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Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2)

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A special issue of Materials (ISSN 1996-1944). This special issue belongs to the section "Manufacturing Processes and Systems".

Deadline for manuscript submissions: closed (10 November 2024) | Viewed by 17656

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Dr. Radu Robert Piticescu

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National Research&Development Institute for Non-Ferrous and Rare Metals—IMNR, 102 Biruinței Boulevard, 077145 Pantelimon, Romania
Interests: advanced nanostructured materials; hydrothermal synthesis; functional graded materials; coatings technologies
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Dear Colleagues,

The development of new material systems and coatings remains a multidisciplinary topic of high importance for scientists and technologists, providing remarkable functional properties improving performances in many traditional and high-tech industrial areas. New or emerging technologies for material synthesis and processing are needed to obtain material systems and coatings with design composition, microstructure, and architectures fulfilling the harsh requirements for applications in extreme mechanical, high temperature, high corrosion, or biological environmental conditions. Green chemical procedures with low environmental impact enable the fine tuning of components and dopants by controlling the kinetics and mechanisms involved in the synthesis of nanostructured composite or hybrid material system. The use of these advanced materials to obtain functionally graded materials and coating architectures may open new directions in the study of nucleation and growth processes using physical or chemical coating technologies and controlling functional properties. Additionally, additive manufacturing combined with coatings technologies may contribute to the reduction of some critical raw materials.

In this Special Issue, modern trends in novel material synthesis and coatings, including fundamental research, modelling, and optimisation are highlighted and discussed. Expected applications are in renewable energy (e.g., solid state batteries, photovoltaics, solid oxide fuel cells), gas turbines, energy-harvesting systems, sensors and actuators, and automotive and aerospace components.

It is my pleasure to invite you to submit a manuscript for this Special Issue. Full papers, communications, and reviews are all welcome.

Dr. Radu Robert Piticescu
Guest Editor

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Keywords

green chemistry synthesis
hydrothermal/solvothermal
sol-gel
mechano-synthesis
coatings
functionally graded materials
additive manufacturing
EB-PVD
RF/magnetron sputtering
chemical vapor deposition methods
laser coating technologies
ab-initio modelling and simulation

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Emerging Technologies for Development of Novel Materials Systems and Coatings in Materials (12 articles)

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Research

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21 pages, 3838 KiB

Open AccessArticle

Computational Fluid Dynamics as a Digital Tool for Enhancing Safety Uptake in Advanced Manufacturing Environments Within a Safe-by-Design Strategy

by Dionysia Maria Voultsou, Stratos Saliakas, Spyridon Damilos and Elias P. Koumoulos

Materials 2025, 18(2), 262; https://doi.org/10.3390/ma18020262 (registering DOI) - 9 Jan 2025

Viewed by 103

Abstract

In modern manufacturing environments, pollution management is critical as exposure to harmful substances can cause serious health issues. This study presents a two-stage computational fluid dynamic (CFD) model to estimate the distribution of pollutants in indoor production spaces. In the first stage, the Reynolds-averaged Navier–Stokes (RANS) method was used to simulate airflow and temperature. In the second stage, the Lagrangian method was applied for particle tracing. The model was applied to a theoretical acrylonitrile butadiene styrene (ABS) filament 3D printing process to evaluate the factors affecting the distribution of ultrafine particles (30 nm). Key parameters such as ventilation system effects, the presence of cooling fans and the print bed, and nozzle temperatures were considered. The results show that the highest flow velocities (1.97 × 10⁻⁶ m/s to 3.38 m/s) occur near the ventilation system’s inlet and outlet, accompanied by regions of high turbulent kinetic energy (0.66 m²/s²). These conditions promote dynamic airflow, facilitating particulate removal by reducing stagnant zones prone to pollutant buildup. The effect of cooling fans and thermal sources was investigated, showing limited contribution on particle removal. These findings emphasize the importance of digital twins for better worker safety and air quality in 3D printing environments. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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14 pages, 5465 KiB

