Search Results (231)

This study proposes a fast material parameter evaluation method for multilayer thin-film structures based on machine learning technology to solve the problems of long time and low efficiency in the traditional material parameter inversion process. Nanoindentation experiments are first conducted to establish an experimental basis across film stacks. A two-dimensional elasto-plastic model of the indentation process is then built to generate a large set of load–depth curves, which serve as training data for a machine learning model. Trained on simulated curves and validated against measurements, the model enables fast inverse identification of layer-wise plastic parameters and interfacial cohesive properties. The experimental results show that the method has high accuracy and efficiency in the inversion of interlayer cohesion parameters, and the correlation coefficient R² is 0.99 or more. Compared with traditional methods, the pipeline supports batch analysis of multiple datasets and delivers parameter estimates within 1 h, substantially shortening turnaround time while improving result reliability. This method can not only effectively solve the challenges faced by traditional material evaluation, but also provide a new and effective tool for the performance evaluation and optimization design of multilayer thin-film materials. It has broad application prospects and potential value. Full article

Membrane technology plays a vital role in environmental protection, chemical industry, and pharmaceuticals, where understanding the “structure-property” relationship of composite membranes through transmission electron microscopy (TEM) is crucial. Conventional ultramicrotomy methods for preparing ultra-thin sections of polymer composite membranes often result in significant damage and non-uniform thickness due to interference from non-woven substrates. In this study, we developed an innovative substrate stripping and double-orientation embedding technique that overcomes these limitations. A special embedding device was designed to facilitate the preparation of polymeric membrane cross-sections for TEM analysis. The device incorporates dual functionality, enabling both non-woven substrate detachment and bidirectional alignment of functional membrane layers. TEM characterization showed that the ultra-thin sections of membrane cross-sections prepared using the improved method were damage-free (0% damage rate), had uniform thickness, and showed distinct structural clarity. This method addressed three major challenges: (i) substrate-induced section damage, (ii) orientation deviation, and (iii) interlayer separation. This advancement provides researchers with a reliable tool for accurate cross-sectional analysis of composite membranes, facilitating deeper insights into membrane microstructure-performance relationships. Full article

Thin-bedded carbonate reservoirs face significant challenges in characterization and development due to their thin formation thickness, strong interlayer heterogeneity, and rapid sedimentary transformation. In recent years, horizontal wells have played an increasingly important role in improving the productivity of thin-bedded carbonate reservoirs. However, building accurate geological models from horizontal well data is a major challenge for geoscientists. Using Middle East Oilfield A as a case study, this paper analyzes the specific challenges of horizontal well geomodeling and proposes a dedicated strategy for integrating horizontal well-derived constraints into the geological modeling workflow. To address the challenges of structural modeling constrained by horizontal well data, this study proposes three methodologies: stratigraphic layer iteration, virtual control point generation, and localized grid refinement. These techniques collectively enable the construction of a higher-fidelity structural framework that rigorously honors hard well data constraints while incorporating geological plausibility. To address the challenges posed by the spatial configuration of vertical and horizontal wells and the dominant trajectory patterns of horizontal wells, this study introduces two complementary approaches: the exclusion of horizontal well section data (relying solely on vertical wells) and the selective extraction of representative horizontal well section data for variogram derivation. These methods collectively enable the construction of a geologically realistic reservoir model that accurately captures the spatial distribution of reservoir properties. These methodologies not only effectively leverage the rich geological information from horizontal wells but also mitigate spatial clustering effects inherent to such data. Validation through development well production data confirms robust performance, providing transferable insights for reservoir characterization in analogous fields worldwide. Full article

