Ductile Matrix Research Articles

Flexible noble-metal-free Fe-based metallic glasses as highly efficient oxygen evolution electrodes

Developing low-cost, and efficient oxygen evolution reaction (OER) electrodes with high flexibility is critical for hydrogen production. Here, flexible noble-metal-free Fe-based metallic glassy OER electrodes were fabricated via an electrochemical dealloying method combined with a dipping process. The sample requires a low overpotential of 258 mV to achieve a current density of 10 mA⋅cm−2 in 1 M KOH solution, and the Tafel slope is 51.7 mV/dec. Galvanostatic test proved the excellent electrochemical stability of the electrodes. The highly efficient performance mainly originated from the high-energy disordered amorphous microstructure combined with the doping effect of nickel. Furthermore, the unique double-layer structure of the nanoporous surface covered with amorphous sheets increased the contact area of the samples. The ductile amorphous matrix together with the amorphous sheets tightly bonded on the nanoporous layer results in high flexibility of the electrodes. Our work provides a simple strategy to fabricate flexible amorphous OER electrodes.

Mechanical properties of MoW–HfN surrogate cermet fuel for nuclear thermal propulsion

AbstractThe mechanical performance of MoW‐HfN, a surrogate cermet for MoW‐UN Nuclear Thermal Propulsion (NTP) fuel, was characterized from room temperature to 1600°C. The modulus of elasticity and flexure strength were obtained from four‐point bend tests. Those tests revealed a loss of stiffness with increasing temperature and systematic increase in ultimate strength up to about 1400°C. This was followed by loss of ultimate strength and the onset of plastic deformation, attributed to the increased ductility of the MoW matrix above 1400°C. Chevron notch tests show that failure originates from features with a critical flaw size of ∼30 εm, which is comparable to the mean particle size of the ceramic phase. X‐ray diffraction (XRD) and Williamson–Hall (WH) analysis suggest that residual stress may contribute to the observed strength‐versus‐temperature behavior.

The cruciality of particle size and shape on fracture mechanism of aluminum matrix composites

Metal matrix composites are generally believed to achieve better performance with spherical reinforcements than irregular ones. In this work, through experiments and computational simulations, we have demonstrated that spherical reinforcements do not necessarily enhance the tensile ductility of composites. There exists a critical size for spherical particles. Using an Al2O3-Al2024 composite as an example, we found that when the size of spherical Al2O3 particles is less than 3 µm, they are not fractured during deformation, resulting in enhanced ductility. We elucidated the competitive mechanism between particle and matrix fracture under various reinforcement sizes and volume fractions, and constructed a deformation map that can be utilized to determine fracture mechanisms. This work clarifies the micro-mechanical mechanisms of reinforcements on material fracture behavior, providing guidance for the design and fabrication of strong and ductile metal matrix composites.

Cold sintering with functionalized polymers for ductile ceramic matrix composites with controllable mechanical performance

Structuring ceramics with polymers in hierarchical morphologies provide mechanisms for substantial toughening. Bi-continuous composites are generated in a single processing step through cold sintering of ceramic and polymer particles, which consolidates the inorganic phase at temperatures compatible with polymer processing. Here, we demonstrate that limited maleation (∼1 %) of polypropylene (PP) provides a chemical handle to alter the interaction between the polymer and inorganic phases that leads to a more homogeneous composite morphology at multiple length scales, as evidenced by X-ray microcomputed tomography (µ-CT) and elemental mapping during electron microscopy for a wide range of composite compositions from from 14.5 vol% to 68.2 vol% polymer. The extensibility of the composite and the ultimate tensile stress (UTS) of the hybrid composites are increased substantially in comparison to unfunctionalized PP at the same composition. Quantitative analysis of µ-CT data identifies an interphase in polymer-ceramic composites where there is significant mixing of inorganic and polymer phases that is associated with the generation of a hierarchical morphology. We find that the impact of the interphase is primarily in the reduction of the thickness of the pure ceramic domain. This domain size is inversely correlated with the UTS with universal behavior irrespective of the functionality of the PP. This observation underscores the pivotal role of functional groups on polymers to enhance composite homogeneity, reduce ceramic domain size, and consequently augment the mechanical response of cold sintered ceramic matrix composites that provides a route to sustainable composite materials.

