Grain Growth Research Articles

Beyond Structural Stabilization of Highly‐Textured AlN Thin Films: The Role of Chemical Effects

AbstractThe crystalline quality and degree of c‐axis orientation of hexagonal AlN thin films correlate directly with their functional properties. Therefore, achieving AlN thin films of high crystalline quality and texture is of extraordinary importance for many applications, but particularly in electronic devices. This systematic study reveals, that the growth of c‐axis‐orientated AlN thin films can be governed by a chemical stabilization effect in addition to the conventionally known structural, strain‐induced, stabilization mechanism. The promotion of in‐plane growth of AlN grains with c‐axis out‐of‐plane orientation is demonstrated on Y, W, or Al seed layers with different thicknesses and crystallinity preliminary exposed to N2 at room temperature. It is established that the stabilization mechanism is chemical in nature: the formation of an N‐rich surface layer on the metal seed layers upon exposure to N2 pre‐determines the polarity of AlN islands at the initial stages of thin film growth while the low energy barrier for the subsequent coalescence of islands of the same polarity contributes to grain growth. These results suggest that the growth of c‐axis oriented AlN thin films can be optimized and controlled chemically, thus opening more pathways for energy‐efficient and controllable AlN thin film growth processes.

Strong observational support for the [formula omitted] timeline in the early universe

JWST’s recent discovery of well-formed galaxies and supermassive black holes only a few hundred Myr after the big bang seriously challenges the timeline predicted by ΛCDM. Now, the latest identification of polycyclic aromatic hydrocarbons (PAHs) at z=6.71, together with these earlier inconsistencies, makes the time compression problem in this model quite overwhelming. We consider the timeline associated with the formation and growth of PAH grains based on current astrophysical models and argue that their appearance at z=6.71 favors the structure formation history in Rh=ct rather than that of Planck-ΛCDM. We estimate the time at which they must have started growing in each case, and then trace their history through various critical events, such as the end of the ‘dark ages’, the beginning of Pop III star formation, and the onset of reionization. Together, these three distinct discoveries by JWST, viz. high-z galaxies, high-z quasars and the surprisingly early appearance of PAHs, all paint a fully consistent picture in which the timeline in ΛCDM is overly compressed at z≳6, while strongly supporting the expansion history in the early Universe predicted by Rh=ct.

Evolution and mechanism of recrystallization microstructure and texture in GH3536 superalloy foil and their influence on strength performance

To achieve isotropic strength in GH3536 foil, this study investigated the influence mechanism of initial recrystallization microstructure and texture characteristics of GH3536 superalloy foil with different cold-rolled reduction rates (referring to the reduction rate in thickness) on annealing recrystallization microstructure, including secondary recrystallization microstructure, and texture. This was studied by controlling the cold-rolled reduction rate and annealing temperature, in conjunction with microstructure and texture analysis. Meanwhile, this study clarified the dependency of strength performance on recrystallization microstructure and texture. The results of this study indicate that the Coincidence Site Lattice (CSL) grain boundaries and High Energy (HE) grain boundaries did not show significant superiorities, and were not the primary reasons for the formation of Brass ({011}<211>) and Goss ({011}<100>) textures, as well as secondary recrystallization. Instead, by controlling the cold-rolled reduction rate, the initial recrystallization stage formed a significant quantity and size superiority of α-fiber texture ({110}∥ND) in each grain size range. This led to preferential growth, and even abnormal growth of Brass and Goss grains in subsequent high-temperature annealing processes. The control of the α-deformation fiber texture was identified as the driving factor behind the formation of the initial recrystallization texture due to the cold rolling reduction rate. Cold-rolled processes with a deformation amount greater than 40 % yielded a quantity superiority of α-fiber texture shear bands and an appropriate stored energy advantage. This facilitated the nucleation and effective growth of more α grains, while suppressing the random growth of grains with γ-fiber texture ({111}∥ND). Ultimately, a quantity and size superiority was achieved in the initial recrystallization stage. The tensile strength of GH3536 foil was controlled by grain size and texture. By controlling the deformation amount to approximately 30 %, GH3536 foil was successfully produced with no pronounced orientation texture and isotropic strength.

A Study of MgZnO Thin Film for Hydrogen Sensing Application.

