CN107278200B - 用于制造由复合物材料制成的耐火部件的方法 - Google Patents

用于制造由复合物材料制成的耐火部件的方法 Download PDF

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CN107278200B
CN107278200B CN201580076983.XA CN201580076983A CN107278200B CN 107278200 B CN107278200 B CN 107278200B CN 201580076983 A CN201580076983 A CN 201580076983A CN 107278200 B CN107278200 B CN 107278200B
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texture
refractory
slip
fibrous texture
preform
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CN107278200A (zh
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M·泊德格斯奇
C·比尔罗特卡贝瑞
B·J·G·戴姆布里尼
L·E·C·莫里埃克斯
E·鲁兹
S·图伦内
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Safran Aircraft Engines SAS
Safran SA
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Safran SA
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Abstract

本发明提供一种由复合物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物(10)；·将所述纤维织构物(10)放入模具(110)中，所述模具具有浸渍腔室(101)，其底部部分中包括由多孔材料制成的部件(120)，所述浸渍腔室(101)通过可变形的不可渗透的隔膜(140)从其顶部部分密闭，所述隔膜将所述浸渍腔室(101)与压缩腔室(102)隔开；·将含有耐火颗粒的粉末的粉浆(150)注射入浸渍腔室(101)；·将受压流体(160)注射入压缩腔室(102)，以迫使粉浆(150)穿过所述纤维织构物(10)；·通过多孔材料部件(120)排出粉浆的液体，同时将耐火颗粒的粉末保持在所述织构物内部，以获得填充有耐火颗粒的纤维预制件(20)；·将所述纤维预制件(20)干燥；·将所述纤维预制件(20)脱模；以及·烧结所述纤维预制件中存在的耐火颗粒，以在所述预制件中形成耐火基质。

