Search Results (264)

Textured Si₃N₄/BN composite ceramics were successfully fabricated using two-step sintering, combining pseudo-hot isostatic pressing (PHIP) and gas pressure sintering. The grain size of h-BN platelets had a significant influence on densification and mechanical and thermal properties. With an increase in h-BN grain size, the volume density of the composite ceramics gradually decreased, while flexural strength gradually increased. Meanwhile, larger h-BN platelets were more likely to trigger toughening mechanisms like large-angle deflection and greatly increase fracture toughness. Through proper selection of h-BN grain size, textured ceramics, with the addition of h-BN platelets of 1–2 μm, showed high thermal conductivity (∼92 W∙m⁻¹∙K⁻¹) and reliable mechanical properties (∼540 MPa, ∼7.5 MPa∙m^1/2, ∼11.1 GPa). Therefore, texture control is an effective means of improving the overall performance of ceramic materials. Novel textured composite ceramics thus have great potential in large-scale fabrication and directional heat dissipation applications. Full article

To address the poor thermal shock resistance and high brittleness of traditional ceramic tools, a novel Si₃N₄/Sc₂W₃O₁₂ (SNS) composite ceramic material was developed via in situ synthesis using WO₃ and Sc₂O₃ as precursors and consolidated by spark plasma sintering. Sc₂W₃O₁₂ with negative thermal expansion was introduced to compensate for matrix shrinkage and modulate interfacial stress. The effects of varying Sc₂W₃O₁₂ content on thermal expansion, residual stress, microstructure, and mechanical properties were systematically investigated. Among the compositions, SNS3 (12 wt.% Sc₂W₃O₁₂) exhibited the best overall performance: relative density of 98.8 ± 0.2%, flexural strength of 712.4 ± 30 MPa, fracture toughness of 7.5 ± 0.3 MPa·m^1/2, Vickers hardness of 16.3 ± 0.3 GPa, and an average thermal expansion coefficient of 2.81 × 10⁻⁶·K⁻¹. The formation of a spherical chain-like Sc-W-O phase at the grain boundaries created a “hard core–soft shell” interface that enhanced crack resistance and stress buffering. Cutting tests showed that the SNS3 tool reduced workpiece surface roughness by 32.91% and achieved a cutting distance of 9500 m. These results validate the potential of this novel multiphase ceramic system as a promising candidate for high-performance and thermally stable ceramic cutting tools. Full article

Silicon nitride (Si₃N₄) ceramic is widely used in the production of structural components. The surface wettability is closely related to the service life of materials. Laser surface texturing is considered an effective method for controlling surface wettability by processing specific patterns. This research focused on the laser surface texturing of a Si₃N₄ ceramic, employing rectangular patterns instead of the typical dimple designs, as these had promising applications in heat transfer and hydrodynamic lubrication. The effects of scanning speed and number of scans on the change of the morphologies and dimensions of the grooves were investigated. The results indicated that the higher scanning speed and fewer number of scans resulted in less damage to the textured surface. As the scanning speed increased, the width and depth of the grooves decreased significantly first, and then fluctuated. Conversely, increasing the number of scans led to an increase in the width and depth of the grooves, eventually stabilizing. The analysis of the elemental composition of different areas on the textured surface presented a notable increase in oxygen content at the grooves, while Si and N levels decreased. It was mainly caused by the chemical reaction between Si₃N₄ ceramic and oxygen during laser surface texturing in an air environment. This study also assessed the wettability of the textured surface, finding that the contact angle of the water droplet was significantly affected by the groove dimensions. After laser surface texturing, the contact angle increased from 35.51 ± 0.33° to 57.52 ± 1.83°. Improved wettability was associated with smaller groove volume, indicating better hydrophilicity at lower scanning speed and enhanced hydrophobicity with a fewer number of scans. Full article

The use of construction and demolition waste (CDW) as an alternative binder to ordinary Portland cement presents a promising solution through alkaline activation. This study evaluates the physical, mechanical, and microstructural behaviour of pastes and mortars produced with CDW—specifically concrete (RH) and ceramic (RC) waste—activated with NaOH and Na₂SiO₃ (SS) solutions. Mortars were prepared with NaOH/SS ratios of 0.2 and 0.3 and an activator-to-precursor (AA/P) ratio of 0.2. Results showed that higher NaOH content accelerated alkaline activation, reducing setting times from 6.2 h to 3.7 h for RC and from 4.6 h to 3.2 h for RH. Conversely, increasing Na₂SiO₃ content led to greater drying shrinkage, from −0.42% to −0.49% in RC and from −0.46% to −0.52% in RH. Compressive strength values at 28 days ranged from 7.6 to 8.2 MPa. X-ray diffraction (XRD) revealed the presence of non-reactive crystalline phases in both precursors, while Fourier transform infrared (FTIR) spectroscopy indicated the formation of CASH, CSH, and/or (N)CASH gels. This study highlights the potential of CDW as a sustainable alternative binder and the usefulness of the proposed method for optimising alkali-activated systems, contributing to circular economy strategies in the construction sector. 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

