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Advances in High-Temperature Ceramics and Refractory Materials

A Special Issue of Materials (ISSN 1996-1944) belonging to the section "Advanced and Functional Ceramics and Glasses".

Deadline for manuscript submissions: closed (20 May 2026) | Viewed by 1683

Editor


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Guest Editor
School of Materials Science and Engineering, Henan Key Laboratory of High Temperature Functional Ceramics, Zhengzhou University, Zhengzhou 450001, China
Interests: high performance castables; oxide-nonoxide refractory composites; controllable synthesis of low-dimensional nanostructures; nanoparticles; molten salt mediated synthesis of ceramic powders

Special Issue Information

Dear Colleagues,

Background: The development of ultra-high-temperature porous materials originated from the pressing demand for thermal protection systems in aerospace applications under extreme environments characterized by ultra-high temperatures (>2000 °C), intense scouring, and oxidation challenges, while also safeguarding internal electronic equipment from damage. Traditional dense materials or metallic thermal protection systems prove inadequate in these conditions. Ultra-high-temperature porous materials successfully integrate the intrinsic extreme-environment resistance of ultra-high-temperature ceramics with the design of porous architectures, making them an ideal solution for next-generation thermal protection, thermal management, and high-temperature filtration systems.

Research Aim and Scope: With continuous innovation in material design and manufacturing technologies, the development of ultra-high-temperature porous materials that are lightweight, resistant to extreme temperatures, highly insulating, and exhibit excellent ablation and thermal shock resistance holds great promise for broader applications in cutting-edge fields including aerospace, nuclear reactors, energy and environmental protection, as well as metallurgy and manufacturing.

Development Process: In the mid-to-late 20th century, research efforts focused on carbon-based porous materials (e.g., carbon foams). However, these materials suffered from poor oxidation resistance. Subsequently, researchers began incorporating ultra-high-temperature ceramic components such as ZrB2, HfB2, and TaC into carbon matrices, resulting in carbon/ceramic composite porous materials that significantly improved oxidation and ablation resistance. Entering the 21st century, with advances in preparation techniques, ceramic porous materials (e.g., ZrC, HfC, ZrB2–SiC) became the mainstream research focus. Essentially, the evolution of these materials has progressed from single-component to multi-phase composites, from simple structures to finely controlled architectures, and from sole focus on temperature resistance to integrated multifunctionality.

Cutting-edge Research: In recent years, substantial progress has been made in this field, focusing primarily on the following:

(1) Precise Structural Control: Advanced techniques such as 3D printing, ice-templating, and precursor conversion combined with sintering have enabled the fabrication of porous materials with tailored gradient structures including aligned pores, layered configurations, and wood-like annual ring patterns, achieving a synergistic balance between mechanical strength and thermal insulation.

(2) Multi-Phase Composite Systems: By incorporating oxidation-resistant phases (e.g., SiC, MoSi2) and nano-reinforcements (e.g., graphene, carbon nanotubes), multiphase composite porous architectures have been developed, greatly enhancing fracture toughness, thermal shock resistance, and ablation performance.

(3) Multifunctional Integration: Researchers are actively working toward creating a new generation of materials that combine thermal insulation, load-bearing, electromagnetic wave transmission/absorption, catalysis, and other functions to meet the multifunctional demands of aircraft in complex environments.

Types of Articles Solicited: Research Articles and Reviews.

Prof. Dr. Quanli Jia
Guest Editor

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Keywords

  • ultra-high temperature porous materials
  • thermal conductivity
  • compressive strength
  • oxidation resistance

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Published Papers (3 papers)

