Fibre bridging during high temperature fatigue crack growth in Ti/SiC composites

Synchrotron X-ray diffraction has been used to map the crack tip stress field, load redistribution and the variation in interfacial shear stress along bridging fibres local to a matrix crack during fatigue crack growth in Ti-6Al-4V/unidirectional SCS-6 SiC monofilament composite at elevated temperature. Quasi-static fatigue cycles were applied in a diffractometer at the same stress amplitudes and temperatures (120 and 300 °C) as those used in prior off-line fatigue testing. The elastic fibre strains were measured ply by ply along the fibres and in the matrix in the region of the crack. In this manner the crack affected zone was mapped, and subsequently the interfacial shear stress levels deduced as a function of distance from the crack at these temperatures. The results are compared with previous studies of load redistribution at room temperature and the fibre sliding stresses compared with those needed to slide pristine fibres to evaluate degradation of the interfacial shear strength caused by interfacial wear during fatigue. The implications for the use of such composites at elevated temperatures, for example in aero engines, are discussed.     

Interface effects on crack deflection and bridging during fatigue crack growth of titanium matrix composites

The effect of the interface on the crack deflection and crack bridging behavior of continuous fiber-reinforced titanium matrix composites has been investigated using three interfaces with significantly different mechanical characteristics. Each of these composites exhibited stress ranges in which fiber bridging was present and stress ranges in which stable fiber bridging was not present. The fatigue crack growth rate for all composites, even for the ones that did not exhibit fiber bridging was significantly below that of the matrix. This phenomenon, believed to be an effect of elastic crack shielding, was most significant for composites with the strongest interfacial bond. Interface failure ahead of the crack tip and its influence on the local stress intensity factor is believed to be responsible for the decrease in the shielding effect of low strength interfaces. Interface debonding was observed in all three composites, and damage to the interface ahead of the crack tip was seen in two of the three composites. A stress-based criterion for predicting debonding appeared to effectively explain the crack deflection behavior for the three composites. Evidence of crack deflection even for the strongest interface suggests that there is scope to increase the interface bond strength in SiC/Ti-alloy system for improved transverse properties without compromising the fatigue life.     

Fatigue crack growth and load redistribution in Ti/SiC composites observed in situ

Sequential synchrotron X-ray microtomography and diffraction have been applied to follow the growth of fatigue cracks and the associated load redistribution in a Ti/SiC fibre composite. A sequence of micron resolution tomographs reveal for the first time how the cracks progress from ply to ply around the fibres. Complementary high spatial resolution (40 μm) diffraction scans interleaved between the tomographic image acquisitions during the fatigue experiment have enabled the fibre strains and thereby the interfacial shear stress to be mapped as a function of crack growth. The matrix crack front was found to bow out between fibres, eventually reconnecting further downstream. This leads to the prolonged retention of bridging matrix ligaments and increased crack path tortuosity. The rate of crack growth was found to slow somewhat as a fibre is approached. As the crack grew past the fibres under observation the extent of the sliding region and the level of the fibre bridging stress increased. The interfacial shear strength after fatigue was around 60 MPa in the crack-tip region, in common with previous experiments.     

Interfacial shear strength behaviour of Ti/SiC metal matrix composites at room and elevated temperature

Synchrotron X-ray strain measurements have been used to follow the distribution of elastic strain, and hence interfacial shear stress, along single SCS-6 and Sigma SM2156 Ti–6Al–4V matrix coated SiC monofilaments sandwiched between Ti–6Al–4V foils during single-fibre-fragmentation testing. The interfacial shear strength behaviours were characteristically different. For the SCS-6 system, the interfacial response was dominated by classical frictional sliding, initiating near the ends and progressing along most of the length of the fragments, in common with previous observations. By contrast, for the SM2156 fibre system, a significant threshold stress was evident which must be exceeded before sliding could occur. As a result, sliding was only found near the ends of the fibre fragments. Upon unloading, reverse frictional sliding was found to take place, initiating from the fibre ends at a shear stress somewhat lower than that for forward sliding. Finite element modelling suggests that this is due to a reduction in the radial fibre clamping stress upon unloading rather than a change in the friction coefficient. For both the systems, the frictional sliding strength fell approximately linearly with increasing temperature towards zero at ～600–700 °C, consistent with a Coulomb friction coefficient of ～0.4 and thermal clamping residual stresses that approach zero at these temperatures. By contrast, the threshold stress required to initiate sliding for SM2156 falls at a slower rate with increasing temperature, such that it would still be significant at these temperatures. Some evidence was found for a decrease in interfacial shear stress with decreasing fragment length.     

