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The plasma-material interaction and evolution mechanism of a solitary crater governs the nature of the surface, either plain or textured, created through the electrical discharge micromachining (EDMM) process. Therefore, it is indispensable to understand the fundamentals of a single crater evolution, which involves melt pool hydrodynamics and material vaporization under intense plasma pressure. The plasma pressure during the workpiece heating phase alters the vaporization phenomenon and melt ejection, warranting an in-depth understanding. In light of this, the current work proposes a two-dimensional (2-D) multiphysics numerical model of the melt pool hydrodynamics during EDMM. The model incorporates thermal evolution along with the effects of active plasma pressure during the heating phase of the substrate with the help of a coupled thermo-fluidic model. The simulation results reveal the predominant role of plasma pressure on the crater morphology evolution, plasma flushing efficiency (PFE) and recast layer thickness (RLT). The predicted single crater profile is validated using single-spark experiments with reasonable agreement. Thereafter, the formation mechanism of a single crater has been extended to multi-crater creation for textured surface generation. [Display omitted] • A multiphysics model of the EDMM implementing plasma pressure is developed. • Maximum liquid-vapour interface temperature increases with active plasma pressure. • Plasma pressure plays a major role in determining crater morphology, PFE and RLT. • The predicted crater dimensions match the single-machined crater on Ti-6Al-4 V. • Single crater model is extended to multi-crater formation for surface texturing. [ABSTRACT FROM AUTHOR]

The utilization of lattice structure in engineering components by additive manufacturing (AM) is gaining attention due to its lightweight design, high strength-to-weight ratio, and effective material utilization. Producing holes in additively manufactured lattice structures with dimensional accuracy is challenging. In the current study, we fabricate near circular through-holes on deterministic lattice structured components fabricated by laser powder bed fusion by utilizing electric discharge machining (EDM). In the additively manufactured Inconel 718 (IN718) lattice structure, nodes are connected by strut leaving voids/pores amongst different nodal points. Due to EDM, the nodes at the boundary of the hole experience concentration plasma interaction, heating, and rapid cooling, which causes a substantial change in the microstructure. The selective removal of material from different nodal positions causes uncharacteristic recast layers, partial damages, and uncontrolled cracking of the struts. In the present study, we investigated and characterized the differential behaviour and mechanism of various surface integrity issues associated with the selective material removal of LPBF IN718 lattice structures and their elements (nodes and struts). [ABSTRACT FROM AUTHOR]

The thermal spalling action of material removal associated with electrical discharge machining of ceramics results in severe surface debris, cracks, pores, etc. This led to a rough machined surface, ultimately rendering the machined component not susceptible for direct applications. Such a behavior points towards the need to further process the machined surface so as to reduce the net severity of the machined surface. The current work utilizes multi-pass wire electrical discharge machining to enhance the machined surface characteristics of alumina composites. Detailed comparison of the surface characteristics with regards to amplitude, spatial, hybrid and functional volume parameters depicted a superior and homogenous machined surface post multi-pass process. The recast layer severity was minimal as well by incorporation of multi-pass. Furthermore, a detailed analysis of the structural fingerprints of the surface elements depicts actual breakage and subsequent burn-out of the filler material. • Successful reduction of the surface severities post multi pass WEDM process, leading to a very fine machined surface. • Detailed surface characterization depicts reduction of peaks/valleys, paving way for high homogeneity of the machined surface. • Spatial and hybrid surface analysis depicts consistent removal of the peaks and subsequent filling of the valleys/voids with multi pass. • The porous network and the recast layer severity decreases considerably post multi pass due to subsequent filling and removal action. [ABSTRACT FROM AUTHOR]