Targeting the classification and evaluation of chemical flooding well groups in medium-thick sandstone reservoirs (single-layer thickness: 5–15 m), this study proposes a multi-level classification model based on decision trees. Through the comprehensive analysis of key static factors influencing chemical flooding efficiency, a four-tier classification index system was established, comprising: interlayer/baffle development frequency (Level 1), thickness-weighted permeability rush coefficient (Level 2), reservoir rhythm characteristics (Level 3), and pore-throat radius-based reservoir connectivity quality (Level 4) as its core components. The model innovatively transforms common reservoir physical parameters (porosity and permeability) into pore-throat radius parameters to enhance guidance for polymer molecular weight design, while employing a thickness-weighted permeability rush coefficient to simultaneously characterize heterogeneity impacts from both permeability and thickness variations. Unlike existing classification methods primarily designed for thin-interbedded reservoirs—which consider only connectivity or apply fuzzy mathematics-based normalization—this model specifically addresses medium-thick reservoirs’ unique challenges of interlayer development and intra-layer heterogeneity. Furthermore, its decision tree architecture clarifies classification logic and significantly reduces data preprocessing complexity. In terms of engineering practicality, the classification results are directly linked to well-group development bottlenecks, as validated in the J16 field application. By implementing customized chemical flooding formulations tailored to the study area, the production performance in the expansion zone achieved comprehensive improvement: daily oil output dropped from 332 tons to 243 tons, then recovered to 316 tons with sustained stabilization. Concurrently, recognizing that interlayer barriers were underdeveloped in certain well groups during production layer realignment, coupled with strong vertical heterogeneity posing polymer channeling risks, targeted profile modification and zonal injection were implemented prior to flooding conversion. This intervention elevated industrial replacement flooding production in the study area from 69 tons to 145 tons daily post-conversion. This framework provides a theoretical foundation for optimizing chemical flooding pilot well-group selection, scheme design, and dynamic adjustments, offering significant implications for enhancing oil recovery in medium-thick sandstone reservoirs through chemical flooding. Full article

This study investigates the microstructure evolution and mechanical properties of DSS2209 duplex stainless steel fabricated via cold metal transfer wire arc additive manufacturing (CMT-WAAM). The as-deposited thin-wall components exhibit significant microstructural heterogeneity along the build height due to thermal history variations. Optical microscopy, SEM-EDS, and EBSD analyses reveal distinct phase distributions: the bottom region features elongated blocky austenite with Widmanstätten austenite (WA) due to rapid substrate-induced cooling; the middle region shows equiaxed blocky austenite with reduced grain boundary austenite (GBA) and WA, attributed to interlayer thermal cycling promoting recrystallization and grain refinement (average austenite grain size: 4.16 μm); and the top region displays coarse blocky austenite from slower cooling. Secondary austenite (γ₂) forms in interlayer remelted zones with Cr depletion, impacting pitting resistance. Mechanical testing demonstrates anisotropy; horizontal specimens exhibit higher strength (UTS: 610 MPa, YS: 408 MPa) due to layer-uniform microstructures, while vertical specimens show greater ductility (elongation) facilitated by columnar grains aligned with the build direction. Hardness ranges uniformly between 225–239 HV. The study correlates process-induced thermal gradients (e.g., cooling rates, interlayer cycling) with microstructural features (recrystallization fraction, grain size, phase morphology) and performance, providing insights for optimizing WAAM of large-scale duplex stainless steel components like marine propellers. Full article

This work presents an innovative hydrothermal approach for fabricating flexible piezoelectric PZT thin films on 20 μm titanium foil substrates using TiO₂ and SrTiO₃ (STO) interlayers. Three heterostructures (Ti/PZT, Ti/TiO₂/PZT, and Ti/TiO₂/STO/PZT) were synthesized to enable low-temperature growth and improve ferroelectric performance for advanced flexible MEMS. Characterizations including XRD, PFM, and P–E loop analysis evaluated crystallinity, piezoelectric coefficient d₃₃, and polarization behavior. The results demonstrate that the multilayered Ti/TiO₂/STO/PZT structure significantly enhances performance. XRD confirmed the STO buffer layer effectively reduces lattice mismatch with PZT to ~0.76%, promoting stable morphotropic phase boundary (MPB) composition formation. This optimized film exhibited superior piezoelectric and ferroelectric properties, with a high d₃₃ of 113.42 pm/V, representing an ~8.65% increase over unbuffered Ti/PZT samples, and displayed more uniform domain behavior in PFM imaging. Impedance spectroscopy showed the lowest minimum impedance of 8.96 Ω at 10.19 MHz, indicating strong electromechanical coupling. Furthermore, I–V measurements demonstrated significantly suppressed leakage currents in the STO-buffered samples, with current levels ranging from 10⁻¹² A to 10⁻⁹ A over ±3 V. This structure also showed excellent fatigue endurance through one million electrical cycles, confirming its mechanical and electrical stability. These findings highlight the potential of this hydrothermally engineered flexible heterostructure for high-performance actuators and sensors in advanced MEMS applications. Full article

