Fatigue behaviour and residual strength evolution of 2D C/SiC Z-pinned joints prepared by chemical vapour infiltration

Z-pinned joints prepared by chemical vapour infiltration are widely used in ceramic matrix composite components. Excellent fatigue behaviour is important for structural safety. In this study, 2D C/SiC Z-pinned joints were loaded in axial direction of the pins under static and cyclic loading. Internal damage was monitored in situ by an acoustic emission system. The binding force between pin and hole is relatively strong. Meanwhile, the joints exhibite promising resistance to fatigue. The residual strength increased first with the fatigue cycles then decreased after 10⁵ cycles. Microstructural analysis indicated that full-developed cracks and local stress redistribution resultes in the increase in the strength of the joints. The acoustic emission analysis also provides a supplementary understanding of the damage mechanism. The results show that damage fully develops at the early stage of fatigue. When the specimen is reloaded, less AE events are collected before the fatigue maximum stress.     

Ring compression properties of SiCf/SiC composites prepared by chemical vapor infiltration

SiC fiber reinforced SiC matrix (SiC_f/SiC) composites prepared by chemical vapor infiltration are one of promising materials for nuclear fuel cladding tube due to pronounced low radioactivity and excellent corrosion resistance. As a structure component, mechanical properties of the composites tubes are extremely important. In this study, three kinds of SiC_f preform with 2D fiber wound structure, 2D plain weave structure and 2.5D shallow bend-joint structure were deposited with PyC interlayer of about 150–200?nm, and then densified with SiC matrix by chemical vapor infiltration at 1050?°C or 1100?°C. The influence of preform structure and deposition temperature of SiC matrix on microstructure and ring compression properties of SiC_f/SiC composites tubes were evaluated, and the results showed that these factors have a significant influence on ring compression strength. The compressive strength of SiC_f/SiC composites with 2D plain weave structure and 2.5D shallow bend-joint structure are 377.75?MPa and 482.96?MPa respectively, which are significantly higher than that of the composites with 2D fiber wound structure (92.84?MPa). SiC_f/SiC composites deposited at 1100?°C looks like a more porous structure with SiC whiskers appeared when compared with the composites deposited at 1050?°C. Correspondingly, the ring compression strength of the composites deposited at 1100?°C (566.44?MPa) is higher than that of the composites deposited at 1050?°C (482.96?MPa), with a better fracture behavior. Finally, the fracture mechanism of SiC_f/SiC composites with O-ring shape was discussed in detail.     

Oxidation behaviors and shear properties of z-pinned joint made of two-dimensional carbon fiber reinforced silicon carbide composite

Chemical vapor infiltration has been introduced for preparing z-pinned joint, which is made of two-dimensional carbon fiber reinforced silicon carbide composite. The effects of oxidation on the shear properties of the joint were investigated. The results showed that the joint strength increases with the increase of oxidation temperature, which is consistent with the oxidation consumption of the carbon phases. An exponential relationship is presented between the weight loss and the joint strength. In contrast, linear relationships are presented between the weight loss and the mechanical properties of the composite. The exponential relationship results from the coupled shear and bending stress states of the pin, according to the failure mechanisms of the joint. It is observed that in-plane and intra-layer cracks are formed under the shear stress. And these cracks are bridged by the fibers under the bending stress. Accordingly, the fiber bridging mechanism contributes to the joint strength before and after oxidation. For the conditions of this study, the joint strength can be roughly estimated as the plus of the in-plane shear strength and the tensile matrix cracking stress.     

Microstructure and properties of diamond/SiC composites prepared by tape-casting and chemical vapor infiltration process

This article reported a novel method for preparing diamond/SiC composites by tape-casting and chemical vapor infiltration (CVI) process, and the advantages of this method were discussed. The diamond particle was proved to be thermally stable under CVI conditions and the CVI diamond/SiC composites only contained diamond and CVI-SiC phases. The SEM and TEM results showed a strong interfacial bonding existed between diamond and CVI-SiC matrix. Due to the strong bonding, the surface HRA hardness could reach up to 98.4 (HV 50 ± 5 GPa) and the thermal conductivity (TC) of composites was five times higher than that of pure CVI-SiC matrix. Additionally, the effects of diamond particle size on microstructure and properties of composites were also investigated. With the increasing of particle size, the density and TC of composites with the size 27 μm reached 2.940 g/cm³ and 82 W/(m K), respectively.     