Surface hardening of high modulus steels through carburizing and nitriding: First insights into microstructure property relationships

High modulus steels are promising materials for future lightweight design solutions, as their embedded boride particles in a ductile steel matrix increase the stiffness/density ratio. One key requirement for maturing them towards industrial application is their suitability for improving the surface hardness. In this study we investigated the effects of low-pressure carburizing and plasma nitriding on the microstructure and mechanical properties of selected Fe-TiB2- and Fe-Cr-M2B-based high modulus steels. Nitriding resulted with the formation of expanded ferrite in the strongest hardness increase to about 1100 HV0.05 from the alloy system's base hardness of 240 and 500 HV0.05, respectively, albeit with different hardness depth profiles. The Fe-Ti-B alloy indicated deformation phenomena in the ferritic matrix after nitriding, whereas nitriding of Fe-Cr-B-C resulted in a diffusion-controlled particle transformation of M2B borides into CrN nitrides of lower stiffness. Carburizing on the other hand led to a slightly lower maximum hardness value of about 800 HV0.05 over an increased depth for Fe-Cr-B, as martensite and additional M23C6 carbides were formed in the surface zone. The surface hardness of the Fe-TiB2-based alloy could not be increased by the deployed carburization parameters, most likely due to excessive Ti dissolved in the matrix. Consequences for the transfer to engineering applications as well as the refinement of both, thermochemical processing parameters and designated alloy concepts, of high modulus steels are outlined and discussed.

Impact toughness of LPBF 316L stainless steel below room temperature

The fracture behavior of LPBF 316L stainless steel in rapid loading conditions was characterized from room to cryogenic temperatures. Instrumented impact toughness tests allow to determine the influence of the microstructural features of this material on its crack initiation and propagation behavior. In the stress-relieved, homogenized/partially recovered and recrystallized states, LPBF 316L exhibit gradual impact toughness decreases between 20 °C and – 193 °C, with close toughness loss ranging from 0.38 to 0.55 J cm−2/°C. These values were similar to those reported by the literature for hot isostatically pressed (0.35–0.58 J cm−2/°C) and wrought (0.45–0.51 J cm−2/°C) 316L stainless steels, meaning that the microstructural features of LPBF 316L (segregations cells, dislocations cells, oxide particles, etc.) did not significantly influence the temperature sensitivity of its fracture properties. Whatever the testing temperature and microstructural state, fully ductile fracture occurred by decohesion at the oxide/matrix interfaces and void growth into dimples. The martensitic transformation during deformation at low temperature did not appears to play a significant role in the temperature sensitivity of the decrease in impact toughness of these materials. The latter is likely a consequence of the loss of ductility of the austenitic matrix, especially, under localized strain conditions.

Comparison of the in situ compressive behavior of carbon fibers woven ply laminates exposed to one‐sided heat flux: Thermoplastic versus thermosetting composites