In this study, the influence of HfO₂ interlayer thickness on the performance of heteroepitaxial α-Ga₂O₃ layer-based metal–insulator–semiconductor–insulator–metal (MISIM) ultraviolet photodetectors is examined. A thin HfO₂ interlayer enhances the interface quality and reduces the density of interface traps, thereby improving the performance of UVC photodetectors. The fabricated device with a 1 nm HfO₂ interlayer exhibited a significantly reduced dark current and higher photocurrent than a conventional metal–semiconductor–metal (MSM). Specifically, the 1 nm HfO₂ MISIM device demonstrated a photocurrent of 2.3 μA and a dark current of 6.61 pA at 20 V, whereas the MSM device exhibited a photocurrent of 1.1 μA and a dark current of 73.3 pA. Furthermore, the photodetector performance was comprehensively evaluated in terms of responsivity, response speed, and high-temperature operation. These results suggest that the proposed ultra-thin HfO₂ interlayer is an effective strategy for enhancing the performance of α-Ga₂O₃-based UVC photodetectors by simultaneously suppressing dark currents and increasing photocurrents and ultimately demonstrate its potential for stable operation under extreme environmental conditions. Full article

Due to factors such as low porosity and permeability, thin sand body thickness, and strong interlayer heterogeneity, the fluid flow in the tight reservoir (beach-bar sandstone reservoir) exhibits obvious nonlinear seepage characteristics. Considering the time-varying physical parameters of different types of sand bodies, a nonlinear seepage coefficient is derived based on permeability and capillary force, and a low-velocity nonlinear seepage model for beach bar sand reservoirs is established. Based on core displacement experiments of different types of sand bodies, the low-velocity nonlinear seepage coefficient was fitted and numerical simulation of low-velocity nonlinear seepage in beach-bar sandstone reservoirs was carried out. The research results show that the displacement pressure and flow rate of low-permeability tight reservoirs exhibit a significant nonlinear relationship. The lower the permeability and the smaller the displacement pressure, the more significant the nonlinear seepage characteristics. Compared to the bar sand reservoir, the water injection pressure in the tight reservoir of the beach sand is higher. In the nonlinear seepage model, the bottom hole pressure of the water injection well increases by 10.56% compared to the linear model, indicating that water injection is more difficult in the beach sand reservoir. Compared to matrix type beach sand reservoirs, natural fractures can effectively reduce the impact of fluid nonlinear seepage characteristics on the injection and production process of beach sand reservoirs. Based on the nonlinear seepage characteristics, the beach-bar sandstone reservoir can be divided into four flow zones during the injection production process, including linear seepage zone, nonlinear seepage zone, non-flow zone affected by pressure, and non-flow zone not affected by pressure. The research results can effectively guide the development of beach-bar sandstone reservoirs, reduce the impact of low-speed nonlinear seepage, and enhance oil recovery. Full article

Background/Objectives: The increasing demand for aesthetics in dentistry has driven significant advancements in both materials and techniques. The primary cause of ceramic detachment in dental restorations is extensive mechanical stress, which often results in detachment and clinical complications. This study aims to improve the bond strength between NiCr-based metal frameworks and ceramic coatings by introducing biocompatible inorganic MeSiON thin films (Me = Cr or Zr) as interlayers. Methods: MeSiON coatings with a thickness of ~2 μm were deposited on NiCr alloy using cathodic arc evaporation. To tailor the stoichiometry, morphology, and mechanical properties of the coatings, the substrate bias voltage was varied: −50 V, −100 V, −150 V, −200 V. Structural and surface characterization was performed using SEM/EDS, XRD, profilometry, and contact angle analysis. The coating adhesion was evaluated by using standardized scratch testing, while the bond strength was evaluated using a three-point bending test. Results: The NiCr alloy exhibited a dendritic microstructure, and the ceramic layer consisted mainly of quartz, feldspar, kaolin, and ZrO₂. ZrSiON coatings showed superior roughness, elemental incorporation, and adhesion compared to Cr-based coatings, these properties being further improved by increasing the substrate bias. The highest bond strength was achieved with a ZrSiON coating deposited at −200 V, a result we attributed to increased surface roughness and mechanical interlocking at the ceramic-metal interface. Conclusions: CrSiON and ZrSiON interlayers enhanced ceramic-to-metal adhesion in NiCr-based dental restorations. The enhancement in bond strength is primarily ascribed to substrate bias-induced modifications in the coating’s stoichiometry, roughness, and adhesion. Full article

