High Temperature Applications Research Articles

The influence of thermo-electromechanical coupling on the performance of lead-free BNT-PDMS piezoelectric composites

In recent times, there have been notable advancements in haptic technology, particularly in screens found on mobile phones, laptops, light-emitting diode (LED) screens, and control panels. However, it is essential to note that the progress in high-temperature haptic applications is still in the developmental phase. Due to their complex phase and domain structures, lead-free piezoelectric materials such as Bi0.5Na0.5TiO3 (BNT)-based haptic technology behave differently at high temperatures than in ambient conditions. Therefore, it is essential to investigate the aspects of thermal management and thermal stability, as temperature plays a vital role in the phase and domain transition of BNT material. A two-dimensional thermo-electromechanical model has been proposed in this study to analyze the thermal stability of the BNT-PDMS composite by analyzing the impact of temperature on effective electromechanical properties and mechanical and electric field parameters. However, the thermo-electromechanical modelling of the BNT-PDMS composite examines the macroscopic effects of the applied thermal field on mechanical and electric field parameters, as phase change and microdomain dynamics are not considered in this model. This study analyzes the impact of thermo-electromechanical coupling on the performance of the BNT-PDMS composite compared to conventional electromechanical coupling. The results predicted a significant improvement in piezoelectric response compared to electromechanical coupling due to the increased thermoelectric effect in the absence of phase change and microdomain switching for temperature boundary conditions below depolarization temperature ( Td∼200∘ C for pure BNT material).

Development of Ag@Si composite sinter joining with ultra-high resistance to thermal shock test for SiC power device: Experiment validation and numerical simulation

Owing to its cost-effectiveness and low coefficient of thermal expansion (CTE), micron Si is incorporated into sintered Ag matrix to develop an Ag@Si composite sintering strategy. The Si integration helps reduce cost and alleviate CTE-mismatch of Ag-sintered die attachments. An innovative Ag@Si composite sintering structure is achieved by low-temperature and pressure-less sintering process, where a possibly slight diffusion of native SiO2 on the Si surface toward Ag is indicated by TEM observation, enabling the integration of Ag and Si into one continuous network. Owing to the robust well-bonded composite sintering, the Ag@Si joining strategy provides mechanical/microstructural reliability far beyond the pure Ag sinter joining, demonstrating significant prospects in high-temperature interconnection applications. During the harsh thermal cycling (−50–250 °C), the mitigating effect of the Si addition on CTE mismatch is manifested through the substantial suppression of microstructure deterioration in Ag@Si joint that occurs in pure-Ag-sintered joint, while the shear strength retention rate is doubled. Detailed investigation into the mechanism for elevated performance was conducted by material property and Missies stress analysis. The incorporation of Si helps modify the CTE, elastic properties, and stress distribution of Ag@Si-sintered material, synergistically contributing to the satisfactory joining reliability.

Numerical analysis-based performance assessment of the small-scale organic Rankine cycle turbine design for residential applications

The organic Rankine cycle (ORC) is one of the most common ways to use energy resources to utilise waste heat. Integrating ORC with other systems, such as cooling or heating applications, is also helpful for residential uses. In the ORC system, the turbines are the most critical component determining the system's efficiency. This study conducted a computational fluid dynamics study on a regenerative flow turbine that can be used in small-scale organic Rankine cycle systems. For the higher temperature applications, the analyses were performed using n-pentane working fluid for 1500 and 3000 rpm turbine speeds, inlet temperature between 475–550 K, outlet pressure between 0.9–1.2 MPa, and mass flow rates between 0.5–1.0 kg/s. As a result of the analysis, the isentropic efficiency varies between 4.97 % and 12.52 %. It was concluded that the output power obtained from the turbine varies between 0.53 kW and 2.96 kW. The analyses were also performed for lower temperature (363 and 393 K), pressure (0.05 MPa and 0.3 MPa) and mass flows (0.1 to 0.25 kg/s) applications. In this case, the isentropic efficiency of the turbine varies between 6.23 % and 14.52 %, whereas the power generation varies between 0.068 and 0.521 kW.

