3Y-ZrO_2纤维增韧ZrB_2基超高温陶瓷材料微观结构及性能研究
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摘要
超高温材料是指能够在超高温环境（>2000℃）以及反应气氛中（原子氧、等离子体）保持物理、化学稳定性的一类特殊材料，其中ZrB_2基超高温陶瓷材料具有高熔点、高强度及抗热震性等优点，成为使用于极端环境下的新型候选材料。本研究针对ZrB_2基超高温陶瓷材料相对较低的韧性和抗热冲击性等缺点，引入3Y-ZrO_2纤维作为增韧相，利用其具备纤维和相变双重增韧的效果，以达到改善材料本征脆性的目的。采用热压烧结法制备了ZrO_2纤维增韧的ZrB_2基超高温陶瓷复合材料，深入研究了材料合成工艺中球磨时间、烧结速率、烧结温度、保温时间、原料形貌、材料组分等因素对材料微观结构以及力学性能的影响，得出了制备ZrO_2纤维增韧ZrB_2基超高温陶瓷复合材料的最优组分和工艺。利用X射线衍射（XRD）、扫描电镜（SEM）、透射电镜（TEM）、电子背散射衍射（EBSD）及能谱分析（EDS）等技术对复合材料的微观组织结构进行了研究。基于断裂力学理论，采用包络线法和压痕-弯曲强度法研究了材料的阻力曲线行为，并且结合材料的微结构特征分析了材料的强韧化机理。最后利用炉内静态氧化考核了ZrO_2纤维增韧ZrB_2基超高温陶瓷复合材料的裂纹自愈合与预氧化性能。
单独引入ZrO_2纤维到ZrB_2基体虽然能够抑制ZrB_2晶粒的长大，但是为了提高ZrB_2-ZrO_(2f)二元陶瓷体系的致密度需要较高的烧结温度和较长的保温时间，会对纤维造成损害，不利于达到增韧的效果。优化复合材料的体系设计，选用碳化硅颗粒（SiC_p）或者碳化硅晶须（SiC_w）复合添加制备了ZrB_2-SiC-ZrO_(2f)三元陶瓷。研究了制备工艺，球磨20h获得混合均匀的粉体，纤维长短均一且在基体中均匀分布，热压烧结升温速率为3.75℃·min~(-1)，降温速率为1.67℃·min~(-1)，在1850℃，30MPa，保温1h可以制成致密的陶瓷块体材料。材料组成为ZrB_2-20vol.%SiC_p--15vol.%ZrO_(2f)（记为Z20S_p15Z_f）和ZrB_2-20vol.%SiC_w-15vol.%ZrO_(2f)（记为Z20Sw15Zf）的室温弯曲强度和断裂韧性分别为1084MPa、680MPa和6.8MPa·m~(1/2)、8.0MPa·m1/2，并且两种材料900℃的高温弯曲强度分别为604MPa和724MPa。
利用透射电镜技术观察了ZrB_2-SiC-ZrO_(2f)复合材料的界面特征，Z20Sp15Zf复合材料的晶界界面轮廓比较模糊归因于SiC晶粒与ZrO_2纤维之间发生微量反应；而Z20S_w15Z_f复合材料的晶界界面清晰，没有明显反应层。衍射斑点标定结果表明ZrO_2纤维的主相为t相，相变的相位关系符合100m//100t，001m//001t晶体学关系，t-ZrO_2相的存在是发生相变增韧的必要条件。此外EBSD分析结果证实了在热压烧结制备的三元ZrB_2-SiC-ZrO_(2f)复合材料中，氧化锆纤维具有相似的取向关系。Z20S_p15Z_f材料中ZrB_2和SiC晶粒随机分布，宏观上表现出各向同性；而Z20S_w15Z_f材料表现出明显的择优取向，宏观上各向异性。在两种材料中均存在低能的小角度晶界和低Σ值的CSL晶界，直接关系到多晶材料的力学性能。
陶瓷的阻力曲线行为可以准确地表征材料的韧性，具有阻力曲线行为的材料在工程应用上拥有较高的可靠性，强度数据离散性小。选用Vickers压痕-弯曲强度法和包络线法研究了ZrO_2纤维增韧ZrB_2基陶瓷的阻力曲线行为。研究表明，采用ZrO_2纤维增韧的ZrB_2基陶瓷表现出明显的阻力曲线行为。根据增韧理论模型定量化分析了每种增韧机制的贡献，利用线性叠加法计算了总断裂韧性Ktot。相对于Z20S_p15Z_f复合材料，Z20S_w15Z_f陶瓷基复合材料具有较高的断裂韧性，归功于裂纹偏转和桥联增韧的效果分别提高了97%和5%，拔出增韧效果提高了26%，相变增韧效果提高了15%。SiC晶须的加入不仅发挥了晶须增韧的效果，还证实了弱界面有利于实现裂纹偏转，对于其他增韧机制也有促进作用。
