CN111971263A - 通过向纤维结构注入负载的陶瓷浆料来制造由复合材料制成的部件的方法 - Google Patents

通过向纤维结构注入负载的陶瓷浆料来制造由复合材料制成的部件的方法 Download PDF

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CN111971263A
CN111971263A CN201980025574.5A CN201980025574A CN111971263A CN 111971263 A CN111971263 A CN 111971263A CN 201980025574 A CN201980025574 A CN 201980025574A CN 111971263 A CN111971263 A CN 111971263A
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pressure
slurry
membrane
chamber
preform
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CN111971263B (zh
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E·菲利普
P·卡米纳提
M·D·布尼亚
B·德卓约克斯
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Safran Ceramics SA
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Abstract

本发明涉及用于制造复合部件的方法，其包含以下步骤：‑在模具(2)中设置纤维预成形件(3)，该模具(2)包含浸渍室(21)，该浸渍室(21)在其下部包含过滤器，使得预成形件(3)的第一面支承在所述过滤器上，浸渍室(21)被位于预成形件(3)的第二面相对位置的挠性膜(23)封闭，所述膜(23)将浸渍室(21)与压实室(22)分离；其特征在于，该方法进一步包含以下步骤：‑将压缩流体注入压实室(22)，从而在膜(23)上施加第一压力；‑以第二压力将包含陶瓷颗粒的浆料注入浸渍室(21)，同时保持注入压缩流体，浆料的第二注入压力低于膜(23)上的第一压力。

Description

通过向纤维结构注入负载的陶瓷浆料来制造由复合材料制成 的部件的方法
背景技术
本发明涉及复合部件的制造的一般领域，尤其是制造陶瓷基质复合(CMC)部件，即包含由陶瓷材料纤维形成的纤维增强件，其被同样由陶瓷材料制成的基质致密化，例如氧化物/氧化物类型。
陶瓷基质复合(CMC)部件通常通过以下方法制造：在模具中披盖由陶瓷材料纤维(例如碳化硅(SiC))制成的多个纤维层以形成纤维预成形件。
然后，通过“RTM”注塑方法，用负载有陶瓷材料颗粒(例如也是SiC)的浆料浸渍预成形件。在制造氧化物/氧化物类型的CMC部件时，纤维和浆料颗粒由氧化物(例如氧化铝(Al2O3))制成。
为此，将负载有陶瓷颗粒的浆料注入空腔，该空腔将预成形件所在的模具和其对模(counter-mold)分离，从而通过施加压力梯度使其通过预成形件。进行浆料注入的模具包含在浆料出口开向模具内的过滤器，从而使陶瓷颗粒能够保留在模具中，并在陶瓷颗粒沉积在模具内的同时浸渍预成形件。
然而，在制造大和薄的部件(例如排气歧管)时，以往的陶瓷基质复合部件的注塑的解决方案会遇到问题。例如，对于直径为1.5m且厚度为1mm的部件，对模具和对模所要求的尺寸容差非常小，使得制造适用于此类部件制造的模具和对模非常困难。
