High Temperature Resistant Materials Research Articles

Test and simulation of high temperature resistant polyamide composite with single lap single bolt connection

The advancement of next-generation aerospace vehicles has presented new requirements and challenges for ensuring the structural integrity of aircraft components in extreme environments. Consequently, the utilization of high temperature resistant polyamide composite materials has become pivotal in the manufacturing of aerospace vehicle parts that operate under high temperatures (250 °C). As a critical connection technology for these materials, the mechanical behavior of bolted connection structures under high temperatures requires further investigation. In this paper, a combination of experimental and numerical simulation is used to investigate the load carrying capacity and failure mechanism of T700/BMP316 composite bolted joints at room temperature and 250 °C. The experimental results show that the ultimate load carrying capacity of the structure at 250 °C is only 13.1 % lower than that of the room temperature environment, indicating that the temperature softening effect of such composites is not significant. Scanning electron microscope (SEM) and computed tomography (CT) results indicate that the structural damage modes were the crushing of the hole edge fibers and matrix due to the extrusion by the bolts, as well as the interlaminar delamination damage. Temperature effects were taken into account for the composite principal structure and finite element modeling was performed using a combination of Pinho criterion and Cohesive model. Numerical simulations allow accurate prediction of the load-displacement response and damage pattern throughout the damage evolution phase. The high temperature test results and the developed finite element model involved in this study can support the design of new-generation aerospace vehicles.

Novel High-Strength and High-Temperature Resistant Composite Material for In-Space Optical Mining Applications: Modeling, Design, and Simulation at the Polymer and Atomic/Molecular Levels.

This study explores the modeling, design, simulation, and testing of a new composite material designed for high-strength and high-temperature resistance in in-space optical mining, examining its properties at both the polymer and atomic/molecular levels. At the polymer level, the investigation includes mechanical and thermal performance analyses using COMSOL Multiphysics 6.1, employing layerwise theory, equivalent single layer (ESL) theory, and a multiple-model approach for mechanical modeling, alongside virtual thermal experiments simulating laser heating. Experimentally, porous Polyaniline (PANI) films are fabricated via electrochemical polymerization, with variations in voltage and deposition time, to study their morphology, optical performance, and electrochemical behavior. At the atomic and molecular levels, this study involves modeling the composite material, composed of Nomex, Kevlar, and Spirooxazine-Doped PANI, and simulating its behavior. The significance of this work lies in developing a novel composite material for in-space optical mining, integrating it into optical mining systems, and introducing innovative thermal management solutions, which contribute to future space exploration by improving resource efficiency and sustainability, while also enhancing the understanding of PANI film properties for in-space applications.

Development of High-Temperature Resistant Joining Materials “Nanosolder”

Development of High-Temperature Resistant Joining Materials “Nanosolder”

Control over phase structures’ evolution within the novel organic–inorganic hybrid system for achieving a comprehensive thermal, mechanical, and dielectric properties

Significant challenges persist in developing high-performance, wave-transparent capable of operating above 500 ℃ using organic–inorganic hybrid materials. This study introduced a novel, highly reactive terminal carborane monomer, 4-(3-carborylphenyl) phthalonitrile (CB-Ph), to create a cross-linked network structure and inorganic phase. By integrating this with the conventional high-performance poly (phthalazine ether nitrate ketone) (PPENK), a novel organic–inorganic hybrid system was successfully constructed. Simultaneously, the modifications in the inorganic layer and phase structure of the material with increasing CB-Ph content were examined through nanoindentation and SEM analysis systems, establishing a structural foundation for optimizing the balance between thermal resistance, mechanical strength, and dielectric properties (balance of T-M−D). The thermal performance testing results indicates that the hybrid materials achieved high glass transition temperatures (Tg exceeding 500 ℃). This enhancement is attributable to the synergistic effects of cyanide side group micro-crosslinking and the phthalonitrile crosslinking network, which collectively restricted the movement of chain segments. The P-CB50 resin (PPENK+50 wt% CB-Ph), with its distinctive transition phase structure, boasts the most outstanding comprehensive performance. In terms of thermal stability, it not only features a Tg surpassing 500 ℃ In terms of thermal stability, it not only has a Tg exceeding 500 °C, but also loses only 5 % weight at 599.3° C in a nitrogen atmosphere (Td5%–N2 = 599.3 °C). Mechanical testing reveals that the flexural strength of the P-CB50 composite reaches an impressive 384.3 MPa, while the impact strength attains a significant 109.4 KJ/m2. Even at temperatures as high as 500 ℃, the dielectric constant of the P-CB50 composite material remains below 4, underscoring its superior high temperature wave-transparent properties. These results have firmly established a correlation between the phase structure of the hybrid system and the comprehensive performance of T-M−D, thereby laying a solid foundation for the development of high-temperature resistant and wave-transparent materials with enhanced overall performance.

