Strength recovery of machined Al2O3/SiC composite ceramics by crack healing

Alumina is used in various fields as a machine component. However, it has a low fracture toughness, which is a weakness. Thus, countless cracks may be initiated randomly by machining, and these cracks decrease the component's mechanical properties and reliability. To overcome this problem, a crack‐healing ability could be a very useful technology. In this study, Al₂O₃/SiC composite was sintered. This alumina exhibits excellent crack‐healing ability. Small specimens for a bending test were made from the Al₂O₃/SiC. A semicircular groove was machined using a diamond ball‐drill. The machining reduced the local fracture stress from approximately 820–300 MPa. The machined specimens were crack‐healed under various conditions. The fracture stress of these specimens after crack healing was evaluated systematically from room temperature (RT) to 1573 K. It was found that the local fracture stress of the machined specimen recovered almost completely after crack healing. Therefore, it was concluded that crack healing could be an effective method for improving the structural integrity of machined alumina and reducing machining costs.     

Crack-healing and mechanical behaviour of Al2O3/SiC composites at elevated temperature

Alumina/silicon carbide (Al₂O₃/SiC) composite ceramics with large self‐crack‐healing ability, high strength and high heat‐resistance limit temperature for strength were developed and subjected to three‐point bending. A semicircular surface crack 100 μm in diameter was made on each sample. Crack‐healing behaviour was systematically studied, as functions of crack‐healing temperature and healing time, and the fatigue strengths of the crack‐healed sample at room temperature and 1373 K were investigated. Four main conclusions were drawn from the present study. (1) Al₂O₃/SiC composite ceramics have the ability to heal after cracking from 1273to 1673 K in air. (2) The heat‐resistance limit temperature for strength of the crack‐healed sample is ?1573 K, and ?68% of the samples fractured from outside the crack‐healed zone in the testing‐temperature range 873–1573 K. (3) The crack‐healed sample exhibited very high fatigue limit at room temperature and also 1373 K. (4) The large self‐crack‐healing ability is a desirable technique for the high structural integrity of ceramic component.     

Fatigue strength of crack-healed Si3N4/SiC composite ceramics

Si₃ N₄ /SiC composite ceramics were sintered and subjected to three-point bending on specimens made according to the appropriate JIS standard. A semi-circular surface crack of 110 μm in diameter was made on each specimen. By using three kinds of specimen (smooth, cracked and crack healed), crack-healing behaviour, cyclic and static fatigue strengths were determined systematically at room temperature and 1000 °C. The main conclusions are as follows: (i) Si₃ N₄ /SiC composite ceramics have the ability to heal after cracking; (ii) crack-healed specimens showed similar cyclic and static fatigue strengths as smooth specimens, this being caused by crack healing; (iii) crack-healed zones had a sufficient fatigue strength and most fractures occurred outside the pre-cracked zone in those crack-healed specimens.     

A new methodology to guarantee the structural integrity of Al2O3/SiC composite using crack healing and a proof test

Structural ceramics are brittle and sensitive to flaws. As a result, the structural integrity of a ceramic component may be seriously affected by inherent flaws. Self-crack-healing is an excellent answer to this problem. At the moment, however, there is no technique to heal embedded flaws. Therefore, a technique to guarantee the reliability of ceramic components is demanded, and thus a technique using crack healing followed by proof test was developed by K. Ando et al. to accomplish this. With this technique, testing the mechanical behaviour of the crack-healed zone is very important for ensuring the structural integrity of a ceramic component. In this study, first Al₂O₃/SiC composite with an excellent crack-healing ability was sintered. Second, a crack was introduced on the sample (3 mm × 4 mm × 36 mm), which reduced the bending strength by about 80%, and subsequently the crack was healed. Third, a proof test was carried out on the crack-healed sample. Last, using the crack-healed and proof-tested sample, a fracture test was carried out up to 1373 K. The measured minimum fracture stress (σ_Fmin) was compared with the theoretical minimum strength (σ_G) from room temperature (R.T.) to 1373 K. It was concluded that σ_G showed good agreement with σ_Fmin up to 1373 K and that the crack healing followed by proof test was an excellent technique to increase the survival probability by administering a proof test and to guarantee the reliability of Al₂O₃/SiC composite.     

