SLM additive manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in the aerospace industry. The importance of the evaluation of residual stresses that arise as a result of the 3D-printing process’ complex thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study, we report the results of a systematic study of residual stresses in 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary (from −80 to +180 MPa) over a significant proportion of the material yield stress (from −⅓ to ¾). All residual stress evaluation techniques considered returned comparable values of residual stresses, regardless of dramatically different dimensional scales, which ranged from millimeters for the contour method, laser speckle interferometry, and XRD down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing printing strategies to enhance mechanical performance and long-term durability.

Electrospinning is a well-established method for the fabrication of polymer biomaterials, including those with core-shell nanofibers. The variability of structures presents a great range of opportunities in tissue engineering and drug delivery by incorporating biologically active molecules such as drugs, proteins, and growth factors and subsequent control of their release into the target microenvironment to achieve therapeutic effect. The object of study is non-woven core-shell PVA–PEG–SiO₂@PVA–GO fiber mats assembled by the technology of coaxial electrospinning. The task of the core-shell fiber development was set to regulate the degradation process under external factors. The dual structure was modified with silica nanoparticles and graphene oxide to ensure the fiber integrity and stability. The influence of the nano additives and crosslinking conditions for the composite was investigated as a function of fiber diameter, hydrolysis, and mechanical properties. Tensile mechanical tests and water degradation tests were used to reveal the fracture and dissolution behavior of the fiber mats and bundles. The obtained fibers were visualized by confocal fluorescence microscopy to confirm the continuous core-shell structure and encapsulation feasibility for biologically active components, selectively in the fiber core and shell. The results provide a firm basis to draw the conclusion that electrospun core-shell fiber mats have tremendous potential for biomedical applications as drug carriers, photocatalysts, and wound dressings.

Successful direct route production of silicon nanostructures from diatomaceous earth (DE) on a single crystalline silicon wafer via the magnesiothermic reduction reaction is reported. The formed porous coating of 6 µm overall thickness contains silicon as the majority phase along with minor traces of Mg, as evident from SEM-EDS and the Focused Ion Beam (FIB) analysis. Raman peaks of silicon at 519 cm⁻¹ and 925 cm⁻¹ were found in both the film and wafer substrate, and significant intensity variation was observed, consistent with the SEM observation of the directly formed silicon nanoflake layer. Microstructural analysis of the flakes reveals the presence of pores and cavities partially retained from the precursor diatomite powder. A considerable reduction in surface reflectivity was observed for the silicon nanoflakes, from 45% for silicon wafer to below 15%. The results open possibilities for producing nanostructured silicon with a vast range of functionalities.

Redox flow batteries (RFBs) are a prospective energy storage platform to mitigate the discrepancy between barely adjustable energy production and fluctuating demand. The energy density and affordability of RFBs can be improved significantly through the transition from aqueous systems to non-aqueous (NAq) due to their wider electrochemical stability window and better solubility of active species. However, the NAqRFBs suffer from a lack of effective membranes with high ionic conductivity (IC), selectivity (low permeability), and stability. Here, we for the first time thoroughly analyse the impact of tape-casting solvents (dimethylformamide—DMF; dimethylsulfoxide—DMSO; N-methyl-2-pyrrolidone—NMP) on the properties of the composite Li-conductive membrane (Li_1.3Al_0.3Ti_1.7(PO₄)₃ filler within poly(vinylidene fluoride) binder—LATP+PVDF). We show that the prolonged exposure of LATP to the studied solvents causes slight morphological, elemental, and intrastructural changes, dropping ceramic’s IC from 3.1 to 1.6–1.9 ∙ 10⁻⁴ S cm⁻¹. Depending on the solvent, the final composite membranes exhibit IC of 1.1–1.7 ∙ 10⁻⁴ S cm⁻¹ (comparable with solvent-treated ceramics) along with correlating permeability coefficients of 2.7–3.1 ∙ 10⁻⁷ cm² min⁻¹. We expect this study to complement the understanding of how the processes underlying the membrane fabrication impact its functional features and to stimulate further in-depth research of NAqRFB membranes.

The use of aluminum alloy AA2024-T4 (Russian designation D16T) in applications requiring a high strength-to-weight ratio and fatigue resistance such as aircraft fuselage often demands the control and modification of surface properties. A promising route to surface conditioning of Al alloys is laser treatment. In the present work, the formation of ripples and conical microstructures under scanning with femtosecond (fs) laser pulses was investigated. Laser treatment was performed using 250 fs pulses of a 1033 nm Yb:YAG laser. The fluence of the pulses varied from 5 to 33 J/cm². The scanning was repeated from 1 to 5 times for different areas of the sample. Treated areas were evaluated using focused ion beam (FIB)- scanning electron microscopy (SEM) imaging and sectioning, energy-dispersive X-ray (EDX) spectroscopy, atomic force microscopy (AFM), and confocal laser profilometry. The period of laser-induced periodic surface structures (LIPSS) and the average spacing of conical microstructures were deduced from SEM images by FFT. Unevenness of the treated areas was observed that is likely to have been caused by ablation debris. The structural and elemental changes of the material inside the conical microstructures was revealed by FIB-SEM and EDX. The underlying formation mechanisms of observed structures are discussed in this paper.