CN107207354B - 由复合材料制造部件的方法 - Google Patents
由复合材料制造部件的方法 Download PDFInfo
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- CN107207354B CN107207354B CN201580074464.XA CN201580074464A CN107207354B CN 107207354 B CN107207354 B CN 107207354B CN 201580074464 A CN201580074464 A CN 201580074464A CN 107207354 B CN107207354 B CN 107207354B
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- 239000002131 composite material Substances 0.000 title claims abstract description 23
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 10
- 239000002245 particle Substances 0.000 claims abstract description 136
- 239000002002 slurry Substances 0.000 claims abstract description 96
- 239000000835 fiber Substances 0.000 claims abstract description 55
- 239000007791 liquid phase Substances 0.000 claims abstract description 36
- 238000005470 impregnation Methods 0.000 claims abstract description 25
- 239000011159 matrix material Substances 0.000 claims abstract description 23
- 238000005245 sintering Methods 0.000 claims abstract description 15
- 230000006835 compression Effects 0.000 claims description 36
- 238000007906 compression Methods 0.000 claims description 36
- 239000011148 porous material Substances 0.000 claims description 33
- 238000000034 method Methods 0.000 claims description 30
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 25
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 25
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 24
- 239000012530 fluid Substances 0.000 claims description 23
- 239000000463 material Substances 0.000 claims description 17
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 16
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 14
- 239000012528 membrane Substances 0.000 claims description 14
- 239000000843 powder Substances 0.000 claims description 14
- 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
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 239000000126 substance Substances 0.000 claims description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 5
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 claims description 5
- 150000004767 nitrides Chemical class 0.000 claims description 4
- -1 borosilicate Chemical compound 0.000 claims description 3
- 229910052799 carbon Inorganic materials 0.000 claims description 3
- 150000001247 metal acetylides Chemical class 0.000 claims description 2
- 230000000717 retained effect Effects 0.000 claims description 2
