Search Results (884)

High-pressure plunger-cylinder pairs in axial piston pumps are prone to brittle failure due to local contact stress, time-dependent material degradation, and cyclic loading, which complicates long-term reliability assessment. To address this issue, an integrated reliability analysis framework is proposed for SiC ceramic plunger pairs, combining local stress identification, strength degradation, and fatigue damage modeling. A three-dimensional finite element model identifies the critical contact region, where the maximum equivalent stress reaches 1291.5 MPa. An exponential strength degradation model and a time-variant stress-strength interference approach based on lognormal stress and Weibull strength distributions are adopted, with 10⁵ Monte Carlo simulations used to evaluate failure probability. The results indicate that although the initial static reliability is close to 1.0, it decreases nonlinearly with service time, reaching 0.9663 at 10,000 h under moderate degradation. In addition, fatigue reliability is assessed by integrating the S-N curve of SiC with a cumulative damage model, enabling reliability-cycle curve construction and fatigue life prediction. The proposed method provides a quantitative framework for static, degradation-driven, and fatigue reliability assessment of high-pressure ceramic tribological structures. Full article

Powder Injection Molding (PIM) is a versatile manufacturing technology widely used for fabricating components with complex geometries from metals and ceramics, yet its application to high-performance thermoplastics remains underutilized. This study explores the feasibility of manufacturing products from Polyphenylene Sulfide (PPS)—a promising linear aromatic polymer synthesized in powder form—using PIM technology and investigates the development of PE-based feedstocks with PPS and solid fillers. Regarding the matrix formulation, it was found that using pure paraffin as a binder limited the maximum PPS content to 20%. Consequently, a modified binder system consisting of Low-Density Polyethylene (LDPE) and paraffin in a 70:30 wt.% ratio was utilized, which successfully increased the PPS loading in the feedstock to 50% and enabled stable molding. Following matrix optimization, the study examined composites incorporating various fillers, including chalk, talc, and carbon fibers. Systematic rheological analysis confirmed that these composite suspensions possess characteristics necessary for molding products with complex geometries. Key results indicate that optimal sintering conditions were established to achieve the required mechanical properties. Among the tested fillers, carbon fibers were the most effective reinforcement, increasing the elastic modulus by 33% and flexural strength by 20%. Representative examples of samples successfully manufactured via this approach are presented. Full article

This study investigates the influence of sintering temperature (850–950 °C) and almond shell content (2–10 wt.%) on the structural, mechanical, and functional properties of natural-clay-based ceramic membranes. Several membranes were prepared by incorporating different proportions of almond shell powder and 2 wt.% lime as additives and sintered under controlled thermal conditions to optimize their performance. The results demonstrate that both sintering temperature and almond shell content significantly affect membrane porosity, mechanical strength, and water permeability. Among all of the tested samples, the membrane designated MP2-900, composed of natural clay, 2 wt.% almond shell powder, and 2 wt.% lime, sintered at 900 °C, exhibited the most balanced performance. It showed high mechanical strength (≈28 MPa), low shrinkage (<5%), and good water permeability (35 L·h⁻¹·m⁻²·bar⁻¹). When tested for the removal of crystal violet (CV) dye and paracetamol (PCT) from synthetic wastewater, the MP2-900 membrane achieved a removal efficiency of 87% for both pollutants. Overall, the MP2-900 membrane represents the optimal configuration, providing an excellent balance between mechanical robustness, porosity, and separation performance. These findings highlight the potential of sustainable clay-based ceramic membranes derived from agricultural by-products for the efficient removal of recalcitrant pollutants from wastewater. Full article

Alumina ceramics used in semiconductor plasma environments require high densification, microstructural homogeneity, and stable performance under increasingly aggressive processing conditions. However, systematic studies linking slurry processing parameters to the plasma resistance of alumina ceramics remain limited. In this study, the effects of slurry preparation parameters—specifically milling and aging—and sintering atmosphere on the densification, mechanical strength, and plasma etching resistance of slip-cast alumina ceramics were systematically investigated. Optimal dispersion stability was achieved under 12 h milling and 12–24 h aging conditions, resulting in homogenized green body packing and a high relative sintered density exceeding 99%. Mechanical strength and plasma resistance were strongly influenced by slurry aging and sintering atmosphere. Specimens aged for 48 h and sintered under a low oxygen partial pressure (N₂ at 1.0 L/min) exhibited the highest flexural strength and significantly improved resistance to SF₆/Ar plasma etching, with reduced etch depth and suppressed surface roughening. These results demonstrate that coordinated slurry processing and sintering atmosphere control is an effective strategy for designing high-reliability, plasma-resistant alumina ceramics for high-demand semiconductor manufacturing environments. Full article

