Search Results (372)

Si powder was deposited onto the surface of Zr-4 alloy via laser cladding to enhance its high-temperature oxidation resistance. The high-power laser radiation and rapid solidification lead to a reaction between Si and Zr, resulting in the formation of a microstructure consisting of lath-like ZrSi₂ and Si-rich phases. The oxidation behavior of the laser-cladding ZrSi coating was evaluated at 1100–1300 °C in water steam. The weight gain follows a parabolic law, and the oxidation activation energy of the ZrSi coating is 182.7 kJ mol⁻¹. The oxides produced by ZrSi₂ oxidation are mainly ZrSiO₄, ZrO₂, and SiO₂, and, under high-temperature conditions, the relative content of ZrSiO₄ in the oxide decreases with increasing temperature. The oxidation of the ZrSi₂ phase induces significant growth stresses, which are susceptible to causing cracks in the oxide, facilitating accelerated oxygen diffusion into the coating. However, the amorphous SiO₂ formed at 1300 °C, which may be softened and fluidized to enable a self-healing effect, can heal the cracks to diminish oxygen permeation into the coating, improving its oxidation resistance. The oxidation resistance of the laser cladding ZrSi coating is better than that of the Zr-4 alloy. Full article

In this study, we investigate the phase transition process during high-alumina, low-lithium glass-ceramics (ZnO-MgO-Li₂O-SiO₂-Al₂O₃) crystallization. The differential scanning calorimetry and high-temperature X-ray diffraction results show that approximately 10 wt.% of (Zn, Mg)Al₂O₄ crystals precipitated when the heat treatment temperature reached 850 °C, indicating that a large number of nuclei had already formed during the earlier stages of heat treatment. Field emission transmission electron microscopy used to observe the microstructure of glass-ceramics after staged heat treatment revealed that cation migration occurred during the nucleation process. Zn and Mg aggregated around Al to form (Zn, Mg)Al₂O₄ nuclei, which provided sites for crystal growth. Moreover, high-valence Zr aggregated outside the glass network, leading to the formation of nanocrystals. Raman spectroscopy analysis of samples at different stages of crystallization revealed that during spinel precipitation, the Q³ and Q⁴ structural units in the glass network increased significantly, along with an increase in the number of bridging oxygens. Highly coordinated Al originally present in the network mainly participated in spinel nucleation, effectively suppressing the subsequent formation of Li_xAl_xSi_1−xO₂, which eventually resulted in the successful preparation of glass-ceramics with (Zn, Mg)Al₂O₄ and ZrO₂ as the main crystalline phases. The grains in this glass-ceramic are all nanocrystals. Its Vickers hardness and flexural strength can reach up to 875 Hv and 350 MPa, respectively, while the visible light transmittance of the glass-ceramic reaches 81.5%. This material shows potential for applications in touchscreen protection, aircraft and high-speed train windshields, and related fields. Full article

Aiming at the problem that traditional fracturing fluids are prone to failure in coalbed methane (CBM) extraction under deep high-temperature and high-shear environments, this study proposes a method to prepare Zr-N-SiO₂ water-based crosslinkers using silane coupling agent-modified nano-silica as the inorganic framework combined with zirconium ions. The optimal fracturing fluid formulation is identified as 0.8 wt% Zr-N-SiO₂ and 0.4% HPAM thickener. This formulation exhibits rapid viscosity recovery under cyclic shear, retains a viscosity exceeding 140 mPa·s at 180 °C, and maintains long-term viscosity stability across 90–180 °C, with operational viability even at 180 °C. Its gel-breaking performance is controllable: with 0.08 wt% ammonium persulfate, viscosity drops to 2.91 mPa·s within 480 min. With 0.10 wt%, it decreases to 2.762 mPa·s in 400 min. This research aims to offer a novel technical approach for efficient and eco-friendly CBM extraction, with significant theoretical and practical value. Full article

