Fiber reinforced ceramic composites : materials, processing and technology

531 Pages·1990·40.579 MB·English

by  K S Mazdiyasni

FIBER REINFORCED
CERAMIC COMPOSITES
Materials, Processing and Technology
Edited by
K.S. Mazdiyasni
General Atomics
San Diego, California
rnpl
NOYES PUBLICATIONS
Park Ridge, New Jersey, USA.
Copyright 0 1990 by Noyes Publications
No part of this book may be reproduced or utilized in
any form or by any means, electronic or mechanical,
including photocopying, recording or by any informa-
tion storage and retrieval system, without permission
in writing from the Publisher.
Library of Congress Catalog Card Number: 89-70989
ISBN: 0-8155-1233-3
Printed in the United States
Published in the United States of America by
Noyes Publications
Mill Road, Park Ridge, New Jersey 07656
109 876 5432 1
Library of Congress Cataloging-in-Publication Data
Fiber reinforced ceramic composites : materials, processing, and
technology 1 edited by K.S. Mazdiyasni.
p. cm.
Includes bibliographical references.
ISBN 0-8155-1233-3 :
1. Fiber-reinforced ceramics. I. Mazdiyasni, K.S.
TA455.C43F5 1990
620.1 '4- -dc20 89-70989
CIP
MATERIALS SCIENCE AND PROCESS TECHNOLOGY SERIES
Editors
Rointan F. Bunshah, University of California, Los Angeles (Materials Science
and Process Technology)
Gary E. McGuire, Microelectronics Center of North Carolina (Electronic Mate-
rials and Process Technology)
DEPOSITION TECHNOLOGIES FOR FILMSANDCOATINGS: by RointanF. Bunshahetal
CHEMICAL VAPOR DEPOSITION IN MICROELECTRONICS: by Arthur Sherman
SEMICONDUCTOR MATERIALS AND PROCESS TECHNOLOGY HANDBOOK: edited
by Gary E. McGuire
SOL-GEL TECHNOLOGY FOR THIN FILMS, FIBERS, PREFORMS, ELECTRONICS
AND SPECIALTY SHAPES: edited by Lisa A. Klein
HYBRID MICROCIRCUIT TECHNOLOGY HANDBOOK: by James J. Licari and Leonard
R. Enlow
HANDBOOK OF THIN FILM DEPOSITION PROCESSES AND TECHNIQUES: edited by
Klaus K. Schuegraf
IONIZED-CLUSTER BEAM DEPOSITION AND EPITAXY: by Toshinori Takagi
DIFFUSION PHENOMENA IN THIN FILMS AND MICROELECTRONIC MATERIALS:
edited by Devendra Gupta and Paul S. Ho
SHOCK WAVES FOR INDUSTRIAL APPLICATIONS: edited by Lawrence E. Murr
HANDBOOK OF CONTAMINATION CONTROL IN MICROELECTRONICS: edited by
Donald L. Tolliver
HANDBOOK OF ION BEAM PROCESSING TECHNOLOGY: edited by Jerome J. Cuomo,
Stephen M. Rossnagel, and Harold R. Kaufman
FRICTION AND WEAR TRANSITIONS OF MATERIALS: by Peter J. Blau
CHARACTERIZATION OF SEMICONDUCTOR MATERIALS-Volume 1: edited by
Gary E. McGuire
SPECIAL MELTING AND PROCESSING TECHNOLOGIES: edited by G.K. Bhat
HANDBOOK OF PLASMA PROCESSING TECHNOLOGY: edited by Stephen M. Ross-
nagel, Jerome J. Cuomo, and William D. Westwood
FIBER REINFORCED CERAMIC COMPOSITES: edited by K.S. Mazdiyasni
HANDBOOK OF SEMICONDUCTOR SILICON TECHNOLOGY: edited by William C.
O’Mara, Robert 8. Herring, and Lee P. Hunt
HANDBOOK OF POLYMER COATINGS FOR ELECTRONICS: by James J. Licari and
Laura A. Hughes
Related Titles
ADHESIVES TECHNOLOGY HANDBOOK: by Arthur H. Landrock
HANDBOOK OF THERMOSET PLASTICS: edited by Sidney H. Goodman
SURFACE PREPARATION TECHNIQUES FOR ADHESIVE BONDING: by Raymond F.
