Search Results (1,175)

In this study, bioceramic composites based on zirconia (ZrO₂) were synthesized and characterized in terms of mechanical properties. Two types of different-sized grains of zirconia powders were used to prepare the composites. A commercial zirconia micropowder (Tosoh) was used as a base for the composites modified with bioactive glass (BG), copper-doped bioactive glass (BGCu), and hexagonal boron nitride (hBN) with a sintering temperature of 1450 °C. The composites with the addition of hydroxyapatite, for which their sintering temperature was 1150 °C, were independently fabricated using a zirconia nanopowder prepared via co-precipitation and hydrothermal methods to achieve high densification and avoid hydroxyapatite decomposition. Mechanical performance of these composites was assessed with regard to biaxial flexural strength, Vickers hardness (HV), and fracture toughness (K_Ic). The reference 3Y-TZP material exhibited Vickers hardness (11.8 GPa) and fracture toughness (6.1 MPa∙m^1/2 values typical for dense tetragonal zirconia ceramics. The addition of all bioactive phases resulted in significant alterations in mechanical properties. Specifically, incorporating 20 wt.% HAp led to a threefold decrease in hardness and a 40% reduction in fracture toughness, while increasing the HAp content to 40 wt.% further reduced these properties. Nonetheless, the fracture toughness of these composites remained higher than that of pure hydroxyapatite materials. The incorporation of BG and BGCu reduced the hardness values by 45% and 30%, respectively, compared to 3Y-TZP. The most significant deterioration of the properties was observed for the 3Y-TZP-hBN composite. The 3Y-TZP–BGCu composite exhibited fracture toughness (5.9 MPa∙m^1/2) representing 95% of the toughness of pure zirconium dioxide, thereby showing the lowest weakness of all the other composites with bioactive additives. A slightly lower fracture toughness value (5.3 MPa∙m^1/2) was also observed in the composite with bioglass but lacking the copper additive. This factor, combined with a relatively small decrease in hardness in both cases, highlights high durability for implantology applications, thus marking the indicated materials the most promising among the composites studied. Full article

Engineered cementitious composite (ECC) is an advanced material known for its superior flexibility, high durability, and crack resistance, making it ideal for a variety of structural applications. However, it uses cement at a rate of 2–3 times more than conventional concrete which raises environmental concerns. This study focused on the production of eco-friendly ECC by incorporating various waste materials as partial cement and sand substitutes. Cement kiln dust (CKD), ceramic powder waste (CPW), and eggshell waste (ESW) were used as partial substitutes for cement in doses of 10% and 20%. Crumb rubber (CR) was used as a partial substitute for sand in doses of 25, 50, 75, and 100%. Chemical treatments using sodium hydroxide, sodium silicate, and a mix of both of them were carried out for the CR in the production of the proposed ECC. Physical treatment using the same cement substitute materials (CKD, CP and ESP) was also carried out for the CR. The effect of fiber type—such as basalt fibers (BF), polypropylene fibers (PPF), and steel fibers (S_tF)—on the performance of ECC was also investigated. Slump, compressive strength, uniaxial tensile strength, flexural strength, and sorptivity were the measured properties for the proposed ECC. Microstructure analyses were also conducted on some selected ECC mixtures. Among the tested mixtures, the results showed that replacing 10% of the cement with CKD improved the compressive strength by up to 22.6% and the tensile strength by up to 18.3%. Using 50% untreated CR reduced compressive and tensile strength by 32.8% and 28.1%, respectively, compared to the control ECC. The physical treatment of CR using CKD improved the compressive strength by up to 12.7% and the tensile strength by up to 3.2% compared to untreated CR. The microstructure analyses revealed an improvement in fiber-matrix bonding and a reduction in crack width in the mixtures, especially in the BF and PPF blends. Full article

