Microstructure and thermal expansion behavior of diamond/SiC/(Si) composites fabricated by reactive vapor infiltration

Diamond/SiC/(Si) composites were fabricated by Si vapor vacuum reactive infiltration. The coefficient of thermal expansion (CTE) of composites have been measured from 50 to 400 °C. With the diamond content increasing, CTE of composite decreased, simultaneously, the microstructure of the composites changed from core–shell particles embedded in the Si matrix to an interpenetrating network with the matrix. The CTEs of composites versus temperature matched well with those of Si. The Kerner model was modified according to the structural features of the composites, which exhibited more accurate predictions due to considering the core–shell structure of the composites. The thermal expansion behavior of the matrix was constrained by diamond/SiC network during heating.     

Effects of SiC content on mechanical,thermal and ablative properties of carbon/phenolic composites

Silicon carbide (SiC) particles were utilized to improve the mechanical, thermal and anti-ablative properties of carbon/phenolic (C/Ph) composites. SiC–C/Ph composites were fabricated with different weight percentage of SiC by vacuum impregnation method. The mechanical and thermal properties were characterized by compression tests, thermal conductivity tests, and thermogravimetric analysis; meanwhile, ablation resistance was investigated using plasma wind tunnel tests and scanning electron microscopy. Experimental results showed that 5 wt% SiC modified C/Ph composites owned the optimum properties. Moreover, introducing SiC particles could result in an obvious decrease of compression strength, but an increase of thermal stability, thermal conductivity and anti-ablative performance. Notably, the ablation rate reached its the lowest point at 5% the SiC content in resin matrix composites.     

Behavior of two-dimensional C/SiC composites subjected to thermal cycling in controlled environments

Thermal fatigue behavior of two-dimensional carbon fiber reinforced SiC matrix composites fabricated by chemical vapor infiltration technique was investigated using an on-line quench method in controlled environments which simulated an aero-engine gas. A system of damage information acquisition (SDIA) was developed to study changes in electrical resistance of the C/SiC composites during their damage in dynamic testing. Damage to composites was assessed by the ultimate tensile strength (UTS) and SEM characterization. The results showed that: (1) under different atmosphere, the 2D-C/SiC composites subjected to thermal cycling behaved very differently and the most sensitive atmosphere was the wet oxygen; (2) external load could accelerate the degradation of the composites and changed the oxidation regimes of fibers; (3) the electrical resistance of the specimen could be detected on-line, stored in real time and analyzed reliably by the newly-developed SDIA; (4) 2D-C/SiC composites had an excellent thermal fatigue resistance in different environments.     

Synthesis and thermal expansion of ZrO2/ZrW2O8 composites

In this work, a ceramic composite of ZrW₂O₈ and ZrO₂ was synthesized, in order to investigate the possibility of compensating the positive thermal expansion of ZrO₂ with the negative thermal expansion (NTE) compound ZrW₂O₈, tailoring the thermal expansion of these composites. The NTE material was mixed with varying amounts of ZrO₂. The thermal expansion coefficients of this series of composites decrease with increasing amounts of ZrW₂O₈. Nevertheless, a negative deviation from the values expected by the rule of mixtures was found to be most pronounced in the middle of the compositional region.     

Effect of thickness of SiC films on compression and thermal properties of SiC/CF composites

Commonly, carbon foam derived from commercially available melamine foam showed brittle characteristics. In this paper, the carbon foam was prepared via the direct carbonization of the melamine foam, and chemical vapor deposition was employed to deposit ultra-thin SiC films on the CF skeleton. The evolution, microstructure, mechanical strength, and thermal properties of the as-prepared SiC/CF composites were investigated. Test results showed that a novel SiC skeleton with a three-dimensional interconnected network was prepared successfully. The thickness of the SiC filmes had a significant influence on the compression and thermal properties of the composites. The SiC/CF-II possessed a higher compression performance than that of SiC/CF-I, while the thermal insulation was relatively much poorer. This present work had some reference meaning to the correlation studies of the thermal insulation material for the potential applications while bearing live loads.     

