Fabrication and characterization of random chopped fiber reinforced reaction bonded silicon carbide composite

This paper deals with the microstructure and mechanical properties of reaction bonded silicon carbide reinforced with random chopped carbon fibers of 3 mm length. The composites were fabricated by dispersing chopped carbon fibers into bimodal SiC/C suspension, forming green body through slip casting, and then reaction sintering at 1700 °C. The effect of the chopped fiber fraction on microstructure and mechanical properties was evaluated. A significant increase of fracture toughness was obtained as the carbon fiber fraction approaches 30 vol.%. The chopped fibers had reacted with liquid silicon during reaction sintering, so little fiber pullout was observed. Crack deflection and bridging is the predominant mechanism for the composite toughening.     

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.     

Electrically induced liquid infiltration for the synthesis of carbon/carbon–silicon carbide composite

The electrically induced liquid infiltration (EILI) method for the synthesis of carbon/carbon–silicon carbide (C/C–SiC) materials was developed. The method involves Joule preheating of a porous carbon/carbon preform surrounded by silicon media, followed by silicon infiltration into the pore structure, and its reaction with carbon to form pore-free C/C–SiC composite. This technique is characterized by high heating rates (10²–10³ K/s) and short processing times (5–20 s), which distinguish it from conventional approaches. The influence of maximum treatment temperature, as well as preheating rate on the depth of infiltration, reaction kinetics, and the material microstructure was investigated. C/C–SiC composite with a compressive strength which was twice that of the initial C/C material was synthesized.     

Synthesis and properties of ceramic-based nanocomposite layer of aluminum carbide embedded with oriented carbon nanotubes

In the present work, carbon nanotubes (CNTs) were embedded in aluminum carbide coating in desired vertical/horizontal direction in order to fabricate a nanocomposite layer with unidirectional enhanced mechanical properties. A novel method based on monopolar pulsed plasma electrolysis under magnetic field was used for this purpose. Nanostructure of the obtained nanocomposite layer was examined with high precision figure analysis of SEM, AFM and TEM nanostructures. The mechanical and tribological properties of these coatings were investigated with respect to the direction of the embedded CNTs. The coefficient of friction was lowered from 0.2 to less than 0.1 in a pin-on-disc test against steel with dramatic affected coating wear rate by a decrease to near 400% with respect to raw substrate. The lower friction is attributed to more extensive creation of amorphous carbon on the counter surface and also in the coating wear track. As a conclusion, this method is appropriate for fabrication of hard coating on the surface of low-melting-point metals and light alloys.     

Mechanical and electrical properties of carbon nanotube buckypaper reinforced silicon carbide nanocomposites

The nanocomposite was produced via phenolic resin infiltrating into a carbon nanotube (CNT) buckypaper preform containing B₄C fillers and amorphous Si particles followed by an in-situ reaction between resin-derived carbon and Si to form SiC matrix. The buckypaper preform combined with the in-situ reaction avoided the phase segregation and increased significantly the volume fraction of CNTs. The nanocomposites prepared by this new process were dense with the open porosities less than 6%. A suitable CNT–SiC bonding was achieved by creating a B₄C modified interphase layer between CNTs and SiC. The hardness increased from 2.83 to 8.58 GPa, and the indentation fracture toughness was estimated to increase from 2.80 to 9.96 MPa m^1/2, respectively, by the reinforcing effect of B₄C. These nanocomposites became much more electrically conductive with high loading level of CNTs. The in-plane electrical resistivity decreased from 124 to 74.4 μΩ m by introducing B₄C fillers.     

