CN112409009A - 一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法 - Google Patents
一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法 Download PDFInfo
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Abstract
本发明提供了一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,属于复合材料技术领域。本发明基于液相浸渍和原位转化工艺,在热结构复合材料完成织物骨架定型和前期致密化基础上,通过在主体浸渍剂中引入抗氧化功能组元,实现了热结构复合材料后期浸渍与涂层一体化制备,在完成复合材料浸渍增密的同时,显著提高了复合材料的抗氧化性能。同时,通过调控不同轮次抗氧化组元的成分及含量,可以获得抗氧化组元可调可控、并呈梯度分布的热结构复合材料,且所形成的表面抗氧化涂层与内部基体无明显的界面,“扎钉”现象明显,结合力强,且与本体热匹配性好。
Description
技术领域
本发明属于复合材料技术领域,特别涉及一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法。
背景技术
进入二十一世纪以来,以HTV-2、X-51A、HyFly等为代表的临近空间高超声速飞行器研制“热浪”席卷全球。其中,热结构复合材料作为关系飞行器性能高低与飞行成败的关键材料,受到了国内外材料研究人员的广泛关注。目前,常用的热结构复合材料有碳/碳复合材料、碳/碳化硅复合材料及碳化硅/碳化硅复合材料三种。由于纤维或基体本身为碳或含一定量的碳组元,上述材料在高温有氧环境下将发生一定的氧化反应,导致热结构材料的性能下降。因此,热结构复合材料在使用前一般需要先进行抗氧化处理,常规的做法是在致密化的热结构复合材料表面制备具有一定厚度及功能的高温抗氧化涂层。但是,由于抗氧化涂层与热结构复合材料热膨胀系数的差异以及相互间的结合力问题,导致抗氧化涂层的可靠性及稳定性较差,且应用温度及功能受到很大局限,最终限制了其工程应用。
发明内容
为了克服现有技术中的不足,本发明人进行了锐意研究,提供了一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,基于液相浸渍和原位转化工艺,在热结构复合材料完成织物骨架定型和前期致密化基础上,通过在主体浸渍剂中引入抗氧化功能组元,实现了热结构复合材料后期浸渍与涂层一体化制备,在完成复合材料浸渍增密的同时,显著提高了复合材料的抗氧化性能。
本发明提供的技术方案如下:
一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,包括以下步骤:
步骤1,按照热结构复合材料的设计尺寸,采用耐高温无机纤维制备纤维预制体;
步骤2,采用碳基浸渍剂或陶瓷基浸渍剂,通过多轮次循环浸渍/裂解工艺,实施热结构复合材料骨架定型及前期致密化,获得密度为1.4~1.8g/cm3、具有孔隙的中间状态热结构复合材料毛坯;
步骤3,将中间状态热结构复合材料毛坯在1200~2000℃下进行高温处理;
步骤4,在浸渍剂中加入抗氧化功能组元,将含抗氧化功能组元的浸渍剂通过真空/压力组合浸渍方式浸入热结构复合材料毛坯的孔隙中,浸渍结束后从浸渍剂中取出热结构复合材料毛坯,并对毛坯表面的残留胶液进行清理和涂覆,使毛坯表面形成一薄层均匀连续的胶层;
