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Fused Filament Fabrication (FFF) of Metal-Ceramic Components
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Metaceramic enables ultrahigh-temperature record rectification and programmable 3D thermal control.

Yishu Su1, Haoliang Huo1,2, Qianqian Wu1

  • 1National Key Laboratory of Science and Technology for Advanced Composites in Special Environments, Center for Composite Materials and Structures, Harbin Institute of Technology, Harbin 150080, P. R. China.

Science Advances
|June 17, 2026
PubMed
Summary
This summary is machine-generated.

This study introduces a novel metaceramic for extreme environments, achieving record thermal rectification ratios. This breakthrough overcomes limitations in high-temperature stability and nonlinear thermal response for advanced thermal management applications.

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Area of Science:

  • Materials Science
  • Thermodynamics
  • Nanotechnology

Background:

  • Thermal rectification is crucial for thermal management, but practical devices face limitations in high-temperature stability and rectification efficiency.
  • Conventional rectifiers operate below 900 K with ratios under 3.5, hindering applications in extreme environments.

Purpose of the Study:

  • To develop a material overcoming the trade-off between high-temperature stability and nonlinear thermal response for thermal rectification.
  • To present a novel metaceramic capable of efficient thermal management under extreme conditions.

Main Methods:

  • Architecting a monolithic metamaterial ceramic (metaceramic) with multiscale graded porosity.
  • Integrating four nonlinear heat transfer mechanisms: ion-tailored conduction, cavity-modulated radiation, chaotic advection-enhanced convection, and spontaneous convective dissipation.

Main Results:

  • Achieved a record thermal rectification ratio of 8.5 at 2473 K, exceeding previous benchmarks by over 140%.
  • Demonstrated a triaxial ultrahigh-temperature rectifier with programmable, volumetric thermal flow control, extending rectification to a tensor-like property.

Conclusions:

  • The metaceramic design overcomes the classical stability-nonlinearity conflict in thermal rectifiers.
  • This metamaterials platform enables breaking thermal reciprocity under extreme conditions, with applications in hypersonic systems, spacecraft, and energy technologies.