Ceramic Layer Research Articles

Data-driven AI for the automated classification of the isothermal heat-treated thermal barrier coatings using pulsed infrared thermography

Abstract Thermal barrier coating (TBC) is a multilayer coating applied to metallic structures exposed to high temperatures, such as aero-engine parts and gas turbine blades. These thermally insulating materials are used to extend the component life by minimizing the high-temperature exposure of structural components. As a result of the high-temperature oxidation tests, a thermally grown oxide (TGO) layer formed at the interface between the ceramic topcoat layer and the bond coat layer. The primary cause of TBC performance decline and structure failure is the growth of the oxide layer. Hence, it is crucial to regularly monitor the formation of the oxide layer and the degradation of coatings. This can be achieved by developing coating-life prediction models, which are vital for quality control, health monitoring of TBCs, maintenance decision-making, and the prevention of catastrophic failures. Existing methods for life estimation, which are dependent on empirical methods and microstructural analysis, often fail due to various material compositions and service conditions. This study proposes an automated classification of iso-thermal heat-treated TBC samples using temperature data, which helps in predicting the TBC life and monitoring the TBC degradation. TBC-coated samples are isothermal heat-treated at 1000 °C, and the initial growth of TGO is monitored using a non-destructive thermal imaging technique. Identifying distinctive features in each class corresponding to layer thickness measurement and service hours is challenging and time-consuming. So, we integrate data-driven AI models and feature extraction techniques to interpret complex thermal patterns. The performance of deep learning models and classical machine learning models demonstrates that our method can achieve maximum classification accuracy and F1-score of 89.2% and 89.0%, respectively. This automated classification framework promises a powerful tool for predictive maintenance and remaining useful lifetime estimation of hot section components reliant on TBCs.

Alumina ceramic insulation layer for strain sensor fabricated by direct laser deposition

ABSTRACT Strain sensors are often used to monitor the use of critical components. The bond strength between the strain sensor and the gear teeth is particularly critical. There is a problem of insufficient bond strength between separated strain sensors and parts. The strain sensor is prone to loosening and flaking in the working environment. Therefore, a method of preparing the ceramic insulation layer of the strain sensor by direct laser deposition (DLD) is proposed. The effects of laser scanning trajectories, laser power, and scanning speed on forming quality were investigated experimentally. In addition, the phase analysis, microstructure characterization, and insulation properties of the insulating layers prepared at different overlap rates were researched. The research shows that the ceramic insulation layer has good insulation properties and hardness. The maximum hardness can reach 2405.74MPa, and the insulation resistance increases with the number of layers. The surface of the ceramic insulation layer is dense and has no cracks.

Thermal cycling performance of GYbZ/YSZ thermal barrier coatings with different microstructures based on finite element simulation

Three (Gd0.9Yb0.1)2Zr2O7/YSZ double ceramic layer (DCL) thermal barrier coatings (TBCs) with different microstructures were manufactured by electron-beam physical vapor deposition (EB-PVD). The thermal cycling behavior of the three TBCs was evaluated comparatively at 1150 ℃. The results showed that TBCs with small columnar grains exhibited the best thermal cycling performance among all the tested TBCs. The effect of microstructure on thermal cycling behavior, including crack evolution and failure mode was discussed. A finite element model tailored to the microstructural characteristics of the DCL coatings was established. Several in-plane stress concentration points appeared in the taller GYbZ column due to discontinuities in strain tolerance resulting from sudden structural or compositional changes. Analysis of the strain energy release rate variation for each concentration point suggested that the predicted delamination position and process aligned with experimental results.

