Creep of SiC–SiC microcomposites

The creep behavior of SiC/C/SiC microcomposites at 1200–1400 °C and 140–450 MPa was investigated in the presence and absence of matrix cracking. The microcomposites consisted of single Hi Nicalon or Carborundum fibers coated with a CVD carbon interlayer and a CVD SiC matrix. Since the fibers and matrix had been examined by the identical experimental technique, direct comparisons of the creep of the composite and of the constituents were performed. The creep of uncracked microcomposites was successfully modeled using a simple rule of mixtures algorithm. When matrix cracks were present, the microcomposites were modeled using a series composite consisting of intact microcomposite, exposed fiber at the matrix crack, and the debonded region in between. Trends for behavior with respect to the various mechanical and structural parameters that control creep are presented.     

Effect of SiC on the corrosion resistance of electroless Cu–P–SiC composite coating

In this work, Cu–P–SiC composite coatings were deposited via electroless plating with the addition of sodium hypophoshite (NaH₂PO₂) as a reducing agent. The coating compositions deposited were determined by using energy dispersive X-ray spectroscopy (EDX). The surface morphology of the coatings that were analyzed using scanning electron microscopy (SEM) showed that SiC particles were uniformly distributed by virtue of surfactant addition and mechanical stirring. The anti-corrosion properties of Cu–P and Cu–P–SiC coatings in NaCl and HCl solutions were investigated by the weight loss and potentiodynamic polarization techniques. The results showed that the corrosion resistance of Cu–P–SiC coatings was superior to that of electroless Cu–P coatings and carbon steel substrates in various concentrations of NaCl and HCl solutions.     

Development of SiC–Si composites with fine-grained SiC microstructures

This work summarises the influence of the original particle-size of the SiC powder on the mechanical properties of silicon infiltrated SiC (SiC-Si) composite. These composites are based on a defined SiC particle-size structure. Using α-SiC powders with a mean particle-size of 12·8, 6·4, 4·5 and 3 μm, a clear linear enhancement of the bending strength with decrease of SiC-particle-size was observed. However, a further decrease of the SiC particle-size (from 3 to 0·5 μm) brought no increase of the strength and toughness, respectively. ©     

Effect of oxidation treatment on KD–II SiC fiber–reinforced SiC composites

Continuous silicon carbide fiber–reinforced silicon carbide matrix (SiC_f/SiC) composites have developed into a promising candidate for structural materials for high–temperature applications in aerospace engine systems. This is due to their advantageous properties, such as low density, high hardness and strength, and excellent high temperature and oxidation resistance. In this study, SiC_f/SiC composites were fabricated via polymer infiltration and pyrolysis (PIP) with the lower–oxygen–content KD–II SiC fiber as the reinforcement; a mixture of 2,4,6,8–tetravinyl–2,4,6,8–tetramethylcyclotetrasiloxane (V4) and liquid polycarbosilane (LPCS), known as LPVCS, was used as the precursor; while pyrolytic carbon (PyC) was used as the interface. The effects of oxidation treatment at different temperatures on morphology, structure, composition, and mechanical properties of the KD–II SiC fibers, SiC matrix from LPVCS precursor conversion, and SiC_f/SiC composites were comprehensively investigated. The results revealed that the oxidation treatment greatly impacted the mechanical properties of the SiC fiber, thereby significantly influencing the mechanical properties of the SiC_f/SiC composite. After oxidation at 1300 °C for 1 h, the strength retention rates of the fiber and composite were 41% and 49%, respectively. In terms of the phase structure, oxidation treatment had little effect on the SiC fiber, while greatly influencing the SiC matrix. A weak peak corresponding to silica (SiO₂) appeared after high–temperature treatment of the fiber; however, oxidation treatment of the matrix led to the appearance of a very strong diffraction peak that corresponds to SiO₂. The analysis of the morphology and composition indicated cracking of the fiber surface after oxidation treatment, which was increasingly obvious with the increase in the oxidation treatment temperature. The elemental composition of the fiber surface changed significantly, with drastically decreased carbon element content and sharply increased oxygen element content.     

