Latest ArticlesContinuous alumina fibers show a great potential for high-temperature insulation and debris shielding in spacecraft. Their advantages include high strength, high modulus, and excellent oxidation resistance at high temperatures. The sol-gel method is the main process for producing these fibers. This method involves several steps, i.e., thermal decomposition, phase transformation, densification, and grain growth. These steps make it difficult to precisely control the fiber microstructure and optimize the mechanical properties.
This review summarizes recent development on controlling the microstructures of alumina fibers. These include selecting appropriate precursors, optimizing processing parameters, and using sintering aids. Sol-gel precursors are usually formed via hydrolyzing and condensing inorganic aluminum salts, carboxylates, or alkoxides. Gelation proceeds by natural aging or concentration, resulting in three-dimensional networks. After dry spinning or electrospinning, pre-sintering removes most organics. Residual hydroxyl groups are eliminated at high temperatures, affecting fiber densification. Metastable alumina phases convert to a stable α-Al2O3 at approximately 1200 ℃ because of a high energy barrier. Additives such as α-Fe2O3, α-Al2O3, or α-Cr2O3 aid nucleation and increase nucleation density. The phase transformation process produces a stable α-Al2O3 phase, but at this stage the material still contains a significant amount of porosity, resulting in a poor mechanical strength. Producing dense, high-performance alumina fibers requires high-temperature treatment for mass transport and pore removal. However, densification and grain growth occur together. A rapid grain growth at high temperatures can trap pores, making their removal difficult. Understanding and balancing the relationship between the two is thus central to the sintering process. The strategies to restrain grain growth and control microstructure include two-step sintering and the addition of SiO2, MgO, or ZrO2.
This review also briefly addresses the mechanisms underlying the performance degradation of alumina fibers under high-temperature service conditions. The microstructural evolution of alumina fibres under high-temperature conditions exerts a dominant influence on their mechanical properties. Regarding failure induced by abnormal grain growth in single-phase alumina fibers at high temperatures, the incorporation of a second phase can regulate fiber microstructure and mechanical properties. For instance, within the Al2O3-SiO2 system, Nextel 720 fibers demonstrate markedly a superior high-temperature creep resistance, compared to Nextel 610 fibers. Nevertheless, studies on the creep failure behavior of such fibers remain limited. Based on the systematic microstructural characterization of high-performance alumina fibers, the elucidation of microstructural evolution mechanisms during sol-gel synthesis, and the in-depth analysis of the intrinsic relationships between microstructural evolution and mechanical property degradation under high-temperature service conditions, this review establishes a theoretical foundation for the fabrication of high-performance continuous alumina fibers and promotes their engineering application in extreme environments.
This review systematically represents recent advances on the sol-gel synthesis of high-performance continuous alumina fibers. The analysis reveals that a precise control of microstructural characteristics, such as grain size, phase composition, and grain boundary properties, can profoundly affects the mechanical properties and high-temperature performance of the fibers. However, some substantial challenges persist in understanding the mechanisms of alumina fiber formation, achieving a precise process control, and enhancing performance in extreme environments. Accordingly, future research should focus on the following directions:
1) Transitioning from empirical trial-and-error to theoretically guided design via developing multiscale simulation techniques to inform holistic process optimization during fiber fabrication. Computational simulations can uncover underlying mechanisms to enable theory-driven fiber design. In an atomic scale, first-principles calculations and molecular dynamics simulations can reveal grain boundary segregation behavior of sintering aids such as rare-earth oxides. molecular dynamics can also simulate atomic rearrangement during α-Al2O3 phase transformation, clarifying heterogeneous nucleation mechanisms induced by iron sol additions. In a mesoscale, phase-field modeling can dynamically simulate densification-grain growth competition, grain boundary pinning by secondary phases, and defect evolution. In a macroscale, the fiber service failure can be simulated to correlate predicted microstructures to mechanical properties.
2) Advancing from static cross-sectional observation to dynamic in-situ characterization via developing advanced in-situ techniques to directly elucidate fiber microstructural evolution mechanisms. The existing understanding of microstructural evolution relies largely on static examination of samples from different processing stages, rendering direct validation difficult and many conclusions speculative. Future work should emphasize in-situ experimental methods applicable to both the preparation and service of alumina fibers, enabling the real-time observation of microstructural evolution.
3) Bridging a gap between laboratory samples and industrial products via addressing challenges in continuity, stability, and cost efficiency in fiber manufacturing. Future efforts should focus on developing online monitoring and feedback systems for precursor sols to maintain viscosity and spinnability, advancing intelligent temperature and tension control to minimize fiber bending damage while collecting real-time data on the effects of thermal and tensile variations and exploring low-cost alternative aluminium sources paired with optimized sintering protocols to reduce energy consumption.
4) Addressing next-generation application requirements via investigating fiber performance limits under ultra-high-temperature, long-duration service conditions and developing novel reinforcement strategies. Systematic studies should be conducted on creep mechanism transitions, grain boundary evolution, and the performance degradation mechanisms in high-temperature environments such as steam and air.
The construction industry faces a dual-challenge of achieving rapid early-age strength development in cement-based materials, while ensuring a long-term durability, which is further complicated due to the demand for reduced carbon emissions. Conventional approaches (i.e., using chloride-based accelerators or steam curing) often compromise later-age performance or incur high energy costs. Calcium silicate hydrate (C-S-H) as a primary binding phase in cement dictates the evolution of both microstructure and macroscopic properties. Consequently, controlling its early formation is a key to enhancing performance. Nanotechnology offers a promising solution, with C-S-H based nano-seeds gaining significant attention due to their compositional and structural similarity to the C-S-H gel. These seeds provide a low-energy nucleation substrate, effectively shifting the nucleation pathway from the surface of cement grains to the pore solution, thereby accelerating hydration without the negative effects associated with conventional methods.
However, the practical application of C-S-H nano-seeds is hindered by their high surface energy, leading to severe agglomeration and reduced efficiency. To overcome this, polycarboxylate ether (PCE) superplasticizers are employed as dispersants. The resulting C-S-H/PCE nanocomposites combine a nucleation effect of C-S-H with a dispersing ability of PCE, forming a stable suspension that represents a significant advancement in the field. Although the existing reviews discuss C-S-H nano-seeds, a comprehensive overview dedicated specifically to the design, mechanisms, and performance of C-S-H/PCE nanocomposites and their recently developed derivatives is lacking.
