Thermal Shock Behavior of an Alumina-SiC Whisker Composite

Thermal shock testing of an alumina-20 vol% SiC whisker composite showed no decrease in flexural strength with temperature differences up to 900°C. Alumina, on the other hand, normally shows a significant decrease inflexural strength with a temperature change of >400°C. The improvement in the thermal shock resistance of the composite is believed attributable to the increased fracture toughness of this material.     

Influence of a Piezoelectric Secondary Phase on Thermal Shock Resistance of Alumina-Matrix Ceramics

Using monolithic alumina ceramics as the reference, the thermal shock behavior of the hot-pressed alumina matrix ceramics with 3 mol% neodymium titanate was investigated. The thermal shock resistance of the materials was evaluated by water quenching and a subsequent three-point bending test to determine the flexural strength degradation. The hot-pressed composite exhibited a temperature differential of the thermal shock resistance 120°C higher than the monolith, mainly because of significantly improved fracture toughness.     

Sintering and Mechanical Properties of Yttria-Doped Tetragonal ZrO2 Polycrystal/Mullite Composites

Yttria-doped tetragonal ZrO₂ polycrystal (Y-TZP)lmullite composites were sintered at 1450° to 1500°C in air to disperse rodlike mullite grains at the grain boundary of Y-TZP and the mechanical and thermal properties were investigated. The aspect ratios of mullite grain were >2. High fracture strength of 1000 MPa and fracture toughness of 12 MPa·m^1/2 were obtained by dispersing <20 vol% of mullite into Y-TZP. The thermal expansion coefficient of Y-TZP/mullite composites decreased with increasing mullite content. The thermal shock resistance of Y-TZP was greatly improved by dispersion of rodlike mullite grains.     

Surface Integrity Effects on the Fracture Resistance of Electrical-Discharge-Machined WC–Co Cemented Carbides

The flexural strength evolution for two WC–16 vol% Co cemented carbides, with different mean carbide size, subjected to sequential and upgrading electrical-discharge machining (EDM) is studied. It is compared with the fracture behavior exhibited by a reference surface finish condition, attained through conventional mechanical grinding and polishing using diamond as abrasive. Considering that rupture is related to existing defects, either introduced during sample elaboration or induced by machining, a detailed fractographic examination by scanning electron microscopy is conducted to discern fracture origins. The experimental findings indicate that the flexural strength of WC–Co hardmetals may be strongly affected by EDM, depending on the correlation existing between natural defects, as given by particular microstructural parameters, and EDM-induced flaws. An analysis of the results using a linear–elastic fracture mechanics approach permits one to establish a clear connection between surface integrity and fracture resistance. Quantitative discrepancies between the estimated and the experimentally measured critical flaw sizes for all the EDM-related grades are rationalized through the existence of local residual tensile stresses of considerable magnitude at the shaped surface. Release of these stresses through final mechanical and annealing treatments is pointed out as a quite effective alternative for improving the fracture behavior of WC–Co cemented carbides shaped by EDM.     

Modeling the Influence of Orientation Texture on the Strength of WC–Co Composites

Two-dimensional finite element simulations were used to study the effects of orientation texture on the transverse rupture strengths of WC–Co composites. The model incorporates observed microstructural geometries, anisotropic thermal and elastic properties, and a fracture criterion that reproduces the strengths of known specimens. The results show that the greatest potential for increasing the strength occurs when the [001] axes of the carbide grains are orientated perpendicular to the sample loading direction. Furthermore, the strength increases in proportion to the degree of texture, and the texture-derived strength enhancement is greater in microstructures with a larger contiguity.     

Interface Character Distributions in WC–Co Composites

The geometric and crystallographic characteristics of interfaces in WC–Co composites with a range of grain sizes and carbide volume fractions have been comprehensively characterized. The carbide crystals are most frequently terminated by (0001) and     surfaces. The average number of carbide vertices per grain and the basal-to-prismatic face area ratio of the WC–Co interfaces increase with the carbide volume fraction. The three most frequently occurring WC/WC grain boundaries are 90° twist boundaries about     , 30° twist boundaries about [0001], and asymmetric 90° boundaries about     . The boundary populations do not vary with grain size or carbide volume fraction, suggesting that they are determined by the grain boundary energy anisotropy.     

