Silicon carbide ceramic materials have many beneficial properties which have led to their adoption in various industrial uses, including its application as an armor material. This is due to the high hardness and stiffness of these materials, as well as a low relative density. The homogeneity of the final properties depends upon the processing history of the material. Factors which affect this include the need for high temperatures and sintering additives to achieve densification, as well as the presence of additive agglomerates and pressing artifacts within the green compact. This dissertation seeks to determine the effect which microstructural variability has on the acoustic and mechanical properties of sintered silicon carbide materials. Sample sets examined included commercially produced, pressurelessly sintered tiles, as well as additional, targeted tiles which were specifically produced for evaluation in this study. Production of these targeted samples was carried out such that particular aspects of the microstructure were emphasized. These included tiles which were fired with an excess of boron sintering aid as well as tiles which had been pressed to a reduced green body density and then fired. The sample evaluation procedure which was developed incorporated non destructive evaluation methods, mechanical testing, and both fractographic and image analysis of fractured and polished sections. Non destructive evaluation of the tiles was carried out by Archimedes density and ultrasound scanning at 20 MHz to determine the acoustic attenuation coefficient. Selected samples were chosen for machining into ASTM B-type bend bars on which 4-pt flexure testing was performed. Strength limiting features were designated for each sample set. The correlation between acoustic attenuation coefficient and quasi-static strength was examined both qualitatively and quantitatively. This was done by comparing the primary fracture location of flexure bars to features within the ultrasound maps along with linear regressions of scatter plots of attenuation coefficient and fracture strength. The analysis showed that while significant variability existed within the strength results from the three sets of flexure bars, the presence of individual strength limiting features were not resolved in the ultrasound scans. However, variations in bulk microstructure corresponding to the three sample sets were represented in the attenuation coefficient values.
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Materials Science and Engineering
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Rutgers University Electronic Theses and Dissertations
Rutgers University. Graduate School - New Brunswick
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