Fabrication of bamboo-inspired continuous carbon fiber-reinforced SiC composites via dual-material thermally assisted extrusion-based 3D printing

doi:10.1016/j.jmst.2024.04.048

Abstract

Abstract: Ceramic matrix composites (CMCs) structural components encounter the dual challenges of severe mechanical conditions and complex electromagnetic environments due to the increasing demand for stealth technology in aerospace field. To address various functional requirements, this study integrates a biomimetic strategy inspired by gradient bamboo vascular bundles with a novel dual-material 3D printing approach. Three distinct bamboo-inspired structural configurations Cf/SiC composites are designed and manufactured, and the effects of these different structural configurations on the CVI process are analyzed. Nanoindentation method is utilized to characterize the relationship between interface bonding strength and mechanical properties. The results reveal that the maximum flexural strength and fracture toughness reach 108.6 ± 5.2 MPa and 16.45±1.52 MPa m^1/2, respectively, attributed to the enhanced crack propagation resistance and path caused by the weak fiber-matrix interface. Furthermore, the bio-inspired configuration enhances the dielectric loss and conductivity loss, exhibiting a minimum reflection loss of -24.3 dB with the effective absorption band of 3.89 GHz. This work introduces an innovative biomimetic strategy and 3D printing method for continuous fiber-reinforced ceramic composites, expanding the application of 3D printing technology in the field of CMCs.

Key words: 3D printing, Cf/SiC composites, Mechanical properties, Electromagnetic wave absorption

Sai Li, Haitian Zhang, Zhongliang Lu, Fusheng Cao, Ziyao Wang, Yan Liu, Xiaohui Zhu, Shuai Ning, Kai Miao, Shaoyu Qiu, Dichen Li. Fabrication of bamboo-inspired continuous carbon fiber-reinforced SiC composites via dual-material thermally assisted extrusion-based 3D printing[J]. J. Mater. Sci. Technol., 2025, 208: 92-103.

