Jiayi Liu , Kaiyuan Hao , Ruonan Zhou , Xuelian Xiao , Guoming Yuan , Kai Xu , Ming Lou , Keke Chang
{"title":"Enhancing the corrosion resistance of cemented carbides using CoCrNi binders in simulated drilling fluids","authors":"Jiayi Liu , Kaiyuan Hao , Ruonan Zhou , Xuelian Xiao , Guoming Yuan , Kai Xu , Ming Lou , Keke Chang","doi":"10.1016/j.ceramint.2025.01.023","DOIUrl":"10.1016/j.ceramint.2025.01.023","url":null,"abstract":"<div><div>As critical surface strengthening materials for drilling tools, the cemented carbides have been observed to suffer from severe corrosion in alkaline drilling fluids. To address such issue, we designed novel WC-based cemented carbides incorporating multi-principal element alloy binders, CoCrNi, based on thermodynamic calculations, and synthesized them via vacuum sintering. The corrosion behaviors of WC-CoCrNi in simulated drilling fluids were assessed via polarization and microelectrochemistry tests, with the WC-Co used as reference. The results showed that the WC-CoCrNi exhibited reduced corrosion current densities by ∼70 % and an improved polarization resistance by an order of magnitude. Such improvement was attributed to the solid-solution of Cr and Ni in Co, which decreased the potential difference between ceramic and metallic phases thus mitigated the galvanic corrosion tendency. The corrosion product layers on the WC-CoCrNi surfaces, in addition, mainly consisted of Cr<sub>2</sub>O<sub>3</sub>, NiO and Ni(OH)<sub>2</sub>, also contributing to corrosion protection. Therefore, the current work demonstrates the viability to obtain corrosion-resistant cemented carbides through the thermodynamic design of binder compositions.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11690-11701"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815249","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hanwen Zhu , Xiang Li , Qingge Feng , Fanghong Qin , Jing Sun , Shuyu Yuan , Xingyu Deng , Hongxing Zhu , Ke Xu
{"title":"Synthesis of transparent and durable antimony tin oxide coatings based on spectrum-selective transmittance for thermal insulation by regulating dispersion","authors":"Hanwen Zhu , Xiang Li , Qingge Feng , Fanghong Qin , Jing Sun , Shuyu Yuan , Xingyu Deng , Hongxing Zhu , Ke Xu","doi":"10.1016/j.ceramint.2025.01.165","DOIUrl":"10.1016/j.ceramint.2025.01.165","url":null,"abstract":"<div><div>Primary energy consumption in buildings is mainly attributed to heat exchange through windows. However, developing transparent and durable thermal insulation coatings for practical applications remains challenging. Therefore, based on the spectrally selective transmittance mechanism, a transparent antimony tin oxide (ATO) inorganic coating for thermal insulation is presented using a simple blending method with low melting point glass powder. The visible light (VIS) transmission and near-infrared (NIR) shielding of the coating reaches 73.33 % and 61.87 %, respectively, under the ball-milling at 200 rpm for 60 min with ATO content of 0.3 g and calcination temperature of 700 °C. The optimized ball-milling pre-blending benefitted the transformation into smaller particle sizes and coating dispersion—crucial for affecting the spectral selective transmittance of the coating. The mechanism of introducing the low-melting-point glass powder, whose cross-linking with ATO by bridging oxygen conduces the disintegration and polymerization of the glass mesh to a denser network structure, was explored. The coating exhibited good durability and stability against abrasion for at least 150 cycles, acid and alkali resistance within 28 d, sunlight exposure, and heat treatment at 105 °C with nearly no change in the light-selective transmittance. The water resistance of the coating was also excellent, indicating the expanded potential of inorganic coatings for outdoor applications. Additionally, the temperature difference between the coated glass in the device and the uncoated glass reached up to 5.2 °C. This study provides a reference for preparing stable and transparent thermal insulation coatings.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 10","pages":"Pages 13197-13206"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815587","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hongjuan Wang , Jing Li , Guobing Jiang , Tian Meng , Wei Zhou , Jieyue Zheng , Hongwu Liu , Hongxian Chen , Yuanyi Yang
