Damage development and lifetime prediction of cross-ply ceramic-matrix composites subjected to cyclic loading at room and elevated temperatures

ABSTRACT

In this paper, the damage development and lifetime prediction of fibre-reinforced ceramic-matrix composites subjected to cyclic loading at elevated temperatures in oxidising atmosphere have been investigated. Considering the damage mechanisms of matrix cracking, interface debonding, interface wear and interface oxidation, the damage evolution of fatigue hysteresis dissipated energy, fatigue hysteresis modulus, fatigue peak strain, interface shear stress and broken fibres fraction have been analysed. The relationships between damage parameters and internal damage of matrix cracking, interface debonding and slipping, and fibres fracture have been established. The experimental fatigue hysteresis, interface slip lengths, peak strain, and the fatigue life curves of cross-ply CMCs under cyclic loading at elevated temperature have been predicted. The different fatigue behaviour in unidirectional and cross-ply CMCs at room and elevated temperatures subjected to low-cycle and high-cycle fatigue has been discussed.     

Multiple Cracking and Tensile Behavior for an Orthogonal 3-D Woven Si-Ti-C-O Fiber/Si-Ti-C-O Matrix Composite

This paper presents experimental results for the multiple microcracking and tensile behavior of an orthogonal 3-D woven Si-Ti-C-O fiber (Tyranno™ Lox-M)/Si-Ti-C-O matrix composite with a nanoscale carbon fiber/matrix interphase and processed using a polymer impregnation and pyrolysis route. Based on microscopic observations and unidirectional tensile tests, it is revealed that the inelastic tensile stress/strain behavior is governed by matrix cracking in transverse (90°) fiber bundles between 65 and 180 MPa, matrix cracking in longitudinal (0°) fiber bundles between 180 and 300 MPa, and fiber fragmentation above 300 MPa. A methodology for estimation of unidirectional tensile behavior in orthogonal 3-D composites has been established by the use and modification of existing theory. A good correlation was obtained between the predicted and measured composite strain using this procedure.     

Acoustic emission and electrical resistance in SiC-based laminate ceramic composites tested under tensile loading

Acoustic emission and electrical resistance were monitored for SiC-based laminate composites while loaded in tension and correlated with damage sources. The ceramic matrix composites were composed of Hi-Nicalon Type S™ fibers, a boron-nitride interphase, and pre-impregnated (pre-preg) melt-infiltrated silicon/SiC matrix. Tensile load-unload-reload or tensile monotonic tests were performed to failure or to a predetermined strain condition. Some of the specimens were annealed which relieved some residual matrix compressive stress and enabled higher strains to failure. Differences in location, acoustic frequency and energy, and quantity of matrix cracking have been quantified for unidirectional and cross-ply type architectures. Consistent relationships were found for strain and matrix crack density with acoustic emission activity and the change in measured electrical resistance measured at either the peak stress or after unloading to a zero-stress state. Fiber breakage in the vicinity of composite failure was associated with high frequency, low energy acoustic events.     

Multiple Cracking of Unidirectional and Cross-PlyCeramic Matrix Composites

This paper examines the multiple cracking behavior of unidirectional and cross-ply ceramic matrix composites. For unidirectional composites, a model of concentric cylinders with finite crack spacing and debonding length is introduced. Stresses in the fiber and matrix are found and then applied to predict the composite moduli. Using an energy balance method, critical stresses for matrix cracking initiation are predicted. Effects of interfacial shear stress, debonding length and bonding energy on the critical stress are studied. All the three composite systems examined show that the critical stress for the completely debonded case is lower than that for the perfectly bonded case. For cross-ply composites, an extensive study has been made for the transverse cracking in 90° plies and the matrix cracking in 0° plies. One transverse cracking and four matrix cracking modes are studied, and closed-form solutions of the critical stresses are obtained. The results indicate that the case of combined matrix and transverse crackings with associated fiber/matrix interfacial sliding in the 0° plies gives the lowest critical stress for matrix cracking. The theoretical predictions are compared with experimental data of SiC/CAS cross-ply composites; both results demonstrated that an increase in the transverse ply thickness reduces the critical stress for matrix cracking in the longitudinal plies. The effects of fiber volume fraction and fiber modulus on the critical stress have been quantified. Thermal residual stresses are included in the analysis.     