- 238000005507 spraying Methods 0.000 claims description 2
- 150000004760 silicates Chemical class 0.000 claims 1
- 239000010410 layer Substances 0.000 description 15
- 239000007788 liquid Substances 0.000 description 14
- 238000009941 weaving Methods 0.000 description 14
- 238000002347 injection Methods 0.000 description 13
- 239000007924 injection Substances 0.000 description 13
- 239000011153 ceramic matrix composite Substances 0.000 description 10
- 238000001035 drying Methods 0.000 description 9
- 238000005086 pumping Methods 0.000 description 9
- 239000000725 suspension Substances 0.000 description 9
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 8
- 239000004372 Polyvinyl alcohol Substances 0.000 description 8
- 239000011230 binding agent Substances 0.000 description 8
- 229920002451 polyvinyl alcohol Polymers 0.000 description 8
- 230000002787 reinforcement Effects 0.000 description 8
- 238000010438 heat treatment Methods 0.000 description 6
- 230000002378 acidificating effect Effects 0.000 description 4
- 239000004744 fabric Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 238000003825 pressing Methods 0.000 description 4
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 4
- 238000001816 cooling Methods 0.000 description 3
- 239000000945 filler Substances 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 229920000049 Carbon (fiber) Polymers 0.000 description 2
- 239000011184 SiC–SiC matrix composite Substances 0.000 description 2
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical compound [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 2
- 230000004888 barrier function Effects 0.000 description 2
- 230000015572 biosynthetic process Effects 0.000 description 2
- 239000006229 carbon black Substances 0.000 description 2
- 239000004917 carbon fiber Substances 0.000 description 2
- 230000000593 degrading effect Effects 0.000 description 2
- 238000000151 deposition Methods 0.000 description 2
- 230000007613 environmental effect Effects 0.000 description 2
- 238000001704 evaporation Methods 0.000 description 2
- 230000008020 evaporation Effects 0.000 description 2
- 239000010439 graphite Substances 0.000 description 2
- 229910002804 graphite Inorganic materials 0.000 description 2
- 239000003921 oil Substances 0.000 description 2
- 239000012071 phase Substances 0.000 description 2
- 229920001296 polysiloxane Polymers 0.000 description 2
- 239000000047 product Substances 0.000 description 2
