Shear failure evolution and its dispersion of plain woven ceramic matrix composites z-pin structure

In this paper, the digital image correlation technique was applied to the shear test of 2D SiC/SiC composites z-pin with the purpose of analyzing the shear behavior of the plain woven pin and studying the structure factors of test results dispersion. After obtaining the strain–stress curves of the joint's connection region, the evolution of z-pin shear failure process was investigated. The z-pin's failure fractures were observed, and the main factors of its dispersion of shear mechanical properties were discussed. Changing the yarn parameter of model building and importing into Workbench for calculation, the average stress results in the shear plane were obtained. Different simulation results show that optimization of plain-woven pin structure parameters can effectively improve its shear strength.     

Ultra-high-temperature mechanical behaviors of two-dimensional carbon fiber reinforced silicon carbide composites: Experiment and modeling

Carbon fiber reinforced silicon carbide (C/SiC) composites are enabling materials for components working in ultra-high-temperature extreme environments. However, their mechanical properties reported in the literature are mainly limited to room and moderate temperatures. In this work, an ultra-high-temperature testing method for the mechanical properties of materials in inert atmosphere is presented based on the induction heating technology. The flexural properties of a 2D plain-weave C/SiC are studied up to 2600 °C in inert atmosphere for the first time. The deformation characteristics and failure mechanisms at elevated temperatures are gained. Theoretical models for the high-temperature Young’s modulus and tensile strength of 2D ceramic matrix composites are then developed based on the mechanical mechanisms revealed in the experiments. The factors contributing to the mechanical behaviors of C/SiC at elevated temperatures are thus characterized quantitatively. The results provide significant understanding of the mechanical behaviors of C/SiC under ultra-high-temperature extreme environment conditions.     

Failure analysis of 2D C/SiC composite z-pinned/bonded hybrid single-lap joints

Z-pinned/bonded hybrid joints are widely used in the 2D C/SiC composite structures, whose mechanical behavior and failure mechanisms are directly related with the structure integrity. The hybrid joints for 2D C/SiC composite structures are formed by depositing SiC into the gap of z-pinned joints. To evaluate the SiC bonding effect, the tensile experiments for two kinds of z-pinned joints with and without bonded layer were conducted. It was proved that the failure modes of the pin were the tensile and shear failure, and the bonded layer was the interlaminar shear failure of the substrate plate instead of the shear failure of SiC bonded layer due to the smaller interlaminar shear strength. The bonded zone states of specimens were also examined, which were reproduced in the shell-fastener numerical model with surface-based cohesive behavior. Combining with shear strength theory, a numerical model is developed to study the failure processes of the hybrid joints. The SiC bonded zone areas can also greatly influence the failure response of the hybrid joints. The large SiC bonded layer zone can improve the shear strength of the joints. The failure of the joints is determined by the SiC bonded layer when the SiC bonded zone is large enough. This study can be helpful to evaluate and design the SiC bonded zone states of the hybrid joints in the engineering application.     

The effects of preparation temperature on the SiCf/SiC 3D4d woven composite

Continuous silicon carbide fiber reinforced silicon carbide matrix (SiC_f/SiC) composites have promising applications in aero-engine due to their unique advantages, such as low density, high modulus and strength, outstanding high temperature resistance and oxidation resistance. As SiC fibers are main reinforcements in SiC_f/SiC composites, the crystallization rate and initial damage degree of SiC fibers are seriously influenced by preparation temperatures of SiC_f/SiC composites, namely mechanical properties of SiC fibers and SiC_f/SiC composites are influenced by preparation temperatures. In this paper, KD-II SiC fibers were woven into 3D4d preforms and SiC matrix was fabricated by PIP process at 1100 °C, 1200 °C, 1400 °C and 1600 °C. Digital image correlation (DIC) method was adopted to measure the uniaxial tensile properties of these SiC_f/SiC composites. In addition, finite element method (FEM) based on representative volume element (RVE) was adopted to predict the mechanical properties of SiC_f/SiC composites. The good agreements between numerical results and experimental results of uniaxial tensile tests verified the validity of the RVE. In last, the transverse tensile, transverse shear, uniaxial shear properties were predicted by this method. The predicted results illustrated that axial tensile, transverse tensile and axial shear properties were greatly influenced by the preparation temperatures of SiC_f/SiC composites while transverse shear properties were not significantly various. And the mechanical properties of SiC_f/SiC composites peaked at 1200 °C among these four temperatures while their values reached their lowest points at 1600 °C because of thermal damage and brittle failure of SiC_f/SiC composites.     

