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Rubber blends based on styrene–butadiene rubber, ethylene–propylene–diene monomer rubber and a combination of both rubbers were cured with different sulfur and peroxide curing systems. In sulfur curing systems, two type of accelerators, namely tetramethylthiuram disulfide, N-cyclohexyl-2-benzothiazole sulfenamide, and combinations of both accelerators were used. In peroxide curing systems, dicumyl peroxide, and a combination of dicumyl peroxide with zinc diacrylate or zinc dimethacrylate, respectively, were applied. The work was aimed at investigating the effect of curing systems composition as well as the type of rubber or rubber combinations on the curing process, cross-link density and physical–mechanical properties of vulcanizates. The dynamic mechanical properties of the selected vulcanizates were examined too. The results revealed a correlation between the cross-link density and physical–mechanical properties. Similarly, there was a certain correlation between the cross-linking degree and glass transition temperature. The tensile strength of vulcanizates based on rubber combinations was higher when compared to that based on pure rubbers, which points out the fact that in rubber combinations, not only are the features of both elastomers combined, but improvement in the tensile characteristics can also be achieved. When compared to vulcanizates cured with dicumyl peroxide, materials cured with a sulfur system exhibited higher tensile strength. With the application of co-agents in peroxide vulcanization, the tensile strength overcame the tensile behavior of sulfur-cured vulcanizates.

Injection molding technology is widely utilized across various industries for its ability to fabricate complex-shaped components with exceptional dimensional accuracy. However, challenges related to injection quality often arise, necessitating innovative approaches for improvement. This study investigates the influence of surface roughness on the efficiency of conformal cooling channels produced using additive manufacturing technologies, specifically Direct Metal Laser Sintering (DMLS) and Atomic Diffusion Additive Manufacturing (ADAM). Through a combination of experimental measurements, including surface roughness analysis, scanning electron microscopy, and cooling system flow analysis, this study elucidates the impact of surface roughness on coolant flow dynamics and pressure distribution within the cooling channels. The results reveal significant differences in surface roughness between DMLS and ADAM technologies, with corresponding effects on coolant flow behavior. Following that fact, this study shows that when cooling channels’ surface roughness is lowered up to 90%, the reduction in coolant media pressure is lowered by 0.033 MPa. Regression models are developed to quantitatively describe the relationship between surface roughness and key parameters, such as coolant pressure, Reynolds number, and flow velocity. Practical implications for the optimization of injection molding cooling systems are discussed, highlighting the importance of informed decision making in technology selection and post-processing techniques. Overall, this research contributes to a deeper understanding of the role of surface roughness in injection molding processes and provides valuable insights for enhancing cooling system efficiency and product quality.

The corrosion behavior of a hybrid laminate consisting of laser-structured aluminum EN AW-6082 ∪ carbon fiber-reinforced polymer was investigated. Specimens were corroded in aqueous NaCl electrolyte (0.1 mol/L) over a period of up to 31 days and characterized continuously by means of scanning electron and light microscopy, supplemented by energy dispersive X-ray spectroscopy. Comparative linear sweep voltammetry was employed on the first and seventh day of the corrosion experiment. The influence of different laser morphologies and production process parameters on corrosion behavior was compared. The corrosion reaction mainly arises from the aluminum component and shows distinct differences in long-term corrosion morphology between pure EN AW-6082 and the hybrid laminate. Compared to short-term investigations, a strong influence of galvanic corrosion on the interface is assumed. No distinct influences of different laser structuring and process parameters on the corrosion behavior were detected. Weight measurements suggest a continuous loss of mass attributed to the detachment of corrosion products.

This paper deals with the optimization of reactive powder concrete mixtures with respect to the addition of silica fume and the type of polycarboxylate superplasticizer used. First, the properties of reactive powder concrete with eight different commercial polycarboxylate superplasticizers were tested in terms of workability, specific weight, and mechanical properties. It was found that different commercially available superplasticizers had significant effects on the slump flow, specific weight, and compressive and flexural strengths. The optimal superplasticizer (BASF ACE430) was selected for further experiments in order to evaluate the influences of silica fume and superplasticizer content on the same material properties. The results showed that the silica fume and superplasticizer content had considerable effects on the mini-cone slump flow value, specific weight, flexural and compressive strengths, and microstructure. There were clearly visible trends and local minima and maxima of the measured properties. The optimal reactive powder concrete mixture had a composition of 3.5–4.0% superplasticizer and 15–25% silica fume.