Subcritical crack growth in CVI SiCf/SiC composites at elevated temperatures: dynamic crack growth model

A dynamic crack-growth model has been developed to predict slow crack growth in ceramic composites containing nonlinear, creeping fibers in an elastic matrix. Mechanics for frictional bridging and nonlinear fiber-creep equations are used to compute crack extension dynamically. Discrete, two-dimensional fiber bridges are employed, which allows separate bridge “clocks”, to compute slow crack-growth rates for composites containing Nicalon-CG and Hi-Nicalon fibers. Predictions for activation energies, time-temperature exponents, crack lengths, and crack-velocity data for composites in bending at 1173 K to 1473 K in inert environments are in good agreement with experimental data. In addition, calculated creep strains in the bridges agree with experimental damage-zone strains. The implications of multiple-matrix cracking are discussed.     

Load transfer in short fibre reinforced metal matrix composites

The internal load transfer and the deformation behaviour of aluminium–matrix composites reinforced with 2D-random alumina (Saffil^®) short fibres was studied for different loading modes. The evolution of stress in the metallic matrix was measured by neutron diffraction during in situ uniaxial deformation tests. Tensile and compressive tests were performed with loading axis parallel or perpendicular to the 2D-reinforcement plane. The fibre stresses were computed based on force equilibrium considerations. The results are discussed in light of a model recently established by the co-authors for composites with visco-plastic matrix behaviour and extended to the case of plastic deformation in the present study. Based on that model, the evolution of internal stresses and the macroscopic stress–strain were simulated. Comparison between the experimental and computational results shows a qualitative agreement in all relevant aspects.     

Chemical kinetic studies on interfacial reaction in SCS-6 SiC/Ti matrix composites

Interfacial reaction and its mechanism of SiC/Ti composite were revealed by chemical kinetic studies. A two-step dynamic model of interfacial reaction in SCS-6 SiC/Ti composites was built up, and the rate constant and the activation energy of the interfacial reactions were obtained based on the quantum chemistry calculation. The results show that the first step, in which the atomic Ti, C and Si are decomposed from Ti matrix and SiC fiber, respectively, is a rate-determined step because the activation energy of the step is much larger than that of the second one in which deferent interfacial reaction products form. The theoretically predicted result of the interfacial reaction is coincident with that of experimental observation.     

Fabrication and mechanical properties of in situ TiC/Ti metal matrix composites

In situ TiC particle reinforced titanium matrix composites (TMCs) were successfully fabricated by reactive sintering of Ti + Mo₂C and Ti + VC compacts. The results of the tensile tests at ambient and elevated temperatures show that the strength of the composites increases with increasing additive content (Mo₂C and VC), and decreases with increasing temperatures. Comparing the two types of TMCs, the Ti + VC composites have a lower strength than the Ti + Mo₂C composites, but can more effectively retain the strength to elevated temperatures. Microstructural analyses show that the main strengthening mechanisms of the TMCs are solid solution, grain refinement and particulate strengthening. Different dominant strengthening mechanisms in different composites are responsible for the variations of the mechanical properties. At elevated temperatures, the volume fraction of TiC particles is the main factor for increasing the strength.     

A prediction for fatigue crack growth rate in diffusion bonded Al/Ti interface

A melt diffusion bonding technique was developed to make a joint of Ti and Al, which had been regarded as almost impossible because of high activity. Fatigue crack growth rates, da/dN of the Al/Ti interfaces were measured experimentally at various stress ratios and compared with pure Ti and Al. The interface showed a resistance to fatigue crack propagation as good as that of aluminum alloy. The proposed universal equations on the basis of the crack closure concept made it possible to predict da/dN for various ΔK and R. Fatigue crack was observed to grow in the Al side adjacent to the interface along the direction parallel to the interface. It was observed to form the intermetallic compounds in the interface region.     

