3D Printed MXene-Based Wire Strain Sensors with Enhanced Sensitivity and Anisotropy.

Stretchable strain sensors play a crucial role in intelligent wearable systems, serving as the interface between humans and environment by translating mechanical strains into electrical signals. Traditional fiber strain sensors with intrinsic uniform axial strain distribution face challenges in achieving high sensitivity and anisotropy. Moreover, existing micro/nano-structure designs often compromise stretchability and durability. To address these challenges, a novel approach of using 3D printing to fabricate MXene-based flexible sensors with tunable micro and macrostructures.  Poly(tetrafluoroethylene) (PTFE) as a pore-inducing agent is added into 3D printable inks to achieve controllable microstructural modifications. In addition to microstructure tuning, 3D printing is employed for macrostructural design modifications, guided by finite element modeling (FEM) simulations. As a result, the 3D printed sensors exhibit heightened sensitivity and anisotropy, making them suitable for tracking static and dynamic displacement changes. The proposed approach presents an efficient and economically viable solution for standardized large-scale production of advanced wire strain sensors.

Microstructure Design Strategy for Molecularly Dispersed Cobalt Phthalocyanine and Efficient Mass Transport in CO2 Electroreduction.

Cobalt phthalocyanine (CoPc) has attracted particular interest owing to its excellent activity during the electrochemical CO2 conversion to CO. However, the efficient utilization of CoPc at industrially relevant current densities is still a challenge owing to its nonconductive property, agglomeration, and unfavorable conductive substrate design. Here, a microstructure design strategy for dispersing CoPc molecules on a carbon substrate for efficient CO2 transport during CO2 electrolysis is proposed and demonstrated. The highly dispersed CoPc is loaded on a macroporous hollow nanocarbon sheet to act as the catalyst (CoPc/CS). The unique interconnected and macroporous structure of the carbon sheet forms a large specific surface area to anchor CoPc with high dispersion and simultaneously boosts the mass transport of reactants in the catalyst layer, significantly improving the electrochemical performance. By employing a zero-gap flow cell, the designed catalyst can mediate CO2 to CO with a high full-cell energy efficiency of 57% at 200 mA cm-2 .

Intermediate Valence Ion-Mediated Electrodeposition Process.

The assembly of biomolecules and ions (e.g., biomineralization process) generates many intricate structures in nature. However, human beings' control over the assembly processes of ions is in its infant stage compared with nature. Here, it is reported that the intermediate valence metal ions in the electrolyte can influence the growth speed of certain crystal facets and in turn adjust the shape of the electrodeposits created by anodic electrodeposition. This is because the intermediate valence metal ions (e.g., Pb2+ , Mn2+ , etc.) can be oxidized by the electrochemically oxidized high valence ions (e.g., Ag2+ and Ag3+ ). Therefore, the concentration of the electrochemically oxidized high valence ions can be controlled by the intermediate valence ions, affecting the growth kinetics of the electrodeposits. Taking the anodic electrodeposition of Ag7 O8 NO3 as an example, the role of intermediate valence ions in tailoring the shape of the Ag7 O8 NO3 electrodeposits is demonstrated. Moreover, the growth location of the second-order structure can be controlled by the intermediate valence metal ions. Additionally, the designed complex microarchitectures starting from certain crystal facets to form hollow nanoframes can be selectively etched. The control capability over the electrochemical assembly process of metal ions is significantly strengthened by introducing intermediate valence ions into the electrolyte.

Microstructure Design of Carbonaceous Fibers: A Promising Strategy toward High-Performance Weaveable/Wearable Supercapacitors.

