Influence of alumina content to mechanical properties and electric discharge machinability of zirconia (1.5Y-1.5Nd-TZP)-tungsten carbide-alumina composites

Composites of yttria neodymia co-stabilized zirconia, 24–32 vol% nanoscale tungsten carbide and 0.5–10 vol% alumina were manufactured by hot pressing and characterized in terms of mechanical properties, phase composition, microstructure and electric discharge machinability. Addition of 10 vol% alumina leads to an increase in hardness and Young’s modulus and an in average slightly higher bending strength. The transformability of the zirconia matrix and thereby fracture toughness is reduced by alumina addition. In EDM alumina reduces the thickness of the re-solidified layer, reduces surface defects and leads to smoother surfaces especially at high discharge currents, the effect on material removal rate is negligible.     

High-entropy carbide-based ceramic cutting tools

In this study, a novel high-entropy carbide-based ceramic cutting tool was developed. The cutting performance of three kinds of high-entropy carbide-based ceramic tools with different mechanical properties for the ISO C45E4 steel were evaluated. Although the pure (Ti_0.2Zr_0.2Nb_0.2Ta_0.2Mo_0.2)C_0.8 ceramic cutting tool exhibited the highest hardness of 25.06 ± 0.32 GPa, the cutting performance was poor due to the chipping and catastrophic failure caused by the low toughness (2.25 ± 0.27 MPa m^1/2). The (Ti_0.2Zr_0.2Nb_0.2Ta_0.2Mo_0.2)C_0.8–15 vol% cobalt cutting tool with highest fracture toughness (6.37 ± 0.24 MPa m^1/2) and lowest hardness (17.29 ± 0.79 GPa) showed the medium cutting performance due to the low wear resistance caused by the low hardness. The (Ti_0.2Zr_0.2Nb_0.2Ta_0.2Mo_0.2)C_0.8–7.7 vol% cobalt cutting tool showed the longest effective cutting life of ∼67 min due to the high wear resistance and chipping resistance caused by the high hardness (21.05 ± 0.72 GPa), high toughness (5.35 ± 0.51 MPa m^1/2), and fine grain size (0.60 ± 0.15 μm). The wear mechanisms of the cobalt-containing (Ti_0.2Zr_0.2Nb_0.2Ta_0.2Mo_0.2)C_0.8 ceramic cutting tools included adhesive wear and abrasive wear and oxidative wear. This research indicated that the high-entropy carbide-based ceramics with high hardness and high toughness have potential use in the field of cutting tool application.     

High-temperature silicon carbide material with wicking and evaporative cooling functionalities fabricated by femtosecond laser surface nano/microstructuring

A multifunctional silicon carbide (6H–SiC) material with efficient wicking and evaporative cooling performances in a temperature range of 23–180 °C is created through hierarchical surface nano/microstructuring by a femtosecond laser. The elaborated hierarchical surface structure is an array of nanotextured microgrooves that includes structural features in a range between about 15 nm and 140 μm, integrating benefits from micro- and nanoscale physics of capillarity and thermodynamics. The spatiotemporal dynamics of both water spreading and temperature field obtained by optical and infrared imaging show the excellent wicking and evaporative cooling functionalities of the created material. The range of applications of the developed multifunctional 6H–SiC material includes the technologies for enhancing power generation efficiency, waste heat recovery, and cooling high-heat-flux Si- and SiC-based electronic devices. The application of the created material in cooling technologies for power generation can result in substantial fuel savings and global reduction in greenhouse gas emissions.     

Tribological behaviors of FeCoNiCrAlx sliding against Si3N4 ceramics under high temperature condition

Tribological behaviors are system responses that not only depend on material properties but also hinge on external environmental factors. This work investigated the tribological behaviors of FeCoNiCrAl_x (x = 0.1, 0.5, 1) sliding against Si₃N₄ ceramics under high temperature conditions. According to experimental findings, the tribological properties of FeCoNiCrAl_x were enhanced as the Al element content increased, particularly FeCoNiCrAl₁ could resist the material softening under high-temperature conditions to enhance the wear resistance. Based on the friction coefficient changes, wear morphology, phase composition, and chemistry element, the high-temperature wear mechanisms of FeCoNiCrAl_x were discussed including adhesive, attrition, and oxidative wear. These new studies will lead to the further improvement of tribological data of high-entropy alloys.     

Stress rupture of SiC/SiC composite tubes under high-temperature steam

SiC-fiber–reinforced SiC matrix composite cladding for light water reactor fuel elements must withstand high-temperature steam oxidation in a loss-of-coolant accident scenario (LOCA). Current composite designs include an outer monolithic SiC layer, in part, to increase steam oxidation resistance. However, it is not clear how such a structure would behave under high-temperature steam in the case when the monolithic layer cracks and carbon interphases and SiC fibers are exposed to the environment. To fill this knowledge gap, stress-rupture tests of prototypic SiC composite cladding at 1000°C under steam and inert environments were conducted. The applied stress was ∼120 MPa, which was beyond the initial cracking stress. The failure lifetime under steam was 400–1300 s, while 75% of the composite specimens did not fail after 3 h of total exposure under inert gases. Microstructural observations suggest that steam oxidation activated slow crack growth in the fibers, which led to failure of the composite. The results from this study suggest that stress rupture in steam environments could be a limiting factor of the cladding under reactor LOCA conditions.     

