Abstract
The formation and characterization of zirconia coatings on graphite/carbon filaments were investigated. The objective was to eliminate or minimize degradative chemical reactions and improve bonding at the metal/carbon-fiber interface when the coated fiber is used as reinforcement in metal matrix composites. Thin, homogeneous films of zirconium oxide, ZrO2, less than 1μm thick, were formed on carbon monofilaments (35 μm diameter) from a zirconium oxychloride solution in water (less than 1.0 wt. % ZrO2) by dip coating and heating. Chemical changes during thermal decomposition and polycondensation were examined by FTIR spectroscopy. Through dynamic x-ray diffraction tests, the zirconia coating was found to transform first to a metastable tetragonal phase on heating to 330 °C, and then upon cooling, to a stable monoclinic structure. Organotitanate coatings were formed by electrodeposition of the ionizable organometallic complex, titanium di(dioctylpyrophosphate) oxyacetate (TDPA). Single fiber tests revealed a slight reduction in the strength of fibers with thicker coatings, probably due to crack initiation by brittle fracture of the ZrO2 coating. Thin coatings applied from 0.25% ZrOCl2 did not cause such strength reduction. Effective bonding of ZrO2 coatings to the filaments was revealed in single filament composite tests which showed the interfacial shear strength (IFSS) of the coated filaments in an epoxy matrix to be higher than that of the uncoated filaments. The IFSS of monofilaments electrocoated by the titanate was also higher. Examination of the fracture surfaces showed fiber pull-out associated with poor bonding in the case of specimens prepared from uncoated monofilaments. The coated monofilaments showed no fiber pull-out, suggesting that maximum fiber strength was achieved and transferred through the interface to the matrix. Finally, the chemical and thermal stability of the interfacial region of coated and uncoated graphite rods embedded in an aluminum matrix were evaluated. The uncoated rod showed little or no interfacial bonding to the metal matrix, suggesting poor wetting, while the dip-coated and electrocoated rods showed good wetting and compatibility with the metal matrix.
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