Erosion behavior of SiC–WC composites

Dense silicon carbide (SiC) ceramics were prepared with 0, 10, 30 or 50 wt% WC particles by hot pressing powder mixtures of SiC, WC and oxide additives at 1800 °C for 1 h under a pressure of 40 MPa in an Ar atmosphere. Effects of alumina or SiC erodent particles and the WC content on the erosion performance of sintered SiC–WC composites were assessed. Microstructures of the sintered composites consisted of WC particles distributed in the equi-axed grain structure of SiC. Fracture surfaces showed a mixed mode of fracture, with a large extent of transgranular fracture observed in SiC ceramics prepared with 30 wt% WC. Crack bridging by WC enhanced toughening of the SiC ceramics. A maximum fracture toughness of 6.7 MPa*m^1/2 was observed for the SiC ceramics with 50 wt% WC, whereas a high hardness of 26 GPa was obtained for the SiC ceramics with 30 wt% WC. When eroded at normal incidence, two orders of magnitude less erosion occurred when SiC–WC composites were eroded by alumina particles than that eroded by SiC particles. The erosion rate of the composites increased with increasing angle of SiC particle impingement from 30° to 90°, and decreased with WC reinforcement up to 30 wt%. A minimum erosion wear rate of 6.6 mm³/kg was obtained for SiC–30 wt% WC composites. Effects of mechanical properties and microstructure on erosion of the sintered SiC–WC composites are discussed, and the dominant wear mechanisms are also elucidated.     

Electrodeposition of Zn–SiC nanocomposite coatings

Zn–SiC composite coatings were obtained on mild steel substrate by electrodeposition technique with high-current efficiency. A slightly acidic chloride bath, containing SiC nanoparticles and gelatine as additive, was used. The electrodeposition was carried out under galvanostatic control with pulsed direct current; the effect of experimental parameters (temperature, average current density and particles concentration) on composition, morphology and structure of the deposit was studied. Coatings were characterized by means of scanning electron microscopy, energy dispersive X-ray analysis, X-ray diffractometry and Vickers microhardness measurements. Zn–SiC electrodeposits with the best characteristics were obtained by performing electrodepositions at 45 °C, with 20 g L^?1 SiC in the bath and with average current density in the range 100–150 mA cm^?2. Under these experimental conditions, homogeneous and compact coatings, with low-grain size and SiC content ranging from 1.7 to 2.1 wt%, were found to be electrodeposited. Microhardness measurements showed for these deposits an increase of about 50 % with respect to those without nanoparticles obtained in the same experimental conditions.     

Processing–microstructure–properties relationships of MoSi2–SiC composites

Silicon carbide green bodies with and without carbon-fibre reinforcement have been infiltrated with MoSi₂–Si–X in order to produce high-temperature resistant materials. X is Cr, Ti, Al or B respectively. By adding silicon and one of these components to MoSi₂ the melting point is lowered dramatically. The composites therefore could be gained by melt infiltration at max. 1600 °C. During infiltration the additives react within the infiltrated body with carbon or silicon to form high-temperature resistant carbides or silicides. Thermodynamic calculations have been performed to analyse the reactions during infiltration. The infiltration parameters have been studied with respect to the resulting microstructure and properties. By fitting the amount of additives to the quantity of carbon in the SiC-body (or vice versa) no decrease in strength could be observed up to 1500 °C. The fracture toughness can be increased by the use of high-modulus carbon fibres. The most promising X-element for a high-temperature resistant material is titanium.     

Oxidation resistance of hot-pressed SiC–BN composites

The oxidation resistance of SiC–BN composites with different BN content hot-pressed from Si₃N₄, B₄C and C was investigated. The oxidized products of SiC and BN were identified to be SiO₂, C and B₂O₃, N₂. SiO₂ and B₂O₃ could further form a borosilicate glass which covered the surfaces of the samples and withstood oxidation because of its flowability and self-healing. The oxidation resistance of the SiC–BN composites in static air atmosphere deteriorated with the increase of temperature as well as of the BN content.     

