Recent Advances in Interface Modification of Cu/graphite Composites and Layered Ternary Carbides of Modified Layer Candidate

We review the fundamental properties and significant issues related to Cu/graphite composites.In particular,recent research on the interfacial modification of Cu/graphite composites is addressed,including the metal-modified layer,carbide-modified layer,and combined modified layer.Additionally,we propose the use of ternary layered carbide as an interface modification layer for Cu/graphite composites.

High-performance grinding of ceramic matrix composites

Ceramic matrix composites(CMCs)are highly promising materials for the next generation of aero-engines.However,machining of CMCs suffers from low efficiency and poor surfacefinish,which presents an obstacle to their wider application.To overcome these problems,this study investigates high-efficiency deep grinding of CMCs,focusing on the effects of grinding depth.The results show that both the sur-face roughness and the depth of subsurface damage(SSD)are insensitive to grinding depth.The material removal rate can be increased sixfold by increasing the grinding depth,while the surface roughness and SSD depth increase by only about 10%.Moreover,it is found that the behavior of material removal is strongly dependent on grinding depth.As the grinding depth is increased,fibers are removed in smaller sizes,with thefiber length in chips being reduced by about 34%.However,too large a grinding depth will result in blockage by chip powder,which leads to a dramatic increase in the ratio of tangential to normal grinding forces.This study demonstrates that increasing the depth of cut is an effective approach to improve the machining efficiency of CMCs,while maintaining a good surfacefin-ish.It provides the basis for the further development of high-performance grinding methods for CMCs,which should facilitate their wider application.

Protective Graphite Coating for Two-Dimensional Carbon/Carbon Composites

Two-dimensional carbon/carbon(2D C/C)composites are a special class of carbon/carbon composites,generally obtained by combining resin-impregnated carbon fiber clothes,which are then cured and carbonized.This study deals with the preparation of a protective coating for these materials.This coating,based on graphite,was prepared by the slurry method.The effect of graphite and phenolic resin powders with different weight ratios was examined.The results have shown that the coating slurry can fill the pores and cracks of the composite surface,thereby densifying the surface layer of the material.With the increase of the graphite powder/phenolic resin weight ratio,the coating density is enhanced while the coating surface flatness decreases;moreover,the protective ability of coating against erosion first increases(from 1:3 to 2:2)and then decreases(from 2:2 to 3:1).When the weight ratio is about 1:1,the coating for 2D C/C composites exhibits the best erosion resistance,which greatly aids these materials during gas quenching.In this case,the erosion rate is decreased by approximately 41.5%at the impact angle of 30°and 52.3%at normal impact,respectively.This can be attributed to the ability of the coating slurry to infiltrate into the substrate,thereby bonding the fibers together and increasing the compactness of the 2D C/C composites.

Effect of WS_2 addition on electrical sliding wear behaviors of Cu-graphite-WS_2 composites

Four kinds of Cu-based composites with different mass ratios of graphite and WS2 as lubricants were fabricated by hot-pressing method. Electrical sliding wear behaviors of the composites were investigated using a block-on-ring tribometer rubbing against Cu-5%Ag alloy ring. The results demonstrated that 800 ~C was the optimum sintering temperature for Cu-graphite-WS2 dual-lubricant composites to obtain the best comprehensive properties of mechanical strength and lubrication performance. Contact voltage drops of the Cu-based composites increased with increasing the mass ratio of WS2 to graphite. The Cu-based composite with 20% graphite and 10% WS2 showed the best wear resistance due to the excellent synergetic lubricating effect of graphite and WS2. The reasonable addition of WS2 into the Cu-graphite composite can remarkably improve the wear resistance without much rise of electrical energy loss which provides a novel principle of designing suitable sliding electrical contact materials for industrial applications.

