Search Results (580)

Red mud, as a by-product of alkaline regeneration of alumina, has limited application due to its strong alkalinity, fine particle size, and complex composition. In this work, red mud porous ceramics with uniform pore size distribution and high mechanical strength were prepared using a foam-gel casting method. The effects of solid loading and sintering temperature on the microstructure of porous ceramics were systematically investigated. The porosity of red mud-based porousceramics sintered at 1150 °C with a solid content of 60.4% was 33.7%, and the maximum compressive strength was 54.70 MPa, while the porousceramics prepared with a solid loading of 34.1% and sintered at 1050 °C achieved a maximum porosity of 79.7% and a compressive strength of 2.36 MPa. Increasing the solid loading reduced porosity and enhanced compressive strength, allowing for the tailoring of mechanical properties to meet specific application requirements. Higher sintering temperature promoted the formation of the liquid phase, enhanced particle bonding, and further improved the compressive strength. Additionally, toxicity leaching tests confirmed that the ceramics are environmentally safe, with leachate levels well within regulated limits. These results demonstrate the potential of foam-gel casting as an effective route for transforming red mud into value-added porous ceramics, thereby contributing to sustainable waste utilization and broadening the application prospects of red mud-based materials. Full article

Porous, crystalline gamma-Al₂O₃ coatings with a thickness of (6 ± 0.5) μm and a uniform distribution of rare earth (RE) dopants are synthesized by plasma electrolytic oxidation of aluminum at a current density of 150 mA/cm² in a boric acid and borax (BB) solution containing added RE oxide particles (Ho₂O₃, Tb₄O₇, and Pr₆O₁₁) at concentrations of 1, 2, and 4 g/L. The concentration of RE oxide particles in the BB solution determines the amount of RE elements incorporated into the coatings but does not significantly affect their surface morphology, crystal structure, or light absorption properties. The coatings exhibit high absorption in the middle/near-ultraviolet region, characteristic of Al₂O₃. Typical 4f-4f transitions of Ho³⁺, Tb³⁺, and Pr³⁺ are observed in the photoluminescence spectra. Photocatalytic evaluations using methyl orange degradation under simulated solar irradiation show that RE doping significantly enhances photocatalytic efficiency. Peak degradation efficiencies are achieved at a concentration of 4 g/L for all RE oxides. After 8 h of irradiation, maximum degradation reaches 88%, 92%, and 85% with pseudo-first-order rate constants (k_app) of about 0.274 h⁻¹, 0.339 h⁻¹, and 0.232 h⁻¹ for coatings synthesized in BB with 4 g/L Ho₂O₃, Tb₄O₇, or Pr₆O₁₁, respectively. In comparison, the pristine Al₂O₃ coating achieves only about 50% degradation (k_app ≈ 0.087 h⁻¹). Photoluminescence indicates that RE³⁺ ions serve as effective charge-carrier traps, suppressing electron–hole pair recombination. RE-doped Al₂O₃ coatings demonstrate exceptional structural stability and reusability over six cycles, highlighting their potential for sustainable wastewater remediation. Full article

Metal anodes offer substantially higher specific and volumetric capacities than conventional anode materials such as graphite in lithium-ion batteries or hard carbon in sodium-ion batteries. However, the integration of metal anodes into solid-state batteries poses significant challenges, particularly with respect to processing, interfacial stability, and cell assembly. Anode-free solid-state batteries (AFSSBs) address these challenges by eliminating the pre-installed metal anode, instead forming the metal in situ during the initial charging (formation) step. In anode-free solid-state batteries, the quality of the interfacial contact is particularly critical, as insufficient contact can lead to locally increased current densities. Consequently, the initial metal plating during the formation step plays a decisive role in determining the homogeneity and stability of the anode interface. Furthermore, conventional battery-grade copper foils (~10 µm) are considerably thicker than required for the targeted C-rates and are difficult to use as stand-alone anode-free current collectors, thereby hindering the industrial production of anode-free solid-state batteries. In this publication, we demonstrate the application of atmospheric plasma spraying (APS) to fabricate thin copper current collectors directly on the ceramic solid electrolytes LAGP (lithium aluminium germanium phosphate) and BASE (beta-alumina solid electrolyte) with superior interface contact. No mechanical damage or diffusion of copper into the solid electrolyte nor formation of secondary phases at the interfaces were observed in SEM or EDS despite the elevated process temperature. LAGP with a thickness as low as 300 µm was successfully coated and subsequently used for plating/stripping experiments. Finally, dense sodium metal was plated at the copper-substrate interface of a 1.4 mm thick BASE sample. Full article

