Residual stresses in alumina–zirconia laminates

Significant residual stresses can arise in hybrid ceramic laminates during the densification and cooling processing cycles. The densification stresses in alumina–zirconia laminates were calculated assuming the layers to be linear viscous with data obtained by cyclic loading dilatometry. These stresses placed the zirconia layers in biaxial tension and even at 1 MPa or less, they were sufficient to cause a type of linear cavitation damage. The methodology was also applied to asymmetric laminates, successfully predicting their observed curling behaviour. Thermal expansion mismatch stresses arise during cooling, again placing the zirconia layers in residual biaxial tension and leading to the formation of transverse (channelling) cracks. The stresses were calculated using both elastic and viscoelastic formulations and were confirmed with indentation measurements. Additions of alumina to the zirconia layers were effective in reducing both sources of residual stress and allowed crack formation during processing to be avoided. Residual stresses were also shown to improve mechanical performance.     

Thermal expansion of β-eucryptite in oxide-based ceramic composites

This paper presents an experimental investigation on the thermal expansion behaviour of β-eucryptite (E) when it is used for processing alumina/β-eucryptite (AE) or zirconia/β-eucryptite (ZE) composites. Composite materials were prepared from a β-eucryptite powder synthetised in our laboratory and commercially available alumina or zirconia nanopowders. In order to preserve the β-eucryptite crystalline phase in sintered materials, the pressureless sintered step was performed at relatively low temperatures (<1300 °C). It is experimentally shown that in well-densified oxide-based composites, the β-eucryptite lost its slightly negative thermal expansion coefficient. This behaviour could be related to compressive residual stresses applied on β-eucryptite grains due to the thermal expansion mismatch between alumina or zirconia and the β-eucryptite.     

Thermal Expansion Mismatch Analysis of Nano‐bonded Refractory Castables

A mathematical model to predict the thermomechanical stresses was used to understand the expansion mismatch damage in castables, evaluated by hot elastic modulus measurements. The results indicated that via elastic modulus evaluation and the tensile stress calculation, the critical interactions among the particles leading to the formation of flaws were identified. To assure the materials' integrity, it is fundamental to keep a low Δα between the components and not only a low overall linear thermal expansion coefficient. For multicomponent compositions, a second‐phase raw material with different properties should be added as finer particles to minimize the thermomechanical stresses generated.     

Thermal shock behaviour of laminated multilayer refractories for steel casting applications reinforced by residual stresses

Ceramic multilayer structures based on tape cast alumina and zirconia substrates have been manufactured for use as carbon-free refractory materials. The laminates were reinforced via residual stresses due to shrinkage mismatch or differences in thermal expansion in order to achieve an improved thermal cycling capability. Thermal shock tests have been carried out using a plasma test stand. The impact of layer sequence and residual stresses has been demonstrated via measurement of Young's modulus and microstructure images of the layered structures. Hasselman parameters as well as the crack propagation behaviour at interfaces have been analysed via wedge splitting test.     

Mechanical properties and microstructures of reaction sintered mullite–zirconia composites in the presence of an additive — dysprosia

Mullite–zirconia composites were prepared from Indian zircon flour and calcined alumina following the reaction sintering route. Zircon flour and calcined alumina with 0–4.5 mol% dysprosium oxide were attrition milled followed by isostatic pressing and sintering at 1400–1650°C for 2 h. Significant densification was achieved after dysprosia addition as an additive. The thermal expansion coefficient values were found to be reduced in the presence of dysprosia. Dysprosia helps in densification by liquid phase formation as well as by stabilisastion in tetragonal zirconia state. The thermo-mechanical and microstructural characteristics of the composites were discussed.     

