Innovations in electrophoretic deposition: Alternating current and pulsed direct current methods

Application of Electrophoretic Deposition as an Advanced Technique of Inhibited Polymer Films Formation on Metals from Environmentally Safe Aqueous Solutions of Inhibited Formulations

The presented paper analyzes polymer films formed from aqueous solutions of organosilanes, corrosion inhibitors and their compositions. Methods of depositing inhibited films on metal samples, such as dipping and exposure of the sample in a modifying solution, as well as an alternative method, electrophoretic deposition (EPD), are discussed. Information is provided on the history of the EPD method, its essence, production process, areas of application of this technology, advantages over existing analogues, as well as its varieties. The article considers the promise of using the EPD method to form protective inhibited polymer films on metal surfaces from aqueous solutions of inhibitor formulations consisting of molecules of organosilanes and corrosion inhibitors.

Directed Assembly of Nanomaterials for Making Nanoscale Devices and Structures: Mechanisms and Applications

Nanofabrication has been utilized to manufacture one-, two-, and three-dimensional functional nanostructures for applications such as electronics, sensors, and photonic devices. Although conventional silicon-based nanofabrication (top-down approach) has developed into a technique with extremely high precision and integration density, nanofabrication based on directed assembly (bottom-up approach) is attracting more interest recently owing to its low cost and the advantages of additive manufacturing. Directed assembly is a process that utilizes external fields to directly interact with nanoelements (nanoparticles, 2D nanomaterials, nanotubes, nanowires, etc.) and drive the nanoelements to site-selectively assemble in patterned areas on substrates to form functional structures. Directed assembly processes can be divided into four different categories depending on the external fields: electric field-directed assembly, fluidic flow-directed assembly, magnetic field-directed assembly, and optical field-directed assembly. In this review, we summarize recent progress utilizing these four processes and address how these directed assembly processes harness the external fields, the underlying mechanism of how the external fields interact with the nanoelements, and the advantages and drawbacks of utilizing each method. Finally, we discuss applications made using directed assembly and provide a perspective on the future developments and challenges.

A Brief Insight to the Electrophoretic Deposition of PEEK-, Chitosan-, Gelatin-, and Zein-Based Composite Coatings for Biomedical Applications: Recent Developments and Challenges

Electrophoretic deposition (EPD) is a powerful technique to assemble metals, polymer, ceramics, and composite materials into 2D, 3D, and intricately shaped implants. Polymers, proteins, and peptides can be deposited via EPD at room temperature without affecting their chemical structures. Furthermore, EPD is being used to deposit multifunctional coatings (i.e., bioactive, antibacterial, and biocompatible coatings). Recently, EPD was used to architect multi-structured coatings to improve mechanical and biological properties along with the controlled release of drugs/metallic ions. The key characteristics of EPD coatings in terms of inorganic bioactivity and their angiogenic potential coupled with antibacterial properties are the key elements enabling advanced applications of EPD in orthopedic applications. In the emerging field of EPD coatings for hard tissue and soft tissue engineering, an overview of such applications will be presented. The progress in the development of EPD-based polymeric or composite coatings, including their application in orthopedic and targeted drug delivery approaches, will be discussed, with a focus on the effect of different biologically active ions/drugs released from EPD deposits. The literature under discussion involves EPD coatings consisting of chitosan (Chi), zein, polyetheretherketone (PEEK), and their composites. Moreover, in vitro and in vivo investigations of EPD coatings will be discussed in relation to the current main challenge of orthopedic implants, namely that the biomaterial must provide good bone-binding ability and mechanical compatibility.

Electrophoretic-deposited Superhydrophobic Coatings

Electrophoretic deposition (EPD) is an excellent surface coating approach widely investigated for applications ranging from solar cells, batteries, electrochemical capacitors, solid oxide fuel cells, sensors, molecular sieves, corrosion-resistant coatings, and biomedical materials. On the other hand, superhydrophobic (SHPC) surfaces have enticed substantial recent research interest owing to their superb surface properties. Here, we provide a comprehensive review of electrophoretic-deposited SHPC coatings. Concise descriptions of EPD and superhydrophobicity are provided first, followed by a brief mentioning of works reported on electrophoretic-deposited SHPC coatings by one-step or two-step processing (§2.1). The next section (§2.2) delivers a comprehensive description of these reports based on the micro/nanoparticles used. Works reported in specific applications such as anti-corrosion, biomedical, and oil-separation are described in §2.3. Future scopes of research also presented.

