Search Results (481)

Applying functional hard protective coatings with friction-reducing and wear-resistant properties to optimize mechanical surfaces and interfaces can significantly enhance the reliability of operating components under extreme conditions and extend their service life. However, the difference of coating preparation technology often leads to great uncertainty in the improvement of the performance and lifetime of functional hard protective coatings. Hence, in this work, TiAlSiCN coatings were deposited at the substrate temperature of 300 °C by varying the C target power from 0 to 900 W using combined high-power impulse magnetron sputtering and pulsed DC magnetron sputtering. The TiAlSiCN coatings deposited at a C target power of 500 W containing the mixed phase of nc-TiAl(C)N, a-Si₃N₄ and a-C exhibit a simultaneous superhardness of 43.5 GPa and favorable toughness, benefiting from the fully dense microstructure and high surface integrity. The superhard TiAlSiCN coatings show excellent friction-reducing and wear-resistant properties with a low friction coefficient of about 0.1 and specific wear rate of 2.78 × 10⁻⁷ mm³·N⁻¹·m⁻¹ under dry reciprocating friction and wear tests. The improved friction and wear performance of TiAlSiCN coatings are mainly attributed to the increased cracking resistance and oxide-based films covering the superhard surface/interface. Full article

In this study, the thermodynamic conditions governing TiC formation were systematically investigated based on Gibbs free energy and interaction parameter theory. The effects of temperature and furnace atmosphere on interaction parameters were explicitly incorporated, enabling an improved thermodynamic description of TiC formation under realistic blast furnace conditions. Furthermore, compared with conventional two-dimensional equilibrium analyses, a three-dimensional Ti-C-temperature thermodynamic precipitation surface was established to quantitatively evaluate the effects of temperature, titanium content, and carbon content on TiC precipitation behavior. The results indicate that titanium is the dominant controlling factor for TiC formation, while carbon plays a secondary synergistic role. Compared with dissolved carbon, solid carbon provides more favorable thermodynamic conditions, suggesting that TiC preferentially forms via interactions with high-activity carbon sources such as coke or refractory materials. Based on the modified thermodynamic framework and boundary conditions, a quantitative precipitation criterion was established as 100 × w[Ti]_% + w[C]_% ≥ 10, which ensures TiC precipitation prior to molten iron solidification under representative blast furnace hearth conditions. The proposed criterion provides a practical guideline for titanium addition and carbon regulation in blast furnace ironmaking and improves the thermodynamic prediction capability for titanium-bearing protective phase formation in complex high-temperature metallurgical environments. Full article

This research developed a ZrSi₂-TiB₂-modified alumina fiber/boron phenolic resin ceramizable composite intended to fulfill the criteria for high-temperature resistance, oxidation resistance, and structural load-bearing capacity in reusable thermal protection systems. The composite exhibits a low thermal conductivity of 0.405 W·m⁻¹·K⁻¹, a reduced density of 2.11 g·cm⁻³, and a high mass retention rate of 89.45% after heat treatment at 1200 °C in air. During thermal cycling at 1200 °C with a 30 min dwell time, it consistently demonstrates excellent stability, mass retention, and mechanical properties, indicating its potential for applications in reusable thermal protection systems. Following 20 cycles, the variation in length and width remains below 0.6%, the mass retention surpasses 80%, and the flexural strength remains above 20 MPa after 15 cycles. Microstructural evolution and thermodynamic analysis disclose that the in situ ceramization reaction of ZrSi₂ and TiB₂ consumes oxygen, inhibits oxygen diffusion, and fills pores and microcracks with oxidation products (SiO₂ and B₂O₃), thereby forming self-healing and densifying phases. This synergistic mechanism of self-healing and densification ensures the reusability of the composite. The research illustrates the performance evolution patterns and strengthening mechanisms of the composite under extreme thermal conditions, confirming its outstanding performance in repeated usage evaluations. Full article

