CN110062750B - 用于纤维预制件气相化学渗透的成型设备和设施 - Google Patents

用于纤维预制件气相化学渗透的成型设备和设施 Download PDF

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CN110062750B
CN110062750B CN201780076293.3A CN201780076293A CN110062750B CN 110062750 B CN110062750 B CN 110062750B CN 201780076293 A CN201780076293 A CN 201780076293A CN 110062750 B CN110062750 B CN 110062750B
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S·泰鲍德
A·戴尔坎普
S·波特兰德
S·戈贾德
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Abstract

本发明涉及用于纤维预制件化学气相渗透的成型设备(100)，其包括：由支撑件(140、170)形成的结构封壳，所述支撑件各自具有多穿孔区(141；171)。支撑件(140、170)在其内表面上包含未封闭区域(143；173)，所述未封闭区域(143；173)包括多穿孔区。成型设备(100)还包括第一和第二成型模具功能元件(120、150)，各成型模具功能元件分别存在于支撑件的未封闭区域中。各成型模具功能元件具有第一面(120a；150a)和第二面(120b；150b)，该第一面(120a；150a)具有与待生产部件的形状相对应的确定形状，该第二面(120b；150b)保持成使其面向支撑件内表面。各功能元件包括多个穿孔(121；151)，并且穿孔的数量、穿孔的尺寸或穿孔的几何形状不同于存在于面对的支撑件上的穿孔的数量、尺寸或几何形状。