Failure behavior study of EB-PVD TBCs under CMAS Corrosion and Thermal Shock Cycles

Abstract Thermal barrier coatings serve as a key heat-insulating technology for the hot components of aircraft engines, enhancing the engine’s operating temperature, thrust, and efficiency.However, the high-temperature operating environment poses significant challenges to the TBCs, particularly from the corrosion caused by environmental deposits, primarily composed of CaO, MgO, Al2O3, and SiO2, referred to as CMAS, which can lead to premature failure of the TBCs. CMAS corrosion has become a major obstacle, limiting the operating temperature and service life of TBCs. Constructing simulation environments that replicate TBCs’ working conditions and exploring online, non-destructive detection techniques are reliable approaches to studying coatings’ failure, representing both a global research hotspot and a challenge in this field. The paper presents an initial endeavor to establish a simulation experiment for TBCs in aviation-engine within a CMAS environment. Experimental results show that electron beam-physical vapor deposition (EB-PVD) Y2O3-stabilized ZrO2 (YSZ), one of the mainstream TBCs technologies, produced 20% surface spallation after 50 thermal-shock cycles under simulated CMAS corrosion conditions. Testing and analysis of the macroscopic and microscopic structures of the failed samples, combined with SEM, EDS, and XRD findings, revealed significant physical and chemical interactions between the ceramic layer and CMAS deposits, as well as phase transformation within the coatings, leading to substantial alterations in mechanical properties and ultimately causing the failure of EB-PVD YSZ.

Investigation of the nonlinear dynamics of thin sandwich shells composed of functionally graded materials with double curvature in thermal environments

Double curvature structures play a crucial role as load-bearing components across various engineering fields. Functionally graded materials, blending metals and ceramics, boast superior material characteristics, fueling their expanding applications. This study pioneers the non-linear dynamic analysis of sandwich shells that feature functional gradient compositions in thermal settings. We assume that both the upper and lower shells of these double curvature structures are crafted from functionally graded materials, with a ceramic core. This variation in material exhibits a ceramic layer on the inner surface and a metallic layer on the outer surface, showing properties that vary along the shell thickness in a power-law gradient. Non-linear dynamic equations are derived using third-order shear theory, encompassing geometric non-linearity and shear deformation. Employing the Galerkin method, we discretize the equations of motion into a non-linear dynamic system with five degrees of freedom, and subsequently give an analytical expression for the nonlinear naturalfrequency by means of multiscale analysis. Our discussion examines the impacts of structural parameters, porosity volume fraction, volume fraction index, and temperature differences on the non-linear/linear frequency ratio of doubly curved sandwich shells. Calculations reveal a sharp rise followed by a rapid decline in the non-linear/linear frequency ratio with increasing structural aspect ratio b/a. Conversely, it decreases with increasing thickness-to-length and radius-to-length ratios, with temperature differences initially reducing and later increasing it. These findings offer practical insights for designing functional gradient double curvature sandwich shells.

THz-TDS characterization of stress evolution of EB-PVD TBCs under thermal cycling

The failure of thermal barrier coatings (TBCs) during service is a critical issue affecting aeroengine efficiency. In this study, electron beam physical vapor deposition (EB-PVD) TBCs were subjected to thermal cycling at 1100 °C. Terahertz time-domain spectroscopy (THz-TDS) was employed to characterize the relationship between the evolution of characteristic frequency and the number of thermal cycles, along with the development of stress in the ceramic layer. In situ tensile test revealed a linear correlation between the characteristic frequency and micro strain derived from THz-TDS data, with a proportional coefficient of −9.94 between the characteristic frequency and the slope of the refractive index curve. The results show that the stress evolution can be effectively monitored by recording the trend of characteristic frequency. During the non-failure stage, the characteristic frequency followed a parabolic trend as thermal cycles increased, influenced by the growth of thermally grown oxide (TGO), ceramic layer sintering, and thermal mismatch. Approaching the failure stage, stress evolution was dominated by the expansion of vertical cracks in the ceramic layer and the widening of transverse cracks at the interface, which corresponded to a sudden change in the characteristic frequency.

