Effects of fiber orientation and jet energy on surface morphology and erosion mechanisms during AWJ milling of 2.5D C/SiC composites

Abstract

Carbon fiber-reinforced silicon carbide (C/SiC) composites are extensively employed in aerospace applications owing to their high-temperature strength, low density, and thermal stability. However, conventional machining of these hard and brittle materials is hindered by severe tool wear, low processing efficiency, and high operational costs. As a non-contact and tool-wear-free technique, abrasive waterjet (AWJ) machining enables efficient bulk material removal and can function as a roughing process that complements conventional finishing operations to ensure dimensional accuracy. In this study, AWJ milling was systematically investigated to elucidate how fiber orientation and jet parameters influenced material-removal behavior and surface integrity. Experiments were conducted on a five-axis AWJ system at traverse speeds ranging from 2 000 mm/min to 4 000 mm/min and standoff distances between 6 mm and 18 mm. Scanning electron microscopy (SEM), white-light interferometry, and depth-profilometry identified three orientation-dependent fiber-damage modes—splitting and pull-out in warp yarns, circumferential fracture in weft yarns, and protrusion-bending in needled fibers—originating from crack deflection and fiber-matrix interfacial debonding under localized jet loading. An increase in standoff distance broadened the kerf width while reducing the maximum removal depth by approximately 50%, owing to jet energy dissipation and the transition of the profile geometry from U-shaped to V-shaped. Elevated traverse speeds shortened the effective jet-material interaction time, reducing surface roughness from 305.6 µm to 167.8 µm while suppressing excessive erosion and interfacial delamination. These findings establish a mechanistic framework for predicting AWJ milling depth and defect evolution in architectured C/SiC composites, thereby providing practical guidance for high-precision, dust-free machining of aerospace thermal protection components.

Keywords

Ceramic matrix composites (CMCs) / Erosion mechanism / Surface integrity / Fiber orientation

References

[1] Wang X, Gao X, Zhang Z, et al.. Advances in modifications and high-temperature applications of silicon carbide ceramic matrix composites in aerospace: a focused review. J Eur Ceram Soc, 2021, 41(9): 4671-4688

[2] Li M, Guo J, Zhang X, et al.. Surface morphology and kerf characteristics during high-efficient abrasive waterjet trimming of 2.5 DC/SiC ceramic matrix composites. Int J Adv Manuf Technol, 2025, 138: 3943-3955

[3] An Q, Chen J, Ming W, et al.. Machining of SiC ceramic matrix composites: a review. Chin J Aeronaut, 2021, 34(4): 540-567

[4] Wen Q, Li Y, Gong Y. Comparative study on micro-grinding performance of 2.5D Cf/SiCs, 2.5 D SiCf/SiCs, and SiC ceramics. Materials, 2023, 16(19): 6369

[5] Krishna R, Wilson P, Williams MA, et al.. Effect of CVI-induced porosity on elastic properties and mechanical behaviour of 2.5D and 3D Cf/SiC composites with multilayered interphase. J European Ceram Soc, 2024, 44(8): 4930-4948

[6] Li Y, Ge X, Wang H, et al.. Study of material removal mechanisms in grinding of C/SiC composites via single-abrasive scratch tests. Ceram Int, 2019, 45(4): 4729-4738

[7] Grinchuk PS, Abuhimd HM, Kiyashko MV, et al.. High productive machining of C/SiC preceramics. Int J Appl Ceram Technol, 2021, 18(6): 2293-2305

[8] Rösiger A, Goller R, Langhof N, et al.. Influence of in-plane and out-of-plane machining on the surface topography, the removal mechanism and the flexural strength of 2D C/C-SiC composites. J Eur Ceram Soc, 2021, 41(5): 3108-3119

[9] Xie Z, Liu Z, Han L, et al.. Optimizing amplitude to improve machined surface quality in longitudinal ultrasonic vibration-assisted side milling 2.5D C/SiC composites. Composite Struct, 2022, 297: 115963

[10] Zhai C, Xu J, Hou Y, et al.. Effect of fiber orientation on surface characteristics of C/SiC composites by laser-assisted machining. Ceram Int, 2022, 48(5): 6402-6413

