High Temperature Ceramic Matrix Composites 8
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Introduction xiii
Preface xv
Symposia Organizers xvii
Ceramic Genome, Computational Modeling, and Design
Design of New Gradient Cemented Carbides and Hard Coatings through Ceramic Genome 3 Weibin Zhang, Yong Du, Li Chen, Yingbiao Peng, Peng Zhou, Weimin Chen, Kaiming Cheng, Lijun Zhang, Wen Xie, Guanghua Wen, and Shequan Wang
The Effects of Nesting and Stacking Sequence on the Structural and Gas Transport Properties of Plain Woven Composites during Chemical Vapor Infiltration Process 15 Kang Guan, Laifei Cheng, Qingfeng Zeng, Yunfang Liu, Haitao Ren, and Litong Zhang
An Efficient Approach to Determine the Effective Properties of Random Heterogeneous Materials 23 Yatao Wu and Yufeng Nie
Contribution of Image Processing Techniques to the Simulation of Chemical Vapor Infiltration of SiC in CMCs 29 G. L. Vignoles, C. ChapoullIé, W. Ros, C. Mulat, G. Couégnat, C. Germain, J.-P. Da Costa, M. Cataldi, and C. Descamps
Image-Based Numerical Simulation of Thermal Expansion in C/C Composites 39 Olivier Caty, Guillaume Couégnat, Morgan Charron, Thomas Agulhon, and Gerard Louis Vignoles
Analysis and Molecular Modeling of Pyrolytic Carbons Nanotextures 45 Jean-Marc Leyssale, Baptiste Farbos, Jean-Pierre Da Costa, Patrick Weisbecker, Georges Chollon, and Gerard Louis Vignoles
A New Kinetic Monte-CarloA/olume-of-Fluid Solver for the Anisotropic Surface Recession of C/C Composites by Ablation 55 A. Delehouzé, G. L. Vignoles, J.-F. Epherre, and F. Rebillat
Numerical Simulation of Oxidation-Assisted Failure of CMC-SiC at Intermediate Temperature 65 Yingjie Xu and Weihong Zhang
Advanced Ceramic Fibers, Interfaces, and Interphases
Suppression of a-AI203 Formation from Alumina Gel Fibers by Urea-Catalyzed TEOS-Derived Silica 79 Jing He and Lifu Chen
Ceramix Matrix Microcomposites Prepared by P-RCVD within the (Ti-Si-B-C) System 91 Sylvain Jacques
Fabrication and Properties of Zr/SiC and Zr/Si3N4 Laminated Composites 99 Liangjun Li, Laifei Cheng, Shangwu Fan, YuPeng Xie, and Litong Zhang
Silicon Carbide Fibers Made from Nano-Powders 105 Antoine Malinge, Yann Le Petitcorps, and Rene Pailler
Composition and Reactivity of Various Silicon Carbide Fibers 113 S. Mazerat, G. Puyoo, G. Chollon, F. Teyssandier, and R. Pailler
The Investigation of Pyrolytic Coating on Carbon Monofilament by Cold Wall CVD using Ethanol as Precursor 125 Song Zhao, Yonghui Zhang, Zhichao Xiao, Junming Su, and Lang Liu
Nanocomposite Materials and Systems
Carbon Nanotube-Reinforced Ceramic Matrix Composites: Processing and Properties 133 Konstantinos G. Dassios
Fabrication of ZAO Ceramic Target and Effect on the Photoelectric Properties of Its Film 159 Meikang Han, Jueming Yang, Xiaowei Yin, and Jianping Li
Mechanical Properties of Carbon Nanotube Reinforced Composites: A Review 167 Qianglai Bai, Hui Mei, Tianming Ji, Yuyao Sun, Haiqing Li, and Laifei Cheng
Effect of the Electrodeposition Parameters on Deposition Morphologies of CNTs on Carbon Fibers 179 Hui Mei, Huwei Wang, Haiqing Li, Hui Ding, Nan Zhang, Yuetang Wang, Qianglai Bai, and Laifei Cheng
Microstructure and Growth Mechanism of SiC Whiskers Synthesized by Carbothermal Reduction of Silicon Nitride 185 Ying Zhang, Junzhan Zhang, Mingxue Jiang, and Minsheng Liu
Polymer Derived Ceramics and Composites
High Temperature Dielectric and Microwave Absorption Properties of Polymer Derived SiCN Ceramic in X Band 195 Quan Li, Xiaowei Yin, Luo Kong, Wenyan Duan, Litong Zhang, and Laifei Cheng
