Carbide Composites Research Articles

Study on micro-grinding mechanism and surface quality of hardened 20 vol% SiCp/Al composites

Particle-reinforced aluminum-based silicon carbide composites (SiCp/Al) are widely used in aerospace, rail transit, and other fields due to their excellent comprehensive properties. However, the incorporation of high-brittle SiC particles poses challenges in the high-performance processing of SiCp/Al composites. This study focuses on hardened 20 vol% SiCp/Al composites, establishing two-dimensional finite element cutting models for single SiC particles. Micro-grinding experiments are conducted under various processing parameters. The influence law of surface defects on individual SiC particles relative to tool position and single factor machining parameters was analyzed, revealing the micro-grinding mechanisms affecting surface and subsurface quality. The results show that the interaction among particle damage mechanisms, crack propagation directions, and the restraining effects of the Al matrix leads to diverse types of defects at different cutting positions. Both simulation and experimental observations reveal surface defects such as pits, gullies, and burrs, while subsurface damage primarily results from crack invasion, cavity interstices, and pits due to particle breakage. The experiment achieved a minimum roughness of 0.057 μm. Taking into account the thermal softening of the material and the micro-behavior of the tool-chip interface, optimal conditions for improved surface quality involve a grinding depth of 0.03 mm, a spindle speed of 12,000 rpm, and a relatively low feed rate.

IMPROVEMENT OF THE ALLOY STRUCTURE OF THE Ni-Cr-Со-W-Mo-Al-Ti-C SYSTEM

Purpose. Establishing the specifics of the influence of alloying elements on the formation of carbides in the structure, their shape and the possibility of separating TLC phases for the system of the Ni-Cr-Co-W-Mo-Al-Ti-C type using the CALPHAD calculation method of prediction in comparison with data obtained by the method of raster electron microscopy. Research methods. The results of experimental and calculated data, formed on the basis of experimental and results taken from open sources, are presented. The chemical composition was determined on a REM-106I scanning electron microscope equipped with an energy dispersive analysis. Experimental values were processed by the method of least squares with obtaining correlation dependencies of the “parameter-property” type and establishing mathematical equations of regression models that optimally describe these dependencies. Results. It was established that when the concentration of titanium is more than 4 % and molybdenum is more than 6 % and 15 % chromium, the formation of TSC phases (Р, s and m- phases) is possible, which reduce the operational properties of the alloy. It was found that when the alloy contains more than 25 % chromium, a solid chromium-based solution is formed, which reduces the properties of the alloy (mechanical and corrosion). It is shown that the obtained dependences correspond to reality and coincide with experimental data at the level of 10 %. Scientific novelty. Obtained dependences of the influence of alloying elements on the chemical composition of carbides will allow predicting properties without conducting experiments. It was established that changes in the course of dependencies are closely correlated with the processes occurring in the structure of alloys. Practical value. The obtained dependencies can be used both for the development of new heat-resistant alloys and for the improvement of the compositions of industrial alloys.

“Skeleton”, diamond-silicon carbide composite material

The paper presents a review of exploratory and applied research carried out in Russia since the 1990s in the field of diamond-silicon carbide composite materials. A new class of isotropic ceramic materials has been created—diamond-silicon carbide composites, which have received the name Skeleton. The physical, mechanical, thermophysical and functional properties of materials depending on their composition are discussed. It is shown that the studied materials simultaneously combine mechanical, thermophysical and functional properties at a level not achieved in other materials, which allows the use of the Skeleton material in various fields of engineering.

