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Keywords = YSZ

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12 pages, 16238 KiB  
Article
Degradation of HVOF-MCrAlY + APS-Nanostructured YSZ Thermal Barrier Coatings
by Weijie R. Chen, Chao Li, Yuxian Cheng, Hongying Li, Xiao Zhang and Lu Wang
Coatings 2025, 15(8), 871; https://doi.org/10.3390/coatings15080871 - 24 Jul 2025
Viewed by 274
Abstract
The degradation process of HVOF-MCrAlY + APS-nanostructured YSZ (APS-nYSZ) thermal barrier coatings, produced using gas turbine OEM-approved MCrAlY powders, is investigated by studying the TGO growth and crack propagation behaviors in a thermal cycling environment. The TGO growth yields a parabolic mechanism on [...] Read more.
The degradation process of HVOF-MCrAlY + APS-nanostructured YSZ (APS-nYSZ) thermal barrier coatings, produced using gas turbine OEM-approved MCrAlY powders, is investigated by studying the TGO growth and crack propagation behaviors in a thermal cycling environment. The TGO growth yields a parabolic mechanism on the surfaces of all HVOF-MCrAlYs, and the growth rate increases with the aluminum content in the “classical” MCrAlYs. The APS-nYSZ layer comprises micro-structured YSZ (mYSZ) and nanostructured YSZ (nYSZ) zones. Both mYSZ/mYSZ and mYSZ/nYSZ interfaces appear to be crack nucleation sites, resulting in crack propagation and consequent crack coalescence within the APS-nYSZ layer in the APS-nYSZ/HVOF-MCrAlY vicinity. Crack propagation in the TBCs can be characterized as a steady-state crack propagation stage, where crack length has a nearly linear relationship with TGO thickness, and an accelerating crack propagation stage, which is apparently a result of the coalescence of neighboring cracks. All TBCs fail in the same way as APS-/HVOF-MCrAlY + APS-conventional YSZ analogs, but the difference in thermal cycling lives is not substantial, although the HVOF-low Al-NiCrAlY encounters chemical failure in the early stage of thermal cycling. Full article
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15 pages, 3416 KiB  
Article
The Study of Tribological Characteristics of YSZ/NiCrAlY Coatings and Their Resistance to CMAS at High Temperatures
by Dastan Buitkenov, Zhuldyz Sagdoldina, Aiym Nabioldina and Cezary Drenda
Appl. Sci. 2025, 15(14), 8109; https://doi.org/10.3390/app15148109 - 21 Jul 2025
Viewed by 288
Abstract
This paper presents the results of a comprehensive study of the structure, phase composition, thermal corrosion, and tribological properties of multilayer gradient coatings based on YSZ/NiCrAlY obtained using detonation spraying. X-ray phase analysis showed that the coatings consist entirely of metastable tetragonal zirconium [...] Read more.
This paper presents the results of a comprehensive study of the structure, phase composition, thermal corrosion, and tribological properties of multilayer gradient coatings based on YSZ/NiCrAlY obtained using detonation spraying. X-ray phase analysis showed that the coatings consist entirely of metastable tetragonal zirconium dioxide (t’-ZrO2) phase stabilized by high temperature and rapid cooling during spraying. SEM analysis confirmed the multilayer gradient phase distribution and high density of the structure. Wear resistance, optical profilometry, wear quantification, and coefficient of friction measurements were used to evaluate the operational stability. The results confirm that the structural parameters of the coating, such as porosity and phase gradient, play a key role in improving its resistance to thermal corrosion and CMAS melt, which makes such coatings promising for use in high-temperature applications. It is shown that a dense and thick coating effectively prevents the penetration of aggressive media, providing a high barrier effect and minimal structural damage. Tribological tests in the temperature range from 21 °C to 650 °C revealed that the best characteristics are observed at 550 °C: minimum coefficient of friction (0.63) and high stability in the stage of stable wear. At room temperature and at 650 °C, there is an increase in wear due to the absence or destabilization of the protective layer. Full article
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9 pages, 953 KiB  
Article
Yttrium Ion Release and Phase Transformation in Yttria-Stabilized Zirconia Under Acidic Conditions: Implications for Dental Implant Durability
by Haochen Zhu, Chao-Ching Chiang, Valentin Craciun, Griffin M. Deane, Fan Ren and Josephine F. Esquivel-Upshaw
Materials 2025, 18(14), 3311; https://doi.org/10.3390/ma18143311 - 14 Jul 2025
Viewed by 262
Abstract
The stability of yttria-stabilized zirconia (YSZ) as a dental implant material is highly dependent on its resistance to low-temperature degradation (LTD) and surface dissolution, particularly in acidic oral environments. This study investigates the effects of yttrium ion (Y3+) release on the [...] Read more.
