Search Results (123)

Production of short-fiber-reinforced carbon/carbon composites (SF-C/C composites) is typically based on the pyrolysis of short-fiber-reinforced plastics (CFRPs) produced by compression molding. The production of C/C composites is generally a highly time- and energy-intensive process, particularly for complex geometries. Injection molding can offer an attractive alternative due to its high level of automation, cost efficiency, and ability to produce complex geometries. However, in contrast to compression molding, the shorter fiber lengths resulting from the compounding process and the parameter/geometry-dependent cavity-filling behavior in injection molding lead to a complex three-dimensional fiber orientation distribution. This can profoundly affect both the pyrolysis behavior of the CFRPs and the properties of the resulting SF-C/C composites. In this study, CFRP plates (150 × 150 × 4 mm³) were injection-molded at varying injection rates and mold temperatures. The influence of these parameters on the properties of the resulting SF-C/C composites was systematically investigated. Characterization included shrinkage and warpage behavior, porosity, microstructure via light microscopy and X-ray computed tomography, and flexural properties. The results show that the homogeneity of fiber orientation within the component is critical for controlling warpage during pyrolysis. In particular, asymmetric flow-line formation leads to non-uniform shrinkage across the thickness and promotes warpage. Therefore, achieving a homogeneous and/or symmetric distribution of the fiber orientation is essential for producing warpage-free SF-C/C composites by injection molding. Full article

Carbon-fiber-reinforced silicon carbide (C/SiC) ceramic matrix composites (CMCs) exhibit substantial application potential in the field of advanced industrial manufacturing, attributed to their inherent superiorities such as high specific strength, excellent high-temperature resistance, and prominent corrosion resistance. Nevertheless, hole-exit delamination is a critical defect in C/SiC composite drilling, which impairs the structural integrity and service reliability of components, restricting their engineering implementation. To address this issue, this study proposes and systematically investigates a compressive stress-assisted drilling method for delamination suppression via applying external compressive stress. Using the delamination factor for quantitative evaluation, comparative experiments were conducted under unassisted drilling, graphite-plate-assisted drilling without preload, and graphite-plate-assisted drilling with varying preload torques. The results indicate that compressive stress significantly mitigates delamination, with a maximum delamination factor reduction rate of 18.29%. Mechanistically, the compressive stress effectively controls delamination by suppressing Mode I crack propagation at the crack tip and elevating the critical strain energy release rate. Furthermore, this work elucidates that the essential role of the graphite plate is to provide a controllable in-plane pre-compressive stress field for the workpiece drilling zone. Full article

Continuous alumina (Al₂O₃) fibers are critical reinforcement materials for ceramic matrix composites (CMCs) utilized in extreme high-temperature environments. While their baseline thermal and mechanical properties are well-documented, their long-term service reliability in complex, multi-field environments—specifically coupled thermal, hygral, and atmospheric conditions—remains insufficiently quantified. This study systematically investigates the degradation mechanisms of alumina ceramic fiber ropes subjected to simulated engine exhaust atmospheres and cyclic rain exposure. By integrating macroscopic tensile testing with rigorous multi-scale microstructural characterizations (SEM, XRD, TGA, and advanced surface chemical state analyses via EDS and XPS), a comprehensive degradation model is proposed. Our findings reveal a pronounced two-stage mechanical degradation behavior: an initial catastrophic strength collapse followed by a stabilization phase. We elucidate that the initial embrittlement is governed not merely by thermal damage, but fundamentally by the hydrothermal volatilization and depletion of the surface amorphous SiO₂ binder, which annihilates the inter-fiber cooperative load-sharing capability. Concurrently, quantitative XPS and XRD analyses strongly suggest that the internal amorphous grain-boundary films undergo rapid structural rearrangement and crystallization, effectively homogenizing the microstructure and shifting the fracture mechanics from energy-dissipative crack deflection to unhindered brittle cleavage. After the preferential depletion of the amorphous silicate phase, the exposed α-Al₂O₃ core dictates a stabilized mechanical response. This research provides critical theoretical frameworks and experimental evidence for the life-cycle assessment and microstructural optimization of advanced oxide ceramic fibers in next-generation aerospace applications. Full article