- 229910052761 rare earth metal Inorganic materials 0.000 description 2
- 229910001404 rare earth metal oxide Inorganic materials 0.000 description 2
- 150000002910 rare earth metals Chemical class 0.000 description 2
- 238000009958 sewing Methods 0.000 description 2
- 239000000243 solution Substances 0.000 description 2
- 239000000853 adhesive Substances 0.000 description 1
- 230000001070 adhesive effect Effects 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- ILRRQNADMUWWFW-UHFFFAOYSA-K aluminium phosphate Chemical compound O1[Al]2OP1(=O)O2 ILRRQNADMUWWFW-UHFFFAOYSA-K 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
- 238000003379 elimination reaction Methods 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 230000002706 hydrostatic effect Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 229920001343 polytetrafluoroethylene Polymers 0.000 description 1
- 239000004810 polytetrafluoroethylene Substances 0.000 description 1
- 239000002244 precipitate Substances 0.000 description 1
- 238000001556 precipitation Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 239000011819 refractory material Substances 0.000 description 1
- 238000009745 resin transfer moulding Methods 0.000 description 1
- 238000004062 sedimentation Methods 0.000 description 1
- 239000002356 single layer Substances 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 239000000758 substrate Substances 0.000 description 1
- 239000004753 textile Substances 0.000 description 1
- 238000003856 thermoforming Methods 0.000 description 1
- 239000002759 woven fabric Substances 0.000 description 1
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Abstract
本发明涉及一种由复合材料制造部件的方法，所述方法包括以下步骤：由耐火纤维形成纤维织构(10)的步骤；用包含第一耐火粒子(151)的第一浆液(150)浸渍纤维织构(10)的第一浸渍步骤；从第一浆液(151)移除液相(152)的步骤，以允许仅第一耐火粒子(151)保留在所述织构内；用包含第二耐火粒子(161)的第二浆液(160)浸渍纤维织构(20)的第二浸渍步骤；从第二浆液(160)移除液相(162)的步骤，以允许仅第二耐火粒子(161)保留在所述织构内以及获得一种填充有第一和第二耐火粒子(151、161)的纤维预制件(30)；以及烧结纤维预制件(30)中第一和第二耐火粒子(151、161)的步骤，从而在所述预制件内形成一种耐火基质。
Description
背景技术
本发明涉及一种由热结构复合材料制造部件的方法，特别地由氧化物/氧化物类型或陶瓷基复合材料(CMC)类型制造部件的方法，即包括由耐火材料纤维制成并用同样由耐火材料制成的基质致密的纤维增强件。
通常通过采用由耐火氧化物纤维制成的数个纤维层并将其覆盖在模具中来制备氧化物/氧化物复合材料部件，每个层都先前浸渍在一种填充有耐火氧化物粒子的浆液(barbotine)中。以这种方式布置的层组然后使用反模或真空板被压缩，并穿过高压釜。以这种方式获得的填充预制件然后进行烧结，从而在该预制件内形成一种耐火氧化物基质，并获得一种由氧化物/氧化物复合材料制成的部件。该技术也可用于由陶瓷基材复合(CMC)材料制造部件。在这种情况下，纤维层由碳化硅(SiC)纤维或碳纤维制成，并且它们浸渍在一种填充有碳化物(如，SiC)、硼化物(如，TiB2)或氮化物(如，Si3N4)粒子的浆液中。
然而，这种类型的制备方法并不能制造如机械性能。
发明目的和概述