A New Strategy for the Design of Triple-Phase Eutectic High-Entropy Alloys Based on Infinite Solid Solution and Pseudo-Ternary Method.

Eutectic high-entropy alloys (EHEAs) have combined both high-entropy alloys and eutectic alloy contributions, with excellent castability and high-temperature application potential. Yet, multielement/triple-phase eutectic high-entropy alloy (TEHEA) designs remain puzzling. This work proposed a new strategy based on an infinite solid solution and pseudo-ternary model to reveal the puzzle of TEHEAs. The designed triple-phase eutectic high-entropy alloys (TEHEAs) with more than seven elements were identified as face-centered cubic (FCC), ordered body-centered cubic (B2), and Laves phase structures. In this work, the alloy C showcases outstanding comprehensive mechanical properties, offering a novel avenue for the design of high-performance EHEAs.

A synergistic approach to optimizing the performance of a concentrating solar segmented variable area leg thermoelectric generator using numerical methods and neural networks

AbstractThis study presents an optimized design for segmented variable area leg thermoelectric modules using finite element methods and Bayesian regularized neural networks. We explored the impact of geometry and thermal parameters on module performance using ANSYS software, identifying optimal parameters for power output and efficiency. Key findings revealed the higher influence of geometric parameters and confirmed the advantages of segmented thermoelectric generators for high-temperature applications like concentrated solar systems. With this optimization, power output and efficiency of the module increased by 875% and 165%, respectively, under 25 Suns. To refine the optimization process, a Bayesian regularized neural network was utilized, proving effective in predicting module performance with a low mean squared error and high coefficient of determination. This research provides important insights into high-performance thermoelectric modules for sustainable energy applications, demonstrating the significant role of advanced computational methods in energy solutions.

Development of thermal barrier coating on single crystal superalloy CMSX-4 by two-source evaporation EB-PVD and hot corrosion performance of the coating in a simulated aero-engine environment

Superalloys are crucial in high-temperature applications, particularly in the gas turbine industries. With the development of high-temperature superalloy materials, efforts are still being made to improve the turbine entry temperature (TET), which will ultimately raise the efficiency of gas turbines. In this research, a second-generation single-crystal superalloy CMSX-4 based on nickel was prepared. The surface was coated by thermal barrier coating (TBC) with a bond coat of NiCoCrAlY with vacuum plasma spray (VPS) and a top coat with Yttria Stabilized Zirconia (YSZ) by Electron Beam Physical Vapor Deposition (EB-PVD) with a minimal current of 2.3 A with two sources compared to the conventional high-current that has been currently employed. These CMSX-4 specimens, both the as-cast and TBC coated, were used to test the effects of cyclic oxidation and hot corrosion at 1000 °C, simulating an aircraft engine. Also, a hot corrosion test using salt compositions (Wt%) of 60Na2SO4 - 40NaCl was performed simulating an aviation engine environmental condition. A FE-SEM/EDS analysis was used to examine the surface and cross-section microstructures of oxidized, hot-corroded as-cast, and hot-corroded TBC-coated CMSX-4 and its corrosion products. Using the XRD technique, the phases that were found in the oxidized and hot-corroded samples were identified. The outcome demonstrated that the EB-PVD TBC-coating on CMSX-4 with beam switching technique and a lower electron beam current has adequate protection without any damage to the coatings at 1000 °C.

