High Temperature Capability Research Articles

Surface-Dependent Performance of Ultrathin TiN Films as an Electrically Conducting Li Diffusion Barrier for Li-Ion-Based Devices.

An in-depth understanding of lithium (Li) diffusion barriers is a crucial factor for enabling Li-ion-based devices such as three-dimensional (3D) thin-film batteries and synaptic redox transistors integrated on silicon substrates. Diffusion of Li ions into silicon can damage the surrounding components, detach the device itself, lead to battery capacity loss, and cause an uncontrolled change of the transistor channel conductance. In this study, we analyze for the first time ultrathin 10 nm titanium nitride (TiN) films as a bifunctional Li-ion diffusion barrier and current collector. Thermal atomic layer deposition (ALD) and pulsed chemical vapor deposition (pCVD) are employed for manufacturing ultrathin films. The 10 nm ALD films demonstrate excellent blocking capability with an insertion of only 0.03 Li per TiN formula unit exceeding 200 galvanostatic cycles at 3 μA/cm2 between 0.05 and 3 V versus Li/Li+. An ultralow electrical resistivity of 115 μΩ cm is obtained. In contrast, a partial barrier breakdown is observed for 10 nm pCVD films. High surface quality with low contamination is identified as a key factor for the excellent performance of ALD TiN. Conformal deposition of 10 nm ALD TiN in 3D structures with high aspect ratios of up to 20:1 is demonstrated. The measured capacities of the surface area-enhanced samples are in good agreement with the expected values. High-temperature blocking capability is proven for a typical electrode crystallization step. Ultrathin ALD TiN is an ideal candidate for an electrically conducting Li-ion diffusion barrier for Si-integrated devices.

Linear Reciprocating Wear of Yttria-Stabilized Zirconia-Based Composite Coatings Developed by Thermal Spray

Ceramic matrix composites are the preferred material for high-temperature application due to their low density, improved strength and toughness, and high-temperature capabilities. In the present study, we report the kinetics and mechanism of linear reciprocating wear of yttria-stabilized zirconia (YSZ)-based composite coatings developed by thermal spray technique. Composite coatings with different volume fractions of CoNiCrAlY and YSZ phases were subjected to linear reciprocating wear under an applied normal load of 10 N against a WC counter-body. The kinetics of wear was investigated by measuring the wear depth over time of coated components against WC surface. Adhesive wear in the 100% CoNiCrAlY coating was responsible for increased friction in the coating which changed to a three-body abrasion in the case of 100% YSZ coating. The composition coatings had a significant effect on the wear mechanism with the ceramic coatings were fractured under reciprocating load. Microcrack propagation and fracturing of ceramic splats were the dominant modes of wear in the ceramic coatings. The 100% YSZ coating showed significant wear than 100% CoNiCrAlY and 50% YSZ + 50% CoNiCrAlY coatings. The mode of wear changed with the presence of a metallic phase in the 50% YSZ + 50% CoNiCrAlY coating. The mode of wear was further studied by the detailed microstructural observation of worn track and correlating it with the wear kinetics and coefficient of friction.

Extreme Environment Integrated Circuits Based on Enhancement Mode SiC JFETs

This paper presents results on developing high temperature capable SiC JFET based IC technology that can operate at temperatures up to 500 °C. All JFET devices are fully planar, formed by ion implantation, and the device design allows the use of semi-insulating or conductive SiC substrates. Basic analog and logic ICs were built in order to demonstrate the technology high temperature capability. All circuits used enhancement mode n-channel JFETs as active transistors, and depletion mode transistors as active loads. The logic circuits built included NOT, NAND, and NOR gates. The analog circuits built included a simple one-stage operational amplifier. JFETs and ICs were packaged in ceramic packages and tested at temperatures up to 500 °C.

