Effect of Interface Form on Creep Failure and Life of Dissimilar Metal Welds Involving Nickel-Based Weld Metal and Ferritic Base Metal

For dissimilar metal welds(DMWs)involving nickel-based weld metal(WM)and ferritic heat resistant steel base metal(BM)in power plants,there must be an interface between WM and BM,and this interface suffers mechanical and microstructure mismatches and is often the rupture location of premature failure.In this study,a new form of WM/BM interface form,namely double Y-type interface was designed for the DMWs.Creep behaviors and life of DMWs containing double Y-type interface and conventional I-type interface were compared by finite element analysis and creep tests,and creep failure mechanisms were investigated by stress-strain analysis and microstructure characterization.By applying double Y-type interface instead of conventional I-type interface,failure location of DMW could be shifted from the WM/ferritic heat-affected zone(HAZ)interface into the ferritic HAZ or even the ferritic BM,and the failure mode change improved the creep life of DMW.The interface premature failure of I-type interface DMW was related to the coupling effect of microstructure degradation,stress and strain concentrations,and oxide notch on the WM/HAZ interface.The creep failure of double Y-type interface DMW was the result of Type IV fracture due to the creep voids and micro-cracks on fine-grain boundaries in HAZ,which was a result of the matrix softening of HAZ and lack of precipitate pinning at fine-grain boundaries.The double Y-type interface form separated the stress and strain concentrations in DMW from the WM/HAZ interface,preventing the trigger effect of oxide notch on interface failure and inhibiting the interfacial microstructure cracking.It is a novel scheme to prolong creep life and enhance reliability of DMW,by means of optimizing the interface form,decoupling the damage factors from WM/HAZ interface,and then changing the failure mechanism and shifting the failure location.

Plasma-assisted aerogel interface engineering enables uniform Zn^(2+)flux and fast desolvation kinetics toward zinc metal batteries

The poor reversibility of Zn anodes induced by dendrite growth,surface passivation,and corrosion,severely hinders the practical applicability of Zn metal batteries.To address these issues,a plasmaassisted aerogel(PAG)interface engineering was proposed as efficient ion transport modulator that can simultaneously regulate uniform Zn^(2+)flux and desolvation behavior during battery operation.The PAG with ordered mesopores acted as an ion sieve to homogenize Zn deposition and accelerate Zn^(2+)flux,which is favorable for corrosion resistance and dendrite suppression.Importantly,the plasma-assisted aerogel with abundant hydrophilic groups can facilitate the desolvation kinetics of Zn^(2+)due to the multiple hydrogen-bonding interaction with the activated water molecules,thus accelerating the Zn^(2+)migration kinetics.Consequently,the Zn/Zn cell assembled with PAG-modified separator demonstrates stable plating and stripping behavior(over 1400 h at 1 mA cm^(-2))and high Coulombic efficiency(99.8%at1 mA cm^(-2)after 1100 cycles),and the Zn‖MnO_(2)full cell shows excellent long-term cycling stability and maintains a high capacity of 154.9 mA h g^(-1)after 1000 cycles at 1 A g^(-1).This study provides a feasible approach for the large-scale fabrication of aerogel functionalized separators to realize ultra-stable Zn metal batteries.

Effect of Metallurgical Behaviour at the Interface between Ceramic and Interlayer on the Si_3N_4/1.25Cr-0.5Mo Steel Joint Strength

By using newly developed CuNi5~25Ti16~28 B rapldly solidifled brazing filler the joining of Si3 N4/1.25Cr-0.5Mo steel has been carried out with interlayer method. If employing the interlayer structure of steel (0.2 mm)/W (2.0 mm)/Ni(0.2 mm), the joint strength can be increased greatly compared with employing that of Ni/W/Ni, and the three point bend strength of the Joint shows the value of 261 MPa. The metallurgical behaviour at the interface between Si3N4 and the interlayer has been studied. It is found that Fe participated in the interfacial reactions between Si3N4 and the brazing filler at the Si3N4/steel (0.2 mm) interface and the compound Fe5Si3 was produced. However, since the reactions of Fe with the active Ti are weaker than those of Ni with Ti, the normal inter facial reactions were still assured at the interface of Si3N4/steel (0.2 mm) instead of Si3N4/Ni (0.2 mm), resulting in the improvement of the joint strength. The mechanism of the formation of Fe5Si3 is also discussed. Finally, some ideas to further ameliorate and simplify the interlayer structure are put forward.

