On understanding the microstructure of SiC/SiC Ceramic Matrix Composites (CMCs) after a material removal process

The unique material nature (e.g. hard, brittle, heterogeneous and orthotropic) of SiC-based Ceramic Matrix Composites (CMCs) highly affects the outcomes of machining process by inducing high thermo-mechanical loads during material removal. This can result in severe material damage which in turn causes a reduction of the in-service life of critical structural ceramic components (such as in aero-engines or nuclear reactors). In this study, the phenomenon by which the material removal mechanism during drilling influences the CMC surface integrity are discussed by characterising the fracture and deformation phenomena on the CMC's constituents - i.e. SiC and Si materials. Moreover, the strain induced to the surface, together with the changes in chemical composition are characterised via micro Raman spectroscopy and related to the principles of residual stresses upon cutting. This results in a novel understanding of the material removal process that governs cutting of SiC-based CMCs while emphasising how the different microstructure, morphology and nature of ceramics behave under the same cutting conditions. This study has therefore led to a comprehension of how the microstructure of complex hierarchical ceramic materials such as SiC/SiC CMCs is affected by a mechanical cutting process and opens avenues to understand the structure damage under other machining operations (e.g. milling, grinding)

Probabilistic modelling of tool unbalance during cutting of hard-heterogeneous materials: a case study in Ceramic Matrix Composites (CMCs)

Compared to other materials, CMCs display a unique high hardness and heterogeneous nature which are critically reflected during the drilling process where asymmetrical high forces are suffered by the tool, resulting in an unbalance of the drill bit. Hence, this study proposes a mechanistic approach where the hard nature resulting in high radial forces is analytically studied and coupled with a probabilistic model where the heterogeneous nature of CMCs is taken into consideration. This theoretical study results in an in-depth understanding of the loading unbalance occurring on different tool sizes during drilling of CMCs which can lead to a premature tool breakage. The nature of this unique force that is assumed in the theoretical approach to influence the cutting of hard-heterogeneous materials is experimentally validated by drilling a homogeneous and a heterogeneous hard ceramics, i.e. a monolithic SiC and a SiC/SiC CMC. Moreover, the model developed together the with drilling experiments with different tool diameters result in an understanding of why small tool diameters suffer a premature tool breakage when drilling difficult-to-machine CMCs

Shear and delamination behaviour of basal planes in Zr3AlC2 MAX phase studied by micromechanical testing

The mechanical properties of layered, hexagonal-structured MAX phases often show the combined merits of metals and ceramics, making them promising material candidates for safety critical applications. While their unique mechanical performance largely arises from the crystal structure, the effect of chemistry on the properties of these materials remains unclear. To study this, here we employed two in situ electron microscope small-scale testing approaches to examine the micromechanical properties of Zr3AlC2, and compared the results with the properties of Ti3SiC2: we used micropillar compression tests to measure basal slip strength, and double cantilever beam splitting tests to evaluate fracture energy for basal plane delamination. We observed distinct and systematic differences in these measured properties between Zr3AlC2 and Ti3SiC2, where Zr3AlC2 appeared to be stronger but more brittle at the microscale, and discussed the implications of the results in the selection, design, and engineering of MAX phases for targeted engineering applications

Determining the fundamental failure modes in Ni-rich lithium ion battery cathodes

Challenges associated with in-service mechanical degradation of Li-ion battery cathodes has prompted a transition from polycrystalline to single crystal cathode materials. Whilst for single crystal materials, dislocation-assisted crack formation is assumed to be the dominating failure mechanism throughout battery life, there is little direct information about their mechanical behaviour, and mechanistic understanding remains elusive. Here, we demonstrated, using in situ micromechanical testing, direct measurement of local mechanical properties within LiNi0.8Mn0.1Co0.1O2 single crystalline domains. We elucidated the dislocation slip systems, their critical stresses, and how slip facilitate cracking. We then compared single crystal and polycrystal deformation behaviour. Our findings answer two fundamental questions critical to understanding cathode degradation: What dislocation slip systems operate in Ni-rich cathode materials? And how does slip cause fracture? This knowledge unlocks our ability to develop tools for lifetime prediction and failure risk assessment, as well as in designing novel cathode materials with increased toughness in-service

