CMC-EBC损伤耦合机理及一体化设计研究进展

陶瓷基复合材料与环境障碍涂层组合(CMC-EBC)是目前航空航天领域最具应用前景的热结构材料体系。本文对CMC-EBC失效机理与分析模型的研究进展进行综述。首先,简要回顾了CMC-EBC材料体系的发展及主要制备工艺。然后,综述了CMC-EBC在服役环境下的主要损伤模式与失效机理,总结发现CMC预制体结构、孔洞缺陷和EBC内裂纹等损伤演化相互影响,这种细观损伤模式的耦合是决定其寿命的关键因素之一,但目前的机理研究主要集中于涂层本身性能及其受环境因素的影响,缺乏对涂层和复合材料编制结构在损伤演化过程中协同效应的考虑。接下来,详细分析了CMC-EBC的失效模拟与预测模型研究的历史与现状,指出其中存在的问题,包括环境因素建模方法和损伤耦合演化模拟技术。目前大部分工作致力于分别开发CMC和EBC的失效模型,而对于CMC-EBC构件的失效预测应考虑其损伤演化与微观结构之间的相互耦合影响。最后,对CMC-EBC材料体系研发与服役性能预测方法进行了展望,认为CMC本体和EBC失效模式相互耦合,开展结构功能一体化设计和分析是CMC-EBC构件研究的趋势。

EVOLUTION OF THE MICROCRACKS IN WHISKER TOUGHENING CERAMIC MATRIX COMPOSITES

The modified equivalent inclusion theory by the authors and the internal variable theory are employed to investigate the evolution of the microcracks in whisker toughening ceramics and the influence of the microcracks on the mechanical properties of the material. The effect of residual thermostrain, whisker content and aspect ratio is considered. The modulus, initial nonlinear load, strength and nonlinear constitutive relation are calculated and some important conclusions are given.

Preparation and Mechanical Properties of Al_2O_3/Al Laminated Ceramic Matrix Composites

Three series of Al2O3/Al laminated ceramic matrix composites,named SPA,SPV and HP,were fabricated by different methods.SPA and SPV were prepared using Al2O3 slices and Al slurry via screen printing and subsequent heat treatment in air or vacuum.HP samples were made by hot pressing the layered stack of Al foils and Al2O3 slices.SEM and XRD were applied to analyze the microstructure and the interlayer crystal phase.The bending strength,fracture toughness and fracture work of the samples made by the three methods were measured and compared.The results show that the composites have much better toughness and higher fracture work than the Al2O3 slice.Among the samples made by the three methods,the samples made by hot pressing have the optimum mechanical performance.The displacement-load curves and fracture mechanism were analyzed.

Nanoparticles Transport in Ceramic Matriсes: A Novel Approach for Ceramic Matrix Composites Fabrication

The results of practical implementation of a new method for porous piezoceramics, and ceramic matrix piezocomposites fabrication were presented. The method was based on nanoparticles transport in ceramic matrices using a polymer nanogranules coated or filled with a various chemicals, with successive porous ceramics fabrication processes. Different types of polymer microgranules filled and coated by metal-containing nanoparticles were used for a pilot samples fabrication. Polymer microgranules were examined using transmission and scanning electron microscopy as well as by EXAFS and X-ray emission spectroscopy. Pilot samples of nano- and microporous ceramics and composites were fabricated using different piezoceramics compositions (PZT, lead potassium niobate and lead titanate) as a ceramic matrix bases. Resulting ceramic matrix piezocomposites were composed by super lattices of closed or open pores filled or coated by nanoparticles of metals, oxides, ferromagnetics etc. embedded in piezoceramic matrix. Dielectric and piezoelectric parameters of pilot samples were measured using piezoelectric resonance analysis method. New family of nano- and microporous piezoceramics and ceramic matrix piezocomposites are characterized by a unique spectrum of the electrophysical properties unachievable for standard PZT ceramic compositions and fabrication methods.

