHS exhibited a total porosity of 0.042% and a good dimensional accuracy with a peak deviation of 17.4 μm. Microstructural analysis indicated that the LPBF-processed BHS had a strong (001) crystallographic orientation and an average size of 9.85 μm. Mechanical analysis revealed the LPBF-processed BHS could withstand over 25 000 times its weight without significant deformation and had the highest specific EA value (5.32 J·g−1) due to the absence of stress concentration and progressive wall failure during compression. Cyclic compression testing showed that LPBF-processed BHS possessed superior viscoelastic and elasticity energy dissipation capacity. Importantly, the uniform reversible phase transition from martensite to austenite in the walls enables the structure to largely recover its pre-deformation shape when heated (over 99% recovery rate). These design strategies can serve as valuable references for the development of intelligent components that possess high mechanical efficiency and shape memory capabilities..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 20, 2024
- Vol. 6, Issue 5, 55001 (2024)
Femtosecond laser ultrafast photothermal exsolution
Xu Lurun, Tao Jingchao, Li Zhuguo, He Guo, and Zhang Dongshi
Exsolution, as an effective approach to constructing particle-decorated interfaces, is still challenging to yield interfacial films rather than isolated particles. Inspired by in vivo near-infrared laser photothermal therapy, using 3 mol% Y2O3 stabilized tetragonal zirconia polycrystals (3Y-TZP) as host oxide matrix anExsolution, as an effective approach to constructing particle-decorated interfaces, is still challenging to yield interfacial films rather than isolated particles. Inspired by in vivo near-infrared laser photothermal therapy, using 3 mol% Y2O3 stabilized tetragonal zirconia polycrystals (3Y-TZP) as host oxide matrix and iron-oxide (Fe3O4/γ-Fe2O3/α-Fe2O3) materials as photothermal modulator and exsolution resource, femtosecond laser ultrafast exsolution approach is presented enabling to conquer this challenge. The key is to trigger photothermal annealing behavior via femtosecond laser ablation to initialize phase transition from monoclinic zirconia (m-ZrO2) to tetragonal zirconia (t-ZrO2) and induce t-ZrO2 columnar crystal growth. Fe-ions rapidly segregate along grain boundaries and diffuse towards the outmost surface, and become ‘frozen’, highlighting the potential to use photothermal materials and ultrafast heating/quenching behaviors of femtosecond laser ablation for interfacial exsolution. Triggering interfacial iron-oxide coloring exsolution is composition and concentration dependent. Photothermal materials themselves and corresponding photothermal transition capacity play a crucial role, initializing at 2 wt%, 3 wt%, and 5 wt% for Fe3O4/γ-Fe2O3/α-Fe2O3 doped 3Y-TZP samples. Due to different photothermal effects, exsolution states of ablated 5 wt% Fe3O4/γ-Fe2O3/α-Fe2O3-doped 3Y-TZP samples are totally different, with whole coverage, exhaustion (ablated away) and partial exsolution (rich in the grain boundaries in subsurface), respectively. Femtosecond laser ultrafast photothermal exsolution is uniquely featured by up to now the deepest microscale (10 μm from 5 wt%-Fe3O4-3Y-TZP sample) Fe-elemental deficient layer for exsolution and the whole coverage of exsolved materials rather than the formation of isolated exsolved particles by other methods. It is believed that this novel exsolution method may pave a good way to modulate interfacial properties for extensive applications in the fields of biology, optics/photonics, energy, catalysis, environment, etc..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 21, 2024
- Vol. 6, Issue 5, 55002 (2024)
Coaxial electrohydrodynamic printing of core–shell microfibrous scaffolds with layer-specific growth factors release for enthesis regeneration
Bai Lang, Xu Meiguang, Meng Zijie, Qiu Zhennan, Xiu Jintao, Chen Baojun, Han Qian, Liu Qiaonan, He Pei, Wen Nuanyang, He Jiankang, Zhang Jing, and Yin Zhanhai
