Journal of Inorganic Materials

   

Alumina-based Directionally Solidified Eutectic Ceramics:Microstructure, Control Strategies and Environmental Stability

ZHOU Cui1, LI Jie2, SUN Luchao2, SU Haijun3, WANG Jingyang2   

  1. 1. Institute of Coating Technology for Hydrogen Gas Turbines, Liaoning Academy of Materials, Shenyang 110016, China;
    2. Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China;
    3. State Key Laboratory of Solidification Processing, Northwestern Polytechnical University, Xi’an 710072, China
  • Received:2025-10-31 Revised:2025-12-26
  • Contact: SUN Luchao, professor. E-mail: lcsun@imr.ac.cn; SU Haijun, professor. E-mail: shjnpu@nwpu.edu.cn
  • About author:ZHOU Cui (1997-), female, PhD. E-mail: zhouc@lam.ln.cn
  • Supported by:
    National Natural Science Foundation of China (52130204, U21A2063); National Key R&D Program of China (2024YFB3714503); LiaoNing Revitalization Talents Program (XLYC2203090); International Partnership Program of the Chinese Academy of Sciences (172GJHZ2022094FN)

Abstract: With rapid advancement of aviation industry, high-temperature structural materials used in aero-engines are encountering increasingly severe service environments and performance challenges. To meet exacting requirements of future technologies, turbine inlet temperature of advanced aero-engines with a thrust-to-weight ratio exceeding 10 is projected to surpass 1500 ℃. Al2O3-based directionally solidified eutectic ceramics are regarded as ideal and key candidate materials for next-generation extreme working conditions, particularly for long-term use in high-temperature oxidative environments, owing to their melting points exceeding 1700 ℃, outstanding high-temperature stability, and inherent oxidation resistance. This paper provides a comprehensive review of microstructural characteristics of Al2O3-based directionally solidified eutectic ceramics, with particular emphasis on their morphological features, crystallographic relationships and interfacial structures. Subsequently, discussion focuses on strategies for microstructure control, including optimization of processing parameters, optimal selection of eutectic components and implementation of innovative approaches such as high-entropy design. Furthermore, a comprehensive analysis is conducted to evaluate stability of these materials under typical high-temperature service conditions, including thermal exposure, oxidative environments, and chemically corrosive media, with particular emphasis on their chemical stability characteristics. Based on this comprehensive review, key scientific issues and core technical challenges in current research are identified. Future research directions are also proposed to establish a theoretical foundation and provide technical guidance for engineering application of these materials in advanced aero-engine systems.

Key words: Al2O3-based eutectic ceramic, directional solidification, microstructure control, microstructure stability, environmental stability, review

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