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Keywords = electrode performance

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18 pages, 1059 KB  
Article
Rapid Biocathode Start-Up with Mixed Methanogenic–Electroactive Inocula for Enhanced Bioelectrochemical Performance
by Tamara Joglar, Andrea Crespo-Barreiro, Mercedes Jiménez-Rosado and Raúl Mateos
Appl. Sci. 2025, 15(19), 10601; https://doi.org/10.3390/app151910601 - 30 Sep 2025
Abstract
This study explores the use of a pre-acclimated Geobacter-enriched inoculum as a novel strategy to accelerate the start-up of biocathodes. Unlike conventional inoculation with broad-spectrum communities, the proposed inoculum combines a long-term electroactive consortium, previously adapted to anaerobic bioelectrochemical conditions, with digestate [...] Read more.
This study explores the use of a pre-acclimated Geobacter-enriched inoculum as a novel strategy to accelerate the start-up of biocathodes. Unlike conventional inoculation with broad-spectrum communities, the proposed inoculum combines a long-term electroactive consortium, previously adapted to anaerobic bioelectrochemical conditions, with digestate produced under controlled laboratory conditions. This prior acclimation ensures the presence of Geobacter strains already conditioned to electrode-associated growth, promoting rapid colonization and early electrochemical activity. Experiments were conducted in a dual-chamber electrochemical cell equipped with a three-electrode setup polarized at −1 V vs. Ag/AgCl. The enriched biocathode reached current densities exceeding 1.4 A/m2 within 24 h, whereas the control exhibited significantly lower, less stable, and inconsistent performance. Unlike previously reported approaches based on broad-spectrum co-inoculation, this work presents a tailor-made inoculum in which the electroactive community is not only dominated by Geobacter, but also selectively preconditioned under functional bioelectrochemical conditions. This prior adaptation is a key differentiator that markedly enhances start-up efficiency. The results demonstrate that strategic enrichment with pre-acclimated Geobacter significantly accelerates start-up and improves electrochemical performance, offering a promising pathway toward more efficient and scalable bioelectrochemical systems for wastewater treatment and renewable energy generation. Full article
(This article belongs to the Section Energy Science and Technology)
43 pages, 2854 KB  
Review
Strategies for Enhancing BiVO4 Photoanodes for PEC Water Splitting: A State-of-the-Art Review
by Binh Duc Nguyen, In-Hee Choi and Jae-Yup Kim
Nanomaterials 2025, 15(19), 1494; https://doi.org/10.3390/nano15191494 - 30 Sep 2025
Abstract
Bismuth vanadate (BiVO4) has attracted significant attention as a photoanode material for photoelectrochemical (PEC) water splitting due to its suitable bandgap (~2.4 eV), strong visible light absorption, chemical stability, and cost-effectiveness. Despite these advantages, its practical application remains constrained by intrinsic [...] Read more.
Bismuth vanadate (BiVO4) has attracted significant attention as a photoanode material for photoelectrochemical (PEC) water splitting due to its suitable bandgap (~2.4 eV), strong visible light absorption, chemical stability, and cost-effectiveness. Despite these advantages, its practical application remains constrained by intrinsic limitations, including poor charge carrier mobility, short diffusion length, and sluggish oxygen evolution reaction (OER) kinetics. This review critically summarizes recent advancements aimed at enhancing BiVO4 PEC performance, encompassing synthesis strategies, defect engineering, heterojunction formation, cocatalyst integration, light-harvesting optimization, and stability improvements. Key fabrication methods—such as solution-based, vapor-phase, and electrochemical approaches—along with targeted modifications, including metal/nonmetal doping, surface passivation, and incorporation of electron transport layers, are discussed. Emphasis is placed on strategies to improve light absorption, charge separation efficiency (ηsep), and charge transfer efficiency (ηtrans) through bandgap engineering, optical structure design, and catalytic interface optimization. Approaches to enhance stability via protective overlayers and electrolyte tuning are also reviewed, alongside emerging applications of BiVO4 in tandem PEC systems and selective solar-driven production of value-added chemicals, such as H2O2. Finally, critical challenges, including the scale-up of electrode fabrication and the elucidation of fundamental reaction mechanisms, are highlighted, providing perspectives for bridging the gap between laboratory performance and practical implementation. Full article
19 pages, 6040 KB  
Article
Impact of Ion Crossover on Mass Transfer Polarization Regulation in High-Power Vanadium Flow Batteries
by Jianbin Li, Zhengxiang Song and Zihan Li
Energies 2025, 18(19), 5192; https://doi.org/10.3390/en18195192 - 30 Sep 2025
Abstract
In order to solve the problems of mass transfer polarization spatiotemporal distribution variations, uncontrollable regulation error, and accelerated capacity decay caused by ion crossover in high-power vanadium liquid flow batteries (VFBs), a three-dimensional battery model with a flow-type flow field based on the [...] Read more.
