Grain size effect on microwave dielectric properties of Na2WO4 ceramics prepared by cold sintering process

In this work, cold sintering was adopted to prepare Na₂WO₄ ceramics with different grain sizes ranging from 0.632 μm to 17.825 μm. Their microstructures, complex impedance, and microwave dielectric properties were studied in-depth. It was found that samples with relative densities higher than 92% can be successfully synthesized by cold sintering process at a low temperature of 240 °C. However, their electrical properties have strong dependence on the grain size. Specifically, the resistance of grain boundaries decreases dramatically with the increase of grain sizes, while the quality factor has a positive correlation with the grain sizes of Na₂WO₄ ceramics. Excellent microwave dielectric properties, including permittivity = 5.80, Q × f = 22,000 GHz, and TCF = −70 ppm/°C, are obtained for Na₂WO₄ ceramics with a grain size of 4.477 μm prepared by cold sintering process.     

Welding process selection for repairing nodular cast iron engine block by integrated fuzzy data envelopment analysis and TOPSIS approaches

The selection of welding process is one of the most significant decision making problems and it requires a wide range of information in accordance with the type of product. Hence, the automation of knowledge through a knowledge-based system will greatly enhance the decision-making process. A combined fuzzy data envelopment analysis (DEA) and TOPSIS is proposed to investigate the relative welding process selection factors and it can compare and evaluate different welding processes. The proposed approach compares each decision making unit (DMU) with the worst and the ideal virtual DMU and it ranks them via the relative closeness index. The proposed approach is used for ranking eleven welding processes which are commonly used for repairing nodular cast iron engine block in four cases and it is shown that the approach is sensitive to changes in dataset.     

Post microbuckling mechanics of fibre-reinforced shape-memory polymers undergoing flexure deformation

The buckling mechanics of fibre-reinforced shape-memory polymer composites (SMPCs) under finite flexure deformation is investigated. The analytical expressions of the key parameters during the buckling deformation of the materials were determined, and the local post-buckling mechanics of the unidirectional fibre-reinforced SMPC were further discussed. The cross section of SMPC under flexural deformation can be divided into three areas: the non-buckling stretching area, non-buckling compression area and buckling compression area. These areas were described by three variables: the critical buckling position, the neutral plane position and the fibre buckling half-wavelength. A strain energy expression of the SMPC thermodynamic system is developed. According to the principle of minimum energy, the analytical expressions of key parameters in the flexural deformation process is determined, including the critical buckling curvature, critical buckling position, position of the neutral plane, wavelength of the buckling fibre, amplitude of the buckling fibre and macroscopic structural strain of the composite material. The results showed that fibre buckling occurred in the material when the curvature increasing from infinitesimal to the critical value. If the curvature is greater than the critical curvature, the neutral plane of the material will move towards the outboard tensile area, and the critical buckling position will move towards the neutral plane. Consequently, the half-wavelength of the buckling fibre was relatively stabilised, with the amplitude increasing dramatically. Along with the increasing of the shear modulus, the critical curvature and buckling amplitude increase, while the critical half-wavelength of the fibre buckling decrease and the critical strain of the composite material increase. Finally, we conducted experiments to verify the correction of the key parameters describing SMPC materials under flexural deformation. The values determined by the experiments proved that the theoretical prediction is correct. Additionally, the buckling deformation of the carbon fibre generated a large macroscopic structural strain of the composite material and obtained a resulting large flexural curvature of the structure with minimal material strain of the carbon fibre.     

‘Two way’ shape memory composites based on electroactive polymer and thermoplastic membrane

A practical and facile strategy was proposed to fabricate composites that not only use the properties of individual components (commercial electroactive polymer and thermoplastic resin) to their advantage, but also produce synergy effect of ‘two way’ shape memory properties. In this design, electroactive polymer is treated as soft segment which provides actuation force via converting electrical energy to dynamic energy. Thermoplastic material serves as ‘hard segment’ to help with fixation of temporary shape thanks to its re-structuring and stiffness/modulus changing abilities through the reversible transitional temperature. Compared with traditional one way and two way shape memory materials, this composite material has the capability of changing shape without pre-programming. High shape recover property (99 ± 0.3%.) has been obtained due to the rubber elasticity of electroactive polymer matrix. Many features could be brought up based on this design, such as accurate control over deformation by changing strength of applied electric field as well as tailorable stimulus temperature and mechanical properties.     

Lightweight carbon-bonded carbon fiber composites with quasi-layered and network structure

Lightweight carbon-bonded carbon fiber (CBCF) composites were fabricated with chopped carbon fibers and dilute phenolic resin solution by pressure filtration, followed by carbonization at 1000 °C in argon. The as-prepared CBCF composites had a homogenous fiber network distribution in xy direction and quasi-layered structure in z direction. The pyrolytic carbon derived from phenolic resin was mainly accumulated at the intersections and surfaces of chopped carbon fibers. The composites possessed compressive strengths ranged from 0.93–6.63 MPa in xy direction to 0.30–2.01 MPa in z direction with a density of 0.162–0.381 g cm^− 3. The thermal conductivity increased from 0.314–0.505 to 0.139–0.368 Wm^− 1 K^− 1 in xy and z directions, respectively. The experimental results indicate that the CBCF composites prepared by this technique can significantly contribute to improve the thermal insulation and mechanical properties at high temperature.     