Production and Study of Microstructure and Mechanical Characteristics of Al7075-Boron Carbide Composites for Automotive Applications

Production and Study of Microstructure and Mechanical Characteristics of Al7075-Boron Carbide Composites for Automotive Applications

An Analysis Comparing the Taguchi Method for Optimizing the Process Parameters of AA5083/Silicon Carbide and AA5083/Coal Composites that Are Fabricated via Friction Stir Processing

Aluminium metal matrix composites are widely used in automotive, aerospace, marine, and structural engineering due to their high strength-to-weight ratio and superior mechanical properties. Optimizing friction stir process parameters is critical to enhancing the performance of these materials. This study investigates the effects of FSP parameters such as rotational speed, tilt angle, and traverse speed, on the mechanical properties of AA5083/Silicon carbide and AA5083/Coal composites. Using a Taguchi L9 design of experiments, signal-to-noise ratio, and analysis of variance, this study identifies the optimal process settings for maximizing ultimate tensile strength, microhardness, and elongation. From the results, the study revealed that for AA5083/Silicon carbide composites, rotational speed was the most significant factor affecting tensile strength, while for AA5083/Coal composites, tilt angle played a more critical role. Rotational speed consistently influenced microhardness and elongation for both materials. The signal-to-noise ratio analysis indicates that optimal FSP parameters vary depending on the reinforcement material used. This study highlights the importance of tailoring FSP settings to specific reinforcements to achieve optimal mechanical properties. These findings contribute to the advancement of friction stir processing techniques for fabricating high-performance aluminium metal matrix composites, particularly for applications in industries requiring strong, lightweight, and corrosion-resistant materials.

Paste extrusion‐based 3D printing of fiber‐reinforced ultra high‐temperature ceramics

AbstractUltra–high‐temperature ceramics (UHTCs) are valued for their extremely high melting temperatures and resistance to active oxidation. However, their low fracture strengths and the difficulties in shaping them into complex geometries hamper their widespread application. This study aims to fabricate zirconium diboride–silicon carbide (ZrB2‐SiC) composites reinforced with aligned SiC fibers by formulating suspensions containing a preceramic polymer, ZrB2, and SiC fibers. This study assessed the influence of fiber alignment on electrical and thermal conductivities, as well as on mechanical strength. The results revealed a significant enhancement in thermal conductivity, particularly when the fibers were aligned, effectively doubling it compared with the non‐aligned parts. Additionally, increasing the fiber content significantly improved the fracture strength, with composites containing 22.5 vol% fibers reaching fracture strengths over 57 MPa. However, the final values did not meet the theoretical expectations because the porosity in pyrolyzed parts exceeded 10%. Furthermore, the study demonstrated a 10‐fold increase in electrical conductivity with fiber alignment compared to that for non‐aligned composites. These results highlight the capability of paste extrusion‐based additive manufacturing in tailoring ultra–high‐temperature ceramic matrix composites (UHTCMCs) with aligned fibers, realizing their suitability for aerospace applications.

Image-Based Peridynamic Modeling-Based Micro-CT for Failure Simulation of Composites

By utilizing computed tomography (CT) technology, we can gain a comprehensive understanding of the specific details within the material. When combined with computational mechanics, this approach allows us to predict the structural response through numerical simulation, thereby avoiding the high experimental costs. In this study, the tensile cracking behavior of carbon–silicon carbide (C/SiC) composites is numerically simulated using the bond-based peridynamics model (BB-PD), which is based on geometric models derived from segmented images of three-dimensional (3D) CT data. To obtain results efficiently and accurately, we adopted a deep learning-based image recognition model to identify the kinds of material and then the pixel type that corresponds to the material point, which can be modeled by BB-PD for failure simulation. The numerical simulations of the composites indicate that the proposed image-based peridynamics (IB-PD) model can accurately reconstruct the actual composite microstructure. It can effectively simulate various fracture phenomena such as interfacial debonding, crack propagation affected by defects, and damage to the matrix.