SiCN-Nanowhiskers Self-Reinforcing CMC Quasi-3D Structure Forming by PIP 203 I. A. Timofeev, O. G. Ryzhova, P. A. Timofeev, S. V. Zhukova, and K. V. Mikhailovski
Ablation Behavior of C/C-ZrB2-SiC Carbon-Ceramic Composites 209 Xiang-Li Meng, Lian-Sheng Yan, Hong Cui, Xing Yang, and Qiang Zhang
Fiber Reinforced Ceramic Matrix Composites
Effect of Heat Exposure on the Flexural Strength of Reinforced Carbon and Glass Fibers Geopolymer Matrix Composites 219 Sotya Astutiningsih, Yulianto Sulistyo Nugroho, Shankar M. L. Sastry, and Dwi Marta Nurjaya
Reaction Mechanism of Titanium with Carbon during Reactive Melt Infiltration of a Carbon Fiber Reinforced TiC and Carbon Composite 227 Shuxin Bai, Yonggang Tong, Hong Zhang, and Yicong Ye
Modelling the Behavior of CMC using Damage Mechanics 237 Emmanuel Baranger
MMS Technology: First Results and Prospects 243 Evgeniy Bogachev, Anton Lakhin, and Anatoly Timofeev
Effect of Oxidation Damage on the Total Emissivity of 2D C/SiC Composites 255 Fuyuan Wang, Laifei Cheng, and Litong Zhang
Effect of Water Vapor on the Oxidation Behavior of CVD-BCX 261 Weihua Zhang, Laifei Cheng, Yongsheng Liu, and Xin'gang Luan
Microstructure and Mechanical Properties of the 2D C/SiC/TC4 Joints Brazed with Cu-Ti + Mo 271 Hongmei Yang, Shangwu Fan, Xing Wang, LaiFei Cheng, and Litong Zhang
Uniaxial Macro-Mechanical Property and Failure Analysis of a 2D-Woven SiC/SiC Composite 279 Hongbao Guo, Bo Wang, and Chengpeng Yang
A Biaxial Flexural Test for Short Carbon Fiber-Reinforced SiC-Matrix Composites 287 Shuqi Guo
C/C-SiC Materials based on Melt Infiltration -Manufacturing Methods and Experiences from Serial Production 295 Bemhard Heidenreich, Severin Hofmann, Markus Keck, Raouf Jemmali, Martin FrieB, and Dietmar Koch
Internal Friction Behavior of SiC Ceramics Subjected to Water Vapor Corrosion 311 Zhiliang Hong, Laifei Cheng, Chunnian Zhao, Xiufeng Han, Litong Zhang, and Yiguang Wang
Fatigue Behavior of C/SiC Ceramic Matrix Composites at Room and Elevated Temperatures 317 Longbiao Li and Yingdong Song
The Effects Originated from Low Earth Orbit Thermal Cycling and Atomic Oxygen on C/SiC Composites 327 Bi-feng Zhang, Song Wang, Wei Li, and Zhao-hui Chen
Processing and Properties of the C/SiBCN Ceramic Matrix Composites Prepared by PIP 335 Wei Liu, Lamei Cao, Caihong Xu, Ling Wang, and Xiaosu Yi
Analysis and Characterization of Amorphous Boron Carbide Coatings Deposited from BCI3-CH4-H2 Mixtures 345 Yongsheng Liu, Nan Chai, Litong Zhang, and Laifei Cheng
Chemical Vapor Deposition of Boron-Doped Carbon Coating from BCI3-C3H6-H2-Ar Gas Mixture 357 Yongsheng Liu, JiaJia Wan, Litong Zhang, and Laifei Cheng
Preparation and Mechanical Properties of 3D-Cf/Mullite Composites Fabricated by Sol-Gel Process 371 Kewei Dai, Haijun Peng, Qingsong Ma, and Haitao Liu
An Alternative to Ceramic Matrix Composites 377 S. T. Mileiko, N.I. Novokhatskaya, Yu. N. Shmotin, D.V. Karelin, and S.A. Grlshikhin
Fabrication of Short Fiber Reinforced SiCN by Injection Molding of Preceramic Polymers 381 A. Muller-Kohn, J. Janik, A. Neubrand, H. Klemm, T. Morltz, and A. Michaelis
X-CVI (with X = I or P), a Unique Process for the Engineering and Infiltration of the Interphase in SiC-Matrix Composites: An Overview 391 R. Naslain, R. Pailler, F. Langlais, A. Guette, and S. Jacques