Sphere contact fatigue of a coarse-grained Al2O3 ceramic

The opposite sphere test is an appropriate tool to determine crack‐growth exponents for fatigue under repeated contact loading. Lifetime measurements for a coarse‐grained Al₂O₃ are reported. To explain the fatigue exponents that strongly deviated from those obtained in cyclic bending tests, a fracture mechanics analysis was carried out. It was aimed at determining the correct stress intensity factor solution for the tests, including limited dimensions of test specimens deviating from the case of a cone crack in a half space. Cone crack development was observed microscopically and the related stress intensity factors were computed for the observed crack shape. For modelling the fatigue behaviour, it is assumed that the fatigue effect is influenced by a reduction of the shielding term of crack growth resistance due to periodical friction between the grain‐interlock bridges in coarse‐grained alumina. This results in a loss of traction at the junctions, crack tip shielding is reduced, and the effective load at the crack tip is increased.     

Fatigue behaviour of SiCp-reinforced aluminium composites in the very high cycle regime using ultrasonic fatigue

The fatigue behaviour of a 2009/SiC/15p‐T4 DRA composite has been examined in the very high cycle fatigue (VHCF) regime where 10⁷≤N_f≤ 10⁹ cycles. Ultrasonic fatigue was used to achieve the very high cycle counts. Careful processing yielded a composite with a very homogeneous particle distribution with minimal clustering. Fatigue crack initiation was observed almost exclusively at AlCuFe inclusions with no crack initiation observed at SiC particle clusters. Fatigue lives at a given stress level exhibited minimal scatter and subsurface crack initiation was observed in all cases. This behaviour is consistent with the presence of a low number density of critical inclusions that are responsible for crack initiation very early in fatigue life.     

旋转超声磨削Si3 N4陶瓷用金刚石磨具磨损行为研究

热压烧结Si₃N₄陶瓷材料常应用于航天飞行器中关键耐高温零部件,但由于高硬度和低断裂韧性,其加工效率和加工表面质量难以满足制造需求。为了提高热压烧结Si₃N₄陶瓷旋转超声磨削加工质量,减小由于金刚石磨具磨损带来的加工误差,开展了磨具磨损行为研究。基于热压烧结Si₃N₄陶瓷旋转超声磨削加工实验,分析了金刚石磨具磨损形式;基于回归分析建立了金刚石磨具磨损量数学模型,揭示了加工参数及磨具参数与金刚石磨具磨损量间映射关系;并研究了磨损形式与磨具磨损量及加工表面粗糙度影响规律。结果表明：磨粒磨耗是旋转超声磨削Si₃N₄陶瓷用金刚石磨具最主要磨损形式,比例超过50%;主轴转速和磨粒粒度对磨具磨损量影响最为显著;且磨损量较小时,加工表面粗糙度值反而增加。以上研究可为提高旋转超声磨削Si₃N₄陶瓷加工精度和加工质量提供指导。     

Microstructure and fracture-mechanical properties of carbon derived Si3N4 + SiC nanomaterials

The microstructure and basic mechanical properties, as hardness, fracture toughness, fracture strength and subcritical crack growth at room temperature were investigated and creep behavior at high temperatures was established. The presence of SiC particles refined the microstructure of Si₃N₄ grains in the Si₃N₄ + SiC nanocomposite. Higher hardness values resulted from introducing SiC nanoparticles into the material. A lower fracture toughness of the nanocomposite is associated with its finer microstructure; crack bridging mechanisms are not so effective as in the case of monolithic Si₃N₄. The strength value of the monolithic Si₃N₄ is higher than the characteristic strength of nanocomposites. Fractographic analysis of the fracture surface revealed that a failure started principally from an internal flaw in the form of cluster of free carbon, and on large SiC grains which degraded strength of the nanocomposite. The creep resistance of nanocomposite is significantly higher when compared to the creep resistance of the monolithic material. Nanocomposite exhibited no creep deformation, creep cracks have not been detected even at a test at 1400 °C and a long loading time, therefore the creep is probably controlled mainly by diffusion. The intergranular SiC nanoparticles hinder the Si₃N₄ grain growth, interlock the neighboring Si₃N₄ grains and change the volume fraction, geometry and chemical composition of the grain boundary phase.     