AbstractThis study investigates the influence of a combined thermal heat flux (imposed by a cone calorimeter) and a compressive loading on the deformation and damage mechanisms within quasi‐isotropic carbon fibers reinforced thermoplastic (polyetherether ketone [PEEK] and polyphenylene sulfide [PPS]) and thermosetting (epoxy) laminates. First, thermogravimetric Analyses conducted under nitrogen provide valuable information on the thermal decomposition of these materials depending on the matrix nature (580–510°C and 350°C, respectively) which is a key factor to explain the mechanical behavior under fire conditions. Second, under the same testing conditions (creep loading under a 50 kW/m2 heat flux), the time to failure is about 17 times as high (C/PEEK), twice as high (C/PPS) with respect to C/epoxy laminates. At the ply scale, the exposure of thermoplastic matrices (PEEK and PPS) to a 50 kW/m2 heat flux causes softening and thermal decomposition, facilitating the micro‐buckling of fiber bundles in matrix‐rich areas. At the laminates scale, this mechanism ultimately leads to the formation and propagation of plastic kink bands in the transverse direction. In epoxy‐based laminates, the onset of matrix pyrolysis occurs at lower temperatures (350°C) during thermal aggression, and thermal decomposition has started in all the plies of the laminates. Combined with the low ductility of the epoxy matrix, the compressive response is elastic‐brittle and results from the buckling of 0° plies outside the thermally‐damaged area.Highlights Study on the compression of polymer composites exposed to a 50 kW/m2 heat flux. The influence of the matrix nature (thermoplastic vs thermoset) is discussed. Time to failure is about 17 times higher in C/PEEK compared to C/Epoxy. Plastic kink bands propagate in thermoplastic composites at T > Tg. C/Epoxy laminates undergo buckling outside the thermally damaged area.

Restoration of Strength in Polyamide Woven Glass Fiber Organosheets by Hot Pressing: Case Study of Impact and Compression after Impact.

Thermoplastic composite organosheets (OSs) are increasingly recognized as a viable solution for automotive and aerospace structures, offering a range of benefits including cost-effectiveness through high-rate production, lightweight design, impact resistance, formability, and recyclability. This study examines the impact response, post-impact strength evaluation, and hot-pressing repair effectiveness of woven glass fiber nylon composite OSs across varying impact energy levels. Experimental investigations involved subjecting composite specimens to impact at varying energy levels using a drop-tower test rig, followed by compression-after-impact (CAI) tests. The results underscore the exceptional damage tolerance and improved residual compressive strength of the OSs compared to traditional thermoset composites. This enhancement was primarily attributed to the matrix's ductility, which mitigated transverse crack propagation and significantly increased the amount of absorbed energy. To mitigate impact-induced damage, a localized hot-pressing repair approach was developed. This allowed to restore the post-impact strength of the OSs to pristine levels for impact energies below 40 J and by 83.6% for higher impact energies, when OS perforation was observed. The measured levels of post-repair strength demonstrate a successful restoration of OS strength over a wide range of impact energies, and despite limitations in achieving complete strength recovery above 40 J, hot-pressing repair emerges as a promising strategy for ensuring the longevity of thermoplastic composites through repairability.

Unveiling the high strength and ductile character of reinforced CNT/geopolymer paste subjected to elevated temperatures

A significant challenge in developing suitable advanced materials in the construction sector is urgent face to the natural disasters affecting our infrastructure and endanger the world population. At this stage, geopolymers renowned as a green and low-carbon material has received considerable attention. Here, novel properties are revealed for Na-based and K-based metakaolin geopolymer paste reinforced by carbon nanotubes with various dosage, exposed to high temperatures. Results show that adding 1.08 wt% of CNT makes the geopolymer matrix thermally stable and resistant up to 1327 °C. It comes out that geopolymer nanostructure with low CNT concentration became tough to shear deformation along (001) plane up to 1127 °C and is easier to shear along (100) plane for highest CNT content. Calculations predict that low CNT dosage double the ductility of Na-based and K-based geopolymer matrix at room temperature. Heating up to 1327 °C enhances the stiffness of both nanostructures. The micro-hardness doubles at 800 °C for Na-based rather than K-based geopolymer matrix when adding low CNT dosage.