In the current study, electro-deposition of hybrid coatings consisting of Cr simultaneously reinforced with nano-scale 3 mol% yttria-stabilized zirconia (YSZ) along with hexagonal boron nitride (Cr-YSZ-BN), graphene (Cr-YSZ-Gr), and diamond (Cr-YSZ-D) was performed using an environmentally-benign trivalent Cr bath. Abrasive wear with ploughing for scratch test is recognized as the dominant wear mechanism in coatings; on increasing the scratch speed, gross spallation occurs in the BN reinforced coatings. While graphene and diamond were strongly adherent to the substrate with no signs of delamination. During fretting, oxidative and three-body abrasive wear in wedge formation mode with severe crack networking was observed in Cr-YSZ-BN. Micro-ploughing was active with intermittent cracking in Cr-YSZ-Gr coatings, indicating lower wear (via solid-lubrication by graphene). Diamond added coating, on the other hand, exhibits fewer cracks with ploughing. High hardness and elastic modulus with a maximum of ~26 GPa and 245 GPa, respectively, were obtained for Cr-YSZ-D coating with a minimum wear rate of ~3.5×10−11 m3/Nm (fretting) and 3.8×10−5 mm3/Nm (scratching). Further, rigid sp3 hybridization of carbon atoms in Cr-YSZ-D leads to the strong interlocking between Cr matrix and diamond, thereby lowering the wear damage of the coating system. The unique combination and uniform dispersion of YSZ and diamond particles displayed enhanced friction and wear resistance (k ~ 1.4×10−3), primarily due to the inherent high hardness of diamond and matrix strengthening by nano and micro-scale particles. Therefore, Cr-YSZ-D coating system emerges out as a highly robust coating capable of providing enhanced damage tolerance towards wear for various tribological applications. • Synergistic YSZ reinforcement with BN, graphene, and diamond in Cr-matrix. • Reduced crystallite size (~15 nm) and high dislocation density (~1011 cm-2) in reinforced coatings. • High compressive residual stresses (~720–1230 MPa) in hybrid coatings. • High fretting damage tolerance (wear rate of ~3.5 × 10–11 m3/Nm) in Cr-YSZ-D hybrid coating. • Low micro-scratch damage (wear rate of 3.8 × 10-5 mm3/Nm) in Cr-YSZ-D hybrid coating. [ABSTRACT FROM AUTHOR]

Graphical abstract Highlights • Mn, and Cu based ternary metal oxide nano adsorbents are studied for arsenic remediation. • XPS of As(3d), Fe(2p), Cu(2p), Mn(2p), and O(1s) is performed to understand remediation mechanism. • As(0) (∼25–78 at.%) onto the adsorbent shows environmentally responsible behavior to address arsenic leaching issue. • Trace metal voltammetry inferred a better As(III) mitigation (∼75–90 % at C i ∼ 1 ppm). • Cyclic voltammetry (CV) confirmed arsenic mitigation, and immobilization by reduction, and sorption. Abstract Arsenic mitigation behavior in aqueous systems is being evaluated for Mn-Al-Fe, Cu-Al-Fe nano adsorbents. Morphological, and vibrational spectroscopy analysis are observed with As-OH, and As-O surface complexes. XPS study of individual As(3d) spectra at different parameters is observed with multiplet peak behavior attributed to redox behavior of Mn-Al-Fe, Cu-Al-Fe. Significant proportions of As(0) signal (∼25 at.% in pH 7, ∼78 at.% in pH 2, ∼58 at.% in pH 12) implicate an environmentally stable behavior of these adsorbents to address the arsenic leaching issue. Adsorption kinetics are observed with Pseudo Second Order (PSO) model, and Freundlich model supported multilayer adsorption behavior is observed for adsorption isotherms. Trace metal voltammetry studies are observed with 75–90 % of As(III) mitigation in aliquot samples. Detailed study of Mn(2p), Cu(2p), Fe(2p), and O(1 s) spectra explains redox active, and surface ligand exchange synergism in arsenic adsorption. Low equilibrium concentrations (C e < 10 ppb) in As(V) systems (C i ∼ 100 and 500 ppb) indicate the drinking water application of these systems. Cyclic-voltammetry (CV) studies implicate the mitigation and immobilization of arsenic species onto adsorbent by both reduction, and sorption phenomenon. [ABSTRACT FROM AUTHOR]

