CN103588485A - 用于复合制品的制造的可消耗芯部及相关方法 - Google Patents
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Abstract
公开了适合于复合制品(例如,陶瓷复合制品)(特别是包括中空特征的复合制品)的容易制造的系统、方法和装置。在一个实施例中,一种系统包括:形成为配置在复合前体的内部分内的可消耗芯部,可消耗芯部适合于在制造过程期间转换为浸渗剂并渗透复合前体。
Description
政府特许权
本发明在能源部授予的合同号DE-FC26-05NT42643下利用政府支持完成。政府具有本发明中的某些权利。
技术领域
本文中公开的主题涉及复合材料,并且更特别地,涉及用于在复合制品的制造中使用的可消耗芯部及相关方法。
背景技术
当前的制造陶瓷复合制品的方法(例如,熔化渗透过程)包括液相浸渗剂材料(例如,硅,硅合金等)的使用,该液相浸渗剂材料引入到容积材料/复合前体中以形成复合制品。在制造期间,该浸渗剂材料吸收在复合前体的暴露表面上面,芯吸到复合前体中以形成复合制品。在具有中空特征的复合制品的制造中,典型过程是将可移除芯部插入到中空复合前体的内部分中以形成空腔。芯部随后被移除,从而使复合前体的内表面暴露。芯部移除必须在熔化渗透之前发生,以防止浸渗剂与芯部反应,使芯部与复合制品结合并阻止芯部移除。一些制造方法包括可移除芯部,其设计成在复合制品的形成之后的单独过程中熔尽或烧尽。一些其它的制造者设计了复合制品,其具有足够大以从制品内提出可移除芯部的结构孔。这些方法可限制制品的设计或性能,在制造过程中要求附加的步骤,并且/或者使复合制品的构件和部分暴露于可损坏或破坏制品的热极端。
发明内容
公开了适合于复合制品的容易制造的方法和系统。在一个实施例中,一种系统包括:形成为配置在复合前体的内部分内的可消耗芯部,可消耗芯部适合于在制造过程期间渗透复合前体并基本上腾出复合前体的内部分。
本公开的第一方面提供了一种系统,其包括:可消耗芯部,其形成为配置在复合前体的内部分内,可消耗芯部适合于在制造过程期间转换为浸渗剂并渗透复合前体。
第二方面提供了一种系统,其包括:复合前体;可消耗芯部,其配置在复合前体的内部分内,可消耗芯部适合于在制造过程期间转换为浸渗剂并渗透复合前体;以及外部供给部,其经由芯部连接于可消耗芯部,外部供给部适合于将浸渗剂材料流供应至复合前体。
第三方面提供了一种方法,其包括:将可消耗芯部插入到复合前体中;将外部供给部连接于复合制品制造系统以供应附加的浸渗剂;调整关于复合制品制造系统的至少一个环境条件,以经由可消耗芯部使复合前体渗透有加强材料;消耗可消耗芯部;以及重新调整环境条件。
附图说明
本发明的这些和其它特征从结合描绘本发明的各个实施例的附图进行的本发明的各个方面的下列详细描述将被更容易地理解,其中:
图1示出根据本发明的实施例的复合制品制造系统的一部分的三维透视图。
图2示出根据本发明的实施例的复合制品的三维透视图。
图3示出根据本发明的实施例的复合制品制造系统的一部分的三维透视图。
图4示出根据本发明的实施例的说明步骤的方法流程图。
注意,本公开的附图不必按比例绘制。附图意图仅描绘本公开的典型方面,并且因此不应当被认为是限制本公开的范围。理解,附图之间相似地编号的元件可为大致相似的。此外,在参考附图示出和描述的实施例中,同样的标记可表示同样的元件。为了清楚,这些元件的重复说明已被省略。最后,理解,附图的构件和它们的附带描述可应用于本文中描述的任何实施例。
部件列表
100,300 复合制品制造系统
110 外部供给块
112,312,316 芯部
120 贮存器
122 排出部
130,330 可消耗芯部
140,340 复合前体
200 复合制品
230 内/中空特征
240 复合本体
250 顶面
270 底面
310 第一外部供给块
314 第二外部供给块
380,382 外部块组。
具体实施例
如本文中指示的,本发明的方面提供了适合于复合制品(特别是包括中空特征的复合制品)的容易制造的系统、方法和装置。这些方法和系统使用适合于配合在复合前体的中空特征内的可消耗芯部,可消耗芯部将浸渗剂材料施加于复合前体的内表面,并且芯部本身在制造过程期间被消耗。
