CA2135061C - A ceramic composite, particularly for use at temperatures above 1400.degre.c - Google Patents
A ceramic composite, particularly for use at temperatures above 1400.degre.c Download PDFInfo
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- CA2135061C CA2135061C CA002135061A CA2135061A CA2135061C CA 2135061 C CA2135061 C CA 2135061C CA 002135061 A CA002135061 A CA 002135061A CA 2135061 A CA2135061 A CA 2135061A CA 2135061 C CA2135061 C CA 2135061C
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- matrix
- al2o3
- interface material
- yag
- interface
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- 239000002131 composite material Substances 0.000 title claims abstract description 26
- 239000000919 ceramic Substances 0.000 title claims abstract description 21
- 239000000463 material Substances 0.000 claims abstract description 45
- 239000011159 matrix material Substances 0.000 claims abstract description 33
- 239000012779 reinforcing material Substances 0.000 claims abstract description 21
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 7
- 230000001590 oxidative effect Effects 0.000 claims abstract description 7
- 230000001747 exhibiting effect Effects 0.000 claims abstract description 5
- 238000004519 manufacturing process Methods 0.000 claims abstract description 4
- 238000002844 melting Methods 0.000 claims abstract description 4
- 230000008018 melting Effects 0.000 claims abstract description 4
- 239000007787 solid Substances 0.000 claims abstract description 4
- 230000009257 reactivity Effects 0.000 claims abstract description 3
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 claims description 13
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 claims description 8
- 229910052863 mullite Inorganic materials 0.000 claims description 8
- 239000000843 powder Substances 0.000 claims description 8
- 239000000835 fiber Substances 0.000 claims description 6
- 239000012783 reinforcing fiber Substances 0.000 claims description 6
- 238000006243 chemical reaction Methods 0.000 claims description 5
- 238000000576 coating method Methods 0.000 claims description 4
- 239000011248 coating agent Substances 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 239000013078 crystal Substances 0.000 claims description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims 10
- 229910052593 corundum Inorganic materials 0.000 claims 10
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 10
- 229910000505 Al2TiO5 Inorganic materials 0.000 claims 2
- 230000009286 beneficial effect Effects 0.000 claims 1
- 230000002708 enhancing effect Effects 0.000 claims 1
- 238000005336 cracking Methods 0.000 abstract description 2
- 238000001035 drying Methods 0.000 description 7
- 238000005245 sintering Methods 0.000 description 7
- 238000005452 bending Methods 0.000 description 6
- 229910003460 diamond Inorganic materials 0.000 description 6
- 239000010432 diamond Substances 0.000 description 6
- 238000007373 indentation Methods 0.000 description 6
- 238000007731 hot pressing Methods 0.000 description 5
- 229910010271 silicon carbide Inorganic materials 0.000 description 5
- 239000002002 slurry Substances 0.000 description 5
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 4
- 229910052582 BN Inorganic materials 0.000 description 3
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 description 3
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
- 229910052878 cordierite Inorganic materials 0.000 description 3
- JSKIRARMQDRGJZ-UHFFFAOYSA-N dimagnesium dioxido-bis[(1-oxido-3-oxo-2,4,6,8,9-pentaoxa-1,3-disila-5,7-dialuminabicyclo[3.3.1]nonan-7-yl)oxy]silane Chemical compound [Mg++].[Mg++].[O-][Si]([O-])(O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2)O[Al]1O[Al]2O[Si](=O)O[Si]([O-])(O1)O2 JSKIRARMQDRGJZ-UHFFFAOYSA-N 0.000 description 3
- 230000003014 reinforcing effect Effects 0.000 description 3
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 3
- 206010037660 Pyrexia Diseases 0.000 description 2
- 239000011184 SiC–SiC matrix composite Substances 0.000 description 2
- 230000003647 oxidation Effects 0.000 description 2
- 238000007254 oxidation reaction Methods 0.000 description 2
- 239000011505 plaster Substances 0.000 description 2
- MTEOMEWVDVPTNN-UHFFFAOYSA-E almagate Chemical compound O.O.[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[OH-].[Mg+2].[Mg+2].[Mg+2].[Al+3].[O-]C([O-])=O MTEOMEWVDVPTNN-UHFFFAOYSA-E 0.000 description 1
