Effects of SiC interphase by chemical vapor deposition on the properties of C/ZrC composite prepared via precursor infiltration and pyrolysis route

Silicon carbide (SiC) interphase was introduced by chemical vapor deposition (CVD) process to prevent carbon fiber degradation and improve fiber–matrix interface bonding of C/ZrC composite prepared via precursor infiltration and pyrolysis (PIP) process. Moderate thickness of SiC interphase in fiber bundles could increase the density of the composite, but when the thickness of SiC interphase was over 0.5 μm, more close pores formed and the density of the composite decreased. The SiC interphase could protect carbon fiber effectively from carbo-thermal reduction, but could not enhance the mechanical properties of C/ZrC composite. The flexural strength and fracture toughness of C/ZrC composites with 0.05 μm thickness SiC layer were 252 MPa and 13.6 MPa m^1/2, and for those with 0.5 μm thickness SiC layer 240 MPa and 12.8 MPa m^1/2, both close to the value of the composite without SiC interphase (254 MPa and 14.5 MPa m^1/2), while those with 0.7 μm thickness SiC layer were only 191 MPa and 10.8 MPa m^1/2, respectively. Moderate content of SiC interphase could improve the ablation property of C/ZrC composites; however excessive content of SiC interphase would decrease the ablation property.     

Microstructure and mechanical properties of carbon fiber reinforced multilayered (PyC–SiC)n matrix composites

Carbon fiber reinforced multilayered (PyC–SiC)_n matrix (C/(PyC–SiC)_n) composites were prepared by isothermal chemical vapor infiltration. The phase compositions, microstructures and mechanical properties of the composites were investigated. The results show that the multilayered matrix consists of alternate layers of PyC and β-SiC deposited on carbon fibers. The flexural strength and toughness of C/(PyC–SiC)_n composites with a density of 1.43 g/cm³ are 204.4 MPa and 3028 kJ/m³ respectively, which are 63.4% and 133.3% higher than those of carbon/carbon composites with a density of 1.75 g/cm³. The enhanced mechanical properties of C/(PyC–SiC)_n composites are attributed to the presence of multilayered (PyC–SiC)_n matrix. Cracks deflect and propagate at both fiber/matrix and PyC–SiC interfaces resulting in a step-like fracture mode, which is conducive to fracture energy dissipation. These results demonstrate that the C/(PyC–SiC)_n composite is a promising structural material with low density and high flexural strength and toughness.     

Characterization of carbon coatings on SiC monofilaments using Raman spectroscopy

The axial residual stresses in the carbon coatings deposited onto different silicon carbide monofilaments have been determined experimentally using Raman spectroscopy. The stress-dependent band shift for the carbon G-band at around 1600 cm⁻¹, due to symmetric in-plane stretching mode of graphite, has been found to be −1.6 cm⁻¹/GPa. Using this calibration, the axial residual stresses in carbon coatings can be estimated from measured band shifts between the broken end and middle of the monofilaments. It was found that the stresses in the coatings of all monofilaments were compressive and between −440 and −810 MPa. Modelling indicated that this was consistent with the coating stress arising from the difference in coefficients of thermal expansion of carbon and the underlying silicon carbide. The coating stress was measured as a function of distance from the broken monofilament end. It was found that the distance for the stress to build up varied greatly, from 40 μm in Ultra-SCS to 500 μm in SM1140+. This suggests there are significantly different shear stresses between the coatings and underlying silicon carbide in the different monofilaments.     

Application of Raman microscopy to the analysis of silicon carbide monofilaments

This paper reviews recent research upon the application of Raman microscopy to the characterisation of silicon carbide monofilaments produced by CVD (chemical vapour deposition). It is demonstrated that Raman microscopy is an invaluable technique allowing qualitative information about stoichoimetry variation in silicon carbide monofilaments to be obtained, as it readily detects both crystalline and amorphous carbon and silicon. It is shown that it is possible to characterise the morphology of the SiC crystallites in the monofilaments from analysis of the Raman line shapes. It is also demonstrated that Raman spectroscopy can be used to follow deformation of SiC monofilaments and to determine residual stresses in SiC-monofilament-reinforced metal-matrix composites. In addition, it is shown that it is possible to evaluate internal stresses in the carbon coatings of SiC monofilaments.     

