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Enhancing the operational efficacy of electrical discharge machining (EDM) is crucial for achieving optimal results in various engineering materials. This study introduces an innovative solution—the use of coated electrodes—representing a significant advancement over current limitations. The choice of coating material is critical for micro-EDM performance, necessitating a thorough investigation of its impact. This research explores the application of different coating materials (AlCrN, TiN, and Carbon) on WC electrodes in micro-EDM processes specifically designed for Ti-6Al-4V. A comprehensive assessment was conducted, focusing on key quality indicators such as depth of cut (Z), tool wear rate (TWR), overcut (OVC), and post-machining surface quality. Through rigorous experimental methods, the study demonstrates substantial improvements in these quality parameters with coated electrodes. The results show significant enhancements, including increased Z, reduced TWR and OVC, and improved surface quality. This evidence underscores the effectiveness of coated electrodes in enhancing micro-EDM performance, marking a notable advancement in the precision and quality of Ti–6Al–4V machining processes. Among the evaluated coatings, AlCrN-coated electrodes exhibited the greatest increase in Z, the most significant reduction in TWR, and the best OVC performance compared to other coatings and the uncoated counterpart.

Even though the coated electrode can enhance the machining efficiency in micro-EDM process, it is essential to introduce optimization approach for further enhancing the process. Hence the present study was performed with multi-criteria optimization in micro-EDM using TiN coated tungsten carbide electrode for machining titanium (Ti–6Al–4V) alloy. The Z coordinator and tool wear rate were used as the quality parameters to evaluate the machinability. The voltage, capacitance and spindle rotational speed were considered the technological parameters. The Technique for order preference by similarity to ideal solution method was a suitable solution to determine the optimal result with the help of S/N analysis and by ranking. It was found that capacitance has more significant nature in the process. The optimal process parameters combination was found with better accuracy and lower prediction error of 1.03%. The better machined surface quality was also observed under optimal conditions.

The coated electrodes with high heat resistant alloy materials can considerably improve the efficiency of electrical discharge machining (EDM) process. In the present study, the influence of Aluminum Chromium Nickel Coated aluminium electrode was investigated on the quality criteria using EDM while machining Titanium alloy (Ti - 6Al-4V). The peak current, gap voltage and pulse-on time were used as input parameters to analyze the material removal rate, tool wear rate and surface roughness under the L16 based Taguchi method and ANOVA method. It was observed that Aluminum Chromium Nickel (AlCrNi) coated electrode could produce higher material removal rate (MRR), lower of tool wear rate (TWR) and surface roughness (Ra) than uncoated electrode. Compared with EDM with uncoated electrodes, the quality indicators in EDM with coated electrode are better, namely 8% higher MRR, the lower TWR and Ra are 8% and 24%, respectively. The better surface finish was also observed with the coated electrode due to its thermal conductivity.

The short service life of the Ti/BDD coated electrode is the main reason that limits its practical use. In this paper, the effect of structural change on the service life was studied using Ti/BDD coated electrodes prepared with the arc plasma chemical vapor deposition (CVD) method. It was found that the microstructural defects and corrosion resistance of BDD coatings were the main factors affecting the electrode service life. By optimizing the process parameters in different deposition stages, reducing the structural defects and improving the corrosion resistance of the BDD coating were conducted successfully, which increased the service life of the Ti/BDD coated electrodes significantly. The lifetime of the Ti/BDD samples increased from 360 h to 655 h under the electrolysis condition with a current density of 0.5 A/cm2, with an increase of 82%.

Since the cost of electrodes in electrical discharge machining (EDM) is usually too high, it leads to a significant increase in the production cost. Hence, it is important to conduct research aimed at reducing the manufacturing cost of electrodes. Currently, coated electrodes are a new process solution in EDM. It can improve the economic and technical efficiency of this technology. In this article, the efficiency of the graphene-coated aluminum (Al) electrode in the EDM for Ti–6Al–4V was analyzed and evaluated. Material removal rate and tool wear rate were used as quality indicators in this work. The research results have shown a significant improvement in quality characteristics in EDM with coated electrodes compared to EDM with uncoated electrodes. The surface quality of the specimen with coated electrodes in EDM was also improved.

The use of thin film-coated micro-tool electrode introduced a new technical solution to bring the best technical–economic efficiency in the field of non-conventional machining processes. Multi-objective optimization of process parameters in micro-electrical discharge machining (EDM) is very limited with the help of thin film-coated micro-tool, which brought benefits for the industry. In this research work, the technological parameters such as voltage ( ), spindle rotation, and capacitance ( ) in micro-EDM using carbon-coated electrode were optimized, and -coordinate depth of cut and tool wear rate were selected as response variables. Taguchi is combined with Deng’s method to solve this multi-objective decision problem. The results showed that Taguchi–Deng’s method is the right solution for multi-target decision in micro-EDM using the coated electrode. is the strongest influence on optimal efficiency, and it is the smallest with . The machining quality under optimal conditions is improved.

