Silicon Carbide Composites Research Articles

Unveiling wear mechanisms of tantalum carbide‐silicon carbide composites: Influence of silicon carbide content and sliding load

AbstractTantalum carbide (TaC), as ceramic coating, is known for its exceptional wear performance, however, the tribological behavior of bulk TaC ceramics is poorly understood and requires persistent research. In the current study, the tribology of spark plasma sintered TaC—SiC composites in dry sliding contacts against silicon carbide (SiC) counterbody under various sliding loads (5, 10, and 15 N) is investigated with respect to change in SiC content (from 0 to 65 vol%). With changes in reinforcement content and load, the coefficient of friction and wear rate varied in the range of 0.25–0.45 and 4.7 × 10−7–2.1 × 10−6 mm3/Nm, respectively. At 5 N load, dominant abrasion is observed for composites containing SiC content up to 35 vol%, while abrasion and mild fracture are observed for the composites containing above 35 vol% SiC. At 15 N load, abrasion and oxidation are observed on worn surfaces of monolithic TaC. TaC composites with ≤ 35 vol% SiC content exhibited abrasion, pull‐outs, and tribo‐oxidation, while composites with ≥ 50 vol% SiC content experienced severe fracture along with tribo‐oxidation. The presence of tribo‐oxidation on worn tracks at a higher sliding load (15 N) is confirmed by X‐ray photoelectron spectroscopy results.

Effects of Temperature and Water Vapor Content on Microstructure, Mechanical Properties and Corrosion Behavior of C/C-SiC Composites.

Carbon-fiber-reinforced carbon and silicon carbide (C/C-SiC) composites were prepared using chemical vapor infiltration (CVI) combined with reactive melt infiltration (RMI). The microstructure and flexural properties of C/C-SiC composites after oxidation in different temperature water vapor environments were studied. The results indicate that the difficulty of oxidation in water vapor can be ranked from easy to difficult in the following order: carbon fiber (CF), pyrolytic carbon (PyC), and ceramic phase. The surface CFs become cone-shaped under corrosion. PyC has a slower oxidation rate and lower degree of oxidation compared to CF. The SiO2 layer formed by the oxidation of SiC and residual Si was insufficient to fully cover the surface of CFs and PyC. As the temperature increased, the oxide film thickened, but the corrosion degree of CF and PyC intensified, and the flexural performance continuously deteriorated. The flexural strength of C/C-SiC composites was 271.86 MPa at room temperature. Their strength retention rates were all higher than 92.19% after water vapor corrosion at 1000 °C, still maintaining the "pseudoplastic" fracture characteristics. After water vapor corrosion at 1200 °C, the CFs inside the composites sustained more severe damage, with a strength retention rate as low as 48.75%. The fracture mode was also more inclined towards brittle fracture.

Multiscale Modeling of Silicon Carbide Cladding for Nuclear Applications: Thermal Performance Modeling

The complex multiscale and anisotropic nature of silicon carbide (SiC) ceramic matrix composite (CMC) makes it difficult to accurately model its performance in nuclear applications. The existing models for nuclear grade composite SiC do not account for the microstructural features and how these features can affect the thermal and structural behavior of the cladding and its anisotropic properties. In addition to the microstructural features, the properties of individual constituents of the composites and fiber tow architecture determine the bulk properties. Models for determining the relationship between the individual constituents’ properties and the bulk properties of SiC composites for nuclear applications are absent, although empirical relationships exist in the literature. Here, a hierarchical multiscale modeling approach was presented to address this challenge. This modular approach addressed this difficulty by dividing the various aspects of the composite material into separate models at different length scales, with the evaluated property from the lower-length-scale model serving as an input to the higher-length-scale model. The multiscale model considered the properties of various individual constituents of the composite material (fiber, matrix, and interphase), the porosity in the matrix, the fiber volume fraction, the composite architecture, the tow thickness, etc. By considering inhomogeneous and anisotropic contributions intrinsically, our bottom-up multiscale modeling strategy is naturally physics-informed, bridging constitutive law from micromechanics to meso-mechanics and structural mechanics. The effects that these various physical attributes and thermo-physical properties have on the composite’s bulk thermal properties were easily evaluated and demonstrated through the various analyses presented herein. Since silicon carbide fiber-reinforced SiC CMCs are also promising thermal–structural materials with a broad range of high-end technology applications beyond nuclear applications, we envision that the multiscale modeling method we present here may prove helpful in future efforts to develop and construct reinforced CMCs and other advanced composite nuclear materials, such as MAX phase materials, that can service under harsh environments of ultrahigh temperatures, oxidation, corrosion, and/or irradiation.

Comparative study of the structural parameters of reaction-sintered ceramics based on silicon carbide using digital materials science methods

Reaction-sintered ceramic materials were synthesized: silicon carbide and diamond-silicon carbide composite. The microstructure was studied and the physical and mechanical properties of composite ceramics were determined. It has been experimentally shown that the numerical parameters of the structure ― lacunarity and Voronoi entropy, obtained using digital materials science methods, allow a comparative assessment of the homogeneity of the ceramic structure and substantiation of its strength advantages.

