Sol-gel coatings provide durable surface protection across automotive, construction, and industrial sectors. The global market was valued at USD 7.8 billion in 2022 and is projected to reach USD 16 billion by 2030, representing a 9.4% compound annual growth rate (CAGR). Automotive applications dominate this growth, with car window coatings alone expected to reach USD 6.5 billion by 2030 at an 11.9% CAGR. These coatings offer superior protection for various surface functions, making them increasingly critical for high-performance industrial applications.^[1]

For research purposes, the most common method of preparation of sol-gel layers is dip-coating. However, this method poses challenges when it comes to large-scale and curvilinear surface substrates. Consequently, ultrasonic atomization has been proposed as a promising alternative: it forms uniform, thin sol-gel films from precisely controlled, ultrafine droplets without degrading the hydrolysate structure.^[2] Ultrasonic atomization is based on ultrasonic vibrations that atomise substances from the liquid phase into a spray form, without any adverse chemical processes degrading the original hydrolysate. The size of the droplets is very fine, with volumes expressed in nanoliters, and their size distribution during ultrasonic spraying can be precisely controlled to form uniform thin films.^[3]

While ultrasonic atomization effectively addresses challenges relating to deposition uniformity, the subsequent thermal stabilization of sol-gel layers remains energy-intensive. Conventional thermal curing typically requires elevated temperatures and extended processing times, creating significant barriers for heat-sensitive substrates and high-throughput manufacturing. To address these limitations, we propose light-induced thermal drying as an energy-efficient stabilization method that reduces energy consumption while maintaining coating performance.

In this study, sol-gel coatings were deposited using ultrasonic atomization and subsequently stabilized by light-induced thermal drying process. Controlled light radiation primarily functions as a thermal energy source to promote solvent evaporation. A dedicated photothermal drying stand enable simultaneous irradiation and temperature control. The resulting layers are evaluated to assess the feasibility of light-assisted thermal drying as a low-energy alternative to the industrial sol-gel coating process.

References:

^[1]Global Industry Analysts. Global Sol-Gel Coatings Industry. February 2024.

² Da-Wei Li et al. Large-scale fabrication of durable and robust super-hydrophobic spray coatings with excellent repairable and anti-corrosion performance. Chemical Engineering Journal, 367 (2019). doi: 10.1016/j.cej.2019.02.093.

³V.N. Khmelev et al. Spray Shape Formation at Ultrasonic Spraying Process. International Conference of Young Specialists on Micro/Nanotechnologies and Electron Devices (2018). doi: 10.1109/EDM.2018.8435017.

Fuel cells (FCs), including those based on proton-exchange membranes (PEMFCs), are a promising energy-conversion technology that is currently being used in electrified transport applications¹. There is an ongoing effort to improve their performance, cost, and durability. However, the components of PEMFCs are made of different materials, and the study of their interactions requires the use of multiscale simulation methods.

In this work, we focus on the atomistic-level study of one component of the PEMFC: the microporous layer (MPL). One fundamental aspect of MPLs is water management (2). We aim to investigate this water management by determining wettability characteristics through the computation of the contact angle using molecular dynamics³.

To streamline this process, we present a Python package designed to analyze simulation outputs and predict the contact angle of droplets surfaces. This computational approach allows for the precise quantification of wetting properties. Indeed, by exploiting such simulations, we can understand better how surface treatment at the nanoscale influences macroscopic efficiency. This integration of molecular modeling and data analysis provides a robust predictive framework for designing the next generation of high-performance surface coatings.

[1] A. Z. Weber et al., Chem. Rev., 2014, 114, 10904–10969.

[2] J. T. Gostick et al., J. Power Sources, 2007, 173, 277–290.

[3] Werder, T.; Walther, J. H.; Jaffe, R. L.; Halicioglu, T.; Koumoutsakos, P. J. Phys. Chem. B 2003, 107, 1345–1352.

