The relationship of casting conditions with the structure and properties of sacrificial materials

The application of cast protectors in systems of cathodic protection of metal structures and structures from electrochemical corrosion is well known. Alloys based on aluminum, magnesium and zinc are widely used as sacrificial materials for the manufacture of sacrificials. The choice of designs and standard sizes of protectors is carried out taking into account the provision of the required service life of the protector protection systems in various operating conditions. The structure of cast protectors plays an important role in stabilizing the electrochemical characteristics of sacrificial materials. The paper describes the characteristics of sacrificial alloys and cast sacrificials, and also shows the influence of casting conditions on increasing the values of the efficiency factor (KPI) of sacrificial materials.

Wafer-scale transfer route for top–down III-nitride nanowire LED arrays based on the femtosecond laser lift-off technique

The integration of gallium nitride (GaN) nanowire light-emitting diodes (nanoLEDs) on flexible substrates offers opportunities for applications beyond rigid solid-state lighting (e.g., for wearable optoelectronics and bendable inorganic displays). Here, we report on a fast physical transfer route based on femtosecond laser lift-off (fs-LLO) to realize wafer-scale top–down GaN nanoLED arrays on unconventional platforms. Combined with photolithography and hybrid etching processes, we successfully transferred GaN blue nanoLEDs from a full two-inch sapphire substrate onto a flexible copper (Cu) foil with a high nanowire density (~107 wires/cm2), transfer yield (~99.5%), and reproducibility. Various nanoanalytical measurements were conducted to evaluate the performance and limitations of the fs-LLO technique as well as to gain insights into physical material properties such as strain relaxation and assess the maturity of the transfer process. This work could enable the easy recycling of native growth substrates and inspire the development of large-scale hybrid GaN nanowire optoelectronic devices by solely employing standard epitaxial LED wafers (i.e., customized LED wafers with additional embedded sacrificial materials and a complicated growth process are not required).

Multi-Layer and Conformally Integrated Structurally Embedded Vascular Antenna (SEVA) Arrays

This work presents the design and fabrication of two multi-element structurally embedded vascular antennas (SEVAs). These are achieved through advances in additively manufactured sacrificial materials and demonstrate the ability to embed vascular microchannels in both planar and complex-curved epoxy-filled quartz fiber structural composite panels. Frequency-reconfigurable antennas are formed by these structures through the pressure-driven transport of liquid metal through the embedded microchannels. The planar multi-layer topology examines the ability to fabricate two co-located radiating structures separated by a single ply of quartz fabric within the composite layup. The multi-element linear array topology composed of microchannels embedded on to a single-layer are used to demonstrate the ability to conformally-integrate these channels into a complex curved surface that mimics an array of antennas on the leading edge of an Unmanned Aerial Vehicle (UAV). A parallel-strip antipodal dipole feed structure provides excitation and serves as the interface for fluid displacement within the microchannels to facilitate reconfiguration. The nominal design of the SEVAs achieve over a decade of frequency reconfiguration with respect to the fundamental dipole mode of the antenna. Experimental and predicted results demonstrate the operation for canonical states of the antennas. Additional results for the array topology demonstrate beam steering and contiguous operation of interconnected elements in the multi-element structure.

Molecular cannibalism: Sacrificial materials as precursors for hollow and multidomain single crystals

The coexistence of single-crystallinity with a multidomain morphology is a paradoxical phenomenon occurring in biomineralization. Translating such feature to synthetic materials is a highly challenging process in crystal engineering. We demonstrate the formation of metallo-organic single-crystals with a unique appearance: six-connected half-rods forming a hexagonal-like tube. These uniform objects are formed from unstable, monodomain crystals. The monodomain crystals dissolve from the inner regions, while material is anisotropically added to their shell, resulting in hollow, single-crystals. Regardless of the different morphologies and growth mechanism, the crystallographic structures of the mono- and multidomain crystals are nearly identical. The chiral crystals are formed from achiral components, and belong to a rare space group (P622). Sonication of the solvents generating radical species is essential for forming the multidomain single-crystals. This process reduces the concentration of the active metal salt. Our approach offers opportunities to generate a new class of crystals.

Using Graphene Sulfonate Nanosheets to Improve the Properties of Siliceous Sacrificial Materials: An Experimental and Molecular Dynamics Study

The fabrication of high-performance cement-based materials has benefited greatly from the extensive use of graphene and its derivatives. This paper studies the effects of graphene sulfonate nanosheets (GSNSs) on sacrificial cement paste and mortar (the tested materials) and other siliceous sacrificial materials, especially their ablation behaviors and mechanical properties. Decomposition temperatures and differential scanning calorimetry were used to examine how different contents of GSNSs determines the corresponding decomposition enthalpy of the tested materials and their ablation behaviors. Molecular dynamics was also used to clarify the mechanism how the GSNSs work in the CSH (calcium silicate hydrated)/GSNSs composite to increase the resistance to high temperature. The experimental results show that: (1) the contents of GSNSs at 0.03 wt.%, 0.1 wt.%, and 0.3 wt.% brought an increase of 10.97%, 22.21%, and 17.56%, respectively, in the flexural strength of siliceous sacrificial mortar, and an increase of 1.92%, 9.16%, and 6.70% in its compressive strength; (2) the porosity of siliceous sacrificial mortar was decreased by 5.04%, 9.91%, and 7.13%, respectively, and the threshold pore diameter of siliceous sacrificial mortar was decreased by 13.06%, 35.39%, and 24.02%, when the contents of GSNSs were 0.03 wt.%, 0.1 wt.%, and 0.3 wt.%, respectively; (3) a decline of 11.16%, 28.50%, and 61.01% was found in the ablation velocity of siliceous sacrificial mortar, when the contents of GSNSs were 0.03 wt.%, 0.1 wt.%, and 0.3 wt.%, respectively; (4) when considering the ablation velocities and mechanical properties of siliceous sacrificial materials, 0.1 wt.% GSNSs was considered to be the optimal amount; (5) the GSNSs contribute to the reinforced effect of GSNSs on CSH gel through the grab of dissociated calcium and water molecules, and the chemical reaction with silicate tetrahedron to produce S–O–Si bonds. These results are expected to promoting the development of new kinds of siliceous sacrificial materials that contain GSNSs.

3D printed self-supporting elastomeric structures for multifunctional microfluidics

Microfluidic devices fabricated via soft lithography have demonstrated compelling applications such as lab-on-a-chip diagnostics, DNA microarrays, and cell-based assays. These technologies could be further developed by directly integrating microfluidics with electronic sensors and curvilinear substrates as well as improved automation for higher throughput. Current additive manufacturing methods, such as stereolithography and multi-jet printing, tend to contaminate substrates with uncured resins or supporting materials during printing. Here, we present a printing methodology based on precisely extruding viscoelastic inks into self-supporting microchannels and chambers without requiring sacrificial materials. We demonstrate that, in the submillimeter regime, the yield strength of the as-extruded silicone ink is sufficient to prevent creep within a certain angular range. Printing toolpaths are specifically designed to realize leakage-free connections between channels and chambers, T-shaped intersections, and overlapping channels. The self-supporting microfluidic structures enable the automatable fabrication of multifunctional devices, including multimaterial mixers, microfluidic-integrated sensors, automation components, and 3D microfluidics.