In recent days, aluminum-based hybrid composites have garnered more interest than monolithic alloys owing to their remarkable properties, encompassing a high strength-to-weight ratio, excellent corrosion resistance, and impressive wear durability. The present study attempts to optimize the multiple wear attribute characteristics of Al6061/SiC/Al₂O₃ hybrid composites using grey and entropy-based VIKOR techniques. The composites were produced by adding equal proportions of SiC/Al₂O₃ (0–12 wt.%) ceramics through the stir-casting process, using an ultrasonication setup. Dry sliding wear experiments were executed with tribometer variants, namely reinforcement content (wt.%), load (N), sliding velocity (v), and sliding distance (SD), following L₂₇ OA. The optimal combination of process variables for achieving high GRG values from grey analysis was found to be A₃-B₃-C₃-D₃. The S/N ratios and ANOVA results for GRG indicated that RF content (wt.%) is the predominant component determining multiple outcomes, followed by sliding distance, load, and sliding velocity. The multi-order regression model formulated for the VIKOR index (Q_i) displayed high significance and more accuracy, with a variance of 0.0216 and a coefficient of determination (R²), and adjusted R² values of 99.60% and 99.14%. Subsequent morphological studies indicated that plowing, abrasion, and adhesion mechanisms are the dominant modes of wear. Full article

The chemical and microstructural transformation of the surface of a 31.5 vol.% ZrB₂-31.5 vol.% HfB₂-27 vol.% SiC-10 vol.% C_CNT ultrahigh-temperature ceramic sample (where C_CNT refers to carbon nanotubes) was studied under the influence of a subsonic N₂-plasma flow with the addition of 5 mol% methane, simulating aerodynamic heating in the atmosphere of Titan. As in the case of pure nitrogen flow, it was found that silicon carbide is removed from the surface. Zirconium and hafnium diborides are partially transformed into a Zr-Hf-B-C-N solid solution in the experiment conducted. XRD, Raman spectroscopy, and SEM-EDX analysis show that the presence of C₂ in the N₂-CH₄ plasma flow leads to surface carbonization (formation of a graphite- and diamond-like coating with a high proportion of amorphous carbon), resulting in significant changes in the microstructure and emissivity, potentially affecting the catalytic properties of the surface. Full article

This study investigates the effect of duo-ceramic zirconia and silicon nitride (ZrO₂-Si₃N₄) particles and their reinforcement proficiencies on a Ti6Al4V alloy, consolidated using the spark plasma sintering (SPS) technique. The selected sintering parameters are, viz., 900 °C temperature, 50 MPa pressure, 10 min of holding time, and 100 °C/min of sintering rate. SEM/EDS and XRD equipment were used to disclose the microstructural evolution and phase identification of created composites. The mechanical characteristics of the resulting composites were determined using the nanoindentation technique. All consolidated sintered composites showed excellent densification, with sample relative densities reaching 96.65%. Significant improvements were also made in their nanomechanical characteristics; among the composite samples with different volume fractions, the ceramics with the lowest volume percentage had the best mechanical characteristics, whereas the sintered samples with the highest ceramic volume percentage showed a decrease in mechanical proficiencies and relative density. Composite S1, with the lowest volume fraction of the duo-ceramic particles, was seen to have a significant mechanical property improvement better than other composites, S2 and S3, in terms of measured Vickers microhardness, elastic modulus, and nano hardness values at a sintering temperature of 900 °C. Consequentially, composite specimens S2 and S3’s mechanical characteristics and relative densities dropped as the volume fractions of the duo-ceramic particles increased. Full article

This paper demonstrates a novel method for preparing electrically conductive silicon carbide (SiC) ceramics by combining hot-press sintering and nitrogen pressure heat treatment. By incorporating graphite and AlN-Y₂O₃ sintering additives, conductive SiC ceramics with intergranular regions containing Y, C, and O elements were fabricated via low-temperature hot-pressing in a hot-press furnace. Following this, the samples were subjected to heat treatment in nitrogen atmosphere at varying temperatures using a gas pressure sintering furnace. It is revealed that Y and N elements were successfully dissolved into SiC grains, enhancing electrical conductivity. Additionally, localized nitridation occurred, and the Y₂Si₄CN₆ phase—a newly identified phase in nitrided regions—was discovered for the first time, potentially contributing to reduced resistivity. After heat treatment, the sample resistivity decreased significantly from an initial 3.1 × 10⁻¹ Ω·cm to the minimum of 7.56 × 10⁻³ Ω·cm. Full article