The stability of yttria-stabilized zirconia (YSZ) as a dental implant material is highly dependent on its resistance to low-temperature degradation (LTD) and surface dissolution, particularly in acidic oral environments. This study investigates the effects of yttrium ion (Y3+) release on the phase stability of zirconia during constant immersion and pH cycling tests, simulating oral conditions. Zirconia disks were immersed in acidic (pH 2), neutral (pH 7), and basic (pH 10) solutions over a 27-day period. Inductively coupled plasma (ICP) analysis revealed significant yttrium ion release during acidic phases, while zirconium ion (Zr4+) release remained minimal. X-ray photoelectron spectroscopy (XPS) showed a shift in zirconium 3d binding energies, indicating a transformation from the tetragonal to the monoclinic phase, driven by yttrium leaching. X-ray diffraction (XRD) confirmed this phase change, with the appearance of the monoclinic (111) peak after exposure to acidic conditions. This study concludes that yttrium ion depletion under acidic conditions destabilizes the tetragonal phase, promoting LTD and compromising the material’s long-term performance as a dental implant or restorative material. Full article
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17 pages, 5119 KiB  
Article
Anode-Supported SOFCs with a Bi2O3-Doped NiO–ScSZ Anode and ScSZ Electrolyte: Low-Temperature Co-Sintering and High Performance
by Shang Peng, Zhao Liu, Pairuzha Xiaokaiti, Tiancheng Fang, Jiwei Wang, Guoqing Guan and Abuliti Abudula
ChemEngineering 2025, 9(4), 66; https://doi.org/10.3390/chemengineering9040066 - 24 Jun 2025
Viewed by 391
Abstract
In this study, a novel anode-supported solid oxide fuel cell (SOFC) comprising a Bi2O3-doped NiO-ScSZ anode and an ScSZ electrolyte was successfully fabricated via a low-temperature co-sintering process at 1300 °C. The incorporation of 3 wt% Bi2O [...] Read more.
In this study, a novel anode-supported solid oxide fuel cell (SOFC) comprising a Bi2O3-doped NiO-ScSZ anode and an ScSZ electrolyte was successfully fabricated via a low-temperature co-sintering process at 1300 °C. The incorporation of 3 wt% Bi2O3 effectively promoted the sintering of both the anode support and electrolyte layer, resulting in a dense, gas-tight electrolyte and a mechanically robust porous anode support. X-ray diffraction (XRD) and scanning electron microscopy (SEM) analyses confirmed the formation of phase-pure, highly crystalline ScSZ with an optimized microstructure. Electrochemical performance measurements demonstrated that the fabricated cells achieved excellent power density, reaching a peak value of 0.861 W cm−2 at 800 °C under humidified hydrogen fuel conditions. The cells maintained stable performance under dry methane operation, with a maximum power density of 0.624 W cm−2 at 800 °C, indicating resistance to carbon deposition. Gas chromatographic analyses further revealed that the Bi2O3-doped NiO-ScSZ anode facilitated earlier and more stable electrochemical oxidation of methane-derived species compared with the conventional NiO-YSZ system, even under conditions of an elevated methane partial pressure. These findings demonstrate that Bi2O3 co-doping, combined with low-temperature co-sintering, provides an effective approach for fabricating high-performance intermediate-temperature SOFCs with enhanced structural integrity and electrochemical stability. The developed methodology presents a promising pathway toward achieving cost-effective and durable SOFC technologies. Full article
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9 pages, 859 KiB  
Article
Fourier-Transform Infrared Spectroscopy Analysis of 3D-Printed Dental Resins Reinforced with Yttria-Stabilized Zirconia Nanoparticles
by Andrea Izabella Borș
Dent. J. 2025, 13(6), 272; https://doi.org/10.3390/dj13060272 - 18 Jun 2025
Viewed by 362
Abstract
Background/Objectives: This study investigates the chemical structure and molecular interactions in 3D-printed dental resins reinforced with varying concentrations of Yttria-Stabilized Zirconia (YSZ) nanoparticles, using Fourier-Transform Infrared Spectroscopy (FTIR) to assess the compatibility and bonding behavior at the molecular level. Methods: Three groups of [...] Read more.
