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    Ceramic Composites

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    Abhey Dogra
    The document discusses ceramic forming polymers and their use in producing ceramic matrix composites (CMCs). CMC brake rotors were developed as a drop-in replacement for steel rotors, offering advantages over competing materials in weight, wear life, noise reduction, and fade resistance. Testing showed the CMC rotors performed well and had significant market potential due to their desirable properties.

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    Ceramic Composites

    Uploaded by

    Abhey Dogra
    418 views29 pages
    The document discusses ceramic forming polymers and their use in producing ceramic matrix composites (CMCs). CMC brake rotors were developed as a drop-in replacement for steel rotors, offering advantages over competing materials in weight, wear life, noise reduction, and fade resistance. Testing showed the CMC rotors performed well and had significant market potential due to their desirable properties.

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    The document discusses ceramic forming polymers and their use in producing ceramic matrix composites (CMCs). CMC brake rotors were developed as a drop-in replacement for steel rotors, offering advantages over competing materials in weight, wear life, noise reduction, and fade resistance. Testing showed the CMC rotors performed well and had significant market potential due to their desirable properties.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    418 views29 pages

    Ceramic Composites

    Uploaded by

    Abhey Dogra
    The document discusses ceramic forming polymers and their use in producing ceramic matrix composites (CMCs). CMC brake rotors were developed as a drop-in replacement for steel rotors, offering advantages over competing materials in weight, wear life, noise reduction, and fade resistance. Testing showed the CMC rotors performed well and had significant market potential due to their desirable properties.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The key takeaways are that ceramic forming polymers allow control over ceramic composition and properties, and a major commercial application is brake rotors and friction materials due to advantages in weight, noise, and fade resistance over competing materials.

    Ceramic forming polymers allow production of ceramics with tailored composition and microstructure through control of the polymer precursor. They offer versatility in shapes, ease of processing, and ability to produce amorphous non-oxide ceramics. The polymers can inherently produce nanostructured materials upon pyrolysis.

    Applications that have been developed include brake rotors, which have been made as drop-in replacements for steel rotors without redesign needs. Other applications include motorcycle components, train rotors, and bus rotors.

    Pioneering Advanced Ceramics

    The Development and Commercialization of Polymer Derived Ceramic Matrix Composites

    Presented at the 2006 ASM/TMS Spring Symposium

    Pioneering Advanced Ceramics

    Outline
    1. 2. 3. 4. 5. 6. 7. Ceramic forming polymers the key to novel ceramic materials Chemistry and structure of Si-C based polymers Polymer properties control ceramic properties Applications for ceramic forming polymers Brake Rotors and Friction Materials Test Results Summary

    Pioneering Advanced Ceramics

    Why Ceramic Precursors?


    Versatility wide variety of ceramics, near net shapes Ease of use low temperature processing Can tailor ceramic - by precursor chemistry, thermal treatment, cure/pyrolysis/heat treatment atmosphere Only known method to easily produce amorphous non-oxide ceramics Inherently produce nano-structured materials

    Pioneering Advanced Ceramics

    Cost and Scale-up Were Issues


    IN THE PAST Ceramic-forming polymers were expensive ($500 $4000/kg) Some were pyrophoric, produced ammonia, solids needed oxygen or catalysts to crosslink Low ceramic yield many infiltration and pyrolysis cycles for dense part Laboratory curiosities, or limited to high end aerospace applications

    Pioneering Advanced Ceramics

    Tailored Si-C Backbone Polymers for Nano-Engineered Ceramic Materials


    corrosion/oxidation resistant to high temperatures HT CMCs

    Polycarbosilanes Silicon Carbide Thermally stable, Polycarbosiloxanes Silicon oxycarbides lower

    shrinkage, widely tailorable ceramics, release coatings, friction modifiers, Mid Temp CMCs air stable to 1100 C

    Alkoxycarbosilanes Silicon oxycarbides - thin films, low K dielectrics, friction modifiers, release coatings, foamed ceramics, photo-resist intermediates

    Polycarbosilanes

    Mg, ether

    Pioneering Advanced Ceramics

    Basic synthesis has two steps, coupling and reduction:


    1. n Cl CH 2
    SiRR' Cl CH 2 SiRR'

    R, R' = Cl, CH 3 , phenyl, OMe, OEt


    CH 2 SiRR'

    Reduction n

    2.

