Composite Materials 5 PDF
Composite Materials 5 PDF
Composite Materials 5 PDF
MATERIALS
Asst. Prof. Dr. Ayşe KALEMTAŞ
Properties
Applications
Fabrication
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Matrix Composites
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
• Carbon fibers
• SiC fibers
• Oxide fibers (glass fibers, mullite fibers, zirconia fibers,
alumina fibers)
• SiC whiskers
• Al2O3-ZrO2 composites
• SiC particulate / Si3N4 matrix composites
• SiC whisker / Al2O3 matrix composites
• SiC whisker / Si3N4 matrix composites
• Continuous fiber / glass matrix composites
• Carbon / carbon composites
• SiC / SiC composites
• Oxide / oxide composites.
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
Powder Dispersion
The powder dispersion method is the most widely used where a simple approach using
substances of known composition or characteristics is required. Most types of matrix can
be positioned using this method. Normally it requires that the fiber or whisker architecture
is opened up so that powder particles can completely surround each reinforcing element,
and that there is sufficient powder entrained for the densified matrix to fill the space
around the reinforcement to an adequate degree, usually completely. Matrix precursors
entrained in this way, even if sinter-active, tend to be reluctant to sinter to full density
because of the restraint posed by the nonshrinking reinforcement structure, and hot-
pressing, usually uniaxial, is required to close voids between reinforcing elements. This
process does not readily lend itself to complex shapesÐgenerally plate shapes with
planar reinforcement are easiest to produce because the reinforcement is not greatly
distorted and thus it is not particularly versatile for producing components with complex
architecture.
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
The disadvantage of this method is that it is not very efficient because the volume
occupied by the resulting solid is much less than that of the impregnating liquid. Several
stages of repeated impregnation and decomposition may be needed to obtain an
impervious final product, which even so still contains interreinforcement closed porosity.
The advantage of the method is that complex shapes can be made based on the
reinforcement preform shape, but the disadvantage is the cost in terms of the number of
processing steps involved.
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
In the liquid phase routes, the fibres first coated with an interphase (e.g. by I-
CVI) are embedded in a liquid precursor of the matrix.
Among other advantages, the RMI-processes are fast and can be applied to
thick preforms. They also yield materials of low residual porosities and high
thermal conductivities.
In the polymer impregnation and pyrolysis (PIP) processes, the fibres are
embedded in a polymeric precursor of the matrix, such as a thermosetting
resin or a pitch for carbon or a polycarbosilane for SiC, and the green
composite is then pyrolyzed.
Such processes are relatively flexible since the composition of the precursor
can be tailored.
Conversely, a shrinking of the matrix occurs during the pyrolysis step owing to
the evolution of gaseous species. As a result, several PIP-sequences have to
be applied in order to achieve a low enough residual porosity, which is time and
labour consuming. Shrinkage can be limited by loading the liquid precursor
with suitable fine powder, i.e. by using a slurry. Finally, the residual porosity can
also significantly be reduced through a hot pressing step, an alternative that
supposes that the matrix displays enough plasticity not to damage the fibres.
This liquid impregnation/hot pressing technique is well suited to the fabrication
of glass-ceramic matrix composites.
Using a reactive gas mixture which deposits a ceramic material within a preform of the
reinforcement, commonly known as chemical vapor deposition (CVD) or chemical vapor
infiltration (CVI), and typically performed at high temperature; all of which have particular
advantages or disadvantages for different types of matrix material.
For those matrix materials which can be produced by reaction between gases, such as
carbon and silicon carbide, a gas phase route can substitute for the liquid impregnation
route. This tends to be a slow process, because if deposition is allowed to occur too
quickly, it mostly occurs at the external surface, blocking penetration.
Comprehensive Composite Materials, Volume 4: Carbon/Carbon, Cement, and Ceramic Matrix Composites, 4.01 Matrix Materials, R. MORRELL
In gas phase routes, i.e. the so-called chemical vapor infiltration (CVI)
processes, the reinforcements (usually as a multidirectional preform) is densified
by the matrix deposited from a gaseous precursor, e.g. an hydrocarbon for
carbon or a mixture of methyltrichlorosilane and hydrogen for silicon carbide.
It is now well established that a fibre coating, referred to as the interphase, has to
be deposited on the fibre prior to the infiltration of the matrix in order to control
the fibre-matrix (FM) bonding and the mechanical behavior of the composite.
The main role of the interphase is to deflect the microcracks which form in the
matrix under loading and hence to protect the fibre form notch effect (mechanical
fuse function).