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 230000004888 barrier function Effects 0.000 description 1
- 238000002485 combustion reaction Methods 0.000 description 1
- 238000009792 diffusion process Methods 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000002223 garnet Substances 0.000 description 1
- 238000001171 gas-phase infiltration Methods 0.000 description 1
- 150000002500 ions Chemical class 0.000 description 1
- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000000034 method Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 229910052727 yttrium Inorganic materials 0.000 description 1
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
- C04B35/645—Pressure sintering
Abstract
A ceramic composite material comprises matrix and possibly reinforcing materials and intermediate weak interface material and is particularly intended for being used at temperatures above 1400°C and in an oxidizing environment, the matrix and possibly reinforcing materials consisting of the same or different ceramic oxides having a melting point above 1600°C. In order to obtain said ceramic composite material the invention suggests that the interface material consists of one or more ceramic oxides not exhibiting solid solubility, eutecticum below the temperature of manufacture or use or reactivity with any of the matrix or possibly reinforcing materials and in combination with said materials providing a stress field liable to micro-cracking, said matrix and possibly reinforcing materials essentially being substantially pure.
Description
"'~7 93/22258 P~.°T/SE92/00297 i ~ 2~.~3~06~. v A ceramic composite, particularly for z s use at temperatures above 1400°C
The present invention refers to a ceramic composite material comprising matrix and possibly reinforcing mate-rials and an intermediate weak interface material and parti-cularly adapted for use at temperatures above 1400°C and in oxidizing environment, said matrix and possibly reinforcing materials consisting of the same or different ceramic oxides having a melting point above 1600°C.
Ceramic composite materials might be divided into materials reinforced by particles, whiskers or elongated ffibres. Said materials are prepared by powder processes and sintering or by gas-phase infiltration. The materials hitherto mentioned in the literature often are based on the provision of desired composite characteristics by means of a weak interface material between the matrix and the reinfor-cing material, preferably fibres, said interface material consisting of carbon or boron nitride, see e.g. Frety, N. , Boussuge, M., "Relationship between high-temperature development of fibre-matrix interfaces and the mechanical behaviour of SiC-SiC composites", Composites Sci: Techn. 37 177-189 (1990) and Singly R.N., "Influence of high tempera-ture exposure on mechanical properties of zircon-silicon carbide composites", J. Mater. Sci. 26 117-126 (1991), respectively. Both carbon and boron nitride have a layered structure which makes them weak in one direction and this can be utilized for deflecting cracks along the interface between fibre and matrix. Both carbon and boron nitride, however, are very sensitive to oxidation which starts al-ready at relatively low temperatures of about 500-800°C. In a order to enable the use of ceramic composites at high tempe-ratures in oxidizing atmosphere, such as in combustion chambers of gas turbines, rocket nozzles etc. other oxida- ' tion-resistent weak interface materials are required. An ~ -. .
WO 93!Z2258 pCT/SE921002~'"' ~~~~~ ' _ attempt to provide such materials has been mentioned in Carpenter, H.W., Bohlen, J.W., "Fiber coatings for ceramic ' matrix composites", Ceram. Eng. Sci. Proc. vol 13 9-10 (1992). In said attempt composites have been manufactured with SiC fibres and a layered SiC interface in an SiC mat-s rix. Experiments also have been made with interfaces of a porous oxide in a SiC/SiC composite. However, SiC is stable in an oxidizing environment only up to 1000°C, at higher temperatures a Si02 layer always is formed on the surface in oxidizing atmosphere. Often Si02~is not stable together with other oxides but reacts therewith and forms strong bonds to adjacent materials. Therefore, Si02 does not constitute a useful interface material in the present connection. Thus there is still a need for improved composite materials which might be used in oxidizing environments at temperatures above 1400°C.
