Yttria-stabilized Zirconia Research Articles

Influence of SS316L Nanoparticles on the Sintered Properties of Two-Component Micro-Powder Injection Moulded Bimodal SS316L/Zirconia Bi-Materials

Two-component micro-powder injection moulding (2C-μPIM) is a prospective approach for fabricating bi-material micro-components of stainless steel 316L (SS316L) and 3 mol% yttria-stabilised zirconia (3YSZ) at an appealing cost. However, the fundamental challenge lies in preventing the formation of large-scale cracks at the interface of two different materials during sintering. This study investigated how SS316L nanoparticles in bimodally configured SS316L powder that incorporated both nanoparticles and microparticles influenced the sintering of 2C-μPIM-processed miniature bi-materials made of bimodal SS316L and 3YSZ. In this study, feedstocks were developed by integrating monomodal (micro-sized) SS316L powder, three types of nano/micro-bimodal SS316L powders, and 3YSZ powder individually with palm stearin and low-density polyethylene binders. The results indicated that increasing the SS316L nanoparticle content to 45 vol.% caused a 19.5% increase in the critical powder loading in the bimodal SS316L powder as compared to that in the monomodal SS316L powder. The addition of SS316L nanoparticles increased the relative density and hardness of the sintered bi-materials, with the maximum values obtained being 96.8% and 1156.8 HV, respectively. Field emission scanning electron microscopy investigations revealed that adding 15 vol.% and 30 vol.% SS316L nanoparticle contents reduced interface cracks in bi-materials significantly, while 45 vol.% resulted in a crack-free interface.

Effect of grain size on mechanical properties and aging of yttria-stabilized tetragonal zirconia polycrystal fabricated by stereolithography-based additive manufacturing

The objective of this investigation was to comprehensively assess the impact of grain size on the mechanical properties and low-temperature degradation (LTD) of yttria-stabilized tetragonal zirconia polycrystal (3Y-TZP) fabricated by stereolithography-based additive manufacturing at the submicron scale. Four 3Y-TZP ceramics with high relative density (>98%), ranging in grain size from 0.2 μm to 1 μm, were successfully prepared and validated for studying mechanical properties (including Vickers hardness, fracture toughness, and flexural strength) as well as LTD progression. This study elucidates the mechanical behavior of zirconia ceramics at the submicron scale, focusing on fracture micromechanisms and the grain size dependence of transformation toughening. Additionally, it examines the influence of grain size on the hydrothermal aging behavior of zirconia ceramics at the submicron scale using Raman spectroscopy.

Improved ionic conductivity of La and Mg co-doped ceria nanocrystals synthesized by auto-combustion method

Ionic conductivity of La3+ and Mg2+ co-doped ceria, synthesized by auto-combustion method, is investigated here as electrolytes for intermediate-temperature solid oxide fuel cells (IT-SOFCs, operating below 800 °C). The prepared nanocrystalline electrolytes, LMDC10 (Ce0.9La0.05Mg0.05O2-δ) and LMDC20 (Ce0.8La0.1Mg0.1O2-δ) have exhibited improved ionic conductivities of 1.31 × 10−2 and 1.39 × 10−1 S cm−1 at 1073 K with reduced activation energies of 0.93 and 0.97 eV, respectively, when compared to conventional electrolytes like yttria-stabilized zirconia. The prepared samples are characterized by XRD, Raman spectra, XPS and FESEM which confirmed the formation of single-phasic cubic fluorite structure. Thus, the potential for La3+ and Mg2+ co-doped ceria electrolytes to offer cost-effective alternatives with low sintering temperatures and high performance for IT-SOFCs.

Coherent Epitaxy of HfxZr1-xO2 Thin Films by High-pressure Magnetron Sputtering

Due to remarkable high-k and ferroelectric properties in CMOS devices, the study of crystalline HfxZr1-xO2 (HZO) thin films has attracted tremendous interest recently. However, up to now, the epitaxial growth of HZO films has only been achieved by pulse laser deposition, a technique scarcely utilized in CMOS devices. Therefore, developing appropriate epitaxial methods of HZO films (such as sputtering) is fairly necessary, but a challenge at present. In this work, high-quality single-crystalline HZO films were synthesized by high-pressure magnetron sputtering. The epitaxial growth of HZO films on yttria-stabilized zirconia (YSZ) substrate was demonstrated by a combination of high-resolution X-ray diffraction, atom force microscope, and scanning transmission electron microscope. In addition, good insulating characteristics were obtained by replacing insulating substrates with conductive substrates as electrodes. Our results provide a novel way for the epitaxial growth of the single-crystalline structure of HZO thin films towards the high performance of high-k and ferroelectric devices.