EFFECT OF FIBER FAILURE ON QUASI-STATIC UNLOADING/RELOADING HYSTERESIS LOOPS OF CERAMIC MATRIX COMPOSITES

The two-parameter Weibull model is used to describe the fiber strength distribution.The stress carried by the intact and fracture fibers on the matrix crack plane during unloading/reloading is determined based on the global load sharing criterion.The axial stress distribution of intact fibers upon unloading and reloading is determined based on the mechanisms of fiber sliding relative to matrix in the interface debonded region.The interface debonded length,unloading interface counter slip length,and reloading interface new slip length are obtained by the fracture mechanics approach.The hysteresis loops corresponding to different stresses considering fiber failure are compared with the cases without considering fiber failure.The effects of fiber characteristic strength and fiber Weibull modulus on the fiber failure,the shape,and the area of the hysteresis loops are analyzed.The predicted quasi-static unloading/reloading hysteresis loops agree well with experimental data.

Sliding wear behavior of copper-based composites reinforced with graphene nanosheets and graphite

The mechanical and tribological properties of hot-pressed copper-based composites containing different amounts of graphene nanosheets（GNSs） are compared with those of copper-graphite（Gr） composites fabricated by the same method.The results show that the Cu-GNSs composites exhibit higher relative density,microhardness and bending strength compared with Cu-Gr composites with the same volume fraction of GNSs and Gr.Moreover,the friction coefficients and wear rates reduce significantly by the addition of GNSs,whereas the limited impact on reducing friction and wear is found on graphite.The abrasive and delamination wear are the dominant wear mechanisms of the composites.It is believed that the superior mechanical and tribological performances of Cu-GNSs composites are attributed to the unique strengthening effect as well as the higher lubricating efficiency of graphene nanosheets compared with those of graphite,which demonstrates that GNS is an ideal filler for copper matrix composites,acting as not only an impactful lubricant but also a favorable reinforcement.

ELASTIC BEHAVIOR ANALYSIS OF 3D ANGLE-INTERLOCK WOVEN CERAMIC COMPOSITES

A micromechanical model for elastic behavior analysis of angle-interlock woven ceramic composites is proposed in this paper. This model takes into account the actual fabric structure by considering the fiber undulation and continuity in space, the cavities between adjacent yarns and the actual cross-section geometry of the yarn. Based on the laminate theory, the elastic properties of 3D angle-interlock woven ceramic composites are predicted. Different numbers of interlaced wefts have almost the same elastic moduli. The thickness of ceramic matrix has little effect on elastic moduli. When the undulation ratio increases longitudinal modulus decreases and the other Young＇s moduli increase. Good agreement between theoretical predictions and experimental results demonstrates the feasibility of the proposed model in analyzing the elastic properties of 3D angle-interlock woven ceramic composites. The results of this paper verify the fact that the method of analyzing polyester matrix composites is suitable for woven ceramic composites.

Enhanced Thermal Conductivity and Bending Strength of Graphite Flakes/aluminum Composites Via Graphite Surface Modification

The effect of graphite surface modification on the thermal conductivity(TC) and bending strength of graphite flakes/Al composites(Gf/Al) prepared by gas pressure infiltration were investigated. Al3 Ni and Al4C3 phase may form at the interface in Ni-coated Gf/Al and uncoated Gf/Al composites, respectively, while the Al-Cu compound cannot be observed in Cu-coated Gf/Al composites. The Cu and Ni coatings enhance TC and the bending strength of the composites in the meantime. TC of Cu-coated Gf/Al composites reach 515 Wm^-1·K^-1 with 75 vol% Gf, which are higher than that of Ni-coated Gf/Al. Meanwhile, due to Al3 Ni at the interface, the bending strength of Ni-coated Gf/Al composites are far more than those of the uncoated and Cu-coated Gf/Al with the same content of Gf. The results indicate that metal-coated Gf can effectively improve the interfacial bonding between Gf and Al.

Preparation of Expanded Graphite-based Composites by One Step Impregnation

A new method for preparing expanded graphite-based composites （EGCs） was developed.The obtained samples were characterized by scanning electron microscopy （SEM）,transmission electron microscope （TEM） and nitrogen adsorption.The experimental results indicated that the EGCs was not simply mechanical mixture of EG and activated carbon,instead the activated carbon was coated on the surface of interior and external pores of the EG in the form of thin carbon layer.The thickness of the activated carbon layer was nearly one hundred nanometers by calculation.It was shown that the higher the impregnation ratio and the activation temperature were,the easier the porosity development would be.And the BET surface area and the total pore volume were as high as 1978 m2/g and 0.9917 cm3/g respectively at 350℃ with an impregnation ratio of 0.9.