Polymer derived ZrO2 reinforced SiC-ZrB2 polycrystalline fiber

Most polycrystalline SiC-based fibers were prepared at a sintering temperature higher than 1600 °C. In this work, a ZrO₂ reinforced SiC-ZrB₂ polycrystalline fiber was prepared at 1400 °C via the polymer-derived ceramic method from a new Zr- and B-containing polycarbosilane. The morphology and microstructure of the polycrystalline nanocomposite fiber were studied using XRD, XPS, EDS, SEM, and TEM. The results showed that t-ZrO₂ was formed at relatively lower temperature (<1000 °C). The most interesting result is that the polycrystalline nanocomposite SiC-ZrB₂ was generated after heat-treatment at 1400 °C, producing an excellent ZrO₂ reinforced SiC-ZrB₂ polycrystalline fiber. The present study provides a novel strategy for the fabrication of SiC-based polycrystalline fiber at a relatively low temperature.     

Fusion welding of refractory metals and ZrB2-SiC-ZrC ceramics

Molybdenum and a molybdenum alloy were fusion welded to ZrB₂-based ceramics to determine if the electrical and thermal properties of the metals and ceramics affected their weldability. Commercial ceramic powders were hot pressed, machined into coupons, and preheated to 1600 °C before joining the ceramics to commercial metals using plasma arc welding. Weldability varied as indicated by the range of porosity observed within the fusion zones. Measured thermal and electrical properties appeared to have little to no effect on the weldability of metal-ceramic welds despite the large range of values measured across each property. Differences in melting temperatures between metal and ceramic coupons did affect weldability by changing the weld penetration depth into ceramic coupons. Future studies on metal-ceramic welds are suggested to investigate the effect that work function, melt viscosity, wetting, or other properties have on weldability.     

The mechanical,thermophysical and electromagnetic properties of UD SiCf/SiC composites in different directions

Unidirectional (UD) silicon carbide (SiC) fiber-reinforced SiC matrix (UD SiC_f/SiC) composites with CVI BN interphase were fabricated by polymer infiltration-pyrolysis (PIP) process. The effects of the anisotropic distribution of SiC fibers on the mechanical properties, thermophysical properties and electromagnetic properties of UD SiC_f/SiC composites in different directions were studied. In the direction parallel to the axial direction of SiC fibers, SiC fibers bear the load and BN interphase ensures the interface debonding, so the flexural strength and the fracture toughness of the UD SiC_f/SiC composites are 813.0 ± 32.4 MPa and 26.1 ± 2.9 MPa·m^1/2, respectively. In the direction perpendicular to the axial direction of SiC fibers, SiC fibers cannot bear the load and the low interfacial bonding strengths between SiC fiber/BN interphase (F/I) and BN interphase/SiC matrix (I/M) both decrease the matrix cracking stress, so the corresponding values are 36.6 ± 6.9 MPa and 0.9 ± 0.5 MPa?m^1/2, respectively. The thermal expansion behaviors of UD SiC_f/SiC composites are similar to those of SiC fibers in the direction parallel to the axial direction of SiC fibers, and are similiar to those of SiC matrix in the direction perpendicular to the axial direction of SiC fibers. The total electromagnetic shielding effectiveness (EM SE_T) of UD SiC_f/SiC composites attains 32 dB and 29 dB when the axial direction of SiC fibers is perpendicular and parallel to the electric field direction, respectively. The difference of conductivity in different directions is the main reason causing the different SE_T. And the dominant electromagnetic interference (EMI) shielding mechanism is absorption for both studied directions.     

Ultra-high temperature oxidation resistance of a novel (Mo,Hf, W,Ti)Si2 ceramic coating with Nb interlayer on Ta substrate

In order to solve the challenge of recyclability of tantalum substrates in high temperature oxidation environments, a novel MoSi₂-WSi₂-HfSi₂-TiSi₂ composite ceramic coating containing an Nb interlayer was prepared on the surface of tantalum substrate by a three-step method. The mix ceramic silicide coating exhibited superior performance and effective protection for 10.2 h at 1800 °C, possibly due to the formation of an outer SiO₂-HfO₂-HfSiO₄ composite oxide film with low oxygen permeability, moderate viscosity and thermal expansion coefficient, as well as good self-healing ability. Furthermore, the coating successfully passed 537 thermal cycles from room temperature to 1800 °C. The presence of Nb interlayer significantly mitigated the thermal mismatch between the ceramic coating and the tantalum substrate, and the bidirectional diffusion of Nb element during the high temperature oxidation and thermal shock process further reduced the tendency of the coating to crack.