Traditional nanoparticle aerogels suffer from inherent brittleness and thermal instability at elevated temperatures. In recent years, ceramic nanofiber aerogels, utilizing flexible nanofibers as structural units, have emerged as mechanically resilient alternatives with ultrahigh porosity (>90%). However, their thermal insulation capabilities are compromised by micron-scale pores (10–100 μm) and overdependence on ultralow density, which exacerbates mechanical fragility. This study pioneers a gas-phase self-assembly strategy to fabricate Si₃N₄ nanoparticle reinforced Si₃N₄ nanofiber aerogels (SNP-R-SNFA) with gradient pore architectures. By leveraging methyltrimethoxysilane/vinyltriethoxysilane composite aerogel (MVa) as a reactive template, we achieved spontaneous growth of Si₃N₄ nanofiber films (SNP-R-SNF) featuring nanoparticle-fiber interpenetration and porosity gradients. The microstructure formation mechanism of SNP-R-SNF was analyzed using field-emission scanning electron microscopy. Layer assembly and hot-pressing composite technology were employed to prepare the SNP-R-SNFA, which showed low density (0.033 g/cm³), exceptional compression resilience, insensitive frequency dependence of dielectric properties (ε′ = 2.31–2.39, tan δ < 0.08 across 8–18 GHz). Infrared imaging displayed backside 893 °C cooler than front, demonstrating superior insulation performance. This study not only provides material solutions for integrated electromagnetic wave-transparent/thermal insulation applications but more importantly establishes an innovative paradigm for enhancing the mechanical robustness of nanofiber-based aerogels. Full article

The expansion of the construction sector has contributed to the depletion of raw materials and an increased demand for resources; therefore, sustainable approaches are required to satisfy the construction demand. The present study explores the development of geopolymers by utilizing industrial by-products from mining, ceramics, olive oil production, and steel manufacturing. Specifically, slate stone cutting sludge (SSCS) and chamotte (CH) are used as aluminosilicate precursors, with olive biomass bottom ash (OSBA) acting as an alkaline activator, along with sodium silicate, and steel granulated slag (SGS) incorporated as an aggregate. Novel geopolymers were prepared with consistent proportions of SSCS and OSBA while varying the CH content from 10 to 2 wt.%. The SGS proportion was adjusted from 35 to 50 wt.%, and different Na₂SiO₃/OSBA ratios (0.35, 0.31, 0.19, and 0.08) were examined. To identify the optimal mix, a series of physical and mechanical tests was conducted, complemented by FTIR and SEM analysis to evaluate the chemical and microstructural changes. The best-performing formulation achieved a compressive strength of 42.8 MPa after 28 days of curing. FTIR analysis identified quartz and carbonate phases, suggesting that quartz did not fully dissolve and that carbonates formed during the heating process. SEM examination of the optimal mixture indicated that the incorporation of SGS (up to 45 wt.%) facilitated the creation of a compact, low-porosity structure. EDX results revealed the presence of Ca-, Na-, Si-, Al-, and K-enriched phases, supporting the formation of (N, C)-A-S-H gel networks. These results demonstrate the potential of utilizing SSCS, CH, OSBA, and SGS to create geopolymer concretes, showcasing the viability of using industrial by-products as eco-friendly substitutes for traditional construction materials. Full article

Purpose Maintaining the surface quality of ceramic restorations after clinical adjustments is critical for both aesthetic outcomes and long-term oral health, yet the optimal approach to restoring gloss and smoothness remains unclear. The purpose of this study is to investigate the effect of different surface finishing and grinding procedures on the surface gloss and roughness of three different monolithic lithium disilicate ceramics and one monolithic ultra-translucent zirconia ceramic. Materials and Methods A total of 104 specimens (1.5 × 12 × 14 mm) were prepared from four ceramic materials: LiSi CEREC Tessera (CT), GC Initial LiSi (LS), IPS e.max CAD (EC), and zirconia disc (KATANA UTML (KAT)). Each was divided into two subgroups based on surface finishing (mechanical polishing or glazing; n = 10). Gloss and surface roughness were measured using a glossmeter and a profilometer, respectively. One specimen per subgroup was analyzed under SEM at ×1000 magnification. Results Gloss and roughness values were analyzed with the two-way robust ANOVA test and multiple comparisons were made with Bonferroni correction. The significance level was set at p < 0.05. Mechanical polishing, glazing, and repolishing increased the gloss values of the materials, with the KAT group achieving the highest gloss in the repolishing groups. The lowest gloss values were observed in the grinding groups. Additionally, these surface treatments reduced the roughness of the surface of all the materials. Conclusions Surface finishing procedures significantly influenced the gloss and roughness of monolithic lithium disilicate and zirconia ceramics. Mechanical polishing systems performed similarly or better than glazing. However, selecting an appropriate polishing system for each material is essential. Full article

