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Abstract Wire arc additive manufacturing (WAAM) is a direct energy deposition (DED) process that uses arc welding. It is a method of stacking beads made by melting metal wires with an arc heat source generated by a short-circuit current. Compared to other metal additive manufacturing methods, this process can be used to quickly produce large and complex-shaped metal parts. However, due to the multi-bead stacking method, the surface is highly curved and the dimensional errors are large; therefore, post-processing of the surface by cutting is required. Impellers, which are widely used in various industries, have complex shapes and high material consumption during cutting; therefore, the WAAM process can improve the manufacturing efficiency. In this study, a manufacturing process for an impeller with a diameter of 160 mm was developed by using the WAAM process. A 6-bladed fan-type impeller used for high-pressure fluid delivery was similarly modeled, and the product was additively manufactured using an Inconel 625 alloy wire. Manufacturing conditions that ensure productivity and quality or the product were determined through experimentation. Considering the post-processing of the WAAM-fabricated structure, the robot and tool paths of the impeller model were designed, and the error in the process coordinate system caused by attaching and detaching the workpiece between the two processes was reduced. Through the post-processing of the WAAM-fabricated structure, the production efficiency and process reliability were verified when the conventional manufacturing method and WAAM process were applied.

Abstract The sustained water repellency of interconnected micropatterned surfaces is explored over an extended duration, with a focus on their resilience during a 90‐day water‐immersion test. Initially, the microstructure surfaces exhibit high water repellency, a characteristic of the Cassie–Baxter state. However, subsequent detailed temporal analyses reveal varying responses depending on the structural topology. The interconnected micropatterned surfaces exhibit remarkable long‐term resistance to water; this is attributed to the formation of large and stable air pockets enabled by their unique microcavity structures. In comparison, hierarchical microcavity surfaces with micropillars exhibit a notable decrease in water repellency, as evidenced by reduced contact angles, suggesting a transition to a wetting state owing to the emergence of surface hydrophilicity during long‐term water exposure. This study demonstrates the importance of stable air‐pocket effects, particularly in applications where the long‐term stability of liquid repellency is critical, and suggests the role of interconnected structures in maintaining water repellency over time.

Given the direct correlation between the hardness of high-hardness armor (HHA) steel and its ballistic performance, mitigating softening in the heat-affected zone (HAZ) becomes essential. In this study, welding was performed using a nanoparticle flux composed of Tungsten Carbide (WC), Titanium Carbide (TiC), Silicon Carbide (SiC) nanoparticles, and ethanol. Subsequently, the shape and hardness distribution of each weld bead were comprehensively analyzed. The analysis revealed an increase in penetration depth in the order of 0.37 mm for WC 8 %, 0.31 mm for SiC 8 %, and 0.12 mm for TiC 2 %. Furthermore, the hardness evaluation results demonstrated a significant improvement at the fusion line (FL) when nanoparticle flux was utilized. Specifically, hardness values of 654.0 HV and 590.4 HV were observed at 8 % WC and 8 % SiC, respectively, representing increases of 16.6 % and 5.28 % compared to the absence of nanoparticle flux. Additionally, further investigations were conducted to elucidate the mechanism behind the improvement in hardness. This experimental evidence confirms the effectiveness of incorporating WC 8 % and SiC 8 % nanoparticles into the welding process of ARMOX 500 T in preventing hardness degradation due to softening.

