Recent Advances in the Development of Highly Conductive Structured Supports for the Intensification of Non-adiabatic Gas-Solid Catalytic Processes: The Methane Steam Reforming Case Study

Structured catalysts are strong candidates for the intensification of non-adiabatic gas-solid catalytic processes thanks to their superior heat and mass transfer properties combined with low pressure drops. In the past two decades, different types of substrates have been proposed, including honeycomb monoliths, open-cell foams and, more recently, periodic open cellular structures produced by additive manufacturing methods. Among others, thermally conductive metallic cellular substrates have been extensively tested in heat-transfer limited exo- or endo-thermic processes in tubular reactors, demonstrating significant potential for process intensification. The catalytic activation of these geometries is critical: on one hand, these structures can be washcoated with a thin layer of catalytic active phase, but the resulting catalyst inventory is limited. More recently, an alternative approach has been proposed, which relies on packing the cavities of the metallic matrix with catalyst pellets. In this paper, an up-to-date overview of the aforementioned topics will be provided. After a brief introduction concerning the concept of structured catalysts based on highly conductive supports, specific attention will be devoted to the most recent advances in their manufacturing and in their catalytic activation. Finally, the application to the methane steam reforming process will be presented as a relevant case study of process intensification. The results from a comparison of three different reactor layouts (i.e. conventional packed bed, washcoated copper foams and packed copper foams) will highlight the benefits for the overall reformer performance resulting from the adoption of highly conductive structured internals.

Influence of Electrodeposition Parameters on Morphology and Polymer Inclusion into Polymer/Zn Composite Coatings

In this study different type of composite coatings was obtained by electrodeposition using zinc as matrix and polymeric particles as disperse phase in zinc sulphate electrolyte. The effects of some electrodeposition parameters on the thickness and morphology of obtained composite coatings were analysed by optical microscopy, Scanning Electron Microscopy (SEM) and Energy-Dispersive X-Ray Spectroscopy (EDX) methods. Polymeric particles inclusion into zinc matrix was correlated with imposed electrodeposition parameters. It was observed that the thickness of the coatings is influenced by electrodeposition parameters. From the morphology of the coatings, it could be concluded that pure zinc has a regular surface with hexagonal crystals, while the composite coatings have fine surface structure. Also, the electrodeposition parameters influence the inclusion of the dispersed phase into metallic matrix that will influence further the different properties of the composite materials.

Deposition, Morphological, and Mechanical Evaluation of W and Be-Al2O3 and Er2O3 Co-Sputtered Films in Comparison with Pure Oxides

Compact and defect-free high melting point oxide strengthened metallic matrix configurations are promising to resolve the hydrogen permeation and brittleness issues relevant to the fusion research community. Previous studies on oxide addition to metallic matrix demonstrated a mitigation in brittleness behavior, while deposition techniques and material configurations are still to be investigated. Thus, here, we report the structural, morphological, and mechanical characterization of metal-oxides thin layers co-deposited by radio frequency (RF)and direct current (DC) magnetron sputtering. A total of six configurations were deposited such as single thin layers of oxides (Al2O3, Er2O3) and co-deposition configurations as metal-oxides (W, Be)—(Al2O3, Er2O3). The study of films roughness by atomic force microscopy (AFM) method show that for Al2O3 metallic-oxides is increased to an extent that could favor gaseous trapping, while co-depositions with Be seem to promote an increased roughness and defects formation probability compared to W co-depositions. Lower elastic modulus on metal-oxide co-depositions was observed, while the indentation hardness increased for Be and decreased for W matrix configurations. These outputs are highly relevant for choosing the proper compact and trap-free configuration that could be categorized as a permeation barrier for hydrogen and furtherly studied in laborious permeation yield campaigns.

Metal Matrix Composite in Heat Sink Application: Reinforcement, Processing, and Properties

Heat sinks are commonly used for cooling electronic devices and high-power electrical systems. The ever-increasing performance of electronic systems together with miniaturization calls for better heat dissipation. Therefore, the heat sink materials should not only have high thermal conductivities, low densities, and cost, but also have coefficients of thermal expansion matching to those of semiconductor chips and ceramic substrates. As traditional materials fail to meet these requirements, new composite materials have been developed with a major focus on metal matrix composites (MMCs). MMCs can be tailored to obtain the desired combination of properties by selecting proper metallic matrix and optimizing the size and type, volume fraction, and distribution pattern of the reinforcements. Hence, the current review comprehensively summarizes different studies on enhancing the thermal performance of metallic matrices using several types of reinforcements and their combinations to produce composites. Special attention is paid to the types of commonly used metallic matrices and reinforcements, processing techniques adopted, and the effects of each of these reinforcements (and their combinations) on the thermal properties of the developed composite. Focus is also placed on highlighting the significance of interfacial bonding in achieving optimum thermal performance and the techniques to improve interfacial bonding.