A novel amorphous Hf-MOFs precursor was successfully synthesized and converted into HfC nanoparticles via one-step pyrolysis. The effects of metal/ligand molar ratios, solvent types, and pyrolysis temperature were systematically studied. High-purity spherical HfC nanoparticles (44.30 ± 9.63 nm) were obtained at 1500 °C using a 1.5:1 metal/ligand molar ratio with mixed anhydrous ethanol/deionized water solvents. At a pyrolysis temperature of 1700 °C, the as-synthesized HfC nanoparticles possessed an exceptionally low oxygen content of 0.76%, alongside a carbon content of 6.42% that almost perfectly matches the theoretical value of stoichiometric HfC. The formation mechanism involving Hf-O-C coordination and carbothermal reduction was clarified. Additive-free HfC ceramics were fabricated using the as-synthesized HfC nanoparticles via spark plasma sintering (1950 °C, 30 MPa, 20 min). The resulting ceramics exhibited a relative density of 96.7% and a Vickers hardness of 20.2 GPa, both of which are significantly superior to those of ceramics sintered from commercial HfC powders under identical conditions (95.8% and 17.8 GPa, respectively). This work provides a promising and feasible pathway for the preparation of other high-quality ultra-high temperature hafnium-based carbide powders and ceramics. Full article

Ceramics are widely evaluated for their extreme hardness, high-temperature stability, and corrosion resistance, which enable applications in harsh service environments. However, these same properties, high melting points, brittleness, and low thermal shock resistance, make conventional manufacturing of complex ceramic components difficult and expensive. Traditional processes often require costly diamond tooling or energy-intensive sintering and tend to produce only simple geometries, with significant waste material and risk of defects. Additive manufacturing (AM) has recently emerged as a promising route to fabricate intricate, near-net-shape ceramic parts without these drawbacks. By building components layer by layer, AM reduces the need for extensive machining and enables the fabrication of geometrically complex, near-net-shape ceramic structures with reduced material waste, although challenges such as porosity, interlayer defects, and cracking during post-processing remain. Nonetheless, ceramic AM technologies lag behind their metal and polymer counterparts, and significant challenges remain in achieving fully dense parts with reliable mechanical properties. This review provides an in-depth overview of the state of the art in ceramics and ceramic composite additive manufacturing. We detail the most widely used AM processes (stereolithography, binder jetting, material extrusion, powder bed fusion, inkjet printing, and direct energy deposition) and typical feedstock formulations for each technique. We examine the resulting mechanical properties (strength, toughness, hardness, wear resistance) and functional properties (thermal stability, dielectric behavior, biocompatibility) of additively manufactured ceramics, and discuss their current and potential engineering applications in the aerospace, defense, automotive, biomedical, and energy sectors. Persistent challenges, including porosity, shrinkage and cracking during sintering, achieving uniform microstructures, high process costs, and scalability issues, are analyzed, and we highlight promising future directions such as multi-material grading, integration of machine learning for process optimization, and sustainable manufacturing approaches. Despite significant progress, challenges remain in achieving fully dense structures, improving process reliability, and scaling ceramic AM for industrial applications, highlighting the need for further research in process optimization, material design, and multi-material integration. Full article

Driven by the demand for miniaturization, high capacitance, and enhanced reliability in high-performance multilayer ceramic capacitors (MLCCs), the continuous thinning of inner electrode layers imposes increasingly stringent requirements on the size, distribution, morphology, and dispersion of nano-nickel powders. We systematically investigate how functional additives regulate the nucleation, growth, and microstructural evolution of nano-nickel synthesized via hydrazine-driven liquid-phase reduction of nickel sulfate. The results demonstrate that the alkanolamine complexing agent (TAC) significantly refines the average particle size and morphology of the nano-nickel through coordination effects. Furthermore, inorganic sulfur salts (ISP), acting via surface adsorption to passivate growth sites and provide catalytic effects, enable a precise and continuous reduction in the average particle diameter from 330 nm down to 60 nm at a mere trace dosage of ~10⁻⁷ mol/L. Regarding dispersion optimization, highly dispersed face-centered cubic (FCC) nano-nickel was successfully prepared by introducing multidentate carboxylate (NNA). High-resolution transmission electron microscopy (HRTEM) was employed to unveil, for the first time, the crystallographic origin of the anomalous surface protrusions typically observed in conventional reaction systems. We confirmed that the family of $\left\{10\overline{1}0\right\}$ crystal planes within these regions, which exhibits interfacial angles of 58.7° and 58.3°, corresponds to a thermodynamically metastable hexagonal close-packed (HCP) nickel phase originating from atomic stacking faults induced by rapid growth kinetics. To address this microstructural defect, a thioether-based amino acid (TAA) was introduced. TAA effectively suppresses the anisotropic growth of the metastable HCP phase through the strong steric hindrance of its long side chains and its selective adsorption onto high-energy facets. Full article