This review systematically summarizes recent progress on C-S-H/PCE nanocomposites. The interaction between C-S-H and PCE is primarily governed by surface adsorption, where carboxylate groups on the PCE backbone coordinate with calcium ions on the C-S-H surface. This interaction, combined with the steric hindrance of PCE side chains, stabilizes the nanoparticles and affects the non-classical nucleation pathway of C-S-H, leading to the formation of smaller, more uniform particles.
The synthesis of these nanocomposites, typically via co-precipitation, is critically examined. Key parameters such as pH value, reactant concentration, and calcium-to-silicon ratio are identified as crucial for controlling particle size, morphology, and subsequent seeding efficiency. Furthermore, the molecular structure of the PCE dispersant (i.e., functional groups, side-chain length and density, and topology) can be tailored to optimize the nanocomposite's properties. Furthermore, novel nanocomposites incorporating aluminum, magnesium, or iron into the C-S-H structure, such as C-A-S-H/PCE and C-M-S-H/PCE, are developed. These next-generation materials demonstrate enhanced stability and superior nucleation seeding effects, paving a way for high-performance and sustainable applications.
The mechanism by which these nanocomposites accelerate cement hydration is elaborated as a dual-action. They adsorb calcium and silicate ions from the dissolving clinker, lowering the supersaturation threshold for nucleation, and they provide a multitude of low-energy sites for the precipitation of new C-S-H gel directly within the pore space. This process significantly shortens the induction period, accelerates early hydration, and leads to a more uniform and densified microstructure. Importantly, this seeding effect does not compromise a long-term strength development. Instead, it can enhance durability via refining the pore structure. The efficiency of this process is affected by both intrinsic factors (i.e., the specific surface area of the nano-seeds), and extrinsic factors (i.e., dosage, water-to-cement ratio, and curing temperature).
The synergistic effects of combining C-S-H/PCE nanocomposites with other chemical admixtures are also discussed. The combination with sodium sulfate exhibits a pronounced "1+1>2" effect in low-cement systems, where the sulfate accelerates the dissolution of supplementary cementitious materials, while the seeds provide nucleation sites for the hydration products. The similar synergistic mechanisms are analyzed with organic accelerators like triethanolamine, though a careful optimization is required to avoid negative interactions.
Finally, the application of C-S-H/PCE nanocomposites across various cementitious systems is reviewed. They prove effective in ordinary Portland cement and in blended systems with fly ash, slag, and calcined clay. Their ability to provide a high early strength without sacrificing later-age performance makes them suitable for a range of applications, including low-temperature construction, emergency repairs, non-steam-cured precast concrete, and high-volume solid-waste binders, contributing to reduced energy consumption and carbon footprint in the construction sector.
C-S-H/PCE nanocomposites represent a significant advancement over conventional accelerators, offering a synergistic approach to enhance early-age strength and durability in cement-based materials. This review systematically discusses the fundamental understanding of their synthesis, the complex interplay between C-S-H and PCE, their unique nucleation seeding mechanism, and the factors governing their performance. The development of novel metal-doped nanocomposites and the exploration of synergistic combinations with other admixtures expand their potential and effectiveness across diverse cementitious systems. These materials demonstrate clear advantages in enabling rapid strength development, improving microstructure, and facilitating sustainable construction practices with reduced clinker content. Despite these advances, several critical gaps remain. A deeper understanding of the dynamic evolution, migration, and in-situ behavior of these nanocomposites within the complex chemical environment of hydrating cement paste is urgently needed. Future research should focus on imparting multifunctionality to these materials, such as self-healing or responsive properties, to create smarter and more durable concrete. The development of cost-effective, scalable, and sustainable synthesis methods, potentially utilizing industrial by-products, is essential for widespread adoption. Leveraging advanced computational tools like molecular dynamics simulations and machine learning can be instrumental in accelerating the rational design and optimization of the next generation of these high-performance nanomaterials.
The interfaces in cement-based materials and their structures(i.e., the cement paste-aggregate, mortar-aggregate, new-to-old concrete, and reinforcement-concrete interfaces) are widely recognized as the most critical and weakest zone governing overall mechanical properties and durability. Under the combined influence of wall, one-sided growth, and bleeding effects, these interfaces are typically characterized by high porosity, elevated calcium hydroxide (CH) crystal content, and a high degree of hydration, resulting in intrinsically low hardness and strength. As a result, cracks initiate, propagate, and interconnect within the interfaces under loading, leading to a macroscopic failure. Meanwhile, their loose and porous structure facilitates the ingress of water and harmful ions, reducing durability and accelerating deterioration.
For the pronounced multi-scale nature of cement-based materials, modifying microstructure in nanoscale provides an effective "bottom-up" approach to improving interfacial bond and overall performance. Compared with conventional top-down methods, this strategy exhibits effective modification for different types of interfaces. With the rapid development of nanotechnology, incorporating nanofillers demonstrates a great potential in interfacial modification. This review represents the effects and underlying mechanisms of nanofillers on the interfaces in cement-based materials and their structures, as well as discusses key challenges and future research directions.
Adding nanofillers can significantly enhance the bond performance of various interfaces in cement-based materials and their structures. The experimental studies show that the incorporation of nanofillers can increase the bond strength of cement paste-aggregate and mortar-aggregate interfaces by 65.3% and 42.8%, respectively. Also, nanofillers effectively enhance the bond of new-to-old cement-based materials, increasing interfacial strength by 39.0%. Their beneficial effects are evident in the interfaces between reinforcements and cement-based materials, where the addition of nanofillers improves bond strength and reduces slip behavior. These modifications contribute to a high stress transfer efficiency, as well as better load-bearing capacity and structural stability. The enhancement efficiency is closely related to the geometric dimensionality of nanofillers, generally following an order, i.e., two-dimensional (2D) > one-dimensional (1D) > zero-dimensional (0D).
The improved bond performance derives from the modified interfacial characteristics. Key effects include increased compactness, reduced porosity, refined CH crystal size, and decreased interfacial thickness. For instance, the thickness of the interfacial transition zone can be reduced from approximately 50 µm to 10 μm or less after nanomodification, as reflected by the reduced porosity and altered Ca/Si ratio of calcium silicate hydrate (C-S-H) gels. Meanwhile, nanofillers also suppress the formation and growth of large CH crystals, replacing them with finer and more uniformly distributed hydration products. Micromechanical characterization techniques such as nanoindentation and atomic force microscopy reveal significant increases in elastic modulus and hardness in the interfacial zone, indicating that new hydration products like superhard C-S-H gels induced by nanomodification are formed.
