24th Annual Conference on

Composites, Advanced Ceramics,

Materials, and Structures: B

Todd Jessen Ersan Ustundag Editors

January 23-28,2000 Cocoa Beach, Florida

Published by The American Ceramic Society 735 Ceramic Place Westerville, OH 43081

0 2000 The American Ceramic Society ISSN 0 196-62 I9

24th Annual Conference on

Corn posites, Advanced Ceramics,

Materials, and Structures: B

24th Annual Conference on

Composites, Advanced Ceramics,

Materials, and Structures: B

Todd Jessen Ersan Ustundag Editors

January 23-28,2000 Cocoa Beach, Florida

Published by The American Ceramic Society 735 Ceramic Place Westerville, OH 43081

0 2000 The American Ceramic Society ISSN 0 196-62 I9

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Cover photo, "TEM image near the interface between diamond and Sic film.," is courtesy of Y Miyamoto, J. Lin, H. Moriguchi, A. Ikegaya, Y Yamashita, T. Kashiwagi, and 0. Yamaguchi and appears as figure 6 in their paper "Reactive Coating o f Sic on Diamond Particles," which begins on page 185.

Contents 24th Annual Conference on Composites, Advanced Ceramics, Materials, and Structures: B

Preface ...................................... .xv

ADVANCED SYNTHESlS and PROCESSING

Materials Synthesis Synthesis of Single Phase (Ba,Sr)TiO, by a Reactive Process . . .3 8. Bhaduri, W.A. Prisbrey, J.B. Jokisaari, and S.B. Bhaduri

Fabrication of CeramiclEpoxy Crystals by Stereolithography . . I 3 S . Kirihara,Y. Miyamoto, and K. Kajiyama

Unidirectionally Porous Oxides Prepared Using Eutectic Reactions .............................. . I 9 Y Suzuki,TYamada, S. Sakakibara, andT Ohji

Plasma Jet Generation over the Liquid Surface and

7: Suzuki and S.Wada I t s Application to Diamond Synthesis . . . . . . . . . . . . . . . . . .25

Synthesis and Characterization of Fine-Grained 3Y-TZP/Hexaferrite In Situ Composites . . . . . . . . . . . . . . . . .3 I Y Suzuki, M.Awano, N. Kondo, andT Ohji

Environment Conscious Ceramics (Ecoceramics) ......... .39 M. Singh

Materials Processing Suspension of Sic Powders in Allylhydridopolycarbosilane (AHPCS): Control of Rheology F.I. Horwitz

...................... .45

V

Biostructure Derived Ceramics ..................... .53 H. Sieber, A. Kaindl, and F1 Greil

Structural Ceramics through Particle-Filled Preceramic Polymers: Suspension and Particle Filtration Characterization ........................ .6 I M. Erdal, L.A.Ambrosoni, and Z. Guo

Texture Development in Reaction-Bonded Alumina (RBAO) Ceramics via Templated Grain Growth ........... .7 I E. Suvaci and G.L. Messing

Oxidation and Transport Phenomena in the Reaction-Bonded Aluminum Oxide (RBAO) Process . ....... .79 E. Suvaci, G. Simkovich, and G.L. Messing

Two-Phase Materials in the Alumina-Yttria System Produced by Mechanical Alloying .................... .87 J.Alkebro, R.Warren, S. Begin-Colin, and A. Mocellin

Spark Plasma Sintering of Mullite-Zirconia-TiO, Ceramics . .. .95 E. Rocha-Rangel, H. Balmori-Ramirez, SDTorre, H. Miyamoto, M. Umemoto, and K.Tsuchiya

Fabrication of Channel Structures in Ceramics That Were Sintered and Joined by Microwave Heating ........ .I03 1.G. Lee, E.D. Case, H.W. Shin, and I? Kwon

Solid Freeform Fabrication Solid Freeform Fabrication and Design . . . . . . . . . . . . . . . .I I I S.Ventura, S. Narang, DTwait, F.F. Lange, P Khandelwal, and E. Cohen

Extrusion Freeform Fabrication of Functional

R.Vaidyanathan, J.L. Lombardi, 1. Walish, S. Kasichainula, I? Calvert, and K. Cooper

Light Weight Ceramic Composites from Laminated

H. Sieber; H. Friedrich, J. Zeschky, and I? Greil

Ceramic Prototypes ............................. I2 I

Paper Structures ............................... I29

vi

Solid Freeform Fabrication of Advanced Ceramics . ....... .I35 C. Gasdaska,V. Jamalabad, M. Ortiz, B. Mitlin, and D.Twait

Solid Freeform Fabrication of a Telescoping Actuator

B.A. Bender; R.J. Rayne, and C.C.Wu via Laminated Object Manufacturing . ................ I43

Solid Freeform Fabrication of lntermetallics and Their Ceramic Composites by Reactive Rapid Prototyping . . . I 5 I K. Matsuura, M. Kudoh, S. Kirihara, andY Miyamoto