Investigation on Critical Microstructure Size for Numerical Analysis of Metal-Matrix Composites with Network Reinforcement Architecture

Finite element method (FEM) is a powerful tool to predict the properties and reveal the mechanisms of metal-matrix composites (MMCs) with very complex architectures and novel microstructures. Recent studies have demonstrated the effectiveness of network reinforcement architectures on simultaneous strengthening and toughening. Here, as a key factor in modeling network architecture, the critical microstructure size was studied via FEM. We found that a critical microstructure size of 23 [Formula: see text]m (cell count [Formula: see text]20) existed in the FEM model, beyond which the crack deflection may be feasibly induced from particle-rich to matrix regions, leading to crack propagation in the ductile matrix cells and thus high strength and elongation. While, with cell size 20–23 [Formula: see text]m in SiC/6061Al model, the composite strength and elongation remained intact, implying that the maximal microstructure size is 23 [Formula: see text]m for effective network architecture simulations.

Chitin Nanocomposites for Fused Filament Fabrication: Flexible Materials with Enhanced Interlayer Adhesion.

In this work, we present a series of nanocomposites for Fused filament fabrication (FFF) based on polycaprolactone (PCL) and chitin nanocrystals (ChNCs). The ChNCs were synthesized by acid hydrolysis using HCl or lactic acid (LA). The approach using LA, an organic acid, makes the ChNCs synthesis more sustainable and modifies their surface with lactate groups, increasing their compatibility with the PCL matrix. The ChNCs characterization by X-ray diffraction, Fourier transform infrared spectroscopy, scanning electron microscopy, and transmission electron microscopy revealed that both ChNCs presented similar morphologies and crystallinity, while differential scanning calorimetry and thermogravimetric analysis proved that they can bear temperatures up to 210 °C without degrading, which allows their processing in the manufacturing of PCL composites by twin-screw extrusion. Therefore, PCL composites in the form of filaments containing 0.5-1.0 wt % ChNCs were produced and used as feedstock in FFF, and standard tensile and flexural specimens were printed at different temperatures, up to 170 °C, to assess the influence of the ChNCs in the mechanical properties of the material. The tensile testing results showed that the presence of ChNCs enhances the strength and ductility of the PCL matrix, increasing the elongation at break around 20-50%. Moreover, the vertically printed flexural specimens showed a very different bending behavior, such that the pure PCL specimens presented a brittle fracture at 7% strain, while the ChNCs composites were able to bend over themselves. Hence, this work proves that the presence of ChNCs aims to improve the interlayer adhesion of the objects manufactured by FFF due to their good adhesive properties, which is currently a concern for the scientific community and the industrial sector.

Scouring erosion resistance of metallic materials with composite microstructures

Slurry erosion can cause severe damage and often constitutes a significant portion of the total production cost in many industries such as oil sands and mining. The most commonly used materials for such applications are metallic materials having a composite microstructure consisting of hard reinforcement phases in a more ductile metal matrix. Typical examples are high chromium white irons and tungsten carbide welding overlays. The main purpose of this work is to evaluate the scouring erosion resistance of such materials for applications in handling fine sand slurries and to introduce a wear model to help understand the correlation between erosion resistance and the characteristics of microstructures.Five high chromium white cast irons and four spray and fusion coatings composed of cast tungsten carbide particles and Ni–Cr–B–Si–Fe matrix have been studied using a Coriolis scouring erosion tester in a fine sand slurry. The relationship between the erosion resistance and different microstructure parameters was explored. For the chromium white cast irons, the erosion resistance increased with increase in carbide volume fraction but the spray and fusion coatings showed the opposite trend, i.e., their erosion resistance decreased with increase in the carbide volume fraction. No clear correlation was found between erosion resistance and free path for the spray and fusion coatings while for the chromium white cast irons, the erosion resistance was found to increase rather than decrease with increase in free path.To help explain the experimental results, a wear model has been proposed for the wear resistance of composite microstructures composed of a reinforcement phase (RP) and a metal matrix. In the model, the wear surface of the material is distinguished by four different features/regions, each having unique wear resistance. The rule of mixtures (ROM) for wear resistance is applied to formulate the wear resistance of the material with the above four wear surface features. It is shown that the results can be reasonably well explained based on the proposed model by using the total edge length, L, of the RP particles exposed on a unit area of the wear surface.