This research introduces a hydrogen sensor made from a thin film of magnesium zinc oxide (MgZnO) deposited using a technique called radiofrequency co-sputtering (RF co-sputtering). Separate magnesium oxide (MgO) and zinc oxide (ZnO) targets were used to deposit the MgZnO film, experimenting with different deposition times and power levels. The sensor performed best (reaching a sensing response of 2.46) when exposed to hydrogen at a concentration of 1000 parts per million (ppm). This peak performance occurred with a MgZnO film thickness of 432 nanometers (nm) at a temperature of 300 °C. Initially, the sensor's responsiveness increased as the film thickness grew. This is because thicker films tend to have more oxygen vacancies, which are imperfections that play a role in the sensor's function. However, further increases in film thickness beyond the optimal point harmed performance. This is attributed to the growth of grains within the film, which hindered its effectiveness. X-ray diffraction (XRD) and field-emission scanning electron microscopy (FE-SEM) were employed to thoroughly characterize the quality of the MgZnO thin film. These techniques provided valuable insights into the film's crystal structure and morphology, crucial factors influencing its performance as a hydrogen sensor.

Single step grown porous polycrystalline nickel microstructures with ultra-thin defect rich surface oxide for alkaline water oxidation

Investigation on the intrinsic catalytic activity of structurally diverse polycrystalline nickel microstructures such as porous nickel sheets (PNS), porous folded/curled nickel structures (PFNS) and porous nickel balls (PNB) revealed the surface bounded electrocatalytic activities within an alkaline reaction environment for water oxidation. Nickel microstructures were grown via template/surfactant-free, single step solution combustion technique in air atmosphere. The distinct morphologies (porous nickel sheets, porous folded/curled nickel structures and porous nickel balls) were achieved through changing the quantity of HNO3 in the reaction mixture. The physicochemical characterisations were done with XRD, FESEM, EDS and XPS. Microscopic studies revealed the growth of nickel grains with numerous macro pores forming microstructures in distinct morphologies. The O ls spectra of XPS studies revealed the presence of O−/O2− sites and Ni 2p spectra were distinguished between the formation of Ni0/Ni2+/Ni3+ states, implied the existence of surface oxide with plenty of defects. The synergistic effect results from the formation of microscopic porous architectures with defect rich surface oxide on the electrochemical behaviour and OER activity of PNS, PFNS and PNB were discussed with electrochemical techniques such as CV, LSV, EIS and CP. The OER kinetics in terms of relatively low value of overpotential at 10 mA cm−2 and Tafel slope along with high specific activity of PNS/GCE with respect to PFNS/GCE and PNB/GCE were attributed to the combined effect of increase in electrochemical surface area, high roughness factor and fast charge transfer kinetics. The better electrochemical performance and OER activities of porous nickel sheets in comparison with folded/curled nickel structures and nickel balls is contributed to the unique 2D porous architecture with plenty of oxygen vacancies. This structure not only expose more surface for the formation of passive oxide layer in an alkaline reaction environment but also exhibit facile charge transport properties, causes the generation of numerous surface-active sites for electrocatalytic water oxidation. The outcome of our work gives new insights on the surface electrochemistry of polycrystalline nickel, enables micro-structuring as a prospective strategy towards the optimization of electrocatalysts as anode material for alkaline water oxidation.

Negative thermal expansion performance of (NaMg)xCr2-x(MoO4)3 (0≤x≤1) ceramics

Cr2Mo3O12 ceramics show negative thermal expansion (NTE) in a narrow high-temperature range due to the phase transition around 385 °C. To widen its NTE temperature range, a series of (NaMg)3+ co-doped Cr2Mo3O12 ceramics has been synthesized via a solid reaction process in this work. The effects of double cation (NaMg)3+ co-doping on the phase composition, morphology, phase transformation, and thermal expansion performance of Cr2Mo3O12 ceramics were studied using XRD, Raman, XPS, SEM, and TMA. Results indicate that double cation (NaMg)3+ can partially substitute Cr3+ in Cr2Mo3O12, which causes a phase transition from monoclinic Cr2Mo3O12 to hexagonal (NaMg)xCr2-xMo3O12. The single-phase (NaMg)xCr2-xMo3O12 ceramics with hexagonal structure is obtained when x = 0.5. (NaMg)3+ co-doping promotes the growth of grains and the density of hexagonal (NaMg)0·5Cr1·5Mo3O12 ceramics. (NaMg)3+ co-doping also successfully eliminates the temperature-induced phase transition of Cr2Mo3O12 at 385 °C. Hexagonal (NaMg)0·5Cr1·5Mo3O12 ceramics presents a better NTE with a coefficient of thermal expansion (CTE) of −3.97 × 10−6 °C−1 over a larger temperature range from 30 °C to 700 °C.

