CN113748096B - 制造cmc部件的方法 - Google Patents

制造cmc部件的方法 Download PDF

Info

Publication number
CN113748096B
CN113748096B CN202080027459.4A CN202080027459A CN113748096B CN 113748096 B CN113748096 B CN 113748096B CN 202080027459 A CN202080027459 A CN 202080027459A CN 113748096 B CN113748096 B CN 113748096B
Authority
CN
China
Prior art keywords
phase
consolidated
tows
equal
silicon carbide
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
CN202080027459.4A
Other languages
English (en)
Other versions
CN113748096A (zh
Inventor
E·布鲁恩
M·范瑞黎
E·菲利普
G·卡尼尔
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Ceramics SA
General Electric Co
Original Assignee
Safran Ceramics SA
General Electric Co
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Safran Ceramics SA, General Electric Co filed Critical Safran Ceramics SA
Priority claimed from PCT/EP2020/058929 external-priority patent/WO2020201202A1/fr
Publication of CN113748096A publication Critical patent/CN113748096A/zh
Application granted granted Critical
Publication of CN113748096B publication Critical patent/CN113748096B/zh
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Images

Classifications

    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62857—Coating fibres with non-oxide ceramics
    • C04B35/62865—Nitrides
    • C04B35/62868—Boron nitride
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • C04B35/573—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide obtained by reaction sintering or recrystallisation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62844—Coating fibres
    • C04B35/62857—Coating fibres with non-oxide ceramics
    • C04B35/62873—Carbon
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
    • C04B35/628—Coating the powders or the macroscopic reinforcing agents
    • C04B35/62884—Coating the powders or the macroscopic reinforcing agents by gas phase techniques
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/71—Ceramic products containing macroscopic reinforcing agents
    • C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
    • C04B35/80—Fibres, filaments, whiskers, platelets, or the like
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/02—Pretreatment of the material to be coated
    • C23C14/024—Deposition of sublayers, e.g. to promote adhesion of the coating
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/04—Coating on selected surface areas, e.g. using masks
    • C23C16/045—Coating cavities or hollow spaces, e.g. interior of tubes; Infiltration of porous substrates
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/30—Deposition of compounds, mixtures or solid solutions, e.g. borides, carbides, nitrides
    • C23C16/32—Carbides
    • C23C16/325—Silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C16/00—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes
    • C23C16/44—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the method of coating
    • C23C16/54—Apparatus specially adapted for continuous coating
    • C23C16/545—Apparatus specially adapted for continuous coating for coating elongated substrates
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/38—Non-oxide ceramic constituents or additives
    • C04B2235/3817—Carbides
    • C04B2235/3821—Boron carbides
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/30—Constituents and secondary phases not being of a fibrous nature
    • C04B2235/42—Non metallic elements added as constituents or additives, e.g. sulfur, phosphor, selenium or tellurium
    • C04B2235/421—Boron
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5216—Inorganic
    • C04B2235/524—Non-oxidic, e.g. borides, carbides, silicides or nitrides
    • C04B2235/5244—Silicon carbide
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02—Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/52—Constituents or additives characterised by their shapes
    • C04B2235/5208—Fibers
    • C04B2235/5252—Fibers having a specific pre-form
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60—Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/614—Gas infiltration of green bodies or pre-forms
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/72—Products characterised by the absence or the low content of specific components, e.g. alkali metal free alumina ceramics
    • C04B2235/728—Silicon content
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74—Physical characteristics
    • C04B2235/77—Density
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70—Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96—Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • General Chemical & Material Sciences (AREA)
  • Ceramic Products (AREA)
  • Inorganic Fibers (AREA)
  • Woven Fabrics (AREA)

Abstract

本发明公开了一种制造CMC部件的方法，所述方法至少包括：‑多根丝束(2)通过输送通过处理腔室(4)而被中间相涂覆，其中，气相(10)被注入处理腔室(4)，所述丝束在其输送期间拉紧，并且中间相由所注入的气相通过气相沉积形成；‑通过使用涂覆有中间相的丝束进行三维织造形成纤维预制件；以及‑通过化学气相渗透对纤维预制件进行处理以在中间相上形成固结相来形成固结纤维预制件，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa，本发明还提供CMC部件，其至少包含：‑包含多根丝束(2)的3D织造的纤维增强件，所述丝束具有各自涂覆有中间相的多根纤维；以及‑使纤维增强件致密且位于中间相上的固结相，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa，所述固结相不含游离硅。

