Search Results (11,329)

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

Cr–N coatings are promising for severe-service applications owing to their high corrosion and wear resistance, yet their performance is governed by phase constitution and multilayer architecture. In this study, a monolithic Cr coating and three Cr-based multilayer coatings, Cr/Cr(N), Cr/Cr₂N, and Cr/CrN, were synthesized by a hybrid DCMS/HiPIMS process and systematically compared with respect to structure, mechanical properties, and oxidation behavior at 900 °C. XRD and TEM showed that Cr/Cr(N) was primarily characterized by a bcc Cr-type structure, while the N-containing layers exhibited slightly expanded lattice spacings relative to pure Cr; no Cr₂N precipitates were detected within the resolution of the analyses. Among the multilayers, Cr/Cr(N) provided the most favorable combination of hardness, adhesion, and indentation damage tolerance, reaching 885 HV and a critical scratch load of 80 N while maintaining damage tolerance comparable to monolithic Cr. By contrast, Cr/Cr₂N and Cr/CrN displayed more pronounced brittle damage and lower interfacial reliability. Upon oxidation at 900 °C, Cr and Cr/Cr(N) formed relatively compact Cr₂O₃ scales, whereas Cr/Cr₂N, and particularly Cr/CrN, experienced stronger oxidation-induced phase decomposition, blistering, and local delamination. These findings identify Cr(N) solid-solution sublayers as an effective alternative to brittle ceramic nitride layers. Full article

Monolithic ceramic catalysts are a key technology for the industrial treatment of coal mine ventilation air methane (VAM). The preparation of straight-channel NiO/CeO₂ monolithic ceramic catalysts via phase inversion addresses critical bottlenecks for industrial VAM abatement. However, high-temperature sintering leads to irreversible NiO agglomeration and coarsening, severely reducing catalytic activity. In this study, an in situ reduction–oxidation reconstruction method is developed to regenerate sinter-degraded NiO. The reconstructed catalyst increases methane conversion from below 70% after sintering to over 95% at 550 °C and achieves full conversion at 600 °C. The catalyst maintains near 100% conversion during 400 h of continuous operation at 600 °C and shows no performance degradation over 15 thermal cycles. Moreover, the reconstructed catalyst exhibits excellent steam tolerance with fully reversible deactivation. The reconstructed catalyst presents a refined porous structure with BET surface area rising from 4.5 to 11.4 m² g⁻¹, an elevated Ni³⁺/Ni²⁺ ratio (1.47 to 1.97), a higher surface adsorbed oxygen proportion (36.8% to 48.7%) and significantly strengthened NiO-CeO₂ interfacial interaction. This work provides a facile and efficient in situ regeneration strategy, greatly enhancing the VAM oxidation activity and stability of sinter-degraded monolithic ceramic catalysts. Full article

Identifying primary ceramic forming techniques is often problematic when surface traces are altered or erased by secondary shaping on the potter’s wheel, particularly in vessels combining hand-building and wheel use. This study aims to develop a quantitative, non-destructive method to distinguish wheel-throwing and wheel-coiling techniques by analyzing internal fabric features. Experimental replicas of Middle Minoan handleless conical cups (18th cent. BC), produced using wheel-throwing-off-the-hump and wheel-coiling techniques, were investigated using X-ray micro-computed tomography (µCT). Macropores were segmented from complete 3D µCT datasets and their shape preferred orientation was quantitatively assessed through ellipsoid fitting, orientation distribution functions, and pole figure analysis. The results reveal systematic and reproducible differences between the two forming techniques: wheel-coiled vessels show predominantly horizontal pore elongation, expressed as equatorial girdle textures and vertically clustered short axes, whereas wheel-thrown vessels display inclined pore orientations, forming displaced girdles and ring-like short-axis distributions. These contrasting orientation patterns reflect distinct deformation fields imposed during vessel shaping. The study demonstrates that quantitative 3D analysis of pore orientation in whole vessels provides reliable criteria for identifying ceramic forming techniques and confirms previous qualitative observations. This approach offers a robust framework for technological analysis of ceramics and can be applied to both complete vessels and suitably oriented fragments. Full article

