Damage monitor and life prediction of carbon fiber-reinforced ceramic-matrix composites at room and elevated temperatures using hysteresis dissipated energy-based damage parameter

In this paper, the damage monitor and life prediction of carbon fiber-reinforced ceramic-matrix composites (C/SiC CMCs) have been investigated using the hysteresis dissipated energy-based damage parameter. The evolution of the interface shear stress, hysteresis dissipated energy, hysteresis dissipated energy-based damage parameter and the broken fibers fraction vs. cycle number, the fatigue life S?N curves of unidirectional, cross-ply and 2.5D C/SiC composites at room temperature and 800 °C in air atmosphere have been analyzed. For unidirectional C/SiC, the hysteresis dissipated energy and hysteresis dissipated energy-based damage parameter first increase and then decrease with cycle number, and the fatigue limit stress decreases from 88% tensile strength at room temperature to 20% of the tensile strength at 800 °C in air atmosphere; for cross-ply C/SiC, the hysteresis dissipated energy and hysteresis dissipated energy-based damage parameter decrease with increasing applied cycles, and the fatigue limit stress decreases from 85% tensile strength at room temperature to 22% tensile strength at 800 °C in air; and for 2.5D C/SiC, the hysteresis dissipated energy and hysteresis dissipated energy-based damage parameter increases with cycle number, and the fatigue limit stress decreases from 70% tensile strength at room temperature to 25% tensile strength at 800 °C in air.     

Comparison of the properties of Nextel 720/SiC composites at room temperature and 1300°C

Continuous Nextel 720 fibers reinforced SiC composites with PyC interface are fabricated by LPCVI at 1000°C for 200 h using SiCH₃Cl₃ as precursor. The mechanical properties at RT and 1300°C are measured by three-point bending. The microstructures of the interface are characterized by TEM. The results indicate the composites have the metal-like behavior of fracture, whether they are at RT or high temperature. The RT and 1300°C strengths are 310 MPa and 140 MPa, respectively. The RT and 1300°C strains are 0.32% and 0.12%, respectively. The loss of flexural strength and strain of the Nextel 720/SiC composites at high temperature result from stronger residual thermal stress caused by the mismatch of CTE between fibers and matrix. A gap appears between fibers and PyC interface after the 1300°C test, which could be resulted from 7.7% compressive strain of PyC interface caused by the residual thermal stress and 0.1% sintering shrinkage of Nextel 720 fiber.     

Predicting Interfacial Strengthening Behaviour of Particulate-Reinforced MMC — A Micro-mechanistic Approach

The fracture properties of particulate-reinforced metal matrix composites (MMCs) are influenced by several factors, such as particle size, inter-particle spacing and volume fraction of the reinforcement. In addition, complex microstructural mechanisms, such as precipitation hardening induced by heat treatment processing, affect the fracture toughness of MMCs. Precipitates that are formed at the particle/matrix interface region, lead to improvement of the interfacial strength, and hence enhancement of the macroscopic strength properties of the composite material. In this paper, a micro-mechanics model, based on thermodynamics principles, is proposed to determine the fracture strength of the interface at a segregated state in MMCs. This model uses energy considerations to express the fracture toughness of the interface in terms of interfacial critical strain energy release rate and elastic modulus. The interfacial fracture toughness is further expressed as a function of the macroscopic fracture toughness and mechanical properties of the composite, using a toughening mechanism model based on crack deflection and interface cracking. Mechanical testing is also performed to obtain macroscopic data, such as the fracture strength, elastic modulus and fracture toughness of the composite, which are used as input to the model. Based on the experimental data and the analysis, the interfacial strength is determined for SiC particle-reinforced aluminium matrix composites subjected to different heat treatment processing conditions.     