Enhanced tribological properties of Y/MoS2 composite coatings prepared by chemical vapor deposition

Chemical vapor deposition (CVD) is an efficient approach to prepare coatings on complex cutting tools. However, MoS₂ with self-lubrication ability and excellent tribological properties fabricated by CVD have been rarely reported in literature. The aim of this study was to deposit pure MoS₂ coatings and yttrium (Y) doped MoS₂ (Y/MoS₂) composite coatings on cemented carbide blades coated with titanium nitride by CVD. The structural and mechanical properties of the coatings were examined by scanning electron microscopy (SEM) and nanoindentation, respectively. The results demonstrated that the microstructure of Y/MoS₂ composite coatings was denser than that of the pure MoS₂ coating. The hardness and the adhesional properties were significantly enhanced for the Y/MoS₂ composite coatings. The tribological performance of the as-deposited coatings were investigated under atmospheric environment. Y/MoS₂ compostite coatings demonstrated an enhanced tribological performance with a stable and low coefficient of friction (COF) over the entire sliding time. In contrast, the COF of pure MoS₂ coating dramatically increased to value above 0.3 after a sliding time of only 30 min. Additionally, the Y/MoS₂ composite coatings showed a decreased wear rate (8.36 ± 0.29 × 10⁻⁷ mm³/Nm) compared to the pure MoS₂ coatings (3.41 ± 0.48 × 10⁻⁵ mm³/Nm) thus reflecting an improvement by two order of magnitude.     

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.     

Friction performance of C/C composites prepared using rapid directional diffused chemical vapor infiltration processes

A technology used to prepare C/C composites using a rapid directional diffused (RDD) chemical vapor infiltration process has been investigated. General RDD technologies were explored, and optimal parameters were determined. The friction and wear properties of this material were researched. The results showed that in the RDD process, propylene and nitrogen were rapidly and directionally diffused into the carbon preforms enabling carbon deposition to occur from the inside of the preform to the outside. This method prevents the formation of an outer crust on the surface of preforms and facilitates uniformity of densification. With the RDD process no surface machining was required between chemical vapor infiltration (CVI) cycles thereby enabling continuous densification and reducing the CVI cycle times. The optimum processing conditions for RDD CVI were as follows; furnace temperature 950 °C; and furnace pressure 6.7 kPa. The C/C composites produced using RDD CVI processing exhibited good friction performance. Their curves of the brake moment with the velocity are stable under dry conditions, and their wet brake moment is greatly reduced. The average thickness wear is decreased to 9.5×10⁻⁴ mm/surface/stop.     

Interlaminar shear behaviors of 2D needled C/SiC composites under compressive and tensile loading

The interlaminar shear strength of 2D needled C/SiC composites was measured using the double-notch shear test method. Interlaminar shear tests were performed under compressive and tensile loading. Shear stress–strain response and shear strain field evolution were studied using the digital image correlation (DIC) technique. The results show that the interlaminar shear strength of the specimen using the compressive loading method is 15% higher than that of the tensile loading method. Severe shear strain concentration was observed near the upper notch of the tensile loading specimen. Acoustic emission (AE) was utilized to monitor the damage during the tests. Typical damage mechanisms were categorized according to AE signal characteristics. The statistical results show that more matrix cracks were produced in the tensile loading specimen and no separate fiber/matrix debonding signal was detected in both specimens.     

Synthesis and properties of macroporous SiC ceramics synthesized by 3D printing and chemical vapor infiltration/deposition

Open porosity cellular SiC-based ceramics have a great potential for energy conversion, e.g. as solar receivers. In spite of their tolerance to damage, structural applications at high temperature remain limited due to high production costs or inappropriate properties. The objective of this work was to investigate an original route for the manufacturing of porous SiC ceramics based on 3D printing and chemical vapor infiltration/deposition (CVI/CVD). After binder jetting 3D-printing, the green α-SiC porous structures were reinforced by CVI/CVD of SiC using CH₃SiCl₃/H₂. The multiscale structure of the SiC porous specimens was carefully examined as well as the elemental and phase content at the microscale. The oxidation and thermal shock resistance of the porous SiC structures and model specimens were also studied, as well as the thermal and mechanical properties. The pure and dense CVI/CVD-SiC coating considerably improves the mechanical strength, oxidation resistance and thermal diffusivity of the material.     