    CH 2

    SiH 2

    R, R' = Cl, OM e, OEt

    Resulting polycarbosilane is ideal for SiC formation


    CH2 SiH2

    850 C, inert gas n SiC (amorphous)

    (85% yield should be possible)

    Pioneering Advanced Ceramics

    SMP-10: a practical polycarbosilane


    H CH 2 SiH 2 CH 2 SiH H

    0.9

    0.1

    Amber liquid, 50 150 cPs. Low toxicity. Soluble in most non-polar and many polar solvents. Oxidizes only slowly in air at ambient temperatures.
    Used at the bench top in the atmosphere with standard protective equipment (gloves, apron, safety glasses, ventilation). For short-term storage, inerting with nitrogen is recommended. Shelf-life > 6 months when inerted and stored at -10 C

    Pioneering Advanced Ceramics

    SMP-10: Conversion to SiC


    Allyl groups improve actual ceramic yield (75 76% for medium MW polymer) With both Si-H and allyl present, Pt catalysts can be used to cure at lower temperatures (250 C) The slight additional C content is bound to Si resulting in high oxidative stability (<0.7% mass change,1000 hours at 900C) Heating to1600 C forms polycrystalline -SiC.
    H CH2 SiH2 0.9 CH2 SiH H 0.1 SiC + H2, some silanes and alkanes.

    Pioneering Advanced Ceramics

    Si-C Forming Polymer Processing

    Pioneering Advanced Ceramics

    SMP-10 Properties and Processing Parameters:


    Density (g/cc) Appearance Viscosity (cps) Solubility Melting Point (C/F) Flashpoint (C/F) Boiling Point (C/F) Moisture Absorption (%) Nominal Cure Temperature (C/F) 0.998 Clear, Amber Color 80-100 Hexane, Tetrahydrofuran, Acetone, Toluene Less than -100/-148 89/192 160/320 < 0.1% in 24 hrs at RT 400/752

    Pioneering Advanced Ceramics CURING PARAMETERS Cure Atmosphere Cure Heating Rate (C/min.) Cure Temperature* (C/F) Cure Hold Time (h) Fixture/Mold/Holder Material Mold Release Pyrolysis Heating Rate (C/min.) Pyrolysis Temperature (C/F) Pyrolysis Atmosphere Pyrolysis Hold Time (h) Pyrolysis Fixture/Holder Material Mold Release (Needed only if NOT cured first) Crystallization Heating Rate (C/min.) Crystallization Temperature (C/F) Crystallization Atmosphere Crystallization Hold Time (h) Crystallization Holder Material Nitrogen, Argon, Helium 1-3 Depending on part thickness 400/752 1-2 hours Aluminum, Brass, Steel, Graphite, Alumina Acrylic Spray/Tape, Kapton polyimides, Boron Nitride PYROLYSIS PARAMETERS 1-2 Depending on part thickness and porosity 850-1000/1562-1832 Nitrogen, Argon, Helium 1 hour Steel (850C Limit), Graphite, Alumina Same as for curing step 2 deg/min 1600/3000 Argon, Helium 6-8 Graphite

    CRYSTALLIZATION HEAT TREATMENT

    Pioneering Advanced Ceramics

    SMP-10, other carbosilanes: Applications


    SiC/C & SiC/SiC ceramic matrix composites (CMCs) for friction systems:
    Durability, high temp. strength Lightweight Controlled friction behavior

    CMCs & SiC powder slurries for industry:


    Chemical resistance, strength Adhesives and coatings Complex shapes easily formed

    Pioneering Advanced Ceramics

    Where to Apply Ceramic Forming Polymers?? Aerospace Still too R&D, no commercial market Electronics high margin, huge potential have
    value proposition

    Industrial chemical industry promising Energy Nuclear, coal, fuel cells - future Biomaterials Long qualification cycle Transportation Huge market, quick entry, obvious
    value proposition, properties create market pull

    Pioneering Advanced Ceramics

    Ceramic Composite Brake Rotors


    Quantifiable advantages over competing materials weight, wear life, reduced noise, inverse
    fade

    Market Pull Doesnt push performance envelope of material Developed drop-in replacement system for metal with better performance Can cut as much as 300 lbs from car Already below cost of competing high end materials MI and C/C closing in on steel

    Pioneering Advanced Ceramics

    Traditional Composite Processing


    Carbon Fabric Cert Fabric Heat Treat Weight 350oC Press Cure Machine Lay-up Rotors Vacuum Impregnation 850oC Kiln Dens Prepreg Fabric Ceramic Polymer & Fillers Total Solids Cad Cut Plies

    Polymer viscosity Grinding

    Delivery
    Dim Insp Surf Fin, DTV

    Pioneering Advanced Ceramics

    Composite Brake Rotor Lay-up


    - 45o 0o + 45o 90o

    Pioneering Advanced Ceramics

    6k T-300 Reinforced SMP-10 with SiC Filler

    Pioneering Advanced Ceramics

    Melt Infiltration Chopped Fiber Reinforcement cost Si + C SiC


    Free Silicon and Carbon Variable Crystal size Moderate Conductivity Fiber Conversion to SiC Low Yield due to porosity Higher Capital Investment

