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Thermal-sprayed ceramic coatings are widely used in industry due to their favorable mechanical properties. However, traditional ceramic coatings are prone to failure due to the differences in physical properties between the bonding coating and the ceramic coating. In order to solve this problem, a continuous transition zone was introduced between the ceramic coating and the bonding coating, then air plasma spraying was used to prepare traditional coatings and continuous transition coatings. The Vickers hardness analysis results show that the existence of the continuous transition zone made the change of hardness between the ceramic coating and the bonding coating more gradual. To understand the stress distribution inside the continuous transition coating, models were established to express the interface between ceramic and metal in the continuous transition zone. Simulation analysis found that the existence of the continuous transition zone can significantly reduce the stress gradient inside the coating, and the gradient index of the continuous transition zone also has a great influence on the stress distribution inside the coating model. SEM (Scanning Electron Microscope) analysis found many pores inside the coating; modeling the pores and simulating the influence of pores on the internal stress of the coating showed that the existence of pores inside the coating can reduce the stress gradient at the interface.

Thermal barrier coatings (TBCs) can effectively protect the alloy substrate of hot components in aeroengines or land-based gas turbines by the thermal insulation and corrosion/erosion resistance of the ceramic top coat. However, the continuous pursuit of a higher operating temperature leads to degradation, delamination, and premature failure of the top coat. Both new ceramic materials and new coating structures must be developed to meet the demand for future advanced TBC systems. In this paper, the latest progress of some new ceramic materials is first reviewed. Then, a comprehensive spalling mechanism of the ceramic top coat is summarized to understand the dependence of lifetime on various factors such as oxidation scale growth, ceramic sintering, erosion, and calcium-magnesium-aluminium-silicate (CMAS) molten salt corrosion. Finally, new structural design methods for high-performance TBCs are discussed from the perspectives of lamellar, columnar, and nanostructure inclusions. The latest developments of ceramic top coat will be presented in terms of material selection, structural design, and failure mechanism, and the comprehensive guidance will be provided for the development of next-generation advanced TBCs with higher temperature resistance, better thermal insulation, and longer lifetime.

Ultrathick battery electrodes are appealing as they reduce the fraction of inactive battery parts such as current collectors and separators. However, thick electrodes are difficult to dry and tend to crack or flake during production. Moreover, the electrochemical performance of thick electrodes is constrained by ion and electron transport as well as fast capacity degradation. Here, we report a thermally induced phase separation (TIPS) process for fabricating thick Li-ion battery electrodes, which incorporates the electrolyte directly in the electrode and alleviates the need to dry the electrode. The proposed TIPS process creates a bicontinuous electrolyte and electrode network with excellent ion and electron transport, respectively, and consequently achieves better rate performance. Using this process, electrodes with areal capacities of more than 30 mAh/cm2 are demonstrated. Capacity retentions of 87% are attained over 500 cycles in full cells with 1-mm-thick anodes and cathodes. Finally, we verified the scalability of the TIPS process by coating thick electrodes continuously on a pilot-scale roll-to-roll coating tool.

Graphene oxide (GO) has been a prized material for fabricating separation membranes due to its immense potential and unique chemistry. Despite the academic focus on GO, the adoption of GO membranes in industry remains elusive. One of the challenges at hand for commercializing GO membranes lies with large-scale production techniques. Fortunately, emerging studies have acknowledged this issue, where many have aimed to deliver insights into scalable approaches showing potential to be employed in the commercial domain. The current review highlights eight physical methods for GO membrane fabrication. Based on batch-unit or continuous fabrication, we have further classified the techniques into five small-scale (vacuum filtration, pressure-assisted filtration, spin coating, dip coating, drop-casting) and three large-scale (spray coating, bar/doctor blade coating, slot die coating) approaches. The continuous nature of the large-scale approach implies that the GO membranes prepared by this method are less restricted by the equipment’s dimensions but rather the availability of the material, whereas membranes yielded by small-scale methods are predominately limited by the size of the fabrication device. The current review aims to serve as an initial reference to provide a technical overview of preparing GO membranes. We further aim to shift the focus of the audience towards scalable processes and their prospect, which will facilitate the commercialization of GO membranes.

Hydroxypropyl-cellulose (HPC), a derivative of naturally abundant cellulose, can self-assemble into helical nanostructures that lead to striking colouration from Bragg reflections. The helical periodicity is very sensitive to pressure, rendering HPC a responsive photonic material. Recent advances in elucidating these HPC mechano-chromic properties have so-far delivered few real-world applications, which require both up-scaling fabrication and digital translation of their colour changes. Here we present roll-to-roll manufactured metre-scale HPC laminates using continuous coating and encapsulation. We quantify the pressure response of the encapsulated HPC using optical analyses of the pressure-induced hue change as perceived by the human eye and digital imaging. Finally, we show the ability to capture real-time pressure distributions and temporal evolution of a human foot-print on our HPC laminates. This is the first demonstration of a large area and cost-effective method for fabricating HPC stimuli-responsive photonic films, which can generate pressure maps that can be read out with standard cameras. Self-assembled structures are typically demonstrated on small scales under well-controlled lab environments. Here, the authors present a roll-to-roll process for the continuous manufacturing of square-meters of self-assembled cellulose-based mechano-chromic films and demonstrate the recording of pressure profiles generated by foot-imprints in real time.

