Transition metal silicides like MoSi2 for high-temperature applications

Transition metal silicides, particularly molybdenum disilicide (MoSi2), have emerged as a cornerstone material for high-temperature applications due to their exceptional oxidation resistance, thermal stability, and mechanical properties. Recent studies have demonstrated that MoSi2 exhibits a high melting point of approximately 2030°C, making it suitable for environments exceeding 1600°C. Advanced characterization techniques, such as in-situ transmission electron microscopy (TEM), have revealed that MoSi2 maintains structural integrity under thermal cycling up to 1800°C with minimal grain growth (<5% increase in grain size after 100 cycles). This stability is attributed to the formation of a protective SiO2 layer during oxidation, which self-heals at elevated temperatures. Recent experiments show that the oxidation rate of MoSi2 at 1600°C is as low as 0.02 mg/cm²·h, outperforming traditional superalloys by an order of magnitude.

The mechanical properties of MoSi2 at high temperatures have been significantly enhanced through nanostructuring and alloying strategies. Nanocomposite MoSi2 reinforced with SiC nanoparticles exhibits a fracture toughness of 8.5 MPa·m¹/² at 1400°C, a 40% improvement over monolithic MoSi2. Additionally, alloying with tungsten (W) has been shown to increase the creep resistance by forming W5Si3 precipitates, reducing the creep rate to 1.2 × 10⁻⁸ s⁻¹ at 1500°C under a stress of 100 MPa. These advancements are critical for applications in turbine blades and aerospace components, where materials must withstand extreme mechanical loads at elevated temperatures.

Thermal conductivity and electrical resistivity are key parameters for high-temperature applications in thermoelectric devices and heating elements. Recent research has optimized the thermoelectric performance of MoSi2 through doping with rare earth elements like lanthanum (La). La-doped MoSi2 achieves a ZT value of 0.45 at 1000°C, a significant improvement over undoped MoSi2 (ZT = 0.25). Furthermore, the electrical resistivity of MoSi2 has been reduced to 15 µΩ·cm at room temperature through controlled defect engineering, making it an ideal candidate for high-temperature heating elements operating up to 1800°C.

The integration of MoSi2 into additive manufacturing processes has opened new frontiers for complex geometries in high-temperature applications. Laser powder bed fusion (LPBF) techniques have been employed to fabricate dense (>99.5%) MoSi2 components with tailored microstructures. Recent studies report that LPBF-produced MoSi2 exhibits a tensile strength of 450 MPa at room temperature and retains 80% of its strength at 1200°C. This breakthrough enables the production of lightweight, high-performance components for aerospace and energy systems.

Environmental sustainability and cost-effectiveness are critical considerations for the widespread adoption of MoSi2-based materials. Life cycle assessments (LCA) reveal that the production of MoSi2 generates approximately 30% less CO₂ emissions compared to nickel-based superalloys due to lower processing temperatures (~1600°C vs ~2000°C). Additionally, recent advances in powder synthesis have reduced raw material costs by up to 25%, making MoSi2 economically viable for large-scale industrial applications such as gas turbines and nuclear reactors.

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