Silicon Carbide Particles Research Articles

Influence of Silane Coupling Agent and Anionic Dispersant on the Dispersion Effect of Silicon Carbide Particles.

Silicon carbide (SiC), as a widely used material, has great properties. To improve the flowability of ultrafine silicon carbide slurry, this study used sodium humate, tetramethylammonium hydroxide (TMAH), and N-(β-monoaminoethyl)-γ-aminopropyltrimethyl(ethoxysilane) (KH792) to modify the ultrafine silicon carbide powder produced by Qingzhou Micro Powder Company. The effects of different modifiers on improving the flowability of ultrafine silicon carbide slurry were investigated by means of viscosity tests, sedimentation experiments, and SEM observations. Their modification mechanisms were investigated by means of zeta potential tests, XPS tests, and so on. In this paper, the initial modification of SiC was carried out with KH792, followed by the secondary modification with anionic and cationic modifiers (tetramethylammonium hydroxide and sodium humate), and the optimal modification conditions were investigated by means of a viscosity test, which showed that the lowest viscosity of the modified SiC reached 0.076 Pa·s and that the absolute maximum value of the zeta potential increased from 47.5 at the time of no modification to 63.7 (maximum values) at the time of modification. This means it has an improved surface charge, which improves dispersion. The adsorption results of the modifier on the silicon carbide surface were also demonstrated by the XPS test results.

FE Investigation of Design and Quality Control-Related Issues Contributing to Metal-On-Metal Hip Implant Failures

High levels of cobalt and chromium ions were detected in the bodies of multiple recipients of modular cobalt chrome molybdenum metal-on-metal hip implants, necessitating the revision of their implants. A forensic engineering investigation of provided discovery documents and existing literature regarding the design, manufacturing, and clinical testing of these modular hip implants was performed. The investigation revealed that the modular interfaces of the implant allowed for micromotion to induce mechanically assisted crevice corrosion at these surfaces. The debris from this corrosion resulted in the release of metal ions into the bodies of the users, forming pseudotumors and compromising the user’s health and wellbeing. The effect of this corrosion was enhanced by the galvanic couple that existed between the modular components of the implant. In addition, scanning electron microscopy (SEM) and electron dispersive spectroscopy (EDS) analysis identified silicon carbide (SiC) and aluminum oxide (AL2O3 ) particles left behind from polishing, which were embedded in the ball and liners. These particles accelerated the wear of the hip implant and further exacerbated the release of metal ions. The designers of future hip implants should take care in preventing the occurrence of the above-stated factors.

Self‐templated magnesiothermic reduction of ORMOSIL particles to monodisperse hollow spherical SiC composite particles

AbstractHollow silicon carbide (SiC) particles have attracted attention due to their well‐defined morphology, low density, and large surface area that can be leveraged for a wide variety of applications. Here, we report the self‐templated synthesis of monodisperse hollow spherical SiC composite particles with controllable shell thicknesses using magnesiothermic reduction of organically modified silica (ORMOSIL) particles. Monodisperse ORMOSIL particles containing three organic groups of methyl, vinyl, and mercaptopropyl were produced by a simple one‐pot sol–gel process and then converted to hollow spherical SiC composite particles via a magnesiothermic reduction at 700°C under an inert atmosphere. The spherical morphologies of the original ORMOSIL particles were well maintained through this self‐templated conversion process, but the sizes of the hollow SiC particles were slightly reduced by the thermal treatment. Field emission transmission electron microscopy studies revealed that the shell of hollow particles mainly consists of primary β‐SiC particles with nanometer‐scale sizes. The physical and chemical properties of the hollow SiC composite particles were investigated by scanning electron microscopy, transmission electron microscopy, X‐ray photoelectron spectroscopy, Brunauer–Emmett–Teller, X‐ray diffraction, Fourier transform infrared spectroscopy, Raman, and solid‐state nuclear magnetic resonance analyses. The shell thickness of hollow spherical SiC composite particles can be controlled by simply changing the duration of the thermal conversion process. This study not only provides a simple and easy approach for the preparation of hollow spherical SiC particles but also opens the possibility of large‐scale manufacturing of such particles for commercial applications.