Stress relaxation during thermal cycling of particle reinforced aluminium matrix composites

Two SiC-particle reinforced composites were produced by powder metallurgy using a 2124 Al-alloy matrix and two powder blending techniques: ball milling and wet blending. The effect of the blending route on the stress relaxation during thermal cycling is studied by in situ neutron diffraction based on the determination of the average stresses in the matrix and the particles. The thermal stresses in both composites partially relax by creep at T ? 90 °C. The higher creep resistance of the composite produced by ball milling reduces relaxation in comparison with the wet blended composite. This results in average axial compressive thermal stresses of ～?50 MPa and ～?10 MPa after heating to 230–300 °C in the matrices of the ball milling and wet blending composites, respectively, which relax at rates ?5 × 10^?9–3 × 10^?8 s^?1.     

Thermal shock behavior of nano-sized SiC particulate reinforced AlON composites

Aluminum oxynitride (AlON) has been considered as a potential ceramic material for high-performance structural and advanced refractory applications. Thermal shock resistance is a major concern and an important performance index of high-temperature ceramics. While silicon carbide (SiC) particles have been proven to improve mechanical properties of AlON ceramic, the high-temperature thermal shock behavior was unknown. The aim of this investigation was to identify the thermal shock resistance and underlying mechanisms of AlON ceramic and 8 wt% SiC–AlON composites over a temperature range between 175 °C and 275 °C. The residual strength and Young's modulus after thermal shock decreased with increasing quenching temperature and thermal shock times due to large temperature gradients and thermal stresses caused by abrupt water-quenching. A linear relationship between the residual strength and thermal shock times was observed in both pure AlON and SiC–AlON composites. The addition of nano-sized SiC particles increased both residual strength and critical temperature from 200 °C in the monolithic AlON to 225 °C in the SiC–AlON composites due to the toughening effect, the lower coefficient of thermal expansion and higher thermal conductivity of SiC. The enhancement of the thermal shock resistance in the SiC–AlON composites was directly related to the change of fracture mode from intergranular cracking along with cleavage-type fracture in the AlON to a rougher fracture surface with ridge-like characteristics, crack deflection, and crack branching in the SiC–AlON composites.     

Strength and toughness: The challenging case of TaC-based composites

This work aims at studying the relationships between strength and toughness of tantalum carbide (TaC) ceramics, a refractory ceramic used in aerospace and energy production sectors. The effect of different secondary phases was explored: (I) the addition of a transition metal silicide with suited thermo-elastic properties, TaSi₂, (II) the addition of SiC particles, platelets or fibers, and (III) chopped carbon fibers. Microstructural analyses, performed by scanning and transmission electron microscopy, were essential in revealing at nanoscale level the morphological changes occurred during sintering in the reinforcing phase and its interaction with matrix and sintering additive. Mechanisms of reinforcement evolution are suggested accordingly. Fracture toughness and flexural strength were measured and the values were compared to unreinforced materials and discussed in agreement to the microstructural features. Strength approaching 1 GPa was obtained upon addition of SiC particles, but residual thermal stresses prevented from notable increase of toughness, which fluctuated around 4 MPa √m. A good compromise between strength and toughness was found for addition of Hi-Nicalon SiC fiber, 550 MPa and 5.3 MPa √m, respectively. More refractory SiC fibers resulted not effective, owing to the rising of tensional state in the matrix. On the other hand, TaSi₂ led to a toughness of 4.7 MPa √m and strength around 680 MPa. Conversely, carbon fiber led to poor toughness due to unfavorable combination of coefficient of thermal expansion with the matrix.     

Effects of polymer derived SiC interphase on the properties of C/ZrC composites

Polymer derived silicon carbide (SiC) interphase was introduced by precursor infiltration and pyrolysis (PIP) to prevent carbon fiber erosion and to improve the fiber–matrix interface bonding of C/ZrC composites prepared by PIP. Introducing SiC interphase increased the density of the composites. The SiC interphase not only protected carbon fibers effectively from erosion by carbo-thermal reduction, but also enhanced the mechanical properties of C/ZrC composites by strengthening the interface bond. The flexural strength and fracture toughness of C/ZrC composites with SiC interphase prepared by two PIP cycles were 319 MPa and 18.8 MPa m^1/2 respectively. The ablation properties of C/ZrC composites were with rising content of SiC interphase but then decreased when excessive. The mass loss rate and the linear recession rate of the C/ZrC composites with SiC interphase prepared by one PIP cycle were 0.0079 g/s and 0.0084 mm/s, respectively.     