Structural origins of dielectric anomalies in the filled tetragonal tungsten bronze Sr2NaNb5O15

The tetragonal tungsten bronze, Sr2NaNb5O15, shows promise for application in high-temperature high-efficiency capacitors vital for the sustainable energy revolution. Previously, the structural complexity of this and related materials has obscured the mechanisms underpinning two large anomalies in relative permittivity (εr) which give rise to their exceptionally broad dielectric response. Here, we comprehensively investigate the structural evolution from −173 to 627 °C, combining electron, X-ray and neutron diffraction, electron microscopy, and first principles electronic structure calculations to unambiguously identify the structural origins of both anomalies. The peak in εr at 305 °C is associated with a polar-nonpolar phase transition, wherein cations displace along the c axis. Guided by DFT, we identify a further transition upon cooling, associated with the second peak at −14 °C, linked to the softening of an in-plane polar distortion with a correlation length limited by ferroelastic nano-domains arising from rigid-unit-like tilting of NbO6 octahedra at high temperature, imparting relaxor-like behaviour. Thus, the two dielectric anomalies in Sr2NaNb5O15 are associated with two distinct crystallographic phase transitions and their interplay with a microstructure that arises from a third, non-polar structural distortion. Chemical control of these will enable development of tuneable materials with dielectric properties suitable for high-temperature energy storage applications.

Fracture toughness evolution and failure mechanisms of two-dimensional SiCf/SiC composites at temperatures up to 1500 °C in air

Silicon carbide fiber reinforced silicon carbide composites (SiCf/SiC) are of the few most promising materials for high-temperature structural applications. In this study, two-dimensional (2D) plain-woven SiCf/SiC composites were prepared by chemical vapor infiltration process and subjected to single-sided notched beam three-point bending tests from room temperature (RT) to 1500 °C in air. The temperature-dependent bending load–deflection curves and fracture toughness were obtained. The results show that the SiCf/SiC composites exhibit linear deformation characteristics initially, followed by nonlinear deformation behavior which become more pronounced with increasing temperature. The fracture toughness decreases in the range of RT to 1000 °C due to the evolution of components properties, and increases at 1200 °C due to the interface property degradation and fiber pull-out. Above 1200 °C, it decreases with increasing temperature owing to the serious high-temperature oxidation. Further, the failure mechanisms of the 2D plain-woven SiCf/SiC composites at different temperatures was analyzed through macro and micro analysis. The evolution of components properties affected by high temperature and oxidation as well as fiber pull-out play a leading role in fracture toughness of composites. The findings of this study provide important support for the mechanical behavior and failure mechanisms of SiCf/SiC composites at ultra-high temperatures in air.

Inductive Heating of Ceramic Matrix Composites (CMC) for High-Temperature Applications

The inductive heating of a CMC susceptor for industrial applications can generate very high process temperatures. Thus, the behavior of a silicon carbide-based matrix with carbon-fiber-reinforced carbon (C/C-SiC) as a susceptor is investigated. Specifically, the influence of fiber length and the distribution of carbon fibers in the composite were investigated to find out the best parameters for the most efficient heating. For a multi-factorial set of requirements with a combination of filling levels and fiber lengths, a theoretical correlation of the material structure can be used as part of a digital model. Multi-physical simulation was performed to study the behavior of an alternating magnetic field generated by an inducing coil. The simulation results were verified by practical tests. It is shown that the inductive heating of a C/C-SiC susceptor can reach very high temperatures in a particularly fast and efficient way without oxidizing if it is ensured that a silicon carbide-based matrix completely encloses the fibers.

Dielectric Properties of Materials Used for Microwave-Based NOx Gas Dosimeters.

