Thermal Shock Research Articles

Thermal/mechanical properties of cordierite synthesized using coal gangue as a refractory material

AbstractCoal gangues i a solid waste during the coal mining process and the accumulation of coal gangue will harm the environment. Therefore, solid waste utilization of coal gangue is required to reduce the environmental damage. In this paper, cordierite ceramics are successfully prepared via a solid‐phase sintering using coal gangue, Al2O3, and MgO as raw materials. The effects of sintering temperatures on the microstructures, phase stability, and thermal properties of ceramics are investigated. The results show that the properties of cordierites prepared at 1200°C are close to those of prepared by the traditional method, and the synthesized ceramics have thermal expansion coefficients (TECs) and conductivity of 4.1–10−6 K−1 and 1.72 W·m−1 K−1 at 900°C, respectively. The sample prepared at 1200°C has good wear resistance (η) with a wear resistance coefficient of 0.507, and an excellent thermal shock resistance, which can withstand 15 times of cold and hot shocks at 1100°C without any cracks on the surface. This study systematically elucidates the thermal/mechanical properties of the synthesized cordierite, and the feasibility of using coal gangue as raw materials prepared cordierite ceramics as refractory materials. This work presents an effective solution to mitigate the challenge of coal gangue disposal.

Prediction of freeze–thaw and thermal shock weathering on natural stones through deep learning-based algorithms

Prediction of freeze–thaw and thermal shock weathering on natural stones through deep learning-based algorithms

Nanomaterials in Solid-State Batteries: Enhancing Safety and Performance

Solid-state batteries (SSBs), utilizing solid electrolytes instead of liquid ones, represent a promising advancement in energy storage technology due to their higher energy density and enhanced safety. Despite their potential, SSBs face significant challenges such as high interfacial resistance, low ionic conductivity, and high production costs. Recent advancements in nanomaterial technology have offered innovative solutions to these issues. Nanomaterials with high specific surface areas and controllable morphologies optimize interfacial contact, reduce resistance, and enhance ionic conductivity through efficient ion transport channels. Additionally, surface modifications and doping improve the chemical and thermal stability of SSB components, extending battery life and preventing adverse reactions. Although initial preparation costs are high, advancements in production technology and large-scale manufacturing are expected to lower these costs, facilitating commercialization. Future research should focus on new nanostructure designs, nanocomposites, and interfacial engineering to further enhance battery performance and safety. Understanding the influence of nanomaterials on safety performance and improving thermal and mechanical shock resistance are crucial for the reliable implementation of solid-state batteries in practical applications.

Anti-Sintering Behavior of GYYSZ, Thermophysical Properties, and Thermal Shock Behavior of Thermal Barrier Coating with YSZ/Composite/GYYSZ System by Atmospheric Plasma Spraying

Anti-Sintering Behavior of GYYSZ, Thermophysical Properties, and Thermal Shock Behavior of Thermal Barrier Coating with YSZ/Composite/GYYSZ System by Atmospheric Plasma Spraying

Size-dependent transient thermal stress analysis of a rotating thin and moderately thick porous FGM microblade under cooling thermal shock

Size-dependent transient thermal stress analysis of a rotating thin and moderately thick porous FGM microblade under cooling thermal shock

An innovative approach to study the influence of microstructure on thermal shock resistance of porous ceramics

AbstractPorosity is a critical microstructural factor in ceramic materials, influencing their mechanical and thermal properties. However, the detailed mechanisms through which porosity, grain size, and grain boundary fracture energy affect the thermal shock resistance of porous ceramics are still not fully understood. This study introduces a dual‐scale model that integrates these microstructural parameters to predict fracture toughness and thermal shock resistance. Using the single‐edge V‐notch fracture toughness testing principle, we calculate the thermal stress intensity factor and establish its relationship with temperature differentials. The critical temperature differential, which marks the onset of thermal shock damage, is determined when the thermal stress intensity factor reaches the fracture toughness threshold. The model reveals a significant interplay between porosity, grain size, and grain boundary fracture energy, with fine‐grained ceramics (grain size < 10 µm) showing a sharp decrease in fracture toughness as porosity increases, while coarser‐grained ceramics are less affected by porosity. These findings provide a deeper understanding of the microstructural optimization needed to enhance the thermal shock resistance of high‐performance porous ceramics.