During the high-temperature deposition of tungsten thin films on alumina ceramic substrates, the inherent mismatch in thermal expansion coefficients frequently triggers interfacial delamination, where uncontrollable factors in stochastic surface topographies can exacerbate localized stress concentrations. To resolve these interfacial failures, the enhancement of interfacial adhesion through a deterministic surface microgroove design is identified as the general objective of the present research. Within this framework, the establishment of a robust quantitative mapping between the transverse scratching offset distances and the resultant periodic microgeometry is first pursued as a specific experimental objective. This methodological approach effectively transforms the stochastic nature of the substrate into deterministic geometric configurations. Second, a specific numerical objective is fulfilled by evaluating the interfacial stress redistribution and damage evolution utilizing refined thermomechanical coupled simulations based on the cohesive zone model. The integrated findings demonstrate that optimizing the microgroove spacing effectively governs the morphological transition and broadens stress diffusion pathways to mitigate thermal mismatch effects. Specifically, the structural optimization at a spacing of 28.8 µm facilitates an approximately 31.8% reduction in the maximum interfacial stress and a 10% decrease in the average film stress compared to the 13.6 µm spacing. Finally, this research clarifies the underlying mechanisms of stress buffering and provides a rigorous engineering methodology for the structural design of reliable high-performance ceramic–metal interfaces in extreme environments. Full article

Inspired by the Bouligand helicoidal architecture of the dactyl club of the peacock mantis shrimp, this study employed direct ink writing (DIW) 3D printing to construct a three-level synergistic toughening system composed of nano-SiO₂, microscale flake alumina, and a macroscale helicoidal structure. The effects of nano-SiO₂ content, Bouligand helix angle, and flake alumina content on the flexural strength and fracture toughness of the composite ceramics were systematically investigated. The results showed that the optimal nano-SiO₂ addition was 7 wt%, yielding a fracture toughness of 1.03 MPa·m^1/2, which was 13% higher than that of pure alumina. The introduced intergranular glassy phase transformed the rigid grain-boundary bonding into a moderately strong gradient interface, resulting in higher fracture toughness for all SiO₂-containing samples than for pure alumina. The Bouligand structure further increased the fracture toughness to a maximum of 1.45 MPa·m^1/2 at a helix angle of 10°, representing a 39% improvement over the 0° sample. When microscale flake alumina was incorporated into the optimal matrix containing 7 wt% SiO₂, the best overall mechanical performance was achieved at a flake alumina content of 5 wt%, where the flakes directly dissipated fracture energy through pull-out, fracture, and bridging mechanisms. The synergistic effect of the three structural levels was most pronounced at a helix angle of 20°, at which the sample containing 5 wt% flake alumina achieved a fracture toughness of 2.07 MPa·m^1/2 with almost no loss in flexural strength, corresponding to a 113% improvement over the sample without flake alumina. These results demonstrate that three-level synergy can be achieved through nanoscale interfacial optimization, microscale energy dissipation by reinforcing phases, and macroscale crack deflection induced by the helicoidal structure, thereby providing important theoretical and experimental support for the multiscale design of high-performance bioinspired ceramic materials. Full article

