Reduction of Functionally Graded Material Layers for Si 3 N 4 -Al 2 O 3 System Using Three-Dimensional Finite Element Modeling

Numerical analysis method was used to reduce the number of functionally graded material (FGM) layers for joining Si 3 N 4 -Al 2 O 3 using polytypoid interlayer by estimating the position of crack. In the past, hot press sintering of multi-layered FGMs with 20 layers of thickness 500 mm each have been fabricated successfully. In this paper, thermal residual stresses were calculated using finite element method (FEM) to find the optimized number of layers and its thicknesses of FGM joint. The number of layers for FGM was reduced to 15 layers from 20 layers. Thicknesses were varied to minimize residual stresses within the layers while reducing the number of FGM layers. The damage caused by thermal residual stress was estimated using maximum principal stress theory and maximum tensile stress theory. The calculated maximum stress was found to be axial stress of 430 MPa around 90% 12H/10% Al 2 O 3 area. For each case, calculated strength of each FGM layer by linear rule of mixture was compared with computed thermal residual stresses. Thermal analysis results correctly predicted the position of crack, and this position agreed well with fabricated joints. Therefore, this numerical analysis method can be applied to reduced FGM layers of crack free joint. Finally, new composition profile of crack free joint was proposed using FGM method

Novel joining of dissimilar ceramics in the Si3N4-Al2O3 system using polytypoid functional gradients

A unique approach to crack-free joining of heterogeneous ceramics is demonstrated by the use of sialon polytypoids as Functionally Graded Materials (FGM) as defined by the phase diagram in the system, Si3N4-Al2O3. Polytypoids in the Al2O3-Si3N4 system offer a path to compatibility for such heterogeneous ceramics. The first part of the dissertation describes successful hot press sintering of multilayered FGM's with 20 layers of thickness 500 mm each. Transmission Electron Microscopy was used to identify the polytypoids at the interfaces of different areas of the joint. It has been found that the 15R polytypoid was formed in the Al2O3-contained layers and the 12H polytypoid was formed in the Si3N4-contained layers. The second part of the dissertation discusses the mechanical properties of these polytypoidally joined Si3N4-Al2O3. The thermal stresses of this FGM junction were analyzed using a finite element analysis program (FEAP) taking into account both coefficient of thermal expansion (CTE) and modulus variations. From this analysis, the result showed a dramatic decrease in radial, axial and hoop stresses as the FGM changes from three layers to 20 graded layers. Scaling was considered, showing that the graded transition layer should constitute about 75 percent or more of the total sample thickness to reach a minimal residual stress. Oriented Vickers indentation testing was used to qualitatively characterize the strengths of the joint and the various interfaces. The indentation cracks were minimally or not deflected at the sialon layers, implying strong interfaces. Finally, flexural testing was conducted at room temperature and at high temperature. The average strength at room temperature was found to be 581 MPa and the average strength at high temperature (1200 degrees C) was found to be 262 MPa. Scanning electron microscope observation of fracture surfaces at a different loading rates indicated that the strength loss at higher temperatures was consistent with a softening of glassy materials present at grain junctions

Novel joining of dissimilar ceramics in the Si3N4-Al2O3 system using polytypoid functional gradients

A unique approach to crack-free joining of heterogeneous ceramics is demonstrated by the use of sialon polytypoids as Functionally Graded Materials (FGM) as defined by the phase diagram in the system, Si3N4-Al2O3. Polytypoids in the Al2O3-Si3N4 system offer a path to compatibility for such heterogeneous ceramics. The first part of the dissertation describes successful hot press sintering of multilayered FGM's with 20 layers of thickness 500 mm each. Transmission Electron Microscopy was used to identify the polytypoids at the interfaces of different areas of the joint. It has been found that the 15R polytypoid was formed in the Al2O3-contained layers and the 12H polytypoid was formed in the Si3N4-contained layers. The second part of the dissertation discusses the mechanical properties of these polytypoidally joined Si3N4-Al2O3. The thermal stresses of this FGM junction were analyzed using a finite element analysis program (FEAP) taking into account both coefficient of thermal expansion (CTE) and modulus variations. From this analysis, the result showed a dramatic decrease in radial, axial and hoop stresses as the FGM changes from three layers to 20 graded layers. Scaling was considered, showing that the graded transition layer should constitute about 75 percent or more of the total sample thickness to reach a minimal residual stress. Oriented Vickers indentation testing was used to qualitatively characterize the strengths of the joint and the various interfaces. The indentation cracks were minimally or not deflected at the sialon layers, implying strong interfaces. Finally, flexural testing was conducted at room temperature and at high temperature. The average strength at room temperature was found to be 581 MPa and the average strength at high temperature (1200 degrees C) was found to be 262 MPa. Scanning electron microscope observation of fracture surfaces at a different loading rates indicated that the strength loss at higher temperatures was consistent with a softening of glassy materials present at grain junctions