Design Tools for Multi-Material layered Manufacturing System ........................... I59 N.A. Langrana, D. Qui,W. Han, M.A. jafari, S.C. Danforth, and A. Safari

Wear Resistant Coatings The Influence of Substrate Microstructure on the Crack Formation of CrN Coatings on Brass . ........... ,167 S. Krishnamurthy and I.E. Reimanis

Environmentally Benign Ceramic Composite Coatings with Advanced Tribological Properties

Reactive Coating of Sic on Diamond Particles

. ............... I77 D F Scherel; R. Gadow, and A. Killinge

. . . . . . . . . . .I85 Y M i yamoto. J. Li n, YYamash ita, T Kas h i wagi, 0. Yamaguc h i, H. Monguchi, and A. lkegaya

Determination of Strength of Double-layer Br i t t le Coatings on Metallic Substrates by Four-Point Bend Test ... I93 0. Unal and D.J. Sordelet

Interface Debond Coutings: Oxide Monazite and Scheelite Deformation Mechanisms . . . . . . . . .203 R.S. Hay

Porous Rare-Earth Aluminate Fiber Coatings for

M.K. Cinibu1k.T.A. Parthasarathy, K.A. Keller, andT. Mah

Oxide-Oxide Composites ......................... .2 I 9

vii

Monazite Coatings on Nextel 720TM, 6 I O'", and Tyranno-SA Fiber Tows: Effect of Precursors on Fiber Strength . ...... .229 E.E. Boakye, M.D. Petry, R.8 Hay, L.M. Douglas

Mg-Si-Al-0 Coatings on Hi-Nicalon Sic Fiber by Alkoxide Method .............................. .237 N. Igawa,TTaguchi, R.Yamada, and 8. Jitsukawa

Effects of MulliteNSZ Coatings on the Performance of SiC/SiC Composite Combustion l iners . . . . . . . . . . . . . . .243 L.C. Russell, 1. Sankar, R.A. Miller, D. Zhu, and A. Calomino

Surface Characterization of Plasma Sprayed H yd roxyapati t e Coatings ......................... .2 5 I L. Sun, C.C. Berndt,A. Kucuk, R.S. Lima, and K.A. Khor

Interface Debond Coatings: Non-oxide Effect of Multiple Coating Interfacial Structures on

W.Yang, H. Araki, J.U. Park,T: Noda,A. Kohyama, and J.Yu Bending Properties of FCVl SiC(SiC Composites . ........ .259

BN and SiBN Fiber Coatings via CVD Using a Single- Source liquid Precursor Based on Borazine . . . . . . . . . . . . .267 F.I. Horwitz, D.R.Wheelec FIV. Chayka, C. Xu,TR. McCue, andYL. Chen

Silicon Carbide Fibers with Boron Nitride Coatings ....... .275 M.D. Sacks and J.J. Brennan

Optimization of New Precursor Systems for Continuous Fluid Carbon Fiber Coating ....................... .283 N. Doslik, R. Fischer; and R. Gadow

FiberlWhisker Synthesis and Characterization Fabrication and Mechanical Properties of Si-M-C-(0) Tyranno Fibers ................................ .29 I K. Kumagawa, H.Yamaoka, M. Shibuya, M. Suzuki, andTYamamura

... V l l l

MONOLITHIC STRUCTURAL MATERIALS

Oxide Based Ceramics

Mechanical Behavior

Environmental Effects on Crack Propagation of Alumina Ceramics ............................. .385 M.E. Ebrahimi, J. Chevalier, and G. Fantozzi

Strengths and Deformation of Single Crystal Oxides at Ambient and Elevated Temperatures for Refractive Solar Concentrator Applications .................... .397 S.R. Choi, D. Zhu, and R.A. Miller

Electrokinetic Aspect of Friction and Wear of Oxide Ceramics ............................... .407 S. Novak and JVizintin

Processing and Structure Conformation of Honey-Rod ...................... .4 15 M. Rodriguez, E. Rocha, and R.T. Hernandez

Transparent MgAI,O, Spinel-Revisited . . . . . . . . . . . . . . . . .423 M.C.L. Patterson, J.E. Caiazza, G. Glide, and D.W. Roy

Processing of Bone Ash Based Dental Implant Material with Zirconia Addition .......................... .43 I R. Artir;Y Karakas, and C. Bindal

The Effects of Waste loading on the Durability of Nuclear Waste Glasses .......................... .439 G. Darby, D.E. Clark, and G. Wicks

Glass-Ceramics in the System Ca,[POJ,F-CaAI,Si,0,-CaMgSi~06 ..................... ,447 D.Tulyaganov

Martensitic Transformation of Y,AI,O, ................ .455 M. Shimada, H.Yamane, and B.A. Hunter

X

Microstructure Control of Alumina Ceramics ........... .46 I S. lio, H.Yamamoto, andT Mitsuoka

On The Mechanism of MoSi, Pesting in the

K. Hansson, M. Halvarsson, J.E.Tang, J.E. Svensson, M. Sundberg, and R. Pompe Temperature Range 400-500°C .................... .469