Effect of irradiation temperature on the mobility of structural and vacancy defects in the damaged layer of Li2ZrO3 ceramics

The paper presents the assessment results of the irradiation temperature effect on the change in the type of structural defects caused by irradiation with helium ions in the near-surface layer of Li2ZrO3 ceramics, as well as determining the nature of structural damage using the electron paramagnetic resonance method in the case of irradiation fluence variation. During characterization of the structural changes caused by helium ion irradiation, the main attention was paid to detailing the type of structural defects and radiolysis products arising during irradiation, alongside alterations in their concentration using the electron paramagnetic resonance method. During the experiments, it was determined that the observed effects of thermally stimulated mobility of vacancy defects in the damaged layer caused by irradiation with helium ions indicate a positive effect of thermal heating of samples during irradiation at low fluences. This effect consists in a decline in the number of oxygen vacancies in the damaged layer at low irradiation fluences (1015 – 1016 cm-2), the concentration of which was determined using the EPR method, and the observed structural changes at low irradiation fluences in the case of an elevation in irradiation temperatures are associated with deformation distortion of the crystalline structure of ceramics caused by transformation energy processes, and thermal expansion effects.

Comprehensive study of the effect of Hf and Ta co-doped MCrAlY bond coat on the high-temperature properties of thermal barrier coating

The MCrAlY bond coat is modified by reactive element (RE) Hf and refractory element Ta, and the high-temperature oxidation resistance of the thermal barrier coating (TBC) before and after the modification are investigated by comparative experiments. The experiments use high-velocity oxygen-fuel (HVOF) to prepare NiCoCrAlY and NiCoCrAlYHfTa bond coats on the surface of GH4099 high-temperature alloy, and then yttrium stabilized zirconia (YSZ) ceramic layers are prepared on the surface of the bond coat by atmospheric plasma spraying (APS), and cyclic oxidation is carried out in air at 1050 °C until failure. It is shown that the oxidation lifetime of the modified TBC reached 1992 h, which is one time higher than that of the unmodified TBC. The doping of Hf and Ta elements reduces the growth rate of the oxide layer, and these diffuse externally and combine with the internally diffused O to form HfO2 and Ta2O5 in the thermally grown oxide (TGO) layer, thereby improving the adhesion and mechanical properties of the oxide layer. In addition, the bond strength and thermal shock resistance of the TBCs are significantly improved after doping with Hf and Ta elements, which prolongs the lifetimes of the TBCs. In this paper, the morphology, structure, and properties of the modified TBCs are characterized to investigate the mechanism of the oxidation lifetime extension.

Enhanced corrosion protection performance using polysilazane-derived amorphous SiCN ceramic coating

In this work, a polymer-derived silicon carbonitride (SiCN) ceramic layer has been deposited on stainless steel 304 (SS304) to enhance the corrosion resistance of SS304 in a seawater environment. SS304 is dip-coated with a polysilazane solution followed by pyrolysis under argon environment at 800 °C to develop SiCN ceramic layer with a thickness of about 3 μm on SS304. Structural characterization of the prepared samples was performed using Fourier transform infrared (FTIR), X-ray diffraction (XRD), Raman spectroscopy, and scanning electron microscopy (SEM). Potentiodynamic polarization tests of SS304 and SiCN-coated SS304 were performed in 0.6 M NaCl solution. SiCN-coated SS304 showed very low corrosion current density of 4.2 × 10−10 A/cm2 whereas corrosion current density of uncoated SS304 was measured to be 1.52 × 10−7 A/cm2. Excellent corrosion resistance performance of SiCN-coated SS304 was observed as confirmed by electrochemical impedance spectroscopic (EIS) measurements.

