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Electronics

Revolutionizing Ultra-High Temperature Ceramic Manufacturing for Space and Defense Applications

Researchers have demonstrated a new technique that uses lasers to create ceramics that can withstand ultra-high temperatures, with applications ranging from nuclear power technologies to spacecraft and jet exhaust systems. The technique can be used to create ceramic coatings, tiles or complex three-dimensional structures, which allows for increased versatility when engineering new devices and technologies.

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The development of ultra-high temperature ceramics has revolutionized the field of space and defense applications. Researchers have successfully demonstrated a new technique that uses lasers to create ceramics that can withstand extreme temperatures. This breakthrough has significant implications for various industries, including nuclear power technologies, spacecraft, and jet exhaust systems.

“Sintering is the process by which raw materials are converted into a ceramic material,” explains Cheryl Xu, co-corresponding author of a paper on this research and a professor of mechanical and aerospace engineering at North Carolina State University. “For this work, we focused on an ultra-high temperature ceramic called hafnium carbide (HfC). Traditionally, sintering HfC requires placing the raw materials in a furnace that can reach temperatures of at least 2,200 degrees Celsius – a process that is time-consuming and energy-intensive.”

The new technique works by applying a 120-watt laser to the surface of a liquid polymer precursor in an inert environment. The laser sinters the liquid, turning it into a solid ceramic. This process can be used to create ceramic coatings or complex three-dimensional structures.

One way engineers can make use of this technique is by applying ultra-high temperature ceramic coatings to materials that may be damaged by sintering in a furnace. Another method involves additive manufacturing, also known as 3D printing. In this approach, the laser sintering method can be used in conjunction with a technique similar to stereolithography.

In proof-of-concept testing, researchers demonstrated that the laser sintering technique produced crystalline, phase-pure HfC from a liquid polymer precursor. This achievement has significant implications for various industries where technologies must withstand extreme temperatures, such as nuclear energy production.

The researchers also demonstrated that laser sintering could be used to create high-quality HfC coatings on carbon-fiber reinforced carbon composites (C/C). The ceramic coating bonded well to the underlying structure and did not peel away. This is particularly useful for various applications, including hypersonic technologies like missiles and space exploration vehicles.

The new laser sintering technique has several advantages over conventional techniques. It allows for the creation of ultra-high temperature ceramic structures and coatings in seconds or minutes, whereas traditional methods take hours or days. The technique also uses significantly less energy and produces a higher yield, converting at least 50% of the precursor mass into ceramic, compared to the 20-40% conversion rate achieved by conventional approaches.

Lastly, the technique is relatively portable, requiring an inert environment but allowing for easier transportation of equipment compared to powerful, large-scale furnaces.

The researchers are excited about this advance in ceramics and are open to working with public and private partners to transition this technology for use in practical applications. The paper, “Synthesis of Hafnium Carbide (HfC) via One-Step Selective Laser Reaction Pyrolysis from Liquid Polymer Precursor,” is published in the Journal of the American Ceramic Society.

Batteries

“Reviving ‘Dead’ Batteries: The Path to a Greener Future”

Lithium battery recycling offers a powerful solution to rising demand, with discarded batteries still holding most of their valuable materials. Compared to mining, recycling slashes emissions and resource use while unlocking major economic potential. Yet infrastructure, policy, and technology hurdles must still be overcome.

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As the world moves towards a cleaner energy future, the importance of recycling ‘dead’ batteries cannot be overstated. With the growing demand for electric vehicles, portable electronics, and renewable energy storage, lithium has become a critical mineral. According to new research from Edith Cowan University (ECU), tapping into used batteries as a secondary source of lithium not only helps reduce environmental impact but also secures access to this valuable resource, supporting a circular economy and ensuring long-term sustainability in the energy sector.

The global lithium-ion battery market size is projected to expand at a compound annual growth rate of 13 per cent, reaching $87.5 billion by 2027. However, only around 20 per cent of a lithium-ion battery’s capacity is used before the battery is no longer fit for use in electric vehicles, meaning those batteries ending up in storage or on the landfill retain nearly 80 per cent of their lithium capacity.

The Australian Department of Industry, Science and Resources has estimated that by 2035, Australia could be generating 137,000 t of lithium battery waste annually. For the end-of-life batteries, the obvious answer is recycling, said first author Mr Asad Ali, quoting figures from the government which estimates that the recycling industry could be worth between $603 million and $3.1 billion annually in just over a decade.

“By recycling these batteries, you can access not only the remaining lithium – which already purified to near 99 per cent – but you can also retrieve the nickel and the cobalt from these batteries,” Mr Ali noted.

While the lithium retrieved through the recycling process is unlikely to impact the lithium extraction or downstream sectors, the recycling process offered significant environmental benefits when compared with the mining industry. Recycling processes can significantly reduce the extensive use of land, soil contamination, ecological footprint, water footprint, carbon footprint, and harmful chemical release into the environment.