On Thermoelastic Impact Modelling of Frozen Composite Target During Pre – Heated Projectile Penetration Starts of Motion

This study investigates a composite double-layer structure for improved thermal shock resistance. A modified Hugoniot elastic limit model is presented for the composite, followed by a 2D thermo-elastic impact simulation using commercial software. The simulation focuses on a composite material under initial extreme low temperature conditions with alternating metallic (Steel, Aluminum) and non-metallic layers (Kevlar 49, Graphite). The frozen target is subjected to pre- heated projectile. The objective is to optimize the composite's durability by strategically placing reinforcement particles within specific layers. The analysis explores the effect of different particle types (oil, water, Aluminum, Steel) and sizes (0.3mm, 0.5mm, 1mm) on the composite's stress response. It was found that aluminum and steel particles significantly reduce stress compared to fluid/gas particles, confirmed qualitatively by literature. Kevlar particles within the SiCp layer enhance its resistance, while Aluminum particles within the Kevlar layer offer weight reduction benefits. Moreover, for Kevlar, larger particles improve resistance, and vice versa for the SiCp case. Considering weight, a particle size of 0.5mm is chosen for both layers. Moreover, a finite element analysis of the optimized composite model subjected to thermoelastic impact loading demonstrates its superior performance compared to the non-reinforced composite. Specific layer combinations (SiCp with Kevlar particles, Graphite or Kevlar with Aluminum particles) show the most significant stress reduction. Finally, separate 3D ballistic analysis was performed for Tungsten having 600m/sec projectile into 5 layered target with thickness of 2.8mm each layer and appropriate interaction friction (SiCp - Steel 304 - Al 7075-T651 - Kevlar 49 - Graphite Crystalline) during penetration time of 0.006sec at 300K. The dynamic explicit transient analysis was confirmed with the predecessors' analytic calculations.

The Cr/Cr2N multilayer coating with high load-bearing capacity and thermal shock resistance

By utilizing the multi-arc ion plating (MAIP) technique, multilayer coatings with varying Cr/Cr2N ratios and uniform thicknesses were deposited onto a nitrided Cr–Ni–Mo–V steel substrate. The evolution of microstructure and mechanical properties was characterized using scanning electron microscopy, X-ray diffraction, and micro-Vickers hardness testing. The load-bearing capacity of the multilayer coatings with varying modulation ratios was comprehensively evaluated through Vickers indentation tests with a 10-kgf load, Rockwell hardness testing with a 150-kgf load, and scratch tests with loads of 60 and 100N. The coating with a Cr/Cr2N layer modulation ratio of 0.2/0.4 μm exhibited a hardness of 1385 HV and an adhesion strength of 91N. Under a 10kgf load, this coating also demonstrated excellent fracture toughness, and did not exhibit any radial cracks in the Vickers indentation. Subsequently, a thermal shock test, involving quenching from 900°C water to 25°C, was conducted on the coating with the best comprehensive performance. The multilayer coating with high load-bearing capacity could withstand 52 thermal shock cycles before delamination occurred. Failure analysis further confirmed that the multilayer coating with enhanced load-bearing capacity effectively resisted thermal shock.

Rheological properties and excellent thermal shock stability of Al2O3-SiC-C castables containing continuous TiC coated graphite

High-flux molten iron and intermittent circulation accelerated the damage process of Al2O3-SiC-C castables under alternating thermal stress. A continuous TiC coated graphite was prepared using sol-gel combined with carbothermal reduction to investigate its influence on the flow properties, microstructure, mechanical properties and thermal shock resistance of Al2O3-SiC-C castables. The results show that a lower Ti/C molar ratio and higher heat treatment temperature are more favorable for the synthesis of TiC and the formation of a continuous and complete TiC coated graphite layer on the graphite surface. The introduction of TiC coated graphite significantly enhance the mechanical properties and thermal shock stability of Al2O3-SiC-C castables, with a remarkable 227% increase in residual strength after thermal shock. In addition, during the oxidation process of the samples with TiC coated graphite, TiO2 generated from the oxidation of TiC fills the pores and facilitates the growth of Al6Si2O13, which enhances the tightness of the bonding of the castable matrix, thus contributing to the improvement of the overall performance.