Titanium matrix composites (TMCs) are increasingly vital in aerospace for their high specific strength and wear resistance, with compositional gradient design serving as a key strategy to mitigate thermophysical mismatches between ceramic and metal phases. This study utilized laser-directed energy deposition with concurrent wire-powder feeding (LDED-WP) to fabricate TiC/Ti6Al4V gradient composites, employing a laser power of 2700 W, wire feed rates of 110–150 cm/min, and calibrated powder feed rates ranging from 50.22 to 497.13 g/h. Along the build direction, the TiC content was progressively increased from 10 wt.% to 60 wt.%. Investigations into microstructural evolution revealed that the reinforcement morphology transitions from chain-like eutectic TiC to dendritic primary TiC, while the lamellarα-Ti width refines significantly from 4.07 ± 1.15 μm to 0.45 ± 0.29 μm. EBSD analysis confirmed that higher TiC concentrations weaken the characteristic <001> solidification texture, reducing intensity from 11.24 to 7.64. Furthermore, KAM analysis highlighted that thermal expansion and elastic modulus mismatches trigger substantial geometrically necessary dislocation (GND) accumulation at interfaces. Consequently, Vickers hardness improved by 164% along the gradient, peaking at 950 HV. Although the composite achieved an ultimate tensile strength of 630 MPa, the elongation was limited to 2.4% due to crack nucleation in TiC-rich regions and interfacial instability. Full article

Mullite fiber materials are widely used in high-temperature thermal insulation applications, especially in aerospace thermal protection systems, due to their excellent thermal stability and low thermal conductivity. However, the material exhibits poor resistance to infrared radiative heat transfer at elevated temperatures. Accordingly, a dual-opacifier system composed of TiO₂ and K₂Ti₆O₁₃ binary whiskers was proposed as an effective strategy for enhancing thermal insulation performance. MF/TiO_2w and MF/TiO_2w/K₂Ti₆O_13w were fabricated in this study using a sol–gel method combined with in situ whisker growth. The results show that upright and interlaced K₂Ti₆O₁₃ and TiO₂ whiskers were uniformly grown on the fiber surface, contributing to a high infrared reflectance of 97.7% in the wavelength range of 2.5–10 μm. Under a front-side temperature of 1000 °C, the modified mullite fiber-based material exhibits a backside temperature of 177.8 °C, corresponding to a reduction of 71.8 °C compared with the original sample (249.6 °C), demonstrating significantly enhanced thermal insulation performance. In addition, the composite exhibits an ultralow density of less than 0.20 g/cm³. The as-prepared thermal insulation material shows a high rebound rate of 76.5% at a strain of 30%, indicating good elasticity. The results demonstrate that the developed composite exhibits excellent infrared shielding and structural stability, confirming that the binary whisker strategy effectively enhances the thermal insulation performance of the mullite fiber-based materials, highlighting its potential for high-temperature aerospace applications. Full article

Non-stoichiometric high-entropy carbides (Nb_0.2Ta_0.2Ti_0.2W_0.2Zr_0.2)C_x (x = 0.71–0.85) nanoscale powders were prepared using oxides and carbon as raw materials via carbothermal reduction. The (Nb_0.2Ta_0.2Ti_0.2W_0.2Zr_0.2)C_0.73 synthesized at 1700 °C exhibited a grain size of approximately 400 nm, an oxygen content of 0.3 wt.%, and uniform nanoscale distribution of the five metal elements. After ball milling, (Nb_0.2Ta_0.2Ti_0.2W_0.2Zr_0.2)C_0.73 powder was sintered by spark plasma sintering to produce high-entropy ceramics with a relative density of 98.1% and an average particle size of about 5.3 μm. The Vickers hardness, nano-hardness, Young’s modulus, and fracture toughness were 17.6 GPa, 29.1 GPa, 514 GPa, and 5.3 MPa·m^1/2, respectively. The thermal conductivity of the ceramic at room-temperature was as low as 8.5 W/m·K. Full article

