Continuous Fiber Ceramic Composite (CFCC) tubes have been manufactured using cure-on-the-fly and no cure-on-the-fly filament winding by preceramic polymer pyrolysis route. Processing guidelines to effectively use the cure-on-the-fly filament winding technique for the manufacture of CFCCs are introduced in this paper. The preceramic polymer used in thiswork is Blackglas™ (a siloxane polymer). Afilament winding machine was designed to adapt to the brittle nature of the fibers and the relatively low temperature cure of the polymer. Seven reinfiltration/pyrolysis cycles, with about 17 hours per cycle, were necessary to reach a convergence by weight. C-ring tests at both room and high temperature were performed to assess the quality of the manufactured parts. Scanning Electron Microscopy (SEM) was used to further examine the microstructure and quality of the parts. Effects of infrared cure-on-the-fly, fiber coating/material system, part thickness, and service temperature on the processing and mechanical performance of the manufactured CFCCs were studied.
Get full access to this article
View all access options for this article.
References
1.
1. Mah, T., M. G. Mendiratta, A. P. Katz, R. Ruh, and K. S. Mazdiyasni. 1985. “High TemperatureMechanical Behavior of Fiber-Reinforced Glass-Ceramic-Matrix Composites,”Journal of the American Ceramic Society,68/9:C248–C251.
2.
2. Mah, T., M. G. Mendriatta, A. P. Katz, and K. S. Mazdiyasni. 1987. “Recent Developments in Fiber-Reinforced High Temperature Ceramic Compounds,”American Ceramic Society Bulletin, 66/2:304–308.
3.
3. Lamicq, P. J., A. B. Gerald, M. D. Martine, and G. M. Jean. 1886. “SiC/SiC Composite Ceramics,”American Ceramic Society Bulletin,65/2:336–338.
4.
4. Prewo, K. M., J. J. Brennan, and G. K. Layden. 1989. “Fiber-Reinforced Glasses and Glass-Ceramics for High Performance Applications,”American Ceramic Society Bulletin, 65/2:305–322.
5.
5. Prewo, K. M.1989. “Fiber-Reinforced Ceramics: New Opportunities for Composite Materials,”American Ceramic Society Bulletin,68/2:395–400.
6.
6. Ko, K. F.1989. “Preform Fiber Architecture for Ceramic-Matrix Composites,”American Ceramic Society Bulletin,68/2:401–414.
7.
7. Strife, J. R., J. J. Brennan, and K. M. Prewo. 1990. “Status of Continuous Fiber-Reinforced Ceramic Matrix Composite Processing Technology,”Ceram. Eng. Sci. Proc.,11/7:871–919.
8.
8. Cornie, A. J., C. Yet-ming, R. U. Donald, M. Andreas, and M. C. Joseph. 1986. “Processing of Metal and Ceramic Matrix Composites,”American Ceramic Society Bulletin,65/2:293–304.
9.
9. Kochendorfer, R. 1991. “Liquid Silicon Infiltration—A Fast and Low Cost CMC-Manufacturing Process,”Proceedings of 8th International Conference on Composite Materials, ICCM/VIII,Composites—Design, Manufacture, and Application, Tsai, S. W. and Springer G. S., Eds., Honolulu, HI, Section 22-29:23.F.1–23.F.9.
10.
10. Riccitiello, S. and M. K. Marshall. 1994. “3-D Ceramic Matrix Composite Development,”Journal of Advanced Materials,25/2:22–28.
11.
11. Tai, N. H. 1990. “Modeling of Chemical Vapor Infiltration (CVI) in Ceramic Matrix Composites Processing,” Ph.D. Dissertation, Newark, DE: Department of Mechanical Engineering, University of Delaware.
12.
12. Kim, Y., J. Song, S. Park, and J. Lee. 1993. Nicalon Fiber-Reinforced Silicon-Carbide Composites via Polymer Solution Infiltration and Chemical Vapor Infiltration,”Journal of Materials Science, 28:3866–3868.
13.
13. Rice, W. R.1983. “Ceramics from Polymer Pyrolysis, Opportunities and Needs—A Materials Perspective,”American Ceramics Society Bulletin,62/8:889–892.
14.
14. Jamet, J., J. R. Spann, W. R. Rice, D. Lewis, andW. S. Coblenz. 1984. “Ceramic-Fiber Composite Processing via Polymer-Filler Matrices,”Ceramic Engineering and Science Proceedings, 5/7–8:677–694.
15.
15. Rogers, J., J. Semen, Y. Yu, and F. Daniel. 1989. “Silicon Carbide and Silicon Nitride Structural Ceramics Derived from a Preceramic Polymer Binder,”Ceramic Engineering and Science Proceedings,10/7–8:833–836.
16.
