CN102992797B - 修改复合材料物件的方法 - Google Patents
修改复合材料物件的方法 Download PDFInfo
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- CN102992797B CN102992797B CN201210326885.5A CN201210326885A CN102992797B CN 102992797 B CN102992797 B CN 102992797B CN 201210326885 A CN201210326885 A CN 201210326885A CN 102992797 B CN102992797 B CN 102992797B
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Abstract
在本公开的某些实施例中，描述了用于修改复合材料物件的方法。该方法包括将由复合材料制成的插塞定位在复合材料物件上的某个部位。该方法还包括使插塞和物件中的至少一个以足以在插塞和复合材料物件的部位之间形成惯性结合的速率旋转。插塞和该部位被接合而在其间实现惯性结合。
Description
技术领域
本发明大体上涉及修改复合材料物件的方法。在特定实施例中，可利用惯性结合(inertia bonding)来修改这种复合材料物件。
背景技术
具有分散在相同或不同组成的连续陶瓷基体中的纤维的增强陶瓷基体复合材料很好地适用于结构应用，因为它们的韧性、抗热性、 高温强度和化学稳定性。这样的复合材料通常具有高的强度质量比，这使得它们在重量为关注点的应用中有吸引力，例如在航空应用中。它们在高温下的稳定性使得它们非常适合于构件与高温气体接触的应用中，例如在燃气涡轮发动机中。
陶瓷基体复合材料是十分昂贵的，因为它们的典型生产工艺是相当复杂的。因此，期望具有修改这种零件(其意外地或在使用期间可能损坏)的方法，使得它们可被挽救或者它们的使用寿命可延长。
常规地，复合材料的损坏用外部结合的补块来修补，其仅仅依靠与复合材料物件外表面的结合。不幸的是，这些类型的修改并未充分接合复合材料物件的基部而形成显著结合到补块。其它修改方法利用铆钉或连结在一起的外部和内部两半插塞来形成浮动的补块，该补块也不直接结合到复合材料物件。
因此，存在着对于用于修改复合材料物件的改进方法的需要。
发明内容
本发明的方面和优点阐述在下面的描述中，或者根据该描述可能是明显的，或者可通过本发明的实践来了解。
在本公开的某些实施例中，描述了一种用于修改复合材料物件的方法。该方法包括将由复合材料制成的插塞定位在复合材料物件上的部位。该方法还包括使插塞和物件中的至少一个以足以在插塞和复合材料物件的部位之间形成惯性结合的速率旋转。插塞和部位被接合以在其间实现惯性结合。
在本公开的其它实施例中，描述了一种用于修改复合材料物件的区域的方法。该方法包括将由纤维增强陶瓷基体复合材料制成的插塞定位在复合材料物件上的部位。复合材料物件包括纤维增强陶瓷基体复合材料。该方法还包括使插塞和物件中的至少一个以足以在插塞和复合材料物件的部位之间形成惯性结合的速率旋转。插塞和部位被接合以在其间实现惯性结合。
通过回顾说明书，本领域技术人员将更好地意识到这样的实施例和其它实施例的特征和方面。
附图说明
本发明的完整且能够实现的公开，包括对于本领域技术人员而言的其最佳模式，更具体地阐述在说明书的剩余部分中，说明书包括对附图的参考，在附图中：
图1是根据本公开的某些实施例的复合材料物件的透视图；
图2是根据本公开的某些方面的正被修改的图1中的复合材料物件的剖面示意图；以及
图3是根据本公开的某些实施例的复合材料物件的透视图。
附图标记：
10 复合材料物件
14 插塞
16 轴
18 修改部位。
具体实施方式
现在将详细地参考本发明的所提出的实施例，这些实施例的一个或更多示例在附图中示出。详细的描述使用数字和字母标记来指代图中的特征。附图和描述中相同或类似的标记用于指代本发明的相同或类似的部分。