化学气相渗透法制备2维和2.5维C/SiC复合材料及其拉伸性能

采用化学气相渗透法制备了2维和2.5维碳纤维增强碳化硅(carbon-fiber-reinforced silicon carbide,C/SiC)复合材料,沿经纱(纵向)和纬纱(横向) 2个方向对2种复合材料进行了室温拉伸性能测试,并从预制体结构和原始缺陷分布的角度对比分析了两者力学性能之间的差异.结果表明:两种C/SiC复合材料均表现出明显的非线性力学行为,在经纱方向和纬纱方向上,2维C/SiC复合材料力学性能表现为各向同性,而2.5维C/SiC复合材料力学性能则表现出明显的各向异性:经纱方向上2.5维C/SiC复合材料的拉伸强度和拉伸模量(326 MPa,153 GPa)均高于2维C/SiC复合材料的(245 MPa,96 GPa),纬纱方向上的(145 MPa,62 GPa)均低于2维C/SiC复合材料的(239 MPa,90 GPa).两种复合材料的拉伸断裂行为均表现为典型的韧性断裂,并伴有大量的纤维拔出.两种复合材料中纱线断裂均呈现出多级台阶式断裂方式,但其断裂位置并不相同.2.5维C/SiC复合材料中由于经纱路径近似于正弦波,弯曲程度较大,在纱线交叉点处造成明显的应力集中,因此经纱多在纱线交叉点处断裂;而纬纱由于其路径近乎直线,应力集中现象不明显,因此纬纱断裂位置呈随机分布.2维C/SiC复合材料中经纱和纬纱由于其路径类似于2.5维C/SiC复合材料中的经纱,因此其断裂位置也多在纱线交叉点处.微观结构观察表明不同的编织结构是造成两种复合材料在不同方向上力学性能差异的主要原因.     

Correlation among crystalline morphology of PEEK,interface bond strength,and in‐plane mechanical properties of carbon/PEEK composites

The effect of the cooling rate on in‐plane and interlaminar properties of carbon fiber/semicrystalline PEEK matrix composites was studied. Strengths and moduli were measured in tension, flexure, and interlaminar shear, all of which were shown to correlate, to different degrees, with the fiber–matrix interface adhesion and the bulk matrix properties. The in‐plane and interlaminar properties, in general, increased with a decreasing cooling rate, which was attributed to changes in the failure mechanism from adhesive failure involving fiber–matrix interface debonding at high cooling rates to matrix‐dominant cohesive failure at low cooling rates. The present study demonstrates that the mechanical properties of semicrystalline thermoplastic composites can be tailored for desired applications by controlling the processing conditions, especially the cooling rate. © 2002 Wiley Periodicals, Inc. J Appl Polym Sci 84: 1155–1167, 2002; DOI 10.1002/app.10406     

Insights into fracture mechanisms and strength behaviors of two-dimensional carbon fiber reinforced silicon carbide composites at elevated temperatures

Carbon fiber reinforced silicon carbide (C/SiC) composites are usually subjected to thermal-mechanical-oxidation-coupled loads during service. However, their mechanical properties at ultra-high temperatures in oxidizing environments have rarely been reported. In this paper, a method based on the induction heating technology is proposed for testing the ultra-high-temperature mechanical properties of materials in air. The flexural behaviors of a 2D plain-weave C/SiC material prepared via chemical vapor infiltration are investigated in air up to 1800 °C for the first time. Inverse temperature dependences of the flexural modulus and strength are observed. New fracture mechanisms that are responsible for the mechanical behaviors at elevated temperatures are elucidated. Fracture modes at different temperatures are proposed. A high-temperature fracture strength model for oxidizing environments is developed, which is in good agreement with the experimental results. The factors affecting the fracture strength behaviors of the C/SiC in air at elevated temperatures are characterized quantitatively.     

三维针刺C/SiC复合材料无纬布纤维方向对材料力学性能的影响

通过化学气相渗透法结合反应熔体浸渗法制备了三维针刺C/SiC复合材料,采用扫描电子显微镜观察材料的显微结构,并研究了无纬布纤维方向对材料力学性能的影响.结果表明,三维针刺C/SiC复合材料由O°无纬布层、短纤维胎网层、90°无纬布层以及针刺纤维束组成,无纬布层纤维方向对材料性能有显著影响.试样的拉伸强度和弯曲强度随着无纬布纤维方向与试样长度方向的夹角θ(0 ～45°)值的增大而减小,面内剪切强度和冲击韧性随θ角的增大而增大.     