In order to solve the problems of mass transfer polarization spatiotemporal distribution variations, uncontrollable regulation error, and accelerated capacity decay caused by ion crossover in high-power vanadium liquid flow batteries (VFBs), a three-dimensional battery model with a flow-type flow field based on the three-dimensional transient COMSOL Multiphysics® 6.1 numerical modeling method was developed in this study. The model combines the ion transmembrane migration equation with the mass transfer polarization theory, constructs an objective function to quantify the regulation error, and is validated by multifluid-field structural simulations. The results indicate the following: (1) Ion crossover induces a 3–5% electrolyte concentration deviation and a current density distribution bias reaching 11%; (2) The intensity of mass transfer polarization exhibits a linear increase with the flow rate difference between the positive and negative electrodes; (3) Ion crossover significantly degrades system performance, causing Coulombic efficiency (CE) and Energy efficiency (EE) to decrease by 1.1% and 1.5%, respectively. This research demonstrates that unlike conventional flow field optimization, our strategy quantifies the regulation error by directly compensating for the ΔQ caused by ion crossing, and further regulation minimizes the effect, providing a theoretical basis for mass transfer intensification and capacity recovery in flow batteries. Full article
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25 pages, 1196 KB  
Review
Microbial Electrosynthesis: The Future of Next-Generation Biofuel Production—A Review
by Radu Mirea, Elisa Popescu and Traian Zaharescu
Energies 2025, 18(19), 5187; https://doi.org/10.3390/en18195187 - 30 Sep 2025
Abstract
Microbial electrosynthesis (MES) has emerged as a promising bio-electrochemical technology for sustainable CO2 conversion into valuable organic compounds since it uses living electroactive microbes to directly convert CO2 into value-added products. This review synthesizes advancements in MES from 2010 to 2025, [...] Read more.
Microbial electrosynthesis (MES) has emerged as a promising bio-electrochemical technology for sustainable CO2 conversion into valuable organic compounds since it uses living electroactive microbes to directly convert CO2 into value-added products. This review synthesizes advancements in MES from 2010 to 2025, focusing on the electrode materials, microbial communities, reactor engineering, performance trends, techno-economic evaluations, and future challenges, especially on the results reported between 2020 and 2025, thus highlighting that MES technology is now a technology to be reckoned with in the spectrum of biofuel technology production. While the current productivity and scalability of microbial electrochemical systems (MESs) remain limited compared to conventional CO2 conversion technologies, MES offers distinct advantages, including process simplicity, as it operates under ambient conditions without the need for high pressures or temperatures; modularity, allowing reactors to be stacked or scaled incrementally to match varying throughput requirements; and seamless integration with circular economy strategies, enabling the direct valorization of waste streams, wastewater, or renewable electricity into valuable multi-carbon products. These features position MES as a promising platform for sustainable and adaptable CO2 utilization, particularly in decentralized or resource-constrained settings. Recent innovations in electrode materials, such as conductive polymers and metal–organic frameworks, have enhanced electron transfer efficiency and microbial attachment, leading to improved MES performance. The development of diverse microbial consortia has expanded the range of products achievable through MES, with studies highlighting the importance of microbial interactions and metabolic pathways in product formation. Advancements in reactor design, including continuous-flow systems and membrane-less configurations, have addressed scalability issues, enhancing mass transfer and system stability. Performance metrics, such as the current densities and product yields, have improved due to exceptionally high product selectivity