Open AccessArticle

Thin and Flexible PANI/PMMA/CNF Forest Films Produced via a Two-Step Floating Catalyst Chemical Vapor Deposition

by Foteini-Maria Papadopoulou, Spyros Soulis, Aikaterini-Flora A. Trompeta and Costas A. Charitidis

Materials 2024, 17(23), 5812; https://doi.org/10.3390/ma17235812 - 27 Nov 2024

Viewed by 622

Abstract

In this paper, we explore a straightforward two-step method to produce high-purity, vertically aligned multi-walled carbon nanofibres (MWCNFs) via chemical vapor deposition (CVD). Two distinct solutions are utilized for this CVD method: a catalytic solution consisting of ferrocene and acetonitrile (ACN) and a carbon source solution with camphor and ACN. The vapors of the catalytic solution inserted in the reaction chamber through external boiling result in a floating catalyst CVD approach that produces vertically aligned CNFs in a consistent manner. CNFs are grown in a conventional CVD horizontal reactor at 850 °C under atmospheric pressure and characterized by Raman spectroscopy, scanning and transmission electron microscopy (SEM and TEM), X-ray diffraction (XRD), and thermogravimetric analysis (TGA). Coating the MWCNTs with polymethyl methacrylate (PMMA) while still on the Si substrate retains the structure and results in a flexible, conductive thin film suitable for flexible electrodes. The film is 62 μm thick and stable in aqueous solutions, capable of withstanding further processing, such as electropolymerization with polyaniline, to be used for energy storage applications. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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12 pages, 2886 KiB

Open AccessArticle

Hydroxyapatite Nanocoatings Deposited by Means of Resonant Matrix-Assisted Pulsed Laser Evaporation

by Dominik Maskowicz, Kacper Maroszek, Rafał Jendrzejewski and Mirosław Sawczak

Materials 2024, 17(23), 5778; https://doi.org/10.3390/ma17235778 - 25 Nov 2024

Viewed by 384

Abstract

Hydroxyapatite (HAp) is one of the most widely studied materials for utilization in the development of artificial implants. Research is mainly aimed at the production and modification of HAp coatings for simplification of the deposition process, cost reduction, and increase in biocompatibility. In this paper, the authors deposited HAp synthetic microparticles by means of matrix-assisted pulsed laser evaporation (MAPLE) on Ti6Al4V alloy plate substrates and obtained uniform HAp coatings without further treatment or modifications. The authors utilized a tunable pulsed laser to adjust its wavelength to the selected solvents, in order to optimize the process for deposition speed and quality. The following solvents were used as matrices: deionized water, isopropyl alcohol, and a 3:2 mixture of isopropanol:acetonitrile. Obtained coatings were examined by means of scanning electron microscopy, Raman spectroscopy, X-ray diffraction, and profilometry in order to evaluate coating quality, uniformity, and structural integrity. MAPLE deposition allowed the acquisition of approx. 200 nm thick coatings for water and isopropanol matrices and approx. 320 nm for isopropanol:acetonitrile matrix, which indicates an increase in deposition rate by 37%. The obtained coatings meet requirements for further biocompatibility testing, material modification, and composite synthesis. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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23 pages, 6257 KiB

Open AccessArticle

Physicochemical Characterization of Ca- and Cu-Decorated TiO₂ Microparticles and Investigation of Their Antimicrobial Properties

by Andreea Neacsu, Viorel Chihaia, Razvan Bucuresteanu, Anton Ficai, Roxana Doina Trusca, Vasile-Adrian Surdu, Adela Nicolaev, Bogdan Cojocaru, Monica Ionita, Ioan Calinescu, Viorica Parvulescu and Lia-Mara Ditu