Description

用于制造由复合物材料制成的耐火部件的方法
背景技术
本发明涉及用于由热结构复合物材料制造部件的方法，特别是由氧化物/氧化物类型或陶瓷基质复合物(CMC)类型制造部件的方法，所述陶瓷基质复合物(CMC)类型包含由耐火材料的纤维制成的纤维强化材料并且通过同样由耐火材料制成的基质进行致密化。
氧化物/氧化物复合物材料部件通常通过以下方式制备：采用多个由耐火氧化物纤维制成的纤维层并覆盖在模具中，各层预先浸渍有粉浆，所述粉浆填充有耐火氧化物颗粒。然后用夹模或真空片将以该方式排列的层组压缩并通过高压釜。然后对以这种方式获得的填充的预制件进行烧结，以在所述预制件内形成耐火氧化物基质并获得由氧化物/氧化物复合物材料制成的部件。该技术也可用于由陶瓷基质复合物(CMC)材料制造部件。在这种情况下，由碳化硅(SiC)纤维或碳纤维制成纤维层，并且用填充有碳化物(例如SiC)颗粒、硼化物(例如TiB2)颗粒或氮化物(例如Si3N4)颗粒的浆料浸渍所述纤维层。
然而，该类型的制备方法仅适于制造厚度薄的和具有二维(2D)纤维强化材料的CMC或氧化物/氧化物复合物材料部件。这些类型的复合物材料的机械性质在某些方向上仍然受限。具体来说，这些材料具有差的分层性能，并且它们也无法很好地耐受剪切力。
在连续的经纱和纬纱之间进行三维编织而获得的纤维织构物能够增加材料的机械强度，并且特别地能够增强其耐受分层的能力。在这种情况和厚的2D纤维织构物的情况下，仅通过利用压力梯度的方法就能够使填充的悬液穿透进入纤维织构物，所述纤维织构物的厚度基于目标应用可达数十毫米，所述利用压力梯度的方法例如有灌注型方法、被称为树脂传递模塑(RTM)的注射模塑型方法，或涉及被称为先进粉末方案(APS)的亚微米粉末的吸入的方法。
但是，在用CMC或氧化物/氧化物材料制备部件的情况下，这些方法具有某些缺点。
特别是，无法使用灌注型方法来浸渍形状复杂和很厚的纤维织构物，原因在于无法达到足够的压力差以实现贯穿织构物的良好浸渍。
APS型方法无法对导入预制件的基质的量进行精密控制。
尽管RTM方法可使用填充的粉浆来浸渍纤维织构物，但是其需要除去粉浆的溶剂的步骤(通过蒸发和排放)，以在烧结之前在预制件中仅保留所述固体填料。在采用RTM方法时通常不实施这种除去溶剂的步骤。这种额外的步骤使得处理预制件需要明显更长的时间。也可能需要重复注入粉浆的操作，以及随之而来的除去溶剂的操作。
进一步，难以对所述溶剂进行蒸发，因为需要从预制件中除去溶剂而不妨碍已通过粉浆沉积的固体颗粒(耐火氧化物、碳化物、硼化物、氮化物等)的分布。特别地，在对已浸渍的预制件进行干燥的同时，溶剂的蒸发和排放可能导致颗粒被溶剂带走，和/或可能改变预制件中颗粒的分布以及可能由于在某些位置缺少基质而导致最终材料中产生大孔。
本发明的目的和内容
本发明的目的在于改进上述缺点并提出能够由厚和/或形状复杂的纤维织构物用复合物材料制造部件的方案，特别是用氧化物/氧化物型或CMC型材料制造部件的方法，并且以快速和可靠的方式实施，同时对固体颗粒在纤维织构物中的沉积和分布进行良好的控制以获得具有很少量的大孔的材料。
为此，本发明提供一种由复合物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物；
·将所述纤维织构物放入模具中，所述模具具有浸渍腔室，其底部部分包括由多孔材料制成的部件，所述织构物的第一表面置于所述部件上，所述浸渍腔室通过可变形的不可渗透的隔膜从其顶部部分密闭，所述隔膜面向所述纤维织构物的第二表面放置，所述隔膜将所述浸渍腔室与压缩腔室隔开；
·将含有耐火颗粒的粉末的粉浆注射入浸渍腔室中的纤维织构物的第二表面与所述隔膜之间；
·将受压流体注射入压缩腔室，所述流体对所述隔膜施加压力，以迫使粉浆穿过所述纤维织构物；
·通过多孔材料部件排出已穿过所述纤维织构物的粉浆的液体，同时通过所述多孔材料部件的方式将耐火颗粒的粉末保持在所述织构物内部，以获得填充有耐火颗粒的纤维预制件；
·将所述纤维预制件干燥；
·将所述纤维预制件脱模；以及
·烧结所述纤维预制件中存在的耐火颗粒，以在所述预制件中形成耐火基质。
通过使用由适合排出粉浆的液体的多孔材料制成的部件，本发明的方法能够从已经导入纤维织构物的粉浆中除去液相，而不会除去也存在于织构物中的耐火固体颗粒。通过排放来除去粉浆的固相使得能够避免妨碍耐火颗粒在纤维织构物中的分布，从而获得具有高体积分数的基质的复合物材料部件。从而，由热结构复合物材料制成的部件具有提高的机械性质。
在本发明方法的第一具体方面中，所述多孔材料部件是刚性的，并且形状与所要制造的复合物材料部件的形状匹配。
在本发明的方法的第二具体方面中，所述多孔材料部件是可变形的，且所述模具的底部的形状与所要制造的复合物材料部件的形状相应，所述多孔材料部件的形状采用所述模具的底部的形状。
