An efficient hybrid conventional method to fabricate nacre-like bulk nano-laminar composites

Bulk nano-laminar composites were fabricated by a novel technique called Hot-press Assisted Slip Casting (HASC) which combines hot-pressing and slip-casting to improve alignment and volume fraction of the reinforcement. Alumina flakes were used as filler in an epoxy matrix. Microstructure of composites and alignment of flakes were characterized by Scanning Electron Microscope (SEM). Three point bending test and Vickers hardness test were done for mechanical characterization of composites. Flexural tests on Chevron-notched specimens revealed a high work-of-fracture in the case of the fabricated composites reaching to 254 J/m². Fracture surface of three point bending samples were examined by SEM. Main fracture mechanism is debonding of flakes from the matrix. With its high volume fraction (60%) of reinforcement phase and high degree of flake alignment, a nacre-like microstructure was achieved with a relatively efficient, cost effective and simple hybrid conventional method.     

A method for testing the interface toughness of ceramic environmental barrier coatings (EBCs) on ceramic matrix composites (CMCs)

A simple interface fracture test for ceramic environmental barrier coatings (EBCs) on ceramic matrix composites (CMCs) was developed. A variation on the asymmetric double cantilever beam (ADCB) test was proposed so that the interface toughness could be measured in a small specimen of simple shape without applying interlaminar loading to the CMC substrate. The proposed test was applied to an EBC consisting of a mullite layer and Si bond coat on a monolithic SiC substrate. A pre-crack was introduced by pop-in cracking, and then a notch overlapping the pre-crack was machined. The pre-crack was opened by inserting a wedge into the notch. From the critical notch opening displacement the crack starts to propagate, interface toughness is calculated. The measured interface toughness was 4.1?J/m2. Finally, the application range of the test was discussed and suggestions were made for introduction of the notch and pre-crack.     

3D Visualization of Morphological Evolution of Large Defects during Spark Plasma Sintering of Alumina Granules

The mechanical reliability of products must be assured for scaling up and production of complex-shaped components by spark plasma sintering (SPS) of spray-dried granules. The evolution of morphologies of pores and defects, which control the mechanical strength, is investigated by using synchrotron X-ray multiscale tomography during SPS of alumina granules at 1300 °C. While large defects arising from the hierarchical granule packing structure cannot be removed by pressureless sintering, crack-like defects and branched rodlike defects are almost eliminated by SPS at stresses higher than 30 and 50 MPa, respectively. But, small ellipsoidal porous regions, which may arise from aggregates or dimples of granules, cannot be removed even at a pressure of 50 MPa. A very large defect is also found by using micro-CT. It is supposed that this defect is formed from a large void in loosely packed granules. The shrinkage of large voids and the elimination of crack-like defects are explained by the theoretical prediction based on the continuum theory of sintering.     

Anisotropic crack propagation behavior for the silicon-bond coat layer in a multilayer coated system

This study sought to examine the relationship between the degradation mechanism, thermal stress, and crack propagation behavior in environmental barrier coating (EBC) systems. An EBC system composed of a mullite topcoat (TC), Si-bond coat (BC), and SiC substrate was prepared by atmospheric plasma spraying. Heat exposure tests were conducted to evaluate the microstructure of the EBC system at 1300°C for 1, 10, 50, and 100 h. The fracture resistance of the Si BC for the in-plane (direction parallel to each layer, 0.4–0.6 MP) and through-thickness directions (direction from the TC to substrate, 1.7–2.1 MP) differed because a thermal compressive stress was induced for the in-plane direction owing to the mismatch of the thermal expansion coefficients for each layer, which acted as a barrier for crack propagation. However, cracks tended to propagate in the in-plane direction because they were not affected by the in-plane compressive stress. These results clearly showed that Si BC exhibited in-plane anisotropy and crack propagation after heat exposure, which were the major sources of delamination of the EBC system.     

Melt film formation and disintegration during novel atomization process

Hybrid atomization is a new powder-making method and can produce economically very fine, clean, spherical tin alloy powders with average particle size about 10μm and narrow size distributions. The key concept of hybrid atomization is to control the liquid film formation on disk for fine powder production. Low-pressure gas atomization was utilized to promote the formation of a very thin stable liquid film before centrifugal breakup and give a better preparation for the final disintegration of melts. Besides the breakup ability of the rotating atomizer, the characteristics of liquid film on rotating disk affect the atomization mechanism and results remarkably. The main disintegration mode of melt is the breakup type of liquid film, which depends on the film instability and the atomization ability of the rotating disk. On the other hand, the mean powder size relates closely to the film thickness. The powder size distribution is mainly controlled by the atomization mode and the stability, flow type of liquid film on the rotating disk. A very thin, stable liquid film with long ligaments and a small pitch in LF mode results in very fine uniform tin alloy powders.     

Tensile behavior change depending on the microstructure of a Fe–Cu alloy produced from rapidly solidified powder

The relationship between consolidating temperature and the tensile behavior of iron alloy produced from Fe–Cu rapidly solidified powder is investigated. Fe–Cu powder fabricated by high-pressure water atomization was consolidated by heavy rolling at 873–1273 K. Microstructural changes were observed and tensile behavior was examined. Tensile behavior varies as the consolidating temperature changes, and these temperature-dependent differences depend on the morphology of the microstructure on the order of micrometers. The sample consolidated at 873 K shows a good strength/elongation balance because the powder microstructure and primary powder boundaries are maintained. The samples consolidated at the higher temperatures have a microstructure of recrystallized grains, and these recrystallized samples show the conventional relationship between tensile behavior and grain size in ordinal bulk materials.     

Fabrication of nature-inspired bulk laminar composites by a powder processing

Among many kinds of “nano-laminar” composites inspired by the brick and mortar structure of nacre in mollusk shells, a bulky, dense and ceramics–base composite has been a missing piece despite its importance. Here we report that such a composite with a submicron-order layered structure can be fabricated by a simple method, sintering aligned flake-like inorganic powder coated with ductile matrix material. The composites fabricated by this method had crack extension resistance by interface delamination, crack deflection, and ligament bridging by the ductile matrix. They showed non-brittle fracture behavior in a bending test despite a quite high flake volume fraction of over 80%, and had a work of fracture (WOF) of more than 300 J/m², several hundreds times as large as that of monolithic glass.