Matrix cracking and creep behavior of monolithic zircon and zircon silicon carbide fiber composites

In this study, the first matrix cracking behavior and creep behavior of zircon matrix silicon carbide fiber composites were studied, together with the fracture and creep behavior of the monolithic zircon. These behaviors are of engineering and scientific importance, and the study was aimed at understanding the deformation mechanisms at elevated temperatures.;The first matrix cracking behavior of zircon matrix uniaxially reinforced with silicon carbide fiber (SCS-6) composites and failure behavior of monolithic zircon were studied as a function of temperature (25°C, 500°C, and 1200°C) and crack length in three point bending mode. A modified vicker's indentation technique was used to vary the initial crack length in monolithic and composite samples. The interfacial shear strength was measured at these temperatures from matrix crack saturation spacing. The composites exhibited steady state and non steady state behaviors at the three different temperatures as predicted by theoretical models, while the failure stress of zircon decreased with increasing stress. The intrinsic properties of the composites were used to numerically determine the results predicted by three different matrix cracking models based on a fracture mechanics approach. The analysis showed that the model based on crack bridging analysis was valid at 25°C and 500°C, while a model based on statistical fiber failure was valid at 1200°C. Microstructural studies showed that fiber failure in the crack wake occurred at or below the matrix cracking stress at 1200°C, and no fiber failure occurred at the other two temperatures, which validated the results predicted by the theoretical models. Also, it was shown that the interfacial shear stress corresponding to debonding determined the matrix cracking stress, and not the frictional shear stress. This study showed for the first time, the steady state and non-steady state matrix cracking behavior at elevated temperatures, the difference in behavior between room temperature and elevated temperatures, and the validity of the various models of first matrix cracking behavior.;In order to understand the creep behavior of composites, it is important to study the creep behavior of matrix, fiber, and composites under identical conditions to determine the role of various constituents. Creep studies were conducted in an inert atmosphere in four point bending and uniaxial tension modes on zircon and zircon silicon carbide fiber composites at four different temperatures of 1250°C, 1300°C, 1350°C, and 1400°C, and over the stress range of 10--200 MPa. The strain rate was measured as a function of the stress and temperature to determine the stress exponent and activation energy, and microstructural analysis was done on crept samples using scanning electron microscopy.;The composites exhibited a much lower creep rate than the monolilth, indicating that the major portion of the creep load was carried by the fibers. In flexural mode, both zircon and composite samples exhibited bimodal creep behavior, with the stress exponent (n) increasing with increasing stress. For zircon, at lower-stresses n was in the range of 2.1--2.6 and increased to 7--7.9 at higher stresses. Microstructural studies showed that diffusional creep was the rate controlling mechanism at lower stresses, while the higher stress exponent observed at higher stresses, was due to linkage of cavities and damage accumulation resulting in a higher strain rate. In the case of composites, the stress exponent was ≈1 at lower stresses, and increased to 3--5 at higher stresses, indicating that diffusional creep (and grain boundary sliding) was rate controlling at lower stresses, and either creep cavitation and crack growth or dislocation creep was the rate controlling mechanism at higher stresses.;Anomalous creep curves with strain jumps were observed for the first time during the creep of ceramic composites at lower temperatures and higher stresses. Microstructural studies showed that matrix cracking during creep results in these strain jumps. These studies showed that even at stresses below the matrix cracking stress, matrix cracking can occur during creep due to load transfer between the fiber and matrix. The lack of these strain jumps at higher temperatures was attributed to higher matrix plasticity which prevented sudden matrix failure.;Tensile creep studies showed that the steady state strain rate was higher in tension than in flexure. A threshold stress of 25 MPa was observed in the temperature range of 1250--1400°C. Strain jumps similar to that observed in flexural creep were also observed in tensile tests. Microstructural studies were conducted to explain the observed creep behavior. A technique was developed for predicting the variation of stress in the fiber and matrix phases of the composite based on the experimental creep data of fiber and matrix.;This study showed for the first time the role of damage mechanisms during creep, the mechanisms of creep in zircon and zircon composite, and the importance of studying the creep behavior of the constituent phases of the composite in order to understand the creep behavior of the composite.