In the micro-EDM blind-hole machining of C_f-ZrB₂-SiC ceramics, defects such as bottom surface protrusion and machining fillets are often encountered. The implementation of an electrode-assisted oscillating device has proven effective in improving machining outcomes. To unravel the fundamental reasons behind the optimization enabled by this auxiliary oscillating device, this paper presents fluid simulation research, providing a quantitative comparison of the differences in machining gap flow field characteristics and debris motion behaviors under conditions with and without the assistance of the oscillating device. Firstly, this paper briefly describes the characteristics of C_f-ZrB₂-SiC discharge products and flow field deficiencies during conventional machining and introduces the working principle of electrode-assisted oscillation devices to establish the background and objectives of the simulation study. Subsequently, this research established simulation models for both conventional machining and oscillating machining based on actual processing conditions. CFD numerical simulations were conducted to compare flow field differences between conditions with and without auxiliary machining devices. The results demonstrate that, compared to conventional machining, electrode oscillation not only increases the maximum velocity of the working fluid by nearly 32% but also provides a larger debris accommodation space, effectively preventing secondary discharge. Regarding debris agglomeration, oscillating machining resolves the low-velocity zone issues present in conventional modes, increasing debris velocity from 0 mm/s to 7.5 mm/s and ensuring continuous debris motion. Furthermore, the DPM was used to analyze particle distribution and motion velocities, confirming that vortex effects form within the hole under oscillating conditions. These vortices effectively draw bottom debris outward, preventing local accumulation. Finally, from the perspective of debris distribution, the formation mechanisms of micro-hole morphology and the tool electrode wear patterns were explained. Full article

ZrB₂-HfB₂ composites allow us to obtain materials characterized by the high chemical resistance characteristic of HfB₂ while reducing density and improving sinterability due to the presence of ZrB₂. Since boride composites are difficult-to-sinter materials. One way to achieve high density during sintering is to add phases that activate mass transport processes and, after sintering, remain as composite components that do not degrade and even improve some properties of the borides. The following paper is a comprehensive review of the effects of various and the most commonly used sintering aids, i.e., SiC, B₄C, WC, MoSi₂, and CrSi₂, on the thermo-chemical properties of the ZrB₂-HfB₂ composites. High-density composites with a complex phase composition dominated by (Zr,Hf)B₂ solid solutions were obtained using a hot pressing method. The tests showed differences in the properties of the composites due to the type of sintering additives used. From the point of view of the thermo-chemical properties, the best additive was silicon carbide. The composites containing SiC, when compared to the initial, pure borides, were characterized by high thermal conductivity λ (80–150 W/m·K at 20–1000 °C), a significantly reduced thermal expansion coefficient (CTE ~6.20 × 10⁻⁶ 1/K at 20–1000 °C), and considerably improved oxidation resistance (up to 1400 °C). Full article

The sustainable valorization of electrolytic manganese residue (EMR) and fly ash (FA) presents critical environmental challenges. This study systematically investigates the performance optimization of EMR-FA ceramic composites through the coordinated regulation of raw material ratios, sintering temperatures, and additive effects. While the composite with 85 g FA exhibits the highest mechanical strength, lowest porosity, and minimal water absorption, the formulation consisting of 45 wt% EMR, 40 wt% FA, and 15 wt% kaolin is identified as a balanced composition that achieves an effective compromise between mechanical performance and solid waste utilization efficiency. Sintering temperature studies revealed temperature-dependent property enhancement, with controlled sintering at 1150 °C preventing the over-firing phenomena observed at 1200 °C while promoting phase evolution. XRD-SEM analyses confirmed accelerated anorthite formation and the morphological transformations of FA spherical particles under thermal activation. Additive engineering demonstrated that 8 wt% CaO addition enhanced structural densification through hydrogrossular crystallization, whereas Na₂SiO₃ induced sodium-rich calcium silicate phases that suppressed anorthite development. Contrastingly, ZrO₂ facilitated zircon nucleation, while TiO₂ enabled progressive performance enhancement through amorphous phase modification. This work establishes fundamental phase–structure–property relationships and provides actionable engineering parameters for sustainable ceramic production from industrial solid wastes. Full article