The object of the present invention now is to suggest such a ceramic composite material and the feature essen-tially distinguishing the invention is that the interface material consists of one or more ceramic oxides not exhi-biting solid solubility, eutecticum below the temperature of manufacture or use or reaction with any of the matrix E..
or possibly reinforcing materials and in combination with said materials providing a stress field liable to micro cracking, said matrix and reinforcing materials being sub stantially pure.
One of the most obvious interface materials is Zr02 which fills the requirements as to oxidation resistance and good high temperature characteristics. In US A 4 732 877 recently has been suggested an interface of Zr02 in a compo-site of A1203/A12o3. According to said patent, however, the only object of Zr02 is to act as a diffusion barrier and ~ t prevent a reaction between reinforcing fibres and matrix.
The interface obtained is strong by its binding to said materials and not weak as is necessary in ceramic composi tes for the present use.
The present invention refers to a ceramic composite material comprising matrix and possibly reinforcing mate-rials and an intermediate weak interface material and parti-cularly adapted for use at temperatures above 1400°C and in oxidizing environment, said matrix and possibly reinforcing materials consisting of the same or different ceramic oxides having a melting point above 1600°C.
Ceramic composite materials might be divided into materials reinforced by particles, whiskers or elongated ffibres. Said materials are prepared by powder processes and sintering or by gas-phase infiltration. The materials hitherto mentioned in the literature often are based on the provision of desired composite characteristics by means of a weak interface material between the matrix and the reinfor-cing material, preferably fibres, said interface material consisting of carbon or boron nitride, see e.g. Frety, N. , Boussuge, M., "Relationship between high-temperature development of fibre-matrix interfaces and the mechanical behaviour of SiC-SiC composites", Composites Sci: Techn. 37 177-189 (1990) and Singly R.N., "Influence of high tempera-ture exposure on mechanical properties of zircon-silicon carbide composites", J. Mater. Sci. 26 117-126 (1991), respectively. Both carbon and boron nitride have a layered structure which makes them weak in one direction and this can be utilized for deflecting cracks along the interface between fibre and matrix. Both carbon and boron nitride, however, are very sensitive to oxidation which starts al-ready at relatively low temperatures of about 500-800°C. In a order to enable the use of ceramic composites at high tempe-ratures in oxidizing atmosphere, such as in combustion chambers of gas turbines, rocket nozzles etc. other oxida- ' tion-resistent weak interface materials are required. An ~ -. .
WO 93!Z2258 pCT/SE921002~'"' ~~~~~ ' _ attempt to provide such materials has been mentioned in Carpenter, H.W., Bohlen, J.W., "Fiber coatings for ceramic ' matrix composites", Ceram. Eng. Sci. Proc. vol 13 9-10 (1992). In said attempt composites have been manufactured with SiC fibres and a layered SiC interface in an SiC mat-s rix. Experiments also have been made with interfaces of a porous oxide in a SiC/SiC composite. However, SiC is stable in an oxidizing environment only up to 1000°C, at higher temperatures a Si02 layer always is formed on the surface in oxidizing atmosphere. Often Si02~is not stable together with other oxides but reacts therewith and forms strong bonds to adjacent materials. Therefore, Si02 does not constitute a useful interface material in the present connection. Thus there is still a need for improved composite materials which might be used in oxidizing environments at temperatures above 1400°C.
The object of the present invention now is to suggest such a ceramic composite material and the feature essen-tially distinguishing the invention is that the interface material consists of one or more ceramic oxides not exhi-biting solid solubility, eutecticum below the temperature of manufacture or use or reaction with any of the matrix E..
or possibly reinforcing materials and in combination with said materials providing a stress field liable to micro cracking, said matrix and reinforcing materials being sub stantially pure.
One of the most obvious interface materials is Zr02 which fills the requirements as to oxidation resistance and good high temperature characteristics. In US A 4 732 877 recently has been suggested an interface of Zr02 in a compo-site of A1203/A12o3. According to said patent, however, the only object of Zr02 is to act as a diffusion barrier and ~ t prevent a reaction between reinforcing fibres and matrix.
The interface obtained is strong by its binding to said materials and not weak as is necessary in ceramic composi tes for the present use.