Micromechanical analysis of fiber and titanium matrix interface by shear lag method

The model based on fracture mechanics is developed to evaluate the fracture toughness Γ of the fiber/matrix interface in titanium alloys reinforced by SiC monofilaments. Theoretical model for single fiber push-out testing is obtained by shear-lag method. The influences of several key factors (such as the applied stress needed for crack advance, crack length, and interfacial frictional shear stress) are discussed. Using the model, the interfacial toughness of typical composites including Sigma1240/Ti-6-4, SCS-6/Ti-6-4, SCS-6/Timetal 834, SCS-6/Timetal 21s, SCS-6/Ti-24-11 and SCS-6/Ti-15-3 are successfully predicted compared with previous results of these composites. It is verified that the model can reliably predict the interfacial toughness of the titanium matrix composites as well as other metal matrix composites, due to interfacial debonding usually occurs at the bottom face of the samples in such composites.     

Interlaminar shear strength of SiC matrix composites reinforced by continuous fibers at 900 °C in air

To reveal the shear properties of SiC matrix composites, interlaminar shear strength (ILSS) of three kinds of silicon carbide matrix composites was investigated by compression of the double notched shear specimen (DNS) at 900 °C in air. The investigated composites included a woven plain carbon fiber reinforced silicon carbide composite (2D-C/SiC), a two-and-a-half-dimensional carbon fiber-reinforced silicon carbide composite (2.5D-C/SiC) and a woven plain silicon carbon fiber reinforced silicon carbide composite (2D-SiC/SiC). A scanning electron microscope was employed to observe the microstructure and fracture morphologies. It can be found that the fiber type and reinforcement architecture have significant impacts on the ILSS of the SiC matrix composites. Great anisotropy of ILSS can be found for 2.5D-C/SiC because of the different fracture resistance of the warp fibers. Larger ILSS can be obtained when the specimens was loaded along the weft direction. In addition, the SiC fibers could enhance the ILSS, compared with carbon fibers. The improvement is attributed to the higher oxidation resistance of SiC fibers and the similar thermal expansion coefficients between the matrix and the fibers.     

The preparation and mechanical properties of carbon–carbon/lithium–aluminum–silicate composite joints

Silica carbide modified carbon cloth laminated C–C composites have been successfully joined to lithium–aluminum–silicate (LAS) glass–ceramics using magnesium–aluminum–silicate (MAS) glass–ceramics as interlayer by vacuum hot-press technique. The microstructure, mechanical properties and fracture mechanism of C–C/LAS composite joints were investigated. SiC coating modified the wettability between C–C composites and LAS glass–ceramics. Three continuous and homogenous interfaces (i.e. C–C/SiC, SiC/MAS and MAS/LAS) were formed by element interdiffusions and chemical reactions, which lead to a smooth transition from C–C composites to LAS glass–ceramics. The C–C/LAS joints have superior flexural property with a quasi-ductile behavior. The average flexural strength of C–C/LAS joints can be up to 140.26 MPa and 160.02 MPa at 25 °C and 800 °C, respectively. The average shear strength of C–C/LAS joints achieves 21.01 MPa and the joints are apt to fracture along the SiC/MAS interface. The high retention of mechanical properties at 800 °C makes the joints to be potentially used in a broad temperature range as structural components.     

Electromagnetic shielding effectiveness of aluminum alloy–fly ash composites

The cenosphere and precipitator fly ash particulates were used to produce two kinds of aluminum matrix composites with the density of 1.4–1.6 g cm⁻³ and 2.2–2.4 g cm⁻³ separately. The electromagnetic interference shielding effectiveness (EMSE) properties of the composites were measured in the frequency range of 30.0 kHz–1.5 GHz. The results indicated the EMSE properties of the two types of composites were nearly the same. By using the fly ash particles, the shielding effectiveness properties of the matrix aluminum have been improved in the frequency ranges 30.0 kHz–600.0 MHz and the increment varied with increasing frequency. The EMSE properties of 2024Al are in the range −36.1 ± 0.2 to −46.3 ± 0.3 dB while the composites are in the range −40.0 ± 0.8 to −102.5 ± 0.1 dB in the frequency range 1.0–600.0 MHz. At higher frequency, the EMSE properties of the composites are similar to that of the matrix. The tensile strength of the matrix aluminum has been decreased by addition of the fly ash particulate and the tensile strength of the composites were 110.2 MPa and 180.6 MPa separately. The fractography showed that one composite fractured brittly and the other fractured in a microductile manner.     