The influence of different abiotic conditions on the concentrations of free and conjugated deoxynivalenol and zearalenone in stored wheat

Environmental factors influence fungal growth and mycotoxin production in stored grains. However, the concentrations of free mycotoxins and their conjugates and how they are impacted by different interacting environment conditions have not been previously examined. The objectives of this study were to examine the impact of storage conditions (0.93–0.98 aw) and temperature (20–25 °C) on (a) the concentrations of deoxynivalenol and zearalenone and their respective glucosides/conjugates and (b) the concentrations of emerging mycotoxins in both naturally contaminated and irradiated wheat grains inoculated with Fusarium graminearum. Contaminated samples were analysed for multiple mycotoxins using Liquid Chromatography Tandem Mass Spectrometry (LC–MS/MS). Method validation was performed according to the acceptable performance criteria set and updated by the European Commission regulations No. 2021/808/EC. As an important conjugate of deoxynivalenol, the concentrations of deoxynivalenol-3-glucoside were significantly different from its precursor deoxynivalenol at 0.93 aw (22% moisture content- MC) at 25 °C in the naturally contaminated wheat with a ratio proportion of 56:44% respectively. The high concentrations of deoxynivalenol-3-glucoside could be influenced by the wheat’s variety and/or harvested season/fungal strain type/location. Zeralenone-14-sulfate concentrations were surprisingly three times higher than Zearalenone in the naturally contaminated wheat at 0.98 aw (26% MC) at both temperatures. Emerging mycotoxins such as moniliformin increased with temperature rise with the highest concentrations at 0.95 aw and 25 °C. These findings highlight the influence and importance of storage aw x temperature conditions on the relative presence of free vs conjugated mycotoxins which can have implications for food safety.

Novel bainitic Ti alloys designed for additive manufacturing

Novel ternary titanium alloys with a bainitic microstructure have been designed specifically for additive manufacturing (AM). The Ti-xCu-yFe alloys take advantage of constitutional supercooling to suppress the growth of large columnar grains usually associated with AM Ti alloys. In the as-built condition the bainitic microstructure consists of a refined α-phase within a matrix of β-phase. The intermetallic phase, Ti2Cu, forms predominantly on the interface of the α- and β-phase and within the β matrix. The high strength of these materials is attributed to the refined α-phase and Ti2Cu particles as well as significant solid solution hardening. This work demonstrates a viable way to fabricate structural components with unique and excellent properties using low-cost elemental powders with AM.

Enhancing mechanical properties and density of WC-Co with pressureless sintering via shell structure binder jetting additive manufacturing

The binder jetting (BJT) additive manufacturing (AM) process is suitable for producing complex WC-Co cemented carbide parts. To achieve near-full-density in the final parts, the hot isostatic pressing (HIP) sintering process is typically employed to enhance densification. However, HIP sintering requires high equipment specifications and is relatively more costly compared to conventional pressureless sintering. To improve the density of WC-Co parts printed by BJT AM under the pressureless sintering environment, the shell structure printing method was used in this study. The shell structure printing only jets binder to the model's outer profile, creating a shell that encapsulates the central powder, mitigates binder pyrolysis and residual effects on particle densification, and enhances post-sintering density. In this work, the effect of shell thickness, binder type, and printing layer thickness on the density and mechanical properties of the WC-12Co parts under pressureless sintering conditions were investigated. The results show that the density and mechanical properties of the WC-12Co parts significantly improved with the decreasing shell thickness. Specifically, the WC-12Co printed using shell structure achieves a relative density of over 98% and a transverse rupture strength (TRS) of 1954 MPa after pressureless sintering, a result comparable to BJT printed samples treated with HIP sintering. Moreover, the results indicate using a binder with lower residual carbon content and smaller printing layer thickness has a more positive effect on improving density and mechanical strength when employing the shell structure printing method. Microstructure morphology and phase analysis results indicate that the shell structure printing method does not affect the growth of WC grains in the shell and center regions, nor does it influence its phase composition. The shell structure printing method offers a new approach to the manufacturing of near-full-dense WC-Co materials using the BJT process.