FRACTURAL PROCESS AND TOUGHENING MECHANISM OF LAMINATED CERAMIC COMPOSITES

Based on the model of multi-layer beam and the assumption of micro-inhomogeneity of material, the 3D fractural characteristics of laminated ceramic composites have been studied with numerical simulation. Under three-point bending load, crack initiation, coalescence, propagation, tuning off in the weak interface and final rupture have been simulated. The spatial distribution and evolution process of acoustic emission are also presented in the paper. The simulation verifies the primary mechanism of the weak interface inducing the crack to expand along there and absorbing the fractural energy. The disciplinary significance of the effect of strength and properties of material on the toughness and strength of laminated ceramic composites is, therefore, discussed in this paper.

Mechanical Behaviors of ZrO_2-Al_2O_3 Ceramic Composites with Y_2O_3 as Stabilizer

The ZrO2-Al2O3 ceramic composites were prepared by appropriate techniques with commercial ZrO2 and Al2O3 powders as raw materials and Y2O3 as stabilizer. The results indicate that with the introduction of Al2O3 into the ZrO2 matrix where the quantity of additive Y2O3 is 3.5% (mole fraction), the growth of ZrO2 grains is efficiently inhibited, which helps the ZrO2 grains exist in a metastable tetragonal manner; thus higher strength and toughness are acquired. When the content of alumina is 20% (mass fraction), the bending strength and fracture toughness of the composites are 676.7 MPa and 10 MPa·m1/2 respectively, the mechanical behaviors are close to those prepared with ZrO2 and Al2O3 powders synthesized through wet chemical approach. The mechanical behaviors of the composites are well improved owing to the dispersion toughening of alumina grains and phase transformation toughening of zirconia grains.

Effect of graphite powder as a forming filler on the mechanical properties of SiCp/Al composites by pressure infiltration

（38vo1% SiCp ＋ 2vo1% A1203f）/2024 A1 composites were fabricated by pressure infiltration. Graphite powder was introduced as a forming filler in preform preparation, and the effects of the powder size on the microstructures and mechanical properties of the final com- posites were investigated. The results showed that the composite with 15 μm graphite powder as a forming filler had the maximum tensile strength of 506 MPa, maximum yield strength of 489 MPa, and maximum elongation of 1.2%, which decreased to 490 MPa, 430 MPa, and 0.4%, respectively, on increasing the graphite powder size from 15 to 60 μm. The composite with 60 μm graphite powder showed the highest elastic modulus, and the value decreased from 129 to 113 GPa on decreasing the graphite powder size from 60 to 15 μm. The differences between these properties are related to the different microstructures of the corresponding composites, which determine their failure modes.

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.

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.

Composites on Base of the Ultradispersed Polytetrafluoroethylene and Graphite Oxide Intercalated Compounds

Composites based on ultradispersed polytetrafluoroethylene and intercalated graphite oxide compounds with dodecahydro-closo-dodecaborates and methods of their fabrication have been developed. The fabricated composites have been characterized using XRD analysis, and optical microscopy. These composites are distinguished with completeness of their combustion, since the combustion products comprise gaseous boron fluorine-containing compounds of boron, boron trifluoride (BF3), and boron oxyfluoride ((BOF)3). Besides, these composites are characterized with increased energy capacity as compared to purely oxygen-containing compounds, since the heat of formation of boron fluorine-containing compounds is higher than that of boron oxide. Introduction of ultradispersed polytetrafluoroethylene imparts composites with hydrophobicity, thus improving their functioning properties.

Piezoresistivity of Carbon Fiber Graphite Cement-based Composites with CCCW

The electrical conductivity and piezoresistivity of carbon fiber graphite cement-matrix composites（CFGCC） with carbon fiber content（1% by the weight of cement）,graphite powder contents （0%-50% by the weight of cement） and CCCW（cementitious capillary crystalline waterproofing materials,4% by the weight of cement） were studied.The experimental results showed that the relationship between the resistivity of CFGCC and the concentration of graphite powders had typical features of percolation phenomena.The percolation threshold was about 20%.A clear piezoresistive effect was observed in CFGCC with 1wt% of carbon fibers,20wt% or 30wt% of graphite powders under uniaxial compressive tests,indicating that this type of smart composites was a promising candidate for strain sensing.The measured gage factor （defined as the fractional change in resistance per unit strain） of CFGCC with graphite content of 20wt% and 30wt% were 37 and 22,respectively.With the addition of CCCW,the mechanical properties of CFGCC were improved,which benefited CFGCC piezoresistivity of stability.