Nickel-tungsten (Ni-W) alloys are promising alternatives to platinum group metals (PGMs) for electrocatalytic applications, offering a balance between cost-effectiveness and catalytic efficiency. While nickel is an effective catalyst for the hydrogen evolution reaction (HER), its performance can be significantly enhanced by alloying with tungsten. This synergistic effect improves catalytic efficiency, durability, and corrosion resistance, making Ni-W alloys suitable for renewable energy and energy storage applications. However, depositing uniform and stable coatings on porous substrates, such as carbon cloth, presents challenges due to non-uniform current distribution, which can lead to inconsistent deposition and degradation over time.

In this work, we present a novel approach to optimizing Ni-W electrodeposition on porous substrates by integrating experimental techniques with advanced computational modeling. Using the Multi-Ion Transport and Reaction Model (MITReM) combined with Butler–Volmer kinetics, we develop a 3D model to predict current density and layer thickness distributions. We also perform a detailed sensitivity analysis of key deposition parameters, including electrolyte conductivity, charge transfer coefficients, and current densities, to better understand their impact on Ni-W coating uniformity. Experimental results, including thickness distribution measurements, show strong agreement with the simulated data, validating the model's effectiveness.

This study not only provides valuable insights into the electroplating of Ni-W alloys on porous substrates but also offers a scalable, efficient approach to optimizing deposition parameters. The findings have significant implications for improving the plating of electrocatalytic materials and process efficiency, with potential applications in renewable energy and industrial-scale electrochemical systems.

The increasing integration of digital printing technologies in printed electronics and biosensor fabrication has intensified the demand for sustainable polymer substrates that combine environmental compatibility with high mechanical durability, dimensional stability, and printability. Poly(lactic acid) (PLA), as a renewable, compostable, and non-toxic biopolymer, represents an attractive alternative to conventional fossil-based substrates commonly used in printed electronic systems. However, the limited resistance to thermo-mechanical stresses of PLA significantly restricts its applicability in digitally printed electronics and disposable biosensor platforms, where repeated handling, deformation, and processing stability are critical.

In this study, neat PLA and PLA-based copolyester cast film sheets was developed and subsequently biaxially stretched to induce molecular orientation via strain-induced crystallization. This approach was employed to enhance the mechanical toughness, dimensional stability, and durability of the films under conditions relevant to digital printing and biosensor integration. The results demonstrated that biaxial orientation improved the durability of PLA-based cast films, enabling their use as sustainable substrates for digitally printed conductive patterns, electronic components, and biosensing platforms. Thus, this work provides a viable pathway toward environmentally friendly substrates suitable for next-generation printed electronics and disposable biosensors, specifically for cost-effective glucose biosensors.

Acknowledgements

Funded by the European Union under the GA no 101070556. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or RIA. Neither the European Union nor the granting authority can be held responsible for them.

Driven by the need for eco-friendly alternatives to fossil-fuel-based products, there has been a growing interest regarding sustainable materials and green chemistry. This shift is particularly evident in the polymer sector, which has been transitioning away from traditional sources over the last several decades. Currently, most industrial epoxy resins rely on Bisphenol A (BPA), a petroleum-based chemical known for its reproductive toxicity. This work explores the development of sustainable thermosetting resins and their subsequent use in Plating on Plastics (PoP) technology. By utilizing sugar-derived precursors such as itaconic acid and isosorbide, epoxy and epoxy-acrylate resins were successfully synthesized. The study optimized reaction parameters and utilized characterization methods—including NMR, FTIR, and EEW titration—to confirm the chemical structure and the successful incorporation of epoxy and acrylate functional groups. Thermal and mechanical assessments (via DSC, TGA, and DMA) revealed that the performance of these bio-derived resins is comparable with standard BPA-based systems when cured under similar conditions. Furthermore, these resins were developed into composite coatings by incorporating nickel salts and applied to ABS surfaces. This approach seeks to replace hazardous traditional PoP steps, specifically eliminating the use of toxic hexavalent chromium in the etching phase and expensive palladium catalysts during activation. The successful loading of nickel salts into the bio-polymeric matrix highlights the potential of these materials for functional coatings. Ultimately, this study validates that bio-based thermosets are viable substitutes for conventional epoxies, offering a path toward more sustainable and less hazardous plastic metallization processes.