Insight of the microstructure evolution and performance enhancement of spinodal decomposition in (Ti, Zr)C composite carbide ceramics: Multiscale simulation and experimental investigation

Traditional carbide ceramics face a sharp trade-off between hardness and toughness, leading to a significantly reduced lifespan under harsh service conditions like wear, impact, corrosion, and high temperatures. The spinodal decomposition leads to the formation of nano-lamellar structures, serving to refine grain sizes, thus paving the way to simultaneously improve the hardness and toughness of composite carbide ceramics. A wide range of composite carbides can be prepared, but their complex microstructure evolution during aging makes performance optimization extremely challenging. In this work, a strategy by combining the multiscale simulations and experiments is proposed to systematically study the influence of the composition and process on the spinodal decomposition structure and performance. Taking (Ti, Zr)C carbide ceramics as a representative example, three distinct compositions of (Ti, Zr)C solid solutions were successfully synthesized via a sol-gel combined with spark plasma sintering method at 1800°C, guided by thermodynamic calculations. The influence of aging temperature and duration on spinodal decomposition microstructure evolution in (Ti, Zr)C carbide ceramics was studied by integrating phase-field simulations and first-principles calculations with key experimental observations. After spinodal decomposition, numerous nanoscale nodular structures form, accompanied by the generation of dislocations, leading to a significant improvement in both hardness and toughness of the composite carbides. After aging at 1300°C for 3 h, the composite carbides achieved peak hardness at 2436 HV, accompanied by a fracture toughness of 3.24 MPa·m1/2. This research provides a scientific approach to improving the hardness and toughness of carbide ceramics through spinodal decomposition, offering essential theoretical foundations for microstructural control and synergistic optimization of performance in innovative carbide ceramics.

Effect of cooling temperature on microstructure and mechanical properties of Nb microalloyed hot-rolled rebar

In this study, the Gleeble-3800 thermal simulation tester was used to simulate various cooling temperature processes for two groups of rebar. Then, the microstructure, precipitation, and mechanical properties of the rebars were characterized using SEM (scanning electron microscopy), EBSD (electron backscatter diffraction), HRTEM (high resolution transmission electron microscopy), and MST810 (universal tensile testing machine). The effect of cooling temperature on the microstructure and mechanical properties was systematically investigated. The results showed that reducing the cooling temperature from 750 °C to 600 °C decreased the ferrite grain size in 0.032 wt % Nb rebar to 7.03 ± 1.5 μm, compared to the 0 wt% Nb rebar. In addition, the pearlite lamellar spacing was refined to 0.103 ± 0.5 μm, and the average particle size of elliptical Nb-rich composite carbides was 9 nm. The tensile strength and yield strength reached 795 ± 9 MPa and 638 ± 8 MPa, respectively, with an elongation after fracture of 17.78 ± 1.0 %. The fracture surface exhibited a dimple morphology.

Experimental, simulation, and theoretical investigations of gamma and neutron shielding characteristics for reinforced with boron carbide and titanium oxide composites

This study investigates the radiation shielding properties of composites containing polyester resin, boron carbide and titanium oxide in varying proportions. The radiation transmittance of the produced composites was measured using radioactive sources 241Am, 137Cs, 133Ba, 60Co, and 22Na across a photon energy range of 59.5 keV–1332.5 keV. To analyze radiation permeability, experimental geometry was simulated using Monte Carlo-based computer codes Monte Carlo N-Particle (MCNP), Particle and Heavy Ion Transport code System (PHITS) and FLUktuierende KAskade or Fluctuating Cascade (FLUKA), and the experimental data were compared with simulation results and theoretical data obtained from WINXCOM. The findings demonstrated a high degree of consistency between experimental, simulation, and theoretical results. Notably, the BCTiO50 sample, which included a 50% addition of TiO2, emerged as the most effective in photon radiation shielding. In addition to gamma shielding, the neutron shielding properties of the produced composites were evaluated using the FLUKA code, revealing that the BCTiO0 sample, with the highest percentage of boron, provided the best neutron shielding. This analysis included composites with decreasing boron carbide content by 10%, 20%, 30%, 40%, and 50% by weight, each replaced with titanium oxide, showcasing the potential applications of these polymer composites in radiation shielding.

