11th Annual Conference on Composites and Advanced Ceramic Materials: Ceramic Engineering and Science Proceedings, Volume 8, Issue 7/8

520 Pages·1987·11.143 MB·English

11th Annual Conference on
Composites and Advanced Ceramic Materials
Proceedings of the
11th Annual Conference on
Composites and Advanced Ceramic Materials
David C. Larsen
Program Chair
A Collection of Papers Presented at the
11th Annual Conference on
Composites and Advanced Ceramic Materials
Sponsored by the
Engineering Ceramics Division
The American Ceramic Society, Inc.
January 18-23, 1987
Cocoa Beach Hilton
Cocoa Beach, FL
ISSN 0196-6219
Published by
The American Ceramic Society, Inc.
757 Brooksedge Plaza Drive
Westerville, OH 43081-6136
@The American Ceramic Society, Inc., 1987
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Editorial Advisory Board: Cameron G. Harman, Jr., chair; Waltraud M.
Kriven, chair elect; Uma Chowdhry; Ellis Gartner; George Gehringer; Carol
M. Jantzen; Ronald E. Loehman; David B. Marshall; William J. Rice; Thomas
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CESPDK Vol. 8, NO. 7-8, pp. 483-991, 1987
The American Ceramic Society assumes no responsibility for the state-
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Preface
The 1 lth Annual Conference on Composites and Advanced Ceramic Materi-
als was the most successful to date based on the number of papers (96) and
attendees (approximately 750). Eleven technical sessions covered various aspects
of ceramic and metal matrix composites and monolithic heat engine ceram-
ics. The Plenary Session included updates of DOD, DOE, and NASA activi-
ties, as well as technology and technoeconomic assessments of the advanced
ceramic industry. The First Annual James I. Mueller Memorial Lecture was
presented by Jerome Persh. This Proceedings volume contains 58 full
manuscripts or extended abstracts of the papers presented in Cocoa Beach.
I wish to extend my sincere thanks to all those who helped make this Cocoa
Beach meeting successful-mainly the session chairs, authors and participants.
Thanks are also due the ECD Cocoa Beach Subcommittee and ACWG Steer-
ing Committee for their suggestions and assistance. Special mention is made
of the help from Don Messier for organizing the Plenary Session and ban-
quet, and to Tom Utsman as guest speaker at the banquet. Also gratefully
acknowledged is the help of David Clark and the student pages from the
University of Florida, Bob Denaburg of NASA-Kennedy Space Center, and
of course, Bill Douglas and his ACerS staff for making the conference run
smoothly.
It is gratifying to observe the Cocoa Beach meeting growing from just
a handful of attendees a few short years ago to what it is today. I have every
confidence that this trend will continue well into the future.
David C. Larsen
Program Chair
Engineering Ceramics Division
American Ceramic Society
...
111
Each issue of Ceramic Engineering and Science Proceedings includes a collection of
technical articles in a general area of interest, such as glass, engineering ceramics,
and refractories. These articles are of practical value for the ceramic industries. The
issues are based on the proceedings of a conference. Both The American Ceramic
Society, Inc., and non-Society conferences provide these technical articles. Each issue
is organized by an editor who selects and edits material from the conference. Some
issues may not be complete representations of the conference proceedings. There is
no other review prior to publication.
iv
Table of Contents
Characterization and NDE
Correlation Between Ultrasonic Velocity and Density of
...................................
Ceramic Turbine Blades 483
P. K. Khandelwal and P. W. Heitman
...............
NDE and Fracture Studies of Hot-Pressed Si,N, 493
R. A. Roberts, J. P. Singh, and J. J. Vaitekunas
High Frequency Ultrasonic Characterization of Sintered Sic ..... 502
George Y. Baaklini, Edward R. Generazio, and James D. Kiser
Characterization of Porosity in Green-State and Partially
Densified AI,O, by Nuclear Magnetic Resonance Imaging. ....... 503
W. A. Ellingson, J. L. Ackerman, L. Garrido, J. D. Weyand,
and R. A. DiMilia
Characterization of Advanced Ceramics by
Thermal Wave Imaging ................................... 513
Douglas N. Rose, Darryl C. Bryk, William Jackson, Milt Chaika,
Glen Schram, Greg Quay, Robert L. Thomas, Lawrence D.