Use of continuous fibers can modify the mechanical properties if suitable fiber
orientations are chosen. A well-designed fiber architecture is first prepared, and the
matrix material introduced into the voids of the structure. Infiltration into the fiber
architecture is often performed using chemical vapor infiltration or pre-ceramic
polymer infiltration-pyrolysis techniques. These techniques have the advantage of
requiring low temperatures in comparison with sintering processes.
Textile production techniques, such as weaving, stitching, knitting and braiding are
used for producing three-dimensional composite structures, and the stacked sheets
of fabrics are used for manufacturing panel structures.
Hot pressing is used for fabricating glass matrix composites due to the relatively low
processing temperatures, and this is also used for the fabrication of whisker
composites.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
HOT PRESSING
The fibers are immersed in a slurry of matrix particles and then dried.
The fiber/matrix powder preform is then cut into suitable dimensions, and
stacked for hot pressing in order to produce dense composites.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
HOT PRESSING
Preceramic polymer can fill a preform with liquid polymers, either molten or
in solution, which are then pyrolized to make a ceramic matrix.
Resins, such as phenol and pitch, are used for producing carbon matrix
composites, and organosilicon compounds, such as polycarbosilane and
polyvinylsilane, are used for the impregnation of silicon carbide.
Sols have also been used for infiltrating preforms to produce oxide
matrices, such as alumina, silica, zirconia and mullite.
The preform is kept in a closed chamber which is surrounded by the heating coils to attain the
desired temperature for the infiltration to take place. The infiltrant infiltrates into the preform
under pressure with the help of a piston.
Advantages
Disadvantages
Infiltration of performs is a complicated task as the ceramics have higher melt viscosities than
metals.
The differential shrinkage between the matrix and reinforcing phase causes crack formation
during solidification.
High melting points of ceramics results in greater possibility of reaction between the liquid
matrix and the reinforcement.
http://nptel.ac.in/courses/112107085/module6/lecture5/lecture5.pdf
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
NOVEL TECHNIQUES
For example, a Nicalon SiC fiber and alumina matrix composite was
produced as follows: stacked fibrics of Nicalon fiber were coated by
CVD. The major purposes of the coating were to protect the fiber from
aluminum alloys during the matrix growth process and to provide a
weak fiber-matrix interface. The fiber architectures were then placed on
molten aluminum to allow the matrix to grow in the fiber preform by
direct oxidation of the aluminum alloy.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
NOVEL TECHNIQUES
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
PARTICULATE COMPOSITES
WHISKER COMPOSITES
The green density of the mixture of whiskers and matrix powders is generally low
due to a high aspect ratio of whiskers. Pressure sintering, such as hot pressing, is
therefore used for densification. Another problem is due to the agglomeration of
whiskers, and careful mixing of whiskers with matrix forming powders is required
to avoid inducing serious damage to the whiskers. A typical procedure for this is
to disperse the whiskers in liquid followed with successive filtration to remove
agglomerated whiskers. The whiskers are then prepared for composite fabrication
by blending with powders of the matrix material.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
CONTINUOUS FIBER COMPOSITES
Moreover, shear failure and compression failure are often observed in flexural
tests, resulting from delamination due to shear stresses and fiber buckling due
to compression.
Such a failure mode is obviously derived from the weak interface between the
fiber and matrix. Therefore, the presence of lubricant carbon and boron nitride
at the interfaces is preferred. Although excess carbon on the surface of SiC
fibers acts as a lubricant, the carbon layer may oxidize in air. Boron nitride
coating on fibers has been carried out to maintain weak interfaces at high
temperatures.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
GLASS MATRIX COMPOSITES
Continuous fibers such as carbon fibers and SiC fibers can be used to reinforce a
glass matrix.
The strengthening mechanism is similar to that in resin matrix composites, and the
fibers carry most of the load due to their much higher Young's modulus compared to
the matrix.
Of all the continuous fiber composites, glass matrix composites are particularly
dense as they are produced by impregnation of a glass melt.
The mechanical properties are characterized by high strength and large fracture
energy. The large fracture energy is explained in terms of intensive pull out of fibers
from the matrix glass. This indicates that the fiber to matrix bond is poor due to the
presence of lubricant carbon layers on the surfaces of both graphite and silicon
carbide fibers. In contrast glass matrix composites using oxide fibers exhibit low
flexural strength due to the high bonding strength between fiber and glass matrix.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
CARBON/CARBON COMPOSITES
The development of carbon/carbon composites began in 1958, and they have been
applied to the hot parts of missiles and the Space Shuttle, such as nose caps and
leading edges.
