CN107810173B - 处理碳化硅纤维的方法 - Google Patents

处理碳化硅纤维的方法 Download PDF

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CN107810173B
CN107810173B CN201680037270.7A CN201680037270A CN107810173B CN 107810173 B CN107810173 B CN 107810173B CN 201680037270 A CN201680037270 A CN 201680037270A CN 107810173 B CN107810173 B CN 107810173B
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fiber
silicon carbide
fibers
equal
layer
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CN107810173A (zh
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赛尔维·卢瓦松
克丽丝特尔·于盖
阿德里安·德尔康
埃米丽安·布尔特
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Safran Ceramics SA
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Abstract

本发明涉及处理至少一种碳化硅纤维的方法,该方法至少包括以下步骤:a)将具有小于或等于1%原子百分比的氧含量的至少一种碳化硅纤维与氧化介质接触,以便化学地转化纤维表面并形成表面二氧化硅层;b)通过将执行步骤a)之后获得的纤维与至少包含氢氟酸的酸性液体介质接触来除去所形成的二氧化硅层;和c)在执行步骤b)之后获得的纤维表面上沉积界面层。

Description

处理碳化硅纤维的方法
背景技术
本发明涉及处理至少一种碳化硅纤维以用于改善纤维与界面层之间的粘合质量的方法。
利用由碳化硅纤维增强的复合材料制造部件是已知的。这种制造包括制备基于碳化硅纤维并且具有接近待制造的部件的形状的形状的纤维预制体,然后用基质使预制体致密化。
在纤维增强的复合材料中,众所周知的是纤维-基质界面的特性对材料的力学性能有主要影响。已经表明,通过在形成基质之前在纤维上形成薄的界面层,可以获得特别是关于冲击和裂纹扩展方面令人满意的特性,所述界面层可以例如由在汽相中沉积的氮化硼或热解碳制成。尽管如此,进一步改善由复合材料制成的部件的力学性能仍然是有益的。
文献WO 98/23555、WO 2013/153336和FR 2984 884也是已知的。那些文献描述用酸性溶液处理碳化硅纤维。Bertrand等人的题为“强纤维/涂层界面对Hi-Nicalon/(PyC/SiC)n/SiC微小复合材料的力学特性和寿命的影响”的文章也是已知的。
因此需要进一步改善包含基于碳化硅纤维的纤维增强件的复合材料部件的力学性能。
发明内容
为此,在第一方面中,本发明提供了处理至少一种碳化硅纤维的方法,所述方法至少包括以下步骤:
a)将呈现小于或等于1%原子百分比的氧含量的至少一种碳化硅纤维与氧化介质接触,以便化学地转化纤维表面并形成二氧化硅表面层;
b)通过将执行步骤a)之后获得的纤维与至少包含氢氟酸的酸性液体介质接触来除去所得的二氧化硅层;和
c)在执行步骤b)之后获得的纤维表面上沉积界面层。
