COMPOSITE MATERIALS HANDBOOK. Volume. Metal Matrix. Composites

Transcription

1 COMPOSITE MATERIALS HANDBOOK Metal Matrix Volume 4 Composites

2 TABLE OF CONTENTS FOREWORD... ii SUMMARY OF CHANGES... xiii 1. GUIDELINES GENERAL INFORMATION INTRODUCTION PURPOSE SCOPE Section 1: Guidelines Section 2: Design Guidelines for Metal Matrix Materials Section 3: Material property data USE OF THE DOCUMENT AND LIMITATIONS Source of information Use of data and guidelines in applications Strength properties and allowables terminology Use of references Use of tradenames and product names Toxicity, health hazards, and safety Ozone depleting chemicals APPROVAL PROCEDURES SYMBOLS, ABBREVIATIONS, AND SYSTEMS OF UNITS Symbols and abbreviations Constituent properties Laminae and laminates Subscripts Superscripts Acronyms Material system codes System of units DEFINITIONS REFERENCES INTRODUCTION TO MMC MATERIALS INTRODUCTION MMC SYSTEMS Systems definitions Distinction from other materials/composites MATRIX MATERIALS Role of matrix materials Forms of matrix materials Types of matrix materials Aluminum Copper Iron Magnesium Nickel Titanium REINFORCEMENT MATERIALS Types of reinforcement iv

3 Role of reinforcement Composition of reinforcement REINFORCEMENT COATINGS Role of coatings Types of coatings MANUFACTURING PROCESSES Overview and general information Assembly and consolidation Powder blending and consolidation Consolidation diffusion bonding Vapor deposition Squeeze casting and squeeze infiltration Spray deposition Slurry casting (compocasting) Reactive processing (in-situ composites) Thermomechanical processing Near net shape manufacturing processes PRODUCT FORMS Intermediate Standard Selectively reinforced components SECONDARY MANUFACTURING PROCESSES Overview and general information Forming Machining Joining Qualitative assessment for MMC joining methods Qualitative performance assessment Joint adaptability, applications and selection Potential issues in joining MMCs Solidification effects Chemical reactions Joint preparation Post-joining heat treatment Classification and discussion of selected joining methods Inertia friction (IF) welding Friction stir (FS) welding Ultrasonic (US) welding Diffusion bonding (DFB) Laser beam (LB) welding Electron beam (EB) welding Gas-tungsten arc (GTA) welding Gas-metal arc (GMA) welding Resistance spot (RS) welding Capacitor discharge (CD) welding Brazing (BZ) Soldering (SD) Adhesive bonding (AB) Mechanical fastening (MF) Cast-insert joining (CI) Transient liquid phase (TLP) bonding Rapid infrared (RI) joining Thermal treatment Coatings and surface treatments QUALITY ASSURANCE v

4 Constituents Preform Final product Statistical process control REPAIR In-process In-service REFERENCES TEST PLANS FOR MATERIALS CHARACTERIZATION INTRODUCTION Objective Classes of data REQUIREMENTS Test method selection Test conditions selection Specimen number and sampling Specimen preparation Data documentation Requirements Checklist MATERIALS PEDIGREE Reinforcement Reinforcement sizing Reinforcement coatings Matrix Intermediate forms characterization Metallized fibers Monotapes Lamina other than monotapes Specialized forms Composite materials CONTINUOUS FIBER REINFORCED MMC CONSTITUENT MATERIAL PROPERTIES Static property data classes Screening data Mean data Fully approved data Composite fatigue properties tests Composite thermal mechanical tests Composite physical properties tests Intermediate forms characterization Metallized fibers Monotapes Lamina other than monotapes Specialized forms Constituent characterization Fiber properties tests Matrix DISCONTINUOUS REINFORCED MMC & CONSTITUENT MATERIAL PROPERTIES Screening Testing requirements for fully approved data Composite static properties tests Composite fatigue properties tests Composite thermal mechanical tests Composite physical properties tests vi

5 Composite corrosion properties tests REFERENCES COMPOSITE TESTING AND ANALYTICAL METHODS INTRODUCTION CONTINUOUS FIBER REINFORCED MMC MECHANICAL PROPERTY TEST METHODS Tension Compression Shear (in-plane) Fatigue Scope Specimen design Waveforms Control mode Compressive loading Failure Data reporting Fatigue crack growth rate Creep/stress rupture Pin bearing tension Pin bearing compression Filled hole tension Open hole tension/notch sensitivity Flexure (three-point bend) Filled hole compression Fiber pushout tests Background General Description of the method Significance and use Apparatus Indenter Support plate Acoustic emission sensor Displacement sensor Remote viewing using a microscope/camera Test specimen preparation Test procedure Effects of environment Analysis of results Microhardness Thermomechanical fatigue (TMF) (in-phase/out-of-phase) Scope Specimen design Temperature control and measurement Waveforms Phasing Pre-test measurements Starting the test Data reporting Residual strength and stiffness Bearing fatigue Open hole fatigue Filled hole fatigue vii