The rapid proliferation of artificial intelligence (AI) has pushed hyperscale data center rack densities beyond 100 kW, driving facility power requirements to the gigawatt scale. As developers attempt to deploy these massive Zettascale compute loads across US wholesale electricity markets, they encounter severe transmission planning bottlenecks, multi-year interconnection delays, and escalating grid transient stability risks. This paper presents a generalizable techno-economic framework for evaluating grid-tied, behind-the-meter (BTM) energy architectures as a means of bypassing these constraints. The framework is demonstrated through a detailed case study in the Electric Reliability Council of Texas (ERCOT), selected for its rapid data center growth and evolving large-load regulatory environment. Using a scenario-based comparative approach, this study models the feasibility of transitioning from pure-grid reliance to hybrid, on-site generation across a three-phase deployment pathway scaling from 25 MW to 250 MW. Six distinct microgrid configurations are evaluated, integrating baseload technologies—including Enhanced Geothermal Systems (EGSs), Small Modular Reactors (SMRs), and Reciprocating Internal Combustion Engines (RICEs)—with a tiered-performance Battery Energy Storage System (BESS) combining high C-rate lithium-ion units and repurposed electric vehicle batteries. System viability is assessed through two primary metrics: the Levelized Cost of Energy (LCOE) and the Avoided Loss of Load Probability (ALOLP). The results indicate that the blended LCOE scenario ranges from $64.50/MWh (Geothermal + Solar PPA) to $94.20/MWh (SMR-anchored), compared to a $75.00/MWh pure-grid baseline. The 100% Geothermal configuration achieves a scenario-dependent ALOLP exceeding 99.9%, while gas-dependent configurations range from 58.0% to 91.2%. These findings suggest that geographic siting co-optimized with localized generation offers a viable pathway for balancing regulatory compliance, capital cost, and Uptime Tier IV operational resilience in early-stage data center development across constrained grid environments. Full article

This study investigates the catalytic activity and surface behaviors of V₂O₅ catalysts modified with promoter components to improve low-temperature activity and suppress SO₂-to-SO₃ oxidation. Moreover, we fabricated corrugated-type catalysts using glass fiber sheets as substrates, because powdered catalysts revealed limitations for practical applications. The modified catalysts were prepared via a slurry mixing method using vanadium precursor with different promoters such as W, Nb, Zr, Mo, Ce, Fe supported on TiO₂. The catalysts were fabricated into slurry coating type catalysts using glass fiber sheets and the catalytic activity, specific surface area, and acid sites were investigated. The performance of corrugated-type catalyst and oxidation of SO₂ to SO₃ over a wide temperature range were evaluated using a Micro-Reactor. Our results showed that adding a promoter improves the catalytic performance of VW/Ti catalysts by enhancing surface acidity. The results varied depending on the catalyst loading and promoter components over a wide temperature range. Among them, VWNb/Ti catalysts exhibited the highest NOx conversion of 80.9% at 350 °C despite the high gaseous velocity (AV of 51 m·h⁻¹) and the large flow rate of 20 L·min⁻¹, with the lowest Ea of 13.7 kJ·mol⁻¹. Among the evaluated promoters, Nb exhibited the most favorable balance of activity and SO₂-to-SO₃ oxidation. These results suggest that the Nb modification strategy can be extended to commercial SCR catalysts, providing a practical approach for improving catalytic performance. Full article

