CN111892406B - 湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷 - Google Patents
湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷 Download PDFInfo
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Abstract
本发明提供一种湿纺‑浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,其特征在于采用以下步骤:1)湿纺法制备纤维独石前驱体,先将固化剂和增塑剂在有机溶剂中搅拌溶解,再加入硼化锆陶瓷粉料,强烈搅拌制成喷丝液,然后将喷丝液通过喷丝头喷入凝胶槽中,凝固成型,即得纤维独石前驱体;2)浸渍法涂覆涂层,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度;3)温压成型;4)真空脱脂;5)热压烧结,即得弱界面纤维独石硼化锆超高温陶瓷,其断裂韧性可达8MPa•m1/2以上。本发明所得的纤维独石硼化锆超高温陶瓷的断裂方式为非脆性断裂,即表现为对裂纹损伤具有一定容忍能力的逐次断裂,性能优良。
Description
技术领域
本发明提供一种湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,属于超高温陶瓷的制备技术领域。
背景技术
硼化锆陶瓷具有优越的耐高温和耐腐蚀性能及相对较低的理论密度, 因此一直被认为是超高温陶瓷(UHTCs)家族中最有应用前景的材料之一。目前,硼化锆陶瓷已广泛用作各种高温结构及功能材料,如:航空工业中的涡轮叶片、磁流体发电电极等。但硼化锆陶瓷断裂韧性较低,韧值仅为4~5 MPa•m1/2,限制了其在苛刻作业环境下的应用,如超声速飞行器鼻锥和前沿、超燃冲压发动机热端部件等。因此,为了保证使用过程中的可靠性和安全性,必须改善硼化锆陶瓷的脆性问题,从而提高其耐热冲击性能。受自然界中贝壳、竹子的微观组织结构的启发,在脆性陶瓷材料中加入耐高温软质材料,设计和制备仿生层状和纤维独石状复合物以提高陶瓷的韧性。
对于仿生纤维独石复合材料的研究。清华大学通过泥料挤出法制备出Si3N4纤维独石前驱体,纤维独石前驱体的直径为1mm,然后,浸涂BN悬浮液,制备出Si3N4/BN纤维独石陶瓷,其弯曲强度为700MPa,断裂韧性为23.9MPa·m1/2。美国密苏里大学以乙烯-丙烯酸乙酯为结合剂,高温矿物油为增塑剂,120℃共挤出泥料制备出有涂层结构的纤维独石前驱体,然后定向排布,经800℃裂解后,1900℃、32MPa下热压烧结制备出纤维独石ZrB2复合材料,胞体组成为ZrB2-30vol.%SiC,直径为300μm,涂层界面组成为石墨-15 vol.%ZrB2,厚度为25μm,纤维独石ZrB2复合材料弯强度为375MPa,临界热震温差△Tc为1400℃。
传统的纤维独石前驱体的成型工艺为泥料挤出成型,即干纺法成型,生坯经过陈腐、真空练泥使其具有一定可塑性,然后通过挤出机喷丝头挤出成型,喷丝头的大小决定了纤维独石前驱体的直径大小,喷丝头直径越小所受到的阻力越大,也就是说,小的喷丝头需要更大的挤出压力,挤出成型制备小于1mm的纤维独石前驱体非常困难,因此,研究人员在原有挤出成型工艺基础上进行了改进,通过将泥料预热到120℃,提高泥料的流动性,使其挤出成型更细的纤维独石前驱体,但没有改变泥料流动性差这一本质属性,喷丝头直径越小,挤出压力越大,挤出成型越困难,纤维独石前驱体挤出后,由于溶剂的挥发迅速固化,纤维独石前驱体韧性差,呈细棒状,连续性差,因此,制备高韧性纤维独石硼化锆超高温陶瓷,必须开发新型的纤维独石前驱体的成型工艺。
发明内容
本发明的目的是为了解决现有纤维独石前驱体成型困难,而提供一种湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷。其技术方案为:
一种湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,其特征在于采用以下步骤:
1)采用湿纺法制备纤维独石前驱体:先将固化剂和增塑剂在有机溶剂中搅拌溶解,再加入硼化锆陶瓷粉料,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中,真空脱气1~5h,在0.2~0.5MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为0~10℃,凝固成型后浸泡8~24h,即得纤维独石前驱体,纤维独石前驱体直径为200~1000µm,称量时,先称量硼化锆陶瓷粉料,再以硼化锆陶瓷粉料为基础计算,按重量百分比称取固化剂10~20%、增塑剂10~20%、有机溶剂100~200%,固化剂为聚乙烯醇缩丁醛,增塑剂为聚乙二醇,有机溶剂为无水乙醇,硼化锆陶瓷粉料由硼化锆粉末和碳化硅粉末按质量百分比80~90%:10~20%混合而成,硼化锆粉末的粒径为1~5µm,碳化硅粉末的粒径为0.5~2µm;
2)浸渍法涂覆涂层:先将粘结剂加入去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌4~12h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,其中粘结剂为羧甲基纤维素,石墨陶瓷粉料由石墨粉末、硼化锆粉末和碳化硅粉末按质量百分比50~60%:20~30%:20~30%混合而成;
3)温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行平行排布或交叉排布,再在60~100℃,20~50MPa下,温压使其致密得到陶瓷生坯;
4)真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为0.25~1℃/min,升温至600~700℃,保温0.5~1h;