每个示例以本发明的说明而不是本发明的限制的方式提供。事实上，对于本领域技术人员而言将显而易见的是，在不偏离本发明的范围或精神的情况下，可在本发明中做出修改和变型。例如，作为一个实施例的部分所示出或描述的特征可用在另一实施例上而产生更进一步的实施例。因此，当落入所附权利要求及其等同的范围内时，本发明意图涵盖这样的修改和变型。
陶瓷基体复合材料被用于形成暴露于航空发动机和燃气涡轮中的热燃烧气体的构件，例如护罩、燃烧器衬套、喷嘴、动叶、叶片以及静叶。陶瓷基体复合材料的有利于它们在这些应用中的使用的一个重要特性是它们的高韧性行为，该高韧性行为由材料中初始基体开裂后的上升的应力-应变曲线来表征。
在工作中，燃气涡轮构件在频繁超过1200℃的温度下运转，并且经受显著的温度梯度。另外，这些构件被暴露于来自夹入热气中的具有高速度的颗粒的冲击负荷。本公开的用于修改由复合材料(如陶瓷基体复合材料)制成的燃气涡轮发动机构件中的损坏的方法能够延长这些构件的寿命。另外，本公开的方法能够修改新制造的构件，并且因此减少不合规格构件的数量。本公开的方法提供了表现出与新制造构件类似的韧性行为的改进构件。
非常普遍地，本公开的方法利用惯性结合来修改复合材料。有利的是，可以修改复合材料元件而不必在修改之前拆卸或预热。
在某些实施例中，复合材料元件是纤维增强的陶瓷基体复合材料。在某些实施例中，纤维包括碳化硅。本文对碳化硅纤维的提及包括单晶或多晶纤维，或者其中碳化硅包封另一种材料(如碳或钨)的芯。纤维还可包括有机前体，其将在制造过程中经历的温度范围内的某一温度下转化为碳化硅。这样的纤维还可包括硅和碳以外的元素。
本公开的修改方法可应用于复合材料物件的修改，该复合材料物件通过复合材料生产的任何方法制成，包括陶瓷基体复合材料生产的方法。例如，陶瓷基体复合材料物件可通过预先浸润/熔体浸渍、预先浸润/化学气相浸渍、浆铸、浆铸/熔体浸渍、浆铸/化学气相浸渍、聚合物浸渍和热解、或者它们的组合来制成。
例如，在预先浸润/熔体浸渍方法中，陶瓷复合材料物件形成为包括多孔纤维预成型件和浸渍剂，多孔纤维预成型件包括陶瓷纤维和基体材料(一起，“纤维预成型件”)。通常，陶瓷纤维形成用于复合材料的增强体的网状物并且被基体和浸渍剂包围。陶瓷纤维预成型件是多孔的，因为尽管一些基体或基体前体材料可能与纤维一起提供，但是在纤维之间仍然有空间(纤维间空间或区域)。这些纤维间区域在生产陶瓷复合材料的过程中被浸渍剂填充。浸渍剂还可与基体前体反应。通常，纤维在直径上在从0.3微米到约150微米的范围内，并且在长度上为大约100米或更长。纤维可用作连续细丝或非连续纤维，其通常具有至少为10和高达1000或更多的长宽比。成形的纤维预成型件可以通过很多方式制成。除了用连续纤维制成的预成型件以外，低长宽比纤维可以与陶瓷基体材料或陶瓷基体前体材料的微粒和结合剂(如有机树脂、纤维质材料或它们的组合)混合，并且形成为期望的形状。
混合物可通过许多已知技术形成或成形为预成型件或压块。例如，它可被挤出、注塑、模压、等静压或者流铸，以产生期望形状和尺寸的预成型件。优选地，预成型件具有最终复合材料物件的形状和尺寸。
作为备选，纤维是连续的，并且如期望那么长。用包括基体或基体前体材料的悬浮液浸渍的连续纤维可为围绕稳定的成形支撑件的细丝缠绕物，以构成具有期望形状和厚度的预成型件。这种被浸渍的连续纤维还可通过将较长纤维长度放置成彼此靠近和平行而首先被成形为预浸渍的板或带。这种预浸渍的板或带可由单层或多层细丝组成。连续的细丝也可被编织、编造或以其它方式排列成所期望的构造。纤维板或带的部分可围绕稳定的成形支撑件设置，以构成具有期望形状和厚度的纤维预成型件。当复合材料期望地具有连续的SiC基体时，有机树脂或碳颗粒可在它们被制成预浸渍带且形成为形状之前引进纤维束中。如本文中使用的，术语“碳颗粒”或“碳微粒”包括但不限于颗粒、薄片、须状物或者非晶纤维、单晶、多晶碳、石墨、碳化植物纤维、灯黑、细碎煤、木炭以及碳化聚合物纤维或毛毡，诸如人造丝、聚丙烯腈和聚乙炔。