Favro, and Pao-Kuang Kuo
High-Resolution Computed Tomography for Flaw Detection
in Advanced Thin-Layer Ceramics for Fuel Cells ............... 525
B. D. Sawicka, W. A. Ellingson, C. McPheeters
Leaky Plate Waves for NDE of Composites ................... 538
D. E. Chimenti and C. J. Fiedler
The Value of Metallographic Examination of Ceramics and
............................................
Composites 547
Rene Hdeg
Coating/ Joining/Tribology
.....
Interface Roughness Effect on Stresses in Ceramic Coatings 559
Robert L. Mullen, Robert C. Hendricks, and Glen McDonald
Thermomechanical Behavior of Plasma-Sprayed Zr0,-Y,O,
........
Coatings Influenced by Plasticity, Creep, and Oxidation 572
J. Padovan, B. T. F. Chung, Glen E. McDonald, and
Robert C. Hendricks
Some Adhesion/Cohesion Characteristics of Plasma-Sprayed
...........................
Zr0,-Y,O, Under Tensile Loading 583
Robert L. Mullen, Brian L. Vlcek, Robert C. Hendricks, and
Glen McDonald
V
Thermal Shock Protection of Dense Alumina Substrates by
Porous Alumina Sol-Gel Coatings ........................... 596
M. F. Gruninger, J. B. Wachtman, Jr., and R. A. Haber
An Advanced Ceramic-to-Metal Joining Process. ............... 602
M. A. DeLuca, J. W. Swain, Jr., and L. R. Swank
High Temperature Properties of an Alumina Enhanced
Thermal Barrier. ......................................... 611
Daniel B. Leiser, Marnell Smith, and Elizabeth A. Keating
Thermal Response of Integral Multicomponent Composites to
a High-Energy Aerothermodynamic Heating Environment
with Surface Temperature to 1800 K.. ....................... 613
David A. Stewart and Daniel B. Leiser
Fracture and Interfaces
Failure Modes in Unidirectional Brittle Matrix
Composites (BMC) ...................................... 626
N. J. Pagano and L. R. Dharani
Fracture Mechanics Characterization of Crack/Fiber
Interactions in Ceramic Matrix Composites .................. 630
T. W. Coyle, E. R. Fuller, Jr., P. Swanson, and T. Palamides
Effect of Boron Nitride Coating on Fiber-Matrix Interactions .... 636
R. N. Singh and M. K. Brun
The Interface Between Sic Filaments and Si .................. 644
H. T. Godard and K. T. Faber
Whisker and Particulate ComDosites
Sic Whisker-MoSi, Matrix Composites ....................... 645
W. S. Gibbs, J. J. Petrovic, and R. E. Honnell
Oxidation of Sic-Containing Composites ..................... 649
Krishan L. Luthra
Kinetics of Oxidation of Carbide and Silicide Dispersed
Phases in Oxide Matrices .................................. 654
M. P. Bororn, M. K. Brun, and L. E. Szala
Numerical Computation of the Toughening Increments Due
to Crack Deflection in Particulate Composites ................. 671
S. G. Seshadri, M. Srinivasan, and K. M. Keeler
Mechanical Properties of Partially Densified SiC/SiO, Gel
Matrix Composites .......................................
B. I. Lee and L. L. Hench
vi
Effect of Sic-w Impurities on the Sintering of
.........................
Mullite/Zirconia/SiC-w Composites. 693
M. I. Osendi and J. S. Moya
Fibers and Whiskers
................