Atomically bonding Na anodes with metallized ceramic electrolytes by ultrasound welding for high-energy/power solid-state sodium metal batteries

A solid-state sodium metal battery has cut a striking figure in next-generation large-scale energy storage technology on account of high safety,high energy density,and low cost.Nevertheless,the large interfacial resistance and sodium dendrite growth originating from the poor interface contact seriously hinder its practical application.Herein,a modified ultrasound welding was proposed to atomically bond Na anodes and Au-metalized Na_(3)Zr_(2)Si_(2)PO_(12) electrolytes associated with the in situ formation of Na–Au alloy interlayers.Thereupon,intimate Na_(3)Zr_(2)Si_(2)PO_(12)-Au/Na interfaces with a low interfacial resistance(~23Ωcm^(2))and a strong dendrite inhibition ability were constructed.The optimized Na symmetric battery can cycle steadily for more than 900 h at 0.3 mA cm^(-2) under a low overpotential(<50 mV)of Na electroplating/stripping and deliver a high critical current density of 0.8 mAcm^(-2) at room temperature.By incorporating the above interface into the solid-state Na metal battery,taking three-dimensional Na_(3)V_(2)(PO_(4))_(3) as the cathode,the full battery offers a high energy density of 291 Wh kg^(-1) at a high power density of 1860Wkg^(-1).A pouch-type solid-state sodium metal full battery based on a ceramic electrolyte was assembled for the first time,and it lit a 3 V LED lamp.Such a strategy of the ultrasound welding metalized solid-state electrolyte/Na interface by engineering the Na-Au interlayer would pave a new pathway to engineer a low-resistance and highly stable interface for high-energy/density solid-state sodium metal batteries.

3D Artificial Array Interface Engineering Enabling Dendrite-Free Stable Zn Metal Anode

The ripple effect induced by uncontrollable Zn deposition is considered as the Achilles heel for developing high-performance aqueous Zn-ion batteries.For this problem,this work reports a design concept of 3D artificial array interface engineering to achieve volume stress elimination,preferred orientation growth and dendrite-free stable Zn metal anode.The mechanism of MXene array interface on modulating the growth kinetics and deposition behavior of Zn atoms were firstly disclosed on the multi-scale level,including the in-situ optical microscopy and transient simulation at the mesoscopic scale,in-situ Raman spectroscopy and in-situ X-ray diffraction at the microscopic scale,as well as density functional theory calculation at the atomic scale.As indicated by the electrochemical performance tests,such engineered electrode exhibits the comprehensive enhancements not only in the resistance of corrosion and hydrogen evolution,but also the rate capability and cyclic stability.High-rate performance(20 mA cm^(-2))and durable cycle lifespan(1350 h at 0.5 mA cm^(-2),1500 h at 1 mA cm^(-2)and 800 h at 5 mA cm^(-2))can be realized.Moreover,the improvement of rate capability(214.1 mAh g^(-1)obtained at 10 A g^(-1))and cyclic stability also can be demonstrated in the case of 3D MXene array@Zn/VO2battery.Beyond the previous 2D closed interface engineering,this research offers a unique 3D open array interface engineering to stabilize Zn metal anode,the controllable Zn deposition mechanism revealed is also expected to deepen the fundamental of rechargeable batteries including but not limited to aqueous Zn metal batteries.

Intelligent optimization method for the dynamic scheduling of hot metal ladles of one-ladle technology on ironmaking and steelmaking interface in steel plants

