CN111704468A - 一种三维机织航空火焰筒及其制备方法 - Google Patents
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Abstract
本发明公开了一种三维机织航空火焰筒及其制备方法，包括：根据2.5D立体机织结构设计，利用变截面一体化编织工艺进行2.5D SiC纤维预制体的制备；以液态聚碳硅烷为先驱体，对SiC纤维预制体进行先驱体浸渍热裂解工艺，制备得到SiCf/SiC火焰筒；采用大气等离子喷涂工艺在SiCf/SiC火焰筒的表面制备环境障碍涂层，得到最终的三维机织航空火焰筒。本发明制备得到的三维机织航空火焰筒具有质量轻、强力高、耐高温、耐腐蚀以及较好的抗压、抗氧化、抗热冲击等综合效能，且结构稳定性能良好，大大提高了航空用火焰筒在高温下的适应性。
Description
技术领域
本发明涉及一种三维机织航空火焰筒及其制备方法，属于航空发动机燃烧室技术领域。
背景技术
航空发动机燃烧室承担着将燃料的化学能转化为热能的任务，主要任务是将燃料或推进剂在其中生成高温燃气的装置，是航空发动机的核心部件之一，在高温服役条件下，需要有极高的稳定性面对极为苛刻的服役环境。燃烧室主要由扩压器、燃烧室壳体、火焰筒、燃料喷嘴、点火装置构成。火焰筒是航空发动机燃烧室中的燃烧场所，是保证空气分股、燃烧充分、掺混均匀并使壁面得到有效冷却的部件。火焰筒主要由筒体和火焰筒头部的涡流器组成。传统的合金火焰筒筒体长期处于高温环境，工作环境最为严苛，长期工作后材料屈服应力或持久强度下降，同时受冷热疲劳、燃气氧化腐蚀、冲刷、磨损等直接影响，工作寿命会大幅度降低。而火焰筒的寿命直接关系到燃机的使用寿命，为了提高火焰筒的使用寿命，且能保证其在服役环境下的稳定性，火焰筒筒体不仅需要适应轻量化，同时能保证高度的耐氧化性、抗腐蚀性，因此研发一种高强度、耐腐蚀性、稳定性好的火焰筒筒体是目前急需解决的问题。
复合材料制备的火焰筒具有质量轻、可设计性强等优点，而碳化硅纤维增强碳化硅基体(SiCf/SiC)复合材料因其具有高比强度、高比模量、耐高温、抗蠕变、抗腐蚀、耐磨损和抗氧化等优异性能，且有效克服了纯粹陶瓷纤维脆性大、断裂韧性低和抗冲击性能差的缺陷，势必成为航空发动机燃烧室/加力燃烧室、涡轮导叶、内涵道和尾喷管等热端高温部件的理想候选材料。
而目前对于SiCf/SiC复合材料的制备，其预制体的制备多集中于二维、三维编织，为了使火焰筒具有层间连接强度高、整体性好的特点，本发明采用2.5D变截面一体化织造技术与先驱体浸渍热裂解技术(PIP)相结合，配合环境障碍涂层，实现三维机织火焰筒的整体成型。其中，变截面一体化技术能够有效提高火焰筒的整体稳定性，复合成型先驱体浸渍热裂解技术(PIP)技术，适用于制备尺寸大、形状复杂的结构，且微观结构可控、成本低，环境障碍涂层进一步增强材料的耐久性能。三者有效结合，充分提高火焰筒的耐久性。
发明内容
发明目的：为了克服现有技术中存在的不足，本发明提供一种三维机织航空火焰筒及其制备方法，采用三维机织变截面一体化成型的结构设计和先驱体浸渍热裂解技术(PIP)的制备方法，满足航空用火焰筒耐高温、抗氧化且稳定性能良好的要求。
技术方案：为实现上述目的，本发明采用的技术方案为：
一种三维机织航空火焰筒的制备方法，包括以下步骤：
(1)根据航空用燃烧室的装备确定火焰筒的具体形状及尺寸，进行2.5D立体机织结构设计，包括所用SiC纤维的经密、纬密等参数的设计；
(2)根据2.5D立体机织结构设计，利用变截面一体化编织工艺在三维纺织机上进行2.5D SiC纤维预制体的制备；
(3)以液态聚碳硅烷为先驱体，对SiC纤维预制体进行先驱体浸渍热裂解(PIP) 工艺，制备得到SiCf/SiC火焰筒；
(4)以SiCf/SiC火焰筒为基底材料，采用大气等离子喷涂工艺在基底材料的表面制备环境障碍涂层，得到最终的三维机织航空火焰筒。
进一步的，所述步骤(3)具体包括：
通过化学气相沉积(CVD)工艺在SiC纤维预制体表面制备PyC界面层，界面层厚度控制在0.2mm左右；随后以液态聚碳硅烷(PCS)为先驱体，进行PIP工艺制备得到SiCf/SiC火焰筒，浸渍-裂解循环为8-15次直至裂解增重率<2％。