Mechanical and thermophysical properties of carbon/carbon composites with hafnium carbide

Carbon/carbon (C/C) composites with addition of hafnium carbide (HfC) were prepared by immersing the carbon felt in a hafnium oxychloride aqueous solution, followed by densification and graphitization. Mechanical properties, coefficients of thermal expansion (CTE), and thermal conductivity of the composites were investigated. Results show that mechanical properties of the composites decrease dramatically when the HfC content is greater than 6.5 wt%. CTE of the composites increases with the increase of HfC contents. The composites with addition of 6.5 wt% HfC show the highest thermal conductivity. The high thermal conductivity results from the thermal motion of CO in the gaps and pores, which can improve phonon–defect interaction of the C/C composites. Thermal conductivities of the composites decrease when the HfC content is greater than 6.5 wt%, which is due to formation of a large number of cracks in the composites. Cracks increase the phonon scattering and hence restrain heat transport, which results in the decrease of thermal conductivity of the composites.     

Preparation and characterization of three-dimensional carbon fiber reinforced zirconium carbide composite by precursor infiltration and pyrolysis process

Three-dimensional carbon fiber reinforced zirconium carbide composite (3D C/ZrC) was fabricated for ultra high temperature applications by precursor infiltration and pyrolysis (PIP) process using the mixture of zirconium butoxide (Zr(OC₄H₉)₄) and divinylbenzene (DVB) as precursor of zirconium carbide. The micro-structural, mechanical and ablative properties of the 3D C/ZrC composite were studied. The flexural strength of the composite was 107.6 MPa, the elastic modulus was 28.8 GPa, and the fracture toughness was 7.03 MPa m^1/2. The mass lose rate and linear recession rate of the 3D C/ZrC composite during oxyacetylene torch test was 0.012 g/s and -0.002 mm/s, respectively. The formation of ZrO₂ melt on the surface of the composite contributed mainly the excellent ablative property.     

Three-dimensional carbon fiber-reinforced silicon carbide matrix composites by vapor silicon infiltration

Three-dimensional carbon fiber-reinforced SiC matrix composites (C_f/SiC) were fabricated by vapor silicon infiltration (VSI) successfully. Scanning electron microscopy (SEM), transmission electron microscopy (TEM) and wavelength dispersive spectrometer (WDS) analysis revealed that the microstructure and composition of constituent phases are strongly dependent on temperature. At 1973 K, the obtained C_f/SiC composite mainly consists of SiC, carbon fiber and residual Si, and shows a densified microstructure. The flexural tests show non-catastrophic fracture behavior for composites fabricated by VSI process, and the ultimate flexural stress is comparable to those of composites fabricated by other processing techniques, demonstrating VSI is an effective way to fabricate the dense C_f/SiC composites with good mechanical properties.     

Tribo-mechanical characterization of spark plasma sintered chopped carbon fibre reinforced silicon carbide composites

Short carbon fibre (C_f) reinforced silicon carbide (SiC) composites with 7.5 wt% alumina (Al₂O₃) as sintering additive were fabricated using spark plasma sintering (SPS). Three different C_f concentrations i.e. 10, 20 and 30 wt% were used to fabricate the composites. With increasing C_f content from 0 to 20 wt%, micro-hardness of the composites decreased ~28% and fracture toughness (K_IC) increased significantly. The short C_f in the matrix facilitated enhanced fracture energy dissipation by the processes of crack deflection and bridging at C_f/SiC interface, fibre debonding and pullout. Thus, 20 wt% C_f/SiC composite showed >40% higher K_IC over monolithic SiC (K_IC≈4.51 MPa m^0.5). Tribological tests in dry condition against Al₂O₃ ball showed slight improvement in wear resistance but significantly reduced friction coefficient (COF, μ) with increasing C_f content in the composites. The composite containing 30 wt% C_f showed the lowest COF.     