已知，文献WO2016/102842中描述了一种注塑工具(RTM)，其使用可形变膜代替对模。这种解决方案避免了尺寸容差的问题。
例如，在WO2016/102842中，向设有纤维预成形件的浸渍室中注入浆料，然后在挠性膜上施加压力以使浆料穿透纤维预成形件。
然而，WO2016/102842中所述的解决方案难以控制纤维体积率。
此外，WO2016/102842中所述的解决方案可能还会遇到浆料粉末颗粒在纤维预成形件内沉积不均匀的问题。
发明主题和概述
因此，本发明的主要目的为，提供制造具有纤维增强件的复合部件的解决方法，其可以更好地控制纤维体积率，从而克服此类缺点。
本发明的另一目的为，使得浆料颗粒更好地沉降于纤维增强件中。
因此，根据第一方面，本发明提供制造复合部件的方法，其包括以下步骤：
-在模具中设置纤维预成形件，该模具包含浸渍室，该浸渍室在其下部包含过滤器，使得预成形件第一面支承在所述过滤器上，浸渍室被位于预成形件第二面相对位置的挠性膜封闭，所述膜将浸渍室与压实室分离；
其特征在于，方法进一步包含以下步骤：
-将压缩流体注入压实室，从而在膜上施加第一压力；
-以第二压力将包含陶瓷颗粒的浆料注入浸渍室，同时保持注入压缩流体，浆料的第二注入压力低于膜上的第一压力。
方法可以包括以下特征，这些特征可以单独运用，或基于技术可能性进行组合：
-方法包含以下步骤：在保持浆料的第二注入压力低于膜上的第一压力的条件下，逐渐增加膜上的第一压力以及浆料的第二注入压力；
-第一压力与第二压力之间的压力差保持恒定于预定值；
-第一压力与第二压力之间的压力差小于5巴；
-第一压力与第二压力之间的压力差小于2巴；
-第一压力与第二压力之间的压力差在0.5与1巴之间；
-方法包含在注入浆料之前进行的预饱和步骤，其中将液体通过预成形件注入浸渍室。
根据第二方面，本发明提供用于制造复合部件的系统，其包含：
-模具，其包含浸渍室，该浸渍室在其下部具有过滤器，以支承预成形件第一面，浸渍室被位于过滤器相对位置的挠性膜封闭，所述膜将浸渍室与压实室分离；
-用于将压缩流体注入压实室从而在膜上施加第一压力的装置；
-用于以第二压力将包含悬浮在液相中的陶瓷颗粒的浆料注入浸渍室的装置；
其特征在于，系统进一步包含控制单元，其被构造用于控制压缩流体注入装置以及浆料注入装置，以保持浆料的第二注入压力低于膜上的第一压力。
系统可以包括以下特征，这些特征可以单独运用，或基于技术可能性进行组合：
-模具包含导向浸渍室内分配格栅的浆料入口开口；
-分配格栅包含相对于浆料入口开口的面，其被多孔不粘层覆盖；
-模具具有导向排放格栅的浆料出口开口，所述排放格栅被过滤器覆盖；
-排放格栅具有相对于浆料出口的面，其被多孔不粘层覆盖。
附图说明
由以下给出的描述中，参考示出的示例实施方式的附图，本发明的其他特征和优点将变得很明显，这些示例实施方式没有限制作用。在附图中：
–图1a所示为用于制造复合部件的系统；
–图1b所示为用于制造复合部件的系统的另一可能变体；
–图2示意性显示了浆料颗粒在纤维预成形件内的沉积；
–图3a和3b所示为根据可能变体的第一压力和第二压力的变化曲线；
–图4所示为通过根据本发明的方法所获得的部件的截面图。
具体实施方式
如图1a、1b和2所示，用于制造复合部件的系统1包含模具2，一方面，该模具包含浸渍室21，在其中设置纤维预成形件3以使其被陶瓷基质浸渍，另一方面，该模具包含压实室22，向其中注入压缩流体，从而在浸渍所述预成形件3的过程中对预成形件3施加压力。
模具2的浸渍室21和压实室22被挠性膜23分离。膜23使得能够通过将压缩流体注入压实室22来对设置在浸渍室21中的预成形件3施加压力，压缩流体在膜上施加压力，膜变形并继而在预成形件3上施加压力。膜23例如由硅制成。