系统地研究了ZrB_2-SiC-ZrO_(2f)复合材料预氧化和裂纹自愈合行为。Z20S_p15Z_f和Z20S_w15Z_f两种材料表现出不同的氧化敏感性，Z20S_p15Z_f材料的氧化起始温度为800℃，低于Z20S_w15Z_f材料的1000℃，Z20S_w15Z_f材料的氧化速率低于Z20S_p15Z_f材料。过快的氧化速率会使材料表面生成过多的氧化层，造成力学性能有所下降。800℃预氧化30min的Z20S_w15Z_f材料弯曲强度提高至757±23MPa，比原始强度提高了11%，主要是由于相对较低的氧化速率降低了表面的氧化程度，新生成的细小颗粒填充于原始材料表面的微缺陷之间，形成了致密的氧化薄层，起到了自愈合作用和钝化效应。此外材料的氧化敏感性为裂纹自愈合提供了契机，借由氧化物的生成，可以填充于材料表面的裂纹缺陷中，达到自愈合裂纹的目的。对于Z20S_p15Z_f和Z20S_w15Z_f材料，裂纹自愈合处理的最佳条件为1200℃保温时间30min，弯曲强度达到了最大值分别为630±51MPa和632±29MPa。
Ultrahigh temperature ceramics (UHTCs) possess physical-chemical stability inultra-high temperature environment (>2000℃) and reaction atmosphere (atomic oxygenand plasma). As a new potential candidate for high temperature structural applications,ZrB_2-based ultra-high temperature ceramics (UHTCs) exhibit unique properties, such ashigh melting point, high strength, as well as great thermal shock resistance. In this study,ZrO_(2f)iber was used as toughening phase in ZrB_2-based ceramics in order to improvethe low toughness and unsatisfactory thermal shock resistance, since ZrO_(2f)iber hadboth the virtue of fiber-toughening and phase transformation toughening. Highly denseand good-properties ZrB_2-based ceramics toughened by ZrO_(2f)ibers were prepared byhot-pressing. The effect of each factor on the microstructure and mechanical propertiesof the final bulk was thoroughly investigated to find the most suitable preparationprocess, including milling time, sintering rate, sintering temperatures, dwelling time,morphology of raw powders and constituents. By means of X-ray diffraction (XRD),scanning electron microscopy (SEM) transmission electron microscopy (TEM), andelectron backscatter diffraction (EBSD) with simultaneous chemical analysis by energydispersive spectroscopy (EDS), the microstructure were investigated. Based on fracturemechanics theory, the damage resistance and R-curves behavior were evaluated by usingthe indentation-strength in bending (ISB) technique, and compared with the envelopemethod, the difference between the two being analyzed. With the combination ofanalysis of microstructure, the strengthening and toughening mechanism were alsodiscussed. In addition, self-crack healing and pre-oxidation were further presented bymeans of muffle furnace.