6 Corrosion fatigue Stress corrosion cracking Wear Impact Damping DISCONTINUOUS REINFORCED MMC MECHANICAL PROPERTY TEST METHODS Tension Compression Shear (in-plane) Fracture toughness Fatigue Fatigue crack growth Creep/stress rupture Corrosion fatigue Stress corrosion cracking Wear Impact Damping PHYSICAL PROPERTY TEST METHODS Density Fiber volume fraction MICROSTRUCTURAL ANALYSIS TECHNIQUES Titanium matrix composites CHEMICAL ANALYSIS TECHNIQUES Analysis of carbon and sulfur Analysis for oxygen and nitrogen by inert gas fusion NONDESTRUCTIVE EVALUATION TEST METHODS ENVIRONMENTAL EFFECTS TEST METHODS Corrosion and corrosion test methods Neutral salt spray (fog) Corrosion testing, cyclic INTERPHASES AND INTERFACES TEST METHODS REFERENCES INTERMEDIATE FORMS TESTING AND ANALYTICAL METHODS INTRODUCTION MECHANICAL PROPERTY TEST METHODS PHYSICAL PROPERTY TEST METHODS MICROSTRUCTURAL ANALYSIS TECHNIQUES CHEMICAL ANALYSIS TECHNIQUES NONDESTRUCTIVE EVALUATION TEST METHODS FIBER TESTING AND ANALYTICAL METHODS INTRODUCTION MECHANICAL PROPERTY TEST METHODS Tensile tests Creep and creep rupture Bend stress relaxation PHYSICAL PROPERTY TEST METHODS Density MICROSTRUCTURAL ANALYSIS TECHNIQUES CHEMICAL ANALYSIS TECHNIQUES ENVIRONMENTAL EFFECTS TEST METHODS REFERENCES viii

7 1.7 FIBER SIZING TESTING AND ANALYTICAL METHODS INTRODUCTION PHYSICAL PROPERTY TEST METHODS CHEMICAL ANALYSIS TECHNIQUES FIBER COATINGS, INTERFACES AND INTERPHASES TESTING AND ANALYTICAL METHODS INTRODUCTION MECHANICAL PROPERTY TEST METHODS PHYSICAL PROPERTY TEST METHODS MICROSTRUCTURAL ANALYSIS TECHNIQUES CHEMICAL ANALYSIS TECHNIQUES MATRIX TESTING AND ANALYTICAL METHODS INTRODUCTION MECHANICAL TEST METHODS Tension Creep Stress relaxation Fatigue Fatigue crack growth PHYSICAL TEST METHOD Density MICROSTRUCTURAL ANALYSIS TECHNIQUES Microstructural analysis techniques titanium Microstructural analysis techniques aluminum CHEMICAL ANALYSIS TECHNIQUES ENVIRONMENTAL EFFECTS TEST METHODS REFERENCES STRUCTURE SENSITIVE PROPERTIES CHARACTERIZATION INTRODUCTION MECHANICALLY-FASTENED JOINTS BONDED, BRAZED, AND WELDED JOINTS CURVED SHAPES STRUCTURAL DESIGN DETAILS TRANSITION AND OTHER SPECIAL REGIONS SIZE EFFECTS OTHER TOPICS ANALYSIS OF DATA GENERAL PROCEDURES OF CALCULATION OF STATISTICALLY-BASED MATERIAL PROPERTIES SAMPLES OF COMPUTATIONAL PROCEDURES STATISTICAL TABLES DESIGN GUIDELINES FOR METAL MATRIX MATERIALS GENERAL INFORMATION INTRODUCTION PURPOSE, SCOPE, AND ORGANIZATION OF SECTION USE OF DATA STRUCTURAL DESIGN AND ANALYSIS INTRODUCTION Analysis methodology classifications ix