发明人已经观察到具有小于或等于1%原子百分比的氧含量的碳化硅纤维呈现出负责降低纤维和界面层之间的粘合质量的表面层。该纤维/界面粘合质量的下降导致由纤维形成的复合材料部件的力学性能下降。通常,表面层包含碳和至少一种碳氧化硅(基于硅、碳和氧的化合物)。
本发明提出了用于消除表面层并由此改善纤维/界面粘合质量的方案,从而改善使用呈现小于或等于1%原子百分比的氧含量的碳化硅纤维获得的复合材料部件的力学性能。
二氧化硅层的厚度可以大于或等于1纳米(nm),例如,5nm或10nm。在步骤a)中,纤维表面上存在的碳完全或部分地被消除,并且存在于纤维表面处的包含元素Si、O和C的碳氧化物全部或部分地转化为二氧化硅。
在实施方式中,二氧化硅层可以在步骤a)中通过使纤维与氧化气相接触来形成,例如,同时施加大于或等于600℃,例如,大于或等于650℃的处理温度,所施加的处理温度可能在600℃至1000℃的范围内,例如,650℃至1000℃的范围内。
在用氧化气相处理期间使用这样的温度值有利于获得用于形成二氧化硅的较快的动力学。
在实施方式中,在步骤a)中,纤维可以用空气和/或蒸汽处理。优选地,在步骤a)中使用的氧化气相由空气构成。
优选地,步骤a)中施加的处理温度可以处于900℃至1000℃的范围内。
在用氧化气相处理期间使用这样的温度值有利于获得用于形成二氧化硅的特别快的动力学。
优选地,步骤b)中使用的酸性液体介质是水溶液的形式。
在实施方式中,酸性液体介质可以包含氢氟酸和硝酸的混合物。
在实施方式中,界面层可以是氮化硼层或热解碳层。界面层优选为氮化硼层。
在实施方式中,将该处理应用于多种碳化硅纤维,每种碳化硅纤维呈现小于或等于1%原子百分比的氧含量。
本发明还提供了制造纤维预制体的方法,其至少包括通过执行如上所述的方法处理多种碳化硅纤维的步骤和通过使用以这种方式处理的所述多种纤维进行一种或多种纺织操作来形成纤维预制体的步骤。
本发明还提供制造纤维预制体的方法,所述方法至少包括通过使用多种碳化硅纤维进行一种或多种纺织操作来形成纤维预制体的步骤,每种碳化硅纤维呈现小于或等于1%原子百分比的氧含量,以及一旦预制体已经形成就通过执行如上所述的方法处理所述多种纤维的步骤。
本发明还提供制造复合材料部件的方法,所述方法至少包括通过执行如上所述的方法制造纤维预制体的步骤,和形成至少一种碳或陶瓷材料的基质相以致密化所述纤维预制体的步骤。
举例来说,复合材料部件可以是涡轮发动机部件,例如涡轮发动机叶片。
附图说明
从以下参照附图的描述中可以看出本发明的其它特征和优点,其中:
图1A至1C是显示在实施本发明的步骤a)和b)时碳化硅纤维的结构如何变化的局部和示意性截面图;
图2是执行本发明的示例方法之后获得的结果的照片;
图3是在执行不是本发明的方法之后获得的结果的照片,其中不执行步骤a)和b);和
图4显示通过进行本发明的处理获得的部件和通过进行非本发明的处理获得的部件(没有步骤a))之间的比较牵引测试的结果)。
具体实施方式
本发明涉及处理具有小于或等于1%原子百分比的氧含量的碳化硅纤维。因此,本发明涉及处理相对低氧的碳化硅纤维,所述纤维因此不同于呈现超出上述范围的氧含量的Si-C-O纤维。
举例来说,通过本发明方法处理的纤维可以具有在1至1.1范围内,例如在1至1.05范围内的C/Si原子比。所谓的“第三代”碳化硅纤维,如“Hi-Nicalon S”类型的纤维具有这样的原子比,其中氧含量小于或等于1%原子百分比。其它类型的碳化硅纤维可以通过本发明的方法处理,如“Hi Nicalon”型纤维,其呈现在上述范围之外的C/Si原子比,但呈现小于或等于1%原子百分比的氧含量。
