RVE Model with Porosity for 2D Woven CVI SiC<Subscript>f</Subscript>/SiC Composites

A representative volume element (RVE) model with porosity for 2D woven chemical vapor infiltration (CVI) SiC_f/SiC composites is presented, and its mechanical properties are analyzed. Samples are divided after a tensile test, and their cross sections are scanned with a scanning electron microscope. The size of the feature structure of the RVE model is determined based on the measurement statistics of the feature structure parameters. In accordance with CVI technology, the deposition rates of the matrix in each direction along the surface of fiber bundles are assumed to be similar. The porosity structure is formed naturally when the RVE model is established. The RVE model conforms to the real structure and accurately shows the location and geometric shape of internal porosity. The relative error of the tensile modulus value estimated from the RVE model through the asymptotic expansion homogenization method and experimental data is 3.26%. Therefore, the RVE model is accurate and efficient.     

C/Ti/Cu interfacial reaction in SiC<Subscript>f</Subscript>/Cu composites

Continuous SiC fiber reinforced copper matrix(SiCf/Cu) composites were prepared by fiber coating method,and Ti6Al4V interlayer was introduced as an interfacial modification coating to improve the interfacial bonding strength.The interfacial reaction characteristics were investigated by transmission electron microscopy(TEM).The results show that nearly all the titanium atoms reacted with the carbon coating of SiC fibers to form two layers of TiC.Also,a thin copper layer that is sandwiched between these two layers was detected.No Ti-Cu interfacial reaction product was observed.The formation process of the interfacial reaction along with its mechanism was discussed.     

Effect of Critical Plasma Spray Parameters on Microstructure and Microwave Absorption Property of Ti<Subscript>3</Subscript>SiC<Subscript>2</Subscript>/Cordierite Coatings

Ti₃SiC₂/cordierite coatings with different critical plasma spray parameters (CPSP) were fabricated via atmospheric plasma spraying method. The microstructure and phase constitution of the as-sprayed Ti₃SiC₂/cordierite coatings were characterized. The effects of CPSP conditions on the electromagnetic shielding, and dielectric and microwave absorption properties of coatings in the frequency of 8.2-12.4 GHz were also measured and investigated. The results showed that both real and imaginary part of the complex permittivity decrease with increasing CPSP values, which can be ascribed to the decomposition of some Ti₃SiC₂ into TiC. The calculated reflection loss of the as-sprayed Ti₃SiC₂/cordierite coatings with different CPSP conditions and thicknesses indicates that coatings with CPSP 0.3, 0.35, and 0.425 exhibit excellent microwave absorption property in the thickness of 1.5 mm. In order to broaden the bandwidth of the coatings, a double-layer coating system was designed. The calculated reflection loss results show that when the thickness of matching layer is 0.3 mm and the thickness of absorbing layer is 1.5 mm, the double-layer coating system shows a proper microwave absorption property with a minimum absorption value of ?17.37 dB at 9.67 GHz and a absorption bandwidth (RL less than ?5 dB) of 4.16 GHz in the investigated frequency.     

Preparation and Characterization of Binder Less Mg/Mg Alloy Infiltrated SiC<Subscript>p</Subscript> Reinforced Composites

SiC_p-reinforced commercial pure magnesium and AZ91 alloy MMCs’ were prepared through infiltration route without the use of any special atmospheres. The preform was prepared using a mixture of reinforcement particles and the matrix metal particles. The composites were prepared with various volume percentage of the reinforcement and their properties with the variation of SiC_p were analyzed. The interfacial properties of the composites were analyzed using microstructure, microhardness, and wear studies. Calculation of thermal conditions during infiltration was done to study the effect of adding matrix metal particles on the infiltration behavior and its effect on the uniformity distribution of the reinforcements.     

The creep behavior of Si<Subscript>3</Subscript>N<Subscript>4</Subscript>/SiC nanocomposites

In an investigation of the creep properties of silicon nitride/silicon carbide nanocomposites, the micro-nano type composites with nano-SiC at intragranular and inter-granular regions show behavior not much different from that of silicon-nitride monolith. The improvement of creep resistance is modest, up to about one order of magnitude decrease in steady-state creep rate. The creep rate parameters such as activation energy and stress exponent measured for this type of nanocomposite are within the range of those of silicon nitride. This evidence suggests that a special strengthening mechanism may not be necessary for this type of material. Nano-nanocomposites show remarkably lower creep rates, possibly pointing to a new creep mechanism such as solid-state diffusion. For more information, contact A.K. Mukherjee, University of California-Davis, Department of Chemical Engineering and Materials Science, Davis, CA 95616; e-mail akmukherjee@ucdavis.edu.     

