Design, fabrication and properties of layered SiC/TiC ceramic with graded thermal residual stress

The finite element method (FEM) was used to design a symmetrical layered SiC/TiC ceramic with gradual thermal residual stress distribution. In the final model ceramic, the sequence of layers, from surface to inside, was SiC, SiC+2 wt.% TiC (S2T), SiC+4 wt.% TiC (S4T), SiC+6 wt.% TiC (S6T), SiC+8 wt.% TiC (S8T), and SiC+10 wt.% TiC (S10T); the thickness ratio of SiC:S2T:S4T:S6T:S8T:S10T was 1:1:1:1:1:10. After the model ceramic had been cooled from assumed sintering temperature 1850–20 °C in FEM calculation, gradual thermal residual stress, varying from surface compressive stress to inner tensile stress, was introduced. The designed ceramic then was fabricated by aqueous tape casting, stacking and hot-press sintering at 1850 °C, under 35 MPa pressure, for 30 min. The surface stress conditions of the sintered ceramic were tested by X-ray stress analysis, and those results were very close to the results from the FEM calculations. Compared with pure SiC and S10T ceramics fabricated by the same process, the designed ceramic showed excellent mechanical properties. The tested strength was close to the theoretical value. The strengthening and toughening mechanisms of the ceramic were ascribed to surface compressive residual stress.