本发明的一个目的是解决上述缺点，并且提出一种可以控制复合材料部件的制造的解决方案，特别地氧化物/氧化物类型或CMC类型的部件，从而优化材料中存在的基质的体积分数和/或从而在其上赋予在材料的厚度方向中变化的特征。
为此，本发明提供了一种由复合材料制造部件的方法，该方法包括以下步骤：
·由耐火纤维形成纤维织构；
·用包含第一耐火粒子的第一浆液浸渍该纤维织构第一时间；
·从已经浸渍纤维织构的第一浆液移除液相，从而仅将第一耐火粒子留在所述织构内；
·用包含第二耐火粒子的第二浆液浸渍该纤维织构第二时间；
·从已经浸渍纤维织构的第二浆液移除液相，从而仅将第二耐火粒子留在所述织构内，并获得一种填充有该第一和第二耐火粒子的纤维预制件；并且
·烧结存在于该纤维预制件中的第一和第二耐火粒子，从而在所述预制件中形成耐火基质。
因此，通过用包含不同尺寸和/或化学性质的粒子的浆液实施至少两种连续浸渍，可以控制最终部件的基质体积分数和/或该部件厚度方向中的基质特征。
在本发明的第一方面，该第一粒子具有与第二粒子的平均尺寸相比更大的平均尺寸。因此，可以使用第二粒子以填充存在于第一粒子之间的空隙，从而在最终部件中获得高基质体积分数。
第一粒子可具有与第二粒子相同的化学性质，或者它们可具有与第二粒子不同的化学性质。通过使用具有不同化学性质的第一和第二粒子，可以在对所产生的基质赋予特定的性质。
在本发明方法的第二方面，在从第二浆液消除液相步骤之后以及在烧结步骤之前，其进一步包括以下步骤：
·用包含第三耐火粒子的第三浆液浸渍该纤维织构第三时间；以及
·从已经浸渍纤维织构的第三浆液移除液相，从而仅将第三耐火粒子留在所述织构内，并获得一种填充有第一、第二和第三耐火粒子的纤维预制件。
因此可以在织构表面上沉积存在于织构核心的粒子不同的粒子。
在这种情况下，第三粒子可具有与第一粒子的平均尺寸相似的平均尺寸，该第一和第三粒子具有与第二粒子的平均尺寸相比更小的平均尺寸。在已经通过烧结粒子形成基质后，由于从与在烧结前存在于预制件核心中的粒子相比更细的粒子获得了在部件表面存在的基质，这可以获得一种具有改进表面形状的部件。
在本发明方法的第三方面，浸渍纤维织构的每个步骤都包括：
·将纤维织构放置在一种具有浸渍腔室的模具中，所述浸渍腔室在其底部包括一种由多孔材料制成的部件，在该部件上支撑有所述织构的第一表面，该浸渍腔室在其顶部通过一个面对该纤维织构的第二表面放置的变形不透水隔膜被封闭，所述隔膜使该浸渍腔室与压缩腔室隔离；
·在该纤维织构的第二表面和隔膜之间将包含耐火粒子的粉末的浆液喷射到该浸渍腔室内；
·将压缩流体喷射到压缩腔室内，该流体在隔膜上施加压力，以迫使浆液穿过该纤维织构；并且
从浆液移除液相的每个步骤包括经由该多孔材料部件排出已经穿过该纤维织构的浆液的液相，该耐火粒子由所述多孔材料部件被保留在所述织构内侧。
通过使用一种用于从浆液中排出液体的多孔材料部件，本发明的方法可以从被引导到该纤维织构内的浆液中消除液相，而不消除也存在于织构中的耐火固体粒子中。通过排出消除浆液的液相也可以避免干扰该纤维织构内耐火粒子的分布，并且从而可以控制最终部件中基质的结构。
多孔材料部件可以是刚性，并且可具有一种与要被制成的复合材料部件的形状相匹配的形状。在一个变型中，该多孔材料部件可变形，模具的底部具有与要被制成的复合材料部件的形状对应的形状；在这种情况下，多孔材料部件与模具底部的形状相匹配。
预制件的纱线可由以下材料的一个或多个组成的纤维形成：氧化铝、莫来石、二氧化硅、硅酸铝、硼硅酸盐、碳化硅和碳。
耐火粒子可由从选择如下的材料制成：氧化铝、莫来石、二氧化硅、硅酸铝、磷酸铝、氧化锆、碳化物、硼化物和氮化物。
在一个实施方式中，所获得的复合材料部件构成涡轮发动机叶片。
附图说明
从作为非限制性示例给出并参照附图的本发明特定实施方式的以下描述，本发明的其他特征和优点显现，其中：
·图1是根据本发明的一个实施方式中的工具的图解分解剖视图；
·图2是示出当用其中适当位置中的纤维织构封闭时，图1工具的图解剖视图；
·图3-6示出了根据本发明方法的一个实施方式中在图2工具中用一种填充有各自不同尺寸的粒子的浆液浸渍纤维织构的两个连续步骤的图解剖视图；
·图7-12示出了根据本发明的另一实施方式中用一种填充有各自不同尺寸的粒子的浆液浸渍纤维织构的三个连续步骤的图解剖视图。
具体实施方式
根据本发明用于由热结构复合材料制造部件的方法，特别地由氧化物/氧化物类型或CMC类型的材料制造部件的方法，通过制造一种用于形成该部件的增强件的纤维织构而开始。
所使用的纤维织构可以是多种类型和形状，诸如特别地：
·通过二维(2D)编织获得的织物；
·通过三维(3D)编织获得的织物；
·编织物；
·针织物；
·毡制品；以及
·纱线或丝束(tow)的单向(UD)片，或通过在不同方向中叠加多个单向片并将这些单向片粘结在一起，如通过缝合、通过化学粘合剂，或通过针刺，而获得的多向(nD)片。
还可以使用一种由织物(fabric)、编织物(braid)、针织物(knit)、毡制品(felt)、片、丝束等多个重叠层组成的纤维织构，这些层结合在一起，如通过缝合、通过植入纱线或刚性元件，或通过针刺结合在一起。
这里的术语“二维编织”用于表示一种常规编织技术，其中每个纬纱在单一层的经纱中从纱线的一侧穿越到另一侧，反之亦然。
这里的术语“三维编织”或“3D编织”，甚至“多层编织”用于表示编织，其中通过可特别地选自以下编织方法进行编织：联锁、多平纹、多缎纹、多斜纹，使至少一些纬纱在多层经纱层中与经纱互连，反之亦然。
用于编织要形成氧化物/氧化物或CMC复合材料部件的纤维增强件的纤维织构的纱线特别地可由如下纤维制成，所述纤维由下列材料构成：氧化铝、莫来石、二氧化硅、硅酸铝、硼硅酸盐、碳化硅、碳，或这些材料的两种或多种的混合物。
根据本发明，一旦已经制成了纤维织构，其用根据本发明的至少两种不同的浆液连续地浸渍。