进一步的，步骤(2)中，所述变截面一体化编织工艺主要通过控制编织路径、纱线变化来实现。
进一步的，步骤(2)中，所述SiC纤维预制体采用第二代SiC纤维(牌号Cansas3200) 织造而成。
进一步的，步骤(2)中，所述SiC纤维预制体的纤维体积含量为40％-55％。
进一步的，步骤(4)中，环境障碍涂层为莫来石/稀土硅酸盐(Mullite/Sc2Si2O7+Sc2O3) 涂层，每层的厚度约为100μm，利用Ar为主气及载气，He为辅气，以内送粉方式送粉，样品在首次喷涂前需预热一次，每层涂层喷涂完毕后采取空冷冷却。
根据上述方法制备得到的三维机织航空火焰筒，其包括三维机织SiC纤维预制体，并利用复合工艺浸渍、热裂解、沉积在所述SiC纤维预制体上，形成碳化硅增强碳化硅(SiCf/SiC)的航空火焰筒；所述三维机织SiC纤维预制体结构是利用三维机织中特殊的2.5D方法进行制备，也就是利用变截面一体化编织技术进行2.5D SiC预制体的制备。 2.5D机织具有更好的整体性、一次成型、更强的剪切性能和结构可设计性等特点，适用于制备火焰筒等复杂构件。
有益效果：本发明提供的一种三维机织航空火焰筒及其制备方法，相对于现有技术，具有以下优点：1、根据航空火焰筒的尺寸需求，进行不同形状、大小的SiC纤维三维机织成型预制体的设计，通过SiC纱线类型组合和纱线排布方向组合，针对性地进行火焰筒预制体的设计。
2、利用变截面、变密度编织技术一次性完成SiC纤维预制体的制备，可针对火焰筒不同部位载荷情况编织成型三维机织结构，生产效率高。
3、以液态聚碳硅烷为先驱体，进行(PIP)制备得到SiCf/SiC火焰筒，并以SiCf/SiC火焰筒为基底材料，采用大气等离子喷涂工艺在火焰筒表面制备环境障碍涂层，制备得到耐久性好、耐腐蚀、耐高温的SiCf/SiC火焰筒。
附图说明
图1为本发明一种三维机织航空火焰筒的结构示意图。
具体实施方式
下面结合附图及实施例对本发明作更进一步的说明。
实施例一
三维机织航空火焰筒的预制体采用变截面一体化成型织造工艺，具体的织造工艺为：利用三维纺织机进行如图1所示的航空火焰筒的织造，其中变截面的实现是采取逐层增加经纱的方法，即沿高度方向以5mm为一层，除第1层和第32层各成对加入4对经纱外，其余每层均成对增加3对经纱，共增加62层，按照以上方法进行加纱，即可实现从上端的754列经纱到下端1130列经纱的过渡。最终预制体的纤维体积含量为45％。
三维机织后的火焰筒预制体采用化学气相沉积(CVD)工艺：以CH4为碳源、H2 为载气，采用950℃的沉积温度，沉积2h，在SiC纤维预制体表面制备PyC界面层，界面层厚度控制在0.2mm左右。随后以液态聚碳硅烷(PCS)为先驱体，在裂解温度为 1200℃的N2气体中进行浸渍、模压、裂解工艺15个循环使其致密化，直至裂解增重率为1％，使SiCf/SiC火焰筒成型。
将制备好的SiCf/SiC火焰筒进行环境障碍涂层加工：采用大气等离子喷涂工艺在材料表面制备Mullite/Sc2Si2O7+Sc2O3涂层，第一层涂层为Mullite涂层，第二层为Sc2Si2O7+Sc2O3，涂层每层的厚度约为100μm；利用Ar为主气及载气，He为辅气，以内送粉方式送粉，样品在首次喷涂前需要预热一次，每层涂层喷涂完毕后采取空冷冷却。
实施例二
三维机织航空火焰筒的预制体采用变截面面一体化成型织造工艺，具体的织造工艺为：利用三维纺织机进行如图1所示的航空火焰筒的织造，其中变截面的实现是采取逐层增加经纱的方法，即沿高度方向以5mm为一层，除第1层和第32层各成对加入4对经纱外，其余每层均成对增加3对经纱，共增加62层，按照以上方法进行加纱，即可实现从上端的754列经纱到下端1130列经纱的过渡。最终预制体的纤维体积含量为50％。
三维机织后的火焰筒预制体采用化学气相沉积(CVD)工艺：以CH4为碳源、H2 为载气，采用1000℃的沉积温度，沉积2h，在SiC纤维预制体表面制备PyC界面层，界面层厚度控制在0.1mm左右。随后以液态聚碳硅烷(PCS)为先驱体，在裂解温度为 1200℃的N2气体中进行浸渍、模压、裂解工艺15个循环使其致密化，直至裂解增重率为1.5％，使SiCf/SiC火焰筒成型。