步骤5,将完成浸渍及涂覆的热结构复合材料毛坯先在室温下表干,然后在80~240℃、0.1~3MPa下处理4~20h,实施热结构复合材料毛坯内部及表面浸渍剂的原位固化;
步骤6,将完成浸渍、原位固化的热结构复合材料毛坯装入仿形石墨维型工装中,之后装入热处理设备中,在600~1400℃下处理4~30h,实施浸渍剂的高温裂解;
步骤7,重复步骤4~步骤6至相邻两次增重率小于1wt%,最终得到浸渍增密与表面涂层一体化完成的热结构复合材料。
根据本发明提供的一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,具有以下有益效果:
本发明基于液相浸渍和原位转化工艺,在热结构复合材料完成织物骨架定型和前期致密化基础上,通过在主体浸渍剂中引入抗氧化功能组元,实现了热结构复合材料后期浸渍与涂层一体化制备,在完成复合材料浸渍增密的同时,显著提高了复合材料的抗氧化性能。同时,通过调控不同轮次抗氧化功能组元的成分及含量,可以获得抗氧化功能组元可调可控、并呈梯度分布的热结构复合材料,且所形成的表面抗氧化涂层与内部基体无明显的界面,“扎钉”现象明显,结合力强,且与本体热匹配性好。该方法还具有适用性广、制造周期短、成本低等显著特点。
具体实施方式
下面通过对本发明进行详细说明,本发明的特点和优点将随着这些说明而变得更为清楚、明确。
本发明提供了一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,包括如下步骤:
步骤1,按照热结构复合材料的设计尺寸制备纤维预制体。纤维可选用炭纤维、碳化硅纤维等多种耐1200~2000℃高温无机纤维,预制体结构可为二维铺层缝合结构、针刺结构、2.5D结构等多种结构形式,具体结构参数及纤维铺叠方式依据力学性能指标及使用环境温度等要求确定。
步骤2,骨架定型及前期致密化。在制得纤维预制体后,采用酚醛树脂、沥青等碳基浸渍剂,或聚碳硅烷、SiBCN等陶瓷基浸渍剂,通过3~6轮次循环浸渍/裂解工艺,并借助仿形精密成型工装及复合防变形工装,实现热结构复合材料骨架定型及前期致密化,获得密度为1.4~1.8g/cm3、具有孔隙的中间状态热结构复合材料毛坯。
该步骤中,复合材料毛坯的密度为1.4~1.8g/cm3,浸渍/裂解工艺循环为3~6轮次。这主要是考虑不同浸渍剂的转化率和真密度不同,在孔隙率一定的情况下,高转化率的浸渍剂所需循环轮次少,较低转化率的浸渍剂所需轮次多,同时真密度高的浸渍剂所得复合材料毛坯的密度较高,真密度低的浸渍剂所得复合材料毛坯的密度较低。
步骤3,高温处理。将完成前期致密化及骨架定型的中间状态热结构复合材料毛坯装入热处理炉中,在1200~2000℃条件下进行高温处理,实现热结构复合材料基体组元的微结构优化及稳定化,并为复合材料的后期浸渍致密化提供开孔及通道。
步骤4,热结构复合材料毛坯的型面尺寸检测及加工。对中间状态热结构复合材料毛坯的型面轮廓及厚度尺寸进行检测,并对不符合设计尺寸的区域进行加工,最终获得满足设计尺寸的半致密化热结构复合材料毛坯。
步骤5,浸渍及涂覆热结构复合材料毛坯。
配制含有抗氧化功能组元的浸渍剂。在浸渍剂中引入具有优良抗氧化性能的微细无机组元(B2O3、B4C、Si、SiC、SiO2、Al2O3、ZrC、ZrO2、HfB2等含硼/硅/铝/锆/铪等元素的单质、碳化物、硼化物及氧化物),并进行充分的混合和均匀分散,同时,通过溶剂或特殊助剂对浸渍剂粘度进行调配,满足后期致密化阶段的均匀浸渍需求。
