CN109291544A - 一种碳/碳复合材料厚板的预制体结构及厚板制备方法 - Google Patents
一种碳/碳复合材料厚板的预制体结构及厚板制备方法 Download PDFInfo
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Abstract
一种碳/碳复合材料厚板的预制体结构及厚板制备方法,所述预制体结构包括芯层和胎网层,所述芯层为厚度为20‑40mm的碳纤维毡,所述胎网层为针刺在芯层两侧的碳纤维网胎。所述厚板制备方法是将所述的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程,直至得到的碳/碳复合材料密度达到设计要求。本发明的碳/碳复合材料厚板的预制体结构,利用网胎层作为碳源气传送介质,将碳源气均匀导向芯层,降低芯层厚度方向的密度差,解决芯层的表面封孔问题,制备高密度碳/碳复合材料厚板,其厚度为20‑40mm、密度为0.4‑0.8g/cm3。
Description
技术领域
本发明涉及一种碳/碳复合材料厚板的预制体结构及碳/碳复合材料厚板制备方法,特指一种化学气相渗碳制备高密度碳/碳复合材料厚板的预制体结构及厚板制备方法。属于化学气相渗碳技术领域。
背景技术
化学气相渗碳是制备高性能碳/碳复合材料的优选方法,它通过在高温下将碳源气中的碳分解、沉积到碳纤维表面而实现,其效率取决于碳纤维表面的碳源气浓度。碳源气是通过碳/碳复合材料表面向内部传送的,在化学气相渗碳过程中,由于表面碳源气充足,优先渗碳,密度较高;内部碳源气较少,滞后渗碳,密度较低,在碳/碳复合材料厚度方向形成由表及里的密度差。当表面密度达到一定数值,如1.85g/cm3以上时,产生表面封孔效应,必须机加工去除表面封孔层,渗碳过程才能继续进行。现有碳/碳复合材料预制体结构是将碳纤维网胎针刺成一定厚度的平板毡,随着平板毡厚度的增加,化学气相渗碳过程中,表面封孔效应加剧,复合材料的整体增密效率降低,因此采用现有碳/碳复合材料预制体结构难以获得高密度碳/碳复合材料厚板。
发明内容
本发明的目的在于克服现有技术之不足而提供一种碳/碳复合材料厚板的预制体结构及碳/碳复合材料厚板的制备方法。本发明的预制体结构,利用网胎层作为碳源气传送介质,将碳源气均匀导向芯层,降低芯层厚度方向的密度差,解决芯层的表面封孔问题,制备高密度碳/碳复合材料厚板。本发明的碳/碳复合材料厚板的制备方法可以制备出密度均匀、密度梯度小的碳/碳复合材料厚板。
本发明一种碳/碳复合材料厚板的预制体结构,所述预制体结构包括芯层和胎网层,所述芯层为厚度为20-40mm的碳纤维毡,所述胎网层为针刺在芯层两侧的碳纤维网胎。
本发明一种碳/碳复合材料厚板的预制体结构,所述芯层的碳纤维毡为碳纤维针刺整体毡或碳纤维三维编制毡,密度为0.4-0.8g/cm3。
本发明一种碳/碳复合材料厚板的预制体结构,所述胎网层的碳纤维为T700,网胎层厚度为2-10mm、密度为0.1-0.3g/cm3。
本发明一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程,直至得到的碳/碳复合材料密度达到设计要求;每次化学气相渗碳增密工艺参数为:以丙烯或天然气为碳源气,控制炉温为900-1200℃、炉压为1-15kPa,化学气相渗碳50-200h。
本发明一种碳/碳复合材料厚板的制备方法,石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2000-2300℃、保温时间为1-2h,随炉冷却。
本发明一种碳/碳复合材料厚板的制备方法,机加工是将经过石墨化处理的工件进行胎网层表面加工,表面加工每次去皮量厚度为1-3mm。
本发明一种碳/碳复合材料厚板的制备方法,碳/碳复合材料厚板预制体结构中,芯层厚度为20-40mm,密度为0.4-0.8g/cm3。
本发明一种碳/碳复合材料厚板的制备方法,渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为20-40mm,密度为1.75-1.85g/cm3。
优点及积极效果
本发明以碳纤维编织体为芯层,厚度为20-40mm、密度为0.4-0.8g/cm3,将碳纤维网胎针刺到芯层两侧形成网胎层,制备碳/碳复合材料预制体,经过化学气相渗碳、石墨化、表面机加工,利用网胎层作为碳源气传送介质,将碳源气均匀导向芯层,降低芯层厚度方向的密度差,解决芯层的表面封孔问题,制备出厚度为20-40mm、密度为1.75-1.85g/cm3的碳/碳复合材料。
本发明利用网胎层作为碳源气传送介质,将碳源气均匀导向芯层,降低芯层厚度方向的密度差,解决芯层的表面封孔问题,制备高密度碳/碳复合材料厚板。其机理及优点简述于下:
1、本发明的网胎层,内部存在大量微米尺度的孔隙,成为碳源气的有效通道,将碳源气均匀导向芯层,实现芯层均匀化学气相渗碳,降低芯层厚度方向的密度差。
2、本发明采用网胎层的初始碳纤维密度与芯层初始碳纤维密度的匹配,使网胎层的初始碳纤维密度小于芯层初始碳纤维密度,使得芯层中碳纤维的比表面积较网胎层更大,芯层中碳纤维对碳源气的吸附更强、渗碳效率更高,实现在渗碳后,芯层获得高于网胎层的密度。
3、本发明的网胎层,作为保护层,将表面封孔控制在该层内,保护芯层不受表面封孔效应影响;
4、本发明的碳/碳复合材料预制体结构,可用于制备高密度碳/碳复合材料厚板,其厚度为20-40mm、密度为0.4-0.8g/cm3。
附图说明
附图1为本发明碳/碳复合材料预制体结构示意图;
图中:1--胎网层,2---芯层;芯层两侧设有网胎层。
具体实施方式
实施例1:
参见附图1,一种碳/碳复合材料厚板的预制体结构,所述预制体结构包括芯层和胎网层,所述芯层为厚度为20-40mm的碳纤维毡,所述胎网层为针刺在芯层两侧的碳纤维网胎;
所述芯层的碳纤维毡为碳纤维针刺整体毡或碳纤维三维编制毡,密度为0.4-0.8g/cm3;
所述胎网层的碳纤维为T700,网胎层厚度为2-10mm、密度为0.1-0.3g/cm3。
实施例2
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程1次,得到的碳/碳复合材料密度为1.85g/cm3;
每次化学气相渗碳增密工艺参数为:以丙烯或天然气为碳源气,控制炉温为900℃、炉压为1kPa,化学气相渗碳50h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2000℃、保温时间为1h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为1mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为20mm,密度为0.8g/cm3;网胎层的厚度为2mm、密度为0.3g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为20mm,密度为1.85g/cm3。
