Sliding Wear of Alumina/Silicon Carbide Nanocomposites

The wear resistance of four Al₂O₃/SiC nanocomposites that contained SiC particles of varying average size (40, 200, and 800 nm) was studied under dry sliding conditions and compared with the results obtained in unreinforced alumina. The wear rate of the alumina and the nanocomposites of equivalent grain size increased as the contact load increased; however, the nanocomposite wear resistance at high contact loads was better than that of the alumina by a factor of 3–5. The wear resistance of the nanocomposites of submicrometer grain size was fairly independent of the contact load, and their wear resistance at high contact loads was up to two orders of magnitude better than that of the alumina. The mechanisms responsible for these behaviors were discussed in terms of the microscopic wear mechanisms that were observed on the worn surfaces.     

Tensile Creep Behavior of Alumina/Silicon Carbide Nanocomposite

Tensile creep and creep rupture behaviors of alumina/17 vol% silicon carbide nanocomposite and monolithic alumina Were investigated at 1200° to 1300°C and at 50 to 150 MPa. Compared to the monolithic alumina, the nanocomposite exhibited excellent creep resistance. The minimum creep rate of the nanocomposite was about three orders of magnitude lower and the creep life was 10 times longer than those of the monolith. The nanocomposite demonstrated transient creep until failure, while accelerated creep was observed in the monolith. It was revealed that rotating and plunging of intergranular silicon carbide nanoparticles into the alumina matrix increased the creep resistance with grain boundary sliding.     

Creep Deformation of an Alumina Matrix Composite Reinforced with Silicon Carbide Whiskers

Whisker-reinforced ceramic composites with enhanced fracture toughness properties are being developed. The creep behavior of such a composite was studied. The introduction of silicon carbide whiskers significantly improves the creep resistance of polycrystaline alumina.     

Polishing Behavior and Surface Quality of Alumina and Alumina/Silicon Carbide Nanocomposites

The response of Al₂O₃ and Al₂O₃/SiC nanocomposites to lapping and polishing after initial grinding was investigated in terms of changes in surface quality with time for various grit sizes. The surface quality was quantified by surface roughness ( R _a ) and by the relative areas of smooth polished surfaces as opposed to rough as-ground areas. Polishing behavior of the materials was discussed in terms of SiC content and grain size. It was concluded that nanocomposites are more resistant to surface damage than Al₂O₃, and this behavior does not depend on the amount of SiC in the range 1–5 vol%. SiC addition ≥1 vol% is enough to produce a noticeable improvement in surface quality during lapping and polishing.     

Processing and Properties of Sol–Gel-Derived Alumina/Silicon Carbide Nanocomposites

Dense alumina/5 vol% SiC nanocomposites were prepared by sol–gel processing using nanosized (180 nm) precoated SiC powders and a commercial boehmite sol. The SiC powder was precoated with boehmite by a controlled heterogeneous precipitation from an aluminum nitrate solution. The coated SiC powder was then dispersed in a boehmite sol, gelled, calcined, and densified by gas pressure sintering under argon atmosphere at 7–8 MPa pressure. The dependence of the calcination conditions on densification, the effect of seeding on the microstructural development, as well as the mechanical behavior of the sintered specimens, are presented and discussed.     

R-Curve Behavior in a Silicon Carbide Whisker/Alumina Matrix Composite

R -curve measurements were performed on a SiC whisker/Al₂O₃ matrix composite. A controlled flaw/strength technique was utilized to determine fracture resistance as a function of crack extension. Rising R -curve behavior with increasing crack extension was observed, confirming the operation of wake toughening effects on the crack growth resistance. Observations of crack/microstructure interactions revealed that bridging by intact whiskers in the crack wake was the mechanism responsible for the rising R -curve behavior.     

Sub-Surface Damage in Ground and Annealed Alumina and Alumina–Silicon Carbide Nanocomposites

High-resolution, grazing incidence, X-ray powder diffraction has been used to probe the strain dispersion (microstrain) and diffracting, domain size as a function of depth in alumina and alumina–silicon carbide nanocomposite. The microstrain was high, and of similar magnitude, below ground surfaces in both materials but declined much more rapidly with distance from the surface in the pure alumina than in the nanocomposite. The depth over which significant microstrain was observed was in good agreement with previous measurement of dislocation density by transmission electron microscopy. In neither case was there a systematic trend in diffracting domain size with depth. The strain dispersion at the surface was reduced to that in the bulk of the nanocomposite on annealing, the value being almost constant with depth while the diffracting domain size changed significantly, resulting in a linear decrease as the surface was approached. We suggest that the increase in the strength of the nanocomposite is associated both with a macrostrain oriented normal to the grinding direction and the greater depth of propagation of the microstrain. Further strength increase on annealing must be associated with the observed reduction of both these types of strain.     