Fiber-based supercapacitors (FSCs) possess great potential as an ideal type of power source for future weaveable/wearable electronics and electronic-textiles. The performance of FSCs is, without doubt, primarily determined by the properties of fibrous electrodes. Carbonaceous fibers, e.g., commercial carbon fibers, newly developed graphene fibers, and carbon nanotube fibers, are deemed as promising materials for weaveable/wearable supercapacitors owing to their exotic properties including high tensile strength and robustness, excellent electrical conductivity, good flexibility, and environmental stability. Nevertheless, bare carbonaceous fiber normally exhibits low capacitance originating from electric double-layer capacitance, which remains unsatisfactory for efficiently powering wearable and portable devices. Numerous efforts have been devoted to tailoring fiber properties by hybridizing pseudocapacitive materials, and impressive progress has been achieved thus far. Herein, the microstructures of pristine carbonaceous fibers are introduced in detail, and the recent advances in rational nano/microstructure design of their hybrids, which provides the feasibility to achieve the synergistic interaction between conductive agents and pseudocapacitive nanomaterials but are normally overlooked, are comprehensively reviewed. Besides, the challenges in developing high-performance fibrous electrodes are also elaborately discussed.

High-throughput quantification of quasistatic, dynamic and spall strength of materials across 10 orders of strain rates.

The response of metals and their microstructures under extreme dynamic conditions can be markedly different from that under quasistatic conditions. Traditionally, high strain rates and shock stresses are achieved using cumbersome and expensive methods such as the Kolsky bar or large spall experiments. These methods are low throughput and do not facilitate high-fidelity microstructure-property linkages. In this work, we combine two powerful small-scale testing methods, custom nanoindentation, and laser-driven microflyer (LDMF) shock, to measure the dynamic and spall strength of metals. The nanoindentation system is configured to test samples from quasistatic to dynamic strain-rate regimes. The LDMF shock system can test samples through impact loading, triggering spall failure. The model material used for testing is magnesium alloys, which are lightweight, possess high-specific strengths, and have historically been challenging to design and strengthen due to their mechanical anisotropy. We adopt two distinct microstructures, solutionized (no precipitates) and peak-aged (with precipitates) to demonstrate interesting upticks in strain-rate sensitivity and evolution of dynamic strength. At high shock-loading rates, we unravel an interesting paradigm where the spall strength vs. strain rate of these materials converges, but the failure mechanisms are markedly different. Peak aging, considered to be a standard method to strengthen metallic alloys, causes catastrophic failure, faring much worse than solutionized alloys. Our high-throughput testing framework not only quantifies strength but also teases out unexplored failure mechanisms at extreme strain rates, providing valuable insights for the rapid design and improvement of materials for extreme environments.

Flexible Aerogel Materials: A Review on Revolutionary Flexibility Strategies and the Multifunctional Applications.

The design and preparation of flexible aerogel materials with high deformability and versatility have become an emerging research topic in the aerogel fields, as the brittle nature of traditional aerogels severely affects their safety and reliability in use. Herein, we review the preparation methods and properties of flexible aerogels and summarize the various controlling and design methods of aerogels to overcome the fragility caused by high porosity and nanoporous network structure. The mechanical flexibility of aerogels can be revolutionarily improved by monomer regulation, nanofiber assembly, structural design and controlling, and constructing of aerogel composites, which can greatly broaden the multifunctionality and practical application prospects. The design and construction criterion of aerogel flexibility is summarized: constructing a flexible and deformable microstructure in an aerogel matrix. Besides, the derived multifunctional applications in the fields of flexible thermal insulation (flexible thermal protection at extreme temperatures), flexible wearable electronics (flexible sensors, flexible electrodes, electromagnetic shielding, and wave absorption), and environmental protection (oil/water separation and air filtration) are summarized. Furthermore, the future development prospects and challenges of flexible aerogel materials are also summarized. This review will provide a comprehensive research basis and guidance for the structural design, fabrication methods, and potential applications of flexible aerogels.

Design of Light-Driven Biocompatible and Biodegradable Microrobots Containing Mg-Based Metallic Glass Nanowires.