Real-time insight into the multistage mechanism of nanoparticle exsolution from a perovskite host surface

In exsolution, nanoparticles form by emerging from oxide hosts by application of redox driving forces, leading to transformative advances in stability, activity, and efficiency over deposition techniques, and resulting in a wide range of new opportunities for catalytic, energy and net-zero-related technologies. However, the mechanism of exsolved nanoparticle nucleation and perovskite structural evolution, has, to date, remained unclear. Herein, we shed light on this elusive process by following in real time Ir nanoparticle emergence from a SrTiO3 host oxide lattice, using in situ high-resolution electron microscopy in combination with computational simulations and machine learning analytics. We show that nucleation occurs via atom clustering, in tandem with host evolution, revealing the participation of surface defects and host lattice restructuring in trapping Ir atoms to initiate nanoparticle formation and growth. These insights provide a theoretical platform and practical recommendations to further the development of highly functional and broadly applicable exsolvable materials

Precursor engineering of hydrotalcite-derived redox sorbents for reversible and stable thermochemical oxygen storage

Chemical looping processes based on multiple-step reduction and oxidation of metal oxides hold great promise for a variety of energy applications, such as CO2 capture and conversion, gas separation, energy storage, and redox catalytic processes. Copper-based mixed oxides are one of the most promising candidate materials with a high oxygen storage capacity. However, the structural deterioration and sintering at high temperatures is one key scientific challenge. Herein, we report a precursor engineering approach to prepare durable copper-based redox sorbents for use in thermochemical looping processes for combustion and gas purification. Calcination of the CuMgAl hydrotalcite precursors formed mixed metal oxides consisting of CuO nanoparticles dispersed in the Mg-Al oxide support which inhibited the formation of copper aluminates during redox cycling. The copper-based redox sorbents demonstrated enhanced reaction rates, stable O2 storage capacity over 500 redox cycles at 900 °C, and efficient gas purification over a broad temperature range. We expect that our materials design strategy has broad implications on synthesis and engineering of mixed metal oxides for a range of thermochemical processes and redox catalytic applications

European Space Agency experiments on thermodiffusion of fluid mixtures in space

Abstract.: This paper describes the European Space Agency (ESA) experiments devoted to study thermodiffusion of fluid mixtures in microgravity environment, where sedimentation and convection do not affect the mass flow induced by the Soret effect. First, the experiments performed on binary mixtures in the IVIDIL and GRADFLEX experiments are described. Then, further experiments on ternary mixtures and complex fluids performed in DCMIX and planned to be performed in the context of the NEUF-DIX project are presented. Finally, multi-component mixtures studied in the SCCO project are detailed

Elective Cancer Surgery in COVID-19-Free Surgical Pathways During the SARS-CoV-2 Pandemic: An International, Multicenter, Comparative Cohort Study.