A MEMS-Based Fast-Response Miniature Five-Hole Probe With Optical Pressure Transducers

This paper presents the first realization of a fiber-optic lever-based, miniature five-hole probe (5HP) for aerodynamic flow angle sensing applications. Five MEMS optical transducers are embedded in a hemispheric probe tip to mitigate the pneumatic lag problem of conventional 5HP technology. A silicon die with five optical pressure transducers of $400~\mu \text{m}$ radius is microfabricated from a silicon-on-insulator (SOI) wafer and bonded to a hemispheric tip of 5 mm diameter. The optimal transducer and probe tip designs are determined using lumped element modeling. Laser micromachining is utilized to drill micro holes of about $50~\mu \text{m}$ radius on the hemispheric tip. The optical transduction allows for remotely located electronics. This facilitates probe miniaturization and offers potential for high-temperature capability. The resulting 5HP has a fast response with a modeled settling time of 0.24 ms and a measured high-frequency range of about 3.5 kHz. [2020-0182]

Design and strategy for next-generation silicon carbide composites for nuclear energy

Silicon carbide (SiC) ceramic-based composites continue to be attractive material options for fusion in-vessel components and fission reactor core structures because of their exceptional high-temperature capability and favorable neutronic properties. As performance data accumulates, the limitations of the current generation of nuclear-grade SiC composites are becoming more apparent. These limitations mainly involve strength degradation during high-dose neutron irradiation. This paper discusses several options for improving the performance of the next generation of SiC composites to enhance the radiation resistance, along with new experimental results on neutron irradiation resistance. The main emphasis is on the selection of the fibers and the design and development of alternative interphase layers for advanced composites.

A Continuous Flow Cell for High‐Temperature/High‐Pressure Electroorganic Synthesis

AbstractA flow electrolysis cell that enables operation at high temperatures and pressures has been designed and developed. The cell, with a cylindrical shape and concentric electrodes, can be easily assembled using commercially available fluidic components. The compact design of the device permits easy temperature control using a commercial column heater. Temperatures ranging from −10 °C to +150 °C and pressures up to 70 bar have been successfully applied for long operation periods. The cell performance has been evaluated using the anodic methoxylation of N‐formylpiperidine as a model. Very high conversions and selectivities have been achieved with single‐pass processing, and high productivities of 73 mmol/h with electrolyte recycling. The high pressure and temperature capabilities of the cell have been used to demonstrate the negative effect that re‐dissolved hydrogen gas can have on hydrogen‐releasing electrochemical reactions in undivided cells, owing to undesired anodic oxidation of hydrogen.

Development of silicon quantum dots based nano-fluid for enhanced oil recovery in tight Bakken cores

A novel silicon quantum dots (SiQDs) based nano-fluid was first developed for effectively recovering Bakken Oil. The Bakken Formation is one of the largest contiguous deposits of unconventional oil in the USA and Canada. However, the oil recovery rate is only 5%−10% due to the existence of abundant tiny pores and ultra-low permeability. In this work, a novel nano-fluid was developed using ultra-small sized silicon quantum dots (SiQDs) coated with a zwitterionic surfactant. The nano-fluid exhibited good stability in synthetic high salinity brine containing divalent cations at high temperature and excellent capabilities in reducing interfacial tension and altering wettability, making it a good enhanced oil recovery (EOR) agent for tight Bakken Formation. Experimental results showed that the developed nano-fluid recovered 25.72 %OOIP (original oil-in-place) from Bakken core samples by spontaneous imbibition, which was 7.49 %OOIP higher than using surfactant alone. Similar results were obtained in the core flooding tests, where 41.98 %OOIP was finally recovered by the nano-fluid, compared to 30.28% in surfactant case. Herein, the mechanisms of disjoining pressure and synergistic effects between surfactant and nanoparticles have also been put forward. In short, the developed quantum dots based nano-fluid has played an instructive and a reference role in the application of oil field and would be a potential oil displacing agent for EOR.