Wear properties and microstructures of alumina matrix composite ceramics used for drawing dies

The alumina matrix ceramics used for drawing dies were prepared by hot-press sintering method. The ceramics materials were made of Al₂O₃/TiC, Al₂O₃/(W,Ti)C and Al₂O₃/Ti(C,N). Mechanical and friction properties of these materials were tested and measured. The experiments for testing friction properties were carried on wear and tear machine. Mechanisms of frictions were analyzed with scanning electron microscope. Results showed that the alumina matrix composite ceramics have good physical and mechanical properties for used as drawing dies. Measured friction coefficients of alumina matrix composite ceramics showed a trend of decline and kept the value of 0.4–0.5 with the rotating speed of 550 rpm. Alumina matrix composite ceramics have smaller wear rate, while the wear rates of Al₂O₃/TiC and Al₂O₃/(W,Ti)C decrease gradually with a rising rotation speed. The wear of alumina matrix ceramics was severe at deformation zone. The primary wear behaviors of alumina matrix ceramics are scraping and furrowing. Even though the mechanisms for wear different, abrasive and adhesive wear were found to be the predominant wear mechanisms for the ceramic drawing die.     

Enhanced thermoelectric properties of carbon fiber reinforced cement composites

Thermoelectric properties of carbon fiber reinforced cement composites (CFRCs) have attracted relevant interest in recent years, due to their fascinating ability for harvesting ambient energy in urban areas and roads, and to the widespread use of cement-based materials in modern society. The enhanced effect of the thin pyrolytic carbon layer (formed at the carbon fiber/cement interface) on transport and thermoelectric properties of CFRCs has been studied. It has been demonstrated that it can enhance the electrical conduction and Seebeck coefficient of CFRCs greatly, resulting in higher power factor 2.08 µW m⁻¹ K⁻² and higher thermoelectric figure of merit 3.11×10⁻³, compared to those reported in the literature and comparable to oxide thermoelectric materials. All CFRCs with pyrolytic carbon layer, exhibit typical semiconductor behavior with activation energy of electrical conduction of 0.228-0.407 eV together with a high Seebeck coefficient. The calculation through Mott’s formula indicates the charge carrier density of CFRCs (10¹⁴–10¹⁶ cm⁻³) to be much smaller than that of typical thermoelectric materials and to increase with the carbon layer thickness. CFRCs thermal conductivity is dominated by phonon thermal conductivity, which is kept at a low level by high density of micro/nano-sized defects in the cement matrix that scatter phonons and shorten their mean free path. The appropriate carrier density and mobility induced by the amorphous structure of pyrolytic carbon is primarily responsible for the high thermoelectric figure of merit.     

A model for the oxidation of carbon silicon carbide composite structures

A mathematical theory and an accompanying numerical scheme have been developed for predicting the oxidation behavior of carbon silicon carbide (C/SiC) composite structures. The theory is derived from the mechanics of the flow of ideal gases through a porous solid. The result of the theoretical formulation is a set of two coupled non-linear differential equations written in terms of the oxidant and oxide partial pressures. The differential equations are solved simultaneously to obtain the partial vapor pressures of the oxidant and oxides as a function of the spatial location and time. The local rate of carbon oxidation is determined using the map of the local oxidant partial vapor pressure along with the Arrhenius rate equation. The non-linear differential equations are cast into matrix equations by applying the Bubnov-Galerkin weighted residual method, allowing for the solution of the differential equations numerically. The numerical method is demonstrated by utilizing the method to model the carbon oxidation and weight loss behavior of C/SiC specimens during thermogravimetric experiments. The numerical method is used to study the physics of carbon oxidation in carbon silicon carbide composites.     

Mechanical and electromagnetic shielding properties of carbon fiber reinforced silicon carbide matrix composites