Preparation of C/SiC Composites by Hot Pressing, Using Different C Fiber Content as Reinforcement

Unidirectional C/SiC composites were successfully prepared by hot pressing at 1850°C under 20 MPa, using different fiber volume fractions (from 28 vol% to 55 vol%) as reinforcement. The densification process of the composites became increasingly difficult with increasing fiber volume fraction, and some small pores were still distributed in the intrabundle regions of the composites. The cracks, resulting from the residual thermal stress in the composites due to the mismatch of the thermal expansion coefficient of the matrix and the fiber, were distributed in the matrix. With the increase of fiber content, the mechanical properties of the composites could be improved and the composites exhibited an obvious noncatastrophic fracture behavior due to a decrease in the thermal residual stress and an increase in the fiber pull outs.     

Strength and Toughness of Continuous-Alumina-Fiber-Reinforced Glass-Matrix Composites

Unidirectional, continuous-fiber composites were fabricated using polycrystalline alumina fibers and four different silicate glass matrices of differing thermal expansion. Fracture toughness measurements, strength measurements, and fractographic analysis of failed specimens are used to identify the failure mechanism. Results show that the elastic modulus mismatch between the matrix and the fibers shields the reinforcing fibers from matrix crack extension, thereby increasing composite toughness without fiber pullout. Fractographic analysis shows that fiber shielding leads to fiber failure ahead of matrix crack. Composite toughness increases linearly with increases in the residual compressive stress in the matrix phase. Ultimate composite strengths are dependent upon thermal-expansion-induced residual stresses and fiber strength.     

Edge Stresses in Alumina/Zirconia Laminates

Using the technique of fluorescence piezospectroscopy, we determine the distribution of thermal residual stresses across the edges of three laminated alumina/zirconia composites. We develop a methodology for separating the measured stress state into microstresses that result from grain-to-grain thermal mismatch and macrostresses that result from lamination-induced thermal mismatch between individual plies. Comparison between the measured edge-stress distributions and those calculated based on a simple force-superposition model shows good agreement, indicating that the laminate system is well approximated as linear elastic. Given the experimental confirmation of significant edge stresses in multi-ply laminates, the possibility of failure initiating at composite edges must be considered in the design of surface-compressed laminate structures with the aim of mediating the detrimental effect of surface flaws.     

Stresses developed in reaction-bonded ceramics

A physical model is presented that predicts the stress distribution created in a particle during its reaction with a surrounding reactant to form a uniform layer of reaction product on its surface, when the reaction involves a volume change. The results of the model are applied specifically to the case of silicon reacting with nitrogen to form Si₃N₄. The model predicts the generation of a high, tensile hydrostatic stress in the Si core as well as high tensile radial stress and compressive tangential stress in the nitride layer. Although the model is restricted to elastic deformation only and therefore predicts unrealistically high stresses in some cases, the results are anyway of relevance in the consideration of possible non-elastic processes such as creep and fracture and also in assessing the possible effect of stress on the reaction equilibrium. It is predicted that the nitride reaction layer would fracture during the nitridation process. A second model is also presented predicting the residual stresses arising during cooling of a partially reacted particle as a result of the difference in thermal expansion of the reactant core and the reaction product layer. In the case of the reaction of silicon to silicon nitride these thermal expansion mismatch stresses are significant but small compared to the stresses due to the chemical reaction. ©     

Effect of bimodal pores on sintering and residual stresses of YSZ membranes prepared by non-solvent induced phase separation method

Densification mismatch and residual stresses of tri-layered yttria-stabilized zirconia (YSZ) membranes prepared by a non-solvent induced phase separation (NIPS) method were investigated. The tri-layered membrane consisted of sponge-like structures and finger-like voids in macroscale. The densification of the two structures were characterized to elaborate their contribution to the densification mismatch, which led to residual stresses of hundreds of megapascal retained in the sintered membranes. The profile of residual stress suggested that it was related to the strain rate mismatch within the NIPS membranes, which was further quantified with an in-situ monitored camber evolution.     

