Fiber Reinforced Silicon Carbide Composites Research Articles

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.

Ultra-precision grinding damage suppression strategy for 2.5D-Cf-SiCs by resin coating protection

2.5D carbon fiber reinforced silicon carbide composites (2.5D-CfSiCs) are extensively applied in the aerospace industry based on excellent properties. However, surface quality is an important challenge. This study proposes a new method to improve the surface quality by coating the surface with resin and extending the surrounding edges, followed by ultra-precision grinding. The experimental results showed that the resin coating improved the quality of the machined surface and reduced edge spalling. The resin coating effectively protects the composite surface from grinding damage, while the extension of the resin helps to reduce edge damage. Resin coating can improve the surface quality, resulting in a more uniform surface. Therefore, this method provides a new way to improve the application potential of 2.5D-Cf-SiCs.

Fracture toughness evolution and failure mechanisms of two-dimensional SiCf/SiC composites at temperatures up to 1500 °C in air

Silicon carbide fiber reinforced silicon carbide composites (SiCf/SiC) are of the few most promising materials for high-temperature structural applications. In this study, two-dimensional (2D) plain-woven SiCf/SiC composites were prepared by chemical vapor infiltration process and subjected to single-sided notched beam three-point bending tests from room temperature (RT) to 1500 °C in air. The temperature-dependent bending load–deflection curves and fracture toughness were obtained. The results show that the SiCf/SiC composites exhibit linear deformation characteristics initially, followed by nonlinear deformation behavior which become more pronounced with increasing temperature. The fracture toughness decreases in the range of RT to 1000 °C due to the evolution of components properties, and increases at 1200 °C due to the interface property degradation and fiber pull-out. Above 1200 °C, it decreases with increasing temperature owing to the serious high-temperature oxidation. Further, the failure mechanisms of the 2D plain-woven SiCf/SiC composites at different temperatures was analyzed through macro and micro analysis. The evolution of components properties affected by high temperature and oxidation as well as fiber pull-out play a leading role in fracture toughness of composites. The findings of this study provide important support for the mechanical behavior and failure mechanisms of SiCf/SiC composites at ultra-high temperatures in air.

Damage identification and fracture behavior of 2.5D SiCf/SiC composites under coupled stress states

Continuous fiber-reinforced silicon carbide composites have received significant attention due to their high-temperature mechanical stability. However, their widespread implementation has been hindered by intricate fracture mechanisms and limited toughness. This study presents a real-time approach for identifying damage type in 2.5D SiCf/SiC composites and highlights the significant impact of minor eccentric loading angle on the fracture behavior and mechanical properties using acoustic emission (AE). Even a slight degree of eccentric loading angle can significantly alter the fracture behaviors, leading to a significant increase in fracture toughness. The fracture damage evolution law of 2.5D SiCf/SiC under varying eccentric loading angles was investigated with the help of the AE damage identification, fracture morphology and finite element analysis. These findings provide valuable insights for multi-axis stress analysis of 2.5D high-performance composites.

Modeling of Chemical Vapor Infiltration for Fiber-Reinforced Silicon Carbide Composites Using Meshless Method of Fundamental Solutions

In this study, the Method of Fundamental Solutions (MFSs) is adopted to model Chemical Vapor Infiltration (CVI) in a fibrous preform. The preparation of dense fiber-reinforced silicon carbide composites is considered. The reaction flux at the solid surface is equal to the diffusion flux towards the surface. The Robin or third-type boundary condition is implemented into the MFS. From the fibers’ surface concentrations obtained by MFS, deposition rates are calculated, and the geometry is updated at each time step, modeling the pore filling over time. The MFS solution is verified by comparing the results to a known analytical solution for a simplified geometry of concentric cylinders with a concentration set at the outer cylinder and a reaction at the inner cylinder. MFS solutions are compared to published experimental data. Porosity transients are obtained by a combination of MFSs with surface deposition to show the relation between the initial and final porosities.