5)热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为1900~2000℃,保温0.5~2h,压力为20~60MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
所述的湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,步骤2)中,石墨料浆的制备方法为先称量石墨陶瓷粉料,然后以石墨陶瓷粉料重量为基础,按重量百分比称取2~5%羧甲基纤维素和500~1000%去离子水。
本发明的工作原理是:提出湿纺法制备纤维独石前驱体的新工艺,先将固化剂和增塑剂在有机溶剂中搅拌溶解,再加入陶瓷粉料形成喷丝液,当喷丝液从喷丝头的细孔中压出,呈细流状,然后在凝固液中固化成形得到纤维独石前驱体,纤维独石前驱体形貌有椭球体、菱形体、纺锤体、扁平体、圆柱体。通过调控固化剂、增塑剂、固液比、喷丝液粘度、挤出速度、凝固液温度等参数,进而实现纤维独石前驱体形貌的可控,提高纤维独石前驱体致密性,减少热压烧结时纤维独石材料胞体形貌的变形,制备出连续、超细、高韧、致密的圆柱状纤维独石前驱体。其中固液比通过有机溶剂和硼化锆陶瓷粉料比控制;喷丝料浆粘度通过固化剂、增塑剂、有机溶剂、陶瓷粉料、搅拌时间控制;挤出速度通过氮气压力控制;凝固速度通过凝胶槽水温控制。
本发明与现有技术相比,具有如下优点:
1、湿纺法成型纤维独石前驱体,制备出连续、超细、高韧、致密、圆柱体的纤维独石前驱体,直径可达200µm,长度可达10米以上,180°弯曲不会断裂。彻底解决了泥料挤出成型,泥料流动性差,纤维独石前驱体直径粗、韧性差、不连续的缺点;
2、固化剂为聚乙烯醇缩丁醛,增塑剂为聚乙二醇,陶瓷生坯真空脱脂后,聚乙烯醇缩丁醛和聚乙二醇高温裂解成小分子的碳颗粒排除,无碳残留,残留的碳会降低纤维独石硼化锆超高温陶的弯曲强度和断裂韧性;
3、纤维独石前驱体在去离子水为溶剂的石墨料浆中浸渍涂覆,纤维独石前驱体不溶解,涂覆均匀;
4、凝胶槽水温为0~10℃,低温快速凝固,纤维独石前驱体不粘连;
5、在本发明制得的纤维独石超高温陶瓷中,胞体组成为硼化锆-碳化硅,涂层界面组成为石墨,这样当超高温陶瓷在受到外力,裂纹扩展至石墨界面时,发生偏转和分叉,增加了裂纹的扩展路径,从而提高了材料的断裂韧性,断裂韧性可达8MPa•m1/2以上;
6、块体陶瓷为脆性断裂,而纤维独石硼化锆陶瓷为非脆性断裂,对裂纹损伤具有一定容忍能力的逐次断裂。
附图说明
图1是本发明实施例1所得弱界面纤维独石硼化锆超高温陶瓷的SEM照片;
图2是本发明实施例1所得弱界面纤维独石硼化锆超高温陶瓷韧性测试后的裂纹扩展路径。
具体实施方式
实施例1
1、纤维独石前驱体的制备:先将10克聚乙烯醇缩丁醛和10克聚乙二醇在100克无水乙醇中搅拌溶解,再加入硼化锆陶瓷粉料,硼化锆陶瓷粉料由80克1µm硼化锆粉末和20克0.5µm碳化硅粉末按质量百分比80%:20%混合而成,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中, 真空脱气1h,在0.2MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为0℃,凝固成型后浸泡8h,即得纤维独石前驱体,纤维独石前驱体直径为1000µm;
2、浸渍法涂覆涂层:先将2克羧甲基纤维素加入500克去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌4h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,石墨陶瓷粉料由50克石墨粉末、20克硼化锆粉末和30克碳化硅粉末按质量百分比50%:20%:30%混合而成;
3、温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行平行排布,再在60℃,20MPa下,温压使其致密得到陶瓷生坯;
4、真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为0.25℃/min,升温至600℃,保温0.5h;
5、热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为1900℃,保温0.5h,压力为20MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
实施例2
1、纤维独石前驱体的制备:先将20克聚乙烯醇缩丁醛和20克聚乙二醇在200克无水乙醇中搅拌溶解,再加入硼化锆陶瓷粉料,硼化锆陶瓷粉料由90克5µm硼化锆粉末和10克2µm碳化硅粉末按质量百分比90%:10%混合而成,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中, 真空脱气5h,在0.5MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为10℃,凝固成型后浸泡24h,即得纤维独石前驱体,纤维独石前驱体直径为200µm;
2、浸渍法涂覆涂层:先将5克羧甲基纤维素加入1000克去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌12h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,其中粘结剂为羧甲基纤维素,石墨陶瓷粉料由60克石墨粉末、20克硼化锆粉末和20克碳化硅粉末按质量百分比60%:20%:20%混合而成;
3、温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行平行排布,再在100℃,50MPa下,温压使其致密得到陶瓷生坯;
4、真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为1℃/min,升温至700℃,保温1h;
5、热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为2000℃,保温2h,压力为60MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