Tribological behaviors of Ag-graphite composites reinforced with spherical graphite

Two kinds of Ag-graphite composites reinforced with spherical graphite(SG)and conventional flake graphite(FG)were prepared by powder metallurgy technology.The effect of graphite morphology on the tribological behavior for the Ag-SG and Ag-FG under the dry sliding wear was investigated with a pin-on-disk tribometer at a load of 3.0 N in atmosphere condition.The results indicated that the minimum wear rate of 3.5×10^-5 mm^3/(N·m)for Ag-FG was achieved and it reduced by nearly an order of magnitude,reaching 1.6×10^-6 mm^3/(N·m)for the Ag-SG.The obviously different tribological behaviors between the Ag-SG and Ag-FG were closely related to the formation of cracks in the sub-surface.The stress concentration tended to generate at the edges of flake graphite during sliding process,which resulted in the cracks and severe delamination wear of Ag-FG.However,no cracks were found around the spherical graphite in Ag-SG.The spherical graphite can effectively inhibit the initiation and propagation of cracks,achieving high wear resistance.

Effect of sintering temperature on morphology and arc erosion properties of La-Ni-O ceramic and its composites

Ceramic LaNiO3 samples were prepared by solid state reaction method at different sintering temperatures. It was found that the resultant was not ABO3 perovskite single phase but dual phase La2NiO4 and NiO, and the percentage of the two phases varied with sintering temperature. Ceramics sintered at 1400 ℃ were well crystallized and the phase ratio of La2NiO4 was the maximum. The surface morphology observed by scanning electron microscopy （SEM） indicated that the grains of the ceramics sintered at 1400 ℃ were uniform and compact, which were in agreement with the properties of high density and low electrical resistivity of the samples. X-ray diffraction （XRD） patterns of ceramics before and after arc erosion indicated their high structural stability, which resulted in the good arc erosion resistance properties for silver-based electrical contact materials. The contact materials prepared with the ceramic sintered at 1400 ℃ exhibited better mass transition and arc erosion resisting properties.

Effects of graphite on the microstructure and properties of ultrafine WC-11Co composites by spark plasma sintering

Ultrafine WC-11Co hard metals added with different proportions of graphite were prepared by spark plasma sintering at 40 MPa/1200°C for 5 min,and the influence of graphite as free carbon on the microstructure and mechanical properties were investigated.The XRD analysis showed that decarbonization could be prevented by adding graphite.Compact hard metals composed of finer and more homogeneous WC grains with little flaws can be achieved after 0 wt.% to 1.5 wt.% graphite was added.The hardness and fracture toughness increase initially with increasing graphite content,and with over 1.5 wt.% they descend due to coarse grains and more defects.Therefore,1.5 wt.% graphite is the optimal addition content in view of the hardness and transverse rupture toughness.Furthermore,the coercive force decreases while the saturated magnetic intensity increases with the increase of graphite content.

Interfacial reaction between zirconium alloy and graphite mold/yttrium oxide ceramic mold

Zirconium alloys are active in the molten state and tend to react with the mold during casting. The casting technology of zirconium is not yet well established; especially in selecting the mold materials, which are difficult to determine. In the present work, the interfacial reactions between zirconium casting and casting mold were studied. The zirconium alloy was melted in a vacuum arc skull furnace and then cast into the graphite mold and ceramic mold, respectively. The zirconium casting samples were characterized using SEM, EDS and XRD with an emphasis on the chemical diffusion of elements. A reaction layer was observed at the casting surface. Chemical analysis shows that chemical elements C, O and Y from the mold are diffused into the molten zirconium, and new phases, such as ZrC, Zr30, YO1.335 and Y6ZrO11, are formed at the surface. In addition, an end product of zirconium valve cast in a yttria mold has a compact structure and good surface quality.