Fabrication and properties of the superhydrophobic ceria-based composite coating on magnesium alloy

A superhydrophobic ceria-based composite coating is developed to improve anticorrosion properties of AZ61 magnesium alloy, fabricating via chemical conversion method followed by hydrothermal treatment. The cerium conversion coating has a block structure with microcracks. After the hydrothermal treatment, a dense CeO₂ layer, porous CeO₂ nanorods, and stearic absorbing layers are grown stepwise on the conversion coating. And the composite coating is hydrophobic or even superhydrophobic and has almost no microcracks. As the hydrothermal reaction time increases, the water contact angle of the composite coating first increases and then decreases, and it reaches the maximum value of 152° after hydrothermal treatment for 4 h. Both the dense CeO₂ layer and the superhydrophobic stearic absorbing layer can effectively prevent the electrolyte from contacting the substrate; the corrosion current density of the superhydrophobic composite coating is lower than that of the hydrophilic composite coating and the cerium conversion coating, and has the best corrosion resistance.     

Bioinspired Supramolecular Slippery Organogels for Controlling Pathogen Spread by Respiratory Droplets

Surface-deposited pathogens are sources for the spread of infectious diseases. Protecting public facilities with a replaceable or recyclable antifouling coating is a promising approach to control pathogen transmission. However, most antifouling coatings are less effective in preventing pathogen-contained respiratory droplets because these tiny droplets are difficult to repel, and the deposited pathogens can remain viable from hours to days. Inspired by mucus, an antimicrobial supramolecular organogel for the control of microdroplet-mediated pathogen spread is developed. The developed organogel coating harvests a couple of unique features including localized molecular control-release, readily damage healing, and persistent fouling-release properties, which are preferential for antifouling coating. Microdroplets deposited on the organogel surfaces will be spontaneously wrapped with a thin liquid layer, and will therefore be disinfected rapidly due to a mechanism of spatially enhanced release of bactericidal molecules. Furthermore, the persistent fouling-release and damage-healing properties will significantly extend the life-span of the coating, making it promising for diverse applications.     

Sputtered Fe1·5CoNi0.5 coating: An improved protective coating for SOFC interconnect applications

In an attempt to optimize the properties of FeCoNi coating for planar solid oxide fuel cell (SOFC) interconnect application, the coating composition is modified by increasing the ratio of Fe/Ni. An Fe_1·5CoNi_0.5 (Fe:Co:Ni = 1.5:1:0.5, atomic ratio) metallic coating is fabricated on SUS 430 stainless steel by magnetron sputtering, followed by oxidation in air at 800°C. The Fe_1·5CoNi_0.5 coating is thermally converted to (Fe,Co,Ni)₃O₄ and (Fe,Co,Mn,Ni)₃O₄ without (Ni,Co)O particles. After oxidation for 1680 h, no further migration of Cr is detected in the thermally converted coating region. A low oxidation rate of 5.9 × 10^?14 g² cm^?4 s^?1 and area specific resistance of 12.64 mΩ·cm² is obtained for Fe_1·5CoNi_0.5 coated steels.     

Manufacturing catalyst-coated membranes by ultrasonic spray deposition for PEMFC: Identification of key parameters and their impact on PEMFC performance

This study deals with the manufacturing of catalyst-coated membranes (CCMs) for newcomers in the field of coating. Although there are many studies on electrode ink composition for improving the performance of proton-exchange membrane fuel cells (PEMFCs), there are few papers dealing with electrode coating itself. Usually, it is a know-how that often remains secret and constitutes the added value of scientific teams or the business of industrialists. In this paper, we identify and clarify the role of key parameters to improve coating quality and also to correlate coating quality with fuel cell performance via polarization curves and electrochemical active surface area measurements. We found that the coating configurations can affect the performance of lab-made CCMs in PEMFCs. After the repeatability of the performance obtained by our coating method has been proved, we show that: (i) edge effects, due to mask shadowing - cannot be neglected when the active surface area is low, (ii) a heterogeneous thickness electrode produces performance lower than a homogeneous thickness electrode, and (iii) the origin and storage of platinum on carbon powders are a very important source of variability in the obtained results.     