High-Temperature Spontaneous Emission Quantum Efficiency Analysis of Different InGaN MQWs for Future Power Electronics Applications

The commercial light-emitting diode (LED) epitaxy materials-blue (i.e., InGaN/gallium nitride (GaN) multiple quantum wells (MQWs)) for lighting and display applications and green (i.e., InGaN/GaN MQWs) for display applications-are evaluated with a varied range of temperatures (10-800 K) for future applications in high-density power electronic modules. Six different InGaN/GaN MQW structures (peak wavelengths λ <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">p</sub> = 448, 467, and 515 nm) are studied and compared to evaluate whether they can satisfy the light output requirements in the optocouplers at high temperatures. The spontaneous emission quantum efficiency (QE) of these LED epitaxy materials are studied using temperature-dependent and power photoluminescence (PL) spectroscopy. The LED materials, which have no pre-QWs, a higher number of QWs, and GaN buffer layer, show the highest QEs at high temperatures. All six LED materials' exhibit 65% QE at 500 K and stable operation at 800 K were without failure or flickering. At 800 K, the spontaneous emission QEs are between 56% and 60% for blue and green LEDs for displays, respectively. This work evaluates the high-temperature capability of various LED epitaxy materials for future applications in the high-temperature optocouplers as the galvanic isolations in high-density power modules.

Opportunities and Issues in the Application of Titanium Alloys for Aerospace Components

The metal titanium (Ti) and its alloys have many attributes which are attractive as structural materials, but they also have one major disadvantage, high initial cost. Nevertheless, Ti and Ti alloys are used extensively in airframes, gas turbine engines (GTE), and rocket engines (RE). The high cost is a deterrent, particularly in airframe applications, in that the other alloys it competes with are, for the most part, significantly lower cost. This is less of a concern for GTE and RE where the cost of titanium is closer to and sometimes even lower than some of the materials it competes with for these applications. In spacecraft the weight savings are so important that cost is a lesser concern. Ti and its alloys consist of five families of alloys; α-Ti, near α-alloys, α + β alloys, β-alloys, and Ti-based intermetallic compounds. The intermetallic compounds of primary interest today are those based on the compound TiAl which, at this time, are only used for engine applications because of their higher temperature capability. These TiAl-based compounds are used in a relatively low, but growing, amounts. The first production application was for low pressure turbine blades in the GE engine (GEnx) used on the Boeing 787, followed by the GE LEAP engine used on A-320neo and B-737MAX. These air foils are investment cast and machined. The next application is for the GE90X which will power the Boeing B-777X. These air foils will be made by additive manufacturing (AM). Unalloyed titanium and titanium alloys are typically melted by vacuum arc melting and re-melted either once (2X VAR) or twice (3X VAR); however a new and very different melting method (cold hearth melting) has recently become favored, mainly for high performance applications such as rotors in aircraft engines. This process resulted in higher quality ingots with a significant reduction in melt-related defects. Once melted and cast into ingots, the alloys can be processed using all the standard thermomechanical working and casting processes used for making components of other types of structural alloys. Because of their limited ductility, the TiAl-based intermetallic compounds are quite difficult to process using ordinary wrought methods. Consequently, the low-pressure turbine blades currently in service are investment cast and machined to net shape. The AM air foils will require minimal machining, which is an advantage. This paper describes some relatively recent developments as well as some issues and opportunities associated with the production and use of Ti and its alloys in aerospace components. Included are new Ti alloys, new applications of Ti alloys, and the current status of several manufacturing processes including a discussion of the promise and current reality of additive manufacturing as a potentially revolutionary method of producing Ti alloy components.

