Ceramic Matrix Composites: Fiber Reinforced Ceramics and their Applications

Ceramic Matrix Composites......Page 4
Foreword......Page 8
Contents......Page 12
Preface......Page 20
List of Contributors......Page 22
1.2 Fibers as Reinforcement in Ceramics......Page 26
1.3.1 Fiber Structure......Page 27
1.3.2 Structure Formation......Page 28
1.3.3 Structure Parameters and Fiber Properties......Page 29
1.4.1.2 Direct Fiber Production......Page 32
1.4.2.1 Comparison of Oxide and Non-oxide Ceramic Fibers......Page 34
1.4.2.2 Oxide Ceramic Filament Fibers......Page 35
1.4.2.3 Non-oxide Ceramic Filament Fibers......Page 36
1.5 Carbon Fibers......Page 37
1.5.1.1 Carbon Fibers from PAN Precursors......Page 40
1.5.1.3 Carbon Fibers from Regenerated Cellulose......Page 42
1.5.2 Commercial Products......Page 43
Acknowledgments......Page 44
2.1 Introduction......Page 46
2.1.2 Yarn Structures......Page 48
2.2.1 Nonwovens......Page 49
2.2.2 Woven Fabrics......Page 50
2.2.3 Braids......Page 52
2.2.4 Knitted Fabrics......Page 53
2.2.5 Non-crimp Fabrics......Page 54
2.3.1 Three-Dimensional Woven Structures......Page 55
2.3.2.1 Overbraided Structures......Page 57
2.3.2.2 Three-Dimensional Braided Structures......Page 59
2.3.3.2 Spacer Warp-Knits......Page 62
2.4.1 One-Step/Multi-Step Preforming......Page 63
2.4.3 Handling and Draping......Page 64
2.4.4 Joining Technologies......Page 65
2.5.2 Bending Stiffness......Page 66
2.5.5 Quality Management......Page 67
2.6.2 Infiltration of the Textile Structure......Page 68
2.7 Summary and Outlook......Page 69
Acknowledgments......Page 70
3.1 Introduction......Page 74
3.2 Role of Interfacial Domain in CMCs......Page 75
3.3 Mechanism of Deviation of Transverse Cracks......Page 77
3.4 Phenomena Associated to Deviation of Matrix Cracks......Page 78
3.5 Tailoring Fiber/Matrix Interfaces. Influence on Mechanical Properties and Behavior......Page 80
3.6 Various Concepts of Weak Interfaces/Interphases......Page 84
3.7 Interfacial Properties......Page 86
3.8 Interface Control......Page 89
3.9 Conclusions......Page 91
4.2 Manufacturing of C/Cs......Page 94
4.2.1 Carbon Fiber Reinforcements......Page 96
4.2.2.1 Thermosetting Resins as Matrix Precursors......Page 98
4.2.2.2 Thermoplastics as Matrix Precursors......Page 99
4.2.2.3 Gas Phase Derived Carbon Matrices......Page 100
4.2.3 Redensification/Recarbonization Cycles......Page 104
4.2.4 Final Heat Treatment (HTT)......Page 105
4.3 Industrial Applications of C/Cs......Page 107
4.3.1.1 Bulk Protection Systems for C/Cs......Page 108
4.3.1.2 Outer Multilayer Coatings......Page 113
4.3.1.3 Outer Glass Sealing Layers......Page 115
4.3.2 Industrial Applications of C/Cs......Page 117
4.3.2.1 C/Cs for High Temperature Furnaces......Page 122
4.3.2.2 Application for Thermal Treatments of Metals......Page 127
4.3.2.3 Application of C/C in the Solar Energy Market......Page 130
5.1 Introduction......Page 138
5.2 Processing......Page 139
5.2.1 Build-up of Fiber Protection and Fiber/Matrix Interface......Page 140
5.2.2 Manufacture of Fiber Reinforced Green Bodies......Page 142
5.2.3 Build-up of a Porous, Fiber Reinforced Preform......Page 143
5.2.4 Si Infiltration and Build-up of SiC Matrix......Page 144