Light-driven microrobots capable of moving rapidly on water surfaces in response to external stimuli are widely used in a variety of fields, such as drug delivery, remote sampling, and biosensors. However, most light-driven microrobots use graphene and carbon nanotubes as photothermal materials, resulting in poor biocompatibility and degradability, which greatly limits their practical bioapplications. To address this challenge, a composition and microstructure design strategy with excellent photothermal properties suitable for the fabrication of light-driven microrobots was proposed in this work. The Mg-based metallic glass nanowires (Mg-MGNWs) were embedded with polyhydroxyalkanoates (PHA) to fabricate biocompatible and degradable microrobots with excellent photothermal effect and complex shapes. Consequently, the microrobot can be precisely driven by a near-infrared laser to achieve high efficiency and remote manipulation on the water surface for a long period of time, with a velocity of 9.91 mm/s at a power density of 2.0 W/cm2. Due to the Marangoni effect, programmable and complex motions of the microrobot such as linear, clockwise, counterclockwise, and obstacle avoidance motions can be achieved. The biocompatible and degradable microrobot fabrication strategy could have great potential in the fields of environmental detection, targeted drug delivery, disease diagnosis, and detection.

Enhanced sensitivity and linear-response in iontronic pressure sensors for non-contact, high-frequency vibration recognition.

Monitoring non-contact high-frequency vibrations requires improving the sensitivity and linear response of iontronic pressure sensors (IPSs). In this study, we incorporate composite electrodes comprising silver nanowires (Ag NWs) and MXene into IPSs to enhance electronic conduction and pseudocapacitance. Moreover, we utilize a novel surface-pillar microstructure, along with an internally randomized multi-bubble structure within the dielectric layer, to significantly expand the linear response range of the sensor. The resulting IPS device demonstrates exceptional linear sensitivity, measuring approximately 153.83 kPa-1, across a broad pressure range of up to 260 kPa. Additionally, it exhibits long-term stability, rapid response and recovery characteristics, and remains functional underwater. Notably, these devices exhibit remarkable capabilities in monitoring ultrasonic vibrations and accurately identifying sound wave vibrations. The integration of composite electrodes, microstructure designs, and their compatibility with underwater applications positions these IPSs as highly promising tools for precise measurements and advancements in flexible electronics technology.

DRAGen - A deep learning supported RVE generator framework for complex microstructure models.

In this study an improved version of the Discrete RVE Automation and Generation Framework, also called DRAGen, is presented. The Framework incorporates a generator for Representative Volume Elements (RVEs). Several complex microstructure features, extracted from real microstructures, have been added to the generator, to enable it to generate RVEs with realistic microstructures. DRAGen is now capable of reading trained neural networks as well as .csv-files as input data for the microstructure generation. Furthermore, features such as pores and inclusions, martensite bands, hierarchical substructures, and crystallographic textures can be reconstructed in the RVEs. Besides the features, the functionality for different solvers was introduced. Therefore, the code was extended by modules for the generation of Finite Element (FE) and spectral solver input files. DRAGen now has the ability to create models for three powerful multiphysics frameworks used in the community: DAMASK, Abaqus and MOOSE. The evaluation of the features, as well as the simulations performed on sample models, show that the new version of DRAGen is a very powerful tool with flexible applicability for scientists in the ICME community. Also, due to the modular architecture of the project, the code can easily be expanded with features of interest. Therefore, it delivers a variety of functions and possible outputs, which offers researchers a broad spectrum of microstructures that can be used in microstructure studies or microstructure design developments.

Shape effect of ultrafine-grained structure on static fracture toughness in low-alloy steel.

A 0.4C-2Si-1Cr-1Mo steel with an ultrafine elongated grain (UFEG) structure and an ultrafine equiaxed grain (UFG) structure was fabricated by multipass caliber rolling at 773 K and subsequent annealing at 973 K. A static three-point bending test was conducted at ambient temperature and at 77 K. The strength-toughness balance of the developed steels was markedly better than that of conventionally quenched and tempered steel with a martensitic structure. In particular, the static fracture toughness of the UFEG steel, having a yield strength of 1.86 GPa at ambient temperature, was improved by more than 40 times compared with conventional steel having a yield strength of 1.51 GPa. Furthermore, even at 77 K, the fracture toughness of the UFEG steel was about eight times higher than that of the conventional and UFG steels, despite the high strength of the UFEG steel (2.26 GPa). The UFG steel exhibited brittle fracture behavior at 77 K, as did the conventional steel, and no dimple structure was observed on the fracture surface. Therefore, it is difficult to improve the low-temperature toughness of the UFG steel by grain refinement only. The shape of crystal grains plays an important role in delamination toughening, as do their refinement and orientation.