Experimental tribological and mechanical behavior of aluminium alloy 6061 composites incorporated ceramic particulates using Taguchi analysis

Aluminium metal-matrix composites are broadly employed in industries like aerospace, marine, automobile-sector, and many others, generating a broad research interest. They are preferred for their high strength and low wear rate. This research work is mainly directed towards the fabrication of two types of metal-matrix composite materials using aluminium-alloy 6061(AA6061) as the matrix material and incorporating aluminium oxide (Al2O3), aluminium nitride (AlN), and silicon carbide (SiC) as a reinforcement material. AA6061 has been reinforced with Al2O3 and SiC particulates in AS series composites, while AA series composites, AA6061 has been reinforced with Al2O3 and AlN particulates. This hybrid metal composite was constructed using the stir-casting method. These hybrid composites have been investigated for their physical and mechanical characteristics, viz. density, hardness, impact strength, void content, flexural strength, and tensile strength following the ASTM standards. Tribological characteristics of these hybrid composites were performed by Pin-on-disc (POD) tribometer. Taguchi’s design of experimental technique was applied taking four factors viz. composition, sliding-velocity (SV), sliding-distance (SD), and load, and each having 4 levels. ANOVA was employed to find out meaningful parameters. SEM analysis of worn-surface was executed to find out the dominant wear mechanism. Experimental density was highest for AS42, and AA42 composites and void content were lowest for the same. Mechanical properties viz. density, hardness, impact strength, void content, flexural strength, and tensile strength were higher than the base alloy. From the response table of Taguchi analysis of AS and AA composite, the load factor significantly impacted the specific wear rate (SWR) to follow filler content (FC). It can be followed from the ANOVA table for AS composite that the load factor had a magnificent impact on the SWR. The SV and SD show no significant effect on SWR.

Mechanical and tribological properties of silicon carbide /carbon fiber/epoxy resin based composites

In this contribution, an epoxy resin based composites which synergistically modified by carbon fiber (MCF) and silicon carbide (SiC) particles were prepared. The chemical structure of MCF and SiC before and after surface treated using silane coupling agent were analyzed by Fourier transform infrared spectroscopy and X-ray diffraction, respectively. The mechanical properties including tensile, flexural, and compression of the composites were investigated. Moreover, the friction and wear performances were studied on a ball-on-ring wear tester. The results indicated that the best tensile, compressive, and friction and wear properties of composites were obtained when SiC particles content is 3.0 wt.%. Compared to the pure epoxy resin, when the SiC particles content is 4.0 wt.%, the best flexural strength and modulus were obtained, which increased by 8.7% and 52.97%, respectively. Both the average coefficient of friction (COF) and the wear mass losses of the composites decreased significantly with the addition of the modified SiC particles. In addition, the main wear mechanism of pure EP is adhesive and fatigue wear, while the SiC/MCF/EP composites exhibit abrasive and fatigue wear.

Advancing Aluminum-Based Composites with Fly Ash and SiC Reinforcement through Stir Casting

This study explores the advancement of aluminum-based composites through the integration of fly ash and silicon carbide (SiC) reinforcement via stir casting. The process involves melting the alloy in a crucible within a muffle furnace at 700°C, gradually introducing fly ash and SiC particles while stirring at 450 rpm for 12 minutes to ensure uniform dispersion. The addition of 5% SiC and 2.5% fly ash led to significant improvements in multiple mechanical properties.Tensile strength experienced a remarkable enhancement of approximately 19.56%, while hardness showcased a substantial increase of about 34.67%. Furthermore, fatigue strength demonstrated a notable improvement of approximately 26.87%, and wear resistance exhibited a significant enhancement of approximately 31.45%. These enhancements underscore the efficacy of integrating fly ash and SiC reinforcement, highlighting the potential for advanced aluminum composites with superior mechanical properties. This approach presents a promising avenue for enhancing material performance, with implications for diverse industrial applications requiring durability, strength, and wear resistance.

