Statistical distribution pattern of strength and microstructural damage analysis of unidirectional fiber bundle SiC/SiC composites
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摘要:
连续碳化硅纤维增韧碳化硅陶瓷基复合材料(SiC/SiC)具备高强度、耐高温、低密度等特点，是国际公认的新型航空发动机优选材料之一。该材料制备工艺会导致其微结构存在非均匀特征，如束内外孔隙、分层、预制体铺层错位和基体开裂等，使其性能离散性较大。以强度为主要参数进行结构设计时，会受其离散性影响限制结构可靠性。该复材已处于工程放大应用阶段，生产制造设备放大会提高微结构的不均匀性，导致其力学性能离散性更显著。本文通过小试炉与中试炉分别制备单向纤维束SiC/SiC(Mini-SiC/SiC)复合材料，评估其拉伸强度可靠性，基于深度学习工具ORS Dragonfly提取微结构特征(基体、裂纹、界面相、纤维)，结合纤维强度和基体间距裂纹公式分析离散性。结果表明：复材基体裂纹间距为(83.2μm，107.8μm)，体现了制备工艺的影响；界面相均匀包裹每根纤维，界面相滑移应力视为定值；连续纤维承载大于99%，纤维对复材性能离散性影响较小；根据拉伸强度与基体裂纹间距公式，计算得出最小和最大裂纹间距所对应的拉伸强度值分别为376.16和406.14MPa，该值都处于小试Mini-SiC/SiC复材拉伸强度(331.02MPa，407.82MPa)和中试复材拉伸强度(161.10MPa，540.95MPa)范围内。然而，中试Mini-SiC/SiC复材拉伸强度范围大于小试炉，且前者威布尔模数5.01比后者威布尔模数20.59低75.7%，中试分散性更大是由于中试炉尺寸放大所致，基体非均匀性是影响复材可靠性的主要原因。 ORS Dragonfly软件处理Mini-SiC/SiC复合材料CT图。 -
关键词:
- 单向纤维束SiC/SiC /
- 微结构 /
- Weibull分布 /
- 深度学习 /
- 拉伸性能
Abstract: The discrete mechanical properties of SiC/SiC composites originate from their structural units and microstructural features. In this paper, for the unidirectional fiber bundle SiC/SiC composites with the simplest structure, the strength distribution pattern was analyzed by the two-parameter Weibull distribution and the median estimated distribution, and the discrete nature was revealed based on the deep learning of the microstructure of each group element (matrix, interface phase, and fiber) of the composites. The results show that the tensile strengths of the unidirectional fiber bundle SiC/SiC prepared in the small and medium test furnaces are located at (331.02 MPa, 407.82 MPa) and (161.09 MPa, 540.95 MPa), respectively; the former Weibull modulus (20.59) is 75.7% higher than the latter (5.01), indicating an increase in the dispersion of the medium test. The results of deep learning of fracture morphology show that matrix cracking, interface deflection and fiber fracture pullout are the main failure mechanisms, and due to the distribution of matrix crack spacing at (83.2 μm, 107.8 μm), the calculation by the micromechanical equation indicates that matrix nonuniformity is the main reason affecting the reliability of the composites. -
图 1 Mini-SiC/SiC复合材料制备示意图
Figure 1. Schematic diagram of preparation of Mini-SiC/SiC composites
图 3 Mini-SiC/SiC复合材料典型的拉伸载荷-位移曲线
Figure 3. Typical tensile load-displacement curves of Mini-SiC/SiC composites
图 4 Mini-SiC/SiC复合材料拉伸强度Weibull分布的线性拟合图
Figure 4. Linear fitting diagram of Weibull distribution of tensile strength of Mini-SiC/SiC composites
图 5 Mini-SiC/SiC复合材料Weibull累积分布函数曲线与中位估计数据的对比
Figure 5. Weibull cumulative distribution function curve compared with the median estimated data for Mini-SiC/SiC composites
图 6 Mini-SiC/SiC复合材料断裂位移Weibull分布线性拟合
Figure 6. Linear fitting of Weibull distribution for fracture displacement of Mini-SiC/SiC composites
图 7 Mini-SiC/SiC复合材料Weibull累积损伤因子分布函数曲线与中位估计数据的对比
Figure 7. Weibull cumulative damage factor distribution function curves for Mini-SiC/SiC composites compared with median estimated data