Influence of Stress Ratio on the Elevated-Temperature Fatigue of a Silicon Carbide Fiber-Reinforced Silicon Nitride Composite

The influence of stress ratio on the tensile fatigue behavior of a unidirectional SiC-fiber/Si₃N₄-matrix composite was investigated at 1200°C. Tensile stress ratios of 0.1, 0.3, and 0.5 were examined. Fatigue testing was conducted in air, at a sinusoidal loading frequency of 10 Hz. For peak fatigue stresses below the proportional limit of the composite (approximately 195 MPa at 1200°C) specimens survived 5 × 10⁶ cycles, independent of stress ratio. At peak stresses above the proportional limit, fatigue failures were observed; fatigue life decreased significantly as the stress ratio was lowered from 0.5 to 0.1. Creep appears to be the predominant damage mechanism which occurs during fatigue below the proportional limit. Both mechanical cycle-by-cycle fatigue damage and creep contribute to specimen failure at peak stresses above the proportional limit.     

Modeling the effect of temperature on first matrix cracking stress and fracture strength of cross-ply fiber reinforced ceramic-matrix composites

In this work, we proposed a temperature-dependent first matrix cracking stress model for cross-ply fiber reinforced ceramic-matrix composites (FRCMCs) first. It takes into account of the effects of interfacial shear stress and residual thermal stress as well as their evolution with temperature. Moreover, in order to characterize the effect of temperature on fracture strength, we defined the critical strain energy density associated with composites fracture, by which and the force-heat equivalence energy density principle, the temperature-dependent fracture strength model for cross-ply FRCMCs was established. The models’ predictions of first matrix cracking stress and fracture strength at different temperatures are in good agreement with experimental results available. This study not only advances our in-depth understanding of the quantitative relationship between temperature and mechanical properties of cross-ply FRCMCs, but also offers a powerful tool to predict the temperature-dependent first matrix cracking stress and fracture strength.     

2维C/SiC复合材料的拉伸损伤演变过程和微观结构特征

通过单向拉伸和分段式加载-卸载实验,研究了二维编织C/SiC复合材料的宏观力学特性和损伤的变化过程.用扫描电镜对样品进行微观结构分析,并监测了载荷作用下复合材料的声发射行为.结果表明:在拉伸应力低于50MPa时,复合材料的应力-应变为线弹性;随着应力的增加,材料模量减小,非弹性应变变大,复合材料的应力-应变行为表现为非线性直至断裂.复合材料的平均断裂强度和断裂应变分别为23426MPa和0.6%.拉伸破坏损伤表现为:基体开裂,横向纤维束开裂,界面层脱粘,纤维断裂,层间剥离和纤维束断裂.损伤累积后最终导致复合材料交叉编织节点处纤维束逐层断裂和拔出,形成斜口断裂和平口断裂.     

Study on interfacial debonding stress and damage mechanisms of C/SiC composites using acoustic emission

Among ceramic matrix composites (CMCs), carbon fiber-reinforced silicon carbide matrix (C/SiC) composites are widely used in numerous high-temperature structural applications because of their superior properties. The fiber–matrix (FM) interface is a decisive constituent to ensure material integrity and efficient crack deflection. Therefore, there is a critical need to study the mechanical properties of the FM interface in applications of C/SiC composites. In this study, tensile tests were conducted to evaluate the interfacial debonding stress on unidirectional C/SiC composites with fibers oriented perpendicularly to the loading direction in order to perfectly open the interfaces. The characteristics of the material damage behaviors in the tensile tests were successfully detected and distinguished using the acoustic emission (AE) technique. The relationships between the damage behaviors and features of AE signals were investigated. The results showed that there were obviously three damage stages, including the initiation and growth of cracks, FM interfacial debonding, and large-scale development and bridging of cracks, which finally resulted in material failure in the transverse tensile tests of unidirectional C/SiC composites. The frequency components distributed around 92.5 kHz were dominated by matrix damage and failure, and the high-frequency components distributed around 175.5 kHz were dominated by FM interfacial debonding. Based on the stress and strain versus time curves, the average interfacial debonding stress of the unidirectional C/SiC composites was approximately 1.91 MPa. Furthermore, scanning electron microscopy (SEM) and energy-dispersive X-ray spectroscopy (EDXS) were used to observe the morphologies and analyze the chemical compositions of the fractured surfaces. The results confirmed that the fiber was completely debonded from a matrix on the fractured surface. The damage behaviors of the C/SiC composites were mainly the syntheses of matrix cracking, fiber breakage, and FM interfacial debonding.     