Novel joining of dissimilar ceramics in the Si{sub 3}N{sub 4}-Al{sub 2}O{sub 3} system using polytypoid functional gradients

A unique approach to crack-free joining of heterogeneous ceramics is demonstrated by the use of sialon polytypoids as Functionally Graded Materials (FGM) as defined by the phase diagram in the system, Si3N4-Al2O3. Polytypoids in the Al2O3-Si3N4 system offer a path to compatibility for such heterogeneous ceramics. The first part of the dissertation describes successful hot press sintering of multilayered FGM's with 20 layers of thickness 500 mm each. Transmission Electron Microscopy was used to identify the polytypoids at the interfaces of different areas of the joint. It has been found that the 15R polytypoid was formed in the Al2O3-contained layers and the 12H polytypoid was formed in the Si3N4-contained layers. The second part of the dissertation discusses the mechanical properties of these polytypoidally joined Si3N4-Al2O3. The thermal stresses of this FGM junction were analyzed using a finite element analysis program (FEAP) taking into account both coefficient of thermal expansion (CTE) and modulus variations. From this analysis, the result showed a dramatic decrease in radial, axial and hoop stresses as the FGM changes from three layers to 20 graded layers. Scaling was considered, showing that the graded transition layer should constitute about 75 percent or more of the total sample thickness to reach a minimal residual stress. Oriented Vickers indentation testing was used to qualitatively characterize the strengths of the joint and the various interfaces. The indentation cracks were minimally or not deflected at the sialon layers, implying strong interfaces. Finally, flexural testing was conducted at room temperature and at high temperature. The average strength at room temperature was found to be 581 MPa and the average strength at high temperature (1200 degrees C) was found to be 262 MPa. Scanning electron microscope observation of fracture surfaces at a different loading rates indicated that the strength loss at higher temperatures was consistent with a softening of glassy materials present at grain junctions

Surface layer formation on Pb/Sn alloys

Thesis (M.S.)--Massachusetts Institute of Technology, Dept. of Materials Science and Engineering, 1995.Includes bibliographical references (leaves 78-80).by Caroine S. Lee.M.S

Evaluation of Efficient and Noble-Metal-Free NiTiO3 Nanofibers Sensitized with Porous gC3N4 Sheets for Photocatalytic Applications

One-dimensional nickel titanate nanofibers (NiTiO3 NFs) were synthesized and loaded with acetic acid-treated exfoliated and sintered sheets of graphitic carbon nitride (AAs-gC3N4) to fabricate a unique heterogeneous structure. This novel fabrication method for porous AAs-gC3N4 sheets using acetic acid-treated exfoliation followed by sintering provided gC3N4 with a surface area manifold larger than that of bulk gC3N4, with an abundance of catalytically active sites. Hybrid photocatalysts were synthesized through a two-step process. Firstly, NiTiO3 NFs (360 nm in diameter) were made by electrospinning, and these NiTiO3 NFs were sensitized with exfoliated gC3N4 sheets via a sonication process. Varying the weight ratio of NiTiO3 fibers to porous AAs-gC3N4 established that NiTiO3 NFs containing 40 wt% of porous AAs-gC3N4 exhibited optimal activity, i.e., removal of methylene blue and H2 evolution. After 60 min exposure to visible light irradiation, 97% of the methylene blue molecules were removed by the hybrid photocatalyst, compared with 82%, 72%, and 76% by pristine AAs-gC3N4, NiTiO3 NFs, and bulk gC3N4, respectively. The optimal structure also displayed excellent H2 evolution performance. The H2 evolution rate in the optimal sample (152 μmol g−1) was 2.2, 3.2 and 3-fold higher than that in pure AAs-gC3N4 (69 μmol g−1), NiTiO3 NFs (47 μmol g−1) and bulk gC3N4 (50 μmol g−1), respectively. This clearly shows that the holey AAs-gC3N4 nanosheets interacted synergistically with the NiTiO3 NFs. This extended the lifetime of photogenerated charge carriers and resulted in superior photocatalytic activity compared with pristine NiTiO3 NFs and bulk gC3N4. The higher Brunauer-Emmett-Teller surface area and the presence of many catalytically active sites also enhanced the photocatalytic performance of the hybrid sample. Moreover, through photoluminescence and photocurrent response analysis, a significant decrease in the recombination losses of the hybrid photocatalysts was also confirmed. Thus, this is a novel strategy to fabricate highly efficient photocatalysts with precisely tunable operating windows and enhanced charge separation