Tough salami-inspired Cf/ZrB2 UHTCMCs produced by electrophoretic deposition

One of the biggest challenges of the materials science is the mutual exclusion of strength and toughness. This issue was minimized by mimicking the natural structural materials. To date, few efforts were done regarding materials that should be used in harsh environments. In this work we present novel continuous carbon fiber reinforced ultra-high-temperature ceramic matrix composites (UHTCMCs) for aerospace featuring optimized fiber/matrix interfaces and fibers distribution. The microstructures – produced by electrophoretic deposition of ZrB₂ on unidirectional carbon fibers followed by ZrB₂ infiltration and hot pressing – show a maximum flexural strength and fracture toughness of 330 MPa and 14 MPa m^1/2, respectively. Fracture surfaces are investigated to understand the mechanisms that affect strength and toughness. The EPD technique allows the achievement of a peculiar salami-inspired architecture alternating strong and weak interfaces.     

Influence of SiC content on the oxidation of carbon fibre reinforced ZrB2/SiC composites at 1500 and 1650 °C in air

The microstructure and the oxidation resistance in air of continuous carbon fibre reinforced ZrB₂–SiC ceramic composites were investigated. SiC content was varied between 5–20?vol.%, while maintaining fibre content at ～40?vol.%. Short term oxidation tests in air were carried out at 1500 and 1650?°C in a bottom-up loading furnace. The thickness, composition and microstructure of the resulting oxide scale were analysed by SEM-EDS and X-Ray diffraction. The results show that contents above 15?vol.% SiC ensure the formation of a homogeneous protective borosilicate glass that covers the entire sample and minimizes fibre burnout. The scale thickness is ～90?μm for the sample containing 5?vol.% SiC and decreases with increasing SiC content.     

Nanoindentation Characterization of Submicro- and Nano-Sized Liquid-Phase-Sintered SiC Ceramics

Submicro- and nano-sized liquid-phase-sintered SiC ceramics were mechanically tested by nanoindentation in the peak load range 5–400 mN. The submicro-sized sample showed a marked indentation size effect which the nano-sized samples did not exhibit. The relevance of indentation depth with respect to the microstructural scale has been outlined. In the investigated grain-size range, the hardness dependence on the grain size could be described by a load-dependent inverse Hall–Petch relation. Young's modulus was less microstructure- and load-dependent. Because of the very fine microstructure, the nano-sized SiC materials gave lower elastic values than the submicro-sized SiC ceramic.     

High-Temperature Stiffness and Damping Measurements to Monitor the Glassy Intergranular Phase in Liquid-Phase-Sintered Silicon Carbides

Detailed stiffness and internal friction ( Q ⁻¹) versus temperature curves were obtained for liquid-phase-sintered silicon carbides using advanced resonant beam analysis up to 1400°C. As-sintered materials display a stable Q ⁻¹-peak near 1100°C, superimposed on an increasing background. The change of stiffness associated with the damping peak is quantitatively related to the amount of matter in pockets of the amorphous intergranular phase in which the refractory SiC matrix grains are embedded. The successful removal of the amorphous pockets by annealing at 1900°C is deduced from the disappearance of the damping peak and confirmed with transmission electron microscopy.     

Additive Manufacturing of Ceramics Enabled by Flash Pyrolysis of Polymer Precursors with Nanoscale Layers

We show that a polymer‐based route to ceramics can be implemented into additive manufacturing by reducing the time for pyrolysis to about a second, which we call flash pyrolysis. Repetitive deposition of nanometer scale coatings of the ceramic, in this way, is employed to create defect‐free infiltrations of carbon fiber composites. The mechanical strength of the fibers is retained in the composite. Excellent wetting properties of the polymer precursor permits three‐dimensional, conformal coating through the three stages of infiltration: nanoscale coating of the single fibers, filling of interstitial spaces between the fibers, and a buildup of the coating over the entire composite. The flash pyrolysis method will enable a new genre of polymer‐derived ceramics made into net shape by this unusual method of additive manufacturing.     