Enhanced anticorrosive, antimicrobial and biocompatible properties of AZ91D magnesium alloy by MAO-polycaprolactone-modified ZnO composite coating

Magnesium alloys are biodegradable metal implant materials that are prone to corrosion in human body fluids and are poor biocompatible as a consequence. Herein, we report the preparation of a ceramic layer on an AZ91D magnesium alloy using the micro-arc oxidation (MAO) technique, after which polycaprolactone/citric-acid-monohydrate-modified nano‑zinc oxide was composited on the ceramic layer using a sol–gel method. The MAO-polycaprolactone-modified ZnO composite coating exhibited superior corrosion resistance compared to magnesium alloy, and a higher electrochemical impedance in simulated body fluid (1.0397 × 107 vs. 8.444 × 102 Ω·cm2). Furthermore, data from immersion, antimicrobial, hemolysis, cell-viability, and-proliferation testing revealed that the composite coating is significantly more antimicrobial and biocompatible than the magnesium alloy. We conclude that such composite coatings have considerable potential for use in biomedical orthopedic-implant applications.

The effect of residual mechanical stresses and vacancy defects on the diffusion expansion of the damaged layer during irradiation of BeO ceramics

The paper presents the results of a study on the application of Raman and UV spectroscopy methods to determine the structural damage kinetics in the near-surface layer of BeO ceramics caused by high-dose irradiation with He2+ ions. Interest in this type of ceramics is due to the combination of its structural and thermophysical parameters, making these ceramics one of the promising classes of materials for microelectronics and structural materials for nuclear reactors, with the possibility of operation in conditions of heightened radiation background. According to the conducted studies, it was established that with the irradiation fluence growth, changes in the nature of deformation structural distortions associated with the accumulation of residual mechanical stresses of tensile and compressive types are observed. At irradiation fluences of 1016-5×1016 Не2+/cm2, tensile stresses play a dominant role in structural distortions, while the value of compressive stresses at fluence growth makes up a small share in the overall nature of the deformations. Moreover, an elevation in the irradiation fluence above 5×1016 He2+/cm2 leads to a rise in the concentration of defects caused by the formation of oxygen vacancies, as well as He-VO type complexes, the presence of which is indicated by the halo intensity growth in the Raman spectra, as well as a change in the intensity of the absorption bands. Analysis of changes in thermophysical parameters revealed that a rise in structural distortions associated with the accumulation of complex defects results in thermal conductivity reduction and a deterioration in heat transfer processes associated with partial amorphization of the damaged layer. Moreover, the established direct relationship between the value of residual mechanical stresses and the degradation of thermal conductivity indicates the cumulative effect of destructive changes caused by irradiation, as well as the influence of diffusion mechanisms on the damaged layer thickness growth.

Ballistic performance of alumina/carbon fiber/aramid composite against impact of different projectile shapes

This study explores the ballistic performance of an alumina/carbon fibre/KevlarⓇ aramid composite panel against impacts from various projectile shapes, including ogive, conical, cylindrical, hemispherical, and 5.56 mm × 45 mm NATO rounds. The aim is to analyse the influence of projectile nose shape on penetration resistance and energy absorption, critical for defence and aerospace applications. Numerical simulations carried out in LS-DYNAⓇ, validated by experimental data, reveal that the ceramic layer effectively initiates projectile deceleration, while the fabric layers absorb the majority of the kinetic energy. Hemispherical projectiles exhibit minimal plastic deformation, highlighting the composite's optimal performance against this shape. In contrast, ogive projectiles demonstrate greater penetrative potential, challenging the composite's multi-layered defence. The study finds that approximately 90% of the kinetic energy is absorbed by the fabric backing, with a small portion absorbed through projectile deformation and ceramic cracking. These results underscore the importance of considering projectile deformation in simulations and suggest that the composite design is well-suited for enhancing protection against high-velocity impacts in defence and aerospace sectors.