This work focuses on joining steel to aluminum alloy using a novel method of joining by resistance spot welding with an insert element based on anticorrosive steel in combination with adhesive bonding. The method aims to reduce the formation of brittle intermetallic compounds by using short welding times and a different chemical composition of the insert element. In the experiment, deep-drawing low-carbon steel, HSLA zinc-coated steel and precipitation-hardened aluminum alloy 6082 T6 were used. Two types of adhesives—one based on rubber and the other based on epoxy resin—were used for adhesive bonding, while the surfaces of the materials joined were treated with a unique adhesion-improving agent based on organosilanes. The surface treatment improved the chemical bonding between the substrate and adhesive. It was proved, that the use of an insert element in combination with adhesive bonding is only relevant for those adhesives that have a load capacity just below the yield strength of the substrates. For bonded joints with higher load capacities, plastic deformation of the substrates occurs, which is unacceptable, and thus, the overall contribution of the insert element to the load capacity of the joint becomes negligible. The results also show that the combination of the resistance spot welding of the insert element and adhesive bonding facilitates the joining process of galvanized and nongalvanized steels with aluminum alloys and suppresses the effect of brittle intermetallic phases by minimizing the joining area and welding time. It is possible to use the synergistic effect of insert element welding and adhesive bonding to achieve increased energy absorption of the joint under stress.

Biochar is a versatile carbon-rich organic material originating from pyrolyzed biomass residues that possess the potential to stabilize organic carbon in the soil, improve soil fertility and water retention, and enhance plant growth. For the utilization of biochar as a soil conditioner, the mutual interconnection of the physicochemical properties of biochar with the production conditions used during the pyrolysis (temperature, heating rate, residence time) and the role of the origin of used biomass seem to be crucial. The aim of the research was focused on a comparison of the properties of biochar samples (originated from oat brans, mixed woodcut, corn residues and commercial compost) produced at different temperatures (400–700 °C) and different residence times (10 and 60 min). The results indicated similar structural features of produced biochar samples; nevertheless, the original biomass showed differences in physicochemical properties. The morphological and structural analysis showed well-developed aromatic porous structures for biochar samples originated from oat brans, mixed woodcut and corn residues. The higher pyrolysis temperature resulted in lower yields; however, it provided products with higher content of organic carbon and a more developed surface area. The lignocellulose biomass with higher contents of lignin is an attractive feedstock material for the production of biochar with potential agricultural applications.

The possibility of the formation of an alkali–silicate reaction (ASR) is a crucial issue for the service life of concrete. The coexistence of key parameters such as the presence of alkalis, reactive SiO2, humidity, and temperature predetermine the possibility of its formation and application. When an ASR gel forms, it results in the concreting cracking and spalling as well as in the deterioration of its overall properties. The risk of ASR depends on the concentration of alkalis and their mobility, which influence their ability to penetrate the concrete. The objective of this study was to determine the ionic mobility of not only Na+ and K+, but Ca2+ as well, from external sources (0.5 and 1.0 mol/L solutions of Na/K carbonate, nitrate, and hydroxide) to a cementitious matrix as the precursor for ASR. The concentrations of ions in both the immersion solutions (ICP) and the cementitious matrix itself (SEM-EDX) were studied as a function of time, from 0 to 120 days, for leaching, and according to temperature (25 and 40 °C). The reaction products were characterized using SEM-EDX. Different diffusion rates and behavior were observed depending on the anion type of the external alkali source. Both sodium and potassium ions in all the three environments studied, namely carbonate, hydroxide, and nitrate, penetrated into the composite and further into its structure by different mechanisms. The action of hydroxides, in particular, transformed the original hydration products into calcium-silicate-hydrate (CASH) or ASR gel, while nitrates crystallized in pores and did not cause any changes in the hydration product. The driving force was the increased temperature of the experiment as well as the increased concentration of the solution to which the test specimen was exposed.

