Thermal management of next-generation high-power microelectronics is increasingly volume-constrained, necessitating advanced hierarchical heat sink topologies. This study proposes a systematic numerical and experimental methodology to evaluate Triply Periodic Minimal Surface (TPMS) architectures augmented with Fins Occupying the Perforated Structure (FOPS). A parametric family of TFS-Gyroid manifolds, with fin heights (HTFS-Gyroid) ranging from 0 to 1.6 mm, was generated and evaluated under forced air cooling. The thermo-hydraulic analysis elucidates a critical engineering trade-off dependent on operational constraints. Under strict energy constraints (e.g., a pumping power of 0.1 W), the intermediate HTFS-Gyroid = 0.5 mm configuration maintains optimal efficiency with a total thermal resistance of 1.47 K/W, compared to 1.64 K/W for the baseline Gyroid (HTFS-Gyroid = 0 mm). Under volume-constrained scenarios, the HTFS-Gyroid = 1.4 mm architecture achieves a peak heat dissipation of 230.2 W (+ 24.2

Additive manufacturing (3D printing) is used to fabricate the complex and customized parts for advanced engineering applications; however, there remains a limited comparative understanding of how different 3D printed parts (core geometries) with the combination of other polymer matrix material (sandwich composite structures) influence under different loading conditions. To address this gap, the present study investigates the mechanical behaviour of sandwich structures incorporating hexagonal, triangular, and tri-hexagonal cores under low velocity impact (LVI) and compression after impact (CAI) loading conditions. The cores were fabricated from polylactic acid (PLA) with a 10

Multi-layer channel heat sinks are widely used in thermal management to improve cooling efficiency. Although increasing the number of channel layers expands the convective heat transfer area, it also leads to the accumulation of solid conduction thermal resistance. Quantifying the interaction between the convective area gain and the thermal resistance penalty helps to determine the optimal number of stacked layers. In this study, periodic circular channel units with 1 to 6 layers are subjected to a uniform heat flux of 20 W/cm2 under fixed dimensional constraints. The maximum base temperature (Tmax) is adopted as the primary performance indicator. First, the thermal impact of layer expansion is evaluated across periodic units under equal pumping power. Based on the variations in maximum base temperature induced by layer addition, two dimensionless metrics, the apparent interlayer enhancement ratio (AIER0) and the intrinsic interlayer enhancement factor (IIEF1), are proposed to quantify the comprehensive effect of layer stacking on heat transfer performance. Subsequently, an evaluation method is established to classify the heat transfer evolution stages according to the metric values: a positive gain region (AIER0 > 0 or IIEF1 > 1), a critical heat transfer saturation point (AIER0 = 0 or IIEF1 = 1), and a performance deterioration region (AIER0 < 0 or IIEF1 < 1). Analysis indicates that IIEF1 shows relatively strong independence from variations in external heat flux and offers a useful reference for selecting the optimal number of layers in multi-layer channel heat sinks.

To address the requirements of moderate strength, high osseointegration, and low bone damage for bone screws applied in non - weight - bearing sites such as ligament reconstruction and bone defect repair, this study designed and fabricated alumina - magnesium silicate (Al2O3/MgSiO3) composite ceramic bone screws using digital light processing (DLP) 3D printing technology. Mechanical compression test results showed that when the doping amount of magnesium silicate (MS) reached 15 wt% (MS15 group), the compressive strength was 222.9% higher than that of the pure alumina (MS0 group). In vitro mineralization experiments and cell experiments indicated that the MS15 group exhibited the most excellent performance in inducing mineralization and stimulating the proliferation and differentiation of osteoblasts. Results of simulated working condition tests showed that the failure torque of the ceramic bone screws reached 3.42 ± 0.42 N m, the pull-out force reached 428.47 ± 10.80 N. Finite element simulation results demonstrated that the shallow thread design effectively reduced stress concentration, verifying the rationality of the structural design. Based on the existing experimental investigations and finite element simulation results, the Al2O3/MgSiO3 composite ceramic bone screws fabricated in this study exhibit favorable performance adaptability and promising application prospects in non-weight-bearing site scenarios, in comparison with their metallic and polymeric counterparts.