Wegman
Contributors
Peter Angelini William B. Hillig
Oak Ridge National Laboratory General Electric Research &
Oak Ridge, TN Development Center
Schenectady, NY
Paul F. Becher
Oak Ridge National Laboratory George F. Hurley
Oak Ridge, TN Los Alamos National Laboratory
Los Alamos, NM
John J. Brennan
United Technologies Corporation Donald D. Johnson
East Hartford, CT 3M Center
St. Paul, MN
Jack Chin
General Atomics W. Jack Lackey
San Diego, CA Georgia Tech Research Institute
Georgia Institute of Technology
Lokesh R. Dharani Atlanta, GA
University of Missouri-Rolla
Rolla, MO Neal R. Langley
Dow Corning
Anthony G. Evans Midland, MI
University of California at
Santa Barbara David C. Larsen
Santa Barbara, CA Corning Glass Works
Corning, NY
Edward E. Hermes
Materials Laboratory Gary E. Legrow
Wright Patterson Air Force Dow Corning
Base, OH Midland, MI
vii
viii Contributors
Jonathan Lipowitz Linda C. Sawyer
Dow Corning Celanese Corporation
Midland, MI Summit, NJ
Tai II Mah Harold G. Sowman
Universal Energy Systems Inc. 3M Center
Dayton, OH St. Paul, MN
David 6. Marshall Thomas L. Starr
Rockwell International Science Georgia Tech Research Institute
Center Georgia Institute of Technology
Thousand Oaks, CA Atlanta, GA
Khodabakhsh S. Mazdiyasni Sharon L. Stuchly
General Atomics Corning Glass Works
San Diego, CA Corning, NY
Nicholas J. Pagano Terry N. Tiegs
Non-Metallic Materials Division Oak Ridge National Laboratory
Wright Patterson Air Force Base, OH Oak Ridge, TN
John J. Petrovic Yuan-Fu Yu
Los Alamos National Laboratory Technical Center
Los Alamos, NM Ethyl Corporation
Baton Rouge, LA
Roy W. Rice
Avigdor Zangvil
W.R. Grace and Co.
Columbia, MD Materials Research Laboratory
University of Illinois
Robert Ruh Urbana, I L
Materials Laboratory
Wright Patterson Air Force Base, OH
NOTICE
To the best of the Publisher's knowledge the information contained
in this book is accurate; however, the Publisher assumes no responsi-
bility nor liability for errors or any consequences arising from the
use of the information contained herein. Final determination of the
suitability of any information, procedure, or product for use con-
templated by any user, and the manner of that use, is the sole re-
sponsibility of the user. The book is intended for informational pur-
poses only. Fiber reinforced ceramic composite raw materials and
processes could be potentially hazardous and due caution should
always be exercised in the handling of materials and equipment. EX-
pert advice should be obtained at all times when implementation is
being considered.
Preface
High temperature, high performance ceramic composites for structural applica-
tions continue to be at the forefront of materials research and development.
Much progress has also been made during the past ten years toward understand-
ing all aspects of fiber reinforced ceramic composites. Theory and modeling
probe microstructural features to atomic dimensions; novel synthetic chem-
istry underlies ceramic fibers and matrices processing science; and mechanical
testing procedures and engineering approaches are fundamental to the character-
ization of engineering ceramics.
New analytical tools and procedures, and greater sophistication in research ap-
proaches have emphasized the importance of, and also provided the impetus
for, exploring the nature of oxide and non-oxide ceramic fibers and whiskers,
matrices microstructures, and the fiber matrix interface. This development has
also stimulated researchers to initiate studies in the processing of microstruc-
ture property relationships emphasizing optimum fiber chemical composition,
fiber phase stability, fiber matrix interface, fiber volume fractions, uniformity
and homogeneity; for these are controlling factors in realizing reliability and
reproducibility.
Despite their scientific interest, technological importance and economic signifi-
cance, no comprehensive work covering the entire field of fiber reinforced
ceramic composites has been written. The numerous original articles and review
articles that have been published about different aspects of this type of com-
posite do not fill this gap. Thus, it was felt timely and appropriate to offer
this book in an attempt to remedy this situation.
This book gives an up-to-date account of continuous and discontinuous ceramic
fibers and whisker reinforced ceramic composites by internationally recognized
V
vi Preface
contributors. Particular attention is given to the synthesis of VLS grown Sic
whiskers, and to the chemistry of sol-gel derived oxide and preceramic polymer
derived non-oxide ceramic fibers and matrices, emphasizing their properties and
characteristics. The theory, modeling and processing methodologies such as
chemical vapor and liquid melt infiltration techniques used for the research,
development and manufacturing of advanced structural ceramic composites are
also included. The importance of the fiber matrix interface and long term
stability of reinforcement fibers within a matrix are stressed. Future global
opportunities and needs for ceramic composites as engineering materials are
also assessed.
In view of space age technology requirements for light-weight, strong, tough and
durable structural materials, the book may be used for teaching advanced
specialty topics. Also because of the comprehensive nature of its contents, with
its up-to-date data, it should serve as a basic reference work on the state of the
art of fiber reinforced ceramic composites.
Finally, the editor wishes to extend and express his gratitude and appreciation
to the contributors for their time, effort and contributions.