在复合制品制造的现有技术中,可移除的芯部通常用于在制作期间形成复合前体的内表面。在这些系统中,在复合制品的形成之后,可移除芯部必须从复合制品内抽出。一些系统使用可经由暴露于热源从复合制品熔尽或烧尽的可移除芯部,一些其它系统要求复合制品本身包括足够大以适应可移除芯部的抽出的结构孔。然而,这些方法可限制制品的设计和性能,在制造过程中要求附加的步骤,并且/或者使复合制品的构件和部分暴露于可损坏或破坏制品的热极端。
当前发明的实施例提供了系统、方法和装置,包括可消耗芯部在复合制品制造过程中的使用。可消耗芯部包括浸渗剂前体材料,并且适合于将浸渗剂材料施加于包括中空特征的复合前体的内表面。在制造期间,该可消耗芯部吸收到复合前体中(例如,经由吸收和毛细作用,从复合前体内自消耗,并且在腾出中空特征的内部时成为复合制品本身的一部分)。该可消耗芯部简化了制造过程,并且在其形成复合制品整体时消除了对烧尽、熔尽、溶解、二次组装、结构孔或其它芯部移除方法的需要。
转向附图,示出包括可消耗芯部的复合制品制造方法和系统的实施例,其中,可消耗芯部可简化制造过程,并且增加复合制品的质量和设计灵活性。附图中的构件中的每一个可经由常规器件连接,例如经由普通导管或其它已知的器件,如图1-4所示。具体地,参考图1,示出根据本发明的实施例的包括复合前体140内的可消耗芯部130(以虚线示出)的复合制品制造系统100的三维透视图。复合前体140可为多孔碳化复合前体,其适合于在浸渗剂材料(例如,具有二次元素(诸如硼)的较少添加的硅)的吸收之后形成复合制品200(如图2所示)。可消耗芯部130放置在复合前体140内,并且可经由芯部112(例如,适合于输送熔融混合物的可渗透带)连接于外部供给块110。供给块110可将附加部分的浸渗剂材料供应至可消耗芯部130,并且可包括由固体、压制和/或烧结的颗粒形成的硅块。可消耗芯部130还可连接于可包括贮存器120的排出部122(例如,适合于输送熔融混合物的可渗透带)。在复合制品的形成(例如,熔化渗透过程)期间,复合制品制造系统100可经受包括热和压力波动的环境条件的循环。该循环使浸渗剂材料(例如,硅)从供给块110经过至可消耗芯部130,从而使可消耗芯部130吸收到复合前体140中。过量部分的浸渗剂材料可经由排出部122流至贮存器120。在一个实施例中,来自可消耗芯部130的材料可经由毛细作用吸收到复合前体140中。
复合前体140可完全包含(例如,包封)可消耗芯部130。可消耗芯部130可由金属、硅或现在已知或以后开发的任何其它材料压制、铸造或机械加工。预形成可使可消耗芯部130成形为与复合前体140的中空特征的轮廓互补。可消耗芯部130的复合物可包括纯硅或硅加合金材料。在一个实施例中,可消耗芯部130可包括硅和硼。在一个实施例中,可消耗芯部130可包括烧结的颗粒,并且包括大约95%的硅和大约5%的硼。在另一个实施例中,可消耗芯部130可包括大约20%硼(B)、20%碳(C)或20%难熔金属(例如,钽、锆、铌等)以及作为剩余物的硅的复合物。可消耗芯部130可在于复合前体140中内在化之前铸造为设定的尺寸和形状。理解,虽然在本文中描述关于某些示例性复合物和化学物的可消耗芯部130,但是这些复合物和化学物仅为说明性的,并且现在已知或以后开发的任何烧结化学物、固体铸造化学物和复合物可包括在可消耗芯部130中。
在制造期间,可消耗芯部130可自消耗到复合前体140中,从而形成复合制品200。在一个实施例中,可消耗芯部130可被完全消耗(例如,内在化成复合制品200)。在一个实施例中,可消耗芯部130和供给块110可包括大致相同的材料。供给块110可包括纯硅、硼、硅加合金材料,或现在已知或以后开发的任何其它材料。
芯部112和排出部122可包括相似的材料和复合物,两者适合于输送熔融混合物(例如,熔融硅硼)。在一个实施例中,芯部112和排出部122可为可互换的。芯部112和排出部122可包括编织或编制成形成芯部112和排出部122的惰性材料。在一个实施例中,芯部112和排出部122可包括编织碳纤维。
