Preparation and Performance of Sintered SiC Fiber-bonded Ceramics

doi:10.15541/jim20240292

Abstract

Abstract:

SiC fiber-bonded ceramics (FBCs), representing a novel class of SiC materials, synthesized via direct sintering of SiC fibers and characterized by lack of a matrix phase, porosity below 3% and fiber volume fraction exceeding 90%, exhibit remarkable properties, including high-temperature resistance, high strength, and robust resistance to oxidation and irradiation. Consequently, they are a promising contender for future aero-engine and advanced nuclear energy applications. Herein, SiC(Al) FBCs were prepared by pre-treating the fibers to form in-situ graphite (iG) layers on their surface, followed by direct sintering the fibers using a hot-press sintering process. Then, macroscopic/microscopic structures, mechanical properties and oxidative properties of the fibers and bulk ceramics were characterized. The results show that pre-treatment of SiC(Al) fibers leads to forming a 300-400 nm thick carbon layer, adhering well to the fibers. Density of the hot-press sintered iG/SiC(Al) FBCs is 3.15 g/cm³, with a porosity of only 0.52%. Meanwhile, the matrix is completely dense, the fibers are deformed in a new form of hexagonal prisms, and the well-defined interfaces are present between the fibers. Furthermore, bending strength, fracture toughness, and work of fracture of the bulk ceramics are 320 MPa, 9.5 MPa·m^1/2 and 1169 J·m^-2, respectively. After oxidation at 1500 and 1600 ℃ for 100 h in air, the retention rates of the flexural strength remain as high as 86% and 72%, respectively, while maintaining a quasi-plastic fracture mode.

Key words: SiC fiber, sintered SiC fiber-bonded ceramic, mechanical performance, oxidation performance

CLC Number:

TB35

LI Wei, XU Zhiming, GOU Yanzi, YIN Senhu, YU Yiping, WANG Song. Preparation and Performance of Sintered SiC Fiber-bonded Ceramics[J]. Journal of Inorganic Materials, 2025, 40(2): 177-183.

Figures/Tables 12

Table 1 Chemical composition of SiC(Al) fiber

Sample	Composition/% (in atom)				C/Si
Sample	Si	C	O	Al	C/Si
SiC(Al) fiber	47.70	51.50	0.30	<1.00	1.08

Fig. 1 Chemical composition of SiC(Al) fiber (a) AES depth profile; (b) Total XPS spectra of surface; (c, d) Si2p XPS spectra of SiC(Al) fiber (c) before and (d) after etching

Fig. 2 XRD patterns of SiC(Al) fiber and iG/SiC(Al) fiber

Fig. 3 (a, c) Surface and (b, d) cross-sectional SEM images of (a, b) SiC(Al) fiber and (c, d) iG/SiC(Al) fiber

Fig. 4 XRD patterns of SiC(Al) FBC and iG/SiC(Al) FBC

Fig. 5 Optical photographs and SEM images of (a) SiC(Al) FBC and (b) iG/SiC(Al) FBC

Fig. 6 (a, c, e, g) TEM and (b, d, f, h) HRTEM images of (a-d) SiC(Al) FBC and (e-h) iG/SiC(Al) FBC with insets in (a, e) showing corresponding distributions of crystal diameters and insets in (d, f, h) showing selected area electron diffraction (SAED) patterns

Fig. 7 (a, e) HAADF images and (b-d, f-h) elemental mappings of (a-d) SiC(Al) FBC and (e-h) iG/SiC(Al) FBC

Fig. 8 Load-displacement curves during the (a) flexural strength and (b) fracture toughness tests of SiC(Al) FBC and iG/SiC(Al) FBC

Fig. 9 SEM images of fracture surfaces of (a-c) SiC(Al) FBC and (d-f) iG/SiC(Al) FBC

Fig. 10 Mass change curves per unit area of iG/SiC(Al) FBC after oxidation at different temperatures

Fig. 11 (a) Load-displacement curves during the flexural strength test and (b) residual bending strength of iG/SiC(Al) FBC after 100 h oxidation at different temperatures

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