Background/Objectives: This study investigates the chemical structure and molecular interactions in 3D-printed dental resins reinforced with varying concentrations of Yttria-Stabilized Zirconia (YSZ) nanoparticles, using Fourier-Transform Infrared Spectroscopy (FTIR) to assess the compatibility and bonding behavior at the molecular level. Methods: Three groups of 3D-printed methacrylate-based resin discs were fabricated: a control (0% YSZ), and experimental groups reinforced with 1% and 3% YSZ nanoparticles. Samples were produced using Digital Light Processing (DLP) technology and post-processed under standardized conditions. FTIR spectra were collected via ATR mode over a wavenumber range of 4000–600 cm−1. Spectral differences at key wavenumbers (1721.16, 1237.11, and 929.62 cm−1) were statistically analyzed using one-way ANOVA and Tukey’s post hoc test. Results: FTIR spectra showed no significant shifts in the ester carbonyl band at 1721.16 cm−1, suggesting the preservation of the core resin matrix. However, a statistically significant increase in absorbance at 1237.11 cm−1 was observed in the 1% YSZ group (p = 0.034), indicating dipolar interaction. A distinct new peak at 929.62 cm−1, corresponding to Zr–O vibrations, emerged in the 3% YSZ group (p = 0.002), confirming successful nanoparticle integration. Conclusions: YSZ nanoparticles enhance specific molecular interactions within methacrylate-based dental resins without compromising structural integrity. These findings support the potential application of YSZ-reinforced 3D-printed resins in durable, biocompatible permanent dental restorations. Full article
(This article belongs to the Special Issue Feature Papers in Digital Dentistry)
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24 pages, 5461 KiB  
Article
Classification and Prediction of Unknown Thermal Barrier Coating Thickness Based on Hybrid Machine Learning and Terahertz Nondestructive Characterization
by Zhou Xu, Jianfei Xu, Yiwen Wu, Changdong Yin, Suqin Chen, Qiang Liu, Xin Ge, Luanfei Wan and Dongdong Ye
Coatings 2025, 15(6), 725; https://doi.org/10.3390/coatings15060725 - 17 Jun 2025
Viewed by 475
Abstract
Thickness inspection of thermal barrier coatings is crucial to safeguard the reliability of high-temperature components of aero-engines, but traditional destructive inspection methods are difficult to meet the demand for rapid assessment in the field. In this study, a new non-destructive testing method integrating [...] Read more.
