Two-dimensional (2D) lead-free (K, Na)NbO 3 (KNN) micro/nano structures with controllable K/Na ratio were successfully fabricated via a two-step molten salt synthesis (MSS). In this work, the reaction factors, including the proportion of molten salts, the types of carbonates, the sintering temperature, and the sintering time, were discussed in detail and the optimized condition was identified. The microstructure of KNN was confirmed by confocal Raman spectroscopy, while piezoresponse force microscopy (PFM) was applied to measure three-dimensional (3D) morphology and piezoelectric properties of KNN particles. The as-synthesized KNN platelets apparently possess anisotropic morphology and uniform structure, the size of which reaches 5-20 µm in length/width and 0.5-1 µm in thickness. It should be noted that the K/Na ratios of the KNN crystals are basically consistent while the proportion of salts changes within a certain range. The enrichment of Na element in the products is also observed, which owes to the smaller ionic radius of Na + comparing to that of K +. This result provides a reference for the further preparation of textured ceramics and flexible piezoelectric generators.

The initiation and propagation of cracks are crucial to the reliability and stability of thermal barrier coatings (TBCs). It is important and necessary to develop an effective method for the prediction of the crack propagation behavior of TBCs. In this study, an extended finite element model (XFEM) based on the real microstructure of nanostructured TBCs was built and employed to elucidate the correlation between the microstructure and crack propagation behavior. Results showed that the unmelted nano-particles (UNPs) that were distributed in the nanostructured coating had an obvious “capture effect” on the cracks, which means that many cracks easily accumulated in the tensile stress zone of the adjacent UNPs and a complex microcrack network formed at their periphery. Arbitrarily oriented cracks mainly propagated parallel to the x-axis at the final stage of thermal cycles and the tensile stress was the main driving force for the spallation failure of TBCs. Correspondingly, I and I–II mixed types of cracks are the major cracking patterns.

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Successive impingement of droplets after refining in supersonic plasma jet generally yields a submicron-sized lamellar coating with excellent comprehensive properties. Nevertheless, physical insight into the flattening and rapid solidification with crystallization behavior of supersonic impingement of refined droplets is difficult to understand. In this research, the content of refinement droplets reached 90% and displayed the multi-scale distribution of equiaxed grains. The boundary migration of equiaxed grains and anisotropic coalescence was found in the dynamic temperature gradient. Furthermore, an optimized model was established in order to accurately reproduce the multi-physical coupling process of supersonic impingement of single or two refined droplets, which was based on the numerical calculation of nonlinear equations (including the Mass and momentum, energy balance, Cahn–Hilliard, phase-field and orientational field equations). The size distribution and growth orientation of columnar grains within single or two flattened droplets were in good agreement with the experimental results. Epitaxial growth of columnar grains was found in the two-flattened droplet interface during the extremely rapid cooling stage. This optimized model could be an effective method in predicting the flattening and solidification with crystallization behavior of droplets during plasma spraying.