ADVANCE MATERIALS

SiC/SiC composite material: A state of the art review

María Camila Belduque Correa

Aeronautical Engineering Faculty, Universidad Pontificia Bolivariana, Medellín, Colombia

ABSTR ACT

Ceramic Matrix Composite materials ‘CMCs’ are the new focus in aerospace industry,
after decades of researching they finally are getting those places in which metals and its
alloys are located, and despite some properties, as its fracture toughness, have to be
improve there are others that overcome for much the metallic ones. Among CMC’s,
SiC/SiC has shown its great capacity to fulfil the aerospace sector requirements, and today
are being a very important part in Boeing 737 and Airbus A320 aircrafts families engines.
This article presents some of those topics concerning to SiC/SiC composites that make
them one of the best choices for innovating and improving aerospace sector.

1. Introduction 500°C, an excellent corrosion resistance

From its earliest days the aeronautica l
industry has aimed to increase engine’s
efficiency in such a way that they save
fuel and remain in a safety condition to
operate. Speaking about conventio na l
materials, actually Titanium is one of the
best choices for fan and compressor
blades [1], and its alloys (Ti-6Al-4V) for
static and rotating components at higher
temperatures, where only some super
alloys (nickelbase and cobaltbase with
almost 25% of chromium additions and
lower quantities of Aluminum, Titanium
and others) can replace them because of
their capacity to maintain an
approximately constant specific strength
when temperature increases above
[2] and other characteristics that allow a
combined-cycle gas turbine operate at
60% fuel efficiency [3].
Not being sufficient, lighter materia ls
that obtain higher temperatures range
have been researched, and though
ceramics are brittle, they could be
reinforced to satisfy the requireme nts
demanded by aero engines. This material
have no ductility, which involves a low
tolerance for stress concentrations or for
high-contact stresses, but they are stiff,
hard, abrasion-resistant and more
attractive for aerospace and aeronautica l
industry, they offer strength above
1500°C while most metals start to
decrease their properties almost at
 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa

800°C, figure 1 depicts this behavior. SiC, reaching temperatures up to 1500°C

[4]. and excellent creep resistance [7],

Figure 1. Strength vs Maximum service temperature of random families of

materials.

Among the ceramic’s family, the Silicon improving its electrical properties and
Carbide (SiC) is one of the most used. It positioning itself as one of the principa l
was discovered by Edward G. Acheson candidates in aeronautical industry for
while running an experiment on the structural components as gas turbine, jet
synthesis of diamonds, he was the first in engines, and heat control on surfaces [8].
synthesize it by passing and electric
In the next pages SiC/SiC composite
current through a mixture of clay and
material fabrication techniques,
carbon, and today is produced via a solid
properties, advantages and
state reaction between sand and
disadvantages will be discuss; those
petroleum coke at very high
innovative characteristics that make it
temperatures in an electric arc furnace
today as one of the most researched
[5]. Due to its high Young’s moduli,
materials in aeronautical and aerospace
hardness, thermal and chemical stability
industry.
[6], high melting point, oxidation
resistance, etc., it’s a perfect candidate 2. The SiC system
for many applications in several
Since its discovery, many SiC polytypes
industries, but it’s brittle, then for
have been found up today, they depends
increasing considerably its ductility and
on the grain orientation and the more
damage tolerance it is reinforced by
common of them are the hexagonal alpha
continuous fibers of the same material,
silicon carbide (αSi-C), which has the