References

[1] J. Liu, X. Wei, L. Gao, J. Tao, L. Xu, G. Peng, H. Jin, Y. Wang, Z. Yao, J. Zhou, J. Eur. Ceram.Soc. 43(2023) 1237-1254.
[2] R. He, N. Zhou, K. Zhang, X. Zhang, L. Zhang, W. Wang, D. Fang, J. Adv. Ceram. 10(2021) 637-674.
[3] K. Miao, L. Liu, J. Cao, R. He, S. Li, L. Wu, Z. Lu, D. Li, J. Mater. Sci.Technol. 159(2023) 184-193.
[4] J. Xu, L. Xia, J. Luo, S. Lu, X. Huang, B. Zhong, T. Zhang, G. Wen, X. Wu, L. Xiong, G. Wang, ACS Appl. Mater. Interfaces 12 (2020) 20775-20784.
[5] Z. Yu, X. Lv, K. Mao, Y. Yang, A. Liu, J. Adv. Ceram. 9(2020) 617-628.
[6] J. Sun, D. Ye, J. Zou, X. Chen, Y. Wang, J. Yuan, H. Liang, H. Qu, J. Binner, J. Bai, J. Mater. Sci.Technol. 138(2023) 1-16.
[7] W. Wang, L. Zhang, X. Dong, J. Wu, Q. Zhou, S. Li, C. Shen, W. Liu, G. Wang, R. He, Ceram. Int. 48(2022) 19542-19556.
[8] M. Tan, D. Chen, Y. Cheng, H. Sun, G. Chen, S. Dong, G. Zhao, B. Sun, S. Wu, W. Zhang, J. Han, W. Han, X. Zhang, Adv. Funct. Mater. 32(2022) 2202057.
[9] Z. Li, C. Chen, R. Mi, W. Gan, J. Dai, M. Jiao, H. Xie, Y. Yao, S. Xiao, L. Hu, Adv. Mater. 32(2020) e1906308.
[10] S.H. Siddique, P.J. Hazell, H. Wang, J.P. Escobedo, A. A. H. Ameri, Addit.Manuf. 58(2022) 103051.
[11] N.S. Ha, G. Lu, Compos. Part B-Eng. 181(2020) 107496.
[12] H. Sun, H. Li, A. Dauletbek, R. Lorenzo, I. Corbi, O. Corbi, M. Ashraf, Constr. Build. Mater. 325(2022) 126656.
[13] Y. Akinbade, I. Nettleship, C. Papadopoulos, K.A. Harries, Wood. Sci. Technol. 55(2020) 155-179.
[14] U.G. Wegst, H. Bai, E. Saiz, A.P. Tomsia, R.O. Ritchie, Nat. Mater. 14(2015) 23-36.
[15] M. Zhang, N. Zhao, Q. Yu, Z. Liu, R. Qu, J. Zhang, S. Li, D. Ren, F. Berto, Z. Zhang, R.O. Ritchie, Nat. Commun. 13(2022) 3247.
[16] W. Li, W. Huang, Y. Xiong, L. Zhou, F. Gao, J. Lin, Compos. Commun. 37(2023) 101464.
[17] A.R. Studart, Chem. Soc. Rev. 45(2016) 359-376.
[18] Y. Duan, Q. Liang, Z. Yang, X. Wang, P. Liu, D. Li, L. Wang, C. Ge, G. Liu, Mater. Res. Bull. 166(2023) 112368.
[19] H. Lei, J. Xiao, Y. Chen, J. Jiang, R. Xu, Z. Wen, B. Dong, X. Sun, Nano Energy 91 (2022) 106670.
[20] X. Zhang, X. Wang, Y. Gao, P. Ma, Compos. Struct. 230(2019) 111423.
[21] C.O. Ufodike, H. Wang, M.F. Ahmed, G. Dolzyk, S. Jung, Mater. Des. 205(2021) 109736.
[22] A. Mao, J. Chen, X. Bu, L. Tian, W. Gao, E. Saiz, H. Bai, Small 19 (2023) 2301144.
[23] P. Zhuo, S. Li, I.A. Ashcroft, A.I. Jones, Compos. Part B-Eng. 224(2021) 109143.
[24] Y. Liu, Y. Cheng, D. Ma, N. Hu, W. Han, D. Liu, S. Wu, Y. An, A. Wang, J. Eur. Ceram.Soc. 42(2022) 3699-3707.
[25] S. Li, H. Zhang, Y. Han, Z. Lu, K. Miao, Z. Wang, D. Li, Compos. Part A-Appl. Sci. Manuf. 172(2023) 107593.
[26] R. Chen, A. Bratten, J. Rittenhouse, M.C. Leu, H. Wen, Ceram. Int. 49(2023) 9839-9847.
[27] Y. Yan, H. Mei, M. Zhang, Z. Jin, Y. Fan, L. Cheng, L. Zhang, Compos. Part A-Appl. Sci. Manuf. 162(2022) 107127.
[28] W. Wang, X. Gao, Z. Li, C. Shen, G. Wang, R. He, Mater. Sci. Eng. A 890 (2024) 145944.
[29] Y. Cheng, Y. Zhang, F. Zhang, Y. Han, Y. Zhang, Y. An, C. Huang, L. Zhao, N. Hu, J. Eur. Ceram.Soc. 44(2024) 721-728.
[30] S. Li, Z.L. Lu, H.T. Zhang, Z.C. Ai, Y. Ran, Y.Z. Li, X. Deng, D.C. Li, J. Eur. Ceram.Soc. 42(2022) 4810-4816.
[31] L. Yan, C. Hong, B. Sun, G. Zhao, Y. Cheng, S. Dong, D. Zhang, X. Zhang, ACS Appl. Mater. Interfaces 9 (2017) 6320-6331.
[32] M.A. Skylar-Scott, J. Mueller, C.W. Visser, J.A. Lewis, Nature 575 (2019) 330-335.
[33] L. del-Mazo-Barbara, M.P. Ginebra, J. Eur. Ceram. Soc. 41(2021) 18-33.
[34] K. Terrani, B. Jolly, M. Trammell, J. Am. Ceram.Soc. 103(2019) 1575-1581.
[35] H. Mei, H. Wang, N. Zhang, H. Ding, Y. Wang, Q. Bai, Compos. Sci. Technol. 115(2015) 28-33.
[36] T.S. Guruprasad, V. Keryvin, L. Charleux, J.P. Guin, O. Arnould, Carbon 173 (2021) 572-586.
[37] P. Galizia, S. Failla, C. Melandri, D. Sciti, J. Eur. Ceram.Soc. 44(2023) 5347-5357.
[38] Z. Xia, L. Li, in: Understanding Interfaces and Mechanical Properties of Ceramic Matrix Composites, Advances in Ceramic Matrix Composites, Woodhead Pub-lishing, 2014, pp. 267-285.
[39] D. Dai, X. Lan, Z. Wang, Compos. Part B-Eng. 248(2023) 110376.
[40] P. Wang, L. Cheng, Y. Zhang, L. Zhang, ACS Appl. Mater. Interfaces 9 (2017) 28844-28858.
[41] F. Wu, K. Yang, Q. Li, T. Shah, M. Ahmad, Q. Zhang, B. Zhang, Carbon 173 (2021) 918-931.
[42] Y. Jiao, Q. Song, X. Yin, L. Han, W. Li, H. Li, J. Mater. Sci.Technol. 119(2022) 200-208.
[43] J. Wang, J. Yan, J. Yun, P. Li, H. Zhao, Y. Zhao, W. Zhao, Z. Deng, Z. Zhang, Z. Zhang, J. Tian, Carbon 196 (2022) 290-303.
[44] M.S. Cao, W.L. Song, Z.L. Hou, B. Wen, J. Yuan, Carbon 48 (2010) 788-796.
[45] C. Song, Y. Liu, F. Ye, L. Cheng, P. Zhang, N. Chai, J. Adv. Ceram. 10(2021) 758-767.
[46] J. Su, B. Wang, X. Cao, R. Yang, H. Zhao, P. Zhang, W. Wang, C. Wang, Ceram. Int. 48(2022) 36238-36248.
[47] X. Lv, F. Ye, L. Cheng, L. Zhang, J. Mater. Sci.Technol. 109(2022) 94-104.
[48] S. Li, Y. Fang, L. Cheng, Z. Li, J. Wang, J. Tu, Ceram. Int. 49(2023) 8331-8338.
[49] X. Ma, X. Yin, X. Fan, M. Zhang, L. Cheng, Carbon 157 (2020) 1-11.
[50] W. Zhang, H. Xiang, F.Z. Dai, B. Zhao, S. Wu, Y. Zhou, J. Adv. Ceram. 11(2022) 545-555.