This paper introduces a new alloying concept for low-density steels. Based on model calculations, samples—or “heats”—with 0.7 wt% C, 1.45 wt% Si, 2 wt% Cr, 0.5 wt% Ni, and an aluminium content varying from 5 to 7 wt% are prepared. The alloys are designed to obtain steel with reduced density and increased corrosion resistance suitable for products subjected to high dynamic stress during operation. Their density is in the range from 7.2 g cm−3 to 6.96 g cm−3. Basic thermophysical measurements are carried out on all the heats to determine the critical points of each phase transformation in the solid state, supported by metallographic analysis on SEM and LM or the EDS analysis of each phase. It is observed that even at very high austenitisation temperatures of 1100 °C, it is not possible to change the two-phase structure of ferrite and austenite. A substantial part of the austenite is transformed into martensite during cooling at 50 °C s−1. The carbide kappa phase is segregated at lower cooling rates (around 2.5 °C s−1).

The very early stages of alkaline activation of slag control its rheology and setting, but also affect its hydration, which occurs later. Simultaneously, these parameters are dictated by the nature and dose of the alkaline activator. Therefore, we investigated and compared the changes in slag particles (SEM, BET, laser diffraction), as well as in the pore solution composition (ICP–OES), pH, and conductivity, of alkali-activated slag (AAS) pastes containing the three most common sodium activators (waterglass, hydroxide, and carbonate) and water during the first 24 h of its activation. To ensure the best possible comparability of the pastes, a fairly nontraditional mixture design was adopted, based on the same concentration of Na+ (4 mol/dm3) and the same volume fraction of slag in the paste (0.50). The results were correlated with the pastes’ hydration kinetics (isothermal calorimetry), structural build-up (oscillatory rheology), and setting times (Vicat). Great differences were observed in most of these properties, in the formation of hydration products, and in the composition of the pore solution for each activator. The results emphasize the role of the anionic groups in the activators and of the pH, which help predict the sample’s behavior based on its calorimetric curve, and offer data for further comparisons and for the modelling of AAS hydration for specific activators.

In bone tissue engineering, the design of in vitro models able to recreate both the chemical composition, the structural architecture, and the overall mechanical environment of the native tissue is still often neglected. In this study, we apply a bioreactor system where human bone-marrow hMSCs are seeded in human femoral head-derived decellularized bone scaffolds and subjected to dynamic culture, i.e., shear stress induced by continuous cell culture medium perfusion at 1.7 mL/min flow rate and compressive stress by 10% uniaxial load at 1 Hz for 1 h per day. In silico modeling revealed that continuous medium flow generates a mean shear stress of 8.5 mPa sensed by hMSCs seeded on 3D bone scaffolds. Experimentally, both dynamic conditions improved cell repopulation within the scaffold and boosted ECM production compared with static controls. Early response of hMSCs to mechanical stimuli comprises evident cell shape changes and stronger integrin-mediated adhesion to the matrix. Stress-induced Col6 and SPP1 gene expression suggests an early hMSC commitment towards osteogenic lineage independent of Runx2 signaling. This study provides a foundation for exploring the early effects of external mechanical stimuli on hMSC behavior in a biologically meaningful in vitro environment, opening new opportunities to study bone development, remodeling, and pathologies.

In this paper, we present the results of an experimental study on WC/C coatings, deposited by using plasma-enhanced chemical vapor deposition in an N2-SiH4 atmosphere, annealed at temperatures of 200, 500 and 800 °C, in which the hexacarbonyl of W was used as a precursor. During the experiments, the topography, chemical composition, morphology, as well as selected mechanical properties, such as hardness, Young’s modulus, and coefficient of friction of the WC/C coatings were analyzed. Annealing without the protective atmosphere in the mentioned temperatures caused a decrease in hardness (up to 15 ± 2.7 GPa). In addition, the coefficient of friction value increased only to 0.37 ± 0.03.