Wear-mechanical properties of filler-added liquid silicon infiltration C/C–SiC composites

A carbon fiber reinforced silicon carbide matrix (C/C–SiC) composites material was manufactured by introducing a filler into the liquid silicon infiltration (LSI) process. The filler consisted of Si:Carbon black = 1:1 mixed with a phenol resin. Use of the filler resulted in a negligible reduction in the residual free Si of approximately 0.7% but increased 15% of reacted SiC amount. Dilatometer and X-ray diffraction (XRD) evaluations also confirmed improved formation of reaction-bonded silicon carbide (SiC) in the matrix. The wear rate was decreased more than 2.5-fold, indicating significantly improved wear-resistance properties. However, flexural strength gradually decreased and fiber damage was observed in fracture surface with increases in filler content.     

Investigation of impact behaviour of aluminium based SiC particle reinforced metal–matrix composites

In this paper, the impact behaviour of aluminium and silicon carbide (SiC) particle reinforced aluminium matrix composites under different temperature conditions was determined. Charpy impact tests were performed on as extruded and heat treated specimen at temperatures varying from −176 to 300 °C. Composite specimens based on aluminium alloys of 2124, 5083 and 6063 and reinforced by SiC particles were manufactured. Two different SiC sizes of 157 μm and 511 μm and two different extrusion ratios of 13.63:1 and 19.63:1 were used. The results of instrumented impact tests were compared with the microstructural and fractographic observations. The failure mechanisms and deformation behaviour of unreinforced alloys and composites were assessed. The impact behaviour of composites was affected by clustering of particles, particle cracking and weak matrix-reinforcement bonding. Agglomeration of particles reduced the impact strength of Al 2124 and 6063 based composites. Alumınum 6063 alloys and composites showed a better impact strength. The impact strength of 6063 composites increased with particle size and extrusion ratio. The effects of the test temperature on the impact behaviour of all materials were not very significant.     

CVD SiC fiber-reinforced barium aluminosilicate glass—ceramic matrix composites

Unidirectional CVD SiC (SCS-6) monofilament reinforced BaOAl₂O₃2SiO₂(BAS) glass—ceramic matrix composites have been fabricated by a tape lay-up method followed by hot pressing. The glass matrix flows around fibers during hot pressing resulting in nearly fully dense (95–98%) composites. Strong and tough composites having first matrix cracking stress of 250–300 MPa and ultimate flexural strength as high as 900 MPa have been obtained. Composite fracture surfaces showed fiber pullout with no chemical reaction at the fiber/matrix interface. From fiber push out, the fiber/matrix interfacial debond strength and the sliding frictional stress were determined to be 5.9 ± 1.2 MPa and 4.8 ± 0.9 MPa, respectively. The fracture surface of an uncoated SiC (SCS-0)/BAS composite also showed fiber/matrix debonding, fiber pullout, and crack deflection around the fibers implying that the SiC fibers may need no surface coating for reinforcement of the BAS glass-ceramic. Applicability of micromechanical models in predicting the first matrix cracking stress and the ultimate strength of these composites has also been examined.     

Effect of submicron size SiC particles on microstructure and mechanical properties of AZ31B magnesium matrix composites

The magnesium matrix composites reinforced with three volume fractions (3, 5 and 10 vol.%) of submicron-SiC particles (∼0.5 μm) were fabricated by semisolid stirring assisted ultrasonic vibration method. With increasing the volume fraction of the submicron SiC particles (SiCp), the grain size of matrix in the SiCp/AZ31B composites was gradually decreased. Most of the submicron SiC particles exhibited homogeneous distribution in the SiCp/AZ31B composites. The ultimate tensile strength and yield strength of the 10 vol.% SiCp/AZ31B composites were simultaneously improved. The study of interface between the submicron SiCp and the matrix in the SiCp/AZ31B composite suggested that submicron SiCp bonded well with the matrix without interfacial activity.     