Analyses of the role of grain boundaries in mesoscale dynamic fracture resistance of SiC-Si3N4 intergranular nanocomposites

Silicon carbide (SiC)-silicon nitride (Si₃N₄) nanocomposites with SiC dispersions as well as Si₃N₄ matrix of mesoscale dimensions (∼1 μm) are considered to have exceptional strength attributed to interactions of SiC dispersions with Si₃N₄ grain boundaries (GBs). However, an account of GBs on the strength of these nanocomposites is not available. In order to analyze this issue, cohesive finite element method (CFEM) based mesoscale dynamic fracture analyses of SiC-Si₃N₄ nanocomposites with an explicit account of length scales associated with Si₃N₄ GBs, SiC particles, and Si₃N₄ grains are performed. Analyses indicate that primary mechanism of fracture in the nanocomposite microstructures is intergranular Si₃N₄ matrix cracking. GBs are responsible for crack deflection and accordingly damage is limited to a smaller geometric region in microstructures with GBs. On an average, a microstructure with GBs present is stronger than the corresponding microstructure with GBs removed. However, in cases where the second phase SiC particles are in the wake of microcracks the microstructure without GB becomes stronger against fracture in comparison to the corresponding one with GBs owing to the crack bridging effect caused by the second phase SiC particles.     

Interfacial Microstructure and Reaction Phases of Solid State Bonded at SiC/V Joints

SiC was bonded to SiC using V foil at temperatures ranging from 1473 K to 1673 K for 1.8 to 64.8 × 10³ s and 30 MPa in vacuum. Interfacial reactions and microstructures were investigated using electron probe microanalyser and X-ray diffractometer. SiC begins to react with V at temperatures above 1473 K. Granular V₂C phase was formed at the V side of the reaction zone, while a layer of V₃Si phase was formed at the interface between V₂C and SiC after bonding at 1573 K for 1.8 and 7.2 × 10³ s. The same reaction structure can be observed at 1473 and 1673 K for 1.8 × 10³ s. Hexagonal V₅Si₃Cx (X < 1) phase was formed at the interface between V₃Si and SiC after bonding at 1573 K for 14.4 and 21.6 × 10³ s, and the interface structure of the joint became SiC/V₅Si₃Cx/V₃Si/V₂C + V/V. This microstructure represents a complete diffusion path which is correlated with the corresponding Si-V-C phase diagram. At the longer bonding time of 64.8 × 10³ s, V was completely consumed, and the joint showed the layer structure of SiC/V₅Si₃Cx/V₃Si/V₂C/V₃Si/V₅Si₃Cx/SiC.     

TORSIONAL FATIGUE OF A MEDIUM CARBON STEEL CONTAINING AN INITIAL SMALL SURFACE CRACK INTRODUCED BY TENSION–COMPRESSION FATIGUE: CRACK BRANCHING,NON-PROPAGATION AND FATIGUE LIMIT

In order to examine the threshold condition for the fatigue limit of materials containing a small crack under cyclic torsion, reversed torsional fatigue tests were carried out on 0.47% C steel specimens containing an initial small crack. Initial small semi-elliptical cracks ranging from 200 to 1000 μm in length were introduced by the preliminary tension–compression fatigue tests using specimens containing holes of 40 μm diameter. The threshold condition for the fatigue limit of the specimens containing artificial small defects under rotating bending and cyclic torsion are also reviewed. Crack growth behaviour from an initial crack was investigated. The torsional fatigue limit for a semi-elliptical small crack is determined by the threshold condition for non-propagation of Mode I branched cracks. The torsional fatigue limit of specimens containing an initial small crack can be successfully predicted by the extended application of the √area parameter model in combination with the σ_θmax criterion.     

Preliminary study of the crack healing and strength recovery of Al2O3-matrix composites

This study focused on the crack‐healing behaviour of three commercial Al₂O₃–ceramic‐matrix composites: TiC_P/Al₂O₃, ZrO₂/Al₂O₃ and SiC_W/Al₂O₃. Vickers indentation was used to introduce surface flaws with different loads of 49, 98 and 196 N. Then the cracked specimens were annealed in air for 1 h at 1000, 1200 and 1400 °C. The annealing treatment was also conducted at 1200 °C in vacuum for 1 h. Results showed that the annealing treatments increased the indentation strength, but the extent of the increase was different. When annealed in air, the main crack‐healing mechanism of TiC_P/Al₂O₃ and SiC_W/Al₂O₃ composites was chemical reaction. When annealed in vacuum, stress relaxation caused much less strength recovery. The main crack‐healing mechanism of ZrO₂/Al₂O₃ was the existence of low melting eutectic and the rearrangement of grains caused by ZrO_2(m)→ ZrO_2(t) transformation in the crack‐opening process zone. The effects of annealing temperature, atmosphere and indentation load on the degree of strength recovery were all related to the crack‐healing mechanisms.     