Machining of Cf/SiC composite with indigenously developed nano green cutting fluid: Machined surface fibre morphology

The Carbon fibre reinforced Silicon Carbide (Cf/Sic) composites are widely used in different industries such as automotive, aerospace, etc. The Cf/SiC is indigenous developed and detail of the fabrication procedure is presented. The nano fluid, namely Graphene Oxide Organo Boron (GOOB) is developed indigenously for using as the cutting fluid. This nano fluid is mixed in green cutting fluid (GCF) in different proportions and the concentration is optimized. The nano fluid is characterized by advanced techniques for the confirmation. To reduce the surface roughness on the fabricated Cf/SiC, end milling operation is carried out with different machining environments such as dry, flood cooling with cutting fluid and nano fluid and minimum quantity cutting fluid with nano fluid. The machining operations are carried out by varying different input parameters, namely, cutting speed, feed rate, and depth of cut. The results indicated that the minimum surface roughness of 1.845 μm is obtained when 0.5 % GOOB with GCF is used. This work would benefit the researchers exploring the preparation and interaction mechanism of the indigenously developed nano green cutting fluid for machining Cf/SiC-based ceramic matrix composites.

Splashing effects and mechanism in water jet-guided laser processing of Cf/SiC composites

Water jet-guided laser (WJGL) processing of ceramic matrix composites offers smooth cutting surfaces and minimizes defects such as delamination, burrs, and recast layers. However, the processing ability of WJGL is limited by the stability of the water jet. Splashing is a critical factor that affects water jet stability. This study investigates the splashing morphology and its impact mechanism during WJGL processing of continuous carbon fiber reinforced silicon carbide (Cf/SiC) composites. High-speed cameras were used to capture splashing morphologies and laser transmission states during drilling and grooving. The results indicate that the splashing morphology was significantly affected by the water jet speed and the micro-hole/groove depth, resulting in behaviors such as water accumulation, droplets falling, rebound droplets, splash impact, water film, and mist, which distorted or even broke the water jet. The laser escaped in the distorted water jet, leading to a reduction in material removal rate. The splashing at the water jet speed of 160 m/s resulted in a 61.1 % reduction in material removal rate during drilling compared to 40 m/s. In addition, a method of placing a porous water-absorbing material on the workpiece surface was proposed, which effectively improved the material removal rate. This paper presents a theoretical basis for comprehending and addressing splashing in WJGL processing.

Studies of SiC‐Filled Al6061 Metal Matrix Composite Optical, Mechanical, Tribological, and Corrosion Behavior with Strengthening Mechanisms

The objective of the current study is to produce metal matrix composites (MMCs) using ultrasonic‐assisted stir casting and Al6061 alloy reinforced with silicon carbide (SiC) microparticle reinforcement in weight percentages of 0, 2, 4, and 6. The microstructural alterations of Al6061–SiC composites are investigated using a scanning electron microscope (SEM) equipped with an energy‐dispersive X‐ray (EDAX). By adding more nucleation sites for the formation of smaller grains, SiC reinforcement of the Al6061 matrix encourages grain refining. The SiC addition significantly changes the microstructure of Al6061 composites, enhancing their mechanical qualities. In addition to increasing density by 0.6%, hardness by 33%, and tensile strength by 33%. The increased SiC content dramatically decreases elongation by 42%. The strength of Al6061–SiC MMCs is predicted using several strengthening mechanism concepts as part of the continuing investigation. For Al6061–SiC composites, the strengthening contribution from thermal mismatch is more significant than that from Orowan strengthening, Hall–Petch mechanism, and load transmitting effect. Grain refinement interactions, load transmission mechanisms, and the strengthening effects of CTE differences and dislocations between matrix and reinforcement particles are studied. The composite with 6‐weight percent SiC reinforcement performs better in dry sliding wear and corrosion resistance.

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.

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.

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.

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.

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.

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.

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.

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.

A study on the effects of hybrid (SIC- PSSA) nano sized reinforcement on mechanical and tribological behaviour of Al alloy-based metal matrix composite produced by ultrasonic assisted stir casting

This study focuses on the effects of hybrid reinforcement consisting of nanosized particles of Palm Sprout Shell Ash (PSSA) and silicon carbide (SiC) on the mechanical and tribological properties of the Al-Cu-Mg alloy. Hybrid reinforced composites with different weight percentages of SiC and PSSA (0:0, 0:4, 1:3, 2:2, and 4:0 wt%) were prepared using the ultrasonic-assisted bottom-poured stir casting technique. Scanning electron microscopy (SEM) and energy-dispersive x-ray spectroscopy (EDS) were used to characterize the hybrid composite made of Al-Cu-Mg alloy. The optical and SEM microstructural analyses demonstrated an even distribution of SiC and PSSA nano size reinforcements within the matrix. The EDS analysis revealed SiC and PSSA reinforcement particles in the composite. The mechanical properties (tensile, flexural, and impact strength) and wear properties (wear rate and coefficient of friction) of the composites and alloys were evaluated according to the ASTM standards. The hybrid reinforced composites outperformed the base alloy. Among all composites, the 2:2 wt% SIC and PSSA hybrid reinforced composites exhibited a significant enhancement in both tensile and flexural strength, with a 29.15% and 27.64% increase in strength, respectively. However, the inclusion of these reinforcements led to a reduction in the ductility and impact strength of the Al-Cu-Mg alloy composite. The 0:4 wt% SiC- and PSSA-reinforced composites experienced the largest reductions in ductility and impact strength, with decreases of 47.67% and 3.56%, respectively. For the 2:2 wt% SiC and PSSA composites, these reductions were 23.64% and 3.16%, respectively. The SEM analysis of the fractured surfaces of the composites tested for mechanical properties revealed evidence of both ductile and brittle fracture mechanisms in the tensile, flexural, and impact tests. The wear behaviour of the prepared samples was evaluated, and all composites exhibited superior performance compared with the base alloy, demonstrating adhesive and abrasive wear mechanisms and varying friction coefficients. Among all the composites, the 2:2 wt% SiC- and PSSA-reinforced composites exhibited high wear resistance and a lower coefficient of friction than the other fabricated composites.