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Ahatract-In this paper the effect of thermal expansion anisotropy on microcracking in ceramic
matrix composites is studied. It is well known that thermal expansion mismatch and thermal
expansion anisotropy in ceramic composites may induce residual stresses which in turn may cause
microcracking, thus reducing the toughness of such materials. In this study it is assumed that the
fiber and matrix materials are both thermally anisotropic, i.e. the coetiicients of thermal expansion
vary with direction. First an exact elasticity solution of the residual stress field generated due to
thermal expansion anisotropy in and around a fiber embedded in an infinite matrix is presented.
Next radial and interfacial microcrack propagation under the residual stress field is studied.
A critical fiber size for microcrack suppression is also determined. Numerical results are obtained
for various material combinations and thermal expansion anisotropy may have a significant effect
on microcracking and toughness of ceramic composites.
ALTHOUGH ceramic materials have, in general, very low toughness, in recent years they have
received a great deal of attention due to their very high resistance to high temperature oxidation.
To increase their use in engineering applications in space and advanced engine technologies,
tougher and at the same time heat resistant materials are being developed. To increase the
toughness of such materials, researchers are giving special attention to the microcracking and the
associated failure mechanisms. Microcracking gives rise to the low toughness of ceramics and in
most cases has a detrimental effect on the toughness and strength of ceramics and ceramic
composites. There have been investigations showing that porosity has a deleterious effect on the
strength and fracture toughness[l-111, although a controlled amount of microcracking may lead
to the toughening of some materials[ 121.
In general, microcra~king may develop due to applied external loads or localized stress fields,
i.e. residual stresses. In the former case, regions with a toughness lower than the surrounding
material may fail before the bulk of the material inducing microcracks in the structure. In the latter
case, during the manufacturing of material, i.e. during the cooling process, residual stresses are
induced due to thermal expansion mismatch, thermal expansion anisotropy or phase transform-
ation. The components of ceramic composites, in general, (the matrix and the fibers in fiber
reinforced composites), (or particles in particulate composites) have different thermal expansion
coefficients inducing residual stresses during the cooling phase of the manufacturing process. These
residual stresses may be tensile or compressive inducing microcracks in the material. For
microstructural design purposes the prevention of microcracking and the determination of the
factors influencing it are very important.
The previous work on microcracking mechanisms is related to ceramics and particulate
ceramic composites yielding the info~ation for a minimum grain or inclusion size below which
microcracking will not occur. Davidge and Green[ 131using an energy balance approach of fracture
mechanics with the assumption that the interface crack reaches the critical size when it encompasses
half of the spherical surface, estimated a critical particle size. Lange[lrt] gave the critical radius
(for the same geometry) below which microcra~king can not occur. Similar studies on the critical
particle size were also carried out by other researchers[lS-201.
The microcracking mechanism in a ceramic-fiber/ceramic-matrix composite due to thermal
expansion mismatch was studied by Delale[21]. After determining the residual stresses due to
thermal expansion mismatch, a critical fiber radius for the suppression of radial and interface
microcracking was presented.
45
46 F. DELALE and H. BODUROGLU
The onset of the mode of microfracture associated with thermal expansion anisotropy was
calculated for single polycrystals by Evans[22], where critical grain facet size for microfracture
initiation was predicted. Tvergaard and Hutchinson[23] studied the effect of both elastic anisotropy
and thermal expansion anisotropy of the grains.
The purpose of this paper is to study the effect of thermal expansion anisotropy in ceramic
matrix composites. First a closed form solution is obtained for the residual stresses due to thermal
expansion anisotropy. Next the relevant radial and interfacial crack problems are solved and the
results are presented.
ag(r,O)= -$+7cos28
rz(r,@)= -
$+F sin28.
( >
At the microscopic level, the effect of elastic anisotropy on thermal stresses is negligible
compared to the effect of thermal expansion anisotropy[22]. Therefore, in studying microcracking
in ceramic matrix composites only the thermal expansion anisotropy is taken into account, and
elastic anisotropy is neglected. Thus, the strain-stress relationships for the ceramic matrix in polar
coordinates are:
1
c::=,[fJ::- ~,(a% + a;)] + a,AT cosz 8 + a,AT sin28 05)
m
1
~~=E[cr~-v,(a~+a~)]+aXATsin2B+aYATcos2B (7)
m
rz= Xl Cl
+ %>~~~+ 2AT(cr, - cc,)sin 8 cos 8. (9)
For the plane strain case (czz= 0), a:, can be determined from eq. (8). Substituting the resulting
a: and eqs (3), (4), and (5) into eqs (6), (7), and (8), we obtain:
6:=-j-
.{
(l+v Is--
-r*[
(l-~:)f$+(l+~,)~
1 Icos2e
Cm- au,:
V (13)
ar
Making use of eqs (10) and (1 l), eqs (13) and (14) can be integrated to give the radial and
transverse displacements as:
1 I
1
p=- -(l+v,)$+ (l-vi)~+(l+~,)~ cos2e
r Em
After going through a similar procedure for the fiber, the stresses and the displacements are
found to be:
C;r = 2c, - 2c, cos 28 (17)
= 2c, + (2c, + 12c,r*)~~~ 28
aA;O (18)
T$ = 2(c, + 3c2r2)sin 20 (19)
u{= -!_ {2(1 - vr- 2vj)c,r - [2(1 + v,)c,r + v,(l + v,)4c2r3]cos 2e}
Ff
uh=~,[2(l+v,)c,r+[2(3+v,-2v:)c2r3]sin28+~(~~-P,)rsin28. (21)
In eqs (6)-(21) u,, aY,a, are thermal expansion coefficients of the matrix, and p,, /I,,, /I, are the
thermal expansion coefficients of the fiber in x, y and z directions respectively.
