c00.52es and manufacturing ELSEVIER Composites: Part A 32(2001)997-1006 Use of electrophoretic deposition in the processing of fibre reinforced ceramic and glass matrix composites: a review A R. Boccaccini,, C. Kaya, K.K. Chawla Fachgebiet Werkstottechnik, Technische Universitat ILmenau, PF 100565, D-98684 ILmenau, germany Interdisciplinary Research Centre(IRC) for High Performance Applications School of Metallurgy and Materials, The University of Birmingham, Edgbaston, Birmingham B15 2TT, UK Department of Materials and Mechanical Engineering, University of Alabama at Birmingham, Birmingham, AL 35294 USA Abstract Electrophoretic deposition(EPD) is a simple and cost-effective method for fabricating high-quality green'composite bodies which, after a suitable high-temperature treatment, can be densified to a composite with improved properties. In this contribution, we describe the use of EPD technique in the fabrication of fibre reinforced composites, with an emphasis on composites with glass and ceramic matrices containing metallic or ceramic fibre fabric reinforcement. EPD has been used to infiltrate preforms with tight fibre weave architectures using different nanosized ceramic particles, including silica and boehmite sols, as well as dual-component sols of mullite composition. The principles of the EPD technique are briefly explained and the different factors affecting the epd behaviour of ceramic sols and their optimisation to obtain high infiltration of the fibre preforms are considered. In particular, the EPD fabrication of a model alumina matrix composite reinforced by Ni-coated carbon fibres is presented. The pH of the solution and the applied voltage and deposition time are shown to have a strong infuence n the quality of the infiltration. Good particle packing and a high solids-loading were achieved in most cases, producing a firm ceramic deposit which adhered to the fibres. Overall, the analysis of the published data and our own results demonstrate that EPD, being simple and expensive, provides an attractive alternative for ceramic infiltration and coating of fibre fabrics, even if they exhibit tight fibre weave architectures. The high-quality infiltrated fibre mats are suitable prepregs for the fabrication of advanced glass and ceramic matrix compo- sites for use in heat-resistant, structural components. C 2001 Elsevier Science Ltd. All rights reserved Keywords: A Ceramic-matrix composites(CMCs); E. Prepreg: Electrophoretic deposition 1. Introduction ceramic fabrics, including SiC-based (e.g. Nicalor Nippon Carbon Co., Japan), alumina and aluminosilicate The development of fibre reinforced ceramic and glass woven fibre mats [2-5]. Metallic fabrics are commercially atrix composites is a promising means of achieving light- available also [6] and are made from a variety of metals weight, structural materials combining high-temperature including stainless steel and special alloys(e.g. Hastelloy strength with improved fracture toughness, damage toler- X). These fabrics provide interesting reinforcing elements ance and thermal shock resistance [1]. Considerable for the fabrication of ductile phase reinforced brittle matrix research e ffort is being expended in the optimisation of composites, including glass matrix composites ceramic composite systems, with particular emphasi Ceramic and glass composites incorporating 2D or 3D being placed on the establishment of reliable and cost- fibre reinforcements are particularly prone to exhibiting effective fabrication procedures. In this context, while the uncontrolled microstructures and residual porosity. This is initial efforts were in the fabrication of unidirectional because it is extremely difficult to achieve complete infiltra- composites, they are increasingly shifting towards the tion of the matrix material into the fibre tows(where the more isotropic composite materials reinforced by two- intra-tow openings may be down to the order of s100 nm) dimensional (2D)and three-dimensional (3D) fibre architec- Traditional processing routes for 2D or 3D fibre reinforced tures. The majority of the research undertaken so far on the ceramic matrix composites have disadvantages. In particu 2D reinforcement of ceramics has been conducted using lar, simple slurry infiltration is unable to penetrate tight fibre weaves, while chemical vapour infiltration (CVI is an Corresponding author. Present address: Department of Materials, expensive technology due to the numerous re- infiltration Imperial College, London SW7 2BP, UK steps required and the high-cost equipment involved [4] E-mail address: a boccaccini@ic ac uk(.R. Boccaccini) Electrophoretic deposition(EPD)has been developed in 1359-835X/01/S.see front matter O 2001 Elsevier Science Ltd. All rights reserved. PI:S1359-835X(00)00168-8
                               
          
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