Effects of heat treatment on the mechanical properties at elevated temperatures of plain-woven SiC/SiC composites

The effects of heat treatment on the mechanical properties of plain-woven SiC/SiC composites at 927 °C and 1200 °C in argon were evaluated through tensile tests at room temperature and at elevated temperature on the as-received and heat-treated plain-woven SiC/SiC composites, respectively. Heat treatment can improve the mechanical properties of composites at room temperature due to the release of thermal residual stress. Although heat treatment can damage the fiber, the effect of this damage on the mechanical properties of composites is generally less than the effect of thermal residual stress. Heat treatment will graphitize the pyrolytic carbon interface and reduce its shear strength. Testing temperature will affect the expansion or contraction of the components in the composites, thereby changing the stress state of the components. This study can provide guidance for the optimization of processing of ceramic matrix composites and the structural design in high-temperature environments.     

Microstructure and Mechanical Properties of Three-Dimensional Textile Hi-Nicalon SiC/SiC Composites by Chemical Vapor Infiltration

Three-dimensional textile Hi-Nicalon SiC-fiber-reinforced SiC composites were fabricated using chemical vapor infiltration. The microstructure and mechanical properties of the composite materials were investigated under bending, shear, and impact loading. The density of the composites was 2.5 g·cm⁻³ after the three-dimensional SiC perform was infiltrated for 30 h. The values of flexural strength were 860 MPa at room temperature and 1010 MPa at 1300°C under vacuum. Above the infiltration temperature, the failure behavior of the composites became brittle because of the strong interfacial bonding and the mismatch of thermal expansion coefficients between fiber and matrix. The fracture toughness was 30.2 MPa·m^1/2. The obtained value of shear strength was 67.5 MPa. The composites exhibited excellent impact resistance, and the dynamic fracture toughness of 36.0 kJ·m⁻² was measured using Charpy impact tests.     

Shear strength enhancement of SiC-coated 3D C/SiC composite joints with a Ni-Ti-Nb multi-interlayer by interfacial microstructure tailoring

SiC-coated three-dimensional (3D) C/SiC composites were successfully joined with a Ni-Ti-Nb multi-interlayer by spark plasma sintering (SPS). The interfacial microstructure, phase evolution, and mechanical properties of the as-prepared joints were investigated. A sawtooth-like interfacial structure was generated as a result of the non-uniform dissolution behavior of SiC during the joining process. This interfacial structure substantially enhanced the interfacial bonding strength of the composites. The evolution of the interfacial microstructure was correlated with the mechanical properties of the joints. Finally, a reliable joint free of microdefects with a shear strength of 108 ± 5 MPa was obtained by precise tailoring of the interfacial microstructure.     

Preparation and properties of 2D C/SiC-ZrB2-TaC composites

Two-dimensional (2D) C/SiC-ZrB₂-TaC composites were fabricated by chemical vapor infiltration (CVI) combined with slurry paste (SP) method. 2D laminate was prepared by stacking carbon cloth that was pasted with a mixture of polycarbosilane-ZrB₂-TaC slurry. A small amount of carbon fiber tows were introduced into the preform in the vertical direction. After heat-treated at 1800 °C, the 2D laminate was densified with SiC by CVI to obtain 2D C/SiC-ZrB₂-TaC composites. Properties including flexural strength, interlaminar shear strength, and thermal expansion of the composites were investigated. The ablation test was carried out under an oxyacetylene torch flame. The morphologies of the ablated specimens were analyzed. The results indicate that the adding vertical fiber tows and heat-treatment at 1800 °C can greatly improve the mechanical properties of the composites. The co-addition of TaC and ZrB₂ powders into C/SiC composite effectively enhance its ablation resistance.     

Comparison of Tensile Behaviors of Carbon/Ceramic Composites with Various Fiber Architectures

Tensile behaviors of 1D (unidirectional), 2D (plain woven), and 3D (braided) C/SiC composites were compared. The results show that 1D C/SiC minicomposites have the highest tensile performance compared to the lowest of 2D C/SiC among the three composites studied. The characteristic slope recovery exhibited in stress–strain curves of 1D composites is absent in those of 2D and 3D composites, which can be attributed to different preform architectures and constituent properties. A straightforward approach was developed to model the tensile properties of the multidimensional composites based on properties of minicomposites. Such relationships are fairly robust for these real composites when orthogonally loaded.     