Introduction of ZrO_2fibers was significantly beneficial for the restriction of graingrowth of ZrB_2during densification. However, in order to obtain nearly full densematerial, higher sintering temperature and longer dwelling time were needed whichwould cause degradation of ZrO_2fibers and was also harmful to the mechanicalproperties. The optimum proportion of ceramic materials was studied, both SiC particleor SiC whisker and ZrO_2fiber were added into ZrB_2matrix ceramics. The preparationprocess was studied, the production of a homogeneous ceramic could be successfullyachieved by using a combination of20h milling time and hot-pressing at1850℃for1hunder a uniaxial load of30MPa with heating velocity of3.75℃·min~(-1)and coolingvelocity of1.67°C·min~(-1). The flexural strength and fracture toughness of thehot-pressed ZrB_2-20vol.%SiC_p-15vol.%ZrO_(2f)(Z20S_p15Z_f) and ZrB_2-20vol.%SiC_w- -15vol.%ZrO_(2f)(Z20S_w15Z_f) ceramics reached1084MPa,680MP and6.8MPa·m1/2,8.0MPa·m1/2, respectively. And the flexural strengths after testing at900℃were604MPa and724MPa, respectively.
A transmission electron microscopy study on the characteristics of grain boundaryof ZrB_2-SiC-ZrO_(2f)ceramics was presented. The contour of grain boundary ofZ20S_p15Z_fceramic was illegible, which was attributed to the weak reaction of SiCparticle and ZrO_(2f)iber. On the contrary, no reaction between the SiC whisker and ZrO_2fiber was existed in Z20S_w15Z_fceramic. The analysis of single crystal electrondiffraction pattern was presented, showing that the ZrO_2in fibers was of the tetragonalcrystalline structure, and the phase relationship between tetragonal and monoclinicphase was consistent to the crystal orientation relationship of100m//100t，
001m//001t. The existence of tetragonal phase was the necessary condition fortransformation toughening. In addition, the orientation distribution of ZrO_(2f)ibers inhot-pressed ZrB_2-SiC-ZrO_(2f)exhibited the same preferred orientation obtained from themeasured data of electron backscatter diffraction. The distribution of ZrB_2and SiCparticles in Z20S_p15Z_fceramic was random, which could reach the macro isotropy. Butthe appearance of preferred orientation was found in Z20S_w15Z_fceramic, which wouldshow the macro anisotropy. The low energy boundaries related to mechanical propertiesof materials, such as low angle and low ΣCSL grain boundaries, were found in bothmaterials.
In order to predict the instability of ceramics, characterizing and understandingcrack resistance curve (R-curve) behavior are very important. The traditional ceramicswithout R-curve behavior exhibit a large strength scatter. In this study, R-curves forZrB_2-SiC-ZrO_(2f)ceramics were evaluated by using the indentation-strength in bending(ISB) technique and the envelope method. The analytical results revealed thatZrB_2-based ceramics toughened by ZrO_(2f)ibers provided obvious R-curve. Based on thetheoretic models for toughening mechanisms, quantification of every tougheningmechanism was analyzed, and the total fracture toughness (Ktot) was calculated by usingthe linear superposition method. Compared to Z20S_p15Z_fceramics, Z20S_w15Z_fceramics had higher fracture toughness, which attributed to improvements oftoughening effects of crack deflection (97%), crack bridging (5%), fiber pull-out (26%)and transformation toughening (15%). The introduction of SiC whisker was benefit tothe crack deflection and also had promotion impact to other toughening mechanisms.