Effect of temperature on apparent crack arrest toughness of Eurofer97 measured by a newly developed small specimen test technique

Neutron embrittlement of in-core and out-of-core components made of ferritic steels is one of the key parameters limiting the life of power plants. Owing to the small volume of available irradiation facilities and the limited number of neutron-irradiated specimens, techniques to measure initiation fracture toughness with small specimens have been developed over the years. Although arrest toughness is of equal importance regarding safety assessment, the emphasis has been put on the effect of specimen size on initiation toughness and only a few small specimen test techniques can be found for arrest toughness measurements. The objective of the current work was to develop an experimental technique for measuring the apparent arrest toughness of ferritic steels with miniaturized specimens. Small cantilevers made of the 9Cr Eurofer97 equiaxed ferritic steel were produced with a brittle thin laser-treated layer, which enables crack initiation. The cracks were successfully arrested in the more ductile equiaxed ferritic matrix in a series of tests that were carried out from -123 °C to room temperature with different test configurations. The mechanical tests showed that brittle fracture could be triggered and stopped inside the specimen with a width of 2 mm over a temperature range of more than 100 °C. An apparent arrest toughness was calculated and its temperature dependence was related to the plastic work dissipated by a propagating crack.

Tailoring high ductility cementitious composite incorporating recycled fine aggregate based on shrinkage and mechanical properties

High ductility cementitious composite (HDCC) is recognized as an ideal structural bonding and repair material due to multiple steady-state cracking and strain-hardening properties. However， higher shrinkage strains and low economic and environmental friendliness limit its wide application. To promote the application of HDCC, recycled high ductility cementitious composite (R-HDCC) was prepared by using recycled fine aggregate (RFA) to replace natural fine aggregate (NFA), and the effects of RFA substitution rate and fly ash content on the mechanical and shrinkage properties of R-HDCC were thoroughly investigated. The results showed that the compressive strength of R-HDCC gradually decreased with the increase of RFA substitution, but its tensile strain was enhanced. R-HDCC, with 100 % RFA substitution, still maintained a tensile strength of 2.66 MPa and a tensile strain capacity of 2.46 %. The high fly ash content improved the matrix ductility, resulting in a 54.19 % increase in tensile strain over natural HDCC. In addition, the incorporation of RFA and fly ash reduced the autogenous shrinkage of R-HDCC due to the internal curing effect, but the total drying shrinkage of the matrix increased with increasing RFA substitution rate. R100-70 showed optimal environmental benefits and engineering application value through environmental impact assessment and economic analysis. Finally, this paper is expected to guide the design of ecological, economical, and high-performance R-HDCC.

A practical approach to fabrication of nano-Al2O3 reinforced MMC coatings by cold spray: Characterization of nanomechanical and tribological performance

Cold spray is a crucial solid-state deposition technique involving high-speed spraying of different-sized particles onto a base material. In this study, Ni-based powder reinforced with different proportions of nano-Al2O3 particles was sprayed onto Al6061 alloy by cold spray to improve the coating performance. Nanoparticles are very difficult to deposition as they are affected by the aerodynamic forces generated during cold spraying. With a practical approach, nanoparticles were agglomerated with micron-sized feedstock powders, and nanoparticles in the sprayed powder acted as larger particles and successfully defeated the aerodynamic force. The effects of adding nano-particles on the microstructural, nanomechanical, and tribological properties were investigated. Microstructural analyses revealed that MMC coating layers comprised ceramic particles and metal matrix (Ni and Zn). Due to the high spraying speed, the nano-particles were spread in the relatively ductile matrix formed by Ni and Zn. The micro- and nanohardness values were increased with nanoparticle volume by two mechanisms. In the first mechanism, the hard particle volume increased with the addition of nano powders, and in the second mechanism, the plastic deformation of the matrix increased due to the nano-particles. The sample without nanoparticle reinforcement exhibited plastic deformation during the initial stage of the nanoscratch test. The dry sliding wear test results showed that the nano-Al2O3-reinforced spraying powders increased the wear resistance approximately 1.9 times. According to FESEM and EDS examinations of worn surfaces and WC counter-bodies, nano-particles reduced the transferred layers caused by adhesion to the abrasive counter-body. In addition, the nano-particles were provided a more homogeneous hard particle distribution and improved wear performance.