Research on hydrogen distribution of electroless nickel plating on aluminum-based silicon carbide composites

Abstract Aluminum-based silicon carbide composite materials have the characteristics of high thermal conductivity, low thermal expansion, and good dimensional stability. Therefore, the composites are widely used in space microwave component shell products. In order to meet the functional requirements of conductivity, welding, and heat dissipation when applied to antenna microwave components, aluminum-based silicon carbide composite materials need to be chemically plated with nickel, which introduces hydrogen, thus requiring research on hydrogen release and control. Here, SEM, XRD, and other methods are used to characterize the microstructure of aluminum-based silicon carbide substrate and nickel plating layer. There are certain pore structures in both the substrate and plating layer, providing a place for hydrogen storage. The experimental method of hydrogen microprinting has been used to characterize the distribution of hydrogen. The results showed that the hydrogen distribution pattern in aluminum-based silicon carbide nickel plating is as follows: after nickel plating on aluminum-based silicon carbide, hydrogen is distributed in the nickel plating layer and the shallow substrate under the coating; with the extension of time, hydrogen spontaneously diffuses to the deep substrate; hydrogen is mainly distributed in the Al matrix and less on SiC particles.

Preparation of graphite/silicon carbide based on SLS/LSI and study of properties

In this paper, graphite/silicon carbide composites with an integrated structure–function were prepared by selective laser sintering (SLS) and liquid silicon infiltration (LSI). The study investigated the influence of different factors on the microstructure, mechanical properties, and thermal conductivity of graphite/silicon carbide composites. The results demonstrated that the open porosity of the precast body gradually decreased with an increase in the content of mesocarbon microbeads (MCMB), while the carbon content gradually increased. The density, mechanical strength, and thermal conductivity (TC) of the composites initially increased, followed by a subsequent decrease. In the absence of MCMB, micropores and a significant amount of free silicon were observed within the composite after LSI, leading to reduced density and mechanical properties. Conversely, the inclusion of 20 wt% MCMB led to the elimination of micropores and free silicon within the composite, resulting in the highest density and TC values of 2.52 g/cm3 and 73.22 W/m·K, respectively. The measured TC values were consistent with those calculated by the Effective Medium Theory Model (EMT). At a 40 wt% addition, micropores and free silicon reappeared within the composites, leading to a decrease in density and properties. Furthermore, the calculated values of the five thermal conductivity models were found to be higher than the measured values. This paper presents a further improvement in the process of preparing graphite-ceramic composites with a complex structure, achieved by controlling the amount of MCMB added. This contributes to the subsequent research.

Experimental investigation of the microstructural and wear behaviours of silicon carbide and boron nitride-reinforced AZ91D magnesium matrix hybrid composites

Experimental investigation of the microstructural and wear behaviours of silicon carbide and boron nitride-reinforced AZ91D magnesium matrix hybrid composites

Synthesis and property enhancement of Ti-Si/SiC composites by reactive infiltration for semiconductor applications

Poor machinability and limited electrical conductivity present significant challenges for silicon carbide (SiC) composites used in the semiconductor industry. In this study, Ti-Si/SiC composites were synthesized by liquid infiltration of a Ti-Si eutectic alloy, using SiC and Carbon black as raw materials. The reactive sintering mechanism and properties of Ti-Si/SiC composites were investigated using the reactive infiltration sintering process. The relative density of Ti-Si/SiC composites reached 98.43 % at 1600 °C. The results indicate that continuous infiltration of the Ti-Si eutectic alloy and dissolution-reprecipitation are critical for synthesizing Ti-Si/SiC composites. The coefficient of thermal expansion for the composites is 5.16 × 10−6 °C−1. Remarkably, the exponential increase in electrical conductivity with rising temperature strongly supports the enhanced conductive properties of this composite semiconductor. The Ti-Si/SiC composites exhibit maximum flexural strength, indentation modulus, and hardness values of 310.4 MPa, 434.1 GPa, and 29.4 GPa, respectively. This research aims to advance the application of high-performance Ti-Si/SiC materials in semiconductor technology.