Multi-scale modelling of progressive damage and failure behaviour of 2D woven SiC/SiC composites

In this paper, a multi-scale modelling approach has been developed to predict the progressive damage and failure behaviour of 2D woven SiC/SiC composites. At the tow scale, non-linear tow properties have been determined by a micromechanics-based damage model, in which two scalar damage variables were introduced to characterize the fibre-dominated and matrix-dominated damage, respectively. Based on periodic boundary conditions, a meso-scale unit cell model has been established to simulate the macroscopic stress-strain responses and progressive damage processes of the composite under uniaxial tensile, compressive and in-plane shear loadings, respectively. In the numerical method, the non-linear properties of constituent materials have been implemented by the user defined subroutine, USDFLD of the finite element package, Abaqus. The numerical results and their comparisons with experimental stress-strain curves have been presented. The failure mechanisms of the composite under each loading have been also discussed. The high efficiency and prediction accuracy of the model make it possible to analyse large scale woven composites.     

Manufacturing 2D carbon-fiber-reinforced SiC matrix composites by slurry infiltration and PIP process

Sub-micrometer SiC particles were firstly added to the preceramic solution in the first infiltration step to enhance the mechanical properties of 2D C_f/SiC composites fabricated via polymer infiltration and pyrolysis (PIP) process. The effects of pyrolysis temperature and SiC-filler content on microstructures and properties of the composites were systematically studied. The results show that the failure stress and fracture toughness increased with the increase of pyrolysis temperature. SiC filler of sub-micron scale infiltrated into the composites increased the mechanical properties. As a result, for the finally fabricated composite infiltrated with a slurry containing 40 wt.% SiC filler, the failure stress was doubled compared to that without SiC filler addition, and the fracture toughness reached ≈10 MPa m^1/2.     

Fabrication of SiC whisker-reinforced SiC ceramic matrix composites based on 3D printing and chemical vapor infiltration technology

Spray drying, binder jetting and chemical vapor infiltration (CVI) were used in combination for the first time to fabricate SiC whisker-reinforced SiC ceramic matrix composites (SiC_W/SiC). Granulated needle-shaped SiC_W was spray dried into SiC_W spherical particles to increase flowability and thereby increase printability. Then, binder jetting was employed to print a novel SiC_W preform with two-stage pores using the SiC_W spherical particles. The subsequent CVI technology produced pure, dense, and continuous SiC matrix with high modulus and strength. Consequently, SiC_W/SiC with appropriate mechanical properties was obtained. Finally, the challenges of the novel method and the ways to improve the mechanical properties of SiC_W/SiC are discussed.     

Ablation behavior of C/C-ZrC and C/SiC-ZrC composites fabricated by a joint process of slurry impregnation and chemical vapor infiltration

C/C-ZrC and C/SiC-ZrC composites were fabricated by a joint process of slurry impregnation and chemical vapor infiltration, in which ZrC matrix was obtained by slurry impregnation process, while C or SiC matrix was introduced by chemical vapor infiltration process. The as fabricated C/C-ZrC and C/SiC-ZrC composites have densities of 1.67 g cm^?3 and 1.91 g cm^?3 respectively. Tensile strength is 89.4±8.4 MPa and 182.2±14.0 MPa respectively for the as prepared C/C-ZrC and C/SiC-ZrC. Ablation behavior of the C/C-ZrC and C/SiC-ZrC composites under air plasma was studied and compared in detail. Due to different oxidation resistance and heat transfer capacity of the matrix, these two ZrC based composites showed various ablation behavior. The linear erosion rate is 48 µm s^?1 and 39 µm s^?1 respectively for C/C-ZrC and C/SiC-ZrC composites.     

Fabrication of highly dense three-layer SiC cladding tube by chemical vapor infiltration method

Three-layer silicon carbide (SiC) cladding architectures are considered to be promising materials for current light-water nuclear reactors. Herein, a novel processing approach was proposed to fabricate dense three-layer SiC tubes by introducing SiC nanowires (NWs) on the graphite rod, which resulted in change in the valley-peak structure of SiC_f tubular preform. A dense three-layer-NWs SiC cladding tube, consisting of a chemical vapor infiltration (CVI)-SiC inner layer, a CVI-SiC_f/SiC composite layer, and a CVI-SiC outer layer, was obtained through CVI process. Microstructure and hoop strength of the as-obtained three-layer-NWs SiC cladding tube were systematically investigated. By avoiding delamination of the layers and reducing the pores, the three-layer-NWs SiC cladding tube exhibited an average hoop strength of 316.6 MPa with a Weibull modulus of 11.55.     