Effect of Interfacial Bonding on the Toughening of Al_2O_3/Ni Ceramic Matrix Composites

The main Iimitation to the toughening of the α-Al2O3/Ni composite is the poor bonding atthe interface. which causes the nickel particles to be pulled-out during crack propagation with-out obvious plastic deformation. A proper control of oxygen content at the Al2O3-Ni interfacecan promote wetting at the intedece, and produce a mechanically interlocked and chemically strengthened intedece, causing most of the nickel particles to be stretched to failure and to expe-rience severe plastic deformation during crack propagation in the composite. Fracture toughnesstesting using a modified double cantilever beam method with in situ observation of crack prop-agation in a scanning electron microscope shows that the composite with the strengthenedinterface has a more desirable R-curve behaviour and a higher fracture toughness value than thenormal composite.

Identification of Growth Promoter to Fabrication SiCp/Al₂O₃Ceramic Matrix Composites Prepared by Directed Metal Oxidation of An Al Alloy

SiC particulates reinforced alumina matrix composites were fabricated using Directed Metal Oxidation (DIMOX) process. Continuous oxidation of an Al-Si-Mg-Zn alloy with different interlayers (dopents) as growth promoters, will encompasses the early heating of the alloy ingot, melting and continued heating to temperature in the narrow range of 950°C to 980°C in an atmosphere of oxygen. Varying interlayers (dopents) are incorporated to examine the growth conditions of the composite materials and to identification of suitable growth promoter. The process is extremely difficult because molten aluminum does not oxidize after prolonged duration at high temperatures due to the formation of a passivating oxide layer. It is known that the Lanxide Corporation had used a combination of dopents to cause the growth of alumina from molten metal. This growth was directed, i.e. the growth is allowed only in the required direction and restricted in the other directions. The react nature of the dopants was a trade secret. Though it is roughly known that Mg and Si in the Al melt can aid growth, additional dopents used, the temperatures at which the process was carried out, the experimental configurations that aided directed growth were not precisely known. In this paper we have evaluated the conditions in which composites can be grown in large enough sizes for evaluation application and have arrived at a procedure that enables the fabrication of large composite samples by determining the suitable growth promoter (dopant). Scanning electron microscopic, EDS analysis of the composite was found to contain a continuous network of Al2O3, which was predominantly free of grain-boundary phases, a continuous network of Al alloy. Fabrication of large enough samples was done only by the inventor company and the property measurements by the company were confirmed to those needed to enable immediate applications. Since there are a large number of variable affecting robust growth of the composite, fabrication large sized samples for measurements is a difficult task. In the present work, to identify a suitable window of parameters that enables robust growth of the composite has been attempted.

Direct deposition of graphene nanowalls on ceramic powders for the fabrication of a ceramic matrix composite

Uniform mixing of ceramic powder and graphene is of great importance for producing ceramic matrix composite. In this study, graphene nanowalls(GNWs) are directly deposited on the surface of Al2 O3 and Si3 N4 powders using chemical vapor deposition system to realize the uniform mixing. The morphology and the initial stage of the growth process are investigated. It is found that the graphitic base layer is initially formed parallel to the powder surface and is followed by the growth of graphene nanowalls perpendicular to the surface. Moreover, the lateral length of the graphene sheet could be well controlled by tuning the growth temperature. GNWs/Al2 O3 powder is consolidated by using sparking plasma sintering method and several physical properties are measured. Owing to the addition of GNWs, the electrical conductivity of the bulk alumina is significantly increased.

