Fiber reinforced ceramic matrix composites(FRCMCs)are the preferred materials for safety critical components in the fields of aerospace,nuclear engineering,and transportation,with broad market and application prospect...Fiber reinforced ceramic matrix composites(FRCMCs)are the preferred materials for safety critical components in the fields of aerospace,nuclear engineering,and transportation,with broad market and application prospects.However,due to the characteristics of multiphase,heterogeneity,and anisotropy,key issues such as poor adhesion,high porosity,and crack propagation urgently need to be addressed in the fabrication and machining of FRCMCs.With the increasing demand for FRCMCs parts,high-quality and reliable design and fabrication,performance evaluation,and precision manufacturing have become a series of hot issues.There is a lack of systematic review in capturing the current research status and development direction of FRCMCs fabrication and machining.This research aims to comprehensively review and critically evaluate the existing understanding of the fabrication and machining of FRCMCs.This study can provide scientists with a deeper understanding of the shape control mechanism of FRCMCs fabrication and machining,the theoretical basis of material synchronous removal,machining performance,and development direction.Firstly,the basic characteristics and application background of FRCMCs are introduced.Secondly,by comparing and analyzing the typical fabrication process of FRCMCs,the advantages,disadvantages,and performance evaluation of different processes are comprehensively evaluated.Thirdly,the material removal mechanisms and machining performance evaluation standards of traditional mechanical machining technologies(drilling,milling,grinding)and non-traditional mechanical machining technologies(ultrasonic,laser,water jet,discharge,wire saw,and multi-field hybrid machining)are discussed and analyzed.Finally,the challenges,development trends,and prospects faced by FRCMCs in the fields of fabrication,machining,and application are analyzed.This study not only elucidates the basic processes and key difficulties in the fabrication of FRCMCs,but also provides valuable insights for low-damage machining.展开更多
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 ...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.展开更多
Continuous fiber reinforced SiC ceramic matrix composites(FRCMCs-SiC)are currently the preferred material for hot section components,safety–critical components and braking components(in the aerospace,energy,transport...Continuous fiber reinforced SiC ceramic matrix composites(FRCMCs-SiC)are currently the preferred material for hot section components,safety–critical components and braking components(in the aerospace,energy,transportation)with high value,and have triggered the demand for machining.However,the high brittleness,anisotropy,and heterogeneity of materials bring great challenges to machining,due to high mechanical and thermal loads,severe tool wear,and poor machining quality.With the increasing demand of FRCMCs-SiC parts,high-quality and high-efficient machining has become a hot issue.This review paper provides a detailed literature survey on the machining of FRCMCs-SiC.The material removal mechanism,defect form,and interfacial mechanical properties of FRCMCs-SiC were summarized.The machining processes of FRCMCs-SiC were introduced,and their respective advantages and disadvantages were compared.Given the low machinability(high hardness,high brittleness,anisotropy,and heterogeneity)of FRCMCs-SiC,preliminary experiments have proved that ultrasonic-assisted machining and laser-assisted machining have shown unique advantages in reducing force and tool wear,improving machining quality and machining efficiency.The machined surface integrity was discussed,the influence of process parameters on the machined surface quality was analyzed,and the machining defects of FRCMCs-SiC were summarized.But for FRCMCs-SiC,the existing quantitative evaluation of the machined surface integrity was weak and unsystematic.展开更多
Additive manufacturing(AM)of ceramic matrix composites(CMCs)has enabled the production of highly customized,geometrically complex and functionalized parts with significantly improved properties and functionality,compa...Additive manufacturing(AM)of ceramic matrix composites(CMCs)has enabled the production of highly customized,geometrically complex and functionalized parts with significantly improved properties and functionality,compared to single-phase ceramic components.It also opens up a new way to shape damage-tolerant ceramic composites with co-continuous phase reinforcement inspired by natural ma-terials.Nowadays,a large variety of AM techniques has been successfully applied to fabricate CMCs,but variable properties have been obtained so far.This article provides a comprehensive review on the AM of ceramic matrix composites through a systematic evaluation of the capabilities and limitations of each AM technique,with an emphasis on reported results regarding the properties and potentials of AM man-ufactured ceramic matrix composites.展开更多
