Lecture Contents

Ceramic Matrix Composites

(CMCs)

• Introduction to CMCs

• Fabrication of CMCs

• Applications of CMCs

• Toughening mechanisms

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 Introduction
Types of composite materials according to matrix type

1. Metal Matrix composites (MMCs)- Mixtures of metals and

ceramics, such as titanium with SiC (powders)

2. Ceramics Matrix composites (CMCs)-Mixture of Ceramics (Al 2O3

or SiC) with fibers.

3. Polymeric Matrix composites (PMCs)-Mixture of polymer resins

with filler or reinforcing fiber.

Introduction: Lec.2
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 A Ceramic matrix composite (CMCs)

 CMCs: A ceramic primary phase imbedded with a secondary

phase, which usually consists of fibers.

 Attractive properties of ceramics: high stiffness, hardness, hot

hardness, and compressive strength; and relatively low density.

 Weaknesses of ceramics: low toughness and bulk tensile

strength, susceptibility to thermal cracking.

 Objective for CMCs: is to increase in the toughness

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A Ceramic matrix composite (CMCs)

Ceramic Materials:

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 A Ceramic matrix composite (CMCs)

Ceramic matrix composites may be classified into two

categories:
1. One is a group of toughened ceramics reinforced with particulates and
whiskers. These materials exhibit brittle behavior in spite of considerable
improvements in fracture toughness and strength. The maximum in
fracture toughness is around 10 MPa M or more.
1/2

2. The second consists of continuous-fiber composites exhibiting quasi-

ductile fracture behavior accompanied by extensive fiber pull out. The
fracture toughness of this class of materials can be higher than 20 MPa
M1/2 when produced with weak interfaces between the fibers and matrix.
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 A Ceramic matrix composite (CMCs)
Classifications
of CMCs.
The uniform
background color
(orange accent 6 (60
%)) in the images
represents ceramic
matrix and different
front colors indicate
reinforcing materials.

SiC
B4C
Carbon

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 A Ceramic matrix composite (CMCs)

Typical Properties of Long-Fiber Ceramic Matrix Composites

• High mechanical strength even at high temperatures;
• High thermal shock resistance;
• High stiffness;
• High toughness;
• High thermal stability;
• Low density;
• High corrosion resistance even at high temperatures.

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 Fabrication techniques of CMCs
 Fabrication of Ceramic Matrix Composites (CMCs)
Currently, all successful techniques for the manufacture of
CMC require processing at temp. of the order of
1000°C and upwards.

 Chemical and thermal expansion compatibility between

fibres and matrix are thus of paramount importance.
Residual stresses are induced when the composite cools
down from the processing temperature which can cause the
composite to crack and fragment even without the external
loading.

 High temperature chemical reactions between fibre

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 Fabrication techniques of CMCs

Processing of CMCs

1.Chemical Vapor Infiltration(CVI)

2. Slurry Infiltration Process(SIP) or Liquid phase Infiltration
3. Polymer Infiltration and Pyrolysis (PIP)
4. Sol-gel process
5. Direct metal Oxidation Process

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 Fabrication of CMCs:Chemical Vapor Infiltration

1.Chemical Vapor Infiltration (CVI)

 In the CVI process,
a solid material is
deposited from
gaseous reactants
onto a heated
substrate made of
long continuous fibers,
and form a precipitation.

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 Fabrication of CMCs:Chemical Vapor Infiltration

Processing of CMCs

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 Fabrication of CMCs:Chemical Vapor Infiltration

 For example, methyltrichlorosilane (CH3SiCl3), the

starting material to obtain SiC, is decomposed at a
temperature between 1200 and 1400 K as per the
following reaction:

The vapors of SiC deposit as solid phase on and in

between the fibers in a free-standing preform to make
the matrix.

The matrix is the precipitated material and the

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 Fabrication of CMCs:Slurry Infiltration

2. Slurry Infiltration/Impregnation
This process involves two main stages :
Stage-1: Incorporation of the reinforcing phase into slurry of the consolidated
matrix.
The fibres are impregnated by passing them through the slurry tank. The
impregnated fibres are then taken over by the take up drum. The prepreg thus
formed is in the form of tapes which is cut into the desired size. Then, the
different layers of tapes are stacked together and the binder is burnt out before
the consolidation takes place.
Stage-2: Matrix consolidation by hot pressing.
After the burning of the binder from the stacked tapes, it is subjected to
consolidation by hot pressing which results in the desired ceramic matrix
composite. 10/29/2024 13
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Fabrication of CMCs:Slurry Infiltration

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 Fabrication of CMCs:Slurry Infiltration

 Advantages
1. Low porosity (due to hot pressing and use of continuous fiber
reinforcement).
2. Good mechanical properties. (because of continuous fibre
reinforcement).
3. Composites with uniform fiber distribution can be processed.

