In this study, a series of nano-Al₂O₃ reinforced polyimide (PI) composites were fabricated using the hot compression method. A silane coupling agent was used to modify the surface of nano-Al₂O₃ powder to enhance the PI/Al₂O₃ interface compatibility. The effects of Al₂O₃ contents on the microstructures, thermal behavior and mechanical properties of PI/Al₂O₃ composites were investigated. The results suggested that chemical reactions occurred during in situ modification. The nano-Al₂O₃ was cross-linked to the PI matrix, which reduced the mobility of PI chains and improved the elastic modulus of the composites. When the Al₂O₃ content was 30 wt.%, the compressive strength of composites reached the maximum value of 313 MPa and increased by 26.5% than that of the PI matrix.

The thermal insulation properties of thermal barrier coatings (TBCs) can be significantly improved with increasing the coating thickness. However, due to the weak bonding of high-thickness TBCs, the low reliability and short lifetime greatly limits their application under some severe operating conditions. In this study, a novel and high-efficiency synchronous dual powder feeding method is used to deposit a series of gradient NiCoCrAlY/YSZ coatings with millimeter level thickness. The tensile bonding strengths and residual stress state of coatings are evaluated in order to explore the effect of thickness on the bonding strength of coatings. The results suggested that, due to some micro-convex structure at the “GC/TC” interface and inside “GC” layer, the bonding strength of 1000-μm-thickness gradient NiCoCrAlY/YSZ TBCs with the 4:6 and 2:8 hybrid ratios is over 44 MPa compared to the common TBCs. The fracture position gradually shifts from NiCoCrAlY bond coat to NiCoCrAlY/YSZ transition zone and finally to the YSZ top coat owing to the different position of residual stress concentrations. After thermal cycling tests, the 1000-μm-thickness gradient coating exhibits a higher thermal cycling life. Some coarse cracks initiate and propagate at the bottom region of TBCs, which is mainly due to thermal expansion mismatch stress that finally results in the failure of the gradient coating between the “BC” layer and the substrate.

The purpose of this paper is to study the thermal shock resistance and failure mechanism of La₂Ce₂O₇/8YSZ double-ceramic-layer thermal barrier coatings (LC/8YSZ DCL TBCs) under extreme temperature gradients. At high surface temperatures, thermal shock and infrared temperature measuring modules were used to determine the thermal cycling life and insulation temperature of LC/8YSZ DCL TBCs under extreme temperature gradients by an oxygen–acetylene gas flame testing machine. A viscoelastic model was used to obtain the stress law of solid phase sintering of a coating system using the finite element method. Results and Conclusion: (1) Thermal cycling life was affected by the surface temperature of LC/8YSZ DCL TBCs and decreased sharply with the increase of surface temperature. (2) The LC ceramic surface of the failure coating was sintered, and the higher the temperature, the faster the sintering process. (3) Accelerated life test results showed that high temperature thermal cycling life is not only related to thermal fatigue of ceramic layer, but is also related to the sintering degree of the coating. (4) Although the high temperature thermal stress had great influence on the coating, great sintering stress was produced with sintering of the LC ceramic layer, which is the main cause of LC/8YSZ DCL TBC failure. The above results indicate that for new TBC ceramic materials, especially those for engines above class F, their sinterability should be fully considered. Sintering affects the thermal shock properties at high temperature. Our research results can provide reference for material selection and high temperature performance research.

Polytetrafluoroethylene (PTFE) is provided with excellent self-lubricating properties and corrosion resistance. However, the lower thermal resistance greatly limits its high-temperature applications. In the present work, two types of fillers with rigid organic polymers and submicron-sized inorganic hexagonal boron nitride (h-BN) were added to the PTFE matrix. The microstructure and thermal–mechanical properties of PTFE-based composites with different filler types or ratios were comparatively investigated. The results suggested that the polyphenyl ester (POB)/h-BN co-filled PTFE composites exhibited excellent thermal–mechanical properties compared with the polyimide (PI)/h-BN/PTFE materials at high temperature. The optimal ratios of POB and h-BN were 25 wt.% and 5 wt.%, respectively. The Vicat softening temperature of 25 wt.% POB/5 wt.% PI/PTFE composite increased by 41.3% compared to that of pure PTFE, which was due to the cross-linked reticulation structure with regularly distributed pores and higher crystallization degree. The storage modulus increased from 51.99 MPa to 685.76 MPa at 260 °C and reached 187.82 MPa at 320 °C. The uniform distribution of anisotropic orientation of the h-BN flakes showed an obvious pinning effect, and further improved the thermal–mechanical stability of POB/h-BN/PTFE composites.