Graphene nanoplatelets(GNPs)are considered to be one of the most promising new reinforcements due to their unique two-dimensional structure and remarkable mechanical properties.In addition,their impressive electrical ...Graphene nanoplatelets(GNPs)are considered to be one of the most promising new reinforcements due to their unique two-dimensional structure and remarkable mechanical properties.In addition,their impressive electrical and thermal properties make them attractive fillers for producing multifunctional ceramics with a wide range of applications.This paper reviews the current status of the research and development of graphene-reinforced ceramic matrix composite(CMC)materials.Firstly,we focused on the processing methods for effective dispersion of GNPs throughout ceramic matrices and the reduction of the porosity of CMC products.Then,the microstructure and mechanical properties are provided,together with an emphasis on the possible toughening mechanisms that may operate.Additionally,the unique functional properties endowed by GNPs,such as enhanced electrical/thermal conductivity,are discussed,with a comprehensive comparison in different ceramic matrices as oxide and nonoxide composites.Finally,the prospects and problems needed to be solved in GNPs-reinforced CMCs are discussed.展开更多
In this work,C_(f)/(CrZrHfNbTa)C-SiC high-entropy ceramic matrix composites with good load-bearing,elec-tromagnetic shielding and ablation resistance were designed and reported for the first time.The compos-ites were ...In this work,C_(f)/(CrZrHfNbTa)C-SiC high-entropy ceramic matrix composites with good load-bearing,elec-tromagnetic shielding and ablation resistance were designed and reported for the first time.The compos-ites were fabricated by an efficient combined processing of slurry infiltration lamination(SIL)and precur-sor infiltration and pyrolysis(PIP).Density and porosity of the as-fabricated composites are 2.72 g/cm^(3) and 12.44 vol.%,respectively,and the flexural strength is 185±13 MPa.Due to the carbon fiber rein-forcement with high conductivity and strong reflection,and high-entropy(CrZrHfNbTa)C ceramic matrix with strong absorbability,the total Electromagnetic interference shielding efficiency(SET)of the compos-ites with a thickness of 3 mm are as high as 88.2 dB and 90 dB respectively in X-band and Ku-band.This means that higher than 99.999999%electromagnetic shielding is achieved at 8-18 GHz,showing excel-lent electromagnetic shielding performance.The C_(f)/(CrZrHfNbTa)C-SiC composites also present excellent ablation resistance,with the linear and mass ablation rates of 0.9μm/s and 1.82 mg/s after ablation at the heat flux of 5 MW/m^(2) for 300 s(∼2450℃).This work opens a new insight for the synergistic de-sign of structural and functional integrated materials with load-bearing,electromagnetic shielding and ablation resistance,etc.展开更多
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...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.展开更多
The panel-type structures used in aerospace engineering can be subjected to severe highfrequency acoustic loadings in service. This paper evaluates the frequency-dependent random fatigue of panel-type structures made ...The panel-type structures used in aerospace engineering can be subjected to severe highfrequency acoustic loadings in service. This paper evaluates the frequency-dependent random fatigue of panel-type structures made of ceramic matrix composites（CMCs） under acoustic loadings. Firstly, the high-frequency random responses from the broadband random excitation will result in more stress cycles in a deinite period of time. The probability density distributions of stress amplitudes will be different in different frequency bandwidths, though the peak stress estimations are identical. Secondly, the fatigue properties of CMCs can be highly frequency-dependent. The fatigue evaluation method for the random vibration case is adopted to evaluate the fatigue damage of a representative stiffened panel structure. The frequency effect through S-N curves on random fatigue damage is numerically veriied. Finally, a parameter is demonstrated to characterize the mean vibration frequency of a random process, and hence this parameter can further be considered as a reasonable loading frequency in the fatigue tests of CMCs to obtain more reliable S-N curves.Therefore, the inluence of vibration frequency can be incorporated in the random fatigue model from the two perspectives.展开更多
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....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.展开更多
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...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.展开更多
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 wide...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.展开更多