5.3 Properties......Page 146
5.3.1 Material Composition......Page 152
5.3.2 Mechanical Properties......Page 153
5.3.3 CTE and Thermal Conductivity......Page 155
5.4.1 Space Applications......Page 156
5.4.3 Long-term Aeronautics and Power Generation......Page 158
5.4.4 Friction Systems......Page 159
5.4.5 Low-Expansion Structures......Page 160
5.4.6 Further Applications......Page 161
5.5 Summary......Page 162
6.1 Introduction......Page 166
6.2 CVI Manufacturing Process for CMCs......Page 168
6.2.1 Isothermal-Isobaric Infiltration......Page 169
6.2.2 Gradient Infiltration......Page 170
6.3.1 General Remarks......Page 171
6.3.2.1 Fracture Mechanism and Toughness......Page 173
6.3.2.2 Stress-Strain Behavior......Page 174
6.3.2.4 High Temperature Properties and Corrosion......Page 176
6.4.1 Hot Structures in Space......Page 178
6.4.2 Gas Turbines......Page 180
6.4.4 Components for Journal Bearings......Page 181
6.5 Outlook......Page 186
7.1.1 Introduction......Page 190
7.1.2 Precursor Systems and Properties......Page 191
7.1.3 Cross-Linking Behavior of Precursors......Page 192
7.1.4 Pyrolysis Behavior of Precursors......Page 194
7.2.1 Introduction......Page 196
7.2.2.1 Preform Manufacturing......Page 198
7.2.2.2 Manufacturing of CMC......Page 200
7.3.1 Launcher Propulsion......Page 205
7.3.2 Satellite Propulsion......Page 207
7.4 Summary......Page 209
8.1 Introduction......Page 212
8.3 CMC Fiber-Matrix Interfaces......Page 214
8.3.1 Interface Control......Page 215
8.3.2 Fiber Coating Methods......Page 216
8.3.3 CMC Processing......Page 219
8.3.4.1 Weak Oxides......Page 220
8.3.4.2 Porous Coatings and Fugitive Coatings......Page 222
8.4 Summary and Future Work......Page 223
9.1 Introduction......Page 230
9.1.1 Oxide Ceramic Fibers......Page 231
9.1.2 \"Classical\" CMC Concepts......Page 232
9.2 Porous Oxide/Oxide CMCs without Fiber/Matrix Interphase......Page 233
9.2.1 Materials and CMC Manufacturing......Page 235
9.2.2 Mechanical Properties......Page 239
9.2.3 Thermal Stability......Page 243
9.2.4 Other Properties......Page 245
9.3 Oxide/Oxide CMCs with Protective Coatings......Page 248
9.4 Applications of Porous Oxide/Oxide CMCs......Page 251
10.1 Introduction......Page 256
10.2.1 Weak Interface Composites WIC......Page 257
10.2.2 Weak Matrix Composites WMC......Page 262
10.2.4 Modeling of the Mechanical Behavior of WMC......Page 263
10.2.5 Concluding Remarks......Page 268
10.3.1 General Mechanical Behavior......Page 269
10.3.2 High Temperature Properties......Page 271
10.3.3 Fatigue......Page 276
10.3.4 Concluding Remarks......Page 280
Acknowledgment......Page 281
11.1 Introduction......Page 286
11.3 Ultrasonic Analysis......Page 287
11.3.1 Physical Principle and Technical Implementation......Page 288
11.3.2 Transmission Analysis......Page 289
11.3.3 Echo-Pulse Analysis......Page 290
11.3.4 Methods and Technical Implementation......Page 291
11.3.5 Ultrasonic Analysis of CMC......Page 292
11.4 Thermography......Page 293
11.4.1 Thermal Imaging (Infrared Photography)......Page 294
11.4.2 Lockin Thermography......Page 296
11.4.4 Damage Detection Using Thermography......Page 297
11.5 Radiography (X-Ray Analysis)......Page 298
11.5.1.2 X-Ray Image Intensifier......Page 299