Postsintering Hot Isostatic Pressing of Ceria-Doped Tetragonal Zirconia/Alumina Composites in an Argon–Oxygen Gas Atmosphere

Ceria-doped tetragonal zirconia (Ce-TZP)/alumina (Al₂O₃) composites were fabricated by sintering at 1450° to 1600°C in air, followed by hot isostatic pressing (postsintering hot isostatic pressing) at 1450°C and 100 MPa in an 80 vol% Ar–20 vol% O₂ gas atmosphere. Dispersion of Al₂O₃ particles into Ce-TZP was useful in increasing the relative density and suppressing the grain growth of Ce-TZP before hot isostatic pressing, but improvement of the fracture strength and fracture toughness was limited. Postsintering hot isostatic pressing was useful to densify Ce-TZP/Al₂O₃ composites without grain growth and to improve the fracture strength and thermal shock resistance.     

Barium Aluminosilicate Reinforced In Situ with Silicon Nitride

Advanced ceramic composite materials that exhibit high strength and toughness with good thermal shock resistance are needed for emerging high-temperature engineering applications. A recently developed in situ reinforced barium aluminosilicate glass-ceramic shows promise of meeting many of the requirements for these types of applications with the added benefit of low-cost fabrication through densification by pressureless sintering. The material is toughened through in situ growth of rodlike β-Si₃N₄ grains resulting from the α–β silicon nitride phase transformation. Microstructural development and material properties for temperatures up to 1400°C are discussed. When compared to monolithic barium aluminosilicate, barium aluminosilicate reinforced with 70% by volume of Si₃N₄ shows a significant increase in flexural strength (from 80 to 565 MPa) and fracture toughness (from 1.8 to 5.74 MPa·m^1/2) with a high resistance to thermal shock.     

Effects of Grain-Boundary Structure on the Strength, Toughness, and Cyclic-Fatigue Properties of a Monolithic Silicon Carbide

An in situ -toughened silicon carbide (ABC-SiC) has been examined in the as-processed condition, where the grain-boundary films are predominantly amorphous, and following thermal exposure at a temperature of 1300°C, where the films become fully crystalline. Previous work has shown that, at elevated temperatures (up to 1300°C), after the grain-boundary films crystallize in situ , only a marginal reduction in strength, fracture toughness, and cyclic-fatigue crack-growth properties is observed, in comparison with those of the as-processed microstructure at 25°C. In the present study, the effect of such crystallization on the subsequent strength, toughness, and fatigue properties at 25°C is examined. Little or no degradation is observed in the room-temperature properties with the crystallized grain-boundary films/phase; in fact, although the strength shows a small reduction (∼3%), the fracture toughness and fatigue-crack-growth threshold both increase by ∼20%, compared with that of the as-processed structure with amorphous grain-boundary films.     

Resistance to Thermal Shock and to Oxidation of Metal Diborides–SiC Ceramics for Aerospace Application

Two SiC-containing metal diborides materials, classified in the ultra-high-temperature ceramics (UHTCs) group, were fabricated by hot-pressing. SiC, sinterability apart, promoted resistance to oxidation of the diboride matrices. Both the compositions, oxidized in air at 1450°C for 1200 min, had mass gains lower than 5 mg/cm². Slight deviations from parabolic oxidation kinetics were seen. The resistance to thermal shock (TSR) was studied through the method of the retained flexure strength after water quenching (20°C of bath temperature). Experimental data showed that the (ZrB₂+HfB₂)–SiC and the ZrB₂–SiC materials retained more than 70% of their initial mean flexure strength for thermal quenchs not exceeding 475° and 385°C, respectively. Certain key TSR properties (i.e., fracture strength and toughness, elastic modulus, and thermal expansion coefficient) are very similar for the two compositions. The observed superior critical thermal shock of the (ZrB₂+HfB₂)–SiC composite was explained in terms of more favorable heat transfer parameters conditions that induce less severe thermal gradients across the specimens of small dimensions (i.e., bars 25 mm × 2.5 mm × 2 mm) during the quench down in water. The experimental TSRs are expected to approach the calculated R values (196° and 218°C for ZrB₂+HfB₂–SiC and ZrB₂–SiC, respectively) as the specimen size increases.     