Self-crack healing and preoxidation treatment of ZrB_2-SiC-ZrO_(2f)ceramics weresystematically studied. The oxidized sensitivity of Z20S_p15Z_fand Z20S_w15Z_fwere different. The initial oxidation temperature of Z20S_p15Z_fceramic was800℃, while thatof Z20S_w15Z_fwas1000℃, and the oxidation rate of Z20S_w15Z_fwas lower than that ofZ20S_w15Z_fceramic. Overquick oxidation rate would produce too much surface oxide,which was harmful to the improvement of mechanical properties. Flexural strength ofZ20S_w15Z_fwas greatly improved to757±23MPa after preoxidation at800℃for30min in air, which was improved by11%compared to the original strength. The effect ofpreoxidation on the mechanical properties was investigated. Microstructure analysissuggested that less oxide was produced because of low oxidation rate, and the formedoxide could heal and blunt the surface defects i.e. microcraks, porosities, which wasalso benefit for self-crack healing. The optimum healing condition for both Z20S_p15Z_fand Z20S_w15Z_fwas treated at1200℃for30min, and the flexural strength wasimproved to630±51MPa and632±29MPa, respectively.
单独引入ZrO_2纤维到ZrB_2基体虽然能够抑制ZrB_2晶粒的长大，但是为了提高ZrB_2-ZrO_(2f)二元陶瓷体系的致密度需要较高的烧结温度和较长的保温时间，会对纤维造成损害，不利于达到增韧的效果。优化复合材料的体系设计，选用碳化硅颗粒（SiC_p）或者碳化硅晶须（SiC_w）复合添加制备了ZrB_2-SiC-ZrO_(2f)三元陶瓷。研究了制备工艺，球磨20h获得混合均匀的粉体，纤维长短均一且在基体中均匀分布，热压烧结升温速率为3.75℃·min~(-1)，降温速率为1.67℃·min~(-1)，在1850℃，30MPa，保温1h可以制成致密的陶瓷块体材料。材料组成为ZrB_2-20vol.%SiC_p--15vol.%ZrO_(2f)（记为Z20S_p15Z_f）和ZrB_2-20vol.%SiC_w-15vol.%ZrO_(2f)（记为Z20Sw15Zf）的室温弯曲强度和断裂韧性分别为1084MPa、680MPa和6.8MPa·m~(1/2)、8.0MPa·m1/2，并且两种材料900℃的高温弯曲强度分别为604MPa和724MPa。
利用透射电镜技术观察了ZrB_2-SiC-ZrO_(2f)复合材料的界面特征，Z20Sp15Zf复合材料的晶界界面轮廓比较模糊归因于SiC晶粒与ZrO_2纤维之间发生微量反应；而Z20S_w15Z_f复合材料的晶界界面清晰，没有明显反应层。衍射斑点标定结果表明ZrO_2纤维的主相为t相，相变的相位关系符合100m//100t，001m//001t晶体学关系，t-ZrO_2相的存在是发生相变增韧的必要条件。此外EBSD分析结果证实了在热压烧结制备的三元ZrB_2-SiC-ZrO_(2f)复合材料中，氧化锆纤维具有相似的取向关系。Z20S_p15Z_f材料中ZrB_2和SiC晶粒随机分布，宏观上表现出各向同性；而Z20S_w15Z_f材料表现出明显的择优取向，宏观上各向异性。在两种材料中均存在低能的小角度晶界和低Σ值的CSL晶界，直接关系到多晶材料的力学性能。
陶瓷的阻力曲线行为可以准确地表征材料的韧性，具有阻力曲线行为的材料在工程应用上拥有较高的可靠性，强度数据离散性小。选用Vickers压痕-弯曲强度法和包络线法研究了ZrO_2纤维增韧ZrB_2基陶瓷的阻力曲线行为。研究表明，采用ZrO_2纤维增韧的ZrB_2基陶瓷表现出明显的阻力曲线行为。根据增韧理论模型定量化分析了每种增韧机制的贡献，利用线性叠加法计算了总断裂韧性Ktot。相对于Z20S_p15Z_f复合材料，Z20S_w15Z_f陶瓷基复合材料具有较高的断裂韧性，归功于裂纹偏转和桥联增韧的效果分别提高了97%和5%，拔出增韧效果提高了26%，相变增韧效果提高了15%。SiC晶须的加入不仅发挥了晶须增韧的效果，还证实了弱界面有利于实现裂纹偏转，对于其他增韧机制也有促进作用。
系统地研究了ZrB_2-SiC-ZrO_(2f)复合材料预氧化和裂纹自愈合行为。Z20S_p15Z_f和Z20S_w15Z_f两种材料表现出不同的氧化敏感性，Z20S_p15Z_f材料的氧化起始温度为800℃，低于Z20S_w15Z_f材料的1000℃，Z20S_w15Z_f材料的氧化速率低于Z20S_p15Z_f材料。过快的氧化速率会使材料表面生成过多的氧化层，造成力学性能有所下降。800℃预氧化30min的Z20S_w15Z_f材料弯曲强度提高至757±23MPa，比原始强度提高了11%，主要是由于相对较低的氧化速率降低了表面的氧化程度，新生成的细小颗粒填充于原始材料表面的微缺陷之间，形成了致密的氧化薄层，起到了自愈合作用和钝化效应。此外材料的氧化敏感性为裂纹自愈合提供了契机，借由氧化物的生成，可以填充于材料表面的裂纹缺陷中，达到自愈合裂纹的目的。对于Z20S_p15Z_f和Z20S_w15Z_f材料，裂纹自愈合处理的最佳条件为1200℃保温时间30min，弯曲强度达到了最大值分别为630±51MPa和632±29MPa。