11.5.2 Application of Radiography for C/SiC Composites......Page 300
11.6.1 Functional Principle of CT......Page 302
11.6.2 Computed Tomography for Defect Detection......Page 304
11.6.3 Micro-structural CT-Analysis......Page 305
11.6.4 Process Accompanying CT-Analysis......Page 307
11.7 Conclusions......Page 308
12.1 Introduction......Page 312
12.2 Analysis of Machining Task......Page 313
12.3.1 Tool......Page 315
12.3.3 Basic Conditions......Page 319
12.4 Process Strategies......Page 320
12.5 Conclusions......Page 325
13.1 Introduction......Page 328
13.3 Joint Design, Analysis, and Testing Issue......Page 329
13.3.1 Wettability......Page 330
13.3.3 Joint Design and Stress State......Page 331
13.3.4 Residual Stress, Joint Strength, and Joint Stability......Page 332
13.4 Joining and Integration of CMC–Metal Systems......Page 334
13.5 Joining and Integration of CMC–CMC Systems......Page 339
13.6 Application in Subcomponents......Page 343
13.7 Repair of Composite Systems......Page 346
13.8 Concluding Remarks and Future Directions......Page 347
Acknowledgments......Page 348
14.1 Introduction......Page 352
14.2.1.1 n-Dimensional Reinforcement......Page 353
14.2.1.2 Three-Dimensional Reinforcement Preforms......Page 354
14.2.1.3 Densification......Page 358
14.2.2.1 Solid Rocket Motors (SRM) Nozzles......Page 360
14.2.2.2 Liquid Rocket Engines (LRE) [9]......Page 362
14.3 Ceramic Composites......Page 363
14.3.1 SiC-SiC and Carbon-SiC Composites Manufacture......Page 364
14.3.2.1 Aeronautical and Space Applications......Page 365
14.3.2.2 Liquid Rocket Engines Applications [12]......Page 366
14.3.3.1 Manufacturing of Ceramic Composites......Page 368
14.3.3.3 Characterization......Page 369
14.3.4.1 Military Aeronautical Applications......Page 372
14.3.4.2 Commercial Aeronautical Applications......Page 374
15.1 Introduction......Page 378
15.2 Gas Reactor Technology and Ceramic Materials......Page 379
15.3 Ceramic Fiber Reinforced Ceramic Matrix Composites (CFRC, CMC)......Page 381
15.4 Innovative SiC/SiC by NITE Process......Page 383
15.5 Characteristic Features of SiC/SiC Composites by NITE Process......Page 384
15.6 Effects of Radiation Damage......Page 387
15.6.1 Ion-Irradiation Technology for SiC Materials......Page 388
15.6.2 Micro-Structural Evolution and Swelling......Page 389
15.6.3 Thermal Conductivity......Page 391
15.6.4 Mechanical Property Changes......Page 394
15.7 Mechanical Property Evaluation Methods......Page 396
15.7.1 Impulse Excitation Method for Young’s Modulus Determination......Page 397
15.7.2 Bulk Strength Testing Methods for Ceramics......Page 398
15.7.3 Test Methods for Composites......Page 399
15.7.4 Development of Materials Database......Page 403
15.8 New GFR Concepts Utilizing SiC/SiC Composite Materials......Page 404
15.9 Concluding Remarks......Page 406
16.2 C/SiC Pads for Advanced Friction Systems......Page 410
16.2.2 C/SiC Brake Pads for High-Performance Elevators......Page 413
16.3 Ceramic Brake Disks......Page 416
16.3.1 Material Properties......Page 417
16.3.2 Manufacturing......Page 419
16.3.3 Braking Mechanism......Page 421
16.3.4 Design Aspects......Page 423
16.3.5 Testing......Page 426
16.4 Ceramic Clutches......Page 428
Index......Page 434