Amorphous metallic foils produced by planar-flow casting (PFC) are central to emerging high-efficiency transformer and motor technologies. Despite its promise, the process remains highly sensitive to fluctuations in melt delivery, nozzle–wheel gap, and interfacial heat transfer, leading to free-surface ridging, uneven thickness, and compromised magnetic properties. Conventional monitoring, based on indirect variables or post-cast inspection, provides delayed feedback and cannot resolve the rapid dynamics of the melt–wheel interface.Here we present a data-driven framework for PFC monitoring that integrates synchronised video and infrared imaging with machine-learning analysis. A multimodal dataset of ≈ 200 runs (≈ 300,000 frames, ≈ 20 GB) was collected with front- and side-view cameras and infrared thermal imaging, paired with detailed metadata. Physics-inspired descriptors—including ridge density, reflection intensity, and thermal gradients—were extracted through automated computer vision pipelines and benchmarked against raw-frame deep learning. Analytical proxies, gradient-boosted decision trees, and multimodal fusion networks were systematically evaluated.Feature-based models achieved near-perfect gap prediction, while ridge and thermal-gradient analysis provided direct indicators of foil integrity. Deep-learning fusion models offered complementary robustness but at higher computational cost. Together, these results demonstrate a reproducible approach for linking process dynamics with foil quality, establishing a foundation for automated, closed-loop optimisation of amorphous steel-foil manufacturing.

The thin physical profile of perovskite-based solar cells (PSCs) fabricated on flexible substrates provides the prospect of a disruptive increase in specific power (power-to-mass ratio), an important figure-of-merit for solar cells to be used in space applications. In contrast to recent reports on space applications of PSCs which focus on rigid glass-based devices, in this work we investigate the suitability of flexible PSCs for low-earth orbit (LEO) applications, where the perovskite layer in the PSCs was prepared using either a Ruddlesden-Popper precursor composition (BA2MA3Pb4I13; BA = butylammonium, MA = methylammonium) or a mixed-cation precursor composition (Cs0.05FA0.81MA0.14Pb2.55Br0.45; FA = formamidinium). The flexible PSC devices display a tolerance to high-energy proton (14 MeV) and electron (>1 MeV) radiation comparable with, or superior to, equivalent glass-based PSC devices. The photovoltaic performance of the PSCs is found to be significantly less dependent on angle-of-incidence than GaAs-based triple-junction solar cells commonly used for space applications. Results from a preliminary test of the robustness of the perovskite film when subjected to LEO-like thermal environments are also reported. In addition, a unique deployment concept integrating printed flexible solar cells with titanium-nickel based shape memory alloy ribbons is presented for thermally actuated deployment of flexible solar cells from a rolled state.

Near-net-shape nickel-titanium shape memory alloy (SMA) foils of long length and larger width have been produced by a planar flow casting facility at CSIRO. The advantages of these thin SMA foils include generating a large actuation force, responding faster to thermal stimulus, low cost, etc, which could be used in the field of thermo-sensors. The study focuses on establishing the characteristics of their reversable actuation using several analytical techniques, such as determining phase transformation temperature - i.e. the required temperature for initiating actuation by differential scanning calorimetry, studying the reversable actuation behaviour as a function of actuating time and temperature, and mechanical testing for measuring the actuation stress. The findings of the study will be presented on actuation behaviour in terms of stress, speed, and reversibility, as well as on the parameters affecting the actuation, such as training cycle. The preparation for future digitizing the data accumulated to be utilised in predictive modelling and the potentials of the reversable SMA foils for future industrial applications are discussed.

The effect of rolling and annealing on microstructures and mechanical properties of V-Ti-Ni alloy for hydrogen separation has been investigated in this work. The rollability of the heat treated alloy is better than that of the as-cast alloy. The microstructure resulting from different processing conditions has a significant influence on hardness. Rolling formed anisotropic microstructures and preferential orientation and resulted in dislocation and hardness increasing. Annealing at elevated temperature can reduce hardness, and eliminate the anisotropic microstructure and reduce dislocation caused by rolling deformation, is positive for hydrogen permeability. The present work has illustrated that rolling and the subsequent annealing may be effective and useful for the fabricating of the high hydrogen flux and permeability V-Ti-Ni alloy membranes.

The microstructure, hardness, and precipitate free zones (PFZ) of V55Ti30Ni15 alloys during heat treatment have been investigated in this study. The microstructure resulting from different heat treatment conditions has a great influence on hardness. The microstructure resulting from different heat treatment conditions has a great influence on hardness. Fine NiTi particles precipitate from the supersaturated V-matrix solid solution at 750 °C, increase in quantity until 800 °C, and then dissolve back into the V-matrix at 850 °C. The resultant hardness decreases with temperature until 800 °C, and then increases from 800 to 850 °C. The microstructure containing small NiTi precipitates resulting from the treatment of 18 h at 800 °C has a good soft condition for workability. PFZ formed at the grain boundary of V-matrix during heat treatment was observed. Vacancies depletion in V-matrix maybe led to the formation of PFZ.