Nanomaterial Fabrication through the Modification of Sol-Gel Derived Coatings

In materials processing, the sol–gel method is one of the techniques that has enabled large-scale production at low cost in the past few decades. The versatility of the method has been proven as the fabrication of various materials ranging from metallic, inorganic, organic, and hybrid has been reported. In this review, a brief introduction of the sol–gel technique is provided and followed by a discussion of the significance of this method for materials processing and development leading to the creation of novel materials through sol–gel derived coatings. The controlled modification of sol–gel derived coatings and their respective applications are also described. Finally, current development and the outlook of the sol–gel method for the design and fabrication of nanomaterials in various fields are described. The emphasis is on the significant potential of the sol–gel method for the development of new, emerging technologies.

Experimental review of PEI electrodeposition onto copper substrates for insulation of complex geometries

Polyetherimide (PEI) was used for coating copper substrates via electrophoretic deposition (EPD) for electrical insulation. Different substrate preparation and electrical field application techniques were compared, demonstrating that the use of a pulsed voltage of 20 V allowed for the best formation of insulating coatings in the 2–6 μm thickness range. The results indicate that pulsed EPD is the best technique to effectively coat conductive substrates with superior surface finish coatings that could pass a dielectric withstand test at 10 kV mm⁻¹, which is of importance within the EV automotive industry.

Electrophoretic deposition relying on electrodeposition of charged polymers via modulated electrical fields is reported. Superior surface finishes that could pass a dielectric withstand test at 10 kV mm⁻¹ were obtained for pulsed potentials at 20 V.

Electrochemical Determination of Hydroxyurea in a Complex Biological Matrix Using MoS2-Modified Electrodes and Chemometrics

Hydroxyurea, an oral medication with important clinical benefits in the treatment of sickle cell anemia, can be accurately determined in plasma with a transition metal dichalcogenide-based electrochemical sensor. We used a two-dimensional molybdenum sulfide material (MoS₂) selectively electrodeposited on a polycrystalline gold electrode via tailored waveform polarization in the gold electrical double layer formation region. The electro-activity of the modified electrode depends on the electrical waveform parameters used to electro-deposit MoS₂. The concomitant oxidation of the MoS₂ material during its electrodeposition allows for the tuning of the sensor’s specificity. Chemometrics, utilizing mathematical procedures such as principal component analysis and multivariable partial least square regression, were used to process the electrochemical data generated at the bare and the modified electrodes, thus allowing the hydroxyurea concentrations to be predicted in human plasma. A limit-of-detection of 22 nM and a sensitivity of 37 nA cm⁻² µM⁻¹ were found to be suitable for pharmaceutical and clinical applications.

New trends in the development of electrophoretic deposition method in the solid oxide fuel cell technology: theoretical approaches, experimental solutions and development prospects

The key features and challenges of the use of electrophoretic deposition for the formation of functional layers of solid oxide fuel cells are considered. Theoretical models and experimental results of the studies of electrophoretic deposition are presented. The analysis covers the physicochemical deposition mechanisms, methods for preparing suspensions and conditions necessary for obtaining thin-film electrode and protective single- and multi-layers with both dense and porous structure for solid oxide fuel cells. The prospects of theoretical simulations of the method and its potential practical applications are evaluated.

The bibliography includes 282 references.