Particulate Matters in Silicon Carbide Whiskers 702
Kenneth W. Lee and Stephen W. Sheargold
Rheological Behavior of Sic Whiskers in a Model lnjection
Molding System. ......................................... 712
E. Krug and S. C. Danforth
...........................
Oxidation of Sic Ceramic Fiber.. 717
Terence J. Clark, Edward R. Prack, M. Ishaq Haider, and
Linda C. Sawyer
..........
Silsesquioxanes as Precursors to Ceramic Composites 732
F. I. Hurwitz, L. Hyatt, J. Gorecki, and L. D’Amore
....................
Properties of Nextel 480 Ceramic Fibers.. 744
D. D. Johnson, A. R. Holtz, and M. F. Grether
.......................
New High-Temperature Ceramic Fiber 755
James C. Rornine
Sic and SLN,
Dynamic and Static Fatigue Behavior of Sintered
..........................................
Silicon Nitrides 766
J. Chang, P. Khandelwal, and P. W. Heitman
High Temperature Mechanical Properties of SiAlON
..........................
Ceramics: Microstructural Effects 778
Ching-Fong Chen and Tseng-Ying Tien
High Temperature Mechanical Properties of SiAlON
Ceramic: Creep Characterization. .......................... 796
Ching-Fong Chen and Tze-Jer Chuang
Corrosion Reactions In Sic Ceramics ........................ 805
N. J. Tighe, J. Sun, and R. M. Hu
Mechanical Behavior of Sic Exposed to Molten Lithium and
Lithium Salts ............................................ 812
J. W. Cree and M. F. Amateau
GIass/Glass Ceramic Matrix ComDosites
Fabrication and Materials Evaluation of High Performance
Aligned Ceramic Fiber-Reinforced, Glass-Matrix Composite ...... 815
D. M. Dawson, R. F. Preston, and A. Purser
vii
Structural Toughening of. Glass Matrix Composites by 3-D
Fiber Architecture ........................................ 822
Frank KO, Michael Koczak, and George Layden
Thermal Conductivity and Diffusivity of Fiber- and
Whisker-Reinforced Glass, Glass-Ceramic and Ceramic
.......................................
Matrix Composites 832
D. P. H. Hasselman, L. F. Johnson, and L. M. Russell
Ceramic Matrix Composites by Means of Melt Infiltration. ....... 834
William B. Hillig
Metal Particle-Toughened Borosilicate Sealing Glass. ........... 839
R. H. Moore and S. C. Kunz
Alumina Comoosites and Oxide Ceramics
Mechanical Properties of Silicon Carbide Whisker/Aluminum
Oxide Matrix Composites .................................. 848
Wallace L. Vaughn, Joseph Homeny, and Mattison K. Ferber
Sintering of Fiber-Reinforced Composites ..................... 860
Claudia Ostertag
Microwave Sintering of AI,O, and
Al,O,-Sic Whisker Composites ............................. 861
T. T. Meek, R. D. Blake, and J. J. Petrovic
SiC/Al,O, Gel-Derived Monolithic Nanocomposites ............ 872
R. S. Haaland, B. I. Lee, and S. Y. Park
Preparation of LanxideTMC eramic Matrix Composites: Matrix
........
Formation by the Directed Oxidation of Molten Metals.. 879
M. S. Newkirk, H. D. Lesher, D. R. White, C. R. Kennedy, A.
W. Urquhart, and T. D. Claar
Evaluation of Japanese Yttria Tetragonal Zirconia Polycrystal
(Y-TZP) Materials ........................................ 886
Jeffrey J. Swab
Environmental Effects in Toughened Ceramics ................. 892
Norman L. Hecht, Dale E. McCullum, G. A. Graves, and
Sung Do Jang
SDIO Materials for Space Structures
Interfacial Characterization and Damping in Metal Matrix
Composites ............................................. 910
S. P. Rawal, J. H. Armstrong, and M. S. Misra
...