A Numerical Study of Densification Behavior of Silicon Carbide Matrix Composites in Isothermal Chemical Vapor Infiltration

We studied the characteristics of two-scale pore structure of preform in the deposition process and the mass transfer of reactant gas in dual-scale pores, and observed the physiochemical phenomenon associated with the reaction. Thereby, we established mathematical models on two scales, respectively, preform and reactor. These models were used for the numerical simulation of the process of ceramic matrix composites densified by isothermal chemical vapor infiltration(ICVI). The models were used to carry out a systematic study on the influence of process conditions and the preform structure on the densification behaviors. The most important findings of our study are that the processing time could be reduced by about 50% without compromising the quality of the material, if the processing temperature is 950-1 000 ℃ for the first 70 hours and then raised to 1 100 ℃.

STUDY ON PREPARATION OF CERAMIC MATRIX COMPOSITE OF WC-Co ULTRAFINE POWDERS

The W -Co compound precursor powders with an average particle sife of 60 nm were prepared by the chemical coprecipitation as the raw materials of Na2WO1 and CoCl2 and as the reagents of HCI and NH3 ?H2O. After re-ducing and carburizing the precursor powders by hydrogen gas and CO-CO 2 mixture gas. the WC-Co composite povvders ivith an average particle size of 0. 18/wi can be obtained. The purity and particle size of powders -were analysed by XRD and TEM. respectively. Meanwhile, the key factors to influ-ence the reducing and carburizing process of powders were also studied.

Corrosion behavior of SiC foam ceramic reinforced Al-23Si composites in NaCl solution

SiC foam ceramic reinforced aluminum matrix composites(SFCAMCs)were prepared by squeeze casting aluminum alloy(Al-23Si)into the SiC foam ceramic with different pore sizes,and the corrosion behavior of the SFCAMCs was studied in NaCl solutions.Static immersion corrosion tests were conducted at 20°C,50°C and 80°C,respectively.Corrosion morphology and products were analyzed by scanning electron microscope,energy dispersive system and X-ray diffraction.It was found that the corrosion rate of SFCAMCs increases as the temperature rising,and the bigger pore size of SiC foam ceramic reinforcement,the better corrosion resistance of SFCAMCs.

Preparation of Fe-M Intermetallic/TiC-M_2O_3 Ceramic Composites from Ilmenite by SHS

Fe-Al intermetallic/TiC-Al2O3 ceramic composites were successfully prepared by selfpropagating high-temperature synthesis （SHS） from natural ilmenite, aluminium and carbon as the raw materials. The effects of carbon sources, preheating time and heat treatment temperature on synthesis process and products were investigated in detail, and the reaction process of the FeTiO3-Al-C system was also discussed. It is shown that the temperature and velocity of the combustion wave are higher when graphite is used as the carbon source, which can reflect the effect of the carbon source structure on the combustion synthesis; Prolonging the preheating time or heat treatment temperature is beneficial to the formation of the ordered intermetallics; The temperature and velocity of the combustion wave are improved, but the disordered alloys are difficult to eliminate with the preheating time prolonged. The compound powders mainly containing ordered Fe3Al intermetallic can be prepared through heat treatment at 750 ℃.

Experimental Investigation on Active Cooling for Ceramic Matrix Composite

Compared with conventional materials,the active cooling ceramic matrix composite used in ramjet or scramjet makes their structures lighter in mass and better in performance.In this paper,an active and a passive cooling refractory composite specimens are designed and tested with an experimental facility composed of multilayer smale scale cooling penel which consists of a water cooling system and a ceramic matrix composite specimen,and a gas generator used for providing lower and higher transfer rate gases to simulate the temperatures in combustion chamber of ramjst.The active cooling specimen can continuously suffer high surface temperature of 2 000 K for 30 s and that of 3 000 K for 9.3 s,respectively.The experiment results show that the active cooling composite structure is available for high-temperature condition in ramjet.