Thermal/environmental barrier coating (T/EBC) protects ceramic matrix composites (CMC) from environmental corrosion and provides thermal insulation simultaneously. As a newly developed TBC material, GdPO₄ has attracted much attention due to its low thermal conductivity, but its relatively high thermal expansion coefficient (TEC) limits the application in the T/EBC system. In this study, Yb-doped GdPO₄ with properties desirable for the T/EBC system is proposed. The high-temperature stability and mechanical and thermophysical properties of Gd_1−xYb_xPO₄ (x = 0, 0.125, 0.25, 0.375, 0.5, 0.625, 0.75, 0.875 and 1) were studied, and the mechanism for doping modification was fully explained. Gd_0.75Yb_0.25PO₄ with Young’s modulus of 82 GPa and thermal conductivity of 1.01 W·m⁻¹·K⁻¹ is considered to have the most desirable properties. Compared with GdPO₄, the TEC of Gd_0.75Yb_0.25PO₄ (6.3 × 10⁻⁶ K⁻¹) is reduced by ~39%, and the fracture toughness is improved by ~30%. Therefore, Gd_0.75Yb_0.25PO₄ is considered to be suitable for usage as a T/EBC material. Full article

This research examines the hydrothermal corrosion behaviour of ceramic matrix composites (CMCs) under highly alkaline conditions (pH > 11.5) in the framework of a deep geological repository for high-level radioactive waste (HLW). The study focuses on the degradation of alumina powder and fibres, key constituents of an oxide/oxide CMC material. Accelerated ageing experiments were conducted in a highly alkaline aqueous environment (pH > 11.5, T = 70 °C for 220 days and T = 150 °C for 30 days). The research used a cross-disciplinary approach integrating thermodynamic calculations and physicochemical analyses to determine the degradation mechanisms of alumina powder and fibres induced by contact with the aqueous ageing solution. Characterisation of the aged alumina powders and fibres revealed the presence of unaltered alumina, hydrated alumina, amorphous phases, and calcium carbonate precipitates from the aqueous solution. Thermodynamic calculations indicate (1) the hydrolysis of alumina to diaspore and (2) the formation of an aluminosilicate phase and calcium carbonate. However, experimental results reveal kinetic limitations, such as the preferential formation of boehmite over diaspore, and morphology-dependent degradation pathways (protective-layer formation on fibres and partial dissolution of powders). Full article

Ceramic Matrix Composite (CMC) are widely used in aerospace due to the advantages such as high-temperature resistance and lightweight properties. Detecting defects within these materials is crucial for ensuring the safety of corresponding structures. In this paper, a finite element model of CMC model for layered structures is established for the ultrasonic non-destructive testing. Based on the computed tomography (CT) scan images and porosity of the material, a randomly distributed pore model is constructed to investigate the effect of pores on the ultrasonic signals. Random pores are also introduced in the simulation to ensure that the model corresponds as closely as possible to reality. Moreover, the feasibility of utilizing air-coupled ultrasonic excitation to generate specific frequency Lamb waves is verified. The effect of pore presence on the signal propagation is analyzed, and the effects of layered structures at different positions and lengths on the signal propagation are investigated. The results demonstrate that the Lamb waves with a specified frequency can be excited using the method described in this paper, and the presence of pores and delamination defects can affect the propagation of the Lamb wave in CMC, in which the signal attenuation can reach up to 7.6 dB. Full article

With the continuous advancement of thrust-to-weight ratios in modern aero-engines, turbine inlet temperatures have reached levels that far exceed the thermal endurance limits of conventional superalloys and emerging ceramic matrix composites (CMCs). Consequently, thermal barrier coatings (TBCs) and environmental barrier coatings (EBCs) have become indispensable multifunctional systems for hot-section component protection. This review systematically delineates the evolutionary trajectory of TBC/EBC systems, transitioning from traditional yttria-stabilized zirconia (YSZ) and simple silicates to advanced multi-rare-earth-doped oxides, A₂B₂O₇ pyrochlore structures, and high-entropy ceramic systems. A critical comparative assessment is provided regarding their phase stability, thermal-physical properties, and durability challenges above 1200 °C. Furthermore, this paper provides an in-depth analysis of high-temperature degradation mechanisms, focusing on the thermochemical and thermomechanical interactions under calcium-magnesium-alumino-silicate (CMAS) attack, water-oxygen corrosion, and molten salt infiltration. By synthesizing current research gaps, we highlight the trade-offs between low thermal conductivity, high toughness, and environmental resistance. Finally, a strategic roadmap for next-generation coatings is proposed, emphasizing the integration of high-entropy material design, multi-scale structural optimization, and AI-driven life prediction models to meet the stringent reliability requirements of future propulsion systems. Full article