The mechanisms underlying nanofiller-induced interfacial modification can be categorized into two key aspects, i.e., the enrichment effect and the nano-core effect. The enrichment effect arises from the preferential accumulation of nanofillers in the interfacial region due to the wall effect, capillary-driven migration, and gravity effect. This leads to a higher local concentration of nanofillers, providing abundant nucleation sites for hydration products. The nano-core effect, which builds upon the intrinsic properties of nanofillers, involves several specific mechanisms, i.e., (1) Adsorption effect: Nanofillers adsorb cations such as Ca2+ and Mg2+, promoting the nucleation of C-S-H and leading to the formation of nano-core-shell elements. These structures inhibit the oriented growth of CH crystals and enhance interfacial densification; (2) Filling effect: Nanofillers fill interfacial pores through the formation of nano-core-shell elements, improving packing density and reducing porosity; (3) Short-range and long-range effect: Nanofillers can modify the nanostructure and properties of hydration products in a short range, and refine and optimize the hydration products near nanofillers in a long range; (4) Pozzolanic effect: Reactive nanofillers, such as nano-silica, react with CH to generate additional C-S-H, refining the microstructure and improving bonding; (5) Thermal conductivity effect: High-conductivity nanomaterials (e.g., carbon nanotubes, graphene) homogenize the temperature distribution during hydration, reducing thermal stress and early-age cracking; (6) Self-curing effect: Hydrophilic nanomaterials, such as nanocellulose, absorb and release water, mitigating early-age shrinkage and enhancing microstructural development; and (7) Pinning and bridging effects: Nanofillers inhibit crack initiation and propagation (pinning effect) and bridge microcracks (bridging effect), thereby improving interfacial toughness and strength.
Despite significant achievements, several challenges remain in understanding and optimizing nanofiller-modified interfaces. First, the existing characterization techniques are limited in their ability to capture the dynamic evolution of interfacial structures at high spatial and temporal resolution. Most methods provide only static, two-dimensional information, making it difficult to fully understand multi-scale and multi-physics processes. Second, the inherent heterogeneity and discontinuity of interfaces complicate quantitative modeling. The existing models often describe average behavior, but fail to capture local weak zones or nanoscale force transfer mechanisms. Third, the introduction of multifunctional nanofillers increases the complexity of multi-field coupling (i.e., mechanical, thermal, chemical, and electrical), posing challenges for unified theoretical frameworks. Finally, the large-scale engineering application of nanomodified interfaces is hindered by some issues such as nanofiller dispersion, cost, and performance stability under complex service conditions.
Future research should focus on several key directions. Advanced characterization techniques with a high spatiotemporal resolution, such as synchrotron radiation-based imaging and X-ray computed tomography, should be developed to enable real-time tracking of interfacial evolution. The integration of artificial intelligence and machine learning can facilitate high-throughput data analysis and predictive modeling, enabling a quantitative design of interfacial properties. Multi-scale theoretical frameworks that link material composition, microstructure, and macroscopic performance are needed to achieve accurate prediction and optimization. Also, efforts should be made to translate laboratory findings into practical engineering applications, particularly in emerging areas such as 3D-printed concrete, recycled concrete, concrete repair, and self-healing cement-based materials.
In summary, nanomodification is demonstrated to effectively tailor interfaces in cement-based materials and their structures, while the enrichment effect and nano-core effect is proposed to clarify the underlying mechanisms. These advances provide a foundation for mitigating the inherent weakness of interfaces. Despite these advances, some challenges remain in terms of characterization, quantitative modeling, and large-scale application. Nevertheless, continued progress in nanotechnology, multi-scale analysis, and intelligent design is expected to enable the rational design and engineering of high-performance, durable, and multifunctional cement-based materials and their structures.
With the increasing depth of oil and gas exploration, high-temperature and high-pressure conditions become common in deep and ultra-deep wells. Under such harsh environments, the long-term integrity of wellbore cement is frequently compromised due to the strength retrogression, posing serious risks to zonal isolation and production safety. Although silica sand is widely used to mitigate strength degradation via modifying the Ca/Si ratio of hydration products, recent studies show that significant strength loss still occurs at ultra-high temperatures.
Previous studies focused on curing regimes involving low-temperature pre-curing followed by high-temperature exposure, which mainly represent upper wellbore conditions. However, in deeper sections of high-temperature wells, cement typically sets and cures directly at elevated temperatures, resulting in more severe degradation. In addition, low-density cement is widely applied in cementing operations, its long-term performance under such conditions remains insufficiently understood, particularly beyond short-term curing periods. This study was to investigate the long-term performance evolution and underlying mechanisms of low-density sand-added oil well cement under different high-temperature conditions, providing a guidance for the design of durable cement systems for deep well applications.
Six low-density cement slurry formulations with a target density of 1.6 g/cm3 were designed, incorporating silica sand, silica fume, and hollow glass microspheres. Two curing regimes were adopted to simulate different downhole environments, i.e., (1) direct curing at 180 ℃ to represent high-temperature deep well conditions, and (2) curing at 80 ℃ for 2 d and then long-term curing at 180 ℃ to simulate upper wellbore conditions. The long-term performance of cement samples was evaluated after curing at 180 ℃ for 2, 30 d, and 90 d, respectively. The compressive strength, Young's modulus, and permeability were measured to assess macroscopic properties. The microstructural and mineralogical evolution was characterized by mercury intrusion porosimetry (MIP), X-ray diffraction (XRD), thermogravimetric analysis (TG), and scanning electron microscopy (SEM), enabling a comprehensive analysis of pore structure development and hydration product transformation.