Acknowledgements: This research has received funding from the European Union’s Horizon Europe research and innovation programme under Grant Agreement No. 101058699 (Project FreeMe).

The transition toward a hydrogen-based economy necessitates the development of advanced materials capable of mitigating hydrogen permeation in Type IV high-pressure storage tanks. This study investigates the synthesis and characterization of silica-based barrier coatings produced via the sol-gel method and applied to PET substrates.

Permeability tests were conducted across a wide pressure range, from low-pressure conditions (2 bar) to high-pressure environments (400 bar). Results demonstrate that the amorphous silica network significantly enhances its barrier properties. Moreover, it was shown that modifications introduced to the silica network, such as doping or aging, improve the barrier properties of the coatings even more. Tests revealed a significant reduction in the permeability coefficient for multilayered and doped coatings, with some samples showing up to 40% improvement in gas transmission rate compared to standard configurations. These findings highlight the strong potential of sol–gel-derived silica-based coatings as effective barrier solutions for next-generation hydrogen storage systems, contributing to improved safety, durability, and performance of Type IV tanks.

Copper is an extremely important metal applied in electronics, transportation, or construction. Despite its great corrosion resistance, Cu can undergo pitting corrosion under certain conditions (polluted air and water). Furthermore, Cu is a component of brass - an alloy that many historic artefacts are made of. Brass similarly to Cu is relatively resistant to corrosion. However, prolonged exposure to atmospheric corrosion may result in its selective corrosion called dezincification leading to severe damages. Thus, it is crucial to develop an efficient and ecological method of protecting aforementioned materials against corrosion, with particular emphasis on historic heritage artefacts, especially due to their cultural values being lost irreversibly.

Coumaric acid (CA) is one of the derivatives of cinnamic acid and is considered to be a green corrosion inhibitor. This compound has been proved to be an efficient corrosion inhibitor for Fe and steel [1]. Our previous investigation results have also proved CA inhibitory effect on corrosion of the second brass component – Zn, similarly as in the case of caffeic acid [2]. However, no reports have been found on application of coumaric acid as a corrosion inhibitor for brass or Cu.

In this study, the impact of coumaric acid coatings on Cu and brass corrosion has been investigated with the application of electrochemical methods such as measurement of open circuit potential (OCP), potentiodynamic polarisation (PDP) and electrochemical impedance spectroscopy (EIS). Different number of CA layers were deposited from CA ethanol solutions of different concentrations. Results indicate that the best inhibition efficiency (86%) for Cu was obtained for 10 layers deposited from 10 mM CA solution, whereas the best inhibition efficiency (70%) for brass was obtained also for 10 layers but deposited from 20 mM CA solution. The EIS measurements confirmed the PDP results. Applied coatings do not change the colour and the appearance of the protected samples indicating their possible application in the case of historic heritage artefacts.

Acknowledgement: This work has been completed while the first author was the Doctoral Candidate in the Interdisciplinary Doctoral School at the Lodz University of Technology, Poland.

References

[1] Quites D., et al., ACS Applied Engineering Materials 2023, 1, 546-555

[2] Kucharek A., et al., Molecules 2025, 30(17), 3648

The EnWaRec project addresses the nexus between energy and water in hydrogen-based steelmaking by implementing with an holistic approach the recovery of waste heat and water from cooling and gas washing circuits including internal energy and water reuse. To overcome traditional barriers of fouling, scaling, and corrosion, the project integrates real-time process monitoring, thermally stable chemical treatments, and specialized anti-wear coatings. These innovations enable the use of microturbines for hydropower, high-temperature heat pumps for steam generation, and membrane distillation for water recovery. By optimizing these processes through predictive simulation software, EnWaRec will provide technologies and tools opening recovery of waste heat and water.