Stress and dislocations in diamond–SiC composites sintered at high pressure,high temperature conditions

Diamond–silicon carbide composites were sintered at 10 GPa and three different temperatures: 1600, 1800, and 2000 °C. Distributions of residual surface stresses in diamond crystals were obtained by the analysis of Raman band shifts and splitting. It was noted that stresses concentrate around points of contacts between diamond crystals. Average stress increase with increasing sintering temperature. Complementary information on average sizes of crystallites, concentration of stacking faults, and population of dislocations in both diamond and SiC were obtained from X-ray diffraction profile analysis. It was observed that for both diamond and silicon carbide phases the average crystallite sizes decrease. The population of dislocations in the diamond phase increases with increasing sintering temperature and the population fluctuates in the SiC phase. Concentration of stacking faults was significant only in SiC.     

Mechanical properties of soil buried kenaf fibre reinforced thermoplastic polyurethane composites

A study on mechanical properties of soil buried kenaf fibre reinforced thermoplastic polyurethane (TPU) composites is presented in this paper. Kenaf bast fibre reinforced TPU composites were prepared via melt-mixing method using Haake Polydrive R600 internal mixer. The composites with 30% fibre loading were prepared based on some important parameters; i.e. 190 °C for reaction temperature, 11 min for reaction time and 400 rpm for rotating speed. The composites were subjected to soil burial tests where the purpose of these tests was to study the effect of moisture absorption on the mechanical properties of the composites. Tensile and flexural properties of the composites were determined before and after the soil burial tests for 20, 40, 60 and 80 days. The percentages of both moisture uptake and weight gain after soil burial tests were recorded. Tensile strength of kenaf fibre reinforced TPU composite dropped to ∼16.14 MPa after 80 days of soil burial test. It was also observed that there was no significant change in flexural properties of soil buried kenaf fibre reinforced TPU composite specimens.     

Study on the mechanical properties,environmental effect,degradation characteristics and ionizing radiation effect on silk reinforced polypropylene/natural rubber composites

Natural silk fiber (20%) reinforced polypropylene (PP) composites were prepared by compression molding. Tensile strength, tensile modulus, bending strength, bending modulus, impact strength and hardness of the prepared composite were found 54.7 MPa, 1826.2 MPa, 58.3 MPa, 3750.7 MPa, 17.6 kJ/m² and 95 shore A, respectively. To improve the biodegradable character of the composite, natural rubber (NR) was blended (10%, 25%, 50% by weight) with PP. It was found that the mechanical properties of the composite decrease with increasing NR in PP (except IS which increased rather decreasing). Environmental effect on the composite and degradation in various media were investigated in this study. Gamma radiation was used to increase the mechanical properties of the prepared composites. Increase in TS and BS were maximum at 250 krad dose for silk fiber/PP, silk fiber/PP:NR (90:10), silk fiber/PP:NR (75:25) and silk fiber/PP:NR (50:50) composites.     

An investigation of residual stresses in brazed cubic boron nitride abrasive grains by finite element modelling and raman spectroscopy

Joining cubic boron nitride (CBN) abrasive grains and tool body made of steel using brazing always creates residual stress due to thermal mismatch of the components when cooling down from the brazing temperature. A large tensile stress perhaps causes grain fracture during the grinding process with single-layer brazed CBN abrasive tools. To evaluate the residual stresses occurring in brazed CBN grains, values and distribution of residual stresses are calculated using the finite element method. Effects of bonding materials, embedding depth, gap thickness and grain size on brazing-induced residual stresses are discussed. Results show that the Cu–Sn–Ti bonding alloy always results in a larger tensile stress in the CBN grains, when compared to Ag–Cu–Ti alloy during the cooling phase of the brazing process. The maximum tensile stress is obtained at the grain–bond junction region irrespective of the choice of bonding material and embedding depth. When the grain side length is 100 μm, gap thickness is 10 μm and grain embedding depth is 30%, the maximum magnitude of the tensile stresses is obtained. The maximum stress is 401 MPa with Ag–Cu–Ti alloy and 421 MPa with Cu–Sn–Ti alloy. The brazing-induced residual stresses have been finally measured experimentally by means of the Raman spectroscopy. The current simulated results are accordingly verified valid.