COMPOSITE MATERIALS. Asst. Prof. Dr. Ayşe KALEMTAŞ

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1 COMPOSITE MATERIALS Office Hours: Tuesday, 16:30-17:30 Phone: Metallurgical and Materials Engineering Department

2 ISSUES TO ADDRESS Ceramic Materials Ceramic Matrix Composites Properties

3 What is "ceramic"? from Greek meaning: "burnt earth" non-metal, inorganic Ceramic materials are inorganic compounds consisting of metallic and nonmetallic elements which are held together with ionic and/or covalent bonds.

4 Introduction to Ceramic Materials Ceramics are inorganic, nonmetallic, solids, crystalline, amorphous (e.g. glass), hard, brittle, stable to high temperatures, less dense than metals, more elastic than metals, and very high melting. Ceramics can be covalent network and/or ionic bonded.

5 Introduction to Ceramic Materials Ductile versus Brittle Fracture Fracture Behavior: Very Ductile Modulate Ductile Brittle Ductile Fracture is Desirable Ductile warning before fracture Brittle no warning before fracture % RA or %EL: Large Moderate Small

6 Introduction to Ceramic Materials A comparison of the properties of ceramics, metals, and polymers

7 Introduction to Ceramic Materials

8 Introduction to Ceramic Materials Bonding: Mostly ionic, some covalent. % ionic character increases with difference electronegativity. CaF2 SiC

9 Introduction to Ceramic Materials Ceramic Materials Advanced Ceramics Traditional Ceramics Advanced ceramics Made from artificial or chemically modified raw materials. Traditional ceramics Mainly made from natural raw materials such as kaolinite (clay mineral), quartz and feldspar.

10 Introduction to Ceramic Materials Ceramic Materials Advanced Ceramics Traditional Ceramics Structural Ceramics Bioceramics Ceramics used in automotive industry Nuclear ceramics Wear resistant ceramics (tribological) Functional Ceramics Electronic substrate, package ceramics Capasitor dielectric, piezoelectric ceramics Magnetic ceramics Optical ceramics Conductive ceramics Whitewares Cement Abrasives Refractories Brick and tile Structural clay products

11 Introduction to Ceramic Materials The technology of ceramics is a rapidly developing applied science in today s world. Technological advances result from unexpected material discoveries. On the other hand, the new technology can drive the development of new ceramics. Currently many new classes of materials have been devised to satisfy various new applications. Advanced ceramics offer numerous enhancements in performance, durability, reliability, hardness, high mechanical strength at high temperature, stiffness, low density, optical conductivity, electrical insulation and conductivity, thermal insulation and conductivity, radiation resistance, and so on. Ceramic technologies have been widely used for aircraft and aerospace applications, wear-resistant parts, bio-ceramics, cutting tools, advanced optics, superconductivity, nuclear reactors, etc. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

12 Introduction to Ceramic Materials Ceramics application could be categorised as structural ceramics, electrical ceramics, ceramic composites, and ceramic coatings. These materials are emerging as the leading class of materials needed to be improved to explore further potential applications. An advanced ceramics application tree, which classifies its current and potential application areas and related advantageous properties, has been developed. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

13 Introduction to Ceramic Materials Advanced ceramic application tree Limitations due to - High cost - Low toughness - Low reliability M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

14 Introduction to Ceramic Materials

15 Introduction to Ceramic Materials OXIDES The raw materials used for oxide ceramics are almost entirely produced by chemical processes to achieve a high chemical purity and to obtain the most suitable powders for component fabrication. NONOXIDES Most of the important nonoxide ceramics do not occur naturally and therefore must be synthesized. The synthesis route is usually one of the following: Combine the metal directly with the nonmetal at high temperatures. Reduce the oxide with carbon at high temperature (carbothermal reduction) and subsequently react it with the nonmetal.

16 Ceramic Matrix Composites (CMCs) A ceramic primary phase imbedded with a secondary phase, which usually consists of fibers. Attractive properties of ceramics: high stiffness, hardness, hot hardness, and compressive strength; and relatively low density. Weaknesses of ceramics: low toughness and bulk tensile strength, susceptibility to thermal cracking. CMCs represent an attempt to retain the desirable properties of ceramics while compensating for their weaknesses.

17 Ceramic Matrix Composites (CMCs) The matrix is relatively hard and brittle The reinforcement must have high tensile strength to arrest crack growth The reinforcement must be free to pull out as a crack extends, so the reinforcement-matrix bond must be relatively weak

18 Ceramic Matrix Composites (CMCs) Ceramic matrix composites (CMC) are used in applications where resistance to high temperature and corrosive environment is desired. CMCs are strong and stiff but they lack toughness (ductility). Matrix materials are usually silicon carbide, silicon nitride and aluminum oxide, and mullite (compound of aluminum, silicon and oxygen). They retain their strength up to 1650 C. Fiber materials used commonly are carbon and aluminum oxide. Applications are in jet and automobile engines, deepsee mining, cutting tools, dies and pressure vessels.

