Ceramic Matrix Composites

Preface xv Contributors xvii Part I Fibers: Interface and Architecture 1 1 Reinforcement of Ceramic Matrix Composites: Properties of SiC-Based Filaments and Tows 3 Jacques Lamon, Stéphane Mazerat, and Mohamed R'Mili 1.1 Introduction 3 1.2 Processing of SiC-Based Filaments 4 1.3 Fracture Characteristics of Single Filaments 6 1.4 Multifilament Tows 11 1.5 Mechanical Behavior at High Temperatures 16 1.6 Summary 23 References 23 2 Carbon Fibers 27 Herwig Peterlik 2.1 Introduction/Production Routes 27 2.2 Structure of Carbon Fibers 28 2.3 Stiffness and Strength of Carbon Fibers 32 2.4 Concluding Remarks and Future Directions 36 Acknowledgments 37 References 37 3 Influence of Interfaces and Interphases on the Mechanical Behavior of Fiber-Reinforced Ceramic Matrix Composites 40 Jacques Lamon 3.1 Introduction 40 3.2 Role of Interfacial Domain in CMCs 41 3.3 Influence of Deflected Cracks 49 3.4 Strengthened Interfaces and Interphases 51 3.5 Various Concepts ofWeak Interfaces/Interphases 56 3.6 Determination of Interfacial Properties 56 3.7 Interface Selection 60 3.8 Conclusions 60 References 61 4 Textile Reinforcements: Architectures, Mechanical Behavior, and Forming 65 Philippe Boisse 4.1 Introduction 65 4.2 Textile Composite Reinforcements 65 4.3 Reinforcements of Ceramic Composites 74 4.4 Preforming Simulation 76 4.5 Conclusion 81 References 82 Part II Composite Materials 85 5 Carbon/Carbons and Their Industrial Applications 87 Hiroshi Hatta, Roland Weiss, and Patrick David 5.1 Introduction 87 5.2 Manufacturing of Carbon/Carbons 87 5.3 Strengths 97 5.4 Thermal Properties of Carbon/Carbon Composites 109 5.5 Oxidation Protection of Carbon/Carbon 118 5.6 Industrial Applications of Carbon/Carbons 126 References 140 6 C/SiC and C/C-SiC Composites 147 Bernhard Heidenreich 6.1 Introduction 147 6.2 Manufacturing Methods 149 6.3 Properties 174 6.4 Applications 191 6.5 Summary 209 Acknowledgments 209 Abbreviations 210 References 211 7 Advances in SiC/SiC Composites for Aero-Propulsion 217 James A. DiCarlo 7.1 Introduction 217 7.2 Materials and Process Requirements for Structurally Reliable High Temperature SiC/SiC Components 218 7.3 Current Fabrication Routes for SiC/SiC Engine Components 219 7.4 Recent NASA Advancements in SiC/SiC Materials and Processes 220 7.5 Current Microstructural Design Guidelines and Potential Service Issues for Higher Temperature SiC/SiC Components 232 7.6 Concluding Remarks 233 Acknowledgments 233 References 233 8 Oxide-Oxide Composites 236 Kristin A. Keller, George Jefferson, and Ronald J. Kerans 8.1 Introduction 236 8.2 Composite Design for Tough Behavior 237 8.3 Fibers and Fiber Architecture 240 8.4 Processing Methods 241 8.5 Porous Matrix Composite Systems 248 8.6 Properties 250 8.7 Composites with Interface Coatings 257 8.8 Technology Development 261 8.9 Potential Future for Oxide-Oxide Composites 263 Acknowledgments 264 References 264 9 Ultrahigh Temperature Ceramic-Based Composites 273 Yutaka Kagawa and Shuqi Guo 9.1 Introduction 273 9.2 Ultrahigh Temperature Ceramic-Based Composites with Particulates 273 9.3 Ultrahigh Temperature Ceramic-Based Composites with Short Fibers 285 9.4 Summary Remarks and Future Outlook 288 References 290 Part III Environmental Effects and Coatings 293 10 Environmental Effects on Oxide/Oxide Composites 295 Marina B. Ruggles-Wrenn 10.1 Introduction/Background 295 10.2 Mechanical Behavior--Effects of Environment 296 10.3 Concluding Remarks and Future Directions 330 References 331 11 Stress-Environmental Effects on Fiber-Reinforced SiC-Based Composites 334 Gregory N. Morscher 11.1 Introduction/Background 334 11.2 Mechanisms 334 11.3 Composite Systems 337 11.4 Modeling and Design for Stress-Oxidation Degradation 345 11.5 Concluding Remarks and Future Directions 350 Acknowledgments 350 References 350 12 Environmental Effects: Ablation of C/C Materials--Surface Dynamics and Effective Reactivity 353 Gerard L. Vignoles, Jean Lachaud, and Yvan Aspa 12.1 Introduction/Background 353 12.2 Materials Observation: Recession Rate 365 12.3 Concluding Remarks and Future Directions 383 Acknowledgments 384 