Description

用于纤维预制件气相化学渗透的成型设备和设施
发明背景
本发明涉及用复合材料制造部件，更具体地，涉及在通过纤维预制件化学气相渗透进行固结和/或致密化期间使用的成型工具，所述纤维预制件将形成复合材料部件的增强物。
本发明申请的领域是由热结构性的复合材料制备部件，即，由这样的复合材料制备的部件，所述复合材料呈现出使其适合构建结构部件的机械性质并在直至高温下保持这些性质的能力。热结构复合材料的常规示例是碳/碳(C/C)复合物和陶瓷基质复合物(CMC)，碳/碳(C/C)复合物具有由被热解碳基质致密化的碳纤维制成的加强织构，所述陶瓷基质复合物(CMC)具有由被陶瓷基质致密化的耐火纤维(碳或陶瓷)制成的加强织构。
用于使纤维预制件固结或致密化以制造C/C或CMC复合部件的熟知的方法是化学气相渗透(CVI)。将用于固结或致密化的纤维预制件置于多穿孔成型工具中，所述成型工具本身放置在反应器或烘箱中进行加热。将反应物气体引入反应器中，所述反应物气体含有一种或多种构成基质的材料的气态前体。对反应器中的温度和压力进行调整以使得反应物气体通过成型器中的穿孔在预制件的孔中扩散，并且通过使得反应物气体的一种或多种组分分解、或通过多种组分之间的反应在预制件的孔中形成构成基质的材料的沉积物，这些组分形成基质的前体。中间相材料也可以通过该方法与基质一起沉积。
然而，固结和/或致密化技术在某些情况下可能导致在纤维预制件厚度方向上出现基质沉积梯度，并且导致在预制件表面出现局部额外厚度或“泡”。特别是，在预制件表面和芯部之间，所沉积的基质厚度或质量可以以5倍系数变化。这些缺陷主要是由于纤维预制件的特征(预制件的厚度、纤维的性质、织法等)与成型器的结构特征(穿孔的数量、尺寸和穿孔的形状等)之间的不匹配。
发明目的和概述
因此，本发明的一个目的是为成型工具提供一种解决方案，其中，结构特性可以限定为待固结和/或致密化的纤维预制件的函数(function)。
该目的通过用于纤维预制件化学气相渗透的成型工具来实现，该工具包括由至少第一支撑件和第二支撑件形成的结构封壳，所述第一支撑件具有由第一接触平面围绕的第一多穿孔区，并且所述第二支撑件具有由第二接触平面围绕的第二多穿孔区，该第一支撑件和第二支撑件通过第一和第二接触区保持彼此相对，该工具的特征在于，第一支撑件在其内表面上包括第一外露区，所述第一外露区包括第一多穿孔区，第二支撑件在其内表面中包括第二外露区，所述第二外露区包括第二多穿孔区，并且成型工具还至少包括分别存在于第一和第二支撑件的第一和第二外露区中的第一和第二成型模具功能元件，各成型模具功能元件具有第一面和第二面，所述第一面具有对应于待制造部件形状的确定形状，所述第二表面保持面向支撑件的内表面，各成型模具功能元件具有多个穿孔并且呈现出至少一种与存在于面对的支撑件中的穿孔数量、穿孔尺寸、穿孔形状不同的穿孔数量、穿孔尺寸、穿孔形状。
因此，本发明的成型工具具有可拆卸的成型模具功能元件，其中，穿孔的尺寸、数量和/或形状可以限定为待固结或致密化的纤维预制件的特征的函数，以使得待沉积的基质和/或中间相以更均匀的方式沉积在所讨论的预制件中。因此，可以制备机械性质得以改进的复合材料部件。
本发明的成型工具可以非常灵活地进行适配，同时限制该适配的成本。具体来说，当使成型工具适应特定纤维预制件时，仅需要改变成型模具功能元件，同时保持工具的主要部分，即，形成结构封壳的支撑件。
根据本发明的成型工具的第一特征，将多孔消耗层(porous depletion layer)插入结构封壳的各支撑件的内表面和成型模具功能元件的第二面之间，所述第二面被保持为面对支撑件内表面。
通过在气相到达纤维预制件之前消耗掉消耗层中的一部分气相前体气体来减少沉积在纤维预制件表面上的基质量，从而避免预制件表面处的孔被快速堵塞并使孔阵列保留更长的时间，使得气相能够流到预制件的芯部。因此，由此获得在整个预制件厚度上更均匀的基质沉积物，并且预制件内的沉积梯度受到限制。
特别是，多孔消耗层可以选自以下织构之一：碳垫、二维碳织物、碳毡。
根据本发明成型工具的第二特性，支撑件和成型模具元件由选自以下材料的至少一种材料制成：石墨、碳/碳(C/C)复合材料和陶瓷基质复合材料(CMC)。
本发明还提供一种用于放置在用于通过化学气相渗透进行致密化的装置中的装料(charge)，所述装料包括保持在本发明成型工具中的纤维预制件。
如上所述，用本发明的成型工具制成的这种装料不仅用于用更均匀的基质或中间相沉积物使预制件固结或致密化，而且还用于避免在预制件的表面形成局部的额外厚度或“泡”。
根据本发明的装料的具体方面，纤维预制件是用于航空发动机部件的预制件。
本发明还提供了一种组件，该组件包括用于通过化学气相渗透使纤维预制件致密化的装置，所述装置包括反应室、位于反应室的第一端并通向预热区的反应物气体进料管以及位于第二端附近的排出管；并且还包括位于装置反应室中的至少一种本发明装料。
本发明还提供了一种制造复合材料部件的方法，所述方法包括：