Creep properties of melt infiltrated SiC/SiC composites with Sylramic™-iBN and Hi-Nicalon™-S fibers

Isothermal tensile creep tests were conducted on 2D woven and laminated, 0/90 balanced melt infiltration (MI) SiC/SiC composites at stress levels from 48 to 138 MPa and temperatures to 1400°C in air. Effects of fiber architecture and fiber types on creep properties, influence of accumulated creep strain on in-plane tensile properties, and the dominant constituent controlling the creep behavior and creep rupture properties of these composites were investigated. In addition, the creep parameters of both composites were determined. Results indicate that in 2D woven MI SiC/SiC composites with Sylramic™-iBN or Hi-Nicalon™-S fibers, creep is controlled by chemical vapor infiltration (CVI) SiC matrix, whereas in 2D laminated MI SiC/SiC composites with Hi-Nicalon™-S fibers, creep is controlled by the fiber. Both types of composites exhibit significant variation in creep behavior and rupture life at a constant temperature and stress, predominantly due to local variation in microstructural inhomogeneity and stress raisers. In both types of composites at temperatures >1350°C, residual silicon present in SiC matrix to reacts with SiC fibers and fiber coating causing premature creep rupture. Using the creep parameters generated, the creep behaviors of the composites have been modeled and factors influencing creep durability are discussed.     

Study on interfacial debonding stress and damage mechanisms of C/SiC composites using acoustic emission

Among ceramic matrix composites (CMCs), carbon fiber-reinforced silicon carbide matrix (C/SiC) composites are widely used in numerous high-temperature structural applications because of their superior properties. The fiber–matrix (FM) interface is a decisive constituent to ensure material integrity and efficient crack deflection. Therefore, there is a critical need to study the mechanical properties of the FM interface in applications of C/SiC composites. In this study, tensile tests were conducted to evaluate the interfacial debonding stress on unidirectional C/SiC composites with fibers oriented perpendicularly to the loading direction in order to perfectly open the interfaces. The characteristics of the material damage behaviors in the tensile tests were successfully detected and distinguished using the acoustic emission (AE) technique. The relationships between the damage behaviors and features of AE signals were investigated. The results showed that there were obviously three damage stages, including the initiation and growth of cracks, FM interfacial debonding, and large-scale development and bridging of cracks, which finally resulted in material failure in the transverse tensile tests of unidirectional C/SiC composites. The frequency components distributed around 92.5 kHz were dominated by matrix damage and failure, and the high-frequency components distributed around 175.5 kHz were dominated by FM interfacial debonding. Based on the stress and strain versus time curves, the average interfacial debonding stress of the unidirectional C/SiC composites was approximately 1.91 MPa. Furthermore, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDXS) were used to observe the morphologies and analyze the chemical compositions of the fractured surfaces. The results confirmed that the fiber was completely debonded from a matrix on the fractured surface. The damage behaviors of the C/SiC composites were mainly the syntheses of matrix cracking, fiber breakage, and FM interfacial debonding.     

Elastic Properties of Laminated Calcium Aluminosilicate/Silicon Carbide Composites Determined by Resonant Ultrasound Spectroscopy

The elastic properties of unidirectional and 0°/90° crossply Nicalon-SiC-fiber-reinforced calcium aluminosilicate (CAS/SiC) ceramic-matrix composites have been measured using a resonant ultrasound spectroscopy (RUS) technique. This approach has allowed the nondestructive determination of the complete set of independent second-order elastic stiffness constants of these ceramic composites. These stiffness data have been used to obtain the orientation dependence of Young's modulus and the shear modulus. The results are in reasonably good agreement with the limited experimental data obtained from mechanical testing. The RUS measurements reveal that the unidirectional CAS/SiC composite is well modeled by transverse isotropic symmetry, indicating relatively isotropic fiber spacing in the transverse plane. The analysis indicates that the overall elastic anisotropy is also small for unidirectional and 0°/90° laminated CAS ceramic-matrix composites, a result that can be attributed to the relatively low modulus ratio of the Nicalon SiC fiber to the CAS matrix and to the moderate fiber volume fraction.     