In recent years, researchers have increasingly focused on alloy design in additive manufacturing (AM) to adjust the microstructure and improve the mechanical properties. The microstructure of columnar grains, strong texture, and chemical inhomogeneity in designed alloy exhibit anisotropic properties, which negatively affect the mechanical properties of the materials. One such material affected by this problem is titanium (Ti), which is known for its exceptional mechanical properties. Unlike other alloys, titanium lacks grain refiners that can ameliorate the columnar structure. Consequently, numerous studies are currently underway to refine the Ti grain through the addition of solute elements. In this study, Ti6Al4V with Cu element was deposited using the directed energy deposition (DED) process to investigate the feasibility of Ti6Al4V-xCu and analyze the effect of Cu addition. Ti6Al4V with Cu addition was successfully deposited and exhibited evenly distributed composition. In addition, finer grains were more created than the deposited Ti6Al4V by converting columnar to equiaxed grain due to the high cooling rate facilitated by high restriction factor Q of Cu. The deposited Ti6Al4V–4Cu of mechanical properties exhibited a 19 % increase in ultimate tensile strength, a 19 % increase in hardness at the top, and reduced elongation compared to the deposited Ti6Al4V, owing to the precipitation of Ti2Cu, grain refinement, and solid solution of Cu. However, although the hardness of the deposited Ti6Al4V–7Cu exhibited a 36 % increase in hardness at the top, Ti2Cu precipitate was generated significantly, which adversely exhibited a 26 % decrease in ultimate tensile strength compared to the deposited Ti6Al4V.

Evaporation patterns of liquid droplets containing nanoparticles or colloids have extensive applications in diagnostics and printing. Controlling these patterns by studying the evaporation behavior of colloidal droplets on surfaces is important for enhancing sensing platforms. In this study, A liquid‐repellent microcavity surface is introduced to robustly capture deposited analytic particles. The proposed microcavity surface maintains stable air pockets for liquid repellency and strong pinning for the spatial stabilization of the evaporating droplet, thereby resulting in a coffee‐ring concentration. This microcavity surface also acts as a “microcontainer” for the deposited particles, thereby protecting them against external damage. To demonstrate the multifaceted capabilities of microcavity surfaces, further comparison is done of three different surface structures, planar, micropillared, and that with microcavities in a hexagonal arrangement, by analyzing their evaporation dynamics and dried deposit patterns. The microcavity surface exhibits superior particle capture, thereby revealing its applicability in on‐site testing. Using the direct rapid sampling of analytical materials, the potential of the fabricated microcavity surface for point‐of‐care testing is demonstrated. The proposed microcavity surfaces suggest new avenues for the development of more robust and sensitive sensing platforms.

Wire arc directed energy deposition (Arc–DED) of metal components has gained considerable attention in different industries, including construction and landscaping. However, the deposition of single metal materials and associated constrained fabrication environments limit their potential in industrial applications. Furthermore, inherent solidification defects in the melting-based Arc–DED processes must be addressed. In this study, a flux cored wire (FCW)-based Arc–DED, which enables the manufacturing of components in outdoor environments, was presented. In addition to the basic Arc–DED equipment, FCW material and an ultrasonic needle peening (UNP) device for slag crushing were incorporated in the essential work tools. By investigating the flow behavior of molten slag and examining the internal solidification defects, the mechanism of slag inclusion based on physical phenomena was determined. Additionally, the microstructure and mechanical properties resulting from the droplet transfer mode were examined based on the variations in the transfer conditions of the molten slag. Further, the microstructure of the deposited layer induced by the slag crushing process of the UNP was characterized by equiaxed particles, which effectively mitigated the degradation of the mechanical properties caused by slag.

This study entailed the development of an advanced photocatalyst model characterized by high efficiency and ease in dispersion and retrieval processes. This model incorporates a multiscale-hierarchical open-cell structure integrated with nanostructured materials, effectively targeting the removal of organic compounds from wastewater. The fabrication of the specimens was achieved through a combined approach of additive manufacturing and chemical synthesis. The open-cell structure, composed of photopolymerized polymers and synthesized nanocrystals, displays a notable aspect ratio, an extensive surface area, and a significant porosity. These features facilitate the concurrent entry of fluid and light into the core of the framework, leading to enhanced light scattering and activation of photoinduced redox reactions on organic contaminants adhered to the anatase TiO2 surface. The photocatalytic performance was quantified through a spectroscopic analysis, monitoring the absorbance changes associated with organic pollutant degradation. In addition, the influence of open-cell structures on nanomaterial growth under hydrothermal synthesis conditions was explored using finite element method simulations, with findings corroborated by microscopic examination. The functional effectiveness of the novel photocatalyst was assessed through compression tests, analysis of changes pre- and post-reaction, and evaluations of reusability. The developed 3D photocatalyst offers straightforward installation, relocation, and operation, presenting a resilient and effective solution for employing nanoscale catalysts while significantly reducing secondary contamination risks from nanomaterials in aquatic environments. This innovative structure holds potential for application in diverse sectors, including hydrogen production, water decomposition, CO2 capture, and biomedicine.