    Polymer Impregnation Continuous Fiber Reinforcement [SiH2-C]n SiC + H2


    Stoichiometric SiC Controllable crystal size Moderate Conductivity Fibers Protected Excess Strength Low Capital Investment

    Low Toughness (4MPa-m1/2) High Toughness(22MPa-m1/2) Polymer Derived Ceramic Toughness Eliminates Cracks

    Pioneering Advanced Ceramics

    2D 6k T-300 w/ Filler Mechanical Properties Property Value Value Tensile Strength 35 - 39ksi 250-288MPa Tensile Modulus 11-12Msi 77-91GPa Flex Strength 28-38ksi 196-275MPa Interlaminar Shear(SBS) 4-5ksi 28-34MPa In Plane Thermal .9-1ppm/oF 1.5-1.8ppm/oC Expansion Thermal Conductivity - x,y 21.8BTU/Hr-ft-oF 25-40W/MK -z 5.4BTU/Hr-ft-oF 5-8W/MK 15-18ksi-in1/2 Toughness 22MPa-m1/2 140lb/ft3 2.25gm/cm3 Density gm/cm3

    Pioneering Advanced Ceramics

    Ducatti 999 StarBlade and Carrier 5 mm thick 320 mm in diameter

    6 lbs weight savings on front axle

    Pioneering Advanced Ceramics

    Motorcycle Structural Analysis

    Fatigue Tested at 150% for 3000 cycles and 200% for 900 cycles

    Pioneering Advanced Ceramics

    StarBlade TM Fatigue Testing Cycles


    1000 900 800 700

    Torque Level ft-lbs

    600 500 400 300 200 100 0 1 10 100 1000 10000 100000

    Brake Cycles

    Pioneering Advanced Ceramics

    Friction Performance:12 on a scale of 10


    Jason DiSalvo, Las Vegas International Speedway, Dec 9, 2004

    Yamaha Factory Racing Team 2004 YZF-R1

    Pioneering Advanced Ceramics

    Motorcycle Friction Summary


    Disc Pad Rider Rank Average Global Sensitivity Speed Sensitivity Temp sensitivity Pad wear (mm) Disc wear (mm)

    CMC CMC
    C/C Cast Iron Stainless Steel Stainless Steel Stainless Steel

    Sintered PRO 129


    C/C PRO 129 PRO 129 CP911 Organic RX Sintered

    12 9
    8 9 10 9 8

    0.65 0.63
    0.55 0.64 0.66 0.60 0.57

    .28 0.32
    0.28 0.18 0.16 0.14 0.23

    .10 0.09
    0.08 0.01 0.05 0.06 0.22

    .05 0.06
    0.12 0.11 0.04 0.02 0.04

    .890 1.376
    3.45 0.452 0.643 0.672 0.304

    -.003 -0.009
    0.250 0.006 0.001 0.001 -0.003

    Pioneering Advanced Ceramics

    Composite Damping Reduces NVH


    Damping Curves

    Cast Iron Resonant Frequency = 956Hz Damping Coeff = 4.62 sec-1 Loss Factor = .0015

    Composite/Al Hub Resonant Freq = 1013Hz Damping Coeff = 12.07sec-1 Loss Factor = .0037

    Composite rotor dampens induced noise 1800 times faster than cast iron

    Pioneering Advanced Ceramics

    Composite Rotor Cost Reduction 13 OD Tahoe Rotor


    Initial
    1000

    Current

    Probable

    Manuf Cost $/Rotor

    800 600 400


    305 650

    200 0 1000 10000

    149

    125

    100000

    1000000

    Combined Volume Rotors/Year

    Current Porsche Option Cost $10,500/Boxter

    Pioneering Advanced Ceramics

    Train Rotor

    Pioneering Advanced Ceramics

    BUS Rotor - 28lbs vs 85 lbs 16,600ft-lb torque

    Pioneering Advanced Ceramics

    Summary
    1. Ceramic forming polymers permit control of the composition, microstructure and properties of ceramic materials 2. A major non-aerospace commercial market for CMCs is brake rotors and friction materials 3. Polymer-derived ceramic brake rotors have been developed as drop-in replacements for steel no redesign needed 4. Major advantages over competing high end materials MI and C/C 5. Significant market pull due to lower weight, lower noise, no fade, etc. 6. Within reach of cost targets at low volume selling product now!

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