In aerospace, defense, and energy systems, ceramic matrix composites (CMCs) are smart structural materials designed to function continuously in harsh mechanical, thermal, and oxidative conditions. Using high-strength fiber reinforcements and tailored interphases that enable damage-tolerant behavior, their creation tackles the intrinsic brittleness and low fracture toughness of monolithic ceramics. With a focus on chemical vapor infiltration, polymer infiltration and pyrolysis, melt infiltration, and additive manufacturing, this paper critically analyzes current developments in microstructural design, processing technologies, and interfacial engineering. Toughening mechanisms are examined in connection to multiscale mechanical responses, including controlled debonding, fiber bridging, fracture deflection, and energy dissipation pathways. Cutting-edge environmental barrier coatings are assessed alongside environmental durability issues like oxidation, volatilization, and hot corrosion. High-performance braking, nuclear systems, hypersonic vehicles, and turbine propulsion are evaluated as emerging uses. Future directions emphasize self-healing systems, ultra-high-temperature design, and environmentally friendly production methods. Full article

The traditional ultrasonic bonding technique for IGBT T2 copper terminals often causes physical damage to ceramic substrates, severely compromising the reliability of power modules. Meanwhile, T2 copper laser welding faces inherent challenges including low laser absorption efficiency and unstable molten pool dynamics. To address these issues, this study targets the high-quality connection of IGBT T2 copper terminals and proposes a welding solution integrating a Fiber-Diode Hybrid Laser system with galvo-scanning technology. Comparative experiments between galvo-scanning and traditional oscillation methods CNC scanning were conducted under sinusoidal and circular trajectories to explore the regulation mechanism of welding quality. The results demonstrate that CNC scanning lacks precision in thermal input control, resulting in inconsistent welding quality. Galvo-scanning enables precise modulation of laser energy distribution and molten pool behavior, effectively reducing spatter and porosity defects. It also promotes the transition from columnar grains to equiaxed grains, significantly refining the weld microstructure. Under the sinusoidal trajectory with a welding speed of 20 mm/s, the Lap-shear strength of the galvo-scanned joint reaches 277 N/mm², outperforming all CNC-scanned joints. This research proposes a non-contact welding strategy targeted at eliminating the mechanical failure mechanism associated with conventional ultrasonic bonding of ceramic substrates. It establishes the superiority of galvo-scanning for precision welding of high-reflectivity materials and lays a foundation for its potential application in new energy vehicle power modules and microelectronic packaging. Full article

The growing demand for portable and wireless electronic devices, along with the necessity to reduce reliance on non-renewable energy sources, has driven the need for energy harvesting materials. Nanocomposites, combining a polymeric matrix and a high-performance dielectric ceramic phase, are a promising solution. In such systems, the design of a hybrid matrix–filler interface is critical for achieving desired properties. Here, nanocomposites (NCs) were prepared by adding various amounts of hydrothermally synthesized BaTiO₃ (BT) nanoparticles (NPs) to polydimethysiloxane (PDMS). To investigate hybrid interfaces, NPs were used either bare or surface-functionalized with two silanes, 3-glycidyloxypropyltrimethoxysilane (GPTMS) or 2-[acetoxy(polyethyleneoxy)propyl]triethoxysilane (APEOPTES). NC films (80–100 μm thick) were characterized by scanning electron microscopy (SEM), energy-dispersive X-ray spectroscopy (EDXS), and thermogravimetric analysis (TGA). Dielectric properties and breakdown strength (E_BD) were measured, and the theoretical volumetric energy density was calculated as a function of the filler loading and functionalization. The results demonstrate that hybrid interface design is pivotal for enhancing dielectric performance in NCs. APEOPTES-functionalized NPs significantly improved the dielectric response at a low filler loading (3.5%vol.), increasing permittivity from 2.8 to 7.5, E_BD from 33.8 to 42.1 kV/mm and energy density from 30 to >100 mJ/cm³. These findings underscore that designing hybrid interfaces through NP functionalization provides an effective strategy to achieve superior dielectric performance in PDMS-based NCs, retaining the advantages of the elastomeric matrix by reducing the amount of ceramic fillers. Full article