A novel core-shell C/SiC bolt prepared by chemical vapor infiltration and its fiber strengthening mechanisms

Integrated manufacturing techniques have been extensively utilized to assemble thermal structural components made of continuous fiber reinforced silicon carbide composites (C/SiC) to fabricate large and complex components. The mechanical joint, always in terms of C/SiC bolts, become the weakest link in the components. Laminated C/SiC bolts have been invented to meet the requirements of the high temperature applications. Due to the low shear strengths of C/SiC, the threads are prone to be damaged. In order to fully employ the high tensile strength of carbon fibers, core-shell C/SiC bolt is proposed with the shell prepared by woven fiber architecture. Uniform circumferential microstructure of the threaded teeth has been obtained and the corresponding strength has been improved through fiber bridging mechanism. The results shows that the thread pull-off strength is 17.96% greater than that of the laminated thread tooth, and the stud tensile strength is slightly improved up to 2.96%. The stud shear strength is enhanced by 45.29% and 46.88% with unidirectional C/SiC rod and ZrO2 ceramic rod, respectively. The improvements are mainly caused by the fiber tension-shear coupling effects. Especially the introduction of unidirectional C/SiC rod improves the shear strength of the bolts by fully utilizing the fiber strengthening mechanisms under in-plane shear loading.

Experimental and numerical studies on low-velocity impact of laminated C/SiC structures

Laminated C/SiC(carbon fiber reinforced silicon carbide composites) has the complicated nature of composite failure which include cracks for void defects at the meso and micro scales, complex cracks propagation of tunnel cracks, matrix cracks, delaminations and fiber cracks, orthotropic, and pseudoplastic behavior. It has technical challenge to solve all of them for complicated-mechanics problems by using multi-scale methodology. This paper focused tackling it by a model that lies between macro and meso scales, and proposed a new conceptual 3D FE-PDM(Finite Element - Progressive Damage Method). 3D FE-PDM was validated by the experiments of low-velocity impact of 2D C/SiC and 3D needled C/SiC. Damage initiation and evolution were controlled by strain in order to preventing stress chaos which could occur as cracks leading local stress relief. The multi-linear constitutive relations were adopted in orthotropic directions. The coupled effects of stresses between in-plane and out-of-plane were computed by adding damage coefficients into stiffness matrix. Cohesive Zone Method was used for delamination. The PDM approach was introduced for the 3D elements for intralaminar and cohesive elements for the interfaces. A parametric inversion methodology was put forward to determine the model parameters iteratively by comparing simulation results with the load-time curves, damage CT details of the experiments. Validation implies that, with small number of parameters, 3D FE-PDM is able to predict damage initiation of each phase knee, damage evolution, and load–displacement curve with good convergence for the low-velocity impact case. 2D woven and 3D needled non-woven C/SiC both have impact energy threshold and different damage evolution types.

Additive manufacturing of continuous carbon fiber-reinforced silicon carbide composite by fused filament fabrication and precursor infiltration pyrolysis

Continuous fiber reinforced silicon carbide composites (Cf/SiC) are known for their advantages such as high strength, high modulus, high thermal conductivity, and low density. In this paper, we propose an integrated Cf/SiC preparation and processing process. The continuous carbon fiber-reinforced resin matrix composite green parts were processed by fused filament fabrication, and then ceramicized by precursor infiltration pyrolysis process. The processing parameters of the green parts, the performance of the green-part specimens, the phase evolution in the post treatment, and the performance of Cf/SiC samples were investigated. The infill line distance (ILD) had a huge influence on the mechanical properties of green parts and Cf/SiC. The bending strength of the green parts and the Cf/SiC specimens increased with the decrease in ILD. The maximum bending strength of 169.48 MPa and 155.83 MPa was achieved for the carbon fiber/polyethylene terephthalate glycol (Cf/PETG) and polylactic acid (Cf/PLA) green parts, respectively. The highest bending strength of 47.73 MPa of the Cf/SiC material was obtained with the Cf/PLA green parts, while the bending strength of 93.79 MPa was obtained for the Cf/SiC with Cf/PETG green parts. The increase in mechanical properties was believed to result from the pyrolyzed carbon brought by PETG and the increase of the equivalent fiber density within the single layer after a larger nozzle size was used.

Effect of heat treatment on the structure, fracture toughness and oxidation behavior of a silicon coating by atmospheric plasma spraying

Silicon coatings produced by atmospheric plasma spraying are used as bond coat in environmental barrier coatings which protect silicon carbide fiber reinforced silicon carbide composites against water vapor induced corrosion at high temperatures. Silicon coatings exhibit structural defects such as interlamellar boundaries, gaps, pores and microcracks, some of which become pathways for oxygen penetration, leading to internal oxidation of the silicon coating. This study was conducted to reduce the pathways for oxygen penetration by heat-treatment under argon atmosphere and investigate the effects of heat-treatment on the structure, fracture toughness and oxidation behavior of the silicon coating. The results show that the structural defects could be reduced by a heat-treatment at T = 1300 °C, which resulted in a lower mass gain of the coating in the initial cycle in a cyclic oxidation test. The fracture toughness of the coating was significantly decreased by the heat-treatment, which led to the formation of microcracks in the coating in the cyclic oxidation test. As a result, the heat-treated coating exhibited a higher mass gain rate than the as-sprayed coating, leading to that both coatings exhibited almost the same mass gain at the end of the cyclic oxidation test of n = 10 cycles.

