The effect of fiber orientation on failure behavior of 3DN C/SiC torque tube

In this paper, the 3DN C/SiC torque tubes were fabricated by chemical vapor infiltration (CVI) combined with silicon melt infiltration (SMI) method with different fiber orientations (0°/90° and ± 45°) which leads to different density, torsional behaviors and failure behaviors. CT test was implemented to characterize the density heterogeneity. Using the density measured from Archimedes drainage method, FEM software was implemented to simulate the stress distribution of the tubes and calculate the failure stress. A good agreement with analytical model was obtained which helps a lot to failure analysis. Torsional tests were conducted using special attachments to a universal material test machine, the shear strain was calculated from the strain gauge, the shear strength was calculated by simplified formula, different torsional behaviors of two different fiber orientations were represented in the stress-strain curves. The fracture morphologies were observed by SEM, and the predominant factors of failure were analyzed. Torque tubes with fiber orientations of ± 45° have a higher torque capacity, modulus, and reasonable fracture morphologies, which is in good agreement with simulation results.     

Effect of fiber orientation on surface characteristics of C/SiC composites by laser-assisted machining

In this paper, the characteristics and mechanism of laser-assisted machining (LAM) of C/SiC composites with different fiber orientations (0°, 45°, 90°, 135°) are studied. For the purpose of this study, a series of LAM experiments have been carried out and supported by a comparative analysis over the conventional machining (CM). Furthermore, the effect of fiber orientation on surface morphology, roughness, and sub-surface damage was explored. It is found that the surface quality of the workpiece treated by LAM is better than that of CM, and a lower surface roughness Ra value is obtained. It is shown that depending on different fiber orientations, the surface roughness decreases in different degrees. The roughness at 90° fiber orientation witnesses the maximum reduction, followed by 0° and 45° fiber orientation, and the roughness at 135° fiber orientation undergoes the slightest reduction. Moreover, surface micro-defects under LAM are significantly reduced, and fiber fractures are tidier. On the other hand, the matrix is mixed with fiber debris under high temperatures and sticks to the machined surface, filling and repairing surface pits and holes and hence improving the processed surface quality. These results provide new guidance for improving the machining quality of C/SiC composites.     

Torsion and flexural-torsional coupled mechanical properties of different C/SiC torque tubes at room and elevated temperatures

In this paper, the torsion and flexural-torsional coupled mechanical properties of different C/SiC torque tubes were investigated for the testing condition at room and elevated temperatures. Effects of fiber types, fiber preforms, and small hole during fabrication process on torsion mechanical properties were investigated. Flexural-torsional coupled mechanical tests for C/SiC torque tubes with different external diameter and wall thickness were conducted at room and elevated temperatures. The torsion and flexural moments and corresponding shear and flexural strength were obtained. The fracture surface and cracks propagation path were observed and analyzed. The torque and shear strength in T300™-3k torque tube were much higher than those of T300™-1k torque tube. Among 3D needled (3DN), 2D plain-woven [0°/90°] and [±45°] C/SiC torque tubes, the density, torque, and shear strength of 3DN-C/SiC torque tube were the highest. For the C/SiC torque tubes with small hole, the small hole not only increased the densification and uniformity (axial and radial) of the torque tube, but also has the potential to make the damage cracks more zigzag, which improved the fracture toughness of the torque tubes.     

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.     

Pressure‐less joining of C/SiC and SiC/SiC by a MoSi2/Si composite

A MoSi₂/Si composite obtained in situ by reaction of silicon and molybdenum at 1450°C in Ar flow is proposed as pressure‐less joining material for C/SiC and SiC/SiC composites. A new “Mo‐wrap” technique was developed to form the joining material and to control silicon infiltration in porous composites. MoSi₂/Si composite joining material infiltration inside coated and uncoated C/SiC and SiC/SiC composites, as well as its microstructure and interfacial reactions were studied. Preliminary mechanical strength of joints was tested at room temperature and after aging at service temperatures, resulting in interlaminar failure of the composites in most cases.     