In this study, the sintering behavior and electrical properties of 0.7Pb(Zr_0.46Ti_0.54)O₃ (PZT)–0.1Pb(Zn₁/₃Nb₂/₃)O₃ (PZN)–0.2Pb(Ni₁/₃Nb₂/₃)O₃ (PNN) piezoelectric ceramics with different Pb(Fe₂/₃W₁/₃)O₃ (PFW) doping contents were investigated to obtain a formulation that can be co-fired with silver (Ag) electrodes below 900 °C for multilayer ceramics. PFW was introduced as a sintering aid, which effectively reduced the sintering temperature of the ceramics from 1200 °C to 850 °C. The sample with x = 0.12 exhibited the largest average grain size of 1.72 μm, achieving excellent comprehensive properties with piezoelectric constant (d₃₃) = 477 pC/N, planar electromechanical coupling factor (k_p) = 0.68, dielectric loss tangent (tanδ) = 0.0154, and relative density of 98.2%. Furthermore, the feasibility of fabricating piezoelectric actuators based on this optimized composition was verified. Multilayer piezoelectric devices were prepared via screen printing combined with a carbon-based sacrificial layer method. No obvious interdiffusion was observed at the interface between the Ag internal electrodes and the ceramic matrix. The 9-layer device attained a high d₃₃ = 1470 pC/N and produced a large displacement of 5.5 μm (corresponding to a strain = 1.83%) with a voltage of 500 V. The thickness of the multilayer piezoelectric film was approximately 0.3 mm. Through this, the feasibility of manufacturing a multilayered actuator with an Ag electrode was confirmed through the composition of 0.58PZT–0.1PZN–0.2PNN–0.12PFW. Full article

6063 aluminum alloy has broad application prospects in aerospace and microelectronic thermal management systems due to its good thermal conductivity and moderate strength. However, its extremely high hot cracking susceptibility during the laser powder bed fusion (LPBF) process limits the direct manufacturing of complex components. This study proposes a strategy combining material composition modification with advanced structural design. By introducing TiH₂ nanoparticles (1.0~4.5 wt.%) to modify the 6063 aluminum alloy powder, Diamond-type porous structures based on triply periodic minimal surfaces (TPMS) were successfully fabricated using LPBF technology. The results show that the introduction of TiH₂ significantly suppresses the solidification cracking of the aluminum alloy. The underlying mechanism is that the L1₂-structured Al₃Ti particles, generated by the in situ decomposition of TiH₂ in the melt pool, provide high-density heterogeneous nucleation sites. This leads to a drastic decrease in the average grain size from 30.46 μm to 0.75 μm (a reduction of 97.5%), achieving a remarkable columnar-to-equiaxed transition (CET). In terms of mechanical properties, the 3.0 wt.% TiH₂ addition group exhibits excellent plateau stress (28.5 MPa) and energy absorption capacity, which is mainly attributed to the synergistic effect of fine-grain strengthening and Orowan dispersion strengthening. Thermal tests reveal that the thermal conductivity of the 3.0 wt.% group reaches 123 W/(m·K) at 100 °C. The healing of cracks reconstructs the macroscopic heat conduction paths, resulting in a significant improvement in thermal conductivity compared with the unmodified group. This work provides a theoretical reference for the development of high-performance, crack-free, and multi-functional integrated aluminum alloy components via additive manufacturing. Full article

We report a straightforward and scalable strategy for the fabrication of three-dimensional Ni-rich bimetallic NiCu foam coatings on Ti substrates ((NiCu)_foam/Ti) via dynamic hydrogen bubble templating (DHBT) electrodeposition, followed by modification with an ultralow amount of Pt to construct an efficient ternary Ni–Cu–Pt catalytic system. The resulting foams exhibit highly porous dendritic architectures with interconnected channels, enabling a high density of electrochemically active sites and uniform metal distribution throughout the framework. Structural and compositional analyses (SEM–EDX) reveal a Ni-dominant composition (28.09–34.61 mg cm⁻²), with significantly lower Cu content (2.47–4.16 mg cm⁻²) and ultralow Pt loading (9.63–19.04 μg cm⁻²), maximizing catalytic efficiency while minimizing noble metal usage. Electrochemical studies in alkaline media demonstrate that the NiCu foam possesses intrinsic borohydride electrooxidation activity, which is substantially enhanced upon Pt incorporation, delivering a threefold increase in activity compared to the unmodified foam and outperforming bulk Pt. This improvement is attributed to the synergistic interplay within the Ni-rich ternary system, where trace Pt acts as a highly effective promoter. When implemented as anodes in NaBH₄–H₂O₂ fuel cells, Pt(NiCu)_foam/Ti achieves peak power densities of 239 and 301.6 mW cm⁻² at 25 °C and 55 °C, respectively. Overall, this study presents a cost-effective and scalable route to high-performance electrocatalysts for alkaline direct borohydride fuel cells, significantly reducing reliance on noble metals while maintaining superior activity. Full article