{"title":"Effect of Li2CO3 on the preparation and performance of lightweight building ceramsite from oil-based drilling cutting pyrolysis residues","authors":"Hongjuan Wang , Jing Li , Guobing Jiang , Tian Meng , Wei Zhou , Jieyue Zheng , Hongwu Liu , Hongxian Chen , Yuanyi Yang","doi":"10.1016/j.ceramint.2025.01.168","DOIUrl":"10.1016/j.ceramint.2025.01.168","url":null,"abstract":"<div><div>In order to achieve promising performance and ensure a high utilization rate of oil-based drilling cuttings pyrolysis residues (ODCPRs) for fabricating the lightweight building ceramsite, Li<sub>2</sub>CO<sub>3</sub> was employed as a novel sintering additive during the sintering process in this work. The influence of Li<sub>2</sub>CO<sub>3</sub> addition on the bulk density, apparent density, expansion rate, 1 h water absorption, compressive strength and pore structure of the ODCPRs-based lightweight building ceramsite under different sintering temperatures were comprehensively studied. Furthermore, the high-temperature phase evolution mechanism and pore structure analysis of the ODCPRs-based lightweight building ceramsite were deeply discussed by the means of the thermal analysis high-temperature phase analysis and Micro-CT. The research findings suggested that the incorporation of Li<sub>2</sub>CO<sub>3</sub> as a sintering additive can reduce the density and foaming temperature of ceramsite, while enhance substrate strength and facilitate the formation of low-temperature liquid phase of ceramsite. Attributed to the disparity in ionic radii between Li<sup>+</sup> and Al<sup>3+</sup>, defect reactions will occur within the celsian crystal structure, thus reducing the activation energy for solid-phase reactions and effectively promoting their occurrence. Consequently, this effect would facilitate the formation of celsian crystals in ceramsite, and the obtained ODCPRs-based lightweight building ceramsite demonstrated desirable performance characterized by a relatively lower density, enhanced mechanical properties, and increased porosity. Thus, above findings has provided valuable insights for the utilization of recycled oil-based drilling cuttings.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 10","pages":"Pages 13237-13252"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815591","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Shao-hua Luo , Xiaolong Li , Zihan Wang , Shengxue Yan , Jianguang Chen
{"title":"Mechanical, low temperature degradation and biocompatibility of Ce-doped dental 3Y-TZP ceramics","authors":"Shao-hua Luo , Xiaolong Li , Zihan Wang , Shengxue Yan , Jianguang Chen","doi":"10.1016/j.ceramint.2025.01.173","DOIUrl":"10.1016/j.ceramint.2025.01.173","url":null,"abstract":"<div><div>3Y-TZP is a high-performance advanced ceramic material, which has a wide range of applications in industrial and biomedical fields. However, 3Y-TZP ceramics may face the problem of low-temperature aging due to this, which limits its development in the medical field. This study is aimed at investigating the effect of a certain amount of CeO<sub>2</sub> doping on the overall properties of 3Y-TZP ceramics. The 3Y-TZP powder was prepared using the co-precipitation method. Subsequently it was mixed with various proportions of cerium oxide powder. The fitting results using the Johnson-Mehl-Avramorow-Kolmogorov (JMAK) equation indicated that CeO<sub>2</sub> doping was a useful addition to enhance its anti-ageing properties. The modified material was found to have good biocompatibility, which suggests a promising outlook for its development in the field of dentistry.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 10","pages":"Pages 13288-13297"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815595","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yan Lou , Qingke Yu , Jiangtao Yu , Piao Qv , Guijian Huang , Mingyu Liu