and surface-area-normalized production compared to abiotic systems, demonstrating the potential of MES for industrial applications. Techno-economic analyses indicate that while MES offers promising economic prospects, challenges related to cost-effective electrode materials and system integration remain. Future research should focus on optimizing microbial communities, developing advanced electrode materials, and designing scalable reactors to overcome the existing limitations. Addressing these challenges will be crucial for the commercialization of MES as a viable technology for sustainable chemical production. Microbial electrosynthesis (MES) offers a novel route to biofuels by directly converting CO2 and renewable electricity into energy carriers, bypassing the costly biomass feedstocks required in conventional pathways. With advances in electrode materials, reactor engineering, and microbial performance, MES could achieve cost-competitive, carbon-neutral fuels, positioning it as a critical complement to future biofuel technologies. Full article
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15 pages, 9550 KB  
Article
Enhancing Energy Harvesting in Plant Microbial Fuel Cells with SnS-Coated 304 Stainless Steel Electrodes
by Nestor Rodríguez-Regalado, Yolanda Peña-Méndez, Edith Osorio-de-la-Rosa, Idalia Gómez-de-la-Fuente, Mirna Valdez-Hernández and Francisco López-Huerta
Coatings 2025, 15(10), 1130; https://doi.org/10.3390/coatings15101130 - 30 Sep 2025
Abstract
Plant microbial fuel cells (PMFCs) represent an eco-friendly solution for generating clean energy by converting biological processes into electricity. This work presents the first integration of tin sulfide (SnS)-coated 304 stainless steel (SS304) electrodes into Aloe vera-based PMFCs for enhanced energy harvesting. [...] Read more.
Plant microbial fuel cells (PMFCs) represent an eco-friendly solution for generating clean energy by converting biological processes into electricity. This work presents the first integration of tin sulfide (SnS)-coated 304 stainless steel (SS304) electrodes into Aloe vera-based PMFCs for enhanced energy harvesting. SnS thin films were obtained via chemical bath deposition and screen printing, followed by thermal treatment. X-ray diffraction (XRD) revealed a crystal size of 15 nm, while scanning electron microscopy (SEM) confirmed film thicknesses ranging from 3 to 13.75 µm. Over a 17-week period, SnS-coated SS304 electrodes demonstrated stable performance, with open circuit voltages of 0.6–0.7 V and current densities between 30 and 92 mA/m2, significantly improving power generation compared to uncoated electrodes. Polarization analysis indicated an internal resistance of 150 Ω and a power output of 5.8 mW/m2. Notably, the system successfully charged a 15 F supercapacitor with 8.8 J of stored energy, demonstrating a practical proof-of-concept for powering low-power IoT devices and advancing PMFC applications beyond power generation. Microbial biofilm formation, observed via SEM, contributed to enhanced electron transfer and system stability. These findings highlight the potential of PMFCs as a scalable, cost-effective, and sustainable energy solution suitable for industrial and commercial applications, contributing to the transition toward greener energy systems. These incremental advances demonstrate the potential of combining low-cost electrode materials and energy storage systems for future scalable and sustainable bioenergy solutions. Full article
(This article belongs to the Special Issue Advances and Challenges in Coating Materials for Battery Cathodes)
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16 pages, 2423 KB  
Article
Numerical Simulation Study and Stress Prediction of Lithium-Ion Batteries Based on an Electrochemical–Thermal–Mechanical Coupled Model
by Juanhua Cao and Yafang Zhang
Batteries 2025, 11(10), 360; https://doi.org/10.3390/batteries11100360 - 29 Sep 2025
Abstract
In lithium-ion batteries, the fracture of active particles that are under stress is a key cause of battery aging, which leads to a reduction in active materials, an increase in internal resistance, and a decay in battery capacity. A coupled electrochemical–thermal–mechanical model was [...] Read more.