Nitrogen oxides (NOx), primarily generated from combustion processes, pose significant health and environmental risks. To improve the coordination of measures against excessive NOx emissions, it is necessary to effectively monitor ambient NOx concentrations, which requires the development of precise and cost-efficient detection methods. This study focuses on developing a microwave- or radio frequency (RF)-based gas dosimeter for NOx detection and addresses the optimization of the dosimeter design by examining the dielectric properties of LTCC-based (Low-Temperature Co-fired Ceramics) sensor substrates and barium-based NOx storage materials. The measurements taken utilizing the Microwave Cavity Perturbation (MCP) method revealed that these materials exhibit more pronounced changes in dielectric losses when storing NOx at elevated temperatures. Consequently, operating such a dosimeter at high temperatures (above 300 °C) is recommended to maximize the sensor signal. To evaluate their high-temperature applicability, LTCC substrates were analyzed by measuring their dielectric losses at temperatures up to 600 °C. In terms of NOx storage materials, coating barium on high-surface-area alumina resolved issues related to limited NOx adsorption in pure barium carbonate powders. Additionally, the adsorption of both NO and NO2 was enabled by the application of a platinum catalyst. The change in dielectric losses, which provides the main signal for an RF-based gas dosimeter, only depends on the stored amount of NOx and not on the specific type of nitrogen oxide. Although the change in dielectric losses increases with the temperature, the maximum storage capacity of the material decreases significantly. In addition, at temperatures above 350 °C, NOx is mostly weakly bound, so it will desorb in the absence of NOx. Therefore, in the future development of a reliable RF-based NOx dosimeter, the trade-off between the sensor signal strength and adsorption behavior must be addressed.

Turning Ultra-Low Coercivity and Ultra-High Temperature Stability Within 897 K via Continuous Crystal Ordering Fluctuations.

High-performance soft magnetic materials are important for energy conservation and emission reduction. One challenge is achieving a combination of reliable temperature stability, high resistivity, high Curie temperature, and high saturation magnetization in a single material, which often comes at the expense of intrinsic coercivity-a typical trade-off in the family of soft magnetic materials with homogeneous microstructures. Herein, a nanostructured FeCoNiSiAl complex concentrated alloy is developed through a hierarchical structure strategy. This alloy exhibits superior soft magnetic properties up to 897K, maintaining an ultra-low intrinsic coercivity (13.6 A m-1 at 297 K) over a wide temperature range, a high resistivity (138.08µΩcm-1 at 297K) and the saturation magnetization with only a 16.7% attenuation at 897 K. These unusual property combinations are attributed to the dual-magnetic-state nature with exchange softening due to continuous crystal ordering fluctuations at the atomic scale. By deliberately controlling the microstructure, the comprehensive performance of the alloy can be tuned and controlled. The research provides valuable guidance for the development of soft magnetic materials for high-temperature applications and expands the potential applications of related functional materials in the field of sustainable energy.

High-temperature mechanical properties of additively manufactured 420 stainless steel

Martensitic stainless steels are indispensable alloys in various high stress and temperature applications such as plastic injection molds and components in steam generators. Subtractive manufacturing methods used to fabricate these parts, however, limits its functionality and performance due to design constraint of cooling channels. This limitation can be resolved by means of additive manufacturing while ensuring that acceptable high-temperature properties can be achieved. In this work, the mechanical behavior of additively manufactured 420 stainless steel (AM420SS) is explored through material constitutive modeling to determine the mathematical model that best describes its flow stress in extreme conditions. This is accomplished by subjecting the samples to hot compression under the strain rates of 0.1–1.0 s−1, and temperatures between 973–1423 K (700 °C–1150 °C) via Gleeble thermomechanical test. The experimental data were used to generate the predictive flow stress curves of constitutive models which includes Johnson-Cook, Zerilli-Armstrong, Zener-Hollomon, and Hensel-Spittel equations. Results showed that Zener-Hollomon and Hensel-Spittel models are the most accurate material constitutive equations with relatively high R values of 0.986 and 0.976, and low average absolute relative error values of 6.96% and 7.69%, respectively. The material constants derived from these models can be applied in finite element analysis simulations to assess the performance of using AM420SS parts at high temperature and strain conditions.

Impact of Alumina-Based Binder on Formation of Dense Strontium Zirconate Ceramics

Strontium zirconate (SrZrO3) is a technical ceramic with potential for refractory applications due to its chemical stability at high temperatures, high melting temperature, and favourable thermal expansion coefficient. Practical use of SrZrO3 is limited by poor mechanical strength relative to ceramics such as alumina (Al2O3). Sintering of SrZrO3 with a hydratable Al2O3 binder is investigated as a method for improving mechanical performance. Density, phase composition, thermomechanical properties, and chemical stability in contact with alloys up to 1350°C are considered. Results are compared with SrZrO3 samples formed using a traditional polyvinyl alcohol (PVA) binder. SrZrO3 reacts with alumina during sintering to form SrAl2O4 and ZrO2. Compared to the PVA binder, the alumina binder drastically reduced porosity in the ceramic, while increasing the indirect tensile strength and fracture toughness. No significant detriment to thermal expansion or chemical stability was found, offering potential for high-temperature applications particularly as a dense crucible material.