Thickness inspection of thermal barrier coatings is crucial to safeguard the reliability of high-temperature components of aero-engines, but traditional destructive inspection methods are difficult to meet the demand for rapid assessment in the field. In this study, a new non-destructive testing method integrating terahertz time-domain spectroscopy and machine learning algorithms is proposed to systematically study the thickness inspection of 8YSZ coatings prepared by two processes, namely atmospheric plasma spraying (APS) and electron beam physical vapor deposition (EB-PVD). By optimizing the preparation process parameters, 620 sets of specimens with thicknesses of 100–400 μm are prepared, and three types of characteristic parameters, namely, time delay Δt, frequency shift Δf, and energy decay η, are extracted by combining wavelet threshold denoising and time-frequency joint analysis. A CNN-RF cascade model is constructed to realize coating process classification, and an attention-LSTM and SVR weighted fusion model is developed for thickness regression prediction. The results show that the multimodal feature fusion reduces the root-mean-square error of thickness prediction to 8.9 μm, which further improves the accuracy over the single feature model. The classification accuracy reaches 96.8%, of which the feature importance of time delay Δt accounts for 62%. The hierarchical modeling strategy reduces the detection mean absolute error from 6.2 μm to 4.1 μm. the method provides a high-precision solution for intelligent quality assessment of thermal barrier coatings, which is of great significance in promoting the progress of intelligent manufacturing technology for high-end equipment. Full article
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18 pages, 4144 KiB  
Article
Integrated Microstructural and Chemical Approach for Improving CMAS Resistance in Thermal and Environmental Barrier Coatings
by Andrew J. Wright, Clara Mock, Timothy Sharobem, Nickolas Sotiropoulos, Chris Dambra, Brian Keyes and Anindya Ghoshal
Coatings 2025, 15(6), 680; https://doi.org/10.3390/coatings15060680 - 5 Jun 2025
Viewed by 561
Abstract
This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at [...] Read more.
This study provides an investigation into the influence of surface roughness, porosity, and chemistry on the wettability and infiltration behavior of calcia-magnesia-alumino-silicates (CMASs) in thermal and environmental barrier coatings (T/EBCs) used in high-temperature gas turbine engines. High-temperature contact angle measurements were performed at 1260 °C on 7 wt.% yttria-stabilized zirconia (7YSZ) and yttrium ytterbium disilicate (YYbDS, (Y1/2Yb1/2)2Si2O7) to evaluate the interaction of CMASs with different surface finishes and coating microstructures. The findings demonstrate that porosity plays a dominant role in determining CMAS infiltration dynamics. In YYbDS, increasing porosity from 6.3% to 22.7% facilitated the formation of an apatite layer that limited CMAS penetration to approximately 2 µm. Surface roughness exhibited a subtler influence in that reducing Sa from 0.61 µm to 0.05 µm increased the change in the contact angle by ~2°, although its impact was found to be less significant compared to porosity and reactive chemistry. These results indicate that an integrated approach that optimizes porosity, chemistry, and surface morphology can significantly enhance CMAS resistance. The study emphasizes that leveraging both microstructural and chemical properties is critical to developing coatings capable of withstanding the harsh conditions encountered in aerospace environments. Full article
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21 pages, 8395 KiB  
Article
Deep Artificial Neural Network Modeling of the Ablation Performance of Ceramic Matrix Composites in the Hydrogen Torch Test
by Jayanta Bhusan Deb, Christopher Varela, Fahim Faysal, Yiting Wang, Chiranjit Maiti and Jihua Gou
J. Compos. Sci. 2025, 9(5), 239; https://doi.org/10.3390/jcs9050239 - 13 May 2025
Viewed by 744
Abstract
In recent years, there has been increasing interest in new materials such as ceramic matrix composites (CMCs) for power generation and aerospace propulsion applications through hydrogen combustion. This study employed a deep artificial neural network (DANN) model to predict the ablation performance of [...] Read more.