Several studies have been conducted to improve combat vehicle capabilities, such as the bulletproof performance of armor and fuel efficiency through weight reduction. Titanium alloys and ceramic materials are expensive and difficult to process; therefore, they can be applied only in specific locations. In addition, arc welding, which is relatively inexpensive compared with other welding processes, is widely used in industrial fields; however, because welding is often performed in multiple passes to join one part, the productivity is reduced. Therefore, in this study, mechanical properties were investigated according to production time and heat input by applying tandem pulse gas metal arc welding (GMAW) to increase productivity. The experimental data were obtained by varying the wire feeding speed. In addition, the current–voltage waveforms were measured, and the volume shift was analyzed by comparison with images captured using a high-speed camera. To analyze the mechanical properties of the tandem weld for the welding of high-hardness armor plates, the appearance (top bead and back bead), cross-section, hardness, tensile test, impact test, and spatter generation of the welded part were analyzed. The results show that all Tank-automotive and Armaments Command (TACOM) standards for the base material were met when the tandem wire feeding speed was 11 + 11 m/min, and the single-pass process increased production speed by a factor of more than 10. Tandem pulse GMAW is shown to be a viable option for improving productivity and maintaining high-quality welds for high-hardness materials.

Abstract The main challenge in preparing a flexible mold stamp using roll-to-roll nanoimprint lithography is to simultaneously increase the imprintable area with a minimized perceptible seam. However, the current methods for stitching multiple small molds to fabricate large-area molds and functional surfaces typically rely on the alignment mark, which inevitably produces a clear alignment mark and stitched seam. In this study, we propose a mark-less alignment by the pattern itself method inspired by moiré technique, which uses the Fourier spectral analysis of moiré patterns formed by superposed identical patterns for alignment. This method is capable of fabricating scalable functional surfaces and imprint molds with quasi-seamless and alignment mark-free patterning. By harnessing the rotational invariance property in the Fourier transform, our approach is confirmed to be a simple and efficient method for extracting the rotational and translational offsets in overlapped periodic or nonperiodic patterns with a minimized stitched region, thereby allowing for the large-area and quasi-seamless fabrication of imprinting molds and functional surfaces, such as liquid-repellent film and micro-optical sheets, that surpass the conventional alignment and stitching limits and potentially expand their application in producing large-area metasurfaces.

Abstract Individuals who are unable to walk independently spend most of the day in a wheelchair. This population is at high risk for developing pressure injuries caused by sitting. However, early diagnosis and prevention of these injuries still remain challenging. Herein, we introduce battery-free, wireless, multimodal sensors and a movable system for continuous measurement of pressure, temperature, and hydration at skin interfaces. The device design includes a crack-activated pressure sensor with nanoscale encapsulations for enhanced sensitivity, a temperature sensor for measuring skin temperature, and a galvanic skin response sensor for measuring skin hydration levels. The movable system enables power harvesting, and data communication to multiple wireless devices mounted at skin-cushion interfaces of wheelchair users over full body coverage. Experimental evaluations and numerical simulations of the devices, together with clinical trials for wheelchair patients, demonstrate the feasibility and stability of the sensor system for preventing pressure injuries caused by sitting.

