Roll-to-roll nanoimprint lithography (RTR-NIL) is a low-cost and continuous fabrication process for large-area functional films. However, the partial ultraviolet (UV) resin filling obstructs the ongoing production process. This study incorporates UV resin filling process into the nanopillars and nanopores by using RTR-NIL. A multiphase numerical model with a sliding mesh method is proposed in this study to show the actual phenomena of imprint mold rotation and feeding of UV resin on the polyethylene terephthalate (PET) substrate. The implementation of UV resin filling under environmental conditions was performed by utilizing the open-channel (OC) boundary conditions. The numerical model was solved by using the explicit volume of fluid (VOF) scheme to compute the filling on each node of the computational domain. The effects of different processing parameters were investigated through the proposed numerical model such as imprinting speed (IS), contact angles (CAs), viscosity, initial thickness of the PET, and supporting roll diameter. A good agreement was found between numerical simulations and experimental results. The proposed numerical model gives better insights of the filling process for the mass production of functional surfaces with nanopillars and nanopores patterns for different applications on an industrial scale.

With increasing demand for Li-ion batteries, studies are focusing on enhancing battery performance and safety. However, studies on battery cases remain scarce. Herein, we propose the use of super duplex stainless steel SAF2507, which is a two-phase (austenite + ferrite) steel, for battery casings. Unlike conventional AISI304, SAF2507 maintains its corrosion resistance and strength at high temperatures and precipitates a secondary phase at approximately 975 °C. However, the effects of Ni plating on this secondary phase are not well documented. Therefore, the electroless Ni plating of SAF2507 after secondary-phase precipitation was studied. Briefly, heat treatment at 1000 °C was used to induce precipitation, and the electroless Ni plating behaviour over varying plating periods was analysed using open-circuit potential, potentiodynamic polarisation, and electrochemical impedance spectroscopy measurements. The plating state and corrosion behaviour were examined using scanning electron microscopy. Heat-treated SAF2507 steel with a secondary phase exhibited excellent electroless Ni plating behaviour, which enhances the safety and durability of Li-ion batteries. Furthermore, uniform plating and electrochemical behaviour were achieved after 180 s, suggesting that SAF2507 is superior to AISI304. These findings contribute to the development of safer and more efficient batteries and address the growing demand for Li-ion battery case materials.

Carbon steel is subjected to several pretreatments to enable its use in highly corrosive environments, such as marine structures. However, its surface treatment is problematic owing to various processes, and these problems can be solved by replacing it with super duplex stainless steel (SDSS), which exhibits remarkable strength and corrosion resistance owing to its austenite and ferrite phases. EN 1.4410 and EN 1.4501 are the most extensively used SDSS grades in marine structures, as they exhibit exceptional strength and corrosion resistance in seawater. This study subjected EN 1.4410 and EN 1.4501 samples to specific heat treatment after casting and observed their structural alterations through field emission scanning electron microscopy. Their passivation states, with or without the Cu and W layers, were determined by examining their corrosion properties through open-circuit potential measurements, electrostatic polarisation tests, electrochemical impedance spectroscopy (EIS), and critical pitting temperature (CPT) analysis. The inclusion of Cu significantly improved the uniform corrosion resistance within the passivation layers, whereas the addition of W enhanced the pitting resistance (E_pit, CPT). Additionally, the EIS analysis confirmed a double-layer structure in the passivation layer of EN 1.4501. Moreover, Cu did not act as a strengthening element of the passivation layer, whereas W significantly reinforced it.