Joining of C<Subscript>f</Subscript>/SiC Ceramics to Nimonic Alloys

C_f/SiC ceramic composites have been brazed to Nimonic alloys using TiCuAg filler metal. In order to improve wettability and to provide compatibility between ceramic and metal, the C_f/SiC surface was metallized through the deposition of a chromium layer. Subsequent heat treatments were carried out to develop intermediate layers of chromium carbides. Excellent wetting of both the composite ceramic and the metal from the filler metal is observed in the fabricated joints. Shear tests show that failure occurs always within the ceramic material and not at the joint. In the filler region depletion of Ti and formation of Ag and Cu rich regions are observed. At the C_f/SiC-filler interface a layered structure of the filler metallic elements is observed. Titanium interacts with the SiC matrix to form carbides and silicides.     

Phase Equilibria and Reactive Chemical Vapor Deposition (RCVD) of Ti<Subscript>3</Subscript>SiC<Subscript>2</Subscript>

The present article addresses the issue of properly modelling the thermodynamic aspect of chemical reactions proceeding at the solid/gas interface in a multi-component system. Attention is more especially paid to the formation of Ti₃SiC₂ by reactive chemical vapor deposition (RCVD) on a silicon carbide substrate heated at 1100 °C. A deposition diagram has been calculated by Gibbs free energy minimization in the C-Cl-H-Si-Ti quinary system. It is shown that this deposition diagram can account for experimental results obtained by RCVD only for the short period of time during which the reaction layer is thin and discontinuous. For thick, dense and continuous reaction layers, the deposition diagram is no longer appropriate and reaction-diffusion models developed for solid-state diffusion couples have to be used in place of it.     

In-process exothermic reaction in high-velocity oxyfuel and plasma spraying with SiO<Subscript>2</Subscript>/Ni/Al-Si-Mg composite powder

Reactive thermal spraying, in which thermodynamically stable compounds are formed by expected inprocess reactions, has attracted considerable attention as a result of the wide availability of in situ composite coatings. Such in-process reactions occur differently in high-velocity oxyfuel (HVOF) and plasma spraying because of differences in the flame temperature and speed. In the current study, a composite powder of SiO₂/Ni/Al-Si-Mg was deposited onto an aluminum substrate to fabricate in situ composite coatings by both spraying methods. The coating hardness sprayed with Al-Si-Mg core powder increases with silicon and magnesium content, whereas the coatings by HVOF spraying show higher hardness than those by plasma spraying. In the present reactive spraying, the exothermic reaction of SiO₂ with molten Al-Si-Mg alloy leads to composite materials of MgAl₂O₄, Mg₂Si, and Al-Si matrix. Moreover, a rapid formation of aluminide (NiAl₃), which is introduced by an exothermic reaction of plated nickel with Al-Si-Mg core powder, enhances the reduction of SiO₂, especially in HVOF spraying. A series of in-process reactions proceed mainly during splat layering on a substrate instead of during droplet flight even in plasma spraying. Plasma-sprayed composite coatings become much harder because of the great progress of in-process reactions.     

Effect of Compaction Load and Sintering Temperature on Tribological and Mechanical Behavior of Ni/SiC/MoS<Subscript>2</Subscript> Composites

In the present investigation, the effects of compaction load and sintering temperature on the tribological and mechanical behavior of Ni/20%SiC/7%MoS₂ hybrid composites was studied. The density, compression strength, and hardness of the composites were evaluated and compared. The wear properties of the composites were evaluated for the test condition of 1 m/s speed and 10 N load using a pin-on-disk tribometer. The braking performance of the composites was evaluated in a subscale dynamometer for the 500 kJ energy condition. The microstructure and wear surface morphology of the composites were analyzed by stereo, optical, and scanning electron microscopes. From the results, the following important conclusions are drawn: (1) the compaction load of 1400 kN and sintering temperature of 900 °C are optimum to obtain the best combination of tribological and mechanical properties; (2) the properties such as density, compression strength, hardness, wear, and friction increase up to a critical sintering temperature, and then decrease later; (3) the composition and thickness of the interface reaction product phases (Ni₂Si, Ni₃Si, and graphite) play a key role in deciding the strength of Ni/SiC interface that consequently affects the mechanical and tribological properties of the composites; (4) the abrasive wear is found to be the main wear mechanism in the highly densified composites, whereas the delamination wear and the third-body wear are major wear mechanisms in the poorly densified composites; and (5) the better braking performance of the highly densified composites is attributed to the absence of third-body wear, controlled flow of solid lubricant, and lower porosity.     

