Journal Home > Volume 12 , Issue 4
Journal of Advanced Ceramics 2023, 12(4): 830-847 https://doi.org/10.26599/JAC.2023.9220724
Research Article | Open Access | Issue | Published: 14 March 2023

Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration

Show Author's Information Xiao Chena,b,  Jie Yina,b( ),  Longzhi Huanga,b,  Sea-Hoon Leec,  Xuejian Liua,b( ),  Zhengren Huanga( )
State Key Lab of High Performance Ceramics and Superfine Microstructures, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
College of Materials Science and Opto-Electronic Technology, University of Chinese Academy of Sciences, Beijing 100049, China
Extreme Materials Institute, Korea Institute of Materials Science, Changwon 51508, Republic of Korea
Keywords:
mechanical properties, thermal properties, microstructural tailoring, chopped carbon fiber (Cf), selective laser sintering (SLS)
Cite this article:
Chen X, Yin J, Huang L, et al. Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration. Journal of Advanced Ceramics, 2023, 12(4): 830-847. https://doi.org/10.26599/JAC.2023.9220724
Download citation
EndNote(RIS)
BibTeX

2009

Views

411

Downloads

Citations

8

Crossref

4

WoS

6

Scopus

1

CSCD

Abstract Full text About this article

Poor flowability of printable powders and long preparation cycles are the main challenges in the selective laser sintering (SLS) of chopped carbon fiber (Cf) reinforced silicon carbide (SiC) composites with complex structures. In this study, we develop an efficient and novel processing route in the fabrication of lightweight SiC composites via the SLS of phenolic resin (PR) and Cf powders with the addition of α-SiC particles combined with the one-step reactive melt infiltration (RMI). The effects of α-SiC addition on the microstructural evolution of the Cf/SiC/PR printed bodies, Cf/SiC/C green bodies, and derived SiC composites were investigated. The results indicate that the added α-SiC particles play an important role in enhancing the flowability of raw powders, reducing the porosity, increasing the reliability of the Cf/SiC/C green bodies, and contributing to improving the microstructure homogeneity and mechanical properties of the SiC composites. The maximum density, flexural strength, and fracture toughness (KIC) of the SiC composites are 2.749±0.006 g·cm−3, 266±5 MPa, and 3.30±0.06 MPa·m1/2, respectively. The coefficient of thermal expansion (CTE, α) of the SiC composites is approximately 4.29×10−6 K−1 from room temperature (RT) to 900 ℃, and the thermal conductivity (κ) is in the range of 80.15–92.48 W·m−1·K−1 at RT. The high-temperature strength of the SiC composites increase to 287±18 MPa up to 1200 ℃. This study provides a novel as well as feasible tactic for the preparation of high-quality printable powders as well as lightweight, high-strength, and high–κ SiC composites with complex structures by the SLS and RMI.


menu
Abstract
Full text
Outline
About this article

Microstructural tailoring, mechanical and thermal properties of SiC composites fabricated by selective laser sintering and reactive melt infiltration

Show Author's information Xiao Chena,b, Jie Yina,b( ), Longzhi Huanga,b, Sea-Hoon Leec, Xuejian Liua,b( ), Zhengren Huanga( )
State Key Lab of High Performance Ceramics and Superfine Microstructures, Shanghai Institute of Ceramics, Chinese Academy of Sciences, Shanghai 200050, China
College of Materials Science and Opto-Electronic Technology, University of Chinese Academy of Sciences, Beijing 100049, China
Extreme Materials Institute, Korea Institute of Materials Science, Changwon 51508, Republic of Korea