Objective: CAD-CAM technology enables biomimetic dentistry by producing highly accurate, minimally invasive restorations that replicate the biomechanical behavior of intact teeth. This study evaluated the fracture resistance of overlays with margins at different supragingival levels, including a flat occlusal design and compared them with conventional full crowns. All restorations were fabricated from chairside CAD/CAM resin-matrix ceramic for maxillary premolars. Methods and Materials: Sixty-four CAD/CAM resin-matrix ceramic restorations were fabricated and randomly assigned to four groups (n = 16): (1) overlay with a margin 2 mm above the gingiva (Ov2m); (2) overlay with a 4 mm supragingival margin (Ov4m); (3) overlay with a 4 mm margin and flat occlusal surface (OvF4m); and (4) full-coverage crown with a gingival-level margin (FCC). Preparations were standardized by one operator. Restorations were adhesively cemented to resin dies, thermocycled 10,000 times (5–55 °C), and loaded to failure in a universal testing machine (1 mm/min). Data were analyzed using one-way ANOVA and post hoc tests (α = 0.001). Results: Among overlays, Ov2m showed the highest fracture resistance (1605 ± 88 N), followed by Ov4m (1403 ± 63 N). OvF4m recorded the lowest value (1257 ± 73 N). FCC exhibited the greatest overall resistance (1838 ± 106 N), significantly higher than that of any overlay group. Conclusions: Overlays with margins 2 mm above the gingiva had higher fracture resistance than those with more coronal margins or flat occlusal designs. Full-coverage crowns showed the greatest strength, highlighting the impact of margin position and preparation design on restoration performance. Full article

Porous, crystalline gamma-Al₂O₃ coatings with a thickness of (6 ± 0.5) μm and a uniform distribution of rare earth (RE) dopants are synthesized by plasma electrolytic oxidation of aluminum at a current density of 150 mA/cm² in a boric acid and borax (BB) solution containing added RE oxide particles (Ho₂O₃, Tb₄O₇, and Pr₆O₁₁) at concentrations of 1, 2, and 4 g/L. The concentration of RE oxide particles in the BB solution determines the amount of RE elements incorporated into the coatings but does not significantly affect their surface morphology, crystal structure, or light absorption properties. The coatings exhibit high absorption in the middle/near-ultraviolet region, characteristic of Al₂O₃. Typical 4f-4f transitions of Ho³⁺, Tb³⁺, and Pr³⁺ are observed in the photoluminescence spectra. Photocatalytic evaluations using methyl orange degradation under simulated solar irradiation show that RE doping significantly enhances photocatalytic efficiency. Peak degradation efficiencies are achieved at a concentration of 4 g/L for all RE oxides. After 8 h of irradiation, maximum degradation reaches 88%, 92%, and 85% with pseudo-first-order rate constants (k_app) of about 0.274 h⁻¹, 0.339 h⁻¹, and 0.232 h⁻¹ for coatings synthesized in BB with 4 g/L Ho₂O₃, Tb₄O₇, or Pr₆O₁₁, respectively. In comparison, the pristine Al₂O₃ coating achieves only about 50% degradation (k_app ≈ 0.087 h⁻¹). Photoluminescence indicates that RE³⁺ ions serve as effective charge-carrier traps, suppressing electron–hole pair recombination. RE-doped Al₂O₃ coatings demonstrate exceptional structural stability and reusability over six cycles, highlighting their potential for sustainable wastewater remediation. Full article