图1A以高度示例性的方式显示在执行本发明的方法之前具有小于或等于1%原子百分比的氧含量的碳化硅纤维10的截面。碳化硅纤维10由碳化硅制成的芯12和位于纤维10的表面附近的表面层11构成。表面层11呈现不均匀的表面状态和组成,特别包括碳和至少一种碳氧化硅。表面层11负责降低纤维和界面层之间的粘合质量。表面层11的厚度e1通常可以大于或等于1nm,例如5nm或10nm。本发明的方法用于消除表面层11。
碳化硅纤维可以通过任何形式被处理,例如,纱线、粗纱、扭绞股线、丝束、织物、毡制品、垫子、及甚至二维或三维预制体。通过本发明的方法处理的碳化硅纤维可以有利地用于制备用于复合材料部件的纤维预制体。
为了形成纤维预制体,可以首先通过执行一种或多种纺织操作来获得纤维织构,其中纤维织构成形以获得具有所需形状的预制体。纤维织构可以通过三维编织获得,例如,使用互锁编织,即其中每层纬纱相互连接多层经纱的编织,其中给定的纬纱柱中的所有纱线在织造平面中具有相同的运动。其它类型的三维编织自然可以用来制造纤维织构。当通过编织来制备纤维织构时,可以使用在织构的纵向方向上延伸的经纱进行编织,可以理解的是在该方向上用纬纱编织也是可能的。文献WO 2006/136755中具体描述了适于制备纤维织构的各种编织方式。
纤维织构也可以通过将至少两种纤维结构组装在一起而形成。在该情况下,纤维结构可以结合在一起,例如,通过缝合或缝纫。每种纤维结构可以特别地从以下多层的层或堆叠获得:
-一维(1D)织物;
-二维(2D)织物;
-编织物;
-针织物;
-毡制品;
-通过在不同方向上重叠多个1D片材并通过例如缝合、化学粘合剂或缝纫将1D片材结合在一起而获得的纱线或丝束的一维(1D)片材或多维(nD)片材。
当使用多层的堆叠时,它们可以通过例如缝合、植入纱线或刚性元件或缝纫而结合在一起。
碳化硅纤维可以在制备预制体之前或之后通过本发明的方法进行处理。
本发明的处理方法如下所述。
呈现小于或等于1%原子百分比的氧含量的碳化硅纤维10首先与氧化介质接触。作为这种接触的结果,表面层11被氧化并转化成具有厚度e2的二氧化硅层22,在所示的实施例中,该厚度e2基本上等于表面层11的厚度e1(见图1B)。在一个变体中,所形成的二氧化硅层的厚度可以大于表面层11的厚度。
在步骤a)中,纤维10可以与包含元素O的氧化气相接触。具体地,在步骤a)中,可以将纤维10与空气或蒸汽混合。在实施方式中,纤维10可以在处于600℃至1000℃范围内,例如在800℃至1000℃的范围内,优选在900℃至1000℃的范围内的处理温度下通过氧化气相进行处理。在步骤a)中进行的处理可以在大气压下或在低于大气压的压力下进行。举例来说,因此可以通过用氧化气相处理纤维10,同时施加处于600℃至1000℃范围内的处理温度而在大气压下进行步骤a)。
碳化硅纤维可以在步骤a)中与氧化介质接触持续大于或等于1分钟(min),例如5min,例如10min,例如30min的时间,该持续时间在例如5min至60min的范围内。
一旦已经获得二氧化硅层22,其随后在步骤b)中通过与至少包含氢氟酸的酸性液体介质接触而溶解来消除。在步骤b)中使用的酸性液体介质可以是例如酸性水溶液的形式。有利的是,酸性液体介质是至少包含氢氟酸的水溶液形式。酸性液体介质中的氢氟酸的浓度可以有利地大于或等于0.5摩尔每升(mol/L)。
在实施方式中,酸性液体介质可以是至少包含氢氟酸和硝酸的混合物的水溶液形式。当酸性液体介质包含氢氟酸和硝酸的混合物时,酸性液体介质中的氢氟酸浓度可以有利地大于或等于0.5mol/L,并且酸性液体介质中的硝酸浓度可有利地大于或等于0.5mol/L。在该情况下,酸性液体介质中的硝酸浓度可以在例如0.5mol/L至5mol/L的范围内。