B4C reinforced NiTi-based composites: Microstructure and wear performance

In this study, NiTi–x wt.% B₄C (x = 0, 2, and 4) composites were consolidated with spark plasma sintering method, and the effects of boron carbide reinforcement addition on the microstructure and wear behavior of samples were investigated. Identification of the constituent phases of samples by the X-ray diffraction method plus Rietveld analysis revealed that the stability of the martensite phase increased in the composite samples because of mismatch stresses between the NiTi matrix phase and the reinforcing particles, which increases the density of the dislocations and facilitates the diffusion process that subsequently leads to the formation of stable intermetallics. The results of hardness test indicated that the hardness value increased from 3.67 GPa for pure NiTi to 10.99 GPa for NiTi–4 wt.% B₄C. Results of wear test revealed that boron carbide reinforced composite specimens had higher wear resistance, whereas wear rate of NiTi sample was 3.6 × 10⁻³ mm³/N m, and it reached to .21 × 10⁻³ mm³/N m for NiTi–4 wt.% B₄C. Investigation of microstructure by scanning electron microscopy images and EDS analysis revealed that the wear mechanism in NiTi samples was abrasive and the addition of B₄C to NiTi changed the wear mechanisms from abrasive to a combination of oxidation, adhesive, and delamination mechanisms.     

Evaluation of tribological behavior of silicon carbide and silicon nitride ceramics under different conditions

A comparative analysis of the tribological behavior of commercially available sintered silicon carbide (SiC) and three different types of silicon nitride (Si₃N₄) ceramics have been carried out using the ball-on-disk method in dry and lubrication (deionized [DI] water and ethanol) environment. Scanning electron microscopy (SEM) was used to understand the morphology and chemical composition of the tribo-surfaces. Sintered SiC (Hexoloy-SA) had the highest friction coefficient during dry sliding with an average of ∼0.34. Deionized water showed a minor improvement in friction (∼0.27) while ethanol reduced the friction greatly to ∼0.18 compared to dry sliding. During dry sliding, the presence of an abrasive third body was responsible for the high wear rates (WRs) in these compositions. Hexoloy-SA showed a lower WR during ethanol and DI water lubrication due to the formation of stable tribofilms as well as higher hardness which resisted the formation of third bodies. In comparison, Si₃N₄ samples showed a lower WR in DI water and ethanol. The samples also showed composition-dependent behavior which indicates that grain structure and grain boundary chemistry are playing a vital role in the tribological process.     

Spark plasma sintering of boron nitride micron tubes reinforced boron carbide ceramics with excellent mechanical property

In this paper, the novel boron nitride micron tubes (BNMTs) were used to reinforce commercial boron carbide (B₄C) ceramics prepared via spark plasma sintering technology. The effects of the sintering parameters, sintering temperature, the holding time, and the BNMTs content on the microstructure and mechanical properties of B₄C/BNMTs composite ceramics were studied. The results indicated that adding a proper amount of BNMTs could inhibit the grain growth of B₄C and improve the fracture toughness of the B₄C/BNMTs composite ceramics. The prepared composite ceramic sample with 5 wt% BNMTs at 1850°C, 8 min and 30 MPa displayed the best mechanical properties. The relative density, hardness, fracture toughness, and bending strength of the samples were 99.7% ± .1%, 35.62 ± .43 GPa, 6.23 ± .2 MPa m^1/2, and 517 ± 7.8 MPa, respectively. Therein, the corresponding value of hardness, fracture toughness, and bending strength was increased by 10.3%, 43.59%, and 61.5%, respectively, than that of the B₄C/BNMTs composite ceramic without BNMTs. It was proved that the high interface binding energy and bridging effect between boron carbide and BNMTs were the toughening principle of BNMTs.     

Mechanical properties of B4C–CrB2 binary eutectic composites prepared by arc-melting

B₄C–CrB₂ composites were prepared by arc-melting using B₄C and CrB₂ powders as raw materials. The eutectic composition of B₄C–CrB₂ system was 30B₄C–70CrB₂ (mol%) with a labyrinth-like irregularly layered eutectic microstructure, composed of B₄C phase about 1–2 μm in thickness dispersing in CrB₂ matrix, much smaller than raw powders. The interface of the eutectic composite was well bonded, and there were edge dislocations at the interface to alleviate the interface mismatch. The eutectic temperature of B₄C–CrB₂ composites was approximately 2200 K. At the eutectic composition, the B₄C–CrB₂ composites showed the maximum Vickers hardness (24.6 GPa) and fracture toughness (4.3 MPa m^1/2) at room temperature.     

Effect of BN nanoparticle content in SiC matrix on microstructure and mechanical properties of SiC/SiC composites

BN-nanoparticle-containing SiC-matrix-based composites comprising SiC fibers and lacking a fiber/matrix interface (SiC/BN + SiC composites) were fabricated by spark plasma sintering (SPS) at 1800°C for 10 min under 50 MPa in Ar. The content of added BN nanoparticles was varied from 0 to 50 vol.%. The mechanical properties of the SiC/BN + SiC composites were investigated thoroughly. The SiC/BN + SiC composites with a BN nanoparticle content of 50 vol.%, which had a bulk density of 2.73 g/cm³ and an open porosity of 5.8%, exhibited quasiductile fracture behavior, as indicated by a short nonlinear region and significantly shorter fiber pullouts owing to the relatively high modulus. The composites also exhibited high strength as well as bending, proportional limit stress, and ultimate tensile strength values of 496 ± 13, 251 ± 30, and 301 MPa ± 56 MPa, respectively, under ambient conditions. The SiC fibers with contents of BN nanoparticles above 30 vol.% were not severely damaged during SPS and adhered to the matrix to form a relatively weak fiber/matrix interface.