Protection and confinement effect of carbon on Co/CoxOy nano-catalyst for efficient NaBH4 hydrolysis

The hydrolysis of sodium borohydride (NaBH₄) over catalysts is a promising method to produce hydrogen. Although Co-based catalysts exhibit high activity for NaBH₄ hydrolysis, they are still far from satisfying practical applications, especially their poor durability in alkaline media. Herein, a carbon shell structure was designed and synthesized to improve the stability of the mixture of Co⁰ and Co_xO_y nanofilms (Co/Co_xO_y@C) during NaBH₄ hydrolysis via a facile polymerization-pyrolysis strategy with Co/Co_xO_y nanofilms as the precursor. As a result, the Co/Co_xO_y@C catalyst can achieve a remarkable H₂ generation rate of 4348.6 mL min^?1 g_Co^?1 with a low activation energy of 43.6 kJ mol^?1, which is superior to most previously reported catalysts. Moreover, the catalyst shows high stability with an H₂ generation-specific rate of 79% after five cycles. The excellent performance of carbon substrate can well prevent the agglomeration of Co-based nanoparticle and improve the corrosion resistance of the active Co to BO₂^? and OH^?. This work would widen the road for the preparation of nanoconfined catalysts, which has prospective application potentials for H₂ production from NaBH₄ hydrolysis.     

Development of titanium bipolar plates fabricated by additive manufacturing for PEM fuel cells in electric vehicles

Bipolar plates (BPs) are one of the main parts of proton exchange membrane (PEM) fuel cell stacks, which constitute a significant percentage of a PEM fuel cell system in terms of cost, weight, and structural strength. Although frequently used graphite BPs have low density, high conductivity, and high corrosion resistance, machining the desired flow channels on these plates is challenging. On the other hand, BPs made of various materials rather than graphite can be also fabricated by additive manufacturing methods. These methods can be considered as a reasonable alternative to conventional machining for the fabrication of graphite BPs in PEM fuel cells regarding material cost, fabrication of flow channels, and some post-processes in which the large-scale manufacturing of graphite BPs is more complex. This study offers a comparison of formed stainless-steel, additive manufactured titanium and machined composite graphite plates having the same flow-field geometry as a bipolar plate. In addition, titanium BPs are coated with gold and their performances are compared. Among the cells tested, the highest peak power of 639 mWcm^?2 is measured from the cell with 450 nm gold coated titanium BP, whereas those of the cell with conventional graphite and stainless-steel BP are only around 322 mWcm^?2 and 173 mWcm^?2, respectively. Moreover, a new titanium bipolar plate design providing high specific power density is also presented.     

Use of La2O3 with 8YSZ as thermal barrier coating and its effect on thermal cycle behavior,microstructure, mechanical properties and performance of diesel engine operated by hydrogen-algae biodiesel blend

In this present work, the effect of lanthanum oxides (La₂O₃) on the thermal cycle behavior of TBC coatings and mechanical properties such as adhesion strength and microhardness of 8% Yttria Stabilized Zirconia (8YSZ) TBCs were investigated. CoNiCrAlY and aluminium alloy (Al–13%Si) were used as bond coat and substrate materials. 8YSZ and different wt % of La₂O₃ (10, 20, and 30%) top coatings were applied using the atmospheric plasma spray (APS) method. The thermal cycling test for TBC coated samples were conducted at 800 °C in the electric furnace. The XRD pattern shows that the La₂O₃ doped 8YSZ material transformed to cubic pyrochloric structured La₂Zr₂O₇ during thermal cycling. Further, the Taguchi-based grey relation analysis (GRA) method was applied to optimize the TBC coating parameters to achieve better mechanical properties such as adhesion strength and microhardness. And the optimized La₂O₃/8YSZ TBC coating was coated on CRDI engine combustion chamber components. The engine was tested with microalgae biodiesel and hydrogen, and the results were promising for the TBC-coated engine. The engine performance increased while using La₂O₃/8YSZ coated components, and the emissions from engine exhaust gas such as CO, HC, and smoke reduced considerably. It was found that there was no separation crack and spallation of the coating layer in the microstructure. Ultimately, the microstructural analysis of the optimized TBC coated piston sample after 50 h of running in the diesel engine confirmed that the developed coating had a superior thermal insulation effect and longer life.     

