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Investigation of Failure Mechanisms in Ceramic Composites As Potential Railway Brake Disc Materials

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Investigation of Failure Mechanisms in Ceramic Composites As Potential Railway Brake Disc Materials materials Article Investigation of Failure Mechanisms in Ceramic Composites as Potential Railway Brake Disc Materials Jeongguk Kim Advanced Railroad Vehicle Division, Korea Railroad Research Institute, Uiwang 16105, Korea; [email protected]; Tel.: +82-31-460-5518 Received: 21 October 2020; Accepted: 13 November 2020; Published: 15 November 2020 Abstract: Ceramic composite materials have been efficiently used for high-temperature structural applications with improved toughness by complementing the shortcomings of monolithic ceramics. In this study, the fracture characteristics and fracture mechanisms of ceramic composite materials were studied. The ceramic composite material used in this study is Nicalon ceramic fiber reinforced ceramic matrix composites. The tensile failure behavior of two types of ceramic composites with different microstructures, namely, plain-weave and cross-ply composites, was studied. Tensile tests were performed on two types of ceramic composite material specimens. Microstructure analysis using SEM was performed to find out the relationship between tensile fracture characteristics and microstructure. It was found that there was a difference in the fracture mechanism according to the characteristics of each microstructure. In this study, the results of tensile tests, failure modes, failure characteristics, and failure mechanisms were analyzed in detail for two fabric structures, namely, plain-weave and cross-ply structures, which are representative of ceramic matrix composites. In order to help understanding of the fracture process and mechanism, the fracture initiation, crack propagation, and fracture mechanism of each composite material are schematically expressed in a two-dimensional figure. Through these results, it is intended to provide useful information for the design of ceramic composite materials based on the mechanistic understanding of the fracture process of ceramic composite materials. Keywords: ceramic composites; mechanical properties; tensile tests; microstructural analysis; failure mode; failure mechanism 1. Introduction Ceramic composites are structural materials used at high temperatures that have been proven over the past few decades [1–4]. For this reason, it has been spotlighted as an excellent material in spacecraft insulation materials, high-temperature gas turbine rotors, and thermal management systems, and, recently, it is expanding its use as a material for brake discs for automobiles and railways [1–6]. Stadler et al. studied ceramic composite materials as friction materials [7]. In recent years, it has also been used as a braking friction material in the railroad field, increasing its utilization [6–9]. Stadler et al. proposed carbon fiber reinforced SiC composites as a railway friction material, and reported that the properties of this material show excellent corrosion and oxidation resistance, and have excellent friction and wear characteristics. It was also recommended that ceramic composites are the material that can be protected from the high temperatures occurring on the disc surface during braking [7]. In general, monolithic ceramics exhibit excellent high-temperature properties, corrosion resistance, abrasion resistance, etc., but their use is limited due to the essential characteristics of brittleness. Therefore, the development of a technology that imparts toughness to such monolithic ceramics has become important, and one solution to this is ceramic composite materials reinforced with ceramic fibers [1–5,10,11]. Materials 2020, 13, 5141; doi:10.3390/ma13225141 www.mdpi.com/journal/materials Materials 2020, 13, x FOR PEER REVIEW 2 of 11 Materials 2020, 13, 5141 2 of 11 such monolithic ceramics has become important, and one solution to this is ceramic composite materials reinforced with ceramic fibers [1–5,10,11]. FigureFigure 11 schematicallyschematically illustratesillustrates aa comparisoncomparison ofof thethe fracturefracture behaviorbehavior betweenbetween monolithicmonolithic ceramicsceramics and and ceramic ceramic composites. composites. As As shown shown in in Figu Figurere 1,1, monolithic ceramics show a typical brittle fracturefracture behavior behavior that that leads leads to to failure failure immediat immediatelyely after after undergoing undergoing elastic elastic deformation deformation without without a a plasticplastic deformationdeformation region.region. On On the th othere other hand, hand, in the in case the of case the ceramicof the ceramic composite composite material reinforcedmaterial reinforcedwith continuous with continuous fibers, it initially fibers, showsit initially the elasticshows behaviorthe elastic of