Micromechanical modeling of thermo-mechanical properties of high volume fraction particle-reinforced refractory composites using 3D Finite Element analysis

Previously, we have developed several particle-reinforced castable ceramic composites for refractory applications with exposure to thermal shock and measured their effective thermo-elastic properties experimentally. These composites contained silicon-carbide (SiC) solid particles, zirconia (ZrO₂) bubbles, and ZrO₂ solid particles, dispersed in an alumina (Al₂O₃) matrix. The present work aims to implement representative volume element (RVE) approach and periodic boundary condition (PBC) to accurately predict those properties, namely elastic and shear modulus, thermal conductivity, and coefficient of thermal expansion (CTE), using three-dimensional (3D) Finite Element (FE) simulations while accounting for the effect of porosity. In comparison to established micromechanical schemes and two-dimensional (2D) FE predictions, 3D FE simulations specifically show more accuracy in prediction of elastic properties and thermal conductivity. This novel and thorough comparison across various thermo-mechanical properties for complex microstructures (with up to three types of inclusions) can be valuable for designing comparable high volume fraction (VF) composites.     

Thermophysical properties of carbon/carbon composites and physical mechanism of thermal expansion and thermal conductivity

Five different carbon/carbon composites (C/C) have been prepared and their thermophysical properties studied. These were three needled carbon felts impregnated with pyrocarbons (PyC) of different microstructures, chopped fibers/resin carbon + PyC, and carbon cloth/PyC. The results show that the X-Y direction thermal expansion coefficient (CTE) is negative in the range 0-100 °C with values ranging from −0.29 to −0.85 × 10⁻⁶/K. In the range 0-900 °C, their CTE is also very low, and the CTE vs. T curves have almost the same slope. In the same temperature range composites prepared using chopped fibers show the smallest CTE values and those using the felts show the highest. The microstructure of the PyC has no obvious effect on the CTE for composites with the same preform architecture. Their expansion is mainly caused by atomic vibration, pore shrinkage and volatilization of water. However, the PyC structure has a large effect on thermal conductivity (TC) with rough laminar PyC giving the highest value and isotropic PyC giving the lowest. All five composites have a high TC, and values in the X-Y direction (25.6-174 W/m K) are much larger than in the Z direction (3.5-50 W/m K). Heat transmission in these composites is by phonon interaction and is related to the preform and PyC structures.     

A new multiscale modeling approach for the prediction of mechanical properties of polymer-based nanomaterials

A detailed knowledge about the physics and chemistry of multiphase materials on different length and time scales is essential to tailor their macroscopic physical and mechanical properties. A better understanding of these issues is also highly relevant to optimize their processing and, thus, their elucidation can be decisive for their final industrial application. In this paper, we develop a new multiscale modeling method, which combines the self-consistent field theory approach with the kinetic Monte Carlo method, to simulate the structural–dynamical evolution taking place in thermoplastic elastomers, where hard glassy and soft rubbery phases alternate. Since the early seventies, it is well established that the properties of the core nanophases in these multiphase materials considerably affect their overall mechanical properties. However, recent experimental studies have clearly demonstrated that, besides the efficient handling of the core nanophases, the appropriate treatment of their interfacial region is another major challenge one has to face on the way of target-oriented development of these materials. In this work, we set a particular focus on the complex structural–dynamical processes occurring at the interphases, and study their influence on the local structural and mechanical properties. To reach our objectives, we apply the new methodology on a thermoplastic elastomer composed of ABA triblock copolymers, subjected to a sizeable external perturbation, and determine its time-averaged internal stress and composition profile. We deduce from this investigation that, to obtain the correct local mechanical properties of these multiphase materials, their structure and dynamics need to be taken into account on an equal footing. Finally, our investigation also provides an explanation and confirms the importance of the chain-pullout mechanism in the viscoelastic and stress relaxation behavior of these materials.     

Effect of thermal residual stress on the tensile properties and damage process of C/SiC composites at high temperatures

Due to the mismatch of the thermal expansion coefficients between the matrix and yarns, thermal residual stress will appear in C/SiC composites. In this paper, a progressive damage model was used to predict the thermal-mechanical behavior of C/SiC composites and reveal the failure mechanism. Firstly, the properties of the composites under tensile load were tested at three different temperatures in vacuum. Then, the elastic-plastic progressive damage constitutive laws were used and implemented by a user-defined subroutine UMAT in ABAQUS. The thermal residual stress evolution in the cooling and heating processes was characterized. Finally, the stress-strain curves of the composites under tensile load at different temperatures were studied. The effects of thermal residual stress on the tensile properties and progressive damage process of C/SiC composites were revealed sequentially. This work can give design guidance for strengthening of C/SiC composites.     