Addressing the inherent trade-off between heat transfer efficiency and flow resistance in high-power-density electronics cooling, and drawing inspiration from the concepts of segmented synergy and flow reconstruction, this study proposes a hybrid heat sink design featuring staggered pin-fins in series with TPMS (Gyroid and Diamond) structures (denoted as Hybrid design-G/D). The structures were integrally fabricated using Selective Laser Melting technology. The synergistic mechanisms were elucidated through a combination of experimental measurements and numerical simulations. The results indicate that the hybrid designs effectively balance the low flow resistance of pin-fins with the high heat transfer performance of TPMS structures. Within the volumetric flow rate range of 7.2-36.0 L/min (Re = 142-1220), the Hybrid design-D enhanced the average convective heat transfer coefficient (have) by 14.84%-18.06% compared to the Pin-fin, while reducing the friction factor (f) by 5.25%-7.23% compared to the Diamond structure. Meanwhile, the Hybrid design-G increased have by 1.89%-9.95%, while significantly reducing the f by 25.76%-28.20% compared to the Gyroid structure. Based on the Performance Evaluation Criteria (PEC) using a smooth tube as the baseline, the PEC values for Hybrid design-D and Hybrid design-G ranged from 1.36-1.94 and 1.24-1.87, respectively. Mechanism analysis reveals that the Hybrid design-D establishes a “Relay enhancement” mechanism, converting wake vortices into high-frequency wall disturbances, whereas the Hybrid design-G exhibits a “Disturbance dissipation” characteristic, where fluid disturbances decay rapidly within the Gyroid channels. This strategy provides a superior engineering trade-off solution for pumping power-constrained applications.

Plunger pairs of axial piston pumps frequently fail due to corrosion and wear. Previous studies on friction-assisted jet electrodeposition (FAJED) have primarily focused on coating preparation on the outer surfaces of planar samples, while fewer have addressed coating preparation on the inner cavities of curved structures of deep small blind hole (DSBH). To address the non-uniform distribution of electric fields and metal ions inside DSBH, this study combines FAJED with an inert auxiliary anode (IAA), effectively alleviating this key issue. Electrolytic ion replenishment (EIR) technology not only offsets the IAA’s inherent inability to replenish metal ions during electrodeposition, but also boosts coating thickness and tin content by 44 % and 380 % respectively, while extending electrolyte service life. Additionally, EIR synergizes with jet-enhanced mass transfer to reduce concentration polarization at the cathode interface, facilitating high-rate coating deposition. Thus, the integrated FAJED-IAA-EIR technology achieves the high-quality, efficient preparation of inner-surface coatings on DSBH. The optimally coated sample exhibited a coefficient of friction that was only 56.6 % of that of the uncoated sample. After 125 h of immersion in a corrosive medium, its corrosion current density was merely 0.7 % of that of the uncoated sample, corresponding to a coating protection efficiency of 99.3 %. The proposed FAJED-IAA-EIR method in this study, with high adaptability, simple process, and low cost, provides a new strategy for the efficient fabrication of high-performance coatings in DSBHs and exhibits broad application prospects.

Anisotropy in laser powder bed fusion (LPBF) alloys significantly impacts their performance, but its role in corrosion is not fully understood. This work investigates how a remelting strategy modifies the microstructure and corrosion behavior of LPBFed IN718. In as-built samples, melt track boundaries (MTBs) exhibited slight Nb segregation and relatively high dislocation density, acting as primary sites for pitting corrosion in a 3.5 wt% NaCl solution. Remelting redistributed these Nb-rich phases but increased the overall dislocation density. Consequently, while remelting reduced the corrosion anisotropy by altering the melt track structure, it simultaneously degraded the overall corrosion resistance by compromising passive film stability. This study reveals a critical trade-off between improving microstructural homogeneity and maintaining corrosion performance, offering key guidance for the use of LPBF-IN718 in demanding environments.