航空发动机陶瓷基复合材料无损表征技术研究进展

随着陶瓷基复合材料在先进航空发动机热端部件中的推广应用,对其在工艺研发、制备加工、试验考核以及使用服役等阶段形成的缺陷/损伤进行高效准确的无损表征尤为重要。由于陶瓷基复合材料复杂的制备成型工艺及多相复合引起的高度非均质和各向异性,导致传统基于整体均质化假设的无损检测技术面临诸多挑战。本文结合陶瓷基复合材料在航空发动机领域的应用情况,分析了其在制备、加工及服役等阶段的典型缺陷/损伤类型及特征,重点回顾了近年来陶瓷基复合材料无损表征技术的研究进展及应用情况,总结了现有无损表征技术面临的主要挑战,并对未来的发展趋势进行了展望。

Cf/C-SiC烧蚀行为及激光复合超声磨削可行性研究

目的揭示激光与Cf/C-SiC陶瓷基复合材料相互作用机理,分析激光能量密度对材料形性演变的影响规律。提出Cf/C-SiC陶瓷基复合材料激光复合超声磨削加工方案,探究硬脆材料多能场复合加工的可行性。方法使用不同能量密度的激光束扫描Cf/C-SiC陶瓷基复合材料表面,以明确材料烧蚀行为。在材料表面预制不同间距的平行纹理沟槽,进而对比传统磨削、超声辅助磨削和激光复合超声磨削的加工效果,同时研究不同扫描间距的预制沟槽对磨削效果的影响规律。结果陶瓷基复合材料(CMC)在激光作用下可呈现2种截然不同的状态,改性状态时材料以氧化等热化学变化为主,样件内出现热影响区和裂纹区。烧蚀状态时材料以热物理和热机械变化为主,样件内出现烧蚀凹坑、重铸层、热影响区和裂纹区。纤维束中界面经整体脱黏后,裂纹向下延伸并发生偏转。基体中的裂纹多起源于纤维界面处,并在扩展过程中发生偏转、分叉。激光烧蚀作用可改变材料的可加工性,有利于后续超声磨削加工。激光复合超声磨削的两方向磨削力相较传统磨削分别减小了51.4%和56.5%,同时表面粗糙度Sa可降低至4.228μm。结论激光复合超声磨削可有效降低磨削力和加工表面粗糙度,从而提高加工质量,该方法在实现硬脆材料高质量低成本加工方面具有较大的潜能。

SiC/SiC复合材料层板低速冲击及其剩余强度试验研究

高速飞行器中的陶瓷基复合材料结构在服役过程中不可避免地会遇到低速冲击问题,低速冲击后的损伤形式以及剩余承载能力是影响飞行器结构安全的关键问题。本研究以二维编织SiC/SiC复合材料板件为研究对象,在不同能量下开展了低速冲击试验,分析了低速冲击载荷下试验件的表面损伤状态,通过计算机断层扫描技术观察了试验件内部的损伤形貌,结合冲击过程中的冲击响应曲线以及应变历史曲线,分析了SiC/SiC复合材料低速冲击过程的损伤机理。针对含勉强目视可见损伤的试验件开展了冲击后剩余强度试验,研究了勉强目视可见损伤对SiC/SiC复合材料剩余承载性能的影响。结果表明,在低速冲击载荷的作用下,试验件的表面损伤主要包括无表面损伤、勉强目视可见损伤、半穿透损伤以及穿透损伤,试验件的内部损伤主要有锥形体裂纹、纱线断裂以及分层损伤。低速冲击损伤会严重影响SiC/SiC复合材料的剩余性能,虽然试验件损伤勉强目视可见,但其剩余压缩强度为无损件81%,剩余拉伸强度仅为无损件的68%。