水泥稳定碎石早期损伤自愈合疲劳特性试验研究

为了使水泥稳定碎石基层微裂技术在实际工程应用中的理论依据得到进一步完善,对水泥稳定碎石早期损伤自愈合疲劳性能进行全面和深入的研究.使用振动压实仪成型水泥稳定碎石梁式试件,并在不同微裂时间对梁式试件进行不同程度的微裂;在龄期为90d时,通过弯拉强度试验和疲劳试验测定微裂前后水泥稳定碎石材料的弯拉强度和疲劳寿命次数,并对试验结果进行分析.研究微裂后水泥稳定碎石材料早期损伤自愈合疲劳寿命的变化规律,并且应用Weibull分布建立了水泥稳定碎石微裂疲劳方程.研究结果表明:微裂前后的水泥稳定碎石材料疲劳寿命随应力水平增加均呈现出线性递减的规律;微裂程度为20％和30％时,水泥稳定碎石材料的疲劳寿命与未微裂时水平基本一致,微裂程度为40％的水泥稳定碎石材料的疲劳寿命相对降低,但仍在使用要求范围内;微裂时间对疲劳试验结果无显著性影响.     

Stress Corrosion Cracking in a Unidirectional Ceramic-Matrix Composite

A study of matrix cracking in a unidirectional ceramic-matrix composite under static loading conditions has been conducted. The evolution of crack density with time has been measured using both flexure and uniaxial tension tests. Subcritical cracking has been observed at stresses below that required to develop matrix cracks in short-duration, monotonic loading tests. Furthermore, a relatively high final crack density has been observed following extended periods (∼10⁶ s) under static load. A fracture mechanics analysis applicable to subcritical crack growth has been developed and used successfully to model the evolution of matrix cracking with time and applied stress. The model incorporates the properties of the matrix, fibers, and interfaces, as well as the residual stress and the initial flaw distribution in the matrix.     

Improving the crack resistance of bulk molding compounds and sheet molding compounds

Fiber-reinforced plastics exhibit two types of mechanical failure: gross fracture and microcracking. Gross fracture involves both matrix and fiber failures. Principal resistance to crack propagation derives from partial decoupling of fibers and then stressing, remove finite volumes of them to fracture. Classical concepts of fracture mechanics can be applied to such composites, though modifications of methodology to treat anisotropy and other special effects are required. Microcracking occurs principally in the matrix phase and usually accompanies cyclic fatigue, drop impact, bending, or rapid cooling from molding temperatures. It lowers composite stiffness, environmental resistance and may reduce strength. Matrix resins require high fracture toughness to minimize or eliminate microcracking. This paper discusses cracking in bulk molding compounds and sheet molding compounds, complex materials containing high percentages of glass fibers and calcium carbonate filler. Microcracking can be greatly reduced by tire addition of small amounts of a rubber to the polyester matrix. Various tests such as impact, bending, acoustic emission and crack propagation demonstrate the improved toughness properties which result. No sacrifice of original strength characteristics occurs, and markedly improved resistance to damage has been noted with rubber modified epoxy and polyester matrix resins.     

Fatigue of Yttria-Stabilized Zirconia: I, Fatigue Damage, Fracture Origins, and Lifetime Prediction

Uniaxial tension–compression fatigue behavior of 3-mol%-yttria-stabilized tetragonal zirconia polycrystals was investigated. Hysteresis in the stress–plastic strain curve featured cumulative plastic strain and weakened elastic stiffness. Fracture statistics in terms of cycle-to-failure depends strongly on the maximum stress and less on the stress amplitude. Preexisting processing flaws were identified as the fracture origins in all cases. We suggest that microcracking is the dominant mechanism of fatigue damage, that nucleation of fatigue crack is usually not necessary, and that fatigue lifetime is primarily controlled by crack propagation, which is most sensitive to the maximum stress.     