Having determined the stress and displacement fields for the infinite ceramic matrix and the
ceramic fiber, one can then write the continuity conditions at the interface (at r = R):
fJm=.f
,, I7 (22)
m-- =#
z,e / (23)
um
r = Ufr (24)
u;;=ui. (25)
Equations (22-25) are utilized to determine the unknown constants b,, 6, , b2, co, c, and c2. It should
be noted that the continuity conditions (22) and (24) yield four equations while eqs (23) and (25)
yield two equations resulting in total of six equations for the unknowns. After some length algebra,
we obtain:
b = R*(a - P + a,)AT
0 (26)
A
b = R*AT(Aa -A/I)
I (27)
2Y
b = _R4AT(Aa -AP)
2 (28)
4Y
2b, 3b2
c,=-+-
R2 R4
b, 2b,
c*=---- (31)
R4 R6
‘Fiber
Thus, the stress and displacement fields in the ceramic matrix and the fiber are fully described.
Let us consider the stresses in the matrix:
1 r2 2Y r4
a/n (r
9
0) = (’ - B+ ‘ljAT + (Aa- AB) AT cos 20
A 2Y
A 2Y
Depending on the values of the thermal expansion coefficients and AT, 0% may be tensile
inducing radial cracks, or a; may be tensile causing debonding along the fiber-matrix interface.
Therefore, the two crack geometries to be studied are, a radial crack in the matrix and an interface
crack along the fiber-matrix boundary as shown in Fig. 2(a) and (b) respectively.
The radial crack geometry shown in Fig. 2(a) is formulated in ref. [24] for uniaxial loading.
In this paper, instead of applying external loads, the crack surfaces will be loaded with the negative
of the residual stress a; obtained in the previous section as:
(34)
with
d =(a -P +a,)AT
2 .
50 F. DELALEand H. BODUROGLU
Referring to ref. [24], the formulation of the problem in terms of the crack surface displacement
derivative f(t) can be written as,
RfC
‘+‘j$ dt + [k,,,(x, t) + k,,,(x, t)]f(t) dt = “(7P+ ‘)p(x) R <x < R + C (35a)
sR sR m
Wb)
sR S(t)df =’
where
(/I,+&)$+$(~s’-R’)
(
1 -;
)I
(37)
The following normalization is used to solve the singular integral equation (35a):
s’ g(r)
-
-15 -P
dr + T
c
s
’
_
I
K,,h 7) + 4& r)lg(r) dr =
~o&i + 1)
2p
m
4(P)- 1<P < 1 (394
s 1
-I
g(r) dr = 0.
The normalized crack surface displacement g(z) is singular at z = + 1 and may be written as
Wb)
ref. [25]:
(40)
where G(r) is a bounded function and - 1 < 6 < 0 is given by ref. [24]:
2 cos xs + (A, + A*) - 4A,(6 + l)* = 0. (41)
Microcracking in ceramic composites 51
At the crack tip embedded in the matrix the stress intensity factor can be defined as:
Using eq. (35a) and the relations (38) and (40), after some lengthy algebra we obtain:
Noting that K, = &k(c), then the strain energy release rate is found to be:
I
= G(l -v%>
=C(l -v;)k*(c) w
Em m
or
(45)
G, = ; (1 - v;)Rc[k’(c)]%?. (46)
m
The radial matrix crack will propagate when the strain energy release rate reaches the critical
strain energy release rate of the matrix, i.e. when G, > (G,,),. Equating eq. (46) with (G,,), we
obtain the critical fiber size as:
(GA&n
R, = (47)
rc(l - v;)c[k’(e)]%* ’
Since, the crack size (or c) is not known a priori, then we can determine only a minimum critical
fiber size which will occur when
Thus,
Rmin = (Gd,J,
C (48)
n(1 - 4Jk(~kllax~*
Formula (48) can be used to determine the critical fiber size for radial matrix crack suppression
on the conservative side.
where
_k -1+&l -1+-K, In v.