Evaluation on the impact behavior of stir-casted Aluminum composites reinforced with SiC and Gr for lightweight applications

Increasing demands for lightweight materials in various industries, such as aerospace, automotive, and manufacturing, have led to a growing interest in the development of advanced materials with enhanced mechanical properties. One promising avenue for achieving lightweight and high-performance materials is the fabrication of aluminum-based composites reinforced with silicon carbide (SiC) and graphite (Gr) particles through stir casting. The current study examines the impact strength behavior of composites reinforced with AA6063 cast materials that contain different amounts of micron sized SiC particles and 5 weight percent graphite. By using liquid metallurgy, hybrid composites of AA6063, SiC, and Gr were created. The numerous created samples underwent the customary Charpy impact testing, and the impact strength was assessed. By reinforcing SiC and graphite to the aluminum matrix, a substantial increase in impact strength was observed. For the three test samples, the average impact strength of pure aluminum was found to be 7 Joule. Average Impact strength for aluminum with 10% silicon carbide was found to be 8 Joule, which is 14.28% greater than for pure aluminum. The average Impact strength for the composite of aluminum with 20% silicon carbide was 10 Joule, which represents a 42.85% increase in strength over pure aluminum.

Enhancement of mechanical and thermal properties of carbon fiber phenolic resin composites using silicon carbide filler for thermal protection system applications

Thermal protection systems (TPS) are vital for re-entry vehicles for their safe passage into the atmosphere from space. Hence, researchers took a keen interest in improving the thermal and ablative properties of composites to be used in making thermal protection systems. Therefore, an attempt was made to improve the thermal and ablative properties of composites made of carbon fibers (Cf) and resorcinol formaldehyde phenolic (Ph) resin with the incorporation of silicon carbide (SiC) particles. The filler was added in various percentages (0 wt% - blank, 1 wt%, 3 wt%, and 5 wt%), and the composites were tested for ablative, thermal and mechanical properties. The results demonstrate that the SiC-modified PAN-based carbon fiber reinforced phenolic (SiC-PANCf-Ph) composite with 3 wt% SiC enhancement exhibited ideal properties. The post-ablation phase composition and microstructure were examined through X-ray diffraction (XRD), Scanning electron microscopy (SEM), and energy-dispersive X-ray spectroscopy (EDS). The surface morphology evidences the formation of a silicon dioxide (SiO2) layer on the composites. The SiC-PANCf-Ph composites demonstrated the lowest ablation rate, enhancing their potentiality for effective TPS applications.

Fabrication and characterization of sic, tio2, and pksa hybrid aluminum-based metal matrix composites

This study's 7075 aluminium uses the potential swirl moulding process, which incorporates silicon carbide, titanium dioxide, and PKSA additives. In this experimental investigation, the weight percentage of the smallest silicon carbide particle was kept constant at 3%. The titanium dioxide content ranged from 2% to 3%, whereas the weight percentage of PKSA was adjusted between 3% and 8%. The produced instances were subjected to a variety of tests, including a mechanical inspection, a microhardness examination, and an overall deterioration evaluation. The maximum tensile stress of this alloy is 8% more than that of the normal alloy. The increased elasticity of these augmented combinations was shown by the elasticity seen in a component. In addition, we saw substantial improvements in the longitudinal stiffness of its material. The microhardness of the solid waste products (PKSA) decreased, indicating their potential suitability for cost-effective reinforcement of a large amount of vehicle components. The degradation tests have been successfully done. There was a notable slowdown in the rate of decline. An extensive examination was performed using the Field Emission Scanning Electron Microscope (FESEM), which unveiled the spatial arrangement of components inside the aluminium composite. 1 Introduction

Diamond reinforced reaction-bonded boron carbide composites: Fabrication, microstructure, mechanical and tribological properties

Reaction-bonded boron carbide composites were fabricated by molten silicon infiltration of diamond-containing boron carbide preforms. The effects of diamond particle size on the microstructure, mechanical and tribological properties of reaction-bonded boron carbide composites were investigated. Fine diamond particles (≤7.7 µm) completely reacted with silicon generating nano silicon carbide particles, which bonded the boron carbide particles forming a 3-D ceramic skeleton and improving the flexural strength of the composites. Coarser diamond (≥24 µm) particles were retained protected by a dense SiC layer generated from the reaction of diamond and molten silicon. A “core-shell” structure with the retained diamond as the “core” and with the reaction formed silicon carbide as the “shell” formed. Relief structures were established on the composites’ surface during the wear process, greatly reducing the friction coefficient and improving the wear resistance.

A Statistical and Optimization Study on the Influence of Different Abrasive Types on Kerf Quality and Productivity during Abrasive Waterjet (AWJ) Milling of Ti-4Al-6V.