Application of novel Dy0.06Gd0.02Er0.02Bi1.9O3 oxide ion electrolyte for intermediate-temperature reversible solid oxide cells

Bismuth-based oxides are promising electrolyte materials for Reversible Solid Oxide Cells (RSOCs) due to their high ion conductivity and rapid surface oxygen exchange kinetics. In this work we propose a multi-element doping strategy to obtain a novel Dy0.06Gd0.02Er0.02Bi1.9O3 (DGESB) quaternary oxide bismuth material whose ionic conductivities and crystal structure are characterized by AC impedance and X-ray diffraction technique in the temperature range from 600 to 700 °C. Along with promising structure stability and durability, our novel DGESB showed a remarkable ionic conductivity that is 65 times higher than the commercial yttria-stabilized zirconia (YSZ) electrolyte at 700 °C. With composite electrode of DGESB + LCN (LaCo0.6Ni0.4O3) and DGESB/YSZ bilayer electrolyte consisting of RSOC symmetric cell, which achieves a high peak power density (PPD) of 1.62 W/cm2 in fuel cell mode which is 2.7 times higher than that of YSZ single-layer electrolyte, while the electrolysis current density is as high as 1.66 A/cm2 at 1.3 V under H2/H2O:50/50 in electrolysis mode at the same operation temperature of 700 °C. The electrochemical performance measurements revealed a certain stable operation for 200 h in fuel cell mode. The performance degradation can be attributed to the microstructure evolution at the interface between electrolyte and electrodes. The high ionic conductive DGESB proves to be an excellent intermediate electrolyte layer for improving cell performance in RSOCs

High-temperature crack resistance of yttria-stabilized zirconia coatings enhanced by interfacial stress transfer

High-temperature crack resistance of yttria-stabilized zirconia coatings enhanced by interfacial stress transfer

Effect of various storage media on the physicochemical properties of plasma-treated dental zirconia

This study investigated the effect of various storage media on the physicochemical properties of plasma-treated 3-mol% yttria-stabilized tetragonal zirconia: air, vacuum, deionized water (DIW), and plasma-activated water (PAW). Each group was divided into five subgroups based on storage periods: immediately after NTP irradiation (T0), and after 1 week (T1), 2 weeks (T2), 3 weeks (T3), and 4 weeks (T4). The control group (C) received no treatment. The storage groups were monitored weekly using various analytical techniques, including contact angle measurements, scanning electron microscopy (SEM), focused ion beam (FIB)-SEM, confocal laser scanning microscopy (CLSM), x-ray photoelectron spectroscopy (XPS), and x-ray diffraction (XRD). Our results demonstrate that plasma-treated zirconia surfaces stored in DIW retained or even increased their hydrophilicity due to the formation of hydrogen bonds and preservation of nitrogen functionalities. In contrast, surfaces stored in air exhibited significant hydrophobic recovery. FIB-SEM analysis showed no adverse internal structural changes regardless of storage medium. The roughness of the zirconia surface slightly increased after plasma treatment and was generally retained across all storage groups for 4 weeks, except for the air storage group. This study concludes that storage in DIW effectively preserves the enhanced surface properties of plasma-activated zirconia for up to 4 weeks.

