Processing Ceramic Matrix Composites

Unfortunately, many of the techniques used for processing ceramics are proprietary and coupled with some restricted information, limits the available literature on ceramic composites. The methods used for processing are fortunately comparable with those practiced for resin matrix composites. 

Basically, processing can be divided into the powder and chemical routes. The powder route includes sintering, slurry impregnation and reaction bonding, whilst the chemical route includes CVI, direct oxidation, sol gel and polymer pyrolysis. Final consolidation and densification must be achieved at high temperature. The powder route produces higher density ceramic matrix composites and the chemical route produces better quality. 

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Directed Oxidation of a Molten Metal. Directed oxidation of a molten metal or the Lanxide process (45,68,91) involves the reaction of a molten metal with a gaseous oxidant, eg, A1 with O2 in air, to form a porous three-dimensional oxide that grows outward from the metal/ceramic surface. The process proceeds via capillary action as the molten metal wicks into open pore channels in the oxide scale growth. Reinforced ceramic matrix composites can be formed by positioning inert filler materials, eg, fibers, whiskers, and/or particulates, in the path of the oxide scale growth. The resultant composite is comprised of both interconnected metal and ceramic. Typically 5—30 vol % metal remains after processing. The composite product maintains many of the desirable properties of a ceramic however, the presence of the metal serves to increase the fracture toughness of the composite. 

Ceramic-matrix composites are a class of materials designed for stmctural applications at elevated temperature. The response of the composites to the environment is an extremely important issue. The desired temperature range of use for many of these composites is 0.6 to 0.8 of their processing temperature. Exposure at these temperatures will be for many thousands of hours. Therefore, the composite microstmcture must be stable to both temperature and environment. Relatively few studies have been conducted on the high temperature mechanical properties and thermal and chemical stability of ceramic composite materials. 

Process-zone shielding, ceramic-matrix composites, 5 566-567... 

Naslain, R. (1993). Fiber-matrix interphase and interfaces in ceramic matrix composites processes by CVI. Composite Interfaces 1, 253-286. 

As noted earlier, CVl is nsed primarily to form ceramic-fiber-reinforced ceramic matrix composites. The most common of these combinations is SiC fiber/SiC matrix composites. One commercially available product has a two-dimensional 0/90 layup of plain weave fabric and fiber volume fraction of about 40%. This same composite can be fabricated with unidirectional fibers and with 45° architectures. The most commonly used SiC fiber for the preforms is Nicalon , the mechanical properties for which were provided earlier in Section 5.4.2.7. A number of other carbide and nitride fibers are also available, including Si3N4, BN, and TiC. Preform geometries can be tailored to the application in order to maximize strength and toughness in the direction of maximnm stresses. The reactions used to form the matrix are similar to those used in CVD processes (cf. Section 7.2.4) and those described previously in Eq. (3.105). 

Access to phase pure silicon nitride materials via processable precursors is limited to just three approaches. The first, shown in reaction 6, provides one of the first oligomers exploited as a preceramic polymer24,253. This simple polysilazane, containing only Si, N and H, is known to be relatively unstable and will crosslink on its own to give intractable gels. Furthermore, it does not offer the 3Si I4N stoichiometry required for Si3N4. Nonetheless, it is useful as a binder and for fiber-reinforced ceramic matrix composites (CMCs)31. 

Whisker-reinforced glass-ceramic matrices are expected to find several applications in automotive components, metal forming, cutting tools, etc., due to their low thermal expansion, high thermal shock resistance, high reliability and low material and processing costs. Some industrial applications for continuous fibre-reinforced ceramic matrix composites (CMCs) are listed below. 

In the presentation of the elevated temperature mechanical behavior of ceramic matrix composites, some degree of separation has also been made between fiber-reinforced and whisker- or particulate-reinforced composites. This has been necessary because of the way the field has evolved. The continuous fiber-reinforced composites area in many ways has evolved as a field in its own right, driven by developments in fiber processing technology. 

Less-conventional processing techniques are also used to make ceramic matrix composites. Siliconized silicon carbide, for example, is made by liquid infiltration.16,17 A compact of SiC particles is formed and then presintered, or reaction bonded. Liquid silicon is then infiltrated into the structure. Many different microstructures of siliconized silicon carbide can be made in this manner. The volume fraction of SiC particles can be as high as 90vol.%. Bimodal structures have also been made by this technique. These materials are used for radiant heaters and heat exchangers.17,19... 

J. R. Porter, Dispersion Processing of Creep-Resistant Whisker-Reinforced Ceramic-Matrix Composites, Mater. Sci. Eng., A107[l-2], 127-131 (1988). 

Oxidation is only one of several environmental problems that face ceramic matrix composites. For example, in combustor environments, which represent some of the most severe applications, vaporization and reactions which produce volatile products are also major degradation routes for ceramic composites. These processes can occur by hydrogen reduction, by reaction with water vapor, or by simple vaporization. Furthermore, some of the most oxidation-resistant ceramics, such as Si02 and A1203, are susceptible to these types of vaporization reactions. Fortunately, it is possible to take advantage of some of the intrinsic properties of ceramics to intelligently allow for the types of severe service environments such as combustion engines. 

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