Morphology of step-wise S–N curves depending on work-hardened layer and humidity in a high-strength steel

The present paper describes the effects of work‐hardened layer and humidity on the fatigue response of high strength steel, JIS SNCM439 (AISI4340). Tests were conducted in laboratory air and in dry air using cantilever‐type rotating bending fatigue testing machines. The dew point of dry air was ?60 °C. Specimens with two different surface conditions were prepared, i.e., buff‐finished and electro‐polished specimens. In the buff‐finished specimens, a stepwise S–N curve was seen in both environments, but the transition stress below which subsurface crack initiation occurred shifted to a higher stress level in dry air than in laboratory air. In the electro‐polished specimens, stepwise S–N curve was not observed in laboratory air, but seen in dry air. At stress levels where cracks initiated at the surface, the fatigue lives of the electro‐polished specimens were shorter than those of the buff‐finished specimens. At stress levels where subsurface cracks initiated, the fatigue lives of both specimens were the same, irrespective of surface finishing condition and humidity.     

Dense and near-net-shape fabrication of Si3N4 ceramics

With silicon nitride significant progress has been made in order to search for fully dense, strong, reliable structural ceramics to find wide use in applications at high temperatures which are allowing new and innovative solutions to component design problems. Taking into account that more and more ceramic components based on Si₃N₄ are being used in the aerospace and automobile industries, it is a great challenge to fabricate such complex-shaped components with high reliability and with defect-free microstructures such as pores, inclusions or any other inhomogeneity at acceptable costs. On the other side, the high hardness of Si₃N₄ ceramics is almost always cost prohibitive to shape components by hard machining. It is therefore great effort exhibited in the development of near-net-shape fabrication processes that can produce complex-shaped components with a minimum of machining as well as to minimize the number and size of microstructural defects within design limits. In this review, the fabrication of near-net-shape Si₃N₄ ceramics is given in detail. All kinds of these techniques (injection molding, gelcasting, robocasting, mold shape deposition, rapid prototyping) and their advantages and disadvantages are explained.     

Vorhersagemodell für die Wachstumsraten kurzer Risse auf der Basis von Kmax‐konstant‐Versuchen an M(T)‐Proben

Prediction model for the growth rates of short cracks based on K_max‐constant tests with M(T) specimens The fatigue crack growth behaviour of short corner cracks in the Aluminium alloys Al 6013‐T6 and Al 2524‐T351 was investigated. The aim was to determine the crack growth rates of small corner cracks at stress ratios of R = 0.1, R = 0.7 and R = 0.8 and to develop a method to predict these crack growth rates from fatigue crack growth curves determined for long cracks. Corner cracks were introduced into short crack specimens, similar to M(T)‐specimens, at one side of a hole (Ø = 4.8 mm) by cyclic compression (R = 20). The pre‐cracks were smaller than 100 μm (notch + precrack). A completely new method was used to cut very small notches (10–50 μm) into the specimens with a Focussed Ion Beam. The results of the fatigue crack growth tests with short corner cracks were compared with long fatigue crack growth test data. The short cracks grew at ΔK‐values below the threshold for long cracks at the same stress ratio. They also grew faster than long cracks at the same ΔK‐values and the same stress ratios. A model was developed on the basis of K_max‐constant tests with long cracks that gives a good and conservative prediction of the short crack growth rates.     