在本发明的方法的第三具体方面中，在形成所述纤维织构物的步骤中，使用三维编织对纱线进行编织。
在本发明的方法的第四具体方面中，通过对用二维编织进行编织的层进行堆叠来制造所述纤维织构物，所述织构物的厚度为至少0.5毫米(mm)，优选为至少1mm。
所述预制件的纱线可由纤维制成，所述纤维由以下材料中的一种或多种制成：氧化铝、多铝红柱石、二氧化硅、铝硅酸盐、硼硅酸盐、碳化硅和碳。
所述耐火颗粒可由选自以下的材料制成：氧化铝、多铝红柱石、二氧化硅、铝硅酸盐、铝磷酸盐、二氧化锆、碳化物、硼化物和氮化物。
在一个实施方式中，所获得的复合物材料部件构成涡轮发动机叶片。
附图的简要说明
本发明的其它特点和优势通过下文关于本发明具体实施方式的描述并参照附图而显见，所述具体实施方式以非限制示例的形式给出，附图中：
图1是根据本发明的一种实施方式的工具的分解截面示意图；
图2是图1的工具被位于其中的纤维织构物密闭时的截面示意图；和
图3和图4是根据本发明的方法的实施的在图2的工具中用填充的粉浆浸渍纤维织构物的步骤的截面示意图。
具体实施方式
本发明的用于由复合物材料制造部件的方法、特别是由氧化物/氧化物型或CMC型复合物材料制造部件的方法中首先制造用于形成部件的增强材料的纤维织构物。
通过已知的方式用提花织机(Jacquard type loom)编织占据多个层的一束经纱或股线，所述经纱通过纬纱互连，或者也可相反。所述纤维织构物可通过堆叠由二维(2D)编织获得的层来制造。所述纤维织构物也可通过三维(3D)编织来直接制造成单一部件。本文所用的术语“二维编织”是指常规的编织方法，其中，各条纬纱从单层经纱中的纱线的一侧穿至另一侧，或者也可以相反。本发明的方法特别适合将填充的粉浆导入2D纤维织构物、通过堆叠2D层而获得的织构物、以及具有很大厚度的织构物，例如厚度为至少0.5mm、优选为至少1mm的2D纤维结构。
本文所用的术语“三维编织”或“3D编织”、或实际上的“多层编织”是指纬纱中的至少一些与多层经纱中的经纱互连或以相反方式进行的编织，可通过具体选自以下编织方法的编织方法来进行：互锁编织(interlock)、多平纹编织(multi-plain)、多缎纹编织(multi-satin)和多斜纹编织(multi-twill)。
本文所用术语"互锁编织或织物"指的是3D编织，其中经纱的各层与多层纬纱互连，其中相同经列中的所有纱线在编织平面中同样地移动。
本文所用术语"多平纹编织或织物"指的是使用多层纬纱的3D编织，其中各层的基本编织(base weave)与常规的平纹类型的编织等同，但是编织的某些点与纬纱层互连在一起。
本文所用术语"多缎纹编织或织物"指的是使用多层纬纱的3D编织，其中各层的基本编织与常规的缎纹类型的编织等同，但是编织的某些点与纬纱层互连在一起。
本文所用术语"多斜纹编织或织物"指的是使用多层纬纱的3D编织，其中各层的基本编织与常规的斜纹类型编织等同，但是编织的某些点与纬纱层互连在一起。
3D织构物具有复杂的形状，难以向其中导入悬液中的固体颗粒并将其均匀铺展。本发明的方法也非常适合将填充的粉浆导入3D编织纤维织构物。
用于编织将要形成复合物材料部件的纤维增强材料的纤维织构物的纱线可具体由纤维制成，所述纤维由以下材料中的任一种构成：氧化铝、多铝红柱石、二氧化硅、铝硅酸盐、硼硅酸盐、碳化硅、碳或这些材料的两种或更多种的混合物。
制成了纤维织构物之后，则将其放入根据本发明的工具，使得能够将耐火颗粒放入纤维织构物内，如以下所说明。出于该目的以及如图1和2所示，将纤维织构物10放入工具100。在当前描述的实施方式中，使用一种上文限定的技术(堆叠2D层或3D编织)和Nextel610氧化铝纱线来制造纤维织构物10。该实施例中的纤维织构物10用于形成叶片的纤维增强材料，所述叶片由氧化物/氧化物复合物材料制成。
工具100包括一个具有底部111的模具110，所述底部具有通气孔112。模具110还具有侧壁113，所述侧壁具有与阀1140对接的注射口114。由多孔材料制成的部件120放置在底部111的内表面111a。由多孔材料制成的部件120具有底部表面120b和顶部表面120a，所述底部表面与底部111的内表面111a接触，所述顶部表面120a用于接收纤维织构物10。在当前描述的实施例中，部件120用可变形的材料制成，模具110的底壁111的内表面111a的形状或轮廓与所要制造的最终部件的形状相应，特别是该实施例中的航空发动机叶片。由于部件120是可变形的，其与底部111的内表面111a的轮廓匹配，并且其顶部表面120a的形状与表面111a的形状相似。通过示例的方式，部件120可由微孔聚四氟乙烯(PTFE)制成，例如由供应商
Figure BDA0001385876280000051