Bronze, as a solid self-lubricating material, is widely used in various frictional applications. However, under increasingly common high-frequency and high-load conditions, particularly in the absence of lubricants, bronze layers are prone to rapid wear. Incorporating MoS2 particles to fabricate solid self-lubricating composite coatings is considered a promising approach to improve overall performance in harsh environments. In this study, a friction-assisted jet electrodeposition process is employed to fabricate Cu-Sn-MoS2 composite coatings. This technique enhances particle embedding and surface leveling, producing uniform and dense coatings with significantly improved tribological performance. The methodological framework of this study involves the fabrication of Cu-Sn-MoS2 composite coatings via friction-assisted jet electrodeposition, followed by systematic characterization of their surface morphology, microhardness, adhesion, and tribological behavior. The results show that a MoS2 content of 5 g/L provides a uniform and compact surface with fine grains, sufficient microhardness and adhesion strength, and a continuous lubricating film formed during wear. The wear mechanism was revealed to explain why the Cu-Sn-MoS2 coating exhibited a strong performance in mechanical properties and wear resistance. This content achieves the lowest friction coefficient and the best wear resistance among all tested compositions.

To further enhance the heat transfer performance of the minichannel heat sink, a minichannel heat sink integrating twisted tape and spiral grooves was designed, drawing inspiration from the concept of synergistic enhancement. Based on the similarity or difference in the rotational direction between the spiral grooves and the twisted tape, the spiral grooves are classified into co-rotating and counter-rotating types. The twisted tape and spiral grooves were integrally fabricated using the selective laser melting (SLM) technique. Experimental methods were employed to validate the synergistic enhancement performance of the twisted tape and spiral grooves, while numerical methods were utilized to elucidate the synergistic enhancement mechanism. Within a volumetric flow rate range of 0.606-2.424 L/min, the heat sink with twisted tape and four co-rotating spiral grooves (HS-TCSG4) exhibited Nusselt numbers (Nu) of 115.06-213.43 and friction factors (f) of 0.63-0.87. The heat sink with twisted tape and four counter-rotating spiral grooves (HS-TXSG4) demonstrated Nu of 118.86-243.98 and f of 0.64-0.99. Taking the comprehensive performance evaluation criterion (PEC) as the evaluation index, the PEC of HS-TXSG4 ranges from 1.61 to 1.73. The results of numerical simulations reveal a synergistic enhancement in heat transfer performance. The co-rotating spiral grooves enhance surface heat transfer via increased interfacial contact, while counter-rotating grooves achieve enhancement through effective area expansion, small-scale vortex generation, and thermal boundary layer disruption.

To address the inherent contradiction between heat transfer enhancement and flow resistance in high-power electronic cooling, this study, inspired by Triply Periodic Minimal Surfaces (TPMS), proposes a Gyroid-like topology design strategy based on the “dimensionality reduction and reconstruction” of implicit equations. By mathematically breaking surface spatial isotropy, corrugated plate-fin channels with directional flow-guiding characteristics are constructed. Through numerical simulations (Re = 500–1500), the thermo-hydraulic behavior of the reconstructed topologies is systematically investigated. Results demonstrate that topological orientation decisively governs performance: the streamwise longitudinal wavy configuration induces coherent Dean vortex pairs to achieve highly efficient radial heat transfer; conversely, the transverse configuration suffers from heat transfer deterioration due to resident vortices' thermal isolation, though these stable vortices act as a “flexible vortex cushion” for fluid slip, substantially reducing pressure drop. Furthermore, the surface perforation strategy exhibits a striking “asymmetrical intervention effect”: in transverse geometries, cross-channel jets erode dead zones, enabling heat transfer to outperform solid counterparts; however, in longitudinal ones, perforations disrupt vortex tube integrity, triggering performance degradation. Comprehensive evaluation reveals that all modified configurations exhibit higher j/f1/3 values than the CSF and consistently maintain PEC values greater than 1.0. Notably, the solid longitudinal wavy model (S-LWGLF) attains a peak PEC of 1.42, yielding a 66.3%–87.9% increase in Nu and a 93.5%–135.4% increase in f versus the straight fin baseline. Finally, empirical correlations for Nu and f within a ± 10% error band are extracted, offering a high-fidelity quantitative basis for designing complex TPMS-derived liquid cold plates.