描述了本发明方法的第一实施方式，其包括由氧化物/氧化物复合材料制造部件，该复合材料的基质由两类耐火氧化物粒子形成，即第一类粒子具有与第二类粒子的平均尺寸相比更大的平均尺寸。如下详细解释的，通过在纤维织构中连续地沉积第一粒子和平均尺寸小于第一粒子的第二粒子，优化了用耐火氧化物粒子对织构的填充，并且明显地减少了最终部件中的微孔。第一和第二耐火氧化物粒子可具有相同的化学性质，或者它们可具有不同的化学性质。通过改变第二粒子的化学性质，可对第一粒子的烧结条件起作用。例如，引入氧化锆的第二粒子可以降低第一粒子氧化铝的烧结温度。使用根据本发明的工具浸渍该示例中的纤维织构，所述工具特别地适用于能够使填充有固体粒子的浆液引入到具有相当厚度的二维纤维织构(二维编织层的堆叠)内或具有复杂形状的三维织构内。
纤维织构10被放置在工具100中。在当前描述的示例中，使用以上限定的技术(如，叠加二维层或三维编织)使用Nextel 610TM氧化铝纱线制成该纤维织构10。在本示例中，纤维织构10用于形成由氧化物/氧化物复合材料制成的叶片的纤维增强件。
工具100包括一种具有底部111的模具110，该底部设置有排气口112。模具110也具有侧壁113，该侧壁具有一个装配有阀1140的喷射端口114。一种由多孔材料制成的部件120放置在底部111的内侧表面111a上。由多孔材料制成的该部件120具有与底部111的内侧表面111a接触的底表面120b，以及用于接收纤维织构10的顶表面120a。在当前描述的示例中，部件120用可变形材料制成，而模具110的底部111的内侧表面111a具有与要被制造的最终部件的形状相对应的形状或外形，特别地在该示例中的航空发动机叶片。由于部件120可变形，它与底部111的内侧表面111a的轮廓相匹配，并且在其顶表面120a上具有与表面111a的形状类似的形状。例如，部件120可由微孔聚四氟乙烯(PTFE)制成，诸如由供应商
出售的“微孔PTEE”产品。
在变型实施方式中，多孔材料部件是刚性的，并具有一种与要被制造的最终部件的形状相对应的形状的顶部表面。在这种情况下，该部件可特别地通过热成形制成。
例如，多孔材料部件可具有几毫米的厚度，以及约30％的平均孔隙率。由多孔材料制成的部件的平均孔隙尺寸(D50)的范围，例如可在1微米(μm)到2μm之间。
工具100还包括盖部130，其具有带有阀1310的喷射端口131以及可变形隔膜140，一旦工具被关闭(图2)，所述隔膜使存在有纤维织构10的浸渍腔室110与位于隔膜140以上的压缩腔室隔离。例如，隔膜140可由硅树脂制成。
在将织构10放置在多孔材料部件120的顶表面120a上以后，模具110用盖部130封闭(图2)。第一浆液150然后经由其阀1140打开的喷射端口114被喷射到浸渍腔室101(图3)。在该示例中，浆液150用于形成织构中的一部分耐火氧化物基质。浆液150在液相152的悬浮液中对应于氧化铝粒子151的粉末，粒子具有在0.1μm到10μm范围内的平均粒径。浆液的液相152可特别地由水(酸性pH)、由乙醇或由可以将所需粉末形成悬浮液的任何其他液体构成。还可以添加有机粘合剂(如，可溶于水的聚乙烯醇(PVA))。粘结剂用于确保未熟化预制件在烘干后和在烧结前保持在一起。
除氧化铝外，耐火氧化物粒子也可等同地是一种从莫来石、二氧化硅、氧化锆、硅酸铝和磷酸铝中选择的材料。根据他们的碱基成分，耐火氧化物粒子也可与氧化铝、氧化锆、硅酸铝、稀土氧化物、稀土二硅酸盐(如，用于环境或热障碍)，或适用于添加特定功能到最终材料的任何其他填料(炭黑、石墨、碳化硅等)的粒子混合。
喷射到浸渍腔室101内的浆液150的数量根据要被浸渍的纤维织构10体积确定。正是初始引入的粉末量控制了最终沉淀物厚度，并且因此控制了纤维体积分数(Fvf)和基质体积分数(Mvf)。
一旦浆液150已经被喷射到浸渍腔室101内，在已经关闭喷射端口114的阀1140后(图4)，通过经由其阀1310打开的喷射端口131将例如油的压缩流体170喷射到压缩腔室102来实施压缩操作。压缩流体170在浆液150上通过隔膜140施加压力，迫使浆液150渗透到纤维织构10内。流体170在整个隔膜140上，并且因此在织构10以上的所有浆液上施加流体静水压力。由隔膜140在浆液上以及在纤维织构上施加的压力优选地小于15巴，例如7巴，从而致使浆液渗透到织构内并且从而足够地压缩该织构以能够经由多孔材料部件排出浆液的液相，而不使所产生的预制件降级。
由位于与表面10a相对的纤维织构的表面10b旁边的多孔材料部件120实施了几个功能，浆液通过所述多孔材料部件渗透到织构内(图3)。具体地，部件120能够从纤维织构排出浆液的液体，以这种方式排出的液体在该示例中经由排气口112排放(图4)。在压缩操作中以及之后实施排出。当没有更多液体通过排气口112流出时，排出已经终止。与通过压缩流体在浆液上施加压力相结合，可以实施泵送P，如通过主真空泵经由排气口112(图1到4未示出)。这种泵送是可选的。加热可满足。然而，它们两者的结合能够加速干燥。
此外，该工具可设置有加热器设备，诸如结合在工具壁中的电阻元件，以增加压缩腔室内侧的温度，并通过蒸发促进液体从浆液的消耗。压缩腔室中的温度可升高到位于80℃到105℃范围中的温度。
该多孔材料部件120也可以保持存在于浆液中的耐火氧化物的固体粒子，耐火氧化物粒子从而通过沉淀在纤维织构中而逐渐地沉积。
部件120也可以在压缩操作中保持纤维织构的形状，由于其顶表面120a复制了与要被制造的最终部件的形状相对应的模具100的底部111的形状。
因此获得了一种填充有耐火氧化物粒子的中间纤维预制件20，在该示例中为氧化铝粒子151(图4)，然后通过清空压缩腔室102外的压缩流体从压缩压力释放该中间预制件，然而该预制件保存其压缩状态。