Strengthening/toughening of 2D C/SiC composites by coating

SiC and SiC_w/SiC coatings were prepared on two-dimensional carbon fiber reinforced silicon carbide ceramic matrix composites (2D C/SiC), and strengthening/toughening of the composite by the coatings was investigated. After coating, the density of the C/SiC composites was increased effectively and the mechanical properties were improved significantly. Compared with SiC coating, SiC_w/SiC coating showed the more significant effect on strength/toughness of the composites. Coatings had two effects: surface strengthening and matrix strengthening. The latter was the dominant effect. The surface strengthening can increase the crack initiation stress, while the matrix strengthening can enhance the crack propagation resistance. The former effect increased the strength and the latter effect increased the toughness.     

Stressed-oxidation behavior of 2D CVI SiC/BN/SiC at elevated temperature in air

The stressed-oxidation behaviors of 2D woven SiCf/BN/SiC composites were investigated at 950 °C and 1100 °C in air. The different proportions (60%–90%) of the ultimate tensile strength (UTS) at corresponding temperatures were chosen as constant stress. The stressed-oxidation experiments were taken to failure or interrupted (240h). The UTS decreases by 20.75% at 950 °C and 30.71% at 1100 °C. The composites did not fail during stressed oxidation when subjected to constant stress corresponding to the initial linear and the beginning of nonlinear segments of the tensile curve, above which the composites failed with a maximum failure life of about 10h. Fiber degradation due to the thermal exposure and the fiber cracks caused by the oxidation of BN interface coating and SiC fiber could be responsible for the strength degradation and failure of the composites during stressed oxidation.     

The effect of heat treatment on tensile properties of 2D C/SiC composites

Two-dimensional (2D) carbon fiber reinforced silicon carbide (C/SiC) composites with different initial strength were prepared by chemical vapor infiltration (CVI). After tensile property testing, results exhibited that as the heat-treatment temperature (HTT) increases to 1900°C, the tensile strength and toughness of the low strength specimen (LSS) increased by 110% and 530%, while the high strength specimen (HSS) increased by 5.4% and 550%, respectively. As observed from morphologies, the heat treatment increases the graphitization of the amorphous PyC interphase, which leads to the weakening of interfacial bonding strength (IBS). Meanwhile, the defects arising from heat treatment cause thermal residual stress relaxation. Therefore, the tensile strength and toughness of LSS with relatively high initial IBS increase significantly as HTT increases. For HSS with moderate initial IBS, the heat treatment slightly improves the tensile strength, but significantly improves the toughness. Consequently, the post-heat-treatment tensile properties of 2D C/SiC composites can be regulated by varying HTTs and different initial strength.     

Effect of off-axis angle on mesoscale deformation and failure behavior of plain-woven C/SiC composites with digital image correlation

In this study, the deformation response and failure behavior of a plain-woven C/SiC composite were investigated under on-axis and off-axis tensile loading. Digital image correlation (DIC) was utilized to characterize the full-field deformation and mesoscale strain distribution. The test results indicate a strong influence of the woven architecture on the mechanical properties and strain distribution, and the materials exhibit failure modes dependent on the loading directions or off-axis angles: the fracture positions of different layers are the same under off-axial load, while for on-axil loading, the fracture positions of different layers do not affect each other. SEM results provide direct evidence that the width of the off-axis specimen has a great influence on the mechanical properties. The reduction of the modulus and strength of off-axis specimen, is not only due to the off-axis loading, but also due to the reduction of effective bearing area or effective bearing fiber.     