Thermal and structural role of additives in P<Subscript>2</Subscript>O<Subscript>5</Subscript>-ZnO-Sb<Subscript>2</Subscript>O<Subscript>3</Subscript> glass for low expansion sealing materials

A glass based on the P₂O₅-ZnO-Sb₂O₃ ternary system was modified with various additives, such as RO (R=Ca, Ba and Mn), B₂O₃ and V₂O₅, for low temperature and low expansion sealing materials. The glass transition temperature (T_g) and coefficient of thermal expansion (CTE) were monitored and reduced with additive compositions of RO. Additional incorporation of B₂O₃ at the expense of RO also showed a similar result. Significant improvement was observed when the glass was modified with V₂O_5. A glass showing T_g<350 °C along with CTE<65×10⁻⁷/°C was found, suggesting a high potential for low temperature sealing materials especially for display applications. The role of the quaternary element within the glass is discussed, along with the structural effect using Raman spectroscopy.     

Viscosity and Structure of CaO-SiO<Subscript>2</Subscript>-P<Subscript>2</Subscript>O<Subscript>5</Subscript>-Fe<Subscript>t</Subscript>O System with Varying P<Subscript>2</Subscript>O<Subscript>5</Subscript> and FeO Content

A rotary viscosimeter and Raman spectrum were employed to measure the viscosity and structural information of the CaO-SiO₂-P₂O₅-Fe_tO system at 1673 K. The experimental data have been compared with the calculated results using different viscosity models. It shows that the National Physical Laboratory (NPL) and Pal models fit the CaO-SiO₂-P₂O₅-FeO_t system better. With the P₂O₅ content increasing from 5% to 14%, the viscosity increases from 0.12 Pa s to 0.27 Pa s. With the FeO content increasing from 30% to 40%, the viscosity decreases from 0.21 Pa s to 0.12 Pa s. Increasing FeO content makes the complicated molten melts become simple, and increasing P₂O₅ content will complicate the molten melts. The linear relation between viscosity and structure parameter Q(Si + P) was obtained by regression analysis. The calculated viscosity by using the optimized NPL and Pal model are almost identical with the fitted values.     

Cyclic polarization analysis of corrosion behavior of ceramic coating on 6061 Al/SiC<Subscript>p</Subscript> composite for marine applications

The study on the corrosion behavior of the composite and evaluation of surface modification technique are of importance since the addition of reinforcement particles affects the continuity of inherent oxide layer on the matrix and hence its corrosion resistance. The present study deals with the investigations of effect of ceramic coating on the corrosion behavior of 6061 Al/SiC_P (20 volume % reinforcement) composite in 3.5 M NaCl solution at high temperatures namely 30 and 40°C using potentiodynamic polarization technique and cyclic polarization plots. Aluminum coating by magnetron sputtering technique is employed on the composite and it is subjected to heat treatment at 200°C for duration of 2 h for the alumina formation. The alumina coating formed on the composite surface acts as corrosion protective coating. The potentiodynamic polarization technique is used to determine the corrosion rate of the composite specimen with and without ceramic coating in the corrosion media. The cyclic polarization technique is used to study the pitting behavior of the composite with and without ceramic coating. The microstructural analysis is carried out using scanning electron microscopy (SEM). X-RD analysis shows the amorphous nature of Alumina coating obtained on the composite. The results show that the peak aged composite is more prone to corrosion among the aged group of composites but when coated with alumina shows a vast improvement in pitting nucleation resistance even at high temperatures.     