在可能的冷却阶段后，中间纤维预制件20用第二浆液160浸渍，第二浆液在其阀1140被打开后通过喷射端口114喷射入(图5)。在该示例中，浆液160用于完成耐火氧化物基质在预制件中的形成。浆液160对应于液相162的悬浮液中氧化铝粒子161的粉末。氧化铝粒子161具有小于粒子151的平均粒径，并且其可位于0.1μm到1μm的范围中(在大粒子和更细粒子之间的因子为10)。浆液的液相162可特别地由水(酸性pH)、由乙醇或由可以将所需粉末形成悬浮液的任何其他液体构成。还可以添加有机粘合剂(如，可溶于水的聚乙烯醇(PVA))。粘结剂用于确保未熟化预制件在烘干后和在烧结前保持在一起。液相162优选地具有与液相152相同的性质。
被喷射到浸渍腔室101内的浆液160的数量根据要被浸渍的中间纤维预制件20体积确定。
一旦浆液160已被喷射到浸渍腔室101内，通过经由其阀1310打开的喷射端口131再次喷射压缩流体170到压缩腔室102内，实施该压缩操作，喷射端口114的阀1140先前被关闭(图6)。压缩流体170在浆液160上通过隔膜140施加压力，其迫使浆液160渗透到中间纤维预制件20内。由隔膜140在浆液上以及在预制件上施加的压力优选地小于15巴，例如7巴，从而致使浆液渗透到织构内并且从而足够地压缩该织构以能够经由多孔材料部件排出浆液的液相，而不使该预制件降级。
当液体不再通过排气口112流出时，排出已经终止。与通过压缩流体在浆液上施加压力相结合，可以实施泵送P，如使用主真空泵到排气口112(图1到4未示出)。该泵送是可选的。加热可满足。然而，它们两者结合能加速干燥。
此外，压缩腔室中的温度可升高，以促进通过蒸发从浆液排出液体，如在在80℃到105℃范围中的温度。
氧化铝粒子161被多孔材料部件120保持在该预制件中。由于粒子161具有与粒子151相比更小的平均尺寸，它们通过在先前沉积的粒子151之间保留的空隙中沉降而沉积。
因此获得了一种填充有氧化铝粒子151和161(图6)的纤维预制件30。然后通过清空压缩腔室102外的压缩流体从压缩压力释放该预制件。
该预制件然后从工具中提取并在1000℃到1200℃范围的温度在空气中受到烧结热处理，从而将耐火氧化物粒子烧结在一起，因此在预制件中形成耐火氧化物基质。这产生了一种由具有通过3D编织获得的纤维增强件的氧化物/氧化物复合材料所制成的部件，其具有高度受控的微孔体积分数，以及从而非常小的大孔隙体积分数。
除氧化铝外，耐火氧化物粒子151和161可等同地是一种从莫来石、二氧化硅、氧化锆、硅酸铝和磷酸铝所选择的材料。根据其碱基成分，耐火氧化物粒子也可与氧化铝、氧化锆、硅酸铝、稀土氧化物、稀土二硅酸盐(如，用于环境或热障碍)，或适用于添加特定功能到最终材料的任何其他填料(炭黑、石墨、碳化硅等)的粒子混合。
通过用碳化硅纤维或碳纤维制成纤维织构，并使用一种填充有碳化物粒子(如，SiC)、硼化物粒子(如，TiB2)，或氮化物粒子(如，Si3N4)的浆液，可以同样方式获得CMC复合材料部件。
接下来是本发明方法的第二实施方式的描述，其包括由CMC复合材料制成部件，其最终表面状态由本发明方法控制。更准确地，并且如下所详细解释的，通过将具有与沉积在织构核心的耐火材料粒子相比明显更小的平均直径的耐火材料粒子沉积在纤维织构的表面附近，最终材料中的微孔明显地降低，同时获得一种具有与气动应用兼容的更平滑表面状态的最终部件。耐火粒子可具有相同的化学性质，或者它们可具有不同的化学性质。
在本示例中，使用与以上参照图1到6描述的工具100类似的工具200浸渍该纤维织构，因此，它包括相同的元件，即：
·模具210，其具有一个设置有排气口212的底部211，以及一个包括装配有阀2140(图7)的喷射端口214的侧壁213；
·盖部230，其具有一个装配有阀2310的喷射端口231以及如由硅树脂制成的可变形隔膜240，工具一旦被关闭(图7)，该可变性隔膜用于使存在有纤维织构40的浸渍腔室201与位于隔膜240以上的压缩腔室202隔离；以及
·多孔材料部件220，其放置在底部211的内侧表面211a上并具有与底部211的内侧表面220a接触的底表面220b以及用于接收纤维织构40的顶表面220a。
在当前描述的示例中，多孔材料部件220由刚性材料制成，并且多孔材料部件220的顶表面220a具有与要被制成的最终部件的形状相对应的形状，特最终部件别地为航空发动机叶片。
仍然在当前描述的示例中，通过使用上述技术之一由碳化硅纤维制成该纤维织构40。在该示例中的纤维织构40用于形成SiC/SiC复合材料叶片的纤维增强件，即由一种包括由SiC基质致密的SiC纤维增强件的CMC材料制成的叶片。
在织构40已被放置在多孔材料部件220的顶表面220a后并且在模具210已用盖部230封闭后，第一浆液250经由喷射端口214被喷射到浸渍腔室201，同时其阀2140打开(图7)。浆液250用于形成存在织构40的底表面40b的基质的部分，所述部分有助于最终部件的底表面的表面状态。浆液250对应于液相252的悬浮液中SiC粒子251的粉末，该粒子具有在0.1μm到5μm范围内的平均粒径。浆液的液相252可特别地由水(酸性pH)、由乙醇或由可以将所需粉末形成悬浮液的任何其他液体构成。还可以添加有机粘合剂(如，可溶于水的聚乙烯醇(PVA))。粘结剂用于确保未熟化(green)预制件在烘干后和在烧结前保持在一起。
喷射到浸渍腔室201内的浆液250的数量根据需要从织构底表面开始形成的粒子251的层的厚度确定。
一旦浆液250被喷射到浸渍腔室201内，通过经由其阀2310打开的喷射端口231将例如油的压缩流体280喷射到压缩腔室202来实施压缩操作，喷射端口214的阀2140先前已经关闭(图8)。压缩流体280通过隔膜240在浆液250上施加压力，其迫使浆液250渗透到纤维织构40内。通过从织构40的底表面40b开始沉降，由多孔材料部件220保持的粒子251沉积，而浆液的液相252通过部件220排出织构40。