PURPOSE: As cancer surgery restarts after the first COVID-19 wave, health care providers urgently require data to determine where elective surgery is best performed. This study aimed to determine whether COVID-19-free surgical pathways were associated with lower postoperative pulmonary complication rates compared with hospitals with no defined pathway. PATIENTS AND METHODS: This international, multicenter cohort study included patients who underwent elective surgery for 10 solid cancer types without preoperative suspicion of SARS-CoV-2. Participating hospitals included patients from local emergence of SARS-CoV-2 until April 19, 2020. At the time of surgery, hospitals were defined as having a COVID-19-free surgical pathway (complete segregation of the operating theater, critical care, and inpatient ward areas) or no defined pathway (incomplete or no segregation, areas shared with patients with COVID-19). The primary outcome was 30-day postoperative pulmonary complications (pneumonia, acute respiratory distress syndrome, unexpected ventilation). RESULTS: Of 9,171 patients from 447 hospitals in 55 countries, 2,481 were operated on in COVID-19-free surgical pathways. Patients who underwent surgery within COVID-19-free surgical pathways were younger with fewer comorbidities than those in hospitals with no defined pathway but with similar proportions of major surgery. After adjustment, pulmonary complication rates were lower with COVID-19-free surgical pathways (2.2% v 4.9%; adjusted odds ratio [aOR], 0.62; 95% CI, 0.44 to 0.86). This was consistent in sensitivity analyses for low-risk patients (American Society of Anesthesiologists grade 1/2), propensity score-matched models, and patients with negative SARS-CoV-2 preoperative tests. The postoperative SARS-CoV-2 infection rate was also lower in COVID-19-free surgical pathways (2.1% v 3.6%; aOR, 0.53; 95% CI, 0.36 to 0.76). CONCLUSION: Within available resources, dedicated COVID-19-free surgical pathways should be established to provide safe elective cancer surgery during current and before future SARS-CoV-2 outbreaks

Elective cancer surgery in COVID-19-free surgical pathways during the SARS-CoV-2 pandemic: An international, multicenter, comparative cohort study

PURPOSE As cancer surgery restarts after the first COVID-19 wave, health care providers urgently require data to determine where elective surgery is best performed. This study aimed to determine whether COVID-19–free surgical pathways were associated with lower postoperative pulmonary complication rates compared with hospitals with no defined pathway. PATIENTS AND METHODS This international, multicenter cohort study included patients who underwent elective surgery for 10 solid cancer types without preoperative suspicion of SARS-CoV-2. Participating hospitals included patients from local emergence of SARS-CoV-2 until April 19, 2020. At the time of surgery, hospitals were defined as having a COVID-19–free surgical pathway (complete segregation of the operating theater, critical care, and inpatient ward areas) or no defined pathway (incomplete or no segregation, areas shared with patients with COVID-19). The primary outcome was 30-day postoperative pulmonary complications (pneumonia, acute respiratory distress syndrome, unexpected ventilation). RESULTS Of 9,171 patients from 447 hospitals in 55 countries, 2,481 were operated on in COVID-19–free surgical pathways. Patients who underwent surgery within COVID-19–free surgical pathways were younger with fewer comorbidities than those in hospitals with no defined pathway but with similar proportions of major surgery. After adjustment, pulmonary complication rates were lower with COVID-19–free surgical pathways (2.2% v 4.9%; adjusted odds ratio [aOR], 0.62; 95% CI, 0.44 to 0.86). This was consistent in sensitivity analyses for low-risk patients (American Society of Anesthesiologists grade 1/2), propensity score–matched models, and patients with negative SARS-CoV-2 preoperative tests. The postoperative SARS-CoV-2 infection rate was also lower in COVID-19–free surgical pathways (2.1% v 3.6%; aOR, 0.53; 95% CI, 0.36 to 0.76). CONCLUSION Within available resources, dedicated COVID-19–free surgical pathways should be established to provide safe elective cancer surgery during current and before future SARS-CoV-2 outbreaks

On the importance of stochasticity of composite workpiece structures for post-processing operations: An analysis of errors on fixturing problems

As woven composites have attracted the attention of high-value industries, their broader implementation should be supported by an enhanced understating of the impact that their characteristic uneven surface has on high-precision post-processing operations (e.g. machining). Here, this gap is addressed by analysing the positioning error (i.e. linear/angular deviations from a reference) of woven composite workpieces prior post-processing operations. A bespoke model, tailored to simulate large stochastic surfaces, is presented and employed to construct several realistic “virtual workpieces” to study the interactions between the woven surface of the composite and the locating elements of a work-holding fixture. Results show that positioning errors are considerably reduced by improving the fixture’s geometric design, highlighting for the first time the crucial effect that the workpiece’s uneven surface has on post-processing operations. The versatility of the model allows its use on other applications where understanding this effect is critical (e.g. gripping during mechanical testing)