The Usability of Boric Acid as an Alternative Foaming Agent on the Fabrication of Al/Al<Subscript>2</Subscript>O<Subscript>3</Subscript> Composite Foams

Pure Al and alumina (2, 5, 10 wt.% Al₂O₃)-added Al composite foams were fabricated through powder metallurgy technique, where boric acid (H₃BO₃) is employed as a new alternative foaming agent. It is aimed to determine the effects of boric acid on the foaming behavior and cellular structure and also purposed to develop the mechanical properties of Al foams by addition of Al₂O₃. Al and Al composite foams with porosity fraction in the range of 46-53% were achieved by sintering at 620 °C for 2 h. Cell morphology was characterized using a combination of stereomicroscope equipped with image analyzer and scanning electron microscopy. Microhardness values were measured via using Vickers indentation technique. Quasi-static compression tests were performed at strain rate of 10^?3 s^?1. Compressive strength and energy absorption of the composite foams enhanced not only by the increasing weight fraction of alumina, but also by the usage of boric acid which leads to formation of boron oxide (B₂O₃) acting as a binder in obtaining dense cell walls. The results revealed that the boric acid has outstanding potential as foaming agent in the fabrication of Al and Al composite foams by providing improved mechanical properties.     

Co-reinforcing Al/SiC composites with MgAl<Subscript>2</Subscript>O<Subscript>4</Subscript> formed in situ during the processing by non-assisted infiltration

In this work, SiC_P and SiC_P/SiO₂ porous preforms were infiltrated without assistance in Ar→N₂ atmosphere with the alloy Al-10.3 Mg-12.04 Si (wt.%) at 1050 and 1100 °C, for 20, 40 and 60 min. It was found that a decrease in residual porosity and an increase in elastic modulus by about 22 % with respect to composites produced without SiO₂ additions to the preforms are associated with the formation of magnesium aluminate spinel (MgAl₂O₄). A concurrent increase of the matrix hardness is ascribed to a strengthening mechanism by MgAl₂O₄ formation, similar to the strengthening observed with Mg₂Si in aluminum alloys. Therefore, the spinel can be considered as a co-reinforcement of SiC_p in the aluminum matrix composites. Reactions for spinel formation and possible mechanisms for hardness enhancement are outlined.     

Tribological Properties of Ni<Subscript>3</Subscript>Al Matrix Composite Sliding Against Si<Subscript>3</Subscript>N<Subscript>4</Subscript>, SiC and Al<Subscript>2</Subscript>O<Subscript>3</Subscript> at Elevated Temperatures

The Ni₃Al matrix self-lubricating composite was fabricated by powder metallurgy technique. The tribological behavior of the composite sliding against commercial Si₃N₄, SiC and Al₂O₃ ceramic balls was investigated from 20 to 1000 °C. It was found that the composite demonstrated excellent lubricating properties with different friction pairs at a wide temperature range, which can be attributed to the synergetic effect of Ag, fluorides, and molybdates formed by oxidations. The Ni₃Al matrix self-lubricating composite/Si₃N₄ couple possessed the stable friction coefficient and wear rate.     

Thermal Spray Deposition,Phase Stability and Mechanical Properties of La<Subscript>2</Subscript>Zr<Subscript>2</Subscript>O<Subscript>7</Subscript>/LaAlO<Subscript>3</Subscript> Coatings

This paper deals with the deposition of La₂Zr₂O₇ (LZO) and LaAlO₃ (LAO) mixtures by air plasma spray (APS). The raw material for thermal spray, single phase LZO and LAO in a 70:30 mol.% ratio mixture was prepared from commercial metallic oxides by high-energy ball milling (HEBM) and high-temperature solid-state reaction. The HEBM synthesis route, followed by a spray-drying process, successfully produced spherical agglomerates with adequate size distribution and powder-flow properties for feeding an APS system. The as-sprayed coating consisted mainly of a crystalline LZO matrix and partially crystalline LAO, which resulted from the high cooling rate experienced by the molten particles as they impact the substrate. The coatings were annealed at 1100 °C to promote recrystallization of the LAO phase. The reduced elastic modulus and hardness, measured by nanoindentation, increased from 124.1 to 174.7 GPa and from 11.3 to 14.4 GPa, respectively, after the annealing treatment. These values are higher than those reported for YSZ coatings; however, the fracture toughness (K _IC) of the annealed coating was only 1.04 MPa m^0.5.     

Kinetics of forward extraction of Ti（IV） from H_2SO_4 medium by P_（507） in kerosene using the single drop technique

The kinetics of forward extraction of Ti(IV) from H2SO4 medium by P507 in kerosene has been investigated using the single drop technique.In the low concentration region of Ti(IV),the rate of forward extraction at 298 K can be represented by F(kmol·m-2·s-1)=10-5.07 [TiO 2 + ][H+]-1 [NaHA 2 ](o)·Analysis of the rate expression reveals that the rate determining step is(TiO)(i)2+ +(HA 2)(i)-[TiO(HA2)](i)+.The values of Ea,H±,S±,and G±298 are calculated to be 22 kJ·mol-1,25 kJ·mol-1,-218 J·mol-1·K-1,and 25 kJ·mol-1,respectively.The experimental negative S± values indicate that the reaction step occurs via SN2 mechanism.     