Non-conventional machining processes offer significant advantages over conventional ones, especially in terms of the productivity, cost, and surface integrity of the produced parts due to their higher flexibility. Abrasive waterjet machining, in particular, constitutes an ecologically friendly process with a negligible thermal impact on a workpiece, and it has considerable capabilities for obtaining the desired outcome by regulating some of its numerous parameters. Among these parameters, the abrasive type is particularly important due to its hardness, mesh size, and shape, which lead to considerable deviations on the obtained depth, kerf characteristics, and productivity. Thus, in this work, a comprehensive comparison is conducted on the use of garnet and silicon carbide particles for the slot milling of the Ti-6Al-4V alloy under different conditions. The capabilities of both abrasive materials are evaluated by statistical analysis regarding the depth of penetration, kerf width, kerf taper angle, and material removal rate (MRR), which are obtained under the same process conditions. Finally, a multi-objective optimization based on grey relational analysis (GRA) is performed for several different practical cases. It was found that, although silicon carbide is more efficient in optimizing individual process outputs, the use of a garnet abrasive can lead to considerably better trade-offs between two or more objectives of the machining process.

Pure-SiC ceramic membrane for ultrafiltration: Morphology, pore characteristics and separation performances

Silicon carbide (SiC) ceramic membranes have gained increasing attention due to their excellent chemical and thermal stability serving in harsh conditions. However, the use of SiC ceramic membrane is limited in micro-filtration fields because of the micro-scale pores in the selective layer. Here, a pure-SiC ultrafiltration (UF) membrane was prepared by dip-coating and recrystallization sintering using fine SiC particles of 100 nm and 50 nm in sizes. EDS and XRD analysis confirmed that the membrane was composed of pure-SiC phase, which endowed the UF membrane with strongly chemical resistance. Because of the refinement in particles, the average pore sizes of the ceramic membrane made of 100 nm and 50 nm particles corresponded to 82 nm and 58 nm, respectively. Due to the refinement in pore size, the oil flux increased from 69.50 L/(m2·h) to 99.01 L/(m2·h) and the oil rejection exceeded 98.8 % for the 50 nm membrane.

Deposition behavior and mechanism of thermal sprayed SiC

AbstractIt is widely known that silicon carbide (SiC) is challenging to thermal spray. However, the nature of deposition and the underlying mechanisms are still not clearly understood. In the current work, the process of atmospheric plasma‐sprayed SiC was investigated in detail. SiC exhibits sublimation severely under the plasma spraying (PS). More than 65 mol.% SiC particles lost by sublimation during PS estimated by calculation. Due to the nonuniformity of temperature in plasma flame, a small amount of SiC particles was retained. Moreover, a small amount of Si and SiO2 was experimentally observed after deposition process from the single‐splat characterization. According to the first‐principles calculations, the detachment energy of C atom from the lattice (0.591 eV) is lower than that of Si atom (1.257 eV). The adsorption energies of an O atom on the Si‐ and C‐terminated surfaces are −9.549 and −7.631 eV, respectively. Therefore, C is more likely to form gaseous products after decomposition, and Si is more likely to be retained to form Si and SiO2. Mullite was found on the grain boundaries of molten Si, which was attributed to the rapid diffusion of the Al2O3 substrate along the grain boundaries of Si, promoting the spreading of molten splats. It is difficult to stack particles through self‐diffusion among SiC particles to form coatings. The discovery on thermal deposition mechanism of SiC in PS is helpful to promote the practical application of SiC coatings on preparation optimization and interfacial bonding improvement.

Investigation of Composites Based on MWCNTs and Si as an Anode Material in Lithium-ion Batteries

In this work, we studied the possibility of using composites based on multi-walled carbon nanotubes (MWCNTs) decorated with silicon (Si) and silicon carbide (SiC) particles as an anode material in lithium-ion current sources. MWCNTSi and MWCNT-SiC composites (with different Si/SiC ratios) were obtained by high-temperature heat treatment of MWCNT-Si at different temperatures (1040 and 1350 °C). The structure and phase composition of the composites were characterized by TEM and XRD methods. The determination of the specific capacity of composites as an anode material was carried out at current densities from 0,05 to 2 A/g.