The effects of fiber orientation on failure behaviors of 2D C/SiC torque tube

Different failure behaviors were observed in the 2D C/SiC torque tubes which were fabricated by chemical vapor infiltration (CVI) with different fiber orientations (0°/90° and ±45°). CT test was implemented to characterize the density heterogeneity of the ceramic matrix composite (CMC) torque tubes. With the density value measured by Archimedes drainage method, FEM software was implemented to simulate the stress distribution of the ceramic matrix composite torque tubes and calculate the failure stress. Torsional tests were conducted using special attachments to a universal material test machine. Different torsional behaviors of CMC torque tubes with two different fiber orientations were presented in the stress-strain curves. The fracture morphologies were observed by SEM, and the predominant factors of failure were analyzed. CMC torque tubes with fiber orientation of ±45° have a higher torque capacity and modulus. In failure analysis, we found that ±45° fiber orientation CMC torque tubes have reasonable fracture morphologies.     

Porous SiCnw/SiC ceramics with unidirectionally aligned channels produced by freeze-drying and chemical vapor infiltration

The current study introduces a methodology for the fabrication of porous silicon carbide nanowire/silicon carbide (SiC_nw/SiC) ceramics with macroscopic unidirectionally aligned channels and reports on their microstructural and mechanical properties. The material was produced by freezing of a water-based slurry of β-SiC nanowires (SiC_nw) with control of the ice growth direction. Pores were subsequently generated by sublimation of the columnar ice during freeze-drying. Chemical vapor infiltration (CVI) of SiC into the open pore network of the SiC_nw aerogel with unidirectionally aligned channels, resulted in the formation of highly porous SiC_nw/SiC ceramics which exhibited a unique microstructure as identified by scanning electron microscopy. The pore size distribution and the mechanical properties of the as-fabricated porous ceramics were examined by mercury intrusion porosimetry and three-point bending and compression tests, respectively, while phase composition was investigated through X-ray diffraction.     

Joining of C/SiC composites by spark plasma sintering technique

CVD–SiC coated C/SiC composites (C/SiC) were joined by spark plasma sintering (SPS) by direct bonding with and without the aid of joining materials. A calcia-alumina based glass–ceramic (CA), a SiC + 5 wt% B₄C mixture and pure Ti foils were used as joining materials in the non-direct bonding processes. Morphological and compositional analyses were performed on each joined sample. The shear strength of joined C/SiC was measured by a single lap test and found comparable to that of C/SiC.     

HfB2 coating on C/C composites prepared by chemical vapor deposition: Thermodynamics and experimental investigation

A thermodynamic calculation on the HfB₂ coating prepared by chemical vapor deposition (CVD) through HfCl₄-BCl₃-H₂-Ar system was performed, together with the relevant verification experiments. The calculation results indicated that HfB₂ coating could be obtained above 900 °C with the ratios of BCl₃/HfCl₄ and H₂/HfCl₄ higher than 1 and 12, respectively. The experimental results demonstrated that the deposition temperature, H₂ and BCl₃ flow rates had significant effects on the grain size, growth rate and phase composition of HfB₂ coatings. A dense and uniform HfB₂ coating was prepared at 1150 °C with a BCl₃/HfCl₄ ratio of 3 and a H₂/HfCl₄ ratio of 20, whose mass and linear ablation rates were 15.61 mg/s and 15.58 μm/s under oxyacetylene flame.     

Effect of diffusion-assisting holes on the tensile properties of a thick-section two dimensional C/SiC composite fabricated by chemical vapor infiltration

The concept of diffusion-assisting holes (DAHs) has been developed to increase matrix deposition in the middle layers of the thick-section ceramic matrix composites (CMCs) that are fabricated by chemical vapor infiltration (CVI). However, the effect of DAHs on the tensile properties of CMCs has not been studied. Here, the tensile properties and the state of matrix deposition of a 10-mm-thick two dimensional (2D) C/SiC with DAHs are investigated. Results showed, with DAHs, a zone of increased deposition with a radius of ca. 1.4 mm around a hole was introduced and the net-section strength of the 10-mm-thick 2D C/SiC was increased by 48.1%. In addition, the tensile load bearing capacity was also increased by 34.1%, although the load bearing section decreased with DAHs. The increased net-section strength and tensile load bearing capacity of the C/SiC are attributed to the increased matrix deposition in the middle layers of the thick-section composite.