Alumina/Silicon Carbide Nanocomposites by Hybrid Polymer/Powder Processing: Microstructures and Mechanical Properties

Nanocomposites with fine, coarse, and bimodal silicon carbide (SiC) particle-size distributions were hot pressed and examined by transmission electron microscopy, scanning electron microscopy, and optical microscopy, as well as by four-point-bend and indentation tests. The finer SiC nanophase was introduced homogeneously by coating a silicon-containing polymer onto the alumina (Al₂O₃) powder, followed by a pyrolysis procedure; for the coarser SiC, nanophase conventional powder processing was used. Powder- and polymer-processed nanocomposites both had their maximum strengths at 5 vol% of SiC. High-strength nanocomposites that contained a higher volume fraction of SiC could be fabricated when the two methods were combined in a hybrid processing route. The SiC phase in the resulting hybrid materials originated from both the polymer and the SiC powder. The mechanical properties of these materials could be correlated with the fabrication route. Processing-flaw populations and calculated Griffith-flaw sizes were not only smaller, but they were also significantly different in the nanocomposites, in comparison to those in Al₂O₃ ceramics; this may explain the strength increase in Al₂O₃/SiC nanocomposite materials.     

Thermal Shock Resistance of Sintered Alumina/Silicon Carbide Nanocomposites Evaluated by Indentation Techniques

The thermal shock resistance of sintered Al₂O₃/1, 2.5, and 5 vol% SiC nanocomposites was studied using two indentation techniques. In the first technique, "indentation thermal shock" measurements were made of the extension of median/radial cracks around Vickers indentations after quenching from various temperatures (up to 480°C) into a bath of boiling water. This technique allowed a critical thermal shock temperature, Δ T _C^Ind, to be quantitatively evaluated. In the second technique, "indentation fatigue" tests were conducted on the thermally shocked specimens; repeated indentations were made at the same site, and the number of load cycles needed to initiate lateral fracture was measured. The results showed that nanocomposites with an addition of SiC nanophase as low as 1 vol% had a thermal shock resistance superior to that of pure Al₂O₃.     

Diffusional Crack Growth and Creep Rupture of Silicon Carbide Doped with Alumina

This study deals with tensile creep and crack growth behavior of silicon carbide doped with alumina at 1400°C. Excellent creep resistance was observed for stresses from 150 MPa to 200 MPa. From the creep exponent of 1.4 and the activation energy of 320 kj/mol, the principal creep mechanism was Coble creep. The creep failure was caused by slow crack growth from a preexisting flaw. The crack was found to grow subcritically along grain boundaries almost in isolation. The relation between the time–to–failure and the applied stress was well treated by a diffusive crack growth model, and the threshold stress of this material at 1400°C was estimated at 165 MPa.     

Fabrication and Microstructure of Micro and Nano Silicon Carbide Reinforced Copper Metal Matrix Composites/Nanocomposites

Silicon - This study investigates the influence of micro and nano silicon carbide on properties of copper matrix composites/nanocomposites containing up to 4 wt% of reinforcement...     

Dispersion of Alumina and Silicon Carbide Powders in Alumina Sol

Dispersion of Al₂O₃ and SiC particles in an alumina sol has been investigated through determination of particle-size distribution, zeta potential, and agglomerate morphology. The particle size of Al₂O₃ and SiC (as determined by the particle-size analyzer) is strongly affected by the presence of alumina sol in the solution. The average agglomerate size is decreased by at least 50%. The zeta potential of Al₂O₃ in 1 M alumina sol increases slightly, whereas that of SiC reverses its sign over a wide range of pH values. It is proposed that these effects are caused by AlO₄Al₁₂(OH)₂₄(H₂O)⁷⁺₁₂ sol clusters (1-2 nm in size) that are absorbed on the surface of the large (1-5 µm) ceramic particles. The electrostatic and steric effects of the cluster absorption help to control the dispersion and stabilize the suspension of ceramic particles in the alumina sol during wet processing. It is expected that the alumina-sol clusters can be used as an efficient, clean dispersant for single-phase and composite ceramic powders.     

Tensile Creep and Creep-Strain Recovery Behavior of Silicon Carbide Fiber/Calcium Aluminosilicate Matrix Ceramic Composites

The tensile creep and creep strain recovery behavior of 0° and 0°/90° Nicalon-fiber/calcium aluminosilicate matrix composites was investigated at 1200°C in high-purity argon. For the 0° composite, the 100-h creep rate ranged from approximately 4.6 × 10⁻⁹ s⁻¹ at 60 MPa to 2.2 × 10⁻⁸ s⁻¹ at 200 MPa. At 60 MPa, the creep rate of the 0°/90° composite was approximately the same as that found for the 0° composite, even though the 0°/90° composite had only one-half the number of fibers in the loading direction. Upon unloading, the composites exhibited viscous strain recovery. For a loading history involving 100 h of creep at 60 MPa, followed by 100 h of recovery at 2 MPa, approximately 27% of the prior creep strain was recovered for the 0° composite and 49% for the 0°/90° composite. At low stresses (60 and 120 MPa), cavities formed in the matrix, but there was no significant fiber or matrix damage. For moderate stresses (200 MPa), periodic fiber rupture occurred. At high stresses (250 MPa), matrix fracture and rupture of the highly stressed bridging fibers limited the creep life to under 70 min.     