将含抗氧化功能组元的浸渍剂通过真空/压力组合浸渍方式浸入热结构复合材料毛坯的孔隙中,浸渍结束后从浸渍剂中取出热结构复合材料毛坯,并对毛坯表面的残留胶液进行清理和涂覆,使毛坯表面形成一薄层均匀连续的保护胶层,经后续固化步骤,在热结构复合材料表面原位形成一薄层均匀的抗氧化涂层。
该步骤中,抗氧化功能组元的含量和粒径要适中,抗氧化功能组元的含量太小,则对复合材料的抗氧化效果提升不明显,抗氧化功能组元的粒径过大,则对应浸渍剂难以分散均匀,且易在材料表面结壳和脱落,粒径过小及含量太多也会对浸渍剂的粘度和粘结性造成不利影响。因此,结合相关研究结果和经验,确定抗氧化功能组元比较适宜的含量范围为2~20wt%,粒径范围为0.2~5μm。
该步骤中,添加的抗氧化功能组元成分可依据应用温度及功能进行选配,满足不同应用环境对热结构复合材料的差别化需求。
步骤6,原位固化。将完成浸渍及涂覆的热结构复合材料毛坯先在室温下表干2~6h,之后在复合防变形工装辅助维型下装入烘箱或固化罐中,在80~240℃及0.1~3MPa下处理4~20h,实现热结构复合材料毛坯内部及表面浸渍剂的原位固化。
步骤7,浸渍相高温裂解。将完成浸渍、原位固化的热结构复合材料毛坯装入仿形石墨维型工装中,之后装入热处理设备中,在600~1400℃下处理4~30h,实现浸渍剂的高温裂解,生成含一定抗氧化功能组元的热结构复合材料基体。
步骤8,含抗氧化功能组元浸渍剂多轮循环浸渍/裂解增密。重复步骤5~步骤7至相邻两次增重率小于1wt%,最终得到浸渍增密与表面涂层一体化完成的热结构复合材料。
该步骤中,步骤5~步骤7的重复次数为2~6次。
该步骤中,浸渍所用的浸渍剂中添加的抗氧化功能组元含量随着浸渍轮次增加而递增,实现梯度分布,减少涂层与基体间的热失配。
实施例
实施例1
预先制备二维铺层结构炭纤维增强体,在仿形精密成型工装夹持情况下,采用酚醛树脂浸渍剂,通过真空/压力循环浸渍及碳化4次,获得密度为1.5g/cm3的C/C中间状态热结构复合材料毛坯,之后通过2000℃高温处理及轮廓加工后,继续采用含有B4C、Si、SiC抗氧化功能组元(粒径0.5μm)的酚醛树脂浸渍剂进行4轮次的循环浸渍/涂覆、原位固化处理(室温下表干4h,之后在防变形工装辅助维型下装入固化罐中,在200℃及2MPa下处理6h)、高温裂解(在1400℃下处理20h),并逐次增加B4C、Si及SiC组元含量(含量依次为3%、7%、11%、15%),最终获得了含B4C/SiC梯度抗氧化涂层的C/C热结构复合材料。相比纯酚醛树脂浸渍/碳化所得致密C/C复合材料,含B4C/SiC梯度抗氧化涂层的C/C复合材料,在1000℃,30min氧化环境下的失重率降低100%。
实施例2
预先制备针刺结构的炭纤维增强体,在仿形精密成型工装夹持情况下,采用聚碳硅烷前驱体浸渍剂,通过真空/压力循环浸渍及裂解5次,获得密度为1.7g/cm3的C/SiC中间状态热结构复合材料毛坯,之后通过1500℃高温处理及轮廓加工后,继续采用含有Zr及B2O3抗氧化功能组元(粒径2μm)的聚碳硅烷前驱体浸渍剂进行3轮次的循环浸渍/涂覆、原位固化处理(室温下表干5h,之后在防变形工装辅助维型下装入固化罐中,在160℃及3MPa下处理8h)、高温裂解(在1200℃下处理15h),并逐次增加Zr及B2O3组元含量(含量依次为4%、10%、16%),最终获得了含ZrC/B4C梯度抗氧化涂层的C/SiC热结构复合材料。相比纯聚碳硅烷浸渍/碳化所得致密C/SiC复合材料,含ZrC/B4C梯度抗氧化涂层的C/SiC复合材料,在1600℃,30min氧化环境下的失重率降低60%。
实施例3