图 8 Mini-SiC/SiC复合材料初始态与断口SEM图像
Figure 8. SEM image of initial state and fracture of Mini-SiC/SiC composites
图 9 ORS Dragonfly软件处理Mini-SiC/SiC复合材料CT
Figure 9. ORS Dragonfly software for processing Mini-SiC/SiC composite CT images
图 10 ORS Dragonfly软件提取Mini-SiC/SiC复合材料周期性裂纹间距图
Figure 10. Extraction of periodic crack spacing diagram of Mini-SiC/SiC composites by ORS Dragonfly software
图 11 基体对Mini-SiC/SiC复合材料形状参数m与力学性能离散的影响
Figure 11. Matrix effects on the shape parameter m and mechanical property dispersion of Mini-SiC/SiC composites
表 1 Mini-SiC/SiC复合材料的制备工艺参数
Table 1. Process parameters of Mini-SiC/SiC composites
Material name Deposition time /h Inside Diam/mm BN interface SiC matrix Mini-SiC/SiC A 100 160 600 Mini-SiC/SiC B 100 160 1200 
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表 4 两种Mini-SiC/SiC复合材料断裂位移双参数Weibull分布参数、线性相关系数
Table 4. Weibull distribution parameters, and linear correlation coefficients of two Mini-SiC/SiC composites with two-parameter fracture displacement
Name Mini-SiC/SiC A Mini-SiC/SiC B shape parameter b 3.09 2.50 scale parameter a/mm 0.87 1.16 linearly dependent coefficient r 0.97 0.99
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表 2 两种Mini-SiC/SiC复合材料拉伸强度双参数Weibull分布的参数和线性相关系数
Table 2. Parameter and linear correlation coefficient of two-parameter Weibull distribution for tensile strength of two Mini-SiC/SiC composites
Name Mini-SiC/SiC A Mini-SiC/SiC B Shape parameter m 20.59 5.01 Scale parameter σ0/MPa 374.79 400.74 Linearly dependent coefficient r 0.94 0.98
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表 3 两种Mini-SiC/SiC复合材料在可靠度50%时的可靠拉伸强度与平均拉伸强度
Table 3. Reliable tensile strength and average tensile strength of two Mini-SiC/SiC composites at 50% reliability
Name Mini-SiC/SiC A Mini-SiC/SiC B Mean tensile strengthMPa 365.08 367.78 Tensile strength of 50% reliability/MPa 368.18 372.47 absolute deviation/MPa 3.10 4.69 Relative deviation 0.8% 1.2%
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表 5 Mini SiC/SiC复合材料的DN与D60,0.01、D60,0.05
Table 5. DN and D60,0.01, D60,0.05 of Mini SiC/SiC composites
Name Mini-SiC/SiC A Mini-SiC/SiC B DN 0.1139 0.1036 D60,0.01 0.2104 0.2104 D60,0.05 0.1756 0.1756 Notes: DN—Kolmogorov distance, N—Total number of samples; D60,0.01—Total sample size is 60 and the significance level a is taken as 0.01; D60,0.05—Total sample size is 60 and the significance level a is taken as 0.05.
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表 6 Mini-SiC/SiC复合材料拉伸载荷-位移关系检验过程主要数据
Table 6. Main data of the test process of tensile load-displacement relationship of Mini-SiC/SiC composites
Name Mini-SiC/SiC A Mini-SiC/SiC B Maximum load P/N 128.79 132.60 Fracture displacement xmax/mm 0.83 1.03 True strength value σ/MPa 368.72 393.48 Fracture strain εmax 0.0166 0.0205 Strength calculation value of constitutive model σ/MPa 373.50 366.40 Error between calculated value and real value +1.2% -6.8%
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