Temperature Effect on C/SiC Composite with SiC Nanowires Grown In Situ 403 Bingbing Pei, Yunzhou Zhu, and Zhengren Huang
Evaluation of Different Carbon Precursors for the Liquid Silicon Infiltration Process 409 Kristina Roder, Andreas Todt, Daisy Nestler, and Bernhard Wielage
Microstructure and Mechanical Properties of C/C-SiC Composites Reinforced with Fibers Treated at Elevated Temperatures 417 J. J. Sha, J. X. Dai, Z. F. Zhang, Z. Q. Wei, J. Li, J-M. Hausherr, and W. Krenkel
Oxidation Behavior of C/C-SiC Composites with Varied Matrix Composition 425 J. X. Dai, J. J. Sha, Z. F. Zhang, J-M. Hausherr, and W. Krenkel
Evaluation and Validation of Elastic Properties and a Failure Criterion for an Oxide Wound Ceramic Composite Material 433 Yuan Shi, Severin Hofmann, Stefan Hackemann, and Dietmar Koch
Mechanical and Ablation Properties of Ultra-High Temperature Composites with a Variable Matrix-Composition 443 Chenglong Hu, Shengyang Pang, Sufang Tang, Shijun Wang, and Hongtao Huang
Carbon-Carbon Composites: Materials, Systems, and Applications
Effects of Preform Structures on Rhenium Coating Prepared on C/C Composites by Chemical Vapor Deposition 453 Jiangfan Wang, Shuxin Bai, Hong Zhang, and Yicong Ye
Application Status of C/C Composites for Thermal Protection System in Re-Entry Spacecraft 461 Sun Guoling and Zhou Ji
Techniques about Fabrication of Thin-Wall Preforms with Complex Shape for Ceramic Composites 465 Lingling Ji, Alin Ji, Xia Bai, and Lingling Wang
Carbon/Carbon Greenbodies for Space Mirrors and Their Thermal Performance 473 Jin Li, Hong Cui, and Ruizhen Li
Oxidation Behavior of SiC Reinforced ZrB2 Composite Coating Prepared by Low Pressure Plasma Spray 481 Cui Hu, Yaran Niu, Hong Li, Xuebin Zheng, Chuanxian Ding, and Jinliang Sun
Structural Analysis of Carbon-Fiber/Pyrolytic Carbon Matrix Composites 487 Boris Reznik
Preparation of ß-Sialon Anti-Oxidation Ceramic Coating for C/C Composites and Infrared Stealthy Characteristic 491 Yang Wang and Zhaofeng Chen
Ultra High Temperature Ceramics and Max Phase Materials
Effect of Carbon Content on the Formation of Ti3SiC2 in the Liquid Silicon Infiltration Process 501 Xiaomeng Fan, Xiaowei Yin, Lei Wang, Litong Zhang, and Laifei Cheng
Modification of Titanium Carbide Powders by Silicidation with Gaseous SiO 509 Elena Istomina, Pavel Istomin, Alexander Nadutkin, and Vladislav Grass
Combustion Synthesis of Ti3SiC2-Based Ceramic Matrix Composites Using Non-Powder Reactant Solids 515 Pavel Istomin, Alexander Nadutkin, and Vladislav Grass
Microstructure Evolution of a-SiC in the Liquid Phase Sintering Process 523 Hanqin Liang, Xiumin Yao, Xuejian Liu, and Zhengren Huang
Mechanical Properties and Thermal Shock Resistance of Anisotropic ZrB2-SiC-Graphite Ceramic 529 Lingling Wang, Jun Liang, and Xiaoyang Wan
Ablation Behavior of ZrB2/SiC Composite by Oxyacetylene Flame 535 Mingfu Wang, Facheng Liu, Qin Wang, and Xuesong Ma
Synthesis of ZrC-ZrB2 Composite Powders by PIRAC Method 541 Shoujun Wu, Yiguang Wang, and Danming Gui
Thermal and Environmental Barrier Coatings
Formation of Fine Ceramics Layer and Intermetallics Network by Thermal Nanoparticles Spraying and Pattering 549 Soshu Kirihara
Formation of Inter-splat Bonding and Intra-splat Microstructure during Plasma Spraying of Ceramic Coating 557 Chang-Jiu Li, Er-Juan Yang, Guan-Jun Yang, and Cheng-Xin Li
Preparation and Ablation Properties of ZrC-TaC Co-Deposition Coating for Carbon-Carbon Composites 569 Guo-dong Li, Min Wu, Xiang Xiong, Ya-lei Wang, and Gang-yi Yang