{"title":"Fabrication of hydrophobic zirconia ceramic mould inserts through the integration of self-assembled monolayer modification and stereolithography 3D printing technology","authors":"Yan Lou , Qingke Yu , Jiangtao Yu , Piao Qv , Guijian Huang , Mingyu Liu","doi":"10.1016/j.ceramint.2024.12.531","DOIUrl":"10.1016/j.ceramint.2024.12.531","url":null,"abstract":"<div><div>Microstructured ceramic mould inserts face significant challenges in practical applications due to their hydrophilicity. Self-assembled monolayers (SAMs), recognized as a promising surface modification technology for micro-nanostructured surfaces, offer a potential solution to this issue. Meanwhile, stereolithography (SLA) 3D printing, with its exceptional flexibility and precise manufacturing capabilities for complex structures, is particularly well-suited for applications in micro-nanostructured moulds. This study proposes a novel method for fabricating hydrophobic zirconia microstructured mould inserts by combining SLA 3D printing with SAM modification. The results show that phosphonic acid SAMs significantly reduce the surface free energy of zirconia ceramics, transforming the surface from hydrophilic to hydrophobic and increasing the water contact angle by 114.8 %. Compared to commercial zirconia ceramics, SAM technology demonstrates superior modification effects on 3D-printed zirconia surfaces, achieving over twofold improvements in hydrophobicity and frictional properties. Among the three SAMs with varying chain lengths, short-chain hexyl phosphonic acid (HPA) SAMs exhibit the highest molecular packing density and order. Additionally, phosphonic acid SAMs significantly reduce the friction coefficient of 3D-printed zirconia, effectively minimizing surface fatigue and wear while enhancing wear resistance. The study identifies molecular packing density and order as critical factors influencing surface wettability, friction performance, and stability, with these properties improving consistently with greater packing density and order. Finally, zirconia microstructured mould inserts modified with HPA SAMs successfully injection-moulded polypropylene (PP) micro-cylinders with a diameter of 650 μm and a height of 1195 μm, achieving automatic demoulding. This study highlights the potential of 3D-printed zirconia moulds in practical applications, offering new directions for innovation in this field.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11121-11135"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815131","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yang Sheng , Li Wang , Rui Dou , Fangyong Zhu , Yufeng Gao
{"title":"Effects of dopants with varying cationic radii on the mechanical properties and hydrothermal aging stability of dental 3Y-TZP ceramics fabricated via vat photopolymerization","authors":"Yang Sheng , Li Wang , Rui Dou , Fangyong Zhu , Yufeng Gao","doi":"10.1016/j.ceramint.2025.01.038","DOIUrl":"10.1016/j.ceramint.2025.01.038","url":null,"abstract":"<div><div>In this study, the mechanical properties and hydrothermal aging stability of small amounts of cation dopant M-doped 3Y-TZP (M = Er<sub>2</sub>O<sub>3</sub>, CeO<sub>2</sub>, Nb<sub>2</sub>O<sub>5</sub>) prepared via vat photopolymerization were investigated. Four zirconia ceramic slurries with high solid content (58 vol%) and low viscosity were prepared by adding three different dopants, along with an undoped control. The phase composition and lattice parameters were analyzed using X-ray diffraction (XRD) and Rietveld refinement. The microstructure was examined via scanning electron microscopy (SEM). Mechanical properties were evaluated for hardness, toughness and the three-point flexural strength with Weibull analysis. Hydrothermal aging stability was also assessed. The dopants had little effect regarding the shrinkage and density of the ceramics in comparison to the undoped ceramics. However, the average grain size of sintered 3Y-TZP at 1500 °C increased with dopant addition. X-ray diffraction showed that both doped and undoped ceramics were predominantly tetragonal, although the monoclinic phase content increased with doping. The doped ceramics also exhibited improved fracture toughness. After 20 h of low-temperature degradation (LTD), 3Y-TZP ceramics exhibited a time-dependent transformation from the tetragonal to the monoclinic phase during aging, with the monoclinic phase content in the Er<sub>2</sub>O<sub>3</sub>-doped 3Y-TZP reaching only 18.30 %. Additionally, Er<sub>2</sub>O<sub>3</sub>-doped 3Y-TZP exhibited lower tetragonality (c/a√2 = 1.0142) and demonstrated flexural strength exceeding 800 MPa. Dental Er<sub>2</sub>O<sub>3</sub>-doped 3Y-TZP, prepared using the VPP technology, demonstrates high LTD resistance and excellent mechanical properties.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11857-11870"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815150","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yang Yu , Ziyue Zhou , Siyuan Li , Xuan Gao , Yu Feng , Weidong Fei , Qingguo Chen