 Disadvantages
1. High melting point matrix materials cannot be processed.
2. Damage of reinforcing phase may occur during the hot pressing.
3. Relatively small and simple parts can be be fabricated.
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 Fabrication of CMCs: PIP
3. Polymer Infiltration and Pyrolysis (PIP)
 Polymer Infiltration and Pyrolysis (PIP) is the method of fabrication of
Ceramic Matrix Composites comprising an infiltration of a low viscosity
polymer into the reinforcing ceramic structure (e.g. fabric) followed by
pyrolysis.
 Pyrolysis: heating the polymer in the absence of oxygen when it
decomposes and converts into a ceramic.
Preceramic polymers are the Polymers, which can be converted into
Ceramics by pyrolysis.

Polymer Infiltration and Pyrolysis (PIP) technique is used mainly for

fabrication Composites with silicon carbide (SiC) matrices.
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Fabrication of CMCs: PIP

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 Fabrication of CMCs: PIP
Polymer Infiltration and Pyrolysis (PIP) involves 6 stages :
1. Fabrication of pre-impregnated material (prepreg). The
reinforcing fibers are impregnated with a resin and then dried or cured
to B-stage (partial curing).
2. Lay-up and Molding. The laid-up prepreg is molded.
3. Infiltration of a preceramic polymer. The pores of the reinforcing
structure are filled with a low viscosity solution of a preceramic polymer
when the preform is immersed into it.

4. Pyrolysis. Pyrolytic decomposition of the preceramic polymer is

performed in the atmosphere of Argon at a temperature in the range
1472-2372°F (800-1300°C). As a result of pyrolysis, the polymer
converts to ceramic.
5. Multiple re-infiltration and pyrolysis. The infiltration-pyrolysis cycle
is repeated 4-10 times until the desired density is achieved.
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 Fabrication of CMCs: PIP
Advantages of PIP:
 Fibers damage is prevented due to the processing at a relatively low temperature;
 Good control of the matrix composition and the microstructure;
 Reinforcing phase of different types (particulate, fibrous) may be used;
 Net shape parts may be fabricated;

Disadvantages of PIP:
 The fabrication time is relatively long due to the multiple infiltration-pyrolysis
cycle;
 There is a residual porosity decreasing the mechanical properties of the composite;
 Relatively high production cost (higher than in Liquid Silicon Infiltration method)

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 5)
Fabrication of CMCs: Sol-gel process
4. Sol-gel process
 Composites involves preparation of the matrix from a liquid of
colloidal suspension fine ceramic particles (sol),Which
impregnate a preform and then transforms to solid (gel).

 Colloidal suspension is formed as a result of chemical reaction

when very small particles with radii up to100nm (nanoparticles)
precipitate within a liquid (water or organic solvent)

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 5)
Fabrication of CMCs: Sol-gel process

 A gel is a semi-rigid mass that forms when the solvent from the sol
begins to evaporate and the particles or ions left behind begin to join
together in a continuous network.

 Drying operation causes shrinkage of matrix material and formation

of pores.

 The resulting material is hot pressed.

 Desired shapes may be produced by Sol-Gel method

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 5)
Fabrication of CMCs: DIMOX
5. Direct metal Oxidation Process (DIMOX)
 involving a formation of the matrix in the reaction of a molten
metal with an oxidizing gas.

Preform of dispersed phase (fibers, particles) is placed on the

surface of parent molten metal in an atmosphere of oxidizing
agent (Oxygen).

Liquid metal oxidizes when it is in contact with oxygen,

forming a thin layer of ceramic with some dispersed phase
incorporated in it.
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 5)
Fabrication of CMCs: DIMOX
Two conditions are necessary for conducting DIMOX:
1. Dispersed phase is wetted by the melt;
2. Dispersed phase does not oxidize in an atmosphere of oxygen.

