Analytical Model of Elastic Modulus and Coefficient of Thermal Expansion for 2.5D C/SiC Composite

To make better use of 2.5D C/SiC composites in industry, it is necessary to understand the mechanical properties. A finite element model＇of 2.5D composites is established, by considering the fiber undulation and the porosity in 2.5D C/SiC composites. The fiber direction of warp is defined by cosine function to simulate the undulation of warp, and based on uniform strain assumption, analytical model of the elastic modulus and coefficient of thermal expansion （CTE） for 2.5D C/SiC composites were established by using dual- scale model. The result is found to correlate reasonably well with the predicted results and experimental results. The parametric study also demonstrates the effects of the fiber volume fraction, distance of warp yarn, and porosity in micro-scale on the mechanical properties and the coefficients of thermal expansion.

Ablation Processes for HfC-Coated 2.5D Needle-Punched Composites Used for Aerospace Engines Under Hypersonic Flight Conditions

The working environment of aerospace engines is extremely harsh with temperature exceeding 1700℃and accompanied by thermal coupling effects.In this condition,the materials employed in hypersonic aircraft undergo ablation issues,which can cause catastrophic accidents.Due to the excellent high-temperature stability and ablation resistance,HfC exhibits outstanding thermal expansion coefficient matching that of C/SiC composites.2.5D needle-punched C/SiC composites coated with HfC are prepared using a plasma spraying process,and a high-enthalpy arc-heated wind tunnel is employed to simulate the re-entry environment of aircraft at 8 Mach and an altitude of 32 km.The plasma-sprayed HfC-coated 2.5D needle-punched C/SiC composites are subjected to long-term dynamic testing,and their properties are investigated.Specifically,after the thermal assessment ablation experiment,the composite retains its overall structure and profile;the total mass ablation rate is 0.07445 g/s,the average linear ablation rate in the thickness direction is-0.0675μm/s,and the average linear ablation rate in the length direction is 13.907μm/s.Results verify that plasma-sprayed HfC coating exhibits excellent anti-oxidation and ablation resistance properties.Besides,the microstructure and ablation mechanism of the C/SiC composites are studied.It is believed that this work will offer guideline for the development of thermal protection materials and the assessment of structural thermal performance.

Multi-scale Modeling and Finite Element Analyses of Thermal Conductivity of 3D C/SiC Composites Fabricating by Flexible-Oriented Woven Process

Thermal conductivity is one of the most significant criterion of three-dimensional carbon fiber-reinforced SiC matrix composites(3D C/SiC).Represent volume element(RVE)models of microscale,void/matrix and mesoscale proposed in this work are used to simulate the thermal conductivity behaviors of the 3D C/SiC composites.An entirely new process is introduced to weave the preform with three-dimensional orthogonal architecture.The 3D steady-state analysis step is created for assessing the thermal conductivity behaviors of the composites by applying periodic temperature boundary conditions.Three RVE models of cuboid,hexagonal and fiber random distribution are respectively developed to comparatively study the influence of fiber package pattern on the thermal conductivities at the microscale.Besides,the effect of void morphology on the thermal conductivity of the matrix is analyzed by the void/matrix models.The prediction results at the mesoscale correspond closely to the experimental values.The effect of the porosities and fiber volume fractions on the thermal conductivities is also taken into consideration.The multi-scale models mentioned in this paper can be used to predict the thermal conductivity behaviors of other composites with complex structures.

2.5D C/SiC复合材料超声振动辅助铣削数值模拟研究

为了揭示2.5D C/SiC陶瓷基复合材料在铣削加工过程中的去除机理及表面损伤特性,开展了其传统铣削和超声振动辅助铣削实验,建立了两类铣削工况下的三维数值模型。结果表明,相对于传统铣削,超声振动辅助铣削在其高频的交变载荷下,降低材料的微切削厚度,减小材料的变形挠度从而使径向和切向的切削力分别都降低了68%、72%;可有效改善2.5D C/SiC复合材料加工表面损伤,如倾斜断裂面、粗糙断裂面;其加工表面残余压应力明显大于传统铣削;经过实验验证,所建立的数值模型可以有效地模拟材料去除过程和0°、90°纤维的断裂形貌;为2.5D C/SiC复合材料的高效低损伤加工提供了理论依据和指导。