Particulate Wetting and Metal: Ceramic Interface Phenomena 912
S-Y. Oh, J. A. Cornie, and K. C. Russell
...
Vlll
Interfacial Shear Strength and Sliding Resistance in Metal
and Glass-Ceramic Matrix Composites ....................... 937
J. F. Mandell, K. C. C. Hong, and D. H. Grande
Correlation of Test Data for Unidirectional P-100/6061 Wire
and Sheet Specimens ..................................... 941
S. W. Bradstreet and L. W. Davis
Sic and Si,N, Matrix Composites
Model for CVI of Short Fiber Preforms ....................... 951
T. L. Starr
CVD Silicon Carbide Components ........................... 958
Peter Reagan, William Cole, and Fred Huffman
Ceramic Composite Heat Exchanger ......................... 968
W. E. Cole, P. Reagan, C. 1. Metcalfe, S. R. Wysk, and
K. W. Jones
Microstructural Characterization of Thermally-Aged SiconexTM
Oxide Fiber/SiC Composite Materials. ....................... 976
Jane Snell Copes and Robert G. Smith
Fiber-Reinforced Ceramic Composites ........................ 977
Helen H. Moeller, William G. Long, Anthony J. Caputo, and
Richard A. Lowden
Reaction-Sintered Silicon Nitride Composites With Short
Fiber Reinforcement ...................................... 985
T. L. Starr, J. N. Harris, and D. L. Mohr
ix
Ceramic Engineering and Science Proceedings
David C. Larsen
copyrightOThe American Ceramic Society, Inc., 1987
Ceram. Eng. Sci. Proc., 8 [7-81 pp. 483-492 (1987)
Correlation Between Ultrasonic Velocity and Density
of Ceramic Turbine Blades
w.
P. K. KHANDELWAALN D P. HEITMAN
Allison Gas Turbine Div.
General Motors Corp.
Indianapolis, IN 46206
A computer-aided ultrasonic velocity measurement system to detect small density
variations in structural ceramic materials has been developed. Longitudinal wave
ultrasonic velocity and density of ceramic turbine blades and bars were measured
and statistically correlated. Density variations of 1 to 2% were reliably detected.
Burst speed of ceramic blades was inversely proportional to the grain size of the
material.
Introduction
P
olycrystalline structural ceramic materials and components are currently being
developed and evaluated in vehicular/industrial gas turbine engines. The cur-
rent state-of-the-art of manufacturing structural ceramics, while developing rapid-
ly, is yet judged to be in a state of infancy. Because of inadequate process control,
microstructural variations are generally observed in these materials which in many
instances adversely affect physical and mechanical properties. The ultrasonic prop-
erties of solids, including velocity and attenuation, are dependent on microstruc-
ture, and, as such, are sensitive functions of chemistry, phase content, grain size,
and porosity. Monitoring these properties can, therefore, be used as an effective
means of tracking material variability. In particular, ultrasonic can be easily
measured with great accuracy. The ultrasonic velocity of waves through a material
is related to the density (p) and elastic modulus (E)b y the following equation:
where V=ultrasonic longitudinal wave velocity
L =t hickness of specimen
t =w ave transit time between two selected back surface echoes
7 = 1 when transit time between first and second back surface echoes
=2 when transit time between first and third back surface echoes
E=elastic modulus
=density of material
By measuring the specimen thickness and transit time of the acoustic wave through
the medium, the preceding relationship provides a means of determining the
ultrasonic velocity of material.
A ceramic blade process development study was conducted to identify the pro-
cessing variables that control the material strength and overall yield. Blades were
manufactured by injection molding sintered silicon carbide in a matrix of 13
variables that would produce 32 groups of recipes of parts, each with a different
combination of variable. Two modulus-of-rupture (MOR) bars were made with
each blade in the same mold simultaneously as shown in Fig. 1. Each recipe,
therefore, was anticipated to have a unique microstructure, density, and mechanical
483