Precipitous weakening of quartz at the α–β phase inversion

Crystalline quartz has long been identified as among the weakest of abundant crustal minerals. This weakness is particularly evident around the α–β phase inversion at 573°C, in which Si–O bonds undergo a displacive structural transformation from trigonal to hexagonal symmetry. Here we present data using indentation testing methodologies that highlight the precipitous extent of the transformational weakening. Although the indentations are localized over relatively small specimen contact areas, the data quantify the essential deformation and fracture properties of quartz in a predominantly (but not exclusively) compressive stress field, at temperatures and pressures pertinent to conditions in the earth's crust.     

In Situ Processing of Silicon Carbide Layer Structures

A novel route to low-cost processing of silicon carbide (SiC) layer structures is desribed. The processing involves pressureless liquid-phase cosintering of compacted power layers of SiC, containing alumina (Al₂O₃) and yttria (Y₂O₃ sintering additives to yield and yttrium aluminum garnet (YAG) second phase. By adjusting the β:α SiC phase ratios in the individual starting powders, alternate layers with distinctively different microstructures are produced: (i) "homogeneous" microstructures, with fine equiaxed SiC grains, designed for high strength; and (ii) "heterogeneous: microstructures with coarse and elongate SiC grains, designed for high toughness. By virtue of the common SiC and YAG phases, the interlayer interfaces are chemically compatible and strongly bonded. Exploratory Hertzian indetation tests across a bilayer interface confirm the capacity of the tough heterogeneous layer to inhibit potentially dangerous cracks propagating through the homogeneous layer. The potential for application of this novel processing approach to other layer architectures and other ceramic systems is considered.     

The effect of high energy milling on the catalytic behaviour of manganese dioxide

A technique of dry high energy milling has been used to increase the catalytic activity of naturally occurring manganese dioxide powder. The effect of the basic milling parameters (ball charge, milling time and milling atmosphere) has been examined. The subsequent catalytic activity of the manganese dioxide powder has been assessed by quantitative measurement of the oxidation of carbon monoxide over a range of temperatures. A surface area increase alone did not explain the results, and hence a change in defect structure is suspected. The activity of a high purity synthetic manganese dioxide powder was reduced by the milling treatment.     

Fracture mechanics model for subthreshold indentation flaws

A fracture mechanics model for subthreshold indentation flaws is. described. The model describes the initiation and extension of a microcrack from a discrete deformation-induced shear fault (shear crack) within the contact zone. A stress-intensity factor analysis for the microcrack extension in residual-contact and applied-stress fields is used in conjunction with appropriate fracture conditions, equilibrium in Part I and non-equilibrium in Part II, to determine critical instability configurations.In Part I, the K-field relations are used in conjunction with the Griffith requirements for crack equilibrium in essentially inert environments to determine: (i) the critical indentation size (or load) for spontaneous radial crack pop-in from a critical shear fault under the action of residual stresses alone; (ii) the inert strengths of surfaces with subthreshold or postthreshold flaws. The theory is fitted to literature data for silicate glasses. These fits are used to calibrate dimensionless parameters in the fracture mechanics expressions, for later use in Part II. The universality of the analysis in its facility to predict the main features of crack initiation and propagation in residual and applied fields will be demonstrated. Special emphasis is placed on the capacity to account for the significant increase in strength (and associated scatter) observed on passing from the postthreshold to the subthreshold domain.     

Correlations between flaw tolerance and reliability in zirconia

Interrelations between flaw tolerance and reliability in Y-TZP, Ce-TZP and Mg-PSZ ceramics are investigated. Indentation-strength tests indicate an enhanced flaw tolerance with increasing R-curve behaviour from tetragonal martensite transformation. The Weibull modulus of unindented specimens increases with the enhanced tolerance. However, even the most tolerant zirconias show persistent scatter in strength, implying that variability in material microstructure may be as important a factor in reliability evaluation in these materials as variability in flaw size.     