8 Basic concepts GENERAL DESIGN GUIDELINES ANALYSIS APPROACHES (CONTINUOUS FIBER MMC) Micromechanics General relationships Effective elastic properties Residual stresses Fiber-matrix bond strength Overall inelastic strain Viscoplastic constitutive relations Axial tensile response Axial compressive response Transverse tensile response Transverse compressive response Macromechanics Effective elastic properties Types of laminates Symmetric laminates Specially orthotropic laminates Cross-ply laminates Angle-ply laminates Balanced laminates Other specially orthotropic laminates Quasi-isotropic laminates Laminate effective elastic properties Effective strength Maximum stress criterion Maximum strain criterion Tsai-Hill criterion Tsai-Wu criterion Hashin criterion Puck and LaRC03 criteria Creep Multiaxial effects Damage tolerance Durability Life prediction DESIGN GUIDELINES (DISCONTINUOUS FIBER REINFORCED MMC) Micromechanics General relationships Effective elastic properties Fiber-matrix bond strength Inelastic mechanisms and damage Viscoplastic constitutive relations Tensile response Compressive response Shear response Crack growth behavior Durability Life prediction REFERENCES APPLICATIONS AND CASE STUDIES COMPONENTS FOR STRUCTURAL APPLICATIONS COMPONENTS FOR TRIBOLOGICAL APPLICATIONS x

9 2.4.3 COMPONENTS FOR THERMAL MANAGEMENT APPLICATIONS COMPONENTS FOR THERMAL EXPANSION CONTROL OTHER MISCELLANEOUS APPLICATIONS MATERIALS PROPERTIES DATA GENERAL INFORMATION INTRODUCTION PURPOSE, SCOPE, AND ORGANIZATION OF SECTION PRESENTATION OF DATA Properties and definitions Sign convention Table formats Fatigue data REFERENCES REINFORCEMENT PROPERTIES INTRODUCTION ALUMINA FIBERS Introduction Virgin Nextel TM 610 fiber BORON FIBERS BORON CARBIDE FIBERS CARBON AND GRAPHITE FIBERS SILICON CARBIDE FIBERS Virgin SCS-6 fiber* Virgin and extracted SCS-6 fibers REFERENCE SCS-6 Fiber REFERENCE STEEL FIBERS TUNGSTEN FIBERS OTHER FIBERS OTHER REINFORCEMENTS PROPERTIES OF MATRIX MATERIALS INTRODUCTION ALUMINUMS COPPERS MAGNESIUMS TITANIUMS Ti-15V-3Cr-3Al-3Sn (NASA-GRC) OTHERS FIBER COATING PROPERTIES INTRODUCTION CARBON TITANIUM DIBORIDE YTTRIA OTHERS ALUMINUM MATRIX COMPOSITE PROPERTIES INTRODUCTION ALUMINA/ALUMINUM Nextel 610/pure Al panel BORON/ALUMINUM xi

10 3.5.4 BORON CARBIDE/ALUMINUM GRAPHITE/ALUMINUM SILICON CARBIDE/ALUMINUM STEEL/ALUMINUM TUNGSTEN/ALUMINUM OTHERS/ALUMINUM COPPER MATRIX COMPOSITE PROPERTIES INTRODUCTION GRAPHITE/COPPER OTHERS/COPPER MAGNESIUM MATRIX COMPOSITE PROPERTIES INTRODUCTION GRAPHITE/MAGNESIUM ALUMINA/MAGNESIUM OTHER/MAGNESIUM TITANIUM MATRIX COMPOSITE PROPERTIES INTRODUCTION SILICON CARBIDE/TITANIUM SCS-6/Ti SCS-6/Ti-15-3 Tension SCS-6/Ti-15-3 Fatigue TRIMARC-1/Ti-6Al-2Sn-4Zr-2Mo wire/fiber wound plate* SCS-6/Ti-6Al-4V fiber/powder Static Properties SCS-6/Ti-6Al-4V fiber/powder* Fatigue Fatigue crack growth ALUMINA/TITANIUM OTHER/TITANIUM OTHER MATRIX COMPOSITES APPENDIX A. TYPICAL PUSHOUT TEST DATA A1. FIBER PUSHOUT APPENDIX B. RAW DATA TABLES FOR MATRIX MATERIALS B1. ALUMINUMS B2. COPPERS B3. MAGNESIUMS B4. TITANIUMS B4.1 Ti 15V 3Cr 3Al-3Sn (Section ) APPENDIX C. RAW DATA TABLES FOR METAL MATRIX COMPOSITE MATERIALS C1. ALUMINUMS C1.1 Nextel 610 / SP Al (Section ) C2. COPPER C3. MAGNESIUMS C4. TITANIUMS C4.1 SiC/TI-15-3 (Section and ) C4.2. TRIMARC-1/Ti (Section ) C4.3 Titanium Matrix Composite Panels (Section ) Index xii