Effect of Carbon and Silicon Carbide/Carbon Interlayers on the Mechanical Behavior of Tyranno-SA-Fiber-Reinforced Silicon Carbide-Matrix Composites

Several CVI-SiC/SiC composites were fabricated and the mechanical properties were investigated using unloading–reloading tensile tests. The composites were reinforced with a new Tyranno-SA fiber (2-D, plain-woven). Various carbon and SiC/C layers were deposited as fiber/matrix interlayers by the isothermal CVI process. The Tyranno-SA/SiC composites exhibited high proportional limit stress (∼120 MPa) and relatively small strain-to-failure. The tensile stress/strain curves exhibited features corresponding to strong interfacial shear and sliding resistance, and indicated failures of all the composites before matrix-cracking saturation was achieved. Fiber/matrix debonding and relatively short fiber pullouts were observed on the fracture surfaces. The ultimate tensile strength displayed an increasing trend with increasing carbon layer thickness up to 100 nm. Further improvement of the mechanical properties of Tyranno-SA/SiC composites is expected with more suitable interlayer structures.     

Experimental study on the mechanical behavior and failure mechanism of 3d MWK carbon/epoxy composites under quasi‐static loading

Quasi‐static tensile, out‐of compression, in‐plane compression, three‐point‐bending and shear tests were conducted to reveal the mechanical behavior and failure mechanisms of three‐dimensional (3D) multiaxial warp‐knitted (MWK) carbon/epoxy composites. The characterization of the failure process and deformation analysis is supported by high‐speed camera system and Digital Image Correlation. The results show that tensile, bending, out‐of‐plane compression, in‐plane compression stress–strain response exhibit obvious linear elastic feature and brittle fracture characteristics, whereas the shear response exhibits a distinct nonlinear behavior and gradual damage process. Meanwhile, 3D MWK carbon/epoxy composites have good mechanical properties, which can be widely used in the fields of engineering. In addition, the failure for tension behaves as interlayer delaminating, 90/+45/−45° interface debonding and tensile breakage of 0° fibers; the damage for out‐of‐plane compression is mainly interlaminar shear dislocation together with local buckling and shear fracture of fibers; the failure pattern for in‐plane compression is 90° fiber separating along fiber/matrix interface as well as 0/+45/−45° fiber shear fracture in the shear plane. The main failure for bending is fiber/matrix interface debonding and fibers tearing on the compression surface, 0° fibers breakage on the tension surface as well as fiber layers delaminating. Although the shear behavior is characterized by a gradually growing shear matrix damage, 90/+45/−45° interface debonding, +45/−45° fibers shear fracture, and final 0° fiber compression failure. POLYM. COMPOS., 37:3486–3498, 2016. © 2015 Society of Plastics Engineers     

Hysteresis loops of carbon fiber-reinforced ceramic-matrix composites with different fiber preforms

The hysteresis loops of C/SiC ceramic-matrix composites (CMCs) with different fiber preforms, i.e., unidirectional, cross-ply, 2D and 2.5D woven, 3D braided, and 3D needled at room temperature have been investigated. Based on fiber slipping mechanisms, the hysteresis loops models considering different interface slip cases have been developed. The effects of fiber volume fraction, matrix cracking density, interface shear stress, interface debonded energy, and fibers failure on hysteresis loops, hysteresis dissipated energy, hysteresis width, and hysteresis modulus have been analyzed. An effective coefficient of fiber volume fraction along the loading direction (ECFL) was introduced to describe fiber preforms. The hysteresis loops, hysteresis dissipated energy and hysteresis modulus of unidirectional, cross-ply, 2D and 2.5D woven, 3D braided and 3D needled C/SiC composites have been predicted.     

模压压力对SiC/SiC复合材料力学性能及力学行为的影响

采用热模压辅助聚合物先驱体浸渍裂解工艺制备了国产近化学计量比SiC纤维增强SiC陶瓷基复合材料,通过阿基米德排水法和SEM技术对SiC/SiC复合材料致密化过程进行表征,采用弯曲强度、拉伸强度和断裂韧性对SiC/SiC复合材料力学性能和力学行为进行评价。研究表明,热模压压力是影响材料结构和性能的重要因素,热模压在提升材料致密度的同时,亦造成纤维的损伤。随着热模压压力的增加,SiC/SiC复合材料力学性能先增加后降低。热模压压力适中时,致密度增加因素占优,材料力学性能较为优异;热模压压力较大时候,热模压操作对纤维性能的损伤因素逐渐凸显,基体致密化和纤维损伤两种作用机制相当。