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Handling the massive quantities of by‐products from metallurgical processes has become a major concern in recent decades. Efforts to develop sustainable alternatives for these secondary resources are ongoing to achieve the transition to climate neutrality. This study has investigated the potential of employing vanadium‐bearing slag as a new value‐added binder in refractories, aiming to replace virgin raw materials. Two types of vanadium‐bearing slags from BOF, each containing <2 wt.% vanadium were studied. Low‐cement vanadium slag‐based castables were prepared by gradually substituting 0, 2.5, and 5 wt.% of the commercial calcium aluminate cements (Secar71 and CMA72) by the slags. The flow values of the mixes containing 5 wt.% of slag decrease significantly from about 90% to 30% after 30 min, showing poor ability to flow and thus are not considered as self‐flow castables. Castables containing 2.5 wt.% of slag present a cold crushing strength value, in the range of 71–116 MPa while values for castables containing 5 wt.% of slag fall into the range of 53–68 MPa due to the lower packing properties leading to higher porosity and reduce in strength. Similar observation was concluded for cold modulus of rupture. The micrographs of the samples containing both slag and cement show promising compatibility between the binder and aggregates after sintering at 1500°C. Overall, characteristics obtained with the samples containing slag show promising alternatives as a refractory lining. This study investigated the use of vanadium‐bearing slag as an alternative to calcium aluminate cement in high‐alumina refractory castables, with the aim to support decarbonization by reducing reliance on natural raw materials.

Two-dimensional (2D) MXene materials have recently been the focus of membrane research due to their unique properties, such as their single-atomic-layer thickness, flexibility, molecular filtration abilities and microstructural similarities with graphene, which is currently the most efficient precursor material for gas separation applications. In addition, the potential to process nanoscale channels has motivated investigations of parameters which can improve membrane permeability and selectivity. Interlayer spacing and defects, which are still challenging to control, are among the most crucial parameters for membrane performance. Herein, the effect of heat treatment on the d-spacing of MXene nanosheets and the surface functionalization of nanolayers was shown regarding its impact on the gas diffusion mechanism. The distance of the layers was reduced by a factor of over 10 from 0.345 nm to 0.024 nm, the defects were reduced, and the surface functionalization was maintained upon treatment of the Ti3C2 membrane at 500 °C under an Ar/H2 atmosphere as compared to 80 °C under vacuum. This led to a change from Knudsen diffusion to molecular sieving, as demonstrated by single-gas permeation tests at room temperature. Overall, this work shows a simple and promising way to improve H2/CO2 selectivity via temperature treatment under a controlled atmosphere.

The retention of nanocrystallinity in dense ceramic materials is still a challenge, even with the application of external pressure during sintering. The compaction behavior of high purity and acetate enriched zinc oxide (ZnO) nano-powders was investigated. It was found that acetate in combination with water plays a key role during the compaction into green bodies at moderate temperatures. Application of constant pressure resulted in a homogeneous green body with superior packing density (86% of theoretical value) at moderate temperature (85 °C) in the presence of water. In contrast, no improvement in density could be achieved if pure ZnO powder was used. This compaction behavior offers superior packing of the particles, resulting in a high relative density of the consolidated compact with negligible coarsening. Dissolution accompanying creep diffusion based matter transport is suggested to strongly support reorientation of ZnO particles towards densities beyond the theoretical limit for packing of ideal monosized spheres. Finally, the sintering trajectory reveals that grain growth is retarded compared to conventional processing up to 90% of theoretical density. Moreover, nearly no radial shrinkage was observed after sinter-forging for bodies performed with this advanced processing method.

Two-dimensional (2D) aluminum nitride (AlN) represents a promising material with unique properties predicted by density functional theory (DFT), characterized by a honeycomb lattice where Al and N atoms exhibit threefold in-plane coordination. However, the synthesis of free-standing AlN nanosheets has been challenging due to the crystal configurations of the well-known bulk AlN, which presents a hexagonal wurtzite structure with a tetrahedral coordination, preventing its exfoliation to obtain nanosheets. Herein, we propose a facile method involving the preparation of layered-structured aluminum carbonitrides, Al 5 C 3 N, followed by exfoliation into AlN nanosheets, offering a potential route for producing 2D AlN. The Al 5 C 3 N precursor was chemically etched in hydrofluoric acid (HF), breaking the Al-C bonds and exposing the AlN nanosheets. The development of this synthesis method opens up opportunities towards the preparation of 2D AlN and the investigation of its unique properties for applications in sensors and microelectronics. Two-dimensional aluminum nitride holds promise for advanced applications, yet its synthesis is hindered by the bulk material’s hexagonal wurtzite structure which prevents facile exfoliation. Here, the authors present a method using layered-structured aluminum carbonitrides as precursors and hydrofluoric acid chemical etching to produce AlN nanosheets, paving the way for innovations in sensors and microelectronics.