Effect of Surface Structure of Nano-CaCO3 Particles on Mechanical and Rheological Properties of PVC Composites

To study the effect of different surface structures on resultant mechanical and rheological properties, nano-CaCO₃ particles were treated with isopropyl tri-stearyl titanate (H928), isopropyl tri-(dodecylbenz-enesulfonyl) titanate (JN198), and isopropyl tri-(dioctylpyrophosphato) titanate (JN114). Scanning electron microscopy (SEM) and dynamic mechanic analysis (DMA), carried out to characterize the effective interfacial interaction between the nano-CaCO₃ particles and a poly(vinyl chloride) (PVC) matrix, indicated that JN114 treated nano-CaCO₃ particles had the strongest interfacial interaction with a PVC matrix, while H928 treated nano-CaCO₃ had the weakest. The rheological and mechanical properties of PVC/nano-CaCO₃ composites were investigated as a function of surface structure and filler volume fraction. The tensile yield stress and elongation at break decreased with the increasing of calcium carbonate content while tensile modulus increased. PVC filled with JN114 treated nano-CaCO₃ had the highest tensile modulus and tensile yield stress, while those filled with H928 treated nano-CaCO₃ had the highest elongation at break at the same filler content. The impact strength of PVC/nano-CaCO₃ composites increased with the increasing of CaCO₃ content, and PVC composites filled with JN198 treated nano-CaCO₃ particle had a higher impact strength than those with JN114 or H928 treated, with the value reaching 23.9 ± 0.7 kJ/m² at 11 vol% CaCO₃, four times as high as that of pure PVC. Rheological properties indicated that a suitable interfacial interaction and a good dispersion of inorganic filler in a PVC matrix could reduce the viscosity of PVC/nano-CaCO₃ composites. The interfacial interaction was quantitatively characterized by semiempirical parameters calculated from the tensile strength of PVC/nano-CaCO₃ composites to confirm the results from the SEM and DMA experiments.     

The Effect of ZrO2 Interphase on Interfacial Frictional Stresses in SiC/ZrO2/SiCf Composites

Two types of SiC fiber tows (Hi-Nicalon? and Hi-Nicalon S?) were coated with stabilized ZrO₂ and composited using preceramic polymer impregnation pyrolysis to form SiC/SiC_f minicomposites. Properties of the fiber/matrix interface in composites were investigated using the indentation method in which a pyramidal indenter was used to push on an individual fiber and cause sliding at the interface. The interfacial frictional stresses were determined from the force–displacement relation. The composites reinforced by the ZrO₂-coated fibers have smaller interfacial frictional stresses than composites reinforced by the initial fibers and show fibers sliding relatively more easily with respect to the SiC matrix.     

The chemical composition of a metal/ceramic interface on an atomic scale: The Cu/MgO {111} interface

The chemical composition profile across a Cu/MgO {111}-type heterophase interface, produced by the internal oxidation of a Cu(Mg) single-phase alloy at 1173 K, is measured via atom-probe field-ion microscopy with a spatial resolution of 0.121 nm; this resolution is equal to the interplanar spacing of the {222} MgO planes. In particular, we demonstrate directly that the bonding across a Cu/MgO {111}-type heterophase interface, along a <111> direction common to both the Cu matrix and an MgO precipitate, has the sequence Cu|O|Mg... and not Cu|Mg|O...; this result is achieved without any deconvolution of the experimental data. Before determining this chemical sequence, it was established, via high-resolution electron microscopy, that the morphology of an MgO precipitate in a Cu matrix is an octahedron faceted on {111} planes with a cube-on-cube relationship between a precipitate and the matrix; that is, {111}_Cu//{222}_MgO and <110>_Cu // <110>_MgO.     

Interphase sizing temperature effect of LaRC PETI-5 on the dynamic mechanical thermal properties of carbon fiber/BMI composites

The dynamic mechanical thermal properties of carbon fiber-reinforced bismaleimide (BMI) composites processed using polyacrylonitrile(PAN)-based carbon fibers unsized and sized with LaRC PETI-5 amic acid oligomer as interphase material at 150°C, 250°C, and 350°C were investigated by means of dynamic mechanical thermal analysis. It was found that the storage modulus, loss modulus, tan δ and the peak temperature significantly depend on the sizing temperature as well as on the presence and absence of LaRC PETI-5 sizing interphase. The result showed that the carbon fiber/BMI composite sized at 150°C had the highest storage modulus at a measuring temperature of 250°C. The storage modulus decreased with increasing sizing temperature from 150°C to 350°C, being influenced by interdiffusion and co-reaction between the LaRC PETI-5 interphase and the BMI matrix resin. The present result is quite consistent with the interfacial result reported earlier in term of interfacial shear strength and interlaminar shear strength of carbon fiber/BMI composites. It is addressed that in the present composite system the sizing temperature of LaRC PETI-5 interphase critically influences not only the interfacial properties but also the dynamic mechanical thermal properties and its control is also important.     

