Since the advent of ceramic fibers, this new material has instantly occupied many markets, from welding protection to aerospace, you can see it.
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How did ceramic fibers upend the field of materials in just a few decades? Heaterk will take stock of the development of ceramic fibers for you.
Development of Ceramic Fiber
In , the American Babcock Wilcox Company used natural kaolin to be melted in an electric arc furnace and blown into ceramic fibers.
In the late s, two companies in the United States produced aluminum silicate fibers and used them for the first time in the aerospace industry.
In the s, ceramic fibers have been formally put into industrial production.
In the s, various ceramic fiber products were developed and used in the wall lining of industrial kilns.
Since the global energy crisis in , ceramic fibers have developed rapidly, among which aluminum silicate fibers have developed the fastest, with an annual growth rate of 10% to 15%.
Development Status of Ceramic Fiber
The United States and Canada are significant producers of ceramic fibers, with an annual output of about 100,000 tons, accounting for about 1/3 of the world's total production of refractory fibers.
The output of ceramic fiber in Europe ranks third, with an annual production of about 60,000 tons. Among the ceramic fibers with a yearly output of 300,000 tons, the proportion of various products is rough: blankets and fiber modules 45%; vacuum forming panels, felts, and special-shaped products 25%; bulk fiber cotton 15%: fiber rope, cloth, and other fabrics 6%; fiber amorphous material 6%: fiber paper 3%.
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Development status of ceramic fiber in China
China's ceramic fiber production started relatively late. In the early s, it was successfully developed and put into mass production in Beijing Refractory Factory and Shanghai Refractory Factory. In the following 10 years, ceramic fiber products were mainly produced by the process of "electric arc furnace melting, primary air blowing into fibers, and wet hand-made felting." The technology is backward, and the products are single.
In , Shougang Company's refractory material factory introduced the resistance method spinning into fiber ceramic fiber needle-punched blanket production line from CE Company in the United States; until , Henan Shanxian Electric Guangdong Gaoming Aluminum Silicate Fiber Factory and Guiyang Refractory Material Factory respectively. The introduction of 3 ceramic fiber acupuncture blanket production lines and vacuum forming technology with different scales and fiber-forming methods from BW Company and Ferro Company in the United States has changed the appearance of backward production equipment and single product in my country's ceramic fiber production process.
Since , my country has developed and designed 82 different types of resistance methods spinning (or blowing) fiber-forming dry acupuncture blanket production lines through the digestion and absorption of the imported ceramic fiber production equipment and technology, combined with national conditions, In 45 companies. The annual output has reached more than 100,000 tons, becoming the world's largest producer. Diversified product varieties: in addition to mass production of low-temperature type, standard type, high-pure type, high-aluminum type, and other ceramic fiber acupuncture blankets and ultra-light resin dry-process felt (board), it can also produce 14%~17% ZrO2 composite fiber blanket. Its operating temperature can reach above &#;.
In the late s, Japan's Naoki Weaving Company, Interlais, and other woven products companies successively invested in and built professional ceramic fiber textile production enterprises in Beijing and produced ceramic fiber cloth, belt, twisted rope, casing, and square packing in batches. Such as ceramic fiber textiles, bulk fiber cotton, and process equipment required for producing fiber fabrics have been localized.
In the early s, Beijing, Shanghai, Liaoning Anshan, Shandong, Henan Sanmenxia, and other places successively introduced ceramic fiber spraying technology and equipment from the United States, France, Kouben, and other countries; and applied ceramic fiber to industrial kilns in metallurgy and petrochemical sectors. Spraying the furnace lining saves energy consumption and achieves good economic benefits. It has been widely promoted and has gained successful experience applying industrial furnaces and heating devices in metallurgical and mechanical sectors. The ceramic fiber castables, plastics, smears, and other fibrous amorphous materials have not only established domestic production enterprises. Still, they have also been popularized and applied in various industrial furnaces, heating devices, and high-temperature pipelines.
At present, my country's ceramic fiber has been in the stage of continuous adjustment and development. The production process and equipment of ceramic fiber, especially the production process and equipment of dry acupuncture blankets, are at the world's advanced level. New ceramic threads and products such as fiber, polycrystalline mullite, and mixed fiber products have been successfully developed. They have been put into industrial production to make fibrous light refractory materials form a complete series of products. The continuous expansion of the application range of ceramic fibers has led to the increasing popularity of the application of high-strength, weather-resistant stiff fiber wall linings. At the same time, the development of ceramic fiber production technology has extensively promoted the development of ceramic fiber application technology and construction methods.
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applications will require new materials with improved thermomechanical and thermochemical properties. CMCs are recognized as having the potential for providing high strength, toughness, creep resistance, notch insensitivity, and environmental stability at temperatures that will meet the anticipated needs of future high-performance turbine engines and power generators.