Dynamic fatigue of brittle materials containing indentation line flaws

A study is made of the dynamic fatigue response of brittle materials containing indentation-induced line flaws. The theoretical fracture mechanics of median crack evolution to failure under applied tension are first developed, with special emphasis on the role of residual contact stresses. In particular, it is shown that use of fatigue curves to evaluate the exponent in an assumed power-law crack velocity function may result in systematic error, by as much as a factor of two, if proper account is not taken of this residual contact contribution. Data from strength tests on soda-lime glass bars in water, using a tungsten carbide cutting wheel to introduce the median pre-cracks, confirm the basic predictions. The results suggest that extreme care needs to be exercised when using surfaces with a contact history, e.g. as with machining damage, in fatigue test programmes for materials analysis.     

Fatigue analysis of brittle materials using indentation flaws

The results of an experimental dynamic fatigue study on glass-ceramic specimens containing indentation flaws are analysed in terms of the theory developed in Part 1. A Vickers indenter is used to introduce the flaws, and a conventional four-point bend apparatus to break the specimens. Base-line data for testing the essential theoretical predictions and for evaluating key material/environment parameters are obtained from polished surfaces, i.e. surfaces prepared to a sufficient finish to ensure removal of any pre-existing spurious stresses. The fatigue tests are carried out in water. Inert strength tests in dry nitrogen are used to calibrate appropriate equilibrium fracture parameters, with dummy indentations on selected control specimens providing a convenient measure of the critical crack dimensions at failure. Regression analysis of the dynamic fatigue data yields values for apparent kinetic parameters, which are converted to true kinetic parameters via the transformation equations of Part I. Regeneration of the fatigue function from the theory using the parameters thus determined gives a curve which passes closely through the experimental data points, thereby providing a self-consistent check of the formalism. The implications of the results in relation to the use of macroscopic fracture parameters in the prediction of strength properties for materials with small-scale flaws is an important adjunct to this work. Finally, a recommended procedure for the general testing of dynamic fatigue properties of ceramics using indentation flaws is described.     

Contact-induced Damage in Ceramic Coatings on Compliant Substrates: Fracture Mechanics and Design

Simple explicit relations are presented for the onset of competing fracture modes in ceramic coatings on compliant substrates from Hertzian-like contacts. Special attention is given to a deleterious mode of radial cracking that initiates at the lower coating surface beneath the contact, in addition to traditional cone cracking and quasiplasticity in the near-contact area. The critical load relations are expressed in terms of well-documented material parameters (elastic modulus, toughness, hardness, and strength) and geometrical parameters (coating thickness and sphere radius). Data from selected glass, Al₂O₃ and ZrO₂ coating materials on polycarbonate substrates are used to demonstrate the validity of the relations. The formulation provides a basis for designing ceramic coatings with optimum damage resistance.     

Lifted flames on fuel jets in co-flowing air

The three principal theories for the stabilization of lifted flames on turbulent jets of fuel are reviewed in the light of the most recent flame imaging experiments in the literature. Most of these experiments have been conducted with a small co-flow of air, but the observations are relevant to lift-off with higher ratios of co-flowing air to fuel jet velocity. The similarity solutions for jets in co-flow are developed, and data from a variety of fluid dynamic sources are assessed to yield the governing parameters for mean flow, turbulence and mixture fraction. New data for lifted flames on a methane jet in diffusing streams of co-flowing air are then presented. These data provide essential information on the intermittency, and on the properties of the jet conditioned on the presence of turbulent fluid. However, the co-flow lifts the flame to stabilize in better-mixed regions than in its absence. The ‘premixture’ model is confirmed for this situation, in which the lift-off heights were more than 20 jet diameters and where there is little intermittency at the stabilization radius. Nevertheless, mixing data for this geometry in the absence of a flame show that, with lift-off heights less than 20 jet diameters, the base of the flame would have been in the outer regions of the jet where the mixture of fuel in air only reaches stoichiometric proportions intermittently, with the passage of large eddies. Trading on many papers from the recent literature where this was the case, both experimental and computational insights as to the processes in this region are reviewed. A question remains about how ignition is maintained in these experiments with low turbulent lift-off. It is hypothesized that the mechanism is the diffusive heating of the slowly moving surrounding air which then provides an energy store for the incoming eddies. Further time-resolved observations of reaction zone and high temperature gas structure are required to test this model.