Abstract

Poor flowability of printable powders and long preparation cycles are the main challenges in the selective laser sintering (SLS) of chopped carbon fiber (Cf) reinforced silicon carbide (SiC) composites with complex structures. In this study, we develop an efficient and novel processing route in the fabrication of lightweight SiC composites via the SLS of phenolic resin (PR) and Cf powders with the addition of α-SiC particles combined with the one-step reactive melt infiltration (RMI). The effects of α-SiC addition on the microstructural evolution of the Cf/SiC/PR printed bodies, Cf/SiC/C green bodies, and derived SiC composites were investigated. The results indicate that the added α-SiC particles play an important role in enhancing the flowability of raw powders, reducing the porosity, increasing the reliability of the Cf/SiC/C green bodies, and contributing to improving the microstructure homogeneity and mechanical properties of the SiC composites. The maximum density, flexural strength, and fracture toughness (KIC) of the SiC composites are 2.749±0.006 g·cm−3, 266±5 MPa, and 3.30±0.06 MPa·m1/2, respectively. The coefficient of thermal expansion (CTE, α) of the SiC composites is approximately 4.29×10−6 K−1 from room temperature (RT) to 900 ℃, and the thermal conductivity (κ) is in the range of 80.15–92.48 W·m−1·K−1 at RT. The high-temperature strength of the SiC composites increase to 287±18 MPa up to 1200 ℃. This study provides a novel as well as feasible tactic for the preparation of high-quality printable powders as well as lightweight, high-strength, and high–κ SiC composites with complex structures by the SLS and RMI.

Keywords: mechanical properties, thermal properties, microstructural tailoring, chopped carbon fiber (Cf), selective laser sintering (SLS)

References(47)