Crack self-healing by high-temperature annealing of a 90W7Ni3Fe tungsten heavy alloy

WNiFe tungsten heavy alloys (WHAs) are leading candidates for fusion plasma-facing components, since they are toughened by embedding brittle W-particles in a ductile phase honeycomb matrix. We show that fatigue cracks in a 90W7Ni3Fe WHA, up to ≈ 1.3 mm long, are completely healed by vacuum annealing at 1300 °C for 24 h, as confirmed by microstructural observations and locating the healed crack initiation site, by both re-loading and re-precracking. Annealing also improves WHA toughness. Healing is not due to previously postulated mechanisms. We hypothesize that it derives from internal annealing stresses that extrude the ductile phase into adjacent cracks.

Brittle‐Ductile Rheological Behavior in Subduction Zones: Effects of Strength Ratio Between Strong and Weak Phases in a Bi‐Phase System

AbstractThe brittle‐ductile rheological behavior in subduction zones is commonly proposed to explain deep transient slips. Generally observed at large scales in tectonic “mélanges”, here we show that it is also observed at the grain scale in exhumed blueschist metagabbros. In these rocks, petrologic and microstructural observations show a bi‐phase material constituted by strong microfractured magmatic pyroxene clasts located in a weak and ductile lawsonite‐rich metamorphic matrix. To constrain the mechanical conditions allowing the brittle deformation of a clast in a ductile matrix, we used two‐dimensional simple shear numerical experiments. Results show four behaviors: (a) entirely brittle; (b) brittle‐ductile with clast fracturing in a ductile matrix; (c) ductile‐dominant with limited plastic deformation at clast edges; and (d) entirely ductile. We propose that the conditions of the brittle‐ductile behavior, commonly associated with deep transient slips, are controlled by the strength ratio between the strong brittle phase and the weak ductile phase.

A finite crack growth energy release rate for interlaminar fracture analysis of composite material at different temperatures

The interlaminar fracture toughness of unidirectional fiber reinforced polymer composite material is temperature and crack growth history dependence. The non-constant interlaminar fracture toughness challenges the wide application of the linear elastic fracture mechanics-based approach for analyzing the interlaminar crack growth in composite material and structures. In addition, a quantitative relationship between the ductility of the matrix and interlaminar fracture toughness of the fiber reinforced composite is still highly desirable. In this paper, both pure resin and composite double cantilever beam (DCB) are tested at different temperatures. A finite crack growth energy release rate is used to analyze the interlaminar crack growth behavior of composite material at different temperatures. The plasticity of the composite DCB is modeled by Hill’s anisotropic plasticity, with the properties determined from multiscale analyses. It is found that a single constant finite growth energy release rate can well predict the interlaminar mode I crack growth of composite material at different temperatures. The roles of the ductility of matrix, thickness of the DCB, and crack growth history on the interlaminar mode I fracture toughness of composite material are quantitatively determined by using the present method.