Materials 2024, 17(18), 4483; https://doi.org/10.3390/ma17184483 - 12 Sep 2024

Viewed by 1521

Abstract

Ca- and Cu-decorated TiO₂ microparticles are titanium dioxide nanoparticles that have been decorated with calcium and copper ions. TiO₂, CaO, and CuO are low-cost, non-toxic, and non-hazardous materials. The aim of the present study was the physicochemical characterization of Ca- and Cu-decorated TiO₂ microparticles and the evaluation of their antimicrobial activity. Thus, Ca²⁺ and Cu²⁺ species were incorporated onto TiO₂ surfaces by a two-step wet method. The obtained TiO₂-CaO-CuO composites were characterized by several experimental techniques. The electronic structure and charge properties of the composites were investigated by density functional theory calculations. Furthermore, the composites were successfully tested for inhibitory effects on Staphylococcus aureus, Pseudomonas aeruginosa, Escherichia coli, and Candida albicans standard strains. The zeta potential data indicate that the physiological condition of investigated microbial strains was strongly affected in presence of a dispersion of 10 μg/L of composites in a saline phosphate buffer also, the recorded SEM images show a damaged microbial cell surface in the presence of composites. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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18 pages, 6181 KiB

Open AccessArticle

Growth of Carbon Nanofibers and Carbon Nanotubes by Chemical Vapour Deposition on Half-Heusler Alloys: A Computationally Driven Experimental Investigation

by Ioannis G. Aviziotis, Apostolia Manasi, Afroditi Ntziouni, Georgios P. Gakis, Aikaterini-Flora A. Trompeta, Xiaoying Li, Hanshan Dong and Costas A. Charitidis

Materials 2024, 17(13), 3144; https://doi.org/10.3390/ma17133144 - 27 Jun 2024

Viewed by 856

Abstract

The possibility of directly growing carbon nanofibers (CNFs) and carbon nanotubes (CNTs) on half-Heusler alloys by Chemical Vapour Deposition (CVD) is investigated for the first time, without using additional catalysts, since the half-Heusler alloys per se may function as catalytic substrates, according to [...] Read more.

{({Z r}_{0.4} {T i}_{0.6})}_{0.33} {N i}_{0.33} {({S n}_{0.98} {S b}_{0.02})}_{0.33}

is utilized as the catalytic substrate. At first, a computational model is developed for the CVD reactor, aiming to optimize the experimental process design and setup. The experimental process conditions are simulated to investigate the reactive species concentrations within the reactor chamber and the activation of certain reactions. SEM analysis confirms the growth of CNFs with diameters ranging from 450 nm to 1 μm. Raman spectroscopy implies that the formed carbon structures resemble CNFs rather than CNTs, and that amorphous carbon also co-exists in the deposited samples. From the characterization results, it may be concluded that a short reaction time and a low acetylene flow rate lead to the formation of a uniform CNF coating on the surface of half-Heusler alloys. The purpose of depositing carbon nanostructures onto half-Heusler alloys is to improve the current transfer, generated from these thermoelectric compounds, by forming a conductive coating on their surface. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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13 pages, 3718 KiB

Open AccessArticle

Preparation of Copper-Based Catalysts for Obtaining Methanol by the Chemical Impregnation Method

by Anisoara Oubraham, Mihaela Iordache, Elena Marin, Claudia Sisu, Simona Borta, Amalia Soare, Catalin Capris and Adriana Marinoiu