In lithium-ion batteries, the fracture of active particles that are under stress is a key cause of battery aging, which leads to a reduction in active materials, an increase in internal resistance, and a decay in battery capacity. A coupled electrochemical–thermal–mechanical model was established to study the concentration and stress distributions of negative electrode particles under different charging rates and ambient temperatures. The results show that during charging, the maximum lithium-ion concentration occurs on the particle surface, while the minimum concentration appears at the particle center. Moreover, as the temperature decreases, the concentration distribution of negative electrode active particles becomes more uneven. Stress analysis indicates that when charging at a rate of 1C and 0 °C, the maximum stress of particles at the negative electrode–separator interface reaches 123.7 MPa, while when charging at 30 °C, the maximum particle stress is 24.3 MPa. The maximum shear stress occurs at the particle center, presenting a tensile stress state, while the minimum shear stress is located on the particle surface, showing a compressive stress state. Finally, to manage the stress of active materials in lithium-ion batteries while charging for health maintenance, this study uses a DNN (Deep Neural Network) to predict the maximum shear stress of particles based on simulation results. The predicted indicators, MAE (Mean Absolute Error) and RMSE (Root Mean Square Error), are 0.034 and 0.046, respectively. This research is helpful for optimizing charging strategies based on the stress of active materials in lithium-ion batteries during charging, inhibiting battery aging and improving safety performance. Full article
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15 pages, 1772 KB  
Article
Towards a Porous Zinc Anode Design for Enhanced Durability in Alkaline Zinc–Air Batteries
by Sarmila Dutta, Yasin Emre Durmus, Eunmi Im, Hans Kungl, Hermann Tempel and Rüdiger-A. Eichel
Batteries 2025, 11(10), 359; https://doi.org/10.3390/batteries11100359 - 29 Sep 2025
Abstract
The commercialization of rechargeable alkaline zinc–air batteries has been constrained by critical challenges associated with the zinc electrode, including passivation, dendrite growth, and hydrogen evolution reaction. These issues severely limit the cycle life and pose a major barrier to large-scale industrial deployment. Integration [...] Read more.
The commercialization of rechargeable alkaline zinc–air batteries has been constrained by critical challenges associated with the zinc electrode, including passivation, dendrite growth, and hydrogen evolution reaction. These issues severely limit the cycle life and pose a major barrier to large-scale industrial deployment. Integration of porous anode structures and electrode additives—two widely investigated approaches for mitigating challenges related to zinc anode—shows significant promise. However, effectively combining these approaches remains challenging. This study introduces a method for fabricating zinc anodes that can combine the benefits of a porous structure and electrode additive. The polytetrafluoroethylene (PTFE) polymer binder used in fabricating the anode material resulted in a stable scaffold, providing the desired anode porosity of approximately 60% and effectively anchoring ZnO nanoparticles. The zinc anodes prepared using a nickel mesh current collector without any electrode additives demonstrated stable cycling performance, sustaining 350 cycles at a current density of 60 mA gZn−1 with a coulombic efficiency of approximately 95%. Incorporating 2 wt.% Bi2O3 as an electrode additive further enhanced the cycling performance, achieving 200 stable cycles with 100% coulombic efficiency under an increased current density of 120 mA gZn−1, signifying the effectiveness of the proposed fabrication strategy. Full article
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18 pages, 4932 KB  
Article
An Investigation of the Performance of Equal Channel Angular Pressed Copper Electrodes in Electric Discharge Machining
by Ülke Şimşek and Can Çoğun
Crystals 2025, 15(10), 849; https://doi.org/10.3390/cryst15100849 - 29 Sep 2025
Abstract
This study examines the mechanical, thermal, and electrical properties of copper tool electrodes processed via Equal Channel Angular Pressing (ECAP), with a specific focus on their performance in Electrical Discharge Machining (EDM) applications. A novel Crystal Plasticity Finite Element Method (CPFEM) framework is [...] Read more.