Interaction of fiber matrix bonding in SiC/SiC ceramic matrix composites

Non-oxide ceramic matrix composites (CMC) based on SiC fibers with SiC matrix were fabricated by polymer infiltration and pyrolysis (PIP) and characterized regarding their microstructural features and their mechanical properties. The fiber preform was made using winding technology. During the winding process, the SiC fiber roving was impregnated by a slurry containing SiC powder and sintering additives (Y₂O_3, Al₂O₃ and SiO₂). This already helped to achieve a partial matrix formation during the preform fabrication. In this way, the number of PIP cycles to achieve composites with less than 10% open porosity could be reduced significantly. Additionally, damage-tolerant properties of the composites were obtained by an optimal design of the matrix properties although only uncoated fibers were used. Finally, composites with a strength level of about 500 MPa and a damage-tolerant fracture behavior with about 0.4% strain to failure were obtained.     

Study of dynamic compressive behaviors of 2D C/SiC composites at elevated temperatures based on in-situ observation

Dynamic and quasi-static compressive behaviors of 2D C/SiC composites were examined from room temperature to 1600 °C based on in-situ observation, under the environment of air and argon. Tests were conducted respectively on a high temperature universal test machine and an improved high temperature split Hopkinson pressure bar. The improvement of the interface strength and the nucleation of multiple cracks influence the compressive strength under dynamic conditions. As the influence of thermal residual stress, the failure angles and compressive strength of the specimen increased with the increase of temperature in the argon environment. Owing to the competition between oxidation and thermal residual stress, the compressive strength of the specimen increased slightly with increasing temperature, and then dropped sharply for temperature above 700 °C in air. The strain rate sensitivity factor of 2D C/SiC composites increased significantly as the temperature increased in the air environment, but decreased in the argon environment.     

Effects of fiber preform structures on the mechanical properties of C/SiC nuts and bolts

Carbon fiber-reinforced silicon carbide (C/SiC) nuts and bolts (M8) with different fiber preform structures were prepared by precursor infiltration and pyrolysis. The influences of fiber preform structures on the mechanical properties of C/SiC nuts and bolts, as well as the failure behaviors of threaded joints were studied. A C/SiC nut, which was fabricated by using the preform prepared by stacking 3K carbon fiber cloth followed by stitching, had the highest shearing strength (64.5 MPa). The bolt with the preform prepared by alternatively stacking 3 K carbon fiber cloth and unidirectional layer of carbon fiber tows followed by stitching had the highest extreme tensile strength (243.2 MPa) and shearing strength (106.3 MPa), but low thread tooth bearing ability (3.5 kN) and critical thread engagement length (9 mm). It is suitable for applications emphasizing the extreme tensile or shearing strengths of threaded joints or possessing enough thread engagement length to ensure bolt rupture as the failure mode. The bolt with the perform prepared by stacking 1K carbon fiber cloth followed by stitching had the highest thread tooth bearing ability (5.0 kN) and the lowest critical thread engagement length (6 mm), as well as moderate extreme tensile strength (163.0 MPa) and shearing strength (82.1 MPa). It works effectively for applications concerning thread tooth strength or possessing limited thread engagement length. Therefore, the preform for preparing a C/SiC bolt should be selected according to its application requirements.     

Tensile and stressed-oxidation behavior of 2D SiC/BN/SiC composites at Intermediate Temperatures in Air

The stressed-oxidation behavior of 2D CVI SiC/BN/SiC composites was studied at intermediate temperatures (800 °C) in air. The ultimate tensile strength (UTS) was acquired to determine the constant stress. The results show that the UTS at intermediate temperature is 14.3 % lower than that at room temperature. The strain-time curves at all stress levels show a deceleration stage and a stable stage. The stressed-oxidation rupture life decreases from 5.4 h to 0.9 h when the stress increases from 60 % to 90 % of the UTS. The element composition and fracture morphologies of the composites were also analyzed. The results show that the oxidation degree increases as the rupture time increases or constant stress decreases. Fiber degradation and interface defects caused by component oxidation induced local fiber failure and ultimate rupture of the composites, which may be attributed to strength degradation at intermediate temperatures and rupture of the composites during stress oxidation.     