Significantly improved high-temperature performance of polymer dielectric via building nanosheets and confined space

Polymer dielectrics generally cannot meet the requirements of high-temperature capability and high dielectric properties due to the exponential increasement of dielectric loss with increasing temperature. Herein, a scalable strategy to significantly enhance the high-temperature dielectric performance of polymer dielectrics was reported. Polyvinylidene fluoride (PVDF) nanosheets with large width/thickness ratio were successfully constructed in the polycarbonate (PC) film utilizing the “extrusion-stretching-compression” technology. This structure endowed PC/PVDF blend films with superior dielectric properties. The dielectric constant (εr') of the blend films increased from 4.4 (common PC/PVDF blend films) to 5.3, and the dielectric loss (tan δ) decreased from 8.2 × 10−3 to 6.1 × 10−3. More importantly, the blend films with highly ordered nanosheets exhibited great restriction effect on the ion conduction owing to the synergistic effect of the phase morphology and chain mobility. Through combining the highly ordered PVDF nanosheets and confined space provided by the PC matrix, a "cage" for impurity ions has been successfully created, rendering the large suppression of ionic conduction loss at elevated temperatures (up to 150 °C). The excellent comprehensive properties demonstrate a facile route to fabricate high-temperature and high dielectric performance polymer dielectrics required in electric vehicles, aerospace power electronics, etc.

Mechanism-Based Models for Predicting the Microstructure and Stress–Strain Response of Additively Manufactured Superalloy 718Plus

Alloy 718Plus, commonly known as ATI 718Plus®, is a Ni-based superalloy that has been developed to exhibit a γ + γ′ microstructure with a higher high-temperature strength capability compared to Alloy 718. In addition to wrought products, Alloy 718Plus has also been processed by additively manufacturing processes via layer-by-layer deposition. Additively manufactured (AM) 718Plus is typically heat-treated using multiple steps in order to provide an optimized microstructure and desired mechanical properties. In this article, mechanism-based heat treatment and constitutive models were developed for Alloy 718Plus. In particular, solution treatment and aging models were developed for predicting the grain size and the size, number density, and volume fraction of δ, secondary γ′, and tertiary γ′ precipitates in the microstructure. This microstructural information was then utilized in conjunction with a physics-based constitutive model, called MicroROM, to predict the stress–strain response of Alloy 718Plus. The predictive capabilities of the heat treatment models, named HTM718Plus, and the constitutive model (MicroROM) were first benchmarked against literature data of ATI 718Plus. Subsequently, the heat treatment models and constitutive model were applied to predict the microstructure and tensile response of AM 718Plus heat-treated by a multi-step procedure with good agreement between computed results and experimental data.

The effects of Fe and Si on the phase equilibria in a γ′-strengthened Co–Al–W-based superalloy

The effects of Fe and Si alloying additions (by replacing Co) in a base alloy composition (expressed as mole fraction times 100) Co–20Ni–10Cr–10Al–7W-0.1B on the stability of the microstructure were investigated at 800 °C and 900 °C. The two-phase γ+γ′ microstructure was found to be greatly destabilized with Fe-additions in a mole fraction of 5% or greater, exhibiting a decrease in γ′ solvus temperature by about 8 °C for each 1% Fe added, and a significantly higher volume of secondary phases μ and B2 compared to the base alloy at both temperatures. In contrast, Si additions of up to a mole fraction of 1% did not decrease the γ′ stability by an appreciable amount. Characterization of the Si additions showed no decrease in γ′ solvus temperature, no change in the fractions of secondary phases in the annealed microstructure after annealing for 168 h at 800 °C with 0.5% Si, and only a slight increase in the secondary phase fractions for a mole fraction of 1% Si. Annealing at 900 °C for 1001 h, however, did show an increase in secondary phase formation, suggesting a decrease in the stability of the two-phase γ+γ’ microstructure at higher temperature. The present results show that it may be possible to add up to a mole fraction of 1% Si for increased oxidation resistance without significantly degrading the high temperature capability of the base Co-base superalloy.