Ultra-high-temperature ceramic matrix composites(UHTCMCs)based on a ZrB_(2)/SiC matrix have been investigated for the fabrication of reusable nozzles for propulsion.Three de Laval nozzle prototypes,obtained by sinteri...Ultra-high-temperature ceramic matrix composites(UHTCMCs)based on a ZrB_(2)/SiC matrix have been investigated for the fabrication of reusable nozzles for propulsion.Three de Laval nozzle prototypes,obtained by sintering with either hot pressing(HP)or spark plasma sintering(SPS),were tested 2-3 times in a hybrid rocket motor for proving reusability.Sections were extracted after oxidation tests to study the microstructural changes and oxidative and thermomechanical stresses induced by the repeated tests.Compared to a reference graphite nozzle,no measurable erosion was observed for the UHTCMC-based nozzles.The oxidation mechanism consisted in the formation of a ZrO_(2)intermediate layer,with a liquid silicon oxide(SiO_(2))layer on the surface that was displaced by the action of the gas flux towards the divergent part of the nozzle,protecting it from further oxidation.Both specimens obtained by HP and SPS displayed similar performance,with very slight differences,which were attributed to small changes in porosity.These tests demonstrated the capability of complex-shaped prototypes made of the developed UHTCMCs to survive repeated exposure to environments representative of a realistic space propulsion application,for overall operating time up to 30 s,without any failure nor measurable erosion,making a promising step towards the development of reusable rocket components.展开更多
The matrix crack evolution of cross-ply ceramic matrix composites under uniaxial tensile loading is investigated using the energy balance method.Under tensile loading,the cross-ply ceramic matrix composites have five ...The matrix crack evolution of cross-ply ceramic matrix composites under uniaxial tensile loading is investigated using the energy balance method.Under tensile loading,the cross-ply ceramic matrix composites have five damage modes.The cracking mode 3 contains transverse cracking,matrix cracking and fiber/matrix interface debonding.The cracking mode 5 only contains matrix cracking and fiber/matrix interface debonding.The cracking stress of modes 3 and 5 appearing between existing transverse cracks is determined.And the multiple matrix crack evolution of mode 3 is determined.The effects of ply thickness,fiber volume fraction,interface shear stress and interface debonding energy on the cracking stress and matrix crack evolution are analyzed.Results indicate that the cracking mode 3 is more likely to appear between transverse cracks for the SiC/CAS material.展开更多
A multiscale method for simulating the dynamic response of ceramic matrix composite （CMC） with matrix cracks is developed. At the global level, the finite element method is employed to simulate the dynamic response ...A multiscale method for simulating the dynamic response of ceramic matrix composite （CMC） with matrix cracks is developed. At the global level, the finite element method is employed to simulate the dynamic response of a CMC beam. While at the local level, the multiscale mechanical method is used to estimate the stress/strain response of the material. A distributed computing system is developed to speed up the simulation. The simulation of dynamic response of a Nicalon/CAS-II beam being subjected to harmonic loading is performed as a numerical example. The results show that both the stress/strain responses under tension and compressive loading are nonlinear. These conditions result in a different response compared with that of elastic beam, such as： 1） the displacement response is not symmetric about the axis of time; 2） in the condition of small external load, the response at first order natural frequency is limited within a finite range; 3） decreasing the matrix crack space will increase the displace- ment response of the beam.展开更多
Carbon fiber reinforced ultra-high temperature ceramic （UHTC） composites, consisting of carbon fibers embedded in a UHTC-matrix or a C-SiC-UHTC-matrix, are deemed as the most viable class of materials that can overc...Carbon fiber reinforced ultra-high temperature ceramic （UHTC） composites, consisting of carbon fibers embedded in a UHTC-matrix or a C-SiC-UHTC-matrix, are deemed as the most viable class of materials that can overcome the poor fracture toughness and thermal shock resistance of monolithic UHTC ma- terials, and also improve the oxidation resistance and ablation resistance of C/C and C/SiC composites at ultra-high temperatures. In this review, we summarize the different processing routes of the compos- ites based on the UHTC introducing methods, including chemical vapor infiltration/deposition （CVI/D）, precursor infiltration and pyrolysis （PIP）, reactive melt infiltration （RMI）, slurry infiltration （SI）. in-sito reaction, hot pressing （HP）, etc; and the advantages and drawbacks of each method are briefly dis- cussed. The carbon fiber reinforced UHTC composites can be highly tailorable materials in terms of fiber. interface, and matrix. From the perspective of service environmental applications for engine propul- sions anti hypersonic vehicles, the material designs （mainly focusing on the composition, quantity, structure of matrix, as well as the architecture of carbon fibers, UHTCs and pores）, their relevant processing routes and properties （emphasizing on the mechanical and ablation properties） are discussed in this paper. In addition, we propose a material architecture to realize the multi-function through changing the distri- bution of carbon fibers, UHTCs and pores, which will be an important issue for future development of carbon fiber reinforced UHTC composites.展开更多
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...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 ℃.展开更多
SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quali...SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quality and low efficiency when drilling small holes,a novel femtosecond laser rotary drilling(FLRD)technique is proposed.Beam kinematic paths and experimental studies were carried out to analyze the effects of processing parameters on the drilling results in the two-step drilling process.In the through-hole drilling stage,the material removal rate increases with increasing laser power,decreasing feed speed and decreasing pitch.As for the finishing stage of drilling,the exit diameter increased with increasing laser power and decreasing feed speed.The drilling parameters were selected by taking the processing efficiency of through-hole and the quality of finished hole as the constraint criteria.Holes with a diameter of 500μm were drilled using FLRD in 3 mm thick SiC_(f)/SiC composites with a drilling time<150 s.The hole aspect ratio was 6,the taper<0.2°,and there was no significant thermal damage at the orifice or the wall of the hole.The FLRD provides a solution for precision machining of small holes in difficult-to-machine materials by offering the advantages of high processing quality and short drilling times.展开更多
To improve the application and service of C_(f)/SiC composites as advanced hightemperature structural materials,it is critical to achieve their high-efficiency and low-damage machining.In this study,the laser-ablating...To improve the application and service of C_(f)/SiC composites as advanced hightemperature structural materials,it is critical to achieve their high-efficiency and low-damage machining.In this study,the laser-ablating assisted grinding(LAAG)method was presented,and the connection of damage behavior and removal mechanism with laser and grinding processes was revealed.The results demonstrated that the surface of C_(f)/SiC composites after laser ablation was covered with a substantial number of loose oxides primarily composed of SiO2.Laser ablating process,grinding parameter and abrasive belt selection have a significant impact on the machining results.By fabricating an ablative layer with small laser scanning spacing,and selecting small abrasive grains and feed rate during grinding,the machinability was improved and a relatively lowerdamage grinding surface could be obtained.Under the optimal combination of process parameters,the grinding force and temperature of LAAG could be reduced by up to 85%and 35%,respectively.In this case,the subsurface damage of C_(f)/SiC composites occurred only in the form of microcracks rather large-scale fracture,and the formation of interface debonding and matrix cracking was significantly reduced.Furthermore,the grinding chips were mostly shown as micron-sized powders,indicating that the removal mechanism of C_(f)/SiC composites was primarily the microfractured and attrition wear of laser-ablated layer.展开更多
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-duci...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.展开更多
Low thermal conductivity, matched thermal expansion coefficient and good compatibility are general requirements for the environmental/thermal barrier coatings(EBCs/TBCs) and interphases for Al2O3 f/Al2O3 composites. I...Low thermal conductivity, matched thermal expansion coefficient and good compatibility are general requirements for the environmental/thermal barrier coatings(EBCs/TBCs) and interphases for Al2O3 f/Al2O3 composites. In this work, a novel high-entropy(HE) rare-earth phosphate monazite ceramic (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 is designed and successfully synthesized. This new type of HE rare-earth phosphate monazite exhibits good chemical compatibility with Al2O3, without reaction with Al2O3 as high as 1600℃ in air. Moreover, the thermal expansion coefficient(TEC) of HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4(8.9 × 10^-6/℃ at 300–1000℃) is close to that of Al2O3. The thermal conductivity of HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 at room temperature is as low as 2.08 W·m^-1·K^-1, which is about 42% lower than that of La PO4. Good chemical compatibility, close TEC to that of Al2O3, and low thermal conductivity indicate that HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 is suitable as a candidate EBC/TBC material and an interphase for Al2O3 f/Al2O3 composites.展开更多
基金supported by Key Laboratory of Higheffciency and Clean Mechanical Manufacture at Shandong University,Ministry of Education,the National Natural Science Foundation of China(Nos.52305484,52305475,and U23A20632)the China Postdoctoral Science Foundation(No.2024M761876)+7 种基金the Youth Innovation Team Program of Universities in Shandong Province(No.2024KJH166)the National Key Research and Development Program of China(No.2023YFC2413301)the Taishan Scholars Program(No.tsqn202408242)the Shandong Provincial Natural Science Foundation(Nos.ZR2022QE053 and ZR2022QE159)the Guangdong Basic and Applied Basic Research Foundation(No.2022A1515111124)the Major Scientific and Technological Innovation Project of Shandong Province(No.2023CXGC010207)the Major Basic Research of Shandong Provincial Natural Science Foundation(No.ZR2023ZD34)the talent research project for the pilot project of integrating science,education,and industries of Qilu University of Technology(Shandong Academy of Sciences)(No.2024RCKY009)。