Experimental study of dual nano-network, high-temperature resistant aerogel material as an integration of thermal management functions

Thermal management system is highly desirable to guarantee the performance and thermal safety of lithium-ion batteries, but it reduces the energy density of battery modules and even is unable to provide highly effective protection. Here, a thermal management function integrated material is presented based on high-temperature resistant aerogel and phase change material and is applied at both charge–discharge process and thermal runaway condition. In this sandwich structure Paraffin@SiC nanowire/Aerogel sheet (denoted as PA@SAS) system, SiC nanowires endow the middle aerogel sheet (SAS) a dual nano-network structure. The enhanced mechanical properties of SAS were studied by compressive tests and dynamic mechanical analysis. Besides, the thermal conductivity of SAS at 600 °C is only 0.042 W/(m K). The surface phase change material layers facilitate temperature uniformity of batteries (surface temperature difference less than 1.82 °C) through latent heat. Moreover, a large-format battery module with four 58 Ah LiNi0.5Co0.2Mn0.3O2 LIBs was assembled. PA@SAS successfully prevents thermal runaway propagation, yielding a temperature gap of 602 °C through the 2 mm-thick cross section. PA@SAS also exhibits excellent performance in other safety issues such as temperature rise rate, flame heat flux, etc. The lightweight property and effective insulation performance achieves significant safety enhancement with mass and volume energy density reduction of only 0.79% and 5.4%, respectively. The originality of the present research stems from the micro and macro structure design of the proposed thermal management material and the combination of intrinsic advantages of every component. This work provides a reliable design of achieving the integration of thermal management functions into an aerogel composite and improves the thermal safety of lithium-ion batteries.

Experimental system and method of aerobic thermal environment simulation based on laser heating

Considering the superior luminous intensity characteristics of lasers, a thermal simulation platform employing laser-induced heating in an aerobic environment was developed. Achieving a uniformly distributed flat-topped square laser beam output was facilitated through optical fibre bundling techniques, while precise control over laser power output was attained through current modulation. Utilising the aforementioned system, thermal shock simulation experiments were conducted in an aerobic environment, subjecting two types of high-temperature-resistant composites, namely C/C and C/SiC, to temperatures up to 1800 °C. These composites were lightweight, heat-resistant materials designed for hypersonic vehicle applications. The results show that the system and method can be used to simulate high temperatures, rapid temperature increases, and thermal shocks on C/C composite materials, with minimal variation in the coupling coefficient under aerobic conditions. The system and method can also provide key technology support for thermal-force-oxygen coupling testing of high temperature resistant materials.

Testing Framework of Polyimide-Based High Temperature Resistant Composite Materials for Aerospace Applications

기 정립되어 있는 KS, ASTM, MIL 등의 시험규격은 일반적인 조건에서의 고분자섬유복합재 시험방법을 제시하고 있다. 본 연구에서는 대기권 이상의 환경조건에서 폴리이미드 기반 고분자섬유복합재가 경험할 수 있는 열특성 및 기계적 강도 파라미터를 포괄하는 특화 시험방법을 정리 및 제안하였다. 각각의 시험방법은 본소에서 특수기능용 고분자섬유복합재를 대상으로 다양한 환경조건 하 수행된 시험들을 거치며 정립되었다. 장비기반 시험방법 이외에도 본소에서 시험의 보조적 검증수단으로 점차 활용폭이 커지고 있는 복합재 내 열 전달 분석과 같은 컴퓨터 모델링의 예시를 소개하였다. 본 연구가 유관 시험, 공공 및 연구기관에서 우주항공용 폴리이미드 기반 고온섬유복합재 시험방법 연구동향 분석에 도움이 되길 기대한다.