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Research

12 pages, 3174 KB  
Article
Thermal Shock Resistance Enhancement of Alumina-Based Castables by Incorporating Porous Alumina Spherical Aggregates
by Tong Fu, Ying Huang, Wei Xiong, Haonan Chen, Qilong Chen, Haoxuan Ma and Quanli Jia
Materials 2026, 19(17), 3761; https://doi.org/10.3390/ma19173761 - 4 Sep 2026
Abstract
Chrome-containing corundum–spinel castables are the preferred materials for ladle purging plugs due to their excellent slag resistance, high mechanical strength, and good volume stability. However, their poor thermal shock resistance often leads to transverse cracking or thermal spalling, thereby limiting their service life [...] Read more.
Chrome-containing corundum–spinel castables are the preferred materials for ladle purging plugs due to their excellent slag resistance, high mechanical strength, and good volume stability. However, their poor thermal shock resistance often leads to transverse cracking or thermal spalling, thereby limiting their service life improvement. Since aggregates typically constitute 70 wt% of castables, modifying the aggregates may be an effective strategy to enhance the thermal shock resistance. To this end, alumina spherical aggregates were prepared via a pan granulation technique using α-Al2O3 powders as the raw material and a ZnCl2 solution as the binder. The effects of the firing temperature on the physical properties and the microstructure of the as-fabricated aggregates were investigated, followed by an evaluation of their impact on castable performance. After firing at 1400 °C for 3 h, the resulting alumina spherical aggregates exhibited a porous interior and a dense exterior structure, with an apparent porosity of 27.21%, a water absorption capacity of 9.38%, and a crushing rate of 51.3%. When these aggregates were incorporated into castables, their apparent porosity increased, while the bulk density and the cold strength showed slight reductions; however, their thermal shock resistance was notably improved. Among the formulations tested, the castable containing 4% of 0.2–0 mm spherical aggregates exhibited the best thermal shock resistance, with a residual strength of 7.96 MPa and a strength retention rate of 27.85%. Full article
(This article belongs to the Special Issue Advances in High-Temperature Ceramics and Refractory Materials)
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18 pages, 16974 KB  
Article
Interface Behavior and Corrosion Study of MgO-Based Refractory Materials in Molten Pharmaceutical Waste Salts
by Qinhao Yang, Feng He, Weiwei Cheng, Manman Gao and Junlin Xie
Materials 2026, 19(10), 2057; https://doi.org/10.3390/ma19102057 - 14 May 2026
Viewed by 394
Abstract
This study addresses the corrosion problem of refractory materials during high-temperature molten treatment of pharmaceutical waste salt, and systematically investigates the interface behavior and corrosion mechanism of MgO-based refractory materials in simulated pharmaceutical waste salt (65 wt% NaCl-30 wt% Na2SO4 [...] Read more.
This study addresses the corrosion problem of refractory materials during high-temperature molten treatment of pharmaceutical waste salt, and systematically investigates the interface behavior and corrosion mechanism of MgO-based refractory materials in simulated pharmaceutical waste salt (65 wt% NaCl-30 wt% Na2SO4-5 wt% CaCO3). Through sessile drop wetting infiltration experiments, static corrosion tests (950 °C and 1150 °C/48 h), combined with SEM-EDS, XRD characterization, and FactSage thermodynamic calculations, the corrosion resistance of high-purity MgO phase (HM-97) refractory materials and magnesium–aluminum spinel composite phase (MA-85) refractory materials was compared and analyzed. The results show that due to the fine periclase grains and rich grain boundaries, the molten salt infiltration rate of HM-97 material in the 644–800 °C range is significantly higher than that of MA-85. After corrosion at 950 °C, HM-97 and MA-85 formed 47 μm and 53 μm transition layers respectively, and the HM-97 surface generated Ca3Mg(SiO4)2 phase leading to uneven corrosion morphology. At 1150 °C, HM-97 produced long cracks and the transition layer thickness remained almost unchanged due to dissolution, while MA-85 formed an approximately 72 μm transition layer and a dense metamorphic layer. Phase analysis and thermodynamic calculations suggest that the MgAl2O4 phase in MA-85 is likely stable at high temperatures, which appears to effectively prevent molten salt infiltration and contribute to forming a protective metamorphic layer, thereby potentially enhancing the material’s corrosion resistance. The MgAl2O4 phase is proposed to improve the service performance of MgO-based refractory materials in the molten pharmaceutical waste salt environment. Full article
(This article belongs to the Special Issue Advances in High-Temperature Ceramics and Refractory Materials)
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11 pages, 3270 KB  
Communication
The Inhibitory Effect of Hafnium Oxide on Grain Growth in Yttrium Aluminum Garnet Composite Fiber
by Ke Gai, Qian Wang, Ketian Guan, Xiaohu Li, Weisen Liu, Yuan Li, Hongwei Zhao and Tong Zhao
Materials 2025, 18(23), 5272; https://doi.org/10.3390/ma18235272 - 21 Nov 2025
Viewed by 767
Abstract
Yttrium aluminum garnet (YAG, Y3Al5O12) fibers are promising materials for high-power lasers and high-temperature structural materials, and it is anticipated that the improvement in the stability of grain size would extend their service life at high temperatures. [...] Read more.
Yttrium aluminum garnet (YAG, Y3Al5O12) fibers are promising materials for high-power lasers and high-temperature structural materials, and it is anticipated that the improvement in the stability of grain size would extend their service life at high temperatures. In this work, YAG-HfO2 composite ceramic fibers were obtained by the solution blow spinning of YAG-HfO2 composite precursor and sintering in steam. The effect of HfO2 on the crystal phase transition and grain growth of YAG-HfO2 fibers was further studied by in situ X-ray Diffraction (XRD), Scanning Electron Microscope (SEM), and Transmission Electron Microscope (TEM). The results show that the HfO2 addition increased the crystallization temperature of the YAG phase from 900 °C to 950 °C and reduced the crystal size at 1400 °C from 41.9 nm to 31.8 nm. The HfO2 grains were distributed at the boundary of YAG grains, which enabled the fiber to maintain its dense structure and uniform grain size even at 1500 °C, exhibiting excellent high-temperature grain size stability of composite fibers. Full article
(This article belongs to the Special Issue Advances in High-Temperature Ceramics and Refractory Materials)
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