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Flammable mixtures of dusts with gases or liquids occur in the process and energy industries. Most research about these so-called "hybrid mixtures" was, and still is, about coal dust with the admixture of methane because of their occurrence in the mining industry. In the modern industry, hybrid mixture explosions play an increasing role in many existing processes like spray-drying, or in emerging technologies like the direct reduction of iron ore with hydrogen or nuclear/fusion reactors. While some safety characteristics of one of the component substances stay the same or are unaffected by the concentrations that occur in the process, others are severely influenced by only traces of the other substance.
This review paper shows in which processes and applications hybrid mixtures pose a risk and gives an overview of the research conducted in the last 150 years. Findings that are reproducible and represent current proven knowledge are stated and compared to each safety characteristic containing only solid particles, gases or liquids as combustible substances. Additionally, fundamental studies on the mechanisms of flame propagation in hybrid mixtures are reviewed. The significance of these studies in enhancing our understanding of explosion behaviors in hybrid mixtures is also discussed. An outlook on what has been missing so far in the literature, is also given comparing the knowledge of single substances with their mixtures, why this might not have been investigated, and where the challenges lie.
The outcome of an implant procedure largely depends on the implant's surface properties. Biomaterials are now designed to have surfaces with multifunctionality, such as favorable tissue integration and the ability to combat bacterial adhesion and colonization. Herein, we report on a simple approach to improve the antibacterial properties of zirconia nanotubes (ZrNTs) coatings by decorating with silver nanoparticles (AgNP), achieved through electrochemical anodization of a zirconium–silver alloy (Zr–Ag). The AgNPs were shown to partially consist of Ag2O, potentially enhancing the availability of Ag+ ions for antibacterial activity. The modified ZrNTs were characterized using SEM, EDS, ToF-SIMS, and XPS to determine their structural morphology and chemical composition, and were further subjected to antibacterial testing. The silver and zirconium ion release behavior was monitored via ICP-MS. ZrNTs decorated with AgNP exhibit strong antimicrobial activity (>99% bacterial killing) against both S. aureus and E. coli. Antimicrobial tests indicate that the antibacterial activity against the Gram-positive pathogen S. aureus was improved by a factor of 100 compared to unmodified ZrNTs, while unmodified ZrNTs already showed a comparable reduction of viable Gram-negative E. coli. This strategy illustrates a straightforward and effective modification that optimizes the interface between the host environment and the biomaterial surface to meet the very important criteria of biocompatibility and active antibacterial response.
Die additive Fertigung von Metallen mittels Laser Powder Bed Fusion (PBF LB/M) ermöglicht die Herstellung komplexer Geometrien und die Nutzung neuartiger Legierungen. Die dabei lokal im Prozess auftretenden Temperaturverteilungen beeinflussen maßgeblich die Bauteileigenschaften sowie die Entstehung von Defekten wie bspw. Risse und Poren. Eine quantitative Bestimmung der Realtemperaturen ist daher essenziell für Prozessvalidierung und -vergleich sowie die Qualitätssicherung und das Verständnis der zugrunde liegenden physikalischen Vorgänge. Bisherige thermografische Monitoring-Ansätze liefern jedoch meist nur qualitative Informationen. Hintergrund sind die Herausforderungen gegeben durch den Prozess: kleine Schmelzbäder (< 300 µm), hohe Temperaturen (> 2500 K) und hohe Scangeschwindigkeiten (ca. 1 m/s). Zusammen mit den dynamischen Änderungen des Emissionsgrads u.a. durch Phasenübergänge ergeben sich äußerst schwierige Bedingungen für thermografische Messungen.
Um dieser Herausforderung zu begegnen, verfolgen wir einen neuartigen Ansatz zur hyperspektralen Thermografie, der eine simultane Messung der emittierten Strahlung im kurzwelligen Infrarotbereich (1 bis 1,6 µm) entlang einer Linie bei ca. 20 kHz ermöglicht. Durch die Bewegung des Schmelzbades senkrecht durch die Messlinie kann ein typisches Schmelzbad rekonstruiert werden. Die Temperatur-Emissionsgrad-Separation (TES) erlaubt dabei die Bestimmung von Realtemperaturen und Emissionsgraden basierend auf parametrisierten spektralen Emissionsgradfunktionen sowie radiometrischen Kalibrationen. Die Umsetzung erfolgt an der Forschungsmaschine der BAM „SAMMIE“, die speziell für thermografische Messungen am PBF LB/M-Prozess konzipiert wurde.