Abstract Tandem welding is extensively used for welding large structures, such as ships and plants, for increased welding speed and volume. Seam tracking is essential because of a large amount of thermal deformation. However, in tandem welding, arc interference causes current and voltage to vary non-uniformly, leading to difficulties in seam tracking. Therefore, in this study, an optimal signal was identified for seam tracking in tandem welding and evaluated. To select the seam-tracking signal, an algorithm was developed that separates the welding signal into peak, average, and base. Based on the collected data, regression and signal-to-noise ratio analyses were performed to identify a suitable seam-tracking signal. To trace the welding line based on the selected signal, the welding signal was checked by weaving on the V-groove specimen. As a result, the current area difference of the welding signal generated between the left and right parts of the center of the V-groove could be calculated. An algorithm and equipment for seam tracking were constructed using the area difference of the welding current. Finally, the seam tracking system was verified by conducting an actual test using the equipment to which the algorithm was applied.

Abstract Biological surfaces in plants are critical for controlling essential functions such as wettability, adhesion, and light management, which are linked to their adaptation, survival, and reproduction. Biomimetically patterned surfaces replicating the microstructures of plant surfaces have become an emerging tool for understanding plant–environment interactions. In this study, we developed a two-step micro-replication platform to mimic the microstructure of seed surfaces and demonstrated that this initial platform can be used to study seed surface–environment interactions. The two-step process involved the extraction of a simplified seed surface model from real seeds and micro-replication of the simplified seed surface model using nanoimprint lithography. Using Allium seeds collected from Mongolia and Central Asia as the model system, we studied the wettability of biological and synthetic seed surfaces. We could independently control the material properties of a synthetic seed surface while maintaining the microstructures and, thereby, provide clear evidence that Allium seed surfaces were highly wettable owing to the high surface energy in the epidermal material rather than a microstructural effect. We expect that this platform can facilitate study of the independent effect of microstructure on the interaction of seed surfaces with their surroundings and contribute to research on the evolution of plant–environment interactions.

Abstract In metal additive manufacturing (AM), arc plasma is attracting attention as an alternative heat source to expensive lasers to enable the use of various metal wire materials with a high deposition efficiency. However, the stepwise material deposition and resulting limited number of degrees of freedom limit their potential for high‐throughput and large‐scale production for industrial applications. Herein, a high‐throughput metal 3D printing pen (M3DPen) strategy is proposed based on an arc plasma heat source by harnessing the surface tension of the molten metal for enabling continuous material deposition without a downward flow by gravity. The proposed approach differs from conventional arc‐based metal AM in that it controls the solidification and cooling time between interlayers of a point‐by‐point deposition path, thereby allowing for continuous metal 3D printing of freestanding and overhanging structures at once. The resulting mechanical properties and unique microstructures by continuous metal deposition that occur due to the difference in the thermal conditions of the molten metal under cooling are also investigated. This technology can be applied to a wide range of alloy systems and industrial manufacturing, thereby providing new possibilities for metal 3D printing.

As improving fuel economy and performance through weight reduction in vehicles are recognized as important tasks, the defense industry is researching ways to reduce the weight of armor plates for combat vehicles and increase bulletproof performance and durability. Most armor plates in combat vehicles are manufactured using weld joints. High-hardness armor (HHA) is used to make armor plates; however, its mechanical properties deteriorate because of hydrogen embrittlement and high-temperature softening during welding. Welding defects, such as pores and cracks, occur frequently. In this study, HHA steel was subjected to single-pulse gas metal arc welding (GMAW), and the welding performance of the shielding gas and heat input was analyzed by the United States army tank-automotive and armaments command (TACOM) standard. The specimen cross-section was visually examined, and hardness, tensile, and impact tests were used to identify the mechanical properties based on the welding conditions. Additionally, flux cored arc welding (FCAW) and GMAW were used and compared, and spatter image analyses were used to assess the integrity of the welding process of the HHA plate applied to a combat vehicle. As a result of the experiment, as the CO2 content and heat input increased, the mechanical strength of the welded zone and the integrity of the welding process deteriorated.