文摘Fiber reinforced ceramic matrix composites(FRCMCs)are the preferred materials for safety critical components in the fields of aerospace,nuclear engineering,and transportation,with broad market and application prospects.However,due to the characteristics of multiphase,heterogeneity,and anisotropy,key issues such as poor adhesion,high porosity,and crack propagation urgently need to be addressed in the fabrication and machining of FRCMCs.With the increasing demand for FRCMCs parts,high-quality and reliable design and fabrication,performance evaluation,and precision manufacturing have become a series of hot issues.There is a lack of systematic review in capturing the current research status and development direction of FRCMCs fabrication and machining.This research aims to comprehensively review and critically evaluate the existing understanding of the fabrication and machining of FRCMCs.This study can provide scientists with a deeper understanding of the shape control mechanism of FRCMCs fabrication and machining,the theoretical basis of material synchronous removal,machining performance,and development direction.Firstly,the basic characteristics and application background of FRCMCs are introduced.Secondly,by comparing and analyzing the typical fabrication process of FRCMCs,the advantages,disadvantages,and performance evaluation of different processes are comprehensively evaluated.Thirdly,the material removal mechanisms and machining performance evaluation standards of traditional mechanical machining technologies(drilling,milling,grinding)and non-traditional mechanical machining technologies(ultrasonic,laser,water jet,discharge,wire saw,and multi-field hybrid machining)are discussed and analyzed.Finally,the challenges,development trends,and prospects faced by FRCMCs in the fields of fabrication,machining,and application are analyzed.This study not only elucidates the basic processes and key difficulties in the fabrication of FRCMCs,but also provides valuable insights for low-damage machining.
基金Supported by the National Natural Science Foundation of China(51075204)the Graduate Innovation Foundation of Jiangsu Province(CX08B-133Z)the Doctoral Innovation Foundation of Nanjing University of Aeronautics and Astronautics(BCXJ08-05)~~
文摘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.
基金the National Natural Science Foundation of China(No.51975368)。
文摘Continuous fiber reinforced SiC ceramic matrix composites(FRCMCs-SiC)are currently the preferred material for hot section components,safety–critical components and braking components(in the aerospace,energy,transportation)with high value,and have triggered the demand for machining.However,the high brittleness,anisotropy,and heterogeneity of materials bring great challenges to machining,due to high mechanical and thermal loads,severe tool wear,and poor machining quality.With the increasing demand of FRCMCs-SiC parts,high-quality and high-efficient machining has become a hot issue.This review paper provides a detailed literature survey on the machining of FRCMCs-SiC.The material removal mechanism,defect form,and interfacial mechanical properties of FRCMCs-SiC were summarized.The machining processes of FRCMCs-SiC were introduced,and their respective advantages and disadvantages were compared.Given the low machinability(high hardness,high brittleness,anisotropy,and heterogeneity)of FRCMCs-SiC,preliminary experiments have proved that ultrasonic-assisted machining and laser-assisted machining have shown unique advantages in reducing force and tool wear,improving machining quality and machining efficiency.The machined surface integrity was discussed,the influence of process parameters on the machined surface quality was analyzed,and the machining defects of FRCMCs-SiC were summarized.But for FRCMCs-SiC,the existing quantitative evaluation of the machined surface integrity was weak and unsystematic.
基金This work was supported by Shenzhen Science and Technology Innovation Commission(Nos.KQTD20190929172505711,20200925155544005)The author(Ji Zou)gratefully acknowledges the support from the National Natural Science Foundation of China(No.52022072)This work was also supported by Shenzhen International Collaboration Programme(No.GJHZ20200731095606021).The authors acknowledge the assistance of SUSTech Core Research Facilities.
文摘Additive manufacturing(AM)of ceramic matrix composites(CMCs)has enabled the production of highly customized,geometrically complex and functionalized parts with significantly improved properties and functionality,compared to single-phase ceramic components.It also opens up a new way to shape damage-tolerant ceramic composites with co-continuous phase reinforcement inspired by natural ma-terials.Nowadays,a large variety of AM techniques has been successfully applied to fabricate CMCs,but variable properties have been obtained so far.This article provides a comprehensive review on the AM of ceramic matrix composites through a systematic evaluation of the capabilities and limitations of each AM technique,with an emphasis on reported results regarding the properties and potentials of AM man-ufactured ceramic matrix composites.