Strain response and damage modelling of glass/epoxy pipes under various stress ratios

Abstract

This paper presents the stress–strain response and general lifetime damage modelling of glass fibre reinforced epoxy (GRE) composite pipes subjected to multi-ratios stress loadings at room temperature (RT). This particular modelling work was developed to predict the non-linear stress–strain response caused by the fatigue static and cyclic loading in the multiaxial ultimate elastic wall stress (UEWS) tests by considering the effects of matrix cracking within the laminates. Although the UEWS procedure is not a standard protocol used for qualification of GRE pipes, it appears to offer an option to existing procedures delineated in ASTM D2992. The ply properties initially expressed as a function of crack density was computed as a function of increasing stress and strain using shear lag approximation. In general lifetime damage model, the effects of stress developed in each ply from ultimate elastic wall stress (UEWS) test were expressed in a single quadratic term of axial and hoop stress. The term then solved to produce limits with respect to axial and hoop stress, which represented in a graphical form of failure envelope. The predictions from both models are found to be in good agreement with the data from the multiaxial UEWS tests of ±55° filament wound GRE pipes. These models thus enable for the long term performance prediction of the pipes under combined loadings.     

Damage development of a woven SiCf/SiC composite during multi-step fatigue tests at room temperature

The monotonic tensile and multi-step fatigue tests of 2D woven SiC_f/SiC composite were performed to explore the damage development, respectively. The acoustic emission-based technique was used to analyze the damage state and select the peak stresses for fatigue tests. The damage evolution after specific mechanical tests was characterized by optical microscopy and scanning electron microscopy. Cracks are prone to occur in the vicinity of flaws and boundaries of different matrix components under relatively low fatigue stress. The cyclic fatigue stress can do much harm to the interfaces and facilitate the interfacial debonding. The damage characteristics of five types of cracking, fiber breakage and pull-out, and interfacial debonding of the composite after specific mechanical tests are concluded and discussed in detail, which can offer help for deeper analysis of the oxidation mechanism in service and more reasonable design of SiC_f/SiC composite.     

Plasticity-Induced Fatigue Damage in Ceria-Stabilized Tetragonal Zirconia Polycrystals

Current studies on the fatigue lifetime of ceramics are mostly focused on the relation between the stress amplitude (or maximum Stress) and cycles to failure. For a more compliant and plastic ceramic which has a pronounced nonlinear stress–strain relation, the role of plastic strain in the fatigue damage is investigated for the first time in this study using a 12 mol% Ce-TZP. By testing at different temperatures, we were able to vary the amount of transformation plasticity with the same microstructure. The Coffin–Manson relationship, which suggests that fatigue lifetime in the low cycle fatigue regime is best correlated with the plastic strain range, was confirmed for the tough ceramic. Fatigue damage is found to be a bulk process which continuously degrades flaw tolerance by microcracking. Evidence for the latter mechanism was also provided by uniaxial cyclic tension–compression stress–strain response and by TEM examination. Despite such damage, the possibility of plasticity-induced surface-crack nucleation in fatiguing ceramics, unlike in metals, appears unimportant.     

Damage Development and Moduli Reductions in Nicalon—Calcium Aluminosilicate Composites under Static Fatigue and Cyclic Fatigue

Unidirectional and cross-ply Nicalon fiber-reinforced calcium aluminosilicate (CAS) glass-ceramic composite specimens were subjected to tension–tension cyclic fatigue and static fatigue loadings. Microcrack densities, longitudinal Young's modulus, and major Poisson's ratio were measured at regular intervals of load cycles and load time. The matrix crack (0° plies) density and transverse crack (90° plies) density increased gradually with fatigue cycles and load time. The crack growth is environmentally driven and depends on the maximum load and time. Young's modulus and Poisson's ratio decreased gradually with fatigue cycles and load time. The saturation crack densities under fatigue loadings were found to be comparable to those under monotonic loading. A matrix crack growth limit strain exists, below which matrix cracks do not grow significantly under fatigue loading. This limit coincides with the matrix crack initiation strain. Linear correlations between crack density and moduli reductions obtained from quasi-static data can predict the moduli reductions under cyclic loading, using experimentally measured crack densities. A logarithmic correlation can predict the Young's modulus reduction in a limited stress range. A fatigue crack growth model is proposed to explain the presence of two distinct regimes of crack growth and Young's modulus reduction.     