This study investigates how sintering temperature affects phase evolution, titanium carbide (TiC) formation, and oil-repellent performance in TiO₂–carbon-coated 304 stainless-steel mesh for oil–water separation applications. Coated meshes sintered at 400, 500, 600, 700, and 800 °C were evaluated using gravity-driven oil permeation tests with 5W-20 motor oil and oil contact-angle measurements, while coating morphology, composition, and phase evolution were characterized by SEM, EDS, and XRD. Sintering temperature strongly influenced coating structure and wettability. Among the tested conditions, the mesh sintered at 600 °C showed the highest oil contact angle (105°) and the highest initial oil retention efficiency (80%), indicating the most favorable balance between oleophobicity and coating stability within the tested range. XRD analysis showed that 600 °C corresponded to the onset of the anatase-to-rutile transition and the initial formation of TiC. These results suggest that intermediate sintering temperatures can provide a favorable balance between retention of beneficial anatase content and enhanced interfacial interaction within the TiO₂–carbon coating. Within the tested conditions, 600 °C was the best-performing sintering condition among the temperatures examined for this coating system. Full article

Despite the growing adoption of Ti6Al4V-ELI made by Laser Powder Bed Fusion (LPBF) in tribologically demanding applications, the influence of hybrid nanoparticle additives on its lubrication behavior under starved contact conditions remains insufficiently explored. The tribological performance of Ti6Al4V was investigated under starved boundary-to-mixed lubrication conditions using engine oil modified with Ag-doped TiO₂ nanoparticles. Double-scan LPBF-fabricated discs were tested in a ball-on-disc configuration against AISI 52100 bearing steel using a TRB³ tribometer. Nanolubricants were prepared by dispersing TiO₂ and Ag–TiO₂ nanopowders with different Ag⁺/Ti⁴⁺ ratios (0.5%, 1.5%, and 2.5%) in SAE 10W-40 engine oil at a constant nanoparticle concentration of 0.05 wt%. Comprehensive physicochemical characterization of the nanopowders and nanolubricants was performed through structural, chemical, optical, morphological, rheological, and stability analyses. Tribological experiments were conducted following a full-factorial design combining three normal loads (5–15 N), three sliding speeds (0.10–0.20 m·s⁻¹), and four lubricant formulations. The steady-state coefficient of friction ranged between 0.281 and 0.359, while the specific wear rate varied from 2.81 × 10⁻⁴ to 4.83 × 10⁻⁴ mm³·N⁻¹·m⁻¹. The contact temperature rise remained relatively moderate, within the interval of 1.9–9.4 °C. Among the investigated formulations, the lubricant containing 1.5% Ag–TiO₂ exhibited the lowest friction coefficient, whereas the formulation with the highest Ag content showed improved stability of tribological performance across the investigated operating domain. These results indicate that Ag-modified TiO₂ nanoparticles are consistent with the formation of protective tribofilms and contribute to the stabilization of friction, wear, and thermal behavior under starved lubrication conditions. ANOVA confirmed that sliding speed and the load–lubricant interaction are the dominant factors governing friction and wear, while normal load controls the thermal response. These findings support the use of Ag–TiO₂ nanolubricants as a viable strategy for stabilizing interfacial behavior in LPBF-fabricated titanium components operating under starved lubrication conditions. Full article