In recent years, there has been increasing interest in new materials such as ceramic matrix composites (CMCs) for power generation and aerospace propulsion applications through hydrogen combustion. This study employed a deep artificial neural network (DANN) model to predict the ablation performance of CMCs in the hydrogen torch test (HTT). The study was conducted in three phases to increase the accuracy of the model’s predictions. Initially, to predict the thermal behavior of ceramic composites, two linear machine learning models were used known as Lasso and Ridge regression. In the second step, four decision tree-based ensemble machine learning models, namely random forest, gradient boosting regression, extreme gradient boosting regression, and extra tree regression, were used to improve the prediction accuracy metrics, including root mean square error (RMSE), mean absolute error (MAE), correlation coefficient (R2 score), and mean absolute percentage error (MAPE), relative to the previously introduced linear models. Finally, to forecast the thermal stability of CMCs with time, an optimized DANN model with two hidden layers having rectified linear unit activation function was developed. The data collection procedure involved preparing CMCs with continuous Yttria-Stabilized Zirconia (YSZ) fibers and silicon carbide (SiC) matrix using a polymer infiltration and pyrolysis (PIP) technique. The samples were exposed to a hydrogen flame at a high heat flux of 183 W/cm2 for a duration of 10 min. A good agreement between the DANN model’s predictions and experimental data with an R2 score of 0.9671, RMSE of 16.45, an MAE of 14.07, and an MAPE of 3.92% confirmed the acceptability of the developed neural network model in this study. Full article
(This article belongs to the Special Issue Feature Papers in Journal of Composites Science in 2025)
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22 pages, 3206 KiB  
Article
CO2 Reforming of Methane over Ru Supported Catalysts Under Mild Conditions
by Alexandros K. Bikogiannakis, Andriana Lymperi, Paraskevas Dimitropoulos, Kyriakos Bourikas, Alexandros Katsaounis and Georgios Kyriakou
Molecules 2025, 30(10), 2135; https://doi.org/10.3390/molecules30102135 - 12 May 2025
Viewed by 690
Abstract
The CO2 (Dry) Reforming of Methane (DRM) is a key process for reducing CO2 and CH4 emissions while producing syngas with an H2/CO ratio of 1, ideal for Fischer–Tropsch synthesis. This study explores DRM and the Reverse Water [...] Read more.
The CO2 (Dry) Reforming of Methane (DRM) is a key process for reducing CO2 and CH4 emissions while producing syngas with an H2/CO ratio of 1, ideal for Fischer–Tropsch synthesis. This study explores DRM and the Reverse Water Gas Shift (RWGS) reaction under mild conditions using Ru-based catalysts supported on CeO2, YSZ, TiO2, and SiO2, with three reactant ratios: (i) stoichiometric, PCO2 = 1 kPa, PCH4 = 1 kPa, (ii) oxidizing, PCO2 = 2 kPa, PCH4 = 1 kPa, and (iii) reducing, PCO2 = 1 kPa, PCH4 = 4 kPa. The results highlight the importance of redox support for catalyst stability, with mobile lattice oxygen aiding carbon gasification. While Ru/CeO2 is stable at high temperatures, it rapidly deactivates at low temperatures, emphasizing the need for precise metal particle size control. This work demonstrates the necessity of fine-tuning catalyst properties for more sustainable DRM, offering insights for next-generation CO2 utilization catalysts. Full article
(This article belongs to the Special Issue New Insight in Catalysis and Electrocatalysis for CO2 Conversion)
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22 pages, 4964 KiB  
Article
Multiphysics-Driven Structural Optimization of Flat-Tube Solid Oxide Electrolysis Cells to Enhance Hydrogen Production Efficiency and Thermal Stress Resistance
by Shanshan Liang, Jingxiang Xu, Yunfeng Liao, Yu Zhao, Haibo Huo and Zhenhua Chu
Energies 2025, 18(10), 2449; https://doi.org/10.3390/en18102449 - 10 May 2025
Viewed by 457
Abstract
The solid oxide electrolysis cell (SOEC) has potential application value in water electrolysis for hydrogen production. Here, we propose an integrated multi-scale optimization framework for the SOEC, addressing critical challenges in microstructure–property correlation and thermo-mechanical reliability. By establishing quantitative relationships between fuel support [...] Read more.
