Increasing demands for environmental accountability and energy efficiency in industrial practice necessitates significant modification(s) of existing technologies and development of new ones to meet the stringent sustainability demands of the future. Generally, development of required new technologies and appropriate modifications of existing ones need to be premised on in-depth appreciation of existing technologies, their limitations, and desired ideal products or processes. In the light of these, published literature mostly in the past 30 years on the sealing process; the second highest energy consuming step in aluminum anodization and a step with significant environmental impacts has been critical reviewed in this systematic review. Emphasis have been placed on the need to reduce both the energy input in the anodization process and environmental implications. The implications of the nano-porous structure of the anodic oxide on mass transport and chemical reactivity of relevant species during the sealing process is highlighted with a focus on exploiting these peculiarities, in improving the quality of sealed products. In addition, perspective is provided on plausible approaches and important factors to be considered in developing sealing procedures that can minimize the energy input and environmental impact of the sealing step, and ensure a more sustainable aluminum anodization process/industry.

Metal additive manufacturing (AM) is a layer-by-layer process that makes the direct manufacturing of various industrial parts possible. This method facilitates the design and fabrication of complex industrial, advanced, and fine parts that are used in different industry sectors, such as aerospace, medicine, turbines, and jewelry, where the utilization of other fabrication techniques is difficult or impossible. This method is advantageous in terms of dimensional accuracy and fabrication speed. However, the parts fabricated by this method may suffer from faults such as anisotropy, micro-porosity, and defective joints. Metals like titanium, aluminum, stainless steels, superalloys, etc., have been used—in the form of powder or wire—as feed materials in the additive manufacturing of various parts. The main criterion that distinguishes different additive manufacturing processes from each other is the deposition method. With regard to this criterion, AM processes can be divided into four classes: local melting, sintering, sheet forming, and electrochemical methods. Parameters affecting the properties of the additive-manufactured part and the defects associated with an AM process determine the method by which a certain part should be manufactured. This study is a survey of different additive manufacturing processes, their mechanisms, capabilities, shortcomings, and the general properties of the parts manufactured by them.

Cellular materials have been used in many applications such as insulation, packaging, and protective gear. Expanded polystyrene has been widely used as energy-absorbing liner in helmets due to its excellent cost-benefit relation. This synthetic material can absorb reasonable amounts of energy via permanent deformation. However, in real-world accidents, helmets may be subjected to multi-impact scenarios. Additionally, oil-derived plastic is presently a major source of societal concern regarding pollution and waste. As a sustainable alternative, cork is a natural cellular material with great crashworthiness properties and it has the remarkable capacity to recover after compression, due to its viscoelastic behavior, which is a desired characteristic in multi-impact applications. Therefore, the main goal is to analyze the applicability of agglomerated cork as padding material in safety helmets. First, a finite element model of a motorcycle helmet available on the market was developed to assess its safety performance and to establish a direct comparison between expanded polystyrene and cork agglomerates as liners. Secondly, a new helmet model with a generic geometry was developed to assess the applicability of agglomerated cork as liner for different types of helmets, based on the head injury risk predictions by the finite element head model, YEt Another Head Model (YEAHM), developed by the authors. Several versions of helmet liners were created by varying its thickness and removing sections of material. In other words, this generic helmet was optimized by carrying out a parametric study, and by comparing its performance under double impacts. The results from these tests indicate that agglomerated cork liners are an excellent alternative to the synthetic ones. Thus, agglomerated cork can be employed in protective gear, improving its overall performance and capacity to withstand multi-impacts.