如图1a所示，通过预成形件3注入的浆料可以通过入口开口注入，该入口开口位于预成形件3的与膜23相同的面上。根据图1b所示的另一变体，入口开口(浆料通过其注入通过预成形件3)可以在与膜23所在的所述预成形件3的面相对的所述预成形件3的面上。
在图1a的变体中，浸渍室21在其下部(对于图1b的变体为上部)包含过滤器210，当所述预成形件3被置于浸渍室内时，该过滤器上支承有预成形件3的第一面。过滤器210的形状适合于将预成形件3的第一面保持为要制造的形状。过滤器210例如可以由微孔聚四氟乙烯(PTFE)、树脂、金属(例如铝或不锈钢)制成。
预成形件3可以通过堆叠由二维(2D)编织获得的层或层片来制得。预成形件3也可以通过三维(3D)编织直接以单件形式制得。本文所述的“二维编织”是指传统的编织方法，在该方法中，每根纬纱从单个经纱层的纱线的一面穿至另一面，反之亦可。本文所述的“三维编织”或“3D编织”是指经纱穿过数层纬纱或纬纱穿过数层经纱的编织方法。
预成形件3也可以通过单向(UD)纤维网制得，其可以通过自动纤维放置(AFP)或细丝缠绕获得。
预成形件3可以由以下材料制得的纤维制成：氧化铝、莫来石、二氧化硅、铝硅酸盐、硼硅酸盐、碳化硅、碳或这些材料的几种的混合物。
如图2所示，系统1可以包括分配格栅211，浆料入口开口在其上开向浸渍室21内。该分配格栅211使得浆料能够更好地分布在预成形件3的整个表面上。另外，可以在分配格栅211的相对于浆料入口开口的面上设置第一多孔不粘层213(例如由多孔特氟隆(Teflon)制成)。该第一多孔不粘层213位于分配格栅211与预成形件3之间，并促进从模具2中移除所述预成形件3。
系统1也可以包括位于过滤器210下方的排放格栅212。排放格栅212在图1a的变体中位于浸渍室21下部，而在图1的变体中位于浸渍室21上部，从而使得所述浸渍室21的浆料出口开口开在所述排放格栅212上。另外，可以在排放格栅212的相对于浆料出口开口的面上设置第二多孔不粘层214(例如由多孔特氟隆制成)。该第二多孔不粘层214位于排放格栅211与预成形件3之间，并促进从模具2中移除所述预成形件3。
系统1也包括浆料注入装置4，其被构造用于以第二压力Pb将浆料注入模具2的浸渍室21。浆料旨在形成要制造的部件的陶瓷基质。浆料包含悬浮于液相中的陶瓷颗粒7。
浆料的液相可以是水(酸性或碱性pH)、乙醇或任何所需粉末可以在其中悬浮的其他液体。还可以添加有机粘合剂(PVA、PEG、PVP，水溶性的)。这种粘合剂确保原料在干燥后和烧结前保持稳定。
浆料的陶瓷颗粒7可以是氧化铝、莫来石、二氧化硅、氧化锆、铝硅酸盐或铝磷酸盐、或这些组分的混合物。陶瓷颗粒7也可以由碳化物制成，例如由碳化硅制成。颗粒7的平均尺寸或平均粒径在0.1μm与10μm之间。“平均尺寸”是指统计学的粒径分布到达半数时所给出的尺寸，称为D50。过滤器210的孔隙的尺寸与浆料颗粒7的尺寸相适应，从而使得所述浆料颗粒7不穿过所述过滤器210并留在浸渍室21内。
系统1还包括压缩流体注入装置5，其被构造用于以第一压力Pm将所述压缩流体注入模具的压实室22。压缩流体例如可以是压缩空气或甚至水。
系统1进一步包含控制单元6，其被构造用于控制浆料注入装置4和压缩流体注入装置5。控制单元6包括例如与存储器相关联的处理器，该存储器上存储着用于实施制造复合部件的方法的指令。
进一步，一方面，系统1包含第一压力传感器41，其被构造用于测量浆料注入装置4提供的浆料注入压力，并且与控制单元6连接，另一方面，系统1包含第二压力传感器51，其被构造用于测量压缩流体注入装置5提供的压缩流体注入压力，并且与控制单元6连接。
用于制造复合部件的方法由以下步骤组成：