Investigation of the Arrangement of Aluminum Fins on the Thermal Behavior of Lauric Acid as a Phase Change Material in a Two-pipe Heat Exchanger by CFD Simulation

BackgroundPhase change material (PCM) thermal storage systems store more thermal energy per unit volume than sensible heat storage systems. PCMs offer a potential solution to reduce energy consumption in various thermal engineering applications. This study aimed to examine how fin arrangement affected the thermal efficiency and melting time of PCMs. MethodsA two-dimensional numerical analysis of the melting process of lauric acid in a heat exchanger featuring two pipelines and fins was conducted using CFD simulation. In most previous investigations, the heat transfer fluid was a single-phase liquid. An enthalpy-porosity technique was used to model the solid and liquid phases of PCM. The governing equations were solved using the commercial software ANSYS Fluent 2021, and the pressure and velocity equations were coupled using the SIMPLE algorithm. Significant FindingsThe best model among the 13 tested was Model 5, which featured 6 fins and a consistent angle of 60 degrees. For Model 5, the melting time was 1818.3 seconds. Due to sensible heating, the fin's temperature (Temp) rose gradually from 300 K to 318 K. Temp then gradually increased as the PCM melted in the phase transition zone between 316.5 K and 321.2 K. Once the phase transition was complete, the PCM's Temp steadily rose from 324 K to 340 K. In Model 5, the inner wall Temp and the maximum Temp of the PCM were closest, at 327.34 K and 333.55 K, respectively. The thermal shock between the PCM and the ambient Temp caused a peak heat flux at the beginning of the PCM loading process.

Optoelectronic and photoacoustic waves in rotating excited semiconductor subjected to thermal shock

In this study, the impact of rotation on the transmission of optical acoustic waves, arising from the movement of the optical carrier within an elastic thermal environment, is examined through theoretical analysis. The theoretical framework incorporates the interaction between acoustic waves and thermomechanics to formulate governing equations specific to a semiconductor medium. The fundamental equations of the physical model, influenced by photothermal and thermoelastic principles, are deduced mathematically while considering the presence of rotation. The model studied the medium under a thermal shock wave from thermal stress resulting from light-induced temperature elevation that is not fixed but decaying over time. The mathematical model is solvable using the normal mode method. The model’s numerical solutions provide access to all physical fields within the physical domain, encompassing displacement, temperature, acoustic pressure, mechanical stress, and carrier density diffusion. Utilizing the harmonic wave method, a two-dimensional graphical representation of the rotation parameter with and without the influence of the decay parameter is obtained. The theoretical analysis involves comparison, analysis, and discussion of the effects of these parameters investigated.

Radio-transparent celsian ceramics modified with glass in a pseudoternary system BaO–Al2O3–SiO2: synthesis, microstructure, thermal and physical properties

The article presents the results of the study of radio-transparent celsian ceramics, in which part of the components were introduced using eutectic glass of the pseudoternary BaO–Al2O3–SiO2 system. The bonding of the components of the experimental glass into the celsian phase was realized according to the principle of reactive structure formation by adding the missing components (crystalline fillers). In this case, the obtained dense sintered water-resistant ceramic, the only crystalline phase in the composition of which is the monoclinic form of celsian, which forms a microhomogeneous structural matrix of the material. Celsian is represented by distinct prismatic crystals of tetragonal and hexagonal shape. The size of celsian crystals increases from 3–5 m to 7–10 m with increasing the content of eutectic glass. The developed celsian ceramic has a set of enhanced physical and thermal properties: zero water absorption and open porosity, mechanical compressive strength (up to 157 MPa), refractory index is 1540–15800C. Celsian ceramic is characterized by a coefficient of linear thermal expansion of 3410–7 0C–1, which provides a sufficiently high thermal shock resistance of 7000C. In terms of the level of relative dielectric permittivity (5.5) and dielectric losses (0.0005) at a frequency of 1010 Hz, the developed ceramic meets the requirements for ultra-high-frequency radio-transparent materials for aviation and rocket technology, which operate under conditions of high-speed high-temperature heating.