Impact of atmospheric plasma spraying parameters on microstructure, mechanical properties and thermal cycling performance of YSZ coatings

Yttria-stabilized zirconia (YSZ) coatings are widely utilized thermal protective layers for metal and superalloy surfaces. These coatings are employed as thermal barrier coating (TBCs) to insulate metallic parts from higher thermal energy, thereby minimizing the cooling need for the topcoat ceramic layer. The choice of material is 7 wt% YSZ due to its exceptional capability to withstand challenging conditions characterized by extremely high temperatures and pressures, typically employed by the atmospheric plasma spraying (APS) in gas turbines, effectively extending their lifespan and improving performance. The deposition process of TBCs is significantly influenced by various spraying parameters, including gas flow rate and current (amp). These key parameters mutually play a significant role in controlling thermal stability, phase composition, and improved mechanical and microstructure properties. The aim of this research is to evaluate and contrast the impact of various spraying parameters on YSZ TBC performance. Accordingly, the influence of Hydrogen (H2), Argon (Ar) flow rate, and Current (amp) was investigated. Microstructure and elemental mapping studying was conducted using Field Emission Scanning Electron Microscopy FESEM/EDS and phase studying was examined with X-ray diffraction (XRD). Porosity was measured by IMAGE J software while hardness measurement was calculated by Vickers hardness tester. Additionally, thermal cycling tests were conducted between 700 °C and 1200 °C. The porous coatings exhibited poor performance, delaminating early during the tests. In contrast, dense coatings performed significantly better, enduring up to 140 cycles before failure.

Aminopropyltriethoxysilane-modified MXene for remarkably enhancing tracking resistance and flame retardancy of silicone rubber

The preparation of silicone rubber with excellent tracking resistance and flame retardancy is of great significance for application in high-voltage electrical insulation. Unfortunately, to date there lacks an effective strategy to simultaneously endow silicone rubber with satisfied tracking resistance and flame retardancy. In this work, aminopropyltriethoxysilane-modified MXene (APTES-MXene) was prepared by dehydrative condensation between the Si-OH in the hydrolyzed aminopropyltriethoxysilane (APTES) and the hydroxyl groups in MXene. The APTES-MXene was homogeneously dispersed in addition-cure liquid silicone rubber (ALSR). The effects of APTES-MXene on the tracking resistance and flame retardancy of ALSR were investigated. Incorporating 0.175 phr APTES-MXene and 15 ppm Pt catalyst enabled ALSR to pass 1A4.5 level, with a low erosion rate of only 0.29 %, indicating a significantly improved tracking resistance. Meanwhile, the 0.175 phr APTES-MXene also endowed ALSR a UL-94 V-0 rating and the limiting oxygen index (LOI) value reached 32.8 %. It was found that APTES-MXene and Pt catalyst synergistically promoted ALSR forming ceramic layer at elevated temperature. The mechanism for APTES-MXene improving the tracking resistance of ALSR was also proposed. This work provided new insights for high performance high-voltage insulation silicone rubber.

High temperature mechanical properties and tribological behavior of nacre-inspired Ti (C, N)/Al-Cu composites

In order to improve the toughness of aluminum matrix composites with high ceramic contents, nacre-inspired Ti (C, N)/Al-Cu composites are prepared via freeze casting and pressure infiltration, and their mechanical properties and tribological behavior are investigated. The prepared composites can maintain excellent compressive strength, hardness and wear resistance when the experimental temperature increases from 25 °C to 300 °C. This can be attributed to the stable load bearing capacity of the Ti (C, N) ceramic layer at high temperature, the high interface binding capability between Ti (C, N) and Al, as well as the high crack growth inhibition ability of “layered network” structures. Moreover, the tribo-oxide layer formed during the wear process can further improve the wear resistance of the composites.