Thus the present invention refers to an interface material for a ceramic composite material in which the matrix and/or the reinforcing material consist of a ceramic oxide comprising one or more metals and having a melting point above 1600°C, said oxide not exhibiting solid solubi lity, eutecticum below the temperature of manufacture or use or reactivity with any of the other oxides. in the interface or the matrix or reinforcing materials. As examples of such oxides there can be mentioned A120~, ZrO~, Hf02, A12Ti05, Sn02, Y203, BeA1204, yttrium aluminium garnet (YAG), LaCr03, mullite, Be0 and Cr2o3. Preferably the reinforcing material is present as fibres but also particulate and layer form are possible.
The present i.nz-ent;ion <~l:~o concerns a ceramic composite materia.:L compoi: _ing rr;atr:.x ruaterial,reinforcing fibers and an intermediate irlterfac_e mat=eri_al, wherein said matrix material and reinforcing fiLaers con~:ists of the same or different ceramic o~~i.des having a mell=ing point above 1600C; said interface material., ire ~vombinati on with t=he matrix and reinforcing materials L:~rcvides a stress field liable to microc:rack.=.ng bEi_ng apl:%1.:_ed ting on said ~s a coa fibers and consisting of at Least or:~r cerami c oxide not exhibiting soiicl so:_ubil.ity, c~utE~ci=icum below the temperature c>f mar~ufccture or i:m>e c>r re=~acti with any it.y of said matrix or rei.nforcng materia.l~; said matrix and reinforcing mat:erial~. k~ei.n~~ :~ub~tar~t.:i_a and wherein i 7. y pure, the combinats.on f=iber/:interface rnatc~.r-ia~l/matrixmaterial.
is selected from t=he group :~orzsi st i n<~ ~ ~ iv A1z03/A12Ti05/A12C?3, YAG/A_L2Ti05/A1~03, 3 0 Al 2~3 /YAG/Al z03 , A1.20_ / SnO~yA1203 , YAG/Sn02/A1 X03, A.L.~O:,%mullite/A1203 .
3a In combination with the matrix and possibly reinfor cing materials the interface material has to form a stress field which either results into micro cracks in the inter face material or into cracks between the latter and the matrix/reinforcing material. Alternatively, the stress field might cause crack deflection as such also without micro cracks occuring. The desired stress field occurs either by the difference in thermal expansion coefficient between the interface material and the matrix/reinforcing materials or by differences in thermal expansion coefficient between various inherent phases of the interface material. Stresses also might be generated by the fact that the interface material as such has an anisotropic structure with diffe-rent thermal expansion coefficients in various crystal directions. A further possibility to form stresses is that phases of the interface material undergo a phase conversion which results in a change of volume. The interface material also might be a composite in which the two inherent phases have different elastic characteristics or different thermal expansion coefficients which creates the desired stress situation. As examples of some well-serving interface mate-rials it might be mentioned A12Ti05, cordierite, unstabili-Zed Zr02, Sn02, Hf02, mullite, YAG, YAG+Zr02, A1203+Zr02 and A12Ti05+A1203. Of said substances, A12Ti05 and cordierite act as iflterface materials due to their anisotropy, while Zr02 and Sn02 act by micro-cracks. YAG, Hf02, Zr02, A12Ti05, cordierite, mullite and Sn02 act as interface materials due to differences in thermal expansion while Zr02 and possibly Hf02 might be subjeacted to phase conversion.
Preferably, the interface material has a thickness of at least 2 um. When the interface material is Zr02, i t is used in the form of powder or sol during coating of a f ibre reinforcing material in order to avoid chemical binding of Zro2 to the fibres.
Based on the above mentioned the fol:Lowing examples of well-serving composite systems of reinforcing material/in-terface/matrix might be mentioned.