To further enhance the heat transfer performance of the heat sink, a twisted square channel heat sink with grooves was designed, inspired by the concept of synergistic enhancement. The twisted and grooved features were integrally fabricated using the selective laser melting (SLM) technique. Experimental methods were employed to validate the synergistic enhancement of the twisted channel and groove configurations. Within a volumetric flow rate (V) range of 0.48-1.92 L/min, the heat sink with only groove features (HS-G9) exhibited Nusselt numbers (Nu) and friction factor (f) ranging from 23.87 to 53.94 and 0.33-0.25, respectively, whereas the heat sink with only twisted features (HS-T2) demonstrated Nu and f of 25.42-60.87 and 0.35-0.26, respectively. For the heat sinks featuring combined twisted and groove features (HS-G9T2), the Nu ranges from 25.6 to 69.79, while the f varies from 0.35 to 0.27. Using the performance evaluation criterion (PEC) as the metric, HS-G9T2 exhibited a PEC range of 1.09-1.39, outperforming HS-G9 (1.03-1.1) and HS-T2 (1.08-1.22). Numerical simulation results revealed the synergistic enhancement mechanism of heat transfer performance. The groove features enabled localized surface enhancement by disrupting the boundary layer, while the twisted features induced secondary flows to promote fluid mixing and thin the thermal boundary layer. The combination of these two features simultaneously achieved both surface-localized and secondary-flow-based enhancements. Furthermore, as the twist angle and groove count increased, the overall heat transfer performance of the heat sink improved further.

Marine biofouling poses a significant challenge to the marine industry, resulting in substantial economic losses due to increased drag, corrosion, and higher maintenance costs in shipping, aquaculture, and offshore infrastructure. Conventional antifouling coatings exhibit poor durability and pose environmental risks due to their inherent toxicity. With increasing environmental awareness and sustainability demands, research has shifted toward eco-friendly alternatives combining durability with nontoxic mechanisms. Bioinspired antifouling strategies have emerged as a transformative solution over the past decade, particularly in microstructural surface designs that mimic of the surfaces of aquatic organisms such as shark skin, lotus leaves, and coral surfaces. This paper reviews the biochemical formation mechanisms and adverse effects of marine biofouling, systematically examines various bionic antifouling strategies inspired by aquatic organisms, advances in biomimetic microstructural fabrication and performance limitations of single-mechanism approaches in dynamic marine environments. Current challenges—such as reconciling mechanical robustness with cost-effective scalability—are critically analyzed. A key conclusion is the necessity of multifunctional synergy: combining mechanical, chemical, and biological antifouling strategies to address the limitations of individual bionic antifouling technologies. This review outlines future research directions for biomimetic microstructures, leveraging artificial intelligence to optimize structural design, establish a multifunctional collaborative platform integrating diversified biomimetic strategies, and enable on-demand fabrication of long-lasting, cost-effective antifouling coatings. It is anticipated that this work will provide valuable insights for developing efficient, durable, and environmentally sustainable marine antifouling coatings.

Traditional heat exchangers often face challenges under operating conditions that simultaneously require efficient heat transfer and compact space. Triply periodic minimal surfaces (TPMS) have a compact structure and show great potential in terms of thermal performance. To further improve the thermal performance of TPMS structures, this research proposes embedding a layer of Voronoi texture on the surface of the standard Gyroid structure, with the thickness of the Gyroid surface texture adjusted by regulating the thickness (t) of the Voronoi. The effect of Voronoi textures on the thermal-hydraulic performance of Gyroid structures was analyzed, and the mechanism of enhanced heat transfer is explained. The results show that when t = 1.2 mm, the convective heat transfer coefficient (h) of the Gyroid structure was increased by 8.6 %-14.6 %, and the Nusselt number (Nu) was increased by 24.9 %-33.3 %. This is mainly because Voronoi textures can disrupt the flow boundary layer, enhance the mixing of near-wall fluid with the core flow, and increase the heat transfer area simultaneously. With the performance evaluation criterion (PEC) as an evaluation index, the optimal performance is achieved at t = 0.8 mm. The method in this study provides a new design idea for the structural optimization of heat exchangers with TPMS structures.