The rotator cuff tear has emerged as a significant global health concern. However, existing therapies fail to fully restore the intricate bone-to-tendon gradients, resulting in compromised biomechanical functionalities of the reconstructed enthesis tissues. Herein, a tri-layered core–shell microfibrous scaffold with laThe rotator cuff tear has emerged as a significant global health concern. However, existing therapies fail to fully restore the intricate bone-to-tendon gradients, resulting in compromised biomechanical functionalities of the reconstructed enthesis tissues. Herein, a tri-layered core–shell microfibrous scaffold with layer-specific growth factors (GFs) release is developed using coaxial electrohydrodynamic (EHD) printing for in situ cell recruitment and differentiation to facilitate gradient enthesis tissue repair. Stromal cell-derived factor-1 (SDF-1) is loaded in the shell, while basic fibroblast GF, transforming GF-beta, and bone morphogenetic protein-2 are loaded in the core of the EHD-printed microfibrous scaffolds in a layer-specific manner. Correspondingly, the tri-layered microfibrous scaffolds have a core–shell fiber size of (25.7 ± 5.1) μm, with a pore size sequentially increasing from (81.5 ± 4.6) μm to (173.3 ± 6.9) μm, and to (388.9 ± 6.9 μm) for the tenogenic, chondrogenic, and osteogenic instructive layers. A rapid release of embedded GFs is observed within the first 2 d, followed by a faster release of SDF-1 and a slightly slower release of differentiation GFs for approximately four weeks. The coaxial EHD-printed microfibrous scaffolds significantly promote stem cell recruitment and direct their differentiation toward tenocyte, chondrocyte, and osteocyte phenotypes in vitro. When implanted in vivo, the tri-layered core–shell microfibrous scaffolds rapidly restored the biomechanical functions and promoted enthesis tissue regeneration with native-like bone-to-tendon gradients. Our findings suggest that the microfibrous scaffolds with layer-specific GFs release may offer a promising clinical solution for enthesis regeneration. Supplementary material for this article is available online.
International Journal of Extreme Manufacturing
- Publication Date: Jun. 27, 2024
- Vol. 6, Issue 5, 55003 (2024)
Remote plasma enhanced cyclic etching of a cyclosiloxane polymer thin film
Wang Xianglin, Luo Xinyu, Du Weiwei, Shen Yuanhao, Huang Xiaocheng, Yang Zheng, and Zhao Junjie
The continuous evolution of chip manufacturing demands the development of materials with ultra-low dielectric constants. With advantageous dielectric and mechanical properties, initiated chemical vapor deposited (iCVD) poly(1,3,5-trimethyl-1,3,5-trivinyl cyclotrisiloxane) (pV3D3) emerges as a promising candidate. HowevThe continuous evolution of chip manufacturing demands the development of materials with ultra-low dielectric constants. With advantageous dielectric and mechanical properties, initiated chemical vapor deposited (iCVD) poly(1,3,5-trimethyl-1,3,5-trivinyl cyclotrisiloxane) (pV3D3) emerges as a promising candidate. However, previous works have not explored etching for this cyclosiloxane polymer thin film, which is indispensable for potential applications to the back-end-of-line fabrication. Here, we developed an etching process utilizing O2/Ar remote plasma for cyclic removal of iCVD pV3D3 thin film at sub-nanometer scale. We employed in-situ quartz crystal microbalance to investigate the process parameters including the plasma power, plasma duration and O2 flow rate. X-ray photoelectron spectroscopy and cross-sectional microscopy reveal the formation of an oxidized skin layer during the etching process. This skin layer further substantiates an etching mechanism driven by surface oxidation and sputtering. Additionally, this oxidized skin layer leads to improved elastic modulus and hardness and acts as a barrier layer for protecting the bottom cyclosiloxane polymer from further oxidation..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 04, 2024
- Vol. 6, Issue 5, 55101 (2024)
Laser-forged transformation and encapsulation of nanoalloys: pioneering robust wideband electromagnetic wave absorption and shielding from GHz to THz
Zhang Shizhuo, Rao Senlin, Li Yunfan, Wang Shuai, Sun Dingyue, Liu Feng, and Cheng Gary J
The emergence of the internet of things has promoted wireless communication’s evolution towards multi-band and multi-area utilization. Notably, forthcoming sixth-generation (6G) communication standards, incorporating terahertz (THz) frequencies alongside existing gigahertz (GHz) modes, drive the need for a versatile muThe emergence of the internet of things has promoted wireless communication’s evolution towards multi-band and multi-area utilization. Notably, forthcoming sixth-generation (6G) communication standards, incorporating terahertz (THz) frequencies alongside existing gigahertz (GHz) modes, drive the need for a versatile multi-band electromagnetic wave (EMW) absorbing and shielding material. This study introduces a pivotal advance via a new strategy, called ultrafast laser-induced thermal-chemical transformation and encapsulation of nanoalloys (LITENs). Employing multivariate metal-organic frameworks, this approach tailors a porous, multifunctional graphene-encased magnetic nanoalloy (GEMN). By fine-tuning pulse laser parameters and material components, the