Materials 2024, 17(4), 847; https://doi.org/10.3390/ma17040847 - 9 Feb 2024

Cited by 1 | Viewed by 1691

Abstract

This paper presents the preparation of heterogeneous catalysts for the direct hydrogenation process of CO₂ to methanol. The development of the modern chemical industry is inextricably linked to the use of catalytic processes. As a result, currently over 80% of new technologies introduced in the chemical industry incorporate catalytic processes. Since the basic factor of catalytic processes is the catalysts, the studies for the deepening of the knowledge regarding the nature of the action of the catalysts, for the development of new catalysts and catalytic systems, as well as for their improvement, represent a research priority of a fundamental or applied nature. The Cu/ZnO/Al₂O₃ catalyst for the synthesis of green methanol, using precursors of an inorganic (copper nitrate, denoted by Cu/ZnO/Al₂O₃-1) and organic (copper acetate, denoted by Cu/ZnO/Al₂O₃-2) nature, are obtained by chemical impregnation that includes two stages: preparation and one of calcination. The preparation methods and conditions, as well as the physico-chemical properties of the catalyst precursor, play a major role in the behavior of the catalysts. The prepared catalysts were characterized using atomic adsorption analysis, scanning electron microscopy (SEM) with energy dispersive X-ray (EDX) analysis, specific surface area and pore size analyses, adsorption, and the chemisorption of vapor (BET). Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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17 pages, 6790 KiB

Open AccessArticle

NASICON Membrane with High Ionic Conductivity Synthesized by High-Temperature Solid-State Reaction

by Mihaela Iordache, Anisoara Oubraham, Irina Petreanu, Claudia Sisu, Simona Borta, Catalin Capris, Amalia Soare and Adriana Marinoiu

Materials 2024, 17(4), 823; https://doi.org/10.3390/ma17040823 - 8 Feb 2024

Cited by 2 | Viewed by 1733

Abstract

In the present work, we studied the impact of excess Na addition on the structure of the standard NASICON ion conductor along with Na ion transport mechanisms. In this sense, NASICON ceramic membranes (NZSP) were prepared by a simple chemical synthesis method, the solid state reaction (SSR), using an excess of 5% Na (Na_3.15Zr₂Si₂PO₁₂) and an excess of 10% Na (Na_3.3Zr₂Si₂PO₁₂), in order to improve the conduction properties of the ceramic membrane. The characterization of the NZSP nanoparticles was performed by measuring the particle size by dynamic light scattering (DLS), the morphology of the NASICON samples pre-sintered at 1100 °C was analyzed by the SEM method (scanning electron microscope), and X-ray diffraction (XRD) analysis was used to investigate the crystal structure of samples, while the surface area was measured using the BET technique. The electrical properties (i.e., ionic conductivity) were evaluated by impedance spectroscopic methods at room temperature (RT). Following the experiments for NASICON membranes without Na excess, with 5% Na excess, and with 10% Na excess synthesized at different pressing forces and sintering temperatures, it was found that membranes with a 10% Na excess, sintered at 1175 °C for 10 h, presented a good ionic conductivity (4.72 × 10⁻⁴ S/cm). Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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16 pages, 20978 KiB

Open AccessArticle

Surface Defect Mitigation of Additively Manufactured Parts Using Surfactant-Mediated Electroless Nickel Coatings

by Anju Jolly, Véronique Vitry, Golnaz Taghavi Pourian Azar, Thais Tasso Guaraldo and Andrew J. Cobley

Materials 2024, 17(2), 406; https://doi.org/10.3390/ma17020406 - 13 Jan 2024

Cited by 1 | Viewed by 1709

Abstract

The emergence of defects during the early production phases of ferrous-alloy additively manufactured (AM) parts poses a serious threat to their versatility and adversely impacts their overall mechanical performance in industries ranging from aerospace engineering to medicine. Lack of fusion and gas entrapment during the manufacturing stages leads to increased surface roughness and porosities in the finished part. In this study, the efficacy of employing electroless nickel–boron (Ni-B) deposition to fill and level simulated AM defects was evaluated. The approach to levelling was inspired by the electrochemical deposition techniques used to fill vias in the electronics industry that (to some extent) resemble the size and shape of AM-type defects. This work investigated the use of surfactants to attenuate surface roughness in electroless nickel coatings, thereby achieving the preferential inhibition of the coating thickness on the surface and promoting the filling of the simulated defects. A cationic surfactant molecule, CTAB (cetyltrimethyl ammonium bromide), and a nonpolar surfactant, PEG (polyethylene glycol), at different concentrations were tested using a Ni-B electrolyte for the levelling study. It was found that the use of electroless Ni-B to fill simulated defects on ferrous alloys was strongly influenced by the concentration and nature of the surfactant. The highest levelling percentages were obtained for the heavy-molecular-weight PEG-mediated coatings at 1.2 g/L. The results suggest that electroless Ni-B deposition could be a novel and facile approach to filling defects in ferrous-based AM parts. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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18 pages, 8450 KiB