{"title":"Enhanced voltage stability of TiO2-based ceramics with colossal permittivity induced by multiple acceptors doping","authors":"Yang Yu , Ziyue Zhou , Siyuan Li , Xuan Gao , Yu Feng , Weidong Fei , Qingguo Chen","doi":"10.1016/j.ceramint.2025.01.039","DOIUrl":"10.1016/j.ceramint.2025.01.039","url":null,"abstract":"<div><div>In view of the demands for colossal permittivity materials in rapidly soaring developments of modern electronics and energy storage, the high dielectric performance co-doped TiO<sub>2</sub> ceramics often suffer from their low voltage stability and poor electrical insulation. Exploring the method of improving the withstand voltage strength and voltage stability for colossal permittivity materials is necessary. In this work, Tb<sup>3+</sup> was added in (Ta<sub>0.5</sub>Tb<sub><em>x</em></sub>Al<sub>0.5-<em>x</em></sub>)<sub>0.02</sub>Ti<sub>0.98</sub>O<sub>2</sub> to investigate the effect of defect complex formed by co-dopants on microstructure, permittivity and current density performance. The results indicated that the addition of Tb<sup>3+</sup> could enhance the permittivity to above 10<sup>5</sup>, featuring excellent frequency-stability. Moreover, the current density of (Ta<sub>0.5</sub>Tb<sub><em>x</em></sub>Al<sub>0.5-<em>x</em></sub>)<sub>0.02</sub>Ti<sub>0.98</sub>O<sub>2</sub> ceramics with <em>x</em> value of 0.1 was reduced three orders of magnitude. This work provides a new strategy for enhance the permittivity and voltage stability of TiO<sub>2</sub>-based CP materials by addition two acceptors with large-radius distinction.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11871-11877"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815151","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Ju Zhou , Na Zheng , Chunmei Liu , Yibing Wu , Mamdouh Omran , Ju Tang , Fan Zhang , Guo Chen
{"title":"Crystal growth mechanism of nano nSc-Y/ZrO2 ceramic powders prepared by co-precipitation method","authors":"Ju Zhou , Na Zheng , Chunmei Liu , Yibing Wu , Mamdouh Omran , Ju Tang , Fan Zhang , Guo Chen","doi":"10.1016/j.ceramint.2025.01.040","DOIUrl":"10.1016/j.ceramint.2025.01.040","url":null,"abstract":"<div><div>The method of co-precipitation is shown to yield nSc-Y/ZrO<sub>2</sub> composite nanopowders with high density, good dispersion and crystallinity. Furthermore, the samples without Sc doping were mainly comprised of monoclinic ZrO<sub>2</sub> phase and trace amounts of tetragonal ZrO<sub>2</sub>, whereas with the addition of Sc, the powders showed a great deal of tetragonal ZrO<sub>2</sub> structure and a minor quantity of cubic phase ZrO<sub>2</sub>. By comparing the sintered specimens with undoped Sc and other sintered specimens with different dopant contents, it was found that the sintered samples with a doping ration of 6Sc-2Y-92Zr have denser microstructures as well as smaller activation energies for grain growth (162.48 kJ/mol). Notably, the sintering shrinkage of nSc-Y/ZrO<sub>2</sub> ceramic powders with different dopant contents increases first and then decreases. The maximum linear shrinkage (41.67 %) and volumetric shrinkage (3.11 %) are observed at 6Sc-2Y-92Zr. Therefore, the addition of Sc helps to promote the degree of sintering of the Sc<sub>2</sub>O<sub>3</sub>-Y<sub>2</sub>O<sub>3</sub>-ZrO<sub>2</sub> samples, but too much Sc leads to a smaller final shrinkage. The nSc-Y/ZrO<sub>2</sub> nanopowders prepared in this experiment can be used to prepare nanoceramics with high density, high dispersion, and good crystallinity, which are good candidates for defense industry, thermal barrier coating.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11878-11888"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815152","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Fatima Tariq , Umaira Rafiq , Sofia Siddique , Zeid A. ALOthman , Imran Shakir , Muhammad Farooq Warsi
