Chemical reactions and thermal stress induced microstructure evolution in 2D-Cf/ZrB2-SiC composites

doi:10.1016/j.jmst.2020.12.054

Abstract

Abstract:

Fibers degradation and matrix cracks are very common during fabrication of composites, which seriously reduces the reliability and properties of the composites. In this work, 2D-C_f/ZrB₂-SiC composites were fabricated by a joint processing of slurry infiltration and hot pressing. Based on thermal kinetics calculation, finite element simulation and detailed microstructure characterization, fibers degradation and matrix cracks formation mechanisms of the composites are discussed and revealed. Oxide impurities including SiO₂ and ZrO₂ react with carbon fibers, resulting in formation of ZrC, SiC particles and etching pits on the fibers, which also leads to a strong bonding between the fibers and matrix. On the other hand, thermal expansion mismatch between the fibers and matrix gives rise to serious thermal stress in the composites. The thermal stress distribution and development are analyzed by finite element simulation, which is in good agreement with the cracks’ formation in the composites. Based on the revealed microstructure evolution mechanisms, a potential solution to mitigate fibers degradation and matrix cracks is put forward.

Key words: Ceramic matrix composites, Carbon fiber, Residual stress

Bo-Wen Chen, De-Wei Ni, Chun-Jing Liao, You-Lin Jiang, Jun Lu, Yu-Sheng Ding, Hong-Da Wang, Shao-Ming Dong. Chemical reactions and thermal stress induced microstructure evolution in 2D-C_f/ZrB₂-SiC composites[J]. J. Mater. Sci. Technol., 2021, 83: 75-82.

Figures/Tables 13

Table 1 The material property parameters used in the simulation [23,33,34].

Properties	C_f(∥)	C_f(⊥)	Matrix
Young’s modulus (MPa)	E_X = 2.3E5	E_X = 2.0E5	4.5E5
	E_Y = 2.0E5	E_Y = 2.0E5
	E_Z = 2.0E5	E_Z = 2.3E5
Poissons’ ratio	NU_XY = 0.026	NU_XY = 0.42	0.138
	NU_YZ = 0.42	NU_YZ = 0.026
	NU_XZ = 0.026	NU_XZ = 0.026
Shear modulus (MPa)	G_XY = 9747	G_XY = 80990	2.21E5
	G_YZ = 80990	G_YZ = 9747
	G_XZ = 9747	G_XZ = 9747
Thermal expansion coefficient (10^-6/K)	ALP_X = 1.1	ALP_X = 1.1	3.98 + 2.33 × 10^-3T
	ALP_Y = 6.8	ALP_Y = 6.8
	ALP_Z = 6.8	ALP_Z = 6.8
Thermal conductivity (W/mK)	10.5	10.5	54 + 12369/T
Specific heat (J/kg K)	45.4	45.4	68.76 + 5×10^-3T^-3-1.95T^-2+6.79 × 10^-3T-9.36 × 10^-7T²-1.32 × 10^-10T³
Density (kg/m³)	1760	1760	5129

Fig. 1. Meshed model of the matrix and the fibers for finite element simulation.

Fig. 2. Schematic diagram of laminated composite (a), macroscopic features of green tape (b) and 2D carbon fibers cloth (e), SEM images of green tape (c, d) and carbon fibers (f, g).

Fig. 3. SEM image (a) and Raman spectra (b) of the matrix after de-binding, XRD patterns of ZrB2 and SiC raw powders (c), XRD patterns of the ZrB2-SiC matrix before and after hot pressing (d).

Fig. 4. The vacuum degree and temperature along the sintering time of the bulk ZrB2-SiC (a) and the Cf/ZrB2-SiC composite (b).

Fig. 5. Thermodynamic equilibrium compositions calculated by HSC 6.0 software.

Fig. 6. SEM images of the carbon fibers after hot pressing (a, b), (c)-(f) EDS analysis of the spots marked in (a), (b), TEM image of carbon fiber and chemical damage (g), the HRTEM of carbon fiber and chemical damage (h), inset: the corresponding SAED pattern of ZrC.

Fig. 7. Schematic diagram of the fiber damage mechanisms.

Table 2 The content of the Cf/ZrB2-SiC composites.

Samples	Volume fraction (%)				Open porosity (vol%)
Samples	ZrB₂	SiC	WC	C_f	Open porosity (vol%)
~35 μm	35.41	8.85	2.33	48.69	4.72
~90 μm	56.74	14.19	3.73	19.83	5.51

Fig. 8. SEM images of the cross-section along the YZ plane (a, b) and XZ plane (c, d) for the Cf/ZrB2-SiC composites with different matrix layer thickness.

Fig. 9. Contour plot of stress distribution in the matrix, (b, c) and (e, f) are the cross-sections along the YZ plane of (a) and (b).

Fig. 10. Cross-sections of the contour plot of matrix stress distribution along the XZ plane.

Fig. 11. Contour plot of stress distribution of the fibers, (b, c) and (e, f) are the cross-sections along the XZ plane of (a) and (b).

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Chemical reactions and thermal stress induced microstructure evolution in 2D-C_f/ZrB₂-SiC composites

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