Conventional anticorrosive coatings suffer from limitations of low solid content and rigorous surface pretreatment, posing environmental and cost challenges in field applications. In this study, a novel high-solid-content (>95%) epoxy-polysiloxane (Ep-PSA) ceramic metal coating was prepared that enables low-surface-treatment application. The originality lies in the synergistic combination of nano-sized ceramic powders, high-strength metallic powders, polysiloxane resin (PSA), and solvent-free epoxy resin (Ep), which polymerize through an organic–inorganic interpenetrating network to form a dense shielding layer. The as-prepared Ep-PSA coating system chemically bonds with indigenous metal substrate via Zn₃(PO₄)₂ and resin functionalities during curing, forming a conversion layer that reduces surface preparation requirements. Differentiating from existing high-solid coatings, this approach achieves superior long-term barrier properties, evidenced by |Z|_0.01Hz value of 9.64 × 10⁸ Ω·cm², after 6000 h salt spray exposure—four orders of magnitude higher than commercial 60% epoxy zinc-rich coatings (2.26 × 10⁴ Ω·cm², 3000 h salt spray exposure). The coating exhibits excellent adhesion (14.28 MPa) to standard sandblasted steel plates. This environmentally friendly, durable, and easily applicable composite coating demonstrates significant field application value for large-scale energy infrastructure. Full article

Ceramic matrix composites (CMCs) exhibit excellent high-temperature strength, oxidation resistance, and fracture toughness, making them superior to traditional metals and single-phase ceramics in extreme environments such as aerospace, nuclear energy equipment, and high-temperature protection systems. The mechanical properties of CMCs directly influence the reliability and service life of structures; thus, accurately predicting their mechanical response and service behavior has become a core issue in current research. However, the multi-phase heterogeneity of CMCs leads to highly complex stress distribution and deformation behavior in traditional mechanical property testing, resulting in significant uncertainty in the measurement of key mechanical parameters such as strength and modulus. Additionally, the high manufacturing cost and limited experimental data further constrain material design and performance evaluation based on experimental data. Therefore, the development of effective numerical simulation and mechanical modeling methods is crucial. This paper provides an overview of the research hotspots and future directions in the field of CMCs numerical simulation and mechanical modeling through bibliometric analysis using the CiteSpace software. The analysis reveals that China, the United States, and France are the leading research contributors in this field, with 422, 157, and 71 publications and 6170, 3796, and 2268 citations, respectively. At the institutional level, Nanjing University of Aeronautics and Astronautics (166 publications; 1700 citations), Northwestern Polytechnical University (72; 1282), and the Centre National de la Recherche Scientifique (CNRS) (49; 1657) lead in publication volume and/or citation influence. Current research hotspots focus on finite element modeling, continuum damage mechanics, multiscale modeling, and simulations of high-temperature service behavior. In recent years, emerging research frontiers such as interface debonding mechanism modeling, acoustic emission monitoring and damage correlation, multiphysics coupling simulations, and machine learning-driven predictive modeling reflect the shift in CMCs research, from traditional experimental mechanics and analytical methods to intelligent and predictive modeling. Full article

In the present study, glass/ceramic hybrid fibers were chosen as a paper matrix, which effectively balance toughness and high-temperature resistance for soot combustion applications. In order to address the issue of unevenness in the performance of paper-type catalysts caused by the differences in the dispersion behavior of glass fibers and ceramic fibers in water, a facile foam-forming technology was proposed. The obtained glass fiber/mullite composite paper with various mass ratios (1:1, 2:1, 3:1, 4:1, and 5:1) exhibit high evenness, and better high-temperature resistance than the pure glass fibers. After impregnating K-Mn active ingredients, 15K5Mn-GFF-3G1C (GF/CF = 3:1) demonstrates high tensile strength, excellent catalytic activity (T50 = 388 °C), reusability (five cycles), and high-temperature stability (800 °C, 12 h). Full article

Magnesium matrix composites formed by incorporating ceramic particles into a magnesium alloy matrix can effectively leverage the complementary properties of the matrix and reinforcement. This approach significantly enhances the mechanical properties of the material at both room and elevated temperatures, offering a viable solution to the inherent limitations of Mg alloys, such as insufficient absolute strength, stiffness, and poor heat resistance. This article reviews the latest research progress in the field of ceramic particle-reinforced magnesium matrix composites in recent years. First, the current research status of magnesium matrix composites reinforced with different types of ceramic particles is comprehensively summarized. Subsequently, it provides a summary and in-depth analysis of the principles, key technologies, and microstructural characteristics of both mainstream and emerging preparation processes, and discusses their advantages and disadvantages. Finally, the challenges in current research are analyzed, and future cutting-edge directions for developing high-performance ceramic particle-reinforced magnesium matrix composites are discussed. Full article

