CN107975551B - 分段式碳纤维预成形件 - Google Patents
分段式碳纤维预成形件 Download PDFInfo
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- CN107975551B CN107975551B CN201710994127.3A CN201710994127A CN107975551B CN 107975551 B CN107975551 B CN 107975551B CN 201710994127 A CN201710994127 A CN 201710994127A CN 107975551 B CN107975551 B CN 107975551B
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- silicon
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Abstract
本发明在一些示例中描述了一种技术,该技术包括以交错结构对准多个碳预成形件节段,其中,多个碳预成形件节段中的每个碳预成形件节段包括含有多个碳纤维或碳泡沫中的至少一个的碳本体以及包含硅颗粒的硅基混合物。该技术可以包括加热交错结构以使得硅颗粒与碳本体反应从而将多个碳预成形件节段结合在一起并形成陶瓷基复合材料部件。
Description
技术领域
本发明涉及陶瓷基复合材料,诸如由陶瓷基复合材料制成的飞行器制动盘的制造。
背景技术
陶瓷基复合材料是包括含有用碳纤维增强的碳的基体的复合材料。陶瓷基复合材料部件能够用于许多高温应用中。例如,航空航天工业使用陶瓷基复合材料部件作为用于商业和军用飞行器的摩擦材料,诸如,制动摩擦材料。
一些复合材料部件(诸如用于航空航天工业的一些陶瓷基复合材料制动盘)可以由包括多层碳纤维的碳纤维预成形件制造,其可以使用例如化学气相沉积/化学气相渗透(CVD/CVI)、真空/压力渗透(VPI)或树脂转移模制(RTM)而密化以便用碳或碳前驱体材料渗透纤维预成形件。
发明内容
在一些示例中,本发明描述了用于形成陶瓷基复合材料部件的技术,该技术包括以交错结构对准多个碳预成形件节段,其中,多个碳预成形件节段中的每个碳预成形件节段包括碳本体和硅基混合物,碳本体包括多个碳纤维或碳泡沫中的至少一个,硅基混合物包括硅颗粒。该技术可以包括加热该交错结构以便使硅颗粒与碳本体反应从而将多个碳预成形件节段结合在一起并形成陶瓷基复合材料部件。
在一些示例中,本发明描述了一种组件,该组件包括以交错结构对准的多个碳预成形件节段以使得直接相邻的碳预成形件节段彼此直接接触,其中,多个碳预成形件节段的每一个包括碳本体和硅基混合物,碳本体包括多个碳纤维或碳泡沫,硅基混合物包括沉积在碳本体上的硅颗粒。
在一些示例中,本发明描述了一种陶瓷基复合材料部件,该陶瓷基复合材料部件包括限定了由碳化硅材料反应性地结合在一起的多个碳材料区域的复合材料本体,其中,多个碳材料区域包括多个碳纤维或碳泡沫,以及其中,多个碳材料区域以交错结构对准。
在以下附图和说明书中阐述了本发明的一个或多个示例的细节。本发明的其他特征、目标和优点将从说明书和附图以及从权利要求中而明确。
本发明包括以下方案:
方案1.一种用于形成陶瓷基符合材料组件的方法,所述方法包括:
以交错结构对准多个碳预成形件节段,其中,所述多个碳预成形件节段中的每个碳预成形件节段包括:
碳本体,所述碳本体包括多个碳纤维或碳泡沫中的至少一个,以及
硅基混合物,所述硅基混合物包括涂覆在所述碳本体上的硅颗粒;以及
加热所述交错结构以便使所述硅颗粒与所述碳本体反应从而使所述多个碳预成形件节段结合在一起并且形成所述陶瓷基复合材料部件。
方案2.根据方案1所述的方法,进一步包括:对于所述多个碳预成形件节段中的每个碳预成形件节段:
形成所述碳本体;以及
用所述硅基混合物涂覆所述碳本体。
方案3.根据方案2所述的方法,其中,形成所述碳本体包括:
针刺包括碳前驱体纤维的多个纤维层;
碳化所述碳前驱体纤维以便形成所述多个碳纤维;以及
密化所述碳本体。
方案4.根据方案2所述的方法,其中,用所述硅基混合物涂覆所述碳本体包括下述内容中的至少一个:将所述碳本体浸没在所述硅基混合物中,在所述碳本体上喷涂所述硅基混合物,或者在所述碳本体上滑涂所述硅基混合物。
方案5.根据方案4所述的方法,其中,所述硅基混合物包括:
所述硅颗粒;
载体流体;以及
至少一种粘附促进剂。
方案6.根据方案1所述的方法,进一步包括形成基本上无氧的环境,其中,加热所述交错结构以便使所述硅颗粒与所述碳本体反应包括在所述基本上无氧的环境中加热所述交错结构以便使所述硅颗粒与所述碳本体反应。
方案7.根据方案6所述的方法,其中,形成所述基本上无氧的环境包括形成局部真空以便形成所述基本上无氧的环境。
方案8.根据方案1所述的方法,其中,以交错结构对准多个碳预成形件节段进一步包括形成所述多个碳预成形件节段的多层结构。
方案9.根据方案1所述的方法,进一步包括在加热所述交错结构的同时机械地压缩所述交错结构以便使所述硅颗粒与所述碳本体反应。
方案10.根据方案1所述的方法,进一步包括将所述陶瓷基复合材料部件机加工成盘制动器的形状。
方案11.一种组件,所述组件包括:
多个碳预成形件节段,所述多个碳预成形件节段以多层交错结构对准以使得直接相邻的碳预成形件节段彼此直接接触,其中,所述多个碳预成形件节段的每一个包括:
碳本体,所述碳本体包括多个碳纤维或碳泡沫;以及
硅基混合物,所述硅基混合物包括沉积在所述碳本体上的硅颗粒。
方案12.根据方案11所述的组件,其中,所述硅基混合物包括所述硅颗粒以及至少一种粘附促进剂。
方案13.根据方案12所述的组件,其中,所述粘附促进剂包括选自由藻酸铵、琼脂、琼脂糖构成的组的至少一种成分。
方案14.根据方案12所述的组件,其中,所述硅基混合物进一步包括载体流体和表面活性剂。
方案15.根据方案11所述的组件,其中,所述交错设置包括所述多个碳预成形件节段的多层交错结构。
方案16.根据方案11所述的组件,其中,所述多个碳预成形件节段的每一个限定相应的形状,其中,所述多个碳预成形件的所述相应形状选自由立方体、正方棱柱、矩形棱柱、五角棱柱和六角棱柱组成的组。
方案17.根据方案11所述的组件,其中,所述多个碳预成形件节段的每一个包括限定了长度在约5mm和约20mm之间的至少一个表面。
方案18.根据方案11所述的组件,进一步包括圆形夹具,所述圆形夹具环绕所述交错结构并且机械地压缩所述交错结构。
方案19.一种陶瓷基复合材料部件,包括:
复合材料本体,所述复合材料本体限定了由碳化硅材料反应性地结合在一起的多个碳材料区域,其中,所述多个碳材料区域包括多个碳纤维或碳泡沫,其中,所述多个碳材料区域以交错结构对准。
方案20.根据方案19所述的陶瓷基复合材料部件,其中,所述多个碳材料区域和所述碳化硅材料形成砖块和灰浆结构,其中,所述多个碳材料区域相当于所述砖块结构,以及所述碳化硅材料相当于所述灰浆结构。
附图说明
图1是由多个单独的碳预成形件节段制成的示例陶瓷基复合材料部件的透视图。
图2A和图2B是可以用于形成图1的碳复合材料的碳预成形件节段的示例单层结构的示意性顶视图(图2A)和横截面图(图2B),图2C是图示了碳本体的碳预成形件节段的放大图。
图3A和图3B是可以用于形成图1的碳复合材料的碳预成形件节段的示例多层结构的示意性顶视图(图3A)和横截面图(图3B)。
图4是可以用于形成图1的碳复合材料的碳预成形件节段的另一示例交错结构的示意性顶视图。
图5是可以用于形成图1的碳复合材料的碳预成形件节段的另一示例交错结构的示意性顶视图。