The foreign body reaction to neuronal electrode implants limits potential applications as well as the therapeutic period. Developments in the basic electrode design might improve the tissue compatibility and thereby reduce the foreign body reaction. In this work, the approach of embedding 3D carbon nanofiber electrodes in extracellular matrix (ECM) synthesized by human fibroblasts for a compatible connection to neuronal cells was investigated. Porous electrode material was manufactured by solution coelectrospinning of polyacrylonitrile and polyamide as a fibrous porogen. Moreover, NaCl represented an additional particulate porogen. To achieve the required conductivity for an electrical interface, meshes were carbonized. Through the application of two different porogens, the electrodes’ flexibility and porosity was improved. Human dermal fibroblasts were cultured on the electrode surface for ECM generation and removed afterwards. Scanning electron microscopy imaging revealed a nano fibrous ECM network covering the carbon fibers. The collagen amount of the ECM coating was quantified by hydroxyproline-assays. The modification with the natural protein coating on the electrode functionality resulted in a minor increase of the electrical capacity, which slightly improved the already outstanding electrical interface properties. Increased cell numbers of SH-SY5Y cell line on ECM-modified electrodes demonstrated an improved cell adhesion. During cell differentiation, the natural ECM enhanced the formation of neurites regarding length and branching. The conducted experiments indicated the prevention of direct cell-electrode contacts by the modification, which might help to shield temporary the electrode from immunological cells to reduce the foreign body reaction and improve the electrodes’ tissue integration.

The microstructure, mechanical, tribological, and corrosion properties of Fe–Cr–Al–Y-based oxide-precipitation-hardened (OPH) alloy at room temperature are presented. Two OPH alloys with a composition of 0.72Fe–0.15Cr–0.06Al–0.03Mo–0.01Ta–0.02Y2O3 and 0.03Y2O3 (wt.%) were prepared by mechanical alloying with different milling times. After consolidation by hot rolling, the alloys presented a very fine microstructure with a grain size of approximately 180 nm. Such a structure is relatively brittle, and its mechanical properties are enhanced by heat treatment. Annealing was performed at three temperatures (1000 °C, 1100 °C, and 1200 °C), with a holding time from 1 to 20 h. Tensile testing, wear testing, and corrosion testing were performed to evaluate the effect of heat treatment on the behavior and microstructural properties. The grain size increased almost 10 times by heat treatment, which influenced the mechanical properties. The ultimate tensile strength increased up to 300% more compared to the initial state. On the other hand, heat treatment has a negative effect on corrosion and wear resistance.

Increasing utilization of secondary raw materials and alternative fuels results in increasing contents of metals in cements. Zinc is one of these elements. It comes to cement with secondary raw materials such as slag or fly ash or by the utilization of used tires as an alternative fuel. Zinc ions significantly prolong the hydration process in cement. This work deals with the influence of zinc ions in the form of very poorly soluble ZnO salt and easily soluble ZnCl2 and Zn(NO3)2 on the hydration of cement blended with fly ash. Zinc was dosed in the range of 0.05%, 0.1%, 0.5% and 1% of cement weight. The effect of zinc on hydration was monitored by isothermal and isoperibolic calorimetry. A 15% addition of fly ash to cement mainly causes further retardation of hydration reactions due to the reactions of fly ash particles with Ca2+ ions from cement. The strongest effect on the hydration retardation from all investigated compounds showed in ZnO as it dissolves very slowly. On the contrary, for the dosage of 1% of zinc in the form of ZnCl2 significant acceleration of hydration occurred. In this work, a synergistic effect on the prolongation of hydration with a combination of cement, zinc and fly ash was demonstrated. The lengths of induction periods were assessed from detected calorimetric curves and from these lengths the curves were gained by fitting with the exponential function. Final products were next analyzed using X-ray diffraction.