{"title":"Evaluating the synergistic effect of Cu/Zr co-doped Co3O4@CNTs nanocomposite for removal of drugs and dyes from industrial wastewater","authors":"Fatima Tariq , Umaira Rafiq , Sofia Siddique , Zeid A. ALOthman , Imran Shakir , Muhammad Farooq Warsi","doi":"10.1016/j.ceramint.2025.01.042","DOIUrl":"10.1016/j.ceramint.2025.01.042","url":null,"abstract":"<div><div>Water treatment faces challenges due to the low efficiency and stability of current photocatalysts in degrading persistent pollutants in wastewater. A photocatalyst should have a larger surface area, better electronic conductivity, a minimum charge recombination rate, and a visible light active narrow optical band gap probability. The Co<sub>3</sub>O<sub>4</sub> (CO) and Cu/Zr co-doped Co<sub>3</sub>O<sub>4</sub> (CZCO) were synthesized by the co-precipitation route. Then carbon nanotubes (CNTs) were incorporated via ultrasonication route to enhance their efficiency by increasing surface area and tuning the band gap energy. The degradation of two model pollutants, Amoxicillin (AMX) and Bromothymol blue dye (BTB), investigated the photocatalytic efficiency of the fabricated samples. Characterization techniques, like FTIR, XRD, UV–visible spectroscopy, photoluminous spectroscopy, EDX, SEM, and TOC analyses confirmed the successful fabrication. Electrical conductivity and charge transfer resistance were analyzed by Mott Schottky and EIS analysis, respectively. Cu/Zr co-doped Co<sub>3</sub>O<sub>4</sub>@CNTs (CZCO/C) showed 83.45 % AMX and 89.55 % BTB degradation within 90 min. CZCO/C showed enhanced performance due to reduced bandgap energy, and charge recombination rate than CO and CZCO. Overall, the results indicated that the CZCO/C nanocomposite is a promising material for effective photocatalytic applications in environmental remediation.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 9","pages":"Pages 11899-11913"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815154","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Yuanqiang Luo , Quancai Zhao , Weidong Tang , Cong Mao , Longzhou Dai , Jize Zhang , Jikai Yao , Abdur Razzak , Xiaoming Kang
{"title":"Material removal mechanism of alumina ceramics with powder-mixed electrochemical discharge-drilling hybrid machining","authors":"Yuanqiang Luo , Quancai Zhao , Weidong Tang , Cong Mao , Longzhou Dai , Jize Zhang , Jikai Yao , Abdur Razzak , Xiaoming Kang","doi":"10.1016/j.ceramint.2025.01.152","DOIUrl":"10.1016/j.ceramint.2025.01.152","url":null,"abstract":"<div><div>Engineering ceramics have excellent properties such as high hardness and strength, resistance to high temperature, wear and corrosion, However, these ceramics also pose great challenges to processing techniques. A novel method of powder-mixed electrochemical discharge-drilling hybrid machining (PMECDDM) for alumina ceramics was proposed in this paper. The thermal removal mechanism of alumina ceramics during the hybrid machining process were analyzed. The temperature distribution on alumina ceramics under the action of the single-pulse electrochemical discharge was obtained based on a thermal-fluid coupling multiphysics simulation model. The axial force during the material removal process in mechanical drilling (MD) was comprehensively analyzed. Experiments were conducted under constant force feed condition to investigate the micro-hole machining performance of alumina ceramics by different machining methods. Experimental results revealed that a new form of discharge was generated after the introduction of the micro copper powder into the electrochemical discharge-mechanical drilling hybrid machining process, which increased the local discharge energy and strengthens the softening effect of the discharge on alumina ceramics. Compared to MD, the machined surface of PMECDDM exhibited fewer brittle fracture areas, resulting in improved surface quality. Compared with the conventional electrochemical discharge-drilling hybrid machining (ECDDM), the machining efficiency of PMECDDM was increased by approximately 47 %.</div></div>","PeriodicalId":267,"journal":{"name":"Ceramics International","volume":"51 10","pages":"Pages 13058-13068"},"PeriodicalIF":5.1,"publicationDate":"2025-04-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"143815158","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}