resulting GEMN excels in low-frequency absorption and THz shielding. GEMN achieves a breakthrough of minimum reflection loss of −50.6 dB in the optimal C-band (around 4.98 GHz). Computational evidence reinforces GEMN’s efficacy in reducing radar cross sections. Additionally, GEMN demonstrates superior electromagnetic interference shielding, reaching 98.92 dB under THz band (0.1–2 THz), with the mean value result of 55.47 dB. These accomplishments underscore GEMN’s potential for 6G signal shielding. In summary, LITEN yields the remarkable EMW controlling performance, holding promise in both GHz and THz frequency domains. This contribution heralds a paradigm shift in EM absorption and shielding materials, establishing a universally applicable framework with profound implications for future pursuits..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 01, 2024
- Vol. 6, Issue 5, 55501 (2024)
Non-contact intelligent sensor for recognizing transparent and naked-eye indistinguishable materials based on ferroelectric BiFeO3 thin films
Yin Shengjie, Li Hongyu, Qian Weiqi, Hasan Md Al Mahadi, and Yang Ya
At present, the research on ferroelectric photovoltaic materials mainly focuses on photoelectric detection. In the context of the rapid development of the Internet of Things (IoT), it is particularly important to use smaller thin-film devices as sensors. In this work, an indium tin oxide/bismuth ferrite (BFO)/lanthanumAt present, the research on ferroelectric photovoltaic materials mainly focuses on photoelectric detection. In the context of the rapid development of the Internet of Things (IoT), it is particularly important to use smaller thin-film devices as sensors. In this work, an indium tin oxide/bismuth ferrite (BFO)/lanthanum nickelate device has been fabricated on an F-doped tin oxide glass substrate using the sol–gel method. The sensor can continuously output photoelectric signals with little environmental impact. Compared to other types of sensors, this photoelectric sensor has an ultra-low response time of 1.25 ms and ultra-high sensitivity. Furthermore, a material recognition system based on a BFO sensor is developed. It can effectively identify eight kinds of materials that are difficult for human eyes to distinguish. This provides new ideas and methods for developing the IoT in material identification..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 03, 2024
- Vol. 6, Issue 5, 55502 (2024)
Synergistically biomimetic platform that enables droplets to be self-propelled
Li Minghao, Lu Yao, Wang Yujie, Huang Shuai, and Feng Kai
Droplet transport still faces numerous challenges, such as a limited transport distance, large volume loss, and liquid contamination. Inspired by the principle of ‘synergistic biomimetics’, we propose a design for a platform that enables droplets to be self-propelled. The orchid leaf-like three-dimensional driving struDroplet transport still faces numerous challenges, such as a limited transport distance, large volume loss, and liquid contamination. Inspired by the principle of ‘synergistic biomimetics’, we propose a design for a platform that enables droplets to be self-propelled. The orchid leaf-like three-dimensional driving structure provides driving forces for the liquid droplets, whereas the lotus leaf-like superhydrophobic surface prevents liquid adhesion, and the bamboo-like nodes enable long-distance transport. During droplet transport, no external energy input is required, no fluid adhesion or residue is induced, and no contamination or mass loss of the fluid is caused. We explore the influence of various types and parameters of wedge structures on droplet transportation, the deceleration of droplet speed at nodal points, and the distribution of internal pressure. The results indicate that the transport platform exhibits insensitivity to pH value and temperature. It allows droplets to be transported with varying curvatures in a spatial environment, making it applicable in tasks like target collection, as well as load, fused, anti-gravity, and long-distance transport. The maximum droplet transport speed reached (58 ± 5) mm·s−1, whereas the transport distance extended to (136 ± 4) mm. The developed platform holds significant application prospects in the fields of biomedicine and chemistry, such as high-throughput screening of drugs, genomic bioanalysis, microfluidic chip technology for drug delivery, and analysis of biological samples..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 04, 2024
- Vol. 6, Issue 5, 55503 (2024)
Sandwich probe temperature sensor based on In2O3-IZO thin film for ultra-high temperatures