This work presents the design, modeling, and experimental validation of an innovative, highly autonomous, and economically viable photovoltaic solar cooker, integrating a robust battery storage system. The system combines 1200 Wp photovoltaic panels, a control block with DC/DC power converters and digital control for intelligent energy management, and a thermally insulated heating plate equipped with two resistors. The objective of the system is to reduce dependence on conventional fuels while overcoming the limitations of existing solar cookers, particularly insufficient cooking temperatures, the need for continuous solar orientation, and significant thermal losses. The optimization of thermal insulation using a ceramic fiber and glass wool configuration significantly reduces heat losses and increases the thermal efficiency to 64%, nearly double that of the non-insulated case (34%). This improvement enables cooking temperatures of 100–122 °C, heating element surface temperatures of 185–464 °C, and fast cooking times ranging from 20 to 58 min, depending on the prepared dish. Thermal modeling takes into account sheet metal, strengths, and food. The experimental results show excellent agreement between simulation and measurements (deviation < 5%), and high converter efficiencies (84–97%). The integration of the batteries guarantees an autonomy of 6 to 12 days and a very low depth of discharge (1–3%), allowing continuous cooking even without direct solar radiation. Crucially, the techno-economic analysis confirmed the system’s strong market competitiveness. Despite an Initial Investment Cost (CAPEX) of USD 1141.2, the high performance and low operational expenditure lead to a highly favorable Return on Investment (ROI) of only 4.31 years. Compared to existing conventional and solar cookers, the developed system offers superior energy efficiency and optimized cooking times, and demonstrates rapid profitability. This makes it a sustainable, reliable, and energy-efficient home solution, representing a major technological leap for domestic cooking in rural areas. Full article

Oxidation can lead to intrinsic degradation and loss in the load-bearing capacity of ceramic matrix composites (CMCs) in high-temperature service, thereby compromising structural integrity and operational safety. To elucidate the mechanism of its oxidation effects, this study predicted the oxygen diffusion coefficient within 2.5D woven C/SiC fibre bundles based on gas diffusion and oxidation kinetics theory, and subsequently constructed a meso-scale constitutive model incorporating oxidation damage and fibre defect distribution. Furthermore, a micro-scale framework for yarns was established by integrating interfacial slip behaviour, and an RVE model for 2.5D woven C/SiC was constructed based on X-ray computed tomography reconstruction of the actual microstructure. Building upon this foundation, an oxidation constitutive model applicable to loading–unloading cycles was proposed and validated through high-temperature oxidation tests at 700 °C, 900 °C, and 1100 °C. Results demonstrate that this model effectively characterizes the strength degradation and stiffness reduction caused by oxidation, enabling prediction of CMCs’ mechanical properties under oxidizing conditions and providing a physics-based foundation for the reliable design and life assessment of C/SiC components operating in oxidizing environments. Full article

Geopolymers are a new breed of construction materials that are environmentally friendly and replace old Portland cement. These materials are produced through the alkaline activation of industrial and agricultural waste rich in aluminosilicates. The growing interest in sustainable building solutions has driven research into their development. Palm oil fuel ash (POFA) and waste ceramic tile powder (WTCP) are both highly rich in reactive aluminosilicates and widely recommended for the production of sustainable geopolymers. This study aims to evaluate the suitability of POFA and WTCP as sustainable alternatives to conventional binders and to identify the potential advantages of each waste material in developing eco-friendly, high-performance geopolymers. The results indicate that specimens prepared with a high content (50 wt%) of POFA or WTCP, incorporating fly ash and slag, can achieve compressive strengths of up to 50 MPa after 28 days of curing. However, increasing the proportion of POFA or WTCP from 50% to 60% and 70% resulted in a significant reduction in compressive strength. In contrast, specimens containing higher proportions of POFA and WTCP demonstrated superior durability when exposed to aggressive environments. In summary, the findings indicate that WTCP is more suitable than POFA for producing geopolymers as eco-friendly construction materials. Its superior reactivity, workability, early-age strength development, and durability make it a promising precursor for sustainable applications in the construction sector. Full article