-将纤维预制件置于本发明的成型工具中；
-通过化学气相渗透用基质使得纤维预制件固结；以及
-使得固结的纤维预制件致密化。
附图说明
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是显示在本发明一实施方式中成型工具如何组装并填装纤维预制件的分解图；
-图2是图1工具一旦组装后从上方看到的视图；
-图3是参照III时图2工具的截面视图；
-图4是参照IV时图2工具的截面视图；
-图5显示出成型器模块元件的变体实施方式；以及
-图6是用于用于通过化学气相渗透进行致密化的装置的示意性透视图，该装置包括由图1的工具和纤维预制件构成的装料。
具体实施方式
本发明应用于用复合材料制造部件，特别是用热结构复合材料制造部件。更具体地，本发明发现在通过化学气相渗透使纤维预制件固结和/或致密化的步骤中有益的应用。
图1显示根据本发明实施方式的装料的制备，包括：将纤维预制件10安装在成型工具100中。一旦制成，将装料插入工业化学气相渗透装置的反应室。在当前所述的示例中，工具100用于接收板形式的纤维预制件，其特别用于特征化复合材料。本发明的成型工具可以用于接收纤维预制件和使之成型，以制造各种形状的部件，例如，用于航空发动机的叶片或可移动喷嘴襟翼(nozzle flap)。
纤维预制件10对应于“干燥”的纤维织构，即，没有用树脂等浸渍。纤维织构可以由多种类型的纤维制成，特别是由陶瓷纤维(例如，碳化硅纤维)或碳纤维制成。所用的纤维织构可具有多种类型和形状，具体例如为如下：
-·二维(2D)织物；
-·三维(3D)织物，其通过3D织法或多层织法获得，具体见述于文件WO 2010/061140，其内容通过引用纳入本文；
-编织束；
-针织物；
-毡；和
-·纱线或丝束的单向(UD)片材，或通过以不同方向重叠多个单向(UD)片材并将UD片材结合在一起(例如，通过缝合、通过化学粘结剂或通过针织)而获得的多向(nD)片材。
还可以采用由织物、编织束、针织物、毡、片材、丝束等的多个重叠层制成的纤维织构，其中多层通过以下方式结合在一起：例如缝合，植入纱线或刚性元件，或针刺。
成型工具100包括在该示例中通过第一支撑件140和第二支撑件170形成的结构封壳。第一支撑件140具有第一多穿孔区141，该第一多穿孔区141具有穿过第一支撑件厚度的多个穿孔1410，所述多穿孔区141被边缘142围绕。
第二支撑件170具有第二多穿孔区171，该第二多穿孔区171具有穿过第二支撑件厚度的多个穿孔1710，所述多穿孔区171被边缘172围绕。
根据本发明，成型工具100还具有第一成型模具功能元件120和第二成型模具功能元件150。第一成型模具功能元件120用于接收在存在于第一支撑件140内表面140a中并包括第一多穿孔区141的第一外露区143中，将该第一成型模具功能元件120置于边缘142，使该元件能够保持与第一支撑件140的内表面140a分开(图3和4)。第二成型模具功能元件150用于接收在存在于第二支撑件170内表面170a上并包括第二多穿孔区171的第二外露区173中，将该第二成型模具功能元件150置于边缘172，以用于使得该元件保持与第二支撑件170的内表面170a分开(图3和4)。第一和第二成型模具功能元件120和150各自具有第一面120a和150a，所述第一面120a和150a具有与待制备部件形状对应的确定形状，特别是板的形状。第一成型模具功能元件120具有第二面120b，该第二面120b通过边缘142保持面对第一外露区143中第一支撑件140的内表面140a，同时第二成型模具功能元件150具有第二面150b，该第二面150b通过边缘172保持面对第二外露区173中第二支撑件170的内表面170a。第一成型模具功能元件120和第二成型模具功能元件150各自包括多个穿孔121和151。
根据本发明，分别存在于第一成型模具功能元件120和第二成型模具功能元件150中的穿孔121和151的数量、尺寸和/或形状不同于存在于所面对的支撑件中的穿孔数量、尺寸和/或形状。在当前所述的示例中，第一成型模具功能元件120的穿孔121的数量大于存在于第一支撑件140中的穿孔1410的数量。同样，第二成型模具功能元件150的穿孔151的数量大于存在于第二支撑件170中的穿孔1710的数量。这能够使得气相进入纤维构件的进入点数量增加，并且在气相与纤维预制件接触之前将通过支撑件140和170中的穿孔1410和1710进入的气相分开。这用于限制局部额外厚度并限制进行固结的部件厚度内的沉积厚度梯度，或限制在纤维预制件中形成泡。
此外，在第一成型模具功能元件120和第二成型模具功能元件150中，相应的穿孔121和151优选定位成相对于存在于第一和第二支撑件140和170中的相应穿孔1410和1710偏移(图3和4)。这也用于限制局部额外厚度的外观并限制待固结部件厚度内的沉积厚度梯度，或限制在纤维预制件中形成泡。