Carbon fiber reinforced SiC matrix composites (C_f/SiC) were fabricated through chemical vapor infiltration. Effects of SiC content on the mechanical and electromagnetic properties of the as-prepared materials were studied systematically. The high volume fraction of SiC matrix is beneficial to the transfer of load to carbon fiber. With the increase of SiC content from 21.5 to 42.2 vol.%, the total porosity decreases from 38.5 to 17.8 vol.%, the flexural strength and fracture toughness of C_f/SiC increase from 38 ± 4 to 375 ± 10 MPa and from 6.2 ± 0.7 to 21 ± 0.3 MPa m^1/2. The electromagnetic interference shielding effectiveness of as-prepared C_f/SiC decreases from 43 ± 1.4 to 31 ± 1.1 dB over the frequency range of 8.2–12.4 GHz with the increase of SiC content. The decease of electromagnetic interference shielding effectiveness is mainly attributed to the decline of absorption loss. With the increase of SiC content, the electrical conductivity of C_f/SiC diminishes, leading to the conspicuous drop of the conductive loss, which plays the key role in lowering the absorption loss of electromagnetic waves.     

The effect of carbon and nickel additions on the precursor synthesis of Cr3C2-Ni nanopowder

Decreasing crystal size to nanoscale is a proven method to enhance material properties. In this study, nanosize Cr₃C₂ and Cr₃C₂-Ni were synthetized and the reaction sequence was studied. Aqueous precursors using only water-soluble raw materials with varying carbon contents and a nickel addition were spray-dried. Glycine was used as a carbon source and chromium acetate hydroxide as a chromium source in the precursor solutions. Nickel nitrate hexahydrate was introduced as a nickel source to yield a metallic binder into the carbide nanopowder.Resulting powders were heat-treating to identify an applicable precursor composition producing the targeted Cr₃C₂ phase with crystal size of tens of nanometers. Thermal synthesis tests of the precursor powders to yield Cr₃C₂ took place at a temperature between 900 and 1300?°C under an Argon atmosphere. The synthesis of nanosize Cr₃C₂-Ni powder was successful at 1000?°C in 30?min, in a case of the best precursor. In order to produce the carbide phase with no residual oxide traces, relative carbon load has to be 48?wt%, while the stoichiometric amount of carbon in Cr₃C₂ is 13?wt%. When also introducing the nickel source into the precursor, an even higher carbon load was required. The carbon surplus needed to enable the Cr₃C₂ synthesis attributes to the non-homogeneity of the precursor composition.The chemical synthesis starting from water-soluble raw materials is a promising way of preparing nanosize Cr₃C₂-Ni with the targeted phase configuration.     

Structure and properties of short fibre reinforced silica matrix composite foams

Glass (GFC) and silica (SFC) fibre reinforced silica matrix composite foams with 84–90% porosity content have been developed through slurry-based processing, involving random dispersion of 10 wt.% fibres with aspect ratios of >1000 in hydrophobized silica-based suspensions, and direct foaming for air entrapment. Fibre entanglement has not been found either in the suspensions or in the sintered composite foams. Microstructural and mercury porosimetry studies of the composite foams have shown a trimodal size distribution with small (4–8 μm), medium (40–200 μm), and large (1 mm or more) pores. The pores appear spherical and interconnected, with the fibres embedded in cell-walls or struts. The dynamic Young's modulus of the silica-coated GFCs is found to be 3.5 and 5.2 times that of the coated and uncoated monolithic silica foams, respectively, confirming that both fibre-reinforcement and the presence of surface coating are beneficial for increase in stiffness of the composite foams.     

Corrosive wear behavior of chromium carbide coatings deposited by air plasma spraying

The corrosive wear behavior of chromium carbide coatings deposited by air plasma spraying was studied, through wet pin-on-disk wear experiments. During the wear tests, the samples were immersed in corrosive environments consisting of watery hydrochloric acid with the acid concentrations of 5, 10 and 15 vol%. The wear tests were performed at both room temperature and 80 °C. The results showed that the wet environment significantly increased the wear rate. In addition, the increase of the acid concentration and temperature considerably deteriorated the wear resistance of the coated samples. It was also realized that, compared to the dry condition, the wear mechanism changed from abrasive to adhesive in the wet environment where a tribochemical wear was observed.     