The one-ladle technology requires an efficient ironmaking and steelmaking interface. The scheduling of the hot metal ladle in the steel plant determines the overall operational efficiency of the interface. Considering the strong uncertainties of real-world production environments, this work studies the dynamic scheduling problem of hot metal ladles and develops a data-driven three-layer approach to solve this problem. A dynamic scheduling optimization model of the hot metal ladle operation with a minimum average turnover time as the optimization objective is also constructed. Furthermore, the intelligent perception of industrial scenes and autonomous identification of disturbances, adaptive configuration of dynamic scheduling strategies, and real-time adjustment of schedules can be realized. The upper layer generates a demand-oriented prescheduling scheme for hot metal ladles. The middle layer adaptively adjusts this scheme to obtain an executable schedule according to the actual supply–demand relationship. In the lower layer, three types of dynamic scheduling strategies are designed according to the characteristics of the dynamic disturbance in the model:real-time flexible fine-tuning, local machine adjustment, and global rescheduling. Case test using 24 h production data on a certain day during the system operation of a steel plant shows that the method and system can effectively reduce the fluctuation and operation time of the hot metal ladle and improve the stability of the ironmaking and steelmaking interface production rhythm. The data-driven dynamic scheduling strategy is feasible and effective, and the proposed method can improve the operation efficiency of hot metal ladles.

Heterostructured bimetallic phosphide nanowire arrays with latticetorsion interfaces for efficient overall water splitting

Designing cost-effective and high-efficiency electrocatalysts is critical to the water splitting performance during hydrogen generation.Herein,we have developed Fe_(2)P-Co_(2)P heterostructure nanowire arrays with excellent lattice torsions and grain boundaries for highly efficient water splitting.According to the microstructural investigations and theoretical calculations,the lattice torsion interface not only contributes to the exposure of more active sites but also effectively tunes the adsorption energy of hydrogen/oxygen intermediates via the accumulation of charge redistribution.As a result,the Fe_(2)P-Co_(2)P heterostructure nanowire array exhibits exceptional bifunctional catalytic activity with overpotentials of 65 and 198 mV at 10 mA cm^(-2) for hydrogen and oxygen evolution reactions,respectively.Moreover,the Fe_(2)P-Co_(2)P/NF-assembled electrolyzer can deliver 10 mA cm^(-2) at an ultralow voltage of1.51 V while resulting in a high solar-to-hydrogen conversion efficiency of 19.8%in the solar-driven water electrolysis cell.

Ultralow Interfacial Thermal Resistance of Graphene Thermal Interface Materials with Surface Metal Liquefaction

Developing advanced thermal interface materials(TIMs)to bridge heat-generating chip and heat sink for constructing an efficient heat transfer interface is the key technology to solve the thermal management issue of high-power semiconductor devices.Based on the ultra-high basal-plane thermal conductivity,graphene is an ideal candidate for preparing high-performance TIMs,preferably to form a vertically aligned structure so that the basal-plane of graphene is consistent with the heat transfer direction of TIM.However,the actual interfacial heat transfer efficiency of currently reported vertically aligned graphene TIMs is far from satisfactory.In addition to the fact that the thermal conductivity of the vertically aligned TIMs can be further improved,another critical factor is the limited actual contact area leading to relatively high contact thermal resistance(20-30 K mm^(2) W^(−1))of the“solid-solid”mating interface formed by the vertical graphene and the rough chip/heat sink.To solve this common problem faced by vertically aligned graphene,in this work,we combined mechanical orientation and surface modification strategy to construct a three-tiered TIM composed of mainly vertically aligned graphene in the middle and micrometer-thick liquid metal as a cap layer on upper and lower surfaces.Based on rational graphene orientation regulation in the middle tier,the resultant graphene-based TIM exhibited an ultra-high thermal conductivity of 176 W m^(−1) K^(−1).Additionally,we demonstrated that the liquid metal cap layer in contact with the chip/heat sink forms a“liquid-solid”mating interface,significantly increasing the effective heat transfer area and giving a low contact thermal con-ductivity of 4-6 K mm^(2) W^(−1) under packaging conditions.This finding provides valuable guidance for the design of high-performance TIMs based on two-dimensional materials and improves the possibility of their practical application in electronic thermal management.