Phase Stabilities and Corrosion/Recession Properties of Rare Earth Silicates under High Speed Steam Jet 579 Shunkichi Ueno, Hua-Tay Lin, and Tatsuki Ohji
Integration Technologies, Component Testing, and Evaluation
Wettability in Joining of Advanced Ceramics and Composites: Issues and Challenges 591 Rajiv Asthana, and Natalia Sobczak
Study on the Ablation Behavior of 3D Needled C/SiC in the Rocket Combustion Environments 601 Chao Chen, Bo Chen, Litong Zhang, Laifei Cheng, and Xiaoying Liu
The Degradation of Hi-Nicalon Monofilament after Proton Irradiation 607 Xiaochong Liu, Laifei Cheng, Litong Zhang, Xiaowei Yin, Bo Chen, Qing Zhang, and Ning Dong
Damage Evaluation in Glass-Ceramic Matrix Composites Via Combined Infrared Thermography and Acoustic Emission 615 Konstantinos G. Dassios, Evangelos Z. Kordatos, Dimitris G. Aggelis, and Theodore E. Matikas
Hybrid Ceramic-Metallic Composite Pipes for High Temperature Power Plant Application 633 Min Huang, Karl Berreth, and Karl Maile
An Experimental Investigation on Shear Behaviors of Single-Lap Four-Pin 2D C/SiC Joints 639 Yi Zhang, Litong Zhang, Xiaoying Liu, Yongsheng Liu, and Bo Chen
The Effect of Dimension Parameters on the Tensile Properties of a C/SiC Pipe 645 Hui Mei, Lidong Zhang, Zhenye Xu, and Laifei Cheng
The Application Research of New Testing Technique on Mechanical Experiment for Large-Size CMC Structure 653 Zhiyong Tan, Xujun Zhan, and Xu Han
Joining of Glassy Carbon with a C/C-SiC Composite by Brazing for an Innovative High Temperature Sensor 661 Andreas Todt, Kristina Roder, Daisy Nestler, and Bernhard Wielage
Strengthening/Toughening of Laminated (SiCw+SiCp)/SiC Ceramic Composites 669 Yupeng Xie, Laifei Cheng, Jie Jian, Yanan Xie, and Litong Zhang
Mechanical Properties of Carbon/Silicon Carbide Composites Materials Bolts 675 Donglin Zhao, Litong Zhang, Laifei Cheng, and Xiang Chen
Development of Full Scale Ramjet Nozzle with C/SiC Ceramic Matrix Composite 681 Riheng Zheng, Zhiyong Li, Jingmin Chen, Lihan Li, Jianmei Li, Litong Zhang, Laifei Cheng, Xiaoying Liu, Chao Chen, and Hui Mei
Author Index 695
DESIGN OF NEW GRADIENT CEMENTED CARBIDES AND HARD COATINGS THROUGH CERAMIC GENOME
Weibin Zhanga, Yong Dua,*, Li Chena, Yingbiao Penga, Peng Zhoua, Weimin Chena, Kaiming Chenga, Lijun Zhanga, Wen Xieb, Guanghua Wenb, and Shequan Wangb
a State Key Lab of Powder Metallurgy, Central South University, Hunan, 410083, China
b Zhuzhou cemented carbide cutting tools limited company, Zhuzhou, Hunan, 412007, China
ABSTRACT
The concept of ceramic genome is briefly introduced, and its combination with CALPHAD (CALculation of PHAse Diagrams) method is a powerful tool for materials process optimization and alloy design. The quality of CALPHAD-type calculations is strongly dependent on the quality of the thermodynamic and diffusivity databases. The development of thermodynamic and diffusivity databases for cemented carbides is described. Several gradient cemented carbides sintered under vacuum and various partial pressures of N2 have been studied via experiment and simulation. Examples of ceramic genome applications in design and manufacture for different kinds of cemented carbides are shown using the databases and comparing where possible against experimental data, thereby validating their accuracies. Metastable Ti-Al-N coatings have been well acknowledged as protective layer for industrial applications due to their excellent mechanical, chemical and thermal properties. Here, we study the effect of Zr addition on structure and thermal properties of Ti1-xAlxN based coatings under the guidance of ab initio calculations. The preparation of Ti1-x-zAlxZrzN by magnetron sputtering verifies the suggested cubic (NaCl-type) structure for x below 0.6–0.7 and z ≤ 0.4. Alloying with Zr also promotes the formation of cubic domains but retards the formation of stable wurtzite AlN during thermal annealing.