Electroassembly of Chitin Nanoparticles to Construct Freestanding Hydrogels and High Porous Aerogels for Wound Healing

The construction of polymeric nanocomponents into a hierarchical structure poses great importance for subsequent biomedical applications. Herein, we report for the first time the electroassembly of chitin nanoparticles (14 nm ± 3 nm from transmission electron microscopy) to construct thick and freestanding hydrogels, which can be further dried to obtain high porous and tough aerogels for wound healing. The electroassembly is a simple, straightforward, and controllable process, which crucially depends on the pH of the chitin nanoparticle suspension and the degree of deacetylation of chitin. Interestingly, the electroassembly of chitin nanoparticles is completely reversible, suggesting the physical assembly feature of the freestanding hydrogel. By using supercritical CO₂ drying and freeze-drying, chitin aerogels and cryogels can be facilely obtained. Because of the intriguing features (i.e., large surface area, interconnected porous structure, and enhanced hydrophilicity), chitin aerogels demonstrate adorable performance to accelerate the healing of wounds.

Enhanced Mechanical and Electrochemical Performances of Silica-Based Coatings Obtained by Electrophoretic Deposition

To solve the existing problems of silicon dioxide (SiO₂) coating fabricated by the sol-gel method, such as complicated process, long production cycle, uncontrollable quality, etc., an improved electrophoretic deposition (EPD) combined with the sintering process was proposed to prepare SiO₂ coating on a dark nickel (Ni)-coated Q235 steel substrate. Silica sol was prepared by basic catalysis, containing silica of ∼130 g L^-1 with viscosities below 4 mPa s. Silica sol powder was characterized by the differential thermal analysis, Fourier transform infrared spectroscopy, X-ray diffraction, and scanning electron microscopy. EPD was applied to prepare SiO₂ coating on the Ni adhesive layer, followed by the sintering process to improve the compactness. In addition, the effects of EPD and sintering parameters were also evaluated. Potentiodynamic polarization and electrochemical impedance spectra were utilized to assess the corrosion behavior of the coating. The results showed that the EPD coating demonstrated excellent wear resistance when deposited at 15 V for 40 s and sintered at 400 °C for 45 min, exhibiting ∼6 μm thickness and a compact morphology. It also showed superior corrosion resistance with i_corr of 1.02 × 10^-7 A cm^-2, which was 2 orders of magnitude lower than that of dip-coating. Combining the EPD and sintering processes could shorten the fabrication period of SiO₂ inorganic coating and also improve the mechanical and corrosion properties, providing guidance for inorganic ceramic fabrication and showing potential for practical applications.

Simultaneous Silicon Oxide Growth and Electrophoretic Deposition of Graphene Oxide

During electrophoretic deposition of graphene oxide (GO) sheets on silicon substrates, not only deposition but also simultaneous anodic oxidation of the silicon substrate takes place, leading to a three-layered material. Scanning electron microscopy images reveal the presence of GO sheets on the silicon substrate, and this is also confirmed by X-ray photoelectron spectroscopy (XPS), albeit that the carbon portion increases with increasing emission angle, hinting at a thin carbon layer. With increasing applied potential and increasing conductivity of the GO solution, the carbon signal decreases, whereas the overall thickness of the added layer formed on top of the silicon substrate increases. Through XPS spectra in which the Si 2p peaks shifted under those conditions to 103-104 eV, we were able to conclude that significant amounts of oxygen are present, indicative of the formation of an oxide layer. This leads us to conclude that GO can be deposited using electrophoretic deposition, but that at the same time, silicon is oxidized, which may overshadow effects previously assigned to GO deposition.

Electrophoretic deposition: a versatile tool against biomaterial associated infections