16. Semen, J. and J. G. Loop. 1990. “Structural Ceramics Derived from a Preceramic Polymer,”Ceramic Engineering and Science Proceedings,11/9–10:1387–1394.
17.
17. Semen, J. and J. G. Loop. 1991. “A Preceramic Polymer Route to Molded SiC Ceramic Parts,”Ceramic Engineering and Science Proceedings,12/9–10:1967–1980.
18.
18. Meyer, M. K., M. Akinc, S. Maghsoodi, X. Zhang, and T. J. Barton. 1991. “Silylene-Acetylene Polymers as Precursors to SiC Fibers,”Ceramic Engineering and Science Proceedings, 12/7–8:1019–1031.
19.
19. Hurwitz, F. I., P. J. Heimann, J. Z. Gyekenyesi, J. Masnovi, and X. Y. Bu. 1991. “Polymeric Routes to Silicon Carbide and Silicon Oxycarbide CMC,”Ceramic Engineering and Science Proceedings, 12/7–8:1292–1303.
20.
20. Toreki, W., D. C. Batich, D. M. D. M. Sacks, and A. A. Morrone. 1990. “Synthesis and Application of a Vinylsilazane Preceramic Polymer,”Ceramic Engineering and Science Proceedings, 11/9–10:1371–1386.
21.
21. Bo, S., F. Liu, X. Wu, C. Xiao, C. Liu, and X. Wang. 1991. “Carbon Fiber Reinforced Silicon Carbide Ceramic Composite via Polymer Pyrolysis,”Proceedings of 8th International Conference on Composite Materials, ICCM/VIII,Compsites—Design, Manufacture, and Application, Tsai, S. W. and Springer, G. S., Eds., Honolulu, HI, Section 22-29:23.B.1–23.F.5.
22.
22. Hurwitz, F. I., J. Z. Gyekenyesi, and J. P. Conroy. 1989. “Polymer Derived Nicalon/Si-C-O Composites: Processing and Mechanical Behavior,”Ceramic Engineering and Science Proceedings, 10/7–8:750–763.
23.
23. Rice, W. R.1990. “Ceramic Processing: An Overview,”American Chemical Engineering Journal, 36/4:481–510.
24.
24. Liu, H-K. and A. Parvizi-Majidi. 1992. “The Effect of Solid Particle Addition in Sol-Gel Processing of Ceramic Matrix Composites,”Ceramic Engineering and Science Proceedings, 13/9–10:642–649.
25.
25. Ching-Li, H. and A. Parvizi-Majidi. 1994. “Investigation of Sol-Gel Processing of Ceramic Matrix Materials,”Mechanics and Materials Processing and Manufacturing,194:353–360.
26.
26. Petrak, D. R.1991. “Polymer-Derived Ceramics,”Engineered Materials Handbook, Vol. 4, Ceramics and Glasses,Eds. S. R. Lampman, M. S. Woods, T. B. Zorc, ASM International, Metals Park, OH, pp. 223–226.
27.
27. Pinter, H.,W. East, W. Hartland, and D. H. Blaney. 1983. “Method of Manufacturing a Filament Wound Article,” US Patent 438 1960.
28.
28. Klemarczyk, P., V. Hanlon, J. Bremmer, S. Levandoski, and Y. Okamoto. 1993. “A UV Cure Filament Winding Process,”39th International SAMPE Symposium,477–485.
29.
29. Ghasemi Nejhad, M. N., M. V. Chandramouli, and A. A. Wereszczak. 1996. “Processing and Performance of SiC/Blackglas™ CFCCs Using FilamentWinding,”Ceramic Engineering and Science Proceedings,17/4:449–458.
30.
30. Kernas, R. J., R. S. Hay, N. J. Pagano, and T. A. Parthasarathy. 1989. “The Role of the Fiber-Matrix Interface in Ceramic Composites,”Am Ceram. Soc. Bull.,68/2:429–442.
31.
31. Evans, A. G. and D. B. Marshall. 1989. “The Mechanical Behavior of Ceramic Matrix Composite,”Acta Metall.,37/10:2567–2583.
32.
32. Kernas, R. J., F. Rebillat, and J. Lamon. 1997. “Fiber-Matrix Interface Properties of Single-Fiber Microcomposites as Measured by Fiber Pushing Tests,”Journal of the American Ceramic Society, 80/2:506–508.
33.
33. Courtney, T. H.1990. Mechanical Behavior of Materials,New York, New York: McGraw-Hill.
34.
34. Evans, A. G. and M. Y. He. 1989. “Interface Debonding and Fiber Cracking in Brittle Matrix Composites,”Journal of the American Ceramic Society,72/12:2300–2303.
35.
35. Charalambides, P. G. and A. G. Evans. 1989. “Debonding Properties of Residually Stressed Brittle-Matrix Composites,”Journal of the American Ceramic Society,72/5:746–753.