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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa
stable form at temperatures higher than
1700°C [9] and the cubic one, beta
silicon carbide (βSi-C), which has the
zinc blend structure and is formed below
1700°C; both theoretical densities of
αSi-C and βSi-C are approximate ly
3.210 g/cm3, this makes the silico n
carbide one of the few light weight
covalently bonded ceramics. Figure 2
depicts the two major crystal structures
[5].
Figure 2. SiC Crystal Structures. The figure
above shows βSi-C, called 3C too. And lower
figure the αSi-C, the majority of its phases are
6H. The crystalline polytypes has a number
for the number of layers in the unit cell,
followed by a letter suffix that designates the
crystal symmetry. In this case, “C” for cubic
and “H” for hexagonal. The more common
are the 3C, 4H and 6H.
SiC common forms are powder,
commonly obtained through Acheson
process, a solid-state reaction mixture of
green petroleum coke and silica sand is
heated at more than 2500°C using two
large graphite electrodes. Fibers, via
pyrolysis of organosilicon polymers, it
consists of melt-spinning
polycarbosilane at 300°C generally,
unfusing with thermal oxidation at
110°C-200°C and baking at 1000°C-
1500°C under a flow of inert gas. Other
forms of SiC are whiskers, coating and
single crystals that could be obtained via
Physical Vapor Transport ‘PVT’,
Chemical Vapor Deposition ‘CVD’, Sol-
gel and others. The methods of
fabrication are selected depending on the
desire form, purity level and applicatio n
[9]. Which are several in the industry,
as an abrasive material or a band gap
semiconductor for high power, high
temperature electronic devises, as
reinforcing material in Al2 O3 or in SiC
and other ceramics for decreasing their
brittleness and be used for cutting tools,
[10], high temperature applicatio ns
including gas turbines and nuclear
reactors [6].
Concerning to SiC as matrix in a
composite material, there are random
ceramics options that can be used as
reinforcement for improving its
properties for ultra-high temperature
services, such as Zirconium Carbide
(ZrC), is a refractory carbide which
melting point is 3540°C approximate ly
and has a low density of 6.7 g/cm3 , it is
used, e.g., for reducing the active
oxidation mode that SiC presents above
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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa

1650°C [11], it occurs after a passive of the SEVIRI instrument on the

oxidation mode, where a protective film
is generated, in the active mode a
volatile sub-oxide is formed and can lead
to rapid material consumption[12 ];
Alumina (Al2 O3 ) is an oxide material
with a thermal conductivity of 17.5
W/m*K at room temperature, employed
as an additive in the fabrication process
of SiC to promote its sintered (which
presents strict and complex pressing,
temperature and vacuum requireme nts)
Meteosat Second Generation (MSG)
spacecraft, figure 3 shows its mechanic a l
design [14], other applications include
microelectronics or calibration of
dimensional control tools; in aerospace
sector has been applied for leading
edges, nose-skirt panels and body flap
control surfaces in the NASA X-38
Keraman, a reentry vehicle [15].

Figure 3. The mechanical design of the 80cm x 50cm elliptical ULS M

and one of the polished mirror blanks. It weights 7kg [14].

without decreasing its heat capacity and
lead to a composite with good thermal
storage and other excellent properties
named before [13]. Carbon (C), the
C/SiC composite has been studied as a
candidate for the telescope mirrors used
in the satellite mission ‘SPICA’, Space
Infrared Telescope for Cosmology and
Astrophysics [43], and for the Ultra-
Lightweight Scanning Mirror ‘ULSM’
It has to be noticed that the lower matrix
porosity the higher thermal conductivity
and creep resistance in multip le
directions, that means to operate above
1300°C, to get this depends on the
manufacturing process, Chemical Vapor
Infiltration ‘CVI’ and Polymer
Infiltration and Pyrolysis ‘PIP’ and Melt
Infiltration ‘MI’ are the best choicest, but