This paper presents a collaborative optimization design methodology aimed at improving heat dissipation efficiency through the modulation of microstructural variations. The approach addresses the thermal protection requirements of high-temperature components, such as ceramic matrix composite turbine blades, which are subjected to complex and elevated thermal loads. Through the integration of numerical simulation and experimental validation, a bidirectional mapping model linking carbon nanotube (CNT) content with the macroscopic anisotropic thermal conductivity of the material was developed. Furthermore, a thermal conduction analysis and optimization framework for Ceramic Matrix Composite (CMC) high-temperature components under non-uniform thermal loads was established. This study expands the adjustable range of the material’s thermal conductivity by allowing flexible modulation of carbon nanotube content. The results demonstrate that this methodology effectively enhances the heat dissipation capacity of CMC materials in extreme thermal environments: the maximum surface temperature of the optimized flat plate is reduced by 8.96%, the peak temperature gradient is lowered by 46.64%, and the maximum thermal stress is decreased by 38.17%. This research provides new insights into the comprehensive integration of thermal dissipation requirements for CMC hot components. Full article

During high-speed flight, intense friction on the aircraft surface always occurs due to atmospheric fluid medium. The resultant high frictional drag will trigger a significant aerothermal effect, and thus raise the surface temperature sharply to 1000–3000 °C. This extreme heat not only remarkably reduces the aerodynamic efficiency but probably also causes thermal failure of the structural integrity and damage of internal components. Therefore, robust heat-resistant materials are the preferred choice for designing high-speed aircraft due to their benign tolerance to high temperature, oxidation and ablation as well as large strength and durability. This work systematically unveils the generation mechanism of frictional drag in high-speed flight and introduces the characteristics and applications of typical thermal insulation materials (TIMs). After that, the recent progress in a thermally protected material system including metal-based alloys and metal-doped compound materials, ultra-high-temperature ceramics (UHTCs), carbon (C)/carbon (C) and C/SiC composites, ceramic matrix composites (CMCs), UHTCs-modified C/C and C/SiC composites is conducted. Finally, the current technical bottlenecks are discussed, simultaneously proposing the development direction of novel TIMs for the potential applications for high-speed aircrafts. Full article

Re-entry flights of reusable first or upper stages typically foresee phases in the hypersonic flight regime, characterized by severe aero-thermal loads which could become critical for the most exposed components, like the vehicle forebody or the fin leading edges. These require consequently dedicated thermal protection systems (TPS), whose design generally requires a multi-disciplinary approach. In this framework, a viable solution is the use of high-temperature resistant ceramic matrix composite (CMC) structures, but the implementation of such technology, especially for the manufacturing of complex components and its application in real flight conditions, still presents significant challenges. In this work, the design activities for the CMC-based TPS of the payload forebody of a hypersonic sounding rocket are presented, developed within the framework of the STORT project, whose mission includes in flight demonstration of multiple critical technologies required for sustained flight at Mach numbers above 8, corresponding to a significantly high integral thermal load. Full article

The design and fabrication of metal matrix materials (MMCs), as well as the densification and joining of ceramic matrix composites (CMC), are still very challenging. For SiC- and C-based composites, liquid-assisted processing routes, such as the spontaneous infiltration process, emerge among the most cost-effective processes. To succeed in Ir-Si/SiC refractory composite fabrication by spontaneous infiltration, the wetting characteristics of the Ir-Si/SiC system, the surface and transport properties (surface tension and viscosity) of liquid Ir-Si alloys, and microstructural evolution at the interfaces formed between solid SiC (or C) with Ir-Si melt, have been carefully examined. Specifically, the wettability and interaction phenomena occurring at the Si-Ir eutectics/SiC interface as a function of temperature were investigated in the temperature range of T = 1350–1400 °C by the sessile drop method under an inert atmosphere with reduced oxygen content, and the results are presented and discussed in this paper. Taking into account the thermodynamics of the Si-C-Ir system, the interfacial phenomena and subsequent microstructural evolution are well-related to the process parameters, and the properties and characteristics of the as-produced interfaces may be predicted accordingly. The experimental conditions and results of wetting experiments, together with thermodynamic-based models predicting thermophysical property values of liquid Ir-Si alloys, are valuable key input data that are now available for the numerical study of infiltration processes. Full article

Ceramic Matrix Composites (CMC) are widely used in critical applications such as leading edges of aircraft wings and thermal insulation layers of thermal protection systems due to their advantages of being lightweight, high-temperature resistant, and impact-resistant. However, influenced by manufacturing processes and service environments, internal defects such as pores and delamination are prone to occur, significantly compromising the mechanical properties and service reliability of the material. This paper primarily evaluates the feasibility and applicability of using Terahertz Frequency Modulated Continuous Wave (FMCW) technology for the non-contact detection of CMC. First, the measurement principle of FMCW is introduced, and the structure of the detection system, including a two-dimensional mechanical scanning platform, optical lenses, a control platform, and a data acquisition unit, is outlined. Subsequently, scanning imaging was performed on CMC specimens and their bonded thermal protection structure (TPS) specimens, demonstrating the feasibility of Terahertz FMCW technology as an advanced non-destructive testing tool for CMC inspection. The issues of diffraction and the Rayleigh limit inherent in real-aperture terahertz imaging were analyzed and discussed. A multi-scale fusion defect detection method incorporating background estimation is proposed to enable precise delineation of defect regions. Experimental results show that, after processing with the proposed algorithm, the minimum detectable pore diameter at the focal plane is 1 mm, with a regional error of approximately 3%. The detection error for pores and debonding areas in CMC is maintained within 6.44%. Analysis indicates that combining terahertz imaging technology with image processing algorithms enables the quantitative analysis of internal defects in composite materials, offering a new technical approach for defect detection in composite materials. Full article