Experimental Observations of Substrate Fracture Caused by Residually Stressed Films

Model systems for studying thin-film cracking consisting of thin plates of alumina and soda-lime glass were diffusion bonded to silica substrates at high temperature. Upon slow cooling, substrate fracture was induced by residual stresses from the thermal and elastic mismatch of the film and substrate. In particular, multiple substrate cracks formed parallel to the interface. The observed crack paths closely followed predictions based on a zero mode II stress intensity. Crack depths were found to be strongly dependent on the relative substrate thickness and the Young's modulus ratio.     

Residual-Stress-Induced Grain Pullout in a 96% Alumina

A comparison of the surface and bulk microstructures of two 96% aluminas indicates that the residual stresses arising from thermal expansion mismatch created by crystallization of the amorphous boundary phase, when combined with stresses created during grinding, can lead to excessive pullout of the alumina grains. However, neither source of residual stress is, by itself, sufficient to cause such pullout. Residual stresses resulting from crystallization of the boundary glass are expected to play a significant role in determining the abrasive wear resistance of these materials.     

Constrained Densification of Alumina/Zirconia Hybrid Laminates, II: Viscoelastic Stress Computation

To analyze the inhibited densification during sintering and differential shrinkage during cooling of Al₂O₃/ZrO₂symmetric and asymmetric laminates, viscoelastic formulations, in which the viscosity and elastic modulus vary with time, have been developed. The viscoelastic mismatch stresses have been numerically computed over the entire processing cycle, including the heating period, the isothermal period, and the cooling period. The viscosity and free sintering rates that are needed for stress computation have been obtained by modifying the parameters that are measured for a normal isotropic densifying compact using cyclic loading dilatometry. The modification is based on the available sintering models to account for the effect of strain history on compact viscosity and sintering rates. The stress calculation shows that, with the exception of the initial heating period, the viscoelastic stress is identical to the viscous stress that is calculated solely from the strain rate mismatch. Sintering damage in the laminates is shown to occur during densification under conditions where the differential sintering stress is smaller than the intrinsic sintering pressure. The magnitude of residual stress in hybrid laminates on cooling is dependent on the cooling rate, and slower cooling rates are capable of almost completely relaxing the expansion mismatch stress at temperatures of >1200°C.     

Effect of weathering on the stress distribution and mechanical performance of automotive paint systems

The sources of stress in complete automative paint systems have been identified and measured as a function of weathering. In addition to the stresses developed during cure, the main sources of stresses developed during exposure are thermal expansion coefficient mismatch, humidity expansion mismatch, and densification of the clearcoat. Stresses generally increase during weathering due to a slow densification of the clearcoat and increasing water absorption and desorption stresses. Finite element analysis (FEA) was used to compute the stress distribution in full paint systems. Stresses are typically in-plane and highest in the primer and clearcoat. Stresses approaching those required to propagate cracks can be attained in weathered paint systems. The presence of flaws, either cracks or incipient delaminations, will lead to large stress concentrations that can give rise to peeling forces not present in coatings without cracks. 20000 Rotunda Dr., P.O. Box 2053, MD 3135 JRL, Dearborn, MI 48121.     

Effect of Interlayers in Ceramic-Metal Joints with Thermal Expansion Mismatches

The internal stress resulting from the thermal expansion mismatch between alumina and steel with and without an interlayer was evaluated. On the basis of the calculation, alumina and steel were bonded using the interlayer method and hot isostatic pressing at 1273 to 1573 K under 100 MPa for 30 min. When a laminated interlayer (niobiumlmolybdenum) was used, a joint with high bonding strength was obtained.     

Calculation of residual stresses in amorphous wires

The residual internal stresses in a cylindrical wire produced in the rotating-water melt spinning process and a coated wire obtained by drawing from a melt have been calculated within the thermal viscoelasticity and structural relaxation theories. The coated wire consists of the core and the sheath with different thermal properties. The problem is considered with allowance made for the generation and the relaxation of stresses in the core and the sheath in the temperature range from initial (corresponding to the liquid state of a two-layer wire) to room temperature. The distributions of the residual stresses have been calculated for the free amorphous metallic wire and the amorphous wire with the sheath having a different elastic modulus and thermal expansion coefficient. The influence of preparation conditions and thermal properties of materials on the calculated parameters is analyzed.     