A review on the research progress of push-out method in testing interfacial properties of SiC fiber-reinforced titanium matrix composites

Experimental analysis of single-fiber push-out for SiC fiber-reinforced titanium matrix composites (TMCs) is complicated by the incorporation of large thermal residual stresses, strong chemical bond of the fiber/matrix interface and matrix plastic deformation. This paper summarizes the development of push-out test and the characteristics of push-out test for TMCs such as crack initiating at the bottom face and theoretical analysis of the test. Moreover, it deeply analyzes the progresses of interfacial shear strength and fracture toughness, and work focus is pointed out in future.     

Microstructure and mechanical properties of continuous Al2O3 fibre reinforced Ni45Al45Cr7.5Ta2.5 alloy (IP75) matrix composites

Single crystalline Al₂O₃ fibres (sapphire), coated with the NiAl alloy IP75 by physical vapour deposition (PVD), were assembled to fabricate composites by means of diffusion bonding. The microstructure and chemistry of both as-coated fibre and as-diffusion bonded composites were investigated by electron microscopy and microanalysis. The interface shear stress for complete debonding was measured by fibre push-out tests at room temperature, and the composite tensile strength was measured at 900°C and 1100°C. An amorphous layer with a thickness of about 400?nm formed between the fibre and the matrix during the PVD process and was maintained during diffusion bonding. A Laves phase precipitated along NiAl grain boundaries in the IP75 matrix. This caused a lower tensile strength of the IP75/Al₂O₃ composite at high temperatures compared to as-cast monolithic IP75 and rendered the composite useless for structural applications.     

Influence of SiC Electron Acceptor–Donor Modification on Thermal and Physical Properties of Carbon Fiber/SiC/Epoxy Composites

In this work, the effects of electron acceptor–donor modification on the surface properties of SiC were investigated in the mechanical interfacial properties of carbon fibers-reinforced SiC-impregnated epoxy matrix composites. The surface properties of the SiC were determined according to acid/base values and FT-IR, and contact angle measurements. The thermal and mechanical interfacial properties of the composites were evaluated using a thermogravimetric analysis, critical strain energy release rate mode II (G _IIC), and impact strength testing. As a result, the electron acceptor-treated SiC had a higher acid value and polar component in surface free energy than did the untreated SiC or the electron donor-treated SiC. The G _IIC and impact strength mechanical interfacial properties of the composites had been improved in the specimens treated by acidic solutions due to the good wetting and a high degree of adhesion with electron donor characteristic epoxy resins.     

Mechanical Properties Comparison of Various Ratios of L-Lactide Grafted Sisal Fibers and Untreated Sisal Fibers Reinforced Poly (lactic acid) Composites

Composites composed of the mixed fibers of L-lactide (LA) grafted sisal fiber (SF-g-LA) and untreated sisal fiber (USF) in a poly (lactic acid) (PLA) matrix were prepared with SF-g-LA/USF fibers ratios of 0, 1:9, 3:7, 5:5, 7:3, 9:1, and 1. The mechanical properties and the interfacial performance of the mixed SF reinforced PLA composites were investigated. The results of the study showed that the introduction of SF-g-LA improved the tensile strength, tensile modulus, flexural strength and flexural modulus of the mixed SF reinforced PLA composites compared with pure PLA or PLA composites with only USF, resulting from the improved interfacial adhesion between SF-g-LA and the PLA matrix. In addition, the introduction of some amount of USF enhanced the reinforcing efficiency of the mixed SF in the composites compared to the PLA composites with only SF-g-LA, owing to the good mechanical properties of USF itself. Furthermore, as for the tensile strength and tensile modulus of the mixed SF reinforced PLA composites, the optimal ratio of SF-g-LA and USF was 7:3, whereas for the flexural modulus of the mixed SF reinforced PLA composites, the optimal mixed ratio of SF-g-LA and USF was 3:7.     