X-ray structure analysis and elastic properties of a fabric reinforced carbon/carbon composite

The effect of heat treatment on microstructure of a plain-weave carbon fabric reinforced carbon-carbon composite with phenolformaldehyde-derived carbon matrix was investigated by X-ray diffraction. The diffraction patterns were analysed by the least-square fitting program Carbonxs. After heat treatment from 1000 to 2800 °C the interplanar distance of (002) planes decreased from 3.488 to 3.420 Å and the lattice parameter in basal plane increased from 2.440 to 2.464 Å, respectively. Simultaneously, the coherent block size in the basal plane directions increased from 18 to 54 Å, which was accompanied by an increase of the fraction of organised carbon atoms from 0.50 to 0.85. The 002 diffraction profile of the composite was much narrower than the sum of peaks of the matrix and fabric alone. This can probably be caused by a better crystallographic ordering (or by a partial graphitisation) of the matrix in the composite. On the other hand, the composite Young’s modulus slightly decreased with the treatment temperature increasing from 2200 to 2800 °C in spite of the established strong improvement of fibre crystallinity and, therefore, fibre modulus. The mechanisms diminishing the modulus of composite (e.g. partial matrix graphitisation at the fibre/matrix interface and decreasing fibre/matrix contact area) probably prevailed over the increasing contribution of the fibre modulus.     

Wear resistant boron carbide compacts produced by pressureless sintering

Boron carbide compacts were produced by pressureless sintering at 2200 °C/2 h and 2250 °C/2 h in Ar atmosphere, using a starting powder with a particle size smaller than 3 µm. Effects of carbon addition (3.5 wt%) and methanol washing of the starting powder were investigated on the densification, Vickers hardness, and micro-abrasive wear resistance of the samples. The removal of oxide phases by methanol washing allowed the production, with no sintering additive, of highly densified (93.6% of theoretical density), hard (25.4 GPa), and highly wear resistant (wear coefficient =2.9×10^–14 m³/N.m) boron carbide compacts sintered at 2250 °C. This optimized combination of properties was a consequence of a reduced grain growth without the deleterious effects associated to the carbon addition. Methanol washing of the starting powder is a simple and general approach to produce, without additives, high quality, wear resistant boron carbide compacts by pressureless sintering.     

Remarkable improvement in tribological behavior of plasma sprayed carbon nanotube and graphene nanoplatelates hybrid reinforced alumina nanocomposite coating

Addition of 0.5?wt% of graphene nanoplatelates (GNPs) and 1?wt% carbonnanotube (CNTs) in plasma sprayed Al₂O₃ coating showed the reduction of 93.25% in wear volume loss and 90.94% in wear rate. This could be attributed to the simultaneous effect of enhanced densification, presence of the transferred layer from the counterpart, strong interface between Al₂O₃, GNP and CNTs and toughening offered by the GNPs and CNTs. The lowest COF value of 0.27 was recorded on addition of 0.5?wt% of GNP in Al₂O₃ coating, which could be attributed to the graphitic lubrication on the worn track during the wear.     

Dielectric properties of BN modified carbon fibers by dip-coating

Continuous and uniform boron nitride (BN) coatings were synthesized on carbon fibers by dip-coating and their microstructure, chemical composition and dielectric properties were investigated. Results show that the as-prepared coatings are composed of phase mixture of h-BN and amorphous t-BN. The oxidation property of the BN modified carbon fibers is improved with higher initial and final oxidation temperatures. Both the real (ε′) and imaginary part (ε″) of permittivity of the BN modified carbon fibers decrease significantly compared with the pure carbon fibers. The decrease of ε′ can be mainly attributed to the absence of dielectric relaxation effect, while the decrease of ε″ can be ascribed to the large decrease in electrical conductivity. The decreasing permittivity leads to increase of microwave impedance which is beneficial for electromagnetic matching. With improved impedance match and still relatively high ε″, the BN modified carbon fibers exhibit a promising prospect as microwave absorbing materials.