This study examines the mechanical, thermal, and electrical properties of copper tool electrodes processed via Equal Channel Angular Pressing (ECAP), with a specific focus on their performance in Electrical Discharge Machining (EDM) applications. A novel Crystal Plasticity Finite Element Method (CPFEM) framework is employed to model anisotropic slip behavior and microscale deformation mechanisms. The primary objective is to elucidate how initial crystallographic orientation influences hardness, thermal conductivity, and electrical conductivity. Simulations are performed on single-crystal copper for three representative Face Centered Cubic (FCC) orientations. Using an explicit CPFEM model, the study examines texture evolution and deformation heterogeneity during the ECAP process of single-crystal copper. The results indicate that the <100> single-crystal orientation exhibits the highest Taylor factor and the most homogeneous distribution of plastic equivalent strain (PEEQ), suggesting enhanced resistance to plastic flow. In contrast, the <111> single-crystal orientation displays localized deformation and reduced hardening. A decreasing Taylor factor correlates with more uniform slip, which improves both electrical and thermal conductivity, as well as machinability, by minimizing dislocation-related resistance. These findings make a novel contribution to the field by highlighting the critical role of crystallographic orientation in governing slip activity and deformation pathways, which directly impact thermal wear resistance and the fabrication efficiency of ECAP-processed copper electrodes in EDM. Full article
(This article belongs to the Section Crystalline Metals and Alloys)
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20 pages, 2989 KB  
Review
Polymer-Based Electrolytes for Organic Batteries
by Chetna Tewari, Kundan Singh Rawat, Somi Yoon and Yong Chae Jung
Energies 2025, 18(19), 5168; https://doi.org/10.3390/en18195168 - 28 Sep 2025
Abstract
The pursuit of sustainable and environmentally benign energy storage solutions has propelled significant interest in organic batteries, which utilize redox-active organic compounds as electrode materials. A pivotal component in determining their electrochemical performance, safety, and long-term stability is the electrolyte. Polymer-based electrolytes (PBEs) [...] Read more.
The pursuit of sustainable and environmentally benign energy storage solutions has propelled significant interest in organic batteries, which utilize redox-active organic compounds as electrode materials. A pivotal component in determining their electrochemical performance, safety, and long-term stability is the electrolyte. Polymer-based electrolytes (PBEs) have emerged as promising candidates owing to their intrinsic advantages, such as enhanced thermal stability, mechanical integrity, and the mitigation of leakage and flammability risks associated with conventional liquid electrolytes. Unlike previous reviews that broadly cover solid electrolytes, this review specifically focuses on the unique developments of polymer-based electrolytes tailored for organic batteries over the past few years. This review presents a comprehensive overview of the recent progress in PBEs specifically designed for organic battery systems. It systematically examines various categories, including solid polymer electrolytes (SPEs), valued for their structural simplicity and stability; gel polymer electrolytes (GPEs), noted for their high ionic conductivity and processability; and polymer-inorganic composite electrolytes, which synergistically integrate the mechanical flexibility of polymers with the ionic conductivity of inorganic fillers. Additionally, the review delves into the latest advancements in ionogels and poly(ionic liquid) electrolytes, highlighting their potential to overcome existing limitations and enable next-generation battery performance. The article concludes with a critical discussion on prevailing challenges and prospective research directions, emphasizing the importance of advanced material design, interfacial engineering, and sustainable synthesis approaches to facilitate the practical realization of high-performance organic batteries. Full article
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15 pages, 1303 KB  
Article
Wastewater Sludge Dewatering Enhancement by Flocculant Selection and Electrochemical Pretreatment
by Binbin Yang, Yingxue Sun, Quanze Liu, Xiaobo Wang and Xiaolei Zhang
Separations 2025, 12(10), 264; https://doi.org/10.3390/separations12100264 - 27 Sep 2025
Abstract
In wastewater treatment, sludge is generated during both the primary and secondary sedimentation processes. With the growing volume of wastewater, sludge production has increased accordingly. Prior to subsequent treatment or disposal, sludge dewatering is a critical step to reduce volume and improve treatment [...] Read more.
