Artificial intelligence inspired design of non-isothermal aging for γ-γ' two-phase, Ni-Al alloys.

In this paper, a state-of-the-art Artificial Intelligence (AI) technique is used for a precipitation hardening of Ni-based alloy to predict more flexible non-isothermal aging (NIA) and to examine the possible routes for the enhancement in strength that may be practically achieved. Additionally, AI is used to integrate with Materials Integration by Network Technology, which is a computational workflow utilized to model the microstructure evolution and evaluate the 0.2% proof stress for isothermal aging and NIA. As a result, it is possible to find enhanced 0.2% proof stress for NIA for a fixed time of 10 min compared to the isothermal aging benchmark. The entire search space for aging scheduling was ~ 3 billion. Out of 1620 NIA schedules, we succeeded in designing the 110 NIA schedules that outperformed the isothermal aging benchmark. Interestingly, it is found that early-stage high-temperature aging for a shorter time increases the γ' precipitate size up to the critical size and later aging at lower temperature increases the γ' fraction with no anomalous change in γ' size. Therefore, employing this essence from AI, we designed an optimum aging route in which we attained an outperformed 0.2% proof stress to AI-designed NIA routes.

Method of Determining Kinetic Parameters of Strength Recovery in Self-Healing Ceramic Composites.

Self-healing ceramic composites are promising smart materials for high-temperature applications. Experimental and numerical studies have been performed to more fully understand their behaviors, and kinetic parameters such as the activation energy and frequency factor have been reported to be indispensable for investigating healing phenomena. This article proposes a method of determining the kinetic parameters of self-healing ceramic composites using the oxidation kinetics model of strength recovery. These parameters are determined by an optimization method using experimental strength recovery data under various healing temperatures, times, and microstructural features on the fractured surfaces. Alumina and mullite matrix-based self-healing ceramic composites such as Al2O3/SiC, Al2O3/TiC, Al2O3/Ti2AlC (MAX phase), and mullite/SiC, were selected as the target materials. The theoretical strength recovery behaviors of the cracked specimens obtained from the kinetic parameters were compared with the experimental results. The parameters were within the previously reported ranges, and the predicted strength recovery behaviors reasonably agreed with the experimental values. The proposed method can also be applied to other self-healing ceramics with matrices reinforced with different healing agents to evaluate oxidation rate, crack healing rate, and theoretical strength recovery behaviors to design self-healing materials used in high-temperature applications. Furthermore, the healing ability of composites can be discussed regardless of the type of strength recovery test.

Full strength and toughness recovery after repeated cracking and healing in bone-like high temperature ceramics.

Bones of humans and animals combine two unique features, namely: they are brittle yet have a very high fracture toughness linked to the tortuosity of the crack path and they have the ability to repeatedly heal local fissures such that full recovery of overall mechanical properties is obtained even if the local bone structure is irreversibly changed by the healing process. Here it is demonstrated that Ti2AlC MAX phase metallo-ceramics also having a bone-like hierarchical microstructure and also failing along zig-zag fracture surfaces similarly demonstrate repeated full strength and toughness recovery at room temperature, even though the (high temperature) healing reaction involves the local formation of dense and brittle alumina within the crack. Full recovery of the fracture toughness depends on the healed zone thickness and process zone size formed in the alumina reaction product. A 3-dimensional finite element method (FEM) analysis of the data obtained from a newly designed wedge splitting test allowed full extraction of the local fracture properties of the healed cracks.

Finite element analysis of the fracture statistics of self-healing ceramics.

Self-healing materials have been recognized as a promising type of next-generation materials. Among them, self-healing ceramics play a particularly important role, and understanding them better is necessary. Therefore, in this study, we applied the oxidation kinetics-based constitutive model to finite element analysis of a series of damage-healing processes in self-healing ceramics (alumina/SiC composites). In the finite element analysis, the data on the microstructure distribution, such as relative density, size and aspect ratio of pores, and grain size, were taken as input values and reflected onto the parameters of a continuum damage model using a fracture mechanical model. We then performed a 3-point bending analysis, to consider both the self-healing effect under certain temperature and oxygen partial pressure conditions and scatter of the strength of the ceramics. Our results confirmed that the proposed methodology can reasonably reproduce both strength recovery and damage propagation behavior in self-healing ceramics.

Self-healing by design: universal kinetic model of strength recovery in self-healing ceramics.

We propose a new theoretical kinetic model of strength recovery by oxidation-induced self-healing of surface cracks in composites containing a healing agent (HA). The kinetics is a key parameter in the design of structural components that can self-heal the damage done in service. Based on three-dimensional (3D) observations of crack-gap filling, two crack-gap filling models, i.e., a bridging model and a tip-to-mouth filling model, are incorporated in the proposed kinetic model. These crack-gap filling models account for the microstructural features of the fracture surfaces, crack geometry, and oxidation kinetics of the healing-agent. Hence, the minimum and maximum remaining flaw sizes in the healed crack gaps are estimated for various healing temperatures, times, and oxygen partial pressure conditions. Further, the nonlinear elastic fracture mechanics suitable for small-sized remaining flaws, together with a statistical analysis of the original Weibull-type strength distribution, enables the prediction of upper and lower strength limits of the healed composites. Three sintered alumina matrix composites containing silicon carbide (SiC)-type HAs with various volume fractions and shapes, together with monolithic SiC ceramics, are considered. The strength of the healed-composite predicted by our model agrees well with the experimental values. This theoretical approach can be applied to HAs other than SiC and enables the design of self-healing ceramic components for various applications.

Finite Element Analysis of the Size Effect on Ceramic Strength.

The most prominent effect of the weakest link theory, which is used to derive the Weibull statistics of ceramic strength, is the size effect. In this study, we analyze the size effect on ceramic strength using the finite element analysis (FEA) methodology previously proposed by the authors. In the FEA methodology, the data of the microstructure distribution (i.e., relative density, size, and aspect ratio of the pore and the grain size) are considered as input parameters of a continuum damage model via a fracture mechanical model. Specifically, we examine five sizes of rectangular specimens under three types of loading conditions. Then, we simulate the fracture stresses of sets of 30 specimens under each size and loading condition and obtain the relationship between the scale parameter and effective volume using the Weibull distribution. The results suggest that the proposed FEA methodology can be applied to the analysis of the fracture probability of ceramics, including the size effect.

A Novel Design Approach for Self-Crack-Healing Structural Ceramics with 3D Networks of Healing Activator.

Self-crack-healing by oxidation of a pre-incorporated healing agent is an essential property of high-temperature structural ceramics for components with stringent safety requirements, such as turbine blades in aircraft engines. Here, we report a new approach for a self-healing design containing a 3D network of a healing activator, based on insight gained by clarifying the healing mechanism. We demonstrate that addition of a small amount of an activator, typically doped MnO localised on the fracture path, selected by appropriate thermodynamic calculation significantly accelerates healing by >6,000 times and significantly lowers the required reaction temperature. The activator on the fracture path exhibits rapid fracture-gap filling by generation of mobile supercooled melts, thus enabling efficient oxygen delivery to the healing agent. Furthermore, the activator promotes crystallisation of the melts and forms a mechanically strong healing oxide. We also clarified that the healing mechanism could be divided to the initial oxidation and additional two stages. Based on bone healing, we here named these stages as inflammation, repair, and remodelling stages, respectively. Our design strategy can be applied to develop new lightweight, self-healing ceramics suitable for use in high- or low-pressure turbine blades in aircraft engines.