当不再有液体流过排气口112时，经由多孔材料部件220的排出已经终止。与通过压缩流体在浆液上施加压力相结合，也可以应用泵送P，如通过主真空泵(图1到4未示出)到排气口112。该泵送是可选的。加热可足够。然而，两者的结合用于加速干燥。
在干燥并且可能地也在泵送后，因此获得了一种在其底表面50b上具有SiC粒子251的层2510的中间纤维预制件50。然后，通过清空压缩腔室202外的压缩流体，中间预制件50从压缩压力释放。
可能地在冷却阶段后，中间纤维预制件50浸渍有经由其阀2140打开的喷射端口214喷射的第二浆液260(图9)。浆液260用于在预制件的50的核心形成耐火基质，即在位于底表面和顶表面50b和50a之间的预制件50的厚度中。该浆液260对应于液相262的悬浮液中SiC粒子261的粉末。SiC粒子261具有与粒子251相比更大的并且可在0.1μm到5μm范围内的平均粒径。浆液的液相162可特别地由水(酸性pH)、由乙醇或由可以将所需粉末形成悬浮液的任何其他液体构成。还可以添加有机粘合剂(如，可溶于水的聚乙烯醇(PVA))。粘结剂可以确保未熟化预制件在烘干后和在烧结前保持在一起。液相262优选地具有与液相252相同的性质。
喷射到浸渍腔室201内的浆液260的数量根据需要被浸渍的中间纤维预制件40的厚度确定。
一旦浆液260被喷射到浸渍腔室201内，如上所述再次通过喷射压缩流体280来实施该压缩操作。在压缩操作过程中，通过在预制件中的沉降，由多孔材料部件220保持的粒子261沉积，而浆液260的液体262通过部件220从预制件排出(图10)。
这产生一种中间纤维预制件60，其在其底表面60b上具有SiC粒子251的层2510，以及延伸通过该预制件厚度的SiC粒子260的层2610。通过清空压缩腔室202外的压缩流体，该中间预制件60然后从压缩压力释放。
在可选的冷却阶段后，中间纤维预制件60浸渍有经由其阀2140打开的喷射端口214喷射的第三浆液270(图11)。浆液270旨在首先在预制件60的核心中完成形成SiC基质，即在位于底表面和顶表面40b和40a之间的预制件40的厚度中，其次形成存在于预制件60的顶表面60a上的基质部分，该部分涉及最终部件的顶表面的表面状态。浆液270对应于液相272的悬浮液中SiC粒子271的粉末，该粒子271具有在0.1μm到5μm范围中的平均粒径。浆液的液相272可特别地由上述阶段的任一个构成，并且优选地具有与液相252和262相同的类型。粒子271可具有与粒子251相同的尺寸。然而，它们可具有与粒子251不同的尺寸，如果期望在最终部件的底表面上和顶表面上具有不同的表面状态。
被喷射到浸渍腔室201内的浆液270的数量根据期望从织构顶表面开始形成的粒子271层的厚度以及存在于粒子261之间并且需要填充有粒子271的间隙的体积确定。
一旦浆液270已被喷射到浸渍腔室201内，如上所述，通过再次喷射压缩流体280来实施压缩操作。在压缩操作过程中，通过初始地沉降在存在于粒子261之间的间隙中然后沉降在预制件60的顶表面60a上，粒子271沉积，同时浆液270的液体271通过部件220从预制件排出。与通过压缩流体在浆液上施加压力相结合，可以实施泵送P，如通过主真空泵到排气口112(图1到4未示出)。这种泵送是可选的。加热可满足。然而，它们两者的结合能够加速干燥。
因此获得一种最终纤维预制件70，其具有在底表面70b上的SiC粒子251的层2510，在预制件厚度上延伸的SiC粒子261的层2610，连同间隙中的粒子271，以及在顶表面70a上的SiC粒子271的层2710。然后通过清空压缩腔室202外的压缩流体使最终预制件70脱模。
预制件70从该工具提取并在1800℃到2000℃范围的温度在空气中烧结热处理，从而将耐火SiC粒子烧结在一起，因此在预制件中形成耐火SiC基质。因此获得了一种SiC/SiC复合材料部件，其具有由具有通过3D编织获得的纤维增强件，并且具有非常小的微孔体积分数以及改进的与空气动力学应用兼容的表面状态。
通过使用耐火氧化物纤维(如，氧化铝纤维)以及通过使用填充有耐火氧化物粒子(如，氧化铝、莫来石、二氧化硅等)的浆液制成该纤维织构，可以相同方式获得一种由氧化物/氧化物复合材料制成的部件。
也可以用不同于上述的技术来实施用多种浆液浸渍纤维结构的步骤以及从每种浆液消除液相的步骤，同时使用模具100或200。还可以使用注入类型的技术、称为树脂传递模塑(RTM)的注塑成型类型，或称为高级粉溶液(advanced powder solution)(APS)的涉及亚微米粉末吸入的方法，以实施用浆液浸渍纤维预制件的织构的步骤以及消除每种浆液的液相的步骤。
Claims (11)
1.一种由复合材料制造部件的方法，该方法包括以下步骤：
由耐火纤维形成纤维织构；
用包含第一耐火粒子的第一浆液浸渍该纤维织构第一时间；
从已经浸渍纤维织构的第一浆液移除液相，从而仅将第一耐火粒子留在所述织构内；
用包含第二耐火粒子的第二浆液浸渍该纤维织构第二时间；
从已经浸渍纤维织构的第二浆液移除液相，从而仅将第二耐火粒子留在所述织构内，并获得一种填充有该第一和第二耐火粒子的纤维预制件；并且
烧结存在于该纤维预制件中的第一和第二耐火粒子，从而在所述预制件中形成耐火基质；
其中，浸渍纤维织构的第一步骤和第二步骤的每个都包括：
将纤维织构放置在一种具有浸渍腔室的模具中，所述浸渍腔室在其底部包括一种由多孔材料制成的部件，其上支撑所述织构的第一表面，该浸渍腔室在其顶部通过面对该纤维织构的第二表面放置的变形不透水隔膜被封闭，所述隔膜使该浸渍腔室与压缩腔室隔离；
在该纤维织构的第二表面和隔膜之间将包含耐火粒子的粉末的浆液喷射到该浸渍腔室内；