Transient liquid phase bonding of HfC-based ceramics

Transient liquid phase (TLP) bonding enables joining at lower temperatures than traditional bonding techniques and preserves the potential for high-temperature applications, making it particularly attractive for joining ultra-high-temperature ceramics (UHTCs) such as carbides and borides. The feasibility of a TLP joint between “pure” carbides has been recently demonstrated. The present study examines the interactions that occur between undoped HfC or MoSi₂-doped HfC and a Ni/Nb/Ni multilayer interlayer during TLP bonding. Bonding is performed at 1400 °C for 30 min in a high-vacuum furnace. SEM–EDS characterization shows that the reaction layer formed at the interlayer/ceramic interface contains mixed carbides and depending upon the ceramic, Ni–Nb–Hf, or Ni–Nb–Hf–Si, or Ni–Nb–Si alloys. Nanoindentation tests traversing the reaction layer between the bulk ceramic and Nb foil midplane also show a clear transition zone across which the indentation modulus and hardness vary. Crack-free joints have been obtained with undoped HfC. The addition of 5 vol% MoSi₂ introduces small (<5 μm long) isolated cracks within the reaction layer, whereas with 15 vol% MoSi₂ added, cracking was pervasive within the reaction layer. When the reaction layer exceeds a critical thickness, as in the case of the bond obtained with HfC doped with 15 vol% MoSi₂, residual stresses become sufficiently large to cause extensive cracking and bond failure. The results suggest a need to characterize and balance the positive role of additives on sintering with the potentially deleterious role they may have on joining.     

Sintering Mechanisms of Zirconium and Hafnium Carbides Doped with MoSi2

The microstructure of two pressureless-sintered ultra-high-temperature ceramics, namely ZrC+20 vol% MoSi₂ and HfC+20 vol% MoSi₂, was characterized by scanning and transmission electron microscopy. With regard to the ZrC–MoSi₂ system, Zr _x Si _y compounds and SiC were detected. In the HfC–MoSi₂ system, a mixed phase was detected at the triple points and identified as (Mo,Hf)₅Si₃. For both the systems investigated, the high wettability of the silicide-based phases on the matrix grains suggests that sintering is assisted by a liquid phase. This contribution reports for the first time on the sintering mechanisms of early transition metal carbides doped with MoSi₂ as a sinter additive, on the basis of the microstructural evolution observed upon sintering and in the light of phase diagrams and thermodynamical calculations.     

ZrB2-MoSi2 ceramics: A comprehensive overview of microstructure and properties relationships. Part II: Mechanical properties

The mechanical behavior of ZrB₂-MoSi₂ ceramics made of ZrB₂ powder with three different particle sizes and MoSi₂ additions from 5 to 70 vol% was characterized up to 1500 °C. Microhardness (12–17 GPa), Young’s modulus (450–540 GPa) and shear modulus (190–240 GPa) decreased with both increasing MoSi₂ content and with decreasing ZrB₂ grain size. Room temperature fracture toughness was unaffected by grain size or silicide content, whilst at 1500 °C in air it increased with MoSi₂ and ZrB₂ grain size, from 4.1 to 8.7 MPa m^½. Room temperature strength did not trend with MoSi₂ content, but increased with decreasing ZrB₂ grain size from 440 to 590 MPa for the largest starting particle size to 700–800 MPa for the finest due to the decreasing size of surface grain pullout. At 1500 °C, flexure strength for ZrB₂ with MoSi₂ contents above 25 vol% were roughly constant, 400–450 MPa, whilst for lower content strength was controlled by oxidation damages. Strength for compositions made using fine and medium ZrB₂ powders increased with increasing MoSi₂ content, 250–450 MPa. Ceramics made with coarse ZrB₂ displayed the highest strengths, which decreased with increasing MoSi₂ content from 600 to 450 MPa.     

Effect of PAN-based and pitch-based carbon fibres on microstructure and properties of continuous Cf/ZrB2-SiC UHTCMCs

In this paper the microstructure and mechanical properties of two different C_f/ZrB₂-SiC composites reinforced with continuous PyC coated PAN-derived fibres or uncoated pitch-derived fibres were compared.Pitch-derived carbon fibres showed a lower degree of reaction with the matrix phase during sintering compared to PyC/PAN-derived fibres. The reason lies in the different microstructure of the carbon. The presence of a coating for PAN-derived fibres was found to be essential to limit the reaction at the fibre/matrix interface during SPS. However, coated bundles were more difficult to infiltrate, resulting in a less homogeneous microstructure.As far as the mechanical properties are concerned, specimens reinforced with coated PAN-derived fibres provided higher strengths and damage tolerance than uncoated pitch-derived fibres, due to the higher degree of fibre pull-out. On the other hand, the weaker fibre/matrix interface resulted in lower interlaminar shear, off-axis strength and ablation resistance.