In situ synthesis and interfacial bonding mechanism of SiC in MgO–SiC–C refractories

Adding SiC directly to MgO–C refractories possesses the disadvantages of low dispersion and interfacial bonding strength. Herein, the in situ synthesized SiC was introduced into the MgO–SiC–C refractories to maintain the original excellent performance of MgO–C refractories and reduce the carbon dissolution in molten steel. With the increase of Si and C content in raw materials, the morphology of SiC changed from whisker to network, whose growth mechanism was vapor–solid and vapor–liquid–solid. The network structure and uniform distribution of SiC improved the thermal shock resistance of MgO–SiC–C refractories. According to the analysis of molecular dynamics simulation by Materials Studio software, SiC strengthened the relationship between periclase and graphite to enhance the structure of the compound.     

Influence of annealing on the mechanical properties of SiC–Si composites with sub-micron SiC microstructures

The influence of annealing temperature (1000, 1100 and 1200°C) on the mechanical properties of SiC–Si composites has been evaluated. Three SiC powders with particle sizes in the range of 0.24 to 0.7 μm were used to produce the composites. Before application the SiC powders were treated with hydrofluoric acid to remove the extent of SiO₂. With this treatment a successful infiltration of green-bodies especially produced of SiC powder with a mean particle size of 0.24 μm was possible. The bending strength decreased with decreasing SiC starting particle size as well as with increasing annealing temperature. However, the fracture toughness was independent on SiC starting particle size and annealing temperature. XRD diffraction analysis showed that internal stress, expressed by broadening of XRD peaks, is low and had no effects on the mechanical properties of the composites.     

Structural characterization of plasma sprayed basalt–SiC glass–ceramic coatings

In the present study, the effect of SiC addition on properties of basalt base glass–ceramic coating was investigated. SiC reinforced glass–ceramic coating was realized by atmospheric air plasma spray coating technique on AISI 1040 steel pre-coated with Ni + 5 wt.%Al bond coat. Composite powder mixture consisted of 10%, 20% and 30% SiC by weight were used for coating treatment. Controlled heat treatment for crystallization was realized on pre-coated samples in argon atmosphere at 800 °C, 900 °C and 1000 °C which determined by differential thermal analysis for 1–4 h in order to obtain to the glass–ceramic structure. Microstructural examination showed that the coating performed by plasma spray coating treatment and crystallized was crack free, homogeneous in macro-scale and good bonded. The hardness of the coated samples changed between 666 ± 27 and 873 ± 32 HV_0.01 depending on SiC addition and crystallization temperature. The more the SiC addition and the higher the treatment temperature, the harder the basalt base SiC reinforced glass–ceramic coating became. X-ray diffraction analysis showed that the coatings include augeite [(CaFeMg)–SiO₃], diopside [Ca(Mg_0.15Fe_0.85)(SiO₃)₂], albite [(Na,Ca)Al(Si,Al)₃O₈], andesine [Na_0.499Ca_0.492(Al_1.488Si_2.506O₈] and moissanite (SiC) phases. EDX analyses support the X-ray diffraction analysis.     

Spark plasma sintering of quadruplet ZrB2–SiC–ZrC–Cf composites

Spark plasma sintering (SPS) route was employed for preparation of quadruplet ZrB₂–SiC–ZrC–C_f ultrahigh temperature ceramic matrix composites (UHTCMC). Zirconium diboride and silicon carbide powders with a constant ZrB₂:SiC volume ratio of 4:1 were selected as the baseline. Mixtures of ZrB₂–SiC were co-reinforced with zirconium carbide (ZrC: 0–10 vol%) and carbon fiber (C_f: 0–5 vol%), taking into account a constant ratio of 2:1 for ZrC:C_f components. The sintered composite samples, processed at 1800 °C for 5 min and 30 MPa punch press under vacuumed atmosphere, were characterized by densitometry, field emission scanning electron microscopy, energy dispersive spectroscopy, X-ray diffractometry as well as mechanical tests such as hardness and flexural strength measurements. The results verified that the composite co-reinforced with 5 vol% ZrC and 2.5 vol% C_f had the optimal characteristics, i.e., it reached a relative density of 99.6%, a hardness of 18 GPa and a flexural strength of 565 MPa.     