将压缩流体喷射到压缩腔室内，该流体在隔膜上施加压力，以迫使浆液穿过该纤维织构；并且
其中，从浆液移除液相的每个步骤包括经由该多孔材料部件排出已经穿过该纤维织构的浆液的液相，该耐火粒子由所述多孔材料部件被保留在所述织构内。
2.根据权利要求1所述的方法，其中，第一粒子具有与第二粒子的平均尺寸相比更大的平均尺寸。
3.根据权利要求1所述的方法，其中，第一粒子具有与第二粒子相同的化学性质。
4.根据权利要求1所述的方法，其中，第一粒子具有与第二粒子不同的化学性质。
5.根据权利要求1所述的方法，其中，在从第二浆液消除液相之后以及在烧结步骤之前，该方法进一步包括以下步骤：
用包含第三耐火粒子的第三浆液浸渍纤维织构第三时间；
从已经浸渍了纤维织构的第三浆液消除液相，从而仅使第三耐火粒子留在织构中，并获得一种填充有第一、第二和第三耐火粒子的纤维预制件。
6.根据权利要求5所述的方法，其中，第三粒子具有与第一粒子的平均尺寸类似的平均尺寸，并且其中，第一和第三粒子具有与第二粒子的平均尺寸相比更大的平均尺寸。
7.根据权利要求1所述的方法，其中，多孔材料部件是刚性的，并且具有一种与要被制成的复合材料部件的形状相匹配的形状。
8.根据权利要求1所述的方法，其中，该多孔材料部件可变形，并且模具的底部具有与要被制成的复合材料部件的形状对应的形状，该多孔材料部件呈现模具底部的形状。
9.根据权利要求1所述的方法，其中，预制件的纱线由以下材料的一种或多种组成的纤维形成：氧化铝、莫来石、二氧化硅、硅酸铝、硼硅酸盐、碳化硅和碳。
10.根据权利要求1所述的方法，其中，耐火粒子由从如下选择的材料制成：氧化铝、莫来石、二氧化硅、硅酸铝、铝磷酸盐、氧化锆、碳化物、硼化物和氮化物。
11.根据权利要求1所述的方法，其中，所获得的复合材料部件构成涡轮发动机叶片。
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| RU2207949C2 (ru) * | 2001-09-13 | 2003-07-10 | Федеральное государственное унитарное предприятие "Обнинское научно-производственное предприятие "Технология" | Устройство для формования керамических изделий из водных шликеров |
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- 2015-12-18 CN CN201580074464.XA patent/CN107207354B/zh active Active
- 2015-12-18 BR BR112017013415-2A patent/BR112017013415B1/pt active IP Right Grant
- 2015-12-18 WO PCT/FR2015/053626 patent/WO2016102842A1/fr active Application Filing
- 2015-12-18 CA CA2972172A patent/CA2972172C/fr active Active
- 2015-12-18 RU RU2017126108A patent/RU2722790C2/ru active
- 2015-12-18 JP JP2017534233A patent/JP6760943B2/ja active Active
- 2015-12-18 EP EP15823676.0A patent/EP3237359B1/fr active Active
- 2015-12-18 US US15/538,762 patent/US10427983B2/en active Active
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Also Published As
| Publication number | Publication date |
|---|---|
| CN107207354A (zh) | 2017-09-26 |
| CA2972172A1 (fr) | 2016-06-30 |
| RU2017126108A3 (zh) | 2019-07-17 |
| US10427983B2 (en) | 2019-10-01 |
| RU2722790C2 (ru) | 2020-06-03 |
| US20170334791A1 (en) | 2017-11-23 |
| JP6760943B2 (ja) | 2020-09-23 |
| EP3237359A1 (fr) | 2017-11-01 |
| BR112017013415A2 (pt) | 2018-03-06 |
| FR3030503B1 (fr) | 2019-08-23 |
| EP3237359B1 (fr) | 2019-05-22 |
| JP2018508443A (ja) | 2018-03-29 |
| FR3030503A1 (fr) | 2016-06-24 |
| BR112017013415B1 (pt) | 2022-05-03 |
| CA2972172C (fr) | 2022-07-12 |
| RU2017126108A (ru) | 2019-01-24 |
| WO2016102842A1 (fr) | 2016-06-30 |
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