Fatigue life prediction of laser powder bed fusion (LPBF) components remains challenging because critical defects cannot be reliably identified before service, resulting in large scatter and limited applicability of existing methods. In this study, an integrated framework combining quasi in-situ X-ray computed tomography (XCT), finite element method (FEM), and machine learning (ML) was developed to rapidly screen critical defects and predict fatigue life prior to loading. The results revealed the early-stage evolution of critical defects during crack initiation, and a Murakami-Basquin model was established to quantitatively link defect features with fatigue life. Moreover, the FEM-driven ML approach achieved high-accuracy life prediction within a 1.5x error band, with sigma FEM identified as the dominant factor, followed by defect depth (h) and root area, in agreement with classical fatigue criteria. Demonstrated with Ti6Al4V, this work establishes a critical-defect-driven pathway for fatigue life prediction, providing a broadly applicable methodology for defect-sensitive design and life assessment of LPBF components.

Copper-tin alloys are critical due to the excellent strength, corrosion resistance, and wide range of applications in engineering and manufacturing. However, it was a significant challenge to fabricate Cu-Sn coatings with uniform thickness and chemical composition in deep small blind holes. In this paper, a friction assisted jet electrode-position with a variable diameter auxiliary anode was proposed. The profile of variable diameter anode was optimized by the validated multiphysics simulation. Experiments of jet electrodeposition and friction assisted jet electrodeposition (FJED) were conducted to fabricated samples. Results of characterizations showed that coatings prepared by FJED had uniform thickness and chemical composition. The hardness and adhesion were enhanced by removing hydrogen bubbles. All coatings exhibited an excellent corrosion resistance. The mechanism of FJED was revealed that the variable diameter anode improved the uniformity of coatings, and frictional brush enhanced the mechanical properties of coatings.

Additive manufacturing of Ti-6Al-4V porous dental implants has become a prominent advancement in the field of prosthetic dentistry, providing enhanced osseointegration and biomechanical long-term stability. To further enhance the biomechanical properties, this study designed different porous structures with axial gradient porosity, investigated their stress distribution, and permeability behavior. The implant–bone mechanical interaction was studied using finite element analysis (FEA). To observe the actual mechanical performance and biological characteristics of implants, the experimental analysis was performed on the laser powder bed fusion LPBF-fabricated specimens together with cytocompatibility tests. The FEA results showed that a Gyroid structure with axial gradient porosity of 40–80

This paper focuses on the study of the unique performance of gradient lattice structures in terms of mechanical properties and dynamic characterization to fill the current research gap in this area. A series of IWP (I-graph-wrapped package) structures with various density gradients were designed and then manufactured by using Laser Powder Bed Fusion (LPBF) technology. Mechanical properties were evaluated via quasi-static compression tests, and frequency sweeping tests and simulations analyzed the dynamic characteristics. The results indicate that the density gradient rate, as a key design parameter, significantly affects the structure's compressive elastic modulus, yield strength, and energy absorption capability. Increased gradient rates reduce stiffness and strength but enhance energy dissipation. Additionally, both experimental and simulation results consistently show that the gradient type has a decisive impact on the structure's natural frequency. Positive gradient structures exhibit lower natural frequencies compared to negative gradient structures, accompanied by shifts in the vibration isolation frequency bands, resulting in varying vibration isolation effects across different frequency ranges. This study not only enhances the understanding of the performance characteristics of gradient lattice structures but also establishes a solid foundation for the optimized design and application of such structures in future engineering practice.