实施例3:
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程4次,得到的碳/碳复合材料密度为1.80g/cm3;
每次化学气相渗碳增密工艺参数为:以丙烯为碳源气,控制炉温为950℃、炉压为6kPa,化学气相渗碳100h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2300℃、保温时间为2h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为2mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为40mm,密度为0.6g/cm3;网胎层的厚度为10mm、密度为0.1g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为40mm,密度为1.80g/cm3。
实施例4:
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程3次,得到的碳/碳复合材料密度为1.78g/cm3;
每次化学气相渗碳增密工艺参数为:以丙烯为碳源气,控制炉温为1000℃、炉压为15kPa,化学气相渗碳80h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2200℃、保温时间为2h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为3mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为30mm,密度为0.4g/cm3;网胎层的厚度为8mm、密度为0.2g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为30mm,密度为1.78g/cm3。
实施例5:
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程1次,得到的碳/碳复合材料密度为1.82g/cm3;
每次化学气相渗碳增密工艺参数为:以丙烯为碳源气,控制炉温为950℃、炉压为10kPa,化学气相渗碳200h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2100℃、保温时间为2h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为2mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为20mm,密度为0.6g/cm3;网胎层的厚度为4mm、密度为0.14g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为20mm,密度为1.82g/cm3。
实施例6:
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程2次,得到的碳/碳复合材料密度为1.81g/cm3;
每次化学气相渗碳增密工艺参数为:以丙烯为碳源气,控制炉温为1200℃、炉压为3kPa,化学气相渗碳100h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2100℃、保温时间为2h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为3mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为30mm,密度为0.4g/cm3;网胎层的厚度为9mm、密度为0.2g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为30mm,密度为1.81g/cm3。
实施例7:
一种碳/碳复合材料厚板的制备方法,是将碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程4次,得到的碳/碳复合材料密度为1.75g/cm3;
每次化学气相渗碳增密工艺参数为:以天然气为碳源气,控制炉温为1100℃、炉压为5kPa,化学气相渗碳120h;
石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2200℃、保温时间为2h,随炉冷却;
机加工是将经过石墨化处理的工件进行胎网层表面加工,每次表面加工去皮量厚度为2mm;
碳/碳复合材料厚板预制体结构中,芯层厚度为40mm,密度为0.7g/cm3;网胎层的厚度为10mm、密度为0.1g/cm3;
渗碳增密完成后,机加工去除胎网层,得到芯层的碳/碳复合材料厚度为40mm,密度为1.75g/cm3。
Claims (8)
1.一种碳/碳复合材料厚板的预制体结构,其特征在于:所述预制体结构包括芯层和胎网层,所述芯层为厚度为20-40mm的碳纤维毡,所述胎网层为针刺在芯层两侧的碳纤维网胎。
2.根据权利要求1所述的一种碳/碳复合材料厚板的预制体结构,其特征在于:所述芯层的碳纤维毡为碳纤维针刺整体毡或碳纤维三维编制毡,密度为0.4-0.8g/cm3。
3.根据权利要求2所述的一种碳/碳复合材料厚板的预制体结构,其特征在于:所述胎网层的碳纤维为T700,网胎层厚度为2-10mm、密度为0.1-0.3g/cm3。
4.一种碳/碳复合材料厚板的制备方法,是将权3所述的碳/碳复合材料厚板的预制体结构置于化学气相渗碳炉中,进行化学气相渗碳增密后,依次进行石墨化处理、机加工;重复上述工艺过程,直至得到的碳/碳复合材料密度达到设计要求;每次化学气相渗碳增密工艺参数为:以丙烯或天然气为碳源气,控制炉温为900-1200℃、炉压为1-15kPa,化学气相渗碳50-200h。
5.根据权利要求4所述的一种碳/碳复合材料厚板的制备方法,其特征在于:石墨化处理制度为:控制炉内气氛为氩气0.11-0.13MPa、炉温为2000-2300℃、保温时间为1-2h,随炉冷却。
6.根据权利要求4所述的一种碳/碳复合材料厚板的制备方法,其特征在于:机加工是将经过石墨化处理的工件进行胎网层表面加工,表面加工每次去皮量厚度为1-3mm。
7.根据权利要求4所述的一种碳/碳复合材料厚板的制备方法,其特征在于:碳/碳复合材料厚板预制体结构中,芯层厚度为20-40mm,密度为0.4-0.8g/cm3。
8.根据权利要求4-7任意一项所述的一种碳/碳复合材料厚板的制备方法,其特征在于:制备得到的碳/碳复合材料厚板的厚度为20-40mm,密度为1.75-1.85g/cm3。
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