-在浸渍室21内设置预成形件3。
-以第一压力Pm将压缩流体注入压实室22。第一压力Pm继而对应于施加于膜23的压力。该步骤压缩纤维预成形件并给予其理想的纤维体积比。通过由控制单元6控制的压缩流体注入装置5进行该步骤。
-以第二压力Pb将浆料注入浸渍室21，同时继续将压缩流体注入压实室22，第二压力Pb低于第一压力Pm。浆料的注入使得沉积通过颗粒7在纤维预成形件3中的沉降得以进行。第二压力Pb(浆料注入压力)低于第一压力Pm(在膜23上施加的压力)这一事实确保了要制造部件的最小纤维体积率。通过由控制单元6控制的浆料注入装置4实施该步骤。
因此，控制单元6被构造用于控制注入装置4和5(特别是使用压力传感器41和51)以保持第二压力Pb低于第一压力Pm。
优选地，在方法过程中逐渐提升第二压力Pb，以补偿颗粒7在纤维预成形件中的沉积所导致的压力损失，并且由此加速所述颗粒7的沉降。为了保持第一压力Pm高于第二压力Pb，在方法过程中还提升第一压力Pm。
根据一有利的变体，方法如下实施：先将压缩流体注入压实室22以对预成形件3施加第一压力Pm(该压力值给予理想的纤维体积比)，例如1巴。然后，以第二压力Pb将浆料注入浸渍室21。然后，提升第一压力Pm，使得第一压力Pm与第二压力Pb之间的压力差ΔP(ΔP＝Pm–Pb)等于第一压力的起始值(在该例中为1巴)，由此使得能够维持纤维体积率与理想值相等。在方法过程中逐渐提升第二压力Pb以补偿压力损失，同时提升第一压力Pm以保持压力差ΔP恒定。例如，在制造方法过程中，第一压力Pm可以达到7巴的最大值，在该例中第二压力Pb的最大值为6巴。图3a和3b显示了为了保持压力差ΔP恒定的第一压力Pm和第二压力Pb的变化的示例。根据图3a所示的变体，第一压力Pm和第二压力Pb交替变化。第一压力Pm增加时第二压力Pb保持恒定，然后第二压力Pb增加时第一压力Pm保持恒定，周而复始。根据图3b所示的另一变体，第一压力Pm和第二压力Pb以线性形式变化。
压力差ΔP优选小于5巴，从而限制预成形件3的压实，因为预成形件3的过分压实减慢浆料通过所述预成形件3的循环，并由此减慢通过颗粒7沉降的沉积过程。更优选地，压力差ΔP小于2巴，并且更优选包含在0.5与1巴之间。
可以在注入压缩流体以及注入浆料前进行预成形件3在载流体中预饱和的步骤，从而消除预成形件3所含的所有空气并适应纤维的湿润性。通过向浸渍室21(其中设置有预成形件3)注入液体(例如水或醇)来进行预饱和步骤。液体未负载有颗粒。
用于制造复合部件的系统1还可以包括加热装置(例如集成于模具2的壁内的电阻元件)，以提高模具2内(特别是浸渍室21内)的温度，并且在所有注入后通过蒸发促进浆料液相的排出。模具2内的温度例如可以设定在包含在80℃与110℃之间的温度。
负载有颗粒7并干燥后，预成形件3被从模具2中移出，所述预成形件3在脱模后保持其压实几何形状。然后，对预成形件3进行烧结热处理(例如在空气中且在包含在1000℃与1300℃之间的温度下)，从而将陶瓷颗粒7烧结在预成形件3中。继而获得具有陶瓷纤维增强件的陶瓷基质复合部件。
图4显示了通过根据本发明的方法所制得的部件8的截面，从该图中可以看出，压力差ΔP(Pm–Pb)为1巴。部件8的纤维增强件81(对应于预成形件3)通过堆叠多个氧化铝纤维层而形成，并且所述部件8的基质82也由氧化铝制成。在制造部件8时，目标纤维体积含量在30％与60％之间，优选在45％与55％之间，目标密度大于2.5，优选大于3，且目标孔隙率包含在15％与40％之间，优选在17％与23％之间。所得部件8的纤维体积含量为48％，孔隙率为20％，且密度为3.1。另外，如图4所示，基质82是均质的，其显示颗粒7在预成形件3中的良好沉降沉积。