图6是图示了根据蒸气压力和温度变化的硅的示例沸点曲线的相变图。
图7是图示了制造诸如图1的陶瓷基复合材料部件的陶瓷基复合材料部件的示例技术的流程图。
具体实施方式
本发明描述了利用多个碳预成形件节段/离散单元形成碳复合材料的技术,该多个碳预成形件节段/离散单元被共同地堆叠并被设置成所需形状并且反应性地结合在一起以便形成碳复合材料。所述碳预成形件节段的每一个可以包括与硅基混合物组合的碳泡沫或多个碳纤维。离散的碳预成形件节段可以具有均匀的或不同的大小以允许以以所需结构对准并堆叠从而形成所需形状(例如,盘制动器)。随后可以在可选的压缩之下加热堆叠结构以便引起硅基混合物的硅与碳泡沫或纤维的碳之间的反应性结合从而形成碳化硅(SiC),并且将各个碳预成形件节段结合在一起形成碳复合材料。在一些示例中,各个碳预成形件节段能够提供关于所得到的碳复合材料的物理架构的更大的控制程度以及可变性,例如包括,陶瓷基复合材料部件内的区域密度,诸如定向和总量的纤维架构等。
图1是由多个单独的碳预成形件节段制成的示例陶瓷基复合材料部件10的透视图。图2A和图2B是可以用于形成图1的碳复合材料的碳预成形件节段22a、22b、22c、22d(共同地作为“碳预成形件节段22”)的示例单层结构20的顶视图(图2A)和横截面图(图2B:沿着图2A的线A-A截取的横截面)。如图2A所示,碳预成形件节段22可以以交错结构对准(例如,偏置的砖块和灰浆式图案,其中,碳预成形件节段22之间的界面没有形成网格图案或者沿x和y方向线性连续)以便满足所需模型设计,诸如,盘制动器模型28。
各个碳预成形件节段22可以是任意合适的大小和形状。例如,碳预成形件节段22可以基本上是方棱柱形状(例如,如图2A和图2B中所示),盒体/立方体形状(例如,如图3A和图3B中所示)、多边棱柱形状(例如,三角形、矩形、五边形、六边形(例如,如图5中所示)等)或其组合。在一些示例中,碳预成形件节段22的大小和形状可以被设定成使得碳预成形件节段22之间的相邻面彼此密切地接触以便消除碳预成形件节段22之间的间隙并且确保相邻节段之间的充分结合。在一些示例中,碳预成形件节段22可以是大小均匀的以便证明高效的堆叠结构以及节段之间的可互换性。在一些示例中,碳预成形件节段的大小和形状的组合可以用于帮助减少在所得到的陶瓷基复合材料部件10内修改接缝架构的废料,如下面进一步所述。在一些示例中,取决于所需形状、行数、层数等,每个碳预成形件节段22的相对大小可以为大约5mm(毫米)至大约陶瓷基复合材料部件10的总厚度(例如,大约40mm)。例如,碳预成形件节段22可以包括限定大约10mm长度的至少一个表面。
在一些示例中,碳预成形件节段22的外表面可以包括一个或多个几何对准特征。例如,碳预成形件节段22的一个或多个表面可以包括与相邻的碳预成形件节段22的对应结构特征匹配并配对的结构特征,诸如,波状表面、突出部和凹陷等。在一些示例中,几何对准特征可以互锁或至少部分地互锁。几何对准特征可以用于提供碳预成形件节段22的更结实的堆叠结构以便减少间隙的存在并且确保在结合之前碳预成形件节段22的适当定位。额外地或替代地,几何对准特征可以通过中断结合接缝线的连续性(即,在结合的碳预成形件节段22之间形成的两个或更多个结合接缝的连续线)而在所得到的陶瓷基复合材料部件10中提供更大的结构整体性,使得所得到的结合接缝是非线性或至少部分地是非线性的。
在一些示例中,碳预成形件节段22可以包括由与硅基混合物组合的多个碳纤维形成的碳本体24。例如,图2C是图示了碳本体24的碳预成形件节段22d的放大图,碳本体24由涂覆有硅基混合物26的多个碳纤维构成。在一些示例中,形成碳本体24的多个碳纤维可以提供由碳纤维或者已经热解成碳纤维的碳前驱体纤维制成的碳纤维预成形件的形式。合适的碳前驱体纤维材料的示例可以包括例如聚丙烯腈(PAN)、氧化聚丙烯腈(O-PAN)、纤维素纤维(例如,人造丝或木质素)、沥青纤维等。纤维预成形件采用可以经受初始碳化循环的碳前驱体纤维构造以便在施加硅基混合物26之前将碳前驱体纤维转化为碳纤维。