Effect of interfacial debonding and matrix cracking on mechanical properties of multidirectional composites

In composites, debonding at the fiber–matrix interface and matrix cracking due to loading or residual stresses can effect the mechanical properties. Here three different architectures — 3-directional orthogonal, 3-directional 8-harness satin weave and 4-directional in-plane multidirectional composites — are investigated and their effective properties are determined for different volume fractions using unit cell modeling with appropriate periodic boundary conditions. A cohesive zone model (CZM) has been used to simulate the interfacial debonding, and an octahedral shear stress failure criterion is used for the matrix cracking. The debonding and matrix cracking have significant effect on the mechanical properties of the composite. As strain increases, debonding increases, which produces a significant reduction in all the moduli of the composite. In the presence of residual stresses, debonding and resulting deterioration in properties occurs at much lower strains. Debonding accompanied with matrix cracking leads to further deterioration in the properties. The interfacial strength has a significant effect on debonding initiation and mechanical properties in the absence of residual stresses, whereas, in the presence of residual stresses, there is no effect on mechanical properties. A comparison of predicted results with experimental results shows that, while the tensile moduli E ₁₁, E ₃₃and shear modulus G ₁₂ match well, the predicted shear modulus G ₁₃ is much lower.     

High-resolution transmission electron microscopy on silicon carbide whiskers

SiC whiskers were grown from the reaction of silicon monoxide (SiO) with activated carbon containing iron impurities. Growth proceeds through a VLS growth mechanism with SiO and CO as reacting gases. HRTEM combined with EDS shows that the SiC whisker is topped by a Fe₃Si catalyst droplet. The SiC whisker is found to be one-dimensionally disordered along the [111] growth direction of an fcc crystal structure. Although the catalyst droplet is usually larger than the top face of the whisker, we observed a number of situations where the diameter of the droplet was smaller. The study of the SiC-Fe₃Si interface showed that the growth is nucleated from the edges.     

First-principles study on the tensile strength and fracture of the Al-terminated stoichiometric α-Al2O3(0001)/Cu(111) interface

The first-principles tensile tests have been applied to the Al-terminated stoichiometric α-Al₂O₃(0001)/Cu(111) interface by using the ab initio pseudo-potential method based on the density-functional theory. Firstly, the Cu/Al and Cu/Cu interlayers have been examined by the rigid-type tensile test. The interlayer potential curves derived from the first-principles calculations are well fitted by the universal binding-energy relation (UBER) curves. The Cu–Al adhesion is weaker than the back Cu–Cu adhesion. Secondly, the relaxed-type tensile test has revealed the tensile strength and features of interfacial fracture. The ideal tensile strength is about 10?GPa, and the local Young's modulus is about 40?GPa, which means that the Cu/Al interface is quite weak and soft compared with the bulk regions and the O-terminated interface. The failure is initiated from the charge depletion region near the interfacial O atoms when the interlayer stretching exceeds about 30%, and the behaviour of electrons and ions indicates no strong Cu–O bond compared with substantial Cu–Al interactions. The present ab initio data are useful for the construction of effective interatomic potentials at the interface.     

Nano-SiC implantation into the structure of carbon/graphite materials made by pyrolysis (carbonization) of the precursor system coal tar pitch/poly(dimethylsiloxane)

Conversion of the air-cured poly(dimethylsiloxane) {–O–Si(CH₃)₂–}_n to SiC during co-pyrolysis with a coal tar pitch is studied with reference to the related SiO₂/pitch system. Each binary mixture is first homogenized at 160 °C followed by carbonization at 500 °C under argon to afford initial carbonizates. In both cases, one part of the initial carbonizate is further pyrolyzed at 1300 °C and another part at 1650 °C under an argon flow resulting in composite products. All products are studied with FT-IR, XRD, and XPS spectroscopic methods supplemented with SEM and ‘wet’ Si-analyses, when applicable. Carbothermally assisted conversion of both silicon precursors to nanocrystalline SiC embedded in the evolving C-matrix, i.e. nano-SiC/C composites, is evident only after the 1650 °C carbonization stage.     