Silicon carbide coatings are therefore coated with a layer of glass to protect them in
high temperature applications. The protection mechanism is as follows. When the
part is cooled down from the coating temperature, microcracks develop in the silicon
carbide layer, resulting from thermal expansion mismatch between carbon and
silicon carbide. These cracks might cause oxidation of the substance if exposed to
the air, but are immediately impregnated with the overcoated glass.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
CARBON/CARBON COMPOSITES
Carbon/carbon composites have successfully replaced metallic brake discs in racing cars
and aircraft because of their lightweight.
Civilian aircraft, such as the Concorde supersonic jet and Boeing 767 use carbon/carbon
composite brakes.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
SiC/SiC COMPOSITES
Since the oxidation resistance of SiC is much better than that of carbon,
SiC/SiC composites have been developed for aerospace application
such as propulsion and high velocity systems.
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
In continuous fiber composites, a weak interface between fiber and matrix is preferred because
a large fracture energy is generated as a result of frictional slip at the fiber/matrix interface after
matrix cracking.
In the case of SiC continuous fibers, the presence of excess carbon on the surface of the SiC
fibers contributes to their sliding ability, although the excess carbon may disappear during
longterm use due to oxidation and the oxide reaction product formed at the cracked matrix may
bond with the interface. As a result, embrittlement occurs. It is therefore important to maintain
weak interfaces at high temperatures in oxidative atmospheres, and successful results have
been obtained for SiC continuous fiber/Al2O3 composites using SiC fibers coated with BN
layers.
Since oxide materials have no oxidation problems, development of all-oxide composites has
been a major goal of recent research. Such composites have an interface configuration which
allows a crack to propagate along the interface after matrix cracking. There are several
microstructural design strategies. The first is to use fugitive layers, the second is to use stable
oxide interfaces with suitably low fracture toughness, and the third is to use a porous matrix
because the porous interlayers act as crack deflection paths
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
EUTECTIC COMPOSITES
Chapter 15.1, Ceramic-Matrix Composites, AKIRA OKADAS, Handbook of Advanced Ceramics, 2003, Elsevier Inc., Somiya et al. (Eds.),
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
• geometry,
• the complexity of shape and
• the production volume of the component.
• Inexpensive
• Ability to produce large • Relatively poor properties to date • Graphite • Cements • 400-1400
2. Cement bonded complex shapes • Nicalon
matrix • Low temperature • New fibres
processing
• Good mechanical
properties • Has requires hotpressing of Si
3. Reaction •Pressureless powder in Si3N4 system prior to • Nicalon •Si3N4 • 800-1500
bonded densification reaction bonding • “New” • SiC • 800-1600
• Simple shapes only fibres
*: Temperature limit depends on fibre. Currently all systems are limited to 1200C available fibres.
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
Some processes for continuous fibre-reinforced CMCs
Processing Advantages Disadvantages Fibre Matrix Temperature
method range* (C)
II. Sol-gel and • Good matrix composition • Low yields • Nicalon • Non-oxide • 800-1200
polymer control • Very high shrinkage •- • Alumina •800-1400
processing • easy to infiltrate fibres • Would require multiple •- • Silicates
•Lower densification infiltration/densification steps
temperature • No promising results reported
III. Melt
infiltration • Potentially inexpensive •High melting temperatures • Graphite • Alumina •800-1100
• Should be easy to infiltrate would damage fibres
a) Ceramic fibres • Nicalon • Oxides • 800-1100
melt • Lower shrinkage on • “New”
solidification fibres
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Processing of CMCs
Some processes for continuous fibre-reinforced CMCs
Processing Advantages Disadvantages Fibre Matrix Temperature
method range* (C)
IV. Chemical
vapour infiltration
•- •- •- • “New” fibres • B4C • 800-1200
•- • Has been commercially • Slow and expensive • Nicalon • SiC • 800-1600
•- developed
• Best mechanical properties • Requires iterative • Nextels • SiC • 800-1800
• Considerable flexibility in process
a) General fibres and matrices • Never achieved full •- • HfC •-
approach • High quality matrix, very density
pure • Capital intensive •- • Nitrides •-
• Little fibre damage
• In-situ fibre surface •- •- • Oxides •-
treatment •- •- • Borides •-
• Ability to fill small pores
•- •- •- •-
• Ability to produce complex
b) Lanxide shapes • Slow reaction and • Graphite • Alumina • 800-1200
• Properties dominated by growth kinetics
•- ceramic • Long processing time • Nicalon • AlN • 800-1200
and high temperature
• Very porous grain limits chemistry
•- boundaries • Wetting and reactions •- • TiN • 800-1200
• Systems include: AlN/Al, are limitations
•- TiN/Ti, ZrN/Zr •- •- • ZrN • 800-1200
*: Temperature limit depends on fibre. Currently all systems are limited to 1200C available fibres.
