Crack Bifurcation in Laminar Ceramic Composites

Abstract

Crack bifurcation was observed in laminar ceramic composites when cracks entered thin Al2O3 layers sandwiched between thicker layers of Zr(12Ce)O2. The Al2O3 layers contained a biaxial, residual, compressive stress of ∼2 GPa developed due to differential contraction upon cooling from the processing temperature. The Zr(12Ce)O2 layers were nearly free of residual, tensile stresses because they were much thicker than the Al2O3 layers. The ceramic composites were fabricated by a green tape and codensification method. Different specimens were fabricated to examine the effect of the thickness of the Al2O3 layer on the bifurcation phenomena. Bar specimens were fractured in four‐point bending. When the propagating crack encountered the Al2O3 layer, it bifurcated as it approached the Zr(12Ce)O2/ Al2O3 interface. After the crack bifurcated, it continued to propagate close to the center line of the Al2O3 layer. Fracture of the laminate continued after the primary crack reinitiated to propagate through the next Zr(12Ce)O2 layer, where it bifurcated again as it entered the next Al2O3 layer. If the loading was stopped during bifurcation, the specimen could be unloaded prior to complete fracture. Although the residual stresses were nearly identical in all Al2O3 layers, crack bifurcation was observed only when the layer thickness was greater than ∼70 μm.