In this work, the development of Al-based metal matrix composites (MMCs) is achieved using hybrid SiC and ZrO₂ reinforcement particles for automotive applications. Powder metallurgy (PM) is employed with various combinations of important process parameters for the fabrication of MMCs. MMCs were characterized using scanning electron microscopy (SEM), X-ray diffractometry (XRD), and a microhardness study. All XRD graphs adequately exhibit Al, SiC, and ZrO₂ peaks, indicating that the hybrid MMC products were satisfactorily fabricated with appropriate mixing and sintering at all the considered fabrication conditions. Also, no impurity peaks were observed, confirming high composite purity. MMC products in all the XRD patterns, suitable for the desired applications. According to the SEM investigation, SiC and ZrO₂ reinforcement components are uniformly scattered throughout Al matrix in all produced MMC products. The occurrence of Al, Si, C, Zr, and O in EDS spectra demonstrates the effectiveness of composite ball milling and sintering under all manufacturing conditions. Moreover, an increase in interfacial bonding of fabricated composites at a higher sintering temperature indicated improved physical properties of the developed MMCs. The highest microhardness value is 86.6 HVN amid all the fabricated composites at 7% silica, 14% zirconium dioxide, 500° sintering temperature, 90 min sintering time, and 60 min milling time. An integrated Particle Swarm Optimization–Support Vector Machine (PSO-SVM) model was developed to predict microhardness based on the input parameters. The model demonstrated strong predictive performance, as evidenced by low values of various statistical metrics for both training and testing datasets, highlighting the PSO-SVM model’s robustness and generalization capability. Specifically, the model achieved a coefficient of determination of 0.995 and a root mean square error of 0.920 on the training set, while on the testing set, it attained a coefficient of determination of 0.982 and a root mean square error of 1.557. These results underscore the potential of the PSO-SVM framework, which can be effectively leveraged to optimize process parameters for achieving targeted microhardness levels for the developed Al-SiC-ZrO₂ Composites. Full article

The improvement of densification and fracture toughness in high-entropy ceramics is important to realizing their practical applications. In this study, SiC whiskers and metal Ni additions were incorporated to solve these problems of high-entropy boride ceramics. The influence of sintering temperatures (1450–1650 °C) on the densification, microstructure, hardness, fracture toughness, and bending strength of (M_0.2Ti_0.2Ta_0.2V_0.2Nb_0.2)B₂-SiC_w-Ni (M=Hf, Zr, or Cr) composites prepared by hot-pressing technology were studied. Results showed that when SiC whiskers and metal Ni additions were used as additives, increasing sintering temperatures from 1450 to 1600 °C promoted the densification of high-entropy boride ceramics. This was mainly attributed to the high sintering driving force. However, when the temperature further increased to 1650 °C, their densification behavior decreased. At a sintering temperature of 1600 °C, these high-entropy borides ceramics all had the highest densification behavior, leading to their high hardness and fracture toughness. The highest relative density was 96.3%, the highest hardness was 22.02 GPa, and the highest fracture toughness was 13.25 MPa·m^1/2, which was improved by the co-function of SiC whiskers and plastic metal Ni. Meanwhile, in the adopted sintering temperature range of 1450 to 1650 °C, the highest bending strength at room temperature of these high-entropy boride ceramics could reach 320.8 MPa. Therefore, this research offers an effective densification, strengthening, and toughening method for high-entropy boride composites at a low sintering temperature. Full article

This study presents a comprehensive finite element investigation into the design optimization of an ultra-high temperature ceramic matrix composite thruster for green bipropellant systems. Focusing on ZrB₂–SiC–Cfiber composites, it explores their thermal and mechanical response under realistic transient combustion conditions. Two geometries, a simplified and a complex full-featured model, were evaluated to assess the impact of geometric fidelity on stress prediction. The complex thruster model (CTM) offered improved resolution of temperature gradients and stress concentrations, especially near flange and convergent regions, and was adopted for optimization. A parametric study with nine wall thickness profiles identified a 2 mm tapered configuration in both convergent and divergent sections that minimized mass while maintaining structural integrity. This optimized profile reduced peak thermal stress and overall mass without compromising safety margins. Transient thermal and strain analyses showed that thermal stress dominates initially (≤3 s), while thermal strain becomes critical later due to stiffness degradation. Damage risk was evaluated using temperature-dependent stress margins at four critical locations. Time-dependent failure maps revealed throat degradation for short burns and flange cracking for longer durations. All analyses were conducted under hot-fire conditions without cooling. The validated methodology supports durable, lightweight nozzle designs for future green propulsion missions. Full article