Active and durable oxygen reduction reaction (ORR) catalysts are of utmost importance to realize the commercialization of hydrogen fuel cells and metal-air batteries. Al-substituted MnFe 2 O 4 -based ternary oxide and reduced graphene oxide (MAF-RGO) nanocomposite is synthesized using an in-situ co-precipitation followed by a hydrothermal process and verified for ORR electrocatalysis in the alkaline electrolyte (0.1 M KOH). MAF-RGO is first analyzed using physicochemical characterization tools including X-ray diffraction, Raman spectroscopy, sorption studies, electron microscopy, X-ray photoelectron spectroscopy, etc. Further, the characteristic ORR peak centered at 0.56 V vs. reversible hydrogen electrode (RHE) in cyclic voltammetry (CV) studies confirms the electrocatalytic performance of MAF-RGO. The ORR onset potential of 0.92 V vs. RHE is obtained in linear sweep voltammetry (LSV) measurement at 1600 rpm in O 2 -saturated electrolyte exhibiting an improved ORR performance as compared to the commercial electrocatalyst. The reduction kinetics is observed to follow the desirable near 4-e- mechanism. In addition, the electrocatalyst exhibits improved relative current stability of 86% and methanol poisoning resistance of 82%, which is better in comparison to the standard Pt/C. The observed electrochemical performance results from the synergism between the oxygen vacancy-rich Al-substituted metallic oxide active species and the functional group enriched predominantly mesoporous RGO sheets with excellent electrical conductivity. The introduction of metallic species enhanced the inter-planar spacing between graphitic sheets easing the maneuver of reactant species through the electrocatalyst and accessing more ORR-active sites. This study establishes the potency of mixed transition metal oxide/nanocarbon composites as durable high-performance ORR-active systems. [Display omitted] • Excellent current durability and poisoning stability are obtained in alkaline medium. • Al-substituted metal oxide and RGO act in synergy to improve the ORR performance. • Effect of Al-induced O-vacancies in MAF-RGO hybrid on the ORR activity is explored. [ABSTRACT FROM AUTHOR]

Graphical abstract Highlights • The first derivative of XANES for As(III) adsorbed systems of all adsorbents are observed to have with mixed oxidation. • As(V) adsorbed samples of Ni, and Cu systems agree with that of As(V) standards. • Both reduction and oxidation behavior of arsenic is observed on to these metal oxide adsorbents. • EXAFS analysis was observed with As O bond distances in the range of 1.7–1.8 Å. • The As-M bond distances are around 2.7, 3.2 and 3.6 Å confirmed the formation of surface complexes. Abstract The present study is about surface complexation behavior of arsenic species adsorbed onto ternary metal oxide adsorbents (Ni-Al-Fe, Co-Al-Fe, Mn-Al-Fe, and Cu-Al-Fe). The analysis is carried out by X-ray absorption spectroscopy (XAS) tool. XANES (μ(E) vs. E) spectra close to the absorption edge (i.e., As K -edge) of all samples are observed along with the As(III) and As(V) standards. The first derivative of XANES for Ni-As(V), and Cu-As(V) samples agree with that of As(V) standards, respectively. Whereas, As(III) adsorbed adsorbent systems (i.e., Ni, Co, Mn, and Cu) are observed with mixed oxidation state of arsenic. A total of 65–85 % is observed with initial oxidation state (As(III) or As(V)), and remaining 15–35 % is observed with modified oxidation state (As(V) or As(III)) that explains the occurrence of possible charge transfer. EXAFS analysis shows the As-O bond distances in the range of 1.7–1.8 Å. The corresponding As-M bond distances are around 2.7, 3.2, and 3.6 Å which confirms the formation various edge sharing (2E), and corner sharing (2C, 1V) surface complexes. Surface coverage is understood as an important parameter as bidentate attachments (2E, 2C) are evident in As(III), and As(V), but monodentate attachments (1V) are only observed in As(V). [ABSTRACT FROM AUTHOR]

The understanding of mechanistic insights in environmental remediation and mitigation systems is attracting larger attention, in recent days. Here in, aluminium substituted copper ferrite impregnated rGO hybrid (CAF-rGO) is verified to understand the adsorption/electrosorption mechanism of arsenic in aqueous systems. Near-surface study (XPS: As 3d, Cu 2p, Fe 2p, Al 2p, O 1s, C 1s) proposes redox, and ligand exchange reactions between contaminant, and CAF-rGO. Adsorption capacities are observed around 128.8 mg g−1 [As(III)], 153.5 mg g−1 [As(V)] with Freundlich model isotherms. Kinetics study follows the PSO model with influence of solar light (> 420 nm). Cyclic voltammetry (CV) analysis in different molarity conditions observed with signals around +0.1 and −0.6 V confirm the redox abilities, and N 2 /O 2 purged environments understood that electrosorption occurred through both reduction and sorption. Electrosorption study with pH variation shows the effect of protonation on the redox activity of individual arsenic species. Consistent signal around −0.6 ± 0.05 V in all the CV plots (i.e., Molarity, Environment, pH) recommends the usage of CAF-rGO for arsenic mitigation. Possible influence of photo-current (∼40 μA/cm2 at ∼ 0 V) towards As(III/V) decontamination is understood though photoelectrochemical analysis. Impedance plot shows low-resistance and better diffusion of arsenic oxy-anions during light irradiation. Synergistic nature of CAF-rGO generates reactive oxygen species (i.e., ●OH/●O 2 −/ 1 O2) in mitigating highly toxic As(III) species is also detailed in the present work. Image 1 • Mechanistic insights of arsenic (As) adsorption and electrosorption in aqueous systems. • In-situ CV analysis in various molarities, gas purging environment and pH conditions. • A constructive correlation is drawn between individual redox signals and CV plot areas. • Photo-catalytic aspects on As loading and photo-electrochemical behavior (I vs. t, EIS). • ROS signals onto the hybrid surface in influencing As remediation and mitigation. [ABSTRACT FROM AUTHOR]