This study aims to reduce the phase transition temperature (PTT) of W-doped vanadium dioxide (VO₂) multilayer thin films. We designed and fabricated two asymmetric multilayer thin film structures; namely, TiO₂/VO₂-5%W/ITO and ITO/VO₂-5%W/TiO₂. The W-doped VO₂-based Trilayer thin films were deposited using an electron beam evaporation combined with the ion-assisted deposition (IAD) technique. An experimental study was conducted on the temperature-dependent residual stress and optical properties of the two asymmetric VO₂-based three-layer structures. The VO₂-based thin films were characterized using UV–Vis–NIR spectrophotometry, Fourier transform infrared spectroscopy (FTIR), Raman spectroscopy, and an improved Twyman–Green interferometer combined with fast Fourier transform (FFT) analysis for residual stress measurement. The trilayer structures incorporated a ~60 nm thick W-doped VO₂ middle layer, which plays a critical role in modulating thermochromic behavior and residual stress evolution. The results show that both trilayer thin films demonstrated excellent optical performance in transmission spectra. Raman spectral analysis revealed a blue shift in the characteristic W-doped VO₂ peaks, accompanied by a decrease in peak intensity as the temperature increased. Heating experiments on asymmetric W-doped VO₂ trilayer thin films revealed that the critical transition temperature of the ITO/VO₂-5%W/TiO₂/B270 trilayer film structure was significantly reduced to 45 °C. This demonstrates the effectiveness of our proposed multilayer film design in improving the PTT of W-doped VO₂ thin films. Analysis of the changes in residual stress of the trilayer thin films during heating experiments revealed that the residual stress shifted from compressive to tensile in the temperature range of 40 °C to 50 °C. The thermal expansion coefficient and biaxial modulus of the TiO₂/VO₂-5%W/ITO trilayer film structure were 5.37 × 10⁻⁶ °C⁻¹ and 295.7 GPa, respectively. In addition, the thermal expansion coefficient and biaxial modulus of the ITO/VO₂-5%W/TiO₂ trilayer film structure were 6.65 × 10⁻⁶ °C⁻¹ and 745.0 GPa. Full article

Hydrogen absorption kinetics in metal hydride beds is constrained by coupled heat and mass transfer, which often leads to a slow refueling response and reduced storage system efficiency. In this work, hybrid molding by mixing silicone gel with various thermally conductive additives was used to prepare TiMn-based metal hydride beds with tailored porosity and thermal conductivity. Three experimental groups were prepared: 5 wt.% silicone gel and 5 wt.% single-walled carbon nanotubes (Group A), 5 wt.% silicone gel only (Group B), and 5 wt.% silicone gel and 5 wt.% silicone sheets (Group C). Hydrogen absorption kinetics at 30 °C and 50 bar were measured experimentally and simulated using a coupled heat-mass transfer model in COMSOL Multiphysics. The physical property results showed that Group A exhibited approximately threefold higher porosity (0.527) compared with the other two groups, while its thermal conductivity (2.476 W·m⁻¹·K⁻¹) was the lowest among them (3.189 W·m⁻¹·K⁻¹ for Group B and 3.246 W·m⁻¹·K⁻¹ for Group C). These property differences led to distinct hydrogen absorption rate-limiting behaviors. Group A dominated in the diffusion-controlled stage (hydrogen uptake between 0.5 and 1.15 wt.%) due to enhanced hydrogen transport through its macroporous network, while Group C exhibited faster kinetics in the later stage (above 1.15 wt.%), where thermal conductivity governed the absorption driving force. Numerical simulations reproduced the experimental kinetic curves and confirmed the transition of rate-limiting mechanisms. This work reveals that the rate-limiting factors of hydrogen absorption in hybrid molding hydride beds vary across different stages, and that independent optimization of porosity and thermal conductivity is required to achieve rapid kinetics across the entire absorption process. Full article