Open AccessArticle

Synthesis and Characterization of ZnO-Nanostructured Particles Produced by Solar Ablation

by Adriana-Gabriela Schiopu, Mihai Oproescu, Vasile Gabriel Iana, Catalin Marian Ducu, Sorin Georgian Moga, Denisa Stefania Vîlcoci, Georgiana Cîrstea, Valentin Marian Calinescu and Omar Ahmed

Materials 2023, 16(19), 6417; https://doi.org/10.3390/ma16196417 - 26 Sep 2023

Cited by 3 | Viewed by 1527

Abstract

Nowadays, nanotechnology offers opportunities to create new features and functions of emerging materials. Correlation studies of nanostructured materials’ development processes with morphology, structure, and properties represent one of the most important topics today due to potential applications in all fields: chemistry, mechanics, electronics, optics, medicine, food, or defense. Our research was motivated by the fact that in the nanometric domain, the crystalline structure and morphology are determined by the elaboration mechanism. The objective of this paper is to provide an introduction to the fundamentals of nanotechnology and nanopowder production using the sun’s energy. Solar energy, as part of renewable energy sources, is one of the sources that remain to be exploited in the future. The basic principle involved in the production of nanopowders consists of the use of a solar energy reactor concentrated on sintered targets made of commercial micropowders. As part of our study, for the first time, we report the solar ablation synthesis and characterization of Ni-doped ZnO performed in the CNRS-PROMES laboratory, UPR 8521, a member of the CNRS (French National Centre for Scientific Research). Also, we study the effect of the elaboration method on structural and morphological characteristics of pure and doped ZnO nanoparticles determined by XRD, SEM, and UV-Vis. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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14 pages, 12019 KiB

Open AccessArticle

Processing of Niobium-Alloyed High-Carbon Tool Steel via Additive Manufacturing and Modern Powder Metallurgy

by Klára Borkovcová, Pavel Novák, Nawel Merghem, Alisa Tsepeleva, Pavel Salvetr, Michal Brázda and Dragan Rajnovic

Materials 2023, 16(13), 4760; https://doi.org/10.3390/ma16134760 - 30 Jun 2023

Cited by 1 | Viewed by 1364

Abstract

Niobium is recently considered one of the potential alloying elements for tool steels due to the formation of hard and stable carbides of MC type. Its use is limited by the fact that these carbides tend to coarsen during conventional melting metallurgy processing. This work explores the potential of additive manufacturing for processing Nb-alloyed tool steel with a high content of carbon. Directed energy deposition was used as the processing method. It was found that this method allowed us to obtain a microstructure very similar to that obtained after the use of consolidation via spark plasma sintering when subsequent heat treatment by soft annealing, austenitizing, oil quenching and triple tempering for secondary hardness was applied. Moreover, the soft annealing process could be skipped without affecting the structure and properties when machining would not be required. The hardness of the steel was even higher after additive manufacturing was used (approx. 800–830 HV 30) than after spark plasma sintering (approx. 720–750 HV 30). The wear resistance of the materials processed by both routes was almost comparable, reaching 5–7 × 10⁻⁶ mm³N⁻¹m⁻¹ depending on the heat treatment. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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Review