Thermal stability and anti-ablation performance of plasma spray coated-YSZ on Al2TiO5 modified novel ablative carbon-phenolic composites

Abstract Despite ongoing challenges, ablative thermal protection systems are among the most promising methods for safeguarding spacecraft during re-entry thermal protection systems (TPS). A novel aluminium titanate (Al2TiO5/AT) and a highly efficient thermal barrier of coating (TB/TBCs) made from yttria-stabilized zirconia (YSZ), powder, but deposited using the plasma spray technique on polyacrylonitrile (PAN)-based carbon fiber fabric(C)-reinforced with resorcinol phenol formaldehyde resin (RF) composites (C-RF)) would be a potential candidate for TPS applications. This study investigates the composites with varying wt.% of AT that were developed, namely 0 wt.% (YSZ-C-RF), 1 wt.%, 3 wt.%, and 5 wt.% (YSZ-AT-C-RF) by utilizing a hot press moulding machine. Thermal stability and ablation performance of unmodified C-RF with modified YSZ-C-RF and YSZ-AT-C-RF composites are examined through thermogravimetric analysis (TGA) and oxyacetylene torch test/OAT (4.0 MW/m2 for 60 sec). Also, the phase composition and microstructure of the ablated surface are determined by X-ray diffraction (XRD) and scanning electron microscopy (SEM) techniques. The TBC of YSZ has an obvious influence on the residual weight ratios at high temperatures in C-RF and also plays a positive role in increasing thermal stability under nitrogen atmosphere for enhancing ablation resistance concerning YSZ-C-RF. The mass and linear ablation rates (MAR and LAR) of the composites after modifying the surface by YSZ-coated particles are reduced by 82.98% and 15.65%, respectively. Similarly, the introduction of AT particles and TBC of YSZ results in evidence of improving the thermal stability and the ablation resistance in varying wt.% of YSZ-AT-C-RF composites. The primary optimum AT weight loading for enhancing ablation resistance in YSZ-C-RF composites is 1wt.%. The modification of 1wt.% AT particles and YSZ-Coated particles reduce MAR and LAR by 54.79% and 61.94%, respectively. This work offers a meaningful method to remarkably enhance the ablation performance of the modified C-RF and YSZ-AT-C-RF composites.

High-Performance Composite Membranes: Embedding Yttria-Stabilized Zirconia in Polyphenylene Sulfide Fabric for Enhanced Alkaline Water Electrolysis Efficiency.

Due to their excellent alkali resistance and chemical stability, polyphenylene sulfide (PPS) fabric membranes are widely used in alkaline water electrolysis (AWE) for hydrogen production. However, traditional PPS membranes suffer from poor hydrophilicity, low airtightness, and high area resistance, resulting in high energy consumption and reduced safety in industrial applications. This study addresses the aforementioned issues by coupling 3-(2,3-epoxy propoxy) propyl trimethoxy silane (KH560) via self-condensation to the PPS membrane and blending it with self-synthesized yttrium-stabilized zirconia nanoparticles (YSZNPs). The YSZNPs are loaded onto the modified PPS fiber surface through dip-coating and hot-pressing processes, forming a micro-mechanical interlocking structure that enhances the overall performance of the membrane in practical hydrogen production applications. The findings indicate that the developed composite membrane demonstrate outstanding hydrophilicity, minimal area resistance (0.21 Ω cm2), and elevated bubble point pressure (2.93224bar). Significantly, tests on gas purity indicate that the produced hydrogen and oxygen attain purities of 99.90% and 99.75%, respectively, when evaluated at a current density of 1.5 A cm-2. Moreover, after 500h of electrolysis testing in a simulated industrial environment, minimal decline in membrane performance is observed, highlighting the competitive edge of this composite membrane in the current AWE market.

Impact of Speed Sintering on Translucency, Opalescence and Microstructure of Dental Zirconia with a Combination of 5 mol% and 3 mol% Yttria-Stabilized Zirconia

Optical characteristics and microstructure of multilayered zirconia with different yttria contents in each layer can be influenced differently with a layer after speed sintering. The layer-wise translucency and opalescence of dental zirconia (E.max, E.max ZirCAD prime; Cercon, Cercon ht ML) after conventional (control) and speed sintering were analyzed using a spectrophotometer (n = 5). Specimens were subjected to microstructural analyses (n = 2) using field-emission scanning electron microscopy (FE-SEM) and phase analyses (n = 1) using high-resolution X-ray diffraction (HRXRD) and Rietveld refinement. The translucency parameter (TP) and opalescence parameter (OP) were analyzed using a 3-way ANOVA, followed by Scheffé’s post hoc test (α = 0.05). The average grain size was analyzed using the Welch’s t-test and Kruskal–Wallis test, followed by the Bonferroni–Dunn post hoc test (α = 0.05). Changes to the TP and OP after speed sintering were only observed in the dentin layers. Although the TP of E.max increased (p < 0.05), the difference was below the 50:50% perceptibility threshold (ΔE00 = 0.8). The OP of E.max decreased slightly, whereas that of Cercon increased slightly (p < 0.05). The microstructure and phase fraction of both zirconia barely changed. Therefore, speed sintering is considered to have a negligible clinical impact on the optical characteristics and microstructure.