Microstructural characterization and failure analysis of 2D C/SiC two-layer beam with pin-bonded hybrid joints

In this paper, the microstructural characteristics and mechanical behavior of 2D C/SiC two-layer beams with pin-bonded hybrid joints were investigated. The pin joints were incorporated into the two-layer beam during the assembling stage, and the adhesively bonded joints can be introduced by subsequent chemical vapor infiltration (CVI) process. For 2D C/SiC two-layer beam it was confirmed that the distribution of the adhesively bonded joints was random. Based on the partial interaction composite beam theory, a simplified method was proposed to characterize the effect of adhesively bonded joints on the bending stiffness of the 2D C/SiC two-layer beam. The stress distribution around the pin joints was described by finite element modeling. It was found that the radial stress, the hoop stress and the in-plane shear stress around the pin joints were unique in their distributions. Under the action of these stresses, two kinds of failure modes can be initiated: one is the debonding of the pin–hole interface, and the other is the fracture of the 2D C/SiC plate. Based on the stress results, an empirical failure criterion was present to predict the ultimate failure of the 2D C/SiC two-layer beam.     

3D C/SiC复合材料的孔隙率与性能的关系

用浸债裂解法（PIP）和均效化学气相渗透法（ICVI）混合工艺制备了3DC／SiC复合材料,研究了3DC／SiC复合材料中基体含量。孔隙分布特征与复合材料性能的关系。结果表明,基体中CVI－SiC相对含量增加,开孔率增加,闭孔率减少,复合材料的弯曲强度和抗氧化性能提高。孔隙对复合材料性能的影响关系是由两种基体的特点、结构、致密化工艺及氧化机理决定的。     

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.     

Characterization of the oxidation of C/C/SiC composites by Xray micro-tomography

The objective of this paper is to determine the influence of the nature of the C/C/SiC composite on the oxidation rate of fibers and the interphase and the development of oxidation pathways using characterization techniques such as Xray micro-tomography (μCT), scanning electron microscope (SEM) and optical microscopy (OM). The microstructure of two C/C/SiC composites (named 2D-RMI and 2D-CVI) was characterized before and after ageing tests performed by Thermogravimetric Analysis (TGA) under dry air at 1000 °C and 1300 °C. The three techniques are complementary and tomography appears to be a promising means for monitoring the oxidation of parts in service. Moreover, the oxidation of a fiber does not develop in a parallel plan to the section but as conical shape. To calculate the oxidation kinetics related to the surface, it is therefore necessary to take into account the geometry of the fibers that offers a much more important reactive surface.     

Effect of the incorporation of SiC nanowire with double protective layers on SiC coating for C/C composites

To maintain the thermal stability of SiC nanowires during SiC coating fabrication process, carbon and SiC double protective layers were covered on the surface of nanowires. And SiC nanowires with double protective layers toughened SiC coating were prepared by pack cementation. The results showed that after introducing the SiC nanowires with double protective layers, the fracture toughness of the SiC coating was increased by 88.4 %. The coating protected C/C for 175 h with a mass loss of 3.67 %, and after 51 thermal shock cycles, the mass losses of the oxidized coating were 3.96 %. The double protective layers are beneficial to improve the thermal stability of nanowires, leading to good fracture toughness and thermal shock resistance of SiC coating. SiC nanowires consume the energy of crack propagation by fracture, pullout and bridging, leading to an increase in fracture toughness.     

Effect of SiC coating and heat treatment on the thermal radiation properties of C/SiC composites

The effects of SiC coating and heat treatment on the emissivity were investigated for 2D C/SiC composites prepared by CVI in the 6–16 μm range. SiC coating had an obvious effect on the spectral emissivity of the composites but caused just 5% difference in the total emissivity. A radiation transport model was applied to explain those changes caused by SiC coating. Heat treatment affected the thermal radiation properties of the composites through the microstructure evolution. Base on the complementary analytical techniques, the changes in the emissivity were attributed to a good graphitization degree of carbon phases, large β-SiC grain sizes and high α-SiC content resulting in high emissivity.