Titanium alloy/carbon fiber-reinforced polymer (TA1/CFRP) laminates, representing the latest fourth generation of fiber metal laminates (FMLs), is a kind of high-performance composite material. However, the fragility of the fiber/resin and metal/resin interface layers in these composites directly impacts their mechanical properties. To enhance these properties, this paper investigates the preparation process of multi-walled carbon nanotube (MWCNT)-reinforced ultra-thin TA1/CFRP laminates and explores the impact of MWCNT content on the interlayer properties of these ultra-thin TA1/CFRP laminates. Initially, the challenge of dispersing carbon nanotubes using ultrasonic dispersion devices and dispersants was addressed. Vacuum-curing pressure studies revealed minimal overflow at 0.8 bar vacuum. Subsequently, the impact of MWCNT content on interlayer properties was investigated. The results indicated a significant increase in interlayer shear strength and interlayer fracture toughness with MWCNT additions at 0.5 wt% and 0.75 wt%, whereas the interlayer properties decreased at 1.0 wt% MWCNT. Fracture morphology analysis revealed that MWCNT content exceeding 0.75 wt% led to agglomeration, resulting in resin cavity formation and stress concentration. Full article

As three-dimensional (3D) printing becomes increasingly prevalent in microfluidic system fabrication, the demand for high precision has become critical. Among various 3D printing technologies, light-curing-based methods offer superior resolution and are particularly well suited for fabricating microfluidic channels and associated micron-scale components. Two-photon polymerization (TPP), one such method, can achieve ultra-high resolution at the submicron level. However, its severely limited printable volume and high operational costs significantly constrain its practicality for real-world applications. In contrast, digital light processing (DLP) 3D printing provides a more balanced alternative, offering operational convenience, lower cost, and print dimensions that are more compatible with practical microfluidic needs. Despite these advantages, most commercial DLP systems still struggle to fabricate intricate, high-resolution structures—particularly curve, thin-walled, or hollow ones—due to over-curing and interlayer adhesion issues. In this study, we developed a DLP-based projection micro-stereolithography (PμSL) system with a simple optical reconfiguration and fine-tuned its parameters to overcome limitations in printing precise and intricate structures. For demonstration, we selected an Archimedes microscrew as the target structure, as it serves as a key component in microfluidic micromixers. Based on our previous study, the most effective design was selected and fabricated in accordance with practical microfluidic dimensions. The PμSL system developed in this study, along with optimized parameters, provides a reference for applying DLP 3D printing in high-precision microfabrication and advancing microfluidic component development. Full article

Batteries are used as energy storage devices in various equipment. Today, research is focused on solid-state batteries (SSBs), replacing the liquid electrolyte with a solid separator. The solid separators provide electrolyte stability, no leakage, and provide mechanical strength to the battery. Separators are mostly manufactured by either traditional processes or 3D printing technologies. These processes involve making a slurry of plastic, active and conductive material and usually adding a plasticizer when making thin films or filaments for 3D printing. This study investigates the additive manufacturing of solid-state electrolytes (SSEs) by employing fused deposition modeling (FDM) with recyclable, bio-derived polylactic acid (PLA) filaments. Precise control of macro-porosity is achieved by systematically varying key process parameters, including raster orientation, infill percentage, and interlayer adhesion conditions, thereby enabling the formation of tunable, interconnected pore networks within the polymer matrix. Following 3D printing, these engineered porous frameworks are infiltrated with lithium hexafluorophosphate (LiPF₆), which functions as the active ionic conductor. A tailored thermal sintering protocol is then applied to promote solid-phase fusion of the embedded salt throughout the macro-porous PLA scaffold, resulting in a mechanically robust and ionically conductive composite separator. The electrochemical ionic conductivity and structural integrity of the sintered SSEs are characterized through electrochemical impedance spectroscopy (EIS) and standardized mechanical testing to assess their suitability for integration into advanced solid-state battery architectures. The solid-state separator achieved an average ionic conductivity of 2.529 × 10⁻⁵ S·cm⁻¹. The integrated FDM-sintering process enhances ion exchange at the electrode–electrolyte interface, minimizes material waste, and supports cost-efficient, fully recyclable component fabrication. Full article