A high-temperature structural and wave-absorbing SiC fiber reinforced Si3N4 matrix composites

The SiC_f/Si₃N₄ composite with low–high–low permittivity sandwich structure was designed for high-temperature electromagnetic (EM) wave absorption and mechanical stability. The SiC_f/Si₃N₄ possessed the remarkable mechanical properties at room temperature (the flexural strength is 357 ± 16 MPa and the fracture toughness is 10.8 ± 1.7 MPa m^1/2) for the strong fiber strength, moderate interface bonding strength and uniform matrix. Furthermore, the retention rate is as high as 80% at 800 °C. The A/B/C nanostructure and the sandwich meta-structure endowed the SiC_f/Si₃N₄ with an excellent EM absorbing property at room temperature. The SiC_f/Si₃N₄ still absorbed 75% of the incident EM waves energy in X and Ku bands when the temperature increases up to 600 °C, which is only 6% lower than that at room temperature, for the partial compensation of the decreased interfacial polarization loss for the increased conductivity loss and dipole polarization loss.     

Effect of polypyrrole deposition of carbon fiber on the thermal expansion of carbon fiber-epoxy composites

Polypyrrole (PPy) was deposited onto carbon fibers via continuous electrochemical deposition (ECD). Composites of PPy-deposited carbon fiber and epoxy were prepared. The thermal expansion coefficients of these materials were determined using either a thermal mechanical analyzer or an imbeded strain gauge. The results show that PPy has a negative thermal expansion coefficient while carbon fiber and epoxy have positive thermal expansion coefficients. The resulting composite has a smaller thermal expansion coefficient, higher interlaminar shear stress and a smaller critical fiber length than the composite using untreated carbon fiber. This suggests that the deposition of PPy can effect an improvement in the fiber-matrix interfacial bonding of the composite.     

Effects of zirconium carbide content on thermal stability and ablation properties of carbon/phenolic composites

Ceramic particles were utilized to improve thermal stability and ablation properties of carbon/phenolic (C/Ph) composites. In this study, zirconium carbide (ZrC) modified C/Ph composites were fabricated by vacuum impregnation method, and effects of ZrC content on thermal stability and ablation properties were investigated by thermogravimetry analysis and plasma wind tunnel test. Moreover, morphological characterization was carried out using X-ray diffraction, scanning electron microscopy and energy dispersive X-ray spectroscopy. Experimental results showed that increasing ZrC content could lead to an evident increase in char yield, but an observable reduction in linear ablation rates and back-face temperatures because of the formation of ZrO₂ layer on the ablation surface. The work provided an effective way to improve thermal stability and ablation properties of C/Ph composites.     

Multiscale thermal modeling of cured cycloaliphatic epoxy/carbon fiber composites

Cycloaliphatic epoxies (CEs) are commonly used for structural applications requiring improved resistance to elevated temperatures, UV radiation, and moisture relative to other epoxy materials. Accurate and efficient computational models can greatly facilitate the development of CE‐based composite materials for applications such as Aluminum Conductor Composite Core high‐voltage power lines. In this study, a new multiscale modeling method is developed for CE resins and composite materials to efficiently predict thermal properties (glass‐transition temperature, thermal expansion coefficient, and thermal conductivity). The predictions are compared to experimental data, and the results indicate that the multiscale modeling method can accurately predict thermal properties for CE‐based materials. For 85% crosslink densities, the predicted glass‐transition temperature, thermal expansion coefficient, and thermal conductivity are 279 °C, 109 ppm °C^?1, 0.24 W m^?1 K^?1, respectively. Thus, this multiscale modeling method can be used for the future development of improved CE composite materials for thermal applications. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci. 2018 , 135, 46371.     