Microstructure and high-temperature wear/oxidation behaviors of TiN/TC4 composites in-situ fabricated by laser melting deposition in N2-containing atmosphere

The TiN/TC4 composites were in-situ fabricated by laser melting deposition in N2-containing atmosphere to investigate their microstructure and high-temperature wear/oxidation behaviors. The well-dispersed TiN reinforcements hindered the growth of grains and facilitated the formation of equiaxed grains. The wear tests at 400 °C indicated that the composite with 25 vol% N2 exhibited the best wear resistance due to its relatively fine grain structure and high microhardness. The oxidation tests at 400 °C demonstrated that the composite with 25 vol% N2 also possessed the best anti-oxidation ability, which is attributed to the existence of a more protective oxidation layer composed of TiO2 and Al2O3.

Stable and Efficient Perovskite Solar Cells by Controlling the Crystal Growth via Introduction of Plasmonic TiN Nanoparticles

AbstractIncorporating noble‐metal plasmonic nanoparticles (NPs) enhances the optoelectronic properties of perovskite solar cells (PSCs) but at a higher cost. In this work, the overlooked potential of refractory plasmonic materials is highlighted as a cost‐effective alternative additive in PSC research. This investigation aims to stimulate interest in this area by showcasing the theoretical and practical impacts of TiN plasmonic NPs when integrated into PSCs. TiN plasmonic NPs present a cost‐effective yet underexplored option. This study explores the impact of TiN NPs on PSCs through theoretical and experimental approaches. Finite‐difference time‐domain (FDTD) optical simulations and empirical data indicate that TiN NPs increase absorption and reduce reflectance in PSCs, driven by surface plasmon resonance and the significant growth of perovskite grains from 450 to 1400 nm. These NPs also regulate the perovskite crystallization rate by adsorbing DMF/DMSO, fostering larger grain formation. Improved band alignment and decreased trap states enhance charge transport and diminish non‐radiative recombination losses. As a result, PSC efficiency with optimal TiN NP concentration increased from 19.07% to 21.37%. Additionally, TiN‐enhanced PSCs display better stability, retaining 98.1% of their original PCE after 31 days under ambient conditions.

Preparation of β-SiAlON/SiC composite ceramic foam filters and their oxidation resistance

In this study, ceramic foam filters with high porosity, strength, and oxidation resistance are produced at low temperatures by preparing porous β-SiAlON/SiC composite ceramic foams using the foam impregnation method with Si, Si, α-Al2O3, AlN, and SiC as the raw materials. The presence of SiC inhibits the growth of β-SiAlON grains, which reduces the amount of β-SiAlON produced. As the proportion of β-SiAlON increases, the porosity of the β-SiAlON/SiC composite ceramic foam decreases, whereas the bulk density and compressive strength increase. Non-isothermal oxidation experiments show that β-SiAlON/SiC composite ceramic foams exhibit high oxidation resistance and their macroscopic morphology does not change significantly after oxidation. As the proportion of β-SiAlON increases, the smooth SiO2 oxide layer on the surface of the ceramic foam gradually changes to acicular and columnar mullite crystals, and the oxidation resistance increases. Therefore, β-SiAlON acts as a high-temperature binder when it is added to SiC. Hence, the prepared β-SiAlON/SiC composite ceramic foams can be used as ceramic filters in the field of molten metal filtration.

Enhancing Internal and External Stability of Perovskite Solar Cells Through Polystyrene Modification of the Perovskite and Rapid Open‐Air Deposition of ZnO/AlOx Nanolaminate Encapsulation

In this study, the internal and external stabilities of a p–i–n methylammonium lead iodide perovskite solar cell (PSC) are improved. Polystyrene (PS) is introduced into the perovskite layer to form a cross‐linked polymer–perovskite network, which enhances the nucleation and growth of the perovskite grains. Moreover, for the first time, 60 nm thick ZnO/AlOx nanolaminate (NL) thin‐film encapsulation (TFE) is deposited directly on the PSC using an atmospheric‐pressure (AP) spatial atomic layer deposition system operated in AP spatial chemical vapor deposition (AP–SCVD) mode. The rapid nature of AP–SCVD enables encapsulation of the PSCs in open air at 130 °C without damaging the perovskite. The PS additive improves the performance and internal stability of the PSCs by reducing ion migration. Both the PS additive and the ZnO/AlOx NL TFEs improve the external stability under standard test conditions (dark, 65 °C, 85% relative humidity [RH]) by preventing water ingress. The number and thickness of the ZnO/AlOx NL layers are optimized, resulting in a water–vapor transmission rate as low as 5.1 × 10−5 g m−2 day−1 at 65 °C and 85% RH. A 14‐fold increase in PSC lifetime is demonstrated; notably, this is achieved using PS, a commodity‐scale polymer, and AP–SCVD, a scalable, open‐air encapsulation method.