The results indicate that curing conditions have a decisive influence on the long-term performance of low-density cement systems. Under direct high-temperature curing at 180 ℃, all formulations exhibit severe strength retrogression. The compressive strength of silica sand-based systems remains approximately 28 MPa within 30 d, but decreased to below 10 MPa after 90 d. The incorporation of hollow glass microspheres significantly enhances the early strength (i.e., up to 45 MPa at 2 d). However, these systems experience a rapid deterioration, with strength nearly disappearing after 30 d. In contrast, the samples subjected to low-temperature pre-curing and followed by high-temperature exposure show significantly improved stability. For formulations without hollow glass microspheres, the compressive strength remains stable or slightly increases for 90 d. However, the systems containing hollow glass microspheres still exhibit a noticeable strength reduction, indicating their limited suitability for high-temperature applications. The evolution of Young's modulus and permeability is consistent with the strength results. Under direct high-temperature curing, Young's modulus decreases markedly, while permeability increases in orders of magnitude, indicating severe degradation of structural integrity. Conversely, under low-temperature pre-curing conditions, the parameters both remain relatively stable, reflecting an improved durability. The microstructural analysis reveals that pore structure coarsening plays a key role in the performance degradation. Under direct high-temperature curing, the median pore size increases significantly from tens to hundreds of nanometers, accompanied by a transformation from harmless pores to harmful large pores. In contrast, the samples subjected to low-temperature pre-curing exhibit slower pore coarsening and more stable pore size distributions. The mineralogical evolution further explains the observed macroscopic behavior. Under direct high-temperature curing, beneficial amorphous hydration products and tobermorite gradually transform into more crystalline phases such as xonotlite, leading to the strength loss. The thermogravimetric analysis confirms significant changes in decomposition peaks, indicating alterations in hydration product composition. In contrast, under low-temperature pre-curing conditions, the content of amorphous phases and tobermorite remains relatively stable, contributing to sustained mechanical performance. The SEM images show that hollow glass microspheres progressively react and disappear under prolonged high-temperature exposure, leaving large voids that significantly deteriorate the microstructure. Although these microspheres enhance the early strength, their long-term effect is detrimental due to the pore enlargement and structural weakening.
This study demonstrated that curing conditions critically affected the long-term performance of low-density sand-added oil well cement. Direct high-temperature curing led to severe strength retrogression, pore structure coarsening, and unfavorable phase transformations, whereas low-temperature pre-curing significantly improved long-term stability. Hollow glass microspheres were effective in enhancing early strength but are not suitable for high-temperature applications due to their negative impact on long-term durability. The stability of hydration products, particularly amorphous phases and tobermorite, could be identified as a key factor governing strength retention. These findings could provide important insights into the design of durable cement systems for high-temperature oil and gas wells and highlight the necessity of considering both curing conditions and material composition in practical applications.
Low-temperature co-fired ceramic (LTCC) technology becomes a cornerstone in the fabrication of high-frequency, high-density microelectronic devices. However, a critical challenge lies in a thermal expansion mismatch between conventional LTCC substrates (typically <7 × 10-6 ℃-1) and printed circuit boards (PCBs, 12-16 × 10-6 ℃-1), leading to interfacial delamination and compromised reliability. To address this issue, developing LTCC materials with high and linear thermal expansion coefficients is essential. Among some potential candidates, BaO-B2O3-SiO2 glass-ceramics stand out due to their tunable properties and relatively high thermal expansion. Nevertheless, achieving dense sintering at < 900 ℃, while maintaining a high thermal expansion coefficient (>11 × 10-6 ℃-1), remains a key obstacle. This study was to investigate the synergistic effects of incorporating CaO and SrO into BaO-B2O3-SiO2 glass-ceramics on the sintering behavior, crystallization characteristics, and overall performance for LTCC applications.
Four glass compositions were designed based on the BaO-B2O3-SiO2 system at different additions of CaO and SrO (in mole fraction), i.e., BBS1 (baseline), BBS2 (with 10% CaO), BBS3 (with 10% SrO), and BBS4 (with 5% CaO and 5% SrO). Raw materials including BaCO3, CaCO3, SrCO3, H3BO3, and SiO2 were melted at 1400 ℃ for 2 h, quenched, and ground into powders with a consistent particle size (D50 ≈ 5 μm). The powders were pressed into pellets and bars, then sintered at 800 ℃ for 20 min. The sintering behavior was analyzed by high-temperature microscopy and dilatometry. The glass transition (Tg) and crystallization (Tc) temperatures were determined by differential scanning calorimetry (DSC). The phase identification and crystallinity were evaluated by X-ray diffraction (XRD), and the microstructural features were characterized by scanning electron microscopy (SEM) and Raman spectroscopy. The thermal expansion, density, dielectric properties, flexural strength, and hardness were measured to assess the performance of the sintered glass-ceramics.
The introduction of CaO and SrO significantly lowers the onset (Tfs) and maximum shrinkage (Tms) temperatures, with SrO having a more pronounced effect. For instance, Tfs decreases from 720 ℃ (BBS1) to 654 ℃ (BBS3), and Tms decreases from 794 ℃ to 761 ℃. This indicates enhanced sintering kinetics due to the larger ionic radius and higher polarizability of Sr2+, which facilitates atomic mobility and reduces activation energy. The results of DSC reveal that the addition of CaO and SrO also decreases Tg and Tc, with SrO again exhibiting a greater influence. The ΔT (Tc-Tg) value, which reflects the processing window for sintering, is increased in SrO-containing samples, indicating an improved sinter-ability.
The XRD patterns show that the baseline sample (BBS1) primarily crystallizes into Ba2Si4O10, while CaO addition (BBS2) promotes the formation of Ba5(Si8O21), and SrO addition (BBS3) and co-addition (BBS4) favor forming Ba2Si3O8. The crystallinity increases due to CaO and SrO incorporation, reaching a maximum of 77.76% in BBS2, indicating that CaO is more effective in promoting crystallization due to its smaller ionic radius and higher field strength, which enhances network disruption and nucleation. The Raman spectra confirm a structural transformation from [BO3] to [BO4] units, indicating a more connected and dense glass network.
The microstructural analysiss reveals that the baseline sample has a porous structure with dispersed spherical crystals. In contrast, CaO and SrO additions lead to denser microstructures with interlocked crystal morphologies. Particularly, BBS4 exhibits a uniform distribution of plate-like Ba2Si3O8 crystals and reduced porosity, contributing to its superior mechanical properties.
