Supersonic Cold Spraying for Energy and Environmental Applications: One-Step Scalable Coating Technology for Advanced Micro- and Nanotextured Materials

Solution-Processable Route for Large-Area Uniform 2D Semiconductor Nanofilms

The semiconductor thin film engineering technique plays a key role in the development of advanced electronics. Printing uniform nanofilms on freeform surfaces with high efficiency and low cost is significant for actual industrialization in electronics. Herein, a high-throughput colloidal printing (HTCP) strategy is reported for fabricating large-area and uniform semiconductor nanofilms on freeform surfaces. High-throughput and uniform printing rely on the balance of atomization and evaporation, as well as the introduced thermal Marangoni flows of colloidal dispersion, that suppresses outward capillary flows. Colloidal printing with in situ heating enables the fast fabrication of large-area semiconductor nanofilms on freeform surfaces, such as SiO2 /Si, Al2 O3 , quartz glass, poly(ethylene terephthalate) (PET), Al foil, plastic tube, and Ni foam, expanding their technological applications where substrates are essential. The printed SnS2 nanofilms are integrated into thin-film semiconductor gas sensors with one of the fastest responses (8 s) while maintaining the highest sensitivity (Rg /Ra = 21) (toward 10 ppm NO2 ), as well as an ultralow limit of detection (LOD) of 46 ppt. The ability to print uniform semiconductor nanofilms on freeform surfaces with high-throughput promises the development of next-generation electronics with low cost and high efficiency.

Enhanced Performance of Triboelectric Nanogenerators and Sensors via Cold Spray Particle Deposition

In this study, a high-performance triboelectric nanogenerator (TENG) is developed based on cold spray (CS) deposition of composite material layers. Composite layers were fabricated by cold spraying of micron-scale tin (Sn) particles on aluminum (Al) and polytetrafluoroethylene (PTFE) films, which led to improved TENG performance owing to functionalized composite layers as friction layers and electrodes, respectively. As-sprayed tin composite layers not only enhanced the flow of charges by strong adhesion to the target layer but also formed a nano-microstructure on the surface of the layers, thereby increasing the surface area during friction. More importantly, the electricity generation performance was improved more than 6 times as compared to the TENG without CS deposition on it. From parametric studies, the TENG using the cold-sprayed composite layer produced an electrical potential of 1140 V for a simple structure with a 25.4 × 25.4 mm² contact area. We also optimize the geometry and fabrication process of the TENG to increase the manufacturing efficiency while reducing the processing cost. The resultant sprayed layers and structures exhibited sustainable robustness by showing consistent electrical performance after the mechanical adhesion test. The proposed manufacturing approach is also applicable for processing three-dimensional (3D) complex layers owing to the technological convergence of a cold spray gun attached to a robotic arm, which makes possible to fabricate the 3D TENG. To elaborate, a composite layer having the shape of a 3D ball is produced, and the exercise status of the ball is monitored in real-time. The fabricated 3D ball using the TENG transmitted a distinguishable signal in real-time according to the state of the ball. The proposed TENG sensing system can be utilized as a self-powered sensor without the need of a battery, amplifier, and rectifier. The results of this study can potentially provide insights for the practical material design and fabrication of self-powered TENG systems.

3D Conformal Fabrication of Piezoceramic Films

Piezoceramic films are an essential class of energy-conversion materials that have been widely used in the electronics industry. Although current methods create a great freedom for fabricating high-quality piezoceramic films, it requires well-controlled synthesis conditions, including special high-cost equipment and planar substrates particularly. The limited substrate selections hinder the applications of piezoceramic films in 3D conformal structures where most objects possess complex curvilinear surfaces. To overcome such limitations, a fast, energy-efficient, and cost-effective approach, named flame treated spray (FTS) coating, is developed for preparing piezoceramic films on free-form surfaces. The flame treatment significantly enhances the hydrophilicity of a substrate, assisting in forming a uniform and continuous thin film. The followed spray coating deposits hundreds of nanometers to several micrometers thick films on 3D free-form surfaces. Given the size controllability and arbitrary surface compatibility of the FTS method, a highly conformal piezoelectric tactile sensor array (4 × 4) is assembled on a spherical surface for mimicking robot fingers and an on-site thin-film sensor on the wing of an aircraft model to monitor the vibration in real-time during flight. The FTS film deposition offers a highly promising methodology for the application of functional thin-film from micro- to marcoscale devices, regardless of conformal problems.