A1203/AlzTiO,'/A1203 YAG/A12Ti05/YAG
A1203/A12Ti0,~/YAG YAG/A12Ti05/A1203 A1203/Zr02/A:L203 YAG/Zr02/YAG
YAG/Zr02JA1~t73 A1203/Zr02/YAG
A1203 /Hf02 /A:L203 YAG/Hf02 / YAG
A1203,'Hf02/Yi~G YAG/Hf02/A1203 Hf02/A12Ti05,IHf02 A1203/YAG/A1203 A1203 /Sn02 /A:L203 YAG/ Sn02 /YAG
YAG/Sn02/Al2c)3 A12D3/Sno2/YAG
A1203/mullite~/A1203 mullite/Zr02/mullite .
rc~2/YAG A1203/YAG+Zr02/A1203 YAG/A1203+Z
YAG/A1203+A12Ti05/YAG Hfc72/A1,203+A12Ti05/Hf02 Example 1 Plates of A12(?3 of 0,25 mm thickness were coated with a thin layer of A12Ti05. This was made by submerging the plates in.a slurry of Al2Tio5 powder in water. After drying the covered plates were stacked and sintered by hot-pressing at 1700°C for 4 hours. After sintering the.A12Ti05 layer was about 5 um thick. The Al2z'i05 layer comprised micro cracks deflecting cracks, which was proved by diamond indentation or bending tests.
Example 2 Fibres of A1203 (ALMAX, Mitsui, Japan) were covered with a thin layer of A12Ti05. This was made by immersing the fibres into a A1-Ti-alkoxide. After gelling and drying the 5 coated fibres were stacked in a plaster mould and a A12~3 powder slurry was poured thereon.
After drying the slip-cast bodies were sintered by hot-pressing at 1500°C for 4 hours. After sintering the A12Ti05 layer was about 3 ~Cm thick. The A12Ti05 layer com-prised micro-cracks deflecting cracks which was proved by diamond indentation or bending tests.
Example 3 Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Zr02. This was made by immersing the plates in a slurry of Zr02-powder in water. After drying the coated plates were stacked and sintered by hot-pressing at 1700°C
or 4 hours. The Zr02 layer had a thickness of about 5 ~cm after sintering. Stress-induced micro cracks occurred bet-ween the layer and the A1203-material. These deflected cracks which was proved by diamond indentation or bending tests.
Example 4 _ Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Hf02. This was made by immersing the plates in a slurry of Hf02-powder in water. After drying the coated plates were stacked and sintered by hot-pressing at 1700°C
for 4 hours. The layer of Hf02 was about 5 ~,m thick after sintering. Stress-induced micro-cracks occurred between the layer and the A1203-material. These deflected cracks, which was proved by diamond indentation or bending tests.
_Example 5 Single-crystal-fibres of A1203 (from Saphicon, USA) were coated with a thin layer of Zr02. This was made by immersing the fibres in an aqueous Zro2-sol. After gelling and drying the coated fibres were stacked in a plaster mould and an A1203-powder slurry was poured thereon. After drying * (trademark) ow ~z.~s~5~~ ~
the slip-cast bodies were sintered by hot-pressing at 1500°C
for 4 hours. After sintering the zr02 layer was about 3 ~Cm thick . Stress-induced micro-cracks occurred between the layer and the A1203-material. These deflected cracks which s was proved by diamond indentation or bending tests.
Example 6 Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Sn02. The plates were immersed in Sn02-sol and stacked on each other and then dried after which they to were sintered in air at 1450°C under a certain uniaxial pressure for 4 hours. After sintering the Sn02-layer was about 2,5 ~m thick.. The Sn02-layer formed micro-cracks deflecting cracks which was proved by diamond indentation or bending tests.
r i
The present i.nz-ent;ion <~l:~o concerns a ceramic composite materia.:L compoi: _ing rr;atr:.x ruaterial,reinforcing fibers and an intermediate irlterfac_e mat=eri_al, wherein said matrix material and reinforcing fiLaers con~:ists of the same or different ceramic o~~i.des having a mell=ing point above 1600C; said interface material., ire ~vombinati on with t=he matrix and reinforcing materials L:~rcvides a stress field liable to microc:rack.=.ng bEi_ng apl:%1.:_ed ting on said ~s a coa fibers and consisting of at Least or:~r cerami c oxide not exhibiting soiicl so:_ubil.ity, c~utE~ci=icum below the temperature c>f mar~ufccture or i:m>e c>r re=~acti with any it.y of said matrix or rei.nforcng materia.l~; said matrix and reinforcing mat:erial~. k~ei.n~~ :~ub~tar~t.:i_a and wherein i 7. y pure, the combinats.on f=iber/:interface rnatc~.r-ia~l/matrixmaterial.
is selected from t=he group :~orzsi st i n<~ ~ ~ iv A1z03/A12Ti05/A12C?3, YAG/A_L2Ti05/A1~03, 3 0 Al 2~3 /YAG/Al z03 , A1.20_ / SnO~yA1203 , YAG/Sn02/A1 X03, A.L.~O:,%mullite/A1203 .