Investigation of mechanical and tribological properties of NiCrAlY/ZrO2-Y2O3 coatings obtained by detonation spraying

In this study, multilayer gradient NiCrAlY/ZrO2-Y2O3 coatings obtained by detonation spraying in 1D (spot sputtering) and 2D (full-surface scanning sputtering) modes were investigated. The structure of coatings was analyzed using scanning electron microscopy and electron dispersion analysis, mechanical properties (hard- ness, modulus of elasticity) were determined using various techniques. The tribological characteristics of the coatings including abrasion resistance and coefficient of friction were also studied. It was determined that the coatings consist of alternating layers of NiCrAlY and ZrO2-Y2O3, creating a multilayer gradient structure. It was found that the NiCrAlY layers act as a bonding element, providing interlayer adhesion, and the ceramic ZrO2-Y2O3 layer serves as a thermal barrier protecting the substrate from high temperature loads. It was found that the coatings in 2D mode have high microhardness compared to coatings in 1D mode. It was deter- mined that the hardness of coatings smoothly increases from the substrate to the surface layers due to the gra- dient increase in the content of ceramic materials. It was found that coatings obtained in 2D mode have better wear resistance and lower coefficient of friction compared to coatings in 1D mode, indicating the greater effi- ciency of coatings in dry friction conditions and their ability to prevent wear of the substrate material.

Effects of nanoceramic particle size and content on the wear resistance of micro-arc oxidation coatings for 2A12 aluminum alloy

The 2A12 aluminum alloy, renowned for its exceptional mechanical properties, encounters significant limitations in applications involving abrasive environments or frequent contact with other surfaces due to its inadequate wear resistance. This shortcoming substantially reduces the service life of components and escalate maintenance costs, highlighting the urgent need for advanced surface modification techniques. This study meticulously investigates the influence of nanoceramic particle size and content on the wear resistance of micro-arc oxidation (MAO) coatings, a surface modification technique renowned for forming dense, adherent ceramic layers on aluminum alloys. The systematic experimentation revealed that the incorporation of 150 nm α-Al2O3 nanoparticles into the MAO matrix achieves an optimal dispersion, leading to a substantial enhancement in wear resistance. The sample with a 5 g/L concentration of 150 nm α-Al2O3 nanoparticles doping in the MAO electrolyte demonstrated the lowest mass loss, underscoring its enhanced wear resistance. The enhanced microstructure, enriched with hard ceramic phases such as α-Al2O3 and mullite, plays a pivotal role in withstanding wear. Moreover, this study identified that an optimal balance of surface roughness and coating thickness is essential for achieving enhanced wear resistance. The findings of this research provide a strategy for the design of wear-resistant coatings tailored for high-performance applications across aerospace, automotive, and general engineering industries. By optimizing the particle size and concentration in MAO coatings, this study paves the way for the development of durable materials capable of thriving in demanding environments, thereby extending the service life and reducing maintenance requirements of components.

Chameleon‐Inspired, Dipole Moment‐Increasing, Fire‐Retardant Strategies Toward Promoting the Practical Application of Radiative Cooling Materials

AbstractToward addressing the aesthetic demand, IR emissivity, and fire hazards of radiative cooling materials in the practical application, chameleon‐inspired is tactfully employed, dipole moment‐increasing, and fire‐retardant strategies to manufacture an advanced polyurea‐based composite coating through incorporating thermochromic microcapsules, boron nitride nanosheets, and montmorillonite nanosheets. The chameleon‐inspired thermochromic microcapsules and admirable IR emissivity (supported by the original IR emittance spectra) realized by the increasing dipole moment allow the composite coatings to spontaneously adjust the solar absorption and reflection during hot daytime, while enabling high‐efficiency radiative cooling throughout the day. The IR emissivity higher than most literature is attributed to the strong interfacial interactions within polyurea composite coatings which improve the dipole moment of C─O─C, Si─O, and B─N bonds by increasing the distance between the centers of positive and negative charges, thus producing more IR emissions. Furthermore, the thermally melted montmorillonite nanosheets can form a ceramic protective layer enhanced by boron nitride nanosheets, further suppressing combustion behavior to improve the fire safety performance of polyurea coatings. The integration of thermochromic functionality, high fire safety, and admirable IR emissivity not only contribute to promoting the practical application of radiative cooling materials, but also provide a precious reference route to design high IR emissivity.