Shaping the morphology of 2D materials is essential for tuning their properties. This is especially true for MXenes, a class of 2D materials, as fine morphological control is the key to unlocking their potential. Here, Ti 3 C 2 T x MXene is synthesized using carbon fibers as both the carbon source and template, creating a unique tubular morphology where the MXene layers align along the tube. The tubular Ti 3 C 2 T x MXene and corresponding precursor MAX phase are synthesized by molten salts shielded synthesis method in air. Comprehensive characterization confirms that the MXene retains the tubular structure conferred by the carbon fiber. Preliminary electrochemical measurements as an anode material in lithium-ion batteries show an initial discharge capacity and good rate performance at a high current density, indicating potential for high-power applications. Furthermore, this tubular morphology opens new possibilities for MXenes in gas sensing, liquid filtration processes, and other applications that require fast diffusion. Choice of MAX phase precursor plays a significant role on the structure and properties of MXenes. Here, carbon fibers are used as the carbon source and template for the MAX phase, resulting in a Ti 3 C 2 T x MXene with a tubular morphology.

The self-passivating yttrium-containing WCr alloy has been developed and researched as a potential plasma-facing armour material for fusion power plants. This study explores the use of yttria (Y2O3) powders instead of yttrium elemental powders in the mechanical alloying process to assess their applicability for this material. Fabricated through field-assisted sintering, WCr-Y2O3 ingots show Y2O3 and Cr-containing oxides (Cr-O and Y-Cr-O) dispersed at grain boundaries (GBs), while WCrY ingots contain Y-O particles at grain boundaries, both resulting from unavoidable oxidation during fabrication. WCr-Y2O3 demonstrates higher flexural strength than WCrY across all temperature ranges, ranging from 850 to 1050 MPa, but lower fracture toughness, between 3 and 4 MPa·√m. Enhanced oxidation resistance is observed in WCr-Y2O3, with lower mass gain as compared to WCrY during the 20-hour oxidation test. This study confirms the effectiveness of both yttria and yttrium in the reactive element effect (REE) for the passivation of WCr alloy, suggesting the potential of Y2O3-doped WCr for first wall applications in a fusion power plant.

The use of tungsten fiber-reinforced tungsten composites (Wf/W) has been demonstrated to significantly enhance the mechanical properties of tungsten (W) by incorporating W-fibers into the W-matrix. However, prior research has been restricted by the usage of single fiber-based textile fabrics, consisting of 150 µm warp and 50 µm weft filaments, with limited homogeneity, reproducibility, and mechanical properties in bulk structures due to the rigidity of the 150 µm W-fibers. To overcome this limitation, two novel textile preforms were developed utilizing radial braided W-yarns with 7 core and 16 sleeve filaments (R.B. 16 + 7), with a diameter of 25 µm each, as the warp material. In this study, bulk composites of two different fabric types were produced via a layer-by-layer CVD process, utilizing single 50 µm filaments (type 1) and R.B. 16 + 7 yarns (type 2) as weft materials. The produced composites were sectioned into KLST-type specimens based on DIN EN ISO 179-1:2000 using electrical discharge machining (EDM) and subjected to three-point bending tests. Both composites demonstrated enhanced mechanical properties with pseudo-ductile behavior at room temperature and withstood over 10,000 load cycles between 50–90% of their respective maximum load without sample fracture in three-point cyclic loading tests. Furthermore, a novel approach to predict the fatigue behavior of the material under cyclic loading was developed based on the high reproducibility of the composites produced, especially for the composite based on type 1. This approach provides a new benchmark for upscaling endeavors and may enable a better prediction of the service life of the produced components made of Wf/W in the future. In comparison, the composite based on fabric type 1 demonstrated superior results in manufacturing performance and mechanical properties. With a high relative average density (>97%), a high fiber volume fraction (14–17%), and a very homogeneous fiber distribution in the CVD-W matrix, type 1 shows a promising option to be further tested in high heat flux tests and to be potentially used as an alternative to currently used materials for the most stressed components of nuclear fusion reactors or other potential application fields such as concentrated solar power (CSP), aircraft turbines, the steel industry, quantum computing, or welding tools. Type 2 composites have a higher layer spacing compared to type 1, resulting in gaps within the matrix and less homogeneous material properties. While type 2 composites have demonstrated a notable enhancement over 150 µm fiber-based composites, they are not viable for industrial scale-up unlike type 1 composites.