Influence of heat treatment on microstructure and mechanical properties of the interface in an EN AW-6082/1.4310 composite extrusion

The presented paper deals with a unidirectional steel wire reinforced aluminum matrix composite manufactured by composite extrusion. The main objective of this work was to determine the effect of heat treatment, and the influence of long solution annealing times on the composites interface regarding microstructural changes and the resulting interface strength. For evaluation of the microstructure high resolution transmission electron microscope (TEM) investigations accompanied with electron dispersive X-ray spectroscopy (EDX) were performed. It could be shown that diffusion from the steel wire into the aluminum matrix occurs and that the diffusion paths as well as particle formation is influenced by the preceded heat treatment. Diffusion paths in the range of 40–150 nm could be observed for Al, Fe, Cr and Ni. After annealing times over 5 h an extensive growth of an intermetallic reaction layer was found. The mechanical properties of the interface were determined by push-out-tests and tensile tests radial to the interface, which provided the debonding shear strength σ_deb and for the latter experiment the interfacial radial strength σ_IR. It has become apparent that debonding shear strength is highly influenced by matrix properties. In radial tensile tests the failure is predominantly controlled by the chemical bond of the interface. It was shown that interface strength of specimen with small reaction zones of about 3 μm were beneficial for the mechanical behavior in both loading conditions. Longer annealing times showed a drastic decrease of interface shear strength. It was concluded from EDX measurements and in comparison with literature that the reaction zone is dominated by the growth of Al₅Fe₂ (η-phase).     

Growth and desorption of indium epitaxial layers investigated by high field microscopy

Growth of indium single crystals on tungsten field emission tips was carried out by deposition of indium from vapour in ultra high vacuum, using substrate temperatures in the range of 293–420 K. Two different tungsten tips were used as the substrate: a perfect W single crystal in one case and a bi-crystal with a distinct grain boundary in the other. No influence of the grain boundary on the epitaxial growth was found. Two orientation relationships were observed mostly: {111}In ∥ {110}W with 〈110〉In ∥ 〈111〉W and {111}In ∥ {100}W with 〈110〉In ∥ 〈110〉W. In the first case the growth was initiated by the indium nucleus created on the ledges of the {110}W plane. A field strength of 0.9 V/Å was found for the evaporation field of indium. The field strength of the desorption of In-W interfacial layer atoms was found to be 4.4–5.2 V/Å. A mechanism of the growth of indium crystals has been proposed.     

Fabrication of composite structure of carbon fibers and high density SiC nanowires

Composite structure of carbon fibers and SiC nanowires was fabricated by a simple chemical vapor deposition process, using commercial silicon dioxide and graphite powders as raw materials. The analysis of scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction indicates that the synthesized SiC nanowires distribute uniformly with high density in the used carbon fiber preform, which are perpendicular to and around each carbon fiber in a radial array. The SiC nanowires located at the interface of advanced composites is very favorable to the interfacial bonding between composites matrix and carbon fibers, thereby increasing the strength of composites greatly.     

Fabrication of composite structure of carbon fibers and high density SiC nanowires

Composite structure of carbon fibers and SiC nanowires was fabricated by a simple chemical vapor deposition process, using commercial silicon dioxide and graphite powders as raw materials. The analysis of scanning electron microscopy, energy dispersive spectroscopy and X-ray diffraction indicates that the synthesized SiC nanowires distribute uniformly with high density in the used carbon fiber preform, which are perpendicular to and around each carbon fiber in a radial array. The SiC nanowires located at the interface of advanced composites is very favorable to the interfacial bonding between composites matrix and carbon fibers, thereby increasing the strength of composites greatly.     

Polymer–Polymer and Single Polymer Composites Involving Nanofibrillar Poly(vinylidene Fluoride): Manufacturing and Mechanical Properties

Nanofibrillar polymer–polymer composites (NFCs) and single polymer composites (SPCs) were produced using linear low density polyethylene (LLDPE) and poly(vinylidene fluoride) (PVDF). The NFCs were fabricated by means of a microfibrillar composite concept comprising melt blending, cold drawing, and compression molding retaining the highly oriented PVDF reinforcing nanofibrils (diameter of approximately 250 nm) dispersed without any agglomeration in the isotropic LLDPE matrix. The SPC films were prepared by partial surface premelting of neat PVDF nanofibrils (diameter of about 130 nm) using hot compaction at 148°C (about 20°C below the complete melting of PVDF), thus preserving the PVDF nanofibrillar identity. Tensile testing of NFCs based on LLDPE and PVDF showed an increase in the tensile modulus by 135% and in the tensile strength at break by 211%, as compared to those of an isotropic LLDPE film. Furthermore, the PVDF SPCs showed an enhancement of tensile modulus of 30% and strength at break of 305% when compared to those of an isotropic PVDF film.