Ceramic Matrix Composites (CMCs) have emerged as a structural material alternative to nickel superalloys for high-pressure turbines (HPT) components operating at high temperature, like shrouds. Despite the outstanding thermal stability of the CMCs, limited cooling is still necessary due to the extreme thermal operating conditions necessary to maximize engine performance and minimize fuel consumption. The design of CMC components, indeed, must consider a maximum service temperature that should not be exceeded to avoid damage and accelerated oxidation. The cooling, on the other hand, may induce the formation of thermal gradients and thermal stresses. In this work, different design options for the cooling system are investigated to minimize the thermal stresses of an HPT shroud-like geometry subjected to maximum temperature constraints on the material. Cooling is obtained via colder air jet streams (air taken from the compressor), whose impact position (the surface where the cold air impacts the component) has a different effect on the temperature field and on the induced stress field. Besides stress evaluation with different cooling systems, an ONERA damage model is investigated at a key location to potentially take into account stress components acting simultaneously and potential stiffness degradation of the CMC. Finally, the design evaluation of potential discrete crack propagation is discussed. A standard cohesive elements approach has been compared with a brittle element death approach. The results showed that the cohesive element approach resulted in shorter crack propagation, underestimating the actual crack behavior due to the embedded stiffness degradation method, while the element death returned encouraging results as a quicker, less complex, but still accurate design evaluation. Full article

In aerospace, defense, and energy systems, ceramic matrix composites (CMCs) are smart structural materials designed to function continuously in harsh mechanical, thermal, and oxidative conditions. Using high-strength fiber reinforcements and tailored interphases that enable damage-tolerant behavior, their creation tackles the intrinsic brittleness and low fracture toughness of monolithic ceramics. With a focus on chemical vapor infiltration, polymer infiltration and pyrolysis, melt infiltration, and additive manufacturing, this paper critically analyzes current developments in microstructural design, processing technologies, and interfacial engineering. Toughening mechanisms are examined in connection to multiscale mechanical responses, including controlled debonding, fiber bridging, fracture deflection, and energy dissipation pathways. Cutting-edge environmental barrier coatings are assessed alongside environmental durability issues like oxidation, volatilization, and hot corrosion. High-performance braking, nuclear systems, hypersonic vehicles, and turbine propulsion are evaluated as emerging uses. Future directions emphasize self-healing systems, ultra-high-temperature design, and environmentally friendly production methods. Full article

Ceramic matrix composites (CMCs) exhibit excellent high-temperature strength, oxidation resistance, and fracture toughness, making them superior to traditional metals and single-phase ceramics in extreme environments such as aerospace, nuclear energy equipment, and high-temperature protection systems. The mechanical properties of CMCs directly influence the reliability and service life of structures; thus, accurately predicting their mechanical response and service behavior has become a core issue in current research. However, the multi-phase heterogeneity of CMCs leads to highly complex stress distribution and deformation behavior in traditional mechanical property testing, resulting in significant uncertainty in the measurement of key mechanical parameters such as strength and modulus. Additionally, the high manufacturing cost and limited experimental data further constrain material design and performance evaluation based on experimental data. Therefore, the development of effective numerical simulation and mechanical modeling methods is crucial. This paper provides an overview of the research hotspots and future directions in the field of CMCs numerical simulation and mechanical modeling through bibliometric analysis using the CiteSpace software. The analysis reveals that China, the United States, and France are the leading research contributors in this field, with 422, 157, and 71 publications and 6170, 3796, and 2268 citations, respectively. At the institutional level, Nanjing University of Aeronautics and Astronautics (166 publications; 1700 citations), Northwestern Polytechnical University (72; 1282), and the Centre National de la Recherche Scientifique (CNRS) (49; 1657) lead in publication volume and/or citation influence. Current research hotspots focus on finite element modeling, continuum damage mechanics, multiscale modeling, and simulations of high-temperature service behavior. In recent years, emerging research frontiers such as interface debonding mechanism modeling, acoustic emission monitoring and damage correlation, multiphysics coupling simulations, and machine learning-driven predictive modeling reflect the shift in CMCs research, from traditional experimental mechanics and analytical methods to intelligent and predictive modeling. Full article