在一些示例中,碳本体24可以包括结合在一起的碳纤维层。例如,多个碳纤维可以组合成已经堆叠并结合在一起的一层或多层网状纤维(例如,随机定向/缠绕的纤维)、丝束纤维、编织纤维或其组合。在一些示例中,纤维层能够通过针刺或戳刺不同层上的一些纤维以便将各层机械地结合在一起而结合,由此产生用于形成各个碳预成形件节段22的纤维预成形件。在一些示例中,纤维层可以包括在将各层结合在一起之后碳化的前驱体碳纤维。
在一些示例中,形成碳本体24的碳纤维可以选择性地定向以使得大部分碳纤维定向在所需方向上。例如,如图2C所示,形成碳本体24的纤维通常与页面垂直对准。在一些示例中,每个碳本体24内的碳纤维的定向能够用于在构造无法使用传统预成形件构造获得的陶瓷基复合材料部件10的纤维架构中提供更大程度的可变性和控制。例如,在单层结构20的组装期间,大部分碳预成形件节段(例如,碳预成形件节段22a、22b和22d)可以被设置成使得形成相应碳本体24的多个碳纤维通常在制动盘模型28的径向方向上对准,而一些节段(例如,碳预成形件节段22c)可以被设置成使得相应碳本体24的多个碳纤维通常在制动盘模型28的轴向方向对准。在一些示例中,每个碳预成形件节段22内的碳纤维的定向能够用于调整所得到的陶瓷基复合材料部件10的机械或热属性。例如,在制动盘模型28的径向方向上对准的碳纤维可以赋予部件更大的断裂强度,而在制动盘模型28的轴向方向上对准的碳纤维可以赋予大的剪切强度。额外地或替代地,碳纤维的定向和长度能够表现为将复合部件10的表面处产生的热量远离该表面传输至其他所需位置的热导管。
额外地,碳预成形件节段22的模块化设计允许在陶瓷基复合材料部件10的纤维架构的调整中的更大的控制程度以使得该复合材料部件最佳地适用于特定应用,而无需用于修改并形成传统碳纤维预成形件的大量的重新加工费用。
在一些示例中,用于碳预成形件节段22的碳本体24的相应纤维密度(例如,单位体积的纤维数量)可以是基本上均匀的以便产生具有相对均匀的纤维密度的陶瓷基复合材料部件10。在其他示例中,可以选择性地改变碳预成形件节段22的纤维密度以便产生包括变化的纤维密度的陶瓷基复合材料部件10。这样的设计灵活性可以允许设计者对于陶瓷基复合材料的特定区域选择性地增加纤维密度以便修改所选区域的强度特性。
在一些示例中,碳本体24可以由涂覆有硅基混合物26的碳泡沫构成。碳泡沫可以包括建立多孔泡沫碳本体24的碳材料的三维交联网络。可以在惰性环境中利用沥青的高温分解来制造碳泡沫。在高温分解之前,沥青材料的交联程度可以用于控制碳本体24内的泡沫/多孔性的程度。在高温分解之前沥青材料内的交联越多,所产生的多孔性越小。与由碳纤维制成的预成形件相反,碳泡沫的预成形件可以被视作是碳材料的基本上连续的联接网络。
在一些示例中,每个碳预成形件节段22的相应碳本体24(例如,碳纤维或碳泡沫)可以在被涂覆有硅基混合物26之前至少部分地密化。可以使用任意合适的密化技术。例如,碳本体24能够使用例如树脂渗透碳化而初始地密化。合适的树脂材料的示例可以包括:例如,热固性树脂,例如其包括呋喃、酚(例如,联苯醚甲醛)、聚酰亚胺等;热塑性树脂,例如其包括煤焦油、石油、或人造沥青、聚醚醚酮(PEEK)、聚醚酰亚胺(PEI)、聚苯并咪唑(PBI)、聚芳基乙炔树脂等。在其他示例中,能够使用化学气相渗透(CVI)或化学气相沉积(CVD)初始地密化碳纤维预成形件以便实现展现所需初始密度的碳预成形件。合适的CVI/CVD材料可以包括与其他轻烷烃或烯烃混合的甲烷。