将制备好的SiCf/SiC火焰筒进行环境障碍涂层加工，采用大气等离子喷涂工艺在材料表面制备Mullite/Sc2Si2O7+Sc2O3涂层，第一层涂层为Mullite涂层，第二层为Sc2Si2O7+Sc2O3，涂层每层的厚度约为200μm；利用Ar为主气及载气，He为辅气，以内送粉方式送粉，样品在首次喷涂前需要预热一次，每层涂层喷涂完毕后采取空冷冷却。
实施例三
三维机织航空火焰筒的预制体采用变截面面一体化成型织造工艺，具体的织造工艺为：利用三维纺织机进行如图1所示的航空火焰筒的织造，其中变截面的实现是采取逐层增加经纱的方法，即沿高度方向以5mm为一层，除第1层和第32层各成对加入4对经纱外，其余每层均成对增加3对经纱，共增加62层，按照以上方法进行加纱，即可实现从上端的754列经纱到下端1130列经纱的过渡。最终预制体的纤维体积含量为55％。
三维机织后的火焰筒预制体采用化学气相沉积(CVD)工艺：以CH4为碳源、H2 为载气，采用1050℃的沉积温度，沉积2h，在SiC纤维预制体表面制备PyC界面层，界面层厚度控制在0.25mm左右。随后以液态聚碳硅烷(PCS)为先驱体，在裂解温度为1300℃的N2气体中进行浸渍、模压、裂解工艺15个循环使其致密化，直至裂解增重率为2％，使SiCf/SiC火焰筒成型。
将制备好的SiCf/SiC火焰筒进行环境障碍涂层加工，采用大气等离子喷涂工艺在材料表面制备Mullite/Sc2Si2O7+Sc2O3涂层，第一层涂层为Mullite涂层，第二层为Sc2Si2O7+Sc2O3，涂层每层的厚度约为100μm；利用Ar为主气及载气，He为辅气，以内送粉方式送粉，样品在首次喷涂前需要预热一次，每层涂层喷涂完毕后采取空冷冷却。
本发明采用SiC纤维三维机织变截面一体化成型的结构设计和先驱体浸渍热裂解技术(PIP)的制备方法，达到航空用火焰筒的耐高温、抗氧化且稳定性能良好的要求，有效解决纤维排布层间结合强度薄弱、合金火焰筒的材料屈服应力下降、耐久性差等问题；同时可根据航空火焰筒的尺寸需求，进行不同形状、大小的SiC纤维三维机织成型预制体的设计，利用变截面编织技术一次性完成SiC纤维预制体的制备，生产效率高，适用于火焰筒等复杂构件的制备。
以上所述仅是本发明的优选实施方式，应当指出：对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以做出若干改进和润饰，这些改进和润饰也应视为本发明的保护范围。
Claims (7)
1.一种三维机织航空火焰筒的制备方法，其特征在于，包括以下步骤：
(1)根据航空用燃烧室的装备确定火焰筒的具体形状及尺寸，进行2.5D立体机织结构设计，包括所用SiC纤维的经密、纬密的设计；
(2)根据2.5D立体机织结构设计，利用变截面一体化编织工艺在三维纺织机上进行2.5D SiC纤维预制体的制备；
(3)以液态聚碳硅烷为先驱体，对SiC纤维预制体进行先驱体浸渍热裂解工艺，制备得到SiCf/SiC火焰筒；
(4)以SiCf/SiC火焰筒为基底材料，采用大气等离子喷涂工艺在基底材料的表面制备环境障碍涂层，得到最终的三维机织航空火焰筒。
2.根据权利要求1所述的制备方法，其特征在于，所述步骤(3)具体包括：
通过化学气相沉积工艺在SiC纤维预制体表面制备PyC界面层，界面层厚度控制在0.1mm-0.3mm；随后以液态聚碳硅烷为先驱体，进行PIP工艺制备得到SiCf/SiC火焰筒，浸渍-裂解循环为8-15次直至裂解增重率<2％。
3.根据权利要求1所述的制备方法，其特征在于，步骤(2)中，所述变截面一体化编织工艺通过控制编织路径、纱线变化来实现。
4.根据权利要求1所述的制备方法，其特征在于，步骤(2)中，所述SiC纤维预制体采用第二代SiC纤维织造而成。
5.根据权利要求1所述的制备方法，其特征在于，步骤(2)中，所述SiC纤维预制体的纤维体积含量为40％-55％。
6.根据权利要求1所述的制备方法，其特征在于，步骤(4)中，所述环境障碍涂层为莫来石/稀土硅酸盐涂层，利用Ar为主气及载气，He为辅气，以内送粉方式送粉，样品在首次喷涂前需预热一次，每层涂层喷涂完毕后采取空冷冷却。
7.根据权利要求1-6任意一项所述的方法制备得到的三维机织航空火焰筒。
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