Key Engineering Materials Vol. 287

Abstract: Previous studies have demonstrated that dense coatings of CVD mullite (3Al2O3×2SiO2) provide excellent oxidation protection for Si3N4 and SiC in a high pressure, steam environment. In this study the mechanical properties of CVD mullite coated silicon nitride materials from different vendors (AS800, NGKSN88, Kyocera SN281) were evaluated following ASTM test procedures. The dynamic fatigue tests werep erformed in ambient air at temperatures of 850 and 1200°C under fast (30 MPa/s) and slow (0.003 MPa/s) load rates. The static fatigue tests were carried out at a constant load of 350 MPa for 1000h at 1200°C. The cyclic fatiguetests at 850°C consisted of a loading ramp from 20 to 400 MPa in 30 seconds followed by unloading ramp from 400 to 20 MPa. A total of 10,000 cycles were applied to the fatigue test specimens before fast fracture tests were conducted at room temperature. The strength test results indicated that CVD mullite coatings showed excellent adhesion during dynamic fatigue tests and exhibited no creep behavior. Minor flexure strength reduction observed at low stressing rate and at high temperatures appeared to be related to Si3N4 properties such as SCG (slow crack growth) susceptibility. During cyclic and static fatigue tests, a glassy silica/aluminosilicate phase was formed due to oxidation. This resulted in localized coating separation and buckling. However, accumulation of this corrosion layer was not critical since the coated specimens showed a flexure strength increase of ~7-9.5%.

Abstract: SiC-composites are candidate structural materials for high temperature applications such as gas turbines. For this purpose, a suitable coating against high temperature oxidation is essential. The coating material selection was made by phase stability/durability under service environment, CTE matching, low elastic modulus and chemical compatibility with SiC. This work is to evaluate the microstructural quality of mullite and erbium silicate coatings on SiC fiber bonded composites. In this work, SiC-fiber bonded 2D-composite (TyrannohexTM) by Ube Industries Ltd., were coated with mullite and erbium silicate by plasma spraying. The thickness of mullite and erbium silicate coatings was determined to be 120 microns and 220 microns, respectively. The fabricated samples were diamond polished for cross-sectional analyses by optical and scanning electron microscopy. The coating-substrate interfaces have been found bit undulating. The bonding between mullite and the substrate was found insufficient as compared to that observed in the erbium silicate coated substrate. The cross-sectional analyses of erbium silicate coating revealed the presence of throughthickness micro- and macro-cracks. The width of the macrocracks was found in the range of 1-3 microns. It is conceived that the evolution of large concentration of through-thickness-cracks is due to the stresses in the coating. The most probable sources of stresses are the precipitation of various second phases in the coating materials and the thermal expansion mismatches that arise during cooling. The mullite coating on the other hand is not found with macrocracks and on the whole the cohesion within the mullite coating is rather strong. The cross-sectional examination also revealed the irregularly distributed pores and cavities in both coating systems that are typical of thermal sprayed coatings. The surfaces of the coatings are characterized of typical lamellar microstructure formed by the flattened platelets of individual particles. The size of these droplets ranges from submicrometer to several micrometers.

Abstract: Silicon nitride ceramics was prepared by tape casting nonaqueous ceramic slurries, laminating the green ceramic tapes, and gas pressure sintering in nitrogen atmosphere. Lu2O3 and SiO2 were used as the sintering additives, and 3 wt.% β-Si3N4 seed was added to enhance β-Si3N4 grain growth unidirectionally. The seeded and tape-cast Si3N4 showed very good high temperature bending strength at 1500oC, when the stress applied along with the grain alignment direction. This was attributable to the formation of a high melting point grain boundary phase and the fibrous Si3N4 grains alignment. After exposure in air at 1500oC for up to 100 h, the oxidation products formed on the Si3N4 surface consist of Lu2Si2O7 and SiO2. The bending strength of the oxidized and tape-cast Si3N4 was degradation, the strength decrease was associated with the formation of new defects on the surface and the interface between the oxide layer and the Si3N4 bulk.

Abstract: Irradiation damage produced by neutrons or energetic particles lead to changes of physical- and mechanical-properties of SiC. Radiation hardening and fracture toughness changing of SiC were clarified by indentation method previously. However, the mechanism studies have received little alteration. The purpose of this study is to improve the understanding of the mechanisms of mechanical property changes under irradiation. In this paper, the microstructural observation beneath and near an indentation will be used to infer mechanisms of radiation hardening and toughening. Indenting polycrystalline SiC creates deformation and cracking in the plastically deformed region. In the case of irradiated SiC, however, small-sized deformation zone was observed below contact indent, which resulted in the restricted size of residual impression. Additionally, the indentation cracks showed complex propagation behaviors such as deflecting, branching and microcracking.

Abstract: Strength degradations of porous silicon carbide hot gas filters bonded with clay and calcium carbonate are investigated in the simulated condition of the pressurized fluidized bed combustion (PFBC). Thermal cycling, static fatigue, thermal shock, and hot corrosion tests are conducted to differentiate the independent parameter that affects the strength degradation during the filtration using silicon carbide filter in PFBC condition. The results indicate that hot corrosive gas mainly causes the strength reduction because of the degradation of grain boundary region.