The solid oxide electrolysis cell (SOEC) has potential application value in water electrolysis for hydrogen production. Here, we propose an integrated multi-scale optimization framework for the SOEC, addressing critical challenges in microstructure–property correlation and thermo-mechanical reliability. By establishing quantitative relationships between fuel support layer thickness, air electrode rib coverage, and Ni-YSZ volume ratio, we reveal their nonlinear coupling effects on the hydrogen production rate and thermal stress. The results show that when the fuel support layer thickness increases, the maximum principal stress of the fuel electrode decreases, and the hydrogen production rate and diffusion flux first increase and then decrease. The performance is optimal when the fuel support layer thickness is 5.4 mm. As the rib area decreases, the hydrogen production rate and thermal stress gradually decrease, but the oxygen concentration distribution becomes more uniform when the rib area portion is 42%. When the Ni volume fraction increases, the hydrogen production rate and the maximum principal stress gradually increase, but the uniformity of H2O flow decreases. When the Ni volume fraction is lower than 50%, the uniformity of H2O flow drops to 20%. As the volume fraction of nickel (Ni) increases, the fuel utilization gradually increases. When the volume fraction of Ni is between 50% and 60%, the fuel utilization reaches the range of 60–80%. This study indicates that the fuel support layer thickness, rib area, and Ni-YSZ ratio have different effects on the overall performance of the SOEC, providing guidance for the optimization of the flat-tube SOEC structure. Full article
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33 pages, 19731 KiB  
Article
Comparative Study of Physicochemical Properties of Biochar Samples Derived from Nutshells as a Solid Fuel for Direct Carbon Solid Oxide Fuel Cells
by Magdalena Dudek, Bartosz Adamczyk, Anita Zych, Katarzyna Król, Przemysław Grzywacz, Krystian Sokołowski, Krzysztof Mech, Maciej Sitarz, Piotr Jeleń, Magdalena Ziąbka, Maja Mroczkowska-Szerszeń, Małgorzata Witkowska and Joanna Kowalska
Materials 2025, 18(9), 2112; https://doi.org/10.3390/ma18092112 - 4 May 2025
Viewed by 759
Abstract
This paper presents the results of an investigation into the effect of the physicochemical properties of carbon chars (biochars) on the performance of direct carbon solid oxide fuel cells (DC-SOFCs). Biochars were obtained from walnut, coconut, pistachio, hazelnut and peanut shells by pyrolysis [...] Read more.
This paper presents the results of an investigation into the effect of the physicochemical properties of carbon chars (biochars) on the performance of direct carbon solid oxide fuel cells (DC-SOFCs). Biochars were obtained from walnut, coconut, pistachio, hazelnut and peanut shells by pyrolysis at a temperature of 850 °C. The results of structural studies conducted using X-ray diffraction and Raman spectroscopy reflected a low degree of graphitisation of carbon particles. Biochar derived from walnut shells is characterised by a relatively uniform content of alkali elements, such as sodium, potassium, calcium, magnesium and iron, which are natural components of the mineral residue and act as catalysts for the Boudouard reaction. This study of gasification of biochar samples in a CO2 atmosphere recorded that the highest conversion rate from solid phase to gaseous phase was for the biochar sample produced from walnut shells. The superior properties of this sample are directly connected to structural features, as well as to the random distribution of alkali elements. DC-SOFCs involving 10 mol% of Sc2O3, 1 mol% of CeO2, 89 mol% of ZrO2 (10S1CeZ) or 8 mol% of Y2O3 in ZrO2 (8YSZ) were used as both solid oxide electrolytes and components of the anode electrode. It was found that the highest electrochemical power output (Pmax) was achieved for DC-SOFCs fuelled by biochar from walnut shells, with around 103 mW/cm2 obtained for such DC-SOFCs involving 10S1CeZ electrolytes. Full article
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17 pages, 10913 KiB  
Article
Study of Gd2O3-Doped La2(Zr0.7Ce0.3)2O7 Thermal Barriers for Coating Ceramic Materials for CMAS Resistance
by Xiaowei Song, Min Xie, Xiaofu Qu, Xiwen Song, Yonghe Zhang and Rende Mu
Coatings 2025, 15(4), 483; https://doi.org/10.3390/coatings15040483 - 18 Apr 2025
Cited by 1 | Viewed by 504
Abstract
The stability of thermal barrier coating (TBC) materials during service is a prerequisite for the normal operation of aircraft engines. The high-temperature corrosion of CaO–MgO–Al2O3–SiO2 (CMAS) is an important factor that affects the stability of TBCs on turbine [...] Read more.