实施例3
1、纤维独石前驱体的制备:先将15克聚乙烯醇缩丁醛和15克聚乙二醇在150克无水乙醇中搅拌溶解,再加入硼化锆陶瓷粉料,硼化锆陶瓷粉料由85克2µm硼化锆粉末和15克1µm碳化硅粉末按质量百分比85%:15%混合而成,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中, 真空脱气2h,在0.4MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为5℃,凝固成型后浸泡12h,即得纤维独石前驱体,纤维独石前驱体直径为800µm;
2、浸渍法涂覆涂层:先将4克羧甲基纤维素加入800克去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌8h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,其中粘结剂为羧甲基纤维素,石墨陶瓷粉料由50克石墨粉末、25克硼化锆粉末和25克碳化硅粉末按质量百分比50%:25%:25%混合而成;
3、温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行交叉排布,再在80℃,30MPa下,温压使其致密得到陶瓷生坯;
4、真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为0.5℃/min,升温至650℃,保温0.75h;
5、热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为1950℃,保温1h,压力为40MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
实施例4
1、纤维独石前驱体的制备:先将18克聚乙烯醇缩丁醛和18克聚乙二醇在180克无水乙醇中搅拌溶解,再加入硼化锆陶瓷粉料,硼化锆陶瓷粉料由88克3µm硼化锆粉末和12克1.5µm碳化硅粉末按质量百分比88%:12%混合而成,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中, 真空脱气4h,在0.3MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为5℃,凝固成型后浸泡20h,即得纤维独石前驱体,纤维独石前驱体直径为700µm;
2、浸渍法涂覆涂层:先将3克羧甲基纤维素加入700克去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌6h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,其中粘结剂为羧甲基纤维素,石墨陶瓷粉料由50克石墨粉末、30克硼化锆粉末和20克碳化硅粉末按质量百分比50%:30%:20%混合而成;
3、温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行交叉排布,再在70℃,40MPa下,温压使其致密得到陶瓷生坯;
4、真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为0.5℃/min,升温至650℃,保温0.5h;
5、热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为1950℃,保温1h,压力为40MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
Claims (2)
1.一种湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,其特征在于采用以下步骤:
1)采用湿纺法制备纤维独石前驱体:先将固化剂和增塑剂在有机溶剂中搅拌溶解,再加入硼化锆陶瓷粉料,强烈搅拌48h制成喷丝液,然后将喷丝液移至不锈钢贮罐中, 真空脱气1~5h,在0.2~0.5MPa氮气压力下, 将喷丝液通过喷丝头喷入盛满水的凝胶槽中,凝胶槽水温为0~10℃,凝固成型后浸泡8~24h,即得纤维独石前驱体,纤维独石前驱体直径为200~1000µm,称量时,先称量硼化锆陶瓷粉料,再以硼化锆陶瓷粉料为基础计算,按重量百分比称取固化剂10~20%、增塑剂10~20%、有机溶剂100~200%,固化剂为聚乙烯醇缩丁醛,增塑剂为聚乙二醇,有机溶剂为无水乙醇,硼化锆陶瓷粉料由硼化锆粉末和碳化硅粉末按质量百分比80~90%:10~20%混合而成,硼化锆粉末的粒径为1~5µm,碳化硅粉末的粒径为0.5~2µm;
2)浸渍法涂覆涂层:先将粘结剂加入去离子水中搅拌均匀,再加入石墨陶瓷粉料搅拌4~12h形成石墨料浆,再采用浸渍法涂覆,将纤维独石前驱体浸入石墨料浆中,通过浸渍提拉次数控制涂层厚度,其中粘结剂为羧甲基纤维素,石墨陶瓷粉料由石墨粉末、硼化锆粉末和碳化硅粉末按质量百分比50~60%:20~30%:20~30%混合而成;
3)温压成型:根据热压烧结用石墨模具大小裁切浸渍涂覆后的纤维独石前驱体,在石墨模具中进行平行排布或交叉排布,再在60~100℃,20~50MPa下,温压使其致密得到陶瓷生坯;
4)真空脱脂:将陶瓷生坯连同石墨模具放入真空脱脂炉中,真空脱脂,升温速度为0.25~1℃/min,升温至600~700℃,保温0.5~1h;
5)热压烧结:脱脂后,在氩气气氛下热压烧结,烧结温度为1900~2000℃,保温0.5~2h,压力为20~60MPa,即得弱界面纤维独石硼化锆超高温陶瓷。
2.如权利要求1所述的湿纺-浸渍法制备弱界面纤维独石硼化锆超高温陶瓷,其特征在于:步骤2)中,石墨料浆的制备方法为先称量石墨陶瓷粉料,然后以石墨陶瓷粉料重量为基础,按重量百分比称取2~5%羧甲基纤维素和500~1000%去离子水。
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