Lignocellulose represents an abundant repository of renewable carbon. Derived from various plant sources, it holds tremendous potential as a renewable and sustainable feedstock for the production of valuable chemicals and fuels. However, its solid fermentable compounds, cellulose and hemicellulose, are embedded within complex lignin structures and are therefore poorly accessible to microbial conversion. This paper describes an artificial rumen reactor (ARR) that uses anaerobic microbes from the cattle rumen to increase the release of fermentable carbon from recalcitrant biomass. We outline the development of an ARR for the efficient conversion of lignocellulosic grass into volatile fatty acids (VFAs), which are valuable precursors for the production of a range of bioproducts, including biofuels, biomaterials, and biochemicals. The ARR, a 4-L bioreactor equipped with a ceramic filtration unit, has been optimised and was operated for extended periods of continuous VFA production. Across distinct short- and long-term observation periods, and independent of the cow from which the rumen microbes originated, the bioreactor demonstrated the ability to sustain VFA production, indicating robustness and stability. At an input of 60–80 g dry grass d⁻¹, the system produced approximately 6 mol VFA per kg of dry matter input (DMI). The decoupling of the Solid Retention Time (SRT; 10 days) and the Liquid Retention Time (LRT; 0.5 days) prevented inhibition of the VFA production. The VFA profile was dominated by acetic and propionic acids, comprising 68% and 19%, respectively, with butyric acid and minor VFAs accounting for the remainder. The application of low oxygen levels (<10%) in the reactor via limited aeration did not affect the VFA yield or its profile. Full article

Background and aim: The influence of fabrication techniques, cement type, and cyclic loading on the marginal adaptation of lithium disilicate crowns remains a clinical concern that may affect their long-term performance. This study aimed to evaluate the effects of cyclic loading and cement type on the marginal fit of milled and pressed lithium disilicate crowns. Methods: Twenty lithium disilicate crowns were fabricated and divided into two groups based on the manufacturing technique: milled and pressed (n = 10 each). Each group was further subdivided according to the cement type: resin or resin-modified glass ionomer (n = 5 per group). Crowns were cemented on standardized epoxy resin dies, and the marginal gap was measured using a stereomicroscope before and after cyclic loading. Cyclic loading was performed at 50 N for 37,000 cycles. Data were statistically analyzed using a three-way ANOVA (α = 0.05). Results: Milled crowns showed marginal gaps ranging from 52 to 57 µm, whereas the pressed crowns exhibited smaller gaps ranging from 39 to 47 µm. Neither the cement type nor the cyclic loading produced a significant difference in the marginal gap values (p > 0.05). Conclusions: Pressed lithium disilicate crowns exhibited superior marginal adaptation compared with the milled crowns. Neither the type of cement nor the cyclic loading had a significant effect on the marginal gap. Both fabrication techniques yielded clinically acceptable fits (<100 µm). Full article

This paper presents a collaborative optimization design methodology aimed at improving heat dissipation efficiency through the modulation of microstructural variations. The approach addresses the thermal protection requirements of high-temperature components, such as ceramic matrix composite turbine blades, which are subjected to complex and elevated thermal loads. Through the integration of numerical simulation and experimental validation, a bidirectional mapping model linking carbon nanotube (CNT) content with the macroscopic anisotropic thermal conductivity of the material was developed. Furthermore, a thermal conduction analysis and optimization framework for Ceramic Matrix Composite (CMC) high-temperature components under non-uniform thermal loads was established. This study expands the adjustable range of the material’s thermal conductivity by allowing flexible modulation of carbon nanotube content. The results demonstrate that this methodology effectively enhances the heat dissipation capacity of CMC materials in extreme thermal environments: the maximum surface temperature of the optimized flat plate is reduced by 8.96%, the peak temperature gradient is lowered by 46.64%, and the maximum thermal stress is decreased by 38.17%. This research provides new insights into the comprehensive integration of thermal dissipation requirements for CMC hot components. 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