3a In combination with the matrix and possibly reinfor cing materials the interface material has to form a stress field which either results into micro cracks in the inter face material or into cracks between the latter and the matrix/reinforcing material. Alternatively, the stress field might cause crack deflection as such also without micro cracks occuring. The desired stress field occurs either by the difference in thermal expansion coefficient between the interface material and the matrix/reinforcing materials or by differences in thermal expansion coefficient between various inherent phases of the interface material. Stresses also might be generated by the fact that the interface material as such has an anisotropic structure with diffe-rent thermal expansion coefficients in various crystal directions. A further possibility to form stresses is that phases of the interface material undergo a phase conversion which results in a change of volume. The interface material also might be a composite in which the two inherent phases have different elastic characteristics or different thermal expansion coefficients which creates the desired stress situation. As examples of some well-serving interface mate-rials it might be mentioned A12Ti05, cordierite, unstabili-Zed Zr02, Sn02, Hf02, mullite, YAG, YAG+Zr02, A1203+Zr02 and A12Ti05+A1203. Of said substances, A12Ti05 and cordierite act as iflterface materials due to their anisotropy, while Zr02 and Sn02 act by micro-cracks. YAG, Hf02, Zr02, A12Ti05, cordierite, mullite and Sn02 act as interface materials due to differences in thermal expansion while Zr02 and possibly Hf02 might be subjeacted to phase conversion.
Preferably, the interface material has a thickness of at least 2 um. When the interface material is Zr02, i t is used in the form of powder or sol during coating of a f ibre reinforcing material in order to avoid chemical binding of Zro2 to the fibres.
Based on the above mentioned the fol:Lowing examples of well-serving composite systems of reinforcing material/in-terface/matrix might be mentioned.
A1203/AlzTiO,'/A1203 YAG/A12Ti05/YAG
A1203/A12Ti0,~/YAG YAG/A12Ti05/A1203 A1203/Zr02/A:L203 YAG/Zr02/YAG
YAG/Zr02JA1~t73 A1203/Zr02/YAG
A1203 /Hf02 /A:L203 YAG/Hf02 / YAG
A1203,'Hf02/Yi~G YAG/Hf02/A1203 Hf02/A12Ti05,IHf02 A1203/YAG/A1203 A1203 /Sn02 /A:L203 YAG/ Sn02 /YAG
YAG/Sn02/Al2c)3 A12D3/Sno2/YAG
A1203/mullite~/A1203 mullite/Zr02/mullite .
rc~2/YAG A1203/YAG+Zr02/A1203 YAG/A1203+Z
YAG/A1203+A12Ti05/YAG Hfc72/A1,203+A12Ti05/Hf02 Example 1 Plates of A12(?3 of 0,25 mm thickness were coated with a thin layer of A12Ti05. This was made by submerging the plates in.a slurry of Al2Tio5 powder in water. After drying the covered plates were stacked and sintered by hot-pressing at 1700°C for 4 hours. After sintering the.A12Ti05 layer was about 5 um thick. The Al2z'i05 layer comprised micro cracks deflecting cracks, which was proved by diamond indentation or bending tests.
Example 2 Fibres of A1203 (ALMAX, Mitsui, Japan) were covered with a thin layer of A12Ti05. This was made by immersing the fibres into a A1-Ti-alkoxide. After gelling and drying the 5 coated fibres were stacked in a plaster mould and a A12~3 powder slurry was poured thereon.