在一些示例中,与密化目标大小和形状相当(例如,当堆叠并设置成陶瓷基复合材料部件10的形状时碳预成形件节段22的大小和形状)的单个碳预成形件结构所需的时间和花费相比,每个碳预成形件节段22的相对大小可以显著地减少共同密化所有碳预成形件节段22内的相应碳本体24所需的时间和花费。例如,与密化碳预成形件相关联的一个特别挑战是将足够量的碳材料输送/形成至预成形件本体的中心中。例如,当使用CVI/CVD密化工艺时,碳材料的输送参数通常取决于预成形件本体的表面积(例如,流入点),预成形件内的开口的大小,以及碳材料到达预成形件本体中心必须行进的距离。在一些示例中,在预成形件本体的表面区域内的碳材料的沉积/形成能够抑制额外的碳材料到达预成形件本体的中心的能力,从而导致预成形件本体内的密度梯度并且限制预成形件能够被密化的量。额外地或替代地,碳材料必须行进的相对较大距离通常与较长的处理时间相关。由于每个碳预成形件节段22的相对小的大小和形状,碳材料到达预成形件段22的中心必须行进的距离保持相对小,由此减少或避免了与密化较大预成形件本体相关联的多个负载问题。在一些示例中,与类似大小的碳纤维预成形件的常规处理时间相比,用于共同密化碳预成形件节段22的处理时间可以减少多达1/6。
碳预成形件节段22在涂覆有硅基混合物26之前的初始密度可以是任何合适的量并且可以部分地取决于用于陶瓷基复合材料部件10的所需应用。在一些示例中,每个碳预成形件节段22可以初始地密化至基本上相同程度以形成具有基本上均匀密度的陶瓷基复合材料部件10(例如,考虑陶瓷基复合材料部件10的本体的均匀或近似均匀的密度)。在其他示例中,各个碳预成形件节段22可以密化至不同程度。例如,朝向单层结构20的内部区域的碳预成形件节段22(诸如,节段22c)或者更靠近于制动盘模型28的内直径的那些节段可以被密化至更大的程度以便向所得到的陶瓷基复合材料部件10的本体内的特定区域提供更大的强度。在包括多层结构(例如图3B的多层结构30)的一些示例中,该结构的内部层或叠层(例如,层34b)可以密化至比外部层或叠层(例如,层34a和34c)更大的程度以便帮助减小所施加的任何结合后的密化周期的量和持续时间。在一些示例中,在用硅基混合物26涂覆之前,碳预成形件节段22的密度可以为大约1.75克每立方厘米(g/cc)至大约1.89g/cc。在一些示例中,在用硅基混合物26涂覆之前,碳预成形件节段22的密度可以为至少1.8g/cc。
碳预成形件节段22包括施加至下层碳本体24的硅基混合物26。硅基混合物26可以包括在载体流体中的硅颗粒。硅颗粒可以具有任何合适的大小以便允许充分渗透至碳预成形件节段22的至少外表面区域中。在一些示例中,硅颗粒可以小于大约30µm。例如,硅颗粒可以具有大约20µm的平均大小。
硅基混合物26可以包括任何合适的载体流体,例如包括蒸馏水、乙醇、碳氢化合物等。在一些示例中,硅基混合物26可以初始地制备为包括相对于载体流体的体积大于大约百分之五十的重量体积比(%w/v),例如大约58%w/v的硅颗粒。
在一些示例中,硅基混合物26可以包括一种或多种添加剂。例如,硅基混合物26可以包括粘附促进剂以便在进行反应性结合之前有助于将硅颗粒固定至下层碳本体24,并且在反应性结合工艺期间从碳预成形件节段22基本上移除(例如,烧蚀)。可以使用任何合适的粘附促进剂,例如,氨、藻酸铵、琼脂、琼脂糖等。额外地或替代地,硅基混合物26可以包括一种或多种表面活性剂以便在涂覆工艺期间辅助运输硅颗粒。在一些示例中,基于载体流体的体积,一种或多种添加剂可以以大约2%w/v(例如,2.15%w/v)的量而存在。
可以使用任何合适的技术(例如包括浸渍涂覆、浆膏喷涂、滑移施加等)将硅基混合物26施加至碳预成形件节段22的下层碳本体24。一旦涂覆至碳本体24中,可以在将各节段结合在一起之前从碳预成形件节段22基本上移除(例如,移除或几乎移除)硅基混合物26的载体流体。在一些示例中,可以通过使用加热气体干燥碳预成形件节段22而移除载体流体。在其他示例中,在硅和碳的反应点之前在加热阶段中作为反应性结合工艺的一部分而移除载体流体。