In wastewater treatment, sludge is generated during both the primary and secondary sedimentation processes. With the growing volume of wastewater, sludge production has increased accordingly. Prior to subsequent treatment or disposal, sludge dewatering is a critical step to reduce volume and improve treatment efficiency. The primary challenge lies in the removal of bonded water within the extracellular polymeric substances (EPSs) and the microorganism cells. In this study, electrochemical pretreatment was employed to improve sludge dewatering performance. The optimal electrochemical treatment was achieved at an electrode spacing of 2 cm, a stirring speed of 500 rpm, and an electrolyte (1 M calcium chloride, CaCl2) dosage of 3 mL for 50 min. Subsequently, flocculation was conducted. Compared with the widely used polyacrylamide (PAM), polydimethyldiallylammonium chloride (PDMDAAC) achieved superior dewatering performance with less than half the dosage required. Under the combined treatment, the final moisture content of the sludge cake was reduced to 53.2%. These findings indicate that the combination of Fe/Ti-based electrochemical pretreatment and flocculation process is a promising and efficient strategy for deep sludge dewatering. Full article
(This article belongs to the Topic Advances in Separation Engineering)
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16 pages, 2181 KB  
Article
Continuous Separation of Lithium Iron Phosphate and Graphite Microparticles via Coupled Electric and Magnetic Fields
by Wenbo Liu, Xiaolei Chen, Pengfei Qi, Xiaomin Liu and Yan Wang
Micromachines 2025, 16(10), 1094; https://doi.org/10.3390/mi16101094 - 26 Sep 2025
Abstract
Driven by the growing demand for sustainable resource utilization, the recovery of valuable constituents from spent lithium-ion batteries (LIBs) has attracted considerable attention, whereas conventional recycling processes remain energy-intensive, inefficient, and environmentally detrimental. Herein, an efficient and environmentally benign separation strategy integrating dielectrophoresis [...] Read more.
Driven by the growing demand for sustainable resource utilization, the recovery of valuable constituents from spent lithium-ion batteries (LIBs) has attracted considerable attention, whereas conventional recycling processes remain energy-intensive, inefficient, and environmentally detrimental. Herein, an efficient and environmentally benign separation strategy integrating dielectrophoresis (DEP) and magnetophoresis (MAP) is proposed for isolating the primary components of “black mass” from spent LIBs, i.e., lithium iron phosphate (LFP) and graphite microparticles. A coupled electric–magnetic–fluid dynamic model is established to predict particle motion behavior, and a custom-designed microparticle separator is developed for continuous LFP–graphite separation. Numerical simulations are performed to analyze microparticle trajectories under mutual effects of DEP and MAP and to evaluate the feasibility of binary separation. Structural optimization revealed that the optimal separator configuration comprised an electrode spacing of 2 mm and a ferromagnetic body length of 5 mm with 3 mm spacing. Additionally, a numerical study also found that an auxiliary flow velocity ratio of 3 resulted in the best particle focusing effect. Furthermore, the effects of key operational parameters, including electric and magnetic field strengths and flow velocity, on particle migration were systematically investigated. The findings revealed that these factors significantly enhanced the lateral migration disparity between LFP and graphite within the separation channel, thereby enabling complete separation of LFP particles with high purity and recovery under optimized conditions. Overall, this study provides a theoretical foundation for the development of high-performance and environmentally sustainable LIBs recovery technologies. Full article
(This article belongs to the Collection Micro/Nanoscale Electrokinetics)
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19 pages, 2445 KB  
Article
Prediction of Multi-Hole Copper Electrodes’ Influence on Form Tolerance and Machinability Using Grey Relational Analysis and Adaptive Neuro-Fuzzy Inference System in Electrode Discharge Machining Process
by Sandeep Kumar, Subramanian Dhanabalan, Wilma Polini and Andrea Corrado
Appl. Sci. 2025, 15(19), 10445; https://doi.org/10.3390/app151910445 - 26 Sep 2025
Abstract
Electric discharge machining processes are prominent in the fastest-growing industries because of their accuracy, achievable complex workpiece shapes, and cost-effectiveness. Furthermore, the machining of high-quality difficult-to-machine alloys is becoming critical in the aerospace, manufacturing, and defence industries. While the optimisation of EDM parameters [...] Read more.