Ultrafast Lattice Engineering for High Energy Density and High-Rate Sodium-Ion Layered Oxide Cathodes

Sodium-ion batteries attract significant interest for large-scale energy storage owing to abundant sodium reserves, while challenges remain in the high synthesis energy consumption, long synthesis period, and poor electrochemical performance of sodium-ion layered oxide materials. This study presents a general high-temperature thermal shock (HTS) strategy to synthesize and optimize sodium-ion layered oxides. The rapid ramping, sintering, and cooling processes minimize volatile sodium loss during HTS, facilitating the improvement of phase purity and effectively optimizing the microstructure of materials in a non-equilibrium state. As a proof of concept, Mn-based Na0.67MnO2 treated with HTS (NMO-HTS) suppresses Mn ion vacancy within transition material layers, thereby increasing the redox centers and lowering the Mn 3d orbital energy level. Besides, the formation of transition metal layer stacking faults mitigates the structural transformation and Na+-vacancies ordering arrangement during cycling. Consequently, the energy density of the NMO-HTS increases by 21.5% to 559 Wh kg-1, with an outstanding rate capability of 108 mAh g-1 at 10C and an impressive capacity retention of 93.7% after 300 cycles at 1C. In addition, we demonstrate the universality of HTS in synthesizing various other sodium-ion layered oxides, including nickel-based and iron-based cathodes, as well as in activating degraded materials.

Preparation and properties of lightweight aluminum silicate-based fibrous ceramic membranes with different binder contents for high-temperature dust removal

Fibrous ceramic membranes are widely regarded as ideal hot-gas filtration media due to their unique three-dimensional network structure. In this work, deionized water and sodium lignosulfonate (NaLS) were respectively introduced into the preparation of fibrous ceramic membranes, with aluminum silicate fibers used as the matrix skeleton and silica sol used as the high-temperature binder. Their effects on the binder content, morphology, structural parameters, and mechanical properties were investigated and compared, and then the application performance of the preferred sample was evaluated. The results indicated that the addition of both significantly reduced the binder content, resulting in decreased bulk density and increased apparent porosity. Notably, compared to the addition of water, the addition of NaLS effectively preserved the binder content at the junctions between fibers so that the flexural strength and stiffness were barely affected, which benefits from the decrease in the viscosity of the binder liquid under the action of electrostatic repulsion and steric hindrance. Moreover, the preferred prepared fibrous ceramic membrane exhibited high-performance characteristics, such as superior thermal shock resistance, low pressure drop, and high filtration efficiency and pulse-jet cleaning efficiency, thereby offering considerable prospects for practical applications.

Experimental investigation on fracture propagation in shale fractured by high-temperature carbon dioxide

The productivity of shale reservoirs was significantly enhanced by the high-temperature CO2 fracturing technique. The injection of high-temperature CO2 into the formation induced rock fracture propagation, creating advantageous pathways for fluid flow. In this research, a self-developed in situ high-temperature convective heat simulation experimental apparatus was employed to systematically conduct simulated experiments on high-temperature CO2 fractured shale under different influencing factors. The experimental results demonstrated that the permeability of CO2 increased as the injection temperature increased. The rock fracture pressure was effectively reduced by high-temperature CO2 fractured shale. Higher complexity was observed in fracture propagation, accompanied by a substantial increase in microcracks and branching fractures. The shale fracture pressure increased with increasing triaxial stress and CO2 injection rate. The confining pressure restricted the further propagation of fractures under relatively high stress conditions, thereby reducing the width and density of fractures, lowering the fracture complexity. Nevertheless, the thermal shock effect of the fluid was exacerbated as the injection rate of high-temperature CO2 increased. The initiation of microcracks was facilitated by the intensification of local thermal stress in shale, inducing multiple curved fractures and forming a more complex fracture network. Compared to horizontal bedding shale, the fracture pressure of vertical bedding shale was relatively higher during high-temperature CO2 fracturing. In addition, the geometric morphology of fracture propagation was more complex, characterized by rougher fracture surfaces, leading to a greater improvement in reservoir reconstruction volume. This research contributed to the optimization of CO2 resource utilization, provided experimental evidence for the application of high-temperature convection fracturing technology in in situ shale conversion projects.

Sintering behavior and thermal shock resistance of MgO-Mg2SiO4 refractories by co-doped silica fume and quicklime

To solve the serious environmental pollution of low-grade magnesite tailings, MgO-Mg2SiO4 refractories were prepared by low-grade magnesite tailings, materials and silica fume and quicklime as raw materials. The effects of calcium-silicate ratio (mol ratio) on the phase composition, microstructure, sintering behavior and thermal shock resistance of MgO-Mg2SiO4 refractories were investigated. When calcium-silicate ratio was 5/5, the samples showed the optimum bulk density and apparent porosity of 2.81 g/cm3 and 16.37 %, respectively. Controlled the calcium-silicate ratio of samples to 5/5 significantly improved the thermal shock resistance of samples, the residual compressive strength rate of 69.78 % and the residual flexural strength rate of 19.86 %, while the thermal parameter R was 34.45. The improvement in the thermal shock resistance can be attributed to the bonding phase transformation from monticellite phase to forsterite phase, thereby enhancing the bond strength between aggregate and matrix.

