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Effect of graded microstructure on the modulus, hardness, and strength of hot-pressed ZrB2-B4C FGM

  • Ceramics
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Abstract

A ZrB2-B4C functionally graded composite (FGM) tile with 100 mm diameter and 6 mm thickness with ZrB2 content varying from 70% in the top layer to 10% in the bottom layer was fabricated using vacuum hot pressing. The density of the fabricated FGM is ~ 35% lower than monolithic ZrB2. To the best of our knowledge, ultra high temperature ceramic FGMs of such large dimensions have never been reported in the published literature. The FGM showed a smooth compositional transition without defects in the interlayer regions. Young’s modulus of the FGM and its individual layers was determined using non-destructive ultrasound phase spectroscopy and overall Young’s modulus of the FGM was correlated to the volume fraction averaged weighted sum of Young’s modulus of each layer. The good interparticle bonding and lack of residual porosity in the top and middle layers resulted in high hardness and excellent wear resistance. The flexural strength of the FGM is approx. 400 MPa and the fracture mode displays a transition with composition along the thickness direction. Even under flexural loading, the interlayer regions remain intact, rendering excellent structural stability to the FGM. The fracture mechanism of the FGM has been discussed in light of the processing-induced thermal residual stress present in each layer and the presence of residual porosity and compositional gradient. The combination of low density, smooth interlayer transition, high flexural strength, as well as excellent hardness and wear resistance at the top layer renders the developed FGM potentially very attractive for thermal protection applications in hypersonic aircraft and re-entry vehicles.

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Acknowledgements

We thank the Material and Manufacturing Panel of Aeronautics R&D Board (ARDB), Govt. of India for the research funding with the project no.1977. The authors extend their appreciation to Mr. Nilesh Thakre (technical officer) and Mr. Vinod kumar Patle (technician) for their invaluable assistance with the hot-pressing process. AKN would like to thank “Mitacs Globalink Research Award to Canada” for funding his stay at UBCO, Canada with the Application Ref.: IT33806.

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Authors and Affiliations

  1. Department of Metallurgical and Materials Engineering, Indian Institute of Technology Kharagpur, Kharagpur, 721302, India

    Ajit Kumar Naik, Tapas Laha & Siddhartha Roy

  2. School of Engineering, The University of British Columbia-Okanagan, Kelowna, BC, V1V 1V7, Canada

    Lava Kumar Pillari & Lukas Bichler

  3. Defence Metallurgical Research Laboratory, Hyderabad, Kanchanbagh, Telangana, 500058, India

    Manish Patel

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  1. Ajit Kumar Naik
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Naik, A.K., Pillari, L.K., Patel, M. et al. Effect of graded microstructure on the modulus, hardness, and strength of hot-pressed ZrB2-B4C FGM. J Mater Sci 59, 8682–8705 (2024). https://doi.org/10.1007/s10853-024-09720-3

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