Preparation and tribological properties of hybrid nanofluid of BNNs and SiC modified by plasma

Aviation superalloy is widely used in aviation parts because of its high temperature strength and good fatigue resistance. Due to its high yield strength and low thermal conductivity, it is easy to produce lots of heat during processing, and its hardening tendency is serious, in the case of insufficient cooling lubrication easy to cause burns and poor processing quality. However, the traditional coolant has insufficient cooling performance, which is difficult to solve the thermal problem of aviation superalloy processing. In order to solve these problems, this paper uses plasma hydroxyl modified hexagonal boron nitride nanosheets (BNNs) and silicon carbide (SiC), and then adds sodium dodecyl benzene sulfonate (SDBS) in deionized water to prepare water-based BNNs/SiC hybrid nanofluid. The method of improving dispersion stability was studied by experimental means, and a single factor experiment was designed to study the influence law of mass ratio, mass concentration and temperature on heat transfer performance. Then the tribological properties of the formula were verified by friction and wear test. The results show that the Zeta potential of the nanofluid prepared by plasma hydroxyl modification is greatly improved, and the nanoparticles are effectively dispersed in the water-based liquid under the action of electrostatic stability mechanism. The viscosity reaches a minimum of 0.36249mPa·s, and the thermal conductivity reaches a maximum of 0.99496 W/(m·K). BNNs and SiC particles produce a synergistic structure like the rolling bearing due to the interface effect, which greatly enhances the anti-wear and anti-friction effect of the base fluid. The average friction coefficient is reduced to 0.068, and the volume wear rate is 37.03%, 30.8% and 69.35% lower than the traditional coolant, BNNs nanofluid and SiC nanofluid, respectively.

Preparation of Nano Silicon Carbide Modified UV Paint and Its Application Performance on Wood Flooring Surface.

This study aims to tackle the drawback of non-abrasion-resistance of wood flooring with paint finish. A new method for preparing wood flooring with super-abrasion-resistant coatings by adding nano silicon carbide (SiC) particles to the paint was developed. As indicated by the results, the best mass fraction of nano SiC powder added in ultraviolet (UV) paint is 2.0%, the suspension liquid is stable when the mass concentration of sodium hexametaphosphate added is 2.5%, and it is better for the site humidity to remain below 75% when the nano SiC paint coating is applied. During the preparation of wood flooring with super-abrasion-resistant coating finish, the dosage of finish applied each time should not exceed 30 g/m2. During the sanding process, the sanding speed needs to be increased by about 2 m/s compared with that for the ordinary UV nano SiC primer in production. The test results of the performance of finished products indicate that the prepared wood flooring has better film abrasion resistance, adhesion of paint film, and film hardness. Meanwhile, because the paint film is durable and weather resistant, the service life of flooring is effectively extended, avoiding a significant waste of the product's use value and broadening the product's application range.

One-step sintering process for high-performance SiC membranes for efficient filtration of dust-laden gas

Silicon carbide (SiC) ceramic membranes are known for their remarkable attributes, including resistance to acid and alkali corrosion, exceptional tolerance to thermal shock, and high mechanical strength. These properties have garnered considerable attention for dust-laden gas filtration. However, large-scale applications of SiC membranes are limited because of the high sintering energy consumption in membrane formation. In this study, a preparation method for high-performance and low-cost SiC membranes using a co-sintering process was proposed. In this method, SiC particles with a 100-μm average particle size were uniformly mixed with sintering aids and SiC green supports were prepared via a dry pressing process. Subsequently, SiC dispersion was coated on the SiC green supports via a spray coating method to prepare membrane layer. Through optimization of the sintering process and sintering atmosphere, the sintering stress difference during co-sintering was released. Finally, a defect-free membrane surface was fabricated. The carbon powder in the green supports was utilized as a pore-forming agent and to prevent small particles in the SiC membrane layers from infiltrating the SiC green supports, decreasing the mass transfer resistance in the application process. The SiC ceramic membrane had a mean pore size and a gas permeance of 3.90 μm and 246.33 m3 m−2 h−1. In addition, when subjected to identical average pore size and porosity conditions, it exhibited a high Darcy's permeability coefficient, indicating favorable structural characteristics for the membrane. Additionally, the membrane was optimized to have a 99.9 % rejection of solid particles in dusty gases, including nanometer (0.3 μm) and micron (2.5 μm) solid particles. This study has introduced a preparation method for low-cost and high-performance SiC membranes for industrial dust-laden gas filtration.