可以将任何合适量的硅材料添加至碳本体24。在一些示例中,可以添加硅材料以便在碳预成形件节段22的相应结合表面上以大约+35%至-10%的公差而实现大约0.15g/cm2的硅颗粒的覆盖率。硅覆盖率的总量将最终基于在结合时的碳本体24的密度和/或多孔率。
虽然图2A和图2B示出了对准为单层结构20的碳预成形件节段22,但在其他示例中,碳预成形件节段22可以堆叠并对准以形成多层结构,该多层结构包括至少两叠层(例如,层)的堆叠的碳预成形件节段22。例如,图3A和图3B是可以用于形成图1的碳复合材料10的碳预成形件节段32的示例多层结构30的顶视图(图3A)和横截面图(图3B,沿着图3A的线B-B截取)。如图3B中所示,在一些示例中,碳预成形件节段32的交错结构可以持续整个多层堆体30以使得相应层34a、34b、34c内的碳预成形件节段32与相邻层的碳预成形件节段32偏移。该交错结构可以用于帮助在整个多层堆体30的碳预成形件节段32之间分散接缝位置,以便减小在堆体内存在的连续接缝线的总数量(即,在结合的碳预成形件节段32之间形成的两个或更多个结合接缝的连续线),该连续接缝线例如另外将出现在标准网格结构中。在一些示例中,在整个多层堆体30中分散接缝可以通过将施加在部件上的任何机械应力通过部件的本体分散而不是沿着特定连续接缝线分散从而增大所得到的部件(例如,陶瓷基复合材料部件10)的强度。
虽然图3B图示了包括碳预成形件节段32的离散层34a、34b、34c的多层堆体30,但在一些示例中碳预成形件节段32的大小和形状可以被设计成使得碳预成形件节段32在垂直方向(例如,在页面中的上下方面)交错堆叠。在这样的示例中,多层堆体30可以缺少离散层,但仍然包含多层碳预成形件节段32以使得多层堆体30的高度大于单个碳预成形件节段32的高度。
图4提供了能够用于形成陶瓷基复合材料部件10的碳预成形件节段42、44的示例交错结构40的另一示意性顶视图。交错结构40可以是单层或多层结构。在一些示例中,交错结构40可以包括矩形碳预成形件节段42与方形碳预成形件节段44的组合。在一些示例中,不同形状和大小的碳预成形件节段42、44的组合能够在整个交错结构40中叠置以便减少连续接缝线的存在、中断或以其他方式断开该接缝线的连续性或其组合。额外地或替代地,能够使用具有不同形状和大小的碳预成形件节段42、44的组合以便减少废料的量(例如,在结合之后为了将陶瓷基复合材料部件10成形为所需构造而需要移除的碳预成形件节段的本体)。
图5提供了能够用于形成陶瓷基复合材料部件10的碳预成形件节段52的示例交错结构50的另一示意性顶视图。交错结构50可以是单层或多层结构。在一些示例中,交错结构50可以包括形状为多面棱柱(诸如,图5所示的五角棱柱、六角棱柱等)的多个碳预成形件节段52。在一些示例中,碳预成形件节段52的多面形状可以帮助减小在将交错结构50结合并成形至盘制动器模型28之后所产生的废料的量。额外地或替代地,碳预成形件节段52的多面形状能够帮助减少、中断和/或消除所得到的陶瓷基复合材料部件10中的连续接缝线的存在。
一旦已经以任何所需形状和图案堆叠并设置了碳预成形件节段,可以将碳预成形件节段加热以便熔化硅基混合物26的硅(例如,加热至大于约1414℃),并引起硅与碳预成形件节段(例如,碳本体24)内的碳之间的反应性结合。