A
Co=Go+iHo
4Pm~m
Ho = f(1 -k)(l + 4J.;)(N, - T,)sin2 a sin 24 + -
1 + K,
x (1 +(cosa +2&sina)e~tn-af
iii kfl +(cosct +2&sincr)e2~f*-‘)~
Here SZ*is the rotation at infinity, Iii is the complex conjugate of N and T, , iV, , R, u, r#~are shown
in Fig. 6. To obtain the solution for a constant crack surface pressure ci given in eq. (34) and
expressed by eqs (33a) and (33b), consider the stress distribution for a cylindrical inclusion
embedded in an infinite matrix under biaxial tension o. and cl (Fig. 7). The radial stress along the
fiber matrix interface may be expressed as[32]:
+2+A(;)‘+B[3(;~-4(f)i]cos28} (so)
where
Equating the radial stress a; to 6, at the interface r = R yields two equations for determining
co and ol. Thus, we obtain:
bo 4
a’ = R2(1 - 4A) + R2(t - 4B)
bo 4
” = R2(1 - 4.4) - R2(1 - 4B) ’
(51)
Microcracking in ceramic composites 53
H,,=O, NN=L2+M2
&!!5
P (53)
B2R
where
d = (a - B + UI W
A
the critical fiber size for the suppression of interface cracking can be obtained by equating G, to
(the total critical strain energy release rate of the interface). Again noting that the crack
(Gc)interracc
length is not known a priori, we obtain the minimum critical fiber size (&)min when G, is maximum.
Thus:
(54)
The results for the radial matrix crack and the circumferential crack are given in Tables l-6
and displayed in Figs 3-5 and 8-10.
For the radial crack case, results are obtained for AT = lOOO”C,and various values of c/R
(ratio of crack length to fiber radius). To ascertain the effect of thermal expansion anisotropy, the
coefficients for matrix are assumed to be thermally isotropic, whereas those of the fiber are varied
in such a way that the average coefficient /? remains constant. Thus, values of g(c) are obtained
for 01,= cly= 9 x 1O-6/“C and p = OS(fi, + &) = 5 x 10-6/“C. In the calculations the Possion’s
ratios for matrix and fiber are assumed to be v, = /_+= 0.2. Table 1 shows the variation of g(c)
with c/R for E,,,/Ef= 5.The same results for Em/Ef=1 and E,,,/Ef= 0.2are shown in Table 2 and
Table 3. The same results are also displayed in Figs 3-5. First it is seen that for each set of thermal
expansion coefficients, g(c) passes through a maximum. The value of g(c) is found to be higher
when & < &, meaning that cracks will propagate more easily in such materials. It can also be
observed that g(E) does not vary significantly with Em/Ef, meaning that for all practical material
combinations, it is sufficient to generate only one set of such curves. However the results vary
significantly with thermal expansion anisotropy. For the interfacial crack case, similar results are
obtained for G, (the normalized interfacial strain energy release rate) vs the half crack angle do.
These results are given in Tables 4-6 and displayed in Figs 8-10. Again the value of Gp passes
through a maximum and has higher values for materials having fiY< fi, . As is clearly seen the results
Table 3. Variation of g(c) with c/R for a radial crack (E,,,/Ef= 0.2)
AT- 1000.
E,/E,'S
v,-v,-a2
fi-ilp, l~~~-Sxl(r61/C~-con~tont
a,-.+-6 x 10-61/c*
0.06
=-3~10-61~~
O(r)
1-2 x10-61/c*
Ox)6
=-I x10-61/c*
= I x10-61/~*
1 2 3 4 5
C/R
Fig. 3. Variation of g(c) with c/R for a radial crack (E,,,/E,= 5).
56 F. DELALE and H. BODUROGLU
0.12
0.10
0.08
OM
, / L /
0 1 2 3 4
C/f?
Fig. 4. Variation of g(c) with c/R for a radial crack (E,,,/Ef= 1).
Microcracking in ceramic composites 57
A/3--3
Ag--2
Ag=-1
AB- 0
A@- 1
A/3- 2
A/¶- 3
1 2 3 4
C/R
Fig. S. Variation of g(c) with c/R for a radial crack (Em/E,= 0.2).
F. DELALE and H. BODUROGLU
i ;
K zL.....q /
Fig. 6. Interface crack under plane loading.
Frn 1.20 -
FT’ 5
ON- p,=9xlo-6
= I x10-6
a, -oy- 5 x 10-61/C*
1.00 -
0.40 -
GP
0.60 -
0.10
1.50
1.40
1.30
1.20
1.10
1.00
cl90
0.60
GP
0.70
0.60
0.50
0.40
0.30
a20
0.10
are affected significantly by thermal expansion anisotropy. Here G, varies also significantly with
~,,,/p~, meaning that results have to be obtained separately for each p,,,/cfi ratio. -
Acknowledgemenrs-This work was partially supported by a grant from NATO Scientific Affairs Division (Grant
# 0073/88) and by PSC-CUNY under Grant # 6-67321.
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