Alumina is a commonly used ceramic material known for high permittivity, low dielectric loss, good thermal conductivity, and low cost. In the development of electronic devices, the size effect of powdery materials is crucial, particularly in applications involving composite materials. This study introduces the field-enhancement method (FEM) to measure the resonant frequency ($f_0$) and the quality factor (Q) of alumina powders packed in a Teflon container and placed on top of the central rod in the proposed cavity. The measured resonant condition ($f_0$ and Q) is mapped to a contour plot and simulated using a high-frequency structure simulator (HFSS). The contour mapping technique allows the researchers to obtain the effective complex permittivity of alumina–air composites. The complex permittivity of the alumina powder is retrieved using a hybrid model and the effective medium theories (EMTs), respectively. The Landau–Lifshitz–Looyenga (LLL) model is compared with the results using the hybrid model for its applicability. The dielectric constant and the loss tangent of the alumina powder are found to increase as the powder size reduces. A power relation is found to fit the obtained permittivity, covering sizes ranging from nanometers to micrometers, and a surface-charge scaling argument is proposed to explain the observed trend. This finding opens a new avenue for manipulation of permittivity in composite materials and has potential applications in stealth/absorber technology and as a self-limiter for grain growth during sintering. Full article

In this work, kyanite-reinforced alumina ceramics were prepared using the prestress reinforcement method and the particle enhancement method. The effects of different preparation methods on the mechanical properties and microstructures of kyanite-reinforced alumina ceramics were investigated. The results showed that, compared to the pure alumina ceramic, the prestressed alumina ceramic (labeled as P-Al₂O₃) prepared by the prestress reinforcement method exhibited a significant improvement (31% higher than that of pure alumina) in flexural strength. This is mainly attributed to the fact that the compressive stress existing on the surface of P-Al₂O₃ inhibited crack propagation; therefore, the fracture energy and strength were increased. However, due to the numerous pores and cracks in the fracture surface caused by the decomposition reaction of kyanite, the alumina composites fabricated through the particle enhancement method (labeled C-Al₂O₃) displayed lower flexural strength and hardness than those with P-Al₂O₃. Additionally, an increase in kyanite content led to a decrease in properties such as flexural strength, Vickers hardness, density, the elastic modulus, and the thermal expansion coefficient, while resulting in an increase in porosity. This work demonstrates the importance of using a suitable preparation method aligned with the specific composite. Full article

3D printing represents a promising fabrication technology for silica-based ceramic cores, which are essential components in the casting of turbine blades, but it is faced with poor high-temperature dimensional stability. Herein, alumina nanopowder was utilized as a modifier agent in digital light processing (DLP) 3D printing of silica-based ceramic cores, and systematic investigations were conducted on the microstructure and properties of ceramic cores throughout sintering and casting dependent on the content of alumina nanopowder (0–1.0 wt.%). Alumina nanopowder increased the sintering barrier of fused silica, significantly reducing the shrinkage in sintering and simulated casting, while improving high-temperature dimensional stability. Even though the alumina nanopowder led to decreased room-temperature and high-temperature flexural strengths attributed to inhibited densification and crystallization, the strengths met investment casting requirements after PVA solution strengthening. Excessive alumina nanopowder (0.8–1.0 wt.%) resulted in poor interlayer bonding and particle spalling, unfavorable to the structural integrity in casting. The optimal alumina content was 0.6 wt.%, which balanced sintering shrinkage of 1.86%, shrinkage of 4.41% after simulated casting, room-temperature flexural strength of 11.13 MPa, high-temperature flexural strength of 31.29 MPa, high-temperature creep deformation of 0.55 mm, and surface roughness of 1.815 μm. This research proposes an effective strategy for the optimization of 3D-printed silica-based ceramic cores in the manufacture of complex hollow turbine blades. Full article

Plasma Enhancement Gases (PEGs) are a set of gaseous elements studied for converting plasma thermal energy and mitigating the heat load on the plasma-facing components of a tokamak fusion power plant. In particular, PEG separation is part of the Plasma Exhaust Processing System of EU-DEMO. This work addresses issues related to the purification of Deuterium-Tritium fusion fuel, introducing ceramic membranes having a low specific area to process and purify unburned streams throughout the fuel cycle. A commercial microporous mono-channel α-Alumina membrane was considered for the evaluation of its efficacy in separating binary mixtures of H₂ with a PEG (Ar and N₂), D₂, or He. Several tests were carried out, feeding equimolar streams of H₂-Ar, H₂-N₂, D₂-Ar, and He-Ar, and the separation factor (SF) of the aforementioned binary mixtures was experimentally assessed. Finally, based on the results from the experimental campaign, the separation factors of several gas mixtures that had not been experimentally investigated were theoretically calculated and proposed. Full article

