Oxide ceramic matrix composite materials for aero-engine applications: a literature review

The development of aircraft gas turbine engines has extensively been required for the development of advanced materials. This complex development process is however justified by the system-level benefits in terms of reduced weight, higher temperature capability, and/or reduced cooling, each of which increases efficiency. This is where high-temperature ceramics have made considerable progress and ceramic matrix composites (CMCs) are in the foreground. CMCs are classified into non-oxide and oxide-based ones. Both families have material types that have a high potential for use in high-temperature propulsion applications. Typical oxide-based ones are based on an oxide fiber and oxide matrix (Ox-Ox). Some of the most common oxide subcategories, are alumina, beryllia, ceria, and zirconia ceramics. Such matrix composites are used for example in combustion liners of gas turbine engines and exhaust nozzles. However, until now a thorough study on the available oxide-based CMCs for such applications has not been presented. This paper focus on assessing a literature survey of the available oxide ceramic matrix composite materials in terms of mechanical and thermal properties

Core - shell particle reinforcements - a new trend in the design and development of metal matrix composites

Metal matrix composites (MMCs) are a constantly developing class of materials. Simultaneously achieving a high strength and a high ductility is a challenging task in the design of MMCs. This article aims to highlight a recent trend: the development of MMCs reinforced with particles of core–shell structure. The core–shell particles can be synthesized in situ upon a partial transformation of metal (alloy) particles introduced into a metal matrix. MMCs containing core–shell particles with cores of different compositions (metallic, intermetallic, glassy alloy, high-entropy alloy, metal-ceramic) are currently studied. For metal core–intermetallic shell particle-reinforced composites, the property gain by the core–shell approach is strengthening achieved without a loss in ductility. The propagation of cracks formed in the brittle intermetallic shell is hindered by both the metal matrix and the metal core, which constitutes a key advantage of the metal core–intermetallic shell particles over monolithic particles of intermetallic compounds for reinforcing purposes. The challenges of making a direct comparison between the core–shell particle-reinforced MMCs and MMCs of other microstructures and future research directions are discussed

Design optimisation of the feeding system of a novel counter-gravity casting process

The appropriate design of feeders in a rigging system is critical for ensuring efficient compensation for solidification shrinkage, thus eliminating (shrinkage-related) porosity and contributing to the production of superior quality castings. In this study, a multi-objective optimisation framework combined with Computational Fluid Dynamics (CFD) simulations has been introduced to investigate the effect of the feeders’ geometry on shrinkage porosity aiming to optimise casting quality and yield for a novel counter-gravity casting process (CRIMSON). The weighted sum technique was employed to convert this multi-objective optimisation problem to a single objective one. Moreover, an evolutionary multi-objective optimisation algorithm (NSGA-II) has been applied to estimate the trade-off between the objective functions and support decision makers on selecting the optimum solution based on the desired properties of the final casting product and the process characteristics. This study is one of the first attempts to combine CFD simulations with multi-objective optimisation techniques in counter-gravity casting. The obtained results indicate the benefits of applying multi-objective optimisation techniques to casting processe

In-situ structural identification of Zr3Al2 type metastable phase during crystallization of a Zr-based MG

A metastable phase was detected using higher energy synchrotron radiation when Zr-based metallic glass (MG) was annealed under vacuum in Linkam hot stage at 848 K. The formation and transformation processes of metastable phase were recorded by synchrotron radiation method. The metastable phase during crystallization was identified as Zr3Al2 structure type according to powder diffraction and TEM analysis. The structure of Zr3Al2 type MCP was experimentally evidenced by 3D diffraction patterns and mathematically described. The identification of Zr3Al2 MCP could be helpful for the understanding of cluster structure of MG

Reciprocating sliding wear behavior of high-strength nanocrystalline Al84Ni7Gd6Co3 alloys

Nanocrystalline Al-Ni-Gd-Co alloys with exceptionally high hardness have been recently developed from amorphous precursors. In the present work, the reciprocating sliding wear in the gross slip regime of these novel nanocrystalline Al-based alloys has been investigated under small amplitude oscillatory sliding motion using a martensitic chrome steel as the counter material. When compared to pure Al or Al-12Si alloy, these nanocrystalline alloys exhibit excellent wear resistance and a lower coefficient of friction when sliding against steel. The enhanced wear resistance of the novel nanocrystaline Al alloys is related to their ultra-high hardness and the hybrid nanostructure that mainly consists of nanometric intermetallic phases embedded in a nanocrystalline fcc-Al matrix. Three body abrasive conditions were created at the initial stages of the wear tests due to the formation of micro- and nano-particulate debris from the worn surface of the Al alloys; the debris was compacted under the subsequent sliding cycles forming layers that are protective to the extensive wear of the Al alloys