High-Throughput Computing Assisted by Knowledge Graph to Study the Correlation between Microstructure and Mechanical Properties of 6XXX Aluminum Alloy.

It is of great academic and engineering application to study the evolution of microstructure and properties of age-strengthened aluminum alloys during heat treatment and to establish quantitative prediction models that can be applied to industrial production. The main factors affecting the peak aging state strength of age-strengthened aluminum alloys are the precipitates, solid solution elements, grain size effects, and textures formed during the material processing. In this work, these multi-scale factors are integrated into the framework of the knowledge graph to assist the following crystal plasticity finite elements simulations. The constructed knowledge graph is divided into two parts: static data and dynamic data. Static data contains the basic properties of the material and the most basic property parameters. Dynamic data is designed to improve awareness of static data. High-throughput computing is performed to further obtain clear microstructure-property relationships by varying the parameters of materials properties and the characteristics of the structure models. The constructed knowledge graph can be used to guide material design for 6XXX Al-Mg-Si based alloys. The past experimental values are used to calibrate the phenomenological parameters and test the reliability of the analysis process.

In-situ construction of nitrogen-doped reduced graphene oxide@carbon nanofibers towards the synergetic enhancement of their microwave absorption properties via integrating point defects and structure engineering.

The aim of this work is to develop materials that can absorb microwave to meet the requirements of stealth technology and solve the problem of electromagnetic pollution. However, the challenge is having materials with high-efficient absorption properties at an ultralow filling rate and visualizing the microwave response. The strategy used in this work was to integrate point defect and microstructure in preparing materials, nitrogen-doped reduced graphene oxide@ carbon nanofibers with high-efficient microwave absorption and double-layered structure. Ethylenediamine (nitrogen source), was doped into the materials, resulting in the generation of the defects. The microwave absorption performance of the materials was affected by the degree of defects due to the dipole polarization loss and conductive loss. The optimal samples gained the maximum reflection loss of -54.7 dB and effective absorption bandwidth of 4.74 GHz at a filling rate of only 8 wt%. More significantly, the microwave absorbing mechanism was analyzed visually in the response field. Furthermore, the actual stealth effects were evaluated by the radar cross section reduction, and the value was 29.2 dBm2. The experimental results illustrated that nitrogen-doped reduced graphene oxide@ carbon nanofibers may be alternative materials with high microwave absorption performance at a low filling rate.

Microstructured BN Composites with Internally Designed High Thermal Conductivity Paths for 3D Electronic Packaging.

Miniaturized and high-power-density 3D electronic devices pose new challenges on thermal management. Indeed, prompt heat dissipation in electrically insulating packaging is currently limited by the thermal conductivity achieved by thermal interface materials (TIMs) and by their capability to direct the heat toward heat sinks. Here, high thermal conductivity boron nitride (BN)-based composites that are able to conduct heat intentionally toward specific areas by locally orienting magnetically functionalized BN microplatelets are created using magnetically assisted slip casting. The obtained thermal conductivity along the direction of alignment is unusually high, up to 12.1 W m-1 K-1 , thanks to the high concentration of 62.6 vol% of BN in the composite, the low concentration in polymeric binder, and the high degree of alignment. The BN composites have a low density of 1.3 g cm-3 , a high stiffness of 442.3 MPa, and are electrically insulating. Uniquely, the approach is demonstrated with proof-of-concept composites having locally graded orientations of BN microplatelets to direct the heat away from two vertically stacked heat sources. Rationally designing the microstructure of TIMs to direct heat strategically provides a promising solution for efficient thermal management in 3D integrated electronics.

Research on Meshing Gears CIMT Design and Anti-Thermoelastic Scuffing Load-Bearing Characteristics.