Biomaterial-associated infections (BAIs) are today considered as one of the most withering complications of orthopedic implant surgery. Even though BAIs occur relatively infrequently in primary joint replacement surgeries (incidence rates around 1-2%), revision arthroplasties carry up to 40% risk of infection recurrence, with devastating consequences for the patient and significant associated cost. Once the responsible pathogens, mainly bacteria, attach to the surface of the biomaterial, they start creating layers of extracellular matrix with complex architectures, called biofilms. These last mentioned, encapsulate and protect bacteria by hindering the immune response and impeding antibiotics from reaching the pathogens. To prevent such an outcome, the surface of the biomaterials, in particular implants, can be modified in order to play the role of inherent drug delivery devices or as substrates for antibacterial/multifunctional coating deposition. This paper presents an overview of novel electrochemically-triggered deposition strategies, with a focus on electrophoretic deposition (EPD), a versatile and cost-effective technique for organic and inorganic material deposition. Other than being a simple deposition tool, EPD has been recently employed to create novel micro/nanostructured surfaces for multi-purpose antibacterial approaches, presented in detail in this review. In addition, a thorough comparison and assessment of the latest antibacterial and multifunctional compounds deposited by means of EPD have been reported, followed by a critical reflection on current and future prospects of the topic. The relative simplicity of EPD's application, has, by some means, undermined the fundamental requirement of rationality of multifunctional coating design. The demanding practical needs for a successful clinical translation in the growing fields of tissue engineering and antibacterial/multifunctional implant coatings, calls for a more systematic in vitro experimental design rationale, in order to make amends for the scarcity of significant in vivo and clinical studies.

Alternating Current Electrophoretic Deposition for the Immobilization of Antimicrobial Agents on Titanium Implant Surfaces

One prominent cause of implant failure is infection; therefore, research is focusing on developing surface coatings that render the surface resistant to colonization by micro-organisms. Permanently attached coatings of antimicrobial molecules are of particular interest because of the reduced cytoxicity and lower risk of developing resistance compared to controlled release coatings. In this study, we focus on the chemical grafting of bioactive molecules on titanium. To concentrate the molecules at the metallic implant surface, we propose electrophoretic deposition (EPD) applying alternating current (AC) signals with an asymmetrical wave shape. We show that for the model molecule bovine serum albumin (BSA), as well as for the clinically relevant antifungal lipopeptide caspofungin (CASP), the deposition yield is drastically improved by superimposing a DC offset in the direction of the high-amplitude peak of the AC signal. Additionally, in order to produce immobilized CASP coatings, this experimental AC/DC-EPD method is combined with an established surface activation protocol. Principle component analysis (PCA) of time-of-flight secondary ion mass spectrometry (ToF-SIMS) data confirm the immobilization of CASP with higher yield as compared to a diffusion-controlled process, and higher purity than the clinical CASP starting suspensions. Scratch testing data indicate good coating adhesion. Importantly, the coatings remain active against the fungal pathogen C. albicans as shown by in vitro biofilm experiments. In summary, this paper delivers a proof-of-concept for the application of AC-EPD as a fast grafting tool for antimicrobial molecules without compromising their activities.

Electrophoretic Deposition of Chitosan/45S5 Bioactive Glass Composite Coatings Doped with Zn and Sr

In this research work, the original 45S5 bioactive glass was modified by introducing zinc and/or strontium oxide (6 mol%) in place of calcium oxide. Sr was added for its ability to stimulate bone formation and Zn for its role in bone metabolism, antibacterial properties, and anti-inflammatory effect. The glasses were produced by means of melting and quenching process. SEM and XRD analyses evidenced that Zr and Sr introduction did not modify the glass structure and morphology while compositional analysis (EDS) demonstrated the effective incorporation of these elements in the glass network. Bioactivity test in simulated body fluid (SBF) up to 1 month evidenced a reduced bioactivity kinetics for Zn-doped glasses. Doped glasses were combined with chitosan to produce organic/inorganic composite coatings on stainless steel AISI 316L by electrophoretic deposition (EPD). Two EPD processes were considered for coating development, namely direct current EPD (DC-EPD) and alternating current EPD (AC-EPD). The stability of the suspension was analyzed and the deposition parameters were optimized. Tape and bending tests demonstrated a good coating-substrate adhesion for coatings containing 45S5-Sr and 45S5-ZnSr glasses, whereas the adhesion to the substrate decreased by using 45S5-Zn glass. FTIR analyses demonstrated the composite nature of coatings and SEM observations indicated that glass particles were well integrated in the polymeric matrix, the coatings were fairly homogeneous and free of cracks; moreover, the AC-EPD technique provided better results than DC-EPD in terms of coating quality. SEM, XRD analyses, and Raman spectroscopy, performed after bioactivity test in SBF solution, confirmed the bioactive behavior of 45S5-Sr-containing coating while coatings containing Zn exhibited no hydroxyapatite formation.