After drying the slip-cast bodies were sintered by hot-pressing at 1500°C for 4 hours. After sintering the A12Ti05 layer was about 3 ~Cm thick. The A12Ti05 layer com-prised micro-cracks deflecting cracks which was proved by diamond indentation or bending tests.
Example 3 Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Zr02. This was made by immersing the plates in a slurry of Zr02-powder in water. After drying the coated plates were stacked and sintered by hot-pressing at 1700°C
or 4 hours. The Zr02 layer had a thickness of about 5 ~cm after sintering. Stress-induced micro cracks occurred bet-ween the layer and the A1203-material. These deflected cracks which was proved by diamond indentation or bending tests.
Example 4 _ Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Hf02. This was made by immersing the plates in a slurry of Hf02-powder in water. After drying the coated plates were stacked and sintered by hot-pressing at 1700°C
for 4 hours. The layer of Hf02 was about 5 ~,m thick after sintering. Stress-induced micro-cracks occurred between the layer and the A1203-material. These deflected cracks, which was proved by diamond indentation or bending tests.
_Example 5 Single-crystal-fibres of A1203 (from Saphicon, USA) were coated with a thin layer of Zr02. This was made by immersing the fibres in an aqueous Zro2-sol. After gelling and drying the coated fibres were stacked in a plaster mould and an A1203-powder slurry was poured thereon. After drying * (trademark) ow ~z.~s~5~~ ~
the slip-cast bodies were sintered by hot-pressing at 1500°C
for 4 hours. After sintering the zr02 layer was about 3 ~Cm thick . Stress-induced micro-cracks occurred between the layer and the A1203-material. These deflected cracks which s was proved by diamond indentation or bending tests.
Example 6 Plates of A1203 of 0,25 mm thickness were coated with a thin layer of Sn02. The plates were immersed in Sn02-sol and stacked on each other and then dried after which they to were sintered in air at 1450°C under a certain uniaxial pressure for 4 hours. After sintering the Sn02-layer was about 2,5 ~m thick.. The Sn02-layer formed micro-cracks deflecting cracks which was proved by diamond indentation or bending tests.
r i
Claims (5)
1. A ceramic composite material comprising matrix material, reinforcing fibers and an intermediate interface material, wherein said matrix material and reinforcing fibers consists of the same or different ceramic oxides having a melting point above 1600°C; said interface material, in combination with the matrix and reinforcing materials, provides at stress field liable to microcracking being applied as a coating on said fibers and consisting of at least one ceramic oxide not exhibiting solid solubility, eutecticum below the temperature of manufacture or use or reactivity with any of said matrix or reinforcing materials, said matrix and reinforcing materials being substantially pure, and wherein the combination fiber/
interface material/matrix is selected from the group consisting of:
Al2O3/Al2TiO5/Al2O3, YAG/Al2TiO5/Al2O3, Al2O3/YAG/Al2O3, Al2O3/SnO2/Al2O3, YAG/SnO2/Al2O3, Al2O3/mullite/Al2O3.
interface material/matrix is selected from the group consisting of:
Al2O3/Al2TiO5/Al2O3, YAG/Al2TiO5/Al2O3, Al2O3/YAG/Al2O3, Al2O3/SnO2/Al2O3, YAG/SnO2/Al2O3, Al2O3/mullite/Al2O3.
2. A composite material according to claim 1, wherein a beneficial stress field for enhancing de-bonding is formed either by differences in thermal expansion coefficient between the interface material and the matrix and reinforcing fibers or between various inherent phases in the very interface material; or by the latter as such having anisotropic structure with different thermal expansion coefficient in different crystal directions; or by providing a phase conversion between the phases of the interface material and hence a volume change or by the interface material being a composite having at least two phases which have different elastic characteristics or different thermal expansion coefficients.
3. A composite material according to claim 1 or 2, wherein said interface material is in the form of powder or sol in order to avoid chemical bonding of the interface material to the reinforcing fibers and/or the matrix material during fiber coating.
4. A composite material according to claim 1, 2 or 3, wherein said interface material has a thickness of at least 2 µm.
5. The composite material of any one of claims 1 to 4, for use at temperatures above 1400°C and in an oxidizing environment for obtaining a weak bond liable to debonding between the interface material and matrix material and/or reinforcing fibers, respectively.