36.
36. Sun, E. Y., S. R. Nutt, and J. J. Brennan. 1997. “Fiber Coating for SiC-Fiber-Reinforced BMAS Glass-Ceramic Composites,”Journal of the American Ceramic Society,80/1:264–266.
37.
37. Jacobson, N. S., G. N. Morscher, D. R. Bryant, and R. C. Tressler. 1999. “High-Temperature Oxidation of Boron Nitride: II, Boron Nitride Layers in Composites,”Journal of the American Ceramic Society,82/6:1473–1482.
38.
38. Naslain, R., O. Dugne, A. Gutte, J. Sevely, C. R. Brosse, J. P. Rocher, and J. Cotteret. 1991. “Boron Nitride Interphase in Ceramic-Matrix Composites,”Journal of the American Ceramic Society, 74/10:2482–2488.
39.
39. Lu, M. C.1990. “Evaluation of Interfacial Properties in Ceramic Coating/Fiber Composites,”Ceramic Engineering and Science Proceedings,11/9–10:1761–1777.
40.
40. Sun, E. Y., S. R. Nutt, and J. J. Brennan. 1996. “High-Temperature Tensile Behavior of a Boron-Nitride-Coated Silicon Carbide-Fiber Glass-Ceramic Composite,”Journal of the American Ceramic Society,79/6:1521–1529.
41.
41. Leung, R.1991. “Blackglas Preceramic Polymer Processing,”AlliedSignal, Inc.
43. Leung, R. and D. P. Wallace. 1997. “Curing and Pyrolysis of Blackglas™ Resins and Composites,”Ceramic Engineering and Science Proceedings,17/4:386–393.
44.
44. Gill, W. N., A. Kulkarni, F. Wang, Y. W. Lee, J. Madsen, A. Tobin, and T. Donnellan. 1997. “ Development of Mechanistic Model for Blackglas™ Pyrolysis: Comparison of Theory and Experiment,”Ceramic Engineering and Science Proceedings,18/4:407–416.
45.
45. Annamalai, J., W. N. Gill, J. Madsen, and T. M. Donnellan. 1997. “Pyrolysis Behavior of Blackglas™ Composites,”Ceramic Engineering and Science Proceedings,17/4:401–410.
46.
46. Hirata, Y., T. Matsura, and K. Hayata. 2000. “Infiltration and Pyrolysis of Polytitanocarbosilane in an Si-Ti-C-O Fabric/Mullite Porous Composite,”Journal of the American Ceramic Society, 83/5:1044–1048.
47.
47. Dow Corning Corporation. 1997. “Information about Nicalon™ Ceramic Fiber.”
48.
48. 3M. 1997. “Properties of Nextel ®312 and 440 Ceramic Fibers, Technical Data.”
49.
49. White, S. R. and Z. Zhang. 1993. “The Effect of Mandrel Material on the Processing-Induced Residual Stresses in Thick FilamentWound Composite Cylinders,”Journal of the Reinforced Plastics and Composites,12:698–710.
50.
50. Leung, R. Y., M Glazier, and M. A. Meador. 1997. “Synthesis and Thermal Stability of Nitrogen-Containing Blackglas™ Ceramic,”Ceramic Engineering and Science Proceedings, 18/4:399–406.
51.
51. Evans, J. R. G. and R. Stevens. 1984. “The C-Ring Test for the Strength of Brittle Materials,”British Ceramic Transactions,83:14–18.
52.
52. Ferber, M. K., V. J. Tennery, S. B. Waters, and J. Ogle. 1986. “Fracture Strength Characterization of Tubular Ceramic Materials Using a Simple C-Ring Geometry,”Journal of Materials Science, 21:2628–2632.
53.
53. Jadaan, O. M., D. L. Shelleman, J. C. Conway, J. J. Mecholsky, and R. E. Tressler. 1991. “Prediction of the Strength of Ceramic Tubular Components: Part 1—Analysis,”Journal of Testing and Evaluation,19/3:181–191.
54.
54. Guynn, E. G., L. W. Bradley, and O. O. Ochoa. 1992. “A Parametric Study of Variables That Affect Fiber Microbuckling Initiation in Composite Laminates: Part 2—Experiments,”Journal of Composite Materials,26/11:1616–1643.
55.
55. Guynn, E. G., O. O Ochoa, and L. W. Bradley. 1992. “A Parametric Study of Variables That Affect Fiber Microbuckling Initiation in Composite Laminates: Part 1—Analysis,”Journal of Composite Materials,26/11:1594–1616.
56.
56. Hyer, M. W. and T. L. Brown. 1993. “The Influence of LayerWaviness on Failure of Hydrostatically Loaded Thick Composite Cylinders,”Mechanics of Thick Composites, ASME,162:183–196.