[1]
Xu YD, Cheng LF, Zhang LT. Carbon/silicon carbide composites prepared by chemical vapor infiltration combined with silicon melt infiltration. Carbon 1999, 37: 1179–1187.
DOI Google Scholar
[2]
Yang JH, Ai YJ, Lv XX, et al. Fabrication of C/C–SiC composites using high-char-yield resin. Int J Appl Ceram Technol 2021, 18: 449–456.
DOI Google Scholar
[3]
Liu GW, Zhang XZ, Yang J, et al. Recent advances in joining of SiC-based materials (monolithic SiC and SiCf/SiC composites): Joining processes, joint strength, and interfacial behavior. J Adv Ceram 2019, 8: 19–38.
DOI Google Scholar
[4]
Huang XT, Chen SG, Sun HR, et al. Honeycomb sandwich structure of Cf/SiC ceramic matrix composites prepared by PIP–CVI. Key Eng Mat 2014, 602–603: 422–425.
DOI Google Scholar
[5]
Kim SY, Woo SK, Han IS, et al. The carbon black effect on crack formation during pyrolysis step in liquid silicon infiltration process for Cf/C–SiC composites. J Ceram Soc Jan 2010, 118: 1075–1078.
DOI Google Scholar
[6]
Wang CP, Tang J, Liu HL, et al. Preparation of Cf/SiC composites by liquid silicon infiltration. Key Eng Mat 2010, 434–435: 103–105.
DOI Google Scholar
[7]
Liang JJ, Xiao HN, Gao PZ, et al. Microstructure and properties of 2D-Cf/SiC composite fabricated by combination of CVI and PIP process with SiC particle as inert fillers. Ceram Int 2017, 43: 1788–1794.
DOI Google Scholar
[8]
Janssen R, Scheppokat S, Claussen N. Tailor-made ceramic-based components—Advantages by reactive processing and advanced shaping techniques. J Eur Ceram Soc 2008, 28: 1369–1379.
DOI Google Scholar
[9]
Li S, Zhang YM, Han JC, et al. Effect of carbon particle and carbon fiber on the microstructure and mechanical properties of short fiber reinforced reaction bonded silicon carbide composite. J Eur Ceram Soc 2013, 33: 887–896.
DOI Google Scholar
[10]
Chen ZW, Li ZY, Li JJ, et al. 3D printing of ceramics: A review. J Eur Ceram Soc 2019, 39: 661–687.
DOI Google Scholar
[11]
Hassanin H, Essa K, Elshaer A, et al. Micro-fabrication of ceramics: Additive manufacturing and conventional technologies. J Adv Ceram 2021, 10: 1–27.
DOI Google Scholar
[12]
Liu G, Zhang XF, Chen XL, et al. Additive manufacturing of structural materials. Mat Sci Eng R 2021, 145: 100596.
DOI Google Scholar
[13]
He RJ, Zhou NP, Zhang KQ, et al. Progress and challenges towards additive manufacturing of SiC ceramic. J Adv Ceram 2021, 10: 637–674.
DOI Google Scholar
[14]
Zou Y, Li CH, Tang YH, et al. Preform impregnation to optimize the properties and microstructure of RB-SiC prepared with laser sintering and reactive melt infiltration. J Eur Ceram Soc 2020, 40: 5186–5195.
DOI Google Scholar
[15]
Jin LZ, Zhang K, Xu TT, et al. The fabrication and mechanical properties of SiC/SiC composites prepared by SLS combined with PIP. Ceram Int 2018, 44: 20992–20999.
DOI Google Scholar
[16]
Xu TT, Cheng S, Jin LZ, et al. High-temperature flexural strength of SiC ceramics prepared by additive manufacturing. Int J Appl Ceram Technol 2020, 17: 438–448.
DOI Google Scholar
[17]
Zhu W, Fu H, Xu ZF, et al. Fabrication and characterization of carbon fiber reinforced SiC ceramic matrix composites based on 3D printing technology. J Eur Ceram Soc 2018, 38: 4604–4613.
DOI Google Scholar
[18]
Chen X, Yin J, Liu XJ, et al. Effect of laser power on mechanical properties of SiC composites rapidly fabricated by selective laser sintering and direct liquid silicon infiltration. Ceram Int 2022, 48: 19123–19131.
DOI Google Scholar
[19]
Lu J, Ni DW, Liao CJ, et al. Fabrication and microstructure evolution of Csf/ZrB2–SiC composites via direct ink writing and reactive melt infiltration. J Adv Ceram 2021, 10: 1371–1380.
DOI Google Scholar
[20]
Amirthan G, Udaya Kumar A, Balasubramanian M. Thermal conductivity studies on Si/SiC ceramic composites. Ceram Int 2011, 37: 423–426.
DOI Google Scholar
[21]
Zhang BH, Yin J, Wang YC, et al. Low temperature densification mechanism and properties of Ta1−xHfxC solid solutions with decarbonization and phase transition of Cr3C2. J Materiomics 2021, 7: 672–682.
DOI Google Scholar
[22]
Chen X, Yin J, Liu XJ, et al. Fabrication of core–shell chopped Cf-phenolic resin composite powder for laser additive manufacturing of Cf/SiC composites. Polymers 2021, 13: 463.
DOI Google Scholar
[23]
Tan JH, Wong WLE, Dalgarno KW. An overview of powder granulometry on feedstock and part performance in the selective laser melting process. Addit Manuf 2017, 18: 228–255.
DOI Google Scholar
[24]
Zegzulka J, Gelnar D, Jezerska L, et al. Characterization and flowability methods for metal powders. Sci Rep 2020, 10: 21004.
DOI Google Scholar
[25]
Shang XJ, Zhu YM, Li ZH. Surface modification of silicon carbide with silane coupling agent and hexadecyl iodiele. Appl Surf Sci 2017, 394: 169–177.
DOI Google Scholar
[26]