基金financially supported by the National Natural Science Foundation of China(Nos.51432004 and 51672041)the Fundamental Research Funds for the Central Universities(No.2232018G-07)+2 种基金the Innovation Program of Shanghai Municipal Education Commission(No.2017-01-07-00-03-E00025)the Program for Innovative Research Team in University of Ministry of Education of China(No.IRT_16R13)Shanghai Sailing Program(No.17YF1400400)。
文摘Graphene nanoplatelets(GNPs)are considered to be one of the most promising new reinforcements due to their unique two-dimensional structure and remarkable mechanical properties.In addition,their impressive electrical and thermal properties make them attractive fillers for producing multifunctional ceramics with a wide range of applications.This paper reviews the current status of the research and development of graphene-reinforced ceramic matrix composite(CMC)materials.Firstly,we focused on the processing methods for effective dispersion of GNPs throughout ceramic matrices and the reduction of the porosity of CMC products.Then,the microstructure and mechanical properties are provided,together with an emphasis on the possible toughening mechanisms that may operate.Additionally,the unique functional properties endowed by GNPs,such as enhanced electrical/thermal conductivity,are discussed,with a comprehensive comparison in different ceramic matrices as oxide and nonoxide composites.Finally,the prospects and problems needed to be solved in GNPs-reinforced CMCs are discussed.
基金supported by the National Key R&D Program of China(no.2022YFB3707700)Program of Shang-hai Academic/Technology Research Leader(no.23XD1424300)National Natural Science Foundation of China(no.52332003).
文摘In this work,C_(f)/(CrZrHfNbTa)C-SiC high-entropy ceramic matrix composites with good load-bearing,elec-tromagnetic shielding and ablation resistance were designed and reported for the first time.The compos-ites were fabricated by an efficient combined processing of slurry infiltration lamination(SIL)and precur-sor infiltration and pyrolysis(PIP).Density and porosity of the as-fabricated composites are 2.72 g/cm^(3) and 12.44 vol.%,respectively,and the flexural strength is 185±13 MPa.Due to the carbon fiber rein-forcement with high conductivity and strong reflection,and high-entropy(CrZrHfNbTa)C ceramic matrix with strong absorbability,the total Electromagnetic interference shielding efficiency(SET)of the compos-ites with a thickness of 3 mm are as high as 88.2 dB and 90 dB respectively in X-band and Ku-band.This means that higher than 99.999999%electromagnetic shielding is achieved at 8-18 GHz,showing excel-lent electromagnetic shielding performance.The C_(f)/(CrZrHfNbTa)C-SiC composites also present excellent ablation resistance,with the linear and mass ablation rates of 0.9μm/s and 1.82 mg/s after ablation at the heat flux of 5 MW/m^(2) for 300 s(∼2450℃).This work opens a new insight for the synergistic de-sign of structural and functional integrated materials with load-bearing,electromagnetic shielding and ablation resistance,etc.
文摘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.
基金supports from the National Natural Science Foundation of China (No. 11572086 , No. 11402052 )the New Century Excellent Talent in University (NCET-11-0086)+3 种基金the Natural Science Foundation of Jiangsu province (No. BK20140616 )the Fundamental Research Funds for the Central Universities and the Scientiic Research Innovation Program of Jiangsu Province College Postgraduates (KYLX_0093, KYLX15_0092)the China Scholarship Council ( 201506090047 )the Ministry of Education, Science and Technological Development of Republic of Serbia ( TR 35011 and ON 74001 )
文摘The panel-type structures used in aerospace engineering can be subjected to severe highfrequency acoustic loadings in service. This paper evaluates the frequency-dependent random fatigue of panel-type structures made of ceramic matrix composites（CMCs） under acoustic loadings. Firstly, the high-frequency random responses from the broadband random excitation will result in more stress cycles in a deinite period of time. The probability density distributions of stress amplitudes will be different in different frequency bandwidths, though the peak stress estimations are identical. Secondly, the fatigue properties of CMCs can be highly frequency-dependent. The fatigue evaluation method for the random vibration case is adopted to evaluate the fatigue damage of a representative stiffened panel structure. The frequency effect through S-N curves on random fatigue damage is numerically veriied. Finally, a parameter is demonstrated to characterize the mean vibration frequency of a random process, and hence this parameter can further be considered as a reasonable loading frequency in the fatigue tests of CMCs to obtain more reliable S-N curves.Therefore, the inluence of vibration frequency can be incorporated in the random fatigue model from the two perspectives.
文摘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.
基金Funded by the Guangdong Province Major Science and Technology Program (No.2008A090300002)
文摘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.
基金supported by the National Natural Science Foundation of China(Grant Nos.92060203,52105453,and 92360304)the Science Center for Gas Turbine Project(No.P2022-A-IV-002-001).
文摘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.