High-throughput approach for investigating interdiffusion in medium- and high-entropy alloys

Interdiffusion experiments are usually time-consuming and tedious since diffusion couples must be annealed at several temperatures for a long time. The efforts required to study interdiffusion in multicomponent alloys increase dramatically as multiple diffusion couples are required to cover broad composition ranges and determine the diffusivities of individual elements in different chemical environments. To circumvent this challenge, we present a high-throughput approach applicable to single-phase and compositionally complex alloys, which are assumed to approximate ideal solid solutions. Here, a simple diffusion-multiple experiment combined with a physically based kinetic model is proposed to efficiently determine the diffusion coefficients of the constituent elements in quaternary CrFeCoNi alloys. Compared with tracer diffusivities reported in the literature, the results, thus, obtained do not differ by more than a factor of 2 and were obtained from a single interdiffusion experiment. In contrast, the diffusivities simulated with commercial mobility and thermodynamic databases are strongly overestimated by a factor ranging from 1 to 16. Therefore, our approach enables high-throughput determination of diffusivities and can help in the design of alloys for high-temperature applications where diffusion plays a key role.

(Ag0.80Bi0.04Sr0.04)(Nb1-xTax)O3 ceramics with enhanced energy storage for high-temperature application via synergic optimization

Dielectric capacitors with high power density are essential components in advanced electronic and micro-electronic products. Nevertheless, the limited energy storage density and efficiency, coupled with poor performance at elevated temperatures, severely restrict their usefulness. In this work, Ta was introduced to the (Ag0.80Bi0.04Sr0.04)NbO3 ceramic prepared via the hydrothermal-synthesized powders to improve the room- and high-temperature energy storage performance. A large breakdown strength of 729kV/cm, a high recoverable energy storage density of 8.5J/cm3 and a benign energy efficiency of 75.6% were simultaneously achieved in (Ag0.80Bi0.04Sr0.04)(Nb0.85Ta0.15)O3 ceramics. Moreover, the larger energy storage efficiency (83.5%) at elevated temperatures than room temperature, the benign frequency and cycle stability foreshow great potential in realizing the application of capacitors at high-temperatures.

ZrN structures doped with 3d transition metals: A computational investigation of main physical properties for high-temperature structural applications

Abstract In the present study, ab initio density functional theory calculations were used to assess the effect of first-row transition metals (X = Sc, Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Zn) on the stability of Zr0.5N0.5 nitrides. Specifically, the structural, mechanical, and electronic properties were studied to evaluate their applicability in high-temperature structural applications such as coating. The heat of formation for all X-doped Zr0.5N0.5 ternaries were found to be lower than that of the undoped Zr0.5N0.5. Specifically, Mn-doped Zr0.5N0.5 was observed to be the most thermodynamically stable structure, due to its lowest heat of formation. The density of states for both the undoped and doped Zr0.5N0.5 nitrides indicated full metallic behavior and observed that doping with 3d-transition metals reduce the density of states at the Fermi energy, thereby enhancing the electronic stability. Furthermore, mechanical stability was observed in these nitrides with increased melting temperatures expect for Zr0.5N0.5 doped Ti. Since Zr0.5N0.5 doped with X is thermodynamically, electronically, and mechanically stable, they are deemed suitable for high-temperature structural applications especially Zr0.5N0.5 doped Mn.

Heat-resistant super-dispersed oxide strengthened aluminium alloys.