References 384 13 Radiation Effects 389 Yutai Katoh 13.1 Introduction 389 13.2 Theory of Radiation Damage 389 13.3 Radiation Effects on Ceramics 392 13.4 Radiation Effects in Ceramic Matrix Composites 394 13.5 Concluding Remarks and Future Directions 401 Acknowledgment 402 References 402 14 Foreign Object Damage in Ceramic Matrix Composites 405 Sung R. Choi 14.1 Introduction/Background 405 14.2 Experimental Techniques 406 14.3 Phenomena of Foreign Object Damage in CMCs 409 14.4 FOD Response of Environmental Barrier Coatings 422 14.5 Comparison of CMCs and Silicon Nitrides 424 14.6 Consideration Factors of FOD in CMCs 425 14.7 Concluding Remarks 426 Acknowledgments 426 References 426 15 Environmental Barrier Coatings for SiCf/SiC 430 Kang N. Lee 15.1 Introduction 430 15.2 Background 431 15.3 Evolution of EBCs 437 15.4 Processing, Testing, and Lifing 442 15.5 Concluding Remarks and Future Directions 448 References 448 16 Oxidation Protective Coatings for Ultrahigh Temperature Composites 452 Qiangang Fu and Yiguang Wang 16.1 Introduction 452 16.2 Basic Requirements of Anti-Oxidation Coating for C/C and C/SiC Composites 453 16.3 Preparation Methods of Anti-Oxidation Coatings 454 16.4 Oxidation-Resistant Coating Systems 456 16.5 Composite Coating 460 16.6 Summary 460 References 461 Part IV Modeling 465 17 Damage and Lifetime Modeling for Structure Computations 467 Pierre Ladevèze, Emmanuel Baranger, Martin Genet, and Christophe Cluzel 17.1 Introduction 467 17.2 Damage Modeling Based on an Anisotropic Damage Theory Including Closure Effects 468 17.3 Multiscale Modeling of the Oxidation/Damage Coupling and the Self-Healing Effects 481 17.4 Prediction Capabilities 503 References 515 18 Approach to Microstructure-Behavior Relationships for Ceramic Matrix Composites Reinforced by Continuous Fibers 520 Jacques Lamon 18.1 Introduction 520 18.2 Composite Mechanical Behavior 521 18.3 Constituent Properties and Length Scales 526 18.4 Modeling of Stress-Strain Behavior 531 18.5 Virtual Testing: Computational Approach forWoven Composites 539 18.6 Predictions of Rupture Time 542 18.7 Conclusions 545 References 546 Part V Joining 549 19 Integration and Joining of Ceramic Matrix Composites 551 Monica Ferraris and Valentina Casalegno 19.1 Introduction/Background 551 19.2 Mechanical Joining and Integration of CMC 552 19.3 Adhesive Joining of CMC 553 19.4 Brazing of CMC 553 19.5 Liquid Silicon Infiltration 554 19.6 ArcJoinT 554 19.7 "Exotic" Techniques for Integration And Joining of CMC 555 19.8 Back to Basic: Joints for CMC Like in Wood-Based Products 558 19.9 Special Issues 560 19.10 Mechanical Tests on Joined CMC 561 19.11 Concluding Remarks and Future Directions 562 Acknowledgments 563 References 563 Part VI Nondestructive Evaluation 569 20 Use of Acoustic Emission for Ceramic Matrix Composites 571 Gregory N. Morscher and Nathalie Godin 20.1 Introduction/Background 571 20.2 AE Principles and Practice 572 20.3 Event-Based AE Monitoring of CMCs 575 20.4 AE Signal Analysis Using Pattern Recognition Techniques 580 20.5 High Temperature Testing and AE Monitoring 584 20.6 Acoustic Emission and Lifetime Prediction During Static Fatigue Tests 586 20.7 Concluding Remarks and Future Directions 588 References 589 Part VII Applications 591 21 CMC Applications to Gas Turbines 593 Patrick Spriet 21.1 Introduction 593 21.2 CMC Developments for Military Engines 594 21.3 CMC R&D for Commercial Engines 600 21.4 Summary and Insertion Issues 607 References 608 22 Ceramic Matrix Composites: Nuclear Applications 609 Cédric Sauder 22.1 Introduction 609 22.2 CMC Fusion Applications 610 22.3 CMC Fission Applications 616 22.4 Processing of C/C Composites for Nuclear Applications 624 22.5 Processing of SiC/SiC Composites for Nuclear Applications 627 22.6 Conclusions and Perspectives 641 Acknowledgment 642 References 642 23 Ceramic Matrix Composites for Friction Applications 647 Walter Krenkel and Jacques Georges Thébault 23.1 Introduction 647 23.2 Carbon/Carbon for Friction Applications 647 23.3 Carbon/Ceramic for Friction Applications 657 23.4 Conclusions 668 Acknowledgments 669 References 669 Index 673