The stability of thermal barrier coating (TBC) materials during service is a prerequisite for the normal operation of aircraft engines. The high-temperature corrosion of CaO–MgO–Al2O3–SiO2 (CMAS) is an important factor that affects the stability of TBCs on turbine blades and causes premature engine failure. For traditional 6-8 YSZ, at temperatures of more than 1200 °C, the thermal insulation performance is significantly reduced, which makes it necessary to find new, alternative materials. La2Zr2O7 has good thermal physical properties; the addition of Ce4+ improves its mechanical properties, while adding Gd2O3 affects its corrosion resistance. Herein, high-temperature corrosion studies of (La1−xGdx)2(Zr0.7Ce0.3)2O7 (L-GZC) (x = 0, 0.3, 0.5, 0.7) ceramic TBC were conducted using CMAS glass at 1250 °C. The results indicate that CMAS rapidly dissolves L-GZC and separates the (La, Gd)8Ca2(SiO4)6O2 apatite phase, ZrO2, and other crystalline phases. These products form a crystalline layer at the contact boundary, which can inhibit further CMAS reactions. Among the coatings examined, the L-GZC ceramic (x = 0.7) exhibits better corrosion resistance, and the penetration depth is <200 μm after high-temperature corrosion at 1250 °C for 5, 10, and 20 h. The failure mechanism and potential risk of CMAS were also analyzed and discussed. The L-GZC ceramic material has good thermal corrosion resistance and is expected to replace the traditional YSZ to better meet the high-temperature working requirements of gas turbines and aircraft engines. Full article
(This article belongs to the Section Corrosion, Wear and Erosion)
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21 pages, 22568 KiB  
Article
Properties Evaluation of a Novel Entropy-Stabilized Ceramic (La0.25Ce0.25Nd0.25Sm0.25)Ti2Al9O19 with Enhanced CMAS Corrosion Resistance for Thermal Barrier Coating Applications
by Fuxing Ye, Ziqi Song, Fanwei Meng and Sajid Ali
Materials 2025, 18(8), 1778; https://doi.org/10.3390/ma18081778 - 13 Apr 2025
Viewed by 507
Abstract
In this work, a novel potential thermal barrier coating material entropy-stabilized titanium–aluminum oxide (La0.25Ce0.25Nd0.25Sm0.25)Ti2Al9O19 (META) was successfully synthesized by the solid-state reaction method, and its thermophysical properties, phase stability, infrared [...] Read more.
In this work, a novel potential thermal barrier coating material entropy-stabilized titanium–aluminum oxide (La0.25Ce0.25Nd0.25Sm0.25)Ti2Al9O19 (META) was successfully synthesized by the solid-state reaction method, and its thermophysical properties, phase stability, infrared emissivity, mechanical properties, and CMAS corrosion resistance were systematically investigated. The results demonstrated that META exhibits low thermal conductivity at 1100 °C (1.84 W·(m·K)−1), with a thermal expansion coefficient (10.50 × 10−6 K−1, 1000–1100 °C) comparable to yttria-stabilized zirconia (YSZ). Furthermore, META displayed desirable thermal stability, high emissivity within the wavelength range of 2.5–10 μm, and improved mechanical properties. Finally, META offers superior corrosion resistance due to its excellent infiltration inhibiting. The bi-layer structure on the corrosion surface prevents the penetration of the molten CMAS. Additionally, doping small-radius rare-earth elements thermodynamically stabilizes the reaction layer. The results of this study indicate that (La0.25Ce0.25Nd0.25Sm0.25)Ti2Al9O19 has the potential to be a promising candidate for thermal barrier coating materials. Full article
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11 pages, 1432 KiB  
Article
Thermal Dynamics of Laser-Irradiated Trilayer Bonded-Zirconia Structures
by Mitchell Tharp, Jaccare Jauregui-Ulloa, Grace Mendonça De Souza and Susana Salazar Marocho
J. Funct. Biomater. 2025, 16(4), 137; https://doi.org/10.3390/jfb16040137 - 11 Apr 2025
Viewed by 443
Abstract
This study aims to assess the thermal dynamics of supporting structures during laser-assisted debonding of bonded yttrium-stabilized zirconia (YSZ) ceramic. We tested the hypothesis that the heat transfer to dentin analog material and composite resin resembles that of dentin. Thirty sintered YSZ (ZirCAD, [...] Read more.