Aluminum (Al3+) doped manganese (Mn)/copper (Cu) ferrite impregnated rGO hybrids are verified for photo-electrocatalytic water-splitting and super-capacitor electrode applications. Energy band gaps of 2.17 eV (Mn) and 2.25 eV (Cu) confirm photocatalytic activity in the visible-band. High anodic photo-currents around 18–40 and 2–9 mA/cm2 (1 V vs. Ag/AgCl) are observed for Mn and Cu systems. Formation of oxygen vacancies due to aluminum doping assisted in efficient charge transfer behavior both at surface and lattice orders due to the structural adjustments. 2-D rGO surface disorders (I D /I 2D) emphasized the retardation of the charge recombination at the metal-oxide and rGO junction. During visible-light irradiation current densities are increased by 0.7–9.2 mA/cm2 with a better redox behavior. The difference in transient currents are observed around 0.01–0.02 mA/cm2 at 0 V vs. Ag/AgCl [0.7 mA/cm2 at 0.5 V]. Intrinsic photo-current at zero voltage infers built-in potentials at the hybrid and electrolyte interface (Schottky- junction). Impedance study implicates better electron-transfer/ion diffusion characteristics during photon irradiation with a semi-infinite diffusion rate-limiting step. Specific-capacities (Three-electrode) are observed around 216 F g−1 (Mn), 142 F g−1 (Cu) with combined pseudo-capacitance and EDLC characteristics. Li+-intercalation results in ultrahigh stability up to 100,000 cycles (t ~ 69.4 h) at 0.8 V s−1 with a capacity retention of 127%. Two-Electrode performance shows 99.1% capacity retention after 5000 cycles with decrease in the impedance (1.38 Ω to 1.06 Ω), and a maximum areal energy density of 0.54 μWh cm−2 at power density of 50 μW cm−2. Image 1 [ABSTRACT FROM AUTHOR]

In electrochemical micromachining (ECMM), improved material dissolution localization and generation of the smooth machined surface under pulsed voltage condition is attributed to the fact that short pulse-duration time results in the generation of relatively less volume of dissolution products. The intermittent supply of voltage provides idle time to flush the hydrogen bubbles and sludge from the machining zone and, also increases control over the dissolution process. From the last few decades, various studies have been carried out to analyze the effect of short pulse voltage to ultra-short pulsed (rectangular) voltage. Development of such a sophisticated system capable of supplying ultra-high frequency voltage pulses is challenging, cost in-effective and complex. Also, the compromising ways of reducing the pulse energy by reducing the duty cycle and increasing the pulse frequency impose increased voltage requirement and idle time while machining. In this study, an approach of reducing pulse energy per unit time by changing the waveform of the voltage pulse (while keeping the pulse-duration time the same) for reducing the overcut is presented. A theoretical model is developed first to quantify the input energy per pulse for rectangular, sinusoidal, and triangular voltage pulses. This ensured that by changing the shape of voltage pulses of same on-time, the energy input per pulse can be further altered. A function generator based pulsed power supply is then developed with the capability of generating rectified voltage pulses of different waveforms. The process of ECMM for generating micro dimples on a flat surface is modeled in two dimensions using finite element method in MATLAB (R2018b). Three numerical models for sinusoidal, rectangular and triangular voltage pulses are developed for predicting the current density and anode shape. Simulation results demonstrated that triangular voltage pulse yields minimum diameter of micro-dimple as compared to sinusoidal and rectangular pulse respectively. Results from the developed model are also validated using experimental observations and a good correlation between the two was observed (with an average deviation of 18%). Image 1 • Theoretical and numerical model considering sinusoidal, rectangular and triangular voltage pulses are developed. • A function generator based pulsed power supply and machining setup are developed for experimental validation. • Micro-dimples are fabricated for determining the reduction in diameter in dimples with reducing the pulse energy. • Experimental comparison of effect of pulse energy by increasing frequency and pulse shape deformation is established. [ABSTRACT FROM AUTHOR]