Er2O3 doped ZnO–Cr2O3-based varistors with high voltage gradient

ZnO varistors are widely used in modern intelligent electrical equipment, and the preparation of miniaturized varistors with high voltage gradient has become a top priority. This work investigated the preparation of high voltage gradient ZnO–Cr2O3-based varistors doped with Er2O3 and analyzed the relationship between their microstructure and electrical properties. As the doping amount of Er2O3 increases from 0.00 to 0.75 mol%, Er2O3 phase obviously dissolving element Co distributed at the trigeminal grain boundaries increases, leading to the grain size d decreases from 3.16 to 1.70 μm, the nonlinear coefficient α increases from 6.22 to 50.48, the voltage gradient E1mA increases from 428.37 to 1616.76 V/mm, and the leakage current density JL decreases from 375.75 to 0.79 μA/cm2, achieving optimal comprehensive electrical performance of the sample with Er2O3 doping of 0.75 mol%, for which, the residual voltage ratios K reaches the minimum value of 1.14 under the impulse current density Jp of 63.7 A/cm2. When the doping amount of Er2O3 further increases to 1.00 mol%, the excessive Er2O3 phase aggregates at the trigeminal grain boundaries and distributes unevenly, leading to the growth of ZnO grains and performance deterioration of the samples. The ZnO–Cr2O3-based varistors have the advantages of much easier doping, and there is no dopant volatilization during the sintering process. This research provides an important reference for the development of high-performance, miniaturized ZnO–Cr2O3-based varistors.

Role of layer arrangement in microstructure and corrosion behavior for 78-mm thick-plate 316L stainless steel fabricated via narrow gap laser wire filling welding

Controlling repeated thermal cycling is one of the key mechanisms to design microstructures in the interlayer regions for narrow gap laser wire filling welding (NGLWFW) of austenite stainless steels. Herein, the optimization of process parameters for individual layers is tailored to customize the molten pool morphology during the NGLWFW process, facilitating precise control over the microstructure and, consequently, enhancing both mechanical properties and corrosion resistance of the joint. The results showed that the molten pool morphology acquired by simulation are obviously diverse from the bottom zone (BZ), middle zone (MZ) to upper zone (UZ) of the welded joint ascribed to the high heat accumulation effect, leading to the variation of microstructure. At BZ, the combination of smaller grain size and reduced dendrite spacing reduce the number of corrosion sites and promote the formation of a denser and more uniform corrosion product layer. Additionally, the diverse grain orientation, characterized by lower texture strength, facilitated a more uniform distribution of elements. Furthermore, the significantly higher content of δ-ferrite showing smallish shape disrupted the directional growth of austenite columnar grains, contributing to the excellent corrosion resistance observed at the BZ.

Densification mechanism and thermal shock resistance improvement of MgF2‐doped Y2O3 ceramics

AbstractThis paper aims to improve the density and thermal shock resistance of Y2O3 ceramics for the preparation of ultra‐pure high‐temperature alloy crucible materials. The doping effect of MgF2 content on the densification behavior, physical properties, and thermal shock resistance of Y2O3 ceramics was systematically investigated in this paper. The results suggested that the presence of MgF2 greatly promoted the growth of Y2O3 grains and the transformation of the pore structure by liquid‐phase sintering. And the mechanical properties of the MgF2‐doped Y2O3 ceramics were significantly improved. Besides, the marked improvement in the thermal shock resistance of MgF2‐doped Y2O3 ceramics was attributed to the synergistic action resulting from the growth of grain size and the enhancement of the crack deflection effect. In particular, the relative density of Y2O3 ceramics doped with 1.5 wt% MgF2 reached 96.4% and the residual flexural strength ratio after thermal shock achieved 45.0%, showing an excellent application prospect.