Si₃N₄ ceramics and composites stand out for their exceptional mechanical and thermal properties. Compared with conventional ceramic forming processes, 3D printing via vat photopolymerization not only ensures high geometric precision but also improves the forming efficiency and strength of green body. Nevertheless, the grayish appearance of Si₃N₄ and its relatively high refractive index can adversely affect the photocuring behavior in ceramic slurries. The primary objectives focus on enhancing the curing performance and rheological properties of slurries, minimizing defects during post-processing, and improving the relative density and mechanical properties of Si₃N₄ ceramics. Key advancements include slurry optimization via refractive index matching, biomodal particle gradation and surface modification, while the integration of whisker/fiber additions or polymer-derived ceramic strategies enhances mechanical properties. In addition, controlling the atmosphere and heating rate of the post-processing innovations can achieve a relative density of more than 95%. This paper introduces the mechanisms of vat photopolymerization and then summarizes the strategies for improving Si₃N₄ ceramic slurries as well as controlling the printing and debinding/sintering processes. It further highlights the ways in which different approaches can be used to enhance the properties of Si₃N₄ slurries and ceramic parts. Finally, applications of Si₃N₄ ceramics and composites via vat photopolymerization in various fields such as aviation, aerospace, energy, electronics, chemical processes, and biomedical implants are also presented to point out future opportunities and challenges. Full article

This study aims to optimize the turning parameters for EN-GJL-250 grey cast iron using hybrid machine learning techniques integrated with multi-objective optimization algorithms. The experimental design focused on evaluating the impact of cutting tool type, testing three tools: uncoated and coated silicon nitride (Si₃N₄) ceramic inserts and coated cubic boron nitride (CBN). Key cutting parameters such as depth of cut (ap), feed rate (f), and cutting speed (Vc) were varied to examine their effects on surface roughness (Ra), cutting force (Fr), and power consumption (Pc). The results showed that the coated Si₃N₄ tool achieved the best surface finish, with minimal cutting force and power consumption, while the uncoated Si₃N₄ and CBN tools performed slightly worse. Advanced optimization models including improved grey wolf optimizer–deep neural networks (DNN-IGWOs), genetic algorithm–deep neural networks (DNN-GAs), and deep neural network–extended Kalman filters (DNN-EKF) were compared with traditional methods like Support Vector Machines (SVMs), Decision Trees (DTs), and Levenberg–Marquardt (LM). The DNN-EKF model demonstrated exceptional predictive accuracy with an R² value of 0.99. The desirability function (DF) method identified the optimal machining parameters for the coated Si₃N₄ tool: ap = 0.25 mm, f = 0.08 mm/rev, and Vc = 437.76 m/min. At these settings, Fr ranged between 46.424 and 47.405 N, Ra remained around 0.520 µm, and Pc varied between 386.518 W and 392.412 W. The multi-objective grey wolf optimization (MOGWO) further refined these parameters to minimize Fr, Ra, and Pc. This study demonstrates the potential of integrating machine learning and optimization techniques to significantly enhance manufacturing efficiency. Full article

Metal alloys continue to be, and are expected to remain, essential materials for fabricating prosthetic elements due to their unique properties, particularly their high strength, durability, and appropriate modulus of elasticity, which make them well-suited for such applications. However, commonly used non-precious metal alloys exhibit lower corrosion resistance compared to precious metal alloys. This reduced resistance leads to the release of metal ions from the alloy into the oral environment. Adverse biological responses to metal alloys can be mitigated through various surface modifications, most commonly by applying coatings. These coatings are typically ceramic, including oxides, nitrides, and carbides. In this study, the mechanical properties (hardness, modulus of elasticity, adhesion, and thickness) of complex Si(C,N) coatings applied to a prosthetic Ni-Cr alloy were investigated. Depending on the proportions of N, C, and Si in the coating, the hardness ranged from 12 to 15 GPa, while the modulus of elasticity varied between 130 and 170 GPa. Adhesion strength, measured via the scratch test method, was within an acceptable range. Microscopic analysis revealed that the coatings had a thickness of 2 to 2.5 μm, exhibiting a homogeneous, columnar structure. In conclusion, the properties of the fabricated Si(C,N) coatings are deemed satisfactory for their intended use as protective layers for prosthetic and orthodontic components. Full article