纤维可有利地由化合物涂覆，该化合物使得它们不向陶瓷基体材料的熔融前体中的一个或更多发生反应。在本公开的一个方面，纤维是用氮化物涂层(如氮化硼或掺硅氮化硼)涂覆的SiC纤维。其它涂层材料可以是为特定应用所选择的金属氮化物，诸如氮化铝或氮化硅。当纤维必须长时期暴露于陶瓷基体材料的熔融前体时，涂层可以防止纤维的大量降解。涂层还可用于在苛刻的应力条件下在最终复合材料中赋予纤维的优异剥离特性。氮化物涂层可通过本领域中公知的方法来沉积，以沉积连续的涂层而不损坏纤维。诸如化学气相沉积或物理气相沉积工艺(例如溅射)的涂覆工艺是合适的。通常，氮化物化合物的化学气相沉积在部分真空中在范围从约900℃到约1800℃的温度下进行，该特定加工条件是本领域中公知的或凭经验可决定的。氮化物涂层为至少足够厚的，从而是连续的且无显著空隙。涂层厚度可在从约0.1微米到约5微米的范围内变化，并且对于直径约8至15微米的纤维而言，其通常为大约1微米。涂层厚度应当足以防止在所用的特定加工条件下纤维与陶瓷基体材料的浸渍前体之间的反应或防止显著反应。在SiC 基体中的SiC纤维复合材料的情况下，陶瓷基体材料的前体通常为硅。在浸渍过程中，取决于时间和温度，氮化物涂层可与或可不与熔融硅反应或者溶解在其中；即，氮化物涂层在更低的温度下且对于更短的浸渍时间将保存得更好。通常，硅浸渍时间随着预成型件的尺寸而增加。因此，更大尺寸的预成型件可能需要更厚的氮化物涂层。增强纤维可涂覆有多于一个涂层，每个包括不同的材料。作为备选，涂层组成可跨过涂层厚度连续地分级。这种分级涂层可通过在沉积过程中改变反应物的组成而制得。
可选地，涂覆氮化物的纤维可由第二连续涂层涂覆，该第二连续涂层选自由碳和金属组成的组中，碳和金属与硅反应而在氮化物涂层上形成硅化物、金属碳化物、金属硅化物、金属氮化物和金属硼化物。金属碳化物可为硅、钽、钛或钨的碳化物。金属硅化物可为铬、钼、 钽、钛、钨或锆的硅化物。氮化物可为硅、铝、钛、锆、铪、铌、钽或硼的氮化物。金属硼化物可为钛、锆、铪或铝的二硼化物。
纤维的外部涂层可通过毛细作用促进润湿而改进浸渍，提供与基体的期望剥离，或者减少在高温工作期间基体与纤维之间的反应。此外，纤维还可用一种材料来涂覆，该材料使得它们可容易地被陶瓷基体材料的熔融前体润湿。
陶瓷基体材料或其前体被直接或间接应用于纤维预成型件的表面。间接应用可能受毛细作用影响。当陶瓷复合材料包括SiC连续相时，前体为硅。例如，硅粉可直接应用在纤维预成型件的表面上。作为备选，熔融硅可通过毛细作用供应至纤维预成型件的表面。带有陶瓷基体材料或其前体的纤维预成型件在真空中(例如在封闭的炉内)被加热到大于或等于陶瓷基体材料前体的熔点的温度。优选地，炉在加热开始之前被抽真空，以避免气孔夹带在纤维预成型件内。在从约1 Pa到约300 Pa的范围内的真空通常是足够的。优选地，真空处于从大约2 Pa到大约150 Pa的范围内。
优选地，用于浸渍工艺的炉为碳炉；即，其内部基本上由元素碳构成的炉。这种炉与炉内气氛中的任何残余氧气反应而产生CO或CO2，其基本上不与碳支撑件、纤维预成型件或者陶瓷基体材料的前体反应。当碳炉未被使用时，它优选地具有设置在炉内部的一定量的碳，使得它可与炉内气氛中的任何残余氧气反应。
浸渍在大于或等于陶瓷基体材料前体的熔点的温度下进行。在硅的情况下，浸渍温度在从约1400℃到约1600℃的范围内，优选地从约1415 ℃到约1500℃，更优选地从约1425℃到约1450℃。更高的温度降低了熔融硅的粘度且促进了熔融硅更好地扩散到纤维预成型件中，但是它们可能不必要地加速了纤维的降解。
可通过本公开的方法来修改的复合材料物件也可通过其它工艺制成。例如，这种复合材料物件可通过浆铸方法制成。可通过编织或编造纤维形成的增强纤维板被层叠而形成本体。纤维可通过诸如化学气相浸渍的方法来涂覆。本体被放置在模具中，该模具然后由包括微粒陶瓷基体材料、陶瓷基体前体材料或它们的混合物的浆料填充以形成预成型件。预成型件随后通过熔体浸渍或化学气相浸渍被致密化，从而形成最终的复合材料物件。
陶瓷复合材料物件，诸如燃烧室衬套、组合燃烧器衬套和过渡件、喷嘴、护环、静叶、动叶以及叶片，可使用上述的制造方法来制成。这些陶瓷复合材料物件中的损坏可通过本公开的方法来修改。
本公开的修改方法利用惯性结合来修改复合材料物件。特别是，插塞通过惯性结合被结合到复合材料结构中的配合孔，以实现这种修改。在惯性结合中，第一工件被旋转到一个特定速度，然后第二工件被迫与第一工件摩擦接触，并且生成摩擦热以将两个构件连结在一起，而不在接触区域中熔化。在基体材料在熔化时具有高流率的情况下，如在频繁用于陶瓷基体复合材料中的硅中，如果基体材料过热且基体材料快速流动远离所期望的结合位置，则修改过程可能引入更多损坏。惯性结合的利用允许复合材料物件的修改，同时有效地控制基体修改区的局部温度。