A simple and feasible method for preparing chromium carbide coating on graphite through binary NaCl-KCl molten salt

Due to excellent high temperatures resistance and wear resistance, graphite showed great potential apply in refractory materials. However, the porosity defects caused by the layered stacked structure of graphite would lead to easy permeability, which would result in reducing material’s lifetime. Surface coating technology was considered to be an ideal method to solve the problems through a stable coating on the surface of graphite. But existing methods have some disadvantages, such as high-cost and complex processes. In this work, a simple, low-cost and green molten salt method was designed. This method successfully prepared a Cr7C3 coating on the graphite surface. The effect of reaction time and temperatures on the chromium carbide coating was investigated by SEM and EDS. The results showed that the thickness of the coating layer increased gradually with the increase in reaction time or reaction temperature, and finally stabilized at about 8 μm. In addition, the reasons behind the formation of Cr7C3 coatings were discussed in terms of both the molten salt reaction and Gibbs free energy, as well as the effect of the coating structure on adhesion. Based on this method, it could not only effectively address the structure defects of graphite, but also showed simple preparation processes and low cost, which would promote the development of graphite materials in high-temperature resistant materials.

Polybenzoxazines containing borosiloxane structures as high-temperature resistance (T g > 300 °C) and environment-friendly flame-retardant materials

A series of borosiloxane structures-containing polybenzoxazines (PBZs) with intrinsic environment-friendly flame-retardant properties and high-temperature resistance are investigated in this study. Initially, borosiloxane structures-containing benzoxazine macromonomers (BZ-BSiO-X) were synthesized through a condensation reaction between silicon ethoxy groups-containing benzoxazine monomers (P-mdes), boric acid (BA) and diphenyldimethoxysilane (DPDMS) with varying feed ratios. Subsequently, the benzoxazine groups in BZ-BSiO-X underwent ring-opening polymerization at elevated temperatures to produce poly(BZ-BSiO-X). The properties of poly(BZ-BSiO-X) were evaluated using Dynamic Mechanical Analysis, Thermogravimetric Analysis and an Oxygen Index instrument. The results show that the heat resistance of poly(BZ-BSiO-X) is enhanced by the cross-linking structures formed by the P-mdes segment and B-N coordination interaction, leading to their glass transition temperatures (T g, tan δ) exceeding 300 °C. The thermal stability and flame-retardant properties of poly(BZ-BSiO-X) are reinforced via the borosiloxane structures formed through DPDMS and BA, resulting in a 5% weight loss temperatures (T d5) around 400 °C and limiting oxygen index (LOI) values above 30. These polymers, containing environment-friendly flame-retardant boron (B) and silicon (Si) elements, exhibit potential as alternatives to halogen- or phosphorus-containing flame-retardant materials and are expected to be used in various fields as environment-friendly flame-retardant materials.

Study on the tensile properties and deformation mechanism of high-temperature resistant nitrogen-containing nickel-based welding material deposited metal

This article uses a new type of nitrogen-containing nickel-based flux cored welding wire as the experimental material to study the tensile properties and deformation mechanism of the deposited metal from room temperature to 900 °C. The results show that the tensile strength gradually decreases with the temperature. The plasticity gradually increases, but the lowest value appears at 700 °C, which is the phenomenon of intermediate temperature brittleness. M23C6 carbides begin to decompose at 700 °C. More carbonitrides are precipitated within the crystal with temperature. In the low-temperature zone (T ≤ 600 °C), the main deformation mechanism is the unit dislocation a/2<110> cutting precipitation phase. In the medium-temperature zone (600 °C < T ≤ 750 °C), initiation of Orowan bypass mechanism for dislocations. In the high-temperature zone (800 °C ≤ T ≤ 900 °C), the slip and climbing mechanism of dislocation is the main deformation mechanism.