在一些示例中,加热和反应性结合可以发生在基本上无氧的环境中(例如,无氧或者包含微量的氧)以便最小化在反应性结合期间经历氧化的硅材料的量或者最小化氧引起的副反应的存在。在一些示例中,基本上无氧的环境可以通过在局部真空下加热碳预成形件节段而建立。局部真空相对于全真空可能是优选的以便防止硅在熔化时气化。图6示出了相变图(P.D.Desai,Thermodyamics Properties of Iron and Silicon,J.Phys.Chem.Ref.Data[15](3)967-983(1985)),其图示了根据蒸气压力和温度变化的硅的示例沸腾曲线。区域60表示压力和温度范围,其可以适于在硅和碳材料之间引起反应性结合。在一些示例中,反应可以在大约1e-3 Torr(托)的局部真空以及大约1450℃的温度下进行。在一些示例中,基本上无氧的环境也可以包括一种或多种氧吸收剂以便进一步减少环境中存在的氧的量。在其他示例中,基本上无氧的环境可以利用例如包括氮气、氩气等的惰性气体而建立。
经由将碳预成形件节段反应性地结合在一起而形成的所得到的陶瓷基复合材料部件10可以包括具有碳化硅的碳-碳-碳化硅复合材料结构。例如,反应性结合碳预成形件节段可以形成呈现出具有砖块和灰浆复合材料本体的陶瓷基复合材料部件,其具有限定的碳材料区域(例如,砖块区域)以及相当于硅材料与碳反应所形成的反应接缝的限定的碳化硅材料区域(例如,灰浆区域)。在一些示例中,与采用熔融硅渗透的相当的单体预成形件相比,碳化硅在整个结构中的存在可以修改所得到的陶瓷基复合材料部件10的机械强度属性、摩擦属性或热特性中的一个或多个。
任何合适的层数以及任何合适数量的碳预成形件节段22、32、42、44、52可以用于形成陶瓷基复合材料部件10。在一些示例中,陶瓷基复合材料部件10可以由至少两叠层(例如,层)碳预成形件节段22、32、42、44、52形成,并且每层包括大约1000量级的单独的碳预成形件节段22、32、42、44、52(例如,两层堆体可以包括大约2000个单独的碳预成形件节段)。
可以使用任何合适的技术形成本文中描述的碳预成形件节段和所得到的陶瓷基复合材料部件。图7是形成本文中描述的碳预成形件节段和陶瓷基复合材料部件的示例性方法的流程图。虽然同时参照图1至图3的概念图描述了图7的技术,但在其他示例中,图7的技术可以用于形成其他碳预成形件节段和复合材料部件,或者可以使用不同于图7中所述的技术来形成图1至图3的物品。
图7的技术包括:形成多个碳本体24(70);用硅基混合物26涂覆多个碳本体24以形成多个碳预成形件节段(72);以交错结构设置多个碳预成形件节段22(74);加热多个碳预成形件节段22以便使多个碳预成形件节段22反应性结合在一起从而形成陶瓷基复合材料部件10(76);以及对陶瓷基复合材料部件施加CVI/CVD(78)。
能够使用任何合适的技术形成碳本体24(70)。如上所述,多个碳预成形件节段22的相应碳本体24可以由多个碳纤维、已经经历碳化以形成碳纤维的碳前驱体纤维、或者大小和形状已经被设计成形成相应碳预成形件节段22的碳本体24的碳泡沫形成。在碳本体24包括碳纤维的一些示例中,可以以任何合适的结构设置碳纤维。例如,多个碳纤维可以组合成已经堆叠并结合(例如,针刺)在一起的一层或多层网状纤维(例如,随机定向/缠绕的纤维)、丝束纤维、编织纤维或其组合。在一些示例中,碳纤维可以选择性地定向以使得单个碳预成形件节段22内的大多数碳纤维沿所需方向对准。
在一些示例中,碳本体24可以在涂覆有硅基混合物26之前至少部分地密化。如上所述,可以使用任何合适的密化技术,例如包括树脂渗透碳化、CVI、CVD或类似的密化工艺。
图7的技术包括用硅基混合物26涂覆碳本体24(72)。如上所述,硅基混合物可以包括混合在载体流体(诸如,蒸馏水、乙醇、碳氢化合物等)中的硅颗粒。在一些示例中,硅基混合物可以包括一种或多种任选的添加剂,例如包括粘附促进剂(诸如,藻酸铵、琼脂、琼脂糖等);表面活性剂;抗氧化剂;碳源材料等。
在一些示例中,碳预成形件节段22可以被机加工成所需大小和形状以便在各节段之间提供足够的对准和可堆叠性。在一些示例中,碳预成形件节段22可以具有大约5mm至大约40mm的相对大小。在一些示例中,碳预成形件节段22可以具有大约5mm至大约陶瓷基复合材料部件10的一半厚度(例如,大约20mm)的相对大小。