Contact Damage of Silicon Carbide/Boron Nitride Nanocomposites

To investigate the deformation mechanism of silicon carbide (SiC)/boron nitride (BN) nanocomposites, Hertzian contact tests were performed on monolithic SiC, and nanocomposite and microcomposite SiC/BN. Monolithic SiC had the typical microstructure of hot-pressed SiC with Y₂O₃ and Al₂O₃ additives, composed of slightly large grains in small matrix grains. The microcomposite comprised large BN grains dispersed along the grain boundaries of elongated SiC grains, while the nanocomposite showed a finer microstructure with fine BN particles and small matrix grains. These microstructural differences led to differences in the mechanism of contact damage. The damage of the monolithic SiC and the SiC/BN microcomposite exhibited classical Hertzian cone fracture and many large cracks, whereas the damage observed in the nanocomposites appeared to be quasi-plastic deformation.     

Constitutive Equations for the Creep of a Silicon Carbide Whisker-Reinforced Polycrystalline Alumina Composite Material

The θ -projection parametric method is used to analyze the creep strain-versus-time data, obtained in four-point flexure, for a 25 wt% silicon whisker-reinforced polycrystalline alumina composite material. The results, used in conjunction with a suggested value of the activation energy for the creep-rate-controlling process for this material of about 620 kJ/mol, led to a postulate that grain-boundary sliding is the rate-determining mechanism. In addition, the use of the results in obtaining the values of relevant design creep parameters (namely, life or strain) is illustrated.     

Mechanical Properties of Alumina/Silicon Carbide Whisker Composites

The improvement of mechanical properties of Al₂O₃/SiC whisker composites has been studied with emphasis on the effects of the whisker content and of the hot-pressing temperature. Mechanical properties such as fracture toughness and fracture strength increased with increasing whisker content up to 40 wt%. In the case of the high SiC whisker content of 40 wt%, fracture toughness of the sample hot-pressed at 1900° decreased significantly, in spite of densification, compared with one hot-pressed at 1850°. Fracture toughness strongly depended on the microstructure, especially the distribution of SiC whiskers rather than the grain size of the Al₂O₃ matrix.     

Threshold Stress in Creep of Alumina-Silicon Carbide Nanocomposites

Tensile creep and the creep ruptures of an alumina-17 vol% silicon carbide nanocomposite at 1200°C were investigated, with a particular interest in the behaviors at low applied stresses. At stresses of <50 MPa, the creep rates were remarkably decayed and the creep lives were substantially prolonged, which suggested the presence of a threshold stress, below which creep stopped, in the creep of the nanocomposite. The stress was estimated to be in the range of 20–35 MPa. This threshold stress was in agreement with that predicted from another model where the motion of grain-boundary dislocations that were responsible for vacancy nucleation and annihilation was considered to be pinned by hard particles.     

Silicon Carbide Whisker/Alumina Matrix Composites: Effect of Whisker Surface Treatment on Fracture Toughness

The fracture toughness of a 30 vol% SiC whisker/Al₂O₃ matrix composite was evaluated as a function of whisker surface chemistry. Two types of SiC whiskers (Silar-SC-9 and Tateho-SCW-1-S) were investigated. Modification of the whisker surface chemistry was achieved by subjecting the whiskers to thermal treatments under controlled atmospheres. Whisker surface chemistry, as determined by X-ray photoelectron spectroscopy, was correlated to the fracture toughness of the composites.     

Residual Stress Measurements in Alumina and Silicon Carbide

Residual stresses were measured in three types of ceramic components. Stresses were measured using X-ray diffraction and an advanced X-ray instrument. Measured stresses in alumina rods were shown to correlate well with breaking strength, and stress variations in an alumina tile were hypothesized to result from inhomogeneous cooling. The compressive stresses induced in a silicon carbide tube, by an outer steel sleeve, were seen to be balanced by tensile stresses in the sleeve.     

Push-Out Tests on a New Silicon Carbide/Reaction-Bonded Silicon Carbide Ceramic Matrix Composite

Fiber push-out tests have been performed on a ceramic matrix composite consisting of Carborundum sintered SiC fibers, with a BN coating, embedded in a reaction-bonded SiC matrix. Analysis of the push-out data, utilizing the most complete theory presently available, shows that one of the fiber/coating/matrix interfaces has a low fracture energy (one-tenth that of the fiber) and a moderate sliding resistance τ∼ 8 MPa. The debonded sliding interface shows some continuous but minor abrasion, which appears to increase the sliding resistance, but overall the system exhibits very clean smooth sliding. The tensile response of a full-scale composite is then modeled, using data obtained here and known fiber strengths, to demonstrate the good composite behavior predicted for this material.