In the process of gear meshing, it is an inevitable trend to encounter failure cases such as contact friction thermal behavior and interface thermoelastic scuffing wear. As one of the cores influencing factors, the gear meshing contact interface micro-texture (CIMT) significantly restricts the gear transmission system (GTS) dynamic characteristics. This subject suggests the contact characteristic model and interface friction dynamics coupling model of meshing gear pair with different CIMT. Considering the influence of gear meshing CIMT on distribution type of hydrodynamic lubricating oil film, contact viscous damping and frictional thermal load, the aforementioned models have involved transient meshing stiffness (TMS) and static transmission accumulated error (STAE). Based on the proposed models, an example verification of meshed gear pair (MGP) is analyzed to reveal the influence of CIMT on the dynamic characteristics of GTS under a variety of micro-texture configurations and input branch power and rated speed/shaft torque conditions. Numerical simulation results indicate that the influence of CIMT on gear dynamic response is extremely restricted by the transient contact regularity of the meshing gear surface. Meshing gears' dynamic characteristics (especially vibration and noise) can be obviously and effectively adjusted by setting a regular MGP with CIMT instead of random gear surfaces.

A Critical Review on the Design, Manufacturing and Assessment of the Bone Scaffold for Large Bone Defects.

In recent years, bone tissue engineering has emerged as a promising solution for large bone defects. Additionally, the emergence and development of the smart metamaterial, the advanced optimization algorithm, the advanced manufacturing technique, etc. have largely changed the way how the bone scaffold is designed, manufactured and assessed. Therefore, the aim of the present study was to give an up-to-date review on the design, manufacturing and assessment of the bone scaffold for large bone defects. The following parts are thoroughly reviewed: 1) the design of the microstructure of the bone scaffold, 2) the application of the metamaterial in the design of bone scaffold, 3) the optimization of the microstructure of the bone scaffold, 4) the advanced manufacturing of the bone scaffold, 5) the techniques for assessing the performance of bone scaffolds.

Composition Optimization and Microstructure Design in MOFs-Derived Magnetic Carbon-Based Microwave Absorbers: A Review.

Magnetic carbon-based composites are the most attractive candidates for electromagnetic (EM) absorption because they can terminate the propagation of surplus EM waves in space by interacting with both electric and magnetic branches. Metal-organic frameworks (MOFs) have demonstrated their great potential as sacrificing precursors of magnetic metals/carbon composites, because they provide a good platform to achieve high dispersion of magnetic nanoparticles in carbon matrix. Nevertheless, the chemical composition and microstructure of these composites are always highly dependent on their precursors and cannot promise an optimal EM state favorable for EM absorption, which more or less discount the superiority of MOFs-derived strategy. It is hence of great importance to develop some accompanied methods that can regulate EM properties of MOFs-derived magnetic carbon-based composites effectively. This review comprehensively introduces recent advancements on EM absorption enhancement in MOFs-derived magnetic carbon-based composites and some available strategies therein. In addition, some challenges and prospects are also proposed to indicate the pending issues on performance breakthrough and mechanism exploration in the related field.

Facile fabrication of Hildewintera-colademonis-like hexagonal boron nitride/carbon nanotube composite having light weight and enhanced microwave absorption.

Hildewintera-colademononis-like hexagonal boron nitride carbon nanotubes (BN@CNT) composites can be fabricated via two steps: a composite structure predesign in a solvent and a subsequent thermal treatment process at high temperature. The as-obtained hildewintera-colademononis-like BN@CNT composites contain porous h-BN microrods as stems and CNTs as spines. The densities and specific surface area of these BN@CNT composites can be tuned by adjusting the relative amounts of CNTs in the composites, which can reach 0.072 ± 0.0046 g/cm3 and 583.63 m2/g, respectively. These BN@CNT composites based absorbers show excellent microwave absorption (MA) properties which have effective frequency absorption width (≤-10 dB) from 2.8 to 18 GHz when the absorber thicknesses are in the range of 1.0-6.0 mm, and the minimum RL values can reach up to -48.45 dB for BN@CNTs-3 based absorber with an absorber thickness only of 1.4 mm. Moreover, the widest absorption bandwidth of 4.24 GHz (12.96-17.20 GHz) can be obtained for BN@CNTs-2 based absorber when the absorber thickness is 1.6 mm. Therefore, these hildewintera-colademononis-like BN@CNT composites are expected to be used as microwave absorption materials as they are lightweight and have broad absorption bands and strong absorption with thin thickness. This facile and controllable fabrication process offers a new strategy for designing and fabricating diverse h-BN/carbon based composites for different applications.