High-temperature mechanical performances of SiC whisker in-situ toughened 3DN C/SiC countersunk bolts prepared by chemical vapor infiltration

High performance bolts, made of continuous fiber reinforced silicon carbide composites (C/SiC), are crucial to the design and preparation of the hot-end C/SiC components with large complex structures both in aerospace and aeronautical fields. In this work, in-situ grown SiC whiskers were uniformly introduced into the porous laminated 3DN C/SiC countersunk bolt, in order to improve the brittle nature of the 3DN C/SiC threads. Results showed that 7 % increase of tensile strength of the 3DN C/SiC countersunk bolts was achieved via in-situ grown SiC whiskers, and a fatigue life of 106 cycles was also passed. The stud fracture morphologies indicated that the SiC whiskers grew within the woven pores and toughened the layered SiC matrix, so that the load transfer between the layered SiC matrix and carbon fibers was improved under tension. Further high temperature tests showed that the tensile and the shear strengths of the in-situ toughened 3DN C/SiC countersunk bolts were degraded to 64.74 % and 28.83 % at 1000 °C in air respectively. During the thermal exposure, the carbon fibers were largely consumed by oxidation, while the SiC whiskers grew slender and formed a fluffy layer to partially reinforce the SiC matrix. The synergy effect of SiC whiskers and carbon fibers to hinder crack propagation and to toughen the SiC matrix contributes to the above mechanical properties of the bolts.

Penetration resistance of honeycomb ceramic matrix composites with filler material

The major purpose of this study is to analyze the resistance of honeycomb ceramic matrix composites to penetration and to explore the effect of the performance characteristics of the filler materials on this capability. We used alumina ceramics, polyurea, quartz sand powder, and boron carbide powder to manufacture composite materials, and conducted impact tests and numerical simulations on them. The simulation results of Abaqus were found to be very consistent with the test results. The results demonstrate that the polyurea coating and filler materials may effectively improve the anti-penetration penetration performance of the composites, and different filler materials have varying energy absorption effects. Extended research on composites was carried out utilizing experimentally validated numerical models with filler materials comprising silicon carbide, aluminum nitride, and silicon nitride. After a comparative analysis of the simulation results of different composites, compared to quartz sand composites, the energy absorption efficiency of boron carbide composites increased by 12.03 %, silicon carbide composites increased by 14.63 %, aluminum nitride composites increased by 15.16 %, and silicon nitride composites increased by 18.29 %. Among the relevant materials in this study, there exists an optimal value of the stress wave impedance difference between the matrix material and the filler material. Honeycomb ceramic matrix composites with an ideal combination of stress wave impedance differences can considerably increase the anti-penetration efficiency of the composites.

A Review of an Investigation of the Ultrafast Laser Processing of Brittle and Hard Materials.

Ultrafast laser technology has moved from ultrafast to ultra-strong due to the development of chirped pulse amplification technology. Ultrafast laser technology, such as femtosecond lasers and picosecond lasers, has quickly become a flexible tool for processing brittle and hard materials and complex micro-components, which are widely used in and developed for medical, aerospace, semiconductor applications and so on. However, the mechanisms of the interaction between an ultrafast laser and brittle and hard materials are still unclear. Meanwhile, the ultrafast laser processing of these materials is still a challenge. Additionally, highly efficient and high-precision manufacturing using ultrafast lasers needs to be developed. This review is focused on the common challenges and current status of the ultrafast laser processing of brittle and hard materials, such as nickel-based superalloys, thermal barrier ceramics, diamond, silicon dioxide, and silicon carbide composites. Firstly, different materials are distinguished according to their bandgap width, thermal conductivity and other characteristics in order to reveal the absorption mechanism of the laser energy during the ultrafast laser processing of brittle and hard materials. Secondly, the mechanism of laser energy transfer and transformation is investigated by analyzing the interaction between the photons and the electrons and ions in laser-induced plasma, as well as the interaction with the continuum of the materials. Thirdly, the relationship between key parameters and ultrafast laser processing quality is discussed. Finally, the methods for achieving highly efficient and high-precision manufacturing of complex three-dimensional micro-components are explored in detail.