公司出售的“微孔PTFE”产品。
在一种变化的实施方式中，所述多孔材料部件是刚性的，并且顶部表面的形状与所要制造的最终部件的形状相应。在这种情况下，所述部件可特别地通过热成型来制造。
通过示例的方式，多孔材料部件的厚度可以是数毫米，平均孔分数可以是约30％。由多孔材料制成的部件的平均孔径(D50)的范围例如可以是1微米(μm)至2μm。
工具100也可包括盖130和可变形的隔膜140，所述盖130具有带阀1310的注射口131，一旦所述工具闭合(图2)，所述隔膜将浸渍腔室110与压缩腔室102隔开，所述浸渍腔室中具有纤维织构物10，所述压缩腔室102安装于隔膜140上方。所述隔膜140例如可由有机硅制成。
将织构物10放置在多孔材料部件120a的顶部表面120a上后，用盖130将模具110闭合(图2)。然后通过注射口114将粉浆150注射入浸渍腔室101，所述注射口的阀1140是打开的(图3)。在该实施例中，粉浆150用于在织构物中形成耐火氧化物基质。粉浆150相当于含有耐火氧化物颗粒的粉末的悬液，所述颗粒的平均粒径范围为0.1μm至10μm。所述粉浆的液相可具体由水(酸性pH)、乙醇或任意其他能够使所需的粉末形成悬液的液体构成。也可添加有机粘合剂(例如可溶于水的聚乙烯醇(PVA))。所述粘合剂用于确保预制件坯体在干燥之后和烧结之前保持在一起。
通过示例的方式，粉浆150可相当于水性悬液，其由平均粒径(D50)为0.1μm至0.3μm且体积分数为27％至42％的氧化铝粉末构成，使用硝酸使所述悬液呈酸性(pH为1.5-4)。除氧化铝之外，耐火氧化物颗粒也可同等地为选自多铝红柱石、二氧化硅、铝硅酸盐、铝磷酸盐和二氧化锆的材料。作为它们的基础组成的功能变化(function)，耐火氧化物颗粒也可与氧化铝颗粒、氧化锆颗粒、铝硅酸盐颗粒、稀土氧化物颗粒、稀土二硅酸盐的颗粒(例如用于环境屏障或热屏障)、或任意其他的适合向最终材料附加特定功能的填料(碳黑、石墨、碳化硅等)混合。
注射入浸渍腔室101的粉浆150的量随着所要浸渍的纤维织构物10的体积而变化。初始导入的粉末的量控制最终的沉降厚度，从而控制纤维体积分数(Fvf)和基质体积分数(Mvf)。
通过阀1310开放的注射口131将压缩液体160(例如油)注射入压缩腔室102，一旦将粉浆注射入浸渍腔室101，则在注射口114的阀1140关闭后来实施压缩操作。压缩流体160通过隔膜140向粉浆150施加压力，迫使粉浆150穿透进入纤维织构物10。流体160在整个隔膜160上施加静水压，由此对织构物10上方的所有粉浆施加静水压。通过隔膜140施加于粉浆以及纤维织构物的压力优选小于15巴，例如7巴，从而使得粉浆穿透进入织构物并充分压缩所述织构物以使粉浆的液相能够通过多孔材料部件排出，而不会使得所得的预制件性能下降。
位于纤维织构物的面10b旁的多孔材料部件120起到多种作用，所述面10b与面10a相反，所述粉浆通过所述多孔材料部件穿透进入所述织构物。特别地，部件120使得粉浆的液体能够从纤维织构物中排出，所述以这种方式排出的液体在该实施例中通过排放口112排放。所述压缩操作的过程中以及之后均进行所述排放。当没有更多液体穿过排放孔112时，停止排放。通过压缩流体的方式向粉浆施加压力的同时，也可组合应用泵P，例如用初级真空泵(图1-4中未示出)通过排放口112来应用。这种泵抽是任选的。加热也可足够地施加压力。然而，两者的组合能够加速干燥。
另外，所述工具也可具有加热装置，例如结合在工具的壁中的电阻元件，以提高压缩腔室内部的温度并通过蒸发来促进粉浆中的液体的耗尽。压缩腔室中的温度也可升高至80℃至105℃的温度范围。
多孔材料部件120也能够保留粉浆中的耐火氧化物的固体颗粒，从而耐火氧化物颗粒通过沉降而逐渐沉积在纤维织构物中。这使得能够在之后(即烧结后)获得所述基质。
所述部件120也能够在压缩操作中保持纤维织构物的形状，原因在于其顶部表面120a复制了模具110的底部111的形状，所述形状与所要制造的最终部件的形状相应。
于是获得了填充有耐火氧化物颗粒、特别是上述类型的氧化铝颗粒的纤维预制件20。之后，通过从压缩腔室中排空压缩流体来将所述预制件脱模，所述预制件在脱模后保持其压缩的形状。
然后将预制件从工具中取出并在空气中以1000℃至1200℃的温度进行烧结热处理，以将耐火氧化物颗粒烧结在一起，藉此在预制件中形成耐火氧化物基质。这产生了由氧化物/氧化物复合物材料制成的部件，所述部件具有获自3D编织的纤维增强材料，所述纤维增强材料具有高基质体积分数且基质在整个纤维增强材料中均匀分布。
可同相同的方式获得CMC复合物材料部件，其中用碳化硅纤维或碳纤维制成纤维织构物，并使用填充有碳化物颗粒(例如SiC)、硼化物颗粒(例如TiB2)或氮化物颗粒(例如Si3N4)的粉浆。