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 5)
Some Fabricated CMCs

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 5)
Solid state fabrication of MMCs

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 Why Ceramic matrix composite (CMCs)?
The main advantages of ceramic matrix composites as compared to
monolithic ceramics are shown in the following stress-strain curve
Objective for CMCs: is to increase in the
toughness

SEM image of the overall fracture cross

section in cross-ply Nicalon/CAS composite.

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Figure 1. The stress–strain behavior in ceramic matrix composites as compared with monolithic ceramics
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 Why Ceramic matrix composite (CMCs) ?
CMCs:
 Fiber reinforcements improve the toughness of the ceramic matrix in
several ways.

 First, a crack moving through the matrix encounters a fiber; if the bonding
between the matrix and the fiber is poor, the crack is forced to propagate
around the fiber in order to continue the fracture process.

 In addition, poor bonding allows the fiber to begin to pull out of the matrix.
Both processes consume energy, thereby increasing fracture toughness.

 Finally, as a crack in the matrix begins, unbroken fibers may bridge the
crack, providing a compressive stress that helps keep the crack from
opening. 10/29/2024 27
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 Toughening mechanisms of (CMCs)
Toughening mechanisms:
There are many different toughening mechanisms.
One or more toughening mechanisms may operative in a composite. The
effectiveness of the toughening mechanisms depends on:
1. Size, morphology and volume fraction of the reinforcement;
2. Interfacial bond;
3. Properties (e. g. mechanical, thermal expansion) of the
matrix and the reinforcement;
4. Phase transformation
Toughening mechanisms in ceramic-matrix composites
1. Crack bowing and deflection
2. Debonding
3. Crack bridging and fiber pullout
4. Microcracking
5. Transformation toughening 10/29/2024 28
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 Toughening mechanisms of (CMCs)

1. crack bowing & Crack deflection

a) Crack approaches to
reinforcements.
b) the crack bowed under stress to
form a nonlinear crack front.
 Decrease in the stress intensity K
along the bowed section in the matrix
 Increase in the stress intensity K at
the reinforcement

 K reached to the fracture toughness

of the reinforcement → the
reinforcement
Bowing needs breaks
more energy to
increase toughness 10/29/2024 229
 Toughening mechanisms of (CMCs)
)

 Crack deflection: Cracks are deflected

from growth plane around fibers due to
differences in thermal expansion
coefficient and modulus between the
fiber and the matrix

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 Toughening mechanisms of (CMCs)
)
2. Debonding
o Debonding: Reinforcement fiber separates from
matrix.
o Debonding toughening: New surface in the composite
require energy in debonding.

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 Toughening mechanisms of (CMCs)
)
3. Crack bridging and fiber pullout
Fibre bridging:
 some fibres debonds
but not break.
 Fibers carry out stresses
under load.
 Reduce the stresses at
crack tip and hinder
crack propagation.

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 Toughening mechanisms of (CMCs)
4.
 The toughness of a materials can
Microcracking
be enhanced by the presence of
microcracks, due to crack blunting,
branching and deflection.

 The microcrack toughening is

effective on the limited density and
size of cracks.

 Toughness of materials increases

and strength decreases in the 10/29/2024 33
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 Toughening mechanisms of (CMCs)
4.
Microcracking
Thermal stress forms between matrix
and reinforcement during cooling,
due to difference in coefficient of
thermal expansion .
(a). >
 Tangential compressive and a
radial tensile stresses in matrix
 Circumferential crack forms

(b). <
under high tensile stress Stress distribution and microcrack
formation around spherical particles
when (a) > , (b) > , C and T for
 Tangential tensile stress in matrix compressive and tensile stresses.

cause radial crack under high tensile stress. 10/29/2024 34

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 Toughening mechanisms of (CMCs)
5. Transformation toughening
 Under the action of the stress field at the crack tip, ZrO 2 particles
undergo tetragonal transformation to monoclinic transformation and
absorb the energy, thus improving the fracture toughness. This is the
stress induced phase transformation.
Energy is absorbed ahead of the
primary crack owing to the
transformation.

 ZrO2 particles at a crack tip will

transfer to monoclinic-ZrO2 under
stress. 10/29/2024 35
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 Toughening mechanisms of (CMCs)

Induced phase transformation.

Closing of microcracks because of the crystal volume
increase caused by the phase change [56].
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