2.5D C/SiC复合材料铣削材料去除的实验研究

为了探究2.5D C/SiC复合材料铣削加工的材料去除特性,分别选用端铣刀和鱼鳞铣刀对2.5D C/SiC复合材料开展普通铣削和超声振动辅助铣削实验。分析了四种铣削工况下切削力、切削温度的变化规律,研究了0°、90°和z向针刺纤维的去除特性。结果表明,相比于传统端铣刀和普通铣削,鱼鳞铣刀和超声振动辅助铣削分别可以显著地降低切削力和切削温度。超声振动辅助铣削可以使纤维的整体去除变为破碎去除,减小表面缺陷。鱼鳞铣刀和超声振动辅助铣削的组合工艺方式可以较大程度地降低表面缺陷、切削力和切削温度,提高工件表面质量,为2.5D C/SiC复合材料低损伤铣削提供了可行性。

Fatigue Life of a 2.5D C/SiC Composite Under Tension–Tension Cyclic Loading:Experimental Investigation and Sensitivity Analysis

Engineering structures made of ceramic matrix composites(CMCs)usually suffer from cyclic loads during service,which could lead to disastrous failures.This work focuses on the fatigue behavior of a 2.5D C/SiC composite under tension–tension cyclic loading.Experiments of the 2.5D C/SiC composite are firstly carried out to determine the fatigue lifetime of the material at different stress levels.The fracture surfaces examined by a scanning electronic microscope indicate that the damage mechanisms under cyclic loading are closely related to crack propagation,fiber/matrix interfacial degradation,and fiber breakage.Considering the damage evolution of fibers and interfacial resistance,a micromechanical model is adopted to describe the fatigue behavior of 2.5D C/SiC composite,and the numerical results are compared with the experimental results.Further,a sensitivity analysis is performed as a function of the interfacial shear stress,fiber Weibull modulus,and fiber strength.The calculation of sensitivity factors shows that the variations of the fiber Weibull modulus and fiber strength have the most significant influence and,thereafter,the variation of interfacial shear stress.

2.5D C/SiC复合材料的热物理性能

分别采用热膨胀仪和激光脉冲导热仪测试2.5D C/SiC复合材料从室温到1400℃纵向、横向的热膨胀系数和厚度方向的热扩散系数。结果表明,2.5D C/SiC复合材料的热膨胀系数随温度的升高而缓慢升高,在350℃和700℃附近出现波动,且横向的热膨胀系数略高于纵向。热扩散系数随温度的升高逐渐降低,且下降速率随温度的升高而变缓。CVD SiC涂层后,材料热扩散系数提高1～2倍。

Elastic Modulus Prediction of Three-dimension-4 Directional Braided C_f/SiC Composite Based on Double-scale Model

Double-scale model for three-dimension-4 directional（3D-4d） braided C/SiC composites has been proposed to investigate its elastic properties. The double-scale model involves micro-scale that takes fiber/ matrix/porosity in fibers tows into consideration with unit cell which considers the 3D-4d braiding structure. Micro-optical photographs of composites have been taken to study the braided structure. Then a parameterized finite element model that reflects the structure of 3D-4d braided composites is proposed. Double-scale elastic modulus prediction model is developed to predict the elastic properties of 3D-4d braided C/SiC composites. Stiffness and eompliance-averaging method and energy method are adopted to predict the elastic properties of composites. Static-tension experiments have been conducted to investigate the elastic modulus of 3D-4d braided C/SiC composites. Finally, the effect of micro-porosity in fibers tows on the elastic modulus of 3D-4d braided C/SiC composites has been studied. According to the conclusion of this thesis, elastic modulus predicted by energy method and stiffness-averaging method both find good agreement with the experimental values, when taking the micro-porosity in fibers tows into consideration. Differences between the theoretical and experimental values become smaller.

Bolt Design of Ceramic Matrix Composite and Superalloy Bolted Joint Based on Damage Failure Load

Ceramic matrix composite(CMC)and superalloy bolted joints are commonly used high temperature connection structures in aerospace and aeronautical fields.In this paper,a finite element model coupled with progressive damage analysis of 2D C/SiC composites and superalloy bolted joint was implemented to simulate the uniaxial tensile loading process by using the ABAQUS finite element software.The parametric effects of raised head bolt on stress distribution,tensile performance,and damage process were studied for the CMC⁃superalloy bolted joint structures.The results showed that the final failure load increased first to the maximum value,and then decreased with the rise of bolt diameter,bolt head diameter,and bolt head thickness,respectively.When the three parameters were 5.0 mm,9.5 mm,and 2.8 mm for the current studied bolt configuration,the joint structure gave the maximum load bearing capacity for the considered parameter ranges.It was also found that around 42%potential improvement in load bearing capacity could be achieved by very small adjustments in bolt parameters of the joints.