Transition of in-plane compressive strength and failure mechanism of 2D-C/SiC: Influence of off-axis loading angle and loading rate

In this study, the in-plane compressive behavior of two-dimensional plain-woven carbon fiber-reinforced silicon carbide composite (2D-C/SiC) was investigated using on- and off-axis compression experiments under both quasi-static and dynamic loading conditions. The failure mechanisms were elucidated through in-situ observations and microanalysis-based methods. As the loading angle increased from 0 to 45°, stress–strain curves exhibited stronger nonlinearity, and the in-plane compressive strength decreased by 50.2% and 41.1% under quasi-static and dynamic loading conditions, respectively. The failure mechanism shifted from fiber-dominant to interface- and matrix-dominant as the loading angle increased, which was responsible for the strength degradation and intensified nonlinearity in curves. A positive strain rate effect on the in-plane compressive strength attributed to the interface enhancement and multiple crack propagation was identified. Additionally, owing to the competition between the dynamic strengthening and damage aggravation effects, the strain-rate sensitivity factors increased with the loading angle up to 30° and then decreased at 45°.

A focused review on the tribological behavior of C/SiC composites: Present status and future prospects

Silicon carbide-based ceramic matrix composites have received extensive attention in recent years. Many excellent reviews have reported on the tribological behavior of carbon fiber-reinforced carbon and silicon carbide dual matrix (C/C-SiC) composites. However, a systematic overview of the tribological properties of carbon fiber-reinforced silicon carbide (C/SiC) composites does not exist. This review focuses on C/SiC composites and summarizes the key factors, including internal factors (constituent content, graphitization process, material structure and fiber direction), and various test conditions (pressure and speed, dry and wet, temperature, and counterparts) that affect their tribological behavior. Their wear mechanisms under different conditions are elaborated. Finally, some potential future development directions for improving the performance of C/SiC composites are proposed to provide high-quality ceramic matrix composites for engineering applications. These directions include structural modification, matrix modification, coating technology, laser surface texturing, and material genome method.

Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration

Poor flowability of printable powders and long preparation cycles are the main challenges in selective laser sintering (SLS) of chopped carbon fiber reinforced silicon carbide composites (SiC composites) with complex structures. In this study, we develop an efficient and novel processing route in the fabrication of lightweight SiC composites via SLS of phenolic resin (PR) and C_f powders with the addition of α-SiC particles combined with one-step reactive melt infiltration (RMI). The effects of α-SiC addition on the microstructural evolution of the C_f/SiC/PR printed bodies, C_f/SiC/C green bodies, and derived SiC composites were investigated. The results indicate that the added α-SiC particles play an important role in enhancing the flowability of raw powders, reducing porosity, increasing the reliability of the C_f/SiC/C green bodies, and contributing to improving the microstructure homogeneity and mechanical properties of the SiC composites. The maximum density, flexural strength, and fracture toughness of the SiC composites are 2.749±0.006 g×cm⁻³, 266±5 MPa, and 3.30±0.06 MPa·m^1/2, respectively. The coefficient of thermal expansion (CTE) of the SiC composites is approximately 4.29×10⁻⁶ K⁻¹ from room temperature (RT) to 900 °C, and the thermal conductivity is in the range of 80.15-92.48 W·m⁻¹·K⁻¹ at RT. The high-temperature strength of the SiC composites increase to 287±18 MPa up to 1200 °C. This study provides a novel as well as a feasible tactic for the preparation of high-quality printable powders as well as lightweight, high strength, and high thermal conductivity SiC composites with complex structures by SLS and RMI.

Synergistic reinforcement effects of ZrB2 on the ultra-high temperature stability of Cf/SiC composite fabricated by liquid silicon infiltration

A carbon fiber-reinforced silicon carbide (Cf/SiC) composite was fabricated with ZrB2 via the liquid silicon infiltration (LSI) method. A prepreg was prepared by impregnating the phenolic resin with the ZrB2 powder. The as-LSIed composites were tested for 5 min with an oxyacetylene torch to evaluate their ablation and oxidation properties under an ultra-high temperature environment. The ZrB2 powders and SiC matrix between carbon fiber bundles generated a dense ZrO2-SiO2 layer, which inhibited further oxygen diffusion into the composite and minimized the ablation and oxidation of the carbon fibers. Weight loss and linear ablation rate were further reduced with the addition of ZrB2 to the Cf/SiC composite; moreover, the synergistic effect of ZrB2 and SiC reinforced the ablation properties with increased ZrB2 content. ZrB2 also reduced the amount of residual silicon, which was detrimental to the mechanical properties of Cf/SiC composite.