Protection of 6061 Al-15%<Subscript>(v)</Subscript> SiC<Subscript>(P)</Subscript> composite from corrosion by a biopolymer and surface morphology studies

The protective action of biopolymer starch on 6061 Al-15%_(v) SiC_(P) composite in 0.25 M hydrochloric acid was studied by potentiodynamic polarization (PDP) and electrochemical impedance spectroscopy (EIS) techniques with temperature ranging from 303 to 323 K. The concentrations of starch used were in the range of 0.1 to 0.8 g L^–1. The surface morphology studies were carried out using Scanning Electron Microscope, Energy Dispersive X-ray analysis, Atomic Force Microscope and X-ray Diffraction analysis techniques. Suitable mechanism was proposed for the corrosion and inhibition process. Results indicated increase in the efficiency of the inhibitor with its increase in the concentration and with temperature. Maximum inhibition efficiency of 84% was observed at 323 K for 0.8 g L^–1. Starch acted as a mixed inhibitor. Kinetic and thermodynamic studies showed that starch underwent chemical adsorption and obeyed Langmuir adsorption isotherm. Surface morphology studies confirmed the adsorption of inhibitor on the surface of metal matrix composite. Results obtained by potentiodynamic polarization method and electrochemical impedance spectroscopy method were in good agreement with one another.     

Chemical Stability and Biological Properties of Plasma-Sprayed CaO-SiO<Subscript>2</Subscript>-ZrO<Subscript>2</Subscript> Coatings

In this work, calcia-stabilized zirconia powders were coated by silica derived from tetraethoxysilane (TEOS) hydrolysis. After calcining at 1400 °C, decalcification of calcia-stabilized zirconia by silica occurred and powders composed of Ca₂SiO₄, ZrO₂, and CaZrO₃ were prepared. We produced three kinds of powders with different Ca₂SiO₄ contents [20 wt.% (denoted as CZS2), 40 wt.% (denoted as CZS4), and 60 wt.% (denoted as CZS6)]. The obtained powders were sprayed onto Ti-6Al-4V substrates using atmospheric plasma spraying. The microstructure of the powders and coatings were analyzed. The dissolution rates of the coatings were assessed by monitoring the ions release and mass losses after immersion in Tris-HCl buffer solution. Results showed that the chemical stability of the coatings were significantly improved compared with pure calcium silicate coatings, and increased with the increase of Zr contents. The CZS4 coating showed not only good apatite-formation ability in simulated body fluid, but also well attachment and proliferation capability for the canine bone marrow stem cells. Results presented here indicate that plasma-sprayed CZS4 coating has medium dissolution rate and good biological properties, suggesting its potential use as bone implants.     

Phase Stability of Ce-Modified La<Subscript>2</Subscript>Zr<Subscript>2</Subscript>O<Subscript>7</Subscript> Coatings and Chemical Compatibility with YSZ

Ce-modified La₂Zr₂O₇ powders, i.e., La₂Zr₂O₇ (LZ), La₂(Zr_0.7Ce_0.3)₂O₇ (LZ7C3), and La₂(Zr_0.3Ce_0.7)₂O₇ (LZ3C7), were used to produce thermal barrier coatings by atmospheric plasma spray process. The chemical compatibility of the CeO₂-doped La₂Zr₂O₇ with the traditional YSZ was investigated in LZ-YSZ powder mixtures and LZ-YSZ bilayer coatings by x-ray diffraction and scanning electron microscope. The powder mixtures and coatings were aged at 1200 and 1300 °C for 100 h. The results showed that LZ and LZ7C3 presented single pyrochlore structure after the heat treatments at both 1200 and 1300 °C. For LZ3C7, however, fluorite structure was observed at 1300 °C, indicating a poor phase stability of LZ3C7 at the elevated temperature. The results further showed that La₂(Zr_0.3Ce_0.7)₂O₇ reacted with YSZ in the bilayer ceramic coatings due to the diffusion of cerium, zirconium, and yttrium. While for La₂Zr₂O₇(LZ) and La₂(Zr_0.7Ce_0.3)₂O₇, a better chemical compatibility with YSZ was shown.