Damage mechanism identification has scientific and practical ramifications for the structural health monitoring, design, and application of composite systems. Recent advances in machine learning uncover pathways to identify the waveform-damage mechanism relationship in higher-dimensional spaces for a comprehensive understanding of damage evolution. This review evaluates the state of the field, beginning with a physics-based understanding of acoustic emission waveform feature extraction, followed by a detailed overview of waveform clustering, labeling, and error analysis strategies. Fundamental requirements for damage mechanism identification in any machine learning framework, including those currently in use, under development, and yet to be explored, are discussed.

In this work, we demonstrate that damage mechanism identification from acoustic emission (AE) signals generated in minicomposites with elastically similar constituents is possible. AE waveforms were generated by SiC/SiC ceramic matrix minicomposites (CMCs) loaded under uniaxial tension and recorded by four sensors (two models with each model placed at two ends). Signals were encoded with a modified partial power scheme and subsequently partitioned through spectral clustering. Matrix cracking and fiber failure were identified based on the frequency information contained in the AE event they produced, despite the similar constituent elastic properties of the matrix and fiber. Importantly, the resultant identification of AE events closely followed CMC damage chronology, wherein early matrix cracking is later followed by fiber breaks, even though the approach is fully domain-knowledge agnostic. Additionally, the partitions were highly precise across both the model and location of the sensors, and the partitioning was repeatable. The presented approach is promising for CMCs and other composite systems with elastically similar constituents.

A combustion facility which includes uniaxial mechanical loading was implemented that enables environmental conditions more akin to jet engine environments compared to conventional static environment tests. Two types of woven SiC/SiC ceramic matrix composites (CMCs), melt-infiltrated (MI) and chemical vapor infiltrated (CVI), were subjected to fatigue loading in the combustion facility and under isothermal furnace conditions. Some CVI test coupons were coated with a multilayer environmental barrier coating (EBC) of mullite + ytterbium monosilicate using slurry infiltration process to demonstrate the performance with a coating. Combustion conditions were applied using a high velocity oxy fuel gun on the front side of the specimen and mechanical loading was applied using a horizontal hydraulic MTS machine. All the specimens considered were subjected to tension-tension fatigue loading at 100 MPa, stress ratio of 0.1 and specimen front-side surface temperature of 1200 ± 20 °C. Nondestructive evaluation (NDE) methods, such as electrical resistance (ER), was used as an in-situ health monitoring technique. Similar fatigue tests were performed in an isothermal furnace for comparison. A much lower fatigue life was observed for the uncoated specimens tested under combustion conditions in comparison to isothermal furnace condition. This difference in fatigue life was attributed to damage associated with added thermal stress due to the thermal gradient and higher rate of oxidative embrittlement due to the presence of high velocity combustion gases in the combustion environment. EBC coating increased the fatigue life in combustion environment. However, EBC coated specimens experienced spallation in the high-velocity flame due to the presence of micro cracks in the coating surface. Fracture surfaces of the failed specimens were investigated under the scanning electron microscope (SEM) to determine the extent of oxidation and damage.

Plasma spray-physical vapor deposition (PS-PVD) environmental barrier coatings (EBCs) of Yb2Si2O7 were deposited on SiC and exposed in a steam environment (90% H2O/O2) at 1426 °C to form a thermally grown oxide (TGO) layer between the substrate and EBC. In advanced ceramic material systems such as coated ceramic matrix composites (CMCs), the TGO layer is the weak interface and directly influences component lifetimes. The effects of surface roughness and TGO thickness on the adhesion strength were evaluated by mechanical testing of the coatings after exposure. Morphology and oxide layer thickness were analyzed with electron microscopy while the composition and crystal structure were tracked with X-ray diffraction. The strength of the system is evaluated with respect to oxidation rate to give a qualitative understanding of coating durability.

Ceramic matrix composites (CMCs) and environmental barrier coatings (EBCs) are key technologies that can enable improvements in the thermal and propulsive efficiency of gas turbine engines. However, CMCs and EBCs are susceptible to various life limiting damage modes associated with the engine operating environment such as oxidation, recession, thermomechanical stress/strain, corrosion, foreign object damage (FOD), and solid particle erosion (SPE). Despite its importance, there is a limited understanding of the SPE behavior of CMCs and EBCs in the literature. This paper reviews the status of SPE research for CMCs and EBCs and provides a perspective towards future research.

Erosion behavior of a large number of gas-turbine grade ceramic matrix composites (CMCs) was assessed using fine to medium grain garnet erodents at velocities of 200 and 300 m/s at ambient temperature. The CMCs used in the current work were comprised of nine different SiC/SiCs, one SiC/C, one C/SiC, one SiC/MAS, and one oxide/oxide. Erosion damage was quantified with respect to erosion rate and the damage morphology was assessed via scanning electron microscopy (SEM) and optical microscopy in conjunction with three-dimensional (3D) image mapping. The CMCs response to erosion appeared to be very complicated due to their architectural complexity, multiple material constituents, and presence of pores. Effects of architecture, material constituents, density, matrix hardness, and elastic modulus of the CMCs were taken into account and correlated to overall erosion behavior. The erosion of monolithic ceramics such as silicon carbide and silicon nitrides was also examined to gain a better understanding of the governing damage mechanisms for the CMC material systems used in this work.