Membrane fouling poses a significant challenge in the widespread adoption and cost-effective operation of membrane technology. Among different strategies to mitigate fouling, dynamic membrane (DM) technology has emerged as a promising one for effective control and mitigation of membrane fouling. Silicon carbide (SiC) membranes have attracted considerable attention as membrane materials due to their remarkable advantages, yet membrane fouling is still inevitable in challenging separation tasks, such as oil-in-water (O/W) emulsion separation, and thus effective mitigation of membrane fouling is essential to maximize their economic viability. This study investigates the use of pre-deposited oxide DMs to mitigate the fouling of SiC membranes during the separation of O/W emulsions. Among five screened oxides (Fe₂O₃, SiO₂, TiO₂, ZrO₂, Al₂O₃), SiO₂ emerged as the most effective DM material due to its favorable combination of particle size, negative surface charge, hydrophilicity, and underwater oleophobicity, leading to minimized oil droplet adhesion via electrostatic repulsion to DM surfaces and enhanced antifouling performance. Parameter optimization in dead-end mode revealed a DM deposition amount of 300 g/m², a transmembrane pressure (TMP) of 0.25 bar, and a backwashing pressure of 2 bar as ideal conditions, achieving stable oil rejection (~93%) and high pure water flux recovery ratios (FRR, >90%). Cross-flow filtration outperformed dead-end mode, maintaining normalized permeate fluxes of ~0.4–0.5 (cf. ~0.2 in dead-end) and slower FRR decline, attributed to reduced concentration polarization and enhanced DM stability under tangential flow. Optimal cross-flow conditions included a DM preparation time of 20 min, a TMP of 0.25 bar, and a flow velocity of 0.34 m/s. The results establish SiO₂-based DMs as a cost-effective strategy to enhance SiC membrane longevity and efficiency in O/W emulsion separation. Full article

The effect of induction heating on alumina ceramics and alumina ceramic composites based on α-Al₂O₃ nanopowders (additives: SiC, Si₃N₄, SiO₂, ZrO₂) has been examined. Various factors such as the structure, grain size, distribution of elements, hardness, fracture toughness, and wear rate of hot-pressed ceramic materials were assessed. Despite achieving improved densification of alumina ceramics at a higher temperature of 1720 °C, there is a consistent trend toward a decline in hardness and fracture toughness. Heating at lower temperatures of 1300–1500 °C results in the development of a strengthened surface layer with a fine-grained structure enriched with carbon. Therefore, the wear rate behavior of such ceramics differs from the behavior of samples made at higher temperatures of 1600–1720 °C. This fact indicates the presence of a non-thermal microwave effect of induction heating. The incorporation of additives to alumina leads to the formation of novel structures with altered crack propagation patterns. The optimal ceramic composite, containing 5 wt. % SiC, displayed superior hardness and the lowest wear rate when compared to pure alumina ceramics. Across all investigated composites, a short dwell time at 1700 °C results in an enhancement of the mechanical properties. Full article

Crosslinked phenolic resin was prepared using hexamethylenetetramine (HMTA) as a crosslinking agent in hydrochloric acid solution. The ablation-heat-resistant material was prepared by a pressure-assisted RTM (resin transfer molding) process with reinforcing material (quartz fibre 2.5D needle-punched fabric/satin fibre cloth/fibre mesh tire) and matrix (crosslinked phenolic resin). The thermal stability of the cured product was studied by a thermogravimetric analyser (TG and DTG). The mechanical properties, heat resistance, and ablation properties of the composites were tested. The ablation morphology, element analysis, and phase structure of the composites were analysed by scanning electron microscopy (SEM), energy dispersive spectrometry (EDS), and X-ray diffraction (XRD), respectively. The results show that the phenolic resin has a lower initial viscosity and a longer pot life at 80 °C, and a higher carbon residue rate (70.18%). The tensile strength of the composites is close to 40 MPa, the tensile modulus is higher than 1.35 GPa, the compression modulus is higher than 10 MPa, and the elongation at break is higher than 1.55%. SiO₂, SiC, and ZrO₂ ceramic phases were formed after ablation, which effectively improved the ablation performance of the composites. Full article