Fluoride ion encapsulated polyhedral oligomeric silsesquioxane: A novel filler for polymer nanocomposites with enhanced dielectric constant and reduced dielectric loss

Polymer dielectrics have been considered as an ideal choice for preparation of advanced power and electronic systems as their good comprehensive performances. However, it remains a challenge to obtain polymer dielectrics with high dielectric constant (εr), low dielectric loss (tan δ) and high temperature capability. Although adding high permittivity inorganic nanofillers has become a promising approach to improve the εr of polymers, it usually causes the adverse increment tan δ. Herein, we demonstrate that fluoride ion encapsulated polyhedral oligomeric silsesquioxane (POSS@F−) can be regarded as a novel filler to enhance the εr and reduce the tan δ of poly(2,6-dimethyl-1,4-phenylene oxide) (PPO) simultaneously. Compared with the pristine PPO, the εr of PPO/POSS@F− composite can be enhanced from 2.81 to 5.31, while its tan δ is still relatively low (0.0011 at 1 kHz). Meanwhile, the breakdown strength of PPO can also be slightly reinforced from 334.9 kV/mm to 394.0 kV/mm. Owing to the good thermal properties of PPO and POSS@F−, these composites exhibit good dielectric properties and improved dimension stability at high temperature. We believe that these results are particularly important for the preparation of advanced dielectric materials for desirable applications.

Nuclear heat storage and recovery for the APR1400

Detailed here is the proposed design of the tertiary side of a Thermal Energy Storage (TES) System to be interfaced with the steam cycle of a Light Water Reactor (LWR) plant. This study extends the understanding provided by many previous investigations (i.e., beyond thermodynamic considerations) by specifically addressing real world constraints associated with the backfit of such a system to an operating LWR. These constraints relate to the feasibility of design modifications during an extended refueling outage, and to licensing, operational, and maintenance considerations. The Korean designed and built APR1400 plant is selected for integration with the TES tertiary system, resulting in a design which can be readily be adapted to most LWR plant. Heat transfer and transport from and to the nuclear steam cycle is by synthetic oil with high temperature capabilities. Heat storage is in the form of packed beds consisting of crushed rock. While the rates of storage and recovery are constrained by the design of the nuclear reactor and steam plant (i.e., 20% of reactor thermal power during storage, and ~11% during recovery) the total stored energy component of the system can be readily and economically scaled to any desired capacity (at the marginal cost of carbon steel vessels filled with rock). Finally, it is proposed that any nuclear installation with water access could employ bulk thermal energy storage built into an Ultra Large Barge for turnkey delivery with a concomitant reduction in installed cost and risk.

Miniature fiber-optic tip pressure sensor assembled by hydroxide catalysis bonding technology.

A miniature fiber-optic tip Fabry-Perot (FP) pressure sensor with excellent high-temperature survivability, assembled by hydroxide catalysis bonding (HCB) technology, is proposed and experimentally demonstrated. A standard single-mode fiber is fusion spliced to a fused silica hollow tube with an outer diameter (OD) of 125 µm, and a 1-µm-thick circular silicon diaphragm with a diameter slightly larger than the OD is bonded to the other endface of the hollow tube by HCB technology. The ultrathin silicon diaphragm is prepared on a silicon-on-insulator (SOI) wafer produced by microelectromechanical systems (MEMS), providing the capability of large-scale mass production. The HCB technology enables a polymer-free bonding between diaphragm and hollow tube on fiber tip with the obvious advantages of high alignment precision, normal pressure and temperature (NPT) operation, and reliable effectiveness. The static pressure and temperature response of the proposed sensor are discussed. Results show that the sensor has a measurable pressure range of 0∼100 kPa, which is well consistent with the measurement range of biological blood pressure. The pressure sensitivity is up to 2.13 nm/kPa with a resolution of 0.32% (0.32kPa). Besides, the sensor possesses a unique high-temperature resistant capability up to 600 °C, which can easily survive even in high-temperature sterilization processes, and it has a low temperature dependence of 0.09 kPa/°C due to the induced HCB bonding technology and the silicon-based diaphragm. Thus, the proposed fiber tip pressure sensor is desirable for invasive biomedical pressure diagnostics and pressure monitoring in related harsh environments.