Thermomechanical Fatigue Behavior of a Silicon Carbide Fiber-Reinforced Calcium Aluminosilicate Composite

Isothermal fatigue and in-phase thermomechanical fatigue (TMF) tests were performed on a unidirectional, continuous-fiber, Nicalon®-reinforced calcium aluminosilicate glass-ceramic composite ([O]_16, SiC/CAS-II). Monotonic tensile tests were performed at 1100°C (2012°F) and 100 MPa/s (14.5 ksi/s) to determine the material's ultimate strength (σ_ult) and proportional limit (σ_pl). Isothermal fatigue tests at 1100°C employed two loading profiles, a triangular waveform with ramp times of 60 s and a similar profile with a superimposed 60-s hold time at σ_max. All fatigue tests used a σ_max of 100 MPa (40% of σ_pl), R = 0.1. TMF loading profiles were identical to the isothermal loading profiles, but the temperature was cycled between 500° and 1100°C (932° and 2012°F). All fatigued specimens reached run-out (1000 cycles) and were tested in tension at 1100°C immediately following the fatigue tests. Residual modulus, residual strength, cyclic stress-strain modulus, and strain accumulation were all examined as possible damage indicators. Strain accumulation allowed for the greatest distinction to be made among the types of tests performed. Fiber and matrix stress analyses and creep data for this material suggest that matrix creep is the primary source of damage for the fatigue loading histories investigated.     

Scratch Damage in Zirconia Ceramics

Scratch damage modes in zirconia-based ceramics—Mg-PSZ, Y-TZP, and Ce-TZP—are investigated. Precursor indentation tests with a tungsten carbide sphere foreshadow the nature of damage: in Mg-PSZ, extensive (quasi-)plastic deformation in the region outside and beneath the contact; in Y-TZP, less plastic deformation beneath the contact but incipient cone cracking in the region of tension outside the contact; in Ce-TZP, intermediate behavior. Scratch testing is conducted using a conical diamond indenter. In all materials the damage mode changes from smooth plastic deformation to limited cracking with increasing scratch load: in Mg-PSZ, plastic deformation is predominant at lower loads, with microcracking at higher loads; in Y-TZP, plastic deformation is predominant over the range of the test loads—macrocracks initiate only at relatively high loads, but penetrate to a relatively large depth; again, Ce-TZP shows intermediate behavior, but with cracking patterns closer to that of Mg-PSZ. Bending tests on specimens subjected to scratch damage indicate a relatively high damage tolerance in the Mg-PSZ and Ce-TZP; Y-TZP shows the highest initial strength, but suffers relatively large strength loss above the critical load for macrocracking. Implications concerning relative merits of each zirconia type for wear properties, contact fatigue, and machining damage are briefly discussed.     

实验分析疲劳累计损伤分段函数表示法的合理性

加工带有半圆形缺口的平板试件,采用应变片对材料局部进行应变监测,通过轴向高周疲劳试验,研究了缺陷试件弹性模量损伤特性。结果表明:直至缺陷根部应力集中位置出现裂纹前弹性模量并无明显变化。这一结论与光滑试件所得结论存在差异,对造成差异原因进行简单分析,最终得到疲劳损伤过程存在明显阶段性的结论,为疲劳损伤历程的分段函数表示提供了实验参考。     

High-Temperature Tensile Behavior of a Boron Nitride-Coated Silicon Carbide-Fiber Glass-Ceramic Composite

Tensile properties of a cross-ply glass-ceramic composite were investigated by conducting fracture, creep, and fatigue experiments at both room temperature and high temperatures in air. The composite consisted of a barium magnesium aluminosilicate (BMAS) glass-ceramic matrix reinforced with SiC fibers with a SiC/BN coating. The material exhibited retention of most tensile properties up to 1200°C. Monotonic tensile fracture tests produced ultimate strengths of 230–300 MPa with failure strains of ∼1%, and no degradation in ultimate strength was observed at 1100° and 1200°C. In creep experiments at 1100°C, nominal steady-state creep rates in the 10⁻⁹ s⁻¹ range were established after a period of transient creep. Tensile stress rupture experiments at 1100° and 1200°C lasted longer than one year at stress levels above the corresponding proportional limit stresses for those temperatures. Tensile fatigue experiments were conducted in which the maximum applied stress was slightly greater than the proportional limit stress of the matrix, and, in these experiments, the composite survived 10⁵ cycles without fracture at temperatures up to 1200°C. Microscopic damage mechanisms were investigated by TEM, and microstructural observations of tested samples were correlated with the mechanical response. The SiC/ BN fiber coatings effectively inhibited diffusion and reaction at the interface during high-temperature testing. The BN layer also provided a weak interfacial bond that resulted in damage-tolerant fracture behavior. However, oxidation of near-surface SiC fibers occurred during prolonged exposure at high temperatures, and limited oxidation at fiber interfaces was observed when samples were dynamically loaded above the proportional limit stress, creating micro-cracks along which oxygen could diffuse into the interior of the composite.