HighlightsWearable and smart textiles are constructed by integrating embroidery technology and 5G cloud communication, showing promising applications in temperature management and real-time dynamic textile displays.Thermochromism is introduced into the natural silk to produce high-performance thermochromic silks (TCSs) through a low cost, sustainable, efficient, and scalable strategy.The interfacial bonding of the continuously produced TCSs is in situ analyzed and improved through pre-solvent treatment and is confirmed using synchrotron Fourier transform infrared microspectroscopy.Silks have various advantages compared with synthetic polymer fibers, such as sustainability, mechanical properties, luster, as well as air and humidity permeability. However, the functionalization of silks has not yet been fully developed. Functionalization techniques that retain or even improve the sustainability of silk production are required. To this end, a low-cost, effective, and scalable strategy to produce TCSs by integrating yarn-spinning and continuous dip coating technique is developed herein. TCSs with extremely long length (> 10 km), high mechanical performance (strength of 443.1 MPa, toughness of 56.0 MJ m−3, comparable with natural cocoon silk), and good interfacial bonding were developed. TCSs can be automatically woven into arbitrary fabrics, which feature super-hydrophobicity as well as rapid and programmable thermochromic responses with good cyclic performance: the response speed reached to one second and remained stable after hundreds of tests. Finally, applications of TCS fabrics in temperature management and dynamic textile displays are demonstrated, confirming their application potential in smart textiles, wearable devices, flexible displays, and human–machine interfaces. Moreover, combination of the fabrication and the demonstrated applications is expected to bridge the gap between lab research and industry and accelerate the commercialization of TCSs.

There is an increased interest in the use of cellulose nanocrystal (CNC) films and coatings for a range of functional applications in the fields of material science, biomedical engineering, and pharmaceutical sciences. Most of these applications have been demonstrated on films and coatings produced using laboratory-scale batch processes, such as solvent casting, dip coating, or spin coating. For successful coating application of CNC suspensions using a high throughput process, several challenges need to be addressed: relatively high viscosity at low solids content, coating brittleness, and potentially poor adhesion to the substrate. This work aims to address these problems. The impact of plasticizer on suspension rheology, coating adhesion, and barrier properties was quantified, and the effect of different pre-coatings on the wettability and adhesion of CNC coatings to paperboard substrates was explored. CNC suspensions were coated onto pre-coated paperboard in a roll-to-roll process using a custom-built slot die. The addition of sorbitol reduced the brittleness of the CNC coatings, and a thin cationic starch pre-coating improved their adhesion to the paperboard. The final coat weight, dry coating thickness, and coating line speed were varied between 1–11 g/m 2 , 900 nm–7 µm, and 2.5–10 m/min, respectively. The barrier properties, adhesive strength, coating coverage, and smoothness of the CNC coatings were characterized. SEM images show full coating coverage at coat weights as low as 1.5 g/m 2 . With sorbitol as plasticizer and at coat weights above 3.5 g/m 2 , heptane vapor and water vapor transmission rates were reduced by as much as 99% and 75% respectively. Compared to other film casting techniques, the process employed in this work deposits a relatively thick coating in significantly less time, and may therefore pave the way toward various functional applications based on CNCs. Graphical abstract

Pharmaceutical film coating is considered a key part in the production of solid pharmaceutical dosage forms since it gives superior organoleptic properties products. In addition, it can improve the physical and chemical stability of dosage forms, and modify the release characteristics of the drug. Several troubleshooting problems such as twinning mottling, chipping, etc., may arise during or after or even during the shelf life of the film coated dosage forms. These troubleshooting problems may be due to tablet core faults, coating formulation faults and/or coating process faults. These problems must be overcome to avoid unnecessary product problems. Film coating as well as other parts of the pharmaceutical technology is subjecting to continuous innovation. The innovation may be at different levels including pharmaceutical excipients, processes, software, guidelines and equipment. In fact, of particular note is the growing interest in process analytical technology, quality by design, continuous coating processing and the inclusion of new ready for use coating formulations. In this review, we tried to explore and discuss the status of pharmaceutical film coating, the challenges that face this manufacturing process and the latest technological advances in this important manufacturing process.

Viruses have been infecting their host cells since the dawn of life, and this extremely long-term coevolution gave rise to some surprising consequences for the entire tree of life. It is hypothesised that viruses might have contributed to the formation of the first cellular life form, or that even the eukaryotic cell nucleus originates from an infection by a coated virus. The continuous struggle between viruses and their hosts to maintain at least a constant fitness level led to the development of an unceasing arms race, where weapons are often shuttled between the participants. In this literature review we try to give a short insight into some general consequences or traits of virus–host coevolution, and after this we zoom in to the viral clades of adenoviruses, herpesviruses, nucleo-cytoplasmic large DNA viruses, polyomaviruses and, finally, circoviruses.

Continuous glucose monitors (CGMs), used by patients with diabetes mellitus, can autonomously track fluctuations in blood glucose over time. However, the signal produced by CGMs during the initial recording period following sensor implantation contains substantial noise, requiring frequent recalibration via finger-prick tests. Here, we show that coating the sensor with a zwitterionic polymer, found via a combinatorial chemistry approach, significantly reduces signal noise and improves CGM performance. We evaluated the polymer-coated sensors in mice as well as in healthy and diabetic non-human primates, and show that the sensors accurately record glucose levels without the need for recalibration. We also show that the coated sensors significantly abrogated immune responses, as indicated by histology, fluorescent whole-body imaging of inflammation-associated protease activity and gene expression of inflammation markers. The polymer coating may allow CGMs to become standalone measuring devices. Coating the sensor in continuous glucose monitors with a zwitterionic polymer significantly reduces signal noise and the need for frequent device recalibration.