Relatively low efficiency of selective laser melting (SLM) in general molding strategy, it is extremely important to seek efficient forming strategy to make fast and precise manufacturing of Ti-based alloy. However, it is found that defects such as porosity and cracks are easily generated during the fast and precise forming process, especially under the ultra-high powder layer thickness (more than 100 mu m) and the corresponding forming strategy. In this paper, the effect of energy input on the melt pool morphology is investigated at different powder layer thickness in SLM, 30 mu m for the low layer thickness (10 mu m-40 mu m) and 90 mu m for the high layer thickness (70 mu m-100 mu m), and melt pool simulations are performed to verify its evolution. Meanwhile, the effect of hatch space on the melt path morphology is investigated at the same powder layer thickness in SLM, 90 mu m for the high layer thickness, and melt path simulations are performed to verify its evolution. The results show that high energy input is a prerequisite for high layer thickness forming, it mainly increases the melt velocity in the melt depth direction, which enhances the melting region by expanding the melt pool morphology, but causes uneven melting path and pore defects. Hatch space has a moderating effect on high energy input, it mainly increases the melt velocity in the melt width direction, which uniform the volume distribution by changing the melt path morphology, reduces the uneven melting path and porosity defects. Finally, the coupling of energy input and hatch space suppress melt pool and melt path defects, and make high layer thickness SLM forming of Ti-based alloy with high quality.

Current research on In718 alloys produced by powder bed fusion-laser beam metals (PBF-LB/M) is mainly focused on the deformation challenges, while porosity has received less attention. This study focused on the porosity of the sub-surface of printed components, which is influenced by thickness, and the need to optimize the contour space to improve the print quality of thin-walled structures. The results illustrated that when the contour space was bigger than 0.04 mm, an asymmetry of contour melt tracks inevitably appeared for thin-walled structures, regardless of the placement angle. It was also found that asymmetric contour melt tracks were caused by the asymmetric hump effect of internal melt tracks. A localized collapse of one side of the internal melt tracks can cause breakage of the contour melt tracks. This is due to the lack of liquid metal at that location during contour melt track formation. Meanwhile, the contour melt track on the opposite side remains mostly undamaged. These broken contour melt tracks could cause asymmetric pore defects during the deposition process. Computational Fluid Dynamics (CFD) simulations were used to validate the contour scanning process. The results showed that a 0.04 mm contour space could significantly reduce the one-sided hump of the internal melt tracks and form a plump contour melt track, which would reduce the problem of local overthickness in the subsequent powder layer during powder spreading processes, thereby reducing the lack of fusion. This research provided valuable theoretical insights and practical guidance for optimizing the PBF-LB/M process for thin-walled In718 parts, with significant implications for engineering applications and academic innovation.

I n the process of selective laser melting (SLM) for precision manufacturing, increasing the powder layer thickness can directly improve the additive manufacturing rate. But the sources of defects in large powder layer thickness are complex and numerous, especially uneven fusion and pores. For 90 µm large powder thickness SLM, it is investigated that for the corrected surface energy density, the effect of line energy density and field width on the top interface morphology and interlayer interface pores. For SLM with a large layer thickness of 90 µm, this study investigates the effect of corrected surface energy density on melt morphology in SLM using numerical simulations, especially the effect of line energy density and field width on the top interface morphology and interlayer interface pores. It investigates the variations of melt morphology at different interfaces, as well as the correlation between the top interface (first interface) morphology and the interlayer interface (third interface) pores. The results show that at a line energy density of 0.30 (+ 0.05) J/mm and a field width of 0.125 (+ 0.015) mm, the melt at the top interface flows backward, the melt at the interlayer interface flows backward, and the melt flow direction at the top interface is the same as that at the interlayer interface so that there is consistency in the melt flow. The melt at the interlayer interface is sufficiently fused, and there are fewer pores at the boundaries of the top and bottom melt channels; the melt at the top interface is sufficiently fused, and there are fewer pores at the boundaries of the neighboring melt channels. Based on the multi-interface numerical model, it can help to reveal the evolution of interface morphology and interface porosity and predict the interlayer interface porosity based on the interlayer interface melt morphology.