Thermal expansion coefficients (30-300 ℃) range from 11.52 × 10-6 ℃-1 to 12.43 × 10-6 ℃-1, with BBS4 showing a balanced value of 11.94 × 10-6 ℃-1. The slight decrease compared to the baseline is attributed to the increased [BO4] content and denser structure. The dielectric constants at 1 MHz vary between 6.51 and 7.82, with BBS3 showing the maximum value due to its high-polarizability Sr2+ and Ba2Si3O8 phase. The flexural strength and hardness are significantly improved in CaO- and SrO-modified samples, with BBS4 achieving the maximum values (i.e., 124.36 MPa and 953.88 HV). These enhancements are attributed to increased crystallinity, reduced porosity, and optimized crystal interlocking.
This study demonstrated that the co-incorporation of CaO and SrO into BaO-B2O3-SiO2 lass-ceramics effectively modulated their sintering and crystallization behaviors, enabling dense sintering at 800 ℃. SrO played a dominant role in lowering sintering temperatures, while CaO was more effective in promoting crystallization. The synergistic effect of both oxides led to a glass-ceramic with a high thermal expansion coefficient (i.e., 11.94 × 10-6 ℃-1), excellent mechanical strength (i.e., 124.36 MPa), and favorable dielectric properties (i.e., 8.71 at 1 MHz), making it highly suitable for LTCC applications. The findings could provide a promising pathway for developing high-performance, low-temperature sintering glass-ceramics with tailored thermal and mechanical properties.
Lithium-sulfur (Li-S) batteries are considered as one of the most promising next-generation energy storage technologies due to their high capacity and low cost in the current shortage of energy resources. However, their low sulfur utilization rate due to the shuttle effect of polysulfides severely limits the commercialization of Li-S batteries. Covalent organic frameworks (COFs) are widely used as cathode carrier materials for lithium-sulfur batteries due to their tunable pore size and high specific surface area. This review represents the research progress on COFs in solving the problem of shuttle effect in Li-S batteries, and provides a comprehensive overview of the design ideas and preparation methods of COFs for Li-S batteries. Furthermore, the existing difficulties in the use of COFs for lithium-sulfur batteries are described, and their future development directions are discussed, providing some ideas and references for future research on the application of COFs in Li-S batteries.
COFs demonstrate a significant potential as advanced sulfur host materials in Li-S batteries, effectively mitigating the polysulfide shuttle effect as a major bottleneck to commercialization through their tunable pore structures, high surface areas, and designable functional sites. This review systematically outlines the development of COF-based materials in Li-S battery cathodes, from early physical confinement strategies to recent advances involving heteroatom doping, multidimensional architectures, flexible frameworks, and conductive composites. These approaches can collectively enhance sulfur utilization, improve reaction kinetics, and increase cycling stability.
Despite these promising developments, several challenges remain for the practical application of COF-based cathodes. The key issues include the limited intrinsic conductivity of most COFs, difficulties in maintaining crystallinity during large-scale synthesis, insufficient chemical stability under prolonged cycling, and high manufacturing costs. Moreover, optimizing electrolyte/sulfur ratios and interface engineering between COFs and sulfur are critical for improving electrochemical performance.
Future research should prioritize 1) enhancing the electronic and ionic conductivity of COFs through structural design and hybridization with conductive substrates; 2) developing scalable and eco-friendly synthesis methods to facilitate commercial adoption; 3) designing COFs with high sulfur loading capacity and strong polysulfide adsorption; 4) improving chemical and mechanical stability under operating conditions; and 5) employing advanced in-situ characterization techniques to elucidate ion transport and reaction mechanisms. With continued innovation in material design and processing, COF-based sulfur hosts are expected to play a vital role in realizing high-energy, long-lasting, and commercially viable Li-S batteries.
Ultra-high performance concrete (UHPC) has emerged as a critical material for achieving structural lightweight design and enhanced longevity in civil engineering due to its exceptional mechanical properties and durability. The optimization of UHPC performance relies on particle gradation design for constructing dense packing systems and interfacial transition zone (ITZ) regulation to enhance matrix continuity. However, traditional UHPC formulations depend on resource-intensive materials such as river sand and silica fume, while existing particle packing theories predominantly assume ideal spherical particles, lacking systematic understanding of the coupling mechanisms associated with natural aggregate complex morphological characteristics. Volcanic rock, characterized by rich active substances and irregular angular morphology, offers a novel material pathway for UHPC performance regulation through multi-scale morphological control when processed into aggregates (replacing standard sand) and mineral admixtures (volcanic rock powder replacing cement).
The study systematically investigated the physicochemical synergistic enhancement mechanisms of volcanic rock materials in UHPC through comprehensive experimental analysis. Volcanic rock aggregates (VRA) with varying replacement ratios (0%-100%) of standard sand and volcanic rock powder (VRP) with different substitution levels (0%-30%) of cement were incorporated into UHPC mixtures. The modified Andreasen-Andersen model guided the mix design optimization. Fresh properties were evaluated through flow spread tests and wet packing density measurements according to the established method. Mechanical performance was assessed via compressive and flexural strength tests at 3, 7 d, and 28 d. Accelerated ASR expansion was measured using mortar bar method. Three-dimensional structural analysis using X-ray computed tomography (CT) characterized macropore structure and fiber orientation distribution. Hydration processes were monitored using isothermal calorimetry, while microstructural features were examined through scanning electron microscopy (SEM) and nanoindentation testing.
The workability and wet packing density of fresh UHPC exhibited an initial increase followed by a decrease with increasing VRA replacement ratios, achieving optimal values at 50% replacement. Flow spread increased from 122 mm to 133.5 mm before declining to 128.5 mm, while wet packing density improved from 0.803 to 0.819 before decreasing to 0.808. VRP substitution demonstrated a monotonic increasing trend in flowability, with wet packing density peaking at 10% replacement. This phenomenon was attributed to the friction network regulation mechanism of "angular-rounded" particle interactions and particle gradation optimization by volcanic rock powder.
Mechanical performance analysis revealed that 75% VRA replacement maximized flexural strength across all curing ages, while 20% VRP substitution yielded optimal 28 d compressive strength. X-ray CT analysis demonstrated that 50% VRA replacement minimized total porosity, with large pores (107-108 μm3) systematically decreasing as VRA content increased. The angular morphology of volcanic rock aggregates promoted preferential horizontal alignment of steel fibers, with significant clustering in low-angle regions (0°-30°), thereby substantially enhancing UHPC flexural performance. VRP optimized pore distribution structure through pozzolanic reactions filling microscopic pores at appropriate replacement levels, achieving a dynamic balance between secondary hydration benefits and cement dilution effects. Nanoindentation results confirmed that VRA-matrix interfacial transition zones exhibited superior mechanical properties compared to those of standard sand interfaces, with elastic modulus improvements of approximately 49.7%.