Titanium dental implants are widely regarded as the gold standard for the rehabilitation of missing teeth due to their high survival rates and favorable mechanical properties. However, in the oral environment, implant materials are continuously exposed to complex chemical, mechanical, and biological factors that may lead to surface degradation, including corrosion, tribocorrosion, and mechanical wear. These processes can alter implant surface characteristics and influence biological responses in peri-implant tissues. Zirconia implants have been introduced as alternative material due to their favorable aesthetics and biocompatibility. Nevertheless, zirconia ceramics are also susceptible to degradation phenomena, including hydrothermal aging, phase transformation, and surface wear under specific conditions, although their clinical relevance remains unclear. In addition, emerging hybrid titanium–zirconia implant systems introduce new considerations regarding surface stability. This scoping review, conducted in accordance with PRISMA-ScR guidelines, summarizes the current evidence on degradation mechanisms affecting titanium, zirconia, and hybrid dental implants, with particular focus on processes occurring in the oral environment and their biological and clinical implications. The available evidence differs substantially between the two materials. While titanium degradation is well documented and supported by both experimental and clinical studies, the evidence for a hybrid implant remains limited and is largely based on in vitro and mechanistic data. Full article

Zirconia is known as a strong and bioinert load-bearing material for dental implants. It typically exhibits no antibacterial activity. Inflammation is a crucial problem for dental implant surgery: about 3–5% of all dental implants experience inflammation. This study demonstrates that either fullerene C₆₀ films or a tribomechanical loading of zirconia without the fullerene C₆₀ coating can cause an improvement in antibacterial activity against Gram-positive Staphylococcus aureus. This moderate antibacterial activity is especially important, because a strong antibacterial effect could disturb the sensitive and beneficial oral bacterial biota. In the present study, different fullerene C₆₀ films were examined. In addition to fullerene C₆₀ film in an “as deposited” condition, treatment with nitrogen plasma as well as tribomechanical produced surface patterns with and without plasma post-treatment were tested. An 85.8% (log reduction 0.85) reduction in Gram-positive Staphylococcus aureus bacterial formation was observed on the zirconia with fullerene C₆₀ film. Plasma treatment of the C₆₀ film increases the antibacterial impact to 72.2% (log reduction 0.56) in comparison to zirconia without fullerene C₆₀ film. Also, tribomechanical loaded fullerene C₆₀ films suppress the growth of Gram-positive Staphylococcus aureus. The tribomechanical loading seems to compensate for the effect of the plasma treatment. ZrO₂ samples with fullerene C₆₀ film and tribomechanical loading achieve an increase in antibacterial impact of 83.36% (log reduction 0.78). Furthermore, surprisingly yttria-stabilized zirconia bioceramic without fullerene C₆₀ film also shows an improved antibacterial efficacy after a tribomechanical patterning procedure. The addition of surface patterning on the ZrO₂ by scratching microgroove arrangements with a diamond tip, increased the antibacterial effect against Gram-positive Staphylococcus aureus by 70.46% (log reduction 0.53). Full article

Soot and black carbon (BC) are typically regarded as troublesome products of incomplete combustion; however, growing interest in circular economy strategies and sustainable manufacturing highlights their potential as secondary functional carbon materials, including additive manufacturing (AM). This review synthesises the recovery, upgrading, and valorization pathways for soot/BC and recovered carbon black (rCB), with a particular focus on streams captured by mandatory emission-control systems (e.g., diesel/gasoline particulate filters, electrostatic precipitators, baghouse filters, and chimney soot) and the requirements for transforming these heterogeneous residues into reproducible AM feedstocks. A two-stage approach was applied, combining (i) an analysis of the European Union regulatory context (waste classification, end-of-waste routes, and chemical safety obligations, including REACH) with (ii) a structured literature review of studies published in 2017–2026 indexed in the Web of Science and Scopus, culminating in a qualitative synthesis of 152 papers. Evidence indicates that scale-up is primarily constrained by strong compositional variability and contaminant burdens (ash, metals, and PAHs), which affect dispersion, rheology, and property reproducibility, necessitating robust standardisation and risk assessment. This review maps key preparation and upgrading strategies (e.g., classification, ash/metal reduction, and control of organic fractions) and discusses their relevance across AM routes such as FDM/FFF, SLS, DLP, and DIW. Overall, realising credible waste-to-value pathways requires aligning technical performance targets with regulatory compliance and developing consistent characterisation protocols to enable the safe and predictable use of soot/rCB-derived fillers in AM. Full article

