Iranian Journal of Materials Science and Engineering

HIGHLIGHTS:
 Gd-doping enhances IT-SOFC cathode performance via TPB density.
 Mixed BaSrCoO3−δ phases reduce area-specific resistance.
 Sol–gel thermolysis enables controlled synthesis of Ba0.5Sr0.5−xGdxCoO3−δ.
 Oxygen-vacancy engineering improves ORR kinetics in BaSr1−xGdxCo2O5+δ.
 Ba0.5Sr0.3Gd0.2CoO3−δ shows optimized electrochemical performance.

• A full factorial design was employed to quantify the effects of baseplate thickness, laser power, dwell time, and interruption strategy (layers per interruption) on residual stress and distortion in DED.
• A 3D thermo–mechanical model was developed and experimentally validated using X-ray diffraction (XRD) residual stress measurements.
• Optimized processing conditions reduced residual stress by 43% and dimensional distortion by 33% relative to the baseline setup.
• Baseplate thickness was identified as the most influential factor on both residual stress and distortion, while dwell time showed the least effect.
• The study reports, for the first time, the combined impact of baseplate thickness, dwell time, interruption layer count, and laser power on residual stress and distortion in DED, providing a quantitative basis for process optimization.

 

- Aging always seems to promote hydrotalcite crystallite growth.
- The first two hours of aging promotes zinc incorporation into malachite structure.
- The second two hours of aging seems to partially deplete the malachite phase of Zn.
- Excessive aging deteriorates the post‑calcination BET surface area of the system.
- Higher Cu⁰ surface area values are yielded at moderate aging durations.
 

Highlights

• Rapid thermodynamic modeling predicts secondary phase fractions.
• Experiments validated the thermodynamic screening framework.
• Predicted phase fractions strongly correlate with corrosion.
• ZX31 (Mg-2.6Zn-1Ca) exhibits optimal biocorrosion resistance.
• Optimized secondary phases led to a low rate of (216 µA/cm²).