Atmospheric plasma spraying (APS) represents a critical solution for enhancing the durability of agricultural components, such as harrow discs, which are subjected to synergistic wear and corrosion during soil cultivation. This study presents experimental results evaluating the electrochemical corrosion behavior and thermal shock resistance of discs coated via atmospheric plasma thermal spraying. Both metallic and ceramic materials, in powder form, from established manufacturers were used to produce the coatings, and the three types of coatings (two metallic and one ceramic) have the following chemical compositions and trade names: W₂C/WC12Co (Metco71NS), Cr₂O₃-4SiO₂-3TiO (Metco136F) and Co25.5Cr10.5Ni7.5W0.5C (Metco45C-NS). The coatings were analyzed using electron microscopy to evaluate the surfaces following corrosion testing. The ceramic coating based on the Cr₂O₃-4SiO₂-3TiO demonstrated the highest protective efficiency by increasing the charge transfer resistance from 307 Ω/cm² to 2213 Ω/cm² for the ceramic coating. It provided a superior physical barrier, reducing the corrosion current density from 0.140 mA/cm² for unprotected substrate to 0.004 mA/cm², representing an improvement of nearly two orders of magnitude. These findings demonstrate that implementing Cr₂O₃-4SiO₂-3TiO ceramic systems can significantly extend the operational lifespan of soil-engaging components, providing a cost-effective strategy for reducing maintenance intervals and material loss in aggressive agricultural environments. Full article

Selective laser melting (SLM) is an additive manufacturing method based on powder bed fusion that has gained prominence in prosthodontics for its capability to create intricate, patient-specific metal restorations with precision and consistency. SLM has become an important part of digital dental workflows, allowing for the direct creation of dental frameworks from computer-aided design (CAD), offering advantages over traditional casting and subtractive milling techniques. This review outlines the fundamentals of SLM, the dental alloys commonly employed, and the microstructural characteristics that affect mechanical properties, corrosion resistance, and biocompatibility. It explores current uses in removable partial denture frameworks, fixed dental prostheses, metal–ceramic restorations, implant-supported prosthetics, and maxillofacial rehabilitation. Alloys based on cobalt–chromium and titanium produced through SLM exhibit strong mechanical properties, fatigue resistance, and biological compatibility when suitable post-processing is conducted. Despite these advantages, issues such as surface roughness, porosity, anisotropy, powder handling, and high costs remain, and there is a lack of extensive long-term clinical data. Ongoing process refinement and clinical validation are crucial for the wider integration of SLM into standard prosthodontic practice. Full article

This paper presents a new ceramic building material produced by the cold sintering process (CSP), as a greener and cleaner technology compared to conventional ones. The ceramic composites were made from recycled clay bricks (RCBs), a byproduct resulting from construction and demolition and waterglass (WG) as a liquid solvent, pressed at 400 MPa and sintered at a temperature of 150–200 °C. After the samples were produced, their structure and physical and mechanical properties were investigated. The internal morphology of samples shows a homogeneous structure with a low porosity (up to 3%). The compressive strength of ceramic building material produced by the CSP was up to 211 MPa, considerably higher than the reference sample whose value was 45 Mpa. This high strength is due to the internal structure of the ceramic composed of a tough amorphous phase that acts like a binder holding together the powder particles and closing most of the porosity inside the material. Full article