Development of WC–ZrO2 Nanocomposites by Spark Plasma Sintering

In the present work, we report the processing of ultrahard tungsten carbide (WC) nanocomposites with 6 wt% zirconia additions. The densification is conducted by the spark plasma sintering (SPS) technique in a vacuum. Fully dense materials are obtained after SPS at 1300°C for 5 min. The sinterability and mechanical properties of the WC–6 wt% ZrO₂ materials are compared with the conventional WC–6 wt% Co materials. Because of the high heating rate, lower sintering temperature, and short holding time involved in SPS, extremely fine zirconia particles (∼100 nm) and submicrometer WC grains are retained in the WC–ZrO₂ nanostructured composites. Independent of the processing route (SPS or pressureless sintering in a vacuum), superior hardness (21–24 GPa) is obtained with the newly developed WC–ZrO₂ materials compared with that of the WC–Co materials (15–17 GPa). This extremely high hardness of the novel WC–ZrO₂ composites is expected to lead to significantly higher abrasive-wear resistance.     

Thermal Shock Testing of Ceramics—A New Testing Method

The thermal shock behavior of Si₃N₄ has been determined with a new type of computer-controlled testing equipment. Thin circular disks are heated up to 1350°C with two tungsten halogen lamps yielding heating rates up to 1000°C/s. The sample temperature is measured in situ with an infrared pyrometer and used to calculate the transient thermal stresses. The simple geometry of radially orientated notches allows in situ observation of the crack growth behavior during thermal shock. Measured failure times are used to determine the fracture toughness of the material under thermal shock loading, K _c^TS, from room temperature (RT) up to 1000°C. Comparison of the results with K _Ic^SENB values measured by the single-edge notch beam method at RT shows excellent agreement.     

Effect of Microstructure on the Properties of TiB2 Ceramics

Samples of a TiB₂ ceramic containing 0 to 10 wt% Ni were fabricated by hot-pressing. Several properties, including fracture strength, indentation fracture toughness, and thermal expansion (between 25° and 1000°C) were measured. Resulting data were correlated with sample microstructure and composition.     

Strength and Toughness of Tape-Cast Yttria-Stabilized Zirconia

The biaxial flexural strength and fracture toughness of tape-cast yttria-stabilized zirconia, for application as the electrolyte in solid oxide fuel cells, have been measured at room temperature and at a typical operating temperature of 900°C. The flexural strength was measured in ring-on-ring loading and decreased from 416 MPa at room temperature to 265 MPa at 900°C. The fracture toughness was measured using two different techniques: indentation fracture and double-torsion loading. The latter was more reliable and gave a fracture toughness of 1.61 ± 0.12 MPa·m^1/2 at room temperature and 1.02 ± 0.05 MPa·m^1/2 at 900°C. The flexural strength and fracture toughness were quantitatively consistent with fracture being initiated at the observed surface defects. The lower fracture toughness at 900°C is partly due to a reduction in elastic modulus and partly due to a reduction in the work of fracture.     

Thermal Shock Resistance and Fracture Behavior of ZrB2–Based Fibrous Monolith Ceramics

The thermal shock resistance and fracture behavior of zirconium diboride (ZrB₂)-based fibrous monoliths (FM) were studied. FMs containing cells of ZrB₂–30 vol% SiC with cell boundaries composed of graphite–15 vol% ZrB₂ were hot pressed at 1900°C. The average flexure strength of the FMs was 375 MPa, less than half of the strength of hot-pressed ZrB₂–30 vol% SiC. Flexure specimens failed noncatastrophically and retained 50%–85% of their original strength after the first fracture event. A critical thermal shock temperature (Δ T _c) of 1400°C was measured by water quench thermal shock testing, a 250% improvement over the previously reported Δ T _c values for ZrB₂ and ZrB₂–30 vol% SiC of similar dimensions (4 mm × 3 mm × 45 mm). The flexure strength was maintained with Δ T _c values of 1350°C and below. As Δ T _c increased, the stiffness of the flexure specimen decreased linearly. The lower stiffness and improvement in thermal shock resistance is attributed to crack propagation in the cell boundary and crack deflection around the load-bearing cells. The critical thermal shock was attributed to the fracture of the ZrB₂–30% SiC cell material.     