Experimental investigation on interlaminar and in-plane shear damage evolution of 2D C/SiC composites using acoustic emission and X-ray computed microtomography

Carbon fiber-reinforced silicon carbide composites (C/SiC) are widely used in lightweight aerospace structures for thermal protection due to its excellent mechanical properties. The low interfacial shear strength of the composites decreases its performance and limits its application. To investigate the shearing performance of C/SiC composite, interlaminar shear and in-plane shear tests were conducted. Real-time X-ray micro-computed tomography (XCT) non-destructive testing technology is an effective method for damage analysis of composite materials. The damage mechanisms of 2D plain weave C/SiC composites prepared by chemical vapor infiltration process under interlaminar shear loading are investigated using the combination of XCT and acoustic emission detection system. The in-situ XCT results reveal the damage visualization mechanisms of the composites and the damage evolution process including matrix damage, interfacial debonding and fiber fracture. The failure mechanisms and morphology of the shear effect for 2D plain weave C/SiC were analysed.

Ablation behavior of C/SiC with YSZ and ZrB2 coatings under high-energy laser irradiation

Carbon fiber-reinforced silicon carbide (C/SiC) composites are important candidates for laser protection materials. In this study, ablation mechanism of C/SiC coated with ZrO2/Mo and ZrB2–SiC/ZrO2/Mo under laser irradiation was studied. ZrB2–SiC multiphase ceramic and ZrO2 ceramic were successfully coated on C/SiC composite by atmospheric plasma spraying technology with Mo as transition layer. Phase evolution and morphology of composite were investigated by X-ray diffraction, scanning electron microscopy, and transmission electron microscopy. Moreover, ablation behavior of the composite was investigated by laser confocal microscopy. Results showed that ablation mechanism of C/SiC composite was controlled by phase transformation, thermal reaction, and thermal diffusion, with solid–liquid transition of ZrB2 and ZrO2 being dominant factor. Endothermic reaction and good thermal diffusivity of coatings were also important factors affecting ablation performance. Reflectivity effect of ZrO2 coating was limited under high-energy laser irradiation. Compared with ZrO2/Mo single-phase-monolayer coating, designed ZrB2–SiC/ZrO2/Mo coating showed better ablation performance, and breakdown time of C/SiC increased from 10 to 40 s. The depletion of liquid phase in molten pool was identified as an important factor responsible for rapid failure of C/SiC. The coating failed when the entire liquid phase was consumed within molten pool, followed by rapid damage of C/SiC substrate. Results of this study can provide theoretical guidance and research ideas for design and application of laser protective materials.

An approach to estimate crack opening displacement in two-dimensional plain-woven silicon carbide fiber-reinforced silicon carbide composite considering different matrix cracking modes

Understanding of cracking opening behavior is important for the prediction of residual strength and lifetime of silicon carbide fiber-reinforced silicon carbide ceramic–matrix composites at elevated temperatures. Under tensile loading below the proportional limit stress, multiple matrix cracking modes in the longitudinal and transverse yarns of a two-dimensional plain-woven silicon carbide fiber-reinforced silicon carbide composite appear in the matrix with debonding at the fiber/matrix interface. Crack opening displacement is a key parameter to characterize the crack opening behavior in silicon carbide fiber-reinforced silicon carbide composites and is affected by the multiple matrix cracking modes. In this article, a damage-based micromechanical crack opening displacement model for two-dimensional plain-woven silicon carbide fiber-reinforced silicon carbide composites is developed considering different matrix cracking modes. Two typical matrix cracking modes in a two-dimensional plain-woven silicon carbide fiber-reinforced silicon carbide composite, that is, cracking mode III with cracking in the matrix of the longitudinal and transverse yarns and cracking mode V with cracking only in the matrix of the longitudinal yarns, are considered. Micro stress field in the fiber, matrix of the longitudinal yarns, and transverse yarns are obtained. The crack opening displacement and related damage parameters are determined. Relationships between composite's crack opening displacement, constitutive properties, woven parameters, and damage state are established. Experimental crack opening displacements of cracking modes III and V in a two-dimensional plain-woven melt-infiltration silicon carbide fiber-reinforced silicon carbide composite from the published literature are predicted. For cracking mode III with partial interface debonding, the crack opening displacement increased nonlinearly with applied stress; and for cracking mode V with complete interface debonding, the crack opening displacement increased linearly with applied stress.