Thermally stabilized polyacrylonitrile/polyphenylene sulfide composite membranes for efficient emission control in harsh environments

In harsh and complex environments, the emission of polluted air poses significant challenges to traditional filtration systems. In contrast to conventional approaches which primarily involve the incorporation of antioxidants into filter materials, this study introduces a novel methodology. Here, we employed polyacrylonitrile (PAN) as a coating for polyphenylene sulfide (PPS) fibers. Furthermore, we innovatively utilized a needle punching process in conjunction with segmented heat treatment to manufacture PAN-PPS composite filter membranes capable of withstanding extreme environmental conditions. During the segmented heat treatment process, the molecular structure of PAN coating underwent a series of changes, ultimately transforming into a heat-resistant ring trapezoidal structure, providing protection for PPS fibers that are prone to oxidation, and thereby enhancing the structural stability of composite filter membrane. Experimental results demonstrated a significant improvement in the mechanical properties of PAN-PPS composite fabric after segmented heat treatment, with the tensile strength increasing by 71.7 % and the Young’s modulus by 91.6 %. Additionally, the flame retardancy and hydrophobic properties of composite membranes were significantly enhanced, exhibiting the excellent stability and better filtration performance in extreme environments. This approach not only addresses the challenges posed by incorporating nano antioxidants into the spinning process but also significantly enhances the high-temperature resistance of the materials. This enables PAN-PPS composite filter bags to effectively control the emission of polluted gases in extreme environments. Furthermore, the thermal treatment process of the PAN coating is easy to implement and cost-effective, providing a novel strategy for the development of extremely high-temperature resistant filtering materials. This makes it possible to explore the development of flexible, high-performance air filtering materials for extreme environments in the future.

Molybdenum-14Rhenium alloy—The most promising candidate for high-temperature semiconductor substrate materials

The development of emerging high-temperature-resistant semiconductor materials is of great significance for the stability of signals and the reliability of sensors during extreme probing processes such as deep earth and space. However, current reports only focused on the properties of the semiconductor materials, neglecting the high-temperature-resistant properties of subsidiary components, such as substrate. In this study, for the first time, the feasibility of the Molybdenum-14Rhenium (Mo-14Re) alloy as a high-temperature semiconductor substrate material was verified at five temperature points (25 ℃ (room temperature, Rt.), 100 ℃, 200 ℃, 300 ℃, and 400 ℃, respectively). The results showed that the hardness (2.8 GPa to 2.4 GPa) of the Mo-14Re alloy changed slightly during the temperature up to 400 ℃; the Mo-14Re alloy generated protective Mo6+ and Re3+ oxides at different temperatures, which enhanced its oxidation resistance; the thermal expansion coefficient of the Mo-14Re alloy was 5.04 × 10−6/℃ at 400 ℃, which can be perfectly adapted to semiconductor components, such as silicon, silicon nitride, and gallium nitride. Simultaneously, the Mo-14Re alloy combined appropriate thermal conductivity, making it the most promising candidate for a new generation of high-temperature semiconductor substrate materials. This study can promote the application of semiconductor materials in extreme environments, such as high temperatures. Concurrently, this study can promote the development of deep earth exploration and aerospace fields and guide the selection of emerging high-temperature resistant substrate materials.

Research of Stirling engines applications in vehicle, electricity, heating and cooling

Natural resources are becoming more and more scarce while pollution continues to increase. It is imperative to reduce emissions and improve energy efficiency. As an efficient, low-emission machine, the Stirling engine may be an answer on the road to emission reduction and improved efficiency. Stirling engine has been used in some areas, such as nuclear-powered submarine engines, combined heat and power and Stirling cryocoolers. However, there are still several problems that cannot be ignored in Sterling generators themselves. Stirling generators, characterized by high efficiency and potential for reducing greenhouse gas emissions, face challenges, including high material and assembly costs, complex waste heat treatment processes, and the need for durable, high-temperature resistant materials. Despite current limitations, ongoing research aims to enhance conversion efficiency, minimize size, and lower manufacturing costs, with promising applications in various sectors, including transportation and household energy, representing a significant stride towards green energy power generation in the future.