The effect of heat treatment on the microstructure, hardness and rollability of V55Ti30Ni15 alloy membranes has been investigated in this study. The microstructure resulting from different heat treatment conditions has a great influence on hardness. Fine NiTi particles precipitate from the supersaturated V-matrix solid solution at temperatures above 600 degrees C, increase in quantity until 800 degrees C, then dissolve back into the V-matrix with a further increase in temperature up to 950 degrees C. The resultant hardness decreases with temperature until 800 degrees C, and then increases from 800 to 950 degrees C. In the present study, a comparison has been made between the rollability of the as-cast and the heat treated state selected for deformation at different rolling temperatures. The percent reduction in thickness of the heat-treated alloy (800 degrees C/18 h) has been found to be up to 30% higher than that of the as-cast alloy, even at room temperature (cold rolling). (C) 2014 Elsevier Ltd. All rights reserved.

Vanadium-based alloys are an emerging alternative to palladium alloys for use in hydrogen-selective alloy membranes. The tendency of vanadium to embrittle, due to its high hydrogen absorption, means it lacks the robustness required for industrial hydrogen separation applications. Alloying vanadium with certain elements reduces hydrogen absorption, but also influences the diffusivity of hydrogen through the bulk material. Consequently, diffusivity and absorption data must be decoupled in order to fully evaluate the influence of various alloying additions on the hydrogen transport properties of vanadium alloys. To address this need, the hydrogen transport properties of V-Al (V95Al5, V90Al10, V85Al15, V80Al20, V75Al25, expressed as atom%) and V-Cr (V95Cr5, V90Cr10, V85Cr15) alloys have been compared through a series of absorption and flux measurements. Pd-coated alloy disks were formed from arc melted and sectioned ingots, and each alloy was subjected to a microstructural analyses and a detailed examination of hydrogen absorption and permeation properties. Additions of Al and Cr reduce the hydrogen absorption and diffusivity of vanadium, with V-Cr alloys exhibiting the greatest hydrogen diffusivity for a given hydrogen feed pressure. The diffusivity of each alloy showed strong concentration dependence. Diffusivity-concentration results have been overlayed with an isoflux curve corresponding to a target flux of 1.0 mol m(-2) s(-1), enabling prediction of the thickness and pressure required to achieve this target flux target for a given alloy. Copyright (C) 2013, Hydrogen Energy Publications, LLC. Published by Elsevier Ltd. All rights reserved.

The ongoing development of H2-selective alloy membranes is gradually increasing the competitiveness of membrane-based H2/CO2 separation against established H2/CO2 separation technologies. Continued advances in terms of their flux, cost and durability, however, will be required before they are widely adopted. Palladium-based alloy membranes have appeared on the market in recent years in the form of thin, supported, alloy films which minimise the Pd consumption (and therefore, cost). Vanadium-based alloys are an emerging alternative to these Pd membranes, and while they potentially offer high H2 flux at much lower cost, they lag behind Pd-based alloy membranes in terms of robustness. The challenge remains to improve the mechanical stability of vanadium (primarily by reducing hydrogen absorption) while minimising the associated permeability penalty. A number of prospective alloying elements have been identified, including Ni, Al, Cr and Ti. This work has shown that substitution of V by Ti increases hydrogen absorption and decreases hydrogen diffusivity, with the overall effect being a negligible change in permeability, but greater hydrogen absorption brings the penalty of poorer mechanical properties. As this is the opposite of the preferred case (i.e., reduced absorption and higher diffusivity), Ti is therefore an unfavourable addition to the base V90Al10 alloy. These findings are in contrast to previous work on V–Ti–Ni alloys, in which the segregation of V, Ti and Ni between multiple phases had the overall effect of increasing hydrogen diffusivity relative to the base V90Ni10 alloy. Whereas the true role of Ti was masked in the V–Ti–Ni system, the single-phase V–Ti–Al system examined here provides a clear illustration of the negative impact of Ti on vanadium solid solution alloy membranes.

Hydrogen-selective membranes formed from body centred cubic alloys can exhibit very high hydrogen permeability, but are prone to brittle failure due to excessive hydrogen absorption. Until issues associated with this are overcome, these materials will not provide a viable alternative to Pd-based membranes. Multi-phase V-Ni-Ti alloys which contain a significant proportion of a BCC component show promise for this application. In order to examine this system in greater detail, alloys of the general form V85-xTixNi15, in which x was varied between 0 and 30 (at.%), were fabricated via arc melting and electrical-discharge wire cutting. Hydrogen permeation measurements of Pd-coated samples at 400 degrees C showed a monotonic increase in permeability with increasing Ti, reaching a maximum of 1.0 x 10(-7) mol H(2)m(-1) s(-1)Pa(-0.5) for the V55Ti30Ni15 alloy at 400 degrees C. The driving force for hydrogen transport is provided by hydrogen absorption, which varies non-linearly with Ti content, and is dependent on the volume fraction of BCC phase, and levels of Ti and Ni solution in the BCC phase. Diffusion coefficients of atomic H through the bulk alloys alloys are dependent largely on microstructure. Whereas the V85Ni15 alloy forms a single phase microstructure, progressive substitution of V with Ti introduced several minor phases; a NiTi-type phase (formed when x >= 5), and a NiTi2-type phase (formed when x >= 10), both as V-containing solid solutions. These minor phases act as barriers to hydrogen diffusion, resulting in a significantly reduced diffusion coefficient compared to single-phase BCC alloys. Importantly, the mechanical stability of these alloys appears to be enhanced by the multi-phase microstructure. These alloys therefore show great promise for meeting future flux, cost and durability targets. (C) 2011 Elsevier B.V. All rights reserved.