Fan Xu, Tian Bian, Shi Meng, Zhang Zhongkai, Liu Zhaojun, Zhou Guoliang, Liu Jiangjiang, Li Le, Lin Qijing, and Jiang Zhuangde
High-temperature thin-film thermocouples (TFTCs) have attracted significant attention in the aerospace and steel metallurgy industry. However, previous studies on TFTCs have primarily focused on the two-dimensional planar-type, whose thermal sensitive area has to be perpendicular to the test environment, and therefore High-temperature thin-film thermocouples (TFTCs) have attracted significant attention in the aerospace and steel metallurgy industry. However, previous studies on TFTCs have primarily focused on the two-dimensional planar-type, whose thermal sensitive area has to be perpendicular to the test environment, and therefore affects the thermal fluids pattern or loses accuracy. In order to address this problem, recent studies have developed three-dimensional probe-type TFTCs, which can be set parallel to the test environment. Nevertheless, the probe-type TFTCs are limited by their measurement threshold and poor stability at high temperatures. To address these issues, in this study, we propose a novel probe-type TFTC with a sandwich structure. The sensitive layer is compounded with indium oxide doped zinc oxide and fabricated using screen-printing technology. With the protection of sandwich structure on electrode film, the sensor demonstrates robust high-temperature stability, enabling continuous working at 1200 °C above 5 h with a low drift rate of 2.3 °C·h−1. This sensor exhibits a high repeatability of 99.3% when measuring a wide range of temperatures, which is beyond the most existing probe-type TFTCs reported in the literature. With its excellent high-temperature performance, this temperature sensor holds immense potentials for enhancing equipment safety in the aerospace engineering and ensuring product quality in the steel metallurgy industry..
International Journal of Extreme Manufacturing
- Publication Date: Aug. 08, 2024
- Vol. 6, Issue 5, 55504 (2024)
Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy
Guo Da, Lambert-Garcia Rubé, Hocine Samy, Fan Xianqiang, Greenhalgh Henry, Shahani Ravi, Majkut Marta, Rack Alexander, Lee Peter D, and Leung Chu Lun Alex
Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron x-ray imaging. We qSpatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron x-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas; and (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced cavity mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts..
International Journal of Extreme Manufacturing
- Publication Date: Jun. 05, 2024
- Vol. 6, Issue 5, 55601 (2024)
Test for the deep: magnetic loading characterization of elastomers under extreme hydrostatic pressures
Zhao Yukai, Zhang Chengqian, Yang Xuxu, Cao Xunuo, Feng Tao, Zhou Fanghao, Wang Xuanqi, Zhao Peng, and Li Tiefeng
Soft robot incarnates its unique advantages in deep-sea exploration, but grapples with high hydrostatic pressure’s unpredictable impact on its mechanical performances. In our previous work, a self-powered soft robot showed excellent work performance in the Mariana Trench at a depth of 11 000 m, yet experienced notable Soft robot incarnates its unique advantages in deep-sea exploration, but grapples with high hydrostatic pressure’s unpredictable impact on its mechanical performances. In our previous work, a self-powered soft robot showed excellent work performance in the Mariana Trench at a depth of 11 000 m, yet experienced notable degradation in deforming capability. Here, we propose a magnetic loading method for characterizing elastomer’s mechanical properties under extremely high hydrostatic pressure of up to 120 MPa. This method facilitates remote loading and enables in-situ observation, so that the dimensions and deformation at high hydrostatic pressure are obtained and used for calculations. The results reveal that the Young’s modulus of Polydimethylsiloxane (PDMS) monotonously increases with pressure. It is found that the relative increase in Young’s modulus is determined by its initial value, which is 8% for an initial Young’s modulus of 2200 kPa and 38% for 660 kPa. The relation between initial Young’s modulus and relevant increase can be fitted by an exponential function. The bulk modulus of PDMS is about 1.4 GPa at 20 °C and is barely affected by hydrostatic pressure. The method can quantify alterations in the mechanical properties of elastomers induced by hydrostatic pressure, and provide guidance for the design of soft robots which serve in extreme pressure environment..
International Journal of Extreme Manufacturing
- Publication Date: Jul. 15, 2024
- Vol. 6, Issue 5, 55602 (2024)
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