Calorimetric analysis revealed that VRA incorporation increased 3 d cumulative heat release compared to standard sand groups, attributed to surface active substances and enhanced interfacial contact promoting early cement hydration. VRP exhibited delayed hydration kinetics with peak heat release occurring at later ages, with 20% replacement achieving the highest 3 d cumulative heat release due to optimized pozzolanic reaction contributions, while higher dosages (30%) inhibited hydration processes due to lower reactivity of VRP and dilution effect.
This study established that volcanic rock materials effectively enhance UHPC performance through physicochemical synergistic mechanisms, with optimal performance achieved at 50%-75% VRA replacement and 20% VRP substitution. The angular morphology of volcanic rock aggregates improved fiber orientation distribution and mechanical interlocking with the cement matrix, while volcanic rock powder optimized particle packing efficiency and promoted secondary hydration reactions. The enhancement mechanisms originate from three synergistic factors: superior intrinsic mechanical properties comparable to standard sand, angular particle morphology creating three-dimensional mechanical interlocking structures that optimize packing efficiency, and surface active components promoting pozzolanic reactions that densify interfacial microstructure. These findings provide experimental evidence for extending particle packing theory beyond conventional spherical particle assumptions, establishing critical relationships between “morphological characteristics-packing efficiency-interface performance” and macroscopic UHPC properties for complex-shaped aggregates design.
Achieving the "carbon peaking and carbon neutrality" targets requires efficient energy storage technologies. Supercapacitors with the high power density, rapid charge-discharge, and long cycle life show a great potential in renewable energy, electric vehicles, and smart grids. However, their low energy density limits wider applications. Transition metal oxides such as RuO2 and MnO2 are promising electrode materials due to their reversible faradaic reactions and high theoretical capacitance. Single-component oxides suffer from insufficient active sites and structural degradation, impairing rate capability and stability. Multi-metal oxide strategies leverage synergistic effects to optimize lattice, charge distribution, morphology, and performance. Cobalt-based oxides provide abundant Co2+/Co3+ redox pairs, manganese adds multiple valence states and structural buffering, while zinc enhances conductivity and stability. Nevertheless, low conductivity and poor kinetics persist. Oxygen vacancies improve conductivity, tune band structure, and create active sites via reducing bandgap and accelerating kinetics. In this work, oxygen-vacancy-rich Ov-Co3Zn1Mn0.5O5 nanoflowers were synthesized via hydrothermal-annealing-NaBH4 reduction and multi-metal synergy and defect engineering to optimize morphology and electronic structure. This approach could validate the synergistic benefits and offer a strategy for high-performance transition metal oxide supercapacitor electrodes.
All chemicals were of analytical grade and used as received. Nickel foam substrates (2 cm × 3 cm) were pretreated in HCl solution of 3 mol/L under ultrasonication for 5 min to remove surface oxides and thoroughly rinsed with deionized water. For the synthesis of Co3Zn1Mn0.5O5, stoichiometric amounts of Co(CH3COO)2·6H2O (3 mmol), Zn(CH3COO)2·H2O (1 mmol), MnC4H6O4·4H2O (0.5 mmol), and urea (0.2 g) were dissolved in deionized water of 60 mL to form a homogeneous precursor solution. The solution together with the pretreated nickel foam was sealed in a 100 mL Teflon-lined autoclave and maintained at 120 ℃ for 6 h. After natural cooling, the nickel foam-supported precursor was washed, dried, and subsequently annealed in air at 400 ℃ for 2 h, yielding Co3Zn1Mn0.5O5 with a mass loading of 1.12 mg·cm-2. For comparison, binary and other ternary oxides (i.e., Co3Zn1O4, Co3Mn0.5O4, Zn1Mn0.5O2, Co2Zn1Mn0.5O4, and Co4Zn1Mn0.5O6) were prepared under the same conditions above. Oxygen vacancies were introduced via immersing the annealed Co3Zn1Mn0.5O5 in NaBH4 solution for 12 min, followed by vacuum drying at 80 ℃ for 2 h to obtain Ov-Co3Zn1Mn0.5O5 (a mass loading of 1.02 mg·cm-2). Comparative samples Ov-Co2Zn1Mn0.5O4 and Ov-Co4Zn1Mn0.5O6 were also prepared.
The morphology was determined by field-emission scanning electron microscopy (S-4800, Hitachi Co., Japan) and transmission electron microscopy (JEM-2100F, JEOL Co., Japan). The rystal structure was identified by X-ray diffraction (D/MAX-2500, Rigaku Co., Japan, Cu Kα, λ = 0.154156 nm). The surface chemical states and valence distributions were analyzed by X-ray photoelectron spectroscopy (K-Alpha, Thermo Co., USA). The oxygen vacancy concentration was quantified by electron paramagnetic resonance (EMXplus, Bruker Co., Germany) and thermogravimetric analysis (TG 209 F3 Netzsch Co., Germany). The electrochemical measurements were conducted in a three-electrode configuration with 6 mol/L KOH electrolyte using a CHI760e workstation. The cyclic voltammetry and galvanostatic charge-discharge within 0-0.5 V at different scan rates of 10-100 mV·s-1 and various current densities were detremined. The electrochemical impedance spectroscopy was performed on a BioLogic SP-150 workstation. The density functional theory calculations were carried out by a software named Materials Studio package using the projector-augmented wave method.