Priority Applications (7)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002135061A CA2135061C (en) | 1992-05-07 | 1992-05-07 | A ceramic composite, particularly for use at temperatures above 1400.degre.c |
| JP5519161A JPH08501266A (en) | 1992-05-07 | 1992-05-07 | Ceramic composites used especially at temperatures above 1400 ° C |
| ES92916352T ES2098522T3 (en) | 1992-05-07 | 1992-05-07 | A CERAMIC COMPOSITE MATERIAL, PARTICULARLY FOR USE AT TEMPERATURES HIGHER THAN 1400 DEGREES C. |
| EP92916352A EP0639165B1 (en) | 1992-05-07 | 1992-05-07 | A CERAMIC COMPOSITE, PARTICULARLY FOR USE AT TEMPERATURES ABOVE 1400 oC |
| PCT/SE1992/000297 WO1993022258A1 (en) | 1992-05-07 | 1992-05-07 | A ceramic composite, particularly for use at temperatures above 1400 °c |
| DE69218260T DE69218260T2 (en) | 1992-05-07 | 1992-05-07 | CERAMIC COMPOSITE MATERIAL, ESPECIALLY FOR USE AT TEMPERATURES OVER 1400 o C |
| US08/331,630 US5567518A (en) | 1992-05-07 | 1992-05-07 | Ceramic composite, particularly for use at temperatures above 1400 degrees celsius |
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CA002135061A CA2135061C (en) | 1992-05-07 | 1992-05-07 | A ceramic composite, particularly for use at temperatures above 1400.degre.c |
| PCT/SE1992/000297 WO1993022258A1 (en) | 1992-05-07 | 1992-05-07 | A ceramic composite, particularly for use at temperatures above 1400 °c |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2135061A1 CA2135061A1 (en) | 1993-11-11 |
| CA2135061C true CA2135061C (en) | 2004-02-10 |
Family
ID=25677591
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002135061A Expired - Lifetime CA2135061C (en) | 1992-05-07 | 1992-05-07 | A ceramic composite, particularly for use at temperatures above 1400.degre.c |
Country Status (3)
| Country | Link |
|---|---|
| CA (1) | CA2135061C (en) |
| ES (1) | ES2098522T3 (en) |
| WO (1) | WO1993022258A1 (en) |
Families Citing this family (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| ES2384356T3 (en) | 2008-10-31 | 2012-07-04 | Avio S.P.A. | Method for the production of components made of ceramic matrix composite material |
| US11686208B2 (en) | 2020-02-06 | 2023-06-27 | Rolls-Royce Corporation | Abrasive coating for high-temperature mechanical systems |
Family Cites Families (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4298385A (en) * | 1976-11-03 | 1981-11-03 | Max-Planck-Gesellschaft Zur Forderung Wissenschaften E.V. | High-strength ceramic bodies |
| DE3518844A1 (en) * | 1985-05-24 | 1986-11-27 | Max-Planck-Gesellschaft zur Förderung der Wissenschaften e.V., 3400 Göttingen | CERAMIC COMPOSITE |
| US5017528A (en) * | 1988-02-04 | 1991-05-21 | Martin Marietta Energy Systems, Inc. | Modified silicon carbide whiskers |
| US5110771A (en) * | 1991-03-13 | 1992-05-05 | Northrop Corporation | Method of forming a precracked fiber coating for toughening ceramic fiber-matrix composites |
-
1992
- 1992-05-07 CA CA002135061A patent/CA2135061C/en not_active Expired - Lifetime
- 1992-05-07 ES ES92916352T patent/ES2098522T3/en not_active Expired - Lifetime
- 1992-05-07 WO PCT/SE1992/000297 patent/WO1993022258A1/en active IP Right Grant
Also Published As
| Publication number | Publication date |
|---|---|
| WO1993022258A1 (en) | 1993-11-11 |
| ES2098522T3 (en) | 1997-05-01 |
| CA2135061A1 (en) | 1993-11-11 |
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