This paper proposes a temperature measurement and system identification method for confined cavity explosions based on an improved type C thermocouple sensor. On the one hand, to address the extreme conditions caused by high-speed fragments and intense shock waves in an enclosed explosive environment, a thermocouple probe structure employing alloy strips of different widths with an alumina insulating layer in between is designed. By optimizing the strip width, the contact issues arising from edge-cutting burrs are effectively suppressed, thereby significantly enhancing the electrical insulation performance and overall reliability of the sensor. Additionally, a wedge-shaped alumina ceramic piece is designed to secure the thermocouple probe, further improving its structural stability under impact conditions. On the other hand, to tackle the highly nonlinear and multi-field coupled characteristics of the post-explosion temperature field, a system identification method based on the least square method is proposed. This method constructs a polynomial function in terms of radial distance and time variables, enabling effective reconstruction of the temperature field from limited measurement points. It provides a useful reference for understanding of the temperature distribution in confined cavity explosions and supports improved estimation of the temperature field. Finally, experimental results demonstrate that the improved sensor exhibits good survivability and measurement reliability under extreme explosive conditions. Meanwhile, the reconstructed temperature field model shows high fitting accuracy and good capability for describing the temperature distribution, confirming the effectiveness of the proposed identification method. Full article

Refractories are advanced ceramics essential for high-temperature operations in the steel, glass, cement, and power sectors. In response to growing sustainability requirements, life cycle assessment (LCA) is increasingly applied to quantify and mitigate their environmental impacts. However, current refractory-related LCA research remains limited by the scarcity of comprehensive inventories and the lack of systematic evaluation of uncertainties affecting results and ecodesign strategies. This study addresses these gaps by presenting the first published LCAs of tabular alumina, white fused alumina, and fused cast high-alumina block production, thereby expanding the environmental knowledge base across alumina products. The analysis shows that uncertainties in characterization models can significantly influence impact-category prioritization, underscoring the need for robust interpretation frameworks. Differences in category criticality across methodological levels and LCIA methods are examined, highlighting the suitability of the Product Environmental Footprint (PEF) approach for refractory applications due to its explicit consideration of model uncertainty and comprehensive coverage of impact categories. Results indicate that alumina products significantly contribute to climate change, fossil resource depletion, particulate matter formation, acidification, freshwater eutrophication, and non-cancer human toxicity. Energy supply constitutes the main environmental hotspot, both through its direct consumption and its indirect contribution during raw material preparation. Red mud disposal is also a major contributor to impacts associated with calcined alumina production. Based on these insights, improvement strategies are proposed, demonstrating the value of LCA as an ecodesign tool. Scenario analysis for fused cast high-alumina block further quantifies the potential for impact reduction under varying operational conditions. Full article

Al₂O₃-Cu ceramic-metal composites containing 2.5 vol.% of a metallic phase were fabricated using the Pulse Plasma Sintering (PPS) method in order to evaluate the influence of sintering temperature on densification, microstructure, and mechanical performance. Consolidation was carried out at 1200 °C, 1250 °C, 1300 °C, and 1400 °C under uniaxial pressure with a short sintering time of 3 min. Regardless of the processing temperature, all composites exhibited very high relative densities exceeding 99% of the theoretical value, indicating the high efficiency of PPS in densifying Al₂O₃-Cu systems while suppressing copper leakage. X-ray diffraction confirmed the presence of only two phases, Al₂O₃ and Cu, with no secondary reaction products. Microstructural observations revealed irregular copper particles and areas of dispersed metallic phase, whose proportion decreased with increasing sintering temperature due to accelerated matrix densification and copper immobilization. Grain growth in the alumina matrix was strongly temperature-dependent, with the average equivalent grain diameter increasing from 0.49 µm at 1200 °C to 2.35 µm at 1400 °C. Hardness decreased from 19.5 ± 2.8 GPa to 12.2 ± 1.6 GPa with increasing temperature, whereas fracture toughness reached a maximum of 5.42 ± 0.65 MPa·m0.5 at 1400 °C. The highest strength under monotonic compression conditions was obtained for samples sintered at 1300 °C, indicating an optimal balance between densification and microstructural coarsening. These results demonstrate that PPS is an effective method for producing dense Al₂O₃-Cu composites with tailored microstructure and mechanical properties. Full article