BaTiO₃-based lead-free ferroelectric films with a large recoverable energy density (W_rec) and a high energy efficiency (η) are crucial components for next-generation dielectric capacitors, which are used in energy conditioning and storage applications in integrated circuits. In this study, grain-engineered (Ba_0.95,Sr_0.05)(Zr_0.2,Ti_0.8)O₃ (BSZT) ferroelectric thick films (~500 nm) were prepared on Si substrates. These films were deposited at 350 °C, 100 °C lower than the temperature at which the LaNiO₃ buffer layer was deposited on Pt/Ti. This method reduced the (001) grain population due to a weakened interface growth mode, while promoting volume growth modes that produced (110) and (111) grains with a high polarizability. As a result, these films exhibited a maximum polarization of ~88.0 μC/cm², a large W_rec of ~203.7 J/cm³, and a high energy efficiency η of 81.2% (@ 6.4 MV/cm). The small-field dielectric constant nearly tripled as compared with that of the same BSZT/LaNiO₃ heterostructure deposited at the same temperature (350 °C or 450 °C). The enhanced linear dielectric response, delayed ferroelectric polarization saturation, and increased dielectric strength due to the nano-grain size, collectively contributed to the improved energy storage performance. This work provides a novel approach for fabricating high-performance dielectric capacitors for energy storage applications. Full article

The microstructure evolution and corrosion behavior of T6-treated Al–Si–Mg alloys were investigated in the presence of Zr and Y additions by using X-ray diffractometry (XRD), optical microscopy (OM), scanning electron microscopy (SEM), electrochemical measurement, and X-ray photoelectron spectroscopy (XPS). The results show that the coarse dendritic α-Al was refined into finer, equiaxed grains by adding 0.2 wt% Zr, which further promoted the formation of a uniform and dense passive layer in 3.5% NaCl solution at room temperature (≈25 °C). In contrast, the Al–Si–Mg alloy containing 0.3 wt% Y exhibited the highest corrosion rate. This phenomenon arises from converting rod-like eutectic Si particles into a spherical morphology, which exacerbates the intergranular corrosion network and enhances galvanic coupling effects. Full article

Nuclear fuel pellets are subject to stress for long periods during the in-pile operation, and this study on high-temperature creep performance is of great significance for predicting the in-pile behaviors and safety evaluation of fuel elements. In the present study, a mixture of ZrC (50 wt%), SiC (46 wt%), and Si (4 wt%) powder was ball-milled for 24 h and then evaporated to obtain ZrC–SiC composite material. ZrC–SiC composite was adopted as the matrix, with ZrO₂ surrogate kernel TRSIO particles and dispersion coated particle fuel pellets prepared with different TRISO packing fractions using the Spark Plasma Sintering (SPS) process. This study on compressive creep performances was conducted under a temperature range of 1373–2073 K and a stress range of 5–250 MPa, elucidating the creep behavior and mechanism of dispersed coated particles fuel pellets, and obtaining the variation laws of key parameters such as creep stress exponents and activation energy with TRISO packing fraction. The results showed that creep stress exponents of the surrogate fuel pellets are between 0.89 and 2.12. The activation energies for high temperature–low stress creep (1873–2073 K, 5–50 MPa) are 457.81–623.77 kJ/mol, and 135.14–161.59 kJ/mol for low temperature high stress creep (1373–1773 K, 50–250 MPa). Based on the experimental results, a high-temperature creep model was established, providing a valuable reference for the research and application of a ceramic matrix dispersed with coated particle fuels. Full article