Oxided-dispersion-strengthened (ODS) alloys are promising high-strength materials used in extreme environments such as high-temperature and radiation tolerance applications. Until now, ODS alloys have been developed for reducible metals by chemical processing methods, but there are no commercially available ODS alloys for unreducible metals, namely, Al, Mg, Ti, Zr and so on, owing to the challenge of uniformly dispersing oxide particles in these alloys by traditional techniques. Here we present a strategy to achieve ODS Al alloys containing highly dispersive 5 nm MgO nanoparticles by powder metallurgy, using nanoparticles that have in situ-grown graphene-like coatings and hence largely reduced surface energy. Notably, the densely dispersed MgO nanoparticles, which have a fully coherent relationship with an Al matrix, show effective suppression of interfacial vacancy diffusion, thus leading to unprecedented strength (~200 MPa) and creep resistance at temperatures as high as 500 °C. Our processing approach should enable the dispersion of ultrafine nanoparticles in a wide range of alloys for high-temperature-related applications.

3D printing of CaBi4Ti3.925(Nb2/3Mn1/3)0.075O15 ceramics for high temperature ultrasound transducer

Bismuth layer-structured CaBi4Ti3.925(Nb2/3Mn1/3)0.075O15 (CBTNM) piezoelectric ceramics have been prepared using stereolithography (SL) technology. The effects of various solid contents (76–82 wt%) of CBTNM ceramics on the slurry viscosity, phase structure, microstructure, and electric performance were studied in detail. At a solid content of 82 wt%, the ceramic exhibits good piezoelectric properties. The piezoelectric constant d 33, thickness-mode electromechanical coupling coefficient k t, and Curie temperature Tc were 21 pC/N, 47%, and 790 °C, respectively. The piezoelectric constant of the ceramic has a good stability up to 500 °C. Furthermore, a high-temperature ultrasound transducer was designed and fabricated based on the CBTNM ceramic, and its pulse-echo performance was characterized from room temperature to 250 °C. The pulse-echo performance indicates that the −6 dB bandwidth and echo amplitude of the transducer decrease slightly, but still work normally up to 250 °C. These results indicate that the transducer fabricated based on CBTNM ceramics has potential in high-temperature testing applications.

Stress-induced transformation on the cubic perovskite RbTaO3 for high-temperature applications: a DFT approach

Stress-induced transformation on the cubic perovskite RbTaO3 for high-temperature applications: a DFT approach

Laser Powder Bed Fusion Processing of Low Cost CoCrFeNiMoxNby High Entropy Alloys with Promising High-Temperature Properties via In Situ Alloying Commercial Powders

A blend of only commercial powders, including Ni625, CoCrF75, and 316L, were used as the raw material for fabricating non-equiatomic CoCrFeNiMoxNby high entropy alloys (HEAs) through laser powder bed fusion (PBF-LB/M) via in situ alloying, instead of using pure elemental powders, thus reducing the raw materials cost. The rapid cooling inherent in the PBF-LB/M process facilitated the dissolution of Mo and Nb, resulting in a single FCC phase characterized by high relative densities. High-temperature tensile tests were conducted at room temperature, 700 °C, 800 °C, and 900 °C, revealing mechanical properties that surpassed those reported in existing HEA literature. The remarkable strength of the HEAs developed in this study primarily stemmed from the incorporation of Mo and Nb, leading to the precipitation of Mo and Nb-rich lave phases at elevated temperatures. While constraining elongation when confined to grain boundaries, these precipitates enhanced strength without compromising elongation when distributed throughout the matrix. This work is a feasibility study to explore the usage of commodity compositions from the market to develop HEAs using PBF-LB/M, which opens the possibility of using scraps to further the development of new materials. Consequently, this study presents a rapid and cost-effective approach for HEA development, improving efficiency and sidestepping the direct utilization of critical raw metals for sustainable manufacturing. Moreover, this work also underscores the outstanding mechanical performance of these HEAs at high temperatures, paving the way for the design of innovative alloys for future high-temperature applications.