Elevated temperature strength and thermal shock behavior of hot-pressed carbon fiber reinforced TiC composites

In order to improve the elevated strength and thermal shock resistance of TiC materials, 20vol% short carbon fiber-reinforced TiC composite (C_f/TiC) was produced by hot pressing. With carbon fiber addition, the strength and fracture toughness of TiC is increased remarkably, and the elastic modulus and thermal expansion coefficient are decreased. The strength value of C_f/TiC composite is 593 MPa at room temperature and 439 MPa at 1400°C, and the fracture toughness value at room temperature is 6.87 MPa m^1/2. The thermal stress fracture resistance parameter, R, thermal stress damage resistance parameter, R^IV, and thermal stress crack stability parameter, R_st, are all increased. The residual strength decreases significantly when the thermal shock temperature difference, ΔT, is higher than 900°C, and the residual strength is 252 MPa when ΔT is 1400°C. Carbon fiber reinforced-TiC composite exhibits superior resistance to thermal shock damage compared with monolithic TiC. The catastrophic failure induced by severe thermal stresses can be prevented in C_f/TiC composite.     

Elevated-Temperature Toughness and Hardness of a Hot-Pressed Al2O3—WC—Co Composite

The fracture toughness and hardness of an Al₂O₃80WC10Co composite were investigated in air at elevated temperatures. The primary phases in the composite were WC, α-Al₂O₃, and Co₃W₃C, but small amounts of Co and C (graphite) appeared at elevated temperatures, related to decomposition of the Co₃W₃C phase. The fracture toughness of the composite was constant with increasing temperature up to 330°C and then increased in the range 400° to 550°C. A transition of brittle to ductile behavior occurred at about 700°C. The enhancement of fracture toughness at elevated temperature is attributed to the decomposition of Co₃W₃C to Co and C, and enhanced crack deflection and bridging. Decreases in hardness with increasing temperature are attributed to the softening of WC matrix and decomposition of Co₃W₃C.     

Effects of Damage on Thermal Shock Strength Behavior of Ceramics

When subjected to severe thermal shock, ceramics suffer strength degradation due to the damage caused by the shock. A fracture-damage analysis is presented to study the effects of damage on the thermal shock behavior of ceramics. It is assumed that a narrow strip damage zone is developed at the tip of a preexisting crack after a critical thermal shock and the damage behavior can be described by a linear strain-softening constitutive relation. Damage growth and strength degradation are determined based on fracture and damage mechanics. Numerical calculations are carried out for two ceramic materials, and the strength degradation agrees quite well with experimental results. The effects of bridging/damage stress, the fracture energy of the bridging/damage zone, and specimen size on thermal shock strength behavior are studied. A higher fracture energy can enhance the residual strength of thermally shocked ceramics and, for a given fracture energy, a higher bridging stress is needed to reduce the strength degradation. It is also shown that the thermal shock strength behavior is size-dependent, and a high value of ( K _IC/O_b)², where K _IC is the intrinsic fracture toughness and O_b is the bending strength, can improve significantly the residual strength.     

The Tetragonal-Monoclinic Transformation in Zirconia: Lessons Learned and Future Trends

Zirconia ceramics have found broad applications in a variety of energy and biomedical applications because of their unusual combination of strength, fracture toughness, ionic conductivity, and low thermal conductivity. These attractive characteristics are largely associated with the stabilization of the tetragonal and cubic phases through alloying with aliovalent ions. The large concentration of vacancies introduced to charge compensate of the aliovalent alloying is responsible for both the exceptionally high ionic conductivity and the unusually low, and temperature independent, thermal conductivity. The high fracture toughness exhibited by many of zirconia ceramics is attributed to the constraint of the tetragonal-to-monoclinic phase transformation and its release during crack propagation. In other zirconia ceramics containing the tetragonal phase, the high fracture toughness is associated with ferroelastic domain switching. However, many of these attractive features of zirconia, especially fracture toughness and strength, are compromised after prolonged exposure to water vapor at intermediate temperatures (∼30°–300°C) in a process referred to as low-temperature degradation (LTD), and initially identified over two decades ago. This is particularly so for zirconia in biomedical applications, such as hip implants and dental restorations. Less well substantiated is the possibility that the same process can also occur in zirconia used in other applications, for instance, zirconia thermal barrier coatings after long exposure at high temperature. Based on experience with the failure of zirconia femoral heads, as well as studies of LTD, it is shown that many of the problems of LTD can be mitigated by the appropriate choice of alloying and/or process control.