Ultrahigh temperature ceramics (UHTCs) possess physical-chemical stability inultra-high temperature environment (>2000℃) and reaction atmosphere (atomic oxygenand plasma). As a new potential candidate for high temperature structural applications,ZrB_2-based ultra-high temperature ceramics (UHTCs) exhibit unique properties, such ashigh melting point, high strength, as well as great thermal shock resistance. In this study,ZrO_(2f)iber was used as toughening phase in ZrB_2-based ceramics in order to improvethe low toughness and unsatisfactory thermal shock resistance, since ZrO_(2f)iber hadboth the virtue of fiber-toughening and phase transformation toughening. Highly denseand good-properties ZrB_2-based ceramics toughened by ZrO_(2f)ibers were prepared byhot-pressing. The effect of each factor on the microstructure and mechanical propertiesof the final bulk was thoroughly investigated to find the most suitable preparationprocess, including milling time, sintering rate, sintering temperatures, dwelling time,morphology of raw powders and constituents. By means of X-ray diffraction (XRD),scanning electron microscopy (SEM) transmission electron microscopy (TEM), andelectron backscatter diffraction (EBSD) with simultaneous chemical analysis by energydispersive spectroscopy (EDS), the microstructure were investigated. Based on fracturemechanics theory, the damage resistance and R-curves behavior were evaluated by usingthe indentation-strength in bending (ISB) technique, and compared with the envelopemethod, the difference between the two being analyzed. With the combination ofanalysis of microstructure, the strengthening and toughening mechanism were alsodiscussed. In addition, self-crack healing and pre-oxidation were further presented bymeans of muffle furnace.
Introduction of ZrO_2fibers was significantly beneficial for the restriction of graingrowth of ZrB_2during densification. However, in order to obtain nearly full densematerial, higher sintering temperature and longer dwelling time were needed whichwould cause degradation of ZrO_2fibers and was also harmful to the mechanicalproperties. The optimum proportion of ceramic materials was studied, both SiC particleor SiC whisker and ZrO_2fiber were added into ZrB_2matrix ceramics. The preparationprocess was studied, the production of a homogeneous ceramic could be successfullyachieved by using a combination of20h milling time and hot-pressing at1850℃for1hunder a uniaxial load of30MPa with heating velocity of3.75℃·min~(-1)and coolingvelocity of1.67°C·min~(-1). The flexural strength and fracture toughness of thehot-pressed ZrB_2-20vol.%SiC_p-15vol.%ZrO_(2f)(Z20S_p15Z_f) and ZrB_2-20vol.%SiC_w- -15vol.%ZrO_(2f)(Z20S_w15Z_f) ceramics reached1084MPa,680MP and6.8MPa·m1/2,8.0MPa·m1/2, respectively. And the flexural strengths after testing at900℃were604MPa and724MPa, respectively.