Polymer–ceramic hybrid composites are emerging as attractive candidates for lightweight, corrosion-resistant absorber components in solar thermal collectors; however, their adoption is constrained by the intrinsically low thermal conductivity of polymers, processing-induced anisotropic heat transport, interfacial thermal resistance at tube/laminate joints, and durability challenges under outdoor exposure. This review provides a collector-centered synthesis of polymer–ceramic hybrid materials, emphasizing the translation of composite properties into collector-level outcomes rather than conductivity enhancement alone. A structure–property–performance mapping approach is presented to connect directional thermal conductivity ((k_in-plane), (k_perp)), thermal diffusivity, heat capacity, coefficient of thermal expansion, and service temperature with collector performance parameters such as heat removal effectiveness, overall heat losses, and stagnation behavior. Ceramic fillers (e.g., boron nitride, aluminum nitride, silicon carbide, alumina) are examined for stable conduction-network formation, coating compatibility, and long-term reliability, while carbon fillers (graphite, graphene nanoplatelets, carbon nanotubes) are evaluated for combined heat spreading and solar absorption benefits, with attention to emissivity penalties. Hybrid ceramic–carbon architectures and multilayer absorber designs are identified as the most promising routes to balance thermal transport, optical selectivity (high solar absorptance and low thermal emittance), manufacturability, and durability under UV, humidity, and thermal cycling. Full article

This paper presents an evaluation of two new approaches to improve the surface quality and the mechanical properties of ceramic parts printed by fused deposition of ceramic (FDC). Dip-coating and aerosol-treatment are performed in order to reduce the staircase effect in the vertical printing direction, which typically represents the weakest orientation in most additive manufacturing processes, particularly in fused filament fabrication (FFF). The post-treatments are applied on two highly filled alumina feedstocks. A commercial aerosol-treatment machine for fused deposition modeling is used with ethanol as solvent. A suspension composition for dip-coating is developed to reduce the surface roughness without compromising the printing resolution. The influence of these post-processing steps on the mechanical properties and surface roughness of the green and sintered parts is investigated using perthometer measurements and four-point bending tests in the vertical build direction on as-processed, aerosol-treated, and dip-coated samples. The mechanical results are compared to extruded strand samples. An improvement in surface quality is achievable by dip-coating despite reduction in the parts strength, with a reduction of 65% of the R_z values in the sintered state compared to untreated samples. Aerosol-treatment neither improves the surface quality nor the mechanical properties of the parts. The feedstock and post-processing steps developed in this research aim at printing dense ceramic parts with high surface quality, serving as a basis for developing ceramic parts with higher strength. This advancement will facilitate the utilization of FDC in structural and aesthetic design applications. Full article

Four compositions of rapidly quenched ribbon brazing alloys based on Ag–Cu–Ti (Ag–26.5Cu–1.5Ti, Ag–25Cu–5Ti) and Ag–Cu–Zr (Ag–26.5Cu–1.5Zr, Ag–25Cu–5Zr) systems were produced. Initial ingots were synthesized by arc melting. Rapidly solidified ribbons, 50–100 μm thick, were then fabricated from homogenized ingots using a “Crystall-702” facility. A comparative analysis of the microstructure and phase composition of both the ingots and ribbons was conducted using scanning electron microscopy and X-ray diffraction. The analysis revealed the presence of Cu₄Ti and CuTi intermetallic compounds in the Ag–Cu–Ti alloys, and AgCu₄Zr and Zr₂Cu in the Ag–Cu–Zr alloys. Rapid quenching was found to produce metastable structures and significantly refine the intermetallic phases. Microhardness measurements of the ingot and ribbon states demonstrated a substantial influence of the processing route on the mechanical properties. The tensile strength of the ingots was also evaluated. The wetting angles of the rapidly quenched alloy melts on 99% Al₂O₃ (alumina) ceramic substrates under vacuum were determined. All produced ribbons, except for the Ag–26.5Cu–1.5Zr composition, demonstrated adequate wettability. Thus, these materials are considered promising for further research into heat-resistant metal–ceramic joints. Full article