Effect of Processing Route on Microstructure and Mechanical Properties in Single-Roll Angular-Rolling.

This paper reports the effect of the processing route on the microstructure and mechanical properties in the pure copper sheets processed by single-roll angular-rolling (SRAR). The SRAR process was repeated up to six passes in two processing routes, called routes A and C in equal-channel angular pressing. As the number of passes increased, the heterogeneous evolution of hardness and microstructural heterogeneities between the core and surface regions gradually became intensified in both processing routes. In particular, route A exhibited more prominent partial grain refinement and dislocation localization on the core region than route C. The finite element analysis revealed that the intense microstructural heterogeneities observed in route A were attributed to effective shear strain partitioning between the core and surface regions by the absence of redundant strain. On the other hand, route C induced reverse shearing and cancellation of shear strain over the entire thickness, leading to weak shear strain partitioning and delayed grain refinement. Ultimately, this work suggests that route A is the preferred option to manufacture reverse gradient structures in that the degree of shear strain partitioning and microstructural heterogeneity between the core and surface regions is more efficiently intensified with increasing the number of passes.

Constructing Highly Uniform Onion-Ring-like Graphitic Carbon Nitride for Efficient Visible-Light-Driven Photocatalytic Hydrogen Evolution.

The introduction of microstructure to the metal-free graphitic carbon nitride (g-C3N4) photocatalyst holds promise in enhancing its catalytic performance. However, producing such microstructured g-C3N4 remains technically challenging due to a complicated synthetic process and high cost. In this study, we develop a facile and in-air chemical vapor deposition (CVD) method that produces onion-ring-like g-C3N4 microstructures in a simple, reliable, and economical manner. This method involves the use of randomly packed 350 nm SiO2 microspheres as a hard template and melamine as a CVD precursor for the deposition of a thin layer of g-C3N4 in the narrow space between the SiO2 microspheres. After dissolution of the microsphere template, the resultant g-C3N4 exhibits uniquely uniform onion-ring-like microstructures. Unlike previously reported g-C3N4 powder morphologies that show various degrees of agglomeration and irregularity, the onion-ring-like g-C3N4 is highly dispersed and uniform. The calculated band gap for onion-ring-like g-C3N4 is 2.58 eV, which is significantly narrower than that of bulk g-C3N4 at 2.70 eV. Experimental characterization and testing suggest that, in comparison with bulk g-C3N4, onion-ring-like g-C3N4 facilitates charge separation, extends the lifetime of photoinduced carriers, exhibits 5-fold higher photocatalytic hydrogen evolution, and shows great potential for photocatalytic applications.

New Scalable Approach toward Shape Memory Polymer Composites via "Spring-Buckle" Microstructure Design.

Shape memory polymers (SMPs) have attracted tremendous research interest since their discovery. However, most advances in research of SMPs are based on molecular designs, i.e., "bottom-up" strategies. Due to the viscoelasticity of polymers, slow and incomplete shape variations are inevitable for most existing SMPs. Here, we propose a simple and scalable approach to design and fabricate SMP composites (SMPCs) based on a "spring-buckle" microstructure design. Specifically, a highly elastic "spring" is employed as a basic skeleton for the SMPCs, onto which self-adhesive and stimuli-responsive "buckles" are installed as reversible switch units. The resultant SMPCs with such "spring-buckle" microstructure enable quick programming at ambient temperature and ultrafast (2-3 s) and nearly complete (∼100%) shape recovery triggered by organic solvents, benefiting from a unique capillary effect. This structural approach provides a novel design philosophy for shape memory materials and opens up new opportunities for their applications in sensor, actuator, aerospace, and other applications.