An Investigation of the Microstructure in the Pest Oxide of a MoSi,-Based Composite . . . . . . . . . . . . . . . . . . .477 J.E.Tang, M. Halvarsson, A. Kvist, K. Hansson, J.E. Svensson, and R. Pompe

Non-Oxide Bused Ceramics

Mechanical Behavior

Gelcast AS800 Materials Characterization for Rocket Engine Applications ....................... .485 S.R. Khoshbin

Intermediate Temperature Inert Strength and Dynamic Fatigue of Candidate Silicon Nitrides for Diesel Exhaust Valves ......................... .497 A.A. Wereszczak,T.P Kirkland, H.T. Lin, and S.K. Lee

Superplastically Sinter-Forged Silicon Nitride . . . . . . . . . . . .509 N. Kondo,Y Suzuki, andT Ohji

Creep Resistant Silicon Nitride Ceramics-Approaches

A. Rendtel and H. Hubner of Microstructural Design ........................ .5 I 5

Testing and Finite Element Analysis of Sintered Silicon Nitride Specimens under Four-Point Bending . . . . . . .527 J. Lua, J. Sankar; S.Yarmolenko, W. Windley Ill, D. Pai, and L.C. Russell

Effect of Heat-Treatment on Creep Behavior of a Self-Reinforced Silicon Nitride ..................... .537 Q. Wei, J. Sankar, and J. Narayan

xi

Material Design to Improve Wear Resistance of Silicon Nitride with CVD Coatings ........................ .545 FK. Mehrotra

Environmental Effects on the Mechanical Properties of Sic-Based Hot Gas Cleaning Filters . . . . . . . . . . . . . . . . . . .553 FIH. Pastila, A.F! Nikkila, andT.A. Mantyla

Corrosion of Ceramic Filters for Hot Cleaning in Thermal Power Plants ........................... .56 I L. Montanaro, A. Negro, 0. Frantz, FI Billard, and R. Rezakhanlou

Tribochemical Wear of Boron Carbide in Sliding Contacts . . .569 FI Larsson and N. Axen

Processing and Structure

Preceramic-Modified Reaction-Bonded Silicon Nitride (PM-RBSN): Processing and Properties with Focus on Long-Term High-Temperature Stability . .............. .575 G. Wotting, A. Herzog, and L. Schonfelder

Shaping SRBSN Parts by a Closed-Mold Casting Method . . . .583 G.M. Crosbie and G.T. Bretz

Joining of Non-Oxide Ceramics Using Conventional

J.G. Lee and E.D. Case

Microwave Sintering at High Temperature ............. .599

and Microwave Heating .......................... .589

H.E. Huey Q.S.Wang, M.S. Morrow, and D.E. Schechter

Processing and Mechanical Properties of Silicon Nitride Formed by Robocasting Aqueous Slurries . . . . . . . . .607 G. He, D.A. Hirschfeld, and J. Cesarano 1 1 1

Influence of Boron and Carbon on the Oxidation of Sintered Silicon Carbide at I 500°C . ................. .6 I S C. Schumacher and K.G. Nickel

xii

Thermal Barrier Coatings

Thermophysical and Thermomechanical Properties

D. Zhu and R.A. Miller of Thermal Barrier Coatings Systems . . . . . . . . . . . . . . . . ,623

Thermal Fatigue Testing of layer-Graded Thick Thermal Barrier Coating Systems . . . . . . . . . . . . . . . . . . .635 R.A. Miller, D. Zhu, J.G. Goedjen, A.M. Calornino, andTA. Cruse

Microstructure, Mechanical, and Thermal Properties of Undirectionally Aligned Silicon Nitride . . . . . . . . . . . . . .645 8.W Lee, 8.Y Lee, D. Park,YH. Choa, K. Niihara, and B. Hockey

Deformation and Strength Behavior of Plasma-Sprayed ZrO,-8wt% Y,O, Thermal Barrier Coatings in Biaxial Flexure and Trans-Thickness Tension . . . . . . . . . . . . . . . . . .653 S.R. Choi, D. Zhu, and R.A. Miller

Residual Stress Characterization of Thermal Barrier Coatings-Comparison of Thermally Sprayed, EB-PVD,

M Buchmann, C Friedrich, and R. Gadow

and CVD Based Coatings ......................... .663

Rapid, Cost-Effective Silicon Carbide Optical Component Manufacturing Technique ........................ .67 I J. Casstevens,A. Rashed, R. Plummer, M. Ferber; and R. Dinwiddie

Deformation Characteristics of Plasma Sprayed Thermal Barrier Coatings ............................... .68 I A. Kucuk, C.C. Berndt, U. Senturk, R.S. Lirna,and C.R.C. Lima

Improvement of High-Temperature Corrosion Resistance

N. Bahlawane and T. Watanabe

of Carbon by Ceramic Oxide Coats . . . . . . . . . . . . . . . . . . ,691

... X l l l