The development of new ablation-resistant and heat-insulating integrated materials for thermal protection of hypersonic vehicles is extremely important, but significant challenges remain. In this study, zirconium-based phosphate ceramics were developed by mixing a nano powder of the traditional ultra-high temperature ceramic oxidation product ZrO₂, which has excellent thermal insulation performance, with an aluminum–chromium phosphate slurry, which provides a certain degree of thermal stability. The zirconium-based phosphate ceramics crosslinked and cured by a polycondensation reaction inherited the high temperature resistance of ZrO₂ and the low thermal conductivity of the phosphate material, and simultaneously achieving excellent thermal stability, mechanical properties, and the desired properties. The mass ablation rate and line ablation rate of the zirconium-based phosphate ceramics were found to be 0.0173 g/s and 0.0114 mm/s, respectively, under oxyacetylene flame ablation at 2527°C for 30 s. In addition, cooling by up to 2301℃ was achieved over a distance of 10 mm in the thickness direction was achieved. The zirconium-based phosphate ceramics also exhibited remarkable compressive strength (6.23–29.22 MPa), good thermal insulation (0.827–1.784 W/m·K), excellent thermal stability, and mass loss within 2.2% in thermogravimetric tests from room temperature to 1400 ℃. These properties indicate that zirconium-based phosphate ceramics can be utilized in thermal protection systems in hypersonic vehicles, rocket propulsion, and missile launchers.

With the advancement of modern aeroengines toward higher thrust-to-weight ratios and increased gas temperatures, the control of rotor–stator clearances has become a critical factor influencing engine performance and efficiency. Abradable seal coatings (ASCs), as an effective means of clearance control, have been widely applied to the inner casings of engines. Under high-temperature service conditions (≥1300 ℃), conventional metal-based ASCs are increasingly exhibiting service performance limitations due to their insufficient thermal stability. In contrast, ceramic-based abradable seal coatings, owing to their excellent high-temperature stability and low thermal conductivity, are considered promising candidates for next-generation high-temperature sealing materials. However, the design of such novel ASCs faces numerous key challenges, including crack propagation, the trade-off between abradability and erosion resistance, and coating failure mechanisms under extremely complex service environments. This review systematically summarizes the recent progress in high-temperature ceramic-based ASCs, with a focus on typical material systems, fabrication techniques, key structural design strategies, and their relationship with performance evolution. Comprehensive analysis reveals significant coupling and trade-offs among abradability, hardness, erosion resistance, thermal shock resistance, and corrosion resistance. Achieving balanced performance requires multiscale structural design and multifunctional synergistic optimization. Finally, this paper summarizes the main challenges currently faced in this field and emphasizes that future research should focus more on understanding the evolution of failure mechanisms under complex service environments and on the design and construction of integrated multifunctional coating architectures.

CrTaO₄ and CrNbO₄, rutile structured ternary scales formed on refractory high-entropy alloys (RHEAs), protect the RHEAs from oxidation and thermal attack. However, the Vickers hardness (12.20/10.20 GPa for CrTaO₄ and CrNbO₄, respectively) is lower than that of YSZ (14 GPa), making them prone to erosion. In addition, further reduction of thermal conductivity (1.31/1.09 W·m⁻¹·K⁻¹ for CrTaO₄ and CrNbO₄, respectively) benefits to protect the substrate materials from thermal attack. As such, optimizing their properties is urgently needed. To enhance the mechanical properties and further reduce the thermal conductivity of rutile-type ternary oxides CrTaO₄ and CrNbO₄, herein we designed a CrTa_0.5Nb_0.5O₄ solid solution based on the mechanism of solid solution strengthening, and systematically investigated its phase composition, microstructure, mechanical and thermal properties. The HAADF and ABF-STEM analyses confirmed the rutile-structure of CrTa_0.5Nb_0.5O₄, while minor impurities of rutile-structured CrNbO₄ and CrO₂ were also identified. The elastic modulus, bulk modulus, and shear modulus of CrTa_0.5Nb_0.5O₄ are 201, 119, and 175 GPa, respectively. Notably, the mechanical properties of CrTa_0.5Nb_0.5O₄ have been significantly improved via solid solution strengthening, with the Vickers hardness of 13.01 ± 0.2 GPa, fracture toughness of 2.07 ± 0.017 MPa·m^1/2, and flexural strength of 201 ± 12 MPa. The measured melting point of CrTa_0.5Nb_0.5O₄ is 2073±20 K, with an average thermal expansion coefficient of (5.91±0.52) × 10⁻⁶ K⁻¹. The room-temperature thermal conductivity of CrTa_0.5Nb_0.5O₄ is 1.07 W·m⁻¹·K⁻¹, which decreases to 0.57 W·m⁻¹·K⁻¹ at 1473 K, being lower than most of the well-known thermal barrier coating materials. In terms of thermal expansion coefficient matching, CrTa_0.5Nb_0.5O₄ is a qualified thermal barrier material for refractory metals and their alloys and ultra-high temperature ceramics. Therefore, this study has not only successfully developed a thermal barrier coating material with excellent mechanical properties and low thermal conductivity, but also provided new ideas for the research and development of materials in high-temperature fields from the perspective of material design.

