Toughness and R-curve behaviour of laminated Si3N4/SiCw ceramics

Laminated Si₃N₄/SiC_w ceramics were successfully prepared by tape casting and hot-pressing. Its mechanical properties were measured and the impact resistance was discussed. The toughness of the laminated Si₃N₄/SiC_w ceramics was 13.5 MPa m^1/2, which was almost 1.6 times that of Si₃N₄/SiC_w composite ceramics, namely 8.5 MPa m^1/2. Moreover, the indentation strength of laminated Si₃N₄/SiC_w ceramics was not sensitive to increasing indentation loads and exhibited a rising R-curve behaviour, indicating that the laminated Si₃N₄/SiC_w ceramics had excellent impact resistance. The improved toughness and impact resistance of laminated Si₃N₄/SiC_w ceramics was attributed to the residual stress caused by a thermal expansion coefficient mismatch between the different layers, resulting in crack deflection and bridging of SiC whiskers in the interface layer, thus consuming a large amount of fracture work.     

Prediction of mode I fracture toughness of rock using linear multiple regression and gene expression programming

Prediction of mode I fracture toughness (K_IC) of rock is of significant importance in rock engineering analyses. In this study, linear multiple regression (LMR) and gene expression programming (GEP) methods were used to provide a reliable relationship to determine mode I fracture toughness of rock. The presented model was developed based on 60 datasets taken from the previous literature. To predict fracture parameters, three mechanical parameters of rock mass including uniaxial compressive strength (UCS), Brazilian tensile strength (BTS), and elastic modulus (E) have been selected as the input parameters. A cluster of data was collected and divided into two random groups of training and testing datasets. Then, different statistical linear and artificial intelligence based nonlinear analyses were conducted on the training data to provide a reliable prediction model of K_IC. These two predictive methods were then evaluated based on the testing data. To evaluate the efficiency of the proposed models for predicting the mode I fracture toughness of rock, various statistical indices including coefficient of determination (R²), root mean square error (RMSE), and mean absolute error (MAE) were utilized herein. In the case of testing datasets, the values of R², RMSE, and MAE for the GEP model were 0.87, 0.188, and 0.156, respectively, while they were 0.74, 0.473, and 0.223, respectively, for the LMR model. The results indicated that the selected GEP model delivered superior performance with a higher R² value and lower errors.     

Refractory interphase and its role on the mechanical properties of boron containing nacre-like ceramic

Bioinspired ceramics based on the nacreous part of the mother-of-pearl microstructure have been developed in recent years to produce materials with high mechanical performance. Although significant advances in terms of simplicity and scalability of the synthesis process have been achieved, the reasons behind the improvement of the mechanical properties remains to be pinpointed. Recently, the development of boron containing nacre-like refractories have offered new insights into the relationship between the interphase composition and the performance increase of nacre-like materials. Based on those achievements, this paper presents a multiscale analysis to evaluate the role of the refractory interphase on the mechanical properties of the nacre-like refractories. The results demonstrate the presence of increased residual stresses and adhesion between the alumina platelets induced by the aluminium borate second phase when compared to composition without secondary phase. These new findings provide additional information towards a better design and fabrication of high-performance nacre-like refractories.     

Influence of Ni/Co binders and Mo2C on the microstructure evolution and mechanical properties of (Ti0.93W0.07)C–based cermets

In this research, solid–solution powder of (Ti_0.93W_0.07)C was synthesized by high–energy ball mill method followed by carbothermal reduction process. Subsequently, the acquired powder was blended with Ni/Co and Mo₂C secondary carbide, and sintered under the optimized temperature (1510?°C) for 1?h to produce the modulated cermets. A typical core–rim structure formation with solid–solution phases was confirmed by backscattered electrons studies using a Field Emission electron scanning microscope. The hardness of the synthesized cermets was enhanced by increasing the specific amount of Mo₂C. The acquired results demonstrate that the binder type has a prominent influence on the microstructure and hardness of the prepared cermets. The hardness of (Ti_0.93W_0.07)C–xMo₂C–Ni cermet increased ~ 9%, when nickel was partially substituted by cobalt.     

Liquid phase sintering and characterization of SiC ceramics

The present study focuses on the sintering of silicon carbide-based ceramics (SiC) by liquid phase sintering (LPS) followed by characterization of the produced ceramics. AlN/Re₂O₃ mixtures were used as additives in the LPS process. In the first step, the LPS-SiC materials were produced in a graphite resistance furnace in the form of discs at different temperatures. The conditions with the best results regarding real density and relative density were taken as reference for sintering in the form of prismatic bars. In the second step, these samples were evaluated regarding fracture toughness (K_IC), by the Single Edge V Notch Beam – SEVNB – method, and flexural strength. K_IC behavior was evaluated according to the depth and curvature radius of the notches. Reliable K_IC values were presented when the ceramic displayed a small curvature radius at the notch tip. When the radius was large, it did not maintain the square root singularity of the notch tip. Tests were carried out to determine K_IC values in atmospheric air and water. K_IC results were lower in water than air, with a decrease ranging between 2.56% and 11.26%. The observations indicated a direct grain size correlation between K_IC values and fracture strength of the SiC ceramics.     