图5显示具有多个穿孔201的成型模具功能元件200的变体实施方式，所述穿孔形状是长椭圆形的。可以设想其它穿孔形状作为与待致密化的纤维预制件相关的参数函数。利用成型模具200，穿孔的总表面积增加，通过所述穿孔，纤维预制件暴露于通过结构封壳的支撑件进入工具的前体气体。在该情况下，这还限制了纤维预制件中的局部额外厚度或泡的外观。
在本发明方法的具体方面，可以将多孔消耗层插入结构封壳的支撑件和成型模具功能元件之间。在当前所述的示例中，将第一多孔消耗层130插入第一支撑件140的内表面140a和第一成型模具功能元件120的第二面140b之间，所述第二面140b通过边缘142保持与内表面140a分开，同时，将第二多孔消耗层160插入第二支撑件170的内表面170a和第二成型模具功能元件150的第二面150b之间，所述第二面150b通过边缘172保持与内表面170a分开.多孔消耗层130和160用于“预消耗”通过支撑件140和170中的穿孔141和171进入的气相中的一部分前体气体。这用于限制纤维预制件中的基质沉积梯度。特别是，通过在气相到达纤维预制件之前消耗掉气相中的前体气体的部分，使得沉积在纤维预制件表面的基质量减少，从而避免预制件表面的孔被快速堵塞并因此使孔阵列保留更长的时间，使得气相能够流到预制件的芯部中。其用于通过限制预制件中的沉积梯度在预制件厚度内获得更均匀的基质沉积物。特别是多孔消耗层可以由碳化硅(SiC)纤维制成的二维织物制成，或者由碳纤维毡制成。
特别是形成结构封壳的支撑件和成型模具功能元件可以由石墨或其它材料制成，所述材料适用于耐受使材料固结或致密化的化学气相渗透操作期间所产生温度，所述材料例如，碳/碳复合物或陶瓷基质复合物(CMC)，例如，C/SiC材料(通过碳化硅基质致密化的碳纤维增强物),或SiC/SiC材料(由碳化硅制成的基质和增强物)。
在当前描述的示例中，纤维预制件10是通过
Figure BDA0002088883660000071
S型SiC纤维的三维织法获得的预制件。
将预制件10放置在成型工具100中(图3和图4)，以通过化学气相渗透进行固结。在该示例中通过由螺钉101和螺母102构成的夹紧构件使工具闭合，其中，间隔件105用于确定两个支撑件140和170之间的间隔。纤维预制件10和工具100构成装料200，其放置在化学气相渗透炉或装置500中，如图6所示。在已知的方式中，化学气相渗透装置500包括限定反应室510的圆柱形外壳501，反应室510在其顶部通过可拆卸的盖子520闭合，具有通向预热区522的进气管521，所述预热区522用于在气体扩散到含有待致密化的预制件的反应室510中之前对气体进行加热。通过连接到抽吸装置(未显示)的排出管531从装置的底部530抽取残余气体。底部530包括支撑件532，在其上将会放置装料200。
在预热区中以及在反应室510内部的加热由与感应线圈(未显示)电磁耦合的石墨基座511产生。存在于预热区522和支撑件532之间的反应室510中的空间对应于渗透装置500的可用装料体积512，即，可用于装载待致密化的纤维预制件的体积。
预制件10通过化学气相渗透进行固结。为了使预制件固结，将反应物气体插入反应室510中，所述反应物气体含有待沉积的基质材料的至少一种或多种前体。对于陶瓷材料，在该示例中例如碳化硅(SiC)，可以以熟知的方式使用甲基三氯硅烷(MTS)作为SiC的前体。例如，对于碳，可以使用气态烃化合物，通常是丙烷、甲烷或两者的混合物。以熟知的方式，通过在多孔预制件中沉积基质材料来使多孔预制件固结，该基质材料通过在预制件的可接触内部孔的孔内扩散的反应物气体中所含前体的分解而产生。通过化学气相渗透获得各种基质沉积物所需的压力和温度条件本身是众所周知的。在进料管521和排出管531之间建立压力梯度，以促使反应物气体流动通过预制件。
使用与上述工具100相同类型的本发明的成型工具对纤维预制件的固结进行了测试。更准确地说，这些测试使用了以下元件：
-通过
Figure BDA0002088883660000081
S型SiC纤维的三维织法获得的预制件，所述预制件具有板的形状；
-第一和第二成型工具支撑件，所述第一和第二成型工具支撑件在其多穿孔区中具有直径为10毫米(mm)(φ10mm)的穿孔，这些穿孔以20mm的中心到中心的间距彼此间隔开；
-第一和第二成型模具功能元件，其具有直径为5毫米(mm)(φ5mm)并且以8mm的中心到中心的间距彼此间隔开的穿孔；以及
-插入成型工具的各支撑件和各成型模具元件之间的多孔消耗层，各层通过由供应商卡朋罗兰集团(Carbone Lorraine)以型号RVG 2000销售的石墨纤维缠结体构成的毡制成。
使用BN和SiC相通过化学气相渗透使预制件固结。
这些测试显示出：与现有技术的成型工具相比，部件厚度内的沉积厚度梯度减少至1/5。此外，与现有技术的成型工具相比，直接暴露于气体的区(面对成型模具功能元件中的穿孔的预制件区)和掩蔽区(位于成型模具功能元件的两个穿孔之间的预制件区)之间位于部件表面处的沉积厚度梯度减少至1/5至1/8。