Predicting crystallite size of Mg-Ti-SiC nanocomposites using an adaptive neuro-fuzzy inference system model modified by termite life cycle optimizer

In this study, Mg-Ti-SiC composite powders with varied micron and nano silicon carbide (SiC) particle sizes were fabricated utilizing the ball milling technology at various milling times. The effect of reinforcement particles sizes and milling time on the morphology and microstructure of the magnesium composite powders was characterized. Then, we developed a machine-learning model based on Adaptive Neuro-fuzzy Inference System (ANFIS) modified with termite life cycle optimizer to predict the crystallite size of the produced composites. The average particles size in all composites including micron SiC (µSiC) and nano SiC (nSiC) always decreased with increasing milling time and SiC content, and the most optimal reduction in particle size was achieved after 16 h of milling for both configurations, which were 5.12 µm and 1.96 µm, respectively. Changing reinforcement particle size from micron to nano caused the peak intensities of Mg and Ti more decreased and phases Ti5Si3 and TiC were observed after milling for 16 h in ND composite powder. With increasing milling time in Mg-25 wt% Ti-5 wt% µSiC, the crystallite size decreased from 31 nm to 13.62 nm after 1 h and 32 h milled, respectively. The most optimum reduction in crystallite size occurred in the composite powders including nSiC, in which crystallite size decreased to 13.35 nm. The developed Machine learning model was able to predict the evolution of the crystallite size of the produce d composites with very good accuracy.

Performance and durability of high temperature proton exchange membrane fuel cells with silicon carbide filled polybenzimidazole composite membranes

High temperature polymer electrolyte membrane fuel cells (HT-PEMFCs) are used for stationary to mobile applications and show increased tolerances to fuel impurities like CO compared to their low temperature counterpart. However, conventional HT-PEMFC membranes, based on polybenzimidazole (PBI), suffer from creeping during long-term operation and thus a significant increase in surface resistance. In this study, inorganic fillers in terms of silicon carbide (SiC) are incorporated into the standard PBI-based Celtec®-P membrane by a well-established large-scale polyphosphoric acid process. Operations over 1000 h of load cycling between 0.6 and 1.0 A cm−2 of SiC and for conventional HT-PEMFCs reveal differences in long-term durability. The ohmic resistance of the SiC-based single cell is 1/3 lower, while the membrane has a higher thickness retention. Cell performances are improved with lower degradation rates (<65 μV h−1 for both SiC and >100 μV h−1 for both conventional HT-PEMFCs) after 1000 h. However, SiC particle mobility and increased hydrogen permeability are observed after testing.

Cutting fluid role in the machinability of AZ91/SiC composite: Tool wear and surface roughness

Metal matrix composites (MMC) introduced special features such as resistance to wear and high strength to weight ratio and these characteristics categorized them as difficult-to-cut materials in the field of machining. In the current paper, a novel study on the cutting fluid emulsion 5% role in the machinability of a magnesium-based metal matrix composite reinforced by silicon carbide (SiC) particles is presented. AZ91 magnesium alloy, with nominal composition Mg-9Al-1Zn, composites were made using stir casting method. Then, the composite samples were machined and the cutting parameters such as cutting speed, feed rate and side cutting edge angle were varied to assess their effects on the wear and surface roughness. To measure and analyze the wear, optical and scanning electron microscope (SEM) were used. Also, elemental analysis through energy-dispersive X-ray spectroscopy (EDS) was accomplished. Surface roughness of machined samples were measured by a profilometer and 3D surface topography. Results of SEM and EDS images indicated that SiC particles included in the composites act as grinders and remove the surface of tool even in a short time because of the severe abrasion. Additionally, surface of machined MMCs contains some defects such as cracks, broken SiC, and unwanted deformations. Using cutting fluid emulsion 5% enhanced the tool life as well as the surface quality remarkably for different cutting speeds, feed rates and cutting edge angles although finished surface of the samples were oxidized. Also, the cutting fluid considerably reduced the amount of adhered materials on the flank face.