Heat-Acid-Resistant Light Concretes on the Base of Volcanic Tuff Lava and Pumice Aggregates of Armenia

The territory of Armenia is characterized by a wide variety of volcanic natural porous rocks with extremely rich natural resources. Tuff stone is one the varieties and is traditionally used as a masonry material, and waste, estimated at millions of cubic meters has accumulated near the mining areas and it’s disposal is an important environmental issue. Slag and pumice stones, as well as some types of tuffs, are used as aggregates for general-construction lightweight concretes, and as heat insulating backfills, etc. Since the 1980s, we have begun systematized scientific studies to identify the natural potential and the most optimal branches for the use of these rocks, where it is possible to obtain the maximum technical and economic benefits through the targeted use of their specific natural properties. Taking into account the conditions of these rock formation, as well as the high prices available on the world market and the demand for lightweight, heat-resistant insulating concrete, first of all, by complex, versatile studies, they are classified by high-temperature properties, technical capabilities and specificity of using some varieties as aggregates for lightweight heat-resistant concrete, with application temperature up to 800...1100°C. It is shown that, compared with the expensive artificial porous heat-resistant aggregates widely used in practice, these rocks are out of concurrence, as the corresponding compositions, porosity of the structure and high-temperature processing were obtained in natural conditions, due to which they do not require manufacturing costs for particular components and high-temperature processing and in the natural form are ready to be used in this area. Along with this, some of them also have high acid resistance and are suitable for use in the most valuable concretes with the simultaneous triple effect of lightness, heat resistance and acid resistance.

Microstructure, oxidation and mechanical properties of a diffusion aluminide (Al3Ti) coated lamellar γ-TiAl alloy

The use of γ-TiAl alloys at higher temperatures exceeding 700–800 °C is restricted due to their inadequate oxidation resistance. Their durability and high temperature capability can be enhanced by the application of oxidation resistant coatings. The present study examines the cyclic oxidation behavior of a diffusion Al3Ti coated lamellar Ti–45Al–5Nb-0.2B-0.2C (in at.%) γ-TiAl alloy during exposure at 800 and 950 °C in air for 500 h. The effect of oxidation on the coating microstructure and the compression properties at room temperature, 800 and 950 °C are assessed. The coating forms a protective Al2O3-rich oxide scale, which lowers the overall oxidation rate and induces steady parabolic weight gain in the coated alloy; unlike the extensive weight loss occurring in the bare/uncoated alloy during oxidation at higher temperatures. The parabolic oxidation rate constant (Kp) for the coated alloy at 6–7 x 10−7 mg2 cm−4 s−2 is two orders of magnitude lower than that of the bare alloy. Surface embrittlement during oxidation causes deterioration in the compression yield strength of the bare alloy. On the other hand, the coating prevents oxidation-induced surface degradation of the alloy, which manifests in improved compression strength of the oxidized coated alloy as compared to that of the oxidized bare alloy. Though the coating is constituted of the brittle intermetallic Al3Ti phase, the cracks in the coating do not penetrate the substrate and are innocuous to the compression properties of the underlying intermetallic γ-TiAl alloy. The coating is beneficial in providing oxidation resistance and prevents significant oxidation-induced deterioration in compression strength of the alloy during high temperature exposure. Besides, the Al3Ti coating does not induce significant deterioration in the tensile strength of the γ-TiAl alloy.