预先制备二维铺层结构碳化硅纤维增强体,在仿形精密成型工装夹持情况下,采用聚碳硅烷前驱体浸渍剂,通过真空/压力循环浸渍及裂解3次,获得密度为1.6g/cm3的SiC/SiC中间状态热结构复合材料毛坯,之后通过1300℃高温处理及轮廓加工后,继续采用含有Si、B4C及ZrO2抗氧化功能组元(粒径1μm)的聚碳硅烷前驱体浸渍剂进行6轮次的循环浸渍/涂覆、原位固化处理(室温下表干3h,之后在防变形工装辅助维型下装入固化罐中,在240℃及2MPa下处理6h)、高温裂解(在1300℃下处理10h),并逐次增加Si、B4C及ZrO2组元含量(含量依次为2%、4%、6%、8%、10%、12%),最终获得了含ZrC/ZrB2/B4C梯度抗氧化涂层的SiC/SiC热结构复合材料。相比纯聚碳硅烷浸渍/裂解所得致密SiC/SiC复合材料,含ZrC/ZrB2/B4C梯度抗氧化涂层的SiC/SiC复合材料,在1400℃,30min氧化环境下的失重率降低80%。
以上结合具体实施方式和范例性实例对本发明进行了详细说明,不过这些说明并不能理解为对本发明的限制。本领域技术人员理解,在不偏离本发明精神和范围的情况下,可以对本发明技术方案及其实施方式进行多种等价替换、修饰或改进,这些均落入本发明的范围内。本发明的保护范围以所附权利要求为准。
本发明说明书中未作详细描述的内容属本领域技术人员的公知技术。
Claims (8)
1.一种基于液相浸渍和原位转化提高热结构复合材料抗氧化性能的方法,其特征在于,包括以下步骤:
步骤1,按照热结构复合材料的设计尺寸,采用耐高温无机纤维制备纤维预制体;
步骤2,采用碳基浸渍剂或陶瓷基浸渍剂,通过多轮次循环浸渍/裂解工艺,实施热结构复合材料骨架定型及前期致密化,获得密度为1.4~1.8g/cm3、具有孔隙的中间状态热结构复合材料毛坯;
步骤3,将中间状态热结构复合材料毛坯在1200~2000℃下进行高温处理;
步骤4,在浸渍剂中加入抗氧化功能组元,将含抗氧化功能组元的浸渍剂通过真空/压力组合浸渍方式浸入热结构复合材料毛坯的孔隙中,浸渍结束后从浸渍剂中取出热结构复合材料毛坯,并对毛坯表面的残留胶液进行清理和涂覆,使毛坯表面形成一薄层均匀连续的胶层;
步骤5,将完成浸渍及涂覆的热结构复合材料毛坯先在室温下表干,然后在80~240℃、0.1~3MPa下处理4~20h,实施热结构复合材料毛坯内部及表面浸渍剂的原位固化;
步骤6,将完成浸渍、原位固化的热结构复合材料毛坯装入仿形石墨维型工装中,之后装入热处理设备中,在600~1400℃下处理4~30h,实施浸渍剂的高温裂解;
步骤7,重复步骤4~步骤6至相邻两次增重率小于1wt%,最终得到浸渍增密与表面涂层一体化完成的热结构复合材料。
2.根据权利要求1所述的方法,其特征在于,步骤2中,浸渍/裂解工艺循环3~6轮次。
3.根据权利要求1所述的方法,其特征在于,步骤3中,高温处理后,还包括对中间状态热结构复合材料毛坯的型面轮廓及厚度尺寸进行检测并对不符合设计尺寸的区域进行加工。
4.根据权利要求1所述的方法,其特征在于,步骤4中,所述抗氧化功能组元选自含硼/硅/铝/锆/铪元素的单质、碳化物、硼化物及氧化物。
5.根据权利要求1所述的方法,其特征在于,步骤4中,所述抗氧化功能组元的粒径为0.2~5μm。
6.根据权利要求1所述的方法,其特征在于,步骤4中,所述抗氧化功能组元的含量为2~20wt%。
7.根据权利要求1所述的方法,其特征在于,步骤7中,步骤4~步骤6的重复次数为2~6次。
8.根据权利要求1所述的方法,其特征在于,步骤7中,浸渍剂中添加的抗氧化功能组元含量随着浸渍轮次增加而递增。
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