The three-step hydrothermal-annealing-NaBH4 reduction process yields uniform flower-like Ov-Co3Zn1Mn0.5O5 nanoflowers directly grown on nickel foam. The SEM images reveal that the binary oxides display irregular nanosheets or nanowires, whereas the ternary Co3Zn1Mn0.5O5 forms large-sized nanosheets assembled into a loose porous flower-like morphology that provides abundant redox active sites. After NaBH4 treatment, the overall morphology is preserved, while porosity is markedly increased. The TEM images confirm the porous nanosheet structure in the both samples, with Co3Zn1Mn0.5O5 exhibiting more mesopores and atomic-level defects evidenced by disordered lattice fringes. The HRTEM images display lattice spacings of 0.202 nm and 0.156 nm, corresponding to the plane (400) of MnCo2O4.5 and the plane (511) of ZnCo2O4. The EDS mapping shows a homogeneous distribution of elements Co, Zn, Mn and O, and Mn content is lower than the nominal ratio. The XRD patterns confirm the coexistence of cubic spinel MnCo2O4.5 and ZnCo2O4 phases in all the samples, and Ov-Co3Zn1Mn0.5O5 shows a higher crystallinity. The TGA and EPR unambiguously verify abundant oxygen vacancies. The XPS analysis reveals positive shifts in Co 2p, Mn 2p, Zn 2p, and O 1s binding energies after reduction, accompanied by increased proportions of low-valence Co2+, Mn3+, and a larger OV peak area, confirming mixed-valence states and defect formation. The results of electrochemical tests demonstrate clear synergistic effects. The CV curves at 10 mV·s-1 exhibit the largest integrated area for the ternary composition. The oxygen-vacancy introduction further enlarges the area due to more active sites and lowered OH- intercalation barrier. The b-values of 0.70 and 0.77 indicate combined diffusion and pseudocapacitive contributions. The GCD measurements deliver an ultrahigh specific capacitance of 1509.8 F·g-1 at 2 A·g-1 and retain 809.1 F·g-1 at 20 A·g-1, demonstrating an excellent rate capability. The assembled Ov-Co3Zn1Mn0.5O5//AC asymmetric supercapacitor maintains stable CV shapes up to 100 mV·s-1 within a 1.6 V window, achieves a high energy density of 53.8 W·h·kg-1 at 750 W·kg-1, and retains 76.4% capacitance after 5000 cycles with the Coulombic efficiency of 99%. The DFT calculations reveal that oxygen vacancies eliminate the original 0.098 eV bandgap, introduce mid-gap defect states, increase carrier concentration and facilitate electron hopping between low-valence Co2+and Mn3+ sites, thereby significantly enhancing conductivity and redox kinetics.
The flower-like Ov-Co3Zn1Mn0.5O5 with rich oxygen vacancies was successfully synthesized by a facile hydrothermal-annealing-NaBH4 reduction method. The unique nanosheets-assembled nanoflower structure could expose abundant active sites and enhance redox kinetics. The introduction of oxygen vacancies regulated the electronic structure, improved conductivity, and induced low-valence Co2+ and intermediate Mn3+ to promote redox reactions. The Ov-Co3Zn1Mn0.5O5 electrode delivered a high specific capacitance of 1509.8 F·g-1 at 2 A·g-1 with the excellent rate performance. The assembled asymmetric supercapacitor achieved 53.8 W·h·kg-1 energy density at 750 W·kg-1 and retained 76.4% of its initial capacitance after 5000 cycles with the Coulombic efficiency of 99%. This work could demonstrate the synergistic optimization of multi-metal composition and oxygen vacancy engineering for advanced transition metal oxide electrodes in supercapacitors.
Lithium-ion batteries (LIBs) with a high energy density are critical for advancing electric vehicles and renewable energy storage systems. Silicon oxycarbide (SiOC) anode materials emerge as promising candidates due to their high cycling stability, suitable operating potential, low cost, and environmental compatibility. Unlike conventional silicon anodes that suffer from severe volume expansion (i.e., >300%), SiOC materials benefit from the uniform distribution of silicon and carbon in an atomic scale, forming protective Li2O and lithium silicate layers during initial lithiation that mitigate volume changes. However, a practical implementation of SiOC anodes remains challenging due to their intrinsically low electronic/ionic conductivity and significant volumetric changes during cycling, leading to electrode pulverization, loss of electrical contact, and excessive solid-electrolyte interphase (SEI) growth. In this study, a novel synthesis strategy was proposed to create SiOC anodes with engineered yolk-shell and porous architectures that could simultaneously optimize structural stability, ionic/electronic transport, and interfacial properties.
This work employed a meticulously controlled sol-gel process followed by selective etching under mild alkaline conditions to fabricate SiOC anode materials with distinctive architectures. A yolk-shell structured material (YS@C) was prepared by a sequential addition approach via incorporating 1,4-bis(triethoxysilyl)benzene (BTEB) to form the core, and then adding tetraethoxysilane (TEOS) to create the shell. For the porous material (P@C), BTEB and TEOS were introduced simultaneously. The structures both underwent selective etching with a 2.4 mol/L Na2CO3 solution, removing portions of the inorganic silica, while preserving the organic-inorganic hybrid framework. Subsequently, resorcinol-formaldehyde resin was coated onto the etched structures and carbonized in 10% H2/Ar atmosphere at 800 ℃ to form conductive carbon layers. The structural and chemical properties were determined by scanning electron microscopy (SEM), transmission electron microscopy (TEM), X-ray diffraction (XRD), Raman spectroscopy, X-ray photoelectron spectroscopy (XPS), and BET surface area analysis. The electrochemical performance was evaluated through cyclic voltammetry, galvanostatic charge-discharge testing, rate capability analysis, long-term cycling, and impedance spectroscopy, respectively.
The mild alkaline etching strategy produces monodisperse YS@C particles (with the sizes of 250-270 nm) featuring a distinctive yolk-shell structure with an intermediate void space, and P@C particles (with the sizes of 320-350 nm) with uniformly distribute internal pores. The structural analyses reveals amorphous characteristics with carbon contents of 75.51% for YS@C and 68.2% for P@C. The specific surface areas measured are 17.041 m2/g for YS@C and 27.458 m2/g for P@C, with the average pore sizes of 2.371 nm and 2.561 nm, respectively. The XPS analysis demonstrates different silicon valence states, with the average values of 2.796 9 for YS@C and 2.999 2 for P@C, indicating varying degrees of silicon oxidation that affect the electrochemical behavior.
In electrochemical testing, YS@C delivers the superior performance with an initial Coulombic efficiency of 55%, compared to 49% for P@C. Most significantly, YS@C maintains an exceptional cycling stability with specific capacities of 453 mA·h·g-1 after 550 cycles at 0.5 A/g and 361 mA·h·g-1 after 1000 cycles at 1 A/g, with the Coulombic efficiency consistently of > 99% after the sixth cycle. The kinetic analyses reveals the superior Li+ diffusion coefficient and remarkable pseudocapacitive contribution of YS@C (i.e., 82.2% at 2.0 mV/s) due to its shortened ion diffusion pathways. The post-cycling SEM examination confirms the structural integrity after 300 cycles of YS@C, while P@C exhibits significant cracking and degradation.