Mechanistically Novel Frontal-Inspired In Situ Photopolymerization:An Efficient Electrode|Electrolyte Interface Engineering Method for High Energy Lithium Metal Polymer Batteries

The solvent-free in situ polymerization technique has the potential to tailor-make conformal interfaces that are essential for developing durable and safe lithium metal polymer batteries(LMPBs).Hence,much attention has been given to the eco-friendly and rapid ultraviolet(UV)-induced in situ photopolymerization process to prepare solid-state polymer electrolytes.In this respect,an innovative method is proposed here to overcome the challenges of UV-induced photopolymerization(UV-curing)in the zones where UV-light cannot penetrate,especially in LMPBs where thick electrodes are used.The proposed frontal-inspired photopolymerization(FIPP)process is a diverged frontal-based technique that uses two classes(dual)of initiators to improve the slow reaction kinetics of allyl-based monomers/oligomers by at least 50%compared with the conventional UV-curing process.The possible reaction mechanism occurring in FIPP is demonstrated using density functional theory calculations and spectroscopic investigations.Indeed,the initiation mechanism identified for the FIPP relies on a photochemical pathway rather than an exothermic propagating front forms during the UV-irradiation step as the case with the classical frontal photopolymerization technique.Besides,the FIPP-based in situ cell fabrication using dual initiators is advantageous over both the sandwich cell assembly and conventional in situ photopolymerization in overcoming the limitations of mass transport and active material utilization in high energy and high power LMPBs that use thick electrodes.Furthermore,the LMPB cells fabricated using the in situ-FIPP process with high mass loading LiFePO_(4)electrodes(5.2 mg cm^(-2))demonstrate higher rate capability,and a 50%increase in specific capacity against a sandwich cell encouraging the use of this innovative process in large-scale solid-state battery production.

Molecular Reactivity and Interface Stability Modification in In-Situ Gel Electrolyte for High Performance Quasi-Solid-State Lithium Metal Batteries

Quasi-solid-state lithium metal battery is a promising candidate for next generation high energy density and high safety power supply.Despite intensive efforts on electrolytes,uncontrolled interfacial reactions on lithium with electrolyte and patchy interfacial contacts still hinder its practical process.Herein,we bring in rationally designed F contained groups into polymer skeleton via in-situ gelation for the first time to establish quasi-solid-state battery.This method achieves a capacity retention of 90%after 1000 cycles at 0.5C with LiFePO_(4)cathodes.The interface constructed by polymer skeleton and reaction with–CF_(3)lead to the predicted solid electrolyte interface species with high stability.Furthermore,we optimize molecular reactivity and interface stability with regulating F contained end groups in the polymer.Comparisons on different structures reveal that high performance solid stable lithium metal batteries rely on chemical modification as well as stable polymer skeleton,which is more critical to construct robust and steady SEI with uniform lithium deposition.New approach with functional groups regulation proposes a more stable cycling process with a capacity retention of 94.2%at 0.5C and 87.6%at 1C after 1000 cycles with LiFePO_(4) cathodes,providing new insights for the practical development of quasi-solid-state lithium metal battery.

Influence of confining prestress on the transition from interface defeat topenetration in ceramic targets

Replica scaled impact experiments with unconfined ceramic targets have shown that the transition velocity,i.e.,the impact velocity at which interface defeat ceases and ceramic penetration occurs,decreased as the length scale increased.A possible explanation of how this scale effect is related to the formation of a cone crack in the ceramic has been presented by the authors in an earlier paper.Here,the influence of confinement and prestress on cone cracking and transition velocity is investigated.The hypothesis is that prestress will suppress the formation and growth of the cone crack by lowering the driving stress.A set of impact experiments has been performed in which the transition velocity for four different levels of prestress has been determined.The transition velocities as a function of the level of confining prestress is compared to an analytical model for the influence of prestress on the formation and extension of the cone crack in the ceramic material.Both experiments and model indicate that prestress has a strong influence on the transition from interface defeat to penetration,although the model underestimates the influence of prestress.