惯性焊接是用于连结金属构件的公知工艺，但是迄今未以本文描述的方式用于复合材料物件的修改。典型的惯性焊接机包括第一和第二相对的头部，第一和第二工件可彼此相对地固定附连至所述头部。第一头部是可旋转的并且由合适的马达提供动力，用于使该头部和第一工件旋转到精确的旋转速度。第二头部是不可旋转的并且简单地支撑第二工件。第一头部包括一个或更多飞轮，以提供转动惯量用于实现两个工件的焊接。通过被供以动力的活塞，第二头部可在轴向上平移，该活塞在大量压缩焊接负荷下使第一和第二工件接合在一起。第二工件因此摩擦结合且制动旋转的第一工件，在它们之间的接触区域产生摩擦热，摩擦热升高了它们的温度以实现惯性焊接而不熔化。
在惯性焊接中只有四个控制变量。这些包括工件几何形状，诸如尺寸和构造；在两个接合的工件的接触区域处施加的焊接负荷和相应的焊接应力；两个工件的初始接触速度，其通常表示为基于接触区域处的旋转速度和半径的接触区域处的表面速度；以及最后，接触区域处的单位能量输入，其基于通常由飞轮函数表示的飞轮的质量惯性矩，该飞轮函数是飞轮重量和回转半径的平方的乘积。
根据本公开，可利用这种常规的惯性焊接配置来用惯性结合修改复合材料物件，如本文中进一步描述的。参照图1，受损的复合材料物件10示出为带有损伤区域12。在惯性结合发生之前，损坏区域可通过机械或化学方法有利地清洗。例如，受损区域可通过机械作用被磨损。作为备选，在复合材料物件为陶瓷基体复合材料的实施例中，该物件可在还原气氛中被处理，以从陶瓷基体复合材料物件的表面去除表面氧化物。这样的还原气氛可包括诸如氢气、一氧化碳或者这些气体之一与惰性气体(例如，氮、氩或氦)的混合物。这些清洗作用可促进材料在它们之间的后续连结。
在本公开的某些实施例中，损坏区域周围的材料被去除而形成凹陷，具有恰当形状、尺寸和组成的插塞可定位在其中。凹陷可采取若干不同形式中的一种，诸如圆筒、倒棱柱、倒圆锥或倒截头圆锥。在复合材料为陶瓷基体复合材料的实施例中，优选地，凹陷具有倒棱柱或倒圆锥的形状，使得在原始陶瓷基体复合材料物件和插塞中的承载纤维之间有重叠。
参照图2，插塞14被连结到轴16。插塞14通常由与修改的复合材料物件互补的材料形成，并且，用于形成这种插塞的材料可包括用于形成复合材料物件的任何上述材料。轴直径小于插塞直径。轴16可被操作地连结到合适的马达(未显示)，诸如液压马达，用于在操作期间以合适的旋转速度旋转。一个或更多飞轮(未显示)也可被连结到轴16，以控制轴的旋转质量惯性矩，用于实现惯性结合能。
插塞14可在高旋转速率下旋转，如在插塞和复合材料物件之间形成惯性结合所必需的。接触速度可以以表面英尺每分钟(SFM)来表述，并且可以从约100到约1000 SFM，以允许惯性结合的形成。轴16也可被连结到活塞(未显示)，诸如液压活塞，其构造成用于将插塞14按压成与复合材料物件10的修改部位18接合。当插塞14被按压成与修改部位18接合时，高旋转速度R和竖直驱动力的法向压力F产生热效应，以局部加热插塞并在修改部位将插塞结合到复合材料物件。
修改的快速加热和冷却的速度可防止复合材料物件中的变形，如果复合材料物件整体被加热到必需的基体结合温度，则该变形将会发生。参照图3，一旦复合材料物件10的基体结合到插塞14，插塞14的旋转能就转移到较小直径的轴16，并且该能量从插塞14剪切轴16，从而防止一旦复合材料物件10的基体与插塞14形成结合时在修改部位18处的任何干扰影响。
本文描述的修改方法可用于修改薄壁和厚壁的复合材料物件两者。重要的是，取决于修改区域，复合材料物件可通过文中描述的方法来修改，而不需要在修改之前被拆卸或预热。
该书面描述使用示例来公开本发明，包括最佳模式，并且还使本领域任何技术人员能够实践本发明，包括制作和使用任何装置或系统以及执行任何结合的方法。本发明的可专利范围由权利要求限定，并且可包括本领域技术人员想到的其它示例。这种其它的示例意图在权利要求的范围内，如果它们包括与权利要求书的字面语言没有区别的结构要素，或者如果它们包括与权利要求书的字面语言没有实质区别的结构要素的话。
Claims (12)