10-Cell Direct Ammonia Solid Oxide Fuel Cell Stack Design Development with Improved Efficiency and Resilience to Thermal Shock

Hydrogen's potential as a green fuel faces a storage challenge, which has prompted recent studies to explore methods to advance solid and liquid storage, with a particular focus on utilizing ammonia. Employing hydrogen in the form of ammonia has shown considerable promise as it capitalizes on well-established and mature technologies. Nevertheless, establishing effective and resilient direct ammonia Solid Oxide Fuel Cell (SOFC) stacks demands a high degree of congruence with stack design, uniform species distribution, and temperature regulation. This research compared the conventional simple cross flow configuration with a novel approach involving two alternating fuel and air flow configurations within a 10-cell direct ammonia SOFC stack. An experimentally validated model of the direct ammonia SOFC was utilized for multi-physics modeling. The results revealed that the alternating fuel and air stacking method creates a superior ammonia decomposition profile compared to simple cross flow stacking. Moreover, the results demonstrate a lower temperature difference of 55 K within the stack. The implementation of the alternating fuel flow and air flow method enhanced the stack's efficiency by 0.74%, primarily due to its improved thermal management capabilities within the stack. This study achieved its goal of optimizing a 10-cell direct ammonia SOFC stack by refining the design while maximizing performance and durability.

Application of the thermal shock response spectrum (TSRS) methodology to various forms of heat sources by pulse thermography and comparison by using a rotating line scan contour search algorithm

Application of the thermal shock response spectrum (TSRS) methodology to various forms of heat sources by pulse thermography and comparison by using a rotating line scan contour search algorithm

Principles of ensuring thermal stability in innovative technology of periclase-spinel refractories

This article presents the results of research on the structural-phase regularities and behavior of periclase-spinel refractories under high-gradient thermal loads. The findings from the analysis of structural-phase variability in the refractory samples are used to achieve the desired thermal resistance. Based on the investigation of the subsolidus structure of the MgO–FeO–Al2O3–TiO2 system, predictions were made regarding the characteristics of solid-phase exchange reactions, considering the existence of solid solutions with various types of crystal structures in specific areas of the system. This enabled the application of new principles for ensuring thermal stability in the developed periclase-spinel refractories, specifically through organizing a fragmented, micro-cracked structure by combining solid-phase exchange reactions with the establishment of mobile equilibrium upon reaching stationary-state temperatures. An additional feature is the possibility of phase invertibility of solid spinel solutions, including changes in the type of spinel structure, in particular quandilite. Physicochemical research methods confirmed the enhanced ability of the material to flexibly adapt its phase composition and microstructure to thermal loads. The feasibility of these principles for achieving the structural-phase adaptability of the material to thermal shocks was validated by electron microscopy analysis.

Failure behavior study of EB-PVD TBCs under CMAS corrosion and thermal shock cycles

Abstract Calcia-magnesia-alumino-silicate (CMAS) erosion has become a major obstacle, limiting the operating temperature and service life of Thermal barrier coatings (TBCs) in aircraft engines. Constructing simulation environments that replicate TBCs’ working conditions and exploring online, non-destructive detection techniques are reliable approaches to studying coatings’ failure, representing both a global research hotspot and a challenge in this field. The paper presents an initial endeavor to establish a simulation experiment for TBCs in aviation-engine within a CMAS environment. Experimental results show that electron beam physical vapor deposition (EB-PVD) Y2O3-stabilized ZrO2 (YSZ), one of the mainstream TBCs technologies, produced 20% surface spallation after 50 thermal-shock cycles under simulated CMAS corrosion conditions. Testing and analysis of the macroscopic and microscopic structures of the failed samples, combined with SEM, EDS, and XRD findings, revealed significant physical and chemical interactions between the ceramic layer and CMAS deposits, as well as phase transformation within the coatings, leading to substantial alterations in mechanical properties and ultimately causing the failure of EB-PVD YSZ.