先驱体转化SiBCN陶瓷的制备、性能与应用

先驱体转化法是制备高性能陶瓷材料的重要方法,尤其在连续纤维及其复合材料(FRCMC)的制备、元素组成与微结构调控等方面具有显著优势。先驱体转化SiBCN陶瓷具有多元素含量可调、化学键合结构可控的特点,构建了不同结构特征和特殊性能的陶瓷材料。近几年,先驱体转化SiBCN陶瓷发展呈现出新的特点,结构功能一体化设计与制备技术受到了国内外的广泛关注。本文主要梳理了2016年至今先驱体转化SiBCN陶瓷的国内外研究进展,首先简要介绍先驱体转化SiBCN陶瓷的主要特点,然后以先驱体转化陶瓷产物的典型特点为分类依据,分别从SiBCN陶瓷先驱体及其陶瓷产物、连续SiBCN陶瓷纤维、SiBCN基复合材料和功能化SiBCN陶瓷4个方面综述了主要研究进展,提出了未来发展趋势和重点任务,期望为SiBCN陶瓷研制与应用研究提供参考,促进我国先进陶瓷材料的发展进步。

飞行器陶瓷基复合材料轻量化结构设计研究进展

高马赫数飞行带来的极端服役环境对新一代高速飞行器的材料、结构设计提出了更加严苛的要求,本文从“选、用、评”三方面对陶瓷基复合材料在飞行器结构设计中的应用进行综述,进而提出未来发展方向,为飞行器陶瓷基复合材料结构设计提供参考。全面综述了陶瓷基复合材料在不同应用场景下的选取准则及相应制备方法,系统介绍了陶瓷基复合材料在飞行器结构中的典型应用,分析了近服役工况下材料的评价准则及地面实验方法。为满足未来飞行器需求,提出需要结合计算机辅助优化技术和创新制备方法,提高陶瓷基复合材料的耐温和抗疲劳性能;发展高可靠、长寿命的连接技术和一体成型设计方案,充分发挥材料优势;开发多物理场耦合作用下的原位表征技术,以获得陶瓷基复合材料在实际使用中的性能演化行为,为飞行器轻量化结构设计提供可靠依据。

陶瓷基复合材料涡轮动叶榫头元件静强度实验及缺陷影响

陶瓷基复合材料(ceramic matrix composites,CMC)涡轮动叶榫头是动叶装配与承受离心载荷的关键。为了研究熔渗工艺制备CMC榫头在叶片旋转径向拉伸载荷下的力学行为,验证榫头内部质量对其静拉伸强度与破坏模式的影响,设计并制备燕尾形CMC高压涡轮动叶榫头元件试件,对其进行单轴静态拉伸实验,采用X射线CT无损检测对实验前试件内部质量进行扫描,采用DIC与声发射方法对实验过程进行监测。结果表明:燕尾形CMC榫头在单轴静态拉伸下保持完好接触,其静态拉伸强度与破坏模式对其内部质量(尤其是分层缺陷)非常敏感。试件不含分层缺陷时,损伤起始于榫头颈部,并迅速扩展,损伤起始载荷与最大破坏载荷接近,断口呈横向锯齿状;试件内部含分层缺陷时,损伤起始于缺陷,分层逐渐扩展并导致试件断裂,损伤起始载荷下降99.05%,最大破坏载荷下降14.29%,断口位置与分层缺陷一致。

环境温度对二维编织SiC/SiC复合材料拉伸性能的影响研究

为了研究环境温度对陶瓷基复合材料拉伸性能的影响,在室温和800℃,1000℃,1200℃惰性气体保护环境下开展了二维编织SiC/SiC复合材料的拉伸试验。采用数字图像相关技术采集了高温环境下试件的变形数据。通过光学显微镜和扫描电子显微镜拍摄了试件的断口形貌。结果表明:800~1200℃内,二维编织SiC/SiC复合材料的拉伸应力-应变响应同样具有明显的双线性特征,初始线性段的弹性模量与室温测试结果相近,高温环境下第二线性段弹性模量低于室温环境;800~1200℃惰性气体环境下材料拉伸强度较室温环境低20%左右;温度主要影响材料中纤维与基体的结合状态和SiC纤维的强度。一方面,温度越高断口纤维拔出情况越严重;另一方面,温度越高SiC纤维强度越低,二维编织SiC/SiC复合材料强度也有所下降。