April 1990 K.S. Mazdiyasni
San Diego, California
Contents
1. MECHANICAL BEHAVIOR OF CERAMIC MATRIX COMPOSITES ....1
Anthony G. Evans and David B . Marshall
Introduction ...................................... 1
Tensile Behavior of Uniaxial Composites ................... 3
Debonding and Sliding ............................. 3
Stress-Strain Curves ............................... 8
Some Basic Mechanics ............................. 9
Matrix Cracking ................................ 11
Resistance Curves and Toughening .................... 13
Transition in Failure Mechanism and Optimization of
Properties .................................... 14
Residual Stress ................................. 14
Transverse Failure ............................... 15
Tensile Behavior of Composites with Unbonded Reinforcing
Fibers ........................................ 16
Pullout ...................................... 16
Matrix Cracking ................................ 18
Ultimate Strength ............................... 19
Resistance Curves ............................... 21
Property Transition .............................. 23
Residual Stress ................................. 25
Mixed Mode Failure ................................ 26
Mode I I Failure Mechanisms ........................ 26
Delamination Cracking ............................ 28
Interfacial Debonding and Sliding ....................... 28
Mechanics of Interfacial Cracks ...................... 28
Debonding Mechanics. ............................ 30
Measurement of the Interface Fracture Resistance ..........3 6
Microstructure Design .............................. 37
References ...................................... 38
IX
x Contents
.
2 MICROMECHANICAL MODELS FOR BRITTLE MATRIX
COMPOSITES ....................................... 40
Nicholas J . Pagano and L .R . Dharani
Introduction ..................................... 40
Cylindrical Models ................................. 42
Energy Relation ................................ 43
Stress Analysis ................................. 44
Critical Cracking Condition ......................... 45
Planar Model .................................... 47
Stress Analysis ................................. 48
Upstream Stresses ............................. 48
Downstream Stresses ........................... 48
Debond Length Analysis ........................... 53
Critical Cracking Conditions ........................ 54
Simplified Planar Model ........................... 56
Results and Discussion .............................. 56
Perfectly Bonded Case ............................ 56
Slipping Case .................................. 59
Initially Bonded-Debonded Case ...................... 59
Conclusions ..................................... 59
References ...................................... 62
3 . PROPERTIES OF CERAMIC FIBERS FROM ORGANOSILICON
POLYMERS ......................................... 63
Neal R . Langley, Gary E . LeGrow and Jonathan Lipowitz
Synthetic Methods for Preceramic Polymers and Ceramic Fibers. ..6 3
Introduction ................................... 63
Polymeric Precursors for Silicon Carbide Ceramic Fibers . . . . . .6 4
Polymeric Precursors for Silicon Nitride Ceramic Fibers ......6 5
Polymer Precursors of Silicon. Carbon, and Nitrogen
Ceramic Fibers ................................ 65
Composition and Structure ........................... 67
Introduction ................................... 67
Composition ................................... 69
Chemical Bonding ............................... 72
Nanostructure .................................. 78
Porosity ...................................... 80
Discussion of Amorphous Structure ...................8 1
Thermal Stability ................................. 82
Introduction ................................... 82
Tensile Property Changes Due to Thermal Aging ...........8 2
Fundamental Factors ........................... 82
Sic Whiskers and CVD Fiber ...................... 82
Si-C-0 NICALON Fiber ......................... 83
Si-N-0 Fibers ................................ 84
Si-C-N-0 Fibers ............................... 84
Compositional Changes Due to Thermal Aging ............8 4
Expected Changes Based on Thermodynamics ...........8 4
Contents xi
Observed Compositional Changes ...................8 7
Structural Changes Due to Thermal Aging ...............8 8
Structure Before Aging .......................... 88
Structure After Aging ........................... 88
Summary ..................................... 89
References ...................................... 90
4 . VAPOR-LIQUID-SOLID (VLS) Sic WHISKERS: SYNTHESIS
AND MECHANICAL PROPERTIES ......................... 93
John J . Petrovic and George F . Hurley
Introduction. .................................... 93
Background on Whisker Growth ...................... 94
Whisker Growth Mechanisms ...................... 94
Past Work on Sic Whiskers ....................... 96
Whisker Growth .................................. 98
Whisker Nucleation and Growth ..................... 102
Si0 Generation ................................ 104
Fluid Mixing .................................. 106
...............
Mechanical Properties of VLS Si0 Whiskers 108
Mechanical Testing Techniques for Whiskers ............. 109
Whisker Room Temperature Mechanical Properties ........ 111
Whisker Fracture Toughness ....................... 113
Mechanical Properties of Long Whiskers ................ 114
Weibull Modulus of Whiskers ....................... 116
Intrinsic Whisker Fracture ......................... 117
References ..................................... 120
5 . OXIDE FIBERS FROM CHEMICAL CERAMIC PROCESSES .......1 22
Harold G. Sowrnan and Donald D . Johnson
Introduction. ................................... 122
High Alumina Fibers .............................. 124
Al2O3C eramic Fibers. ........................... 125
A1,03.Zr0, Ceramic Fibers ........................ 125
AI2O3-SiO2C eramic Fibers ........................ 126
ZrOz-SiOzC eramic Fibers ......................... 133
Coated Ceramic Fibers ............................. 135
Other Oxide Fibers Potentially Useful in Ceramic Composites ...1 35
Properties of Oxide Reinforcement Fibers ................1 38
References ..................................... 138
6. MICROSTRUCTURE OF CERAMIC FIBERS .................1 41
Linda C. Sawyer
Introduction. ................................... 141
Background .................................. 142
Structure-Property-Process Relationships ...............1 43
Description of Ceramic Fibers ........................ 144
Materials .................................... 144
Process ..................................... 144