Self-passivating Metal Alloys with Reduced Thermo-oxidation (SMART) are under development for the primary application as plasma-facing materials for the first wall in a fusion DEMOnstration power plant (DEMO). SMART materials must combine suppressed oxidation in case of an accident and an acceptable plasma performance during the regular operation of the future power plant. Modern SMART materials contain chromium as a passivating element, yttrium as an active element and a tungsten base matrix. An overview of the research and development program on SMART materials is presented and all major areas of the structured R&D are explained. Attaining desired performance under accident and regular plasma conditions are vital elements of an R&D program addressing the viability of the entire concept. An impressive more than 104-fold suppression of oxidation, accompanied with more than 40-fold suppression of sublimation of tungsten oxide, was attained during an experimentally reproduced accident event with a duration of 10 days. The sputtering resistance under DEMO-relevant plasma conditions of SMART materials and pure tungsten was identical for conditions corresponding to nearly 20 days of continuous DEMO operation. Fundamental understanding of physics processes undergone in the SMART material is gained via fundamental studies comprising dedicated modeling and experiments. The important role of yttrium, stabilizing the SMART alloy microstructure and improving self-passivating behavior, is under investigation. Activities toward industrial up-scale have begun, comprising the first mechanical alloying with an industrial partner and the sintering of a bulk SMART alloy sample with dimensions of 100 mm × 100 mm × 7 mm using an industrial facility. These achievements open the way to further expansion of the SMART technology toward its application in fusion and potentially in other renewable energy sources such as concentrated solar power stations.

To prevent spontaneous oxidation during the high-temperature synthesis of non-oxide ceramics, an inert atmosphere is conventionally required1,2. This, however, results in high energy demand and high production costs. Here, we present a process for the synthesis and consolidation of oxidation-prone materials, the ‘molten salt shielded synthesis/sintering’ process (MS3), which uses molten salts as a reaction medium and also to protect the ceramic powders from oxidation during high-temperature processing in air. Synthesis temperatures are also reduced, and the final product is a highly pure, fine and loose powder that does not require additional milling steps. MS3 has been used for the synthesis of different ternary transition metal compounds (MAX phases, such as Ti3SiC23, Ti2AlN4, MoAlB5), binary carbides (TiC) and for the sintering of titanium. The availability of high-quality powders, combined with energy and cost savings, may remove one of the bottlenecks for the industrial application of these materials.Molten salts are used as a reaction medium to protect carbide, nitride and boride powders from oxidation during high-temperature synthesis in air, thus avoiding the need to carry out these processes in a vacuum or inert environment.

The self-passivating tungsten-based alloy W-11.4Cr-0.6Y (in wt.%) is a potential plasma-facing material for the first wall of future fusion reactors, which has been shown to suppress oxidation of tungsten and withstand temperatures of up to 1000 °C. In this study, the effect of Y addition on the microstructure and oxidation behavior of W-11.4Cr alloy at 1000 °C is analyzed by comparing it with W-11.4Cr-0.6Y, both prepared using identical synthesis routes. While the binary W-Cr alloy already exhibits improved oxidation resistance over pure W due to the formation of an outer Cr2WO6 layer, it still shows a tendency for spallation and, hence, is not protective. A continuous passivating chromia layer is only obtained with the addition of Y, and we demonstrate that it results in a 50-fold decrease in the oxide growth rate and eliminates the preferred growth of the oxide at edges seen in the binary alloy. Although a porous, complex oxide scale containing mixed oxide layers and WO3 is formed in both cases, the addition of Y results in lower porosity, which makes the oxide scale more adherent.