The development of Li-ion battery cases requires superior electrical conductivity, strength, and corrosion resistance for both cathode and anode to enhance safety and performance. Among the various battery case materials, super duplex stainless steel (SDSS), which is composed of austenite and ferrite as two-phase stainless steel, exhibits outstanding strength and corrosion resistance. However, stainless steel, which is an iron-based material, tends to have lower electrical conductivity. Nevertheless, nickel-plating SDSS can achieve excellent electrical conductivity, making it suitable for Li-ion battery cases. Therefore, this study analysed the plating behaviour of SDSS plates after nickel plating to leverage their exceptional strength and corrosion resistance. Electroless Ni plating was performed to analyse the plating behaviour, and the plating behaviour was studied with reference to different plating durations. Heat treatment was conducted at 1000 °C for one hour, followed by cooling at 50 °C/s. Post-heat treatment, the analysis of phases was executed using FE-SEM, EDS, and EPMA. Electroless Ni plating was performed at 60–300 s. The plating duration after the heat treatment was up to 300 s, and the behaviour of the materials was observed using FE-SEM. The phase analysis concerning different plating durations was conducted using XRD. Post-heat treatment, the precipitated secondary phases in SAF2507 were identified as Sigma, Chi, and CrN, approximating a 13% distribution. During the electroless Ni plating, the secondary phase exhibited a plating rate equivalent to that of ferrite, entirely plating at around 180 s. Further increments in plating time displayed growth of the plating layer from the austenite direction towards the ferrite, accompanied by a reduced influence from the substrate. Despite the differences in composition, both the secondary phase and austenite demonstrated comparable plating rates, showing that electroless Ni plating on SDSS was primarily influenced by the substrate, a finding which was primarily confirmed through phase analysis.

High-entropy alloys (HEAs), a relatively new class of materials, have attracted significant attention in materials science owing to their unique properties and potential applications. High entropy stabilizes the phase of a solid solution over a wide range of chemical compositions, yielding unique properties superior to those of conventional alloys. Therefore, this study analyzed the microstructure and electrochemical behavior of HEAs (Cantor) to evaluate their corrosion resistance, according to their manufacturing process (casting, cold rolling, and annealing). The microstructural morphologies and sizes were analyzed using electron backscatter diffraction. The electrochemical behavior was examined using open circuit potential measurements, electrochemical impedance spectroscopy, potentiodynamic polarization tests, and critical pitting temperature measurements using a potentiostat. The casting process formed a nonuniform microstructure (average grain size = 19 μm). The cold rolling process caused the formation of fine grains (size = 4 μm). A uniform microstructure (grain size > 151 μm) was formed after heat treatment. The corrosion resistance of the HEAs was determined from the passivation layer formed by Cr oxidation. These microstructural differences resulted in variations in the electrochemical behavior. Microstructural and electrochemical analyses are crucial because HEAs have diverse potential applications. Therefore, this study contributes to future improvements in HEA manufacturing processes.

The demand for Li-ion batteries has significantly increased in recent years, driven by the growing need for electric vehicles and electronic devices like smartphones. Among various materials, super duplex stainless steel (SDSS) is considered a suitable material for Li-ion batteries due to its excellent strength and corrosion resistance. However, SDSS is sensitive to heat-treatment conditions, necessitating research on heat treatment and Ni plating for battery case usage. While extensive research has been conducted on SDSS and its heat-treatment conditions, there is a research gap concerning the Ni plating of SDSS. This study addresses this gap by performing Ni plating on heat-treated SDSS. Ni plating can be executed via two methods: electroless and electro-Ni plating. To achieve a uniform plating layer, Ni plating was conducted after heat treatment at temperatures ranging from 1000 °C to 1300 °C, followed by an analysis of the behavior of electroless Ni plating. The heat-treated SDSS displayed three primary characteristics: secondary phase precipitation, solution annealing, and ferritization (ferrite fractions of 61% and 73%). The presence of secondary phases led to a slower Ni plating rate due to its lower reactivity with Ni. Post-solution annealing, the texture of SDSS exhibited the thickest Ni plating layer at the same plating time. As the volume fraction of ferrite increased from 50% to 73% on electrochemical impedance spectroscopy, the resistance of the Ni plating layer decreased from 45 kOhms to 13 kOhms. The lowest resistance was observed when the ferrite fraction reached 73%, attributed to the lower reactivity of ferrite compared to austenite. Both secondary phases and ferrite contributed to reducing the thickness of the electroless Ni plating layer. Therefore, optimizing the volume fraction of SDSS using solution annealing proves beneficial for optimizing Ni plating and enhancing corrosion resistance.