Mechanochemical synthesis of MoSi2–SiC nanocomposite powder

MoSi₂–25 wt.%SiC nanocomposite powder was successfully synthesized by ball milling Mo, Si and graphite powders. The effect of milling time and annealing temperature were investigated. Changes in the crystal structure and powder morphology were monitored by XRD and SEM, respectively. The microstructure of powders was further studied by peak profile analysis and TEM. MoSi₂ and SiC were synthesized after 10 h of milling. Both high and low temperature polymorphs (LTP and HTP) of MoSi₂ were observed at the short milling times. Further milling led to the transformation of LTP to HTP. On the other hands, an inverse HTP to LTP transformation took place during annealing of 20 h milled powder at 900 °C. Results of peak profile analysis showed that the mean grain size and strain of the 20 h milled powder are 31.8 nm and 1.19% that is in consistent with TEM image.     

Combustion synthesis of AlN–SiC solid solution particles

The feasibility of synthesising AlN–SiC solid solution ceramics by combustion synthesis (CS) reaction is demonstrated through igniting the mixtures of aluminium, silicon and carbon black under different nitrogen pressure values. The effects of the nitrogen pressure and the atomic ratio of (Si+C)/Al on the crystalline phases formed in the reaction product and on the characteristics of combustion behaviour were investigated. Combining thermodynamic analysis and the combustion characteristics, the reaction sequence and the formation of AlN–SiC solid solution by CS were explained.     

Polymeric liquid precursor of multi-component ZrC–SiC ceramic

Polymeric liquid ceramic precursors for the production of multi-component ZrC–SiC ceramics were prepared by reactive blending of polyzirconoxanesal, phenylacetylene-terminated polysilane and bisphenol-A type benzoxazine. The polymeric liquid precursors of ZrC–SiC ceramic have the processing capability of Precursor-Infiltration-and-Pyrolysis technique in ceramic composites fabrication. The thermal cure reactions included by the catalytic polymerisation of ethynyl groups, the ring opening polymerisation of benzoxazine rings, and the condensation of zirconate with phenolic hydroxyl and Si–H at 200–350°C. The monolithic ceramics were formed upon pyrolysis at 1000, 1200 and 1600°C in a yield of 65, 62 and 40%, respectively. X-ray diffraction and SEM–EDS results revealed that almost pure, elemental, uniformly distributed ZrC–SiC multi-component ceramic monolith was obtained through pyrolysis at 1600°C via carbothermal reduction of ZrO₂.     

Ablation resistance and mechanism of SiC–LaB6 and SiC–LaB6–ZrB2 ceramics under plasma flame

In this study, silicon carbide-lanthanum hexaboride (SiC–LaB₆) and silicon carbide–lanthanum hexaboride–zirconium boride (SiC–LaB₆–ZrB₂) ceramics were fabricated by spark plasma sintering at 1900 °C, and their ablation resistance was tested under plasma flames over 2300 °C. The results indicate that the SiC–LaB₆–ZrB₂ ceramic exhibits better ablation resistance than the SiC–LaB₆ ceramic. After ablation under the plasma flame for 60 s, the mass and linear ablation rates of the SiC–LaB₆ ceramic were 15.83 μg/s and 1.08 μm/s, respectively, while those of SiC–LaB₆–ZrB₂ were -8.42 μg/s and -0.27 μm/s. With the addition of ZrB₂, SiC–LaB₆–ZrB₂ ceramic attained a high density and fewer inner oxygen diffusion channels. Moreover, the ZrO₂–La₂O₃–SiO₂ oxide scale with good self-healing ability and excellent stability was formed in the ablation centre, which can retard the further oxidation during ablation.     