A transmission electron microscopy study on the characteristics of grain boundaryof ZrB_2-SiC-ZrO_(2f)ceramics was presented. The contour of grain boundary ofZ20S_p15Z_fceramic was illegible, which was attributed to the weak reaction of SiCparticle and ZrO_(2f)iber. On the contrary, no reaction between the SiC whisker and ZrO_2fiber was existed in Z20S_w15Z_fceramic. The analysis of single crystal electrondiffraction pattern was presented, showing that the ZrO_2in fibers was of the tetragonalcrystalline structure, and the phase relationship between tetragonal and monoclinicphase was consistent to the crystal orientation relationship of100m//100t，
001m//001t. The existence of tetragonal phase was the necessary condition fortransformation toughening. In addition, the orientation distribution of ZrO_(2f)ibers inhot-pressed ZrB_2-SiC-ZrO_(2f)exhibited the same preferred orientation obtained from themeasured data of electron backscatter diffraction. The distribution of ZrB_2and SiCparticles in Z20S_p15Z_fceramic was random, which could reach the macro isotropy. Butthe appearance of preferred orientation was found in Z20S_w15Z_fceramic, which wouldshow the macro anisotropy. The low energy boundaries related to mechanical propertiesof materials, such as low angle and low ΣCSL grain boundaries, were found in bothmaterials.
In order to predict the instability of ceramics, characterizing and understandingcrack resistance curve (R-curve) behavior are very important. The traditional ceramicswithout R-curve behavior exhibit a large strength scatter. In this study, R-curves forZrB_2-SiC-ZrO_(2f)ceramics were evaluated by using the indentation-strength in bending(ISB) technique and the envelope method. The analytical results revealed thatZrB_2-based ceramics toughened by ZrO_(2f)ibers provided obvious R-curve. Based on thetheoretic models for toughening mechanisms, quantification of every tougheningmechanism was analyzed, and the total fracture toughness (Ktot) was calculated by usingthe linear superposition method. Compared to Z20S_p15Z_fceramics, Z20S_w15Z_fceramics had higher fracture toughness, which attributed to improvements oftoughening effects of crack deflection (97%), crack bridging (5%), fiber pull-out (26%)and transformation toughening (15%). The introduction of SiC whisker was benefit tothe crack deflection and also had promotion impact to other toughening mechanisms.
Self-crack healing and preoxidation treatment of ZrB_2-SiC-ZrO_(2f)ceramics weresystematically studied. The oxidized sensitivity of Z20S_p15Z_fand Z20S_w15Z_fwere different. The initial oxidation temperature of Z20S_p15Z_fceramic was800℃, while thatof Z20S_w15Z_fwas1000℃, and the oxidation rate of Z20S_w15Z_fwas lower than that ofZ20S_w15Z_fceramic. Overquick oxidation rate would produce too much surface oxide,which was harmful to the improvement of mechanical properties. Flexural strength ofZ20S_w15Z_fwas greatly improved to757±23MPa after preoxidation at800℃for30min in air, which was improved by11%compared to the original strength. The effect ofpreoxidation on the mechanical properties was investigated. Microstructure analysissuggested that less oxide was produced because of low oxidation rate, and the formedoxide could heal and blunt the surface defects i.e. microcraks, porosities, which wasalso benefit for self-crack healing. The optimum healing condition for both Z20S_p15Z_fand Z20S_w15Z_fwas treated at1200℃for30min, and the flexural strength wasimproved to630±51MPa and632±29MPa, respectively.
引文
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