Influence of Cooling Rate on Microstructure Formation of Si–Mo Ductile Iron Castings

The present study highlights the effect of the cooling rate on the microstructure formation of Si–Mo ductile iron. In this study, experiments were carried out for castings with different wall thicknesses (i.e., 3, 5, 13, and 25 mm) to achieve various cooling rates. The simulation of the cooling and solidification was performed through MAGMASOFT to correlate the cooling conditions with the microstructure. The phase diagram of the investigated alloy was calculated using Thermo-Calc, whereas the quantitative metallography analyses using scanning electron microscopy and optical microscopy were performed to describe the graphite nodules and metallic matrix morphologies. The present study provides insights into the effect of the cooling rate on the graphite nodule count, nodularity, and volumetric fractions of graphite and ferrite as well as the average ferritic grain size of thin-walled and reference Si–Mo ductile iron castings. The study shows that the cooling rates of castings vary within a wide range (27 °C–1.5 °C/s) when considering wall thicknesses of 3 to 25 mm. The results also suggest that the occurrence of pearlite and carbides are related to segregations during solidification rather than to cooling rates at the eutectoid temperature. Finally, the present study shows that the longitudinal ultrasonic wave velocity is in linear dependence with the number of graphite nodules of EN-GJS-SiMo45-6 ductile iron.

Research Summary on the Processing, Mechanical and Tribological Properties of Aluminium Matrix Composites as Effected by Fly Ash Reinforcement

Fly ash is the main waste as a result of combustion in coal fired power plants. It represents about 40% of the wastes of coal combustion products (fly ash, boiler ash, flue gas desulphurization gypsum and bottom ash). Currently, coal waste is not fully utilized and waste disposal remains a serious concern despite tremendous global efforts in reducing fossil fuel dependency and shifting to sustainable energy sources. Owing to that, employment of fly ash as reinforcement particles in metallic matrix composites are gaining momentum as part of recycling effort and also as a means to improve the specifications of the materials that are added to it to form composite materials. Many studies have been done on fly ash to study composite materials wear characteristics including the effects of fly ash content, applied load, and sliding velocity. Here, particular attention is given to studies carried out on the influence FA content on physical, mechanical, and the thermal behavior of Aluminium-FA composites. Considerable changes in these properties are seen by fly ash refinement with limited size and weight fraction. The advantage of fly ash addition results in low density of composites materials, improvement of strength, and hardness. It further reduces the thermal expansion coefficient and improve wear resistance.

Features of the Synthesis of the Dispersed TiC Phase with Nickel Nanostructures on the Surface to Create an Aluminum-Based Metal Composite

The development of new composites with improved functional properties is the important task of modern materials science. The composites must be structurally organized to provide improved properties. For metal-ceramic composites, there is a need for a uniform distribution of the dispersed ceramic phase in the bulk metallic matrix The modification of the dispersed ceramic phase surface with a metal coating is one of the more effective ways to accomplish this. Particularly, in this work, the conditions of Ni nanolayer deposition on titanium carbide (TiC) particles were studied. The goal was to create core–shell particles with a thickness of the Ni coating on TiC not exceeding 90 nm. Preliminary work was also carried out to study the effect of the dispersed phase composition on the mechanical properties of the composite with an Al matrix.

Cytotoxicity assessment of Bio-C Repair Íon+: A new calcium silicate-based cement

Background. Direct pulp capping is a method designed to preserve the exposed dental pulp. Due to good biological, physical, and mechanical properties, new versions of calcium silicate-based materials have been developed as pulp capping materials. The present study aimed to evaluate the cytotoxic effects of four calcium silicate-based pulp capping materials, of which the Bio-C Repair Íon+ is still in an experimental phase. Methods. Biodentine, MTA Repair HP, Bio-C Repair, and Bio-C Repair Íon+ cements were dispensed in a metallic matrix to produce 125-mm3 specimens, which were immersed in Dulbecco’s Modified Eagle Medium (DMEM) to obtain extracts. NIH 3T3 cells were cultured and exposed to the extracts for 24 hours and seven days. Cell viability was assessed by the methyl tetrazolium test (MTT). The mean values for the experimental and control groups (without treatment) were compared by analysis of variance (ANOVA) and post hoc Tukey tests, considering a significance level of 5%. Results. All the tested materials demonstrated a reduction in cell viability (P<0.05). According to ISO 10993-5: 2009 (E), Bio-C Repair Íon+ exhibited mild and moderate cytotoxicity in the 24- hour and 7-day analyses, respectively. Bio-C Repair and Biodentine showed mild cytotoxicity, and MTA Repair HP exhibited moderate cytotoxicity at both intervals. Conclusion. The highest cell viability was demonstrated by Biodentine, MTA, and Repair HP, in descending order. Bio-C Repair and Bio-C Repair Íon+ showed moderate cytotoxicity, similar to MTA Repair HP in the 7-day analysis.