A systematic approach for horizontal and vertical scale up of sintered Ultra-High Temperature Ceramic Matrix Composites for aerospace – Advances and perspectives

Sciti, Diletta; Zoli, Luca; Reimer, Thomas; Vinci, Angela Di; Galizia, Pietro

doi:10.1016/j.compositesb.2022.109709

Cited by 54 publications

(18 citation statements)

References 50 publications

(77 reference statements)

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“…Nozzles were machined from three distinct pellets sintered either by hot pressing or spark plasma sintering. Features of the as produced specimens were already presented in previous papers [42,52] and were very similar amongst each other. The basic microstructure/texture of the samples is reported in Fig.…”

Section: Microstructure Of the As Sintered Specimenssupporting

confidence: 69%

“…SiC was added as sintering aid and also to promote the formation of a silica-based glass under oxidation, which improves the oxidation resistance of the boride matrix [41]. A recent work has demonstrated that these composites can be efficiently scaled-up without significant variations of microstructure and thermomechanical properties and indistinctly processed by either hot pressing or spark plasma sintering [42].…”

Section: J U S T a C C E P T E Dmentioning

confidence: 99%

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Propulsion tests on ultra-high-temperature ceramic matrix composites for reusable rocket nozzles

Sciti¹,

Vinci²,

Zoli³

et al. 2023

Journal of Advanced Ceramics

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Ultra-high temperature ceramic matrix composites based on a ZrB2/SiC matrix have been investigated for the fabrication of reusable nozzles for propulsion. Three De Laval nozzle prototypes, obtained by sintering with either hot pressing or spark plasma sintering, were tested 2-3 times in a hybrid rocket motor for proving reusability. Sections were extracted after oxidation tests to study the J u s t A c c e p t e dJournal of Advanced Ceramics https://mc03.manuscriptcentral.com/jacer 2 microstructural changes and oxidative and thermomechanical stresses induced by the repeated tests.Compared to a reference graphite nozzle, no measurable erosion was observed for the UHTCMC-based nozzles. The oxidation mechanism consisted in the formation of a ZrO2 intermediate layer, with a liquid SiO2 layer on the surface that was displaced by the action of the gas flux towards the divergent part of the nozzle, protecting it from further oxidation. Both specimens obtained by HP and SPS displayed similar performance, with very slight differences which were attributed to small changes in porosity.These tests demonstrated the capability of complex-shaped prototypes made of the developed UHTCMC to survive repeated exposure to environments representative of a realistic space propulsion application, for an overall operating time up to 30 s, without any failure nor measurable erosion, making a promising step towards the development of reusable rocket components.

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Section: Microstructure Of the As Sintered Specimenssupporting

confidence: 69%

Section: J U S T a C C E P T E Dmentioning

confidence: 99%

Propulsion tests on ultra-high-temperature ceramic matrix composites for reusable rocket nozzles

Sciti¹,

Vinci²,

Zoli³

et al. 2023

Journal of Advanced Ceramics

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“…As can be seen, the carbonized polydopamine (C-PDA) coated C f /ZrB 2 -based composite possesses competitive strength and toughness. For example, the flexural strength of pich-based C f /ZrB 2 -based composite was 235 MPa at RT and 240 MPa at 1800 °C 51 . Carbon coating was shown to be able to modulate the fiber-matrix bonding well to balance the trade-off between strength and toughness.…”

Section: Resultsmentioning

confidence: 99%

Ultrafast deposition of polydopamine for high-performance fiber-reinforced high-temperature ceramic composites

Liu

Cheng

et al. 2022

Sci Rep

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The low deposition time efficiency and small thickness limit the expansion of polydopamine (PDA) application to fiber-reinforced high-temperature ceramic composites. In this work, the electric field-assisted polymerization (EFAP) route was developed to improve the deposition time efficiency of PDA coating and overcome the thickness limitation. Carbonized polydopamine (C-PDA) coating was used as the interphase of carbon fiber-reinforced ZrB2-based composites (Cf/ZrB2-based composite) to bond rigid fibers and brittle ceramics, where C-PDA coating was prepared by the carbonization of PDA coating. Firstly, uniform and dense PDA coatings were deposited on carbon fibers (Cf) by EFAP. The thickness of PDA coating reached the micron level (over 1800 nm) for the first time. Benefiting from the EFAP route promoting the oxidation process of dopamine (DA) and accelerating the aggregation and in-situ polymerization of DA and its derivatives on the surface of Cf, the deposition rate of PDA coating reached 5589 nm/h, which was 3 orders of magnitude higher than that of the traditional self-polymerization process. By adjusting the EFAP parameters (e.g. DA-concentration, current, and deposition time), the thickness of PDA coating could be conveniently designed from nano-scale to micro-scale. Then, PDA coating was pyrolyzed to obtain C-PDA coating. C-PDA coating was well bonded on Cf without visible cross-sticking among neighboring fibers. C-PDA coating presented a layered structure and the thickness of C-PDA coating could be designed by controlling the thickness of PDA. C-PDA coating was used as the interfacial phase of the Cf/ZrB2-based composite, which ensured that the composite possessed good load-bearing capacity and thermal stability. Moreover, extraordinary damage resistance of the composite was achieved, with work of fracture up to 9936 ± 548 J/m2 at room temperature and 19,082 ± 3458 J/m2 at 1800 °C. The current work provides a high time efficiency processing route for depositing PDA coating on carbon fibers and demonstrates the attractive potential of PDA coating in fiber-reinforced high-temperature ceramic composites.

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“…Finally, a hot-pressing cycle was carried out at 1900 ℃ for 20 min and a 35 MPa of pressure was applied from 900 ℃, similar to those of Refs. [39][40][41]. To control the thickness of the sheet and to obtain the same dimensions, each sheet was created by introducing the same amount of ceramic powder loading and dispersant into a mould of 15 cm × 15 cm.…”

Section: Processmentioning

confidence: 99%

A novel approach for manufacturing of layered, ultra-refractory composites using pliable, short fibre-reinforced ceramic sheets

MOR¹,

Vinci²,

Failla³

et al. 2023

Journal of Advanced Ceramics

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A new additive technique for manufacturing of short fibre-reinforced ultra-refractory ceramics is presented. This technique allows the fabrication of solvent-free, thin (~100 µm), flexible, and easy-to-handle sheets suitable for fabricating homogeneous or layered structures. A large range of compositions, in terms of matrix and fibre volumetric contents, from 0% to 100% is possible. The amount of short carbon fibres incorporated in the sheets ranged from 20 to 50 vol%, whereas the fibre length ranged from 3 to 5 mm. The matrix composition investigated with this technique consisted of ZrB 2 /SiC/Y 2 O 3 . By increasing the fibre amount from 35 to 50 vol%, an improvement of mechanical properties was observed. Four-point flexural strength (σ) ranged from 107 to 140 MPa, depending on the amount of carbon fibres (C f ). The same holds true for the work of fracture, ranging from 108 to 253 J/m 2 . Functionally graded composites were fabricated by overlapping sheets with a fibre gradient (0%-50%).

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A systematic approach for horizontal and vertical scale up of sintered Ultra-High Temperature Ceramic Matrix Composites for aerospace – Advances and perspectives

Cited by 54 publications

References 50 publications

Propulsion tests on ultra-high-temperature ceramic matrix composites for reusable rocket nozzles

Propulsion tests on ultra-high-temperature ceramic matrix composites for reusable rocket nozzles

Ultrafast deposition of polydopamine for high-performance fiber-reinforced high-temperature ceramic composites

A novel approach for manufacturing of layered, ultra-refractory composites using pliable, short fibre-reinforced ceramic sheets

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