Interface defeat studies of long-rod projectile impacting on ceramic targets

The interface defeat phenomenon always occurs when a long-rod projectile impacting on the ceramic target with certain velocity,i.e.,the projectile is forced to flow radially on the surface of ceramic plates for a period of time without significant penetration.Interface defeat has a direct effect upon the ballistic performance of the armor piercing projectile,which is studied numerically and theoretically at present.Firstly,by modeling the projectiles and ceramic targets with the SPH(Smoothed Particle Hydrodynamics)particles and Lagrange finite elements,the systematic numerical simulations on interface defeat are performed with the commercial finite element program AUTODYN.Three different responses,i.e.,complete interface defeat,dwell and direct penetration,are reproduced in different types of ceramic targets(bare,buffered,radially confined and oblique).Furthermore,by adopting the validated numerical algorithms,constitutive models and the corresponding material parameters,the influences of projectile(material,diameter,nose shape),constitutive models of ceramic(JH-1 and JH-2 models),buffer and cover plate(thickness,constraints,material),as well as the prestress acted on the target(radial and hydrostatic) on the interface defeat(transition velocity and dwell time) are syste matically investigated.Finally,based on the energy conservation approach and taking the strain rate effect of ceramic material into account,a modified model for predicting the upper limit of transition velocity is proposed and validated.The present work and derived conclusions can provide helpful reference for the design and optimization of both the long-rod projectile and ceramic armor.

Alternating-Current Transport Properties of the Interface between Nd_(0.7)Sr_(0.3)MnO_(3) Ceramic and a Ag Electrode

Electrical transport properties of the interface between a Nd_(0.7)Sr_(0.3)MnO_(3) ceramic and a Ag electrode are investigated using the ac impedance over a wide temperature and frequency ranges.The ac impedance measurements give the compressed semicircle arcs at different temperatures,which are used for the analysis of different contributions to electrical transport based on an electrical equivalent circuit.A significant interface-dependent electroresistance effect of 530% is clearly developed around the metal-insulator transition temperature 130K,which is confirmed as the interface-layer dependent Curie temperature by the plot of interfacial conductance with frequency at different temperatures.

An investigation on bonding interface microstructure of ceramic coating prepared on AZ91D by evaporated pattern casting technique

PbO-ZnO-Na2O ceramic coating was fabricated on the AZ91D Mg-alloy substrate surface by using of evaporated pattern casting(EPC) process.The ceramic coating was characterized through scanning electron microscopy(SEM) observation,energy dispersive X-ray spectrometer(EDS) and so on.The research was emphasized on the formation process of ceramic coating and the interface bonding conditions between ceramic coating and the substrate.Results show that the glass powder(PbO-ZnO-Na2O) melts when contacts with the high temperature liquid metal,and solidifies on the surface of the substrate with the decrease of temperature.Therefore,the ceramic coating was successfully prepared with the formation of the bonding interface with the substrate.Beside the influence of coating layer thickness,the vacuum level was also investigated.Further analysis indicates that oxide inclusions and decomposition products of foam pattern had a significant effect on the bonding interface.To obtain a good bonding interface between the ceramic coating and the substrate,the metal liquid oxidation and inclusions must be decreased and the decomposition products of foam pattern should be exhausted from the EPC coating completely.

Interface and M^(3+)/M^(2+)Valence Dual-Engineering on Nickel Cobalt Sulfoselenide/Black Phosphorus Heterostructure for Efficient Water Splitting Electrocatalysis

The catalyst innovation that aims at noble-metal-free substitutes is one key aspect for future sustainable hydrogen energy deployment.In this paper,a nickel cobalt sulfoselenide/black phosphorus heterostructure(NiCoSe|S/BP)was fabricated to realize the highly active and durable water electrolysis through interface and valence dual-engineering.The NiCoSe|S/BP nanostructure was constructed by in-situ growing NiCo hydroxide nanosheet arrays on few-layer BP and subsequently one-step sulfoselenization by SeS2.Besides the conductive merit of BP substrate,holes in p-type BP are capable of oxidizing the Co^(2+)to high-valence and electron-accepting Co^(3+),benefiting the oxygen evolution reaction(OER).Meanwhile,Ni^(3+)/Ni^(2+)ratio in the heterostructure is reduced to maintain the electrical neutrality,which corresponds to the increased electron-donating character for boosting hydrogen evolution reaction(HER).As for HER and OER,the heterostructured NiCoSe|S/BP electrocatalyst exhibits small overpotentials of 172 and 285 mV at 10 mA cm^(-2)(η_(10))in alkaline media,respectively.And overall water splitting has been achieved at a low cell potential of 1.67 V at η_(10) with high stability.Molecular sensing and density functional theory(DFT)calculations are further proposed for understanding the rate-determine steps and enhanced catalytic mechanism.The investigation presents a deep-seated perception for the electrocatalytic performance enhancement of BP-based heterostructure.