Ternary layered material MAX/MAB phases have become a highly promising candidate for fourth-generation nuclear energy systems, combining the excellent properties of metals and ceramics. This paper reviewed the irradiation response and resistance mechanisms of Ti/Cr/Zr/Nb/V/Ta-based MAX phases, doped/entropy-enhancing MAX phases, and MAB phases. The performance differences between the MAX/MAB phases under irradiation with neutrons, heavy ions, self-ions, He ions, protons, or electrons were investigated. Studies have confirmed that they possess high damage tolerance and resistance to amorphization. This is manifested in the following aspects: accommodating point defects through antisite defects and Frenkel defects; resisting amorphization via atomic rearrangement and crystalline transformation; capturing He atoms by the low-bond-energy A-layer and restricting the growth of He bubbles through M-X layers or B layers; inhibiting further diffusion and penetration of energetic particles; and achieving defect annihilation and damage recovery during high-temperature irradiation and annealing processes. Finally, scientific research strategies are proposed, including regulating MAX/MAB phases to achieve optimal entropy values, designing component structures based on electronegativity and lattice distortion, and investigating the synergistic effects of multiple irradiation particles. Additionally, prospects for the further development of MAX/MAB phases in nuclear energy systems are presented.

Carbon-based composites are widely utilized in aerospace engines, thermal protection systems of hypersonic vehicles, and ultrahigh-temperature structural components, due to their lightweight nature, high strength, excellent mechanical properties, and thermal stability. However, the inherent susceptibility of carbon-based composites to high-temperature oxidation significantly limits their service life, highlighting the urgent need for the development of efficient oxidation-resistant barriers to enhance the long-term operational stability. In recent years, ultra-high temperature ceramic (UHTC) coatings have attracted considerable attention owing to their outstanding oxidation resistance. Nevertheless, such protective coatings still face critical challenges to hinder practical applications, including crack propagation, dynamic consumption instability of oxidation glass films, generation of oxidation holes and interfacial damage, which remain prevalent. In this work, a comprehensive overview of the research progress in UHTC coatings for carbon-based composites is provided, with particular emphasis on examining the influence of hierarchical structural design on oxidation resistance. Specifically, the role of advanced manufacturing techniques in optimizing microstructural stability and interfacial bonding strength is thoroughly discussed. Furthermore, the high-temperature oxidation protection mechanisms of UHTC coatings are examined, including strategies to optimize the composition of the oxidation glass film, stabilize the self-generated glass phase, and enhance densification of coating. In addition, various characterization methods are discussed for evaluating the oxidation resistance of the coatings, along with a systematic evaluation of stability under different service conditions. Finally, analysis of current technical challenges and unresolved issues, especially challenges and technical prospects regarding the field of oxidation-resistant coatings for carbon-based composites are discussed, while offering perspectives on future developments.

Cr₂AlC, as a ternary layered MAX phase ceramic with excellent oxidation resistance and ablation resistance, has great potential in thermal protection materials. To further tap its potential as a recyclable thermal protection material in extreme environment, the cyclic ablation performance of Cr₂AlC under nitrogen plasma flame at 1600^° C was systematically studied in this paper. During the cycles (each lasting three minutes) of ablation, Cr₂AlC maintained structural integrity and exhibited low linear and mass ablation rates. After three cycles of ablation, the linear ablation rate and mass ablation rate were 0.050μ" " m/s and 0.048mg/s, respectively. The analysis of surface and near-surface components shows that Al_8 Cr_5 produced by the decomposition of Cr₂AlC is the origin of the excellent ablation performance of Cr₂AlC ceramics. However, as the cycle time and total ablation time increase, Cr₂AlC and Al_8 Cr_5 near the surface will be depleted under high-temperature oxidation, leading to material failure. This study presents the excellent cycling and long-term ablation properties of Cr₂AlC ceramics, revealing their enormous application prospects in reproducible thermal protection materials.

This study explored the prevention of mild steel (MS) corrosion in sulfuric acid through deployment of N, N-dibutylaniline (NNDBA) as an organic inhibitor. The inhibition efficacy was meticulously scrutinized using a blend of qualitative and quantitative methodologies. The gravimetric method was executed across a spectrum of NNDBA concentrations (10^-1 M -10^-7 M ) and temperatures, 298 K-328 K (with 10 K increments), facilitating an intricate kinetic and thermodynamic exploration of the inhibition mechanism. Adsorption isotherm analyses affirmed NNDBA's adherence to Langmuir's model, signifying a monolayer adsorption paradigm. The adsorption process was found to be spontaneous and thermodynamically favorable, predominantly governed by physisorption. Empirical data delineated an inverse relationship between temperature and inhibition efficiency, whereas an augmentation in NNDBA concentration bolstered corrosion resistance. Potentiodynamic Polarisation (PDP) confirmed that NNDBA is a mixed-type inhibitor with a maximum efficiency of 92.4%. Electrochemical Impedance Spectroscopy (EIS) measurements revealed a marked decrement in the double-layer capacitance at the Fe/H₂SO₄ interface, corroborating inhibitor adsorption. Notably, the lower value of the phase shift exponent n for NNDBA suggests increased surface heterogeneity due to inhibitor film formation. Scanning Electron Microscopy (SEM-2D) and Atomic Force Microscopy (AFM-3D) unveiled distinct morphological alterations indicative of surface passivation. Density functional theory (DFT) calculations provided insights into the electronic structure of NNDBA, revealing a highly negative E_HOMO, low E_LUMO, and a small ΔE(5.24eV), all suggesting strong reactivity and the formation of a stable metal-inhibitor complex. The mechanistic pathway and spatial orientation of the interaction between the NNDBA molecule and MS surface were explored through molecular dynamics simulation to gain insights into its inhibitory behavior. Thus, the theoretical insights harmonize with experimental findings, substantiating its efficacy as a potent corrosion mitigant.