behavior monolithic of monolithic ceramics, and ceramics, then shows and thenthe first shows matrix the crackingfirst matrix as the cracking load applied as the toload the a specimenpplied to increases.the specimen However, increases. as the However, stress increases, as the stressthe continuous increases, increasethe continuous in load increase continues in load due tocontinues complex due interactions to complex such interactions as further such matrix as further failure matrixdue to failure fibers presentdue to fibers inside presen the matrixt inside and the crack matrix deflection and crack at the deflection interface atbetween the interface the fibers between and the the fibersmatrix and (Figure the 1matrix)[ 3,4, 10(Figure–12]. After 1) [3,4,10–12]. the ultimate After tensile the stressultimate (UTS) tensil is reached,e stress the(UTS) composite is reached, shows the a compositestress-strain shows behavior a stress-strain like the shape behavior of plastic like the deformation shape of plastic exhibited deformation by a metallic exhibited material by a due metallic to the materialsequential due pullout to the of sequential the fibers untilpullout the of final the failure. fibers Dueuntil to the this final fracture failure. mechanism, Due to this it is fracture possible mechanism,to improve theit is fracturepossible toughnessto improve of the monolithic fracture toughness ceramics. of In monolithic other words, ceramics. the fracture In other toughness words, theincreases fracture by toughness the larger increases area in the by stress-strainthe larger area curve. in the In stress-strain addition, Figure curve.1 shows In addition, that interfacial Figure 1 showsbonding that between interfacial fiber bonding and matrix between material fiber is and also matrix an important materialfactor. is also Ifan there important is a strong factor. interfacial If there isbonding a strong between interfacial the fiberbonding and thebetween matrix, the the fiber fiber and reinforcement the matrix, etheffect fiber will notreinforcement be seen, and effect if there will is notproper be seen, interfacial and bondingif there betweenis proper the interfacia fiber andl bonding matrix, a between ceramiccomposite the fiber materialand matrix, with a reinforced ceramic compositetoughness material as shown with in Figure reinforced1 can toughness be expected. as shown in Figure 1 can be expected. Figure 1. A schematic comparison of fracture behavior between monolithic ceramics and ceramic Figure 1. A schematic comparison of fracture behavior between monolithic ceramics and ceramic composites [3]. composites [3]. Figure2 schematically shows the typical failure patterns found in ceramic composites [ 3,4,10]. As theFigure load 2 increasesschematically after shows the initial the typical matrix failure cracking, patterns phenomena found in such ceramic as interfacial composites debonding [3,4,10]. Asand the sliding, load increases crack deflection, after the and initial crack matrix bridging cracking, between phenomena the fiber andsuch the as matrixinterfacial material debonding go through. and sliding,After that, crack the deflection, fiber is finally and broken,crack bridging and the between final failure the mechanismfiber and the is completedmatrix material through go extensivethrough. Afterfiber pullout.that, the fiber The fractureis finally toughness broken, and of thethe ceramicfinal failure composite mechanism material is completed is improved through by delaying extensive the fiberfinal pullout. fracture throughThe fracture those toughness energy absorption of the ceramic mechanisms composite [10]. material Marshal is et improved al. investigated by delaying the failure the finalmechanisms fracture inthrough ceramic those matrix energy composites absorption [10]. mechanisms [10]. Marshal et al. investigated the failureFigure mechanisms3 shows in an ceramic example matrix of the schematiccomposites representation [10]. shown in Figure2. It is obtained from the fractureFigure 3 surface shows ofan theexample actual of ceramic the schematic composite repres material,entation and shown it shows in Figure in detail 2. theIt isprocess obtained of fromabsorbing the fracture fracture surface energy of suchthe actual as matrix ceramic cracking composite and propagation material, and of it crack, shows interfacial in detail the sliding process and debonding between fiber and matrix, fiber bridging, and fiber pullout [10,13,14]. Materials 2020, 13, x FOR PEER REVIEW 3 of 11 Materials 2020, 13, x FOR PEER REVIEW 3 of 11 of absorbing fracture energy such as matrix cracking and propagation of crack, interfacial sliding and of absorbing fracture energy such as matrix cracking and propagation of crack, interfacial sliding and Materialsdebonding2020 ,between13, 5141 fiber and matrix, fiber bridging, and fiber pullout [10,13,14]. 3 of 11 debonding between fiber and matrix, fiber bridging,
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