基金This work received support by the EU's Horizon 2020 research and innovation programme under Grant No.685594(C^(3)HARME:Next Generation Ceramic Composites for Harsh Combustion Environment and Space)project CARBOSPACE(Ultrarefractory Ceramic Composites for Aerospace Defense Transport Energy).
文摘Ultra-high-temperature ceramic matrix composites(UHTCMCs)based on a ZrB_(2)/SiC matrix have been investigated for the fabrication of reusable nozzles for propulsion.Three de Laval nozzle prototypes,obtained by sintering with either hot pressing(HP)or spark plasma sintering(SPS),were tested 2-3 times in a hybrid rocket motor for proving reusability.Sections were extracted after oxidation tests to study the microstructural changes and oxidative and thermomechanical stresses induced by the repeated tests.Compared to a reference graphite nozzle,no measurable erosion was observed for the UHTCMC-based nozzles.The oxidation mechanism consisted in the formation of a ZrO_(2)intermediate layer,with a liquid silicon oxide(SiO_(2))layer on the surface that was displaced by the action of the gas flux towards the divergent part of the nozzle,protecting it from further oxidation.Both specimens obtained by HP and SPS displayed similar performance,with very slight differences,which were attributed to small changes in porosity.These tests demonstrated the capability of complex-shaped prototypes made of the developed UHTCMCs to survive repeated exposure to environments representative of a realistic space propulsion application,for overall operating time up to 30 s,without any failure nor measurable erosion,making a promising step towards the development of reusable rocket components.
基金Supported by the Graduate Innovation Foundation of Jiangsu Province(CX08B-133Z)the Doctoral Innovation Foundation of Nanjing University of Aeronautics and Astronautics(BCXJ08-05)~~
文摘The matrix crack evolution of cross-ply ceramic matrix composites under uniaxial tensile loading is investigated using the energy balance method.Under tensile loading,the cross-ply ceramic matrix composites have five damage modes.The cracking mode 3 contains transverse cracking,matrix cracking and fiber/matrix interface debonding.The cracking mode 5 only contains matrix cracking and fiber/matrix interface debonding.The cracking stress of modes 3 and 5 appearing between existing transverse cracks is determined.And the multiple matrix crack evolution of mode 3 is determined.The effects of ply thickness,fiber volume fraction,interface shear stress and interface debonding energy on the cracking stress and matrix crack evolution are analyzed.Results indicate that the cracking mode 3 is more likely to appear between transverse cracks for the SiC/CAS material.
基金Jiangsu Postdoctoral Science Foundation (0902013C)Innovation Foundation for Young Teachers in University of Aeronautics and Astronautics (Y1024-054)
文摘A multiscale method for simulating the dynamic response of ceramic matrix composite （CMC） with matrix cracks is developed. At the global level, the finite element method is employed to simulate the dynamic response of a CMC beam. While at the local level, the multiscale mechanical method is used to estimate the stress/strain response of the material. A distributed computing system is developed to speed up the simulation. The simulation of dynamic response of a Nicalon/CAS-II beam being subjected to harmonic loading is performed as a numerical example. The results show that both the stress/strain responses under tension and compressive loading are nonlinear. These conditions result in a different response compared with that of elastic beam, such as： 1） the displacement response is not symmetric about the axis of time; 2） in the condition of small external load, the response at first order natural frequency is limited within a finite range; 3） decreasing the matrix crack space will increase the displace- ment response of the beam.
基金supported by the Major Program of Aerospace Advanced Manufacturing Technology Research Foundation NSFC and CASC, China (Grant No. U1537204)the Research Fund of Youth Innovation Promotion Association CAS, China (Grant No. 2014171)
文摘Carbon fiber reinforced ultra-high temperature ceramic （UHTC） composites, consisting of carbon fibers embedded in a UHTC-matrix or a C-SiC-UHTC-matrix, are deemed as the most viable class of materials that can overcome the poor fracture toughness and thermal shock resistance of monolithic UHTC ma- terials, and also improve the oxidation resistance and ablation resistance of C/C and C/SiC composites at ultra-high temperatures. In this review, we summarize the different processing routes of the compos- ites based on the UHTC introducing methods, including chemical vapor infiltration/deposition （CVI/D）, precursor infiltration and pyrolysis （PIP）, reactive melt infiltration （RMI）, slurry infiltration （SI）. in-sito reaction, hot pressing （HP）, etc; and the advantages and drawbacks of each method are briefly dis- cussed. The carbon fiber reinforced UHTC composites can be highly tailorable materials in terms of fiber. interface, and matrix. From the perspective of service environmental applications for engine propul- sions anti hypersonic vehicles, the material designs （mainly focusing on the composition, quantity, structure of matrix, as well as the architecture of carbon fibers, UHTCs and pores）, their relevant processing routes and properties （emphasizing on the mechanical and ablation properties） are discussed in this paper. In addition, we propose a material architecture to realize the multi-function through changing the distri- bution of carbon fibers, UHTCs and pores, which will be an important issue for future development of carbon fiber reinforced UHTC composites.
