Lithium nitrate salt-assisted CO2 absorption for the formation of corrosion barrier layer on AZ91D magnesium alloy.

Mg alloy corrosion susceptibility is a major issue that limits its wide industrial application in transport, energy and medical sectors. A corrosion-resistant layer containing crystalline MgCO3 was formed on the surface of AZ91D Mg alloy by Li salt loading and thermal CO2 treatment. Compared to the uncoated AZ91D surface, the surface layer exhibited up to a ∼15-fold increase in corrosion resistance according to the electrochemical results in 3.5 wt% NaCl solution and ∼32% decrease in wear rate compared to untreated AZ91D. The improved corrosion resistance is attributed to the formation of a <10 µm thick dense layer containing Mg, O, C and Li with crystalline MgCO3 phases. The initial step was to form a porous MgO layer on the surface of AZ91D Mg alloy, followed by loading an alkali metal salt (i.e., LiNO3) onto the MgO surface. The porous MgO surface was then reconstructed into a dense insulation layer containing Mg carbonate through CO2 absorption facilitated by molten Li salt during thermal CO2 treatment at 350 °C. As a potential method to utilize excessive CO2 for beneficial outcomes, the formation of the carbonate-containing film introduced in this study opens a new pathway for protecting various existing Mg alloys for diverse industrial applications.

Probing corrosion using a simple and versatile in situ multimodal corrosion measurement system.

In this work, we have developed a unique in situ multimodal corrosion system that is capable of acquiring electrochemical data, sample imaging/visualization and hydrogen collection, simultaneously. Each of these modalities yield valuable information pertaining to the ongoing corrosion process. Combining them can yield holistic information on the role of microstructure, processing history, presence of coatings, etc., on the sequence of steps occurring during the corrosion process, and how they correlate with the acquired electrochemical data. Four materials systems, namely AA6061-T6 aluminum alloy, AZ91 magnesium alloy, galvanized DP590 steel, and pure Zn, were investigated under open circuit potential and under potentiodynamic polarization. The multimodal corrosion system was utilized to observe processes such as surface passivation and dissolution, pit and filiform corrosion initiation and propagation, and was correlated with location and magnitude of hydrogen evolution. This approach is shown to yield a truly multimodal understanding of the ongoing corrosion processes.

Unraveling the Mechanisms of the Apis mellifera Honeycomb Construction by 4D X-ray Microscopy.

Honeycomb is one of nature's best engineered structures. Even though it has inspired several modern engineering structures, an understanding of the process by which the hexagonal cells are formed in 3D space is lacking. Previous studies on the structure of the honeycomb are based on either 2D microscopy or by direct visual observations. As a result, several critical features of its microstructure and the precise mechanisms of its growth are not well understood. Using 4D X-ray microscopy, this study shows how individual and groups of honeycomb cells are formed. Cells grow additively from a corrugated central spine in a dynamic manner. The previously undocumented, corrugated spine contributes significantly to the comb's robust mechanical properties in all three dimensions. As cells grow, honey bees create a "coping," which this study shows to be the location where new wax material is deposited behind where compaction and densification take place. This is exemplified by pores in the wax observed at the coping and alternating rear junctions between the comb cells that arise from the additive building technique and the highly efficient cell packing methodology, respectively. Additional mechanisms for growth and formation are discussed and described.

Reducing the risk of rostral bending failure in Curculio Linnaeus, 1758.

With over 300 species worldwide, the genus Curculio Linnaeus, 1758 is a widespread, morphologically diverse lineage of weevils that mainly parasitize nuts. Females use the rostrum, an elongate cuticular extension of the head, to excavate oviposition sites. This process causes extreme bending and deformation of the rostrum, without apparent harm to the structure. The cuticle of the rostral apex exhibits substantial modifications to its composite structure that enhance the elasticity and resiliency of this structure. Here we develop finite element models of the head and rostrum for three Curculio species representing disparate North American clades and rostral morphotypes. The models were subjected to varying apical loads and to prescribed dislocation of the head capsule, with and without representing the cuticular modifications of the rostral apex. We found that the altered layer thicknesses and macrofiber orientation angles of the rostral apex fully explain the observed elasticity of the rostrum. These modifications have a synergistic effect that greatly enhances the flexibility of the rostral apex. Consequently, the cuticle composite profile of the rostral apex substantially mitigates the risk of fracture in dorso-apical flexion. Removing the cuticular modifications, in turn, causes a negative margin of safety for rostral bending, implying strong risk of catastrophic structural failure. The occipital sulci were identified as an important source of biomechanical constraint upon the elasticity of the rostrum, and exhibit the greatest risk of failure within this structure. The apical cuticle profile greatly reduced the maximum stresses and strain energy accumulated in the rostrum, thereby resulting in a positive margin of safety and reducing the risk of fracture. Our findings imply that the primary selective pressure influencing the evolution of the rostral cuticle was most likely negative selection of structural failure caused by bending. STATEMENT OF SIGNIFICANCE: Weevils are among the most diverse and evolutionarily successful animal lineages on Earth. Their success is driven in part by a structure called the rostrum, which gives weevil heads a characteristic "snout-like" appearance. Nut weevils in the genus Curculio use the rostrum to drill holes into developing fruits and nuts, into which they deposit their eggs. During oviposition this exceedingly slender structure is bent into a straightened configuration - in some species up to 90∘ - but does not suffer any damage during this process. Using finite element models of the rostra of three morphologically distinct species, we show that the Curculio rostrum is only able to withstand repeated, extreme bending because of modifications to the composite structure of the cuticle in the rostral apex. These modifications were shown previously to enhance the intrinsic toughness of the cuticle; in this study, we demonstrate that modification of the rostral cuticle also results in more evenly distributed bending stresses, further reducing the risk of fracture. This is the first time that the laminate profile, orthotropic behavior, and functional gradation of the cuticle have been incorporated into a three-dimensional finite element model of an insect cuticular structure. Our models highlight the significance of biomechanical constraint - i.e., avoidance of catastrophic structural failure - on the evolution of insect morphology.

Bioinspired Honeycomb Core Design: An Experimental Study of the Role of Corner Radius, Coping and Interface.

The honeybee's comb has inspired the design of engineering honeycomb core that primarily abstract the hexagonal cell shape and exploit its mass minimizing properties to construct lightweight panels. This work explored three additional design features that are part of natural honeybee comb but have not been as well studied as design features of interest in honeycomb design: the radius at the corner of each cell, the coping at the top of the cell walls, and the interface between cell arrays. These features were first characterized in natural honeycomb using optical and X-ray techniques and then incorporated into honeycomb core design and fabricated using an additive manufacturing process. The honeycomb cores were then tested in out-of-plane compression and bending, and since all three design features added mass to the overall structure, all metrics of interest were examined per unit mass to assess performance gains despite these additions. The study concluded that the presence of an interface increases specific flexural modulus in bending, with no significant benefit in out-of-plane compression; coping radius positively impacts specific flexural strength, however, the corner radius has no significant effect in bending and actually is slightly detrimental for out-of-plane compression testing.