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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa
the lower porosity (±5%) is achieve by
CVI [16].
SiC properties are summarized in Table
1, its density is nearly the half of
conventional materials used in aero
engines (Ni alloys= 8.83-8.95 mg/m3 , Ti
Alloys= 4.4-4.8 mg/m3) but its fracture
toughness definitely is too low in
comparison with the same materials (Ni
alloys= 80-110 Mpa*m1/2 , Ti Alloys=
14-120 Mpa*m1/2 ) [4].
Table 1. SiC properties
3. The SiC/SiC system
As the Al2O3, ZrC, C and other
ceramics, SiC can be used as a fiber-
reinforcement and improve in a
considerably way the SiC matrix
properties by receiving a part of the
mechanical stresses applied to it. This
Properties can varying depending on the
geometry and concentration of the
constituents and the manufactur ing
processes: ‘CVI’ [17], Chemical Vapor
Deposition ‘CVD’ [18], Hot Pressing
‘HP’, Reaction Sintering ‘RS’, Liquid
Phase Sintering ‘LPS’ [19].
3.1. Properties
SiC/SiC presents a strong embrittle me nt
and fracture when are exposed to
oxidizing environments at 700°C -900°C
under stresses that are below their
ultimate strength, above or below this
temperature range the embrittlement is
slower [7], this material degradation
occurs mainly due to the propagation of
the premature fracture of the SiO 2 layer
[20, 21]; to improve the fracture
resistance an interfacial or multip le
layers -pyrolytic carbon, hexagonal BN
or alternating C/SiC layers- between the
fiber and the matrix can be produced, this
will weaken the fiber-matrix bonding,
and the fracture toughness will increase
from 5Mpa m1/2 to 20-30Mpa.m1/2 [22].
Zirconia ‘ZrO 2 ’, being a refractory oxide
has been used as interphase to achieve
the same purpose, the outcome with this
multilayered coating is a ductile fracture;
but the interphase thick affects those
results, a very thick interphase will
decrease mechanical properties owing to
the lower load transfer at the same; while
a too thin interphase will induce a brittle
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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa
fracture [17, 23]. Different coatings are
employed to mitigate negative effects
and improve coating properties, or
fabricate the composite with a process
with which a high crystallinity can be
obtained, then, the mechanical properties
will not subject to the interphase
thickness effect [17, 24] . Figures 4 and
5 depicts the results when coating SiC
fibers with ZrO 2.
Figure 4. a) SiC/SiC with uncoated fibers
shows no fiber pullout.
Figure 5. b) Fibers with multilayered coatings,
the fibers are pulled out of the matrix. One of
the design concepts for the interaction
between fiber and matrix in CMCs is a weak
interface: the fibers are coated to reduce
adhesion to the matrix, then, during the
fracture fibers are pulled out of the matr i x
and absorb fracture energy [23, 25].
The fibers more commonly used are Hi-
Nicalon, TyrannoT M and Sylramic [17];
according to the NASA, for aero-engine
applications, SiC/SiC grains have to
present a sizes that not exceed 500nm
and a near stoichiometric SiC
composition with low porosity and be
commercially available , figure 6 depicts
the strength and stiffness retention
during service at high temperatures [16],
it has to be taken into account that their
mechanical properties can chance
according to the volume fraction, their
coating, or architecture. The porosity and
transverse stress wave interactions can
cause interlaminar delamination, then,
interlaminar properties as shear and
tension strengths will be affected in the
whole composite [26].
Figure 6. Creep strain behavior of SiC fiber
types in single fiber form.
Generally this fibers are found in a
volume fraction of 20% to 40%, and
depending of the architecture, UD, 2D-
woven (more common) and 3D woven,
its E can vary from 125 to 305 GPa and
its Ultimate Tensile Strength ‘UTS’ from
204 to 480 MPa [17, 26, 27].
Some studies have shown results of how
this and foreign objects velocities
(specifically from 100m/s on, at room
temperature and 1316°C) may start to
cause front damage in a 2D woven
SiC/SiC composite of an E= 220GPa, the
back side damage starts with higher
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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa
velocities than 350m/s. Concerning to
how the strength is affected, figure 7
depicts a comparison of normalized post-
impact strength between the SiC/SiC
composite (one specific in that
experiment) and the silicon nitride used
in gas turbine, the composite exhibits a
greater FOD tolerance than its
monolithic counterparts, which have a
fracture toughness of 5.5 and 8.1 MPa
m1/2 respectively [28].
Figure 7. Comparison of normalized post-
impact strength between the SiC/SiC
composite of this study and the AS800 and
SN282 silicon nitrides (2-mm thick) in full
support at ambient temperature. Vc, critical
impact velocity.
It should be noticed that the SiC/SiC
performance is better than the monolithic
ceramics but given the catastrophica lly
damage that can cause a FOD on a gas
turbine this feature still needs to be
improved.
Other properties very named are its good
thermal stability, excellent irradiatio n
tolerance and low tritium permeability
[29];
Chemically, SiC fibers have good
resistance to oxidation at higher
temperatures than 1300°C. And
thermally, SiC/SiC has a low thermal
conductivity in the direction
perpendicular to the fibers because of the
porosity in the manufacturing processes,
it’s about 73 W/m*K at room
temperature and 35 W/m*K at 1000°C
[22].
3.2. Manufacturing Processes
 Chemical Vapor Infiltration ‘CVI’
Among the SiC/SiC manufactur ing
processes this is the more common. Has
the advantages of an excellent control
interphase formation, low toxicity, low
thermal and mechanical stresses and
high crystallinity, purity and density are
achieved. But presents the disadvanta ges
of high cost, complexity and high
fabrication time [17].
It’s a method used for producing
continuous fiber ceramic by introduc ing
reactants on the internal surface of a
porous preform via diffusion or forced
convection. As infiltration occurs, the
reactants thick grows and after a certain
time fills the voids in the matrix [30].
One of the precursors for the deposition
of SiC is methyltrichlorosilane ‘MTS’.
[18]
 Liquid Phase Sintering ‘LPS’
It provides a high density and superior
crystalline for monolithic SiC and
SiC/SiC composites due to the
transformation of additive materials into
some eutectoids; in comparison with
those solid state manufactur ing
processes, it has lower sintering
temperature and time requirements [19].
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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa

 Melt Infiltration Process ‘MI’ being used in reusable launch vehicles

under the Next Generation Launch
This process offers high density, a
Technology (NGLT) Program,
thermal conductivity about 50W/m*K,
more than the offered by CVI and PIP specifically as heat exchanger panels
processes, low cost production [31] and turbine blades, vanes, combustors,
enhance to fabricate a SiC/SiC net- bearings and tubular casing pumps [15,
shapes. It’s about a molten silico n
16, 36]; the aim is arise engines
infiltrated into a porous carbon preform
for an in-situ formation of SiC ; It has the efficiency by increasing the turbine inlet
disadvantages of degrade the matrix and temperature and decrease the cooling
induce and extensive debonding due to needed in the components named before.
the thermal exposure; the MI-SiC/SiC
Under NASA’s High-Speed Research
allow a flexural strength of 330Mpa at
room temperature, which decrease at Enabling Propulsion Materials
temperatures higher than 1100ºC [32]. (HSR/EPM) and Ultra Efficient Engine
 Hot Pressing ‘HP’ Technology ‘UEET’ programs, a vane,
showed in figure 8, was fabricated and
Is a method that combines powder
probed at 1315°C and the outcome was
pressing and sintering into a single
operation for densifying materials. It is that this can successfully withstand the
conducted by placing a compacted hard environmental conditions at which
preform into a die, of graphite generally, an engine is undergo for up to 1000h
then, uniaxial pressure is applied to the
[37], other good results can be found in
entire system, which previously was
heated at 2000°C (for SiC) by resistance reference 43.
or by induction temperature method.
Finally, the mold is cold slowly under
pressure and with a controlled
temperature for avoiding the material
oxidation [33, 34]. The general
composition includes SiC Nano-powder
> 95%, 1%-2% free carbon and 1%-1.5%
oxygen [35].
Other common processes to obtain
SiC/SiC are Sol-gel, ‘PIP’, CVD and
chemical vapor reaction [22]. Figure 8. SiC/SiC turbine stator vane fabricated
by NASA's UEET Program.

3.3. Applications
Because of the properties named before,
SiC/SiC is been investigated to be used
in nuclear applications, e.g., differe nt
core structures of Sodium Fast Reactor
‘SFR’ [29]. But actually its major
application is in both aerospace and
aeronautical sectors, SiC/SiC as C/SiC is
In aeronautical industry, figure 9
shows the more recent innovatio n
carried out by General Electric
Aviation, IHI Corporation (Japan)
and Techspace Aero (Safran, France),
this three companies have invested
more than $1 billion to fabricate the

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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa

Figure 9. The GE9X has 15 CMC parts, among them, the combustor and the
high pressure turbine are SiC/SiC composite [39].

new engine GE9X, which was air to enhance the lean-burn

certificated in 2015 after
accumulating more than 2000 hours
an cycles on ground in flight testing,
and fulfil with FAA nose and
emissions requirements without any
problem [40], for entering in service
this year on Boeing 747X, Airbus
A320 aircraft and Bombardier’s
Global 7000 and 8000 ultra-long-
range twinjets. Among its
characteristics, the combustors and
high pressure turbines material is the
most remarkable because those are
made in SiC/SiC, improving its
durability and requiring less cooling
combustion process, adding to that
the reduction in mass density and a
27:1 pressure ratio, the biggest than
any other engine in commercia l
aviation can has until moment. [41].
Now, the challenge is to understand in
a deep way the SiC/SiC behavior and
improve its durability, at the moment
large safety factors, lifetimes and
other operational limitations must be
used [42].

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 SiC/SiC composite material: A state of the art review | Maria Camila Belduque Correa
4. Conclusions
Because of its high properties CMCs are
marking a new age in materials and
thereby in applications, industries are
investment every day more money, time
and effort for improving the systems
already settled, in the aeronautica l
sector, that race for being the most
innovative has not finished, CMCs are
the tool to get the first one on it but are
still under researching to get their highest
properties and extend their time in
service by reducing time in maintena nce,
now they are supplying aircraft
requirements but in the way there will be
more new necessities and new materia ls
to be studied.
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