This research demonstrated that the gradient composition and hierarchical architecture of YS@C, featuring a high-capacity siloxane-rich core, intermediate void space, and protective carbon/SiOx shell, could collectively address the fundamental limitations of SiOC anode materials. The internal void space effectively accommodated volume expansion during lithiation/delithiation, while the carbon-rich shell enhanced conductivity and minimized detrimental side reactions with the electrolyte. The mild alkaline etching approach presented could offer a gentle yet effective method for engineering complex architectures without damaging the organic components critical for performance. The exceptional electrochemical performance of YS@C, particularly its unprecedented cycling stability at high current densities, could establishe a benchmark for SiOC-based anodes. This work could advance the development of high-performance lithium-ion battery anodes and provide valuable design principles for engineering gradient-structured materials for various energy storage applications. Future research could focus on scaling this synthesis approach and exploring its applicability to other conversion/alloying-type electrode materials requiring volume change accommodation.
Functional ceramics are a class of key inorganic, non-metallic materials that can couple with and respond to electric, magnetic, mechanical, thermal and optical fields. They underpin a wide range of advanced technologies, including energy conversion, information storage and intelligent sensing. As high-end equipment and frontier science develop rapidly worldwide, the demands placed on the performance of functional ceramics are increasing, pushing materials design towards increasingly extreme compositional, structural and processing conditions. However, progress in this field has long been constrained by the intertwined challenges of multiple objectives, scales and fields. Firstly, the performance of materials and the feasibility of processing are often in strong competition with each other. This means that the design is inherently a problem of multi-objective trade-offs and optimization within a restricted feasible space. Secondly, macroscopic functional responses are regulated by factors spanning multiple length scales, including electronic structure, lattice characteristics, and microstructure. Feedback across these scales can greatly amplify the effect of local perturbations on properties. Thirdly, functional ceramics may undergo nonlinear and irreversible evolution under the combined action of high electric fields, elevated temperatures and mechanical loading, further complicating performance evaluation and controllable design. In recent years, AI for materials has emerged as an important paradigm for addressing complex design problems. Through the integration of machine learning and automation, substantial advances have been achieved in metals, polymers and composites, including property prediction, structure-property correlation analysis and inverse design. For functional ceramics, field coupling, defect sensitivity and process dependence make them a particularly challenging yet highly promising target for AI-enabled research. Against this backdrop, a systematic review of recent progress in AI-driven functional ceramics research, outlining how AI is reshaping the broader material design, is important for accelerating the intelligent design of functional ceramics.
AI-enabled research in functional ceramics can be understood through three connected layers: data, model and application. At the data level, the properties of functional ceramics are jointly governed by composition, microstructure and processing history, rendering the associated datasets intrinsically heterogeneous and complex. Composition is typically represented by stoichiometry and dopant species; microstructural information spans multiple hierarchical levels, from lattice distortion and domain structures to grain size and pore morphology; process data are strongly path dependent and require continuous descriptions of heating, cooling and atmosphere switching; and response data are expressed not only as scalar quantities, such as dielectric, piezoelectric and thermoelectric metrics, but also as spectra, loops and other unstructured responses. Accordingly, the foundation of AI for functional ceramics lies in the construction of high-quality, multimodal and traceable datasets, supported by high-throughput techniques, knowledge extraction and multi-fidelity data fusion to improve both data quantity and quality. At the model level, current studies are converging on an integrated framework comprising prediction, uncertainty, generation and decision models. Prediction models establish forward mappings among composition, processing, structure and properties; uncertainty models support out-of-distribution prediction and reliability assessment; generation models enable inverse searches conditioned on target properties; and decision models combine experimental cost and information gain to guide closed-loop optimization. Within this framework, robustness and interpretability have emerged as central requirements: models could generalize across different systems, processing routes and testing conditions, while physically informed descriptors and mechanistic correlations are needed to reveal the factors that govern functional responses. At the application level, AI has increasingly permeated the full design workflow, giving rise to surrogate modelling, demand-driven exploration, multi-objective optimization and closed-loop pipeline, and thereby creating a more targeted, iterative and efficient design paradigm.
AI is reshaping the design workflow of functional ceramics through three major directions: intelligent inverse design, cross-scale intelligent computation and large-language-model-driven research platforms. First, intelligent inverse design targets on-demand materials design by integrating multiple representations of composition, processing, microstructure and property with uncertainty quantification, physical feasibility constraints and active learning, thereby establishing a closed loop spanning data alignment, forward prediction, inverse design and experimental validation. This strategy can improve the hit rate, manufacturability and reproducibility of proposed candidates. Second, cross-scale intelligent computation leverages machine learning to bridge models at different scales, including electronic structure, atomic dynamics, mesoscale microstructural evolution and continuum responses. By retaining key physical constraints while reducing computational cost, such approaches enable density functional theory, machine-learning interatomic potentials, phase-field models and finite-element analysis to operate within a unified framework for materials design. Third, large-language-model-driven research platforms are evolving from tools for knowledge extraction and literature analysis into collaborative hubs that connect knowledge, computation, decision and experimental execution. By integrating information from papers, patents, laboratory records and process documentation, large language models can assist in building high quality datasets, extracting process pathways and failed experiment information, and coupling with agentic systems and automated experimental platforms, thus paving the way for self-driving closed-loop laboratories in functional ceramics research.
As functional ceramics are increasingly required for more advanced device platforms and harsher service environments, the demand for even higher levels of performance continues to grow. At the core of this challenge lies the persistent coexistence of multi-objective trade-offs and multi-scale problems. Therefore, we systematically summarize the paradigm shifts and representative advances brought about by the introduction of AI into materials research. We outline the broader landscape of AI-enabled functional ceramics research from the perspectives of data, model and application, and further summarize the key strategies and transformative pathways for this field through three major directions: intelligent inverse design, cross-scale intelligent computation and large-language-model-driven research platforms. As data infrastructure, model capability and closed-loop deployment technologies continue to mature, artificial intelligence is poised to evolve from an auxiliary analytical tool into a systematic design framework that connects knowledge, computation, decision and experimental execution, thereby advancing functional ceramics research towards a more efficient and scalable paradigm.