19 Ceramic Matrix Composites (CMCs) Monolithic ceramics have reasonably high strength and stiffness but are brittle. Thus one of the main objectives in producing ceramic matrix composites is to increase the toughness. Naturally it is also hoped, and indeed often found, that there is a concomitant in strength and stiffness. Typical stress strain curves for composites with that for a monolithic ceramic; the area under the stress strain curve is the energy of fracture of the sample and is a measure of the toughness. It is clear from this figure that the reinforcement with particulates and continuous fibres has lead to an increase in toughness but that the increase is more significant for the latter. Schematic force displacement curves for a monolithic ceramic and CMCs illustrating the greater energy of fracture of the CMCs M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

20 Ceramic Matrix Composites (CMCs) Both the monolithic and the particulate-reinforced composite fail in a catastrophic manner, which contrast with the failure of the continuous fibre composite where a substantial load carrying capacity is maintained after failure has commenced. Therefore not only has the continuous fibre composite a better toughness but the failure mode is more desirable. However, fibres are a more expensive reinforcement than particles and the processing is more complex, therefore the improvement in toughness is associated with an extra cost burden. Schematic force displacement curves for a monolithic ceramic and CMCs illustrating the greater energy of fracture of the CMCs M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

21 Ceramic matrix composites Ceramic matrix composite (CMC) development has lagged behind other composites for two main reasons. First more of the processing routes for CMCs involve high temperatures and can only be employed with high temperature reinforcements. It follows that it was not until fibres and whiskers of high temperature ceramics, such as silicon carbide, were readily available was there much interest in CMCs. The high temperature properties of the reinforcement are also of importance during service. A major attribute of monolithic ceramics is that they maintain their properties to high temperatures and this characteristic is only retained in CMCs if the reinforcements also have good high temperature properties. Hence, there is only limited interest in toughening ceramics by incorporation of reinforcements of materials, such as ductile metals, that lose their strength and stiffness at intermediate temperatures. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

22 Ceramic matrix composites The second factor that has hindered the progress of CMCs is also concerned with the high temperatures usually employed for production. Differences in coefficients of thermal expansion,, between the matrix and the reinforcement lead to thermal stresses on cooling from the processing temperature. However, whereas the thermal stresses can generally be relieved in metal matrix composites by plastic deformation of the matrix, this is not possible for CMCs and cracking of the matrix can result. The nature of the cracking depends on the whether the reinforcement contracts more or less than the matrix on cooling as their determines the character (tensile or compressive) of the local thermal stresses. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

23 Ceramic matrix composites If R for a particulate reinforcement is great than that for the matrix M then the circumferential cracks may be produced in the matrix, and for R < M radial cracks may be found. With a fibre reinforcement, when R > M the axial tensile stresses induced in the fibres produce an overall net residual compressive stresses in the matrix and, as the fibres contract, there is a tendency for them to pull away from the matrix. The stress situation is reversed when R < M and cracking of the matrix due to the axial tensile stresses may occur. Clearly there has to be some matching of the coefficients of thermal expansion in order to limit these problems. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

24 Ceramic Matrix Composites (CMCs) A variety of ceramic particulate, whiskers high-strength single crystals with length/diameter ratios of 10 or more), and fibers may be added to the host matrix material to generate a composite with improved fracture toughness. The presence of these reinforcements appears to frustrate the propagation of cracks by at least three mechanisms. First, when the crack tip encounters a particle or fiber that it cannot easily break or get around, it is deflected off in another direction. Thus, the crack is prevented from propagating cleanly through the structure. Second, if the bond between the reinforcement and the matrix is not too strong, crack propagation energy can be absorbed by pullout of the fiber from its original location. Third, fibers can bridge a crack, holding the two faces together, and thus prevent further propagation. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

25 CMCs Ceramic Matrix Composite (CMC) is a material consisting of a ceramic matrix combined with a ceramic (oxides, carbides) dispersed phase. Ceramic Matrix Composites are designed to improve toughness of conventional ceramics, the main disadvantage of which is brittleness. Ceramic Matrix Composites are reinforced by either continuous (long) fibers or discontinuous (short) fibers. Short-fiber (discontinuous) composites are produced by conventional ceramic processes from an oxide (alumina) or non-oxide (silicon carbide) ceramic matrix reinforced by whiskers of silicon carbide (SiC), titanium boride (TiB 2 ), aluminum nitride (AlN), zirconium oxide (ZrO 2 ) and other ceramic fibers. Most of CMC are reinforced by silicon carbide fibers due to their high strength and stiffness (modulus of elasticity). Whiskers incorporated in a short-fiber Ceramic Matrix Composite improve its toughness resisting to cracks propagation. However a character of failure of short-fiber reinforced materials is catastrophic. Long-fiber (continuous) composites are reinforced either by long monofilament of long multifilament fibers.

26 CMCs The best strengthening effect is provided by dispersed phase in form of continuous monofilament fibers, which are fabricated by chemical vapor deposition (CVD) of silicon carbide on a substrate made of tungsten (W) or carbon (C) fibers. Monofilament fibers produce stronger interfacial bonding with the matrix material improving its toughness. Failure of long-fiber Ceramic Matrix Composites is not catastrophic.