Effect of rare earth element on H13 microscopic structure and mechanical properties

In view of the phenomenon that irregular inclusions are easy to use as crack sources, rare earth H13 steel with different gradients is designed. The results showed that ellipsoidal rare earth inclusions (Ce2O3, CeAlO3 and Ce2O2S) were formed from irregular Al2O3 inclusions with the assistance of rare earths. The carbides that precipitated from liquid phases were arranged in a network along the grain boundary, forming composite carbides that are rich in Mo and V. Along the grain boundary, the morphology of the composite carbides got finer, and MC-type carbides enclosed the modified inclusions into nuclei, facilitating their precipitation. After annealing, the microstructure revealed that the carbides were dispersed in black segregated patches along the grain boundary and were discontinuous. The average diameter of carbides decreased from 109.7 to 79.2 nm in the same region according to a statistical comparison of the number of carbides before and after the addition of rare earth elements. The carbides were distributed alongside primary carbides as tiny particles of M7C3 and M23C6 secondary carbides. Especially when the rare earth content was 0.032 wt-%, the impact toughness increased to 34%. This work offers a reference value for the practical application of rare earth in hot work die steel in addition to revealing the strengthening mechanism of ultra-high strength RE-13 steel.

Improving thermal conductivity of Al/SiC composites by post-oxidization of reaction-bonded silicon carbide preforms

High thermal conductivity aluminium-based silicon carbide (Al/SiC) composites were successfully fabricated through post-oxidization of reaction-bonded silicon carbide preforms (RS preforms), utilizing vacuum pressure infiltration technology. The study investigated the regulation of interfacial reactions in conventional sintering and reaction sintering. Conventional sintering introduced a large amount of SiO2, which negatively impacted the thermal conductivity of the Al/SiC composite, but the reaction sintering not. The proposed post-oxidization treatment of RS preforms effectively removed residual carbon from the SiC particle surfaces, thereby forestalling the formation of Al4C3. Furthermore, the post-oxidization treatment effectively formed lightweight SiO2 deposits onto the surface of SiC particles, improving Al-SiC interfacial wettability and reducing thermal resistance, thereby enhancing composite thermal conductivity. Notably, the thermal conductivity of the post-oxidized sample exhibited an increase of 6.5% compared to the untreated sample. The study also evaluated the impact of particle size distribution on volume fraction and thermal properties. The optimized Al/SiC composites yielded thermal conductivity, coefficient of thermal expansion, bending strength, and Young’s modulus values of 237.3 W/m K, 8.5 × 10−6/°C, 325 MPa, and 75.9 GPa, respectively.

Mechanical Properties of Silicon Carbide Composites Reinforced with Reduced Graphene Oxide.

This article presents research on the influence of reduced graphene oxide on the mechanical properties of silicon carbide matrix composites sintered with the use of the Spark Plasma Sintering method. The produced sinters were subjected to a three-point bending test. An increase in flexural strength was observed, which reaches a maximum value of 503.8 MPa for SiC-2 wt.% rGO composite in comparison to 323 MPa for the reference SiC sample. The hardness of composites decreases with the increase in rGO content down to 1475 HV10, which is correlated with density results. Measured fracture toughness values are burdened with a high standard deviation due to the presence of rGO agglomerates. The KIC reaches values in the range of 3.22-3.82 MPa*m1/2. Three main mechanisms responsible for the increase in the fracture toughness of composites were identified: bridging, deflecting, and branching of cracks. Obtained results show that reduced graphene oxide can be used as a reinforcing phase to the SiC matrix, with an especially visible impact on flexural strength.