Influence of SiC, Si3N4 and Al2O3 particles on the structure and properties of electrodeposited Ni

The structure and properties of electrodeposited nickel composites reinforced with inert particles like SiC, Si₃N₄ and Al₂O₃ were compared. A comparison was made with respect to structure, morphology, microhardness and tribological behaviour. The coatings were characterized with optical microscopy, Scanning electron microscopy (SEM), Energy dispersive X-ray analysis (EDX) and X-ray diffraction (XRD) technique. The cross-sectional microscopy studies revealed that the particles were uniformly distributed in all the composites. However, a difference in the surface morphology was revealed from SEM studies. The microhardness studies revealed that Si₃N₄ reinforced composite showed higher hardness compared to SiC and Al₂O₃ composite. This was attributed to the reduced crystallite size of Ni — 12 nm compared to 16 nm (SiC) and 23 nm (Al₂O₃) in the composite coating. The tribological performance of these coatings studied using a Pin-on-disk wear tester, revealed that Si₃N₄ reinforced composite exhibited better wear resistance compared to SiC and Al₂O₃ composites. However, no significant variation in the coefficient of friction was observed for all the three composites.     

Micro/nanoscale mechanical characterization and in situ observation of cracking of laminated Si3N4/BN composites

Micro/nanoscale mechanical characterization of laminated Si₃N₄/BN composites was carried out by nanoindentation techniques. A custom-designed micro mechanical tester was integrated with an optical microscope and an atomic force microscope to perform in situ three-point bending tests on notched Si₃N₄/BN composite bend specimens where the crack initiation and propagation were imaged simultaneously with the optical microscope and atomic force microscope during bending loading. The whole fracture process was in situ captured. It was found that crack deflection was initiated/induced by the pre-existing microvoids and microcracks in BN interfacial layers. New fracture mechanisms were proposed to provide guidelines for the design of biomimetic nacre-like composites.     

Surface damage in ZrB2-based composite ceramics induced by electro-discharge machining

Electro-conductive ZrB₂-based composite ceramics, containing SiC and B₄C, were machined with an electro-discharge machining (EDM) process. The EDMed surfaces were covered with resolidified ZrB₂ layers. Many open pores and surface cracks were observed on the surfaces. The strength degradation of the ceramics caused by machining was evaluated by three point bending tests of the partially EDMed bending specimens. The effects of pulsed current, pulse duration and duty factor on the strength and the roughness of EDMed surfaces are discussed. The strength of EDMed specimens was increased with decreases in pulse current, pulse duration and duty factor. The roughness of EDMed surfaces was decreased with decreases in pulse current, pulse duration and duty factor. The reliability of the ceramics EDMed with the appropriate conditions was as high as that of the ceramics ground with a 400 grit diamond wheel. It would be possible to use the carefully EDMed ZrB₂-based composite ceramics as structural components without any additional finishing processes.     

R-Curve Behavior of Si3N4/BNNT Composites

The crack propagation rsistance behavior of Si₃N₄ ceramics reinforced by boron nitride nanotubes (BNNT) has been discussed in the work. And, bending strength and fracture toughness of Si₃N₄/BNNT composites were tested by three point bending method. It is shown that crack propagation resistance of BNNT/Si₃N₄ composites is increased distinctly owing to addition of BNNT. It is attributed to the pinning and bridging roles of BNNT. One kind of mathematical model was constructed for calculating crack propagation resistance of Si₃N₄ ceramics and BNNT/Si₃N₄ composites. Crack resistance curve (R-Curve) of Si₃N₄ ceramics and BNNT/Si₃N₄ composites was also calculated. Crack propagation of them was simulated using finite element methods. The results show that strong shielding area is formed in crack tip owing to existence of BNNT and crack propagation is prevented by strong stress shielding roles.     

Notched fatigue testing of Inconel 718 prepared by selective laser melting

Selective laser melting (SLM) was used to prepare notched high‐cycle fatigue test specimens made from nickel‐based superalloy Inconel 718. Samples were designed to have 1 of 3 different notch geometries, including V notches with K_t of 2.2 or 3.1, a U notch with K_t of 2.0, and were printed in either vertical or horizontal orientations. Samples were tested with as‐printed dimensions and surfaces after heat treatment, but a separate set of SLM samples were printed as plates and machined to final dimensions comporting to the V‐notch specimen with K_t = 3.1. High‐cycle fatigue testing showed that machined SLM specimens behaved similar to wrought Inconel 718 plate specimens, but testing with as‐produced surfaces led to a decrease in fatigue life. The explanation for this difference is based on approximations of linear elastic fracture mechanics solutions for short cracks emanating from notch roots, with intrinsic surface features of SLM materials serving as the cracks. Analysis of the actual notch geometries after SLM fabrication indicates that stress intensity in the presence of these features plays a prominent role in determining number of cycles before fatigue crack initiation and propagation occurs.