Enhancing microstructure homogeneity and electrical conductivity in flash-sintered 8YSZ: Impact of electric-current ramp control and thermal insulation

Our study aimed to comprehend how variations in flash sintering parameters affect the evolution of microstructure and electrical properties of yttria-stabilised zirconia. For this purpose, cylindrical samples were sintered via a classic flash method (voltage-current control), with controlled increase in the current ramp, employing thermal insulation, and combining current ramp control with thermal insulation. The results demonstrated that the combination of current ramp control and thermal insulation yielded higher densification compared to other variations. Microstructural analysis revealed finer grain sizes and lower grain-boundary tensions on employing current ramp control, particularly when combined with thermal insulation. For all flash-sintering methods, greater electrical conductivity of grain boundaries was observed compared to conventional sintering, suggesting an enhancement in ionic conduction. This study underscores the potential of customised FS techniques in optimising sintering processes and enhancing material properties.

Direct observation of space-charge-induced electric fields at oxide grain boundaries.

Space charge layers (SCLs) formed at grain boundaries (GBs) are considered to critically influence the properties of polycrystalline materials such as ion conductivities. Despite the extensive researches on this issue, the presence of GB SCLs and their relationship with GB orientations, atomic-scale structures and impurity/solute segregation behaviors remain controversial, primarily due to the difficulties in directly observing charge distribution at GBs. In this study, we directly observe electric field distribution across the well-defined yttria-stabilized zirconia (YSZ) GBs by tilt-scan averaged differential phase contrast scanning transmission electron microscopy. Our observation clearly reveals the existence of SCLs across the YSZ GBs with nanometer precision, which are significantly varied depending on the GB orientations and the resultant core atomic structures. Moreover, the magnitude of SCLs show a strong correlation with yttrium segregation amounts. This study provides critical insights into the complex interplay between SCLs, orientations, atomic structures and segregation of GBs in ionic crystals.

Fine-Grain High-Performance Densified Oxide Fibers Produced by Open Ultrafast High-Temperature Sintering.

The considerable grain growth occurring during the long-term high-temperature sintering of polycrystalline oxide fibers negatively affects their mechanical properties, which highlights the need for alternative sintering methods. Herein, open ultrafast high-temperature sintering (OUHS) in air, characterized by rapid heating/cooling (>10000 K min-1) and a short high-temperature holding time (<10 s), is used to produce 3 mol% yttria-stabilized zirconia continuous fibers with coherent boundaries forming robust connections between fine grains. The tensile strength of these fibers (2.33GPa on average, sintering temperature = 1673 K) notably exceeds that of their counterparts produced by traditional sintering (1.17GPa). The effects of pores on fiber mechanicalproperties are analyzed using experimental and theoretical methods. For a versatility demonstration, OUHS is applied to several types of polycrystalline oxide fibers (HfO2, Al2O3, TiO2, Y2O3, and La2Zr2O7), considerably improving their mechanical properties and enabling crystalline phase control, which demonstrates the suitability of this procedure for the development of high-performance materials.

