Graphene added multilayer ceramic sandwich (GMCS) composites: Structure, preparation and properties

10 years of research on toughness enhancement of structural ceramics by graphene

Over the past decade, a new family of ceramic matrix composites has been developed from the incorporation of homogeneously dispersed graphene-based fillers (graphene nanoplatelets/GNP, graphene oxide sheets/rGO or graphene nanoribbons/GNR) into the ceramic matrices. These composites have shown a significant increment of their fracture toughness accompanied by other electrical and thermal functionalities, which make them potentially attractive for a wide range of applications. Here, the main methods for testing the fracture toughness of these composites are described, then the principal observations on the reinforcing mechanisms responsible for this improvement are briefly reviewed, and we discuss the relation with graphene platelets type, morphology and alignment. This article is part of the theme issue 'Nanocracks in nature and industry'.

Microstructure, Mechanical and Tribological Properties of Si3N4/Mo-Laminated Composites

(1) Background: the applications of ceramic materials in a friction pair and a moving pair are limited, just because of their poor toughness and unsatisfactory tribological characteristics. In view of this, Mo as a soft metal layer was added into a Si₃N₄ matrix to improve its toughness and tribological characteristics. (2) Methods: The microstructure and metal/ceramic transition layer were examined using X-ray diffraction, scanning electron microscope, electron dispersive X-ray spectroscopy, and Vickers hardness. Bending strength and fracture toughness were also measured. Tribological characteristics were obtained on the pin-on-disc wear tester. (3) Results: It can be found that the multilayer structure could improve the fracture toughness of laminated composite compared with single-phase Si₃N₄, but the bending strength was significantly reduced. Through microstructure observation, the transition layer of Si₃N₄/Mo-laminated composite was revealed as follows: Si₃N₄→MoSi₂→Mo₅Si₃→Mo₃Si→Mo. Moreover, the addition of the Mo interface to silicon nitride ceramic could not significantly improve the tribological properties of Si₃N₄ ceramic against titanium alloy in seawater, and the friction coefficients and wear rates of the sliding pairs increased with the increase in load. (4) Conclusions: The process failed to simultaneously improve the comprehensive mechanical properties and tribological performance of Si₃N₄ ceramic by adding Mo as the soft interfacial layer. However, the utilization of metal interfacial layers to enhance the toughness of ceramics was further recognized and has potential significance for the optimization of ceramic formulation.

Mechanical Properties and Deformation Mechanisms of Graphene Foams with Bi-Modal Sheet Thickness by Coarse-Grained Molecular Dynamics Simulations

Graphene foams (GrFs) have been widely used as structural and/or functional materials in many practical applications. They are always assembled by thin and thick graphene sheets with multiple thicknesses; however, the effect of this basic structural feature has been poorly understood by existing theoretical models. Here, we propose a coarse-grained bi-modal GrF model composed of a mixture of 1-layer flexible and 8-layer stiff sheets to study the mechanical properties and deformation mechanisms based on the mesoscopic model of graphene sheets (Model. Simul. Mater. Sci. Eng. 2011, 19, 54003). It is found that the modulus increases almost linearly with an increased proportion of 8-layer sheets, which is well explained by the mixture rule; the strength decreases first and reaches the minimum value at a critical proportion of stiff sheets ~30%, which is well explained by the analysis of structural connectivity and deformation energy of bi-modal GrFs. Furthermore, high-stress regions are mainly dispersed in thick sheets, while large-strain areas mainly locate in thin ones. Both of them have a highly uneven distribution in GrFs due to the intrinsic heterogeneity in both structures and the mechanical properties of sheets. Moreover, the elastic recovery ability of GrFs can be enhanced by adding more thick sheets. These results should be helpful for us to understand and further guide the design of advanced GrF-based materials.

Preparation and Properties of Layered SiC-Graphene Composites for EDM

Three and five-layered silicon carbide-based composites containing 0, 5, and 15 wt.% of graphene nanoplatelets (GNPs) were prepared with the aim to obtain a sufficiently high electrical conductivity in the surface layer suitable for electric discharge machining (EDM). The layer sequence in the asymmetric three-layered composites was SiC/SiC-5GNPs/SiC-15GNPs, while in the symmetric five-layered composite, the order of layers was SiC-15GNPs/SiC-5GNPs/SiC/SiC-5GNPs/SiC-15GNPs. The layered samples were prepared by rapid hot-pressing (RHP) applying various pressures, and it was shown that for the preparation of dense 3- or 5-layered SiC/GNPs composites, at least 30 MPa of the applied load was required during sintering. The electrical conductivity of 3-layered and 5-layered composites increased significantly with increasing sintering pressure when measured on the SiC surface layer containing 15 wt.% of GNPs. The increasing GNPs content had a positive influence on the electrical conductivity of individual layers, while their instrumented hardness and elastic modulus decreased. The scratch tests confirmed that the materials consisted of well-defined layers with straight interfaces without any delamination, which suggests good adhesion between the individual layers.

Microstructure and Fracture Mechanism Investigation of Porous Silicon Nitride-Zirconia-Graphene Composite Using Multi-Scale and In-Situ Microscopy

Silicon nitride–zirconia–graphene composites with high graphene content (5 wt.% and 30 wt.%) were sintered by gas pressure sintering (GPS). The effect of the multilayer graphene (MLG) content on microstructure and fracture mechanism is investigated by multi-scale and in-situ microscopy. Multi-scale microscopy confirms that the phases disperse evenly in the microstructure without obvious agglomeration. The MLG flakes well dispersed between ceramic matrix grains slow down the phase transformation from α to β-Si₃N₄, subsequent needle-like growth of β-Si₃N₄ rods and the densification due to the reduction in sintering additives particularly in the case with 30 wt.% MLG. The size distribution of Si₃N₄ phase shifts towards a larger size range with the increase in graphene content from 5 to 30 wt.%, while a higher graphene content (30 wt.%) hinders the growth of the ZrO₂ phase. The composite with 30 wt.% MLG has a porosity of 47%, the one with 5 wt.% exhibits a porosity of approximately 30%. Both Si₃N₄/MLG composites show potential resistance to contact or indentation damage. Crack initiation and propagation, densification of the porous microstructure, and shift of ceramic phases are observed using in-situ transmission electron microscopy. The crack propagates through the ceramic/MLG interface and through both the ceramic and the non-ceramic components in the composite with low graphene content. However, the crack prefers to bypass ceramic phases in the composite with 30 wt.% MLG.