This study aims to assess the thermal dynamics of supporting structures during laser-assisted debonding of bonded yttrium-stabilized zirconia (YSZ) ceramic. We tested the hypothesis that the heat transfer to dentin analog material and composite resin resembles that of dentin. Thirty sintered YSZ (ZirCAD, Ivoclar, Schann, Liechtenstein) slabs (4 mm diameter, 1 mm thickness) were air particle abraded, followed by two coats of Monobond Plus (Ivoclar). The slabs were bonded to exposed occlusal dentin, NEMA G10 dentin analog, or composite resin cylinders using Multilink Automix (Ivoclar) dual-cured cement. The bonded YSZ specimens (n = 10/group) subjected to irradiation with an Er,Cr:YSGG laser (Waterlase MD, Biolase, Foothill Ranch, CA, USA) at 7.5 W, 25 Hz, with 50% water and air for 15 s. Heat transfer during laser irradiation was monitored with an infrared camera (Optris PI 640, Optris GmbH, Berlin, Germany) at 0.1-s intervals. Data were analyzed using one-way ANOVA, which showed no significant differences in mean temperature between zirconia and cement layers across the substrates (composite resin, G10, dentin) (p = 0.0794). These results suggest flexibility in substrate choice for future thermal dynamics studies under laser irradiation. Full article
(This article belongs to the Special Issue Property, Evaluation and Development of Dentin Materials)
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20 pages, 35477 KiB  
Article
Microstructural Evolution and Failure Analysis for 8YSZ/(Y0.5Gd0.5)TaO4 Double-Ceramic-Layer Thermal Barrier Coatings on Copper Substrate
by Xiao Zhang, Jing Ma, Huizhi Lin, Qingwei Jiang, Jun Wang and Jing Feng
Coatings 2025, 15(4), 451; https://doi.org/10.3390/coatings15040451 - 11 Apr 2025
Viewed by 465
Abstract
The main purpose of this work is to suppress the rate of thermal and oxidative corrosion of copper substrates using double-ceramic-layer thermal barrier coatings (TBCs). Herein, the orthogonal spray experiment was employed to optimize the spraying parameters for TBCs consisting of Cu/NiCoCrAlY/8YSZ/(Y0.5 [...] Read more.
The main purpose of this work is to suppress the rate of thermal and oxidative corrosion of copper substrates using double-ceramic-layer thermal barrier coatings (TBCs). Herein, the orthogonal spray experiment was employed to optimize the spraying parameters for TBCs consisting of Cu/NiCoCrAlY/8YSZ/(Y0.5Gd0.5)TaO4. The thermal cycling and average mass loss rate of TBCs prepared by atmospheric plasma spraying (APS) with optimum spraying parameters correspond to 20 cycles and 0.56‰, respectively. The thermal conductivity (0.39 W·m−1·K−1 at 900 °C) of (Y0.5Gd0.5)TaO4 is 71.68% and 52.7% lower than that of (Y0.5Gd0.5)TaO4 bulk and 8YSZ, respectively. Meanwhile, the bond strength increased from 8.86 MPa to 14.03 MPa as the heat treatment time increased from 0 h to 24 h, benefiting from the heat treatment to release the residual stresses inside the coating. Additionally, the hardness increased from 5.88 ± 0.56 GPa to 7.9 ± 0.64 GPa as the heat treatment temperature increased from room temperature to 1000 °C, resulting from the healing of pores and increased densification. Lastly, crack growth driven by thermal stress mismatch accumulated during thermal cycling is the main cause of coating failure. The above results demonstrated that 8YSZ/(Y0.5Gd0.5)TaO4 can increase the service span of copper substrate. Full article
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