RINA-CSM in EnWaRec intends to model ADI Steel producer cooling water circuit plant. The model evaluates maximum energy extraction and micro-turbine operating ranges using real-time industrial data and simulations. Moreover, will be tested and defined steel materials suitable for industrial water circuit by electrochemical tests as Open circuit potential (OCP) and polarization curves measurements in electrolyte simulating ADI industrial water.

Tailored silicon alkoxides (as TEOS, GPTMS) based sol-gel coatings will be developed for applications to prevent scaling and corrosion on heat exchangers surfaces, cooling nozzles and turbine inner parts. The aim is to achieve very thin coatings, with low wettability, also adaptable to complex component geometries. The thin layer will not impact the flow and the section of the turbine inner parts and cooling nozzles. Moreover, the low wettability will disfavour the settlement and growing of scaling and corrosion agents of the industrial water on heat exchangers, maintaining heat transfer efficiency.

The authors are presenting this work on behalf of the EnWaRec Consortium

This work was supported by the Research Fund for Coal and Steel (RFCS) under grant agreement No 101216643. The project EnWaRec funded this research.

To integrate the Safe and Sustainable by Design (SSbD) framework into advanced material development, there is a critical need for robust tools and Decision Support Systems (DSSs). These enable early-stage evaluation of safety, sustainability, and performance trade-offs.

Within the NICKEFFECT project, we have developed a prototype of such a tool, consisting of a Material and Process Information Management System (M&P IMS) coupled with a series of modular analysis components. These include machine learning algorithms for performance optimization, early-stage safety assessment modules, and a simplified life-cycle analysis (LCA) engine to evaluate environmental impacts.

The M&P IMS employs a carefully designed schema linking materials, batches, samples, equipment, tests, and chemical substances—ensuring full traceability and enabling structured search, comparison, and reuse of data. On top of this knowledge base, the DSS offers modular applications that transform raw experimental data into actionable insights: comparing performance, conducting regulatory risk assessments, and estimating environmental impacts, all within a unified web-based interface. It caters to both experts and non-specialists, enabling SSbD decision-making early in the development pipeline and minimizing costly redesigns.

In the contribution we will show how the system can be utilized to support the replacement of Platinum group metals in ferromagnetic coating materials.

High-temperature polymer electrolyte membrane fuel cells (HT-PEMFCs) offer improved tolerance to fuel impurities, simplified water management, and enhanced reaction kinetics relative to low-temperature systems. Despite these advantages, their large-scale deployment is still limited by the high platinum loadings required at both electrodes: the anode, to sustain efficient hydrogen oxidation (HOR) under elevated temperatures, and especially the cathode, where oxygen reduction reaction (ORR) kinetics dominate performance losses and cost. Reducing Pt content at both electrodes without compromising activity or durability remains a critical challenge. This work presents a scalable approach to the fabrication of electrocatalysts based on electrodeposited core-shell nanoparticles, enabling a drastic reduction in Pt loading and achieving notable HT-PEMFC performance.

Catalyst nanoparticles were electrodeposited directly onto the microporous layer (MPL), which already contains conductive carbon-based supports, ensuring precise control over particle size, distribution, and metal content, and achieving ultra-low Pt loadings. Beyond catalyst synthesis, this study focuses on the critical role of ionomer content within the catalyst layer on membrane electrode assembly (MEA) performance. While ionomer is essential for proton transport and catalyst utilization, excessive or insufficient ionomer concentrations can severely hinder gas diffusion, electronic connectivity, and active site accessibility. Systematic optimization of ionomer concentration revealed a narrow operating window in which electrodeposited nanoparticle catalysts exhibit maximal performance. At optimized ionomer loadings, improved triple-phase boundary formation and reduced mass transport losses were observed, resulting in enhanced cell voltage and power density.

The combined strategy of electrodeposition-based catalyst fabrication and ionomer optimization demonstrates a viable pathway toward high-performance HT-PEMFCs with drastically reduced Pt loadings. These findings underscore the importance of integrated catalyst-ionomer design in MEA engineering and provide valuable insights for the development of next-generation, low-cost fuel cell technologies.