Claims (8)

1.一种用于纤维预制件的化学气相渗透的成型工具(100)，所述工具包括至少由第一支撑件(140)和第二支撑件(170)形成的结构封壳，所述第一支撑件(140)具有第一多穿孔区(141)，并且所述第二支撑件具有第二多穿孔区(171)，所述第一支撑件和第二支撑件保持彼此相对，
该工具的特征在于，第一支撑件(140)在其内表面(140a)上包括第一外露区(143)，所述第一外露区(143)包括第一多穿孔区(141)，第二支撑件在其内表面(170a)中包括第二外露区(173)，所述第二外露区(173)包括第二多穿孔区(172)，并且成型工具(100)还至少包括在第一和第二支撑件(140、170)的第一和第二外露区(143、173)中分别存在的第一和第二成型模具功能元件(120、150)，各成型模具功能元件具有第一面(120a；150a)和第二面(120b；150b)，所述第一面(120a；150a)具有对应于待制造部件形状的确定形状，所述第二面(120b；150b)保持面对支撑件的内表面，各成型模具功能元件具有多个穿孔(121；151)并且具有与存在于所面对的支撑件中的穿孔数量、穿孔尺寸或穿孔形状不同的至少一种穿孔数量、穿孔尺寸或穿孔形状。
2.如权利要求1所述的工具，其中，将多孔消耗层(130；160)插入所述结构封壳的各支撑件(140；170)的内表面与成型模具功能元件(120；150)的第二面之间，所述第二面保持面对支撑件内表面。
3.如权利要求2所述的工具，其中，所述多孔消耗层选自以下织构之一：碳垫、二维碳织物、碳毡。
4.如权利要求1至3中任一项所述的工具，其中，支撑件(140、170)和成型模具功能元件(120、150)由选自以下材料的至少一种材料制成：石墨、碳/碳(C/C)复合材料和陶瓷基质复合(CMC)材料。
5.一种用于放置在通过化学气相渗透进行致密化的装置中的装料(200)，所述装料包括保持在如权利要求1至4中任一项所述的成型工具(100)中的纤维预制件(10)。
6.如权利要求5所述的装料，其中，所述纤维预制件是用于航空发动机部件的预制件。
7.一种包括用于通过化学气相渗透使纤维预制件致密化的装置(500)的组件，所述组件包括反应室(510)、位于反应室的第一端并通向预热区(522)的反应物气体进料管(521)以及位于第二端附近的排出管(531)，所述组件还包括位于反应室中的至少一种如权利要求5或权利要求6所述的装料(200)。
8.一种制造复合材料部件的方法，所述方法包括：
-将纤维预制件(10)放置在如权利要求1至4中任一项所述的成型工具(100)中；
-通过化学气相渗透用基质使纤维预制件固结；以及
-使固结的纤维预制件致密化。
CN201780076293.3A 2016-12-07 2017-12-04 用于纤维预制件气相化学渗透的成型设备和设施 Active CN110062750B (zh)

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FR3059679B1 (fr) 2021-03-12
CN110062750A (zh) 2019-07-26
RU2751708C2 (ru) 2021-07-16
BR112019011729A2 (pt) 2019-10-22
WO2018104640A1 (fr) 2018-06-14
JP2020500823A (ja) 2020-01-16
US20200061868A1 (en) 2020-02-27
RU2019120797A3 (zh) 2021-03-09
CA3046126A1 (fr) 2018-06-14
US10906205B2 (en) 2021-02-02
RU2019120797A (ru) 2021-01-11
EP3551593B1 (fr) 2021-01-27

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