Claims (8)

1.一种由复合物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物；
·将所述纤维织构物放入模具中，所述模具具有浸渍腔室，其底部部分包括由多孔材料制成的部件，所述织构物的第一表面置于所述部件上，所述浸渍腔室通过可变形的不可渗透的隔膜从其顶部部分密闭，所述隔膜面向所述纤维织构物的第二表面放置，所述隔膜将所述浸渍腔室与压缩腔室隔开；
·将含有耐火颗粒的粉末和水的粉浆注射入浸渍腔室中的纤维织构物的第二表面与所述隔膜之间，其中所述粉浆的pH为1.5-4；
·将受压流体注射入压缩腔室，所述流体对所述隔膜施加压力，以迫使粉浆穿过所述纤维织构物，其中，通过所述隔膜施加于所述粉浆以及所述纤维织构物的压力小于15巴；
·通过多孔材料部件排出已穿过所述纤维织构物的粉浆的液体，同时通过所述多孔材料部件的方式将耐火颗粒的粉末保持在所述织构物内部，以获得填充有耐火颗粒的纤维预制件；
·将所述纤维预制件干燥；
·将所述纤维预制件脱模；以及
·烧结所述纤维预制件中存在的耐火颗粒，以在所述预制件中形成耐火基质。
2.如权利要求1所述的方法，其中，所述多孔材料部件是刚性的，并且形状与所要制造的复合物材料部件的形状匹配。
3.如权利要求1所述的方法，其中，所述多孔材料部件是可变形的，所述模具的底部的形状与所要制造的复合物材料部件的形状相应，所述多孔材料部件的形状采用所述模具的底部的形状。
4.如权利要求1所述的方法，其中，在形成所述纤维织构物的步骤中，使用三维编织对纱线进行编织。
5.如权利要求1所述的方法，其中，对用二维编织进行编织的层进行堆叠，来制造所述纤维织构物，所述织构物的厚度为至少0.5mm。
6.如权利要求1所述的方法，其中，所述预制件的纱线由纤维形成，所述纤维由一种或多种以下材料制成：氧化铝、多铝红柱石、二氧化硅、铝硅酸盐、硼硅酸盐、碳化硅和碳。
7.如权利要求5所述的方法，其中，所述耐火颗粒由选自以下的材料制成：氧化铝、多铝红柱石、二氧化硅、铝硅酸盐、铝磷酸盐、二氧化锆、碳化物、硼化物和氮化物。
8.如权利要求1所述的方法，其中，所获得的复合物材料部件构成涡轮发动机叶片。
CN201580076983.XA 2014-12-23 2015-12-18 用于制造由复合物材料制成的耐火部件的方法 Active CN107278200B (zh)

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FR3071245B1 (fr) * 2017-09-21 2019-09-20 Safran Ceramics Procede d'injection d'une barbotine chargee dans une texture fibreuse
FR3072672B1 (fr) * 2017-10-24 2019-11-08 Safran Ceramics Installation pour le depot d'une meche chargee mise en forme
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CA2972168C (fr) 2022-07-12
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JP6691126B2 (ja) 2020-04-28
JP2018508441A (ja) 2018-03-29
FR3030502B1 (fr) 2017-01-13
RU2017125601A (ru) 2019-01-25
WO2016102837A1 (fr) 2016-06-30
CA2972168A1 (fr) 2016-06-30
FR3030502A1 (fr) 2016-06-24
US20170341263A1 (en) 2017-11-30
EP3237358A1 (fr) 2017-11-01
EP3237358B1 (fr) 2018-09-19
RU2698789C2 (ru) 2019-08-29
US10328604B2 (en) 2019-06-25
BR112017013591B1 (pt) 2022-04-26

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