In-situ TEM study of the crystallization sequence in a gold-based metallic glass

The composition Au49Ag5.5Pd2.3Cu26.9Si16.3 (at.%) is of interest as the basis for the development of gold-based bulk metallic glasses for application in jewellery. In-situ heating in transmission electron microscopy (TEM) and differential scanning calorimetry (DSC, both conventional and fast) are used to obtain a comprehensive characterization of the decomposition on heating a melt-spun glass of this composition. Linking TEM with DSC over a range of heating rates 0.083‒2000 K s‒1, allows the sample temperature in the TEM heating stage to be calibrated. On heating up to melting, the glass decomposes in up to four stages: (1) complete transformation to single-phase nanocrystalline (Au,Cu)7Si; (2) grain growth of this phase; (3) precipitation of (Pd,Ag)Si, reducing the supersaturation of silicon in the (Au,Cu)7Si matrix; (4) with the precipitate phase remaining stable, decomposition of the matrix to a mixture of (Au,Ag)8Cu2, AuCu and Cu3Au phases. At all stages, grain diameters remain sub-micrometre; some of the stable nanocrystalline microstructures may themselves be of interest for applications. The characterization of the decomposition can assist in the optimization of the glass composition to improve tarnish-resistance, while retaining adequate glass-forming ability, formability in thermoplastic processing, and resistance to crystallization. For materials in general, the close correlation of in-situ TEM and DSC results should find wide use in characterizing complex transformation sequences

Tensile properties of Zr70Ni16Cu6Al8 BMG at room and cryogenic temperatures

The mechanical behaviour in tension of a hypoeutectic Zr70Ni16Cu6Al8 Bulk Metallic Glass (BMG) was studied at room (295 K) and cryogenic temperatures (150 K and 77 K) using various strain rates between 10−4 and 10−1 s−1. The yield strength was found to increase at lower temperatures with average values increasing by 16%, from 1503 MPa at 295 K to 1746 MPa at 77 K. The Zr-based BMG was found to exhibit tensile plastic elongation of about 0.4% before fracture at room temperature and high strain rates (10−1 s−1). Even higher tensile plasticity was recorded at low temperatures; plastic deformation was found highest at the intermediate temperature (150 K) reaching remarkable plastic strains in the order of 3.9%, while values up to 1.5% were recorded at 77 K. The lateral surface of the tensile specimens was observed in-situ during deformation using a high frame rate camera offering interesting insights with regard to the deformation mechanisms. Room temperature plasticity occurred through the formation and interaction of several nucleated shear bands before critical failure, while at intermediate and liquid nitrogen temperatures, most of the plastic deformation was accommodated through stable flow within a single shear band

Probing heat generation during tensile plastic deformation of a bulk metallic glass at cryogenic temperature

Despite significant research efforts, the deformation and failure mechanisms of metallic glasses remain not well understood. In the absence of periodic structure, these materials typically deform in highly localized, thin shear bands at ambient and low temperatures. This process usually leads to an abrupt fracture, hindering their wider use in structural applications. The dynamics and temperature effects on the formation and operation of those shear bands have been the focus of long-standing debate. Here, we use a new experimental approach based on localized boiling of liquid nitrogen by the heat generated in the shear bands to monitor the tensile plastic deformation of a bulk metallic glass submerged in a cryogenic bath. With the “nitrogen bubbles heat sensor”, we could capture the heat dissipation along the primary shear banding plane and follow the dynamics of the shear band operation. The observation of nitrogen boiling on the surface of the deforming metallic glass gives direct evidence of temperature increase in the shear bands, even at cryogenic temperatures. An acceleration in bubble nucleation towards the end of the apparent plastic deformation suggests a change from steady-state to runaway shear and premonitions the fracture, allowing us to resolve the sequence of deformation and failure events

Novel micro-flat springs using the superior elastic properties of metallic glass foils

A thin metallic glass foil of 100 mg mass forming a sinusoidal arc behaves as non-conventional flat micro-spring withstanding loads 105 times higher than its load. Upon a normal load applied on the top of the arc, the foil deforms elastically leading to sinusoidal wavy patterns of higher order. The lifespan of the novel spring is higher than conventional low cycle springs and can potentially be further improved by eliminating surface and edge preparation induced defects. This unique behavior of metallic glass foils has the potential to revolutionize the field of springs and can be exploited for numerous applications