Roll-to-Roll Nanomanufacturing of Hybrid Nanostructures for Energy Storage Device Design

A key limitation to the practical incorporation of nanostructured materials into emerging applications is the challenge of achieving low-cost, high throughput, and highly replicable scalable nanomanufacturing techniques to produce functional materials. Here, we report a benchtop roll-to-roll technique that builds upon the use of binary solutions of nanomaterials and liquid electrophoretic assembly to rapidly construct hybrid materials for battery design applications. We demonstrate surfactant-free hybrid mixtures of carbon nanotubes, silicon nanoparticles, MoS2 nanosheets, carbon nanohorns, and graphene nanoplatelets. Roll-to-roll electrophoretic assembly from these solutions enables the controlled fabrication of homogeneous coatings of these nanostructures that maintain chemical and physical properties defined by the synergistic combination of nanomaterials utilized without adverse effects of surfactants or impurities that typically limit liquid nanomanufacturing routes. To demonstrate the utility of this nanomanufacturing approach, we employed roll-to-roll electrophoretic processing to fabricate both positive and negative electrodes for lithium ion batteries in less than 30 s. The optimized full-cell battery, containing active materials of prelithiated silicon nanoparticles and MoS2 nanosheets, was assessed to exhibit energy densities of 167 Wh/kgcell(-1) and power densities of 9.6 kW/kgcell(-1).

Low-temperature synthesis and electrophoretic deposition of shape-controlled titanium dioxide nanocrystals

A comprehensive, low-temperature strategy for obtaining optimized, dense and nanostructured TiO₂ thin films is proposed.

Alternating current electrophoretic deposition of antibacterial bioactive glass-chitosan composite coatings

Alternating current (AC) electrophoretic deposition (EPD) was used to produce multifunctional composite coatings combining bioactive glass (BG) particles and chitosan. BG particles of two different sizes were used, i.e., 2 μm and 20-80 nm in average diameter. The parameter optimization and characterization of the coatings was conducted by visual inspection and by adhesion strength tests. The optimized coatings were investigated in terms of their hydroxyapatite (HA) forming ability in simulated body fluid (SBF) for up to 21 days. Fourier transform infrared (FTIR) spectroscopy results showed the successful HA formation on the coatings after 21 days. The first investigations were conducted on planar stainless steel sheets. In addition, scaffolds made from a TiAl4V6 alloy were considered to show the feasibility of coating of three dimensional structures by EPD. Because both BG and chitosan are antibacterial materials, the antibacterial properties of the as-produced coatings were investigated using E. coli bacteria cells. It was shown that the BG particle size has a strong influence on the antibacterial properties of the coatings.

Electrophoretic deposition of cellulose nanocrystals (CNs) and CNs/alginate nanocomposite coatings and free standing membranes

This study presents the electrophoretic deposition (EPD) of cellulose nanocrystals (CNs) and CNs-based alginate composite coatings for biomedical applications. The mechanism of anodic deposition of CNs and co-deposition of CNs/alginate composites was analyzed based on the results of zeta-potential, Fourier transform infrared spectroscopy and scanning electron microscopy (SEM) analyses. The capability of the EPD technique for manipulating the orientation of CNs and for the preparation of multilayer CNs coatings was demonstrated. The nanotopographic surface roughness and hydrophilicity of the deposited coatings were measured and discussed. Electrochemical testing demonstrated that a significant degree of corrosion protection of stainless steel could be achieved when CNs-containing coatings were present. Additionally, the one-step EPD-based processing of free-standing CNs/alginate membranes was demonstrated confirming the versatility of EPD to fabricate free-standing membrane structures compared to a layer-by-layer deposition technique. CNs and CNs/alginate nanocomposite coatings produced by EPD are potential candidates for biomedical, cell technology and drug delivery applications.