Calculation of residual stresses in amorphous wires

The residual internal stresses in a cylindrical wire produced in the rotating-water melt spinning process and a coated wire obtained by drawing from a melt have been calculated within the thermal viscoelasticity and structural relaxation theories. The coated wire consists of the core and the sheath with different thermal properties. The problem is considered with allowance made for the generation and the relaxation of stresses in the core and the sheath in the temperature range from initial (corresponding to the liquid state of a two-layer wire) to room temperature. The distributions of the residual stresses have been calculated for the free amorphous metallic wire and the amorphous wire with the sheath having a different elastic modulus and thermal expansion coefficient. The influence of preparation conditions and thermal properties of materials on the calculated parameters is analyzed.     

Delayed curvature and residual stresses in porcelain tiles

Most industrial porcelain tiles suffer changes in their curvature after firing: such process is known as delayed curvature. One of the hypotheses used to explain this phenomenon is based on the relaxation of residual stresses by creep. In this study two types of industrial glazed porcelain tiles have been studied. One of them displayed delayed curvature after firing, whereas the other one presented a stable curvature. The main objective was to determine if the delayed curvatures were caused by the residual stresses generated during rapid industrial cooling. Both types of existing residual stresses (thermal stresses, caused by thermal gradients inside the tile during cooling, and body–glaze fit stresses, due to the thermal expansion mismatch between body and glaze) were measured, as well as related samples properties (elastic modulus, creep behaviour, thermal expansion). The results demonstrated that the residual stresses are not the main cause of the delayed curvature phenomenon.     

Thermal residual stress gradients in an alumina–zirconia composite obtained by electrophoretic deposition

In order to understand the mechanical behavior of layered composites with compositional gradient, it is necessary to determine their state of residual stresses. Compositionally graded materials can offer the advantage of eliminating abrupt changes in composition between layers having different thermal expansion coefficient. The existence of a compositional gradient can reduce discontinuities in thermal residual stresses, something beneficial from the point of view of the mechanical properties.We present here a study of the microstructure and state of residual stressses in a layered material made of homogeneous layers of alumina and alumina–zirconia separated by thin (less than 300 μm) intermediate compositionally graded layers. The composite was obtained by controlled deposition of powders from solution using an electrophoretic deposition (EPD) method. The phase distribution and compositional gradient in the sintered composite were investigated using scanning electron microscopy (SEM). Thermal residual stresses generated during cooling after sintering were measured by using fluorescence ruby luminiscence piezo-spectroscopy and the profile of hydrostatic stress on alumina was determined at steps of about 300 μm along the direction of the compositional gradient, and at steps of about 30 μm in the compositionally graded layers. The obtained profile of hydrostatic stresses on alumina grains follows closely the profile of compositional changes along the layered composite. The presence of thin intermediate graded layers reduce significantly changes in stress in the layered composite.     

Finite Element Simulation of Thermal Residual Stresses in Joining Ceramics with Thin Metal Interlayers

Finite element analysis was used to estimate thermal residual stresses developed in silicon nitride bodies bonded by metallic interlayers. Stresses were calculated for various characteristic metals, namely, Ni, Al, and Si, assuming elastic and elastic-plastic behavior. The relative importance of the metal properties, such as thermal expansion coefficient, stiffness and ductility, has been evaluated. Two different joint geometries, butt and lap, have been used in stress calculations, and special care was taken in the mesh generation, to obtain comparable results. The yield stress of the interlayer material rather than thermal expansion mismatch is the critical factor in thermal residual tensile stress buildup inside ceramic adherents.