STRUCTURAL POSITION AND DISTRIBUTION OF THE LOWER CRETACEOUS BLACK SHALE DEPOSITS WITHIN THE SILESIAN NAPPE OF THE UKRAINIAN CARPATHIANS

The article presents the results of studying the structural position and distribution of potentially oil-generating, organic-enriched Lower Cretaceous black shale deposits of the Shypot Formation, developed within the Silesian Nappe, using the methods of geological mapping and structural analysis. We concluded, that these deposits, which are exposed in the Vicha River basin near the town of Volovets among a continuous field of Oligocene flysch, are the part of the stratigraphic succession of the Silesian Nappe, and they are not a large olistolith or an allochthonous tectonic remnant of another, more internal nappe. Shypot Formation fills a large (1 × 3 km) subvertical tectonic lens. The rocks of the Shypot Formation are represented here by medium-rhythmic flysch: sandstone beds alternating with dark gray and black foliated mudstone (black shale) layers. They are lithified products of both medium-density turbidite flows and hemipelagic deposition of clayey material with a significant amount of organic matter. In the contact zone of the tectonic lens with the surrounding rocks, the deposits are intensively deformed, almost isoclinal folds with subvetrical hinges are observed, which suggest the strike-slip movements. A tectonic mélange is recorded here, which is represented by small blocks (clastolites) of brittle sandstones, sometimes similar to Shypot sandstones, placed in a silt-pelitic ductile matrix. Foliation of the mélange matrix is also subvertical and close to the meridional and/or subcarpathian direction. The structural studies carried out show that in the zone of this contact there were compressive stresses perpendicular to the Carpathian orogen, and stress fields that caused strike-slip movements, most likely right-lateral along the Carpathian thrusts. The tectonic lens is located within the broad Latorytsa-Stryi shear zone, and probably extruded out from deep horizons by transpressive movements (compression and strike-slip) and forms a “positive flower structure”. The vertical foliation in the mélange suggests that small blocks of Shypot sandstones were extruded up together with the ductile mélange matrix during diapirism. Similar processes probably led to the rise of a large lens of Shypot sandstones as the positive flower structure. The studies suggests that the black shale deposits of the Shypot Formation, enriched with organic matter, are widespread at some depth within the Silesian Nappe, and in some places are pushed up to the level of the Oligocene flysch. As a result, the Shypot Formation and Oligocene flysch are now in direct contact along faults/mélange zones. The presence of Lower Cretaceous potentially oil- and gas-generating black shale deposits within the Silesian Nappe significantly increases the prospects for oil and gas exploration in this area.

Rubber-based phosphaphenanthrene grafted polymer and its application to fabricate flame retardant polycarbonate blend with satisfied comprehensive mechanical properties

Grafting flame retardant groups onto common polymer molecule can be a good strategy to constructing superior flame retardant macromolecules, which provides a promising direction to fabricate fire safety polymer materials with satisfied comprehensive mechanical properties. In this thesis, a rubber-based phosphaphenanthrene grafted polymeric molecule (P-SBS) was synthesized via the grafting reaction of 9, 10-dihydro-9-oxa-10-phenanthrene-10-oxide (DOPO) with thermoplastic styrene-butadiene-styrene copolymer (SBS), and then applied to melt blending with polycarbonate (PC) to form P-SBS/PC blend with sea-island structure. The incorporated P-SBS not only brought PC much higher comprehensive flame retardancy, including higher limited oxygen index, shorter self-extinguishing time, less heat release during burning process, higher-quality char layer structure, and fewer amount of flammable volatile emission; but also endowed it with more satisfied comprehensive mechanical properties, including larger elongation at break, better anti-impact, higher flexural strength, and maintained tensile strength. By analysing burning residue, tracking thermal decomposition volatile emission, and inferring the pyrolysis route of P-SBS, the gas- and condensed-phase flame retardant mechanisms of P-SBS in suppressing the flammability of PC matrix were disclosed. The morphology analysis on the matrix fracture section and the embeded P-SBS particles before and after mechanical fracture, revealed the behavioral mechanism of P-SBS particles in improving the ductility, toughness, and stiffness of PC matrix. This study provides a beneficial reference to superior flame retardant molecule constructing and advanced flame retardant polymer material manufacturing.