Non-destructive testing for thickness measurement of the adhesive layer and defect detection in ceramic-metal bonded structures using THz waves

Ceramics, owing to their superior thermal barrier properties, are employed by bonding them to primary structures exposed to elevated temperatures, such as the external components of aircraft and spacecraft. However, when these bonded structures are subjected to thermal impact resulting from high-temperature environments or rapid temperature variations, issues such as debonding, crack formation, and degradation may ensue. These issues can significantly undermine the reliability of the structures, necessitating nondestructive testing (NDT) to monitor the condition of the adhesive layer before and after thermal impact. In this article, we evaluated the integrity of adhesive structures before and after thermal impact using Terahertz (THz) waves, which offer exceptional penetration and resolution for NDT of nonmetallic materials without causing damage to the structure. To achieve this, ceramic-metal bonded structures were mounted on a robotic arm, and scanning was performed over a 70 mm area at 1 mm intervals and 0.5° increments. The peak-to-peak time of the THz signal through the adhesive layer was calculated to determine the thickness distribution. Based on experimental results, the average thickness of the ceramic layer before thermal shock was measured at 9.48 mm (standard deviation: 0.03) and the average thickness of the adhesive layer was 0.234 mm (standard deviation: 0.03). Additionally, four suspected defect areas within the adhesive layer were identified. After thermal shock, the ceramic layer’s thickness decreased by an average of 0.02 mm (0.17%), resulting in an average thickness of 9.46 mm, and the adhesive layer’s thickness decreased by an average of 0.002 mm (0.99%), resulting in an average thickness of 0.232 mm. The four suspected defect areas were confirmed to be in the same locations before thermal impact. To validate the NDT method using THz wave, the ceramic-metal bonded structure was cut to identify debonding defects in the suspected areas. The difference between the thickness distribution obtained using the THz wave-based NDT and that measured using optical microscopy after cutting was 4.4%, confirming the accuracy of the THz wave-based method for defect detection and thickness measurement.

Concentrated solar thermoelectric power generator equipped with a novel ultrathin wet porous membrane cooling technique; experimental study

One side of any thermoelectric power generator (TEG) is hot while the other side should always stay cold. The higher the temperature difference, the greater the power generation. This paper offers a particular ultrathin wet porous membrane (UWPM) as a new cooling method for a solar thermoelectric power generator. According to the graphical abstract, the membrane has a capillary-wicking feature on one side, making it possible to be soaked spontaneously and create a steady thin water film on the ceramic layer of the thermoelectric, thereby serving as an energy-free, enthalpy of vaporization-based cooling method (surface vaporization). Interestingly, water is replenished spontaneously as long as the water exists in the tank. The suggested mechanism is tested under two weather conditions: one hot, dry day (ambient air around 40 °C) and one moderate day (ambient air around 30 °C), with different air speeds between 1.5 and 4.5 m/s to simulate different wind speeds in real applications. Power, cold side surface temperature, maximum conversion efficiency, etc., are measured, evaluated, discussed, and compared with the common fin-pin heatsink/fan thermal management tool. Notably, the implementation of the UWPM demonstrates a substantial enhancement in thermoelectric generator performance. It is noted that the lowest temperature that can be obtained through vaporization can be colder than ambient air temperature, approaching the wet-bulb temperature. The UWPM keeps the cold side temperature up to 10 degrees colder than that achieved in the heatsink method. This is why the generated power by the TEG is around 2.5 times higher when utilizing the UWPM. Furthermore, unlike the fin-pin heatsink (FPH) thermal management tool, warmer weather conditions do not diminish the cooling quality of the UWPM method. Indeed, the cold side temperature on a hot, dry day is almost the same as that on a moderate day using the UWPM technique. This is because hot ambient temperature induces greater and easier vaporization, leading to a higher cooling effect.