Lightweight reactor materials that simultaneously possess low heat capacity and large surface area are desirable for various applications such as catalytic supports, heat exchangers, and biological scaffolds. However, they are challenging to satisfy this criterion originating from their structural property in most porous cellular solids. Microlattices have great potential to resolve this issue in directing transport phenomena because of their hierarchically ordered design and controllable geometrical features such as porosity, specific surface, and tortuosity. In this study, we report hollow ceramic microlattices comprising a 10 μm thick hollow nickel oxide beam in an octet-truss architecture with low heat capacity and high specific surface area. Our microarchitected reactors exhibited a low heat capacity for a rapid thermal response with a small Biot number (Bi << 1) and large intertwined surface area for homogeneous flow mixing and chemical reactions, which made them ideal candidates for various energy applications. The hollow ceramic microlattice was fabricated by digital light three-dimensional (3D) printing, composite electroless plating, polymer removal, and subsequent thermal annealing. The transient thermal response and fluidic properties of the 3D-printed microstructures were experimentally investigated using a small-scale thermal and fluid test system, and analytically interpreted using simplified models. Our findings indicate that hollow microarchitected reactors provide a promising platform for developing multifunctional materials for thermal and fluid applications.

Global regulations for emission reduction are continually becoming stricter, and conventional catalytic converters may be efficient in the future because of their low conversion efficiencies at cold-start. In this study, to overcome the performance limitations of conventional catalytic converters, a three-dimensional (3D) microstructured catalytic substrate was designed, and simulations of the fluid flow, heat transfer, and chemical reaction for the proposed catalytic substrates were performed using computational fluid dynamics (CFD) analysis. The effect of the pressure drop on the catalytic conversion efficiency of various 3D microarchitectures was investigated. Due to the three-dimensional microstructure, the fluid flow changed and fluid pressure increased, which led to energy loss. It was confirmed that the abrupt change in flow increased the heat transfer. The findings showed that the fluid flow changed due to the existence of a complex periodic microlattice structure instead of the existing monolithic structure, which promoted the conversion of harmful substances. Based on the CFD analysis of the thermal and fluid properties, it was confirmed that 3D microarchitectures can provide alternatives to conventional catalytic supports structures for efficient catalytic converters.

The bearing is a machine element that plays an important role in rotating the shaft of a machine while supporting its weight and load. Numerous bearings have been developed to improve durability and life, depending on the functions and operating conditions in which they are desired. White metal is one of method to improve durability that is soft and bonded to the inner surface of the bearing to protect the bearing shaft. Currently, the centrifugal casting process is used as a white metal lamination method, but it involves problems such as long processing times, high defect rates and harmful health effects. In this paper, a laser cladding treatment is applied to bond powdered white metal to SCM440 alloy steel, which is used as bearing material in terms of replacing the risks of a centrifugal process. In order to understand whether laser cladding is a suitable process, this paper compares the mechanical properties of white metal produced on SCM440 alloy steel by centrifugal casting and the laser cladding process. The laser power, powder feed rate and laser head speed factors are varied to understand the mechanical properties and measure the hardness using micro Vickers and conduct field emission scanning electron microscopy, energy-dispersive X-ray spectroscopy, X-ray diffraction and friction testing to understand the mechanical properties and surface characteristics. Based on the results, the hardness values of the cladding (white metal) layer ranged between 24 and 26 HV in both the centrifugal casting and laser cladding methods. However, the hardness of the white metal produced by laser cladding at about a depth of 0.1 mm rose rapidly in the cladding process, forming a heat-affected zone (HAZ) with an average hardness value of 200 HV at a laser power of 1.1 kW, 325 HV at 1.3 kW and 430 HV at 1.5 kW. The surface friction testing results revealed no significant differences in the friction coefficient between the centrifugal casting and laser cladding methods, which allows the assumption that the processing method does not significantly influence the friction coefficient.