Performance of YSZ and Gd2Zr2O7/YSZ double layer thermal barrier coatings in burner rig tests

Double layer thermal barrier coatings (TBCs) consisting of a Gd2Zr2O7 (GZO) top and an ytrria stabilized zirconia (YSZ) interlayer have been tested in a burner rig facility and the results compared to the ones of conventional YSZ single layers. In order to gain insight in the high temperature capability of the alternative TBC material, high surface temperatures of up to 1550 °C have been chosen while keeping the bond coat temperature similar. It turned out that the performance of all systems is largely depending on the microstructure of the coatings especially reduced porosity levels of GZO being detrimental. In addition, it was more difficult in GZO than in YSZ coatings to obtain highly porous and still properly bonded microstructures. Another finding was the reduced lifetime with increasing surface temperatures, the amount of reduction is depending on the investigated system. The reasons for this behavior are analyzed and discussed in detail.

Stackable SiC-Embedded Ceramic Packages for High-Voltage and High-Temperature Power Electronic Applications

Abstract This study encompasses the development of a high-voltage and high-temperature–capable package for power electronic applications based on the embedding of silicon carbide (SiC) semiconductor devices in the ceramic circuit carrier such as the direct bonded copper (DBC) substrate. By sealing semiconductor devices into DBC substrates, high temperature, high voltage, and high current capability as well as high corrosion resistance can be achieved compared with the state-of-the-art printed circuit board (PCB) embedding technology. The power devices are attached with high-temperature stable solder and sinter material and are surrounded by thermal conductive ceramic and high-temperature–capable potting materials that enable the complete package to operate at 250°C or above. Furthermore, the single embedded packages can be stacked together to multilevel DBC topologies with increased voltage blocking characteristics. Thus, current limits of the PCB and low-temperature cofired ceramic–based multilayer solutions are exceeded and will be confirmed in the course of this study. This package is designed to carry out the maximal performance of SiC and future wide bandgap devices. It is a promising solution not only for applications in harsh ambient environments such as aerospace and turbine, geothermal well logging, and downhole oil and gas wells but also for hybrid electric/electric vehicle and energy conversion.

Influence of resin infiltrants on mechanical and thermal performance in plaster binder jetting additive manufacturing

Plaster Binder Jetting (BJ) is one of the major Additive Manufacturing (AM) technologies which has been in use since the 1990s. It has many advantages such as the ability to print in full color CMY(K), no support structures, and is relatively faster and less expensive when compared to other AM technologies. Since there is no phase transformation (e.g. powder to molten pool in powder bed fusion, directed energy deposition), BJ does not require support structures and enables higher packing density in the build volume. However, relatively lower mechanical strength when compared to other AM processes has mostly limited it to non-functional applications such as prototyping. This paper investigates novel methods to improve the mechanical and temperature performance of plaster BJ additive manufactured parts via improved infiltration processes and incorporation of infiltrants with higher strength. Potential applications include functional end use products, including tooling, jigs and fixtures for higher temperature applications. Three 2-part epoxy resin systems were evaluated as infiltrants in comparison to epoxy and cyanoacrylate (CA) resins recommended by the original equipment manufacturer (OEM). Multiple impregnation methods including hot and wet vacuum were evaluated on their infiltration effectiveness. The best impregnation method was then used to prepare tensile, flexural and compressive samples for additional evaluation of each resin. Statistical analysis was conducted to analyze and compare the data. Both resins and infiltrated samples were individually evaluated using Differential Scanning Calorimetry (DSC) to determine glass transition temperatures and other thermal events. Infiltrated specimens of the best performing resins were evaluated for Heat Deflection Temperature (HDT) performance utilizing Dynamic Mechanical Analysis (DMA). It was found that infiltration is anisotropic, with the higher penetration depth from the sides (between layers) than top and bottom (across layers). Vacuum impregnation resulted in the highest infiltration depth by fully impregnating the 25 mm cubic samples. The best performing epoxy showed a 10% increase in mechanical strength over the OEM epoxy at 76% reduction in cost. The OEM cyanoacrylate had the lowest mechanical strength across all tests. DSC analysis revealed that the plaster and gypsum base material will start to dehydrate above 100 °C and will ultimately limit the parts’ high temperature capabilities. The OEM epoxy showed the highest HDT.