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24 pages, 4081 KiB

Open AccessReview

Closing the Loop: Solid Oxide Fuel and Electrolysis Cells Materials for a Net-Zero Economy

by Mirela Dragan

Materials 2024, 17(24), 6113; https://doi.org/10.3390/ma17246113 - 13 Dec 2024

Viewed by 760

Abstract

Solid oxide fuel cells (SOFCs) and solid oxide electrolyzer cells (SOECs) represent a promising clean energy solution. In the case of SOFCs, they offer efficiency and minimal to zero CO₂ emissions when used to convert chemical energy into electricity. When SOFC systems are operated in regenerative mode for water electrolysis, the SOFCs become solid oxide electrolyzer cells (SOECs). The problem with these systems is the supply and availability of raw materials for SOFC and SOEC components. This raises significant economic challenges and has an impact on the price and scalability of these technologies. Recycling the materials that make up these systems can alleviate these economic challenges by reducing dependence on the supply of raw materials and reducing overall costs. From this point of view, this work is a perspective analysis and examines the current research on the recycling of SOFC and SOEC materials, highlighting the potential paths towards a circular economy. The existing literature on different approaches to recycling the key materials for components of SOFCs and SOECs is important. Mechanical separation techniques to isolate these components, along with potential strategies like chemical leaching or hydrometallurgical and material characterization, to ensure the quality of recycled materials for reuse in new SOFCs and SOECs are important as well. By evaluating the efficiency of various methods and the quality of recovered materials, this study aims to provide valuable insights for advancing sustainable and economically viable SOFC and SOEC technologies within a net-zero economic framework. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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24 pages, 15290 KiB

Open AccessReview

Photo-Thermal Dry Reforming of Methane with PGM-Free and PGM-Based Catalysts: A Review

by Alessio Varotto, Umberto Pasqual Laverdura, Marta Feroci and Maria Luisa Grilli

Materials 2024, 17(15), 3809; https://doi.org/10.3390/ma17153809 - 1 Aug 2024

Viewed by 1259

Abstract

Dry reforming of methane (DRM) is considered one of the most promising technologies for efficient greenhouse gas management thanks to the fact that through this reaction, it is possible to reduce CO₂ and CH₄ to obtain syngas, a mixture of H₂ and CO, with a suitable ratio for the Fischer–Tropsch production of long-chain hydrocarbons. Two other main processes can yield H₂ from CH₄, i.e., Steam Reforming of Methane (SRM) and Partial Oxidation of Methane (POM), even though, not having CO₂ as a reagent, they are considered less green. Recently, scientists’ challenge is to overcome the many drawbacks of DRM reactions, i.e., the use of precious metal-based catalysts, the high temperatures of the process, metal particle sintering and carbon deposition on the catalysts’ surfaces. To overcome these issues, one proposed solution is to implement photo-thermal dry reforming of methane in which irradiation with light is used in combination with heating to improve the efficiency of the process. In this paper, we review the work of several groups aiming to investigate the pivotal promoting role of light radiation in DRM. Focus is also placed on the catalysts’ design and the progress needed for bringing DRM to an industrial scale. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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41 pages, 6193 KiB

Open AccessReview

Review on Synthesis and Properties of Lithium Lanthanum Titanate

by Alexandru Okos, Cristina Florentina Ciobota, Adrian Mihail Motoc and Radu-Robert Piticescu

Materials 2023, 16(22), 7088; https://doi.org/10.3390/ma16227088 - 8 Nov 2023

Cited by 4 | Viewed by 2742

Abstract

The rapid development of portable electronic devices and the efforts to find alternatives to fossil fuels have triggered the rapid development of battery technology. The conventional lithium-ion batteries have reached a high degree of sophistication. However, improvements related to specific capacity, charge rate, safety and sustainability are still required. Solid state batteries try to answer these demands by replacing the organic electrolyte of the standard battery with a solid (crystalline, but also polymer and hybrid) electrolyte. One of the most promising solid electrolytes is Li_3xLa_2/3−xTiO₃ (LLTO). The material nevertheless presents a set of key challenges that must be resolved before it can be used for commercial applications. This review discusses the synthesis methods, the crystallographic and the ionic conduction properties of LLTO and the main limitations encountered through a number of selected studies on this material. Full article

(This article belongs to the Special Issue Emerging Technologies for Development of Novel Materials Systems and Coatings (Volume 2))

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