Despite their inherent high permeability, unalloyed body-centred cubic (BCC) metals are prone to brittle failure due to their excessive hydrogen solubility. The primary challenge for BCC metal membrane development is therefore to control the solubility to a point where embrittlement is inhibited, while increasing the rate of hydrogen diffusion through the alloy. This can be potentially achieved through alloying, with several V-based BCC alloys exhibiting much improved resistance to embrittlement compared to pure vanadium, while maintaining higher hydrogen permeabilities than palladium alloys. While several binary and ternary V-based alloys have been investigated, a systematic approach is needed to properly evaluate potential alloying elements. In response, alloys of the general formula V85Ni10M5 (atom%), where M is Si, Mn, Fe, Co, Ni, Cu, Pd, Ag, or Al have been fabricated, coated with 500nm of Pd, and their microstructure, hydrogen permeability and hydrogen solubility evaluated. The results obtained showed small compositional variations can lead to large changes in permeability, whereas diffusivity is less-dependent on composition. Formation of multi-phase microstructures can enhance the permeability by increasing the vanadium content and hydrogen solubility of the BCC primary phase. The multiphase V85Ni10Ti5 alloy exhibited a hydrogen permeability of 9.3×10−8molm−1s−1Pa−0.5 at 400°C.

The surface preparation and hydrogen embrittlement in particular are research challenges facing the practical application of vanadium alloy membranes. These two issues are addressed by surface characterization and fracture analysis in order to find the reasons why delamination and crack failures occur during hydrogen permeation. Post-failure analysis of the hydrogen-induced cracking membrane specimen suggests a new failure mechanism for hydrogen embrittlement.

Sheets of a Mg60Cu29Gd11 alloy were produced by twin roll casting with all operational variables, except roll speed, being kept constant. As a function of the roll speed, the structure of the as-cast sheet changed from being crystalline to fully amorphous and then back to crystalline. Through careful selection of the casting speed that is suitable for the selected alloy system and with which the exit temperature of the sheet remains within the supercooled liquid region, a malleable sheet with no surface defects is produced. This work shows that twin roll sheet casting is a viable process for the production of magnesium-based bulk amorphous sheet in a continuous manner and on an industrial scale.

V-based alloy membranes with the body-centred-cubic structure are of great interest for hydrogen separation applications due to their low cost and high permeability. As microstructure can greatly influence membrane performance, internal microstructures resulting from different processing conditions, and their effects on hydrogen permeability, have been investigated for the V-15Ni (wt%) BCC alloy. The initial coarse-grained, as-cast microstructure evolved into a fibrous/lamellar microstructure with a small grain size during cold-rolling deformation, and a significant reduction in hydrogen permeability accompanied this deformation. Subsequent annealing decreased the defect density and increased the grain size and hydrogen permeability. These results show that, aside from compositional optimization of these BCC alloys to minimize the effects of hydrogen embrittlement, the control of microstructural defects is central to the development of high-permeability alloy membranes. (C) 2010 Published by Elsevier B.V.

The suitability of a twin-roll cast (TRC) age-hardenable alloy for wrought applications is explored. A Mg-4Zn (wt.%) alloy, 3mm thick, was cast using the TRC route. Deviating from the traditional practice of homogenization followed by age-hardening in die/sand cast parts, the TRC sheet, cut into small strips, was hot rolled and annealed after homogenization. They were then deep drawn and subsequently age-hardened. The rollability, mechanical properties and microstructure of the alloy at different stages of processing and after forming, are presented and discussed.

Amorphous alloy membranes composed primarily of Ni and early transition metals (ETMs) are an inexpensive alternative to Pd-based alloy membranes, and these materials are therefore of particular interest for the large-scale production of hydrogen from carbon-based fuels. Catalytic membrane reactors can produce hydrogen directly from coal-derived synthesis gas at 400°C, by combining a commercial water–gas-shift (WGS) catalyst with a hydrogen-selective membrane. In order to explore the suitability of Ni-based amorphous alloys for this application, the thermal stability and hydrogen permeation characteristics of Ni–ETM amorphous alloy membranes has been examined. A fundamental limitation of these materials is that hydrogen permeability is inversely proportional to the thermal stability of the alloy. Alloy design is therefore a compromise between hydrogen production rate and durability. Amorphous Ni60Nb40−XZrX membranes have been tested at 400°C in pure hydrogen, and in simulated coal-derived gas streams with high steam, CO and CO2 levels, without severe degradation or corrosion-induced failure. Ni–Nb–Zr amorphous alloys are therefore prospective materials for use in a catalytic membrane reactor for coal-derived syngas.