Tensile Properties of 3-Dimension-4-directional Braided C_f/Si C Composite based on Double-scale Model

The longitude tensile properties of 3-Dimension-4-directional（3D-4d） braided C/Si C composites（CMCs） were investigated with the help of a double scale model. This model involves micro-scale and unit-cell scale. In micro-scale, the tensile properties of fiber tows which involves matrix cracking, interfacial debonding, and fiber failure are studied. The unit-cell scale model can reflect the braided structure and simulate the tensile properties of 3D-4d CMCs by introducing the tensile properties of fiber tows into it. Quasi-static tensile tests of 3D-4d braided CMCs were performed on a PWS-100 test system. The predicted tensile stressstrain curve by the double scale model is in good agreement with that of the experimental results.

3D-C/SiC复合材料在室温和1300℃的拉-拉疲劳行为

采用应力比为 0 .1,频率为 6 0 Hz的正弦波在室温和 130 0℃ ,10 - 4Pa真空中对 3D- C/Si C复合材料进行了拉 -拉疲劳试验。同时用 SEM分析了疲劳断口特征。结果表明 :若取循环基数为 10 6 ,130 0℃疲劳极限为 2 85 MPa,约为抗拉强度的 94 % ;室温疲劳极限为 2 35 MPa,约为抗拉强度的 85 %。 130 0℃疲劳断口的纤维拔出长度比室温短。疲劳损伤主要起源于纤维束编织交叉部位 ,随着疲劳循环次数的增加 。

3D-C／SiC复合材料的高温疲劳性能

采用应力比为0.1和0.5,频率为60和20Hz的正弦波从室温至1500℃,在10-4Pa真空中对3D-C/SiC复合材料进行拉—拉疲劳实验;获得其在应力比0.1频率60Hz条件下室温、1100、1300和1500℃的疲劳曲线,以及应力比0.1频率20Hz和应力比0.5频率20Hz条件下1500℃的疲劳曲线。结果表明,若取循环基数为106周,应力比0.1频率60Hz条件下,3D-C/SiC复合材料在室温、1100、1300和1500℃的疲劳极限分别为235、350、285和240MPa,约为其拉伸强度的87%、97%、94%和90%;疲劳极限与比例极限和拉伸强度随温度有相似的变化规律,即随温度升高而增加,在1100℃达到最大值,尔后随温度增加而下降;但是S—Nf曲线的斜率的变化规律恰好与此相反。应力比的增加和频率的降低,均使复合材料1500℃的疲劳极限有所减小。

Fiber orientation effects on grinding characteristics and removal mechanism of 2.5D C_(f)/SiC composites

Carbon fiber reinforced silicon carbide(C_(f)/SiC)composites are widely used in aerospace for their excellent mechanical properties.However,the quality of the machined surface is poor and unpredictable due to the material heterogeneity induced by complex removal mechanism.To clarify the effects of fiber orientation on the grinding characteristics and removal mechanism,single grit scratch experiments under different fiber orientations are conducted and a three-phase numerical modelling method for 2.5D C_(f)/SiC composites is proposed.Three fiber cutting modes i.e.,transverse,normal and longitudinal,are defined by fiber orientation and three machining directions i.e.,MA(longitudinal and normal),MB(longitudinal and transverse)and MC(normal and transverse),are selected to investigate the effect of fiber orientation on grinding force and micro-morphology.Besides,a three-phase cutting model of 2.5D C_(f)/SiC composites considering the mechanical properties of the matrix,fiber and interface is developed.Corresponding simulations are performed to reveal the micro-mechanism of crack initiation and extension as well as the material removal mechanism under different fiber orientations.The results indicate that the scratching forces fluctuate periodically,and the order of mean forces is MA>MC>MB.Cracks tend to grow along the fiber axis,which results in the largest damage layer for transverse fibers and the smallest for longitudinal fibers.The removal modes of transverse fibers are worn,fracture and peel-off,in which normal fibers are pullout and outcrop and the longitudinal fibers are worn and push-off.Under the stable cutting condition,the change of contact area between fiber and grit leads to different removal modes of fiber in the same cutting mode,and the increase of contact area results in the aggravation of fiber fracture.

声发射技术在三维编织C/SiC复合材料拉伸损伤分析中的应用

通过声发射技术(Acoustic Emission简称AE)对三维编织C/SiC复合材料试件单向拉伸实验过程进行全程动态监测,利用声发射特征参数的综合分析法揭示了三维编织C/SiC复合材料单向拉伸时损伤演化过程和规律。实验结果表明三维编织C/SiC复合材料单向拉伸时损伤发展的四个阶段及声发射特性并利用声发射相对能量定义了材料临界损伤强度。