Electrophoretic Deposition of Carbon Nanotubes on 3-Amino-Propyl-Triethoxysilane (APTES) Surface Functionalized Silicon Substrates

Fabrication of uniform thin coatings of multi-walled carbon nanotubes (MWCNTs) by electrophoretic deposition (EPD) on semiconductor (silicon) substrates with 3-aminopropyl-triethoxysilane (APTES) surface functionalization has been studied extensively in this report. The gradual deposition and eventual film formation of the carbon nanotubes (CNTs) is greatly assisted by the Coulombic force of attraction existing between the positively charged –NH₂ surface groups of APTES and the acid treated, negatively charged nanotubes migrating towards the deposition surfaces. The remarkable deposition characteristics of the CNT coatings by EPD in comparison to the dip coating method and the influence of isopropyl (IPA)-based CNT suspension in the fabricated film quality has also been revealed in this study. The effect of varying APTES concentration (5%–100%) on the Raman spectroscopy and thickness of the deposited CNT film has been discussed in details, as well. The deposition approach has eliminated the need of metal deposition in the electrophoretic deposition approach and, therefore, establishes a cost-effective, fast and entirely room temperature-based fabrication strategy of CNT thin films for a wide range of next generation electronic applications.

Directing cluster formation of Au nanoparticles from colloidal solution

Discrete clusters of closely spaced Au nanoparticles can be utilized in devices from photovoltaics to molecular sensors because of the formation of strong local electromagnetic field enhancements when illuminated near their plasmon resonance. In this study, scalable, chemical self-organization methods are shown to produce Au nanoparticle clusters with uniform nanometer interparticle spacing. The performance of two different methods, namely electrophoresis and diffusion, for driving the attachment of Au nanoparticles using a chemical cross-linker on chemically patterned domains of polystyrene-block-poly(methyl methacrylate) (PS-b-PMMA) thin films are evaluated. Significantly, electrophoresis is found to produce similar surface coverage as diffusion in 1/6th of the processing time with an ~2-fold increase in the number of Au nanoparticles forming clusters. Furthermore, average interparticle spacing within Au nanoparticle clusters was found to decrease from 2-7 nm for diffusion deposition to approximately 1-2 nm for electrophoresis deposition, and the latter method exhibited better uniformity with most clusters appearing to have about 1 nm spacing between nanoparticles. The advantage of such fabrication capability is supported by calculations of local electric field enhancements using electromagnetic full-wave simulations from which we can estimate surface-enhanced Raman scattering (SERS) enhancements. In particular, full-wave results show that the maximum SERS enhancement, as estimated here as the fourth power of the local electric field, increases by a factor of 100 when the gap goes from 2 to 1 nm, reaching values as large as 10(10), strengthening the usage of electrophoresis versus diffusion for the development of molecular sensors.

Applications of graphene electrophoretic deposition. A review

This Review summarizes research progress employing electrophoretic deposition (EPD) to fabricate graphene and graphene-based nanostructures for a wide range of applications, including energy storage materials, field emission devices, supports for fuel cells, dye-sensitized solar cells, supercapacitors and sensors, among others. These carbonaceous nanomaterials can be dispersed in organic solvents, or more commonly in water, using a variety of techniques compatible with EPD. Most deposits are produced under constant voltage conditions with deposition time also playing an important role in determining the morphology of the resulting graphene structures. In addition to simple planar substrates, it has been shown that uniform graphene-based layers can be deposited on three-dimensional, porous, and even flexible substrates. In general, electrophoretically deposited graphene layers show excellent properties, e.g., high electrical conductivity, large surface area, good thermal stability, high optical transparency, and robust mechanical strength. EPD also enables the fabrication of functional composite materials, e.g., graphene combined with metallic nanoparticles, with other carbonaceous materials (e.g., carbon nanotubes) or polymers, leading to novel nanomaterials with enhanced optical and electrical properties. In summary, the analysis of the available literature reveals that EPD is a simple and convenient processing method for graphene and graphene-based materials, which is easy to apply and versatile. EPD has, therefore, a promising future for applications in the field of advanced nanomaterials, which depend on the reliable manipulation of graphene and graphene-containing systems.