Fabrication and high-temperature performance evaluation of silicon carbide – Hafnium carbide nanocomposite fiber

Silicon carbide fibers are used in silicon carbide fiber reinforced silicon carbide composite (SiCf/SiC) as reinforcement materials because of their outstanding mechanical properties, high-temperature durability and oxidation resistance. Owing to its excellent high-temperature performance, SiCf/SiC finds extensive application in materials exposed to extreme environments for long periods, such as nuclear fusion reactors, gas turbines, and rocket nozzles. Transition metal-based carbides, in particular hafnium carbide, have attracted considerable attention owing to their high melting point, high self-diffusion coefficient and chemical bonding energy. This study aims to improve the high-temperature creep characteristics of polycrystalline silicon carbide fibers by dispersing hafnium carbide nanocrystals in crystalline silicon carbide fibers and the changes in the microstructure, crystal phase and crystallite size were observed under various sintering conditions by different experiments. The results confirmed that hafnium carbide was uniformly dispersed, and that the crystal size grew to approximately 40 nm at a sintering temperature of 2000 °C. For high-temperature property evaluation, bend stress relaxation tests were conducted at temperatures in the range of 1000–1500 °C, and the effects of hafnium carbide were compared with those of other single silicon carbide fibers.

Size effect of carbon fiber-reinforced silicon carbide composites (C/C-SiC): Part 2 - tensile testing with alignment device

The appropriate assessment of mechanical properties is essential to design ceramic matrix composites. The size effect of strength plays a key role for the material understanding and the transfer from lab-scale samples to components. In order to investigate the size effect for carbon fiber-reinforced silicon carbon (C/C-SiC) under tensile load, a tensile testing with a minimum of deviation from the pure tensile loading is necessary. Hence, a hybrid edge/face-loading test device for self-alignment and centering of C/C-SiC tensile samples was developed, evaluated and proved to ensure pure tensile load. The mechanical analysis of more than 190 samples with two different cross-sections fabricated from the same material population revealed no significant difference in tensile strength. Although the volume under load was increased from 129 to 154 mm3, the tensile strengths of 162 ± 7 and 164 ± 6 MPa did not change. These results are discussed regarding the weakest link and energetic size effect approaches.

Insights into fracture mechanisms and strength behaviors of two-dimensional carbon fiber reinforced silicon carbide composites at elevated temperatures

Carbon fiber reinforced silicon carbide (C/SiC) composites are usually subjected to thermal-mechanical-oxidation-coupled loads during service. However, their mechanical properties at ultra-high temperatures in oxidizing environments have rarely been reported. In this paper, a method based on the induction heating technology is proposed for testing the ultra-high-temperature mechanical properties of materials in air. The flexural behaviors of a 2D plain-weave C/SiC material prepared via chemical vapor infiltration are investigated in air up to 1800 °C for the first time. Inverse temperature dependences of the flexural modulus and strength are observed. New fracture mechanisms that are responsible for the mechanical behaviors at elevated temperatures are elucidated. Fracture modes at different temperatures are proposed. A high-temperature fracture strength model for oxidizing environments is developed, which is in good agreement with the experimental results. The factors affecting the fracture strength behaviors of the C/SiC in air at elevated temperatures are characterized quantitatively.

Design and material selection of optomechanical systems for the extreme environment on Mars

Mars surface composition detector (MarSCoDe) is a scientific instrument suite onboard the Mars rover of the “Tianwen-1” mission, which uses laser-induced breakdown spectroscopy and shortwave infrared spectroscopy to detect the composition of soils and rocks at the surface of Mars. The optical head unit (OHU) is the core hardware of MarSCoDe, containing a Cassegrain telescope and other optical modules for lasers generation and signals transmission. The unit lacks thermal control resources and is located outside the rover’s cabin, which will directly face the Martian surface drastic temperature changes. We introduce the optomechanical designs that realize the lightweight and high thermal stability of the OHU optical system, especially the designs and implementations of the semiopen primary mirror based on silicon carbide and the fully closed optical bench based on carbon fiber-reinforced polymer. Meanwhile, the advantages and difficulties of silicon carbide, long carbon fiber-reinforced silicon carbide composites, and carbon fiber-reinforced polymer materials used for small and compact optomechanical systems are discussed. Subsequently, the environmental adaptability of the telescope system of OHU was studied through analytical and experimental methods, which show that it can achieve the required optical performance over a temperature range of approximately 100°C.