Die Ergebnisse zeigen das Potenzial der hyperspektralen Thermografie zur Erfassung von Realtemperaturen im Prozess. Dies stellt einen wichtigen Schritt zur verbesserten Vergleichbarkeit und Wiederholbarkeit der Fertigung sowie zur Validierung komplexer Simulationen dar. Damit trägt der neuartige Ansatz langfristig zur Erhöhung der Sicherheit und des Verständnisses additiver Fertigungsprozesse bei.
Additive manufacturing (AM) with metals creates new, exciting opportunities for industrial applications. Especially industries with high relevance for the future like transport and energy benefit from optimized designs and novel materials. However, a reliable in-situ quality assurance for metal AM is still missing while process optimization is slow. This directly hinders the huge potential of metal AM technologies. A promising method to counteract this issue is the investigation of the emitted thermal radiation. It is optimal for monitoring and understanding the thermal history of the high-temperature AM process. The thermal history holds virtually all information about the properties and the quality of the manufactured components. The thermal information is also highly valuable for tuning and validating numerical simulations to gather further insights into the process. Despite this importance, the usage of thermal radiation in commercial AM machines is only marginal (like simple pyrometry or long-time exposure for optical tomography (OT) at a single wavelength). Based on this deficit and potential, this work gives an overview of the research in division “8.3 Thermographic Methods” at the Bundesanstalt für Materialforschung und -prüfung (BAM) in Berlin, Germany. Different wavelengths of the thermal radiation are investigated: the visible range (VIS), the short-wave infrared (SWIR), and the mid-wave infrared (MWIR) with their respective optimal field of application. Focus lies on laser powder bed fusion of metals (PBF-LB/M), but directed energy deposition with laser beam (DED-LB/M) is investigated as well. The presented research is performed not only on commercial AM machines, but also on an in-house developed PBF-LB/M research system specifically designed for sensor testing. This ensures an exciting mélange of applied research for industrial applications, and fundamental research for process understanding and validation. Therefore, a crucial contribution to industrial and scientific insights of metal AM is given.
Single-use plastics strongly contribute to plastic pollution, and less than 10% of plastic waste is recycled globally. Here, we present a selective mechanochemical protocol for converting post-consumer polyethylene terephthalate (PET) transparent bottles and coloured textile waste into the porous metal–organic framework (MOF) UiO-66 materials. We used time-resolved in situ (TRIS) synchrotron powder X-ray diffraction and Raman spectroscopy to monitor the depolymerization of PET during ball milling. To convert disodium terephthalate to UiO-66, we developed base and base-free synthetic routes that lead to fcu and hcp UiO-66 phases, respectively, including the first ever synthesis of hcp UiO-66 by mechanochemistry. Our results demonstrate the potential of mechanochemistry to selectively access fcu and hcp UiO-66 phases using post-consumer PET waste.
Starting with the discovery of fire and the preparation of food in prehistoric times, mechanochemistry is the oldest form of chemistry that humans have controlled. Mechanochemical practices, such as grinding with a mortar and pestle, continued into the Middle Ages until dedicated scientific studies began in the 19th century. Since then,research in mechanochemistry has shown that many chemicalreactions can be performed via mechanical force without or with small amounts of solvent. Besides being time, material, and energy efficient, mechanochemical reactions often yield products that differ from those obtained in solution. Therefore, not only is mechanochemistry greener and more sustainable than conventional solution chemistry, but it also has the added value of providing new reactivity and selectivity. This is especially important today, when chemists need to invent high-performance materials, intermediates, and products with the use of sustainable feedstocks and develop environmental remediation pathways. At the same time, time-resolved in situ monitoring and computational modeling are necessary for addressing fundamental questions about the atomistic, molecular, and electronic nature of mechanochemical reactivity. Integrating digitalization, robotics, and artificial intelligence tools promises to increase the reproducibility and scalability of mechanochemical processes. Further evolution of mechanochemistry is expected to have a transformative effect on the chemical industry.