INTRODUCTION
Cemented carbides have long been used in applications such as cutting, grinding, and drilling1. Cemented carbides2 are hard and tough tool materials consisting of micrometer-sized tungsten carbide embedded in a metal binder phase, usually rich in Co. Cubic carbides or carbonitrides based on Ta, Ti, and Nb are often added in cemented carbides to increase the resistance to plastic deformation or as gradient formers1. Some grain growth inhibitors such as Cr and V may also be added in small amounts. In order to increase cutting performance of the cemented carbide inserts, the wear surface are usually coated with a thin layer of hard material3. Due to the high deposition temperature and a large difference in thermal expansion coefficients between the coating and substrate, cracks would be introduced into the coating unavoidably4. And the formed cracks might easily propagate into the substrate to cause failure when coating tools are employed in metal machining5. In order to prevent crack propagation from the coating into the substrate, a gradient layer, which is free of cubic phases and enriched in binder phase, is introduced between coating and substrate5.
In the past decades, cemented carbides were mainly developed through a large degree of testing. However, there are numerous factors influencing the microstructure and properties of cemented carbides, such as alloy composition, sintering temperature, time and partial pressure and so on. These factors can only be varied in an infinite number of ways through experimental method. In order to shorten development time, reduce the cost and improve outcome, the concept of materials genome has been proposed. Computation, experimentation, and database are identified as three major components of materials genome. The ceramic genome can describe the interaction of the various process conditions, which presents the opportunity to design and produce new kinds of cemented carbides more efficiently. CALPHAD (CALculation of PHAse Diagrams) method is a powerful tool to establish the database of various properties in the ceramic genome. Computational thermodynamics, using, e.g. the Thermo-Calc and DICTRA packages, has shown to be a powerful tool for processing advanced materials in cemented carbides, which is more efficient on composition and process parameters optimization compared with expensive and time consuming experimental methods. With the development of thermodynamic and diffusivity databases, it is possible to make technical calculations on commercial products which are multicomponent alloys. On the basis of thermodynamic database, thermodynamic calculations can give an easy access to what phases form at different temperatures and alloy concentrations during the manufacture process. By combining CSUTDCC1 and CSUDDCC1 databases, DICTRA6 permits simulations of the gradient process, which is a major advance in the understanding of the gradient zone formation in the cemented carbides.