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
CMCs
Carbon-carbon (C—C)
composites are used for
extraordinary temperature
resistance in aerospace
applications.
Carbon-carbon composites
can operate at temperatures
of up to 3000C and, in fact,
are stronger at high
temperatures than at low
temperatures. A comparison of the specific strength of various carbon-
carbon compositeswith that of other high-temperature
materials relative to temperature.
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
CMCs
Finally, the part is coated with silicon carbide to protect the carbon-carbon
composite from oxidation. Strengths of 300,000 psi and a Young’s modulus
(measure of sti¤ness) of 50 x106 psi can be obtained.
First, a crack moving through the matrix encounters a fiber; if the bonding
between the matrix and the fiber is poor, the crack is forced to propagate
around the fiber in order to continue the fracture process.
In addition, poor bonding allows the fiber to begin to pull out of the matrix.
Finally, as a crack in the matrix begins, unbroken fibers may bridge the
crack, providing a compressive stress that helps keep the crack from
opening.
Two failure modes in ceramic-ceramic composites: (a) Extensive pull-out of SiC fibers in a glass matrix provides good
composite toughness. (From Metals Handbook, American Society for Metals, Vol. 9, 9th Ed., 1985.) (b) Bridging of
some fibers across a crack enhances the toughness of a ceramic-matrix composite. (From Journal of Metals, May
1991.)
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
CMCs
Ceramic fibres such as SiC and Si3N4 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.
CMCs have been used in jet fighters. Industrial uses of CMCs include furnace
materials, energy conversion systems, gas turbines and heat engines.
Automotive industry.
Heat exchangers
Aerospace and military applications.
Bearings in missiles.
Other applications include wear parts, such as seals, nozzles, pads,
liners, grinding wheels, brakes, etc. For instance, carbon fiber
reinforced carbon composites are being used in aircraft brakes.
They are also used in dies and tool bits, medical implants and land-
based power and transport engines.
…
http://www.tunemytoyota.com/forum/showthread.php?t=2991
For producing these composites, the carbon fiber mats are imprignated with the Fast-Sol-Gel, a
resin based on rapid hydrolysis and polymerization of a mixture of (Me)xSi(O-Me)4-x monomers.
After a gradual heat-pressure process under inert atmosphere the green composites are
converted into C-SiC composites. Schematic reaction: (SiRO3/2)n → SiC + CO2 + H2O
http://www.aac-research.at/products/products_AAC_Service_CeramicMatrix_en.html
SEM view of hot-pressed SEM view of C/SiC composite with two layers of
(1600°C 30MPa) Fast-Sol-Gel-derived OPS.
carbon-fabric composites: Fibers extending
from molten glass.
http://www.aac-research.at/products/products_AAC_Service_CeramicMatrix_en.html
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Applications of CMCs
BrakeTech Ceramic Matrix Composite (CMC) Rotor on a BST Carbon Fiber wheel,
paired with Brembo Monobloc Calipers, custom anodized spacers & bottons and
Ohlins Superbike Forks.
http://www.oppracing.com/category/808-braketech-brake-rotors/
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Applications of CMCs
CMCs are excellent candidates for replacing the nickel-based superalloys currently used in exhaust nozzle
parts, primarily due to their capacity to withstand the high temperatures and severe operational environment
for much longer periods of time with minimal changes in structural behavior.
In examining the feasibility of using the A500 seals on the divergent section of the exhaust nozzles, AFRL
researchers are addressing a number of key Air Force issues--one of which involves the performance
comparison of CMC parts in flight and during engine ground testing. SPS has developed a novel CMC that
uses carbon fibers in a sequentially layered carbide matrix produced via chemical vapor infiltration. Because
this resultant matrix is self-sealing, it helps protect the carbon fibers from oxidation. The fibers are woven in a
multidimensional, ply-to-ply angle interlock pattern to reduce the chance of delamination.
http://www.wpafb.af.mil/news/story.asp?id=123116097
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Applications of CMCs
http://matse101.mse.uiuc.edu/
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Ceramic Matrix Composites
Ceramic matrix composite (CMC) development
has lagged behind other composites for two main
reasons.
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
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 PMC
reinforcement lead to thermal stresses on
cooling from the processing temperature.
MMC
However, whereas the thermal stresses can
generally be relieved in metal matrix composites
by plastic deformation of the matrix, this is not CMC
possible for CMCs and cracking of the matrix
can result.
M. Rosso, Ceramic and metal matrix composites: Routes and properties, Journal of Materials Processing Technology 175 (2006) 364–375
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
THE END
Composite Materials Asst. Prof. Dr. Ayşe KALEMTAŞ
Any
Questions