In recent years, frequent vehicle–bridge pier collision accidents have posed a serious threat to people’s economic and life security. In order to avert the impairment of reinforced concrete bridge piers (RCBPs) under the impact of vehicles, three kinds of Mg–Al alloy AlSi10Mg anti-collision structures designed by selective laser melting (SLM) printing were tested by the numerical simulation method in this study: an ultra-high performance concrete (UHPC) anti-collision structure, a bio-inspired honeycomb column thin-walled structure (BHTS) buffer interlayer, and a UHPC–BHTS composite structure were used to reduce the damage degree of RCBPs caused by vehicle impact. In accordance with the prototype configuration of the pier, a scaled model with a scale ratio of 1:10 was fabricated. Three anti-collision structures were installed on the reinforced concrete (RC) column specimens for the steel ball impact test. The impact simulation under low-energy and high-energy input was carried out successively, and the protective effect of the three anti-collision devices on the RC column was comprehensively evaluated. The outcomes demonstrate that the BHTS buffer interlayer and the UHPC–BHTS composite structure are capable of converting the shear failure of RC columns into bending failure, thereby exerting an efficacious role in safeguarding RC columns. The damage was evaluated under all impact conditions of BHTS and UHPC–BHTS composite structures, and the RC column only suffered slight damage, while the RC column without protective measures and the RC column with the UHPC anti-collision structure alone showed serious damage and collapse behavior. This approach can offer a valuable reference for anti-collision design within analogous projects. Full article

Thermoplastic fiber metal laminates (FMLs) are hybrid material systems that consist of a thin aluminum alloy sheet bonded to plies of fiber-reinforced adhesive. They provide excellent properties like fatigue strength, damage-tolerant properties, and inherent resistance to corrosion. However, they are still challenging materials in terms of the metal–composite interface, which is the weakest link in this material system. In this paper, an experimental–numerical method for the determination of the fracture stress and energy for metal–composite interlayer is presented and verified. The proposed method utilizes four different experimental tests: DCB test (interface opening—mode I), ENF test (interface shearing—mode II), MMB test (mixed-mode I+II—opening with the shearing of the interface) and three-point bending test (3PB). For each test, digital twin in the form of a numerical model is prepared. The established numerical models for DCB and ENF allowed us to determine fracture stress and energy for mode I and mode II, respectively. On the basis of the numerical and experimental (from the MMB test) data, the B-K exponent is determined. Finally, the developed material model is verified in a three-point bending test, which results in mixed-mode conditions. The research is conducted on the thermoplastic FML made of aluminum alloy sheet and glass fiber reinforced polyamide 6. The research presented is complemented by fundamental mechanical tests, image processing and Scanning Electron Microscopy (SEM) analysis. As an effect, for the tested material, fracture parameters are determined using the described method. Full article

A new brazing process for thin-walled stainless steel was proposed by combining green and efficient Ni-Cr-P electrodeposition with brazing technology. Novel information was attained by analyzing the electrodeposited Ni-Cr-P interlayers and the brazed joints and characterizing them using a combination of advanced techniques. The incorporation mechanisms of impurities (i.e., oxygen and carbon) in the Ni-Cr-P interlayers electrodeposited from a Cr(III)–glycine solution were revealed. The oxygen mainly came from the Cr(III)–hydroxy complexes formed by the hydrolysis and olation between Cr(III) complexes and OH⁻ ions near the cathode. Glycine did not directly participate in the cathode reactions but decomposed on the anode surface. These byproducts (carbonyl compounds) were directly incorporated into the interlayers in a molecular pattern, forming a weak link to the metallic chromium. Brazing test results showed that a certain amount of Cr₂O₃ powder, formed by the decomposition of chromium hydroxides in the interlayers under high-temperature catalysis, would cause the degradation of the brazed joints. Using the step-wise brazing method, the brazing sheets were first annealed to eliminate the impurities by utilizing the strong reducing effect of hydrogen and the weak link characteristics between carbonyl compounds and metallic chromium atoms. An excellent joint with a shear strength of 63.0 MPa was obtained by subsequent brazing. The microstructural analysis showed that the brazed seam was mainly composed of a Ni-Fe-Cr solid solution, the Ni₃P eutectic phase, and small quantities of the Ni₅P₂ phase scattered in the Ni₃P eutectic phase. Fracture mode observations showed that the cracks extended along the interface between the brittle P-containing phase and the primary phase, resulting in fracture. Full article