在步骤b)中施加的温度可以在10℃至100℃的范围内,例如在10℃至40℃的范围内。在步骤b)中纤维与酸性液体介质接触的持续时间可以例如大于或等于1min,例如等于5min,例如在5min至60min的范围内。
图1C显示在执行步骤a)和b)之后获得的结果。在该情况下,获得呈现均匀的表面状态和组成的碳化硅纤维。在所示的实施例中,在步骤b)之后,整个表面层11被消除而基本上不影响纤维的芯12。在执行步骤a)和b)之后,获得呈现纯碳化硅的表面的纤维12。该结果与用例如包含氢氟酸和硝酸的混合物的酸性液体介质处理呈现大于1%原子百分比的氧含量的碳化硅纤维(例如“Nicalon”纤维)时得到的结果是完全不同的。具体而言,在该情况下,在处理过的纤维的表面处获得一层碳,而不是获得均匀的碳化硅表面。换言之,通过本发明的处理剥离碳化硅纤维的表面的能力与使用呈现小于或等于1%原子百分比的氧含量的碳化硅纤维有关。
然后沉积界面层,与执行步骤a)和b)之后获得的纤维表面接触。直接在纤维表面上沉积界面层是以已知的方式进行的。通过本发明的方法处理的纤维呈现与界面层的改善的粘合。界面层可以是氮化硼(BN)层或热解碳层(PyC)。例如,界面层的厚度可以大于或等于200nm,例如在200nm至300nm的范围内。一个或多个附加层,例如,诸如SiBC、BNSi或碳化硅的陶瓷材料的附加层,可以沉积在界面层上。
当然,可以通过本发明的方法同时处理多种碳化硅纤维,其各自呈现小于或等于1%原子百分比的氧含量。
一旦界面层已经沉积,则可以使用至少一种基质相致密化界面层中涂布的处理过的纤维的纤维预制体,来形成具有改善的力学性能的复合材料部件。纤维预制体构成复合材料部件的纤维增强件,且基质相在纤维预制体的孔中形成。例如,基质相可以由碳化硅或碳制成。
致密化以已知的方式进行。因此可以使用液体技术(用基质前体树脂将其浸渍并通过交联和热解转化树脂,该过程可以重复)或通过气体技术(基质的化学汽相渗透(CVI))使纤维预制体致密化。本发明特别适用于制备由碳化硅纤维制成的纤维增强件构成并且用陶瓷基质,特别是碳化物、氮化物、耐高温氧化物等基质致密化的陶瓷基质复合材料(CMC)部件。该CMC材料的实例通常为SiC-SiC材料(具有碳化硅基质的碳化硅增强纤维)。也可以通过使熔融状态的硅渗入来制备基质相,其称为“熔化浸渗”方法。
实施例
实施例1
“Hi-Nicalon S”型纤维与由空气构成的氧化气相接触,同时施加650℃处理温度,处理时间为45分钟。这样的处理可以化学地转化纤维的表面以形成表面二氧化硅层。通过二次离子质谱(SIMS)进行的分析可以估计以那种方式形成的二氧化硅层的厚度。因此二氧化硅层的厚度被估计为1.6nm。
然后将呈现二氧化硅表面层的氧化的纤维排成五组,并且每组纤维用不同的酸性溶液进行处理。所有的酸处理都通过将纤维在30℃的温度下在酸性溶液浴中浸渍1小时(h)来进行。所使用的五种酸性溶液的组成如下:
-每升80克(g/L)的氢氟酸性溶液;
-448g/L氢氟酸性溶液;
-包含80g/L氢氟酸和180g/L硝酸的混合物的溶液;
-包含80g/L氢氟酸和325g/L硝酸的混合物的溶液;和
-包含470g/L氢氟酸和325g/L硝酸的混合物的溶液。
一旦那些酸处理已经执行,二次离子质谱分析证实所有五组纤维的二氧化硅表面层已被消除。
然后在通过进行上述氧化,接着用448g/L氢氟酸性溶液进行酸处理而获得的纤维上形成氮化硼的界面层。通过执行以下操作条件,在碳化硅纤维的表面上直接形成氮化硼界面层:
-用包含N2、NH3和BCl3的气相进行处理;
-施加1100℃的温度;
-施加2毫巴(mbar)的压力;
-将比率α设定为1(即,(NH3体积流率)/(BCl3体积流率)的比率);
-将比率β设定为10(对应于比率(N2体积流率)/(BCl3的体积流率+NH3的体积流率));和
-将处理气相的总体积流率设定为367立方厘米每分钟(cm3/min)。
图2是获得的结果的照片。在纤维和氮化硼界面层之间可以观察到良好的粘聚力。以这种方式获得的涂布的纤维构成用于复合材料部件的纤维增强件,并且其赋予所述部件改善的力学性能。通过比较提供图3,并且其显示当不执行本发明的步骤a)和b)的处理时,在纤维和氮化硼界面层之间观察到剥离。这种剥离导致由以这种方式涂布的纤维形成的复合材料部件的力学性能的降低。
实施例2
在与实施例1相同的条件下进行另一项测试,不同之处在于步骤a)中的氧化是通过使纤维在1000℃的温度下与空气接触15分钟的处理持续时间来进行的。在该情况下形成的二氧化硅层的厚度通过二次离子质谱估计为约十纳米。在用酸性介质处理后,获得与实施例1相同的纤维的表面状态,因此获得相似的力学性能。
(比较)实施例3
图4显示在通过依照实施例1的方法处理纤维之后首先获得的部件(曲线I)与除了没有进行之前的氧化处理(步骤a))之外,以与实施例1相同的方式处理纤维之后其次获得的部件(曲线II)之间的牵引试验中获得的结果。可以看出,执行本发明的处理有利地用于显著改善所得部件的断裂处的伸长率。
术语“在......至......的范围内”应理解为包括界限。

Claims (11)

1.一种处理至少一种碳化硅纤维的方法,所述方法至少包括以下步骤:
a)将呈现小于或等于1%原子百分比的氧含量的至少一种碳化硅纤维与氧化气相接触大于或等于1分钟的持续时间,并施加大于或等于600℃的处理温度,以便化学地转化纤维表面并形成二氧化硅的表面层;
b)通过将执行步骤a)之后获得的纤维与至少包含氢氟酸的酸性液体介质接触以消除所得二氧化硅层和
c)在执行步骤b)之后获得的纤维的表面上沉积界面层。
2.根据权利要求1所述的方法,其中步骤a)中施加的处理温度在600℃至1000℃的范围内。
3.根据权利要求2所述的方法,其中步骤a)中施加的处理温度在900℃至1000℃的范围内。
4.根据权利要求1所述的方法,其中在步骤a)中用空气和/或蒸汽处理所述纤维。
5.根据权利要求1所述的方法,其中所述酸性液体介质包含氢氟酸和硝酸的混合物。
6.根据权利要求1所述的方法,其中所述界面层是氮化硼层或热解碳层。
7.根据权利要求1所述的方法,其中所述处理被应用于多种碳化硅纤维,每种碳化硅纤维均呈现小于或等于1%原子百分比的氧含量。
8.制造纤维预制体的方法,所述方法至少包括以下步骤:通过执行根据权利要求7所述的方法处理多种碳化硅纤维的步骤,和通过使用以这种方式处理的所述多种纤维执行一种或多种纺织操作来形成纤维预制体的步骤。
9.制造纤维预制体的方法,所述方法至少包括以下步骤:通过使用多种碳化硅纤维进行一种或多种纺织操作来形成纤维预制体的步骤,每种碳化硅纤维呈现小于或等于1%原子百分比的氧含量,和一旦预制体已经形成,通过执行根据权利要求7所述的方法处理所述多种纤维的步骤。
10.制造复合材料部件的方法,所述方法至少包括通过执行根据权利要求8或权利要求9所述的方法来制造纤维预制体的步骤,接着形成碳或陶瓷材料的至少一种基质相的步骤以致密化所述纤维预制体。
11.根据权利要求10所述的方法,其中所述复合材料部件是涡轮发动机叶片。
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