Slow crack growth resistance and bridging stress determination in alumina-rich magnesium aluminate spinel/tungsten composites

The slow crack growth (SCG) resistance (V–K_I diagrams) of magnesium aluminate spinel and its tungsten composites with different metallic content (7, 10, 14 and 22 vol.%) is reported. It is found that tungsten plays a crucial role in the composite by increasing crack resistance: the higher the W content, the higher the stress intensity factor needed for crack extension at a given rate. The reinforcement is due to the bridging mechanism performed by metal particles, as it strongly affects the compliance of cracked specimens. Its magnitude is estimated by a compliance function Φ(a) from a double torsion test. From the compliance function, R-curve behaviour is predicted for the composite with highest tungsten content. It explains the effect of metal particles on SCG curves. The W–MgAl₂O₄ interface is believed to influence the reinforcement mechanism.     

Long fatigue crack growth behaviour of ferritic steel weld metal

Abstract

Single edge notched weld joint specimens were tested at different stress levels to study the long fatigue crack growth behaviour of a ferritic steel (nuclear grade SA333 Grade 6 steel) weld metal at two stress ratios R of 0·1 and – 1. A two slope behaviour was noticed in the crack growth rate versus stress intensity factor range plots at both stress ratios. Different parameters were employed to generalise the load ratio effect on fatigue crack growth rate.     

SiC颗粒对SiC_p/2009Al复合材料疲劳短裂纹扩展的影响

采用粉末冶金法制备15%(体积分数)SiC_p/2009Al复合材料,研究该材料的微观组织、力学性能、高周疲劳性能以及疲劳断口形貌.结果表明:在SiC_p/2009Al复合材料的疲劳短裂纹扩展阶段,SiC颗粒及其表面包覆的2009Al薄层在裂纹扩展面上形成"丘陵"状形貌,使疲劳断口的粗糙度增大,裂纹的闭合效应也随之增大:同时"丘陵"状形貌可以引发疲劳裂纹扩展路径偏析,使裂纹扩展的有效驱动力减小并使裂纹扩展路径增加;上述裂纹迟滞效应使SiC_p/2009Al复合材料在短裂纹扩展阶段具有较高的疲劳裂纹扩展抗力.     

粉末布法制备SiC/Ti基复合材料

用粉末布法制备了低成本SiC/Ti基复合材料.结果表明,采用合适的轧制参数即可容易地获得厚度合适、均匀的粉末布;热失重分析和热解残余物分析指出用来制备粉末布的有机粘结剂的去除过程分成两个阶段,合理除气后,基本没有残余物.使用真空热压工艺制备的SiC/Ti基复合材料,纤维分布基本均匀,纤维与基体的界面结合良好.     

Surface characterization in ultra-precision machining of Al/SiC metal matrix composites using data dependent systems analysis

This paper presents a data dependent systems (DDSs) method for the analysis of surface generation in ultra-precision machining of Al/SiC metal matrix composites (MMCs). The DDS analysis provides a component by component wavelength decomposition of the surface roughness profile of the machined surface. A series of face cutting experiments was done on Al6061/15SiC_p MMCs under different cutting conditions. The cutting results indicate that the characteristics of the wavelength components analyzed by the DDS analysis method are correlated well with the surface generation mechanisms. Since the relative powers of the wavelength components are used to measure the contributions of the cutting mechanisms to the total roughness, this resolves the shortcomings of the conventional spectrum analysis method in characterizing the surface properties such as pits and cracks in ultra-precision machining of MMCs.     

Short fatigue crack growth behaviour of a ferritic steel weld metal

Abstract

The present study deals with the short fatigue crack growth behaviour of a ferritic steel (nuclear grade SA 333 Grade 6 steel) weld metal at two load ratios R of 0.1 and –1. Single edge notched weld joint specimens were tested at different stress levels. The acceleration and deceleration in short crack growth with increasing stress intensity factor range was explained in terms of microstructure of weld metal. Acicular ferrite and grain boundary ferrite acted as barriers to crack growth. Non-propagating cracks were observed due to multiple cracks and blocking by ferrite grain boundaries. Transition crack length, the limiting crack length above which the crack exhibited a typical long crack behaviour, was determined to be 1 mm at R=0.1 and 1.5 mm at R=2 1.     