The effect of Fe2O3 doping on a Pt/Co3O4 catalyst for CO oxidation: Improvement of thermal stability and catalytic activity

Although Pt/Co3O4 is an active catalyst for CO oxidation, its low thermal stability may impede its application. The thermal stability and catalytic performance of Pt/Co3O4 were considerably enhanced by Fe2O3 doping. Fe2O3 doping stabilized the mesostructured material during the high-temperature treatment, and the Fe2O3-doped samples retained a larger specific surface area. The characterization results revealed that Fe2O3 doping inhibited catalyst crystallization and decomposition and the growth of catalyst grains during high-temperature calcination. The Fe2O3 doping reduced the Co-O bond strength in the surface Co3O4 lattice, increased the Co3+ ratio, and generated highly active surface oxygen species. Fe2O3 doping also facilitates CO2 desorption, which improves CO adsorption and oxidation. SO2 and NO impede CO oxidation on Pt/Fe2O3/Co3O4. This negative impact was caused by the inert species formed when SO2 or NO reacted with O2 on the catalyst, such as SO42-, HSO4-, or nitrate species, which covered the active sites.

Unveiling the recrystallization mechanism and kinetics parameters in cold-rolled dual-phase stainless steel using differential scanning calorimetry

The present work aims to assess the Recrystallization mechanism and Kinetics parameters in Cold-Rolled Dual-Phase stainless steel. For this purpose, Differential Scanning Calorimetry was used over a range of 5–20 K/mn of heating rate, to identify the classical kinetic parameters such as recrystallization temperature, activation energy, and growth mechanism following 90 % reduction in thickness. The findings revealed that the recrystallization temperature increased with rising heating rates within the range [706.8–732] for the ferrite phase, as well as [1282.0–1360.3] K for the austenite phase. The estimated activation energies for ferrite and austenite recrystallization fell within the range of [207.2 ± 1.4–220.1 ± 2.5] kJ/mol and [220.2 ± 2.0–241.1 ± 4.0] kJ/mol, respectively. The Avrami parameter approached half-unity for both ferrite and austenite recrystallized phases for which results can be interpreted to be chiefly responsible for a general mechanism involving the growth of new grains with appreciable initial volume through a diffusion-controlled process.

The role of TiN inoculant on microstructure and properties in wire arc directed energy deposition of super duplex stainless steels

The challenges in Wire Arc Directed Energy Deposition (Wire-DED) of super duplex stainless steels (SDSS) are the growth of large columnar grains and undesirably high austenite content. This results in a detrimental effect on the material properties. Here we report the additively manufactured SDSS with the addition of TiN inoculant via Wire-DED. And the effectiveness of incorporating TiN inoculant into additively manufactured SDSS was explored. The addition of trace amounts of TiN reduced the content of the austenite phase from 74.0% to 61.5%. Additionally, the introduction of TiN facilitated deoxidation and slag formation, leading to decreased inclusion content and a shift in inclusion type, which acted as nucleation sites for ferrite, promoting grain refinement. This results in weakened anisotropy of tensile properties and enhanced corrosion resistance. The anisotropy of the ultimate tensile strength and yield strength reduced from 9% to 3% and from 5% to 2%, respectively. This study demonstrates the potential of TiN inoculation in fabricating Wire-DEDed SDSS with tailored microstructures and improved performance, making them suitable for a wide range of practical applications.

Interweaved filler network in epoxy resin with reduced interface thermal resistance via in-situ high-temperature “welding” for significantly improved thermal conductivity

For heterogeneous integration in harsh environments, polymeric materials are required to integrate excellent insulating property with significant thermal conductivity. Traditional discrete fillers used in polymeric matrix to create thermal pathways introduce numerous contact interfaces, leading to limited thermal conductivity enhancement efficiency (TCE) and unstable dielectric properties. Here, a distinctive strategy, involving the preparation of an interweaved thermally conductive filler with inherent heat channels through self-templated electrospinning and in-situ high-temperature “interface welding”, is proposed to reduce the interface thermal resistance (ITR). The growth of grains at high temperature facilitates the process of “interface welding”, while self-templated electrospinning establishes intrinsic thermal conduction pathways. Consequently, the epoxy resin fortified with this interweaved filler exhibits an exceptionally TCE of 162.15 % and enhanced in-plane thermal conductivity of 3.75 W m−1 K−1 at ultra-low filler ratio of 7.10 vol%. The combination of high electrical insulation of filler and low filler content results in excellent electrical insulating property (>1017 Ω cm) and stable dielectric properties over a frequency range of 103-106 Hz, enabling the successful implementation of heterogeneous integration in challenging environments. This work has the potential to offer a groundbreaking approach for achieving interconnected functional networks within polymer-based composites.