Functional films with hydrophobic, oleophobic, anti-fouling, anti-icing, anti-bacterial and low reflectance properties can be produced by patterning nano- or micro-structures on films via nano imprint lithography. Here, an omni-phobic surface showing both hydrophobicity and oleophobicity was obtained without chemical surface treatment by increasing the surface roughness and deforming the pattern morphology using only nano imprint lithography and the oxygen-inhibited curing properties of polyurethane acrylate (PUA) resin. A tulip-shaped pattern imprinting process was designed in which microscale patterns were fabricated using a porous polydimethylsiloxane (PDMS) mold with high oxygen transmission. During ultraviolet (UV) curing, a curing inhibiting layer was formed by reaction with oxygen. Next, a PDMS pad was used for the pressurized curing of the curing inhibition layer to modify the micro scale structures. Finally, final curing of the deformed pattern was performed using ultra high-power UV light. The deformation of the pattern into tulip-like shapes with increased surface roughness was confirmed by microscopy, and contact angle measurement was performed to confirm omni-phobicity. The final cured imprinted samples showed water and oil contact angles reaching 169.2° and 115°, respectively; thus, the omni-phobic surface could be demonstrated by a tulip-shaped pattern imprinting process.

Drilling work on Inconel, a well-known super-heat-resistant alloy, requires a significant quantity of cutting oil to prevent heat-induced abrasion and damage to the cutting tool, caused by the strength and toughness of the alloy. This high requirement of cutting oil, however, negatively affects the processing environment; therefore, minimum-quantity lubrication (MQL), an eco-friendly cutting-oil-supply method, is attracting attention. The conventional MQL method, however, has the disadvantage that an oil-mist is produced along with high-pressure air; hence, the mist is scattered in the air, making the application of the oil to the cutting point inefficient and rendering the cooling effect to be less than that in wet processing. In this study, therefore, an eco-friendly compound, polyhedral oligomeric silsesquioxane (POSS)—a nanostructured organic–inorganic hybrid material that exhibits better adhesion to materials than conventional MQL-specific oil and is resistant to the heat generated during drilling—was developed by adding POSS to the conventional MQL-specific oil, and the effects were verified.

Printed electronics is one of the emerging technologies owing to its low cost and productivity. Recently, many researchers tried to adapt printing technology to the fabrication of fine electronic patterns on flexible substrates, including the gate line of thin film transistors. In this study, we fabricated a flexible cliché using the nanoimprint process and used it in reverse offset printing. Then, we analyzed the effect of the surface energy of the imprinted cliché on process parameters, such as printing speed and rolling direction. We showed that the productivity of the process and quality of printed pattern can be considerably enhanced by controlling the surface energy of the cliché. When a flexible cliché is manufactured using a resin with a surface energy considerably different from that of the blanket, the ink can be detached easily and fine patterns can be engraved successfully regardless of the pattern shape.

Nanowire structures have attracted attention in various fields, since new characteristics could be acquired in minute regions. Especially, Anodic Aluminum Oxide (AAO) is widely used in the fabrication of nanostructures, which has many nanosized pores and well-organized nano pattern. Using AAO as a template for replication, nanowires with a very high aspect ratio can be fabricated. Herein, we propose a facile method to fabricate a nano-micro hybrid structure using nanowires replicated from AAO, and surface treatment. A polymer resin was coated between Polyethylene terephthalate (PET) and the AAO filter, roller pressed, and UV-cured. After the removal of aluminum by using NaOH solution, the nanowires aggregated to form a micropattern. The resulting structure was subjected to various surface treatments to investigate the surface behavior and wettability. As opposed to reported data, UV-ozone treatment can enhance surface hydrophobicity because the UV energy affects the nanowire surface, thus altering the shape of the aggregated nanowires. The hydrophobicity of the surface could be further improved by octadecyltrichlorosilane (OTS) coating immediately after UV-ozone treatment. We thus demonstrated that the nano-micro hybrid structure could be formed in the middle of nanowire replication, and then, the shape and surface characteristics could be controlled by surface treatment.