Si₃N₄@MgSiN₂ composite powder with a core–shell structure was successfully synthesized via the in situ reaction between Mg and α-Si₃N₄ using a NaCl–KCl mixed molten salt in this study. The effects of process parameters, including the molten salt system, reaction temperature, and Mg/Si₃N₄ mass ratio, on the morphology, phase composition, and microstructure of the coating layer were investigated. The results indicate that the reaction follows a “template growth” mechanism. Mg-containing species dissolve in the molten salt, diffuse to the surface of Si₃N₄ particles, and react with α-Si₃N₄, resulting in a relatively uniform MgSiN₂ layer at 1300 °C. The yield of MgSiN₂ layer exhibits a linear positive correlation with the Mg/Si₃N₄ mass ratio, enabling controllable microstructural regulation through adjustment of the starting materials composition. The core–shell powder forms a liquid phase at a relatively low temperature (approximately 1350 °C), demonstrating excellent sintering activity. This work provides a new material foundation for the fabrication of silicon nitride ceramics with high thermal conductivity. Full article

CaFe₂O₄ is a p-type ferrite semiconductor of interest for photo-assisted environmental remediation due to its narrow band gap and high chemical stability. In this work, CaFe₂O₄ powders were synthesized via the Pechini polymeric precursor method and calcined between 550 and 850 °C to investigate the influence of calcination temperature on structural order and material properties. X-ray diffraction combined with Rietveld refinement revealed the progressive stabilization of the orthorhombic Pnma phase, accompanied by relaxation of the FeO₆ octahedral framework. Raman and FT-IR spectroscopies confirmed a significant increase in vibrational coherence with increasing calcination temperature, quantified by a nearly three-fold increase in the global Raman order parameter and phonon lifetimes. Nitrogen physisorption showed a modest specific surface area and a pore system dominated by interparticle meso–macroporosity, typical of thermally treated ferrites. Removal tests using ciprofloxacin under UV-A irradiation showed limited photo-assisted activity, while agar diffusion assays against Escherichia coli and Staphylococcus aureus revealed no inhibition halos, indicating the absence of detectable antibacterial activity under the experimental conditions employed. Overall, CaFe₂O₄ combines photo-assisted response with good structural stability, highlighting its potential as a chemically stable ceramic material with no detectable antibacterial activity under the tested conditions. Full article

Ti₂AlC, an important member of the MAX phase family, exhibits combined metallic and ceramic characteristics, showing potential for applications in conductive composites and high-temperature structural components. However, this phase possesses a narrow thermodynamic stability window, making high-purity synthesis challenging. Conventional solid-state synthesis requires temperatures exceeding 1300 °C, where aluminum volatilization and kinetic limitations of carbon diffusion lead to impurity phases such as TiC and Ti₃AlC₂. Based on the ionic transport characteristics of molten salt media, this study employed the eutectic NaCl-KCl molten salt method to synthesize Ti₂AlC using Ti, Al, and TiC powders within the temperature range of 1000–1150 °C. Systematic investigations revealed that an optimized raw powder composition (Ti:Al:TiC = 1:1.10:0.95) at 1100 °C yielded Ti₂AlC powders with 96.1% phase purity, high crystallinity, and typical laminated structure with stable stoichiometry (Ti/Al ≈ 2:1). Furthermore, Ag/Ti₂AlC composites demonstrated excellent electrical conductivity (resistivity of 5.72 μΩ·cm) and favorable mechanical properties, validating the applicability of this synthetic route for conductive composite materials. Full article

