Interactions of Li2O volatilized from ternary lithium-ion battery cathode materials with mullite saggar materials during calcination

In recent years, the rapid development of Li(Ni_xCo_yMn_1-x-y)O₂ (LNCM) materials for application in ternary lithium-ion batteries has led to an increased demand for refractory kiln saggars in industries. However, saggars used for firing ternary Li-ion battery cathode materials are often subjected to severe corrosion and spalling. To investigate the damage mechanism of the saggar materials, non-contact corrosion experiments were designed to study the effects of the precursor additions, calcination temperature, and number of calcinations during the interaction between mullite saggar and LNCM materials. The phase composition and microstructure of the mullite saggar specimens before and after corrosion were characterized using X-ray diffraction and scanning electron microscopy, respectively, to obtain a comprehensive understanding of the causes of the deterioration of mullite saggar materials during corrosion.     

Microstructures and properties of nickel-titanium carbide composites fabricated by laser cladding

In this work, Ni/TiC composites were synthesized by the laser cladding technique (LCT). A scanning electron microscope (SEM), X-ray diffractometer (XRD), microhardness meter, electrochemical workstation, and friction and wear tester examined the microstructure, surface morphology, phase structure, microhardness, wear, and corrosion resistances of the Ni/TiC composites. These results indicated the Ni/40TiC composite contained finer equiaxed crystals than the Ni and Ni/20TiC composites. In addition, numerous TiC particles in the Ni/40TiC composite impeded growth of the nickel crystals, which resulted in the fine microstructure of the Ni/40TiC composite. The Ni, Ni/20TiC, and Ni/40TiC composites exhibited face-centered cubic (f c c) lattices. The average microhardness values of the Ni/20TiC and Ni/40TiC composites were approximately 748 HV and 851 HV, respectively. The Ni/40TiC composite had the lowest friction coefficient (0.43) among all three coatings, and only some shallow scratches appeared on the surface of the Ni/40TiC composite. The corrosion potential (E) of Ni/40TiC exceeded the Ni/20TiC composite, and both were larger than the Ni composite, which indicated the Ni/40TiC composite had outstanding corrosion resistance and the Ni composite had poor corrosion resistance. The corrosion current densities (i) of Ni, Ni/20TiC, and Ni/40TiC composites were 5.912, 4.405, and 3.248 μA/cm², respectively.     

UV curing-assisted 3D plotting of ceramic feedstock containing thermo-regulated phase-separable,photocurable vehicle for dual-scale porosity structure

We propose a novel approach for manufacturing dual-scale porosity alumina structures by UV curing-assisted 3D plotting of a specially formulated alumina feedstock using a thermo-regulated phase separable, photocurable camphene/triethylene glycol dimethacrylate (TEGDMA) vehicle. In particular, 3D plotting process was conducted at - 5 °C, and thus an alumina suspension prepared using liquid camphene/TEGDMA at room temperature could undergo phase separation, resulting in camphene crystals surrounded by walls comprised of liquid photopolymer enclosing alumina particles. To enhance the shape retention ability of extruded filaments, polystyrene (PS) polymer was used as the tackifier. The phase-separated feedrod could be extruded favorably through a nozzle and rapidly photopolymerized by UV light during the 3D plotting process. Three-dimensionally interconnected macropores were tightly constructed, which were separated by microporous alumina filaments, where micropores were created by the removal of camphene crystals via freeze-dying. The macroporosity of porous alumina ceramics was controlled by adjusting the distance between deposited filaments, while their microporosity was kept constant, leading to tightly tailored overall porosity and mechanical properties.     

Catalytic combustion synthesis of CNTs/MgO composite powders and the influences on the thermal shock resistance of low-carbon Al2O3–C refractories

Using MgC₂O₄, Mg powders as raw materials and Ni(NO₃)₂?6H₂O as a catalyst, CNTs/MgO composite powders were prepared by a catalytic combustion synthesis method. The CNTs/MgO composite powders were characterized by XRD, Raman spectroscopy, FESEM/EDS and HRTEM. The effects of catalyst content on the degree of graphitization and aspect ratio of the CNTs in composite powders were investigated. Moreover, the thermal shock resistance of low-carbon Al₂O₃–C refractories after adding the composite powder was investigated. The results indicated that the CNTs prepared with 1 wt% Ni(NO₃)₂?6H₂O addition had a higher degree of graphitization and aspect ratio. In particular, the aspect ratio could reach approximately 200. The growth mechanism of hollow bamboo-like CNTs in the composite powders was proven to be a V-L-S mechanism. The thermal shock resistance of Al₂O₃–C samples could be improved significantly after adding CNTs/MgO composite powders. In particular, compared with CM0, the residual strength ratio of Al₂O₃–C samples with added 2.5 wt% composite powders could be increased 63.9%.     