The potential of in situ melt pool monitoring (MPM) for parameter development and furthering the process understanding in Laser Powder Bed Fusion (LPBF) of CuCr1Zr was investigated. Commercial MPM systems are currently being developed as a quality monitoring tool with the aim of detecting faulty parts already in the build process and, thus, reducing costs in LPBF. A detailed analysis of coupon specimens allowed two processing windows to be established for a suitably dense material at layer thicknesses of 30 µm and 50 µm, which were subsequently evaluated with two complex thermomechanical-fatigue (TMF) panels. Variations due to the location on the build platform were taken into account for the parameter development. Importantly, integrally averaged MPM intensities showed no direct correlation with total porosities, while the robustness of the melting process, impacted strongly by balling, affected the scattering of the MPM response and can thus be assessed. However, the MPM results, similar to material properties such as porosity, cannot be directly transferred from coupon specimens to components due to the influence of the local part geometry and heat transport on the build platform. Different MPM intensity ranges are obtained on cuboids and TMF panels despite similar LPBF parameters. Nonetheless, besides identifying LPBF parameter windows with a stable process, MPM allowed the successful detection of individual defects on the surface and in the bulk of the large demonstrators and appears to be a suitable tool for quality monitoring during fabrication and non-destructive evaluation of the LPBF process.

The present work studies the tungsten carbide (WC/C) coatings deposited by using Plasma Enhanced Chemical Vapor Deposition (PECVD), with and without gases of Ar and N2. Volatile hexacarbonyl of W was used as a precursor. Their mechanical and tribological properties were evaluated. The following values were obtained by using deposition process with N2 of HIT = 19.7 ± 4.1 GPa, EIT = 221 ± 2.1 GPa, and coefficient of friction (COF) = 0.35 ± 0.09. Secondly, deposition without the aforementioned gas obtained values of HIT = 20.9 ± 2 GPa, EIT = 292 ± 20 GPa, and COF = 0.69 ± 0.05. WC/C coatings were annealed at temperatures of 200, 500, and 800 °C, respectively. Evaluated factors include the introduced properties, the observed morphology, and the structural composition of WC/C coatings. The process of degradation was carried out by using various velocities, depending on used gases and annealing temperatures.

The contour scan strategies in laser powder bed fusion (LPBF) of Ti-6Al-4V were studied at the coupon level. These scan strategies determined the surface qualities and subsurface residual stresses. The correlations to these properties were identified for an optimization of the LPBF processing. The surface roughness and the residual stresses in build direction were linked: combining high laser power and high scan velocities with at least two contour lines substantially reduced the surface roughness, expressed by the arithmetic mean height, from values as high as 30 µm to 13 µm, while the residual stresses rose from ~340 to about 800 MPa. At this stress level, manufactured rocket fuel injector components evidenced macroscopic cracking. A scan strategy completing the contour region at 100 W and 1050 mm/s is recommended as a compromise between residual stresses (625 MPa) and surface quality (14.2 µm). The LPBF builds were monitored with an in-line twin-photodiode-based melt pool monitoring (MPM) system, which revealed a correlation between the intensity quotient I2/I1, the surface roughness, and the residual stresses. Thus, this MPM system can provide a predictive estimate of the surface quality of the samples and resulting residual stresses in the material generated during LPBF.

Implants elicit an immunological response after implantation that results in the worst case in a complete implant rejection. This biomaterial-induced inflammation is modulated by macrophages and can be influenced by nanotopographical surface structures such as titania nanotubes or fractal titanium nitride (TiN) surfaces. However, their specific impact on a distinct macrophage phenotype has not been identified. By using two different levels of nanostructures and smooth samples as controls, the influence of tubular TiO2 and fractal TiN nanostructures on primary human macrophages with M1 or M2-phenotype was investigated. Therefore, nanotopographical coatings were either, directly generated by physical vapor deposition (PVD) or by electrochemical anodization of titanium PVD coatings. The cellular response of macrophages was quantitatively assessed to demonstrate a difference in biocompatibility of nanotubes in respect to human M1 and M2-macrophages. Depending on the tube diameter of the nanotubular surfaces, low cell numbers and impaired cellular activity, was detected for M2-macrophages, whereas the impact of nanotubes on M1-polarized macrophages was negligible. Importantly, we could confirm this phenotypic response on the fractal TiN surfaces. The results indicate that the investigated topographies specifically impact the macrophage M2-subtype that modulates the formation of the fibrotic capsule and the long-term response to an implant.