Cr₂O₃-based ceramic coatings are widely used in wear-critical applications; however, their tribological performance under dry sliding conditions can be limited by brittleness and frictional instability. In heavy-duty vehicles, the king pin–bushing contact operates under severe dry sliding conditions, motivating the investigation of composite Cr₂O₃–nTiO₂ coatings as a potential surface engineering solution. In this study, Cr₂O₃–TiO₂ coatings containing 0, 10, 20, 30, and 40 wt% TiO₂ were deposited by atmospheric plasma spraying (APS) from mechanically mixed powders. Phase composition was analyzed by X-ray diffraction using an X’Pert PRO MRD diffractometer, while microstructure and elemental distribution were examined by scanning electron microscopy (SEM) coupled with energy-dispersive X-ray spectroscopy (EDS) on a FEG Quattro C microscope. Mechanical properties were evaluated by Vickers microhardness, instrumented indentation and scratch testing, while dry sliding wear behavior was assessed by pin-on-disc tests performed on a CETR UMT-2 tribometer against a bronze counterbody, with continuous monitoring of the coefficient of friction (COF). The results show that plasma spraying produces lamellar composite coatings with intrinsic porosity and locally modified phase composition. Cr₂O₃-rich coatings exhibit higher hardness (1198 HV2 compared with 877 HV2 for Cr₂O₃–40TiO₂ corresponding to an increase of approximately 36%) and improved resistance to indentation, reflected by lower penetration depths and higher elastic modulus values (134 GPa for S0 compared with 77 GPa for S2). These coatings also exhibit a more stable friction response and reduced material transfer from the bronze counterbody, as confirmed by the lower mass loss of the pins (0.0295 g for S0 compared with 0.0473 g for S4, corresponding to a reduction of about 38%). Increasing TiO₂ content leads to changes in friction stability and wear behavior associated with microstructural heterogeneity. These findings indicate that the sliding wear performance of Cr₂O₃–nTiO₂ coatings is governed by elastic–plastic stability under localized contact loading and support their applicability for dry sliding king pin–bushing systems in heavy-duty vehicles. 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

The development of sustainable ceramic membranes remains a major challenge for advanced wastewater treatment, particularly regarding the trade-off between mechanical durability and the removal of dissolved micropollutants. While bentonite membranes offer high stability, they often lack the selective adsorption sites required for complex effluents, and the recovery of high-capacity powder adsorbents remains technically prohibitive. This paper addresses these gaps by developing an integrated hybrid system that combines eco-friendly bentonite-based tubular membranes with regenerable clam shell-derived adsorbents. The membranes were synthesized using natural plasticizers and binders with optimization at a sintering temperature of 1000 °C yielding an average pore size of 1.7 µm, a high flexural strength of 24.06 MPa, and a permeability of 525 L h⁻¹ m⁻² bar⁻¹. To enhance the performance, clam shell powder was integrated as a functional adsorbent layer. When applied to real textile effluent from a jeans washing plant, this integrated process achieved superior removal efficiencies: 85.6% COD, 86.5% BOD₅, 86.5% TSS, and 96.5% color. A key scientific contribution of this paper is the successful application of a photochemical regeneration approach, which ensures complete adsorbent recovery and maintains membrane flux, directly supporting circular economy objectives. These results demonstrate that combining low-cost ceramic scaffolds with marine waste-derived materials provides a unique, efficient, and green solution for the scalable treatment of industrial wastewater. Full article

This research aims to investigate the modifications of the structural, dielectric, and sensing properties of CaFeO_3−δ ceramics produced by solid-state reaction induced by varying sintering temperatures in the range of 1000–1200 °C. A single crystallographic orthorhombic (Pcmn) structure was revealed by X-ray diffraction with Rietveld analysis, both for the powders and sintered ceramics, irrespective of the sintering temperature. The increase in the sintering temperature induces better densification and a larger grain size. Dielectric measurements reveal a pronounced enhancement of the relative permittivity, reaching 2 × 10⁵ at 1 kHz and 330 °C for the sample sintered at 1200 °C/4 h. This composition also displays the highest electrical conductivity, 0.4 S/m at 1 MHz. Cole–Cole analysis indicates a clear deviation from ideal Debye behavior, while the relaxational features of the dielectric permittivity suggest a strong correlation between the dielectric response and Fe-related conduction mechanisms. Gas sensing tests show that the ferrite ceramics exhibit consistent ethanol response trends. The ceramic sintered at 1200 °C/4 h achieved the highest sensitivity, of 56.28%, which can be attributed to its higher density, larger ceramic grains, and reduced low-frequency conductivity. The CaFeO_3−δ ceramic sintered at 1200 °C/4 h shows a combination of high permittivity, enhanced conductivity, and strong ethanol sensitivity, making it a promising material for dielectric components, capacitive devices, and gas sensing applications. Full article