Fatigue crack growth mechanism in cast hybrid metal matrix composite reinforced with SiC particles and Al2O3 whiskers

The fatigue crack growth (FCG) mechanism of a cast hybrid metal matrix composite (MMC) reinforced with SiC particles and Al₂O₃ whiskers was investigated. For comparison, the FCG mechanisms of a cast MMC with Al₂O₃ whiskers and a cast Al alloy were also investigated. The results show that the FCG mechanism is observed in the near-threshold and stable-crack-growth regions. The hybrid MMC shows a higher threshold stress intensity factor range, ΔK_th, than the MMC with Al₂O₃ and Al alloy, indicating better resistance to crack growth in a lower stress intensity factor range, ΔK. In the near-threshold region with decreasing ΔK, the two composite materials exhibit similar FCG mechanism that is dominated by debonding of the reinforcement–matrix interface, and followed by void nucleation and coalescence in the Al matrix. At higher ΔK in the stable- or mid-crack-growth region, in addition to the debonding of the particle–matrix and whisker–matrix interface caused by cycle-by-cycle crack growth at the interface, the FCG is affected predominantly by striation formation in the Al matrix. Moreover, void nucleation and coalescence in the Al matrix and transgranular fracture of SiC particles and Al₂O₃ whiskers at high ΔK are also observed as the local unstable fracture mechanisms. However, the FCG of the monolithic Al alloy is dominated by void nucleation and coalescence at lower ΔK, whereas the FCG at higher ΔK is controlled mainly by striation formation in the Al grains, and followed by void nucleation and coalescence in the Si clusters.     

Subcritical crack growth in CVI SiCf/SiC composites at elevated temperatures: effect of fiber creep rate

Subcritical crack-growth studies in SiC_f/SiC composites were conducted with composites reinforced with Hi-Nicalon fibers over a broad temperature range for comparison to earlier studies on materials reinforced with Nicalon-CG fibers. Composites with a 0/90 plain weave architecture and carbon interphase were tested in argon from 1173 to 1473 K. Crack growth data obtained in inert environments are consistent with a proposed fiber-creep-controlled crack-growth mechanism. Measured crack-growth activation energies and time–temperature exponents in argon agree with fiber creep-activation energies and nonlinear creep equations for both fiber types. Estimates of local strains during crack growth are in reasonable agreement with estimated fiber creep strains for the given times and temperatures. The increased creep resistance of Hi-Nicalon fibers is reflected in reduced crack-growth rates for composites containing those fibers.     

A neutron diffraction study of load partitioning in continuous Ti/SiC composites

Neutron diffraction measurements are described of the internal strain response of Ti–6Al–4V/35 vol.% SiC continuous fibre composites to loading axial and transverse to the fibre alignment direction. In the as-fabricated condition large thermal residual strCTains are observed, being equivalent to average axial fibre and matrix stresses of −840 and 450 MPa, respectively. As one might expect, upon loading there are marked differences in load sharing according to whether the fibres are parallel or perpendicular to the loading direction. In the former case, load is transferred towards the fibres; a process which is accelerated when the matrix deforms plastically, while in the latter case, load is transferred to the fibres only at very low loads. At higher loads, the process reverses with the reinforcement shedding load back into the matrix. The measurements suggest that this is caused by matrix/fibre interface failure at transverse loads of around 300 MPa. Simple calculations suggest that this would require a non-zero matrix/fibre normal interface strength of around 100 MPa. The measured thermal and load-induced strains are interpreted in the light of Eshelby-based models throughout.     

SiC/MB2复合材料高应变速率超塑性变形的空洞行为

在高应变速率超塑性变形过程中 ,SiC(10 % ) /MB2复合材料内部有空洞生成。对不同应变量拉伸试样轴剖面上的空洞进行观察 ,结果表明 :空洞量随应变量的增加而增加 ,并且与颗粒的尺寸大小密切相关 ,其生长服从指数定律。