Effect of Process Parameters on Yttria‐Stabilized Zirconia Particles In‐Flight Behavior and Melting State in Atmospheric Plasma Spraying

The preparation of coatings by atmospheric plasma spraying gives rise to complex physical processes, which present challenges to the study of plasma jet characteristics and particle in‐flight behavior. Herein, a 3D numerical model that integrates multiple physical phenomena, including electromagnetism and thermal and gas dynamics, to simulate the heating, acceleration, and melting of particles under the thermal–mechanical effect, is developed. Meanwhile, yttria‐stabilized zirconia (YSZ) coatings are prepared under varying process parameters. The DPV‐2000 system is employed for the diagnosis of particle velocity, surface temperature, and diameter. Following comparison, the simulation exhibits errors of 4.5% and 14.8% for the maximum temperature and velocity, respectively. An increase in current intensity from 500 to 600 A results in a rise in the proportion of particles exhibiting temperatures above the melting point (2963 K), from 75.1 to 93.4%, accompanied by an increase in average velocity of ≈16.6%. As the spraying distance increases from 60 to 100 mm, the proportion of particles melting decreases from 93.5 to 66.3%, and the average velocity decreases by ≈9.2%. This work will provide a theoretical foundation for the optimization of process parameters to adjust particle behavior and melting state, thus achieving an optimal spraying effect.

Improving hot corrosion behaviour of Cr3C2-25NiCr coatings by reinforcing nano yttria stabilized zirconia at 850 °C

Yttria-Stabilized Zirconia (YSZ)-enhanced Cr3C2-25NiCr coatings were applied to T22 boiler tube steel using the High Velocity Oxy Fuel (HVOF) method. Conventional Ni-20Cr, 5 wt.% YSZ- Cr3C2-25NiCr, and 10 wt.% YSZ- Cr3C2-25NiCr composite coatings were prepared. High-temperature corrosion tests were conducted on both uncoated and coated samples in a Na2SO4-60%V2O5 environment at 850°C under fluctuating thermal conditions. These experiments were carried out in a silicon tube furnace at high temperatures, with each sample subjected to 50 cycles of exposure. Each cycle consisted of 1 hour in the corrosive environment followed by 20 minutes of cooling at room temperature. Corrosion products were analyzed using energy-dispersive x-ray analysis (EDS) and scanning electron microscopy (SEM). The addition of YSZ to the Cr3C2-25NiCr coatings significantly improved corrosion resistance, with the Ni-20Cr, 5 wt.% YSZ-Ni-20Cr, and 10 wt.% Cr3C2-25NiCr coatings reducing overall weight gain by 73.08%, 84.70%, and 89.96%, respectively, compared to uncoated T22 steel.

Tensile Properties and Coefficient of Thermal Expansion of Laser Powder Bed Fusion Fabricated IN718‐YSZ Compositionally Graded Composite

The microstructure, tensile properties, and thermal expansion characteristics of a laser powder bed fusion (LPBF) manufactured compositionally graded composite with 0.5–8 wt% yttria‐stabilized zirconia (YSZ) reinforced Inconel 718 are investigated. Along the composition gradient, which is perpendicular to the build direction, in all cross sections, the YSZ segregates at the melt‐pool boundaries and the IN718 matrix has randomly oriented equiaxed grains. Cross sections with &gt;2 wt% YSZ contain significant porosity (&gt;2%) and solidification cracks, which reduces their strength and ductility significantly. In the section with 1.5 wt% YSZ, the YS, UTS, and ductility are 819 ± 30, 1008 ± 40, and 7.4 ± 0.4 MPa, which matches well with that of LPBF fabricated YSZ‐free IN718. Dilatometry measurements on sections with 0.5–1.5 wt% YSZ in the temperature range of 25–1200 °C indicate that their coefficient of thermal expansion (CTE) is intermediate to that of IN718 and YSZ. Finally, the variations in CTE with temperature are discussed in detail by considering the microstructural evolution in the composite with changes in temperature.

Physical and microstructural properties of YSZ + Cr2O3 thermal barrier coatings developed using HVOF technique

A composite coating material of Yttria-Stabilized Zirconia (YSZ) and Chromium Oxide (Cr2O3) was developed on the surface of Al-6061 substrates. The coating consisting of equal measures of the composite material of YSZ and Cr2O3 was successfully obtained using the High-Velocity Oxy Fuel (HVOF) technique. The surface roughness and coating thickness of the composite coatings are evaluated. The surface roughness (Ra) was evaluated showing an average of 6.0848 µm using the Surface Roughness Tester (SRT). The coating thickness was evaluated showing an average of 220.8 µm using the Coating Thickness Tester (CTT). The surface roughness and the coating thickness obtained are comparable to typical physical properties of Thermal Barrier Coatings (TBC’s). The microstructural evaluation of the coated specimens was performed through the Scanning Electron Microscope (SEM), showing the clear unification of materials The determination of the elemental composition of surface coatings was performed through the EDAX tests, which clearly established the elements in the coatings. This article is indicative of the achievement of TBC’s consisting of composite materials though HVOF technique as an alternative to TBC’s obtained through surface coats and bond coats.