Mining emits up to 37% tons of CO2 per ton of lithium. Recycling processes produce up to 61 per cent less carbon emissions compared with mining and uses 83 per cent less energy and 79 per cent less water as compared to mining.

ECU lecturer and corresponding author Dr Muhammad Azhar said that while Australia holds one of the largest hard rock lithium reserves in the world, the recovery of lithium from end-of-life batteries could provide socio-economic benefits and fulfils environmental sustainability.

The benefits of lithium-ion battery recycling seem obvious, but there are still some challenges to be addressed. The rate of innovation significantly outstrips policy development, and the chemical make-up of the batteries also continuously evolve, which makes the recycling of these batteries more complicated.

However, there is a definite need for investment into the right infrastructure in order to create this circular economy. Several Australian companies are looking at the best ways to approach this, and ECU is exploring the second life of retired lithium batteries, providing a promising future for a greener tomorrow.

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Detectors

“Pioneering Electronics for Particle Physics: Columbia’s Breakthroughs at CERN”

Deep beneath the Swiss-French border, the Large Hadron Collider unleashes staggering amounts of energy and radiation—enough to fry most electronics. Enter a team of Columbia engineers, who built ultra-rugged, radiation-resistant chips that now play a pivotal role in capturing data from subatomic particle collisions. These custom-designed ADCs not only survive the hostile environment inside CERN but also help filter and digitize the most critical collision events, enabling physicists to study elusive phenomena like the Higgs boson.

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The Large Hadron Collider (LHC) is an extraordinary scientific instrument that accelerates particles close to the speed of light before smashing them together. This process produces tiny maelstroms of particles and energy, which hold secrets about the building blocks of matter. However, these collisions also generate enormous amounts of data and enough radiation to scramble electronic equipment.

Despite this challenge, physicists at CERN have made groundbreaking discoveries, including the Higgs boson, whose exact properties still hold mysteries. To advance research further, engineers from Columbia University have collaborated with their colleagues at CERN and other institutions to design specialized silicon chips that can collect data in one of the harshest environments in particle physics.

These chips are called analog-to-digital converters (ADCs), which capture electrical signals produced by particle collisions inside detectors and translate them into digital data. The Columbia-designed ADC chips have been tested and validated for radiation resistance, ensuring they can withstand the severe conditions at LHC for more than a decade.

The collaboration between physicists and engineers has led to the development of two essential components: the trigger ADC and the data acquisition ADC. The first chip enables the trigger system to filter billions of collisions each second, selecting only the most scientifically promising events to record. The second chip will very precisely digitize selected signals, allowing physicists to explore phenomena like the Higgs boson.

This project showcases the power of direct collaboration between fundamental physicists and engineers, creating opportunities for innovation and scientific discovery. As research at CERN advances, Columbia-designed components will contribute to data acquisition systems that support physicists in analyzing phenomena beyond the current limits of knowledge.

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Construction

Scientists Harness Quantum Motion using Ultrafast Laser Trick

Harvard and PSI scientists have managed to freeze normally fleeting quantum states in time, creating a pathway to control them using pure electronic tricks and laser precision.

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Scientists at Harvard University and the Paul Scherrer Institute PSI have made a groundbreaking discovery that could revolutionize our understanding of quantum materials. By using an ultrafast laser technique, they were able to freeze the quantum motion of these materials, paving the way for new technologies such as lossless electronics and high-capacity batteries.

The researchers, led by Matteo Mitrano from Harvard University, used a copper oxide compound called Sr14Cu24O41, which is nearly one-dimensional in structure. This allowed them to study complex physical phenomena that also show up in higher-dimensional systems.

One way to achieve a long-lived non-equilibrium state is to trap it in an energy well from which it does not have enough energy to escape. However, this technique risks inducing structural phase transitions that change the material’s molecular arrangement. Mitrano and his team wanted to avoid this and instead used an alternative approach, where they precisely engineered laser pulses to break the symmetry of electronic states in the compound.

This allowed charges to quantum tunnel from the chains to the ladders, trapping the system in a new long-lived state for some time. The ultra-bright femtosecond X-ray pulses generated at the SwissFEL facility enabled the researchers to catch these ultrafast electronic processes in action and study their properties.

The use of time-resolved Resonant Inelastic X-ray scattering (tr-RIXS) at the SwissFEL Furka endstation gave unique insight into magnetic, electric, and orbital excitations – and their evolution over time. This capability was key to dissecting the light-induced electronic motion that gave rise to the metastable state.

The findings of this study have broad implications for future technologies, including ultrafast optoelectronic devices and non-volatile information storage, where data is encoded in quantum states created and controlled by light.

This work represents a major step forward in controlling quantum materials far from equilibrium, with potential applications in fields such as quantum communication and photonic computing. The use of tr-RIXS at the SwissFEL Furka endstation has opened new scientific opportunities for users, allowing them to study individual and collective excitations in various materials.

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