Ultrasonic vibration-assisted laser engineering net shaping of ZrO2-Al2O3 bulk parts: Effects on crack suppression,microstructure, and mechanical properties

Laser additive manufactured zirconia-alumina ceramic (ZrO₂-Al₂O₃) parts demonstrate severe problems resulting from cracking and inhomogeneous material dispersion. To reduce these problems, we propose a novel ultrasonic vibration-assisted laser engineered net shaping (LENS) process for fabrication of bulk ZrO₂-Al₂O₃ parts. Results showed that the initiation of cracks and the crack propagation were suppressed in the parts fabricated by LENS process with ultrasonic vibration. For the parts fabricated without ultrasonic vibration, the sizes of cracks decreased with the increase of laser power. Scanning electron microscope analyses proved that the introduction of ultrasonic vibration was beneficial for grain refinement and uniform material dispersion. Due to the suppressed cracking, refined grains, and homogenized material dispersion, the parts fabricated with ultrasonic vibration demonstrated better mechanical properties (including higher microhardness, higher wear resistance, and better compressive properties), compared with the parts fabricated without ultrasonic vibration.     

Grain growth kinetics in microwave sintered graphene platelets reinforced ZrO2/Al2O3 composites

The grain growth kinetics and mechanical properties of graphene platelets(GPLs) reinforced ZrO₂/Al₂O₃(ZTA) composites prepared by microwave sintering were investigated. The calculated grain growth kinetics exponent n indicated that the GPLs could accelerate the process of the Al₂O₃ columnar crystal growth. And the grain growth activation energy of the Al₂O₃ columnar crystal indicated that the grain growth activation energy of the GPLs doped ZTA composites is much higher than those of pure Al₂O₃ and ZTA in microwave sintering. The optimal mechanical properties were achieved with 0.4?vol% GPLs, whose relative density, Vickers hardness and fracture toughness were 98.76%, 18.10?GPa and 8.86?MPa?m^1/2, respectively. The toughening mechanisms were crack deflection, bridging, branching and pull-out of GPLs. The results suggested that GPLs-doped are good for the Al₂O₃ columnar crystal growth in the ZTA ceramic and have a potentially improvement for the fracture toughness of the ceramics.     

Extraordinary toughening enhancement and flexural strength in Si3N4 composites using graphene sheets

Two types of Si₃N₄ composites containing graphene nanostructures using two different graphene sources, pristine graphene nanoplatelets and graphene oxide layers were produced by Spark Plasma Sintering. The maximum toughness of 10.4 MPa m^1/2, measured by flexure testing of pre-cracked bars, was achieved for a composite (∼60β/40α-Si₃N₄, ∼300 nm grain size) with 4 vol.% of reduced graphene oxide, indicating a toughening enhancement of 135% when compared to a similar Si₃N₄. This was also accompanied by a 10% increase in flexure strength (1040 MPa). For the composites with thicker graphene nanoplateletes only a 40% of toughness increase (6.6 MPa m^1/2) without strength improvement was observed for the same filler content. The large difference in the maximum toughness values accomplished for both types of composites was attributed to variations in the graphene/Si₃N₄ interface characteristics and the extent of monolayer graphene exfoliation.     

Preparation of Poly(N-butyl methacrylate-co-glycidyl methacrylate) and Toughness Improvement for Powder Epoxy Resin E663

Copolymers of poly(n-butyl methacrylate-co-glycidyl methacrylate) were prepared by a free radical polymerization. The structures of the copolymers were characterized. The copolymers could be added to a powder epoxy resin (E663) to form modified epoxy resins. It was found that toughness of the cured modified epoxy resins were greatly improved, impact strength increased 3 times and fracture elongation increased 20% compared to the cured unmodified E663 resin. This is because that the copolymers had epoxy groups and flexible butyl groups, the former were involved in cross-linking reaction of the E663, and the latter made contribution to the toughness improvement.     

A reinvestigation of the validity of the indentation fracture (IF) method as applied to ceramics

Poor correlation between indentation fracture resistance, K_IFR, and fracture toughness, K_IC, has long been considered a weak point of the indentation fracture (IF) method of materials analysis. The present work therefore assessed the reliability of the experimental data that has historically been used for comparisons of K_IFR and K_IC. A painstaking survey of primary literature reports concerning the IF method revealed that the comparisons of K_IC with K_IFR in most studies were imperfect because both K_IC and K_IFR were measured using unreliable techniques and because improper test materials such as silicate glass were employed. These findings indicate that the standard objections against the use of the IF model are not well supported, and also that the majority of the empirically-derived calibration constants used in various IF equations are suspect. Accordingly, it is evident that new experimental measurements using the latest and most reliable techniques will be required to allow well-informed discussions of the validity of this test method in future.