1.一种用于修改复合材料物件的方法，包括：
将包括复合材料的插塞定位在所述复合材料物件上的部位，其中所述复合材料物件包括第一纤维增强陶瓷基体复合材料，所述第一纤维增强陶瓷基体复合材料包括多个第一纤维，所述第一纤维包括碳化硅，并且其中所述插塞包括第二纤维增强陶瓷基体复合材料，所述第二纤维增强陶瓷基体复合材料包括多个第二纤维，所述第二纤维包括碳化硅；
提供连结至所述插塞的轴，所述轴具有小于所述插塞直径的直径；
使所述插塞和所述物件中的至少一个以足以在所述插塞和所述复合材料物件的所述部位之间形成惯性结合的速率旋转；以及
使所述插塞和所述部位接合以在其间实现惯性结合；
其中一旦形成所述惯性结合，就将所述插塞或所述物件的旋转能转移到较小直径的所述轴上以从所述插塞剪切所述轴。
2.根据权利要求1所述的方法，其特征在于，还包括在所述部位形成凹陷以接受所述插塞。
3.根据权利要求2所述的方法，其特征在于，所述凹陷能够容纳圆锥形状。
4.根据权利要求2所述的方法，其特征在于，所述凹陷能够容纳棱柱形状。
5.根据权利要求3所述的方法，其特征在于，所述插塞包括圆锥形状。
6.根据权利要求1所述的方法，其特征在于，还包括在将包括复合材料的插塞定位在所述部位之前清理所述部位。
7.根据权利要求1所述的方法，其特征在于，还包括从所述部位去除所述复合材料物件的一部分。
8.根据权利要求1所述的方法，其特征在于，所述复合材料物件包括燃烧室衬套、喷嘴、护环、静叶或动叶。
9.根据权利要求1所述的方法，其特征在于，其中所述第一纤维和第二纤维中至少一个包括可转化为碳化硅的有机前体。
10.一种用于修改复合材料物件的区域的方法，包括：
将包括第一纤维增强陶瓷基体复合材料的插塞定位在所述复合材料物件上的部位，所述复合材料物件包括第二纤维增强陶瓷基体复合材料，其中第一纤维增强陶瓷基体复合材料和第二纤维增强陶瓷基体复合材料中至少一个包括可转化为碳化硅的有机前体；
提供连结至所述插塞的轴，所述轴具有小于所述插塞直径的直径；
使所述插塞和所述物件中的至少一个以足以在所述插塞和所述复合材料物件的所述部位之间形成惯性结合的速率旋转；以及
使所述插塞和所述部位接合以在其间实现惯性结合；
其中一旦形成所述惯性结合，就将所述插塞或所述物件的旋转能转移到较小直径的所述轴以从所述插塞剪切所述轴。
11.根据权利要求10所述的方法，其特征在于，还包括在所述部位形成凹陷以接受所述插塞。
12.根据权利要求11所述的方法，其特征在于，所述凹陷能够容纳圆锥形状。
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| US4387844A (en) | 1981-06-01 | 1983-06-14 | The United States Of America As Represented By The Secretary Of The Army | Method and apparatus for radial inertia welding of dissimilar metals |
| US4468299A (en) | 1982-12-20 | 1984-08-28 | Aluminum Company Of America | Friction welded nonconsumable electrode assembly and use thereof for electrolytic production of metals and silicon |
| US5188279A (en) | 1991-08-15 | 1993-02-23 | United Technologies Corporation | Inertia bonding utilizing alternative axial load paths |
| US6138896A (en) | 1998-10-05 | 2000-10-31 | General Electric Company | Superspeed inertia welding |
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