A fiber fracture model for metal matrix composite monotape consolidation

Abstract

The consolidation of plasma sprayed monotapes is emerging as a promising route for producing metal and intermetallic matrix composites reinforced with continuous ceramic fibers. Significant fiber fracture has been reported to accompany the consolidation of some fiber/matrix systems, particularly those with creep resistant matrices. Groves et al. [ Acta metall. mater. 42, 2089 (1994)] determined the predominant mechanism to be bending at monotape surface asperities and showed a strong dependence of damage upon process conditions. Here, a previous model for the densification of monotapes [Elzey and Wadley, Acta metall. mater. 41, 2297 (1993)] has been used with a stochastic model of the fiber failure process to predict the evolution of fiber fracture during either hot isostatic or vacuum hot pressing. Using surface profilometer measured roughness data for the monotapes and handbook values for the mechanical properties of different matrices and fibers, this new model is used to elucidate the damage dependence on process conditions, monotape surface roughness, and the mechanical properties both of the fiber and matrix. The model is used to investigate the “processibility” of several currently important matrix and fiber systems and to identify the factors governing this. An example is also given of its use for the simulation of a representative consolidation process cycle. This approach to the analysis of a complex, nonlinear, time-varying process has resulted in a clear understanding of the causal relationships between damage and the many process, material and geometric variables of the problem and identified new strategies for its elimination.