基金Funded by the National Natural Science Foundation of China(No.51472092)
文摘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 ℃.
基金the support of the Xingliao Talent Program of Liaoning Province(No.XLYC2001004)the High Level Talents Innovation Plan of Dalian(No.2020RD02)the Fundamental Research Funds for the Central Universities(No.DUT22LAB501).
文摘SiC_(f)/SiC ceramic matrix composites(SiC_(f)/SiC composites)are difficult to drill small holes due to their heterogeneity,high hardness,and low electrical conductivity.In order to solve the difficulties of poor quality and low efficiency when drilling small holes,a novel femtosecond laser rotary drilling(FLRD)technique is proposed.Beam kinematic paths and experimental studies were carried out to analyze the effects of processing parameters on the drilling results in the two-step drilling process.In the through-hole drilling stage,the material removal rate increases with increasing laser power,decreasing feed speed and decreasing pitch.As for the finishing stage of drilling,the exit diameter increased with increasing laser power and decreasing feed speed.The drilling parameters were selected by taking the processing efficiency of through-hole and the quality of finished hole as the constraint criteria.Holes with a diameter of 500μm were drilled using FLRD in 3 mm thick SiC_(f)/SiC composites with a drilling time<150 s.The hole aspect ratio was 6,the taper<0.2°,and there was no significant thermal damage at the orifice or the wall of the hole.The FLRD provides a solution for precision machining of small holes in difficult-to-machine materials by offering the advantages of high processing quality and short drilling times.
基金co-supported by the National Natural Science Foundation of China(No.52205444)the Natural Science Foundation of Chongqing(No.CSTB2022NSCQMSX1128)。
文摘To improve the application and service of C_(f)/SiC composites as advanced hightemperature structural materials,it is critical to achieve their high-efficiency and low-damage machining.In this study,the laser-ablating assisted grinding(LAAG)method was presented,and the connection of damage behavior and removal mechanism with laser and grinding processes was revealed.The results demonstrated that the surface of C_(f)/SiC composites after laser ablation was covered with a substantial number of loose oxides primarily composed of SiO2.Laser ablating process,grinding parameter and abrasive belt selection have a significant impact on the machining results.By fabricating an ablative layer with small laser scanning spacing,and selecting small abrasive grains and feed rate during grinding,the machinability was improved and a relatively lowerdamage grinding surface could be obtained.Under the optimal combination of process parameters,the grinding force and temperature of LAAG could be reduced by up to 85%and 35%,respectively.In this case,the subsurface damage of C_(f)/SiC composites occurred only in the form of microcracks rather large-scale fracture,and the formation of interface debonding and matrix cracking was significantly reduced.Furthermore,the grinding chips were mostly shown as micron-sized powders,indicating that the removal mechanism of C_(f)/SiC composites was primarily the microfractured and attrition wear of laser-ablated layer.
文摘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.
基金financially supported by the National Natural Science Foundation of China (Nos. 51672064 and U1435206)
文摘Low thermal conductivity, matched thermal expansion coefficient and good compatibility are general requirements for the environmental/thermal barrier coatings(EBCs/TBCs) and interphases for Al2O3 f/Al2O3 composites. In this work, a novel high-entropy(HE) rare-earth phosphate monazite ceramic (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 is designed and successfully synthesized. This new type of HE rare-earth phosphate monazite exhibits good chemical compatibility with Al2O3, without reaction with Al2O3 as high as 1600℃ in air. Moreover, the thermal expansion coefficient(TEC) of HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4(8.9 × 10^-6/℃ at 300–1000℃) is close to that of Al2O3. The thermal conductivity of HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 at room temperature is as low as 2.08 W·m^-1·K^-1, which is about 42% lower than that of La PO4. Good chemical compatibility, close TEC to that of Al2O3, and low thermal conductivity indicate that HE (La0.2Ce0.2Nd0.2Sm0.2Eu0.2)PO4 is suitable as a candidate EBC/TBC material and an interphase for Al2O3 f/Al2O3 composites.