Electric discharge machining processes are prominent in the fastest-growing industries because of their accuracy, achievable complex workpiece shapes, and cost-effectiveness. Furthermore, the machining of high-quality difficult-to-machine alloys is becoming critical in the aerospace, manufacturing, and defence industries. While the optimisation of EDM parameters is essential for improving machining outcomes, it is also important to consider the trade-offs between different performances metrics, such as material removal rate and part accuracy. Part accuracy in terms of dimensional and geometric deviations from nominal values was rarely considered in the literature, if not by the authors. Balancing these factors remains a challenge in the field of EDM. Therefore, this work aims to carry out a multi-objective optimisation of both MRR and part accuracy. A Ni-based alloy (Inconel-625) was used that is widely used in creep-resistant turbine blades and vanes and turbine disks in gas turbine engines for aerospace and defence industries. Four performance indices were optimised simultaneously: two related to the performance of the EDM process and two connected with the form deviations of the manufactured surfaces. Multi-hole copper electrodes having different diameters and three process parameters were varied during the experimental tests. Grey relational analysis and the Adaptive Neuro-Fuzzy Inference System method were used for optimisation. Grey relational analysis found that the following values of the process parameter—0.16 mm of multi-hole electrode diameter, 12 Amperes of Peak current, 200 µs of pulse on time and 0.2 kg/m2 as dielectric pressure—produce the optimal performance, i.e., a material removal rate of 0.099 mm3/min, an electrode wear rate of 0.0002 g/min, a circularity deviation of 0.0043 mm and a cylindricity deviation of 0.027 mm. From the experimental examination using multi-hole electrodes, it is concluded that the material removal rate increases and the electrode wear rate decreases because of the availability of higher spark discharge areas between the electrode and work material interface. The Adaptive Neuro-Fuzzy Inference System models showed minimum mean percentage error and, therefore, better performance in comparison with regression models. Full article
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18 pages, 2289 KB  
Article
GaN/InN HEMT-Based UV Photodetector on SiC with Hexagonal Boron Nitride Passivation
by Mustafa Kilin and Firat Yasar
Photonics 2025, 12(10), 950; https://doi.org/10.3390/photonics12100950 - 24 Sep 2025
Viewed by 90
Abstract
This work presents a novel Gallium Nitride (GaN) high-electron-mobility transistor (HEMT)-based ultraviolet (UV) photodetector architecture that integrates advanced material and structural design strategies to enhance detection performance and stability under room-temperature operation. This study is conducted as a fully numerical simulation using the [...] Read more.
This work presents a novel Gallium Nitride (GaN) high-electron-mobility transistor (HEMT)-based ultraviolet (UV) photodetector architecture that integrates advanced material and structural design strategies to enhance detection performance and stability under room-temperature operation. This study is conducted as a fully numerical simulation using the Silvaco Atlas platform, providing detailed electrothermal and optoelectronic analysis of the proposed device. The device is constructed on a high-thermal-conductivity silicon carbide (SiC) substrate and incorporates an n-GaN buffer, an indium nitride (InN) channel layer for improved electron mobility and two-dimensional electron gas (2DEG) confinement, and a dual-passivation scheme combining silicon nitride (SiN) and hexagonal boron nitride (h-BN). A p-GaN layer is embedded between the passivation interfaces to deplete the 2DEG in dark conditions. In the device architecture, the metal contacts consist of a 2 nm Nickel (Ni) adhesion layer followed by Gold (Au), employed as source and drain electrodes, while a recessed gate embedded within the substrate ensures improved electric field control and effective noise suppression. Numerical simulations demonstrate that the integration of a hexagonal boron nitride (h-BN) interlayer within the dual passivation stack effectively suppresses the gate leakage current from the typical literature values of the order of 108 A to approximately 1010 A, highlighting its critical role in enhancing interfacial insulation. In addition, consistent with previous reports, the use of a SiC substrate offers significantly improved thermal management over sapphire, enabling more stable operation under UV illumination. The device demonstrates strong photoresponse under 360 nm ultraviolet (UV) illumination, a high photo-to-dark current ratio (PDCR) found at approximately 106, and tunable performance via structural optimization of p-GaN width between 0.40 μm and 1.60 μm, doping concentration from 5×1016 cm3 to 5×1018 cm3, and embedding depth between 0.060 μm and 0.068 μm. The results underscore the proposed structure’s notable effectiveness in passivation quality, suppression of gate leakage, and thermal management, collectively establishing it as a robust and reliable platform for next-generation UV photodetectors operating under harsh environmental conditions. Full article
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11 pages, 2008 KB  
Article
Corrosion-Resistant Plasma Electrolytic Oxidation Composite Coatings on Ti6Al4V for Harsh Acidic Environments
by Michael Garashchenko, Yuliy Yuferov and Konstantin Borodianskiy
J. Compos. Sci. 2025, 9(10), 515; https://doi.org/10.3390/jcs9100515 - 23 Sep 2025
Viewed by 166
Abstract
Titanium alloys are widely employed in structural and electrochemical applications owing to their excellent mechanical properties and inherent corrosion resistance. However, their stability in harsh acidic environments, such as those encountered in energy storage systems, remains a critical issue. In this study, composite [...] Read more.