Background: The wear resistance of modern commercial glass-ceramic materials used in dental prostheses was investigated under cyclic contact conditions that included a rotational component. This loading mode has been largely overlooked in conventional in vitro wear testing, yet may be clinically relevant in patients with parafunctional conditions such as bruxism. Methods: Rotational loading was applied using an all-electric testing machine equipped with a biaxial actuator. Loading cycles combined a normal load (50 N) and a rotation (30°), at a frequency of 1 Hz. Microstructure and damage were characterized using advanced microscopy. Results: Rotational loading induced substantial damage across this class of materials, including the formation of glassy tribolayers with limited protective capability under the low-humidity conditions examined. Significant microstructure-dependent variations in wear volume were observed, with specific wear rates indicating severe wear (SWR above 10⁻⁶ mm³/N·m threshold) in three of the five materials tested. Lithium disilicate glass-ceramics, characterized by a high fraction of elongated reinforcement crystals, exhibited the greatest resistance to damage, whereas leucite-based glass-ceramics showed the lowest. The dominant wear mechanisms were plastic-deformation-induced grooving and fracture-driven chipping. The findings are interpreted within established wear models for brittle materials (Archard and fracture-based) and supported by numerical simulations of stress fields across multiple length scales. Implications: The results provide mechanistic insight into rotational wear damage in glass-ceramic systems, a material class particularly susceptible to such loading, and inform strategies for material selection and microstructural design aimed at improving prosthetic durability. Full article

The conservation of tuff- and coral rock-built architectural heritage structures (AHS) is challenging because access to original tuff and coral rock has become difficult and severely limited due to urbanization, land reclamation, the depletion of stone quarries, anti-mining and anti-quarrying legislation. An emerging approach to address this issue is to create compatible “replacement” rocks via geopolymerization, a process that is more sustainable and greener than the use of conventional cement and concrete. To explore the potential of geopolymers for AHS conservation strategies, the Preferred Reporting Items for Systematic Reviews and Meta-Analyses (PRISMA) guidelines were implemented; 103 eligible articles were identified and classified into geopolymers for AHS (34 articles), tuff-built AHS (60 articles), and coral rock-built AHS (9 articles). Tuff substrates in AHSs appear in a variety of colors (yellowish-brown, grayish-cream, reddish-brown, pale greenish-gray and pink hues), densities (1.0–2.5 g/m³), and compressive strengths (3–100 MPa). Meanwhile, coral rock substrates in AHSs appear in whitish-cream color and are coarse-pored (1–5 MPa), fine-grained (8–15 MPa), and calcarenite (50–60 MPa). In terms of geopolymer formulation, metakaolin was reported as the most popular main precursor or admixture, while NaOH and Na₂SiO₃ were used simultaneously as alkaline activators. Aggregates used in geopolymer formulations depended on local availability, including quartz sand, river sand, crushed stones, carbonate stones, volcanic rock, volcanic sand, tuff, brick, ceramic tiles, and waste materials. Aesthetics, chemical composition, physical attributes, and mechanical properties have been identified as key criteria to ensure geopolymer compatibility for AHS conservation application. To date, geopolymers have been applied for AHS conservation as repair mortars, consolidants (i.e., grout and adhesives), and masonry strengthening (i.e., fiber-reinforced mortar). Finally, geopolymers formulated for AHS conservation have similar durability as the original substrate based on accelerated aging tests (i.e., salt mist, wet-dry, and freeze–thaw) and long-term outdoor exposure experiments. Full article