Ti-Al-N hard coatings with cubic (c) NaCl structure, where Al substitutes for Ti in the TiN-based structure (i.e., c-Ti1-xAlxN), are widely used in cutting tools because of their high hardness and wear resistance as well as good thermal properties7. Because of the spinodal decomposition of c-Ti1-xAlxN into nano-size cubic Ti-rich and Al-rich domains at elevated temperatures, the age-hardening abilities of Ti-Al-N coatings can improve the mechanical properties of coatings8. Due to solid solution strengthening, alloying Zr to Ti-Al-N coating can improve the hardness. Unfortunately, a huge amount of work is needed to find appropriate elements by using experimental method, while first-principles calculations on the investigation of structural and mechanical properties can reduce the workload effectively and provide the reasonable explanation for the experimental observation.
This paper is devoted to 1) describe the development of the thermodynamic and diffusion databases in cemented carbides, 2) design experiments to investigate the gradient zone formation under different sintering environments, 3) validate the accuracy and reliability of the presently established databases in ceramic genome by comparing the experimental and simulation results, 4)investigate the structural and thermal properties of Ti-Al-Zr-N hard coatings by first-principles calculations and experiment, and 5) present the schematical ceramic genome strategy for the development of new cemented carbides and hard coating.
ESTABLISHMENT OF THE CERAMIC GENOME
Development of Thermodynamic and Diffusivity Databases
The development of thermodynamic and diffusivity databases in cemented carbides has started from the major elements in gradient cemented carbides C-Co-Cr-W-Ta-Ti-Nb-N. The usage of ceramic genome in industry will necessarily require that thermodynamic and diffusivity databases provide data that is not only of high quality, but relevant to industrially complex materials.
Developed using the CALPHAD approach, the thermodynamic database, CSUTDCC1, is based on critical evaluations of binary, ternary and even higher order systems which enable making predictions for multicomponent systems and alloys of industrial importance. Six important phases in cemented carbides, e.g. liquid, WC, carbides or carbonitrides, binder (Co), and eta (M6C or M12C) phases, are the main focus during the modeling. A large number of additional phases are also included in CSUTDCC1, because many of the binary and ternary systems in CSUTDCC1 have been assessed over their entire composition and temperature ranges. It is important to have reliable descriptions for all the stable phases in the system when developing new alloys and exploring new composition ranges. The thermodynamic models describe the thermodynamic properties of various types of phases depending on the crystallography, order-disorder transitions, and magnetic properties of the phases. With parameters stored in database, many different models9, including the substitution solution model, sublattice model, order-disorder model, have been adopted for the phases in cemented carbide systems. The thermodynamic models for Gibbs energy of a phase can be represented by a general equation:
(1)
Here refGmθ represents the Gibbs energy of the pure elements of the phase and idGmθ represents the contribution due to the ideal mixing. The term EGmθ represents the excess energy and magnGmθ the magnetic contribution.
In contrast to extensive efforts on the establishment of thermodynamic database for multicomponent cemented carbides, diffusivities in the multicomponent cemented carbides have received limited investigations both experimentally and theoretically. In a multicomponent system, a large number of diffusivities need to be evaluated, making a database very complex. A superior alternative is to model atomic mobility instead. In this way, the number of the stored parameters in the database is substantially reduced and the parameters are independent. A detailed description for the atomic mobility is given by Andersson and Ågren10. The atomic mobility for an element B, MB, can be expressed as
(2)
where R is the gas constant, T the temperature, MB0 a frequency factor and QB the activation enthalpy. Both MB0 and QB are in general dependent on composition and temperature.
The simulation of gradient zone formation is based on the model for long-range diffusion occurring in a continuous matrix with dispersed phases. Due to the presence of dispersed phases (WC, carbides and carbonitrides), the diffusion is reduced in the matrix (the liquid binder phase)11. A so-called labyrinth factor λ(f), where f is the volume fraction of the...