Thermal diffusivity of 3D C/SiC composites from room temperature to 1400 °C

A 3D C/SiC composite and a bulk CVD SiC material were prepared. The effects of the CVD SiC coating and the heat treatment on the longitudinal and transverse thermal diffusivity of the C/SiC composites were investigated. The thermal diffusivity of the C/SiC composites could be well fitted by a multinomial function from room temperature to 1400 °C which includes a power term, an exponential term and a constant term. The exponential term affected the thermal diffusivity and led to its increase above 1200 °C with activation energy of 77 kcal/mol. The microstructure change in the composites was the reason that the thermal diffusivity was increased above 1200 °C. The longitudinal thermal diffusivity of the composite was twice or more than the transverse one and increased more rapidly by the exponential term. The former was decreased by the CVD SiC coating, but the latter was increased by it. The heat treatment could increase the thermal diffusivity and make the exponential term disappeared in the functions. The functional curve before the treatment intersected that after the treatment at the treatment temperature.     

Properties of polyphenylene sulphide/glass fibre composites with negative thermal expansion ceramic fillers

The high coefficient of thermal expansion (CTE) of polymeric composites can cause large deformation under temperature changes, affecting coupling with devices made of other materials in radio frequency (RF) communication systems and limiting their application in RF systems. In order to obtain polyphenylene sulphide (PPS)-based composites with low CTE, a series of PPS-based composites containing different loadings of ceramic powders (including Zr₂WP₂O₁₂, BN, AlN, Al₂O₃) were fabricated by melt extrusion method using PPS with 40 wt% glass fibre (GF) as matrix material. The experimental results showed that the PPS composites with Zr₂WP₂O₁₂ (ZWP) as a filler had a lower CTE compared to the samples with other fillers at the same filler loading. The CTE of PPS/GF/ZWP steadily decreased with increasing ZWP addition. At 20 vol% ZWP loading, a 67% (about 18 ppm/°C) reduction of CTE compared to the PPS/GF was achieved. The addition of ZWP powder to PPS/GF also led to an improvement in the dielectric loss of the composite. When the ZWP content is 20 vol%, the dielectric loss of the composites is about 0.0035, which is 24.4% lower than PPS/GF. Hence, the PPS/GF/ZWP composites have great potential for applications in RF communication systems.     

Enhancing thermal conductivity of C/SiC composites containing heat transfer channels

In this study, CNTs/SiC micro-pillars at controlled content ratios were introduced into C/SiC composites as heat transfer channels to improve the thermal conductivity in the thickness direction. The thermal conductivities and bending strengths before and after heat treatment at 1650 °C were investigated and the results were discussed. The theoretical calculations and finite element analyses confirmed that CNTs/SiC micro-pillars successfully worked as heat transfer channels. The theoretical thermal conductivity calculated by effective medium theory (EMT) model was 19.25 W/m⋅k and agreed-well with the experimental value. The measured thermal conductivity was estimated to 20.69 W/m⋅k and improved to 22.36 W/m⋅k after heat treatment. The latter was 3.56-fold higher than that of traditional C/SiC and attributed to increased grain growth during heat treatment. The optimal bending strength before heat treatment was recorded as 324.5 ± 23.74 MPa due to microstructure evolution caused by CNTs. After heat treatment, the bending strength improved by 138 % with ductile fracture mode attributed to ordered layer structure of PyC interphase and complex phase composition of the composites. These features benefited the abundant propagation of cracks and energy consumption. In sum, introduction of heat transfer channels into C/SiC composites provided a new way to improve the thermal conductivity in thickness direction of ceramic matrix composites.     

Properties and microstructure of graphitised ZrC/C or SiC/C composites

Doped graphites were prepared from calcined coke, coal-tar pitch and dopants (Zr, Si and Si-Zr) by hot-pressing in order to investigate the effects of the composition and amount of dopants on their thermal conductivity, electrical resistivity, bending strength and microstructure. Experimental results showed that the single element (Zr or Si) and bi-element (Si-Zr) graphitised doped-carbons exhibited highly improved conductivity, but the bending strength is lower in the case of Si-doped graphite. Microstructure analyses showed that the d₀₀₂ spacing decreased with the increasing dopant concentration for the single element (Zr or Si) doped graphite. From this result, it is inferred that the degree of graphitization increased. The thermal conductivity of a (9% Zr, 2% Si) graphitised doped-carbons is 380 W m⁻¹ K⁻¹. Correlations between the composition and content of dopants and the microstructure of doped graphite are tentatively discussed.