一旦用硅基混合物26涂覆了碳本体24(76),碳预成形件节段22可以设置成交错结构(74)(例如,单层结构20,多层结构30,交错结构40、50等)。在一些示例中,与栅格结构相反的交错结构可以减少或分散在所得到的陶瓷基复合材料部件10内的结合接缝线的存在,这可以帮助在整个陶瓷基复合材料部件10中在接缝上而更均匀地分布机械力。在一些示例中,交错结构可以包括单层结构20或多层结构30。
在对准之后,可以加热碳预成形件节段22以便将多个碳预成形件节段22反应性结合在一起从而形成陶瓷基复合材料部件10(76)。在一些示例中,可以均匀地加热碳预成形件节段22以便熔化硅(例如,大于大约1414℃)并且在硅与碳本体24的碳之间引起反应以便产生碳化硅(SiC)。在一些示例中,该加热过程可以在基本上无氧的环境中进行,例如包括惰性气体环境(例如,氩气或氮气)或在局部真空下(例如,大约1e-3 Torr)进行。可选地,可以使用一个或多个氧气吸附剂以捕获微量的氧。
在一些示例中,可以在加热过程期间机械地压缩碳预成形件节段22以基本上消除(例如,消除或几乎消除)交错结构20、30、40、50内沿着结合接缝的任何间隙的存在。例如,碳预成形件节段22可以放置在圆形夹具或弹性模具中,该圆形夹具或弹性模具环绕交错结构20并且施加径向压力至碳预成形件节段22。在包括多层结构30的一些示例中,可以施加额外的压缩力至多层结构30的两个主表面以将层(例如,层34a、34b、34c)或叠层压缩在一起。
一旦已经结合,随后可以对所得到的陶瓷基复合材料部件10进行加工,例如包括机械加工成所需形状(例如,制动盘),进一步通过对陶瓷基复合材料部件施加CVI/CVD而密化(78),热处理(例如,在大于大约1600℃的温度下石墨化)、局部处理(例如,局部施加抗氧化剂涂层或密封剂)等。
已经描述了各个示例。这些及其他示例均在以下权利要求的范围内。
Claims (3)
1.一种用于形成陶瓷基复合材料部件的方法,所述方法包括:
以交错二维结构对准多个碳预成形件节段以形成所述多个碳预成形件节段的至少一个层,其中,每个碳预成形件节段限定了包括多个直边的相应的形状,其中,所述多个碳预成形件节段被对准以使得相邻的碳预成形件节段的相应的直边邻接并形成所述交错二维结构,其中,所述碳预成形件节段之间的界面没有形成网格图案并且没有沿所述交错二维结构的两个维度线性连续,并且其中,所述多个碳预成形件节段中的每个碳预成形件节段包括:
碳本体,所述碳本体包括多个碳纤维或碳泡沫中的至少一个,以及
硅基混合物,所述硅基混合物包括涂覆在所述碳本体上的硅颗粒;以及
加热所述交错二维结构以便使所述硅颗粒与所述碳本体反应从而使所述多个碳预成形件节段结合在一起并且形成所述陶瓷基复合材料部件。
2.根据权利要求1所述的方法,其中,以所述交错二维结构对准所述多个碳预成形件节段进一步包括形成所述多个碳预成形件节段的多层结构。
3.一种碳预成形件组件,所述碳预成形件组件包括:
多个碳预成形件节段,所述多个碳预成形件节段以交错二维结构对准,其形成所述碳预成形件组件的至少一个层,其中,每个碳预成形件节段限定了包括多个直边的相应的形状,其中,所述多个碳预成形件节段被对准以使得相邻的碳预成形件节段的相应的直边邻接并形成所述交错二维结构,其中,所述碳预成形件节段之间的界面没有形成网格图案并且没有沿所述交错二维结构的两个维度线性连续,并且其中,所述多个碳预成形件节段中的每一个包括:
碳本体,所述碳本体包括多个碳纤维或碳泡沫;以及
硅基混合物,所述硅基混合物包括沉积在所述碳本体上的硅颗粒。
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