High powered output flexible aerogel triboelectric nanogenerator under ultrahigh temperature condition

Triboelectric nanogenerators (TENGs) have emerged as promising devices for harvesting low-frequency energy, but its application in high-temperature environments is limited. In this article, a flexible high-temperature resistant fiber substrate material was developed using needled felt and silicon aerogel. This material demonstrated exceptional resistance, withstanding exposure to a butane flame at approximately 1300 ℃ for a minimum of 10 min without experiencing burn-through. Following the application of electrodes and protective encapsulating, a high-temperature resistant silicon aerogel and fiber felts based triboelectric nanogenerator (HTFs-TENG) was successfully created. In addition, we achieved remarkable enhancements in the electrical output performance of the HTFs-TENG by precisely regulating its dielectric properties, resulting in an impressive increase in peak voltage from 17 V to 135 V. The current output increased from 1.4 μA to 6 μA. The HTFs-TENG demonstrated remarkable adaptability, operating effectively at temperatures as high as 275 ℃ and as low as approximately − 75 ℃. Moreover, it showcased an instantaneous power density output of 31.9 mW/m2 under a 100 MΩ resistance load. The HTFs-TENG displayed impressive electrical signal response capabilities at ultralow frequencies (≤1 Hz) across various temperatures and frequencies, positioning it as an ideal self-powered vibration sensor and temperature sensor for diverse generator applications.

An investigation of the thermal stability and mechanical properties of carbon framework materials hybridized by graphene and double benzene rings through combining first-principles calculations and classical molecular dynamic simulations

Carbon materials with a diverse hybridization of states have been studied for many decades due to their excellent customizable properties. In current work, a proposed carbon-based framework material named Double Benzene rings Graphene-based Frameworks (DBGFs) was studied. DBGFs was designed from the hybridization of 2D graphene (sp2) and 0D double benzene-ring molecules (sp2). Its thermal stability and mechanical properties were investigated using molecular dynamic simulation and first-principles calculation. The results showed that DBGFs had a relatively higher thermal stability up to 1557 K due to the interlayer cohesive strength of the double benzene rings. Furthermore, the concentration of double benzene rings directly affects the tensile and shear modulus of DBGFs, highlighting their significance as functional components. Additionally, an intermediate and metastable phase (named as “douben”) was observed under unidirectional compression of DBGFs-128 and other lower concentration of benzene rings, whereas the douben exhibits the slightly reduced thermal stability but improved mechanical properties in comparison to its original structure (DBGFs-128). In summary, these results of carbon materials show potential stratagem for designing high temperature and pressure resistant materials with hybridization of low dimensional materials in future.

Hafnium boride whiskers prepared by boro/carbothermal reduction for high-performance electromagnetic wave absorption

In this study, a chloride-assisted boro/carbothermal reduction method was employed to prepare HfB2 whiskers, aiming to address the challenges associated with large-scale preparation of HfB2 whiskers and the development of high-temperature resistant electromagnetic wave absorbing materials. When the precursors were mechanically stirred, the resulting mixture underwent calcination at 1450 °C for 3 h, leading to the formation of single-phase HfB2 whiskers. The as-synthesized HfB2 whiskers showed exceptional resistance to oxidation at temperatures up to 700 °C. The microwave absorption performance and mechanism of the HfB2 whiskers/paraffin composite were also investigated. The results revealed that the composite achieved a minimum reflection loss of −41.29 dB when the HfB2 whiskers content reached 80 wt%, while the widest effective absorption bandwidth of the composite reached 3.6 GHz when the HfB2 whiskers content increased to 82.5 wt%. This work presents a novel candidate for high-temperature resistant materials used in absorbing electromagnetic wave.

Experimental study on high-temperature resistance of alkali-activated slag concrete block masonry