三维针刺C/SiC复合材料无纬布纤维方向对材料力学性能的影响

通过化学气相渗透法结合反应熔体浸渗法制备了三维针刺C/SiC复合材料,采用扫描电子显微镜观察材料的显微结构,并研究了无纬布纤维方向对材料力学性能的影响。结果表明,三维针刺C/SiC复合材料由0°无纬布层、短纤维胎网层、90°无纬布层以及针刺纤维束组成,无纬布层纤维方向对材料性能有显著影响。试样的拉伸强度和弯曲强度随着无纬布纤维方向与试样长度方向的夹角θ(0～45°)值的增大而减小,面内剪切强度和冲击韧性随θ角的增大而增大。

二维编织C/SiC复合材料的热膨胀系数预测

根据二维编织C/SiC复合材料的细观结构及其制备工艺特点,提出了一种预测该材料面内热膨胀系数的单胞模型。模型充分考虑了编织结构复合材料中的纤维束弯曲和CVI工艺制备陶瓷基复合材料产生的孔洞对热膨胀系数的影响。利用单胞模型预测了二维编织C/SiC的结构参数、纤维体积含量、孔洞含量对复合材料热膨胀系数的影响规律,结果表明:随着纤维束扭结处产生间隙与纱线宽度比值的增大,热膨胀系数增大;当其它参数不变时,随着纤维体积含量的增大,热膨胀系数反而下降;随着孔洞含量的增加,热膨胀系数也出现了下降的趋势。利用DIL402C热膨胀仪测试了二维编织C/SiC复合材料纵向热膨胀系数,试验结果与模型预测结果吻合较好。

三维编织C/SiC复合材料拉伸损伤演化

利用声发射技术,对三维编织C/SiC复合材料在拉伸过程中损伤发展、演化进行了实验研究。实验采集了三维编织C/SiC复合材料拉伸过程的声发射信号。运用多参数分析法,分析了三维编织C/SiC复合材料拉伸损伤的声发射特性,宏观上揭示了材料拉伸损伤的发展、演化过程和规律。研究结果表明三维编织C/SiC复合材料拉伸损伤演化可被分为两个主要阶段,损伤初始阶段和损伤严重阶段。

Real-time damage analysis of 2D C/SiC composite based on spectral characters of acoustic emission signals using pattern recognition

In this study,unsupervised and supervised pattern recognition were implemented in combination to achieve real-time health monitoring.Unsupervised recognition(k-means++)was used to label the spectral characteristics of acoustic emission(AE)signals after completing the tensile tests at ambient temperature.Using in-plane tensile at 800 and 1000°C as implementing examples,supervised recognition(K-nearest neighbor(KNN))was used to identify damage mode in real time.According to the damage identification results,four main tensile damage modes of 2D C/SiC composites were identified:matrix cracking(122.6–201 kHz),interfacial debonding(201–294.4 kHz),interfacial sliding(20.6–122.6 kHz)and fiber breaking(294.4–1000 kHz).Additionally,the damage evolution mechanisms for the 2D C/SiC composites were analyzed based on the characteristics of AE energy accumulation curve during the in-plane tensile loading at ambient and elevated temperature with oxidation.Meanwhile,the energy of various damage modes was accurately calculated by harmonic wavelet packet and the damage degree of modes could be analyzed.The identification results show that compared with previous studies,using the AE analysis method,the method has higher sensitivity and accuracy.

2.5维C/SiC复合材料单胞模型及刚度预测

通过提取2.5维C/SiC复合材料经纱边界曲线,采用鲁棒最小二乘拟合得到了经纱轴向函数表达式,对拟合后的曲线进行合理简化,建立了参数化的2.5维C/SiC复合材料的有限元模型.采用双尺度模型对2.5维C/SiC复合材料进行刚度预测,分别为考虑纤维/基体/孔隙的微观尺度和考虑经纱/纬纱/孔隙的单胞尺度模型,刚度预测的方法采用刚度平均法和能量法.最后讨论了微观尺度的孔隙率对2.5维C/SiC复合材料弹性模量的影响.结果表明,刚度平均法和能量法的计算结果差异较小,考虑微观孔隙率后,计算结果与试验结果吻合得更好.

2.5维自愈合C/SiC复合材料的拉伸应力-应变关系

根据2.5维自愈合C/SiC复合材料的细观结构特点,基于界面开裂和基体开裂的损伤机理,分别建立了该材料经向和纬向拉伸的细观力学模型,进而得到了经向和纬向拉伸的非线性应力-应变关系,应力-应变曲线的预测结果与试验值吻合较好.结果表明:纬向应力-应变曲线的最大预测误差为9%,经向应力-应变曲线的最大预测误差约为10%,经向和纬向的应力-应变关系不同.该模型采用切线弹性模量和平均裂纹间距的方法,省去了以往模型复杂的应变计算过程,使模型得到简化,便于应用.