转向图2,示出根据本发明的实施例的复合制品200的部分的三维透视图。在该实施例中,复合制品200可包括限定内/中空特征230(以虚线示出)的复合本体240。复合本体240可具有形成复合制品200的大致均匀的材料复合物。内/中空特征230可基本上没有可消耗芯部130(在图1中示出),其腾出内/中空特征230,这是因为其在熔化渗透过程期间被消耗干净。复合本体240可包括密封内/中空特征230的顶面250和底面270。
转向图3,示出根据本发明的实施例的包括内在化在复合前体340内的可消耗芯部330(以虚线示出)的复合制品制造系统300的示意性三维透视图。在该实施例中,一组外部块380和382配置在复合前体340周围,并且适合于向复合前体340的外表面施加浸渗剂材料。附加的浸渗剂块380和382可在材料成分上与可消耗芯部330相似。附加的浸渗剂块380和382的施加和/或包括可取决于完全填充复合前体340内的毛细孔所需的浸渗剂的体积。复合前体340经由芯部312连接于第一外部供给块310,并且经由芯部316连接于第二外部供给块314。在制造过程(例如,熔化渗透过程)期间,高温可施加于复合制品制造系统300,从而引起浸渗剂材料(例如,基质)经由可消耗芯部330、外部供给块310、外部供给块314、外部块380和/或外部块382引入到复合前体340(例如,容积材料)中。如可在图3中看到的,可消耗芯部330和复合前体340可形成为生产任何形式的复合制品,包括复杂的几何形状,翼型件,涡轮叶片等。根据确保浸渗剂材料包围复合前体340的全部纤维并填充陶瓷复合物中的全部空隙的需要,浸渗剂材料可经由外部块380、外部块382、外部供给块310、外部供给块314以及可消耗芯部330中的任何一个引入到复合前体340中。
转向图4,示出根据本发明的实施例的示例性方法流程图:在初始步骤P1(以虚线示出)中,可消耗芯部130配置在复合前体140内。可消耗芯部130可内在化在复合前体140内,被复合前体140完全包封。这可通过技术人员和/或机械响应于预定或用户提示的制造过程进行。在一个实施例中,可消耗芯部130可在复合前体140的组装期间插入在复合前体140中,其中,在插入之后,复合前体140的剩余部分形成为将可消耗芯部130基本上密封在复合前体140内。在步骤P1之后,在步骤P2中,外部供给块110经由芯部112连接于可消耗芯部130。在步骤P2之后,在步骤P3中,可消耗芯部130经由排出部122连接于贮存器120,由此形成复合制品制造系统100。在步骤P3之后,在步骤P4中,复合制品制造系统100经受一组环境调整(例如,熔化渗透过程,增大的温度,增大的压力等),这使可消耗芯部130转换为浸渗剂材料并开始渗透复合前体140的部分。在步骤P4之后,在步骤P5中,可消耗芯部130在熔化渗透过程期间被消耗,从而与复合前体140集成以腾出内/中空特征230并形成复合制品200。在步骤P5之后,在步骤P6中,关于复合制品制造系统100的环境条件重新调整至周围环境,并且芯部112和排出部122从复合制品200断开。
附图中的数据流程图和方框图示出根据本发明的各个实施例的系统、方法和计算机程序产品的可能实施的构架、功能和操作。在这点上,流程图或方框图中的每个方框可表示代码的模块、节段或部分,其包括一个或更多个可执行指令,用于实施(多个)特定逻辑功能。还应当注意到,在一些可选的实施中,方框中提到的功能可不按附图中提到的顺序发生。例如,事实上,接连地示出的两个方框可基本上同时执行,或者方框有时可以以相反的顺序执行,这取决于涉及的功能。还将注意到,方框图和/或流程图的每个方框以及方框图和/或流程图中的方框的组合可通过基于特殊用途硬件的系统实施,该基于特殊用途硬件的系统执行特定功能或动作,或特殊用途硬件和计算机指令的组合。
本公开的可消耗芯部、系统和方法不受限于任何一种特定的复合材料、复合制品、过程或其它系统,并且可与其它制造过程和/或系统一起使用。另外,本发明的可消耗芯部和系统可与本文中未描述的其它系统一起使用,该其它系统可受益于自消耗、精加工和本文中描述的制造益处。