Investigation of liquid water heterogeneities in large area proton exchange membrane fuel cells using a Darcy two-phase flow model in a multiphysics code

Proper management of the liquid water and heat produced in proton exchange membrane (PEM) fuel cells remains crucial to increase both its performance and durability. In this study, a two-phase flow and multicomponent model, called two-fluid model, is developed in the commercial COMSOL Multiphysics® software to investigate the liquid water heterogeneities in large area PEM fuel cells, considering the real flow fields in the bipolar plate. A macroscopic pseudo-3D multi-layers approach has been chosen and generalized Darcy's relation is used both in the membrane-electrode assembly (MEA) and in the channel. The model considers two-phase flow and gas convection and diffusion coupled with electrochemistry and water transport through the membrane. The numerical results are compared to one-fluid model results and liquid water measurements obtained by neutron imaging for several operating conditions. Finally, according to the good agreement between the two-fluid and experimentation results, the numerical water distribution is examined in each component of the cell, exhibiting very heterogeneous water thickness over the cell surface.     

High quality 3D reconstruction based on fusion of polarization imaging and binocular stereo vision

Polarization imaging can retrieve inaccurate objects’ 3D shapes with fine textures, whereas coarse but accurate depths can be provided by binocular stereo vision. To take full advantage of these two complementary techniques, we investigate a novel 3D reconstruction method based on the fusion of polarization imaging and binocular stereo vision for high quality 3D reconstruction. We first generate the polarization surface by correcting the azimuth angle errors on the basis of registered binocular depth, to solve the azimuthal ambiguity in the polarization imaging. Then we propose a joint 3D reconstruction model for depth fusion, including a data fitting term and a robust low-rank matrix factorization constraint. The former is to transfer textures from the polarization surface to the fused depth by assuming their relationship linear, whereas the latter is to utilize the low-frequency part of binocular depth to improve the accuracy of the fused depth considering the influences of missing-entries and outliers. To solve the optimization problem in the proposed model, we adopt an efficient solution based on the alternating direction method of multipliers. Extensive experiments have been conducted to demonstrate the efficiency of the proposed method in comparison with state-of-the-art methods and to exhibit its wide application prospects in 3D reconstruction.     

Fabrication of alumina ceramics with functional gradient structures by digital light processing 3D printing technology

Alumina ceramics with different unit numbers and gradient modes were prepared by digital light processing (DLP) 3D printing technology. The side length of each functional gradient structure was 10 mm, the porosity ratio was controlled to 70%, and the number of units were (1 × 1 × 1 unit) and (2 × 2 × 2 unit) respectively. The different gradient modes were named FCC, GFCC-1, GFCC-2 and GFCC-3. SEM, XRD, and other characterization methods proved that these gradient structures of alumina ceramics had only α-Al2O3 phase and good surface morphology. The mechanical properties and energy absorption properties of alumina ceramics with different functional gradient structures were studied by compression test. The results show that the gradient structure with 1 × 1 × 1 unit has better mechanical properties and energy absorption properties when the number of units is different. When the number of units is the same, GFCC-2 and GFCC-3 gradient structures have better compressive performance and energy absorption potential than FCC structures. The GFCC-2 gradient structure with 1 × 1 × 1 unit has a maximum compressive strength of 19.62 MPa and a maximum energy absorption value of 2.72 × 105 J/m3. The good performance of such functional gradient structures can provide new ideas for the design of lightweight and compressive energy absorption structures in the future.     

Nonlinearity in regulating the metal to insulator transition of ReNiO3 towards low temperature range

Among the existing material family of the correlated oxides, the rare earth nickelates (ReNiO₃) exhibit broadly adjustable metal to insulator transition (MIT) properties that enables correlated electronic applications, such as thermistors, thermochromics, and logical devices. Nevertheless, how to accurately control the critical temperature (T_MIT) of ReNiO₃ via the co-occupation of the rare-earth elements is yet worthy to be further explored. Herein, we demonstrate the non-linearity in adjusting the T_MIT of ReNiO₃ towards lower temperatures via introducing Pr co-occupation within ReNiO₃ (e.g., Pr_xNd_1-xNiO₃ and Pr_xSm_1-xNiO₃) as synthesized by KCl molten-salt assisted high oxygen pressure reaction approach. Although the T_MIT is effectively reduced via Pr substitution, it does not strictly follow a linear relationship, in particular, when there is large difference in the ionic radius of the co-occupation rare-earth elements. Furthermore, the most significant deviation in T_MIT from the expected linear relationship appears at an equal co-occupation ratio of the two different rare-earth elements, while the abruption in the variation of resistivity across T_MIT is also reduced. The present work highlights the importance to use adjacent rare-earth elements with co-occupation ratio away from 1:1 for achieving more linear adjustment in designing the metal to insulator transition properties for ReNiO₃.     

Fabrication of barium titanate ceramics via digital light processing 3D printing by using high refractive index monomer

A digital light processing (DLP) technology has been developed for 3D printing lead-free barium titanate (BTO) piezoelectric ceramics. By comparing the curing and rheological properties of slurries with different photosensitive monomer, a high refractive index monomer acryloyl morpholine (ACMO) was chosen, and a design and preparation method of BTO slurry with high solid content, low viscosity and high curing ability was proposed. By further selecting the printing parameters, the single-layer exposure time was reduced and the forming efficiency has been greatly improved. Sintered specimens were obtained after a nitrogen-air double-step debinding and furnace sintering process, and the BTO ceramics fabricated with 80 wt% slurry shows the highest relative density (95.32 %) and piezoelectric constant (168.1 pC/N). Furthermore, complex-structured BTO ceramics were prepared, impregnated by epoxy resin and finally assembly made into hydrophones, which has significance for the future design and manufacture of piezoelectric ceramic-based composites that used in functional devices.