In addition to turbine engine components, there are several industrial applications for which a comparatively large market could be realized for a broad range of CMC components. For example, hot gas filters for pressurized fluidized bed combustion (PFBC) and furnace hardware, such as pipe hangers for petroleum refining, represent potential near-term applications for CMCs. These relatively low-risk industrial applications could provide the market volume necessary to lower fiber costs (and prices) significantly, as well as to develop experience and confidence in using CMCs. Longer-range industrial uses for CMCs include heat exchangers for externally fired combined cycle (EFCC) power systems and reforming tubes for the chemical processing industry. Substantial improvements will be required, however, in the thermomechanical and thermochemical properties of ceramic fibers and coatings to enable CMCs to meet the service lifetime requirements.
Composite materials derive benefits both from the properties of their constituent phases and from the method of their combination, including the tailoring of interfaces between phases, to achieve properties that none of the constituents exhibits individually. For example, CMCs have well demonstrated damage tolerance, which is attributed to frictional sliding at fiber matrix interfaces (see, for example, Box 1-1). Frictional sliding is enabled by fiber interfacial coatings. Damage tolerance is manifested in ductilities on the order of 1 percent and notch sensitivity comparable to aluminum (Al) alloys. CMCs also have excellent room-temperature fatigue properties, with thresholds (stress below which fatigue does not occur) at about 90 percent of their ultimate tensile strength (UTS). However, fatigue problems are evident at elevated temperatures. The UTS of CMCs (typically 300 MPa [44 ksi]), although not exceptional, is volume invariant because the damage tolerance suppresses the weakest link scaling effects found in monolithic ceramics. That is, because of crack deflection and crack tip blunting mechanisms, CMCs can tolerate cracking that would lead to catastrophic failure in monolithic ceramics. These thermomechanical properties are particularly attractive for large, static, thermally-loaded components.
The CMC market is divided into two classes, oxide and non-oxide materials. Oxide composites consist of oxide fibers (e.g., alumina [Al2O3]), interfacial coatings, and matrices. If any one of these three components consists of a non-oxide material (e.g., silicon carbide [SiC]), the composite is classified as a non-oxide composite. These classes have different properties, different levels of development, and different potential applications.
Because most development work has been done on non-oxide materials, particularly SiC fiber-reinforced SiC CMCs (SiC/SiC) with fiber interfacial coatings of either carbon or boron nitride, non-oxide CMCs are more advanced than oxide CMCs. Non-oxide CMCs have attractive high temperature properties, such as creep resistance and microstructural stability. They also have high thermal conductivity and low thermal expansion, leading to good thermal stress resistance. Therefore, non-oxide CMCs are attractive for thermally loaded components, such as combustor liners (see Figure 1-4), vanes, blades, and heat exchangers.
Composite behavior has also been studied in oxide systems (e.g., oxide fiber-reinforced porous oxide matrix composites with no interfacial coatings). Oxide composites have the attractive features of oxidation resistance, alkali corrosion resistance, low dielectric constants, and potentially low cost. Because of these properties, oxide CMCs could be attractive for hot gas filters, exhaust components of aircraft engines, chemical processing equipment, and long-life, lower temperature components.
Both oxide and non-oxide CMCs have demonstrated shortcomings. Embrittlement occurs at intermediate temperatures (~700°C [1,292°F]) in all non-oxide composites, exemplified by SiC/SiC. Embrittlement is most severe with cyclic loading beyond the proportional limit, whereupon matrix cracking occurs because oxygen that ingresses through the matrix cracks reacts locally with the fibers and fiber coatings to form oxide products. These reaction products suppress the internal friction mechanisms that otherwise impart toughness. Although this effect does not occur when the stresses remain below the proportional limit, design studies and end-user experience indicate that stress excursions above the proportional limit must be anticipated. Local embrittlement is, therefore, the dominant life-limiting phenomenon of non-oxide composites. The committee considers the solution to this problem to be imperative for long-life applications of non-oxide CMCs. A systems-level approach that includes considerations of fibers and fiber coatings, as well as ways to diminish oxygen ingress, is discussed in this report.
Oxide CMCs are not subject to oxidative embrittlement but have higher temperature limitations (~1,000°C [1,832°F]) associated with creep and sintering, both governed by the high diffusivities of oxides compared to SiC. Also, fiber coating technologies for oxide materials are less mature than coating technologies for non-oxide materials. In fact, nearly all of the performance data available for oxide CMCs are for systems in which interfacial coatings were not used, and damage tolerance was a result of matrix porosity. Concepts for suppressing the high-temperature degradation mechanisms (e.g.,
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