This work deals with the influence of zinc on cement hydration. The amount of zinc in cement has increased over recent years. This is mainly due to the utilization of solid waste and tires, which are widely used as a fuel in a rotary kiln. Zinc can also be introduced to cement through such secondary raw materials as slag, due to increased recycling of galvanized materials. The aim of this work was to determine the effect of zinc on the hydration of Portland cement, blended with ground blast furnace slag (GBFS). This effect was studied by isothermal and isoperibolic calorimetry. Both calorimetry methods are suitable for measurements during the first days of hydration. Isoperibolic calorimetry monitors the hydration process in real-life conditions, while isothermal calorimetry does so at a defined chosen temperature. Zinc was added to the cement in the form of two soluble salts, namely Zn(NO3)2, ZnCl2, and a poorly soluble compound, ZnO. The concentration of added zinc was chosen to be 0.05, 0.1, 0.5, and 1mass percent. The amount of GBFS replacement was 15% of cement dosage. The newly formed hydration products were identified by X-ray diffraction method (XRD).

Magnetron sputtering is a well-known technique that is commonly used for the deposition of thin compact films. However, as was shown in the 1990s, when sputtering is performed at pressures high enough to trigger volume nucleation/condensation of the supersaturated vapor generated by the magnetron, various kinds of nanoparticles may also be produced. This finding gave rise to the rapid development of magnetron-based gas aggregation sources. Such systems were successfully used for the production of single material nanoparticles from metals, metal oxides, and plasma polymers. In addition, the growing interest in multi-component heterogeneous nanoparticles has led to the design of novel systems for the gas-phase synthesis of such nanomaterials, including metal/plasma polymer nanoparticles. In this featured article, we briefly summarized the principles of the basis of gas-phase nanoparticles production and highlighted recent progress made in the field of the fabrication of multi-component nanoparticles. We then introduced a gas aggregation source of plasma polymer nanoparticles that utilized radio frequency magnetron sputtering of a polymeric target with an emphasis on the key features of this kind of source. Finally, we presented and discussed three strategies suitable for the generation of metal/plasma polymer multi-core@shell or core-satellite nanoparticles: the use of composite targets, a multi-magnetron approach, and in-flight coating of plasma polymer nanoparticles by metal.

The thickness characterization of transparent protective coatings on functional, transparent materials is often problematic. In this paper, a toolbox to determine the thicknesses of a transparent coating on functional window films is presented. The toolbox consists of a combination of secondary ion mass spectrometry and profilometry and can be transferred to other transparent polymeric materials. A coating was deposited on designed model samples, which were characterized with cross-sectional views in transmission and in scanning/transmission electron microscopy and ellipsometry. The toolbox was then used to assess the thicknesses of the protective coatings on the pilot-scale window films. This coating was synthesized using straightforward sol-gel alkoxide chemistry. The kinetics of the condensation are studied in order to obtain a precursor that allows fast drying and complete condensation after simple heat treatment. The shelf life of this precursor solution was investigated in order to verify its accordance to industrial requirements. Deposition was performed successfully at low temperatures below 100 °C, which makes deposition on polymeric foils possible. By using roll-to-roll coating, the findings of this paper are easily transferrable to industrial scale. The coating was tested for scratch resistance and adhesion. Values for the emissivity (ε) of the films were recorded to justify the use of the films obtained as infrared reflective window films. In this work, it is shown that the toolbox measures similar thicknesses to those measured by electron microscopy and can be used to set a required thickness for protective coatings.

Selective laser melting is a promising powder-bed-based additive manufacturing technique for titanium alloys: near net-shaped metallic components can be produced with high resource-efficiency and cost savings [...]

Ti-6Al-4V bridges were additively fabricated by selective laser melting (SLM) under different scanning speed conditions, to compare the effect of process energy density on the residual stress state. Subsurface lattice strain characterization was conducted by means of synchrotron diffraction in energy dispersive mode. High tensile strain gradients were found at the frontal surface for samples in an as-built condition. The geometry of the samples promotes increasing strains towards the pillar of the bridges. We observed that the higher the laser energy density during fabrication, the lower the lattice strains. A relief of lattice strains takes place after heat treatment.