Yang Y, Gu DD, Dai DH, et al. Laser energy absorption behavior of powder particles using ray tracing method during selective laser melting additive manufacturing of aluminum alloy. Mater Design 2018, 143: 12–19.
DOI Google Scholar
[27]
Hozer L, Lee JR, Chiang YM. Reaction-infiltrated, net-shape SiC composites. Mater Sci Eng 1995, 195: 131–143.
DOI Google Scholar
[28]
Chen H, Wei QS, Zhang YJ, et al. Powder-spreading mechanisms in powder-bed-based additive manufacturing: Experiments and computational modeling. Acta Mater 2019, 179: 158–171.
DOI Google Scholar
[29]
Evans AG, Zok FW. The physics and mechanics of fibre-reinforced brittle matrix composites. J Mater Sci 1994, 29: 3857–3896.
DOI Google Scholar
[30]
Baxter RI, Rawlings RD, Iwashita N, et al. Effect of chemical vapor infiltration on erosion and thermal properties of porous carbon/carbon composite thermal insulation. Carbon 2000, 38: 441–449.
DOI Google Scholar
[31]
Ching WY, Xu YN, Rulis P, et al. The electronic structure and spectroscopic properties of 3C, 2H, 4H, 6H, 15R and 21R polymorphs of SiC. Mater Sci Eng 2006, 422: 147–156.
DOI Google Scholar
[32]
Grewal G, Ankem S. Modeling matrix grain growth in the presence of growing second phase particles in two phase alloys. Acta Metall Mater 1990, 38: 1607–1617.
DOI Google Scholar
[33]
Hu J, Shi YN, Sauvage X, et al. Grain boundary stability governs hardening and softening in extremely fine nanograined metals. Science 2017, 355: 1292–1296.
DOI Google Scholar
[34]
Fu H, Zhu W, Xu ZF, et al. Effect of silicon addition on the microstructure, mechanical and thermal properties of Cf/SiC composite prepared via selective laser sintering. J Alloys Compd 2019, 792: 1045–1053.
DOI Google Scholar
[35]
Zhang H, Yang Y, Hu KH, et al. Stereolithography-based additive manufacturing of lightweight and high-strength Cf/SiC ceramics. Addit Manuf 2020, 34: 101199.
DOI Google Scholar
[36]
Watanabe H, Yamada N, Okaji M. Linear thermal expansion coefficient of silicon from 293 to 1000 K. Int J Thermophys 2004, 25: 221–236.
DOI Google Scholar
[37]
Li Z, Bradt RC. Thermal expansion and thermal expansion anisotropy of SiC polytypes. J Am Ceram Soc 1987, 70: 445–448.
DOI Google Scholar
[38]
Nakajo H, Utsumi Y. Thermal conductivity of pressureless-sintered SiC with B4C and C. Int J High Technol Ceram 1986, 2: 242–243.
DOI Google Scholar
[39]
Liu DM, Lin BW. Thermal conductivity in hot-pressed silicon carbide. Ceram Int 1996, 22: 407–414.
DOI Google Scholar
[40]
Xia HY, Wang JP, Lin JP, et al. Thermal conductivity of SiC ceramic fabricated by liquid infiltrating molten Si into mesocarbon microbeads-based preform. Mater Charact 2013, 82: 1–8.
DOI Google Scholar
[41]
Huang QW, Zhu LH. High-temperature strength and toughness behaviors for reaction-bonded SiC ceramics below 1400 ℃. Mater Lett 2005, 59: 1732–1735.
DOI Google Scholar
[42]
Chen J, An QL, Ming WW, et al. Investigations on continuous-wave laser and pulsed laser induced controllable ablation of SiCf/SiC composites. J Eur Ceram Soc 2021, 41: 5835–5849.
DOI Google Scholar
[43]
Ness JN, Page TF. Microstructural evolution in reaction-bonded silicon carbide. J Mater Sci 1986, 21: 1377–1397.
DOI Google Scholar
[44]
Dang XL, Zhao DL, Guo T, et al. Oxidation behaviors of carbon fiber reinforced multilayer SiC–Si3N4 matrix composites. J Adv Ceram 2022, 11: 354–364.
DOI Google Scholar
[45]
Wahl L, Lorenz M, Biggemann J, et al. Robocasting of reaction bonded silicon carbide structures. J Eur Ceram Soc 2019, 39: 4520–4526.
DOI Google Scholar
[46]
Tang J, Chang HT, Guo XT, et al. Preparation of carbon fiber-reinforced SiC ceramics by stereolithography and secondary silicon infiltration. Ceram Int 2022, 48: 25159–25167.
DOI Google Scholar
[47]
Lu ZL, Xia YL, Miao K, et al. Microstructure control of highly oriented short carbon fibres in SiC matrix composites fabricated by direct ink writing. Ceram Int 2019, 45: 17262–17267.
DOI Google Scholar
Publication history
Copyright
Acknowledgements
Rights and permissions

Publication history

Received: 22 October 2022
Revised: 17 January 2023
Accepted: 19 January 2023
Published: 14 March 2023
Issue date: April 2023

Copyright

© The Author(s) 2023.

Acknowledgements

The authors would like to express sincere thanks to Prof. Jiang Li from Shanghai Institute of Ceramics, Chinese Academy of Sciences (CAS) for his constructive and very detailed suggestions on the improvement of the quality of this manuscript. This work was supported by the National Natural Science Foundation of China (Nos. 52073299, 52172077, U22A20129, and 51902329), the National Key R&D Program of China (No. 2022YFB3706303), and the Youth Innovation Promotion Association CAS (No. 2018289).

Rights and permissions

Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made.

The images or other third party material in this article are included in the article’s Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder.

To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/.

Return