[11] Yue X, Li Q, Yang X. Influence of thermal stress on material removal of Cf_SiC composite in EDM. Ceram Int, 2020, 46(6): 7998-8009

[12] Xie Z, Liu Z, Wang B, et al.. Longitudinal amplitude effect on material removal mechanism of ultrasonic vibration-assisted milling 2.5 DC/SiC composites. Ceram Int, 2021, 47(22): 32144-32152

[13] Diaz OG, Luna GG, Liao Z, et al.. The new challenges of machining ceramic matrix composites (CMCs): review of surface integrity. Int J Mach Tools Manuf, 2019, 139: 24-36

[14] Hashish M. Turning with abrasive-waterjet─a first investigation. J Eng Ind, 1987, 109(4): 281-290

[15] Shanmugam DK, Masood SH. An investigation on kerf characteristics in abrasive waterjet cutting of layered composites. J Mater Process Technol, 2009, 209(8): 3887-3893

[16] Gulia V, Nargundkar A. Experimental investigations of abrasive water jet machining on hybrid composites. Mater Today: Proc, 2022, 65: 3191-3196

[17] Zhang Y, Liu D, Zhang W, et al.. Mechanism of Cf/SiC hole making with high shape precision using abrasive waterjet based on response surface method. Ceram Int, 2023, 49(3): 4129-4140

[18] Zhang Y, Liu D, Zhang W, et al.. A novel quantitative analysis approach for hole surface damage of ceramic matrix composites machined by abrasive waterjet. J Manuf Process, 2023, 108: 217-226

[19] Ramulu M, Jenkins MG, Guo Z. Abrasive water jet machining mechanisms in continuous-fiber ceramic composites. Composites Technol Res, 2001, 23(2): 82-91

[20] Zhang W, Liu D, Zhang Y, et al.. Numerical investigations on the material response of nickel-based superalloys during abrasive waterjet milling. J Manuf Process, 2024, 120: 878-894

[21] Prabhu R, Kanthababu M. Prediction of surface roughness and depth of cut in abrasive waterjet milling of alumina ceramic using machine learning algorithms. Expert Syst Appl, 2024, 246 ArticleID: 123168

[22] Sourd X, Zitoune R, Crouzeix L, et al.. New model for the prediction of the machining depth during milling of 3D woven composite using abrasive waterjet process. Compos Struct, 2020, 234 ArticleID: 111760

[23] Hejjaji A, Zitoune R, Crouzeix L, et al.. Surface and machining induced damage characterization of abrasive water jet milled carbon/epoxy composite specimens and their impact on tensile behavior. Wear, 2017, 376: 1356-1364

[24] Hejjaji A, Zitoune R, Toubal L, et al.. Influence of controlled depth abrasive water jet milling on the fatigue behavior of carbon/epoxy composites. Compos A Appl Sci Manuf, 2019, 121: 397-410

[25] Kong L, Wang Y, Lei X, et al.. Integral modeling of abrasive waterjet micro-machining process. Wear, 2021, 482(483 ArticleID: 203987

[26] Tanaka M. Fracture toughness and crack morphology in indentation fracture of brittle materials. J Mater Sci, 1996, 31(3): 749-755

[27] Wang Z, Dong Z, Ran Y, et al.. On understanding the mechanical properties and damage behavior of Cf/SiC composites by indentation method. J Mater Res Technol, 2023, 26: 3784-3802

[28] Ba Z, Zhao J, Hao Z, et al.. Effects of the nozzle contraction angle on particle flow behaviors in a gas-particle two-phase jet. Exp Thermal Fluid Sci, 2022, 135 ArticleID: 110624

[29] Nguyen T, Wang J. A review on the erosion mechanisms in abrasive waterjet micromachining of brittle materials. Int J Extreme Manuf, 2019, 1(1 ArticleID: 012006

Funding

National Natural Science Foundation of China(52275422)

RIGHTS & PERMISSIONS

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature

Just Accepted

This article has successfully passed peer review and final editorial review, and will soon enter typesetting, proofreading and other publishing processes. The currently displayed version is the accepted final manuscript. The officially published version will be updated with format, DOI and citation information upon launch. We recommend that you pay attention to subsequent journal notifications and preferentially cite the officially published version. Thank you for your support and cooperation.