Anisotropy investigation of a single crystal superalloy using laser-spot infrared thermography
(2024)
Thermal property investigation of anisotropic materials such as single crystal superalloys are still in interest of practical and fundamental reasons but remains challenging using conventional testing methods. In this study, a single crystal superalloy is tested using laser-spot thermography, and its thermal anisotropy is investigated. Determining anisotropic thermal conductivity at microscopic scales is challenging, as it appears isotropic at the macroscopic scale. Infrared thermography is one of the best-known techniques for measuring material heat transfer properties and facilitating visualization of temperature distribution through the specimen. The proposed study uses the active thermography method of laser-spot infrared thermography, in which a laser spot is focused onto the sample surface and the thermal response is captured from the surface of the specimen with an infrared camera. A detailed analysis of temperature gradients and heat diffusion patterns aids in the measurement of thermal conductivity values along the sample's different crystallographic directions. The directional bonding characteristics and inherent crystallographic structure of the alloy account for the inplane thermal conductivities calculated from experimental thermal measurements. The laser-spot thermography method has proven to be an effective tool for mapping the material's thermal conductivity anisotropy with high sensitivity and high spatial and temporal resolution. The investigation into the anisotropy of the material provides an insight into heat flow in the structure and helps in optimizing the design and overall performance of the material system.
The efforts to substitute both tungsten carbide (WC) and cobalt (Co) has gained prominence in recent years due to the classification of Co as a carcinogen and the classification of Co and W as critical raw materials in the EU as well as within regulations of the U.S. National Toxicology Program. In this study, substitution of both WC and Co with advanced hardmetals consisting of NbC with Ni and Fe-based metal binders are investigated for their use of machining of metals used electric vehicle manufacturing. The developed NbC-Ni/Fe based hardmetals employ a Machining Property Led Tailored Design (MPLTD) approach. This reverse engineering strategy uses data from machining performance to guide the development of microstructural, mechanical, and behavioral properties. Four advanced NbC-based hardmetals were produced, two with Ni-based binders and two with Fe-based binders, along with two reference materials for comparison (WC-Co and straight NbC-12Ni). Hardmetals were characterized using field emission scanning electron microscopy (FE-SEM), annular dark-field scanning transmission electron microscopy (ADF-STEM), Vickers hardness, fracture toughness, and elastic moduli. Cutting tool inserts were manufactured from the developed hardmetals and enhanced using femto-second laser surface engineering. The inserts’ performance was evaluated through face milling tests on AZ31 automotive magnesium alloy, providing insights into their suitability for high-demand industrial applications.
Biocides are used in large amounts in industrial, medical, and domestic settings. Benzalkonium chloride (BAC) is a commonly used biocide, for which previous research revealed that Escherichia coli can rapidly adapt to tolerate BAC-disinfection, with consequences for antibiotic susceptibility. However, the consequences of BAC tolerance for selection dynamics and resistance evolution to antibiotics remain unknown. Here, we investigated the effect of BAC tolerance in E. coli on its response upon challenge with different antibiotics. Competition assays showed that subinhibitory concentrations of ciprofloxacin—but not ampicillin, colistin and gentamicin—select for the BAC-tolerant strain over the BAC-sensitive ancestor at a minimal selective concentration of 0.0013–0.0022 µg/mL. In contrast, the BAC-sensitive ancestor was more likely to evolve resistance to ciprofloxacin, colistin and gentamicin than the BAC-tolerant strain when adapted to higher concentrations of antibiotics in a serial transfer laboratory evolution experiment. The observed difference in the evolvability of resistance to ciprofloxacin was partly explained by an epistatic interaction between the mutations conferring BAC tolerance and a knockout mutation in ompF encoding for the outer membrane porin F. Taken together, these findings suggest that BAC tolerance can be stabilized in environments containing low concentrations of ciprofloxacin, while it also constrains evolutionary pathways towards antibiotic resistance.