Thermodynamic evaluation of SiC oxidation in Al2O3–MgAl2O4–SiC–C refractory castables

The literature suggests that MgAl₂O₄ can accelerate SiC oxidation in Al₂O₃–MgAl₂O₄–SiC–C refractory castables. Thus, in this work thermodynamic calculations have been carried out using FactSage^® software in order to explore, search for and understand the role of MgAl₂O₄ on the SiC oxidation. According to the thermodynamic predictions, at 1500 °C and under a reducing atmosphere, there is no evidence that spinel might directly affect SiC oxidation. The increase of SiC content in an Al₂O₃–SiC–C (AL) castable composition was mainly related to the reaction between mullite and carbon. On the other hand, the SiC generation in the Al₂O₃–MgAl₂O₄–SiC–C (SP) composition was a result of the reaction involving liquid SiO₂ and carbon from the refractory. Therefore, the lower SiC content in the SP castable resulted from the refractory's phase transformations. It was also suggested that the samples thermally treated 15 times at 1500 °C did not reach the equilibrium condition, which explains the differences between experimental and thermodynamic results.     

Reaction Synthesis and Mechanical Properties of TiB2–AlN–SiC Composites

TiB₂–AlN–SiC (TAS) ternary composites were prepared by reactive hot pressing at 2000°C for 60 min in an Ar atmosphere using TiH₂, Si, Al, B₄C, BN and C as raw powders. The phase composition was determined to be TiB₂, AlN and β-SiC by XRD. The distribution of elements Al and Si were not homogeneous, which shows that to obtain a homogeneous solid solution of AlN and SiC in the composites by the proposed reaction temperatures higher than 2000°C or time duration longer than 60 min are needed. The higher fracture toughness (6·35±0·74 MPa·m^1/2 and 6·49±0·73 MPa·m^1/2) was obtained in samples with equal molar contents of AlN and SiC (TAS-2 and TAS-5) in the TAS composites. The highest fracture strength (470±16 MPa) was obtained in TAS-3 sample, in which the volume ratio of TiB₂/(AlN+SiC) was the nearest to 1 and there was finer co-continuous microstructure. ©     

Creep behaviour of Al2O3–SiC nanocomposites

Compared with monolithic fine grained Al₂O₃, Al₂O₃ nanocomposites reinforced with SiC nanoparticles display especially high modulus of rupture as well as reduced creep strain. Taking into account the fracture mode change, the morphology of ground surfaces showing plastic grooving, the low sensitivity to wear and the low dependence of erosion rate with grain size, it can be reasonably assumed that the strength improvement is associated with an increase of the interface cohesion (due to bridging by SiC particles) rather than with a grain size refinement involving substructure formation (as initially suggested by Niihara). In the present work, creep tests have been performed and the results agree with such a reinforcement of the mechanical properties by SiC particle bridging Al₂O₃–Al₂O₃ grain boundaries. Indeed, particles pinning the grain boundaries hinder grain boundary sliding resulting in a large improvement in creep resistance. In addition, SiC particles, while counteracting sliding, give rise to a recoverable viscoelastic contribution to creep. Because of the increased interface strength, the samples undergoing creep support stress levels, greater than the threshold value required to activate dislocation motion. The high stress exponent value as well as the presence of a high dislocation density in the strained materials suggests that a lattice mechanism controls the deformation process. Finally, a model is proposed which fits well with the experimental creep results.     

Room temperature fatigue of ZrB2–SiC ceramic composites

Room temperature time dependent properties of ZrB₂–30 wt%SiC ceramic composite have been studied. Both static slow crack growth and cyclic fatigue deformation have been investigated. While static slow crack growth has been evaluated only in air, three different environments, water, air, and dry air, have been used to study the cyclic fatigue. It was established that under cyclic fatigue the environment plays an important role and humidity significantly facilitate crack growth in ZrB₂–30wt%SiC. The fractography of selected ZrB₂–30wt%SiC samples was performed and it was established that both defects introduced during machining as well as larger defects introduced during the processing served as fracture origins of ceramic composites.