Titanium alloys are widely employed in structural and electrochemical applications owing to their excellent mechanical properties and inherent corrosion resistance. However, their stability in harsh acidic environments, such as those encountered in energy storage systems, remains a critical issue. In this study, composite ceramic coatings were synthesized on a Ti6Al4V alloy using plasma electrolytic oxidation (PEO) in silicate-, phosphate-, and sulfate-based electrolytes, with and without the addition of α-alumina nanoparticles. The resulting coatings were comprehensively characterized to assess their surface morphology, chemical and phase compositions, and corrosion performance. Thus, the corrosion current density decreased from 9.7 × 104 for bare Ti6Al4V to 143 nA/cm2 for the coating fabricated in phosphate electrolyte with alumina nanoparticles, while the corrosion potential shifted anodically from –0.68 to +0.49 V vs. silver chloride electrode in 5 M H2SO4. Among the tested electrolytes, coatings produced in the phosphate-based electrolyte with Al2O3 showed the highest polarization resistance (113 kΩ·cm2), outperforming those fabricated in silicate- (71.6 kΩ·cm2) and sulfate-based (89.0 kΩ·cm2) systems. The composite coatings exhibited a multiphase structure with reduced surface porosity and the incorporation of crystalline oxide phases. Notably, titania–alumina nanoparticle composites demonstrated significantly enhanced corrosion resistance. These findings confirm that PEO-derived composite coatings provide an effective surface engineering strategy for enhancing the stability of the Ti6Al4V alloy in aggressive acidic environments relevant to advanced electrochemical systems. Full article
(This article belongs to the Special Issue Metal Composites, Volume II)
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22 pages, 3236 KB  
Review
Nano Gel/Hydrogel-Based Components for Battery Technology: An Overview
by Md Murshed Bhuyan and Kyungjun Lee
Gels 2025, 11(9), 762; https://doi.org/10.3390/gels11090762 - 22 Sep 2025
Viewed by 295
Abstract
Battery technology represents a cornerstone in the evolution of the energy sector, driven by the urgent need for sustainable and efficient energy storage systems. Various materials, including metals, non-metals, semiconductors, and polymeric gel conductors comprise batteries, and their size and composition can significantly [...] Read more.
Battery technology represents a cornerstone in the evolution of the energy sector, driven by the urgent need for sustainable and efficient energy storage systems. Various materials, including metals, non-metals, semiconductors, and polymeric gel conductors comprise batteries, and their size and composition can significantly affect battery performance. The essential components of a battery are electrolytes, electrodes, nanogelators, and membranes that can be built up by using nanogels. The nanogel components significantly enhance the efficiency and stability of redox-active flow batteries, which makes them cheaper and eco-friendly. Little research has been conducted on nanogel-based battery technology. This study mainly focuses on the nanogels used in the components of batteries. The review explains the functions of nanogels in different electrolytes, electrodes, nanogelators, and membranes. This review explicitly discusses the current status and literature background of nanogels and hydrogels in battery technology. For anyone interested in delving deeper into the realm of nanogel-based batteries, this review article serves as a valuable resource, offering a thorough exploration of their role in revolutionizing modern energy storage systems. Full article
(This article belongs to the Special Issue Recent Advances in Multi-Functional Hydrogels)
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