Nano silica aerogel-induced formation of an organic/alloy biphasic interfacial layer enables construction of stable high-energy lithium metal batteries

Lithium metal batteries represent promising candidates for high-energy-density batteries, however, many challenges must still be overcome,e.g., interface instability and dendrite growth. In this work, nano silica aerogel was employed to generate a hybrid film with high lithium ion conductivity(0.6 mS cm^(-1)at room temperature) via an in situ crosslinking reaction. TOF-SIMS profile analysis has revealed conversion mechanism of hybrid film to Li–Si alloy/Li F biphasic interface layer, suggesting that the Li–Si alloy and Li F-rich interface layer promoted rapid Li+transport and shielded the Li anodes from corrosive reactions with electrolyte-derived products. When coupled with nickel-cobalt-manganese-based cathodes, the batteries achieve outstanding capacity retention over 1000 cycles at 1 C. Additionally the developed film coated on Li enabled high coulombic efficiency(99.5%) after long-term cycling when coupled with S cathodes. Overall, the results presented herein confirm an effective strategy for the development of high-energy batteries.

Progress in Joining Ceramics to Metals

The research and development of joining methods of ceramics to metals, especially brazing, diffusion bonding and partial transition liquid phase bonding, were introduced. Some opinions were put forward. For new composites emerging, it is necessary to develop new joining methods, particularly in the field of high temperature technique for joining ceramics to superalloys.

Microstructure and properties of the joints of ZrO2 ceramic/ stainless steel brazed in vacuum with AgCuTi active filler metal

The ZrO2 ceranfic was successfully jointed to stainless steel by vacuum brazing with active filler metal. The AgCuTi active filler metal was used and the joining was performed at a temperature of 850 ℃ for 10 rain. The microstructures of the joints were characterized by metallographic microscopy, scanning electron microscopy （SEM）, and energy dispersive spectroscopy （EDS）. Metallographic microscopy analysis shows that the morphology of the cross section was a sandwich structure and the TiO is observed in the surface of ZrO2/ stainless steel. The diffusion and enrichment of the elements are the key roles in the brazing of ZrO2 ceramic and stainless steel. The formation of TiCu compounds inhibited the further diffusion of titanium into stainless steel or the ZrO2 ceramic to form TiO compound. In the experimental conditions, the average tensile strength is 80MPa for the joint of ZrO2 ceramic / AgCuTi/ stainless steel systems. A complete joint is formed between the ZrO2 ceramic and stainless steel with the leakage rate at the degree of 10 ^-12 Pa · m^3/s.

MICROSTRUCTURE AND INFRARED EMISSIVITY AT NORMAL TEMPERATURE IN TRANSITIONAL METAL OXIDES SYSTEM CERAMICS

The fabrication of Fe2O3-MnO2-Co2O3-CuO system ceramics, and the composite system ceramics of transitional metal oxides-cordierite and transitional metal oxides-kaolinit are presented in this work. The research was carried out with the main attention to the infrared emissivity in the band of 8 similar to 14 mu m at room temperature, the microstructure of the ceramics and the relation between them. High infrared emissivities exceeding 0.9 in the band of 8 similar to 14 mu m at room temperature were gained in the transitional metal oxide ceramics and the composite system ceramics. It is suggested that the formation of inverse spinels and partially inverse spinels, such as Fe3O4, CoFe2O4, CuFe2O4 and CuMn2O4, is beneficial to the enhancement of the infrared emissivity of the transitional metal oxide ceramics. The transitional metal oxides play an important role in determining the infrared emissivity of the composite system ceramics.

A Study on Solid/Melt Interfaces and the Formation of<100> Texture in Solidified FCC Metals

The (100) texture of solidified fcc metals, caused by the preferential (100) dendrite growth, could be closeIy related to solid/melt interfaces which behave differently along different crystallographic orientation. The stability and roughness of {111} and {100} solid/melt interfaces of fcc metals were investigated using a modified Temkin multi-layer model. It is demonstrated that {100}crystal/melt interface is more unstable and rougher than {111} interface. The effect of the stability of crystal/melt interface on the (100) texture formation in solidified fcc metals has been analysed and discussed.