27 CMCs Typical properties of long-fiber Ceramic Matrix Composites: High mechanical strength even at high temperatures; High thermal shock resistance; High stiffness; High toughness; High thermal stability; Low density; High corrosion resistance even at high temperatures.

28 CMCs Ceramic composites may be produced by traditional ceramic fabrication methods including mixing the powdered matrix material with the reinforcing phase followed by processing at elevated temperature: hot pressing, sintering. Such fabrication routs are successfully employed for preparing composites reinforced with a discontinuous phase (particulate or short fibers). However the composites reinforced with continuous or long fibers are rarely fabricated by conventional sintering methods due to mechanical damage of the fibers and their degradation caused by chemical reactions between the fiber and matrix materials at high sintering temperature. Additionally sintering techniques result in high porosity of the fiber reinforced composites.

29 CMCs Ceramic matrix composites reinforced with long fibers are commonly fabricated by infiltration methods. In this group of fabrication techniques the ceramic matrix is formed from a fluid (gaseous or liquid) infiltrated into the fiber structure (either woven or non-woven). Prior to the infiltration with a ceramic derived fluid the reinforcing fibers surface is coated with a debonding interphase providing weak bonding at the interface between the fiber and matrix materials. Weak bonding allows the fiber to slide in the matrix and prevents brittle fracture.

30 CMCs Matrix material for long-fiber (continuous fiber) composite may be silicon carbide ceramic, alumina (alumina-silica) ceramic or carbon. Silicon carbide matrix composites are fabricated by chemical vapor infiltration or liquid phase Infiltration methods of a matrix material into a preform prepared from silicon carbide fibers. Alumina and alumina-silica (mullite) matrix composites are produced by sol-gel method, direct metal oxidation or chemical bonding. Carbon-Carbon composites are fabricated by chemical vapor infiltration or Liquid phase infiltration methods of a matrix material into a preform prepared from carbon fibers.

31 Ceramic matrix composites Following table presents the fracture toughness and critical flaw sizes (assuming a typical stress of 700 MPa, or about 100,000 psi of a variety of ceramics and compares them with some common metals. Toughness of monolithic ceramics generally falls in the range of 3 to 6 MPa.m 1/2, corresponding to a critical flaw size of 18 to 74 µm. With transformation toughening or whisker dispersion, the toughness can be increased to 8 to 12 MPa.m 1/2 (the critical flaw size is 131 to 294 µm); the toughest ceramic matrix composites are continuous fiber-reinforced glasses, at 15 to 25 MPa.m 1/2. In these glasses, strength appears to be independent of preexisting flaw size and is thus an intrinsic material property. By comparison, metal alloys such as steel have toughnesses of more than 40 MPa.m 1/2, more than 10 times the values of monolithic ceramics; the toughness of some alloys may be much higher. The critical flaw size gives an indication of the minimum flaw size that must be reliably detected any nondestructive evaluation (NDE) to ensure reliability of the component. Most NDE techniques cannot reliably detect flaws smaller than about 100 µm (corresponding to a toughness of about 7 MPa.m 1/2 ). Toughnesses of at least 10 to 12 MPa.m 1/2 would be desirable for most components.

32 Ceramic matrix composites Fracture Toughness and Critical Flaw Size of Monolithic and Composite Ceramic Materials Compared With Metals. LAS: lithium aluminosilicate; CVD: chemical vapor deposition a: Assumes a stress of 700 MPa (-100,000 psi). b: The strength of these composites is independent of preexisting flaw size. c: The toughness of some alloys can be much higher SOURCES: David W. Richerson, Design, Processing Development, and Manufacturing Requirements of Ceramics and Ceramic Matrix Composites, contractor report for OTA December 1985; and Elaine P. Rothman, Ultimate Properties of Ceramics and Ceramic Matrix Composites, contractor report for OTA, December 1985

33 Ceramic matrix composites Ceramic fibres such as SiC and Si 3 N 4 use polysilane as the base material. CMCs, in which ceramic or glass matrices are reinforced with continuous fibres, chopped fibres, whiskers, platelets or particulates, are emerging as a class of advanced engineering structural materials. They currently have limited high-temperature applications but a large potential for much wider use in military, aerospace and commercial applications such as energy-efficient systems and transportation. There are also other specialty CMCs such as nanocomposites (made from reactive powders) and electroceramics. CMCs are unique in that they combine low density with high modulus, strength and toughness (contrasted with monolithic ceramics) and strength retention at high temperatures. Many have good corrosion and erosion characteristics for high temperature applications. M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006)

34 Ceramic matrix composites CMC Development The 1970 s-1990 s The Honeymoon composite synthesis and characterisation via ceramics technology toughness and strength via fibers and interfaces The Realization realistic environments and realistic tests interfaces and interphases control performance the fibers manufacturers are key CMC s are not materials, they are structures The 30 Year Long Haul continuous improvement ever changing industrial business base

35 THE END Thanks for your kind attention

36 Any Questions

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