A Ti3C2Tx-carbon black-acrylic epoxy coating for 304SS bipolar plates with enhanced corrosion resistant and conductivity

A conducting and anticorrosive coating is crucial for the application of metal bipolar plates (BP) in proton exchange membrane fuel cell (PEMFC). In this work, a Ti₃C₂T_x (T)-carbon black (C)-acrylic epoxy (AE) coating is prepared on 304 stainless steel (SS) with enhanced corrosion resistance and conductivity. The corrosion resistance of the T-C-AE coating is investigated in a 0.5 M H₂SO₄ solution as compared to the AE, T, and T-AE coatings. The T-C-AE coated 304SS exhibits the strongest corrosion resistance with the most positive corrosion potential and the lowest corrosion current density of 0.00673 μA cm^?2 in all the samples, while retaining intact and compact surface morphology with the lowest metal ion dissolution even after immersed for 720 h. The addition of Ti₃C₂T_x and carbon black into the AE matrix greatly decreases interfacial contact resistance (ICR), and the T-C-AE coating achieves a low ICR of 15.5 mΩ cm^?2 under 140 N cm^?2 compaction force. The excellent anticorrosion performance is mainly attributed to the physical barrier and the cathodic protection provided by the stacked Ti₃C₂T_x (MXene) nanosheets in the T-C-AE coating. This eco-friendly, conducting, and anticorrosive T-C-AE coating has a good application prospect on SS BP of PEMFC.     

Effect of slot-die configurations on coating gap dependence of maximum and minimum wet thicknesses

The dependence of the maximum and minimum wet thicknesses on the coating gap is derived for the slot-die coating process, under different slot-die configurations. Analytical expressions for the wet thickness and its derivative with respect to the coating gap are obtained using a simple flow model. The results indicate that, as expected, the minimum wet thickness increases linearly with the coating gap; however, the maximum wet thickness demonstrates a counterintuitive trend of decreasing as the coating gap increases, when a specific slot-die configuration is assumed. Moreover, the results are also validated by numerically solving the complete two-dimensional (2D) Navier–Stokes equation.     

Poly(4-styrenesulfonic acid) doped polypyrrole/tungsten oxide/reduced graphene oxide nanocomposite films based surface acoustic wave sensors for NO sensing behavior

Poly(4-styrenesulfonic acid) (PSSA) doped polypyrrole (PPy)/tungsten oxide (WO₃)/reduced graphene oxide (rGO) hybrid nanocomposite have been successfully synthesized using appropriate amounts of PSSA, pyrrole monomer, WO₃, and rGO dispersed in aqueous solution through in situ chemical oxidation polymerization. Here, a simple spin coating method was used to fabricate a nitric oxide (NO) gas sensor composed of the aforementioned nanocomposite on a surface acoustic wave (SAW) resonator. This sensor can detect NO gas at concentrations of 1–110 parts per billion (ppb) at room temperature in dry air, with a sensitivity of 12 Hz/ppb and response and recovery times of <2 min. Moreover, its limit of detection (LOD) is 0.31 ppb for a signal to noise ratio of 3. It demonstrates repeatability, fast response, and recovery at room temperature. Moreover, its sensory performance remains highly stable over 30 days with only a 6.3% decrease in sensitivity. In addition, the sensor is highly selective for NO, even when nitrogen dioxide, ammonia, and carbon dioxide are applied as interfering gases. The inclusion of rGO (with large specific surface area) and the synergic effect of n-type WO₃ nanoparticles in the p-type PPy matrix (leading to p-n heterojunction region formation) possibly underlie the efficient sensing performance of our sensor.