Impact of atmospheric plasma spraying parameters on microstructure, mechanical properties and thermal cycling performance of YSZ coatings

Yttria-stabilized zirconia (YSZ) coatings are widely utilized thermal protective layers for metal and superalloy surfaces. These coatings are employed as thermal barrier coating (TBCs) to insulate metallic parts from higher thermal energy, thereby minimizing the cooling need for the topcoat ceramic layer. The choice of material is 7 wt% YSZ due to its exceptional capability to withstand challenging conditions characterized by extremely high temperatures and pressures, typically employed by the atmospheric plasma spraying (APS) in gas turbines, effectively extending their lifespan and improving performance. The deposition process of TBCs is significantly influenced by various spraying parameters, including gas flow rate and current (amp). These key parameters mutually play a significant role in controlling thermal stability, phase composition, and improved mechanical and microstructure properties. The aim of this research is to evaluate and contrast the impact of various spraying parameters on YSZ TBC performance. Accordingly, the influence of Hydrogen (H2), Argon (Ar) flow rate, and Current (amp) was investigated. Microstructure and elemental mapping studying was conducted using Field Emission Scanning Electron Microscopy FESEM/EDS and phase studying was examined with X-ray diffraction (XRD). Porosity was measured by IMAGE J software while hardness measurement was calculated by Vickers hardness tester. Additionally, thermal cycling tests were conducted between 700 °C and 1200 °C. The porous coatings exhibited poor performance, delaminating early during the tests. In contrast, dense coatings performed significantly better, enduring up to 140 cycles before failure.

Comprehensive study of the effect of Hf and Ta co-doped MCrAlY bond coat on the high-temperature properties of thermal barrier coating

The MCrAlY bond coat is modified by reactive element (RE) Hf and refractory element Ta, and the high-temperature oxidation resistance of the thermal barrier coating (TBC) before and after the modification are investigated by comparative experiments. The experiments use high-velocity oxygen-fuel (HVOF) to prepare NiCoCrAlY and NiCoCrAlYHfTa bond coats on the surface of GH4099 high-temperature alloy, and then yttrium stabilized zirconia (YSZ) ceramic layers are prepared on the surface of the bond coat by atmospheric plasma spraying (APS), and cyclic oxidation is carried out in air at 1050 °C until failure. It is shown that the oxidation lifetime of the modified TBC reached 1992 h, which is one time higher than that of the unmodified TBC. The doping of Hf and Ta elements reduces the growth rate of the oxide layer, and these diffuse externally and combine with the internally diffused O to form HfO2 and Ta2O5 in the thermally grown oxide (TGO) layer, thereby improving the adhesion and mechanical properties of the oxide layer. In addition, the bond strength and thermal shock resistance of the TBCs are significantly improved after doping with Hf and Ta elements, which prolongs the lifetimes of the TBCs. In this paper, the morphology, structure, and properties of the modified TBCs are characterized to investigate the mechanism of the oxidation lifetime extension.

Enhanced densification and phase transformations during rapid microwave sintering of alumina – yttria-stabilized zirconia ceramics

Alumina – 7.5wt. % yttria-stabilized zirconia (YSZ) ceramic composites were sintered using 24GHz microwave heating at rates of 10 – 200°C/min with zero isothermal hold. The starting powders were nanophase η-Al2O3 and YSZ prepared by a laser evaporation method. The final densities of the sintered samples were up to 97.5% of the theoretical value. The samples exhibited rapid densification until transformation to the α-Al2O3 phase. The temperature of the densification rate peak (and hence of the phase transformation) decreased consistently with increasing microwave electromagnetic field intensity (varied by using different susceptor materials). The densification peak temperature difference between microwave and conventional sintering experiments exceeded 200 °C.