本发明特别适用于具有小厚度和大表面积的部件，例如涡轮发动机壳体(例如风扇壳体、压缩机壳体和排气机壳体)。
表述“包含在……与……之间”应理解为包括界限(端值)。

Claims (11)

1.一种制造复合部件(8)的方法，其包含以下步骤：
-在模具(2)中设置纤维预成形件(3)，该模具(2)包含浸渍室(21)，该浸渍室(21)在其下部包含过滤器(210)，使得预成形件(3)的第一面支承在所述过滤器(210)上，浸渍室(21)被位于预成形件(3)的第二面相对位置的挠性膜(23)封闭，所述膜(23)将浸渍室(21)与压实室(22)分离；
其特征在于，所述方法进一步包含以下步骤：
-将压缩流体注入压实室(22)，从而在膜(23)上施加第一压力(Pm)；
-以第二压力(Pb)将包含陶瓷颗粒(7)的浆料注入浸渍室(21)，同时保持注入压缩流体，浆料的第二注入压力(Pb)低于膜(23)上的第一压力(Pm)，
其中，所述方法包含以下步骤：
-在保持浆料的第二注入压力(Pb)低于膜(23)上的第一压力(Pm)的条件下，逐渐增加膜(23)上的第一压力(Pm)以及浆料的第二注入压力(Pb)。
2.如权利要求1所述的方法，其中，第一压力(Pm)与第二压力(Pb)之间的压力差(ΔP)保持在预定值不变。
3.如权利要求1或2所述的方法，其中，第一压力(Pm)与第二压力(Pb)之间的压力差(ΔP)小于5巴。
4.如权利要求3所述的方法，其中，第一压力(Pm)与第二压力(Pb)之间的压力差(ΔP)小于2巴。
5.如权利要求4所述的方法，其中，第一压力(Pm)与第二压力(Pb)之间的压力差(ΔP)在0.5与1巴之间。
6.如权利要求1～5中任一项所述的方法，其中，所述方法包含在注入浆料之前进行的预饱和步骤，其中将液体通过预成形件(3)注入浸渍室(21)。
7.一种用于制造复合部件(8)的系统(1)，其包含：
-模具(2)，其包含浸渍室(21)，所述浸渍室在其下部具有过滤器(210)，以支承预成形件(3)的第一面，浸渍室(21)被位于过滤器(210)相对位置的挠性膜(23)封闭，所述膜(23)将浸渍室(21)与压实室(22)分离；
-用于将压缩流体(5)注入压实室(22)从而在膜(23)上施加第一压力(Pm)的装置；
-用于以第二压力(Pb)将包含悬浮在液相中的陶瓷颗粒(7)的浆料(4)注入浸渍室(21)的装置；
其特征在于，系统(1)还包含控制单元(6)，其被构造用于控制压缩流体注入装置(5)以及浆料注入装置(4)，以保持第二浆料注入压力(Pb)低于膜(23)上的第一压力(Pm)；控制单元进一步被构造用于在保持浆料的第二注入压力(Pb)低于膜(23)上的第一压力(Pm)的条件下，逐渐增加膜(23)上的第一压力(Pm)以及浆料的第二注入压力(Pb)。
8.如权利要求7所述的系统(1)，其中，模具(2)包含导向浸渍室(21)内分配格栅(211)的浆料入口开口。
9.如权利要求8所述的系统(1)，其中，分配格栅(211)包含相对于浆料入口开口的面，其被第一多孔不粘层(213)覆盖。
10.如权利要求7～9中任一项所述的系统(1)，其中，模具(2)包含导向排放格栅(212)的浆料出口开口，所述排放格栅(212)被过滤器(210)覆盖。
11.如权利要求10所述的系统(1)，其中，排放格栅(212)包含相对于浆料出口的面，其被第二多孔不粘层(214)覆盖。
CN201980025574.5A 2018-04-13 2019-04-04 通过向纤维结构注入负载的陶瓷浆料来制造由复合材料制成的部件的方法 Active CN111971263B (zh)

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