本文中使用的术语仅出于描述特定实施例的目的,并且不意图限制本公开。如本文中使用的,单数形式“一”、“一个”和“该”意图也包括复数形式,除非上下文另外明确地指出。将进一步理解,用语“包含”和/或“包括”在于本说明书中使用时表明叙述的特征、整数、步骤、操作、元件和/或构件的存在,但是不排除一个或更多个其它特征、整数、步骤、操作、元件、构件和/或它们的组的存在或添加。
该书面的描述使用实例以公开本发明(包括最佳模式),并且还使本领域技术人员能够实践本发明(包括制造和使用任何装置或系统并且执行任何并入的方法)。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实例。如果这些其它实例具有不与权利要求的字面语言不同的结构元件,或者如果这些其它实例包括与权利要求的字面语言无显著差别的等同结构元件,则这些其它实例意图在权利要求的范围内。
Claims (20)
1.一种系统,其包括:
可消耗芯部,其形成为配置在复合前体的内部分内,所述可消耗芯部适合于在制造过程期间转换为浸渗剂并渗透所述复合前体。
2.根据权利要求1所述的系统,其特征在于,还包括外部供给部,其经由芯部连接于所述可消耗芯部,用于将浸渗剂材料流供应至所述复合前体。
3.根据权利要求2所述的系统,其特征在于,所述可消耗芯部适合于在所述制造过程期间基本上腾出所述复合前体的内部分。
4.根据权利要求1所述的系统,其特征在于,所述可消耗芯部包括铸造材料。
5.根据权利要求1所述的系统,其特征在于,所述可消耗芯部包括硅或硼中的至少一种。
6.根据权利要求1所述的系统,其特征在于,所述可消耗芯部被所述复合前体基本上包封。
7.根据权利要求1所述的系统,其特征在于,还包括外部块,其配置在所述复合前体附近,用于将浸渗剂材料供应至所述复合前体。
8.一种系统,其包括:
复合前体;
可消耗芯部,其配置在所述复合前体的内部分内,所述可消耗芯部适合于在制造过程期间转换为浸渗剂并渗透所述复合前体;以及
外部供给部,其经由芯部连接于所述可消耗芯部,所述外部供给部适合于将浸渗剂材料流供应至所述复合前体。
9.根据权利要求8所述的系统,其特征在于,还包括外部块,其基本上配置在所述复合前体附近,并且适合于供应用以渗透所述复合前体的附加浸渗剂材料。
10.根据权利要求8所述的系统,其特征在于,所述复合前体包封所述可消耗芯部。
11.根据权利要求8所述的系统,其特征在于,还包括经由排出部连接于所述可消耗芯部的贮存器,所述贮存器适合于接收来自所述可消耗芯部的浸渗剂材料流。
12.根据权利要求8所述的系统,其特征在于,所述可消耗芯部由烧结的粉末形成,并且包括硅和硼中的至少一种。
13.根据权利要求8所述的系统,其特征在于,所述芯部包括编织碳纤维。
14.根据权利要求8所述的系统,其特征在于,所述复合前体为多孔且碳化的。
15.一种方法,其包括:
将可消耗芯部插入到复合前体中;
经由芯部将外部供给部连接于所述复合前体,以形成复合制品制造系统;
调整关于所述复合制品制造系统的至少一个环境条件,以使所述复合前体渗透有来自所述可消耗芯部的浸渗剂;
消耗所述可消耗芯部;以及
重新调整所述环境条件。
16.根据权利要求15所述的方法,其特征在于,还包括经由排出部将贮存器连接于所述可消耗芯部,所述排出部适合于接收来自所述可消耗芯部的过量的浸渗剂。
17.根据权利要求15所述的方法,其特征在于,消耗所述可消耗芯部包括使所述可消耗芯部内在化到所述复合前体中。
18.根据权利要求15所述的方法,其特征在于,调整所述环境的至少一个环境条件包括:
增大所述环境的温度;和
增大所述环境的压力。
19.根据权利要求15所述的方法,其特征在于,所述可消耗芯部包括硅、硼和难熔金属中的至少一种。
20.根据权利要求15所述的方法,其特征在于,还包括将一组外部块基本上配置在所述复合前体附近,所述外部块适合于将浸渗剂材料流供应至所述复合前体。
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