The use of blast furnace slag improves resource utilization and supports the achievement of sustainable development goals. The use of alkali-activated slag cementitious material (AASCM) provides a new direction for improving the fire resistance of masonry structures. The masonry investigated in this study was alkali-activated slag crushed aggregate concrete masonry (ASCCM) in which aggregates of blocks and mortars were crushed and screened using AASCM paste specimens. The compression behavior of 12 specimens during and after exposure to high temperatures, specifically 300, 500, 600, 700, 800, and 900°C was investigated. The specimens were maintained under the target temperature for 2 h. The compressive strength and axial deformation of the specimen were recorded. The compressive strength losses during exposure to 300, 500, 600, 700, 800, and 900°C are 15.9, 20.3, 38.3, 43.9, 63.3 and 73.8%, respectively. The compressive strength losses after exposure to 300, 500, 600, 700, 800, and 900°C are 10.6, 15.8, 34.0, 37.2, 58.6 and 72.2%, respectively. The rate of loss in elastic modulus is greater than that in compressive strength. During exposure to 300, 500, 600, 700, 800, and 900°C, the loss rates of elastic modulus are 56.5, 74.4, 83.3, 86.3, 92.9 and 93.9%, respectively. After exposure to 300, 500, 600, 700, 800, and 900°C, the loss rates of elastic modulus are 49.6, 67.3, 77.5, 82.0, 90.7 and 94.5%, respectively. The peak compressive strain values are 9.9 and 11.1 times that at room temperature. Equations for calculating the compressive strength, elastic modulus, peak compressive strain, and ascending section curve of the stress–strain relationship with temperature were derived. The research results provide a new choice for high temperature resistant masonry materials, and provide theoretical basis and data support for the application of AASCM in masonry structures in high-temperature environments.

A novel salt-barrier method of preparation flexible temperature resistant full-component nanocellulose membranes

With the simplification and diversification of separation technologies, nanocellulose membranes have become widely used as insulating materials. Recently, study of nanocellulose membrane modification has become a hot topic. However, the application of nanocellulose membrane has been limited due to their inadequate heat resistance and flexibility. Herein, based on the pyrolytic and thermoplastic properties of cellulose, we innovatively introduced a salt barrier scheme to regulate the degree of hydrogen bonding and thermoplastic bonding between fibers. This was achieved by adding a salt barrier agent, NaCl, in the middle of the nanocellulose to prepare and obtain flexible, high-temperature-resistant nanocellulose film materials. The full-component cellulose films thus prepared exhibited high tensile strength (8 MPa), excellent flexibility (105 mN), high electrical breakdown strength (67 KV/mm), and volume resistivity meeting the standard of insulation materials (3.23 × 1013 Ω·m). This scheme adheres to the principles of low cost, green, non-toxic and non-hazardous, providing a brand new approach for the research and development of high temperature resistant cellulose membrane materials, which is of significant commercial value and industrialization prospect.

In-situ crosslinked polyetherimide/BNNS composites with ultrahigh charged-discharged efficiency at high temperature

High performance dielectric polymer composites for capacitive energy storage have been a hot topic in recent years. However, dielectric materials tend to breakdown at high temperature, and its charged-discharged efficiency is greatly reduced. Therefore, preparing high-efficient high-temperature dielectric material is the main challenge in this field. In this work, based on the synergistic effect of in-situ composite and controlled thermal cross-linking, the thermal conducting nano filler and crosslinking system composite has ultra-high charged-discharged efficiency at high temperature. It is proved that the addition amount of BNNS for the peak performance of this kind of composite is 10 vol% and the discharge energy density is 4.58 J/cm3 and the charged-discharged efficiency reaches 96 % at 150 °C and 500 MV/m. At 200 °C and 300 MV/m, these are 1.76 J/cm3 and astonishing 95 %. It is expected to be a candidate for a new generation of high temperature resistant dielectric materials.

Failure analysis on tube weldment cracking of a high-temperature carbon black air preheater

In this study, the failure analysis on weldment joining the medium-to-high temperature steel tube (the jointed materials are S30815 and HK40Nb, respectively) sections of a high-temperature carbon black air preheater was conducted. The root cause of the cracking is identified as metal dusting appearing in the high-temperature carbon black flue gas environment, as indicated by the result of the macroscopic analysis, the chemical composition analysis, the metallographic examination, and the corrosion product analysis. As revealed by the result, the metal was directly exposed to the flue gas due to the damage of the surface protective film (i.e., Cr2O3) of the stainless-steel tube weldment. The result suggested that elemental sulfur within the flue gas and overheating in the operation destroyed the oxide film. Under the effect of the high carbon activity in the flue gas, carbon atoms were driven to attack metals. The accumulated carbon particles arising from weld reinforcement promoted the failure of the weldment. To prevent metal dusting, it is recommended to increase the amount of water vapor in the flue gas for the reduction of the carbon activity, choose high-temperature resistant materials for the prevention of direct contact between the flue gas and the material, and improve the welding quality to prevent the flue gas from being disturbed.