Antibacterial Efficacy of Cold-Sprayed Copper Coatings against Gram-Positive Staphylococcus aureus and Gram-Negative Escherichia coli

Contact surfaces have been identified as one of the main routes for pathogen transmission. The efficacy to kill both viruses and bacteria on touch surfaces is critical to reducing the rampant spread of harmful pathogens. Copper is one such material that has been traditionally used for its antimicrobial properties. However, most contact/touch surfaces are made up of steel or aluminum due to their structural properties. Therefore, coating high-touch components with copper is one possible solution to improve antibacterial efficacy. In this study, copper was coated on both stainless steel and aluminum substrates using a cold spray process which is a fast and economic coating technique. The coated samples in both as-deposited and heat-treated states were exposed to Escherichia coli and Staphylococcus aureus bacteria, and their efficacy was compared with bulk copper plate. It was found that both bacterial cells responded differently to the different coating properties such as coating thickness, porosity, hardness, surface roughness, oxide content, and galvanic coupling effect. These correlations were elucidated in light of various results obtained from antibacterial and bacterial attachment tests, and materials characterizations of the coatings. It is possible to tailor copper coating characteristics to render them more effective against targeted bacteria.

Supersonically Sprayed Washable, Wearable, Stretchable, Hydrophobic, and Antibacterial rGO/AgNW Fabric for Multifunctional Sensors and Supercapacitors

Wearable electronic textiles are used in sensors, energy-harvesting devices, healthcare monitoring, human-machine interfaces, and soft robotics to acquire real-time big data for machine learning and artificial intelligence. Wearability is essential while collecting data from a human, who should be able to wear the device with sufficient comfort. In this study, reduced graphene oxide (rGO) and silver nanowires (AgNWs) were supersonically sprayed onto a fabric to ensure good adhesiveness, resulting in a washable, stretchable, and wearable fabric without affecting the performance of the designed features. This rGO/AgNW-decorated fabric can be used to monitor external stimuli such as strain and temperature. In addition, it is used as a heater and as a supercapacitor and features an antibacterial hydrophobic surface that minimizes potential infection from external airborne viruses or virus-containing droplets. Herein, the wearability, stretchability, washability, mechanical durability, temperature-sensing capability, heating ability, wettability, and antibacterial features of this metallized fabric are explored. This multifunctionality is achieved in a single fabric coated with rGO/AgNWs via supersonic spraying.

MnO2 -Based Materials for Environmental Applications

Manganese dioxide (MnO₂ ) is a promising photo-thermo-electric-responsive semiconductor material for environmental applications, owing to its various favorable properties. However, the unsatisfactory environmental purification efficiency of this material has limited its further applications. Fortunately, in the last few years, significant efforts have been undertaken for improving the environmental purification efficiency of this material and understanding its underlying mechanism. Here, the aim is to summarize the recent experimental and computational research progress in the modification of MnO₂ single species by morphology control, structure construction, facet engineering, and element doping. Moreover, the design and fabrication of MnO₂ -based composites via the construction of homojunctions and MnO₂ /semiconductor/conductor binary/ternary heterojunctions is discussed. Their applications in environmental purification systems, either as an adsorbent material for removing heavy metals, dyes, and microwave (MW) pollution, or as a thermal catalyst, photocatalyst, and electrocatalyst for the degradation of pollutants (water and gas, organic and inorganic) are also highlighted. Finally, the research gaps are summarized and a perspective on the challenges and the direction of future research in nanostructured MnO₂ -based materials in the field of environmental applications is presented. Therefore, basic guidance for rational design and fabrication of high-efficiency MnO₂ -based materials for comprehensive environmental applications is provided.

Post-Process Treatments on Supersonic Cold Sprayed Coatings: A Review

Cold Gas Dynamic Spray or Supersonic Cold Spray, or simply ‘Cold Spray’, is an emerging technology for rapidly building thin films, thick coatings and large-scale additive manufacturing at relatively low temperatures. In a cold spray process, particles are accelerated to supersonic speeds by a propellant gas and impact a substrate, thus producing a strong bonding with the substrate and subsequently forming a deposit via layer-by-layer buildup. The scalability and low cost of this method make it promising for many applications in industry, such as metal component surface repair/enhancement/restoration and functional coatings for electrical, thermal, biomedical, energy storage, and nuclear plant applications. However, cold sprayed deposits usually require post process treatments to further modify their microstructures and mechanical properties in order to obtain the desired performances. A number of studies have been carried out on this topic. Here, recent progress in different post process treatments on cold sprayed deposits is reviewed, including heat treatment, friction-stir processing, shot peening, and laser re-melting. The effects of these post treatments on the microstructure, residual stress and mechanical properties of cold sprayed deposits are discussed.