Ceramic matrix composite manufacture

Twitty, A., Russell-Floyd, R.S., Cooke, R.G., Harris, B. (1995), Thermal shock resistance of Nextel/sllica-znconla ceramic-matrix composites manufactured by freeze-gelation , J. Eur. Ceram. Soc., 15, 455-461. 

Various combiaations of ceramic—matrix composites have been manufactured at the research level. Their properties are given ia Table 1 for oxide-based matrices and ia Table 2 for aoaoxide matrices. Some commercial products are ideatifted for information only. Such identification does not imply recommendation or endorsement by NIST, nor does it imply that the products are the best available for the purpose. 

Although few applications have so far been found for ceramic matrix composites, they have shown considerable promise for certain military applications, especially in the manufacture of armor for personnel protection and military vehicles. Historically, monolithic ("pure") ceramics such as aluminum oxide (Al203), boron carbide (B4C), silicon carbide (SiC), tungsten carbide (WC), and titanium diboride (TiB2) have been used as basic components of armor systems. Research has now shown that embedding some type of reinforcement, such as silicon boride (SiBg) or silicon carbide (SiC), can improve the mechanical properties of any of these ceramics. 

Methods for manufacturing different fibre-reinforced glass/glass-ceramic matrix composites... 

SiC whiskers are known to vary in their physical and chemical characteristics from manufacturer to manufacturer and in some cases from batch to batch. While the differences can be quite minor, they can make major impacts in the performance of ceramic matrix composites both at room and elevated temperature. 

These fibers are, due to their high thermal stability, particularly suitable for applications in high temperature thermal insulation and for the manufacture of metal matrix and ceramic matrix composites. They arc clearly superior to metal materials due to their lower weight, particularly in the lightweight construction of accelerated structure elements for which the basic material should represent an improve-... 

A ceramic test rig for biaxial measurement (ball-on-ring) has been developed to accommodate a variety of different pellet sample dimensions from 21 to 28mm diameter inclusive. This was achieved by manufacturing a number of fittings as seen in Fig. 3 from a ceramic matrix composite material (Zircar RSLE 57), which is a low expansion high strength reinforced silica matrix composite product designed for use with temperatures up to 1100°C. 

At manufacturing level, chemical reactions between the matrix and the liber produce an interface zone of different mechanical properties from the two phases producing it [158]. The load of a composite is usually transferred through the interface between the matrix and the fiber, and the toughness of the composite is determined. Karpur et al. measured ultrasonically the shear stiffness coefficient of the interface in fiber reinforced metal matrix and ceramic matrix composites [158]. They claim that the significance of the quantification of the shear stiffness coefficient of the interface is that the clastic property of the interface can be used as a basis for composite life prediction. 

The fibres are not resistant to the temperatures encountered in metal and ceramic matrix composite melt processing, and protective coatings or low-temperature manufacturing routes are needed. 

Narisawa, H.P., K. Nakoshiba, and K. Okamara. 1995. Effect of rapid heat treatments on electrical properties of polymer derived ceramic fibers. Pp. 287 292 in High-Temperature Ceramic-Matrix Composites II Manufacturing and Materials Development Vol. 58 in Ceramic Transactions, A.G. Evans and R. Naslain (eds.). Westerville, Ohio American Ceramic Society. 

H. Wurtinger and A. Miihlratzer, Cost effective manufacturing methods for structural ceramic matrix composite (CMC) components, ASME Paper 96-GT-296, 1996. 

R. Weiss, Caibon Fibre Reinforced CMCs Manufacture, Properties, Oxidation Protection, High Temperature Ceramic Matrix Composites ( jAs. W. Krenkel, R. Naslain, H. Schneider), WILEY-VCH, Weinheim, Germany, (2001), p. 440-456. 

R. Gadow and M. Speicher, Manufacturing of Ceramic Matrix Composites for Automotive Applications, Ceramic Transactions Vol. 128 (2001), p. 25-41. 

T. J. lUston et al., The Manufacture of Woven Fibre Ceramic Matrix Composites Using Electrophoretic Deposition, in Third Euroceramics 1, 419 24 (1993). 

M, H. Lewis, M. G. Cain, P. Doleman, A. G. Razzell, J. Gent, Development of Interfaces in Oxide and Silicate Matrix Composites, High-Temperature Ceramic-Matrix Composites II Manufacturing and Materials Development, A. G. Evans, and R. G. Naslain, editors, American Ceramic Society, 41-52 (1995). 

Depending on the method, the SiC composites vary in their properties as well as in their manufacturing costs. The advantages of the MI processes are a short manufacturing time and the use of low-cost raw materials. The unique thermal and mechanical properties of these MI ceramic matrix composites (CMCs) has opened up a wide field of new applications beyond aerospace. The data relating to these different materials are listed in Table 4.4. 

H. Ichikawa, K. Okamura and T. Seguchi, Oxygen-free ceramic fibers from organosilicon precursors and E-beam curing, in High-Temperature Ceramic-matrix Composites II Manufacturing and Materials Development, A. G. Evans, R. Naslain, eds., Ceram. Trans., 58,65-74 (1995). 

Hillig WB, Ceramic Composites by Infiltration, Ceramic Eng Sci Proc, 5(7 ), 674-683, 1985. Grenet C, Plunkett L, Veyret JB, Bullock E, Carbon fibre-reinforced silicon nitride composites by slurry infiltration, Evans AG, Naslain R eds., High-Temperature Ceramic-Matrix Composites II, Manufacturing and Materials Development, Ceramic Trans, American Ceramic Soc Inc., Santa Barbara, 58, 125-130, Aug 21 24 1995. 

Oxide fibers include glass fibers, mullite fibers, zirconia fibers and alumina fibers. Of these, a-alumina-based fibers have been used intensively for ceramic matrix composites. Fiber FP, manufactured by Du Pont in 1979, was the first wholly a-alumina fiber produced [34]. At present, Almax (Mitsui Mining Material Co. Ltd., Japan) and Nextel 610 (3M Co., USA) are commercially available a-alumina fibers. Almax contains 99.5% alumina and has an elastic modulus of 330 GPa, and Nextel 610 has a tensile strength of 2.4 GPa and an elastic modulus of 380 GPa [35]. 

Sato, K., Morizumi, H., Tezuka, A., Furuyama, O., andlsoda, T. (1993). Interface and mechanical properties of ceramic fiber reinforced silicon nitride composites prepared by a preceramic polymer impregnation method, High-Temperature Ceramic-Matrix Composite II Manufacturing and Materials Development, pp. 199-203, Evans, A. G. and Naslain, R. eds., Westerville, OH The American Ceramic Society. 

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