To prevent endocochlear insertion trauma, the development of drug delivery coatings in the field of CI electrodes has become an increasing focus of research. However, so far, the effect of a polymer coating of PLLA on the mechanical properties, such as the insertion pressure and friction of an electrode array, has not been investigated. In this study, the insertion pressure of a PLLA-coated, 31.5-mm long standard electrode array was examined during placement in a linear cochlear model. Additionally, the friction coefficients between a PLLA-coated electrode array and a tissue simulating the endocochlear lining were acquired. All data were obtained at different insertion speeds (0.1, 0.5, 1.0, 1.5, and 2.0 mm/s) and compared with those of an uncoated electrode array. It was shown that both the maximum insertion pressure generated in the linear model and the friction coefficient of the PLLA-coated electrode did not depend on the insertion speed. At higher insertion speeds above 1.0 mm/s, the insertion pressure (1.268 ± 0.032 mmHg) and the friction coefficient (0.40 ± 0.15) of the coated electrode array were similar to those of an uncoated array (1.252 ± 0.034 mmHg and 0.36 ± 0.15). The present study reveals that a PLLA coating on cochlear electrode arrays has a negligible effect on the electrode array insertion pressure and the friction when higher insertion speeds are used compared with an uncoated electrode array. Therefore, PLLA is a suitable material to be used as a coating for CI electrode arrays and can be considered for a potential drug delivery system.

From mobile devices to the power grid, the needs for high-energy density or high-power density energy storage materials continue to grow. Materials that have at least one dimension on the nanometer scale offer opportunities for enhanced energy storage, although there are also challenges relating to, for example, stability and manufacturing. In this context, Pomerantseva et al. review fundamental processes of charge storage that apply specifically to nanostructured materials and briefly explore potential manufacturing processes. The authors also consider some of the skepticism, such as that found in the battery community, to the use of these materials. Science , this issue p. eaan8285 Lithium-ion batteries, which power portable electronics, electric vehicles, and stationary storage, have been recognized with the 2019 Nobel Prize in chemistry. The development of nanomaterials and their related processing into electrodes and devices can improve the performance and/or development of the existing energy storage systems. We provide a perspective on recent progress in the application of nanomaterials in energy storage devices, such as supercapacitors and batteries. The versatility of nanomaterials can lead to power sources for portable, flexible, foldable, and distributable electronics; electric transportation; and grid-scale storage, as well as integration in living environments and biomedical systems. To overcome limitations of nanomaterials related to high reactivity and chemical instability caused by their high surface area, nanoparticles with different functionalities should be combined in smart architectures on nano- and microscales. The integration of nanomaterials into functional architectures and devices requires the development of advanced manufacturing approaches. We discuss successful strategies and outline a roadmap for the exploitation of nanomaterials for enabling future energy storage applications, such as powering distributed sensor networks and flexible and wearable electronics.

The propensity of metals to form irregular and nonplanar electrodeposits at liquid-solid interfaces has emerged as a fundamental barrier to high-energy, rechargeable batteries that use metal anodes. We report an epitaxial mechanism to regulate nucleation, growth, and reversibility of metal anodes. The crystallographic, surface texturing, and electrochemical criteria for reversible epitaxial electrodeposition of metals are defined and their effectiveness demonstrated by using zinc (Zn), a safe, low-cost, and energy-dense battery anode material. Graphene, with a low lattice mismatch for Zn, is shown to be effective in driving deposition of Zn with a locked crystallographic orientation relation. The resultant epitaxial Zn anodes achieve exceptional reversibility over thousands of cycles at moderate and high rates. Reversible electrochemical epitaxy of metals provides a general pathway toward energy-dense batteries with high reversibility.

Electrocatalysis, whose reaction venue locates at the catalyst–electrolyte interface, is controlled by the electron transfer across the electric double layer, envisaging a mechanistic link between the electron transfer rate and the electric double layer structure. A fine example is in the CO 2 reduction reaction, of which rate shows a strong dependence on the alkali metal cation (M + ) identity, but there is yet to be a unified molecular picture for that. Using quantum-mechanics-based atom-scale simulation, we herein scrutinize the M + -coupling capability to possible intermediates, and establish H + - and M + -associated ET mechanisms for CH 4 and CO/C 2 H 4 formations, respectively. These theoretical scenarios are successfully underpinned by Nernstian shifts of polarization curves with the H + or M + concentrations and the first-order kinetics of CO/C 2 H 4 formation on the electrode surface charge density. Our finding further rationalizes the merit of using Nafion-coated electrode for enhanced C2 production in terms of enhanced surface charge density. CO2 reduction rate shows a strong dependence on alkali metal cation identity but a unified molecular picture for underlying mechanism requires further investigation. Using advanced molecular simulations and experimental kinetic studies, here the authors establish a unified mechanism for cation-coupled electron transfer.