Description

制造CMC部件的方法
技术领域
本发明涉及陶瓷基质复合材料(CMC)部件和用于制造该部件的方法。
本发明的应用领域是制造在使用中暴露于高温的部件，特别是在航空和航天领域中，尤其是用于航空涡轮发动机的热部分的部件，应当理解，本发明可以应用于其他领域，例如，应用于工业燃气轮机领域。
发明背景
CMC材料具有良好的热结构性能(即，使其适用于构成结构部件的良好机械性能)以及在高温下保持这些性能的能力。CMC材料包含由存在于陶瓷基质中的陶瓷或碳材料丝束制成的纤维增强件。对于在使用中暴露于高温的部件，使用CMC材料代替金属材料是理想的，特别是因为该类材料的密度远小于其所替代的金属材料的密度。
尤其已知通过以下技术制造CMC部件：其中，用树脂混合物浸渍涂覆有中间相的纤维层(plies)，然后以需要的取向进行铺设，获得待制备部件的预制件。在形成预制件后，树脂进行热解，随后通过用熔融硅或熔融硅合金渗透形成陶瓷基质来进行预制件致密化。发明人已经观察到，由此获得的产品可能并不完全令人满意，因为由于游离硅的存在，各层之间的基质层会导致高温蠕变缺点。在该类型产品中，所掺入基质相的特点是抗蠕变性低，因为通过熔体渗透所获得的基质中的游离硅可能导致纤维过载超过其抗蠕变性，从而缩短了发生断裂时间。
因此需要提供高温下机械性能得以改进(尤其是更好的抗蠕变性)的CMC部件。
发明目的和概述
本发明提供了一种制造CMC部件的方法，所述方法至少包括：
-多根丝束通过输送通过处理腔室而被中间相涂覆，其中，气相被注入处理腔室，所述丝束在其输送期间拉紧，并且中间相由所注入的气相通过气相沉积形成；
-通过使用涂覆有中间相的丝束进行三维织造形成纤维预制件；以及
-通过化学气相渗透对纤维预制件进行处理以在中间相上形成固结相来形成固结纤维预制件，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa。
除非另有说明，否则，固结相的杨氏模量是在20℃下测量的。
通过三维织造获得的增强件与具有高模量的CVI(“化学气相渗透”)碳化硅固结相结合产生了不含游离硅的互连且刚性的3D网络，可为材料提供高温下高抗蠕变性。本发明人还观察到，由于丝束中纤维间隔的有益效果，在拉紧的情况下所输送的丝束上通过气相沉积形成中间相提供了围绕丝束各纤维的单独涂层，以及良好的丝束内填充。因此，与在已织造的预制件(其中，丝束的透气性受到限制)的纤维上通过CVI形成中间相相比，丝束的填充更加均匀。在本发明中，所形成的中间相尤其提供了改进的纤维与纤维的载荷转移，并且还避免了在氧化暴露期间玻璃连接和相邻纤维束断裂的风险。本发明所提供的方案由此提供了具有改进的高温下机械性能的CMC部件。
在一个实施方式中，固结相的杨氏模量大于或等于375GPa，例如，大于或等于400GPa。
该特征有利地进一步改进了CMC部件的抗蠕变性。
在一个实施方式中，固结纤维预制件的剩余体积孔隙率为25％至45％，例如30％至35％。
发明人已观察到该特征有利地优化了高温下抗蠕变性。
在一个实施方式中，所述方法还包括：通过用包含硅的熔融组合物进行渗透，在固结相上形成碳化硅基质相以使固结纤维预制件致密化，碳和/或陶瓷颗粒在渗透前就存在于固结预制件的孔隙中。
该特征有利地产生具有低孔隙率的陶瓷基质，由此减少机械载荷下的应力集中并改进基质的抗开裂性。
在一个实施方式中，中间相通过至少一层以下材料层形成：氮化硼、掺杂有硅的氮化硼、热解碳或硼掺杂碳。在一个示例中，中间相可以被至少一种以下材料的保护层覆盖：氮化硅或碳化硅。
在一个实施方式中，丝束包含碳化硅纤维，以原子百分比计，其氧含量小于或等于1％。
本发明还提供了一种CMC部件，其至少包含：
-包含多根丝束的3D织造的纤维增强件，所述丝束具有各自涂覆有中间相的多根纤维；以及
-使纤维增强件致密且位于中间相上的固结相，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa，所述固结相不含游离硅。
该CMC部件可以通过实施如上所述方法获得。
在一个实施方式中，固结相的杨氏模量大于或等于375GPa，例如，大于或等于400GPa。
如上所述，该特征还有利地改进了CMC部件的抗蠕变性。
在一个实施方式中，固结相的体积分数为5％至30％，例如10％至30％。
该特征有利地优化了高温下抗蠕变性。
在一个实施方式中，部件还包括位于固结相上的碳化硅基质相，所述碳化硅基质相的剩余体积孔隙率小于或等于8％。
如上所述，该特征有利地减少了机械载荷下的应力集中并改进基质的抗开裂性。
在一个实施方式中，中间相通过至少一层以下材料层形成：氮化硼、掺杂有硅的氮化硼、热解碳或硼掺杂碳。
在一个实施方式中，丝束包含碳化硅纤维，以原子百分比计，其氧含量小于或等于1％。
例如，该部件可以是涡轮发动机部件。例如，所述部件可以是涡轮环或涡轮环区段、叶片(blade)、叶(vane)、燃烧器内衬或喷嘴。
附图的简要说明
本发明的其它特点和优势通过下文描述并参照附图而显而易见，其以非限制方式给出，附图中：
-图1是本发明方法的一个示例的流程图；并且
-图2大致显示了用于在将丝束输送通过本发明可用的处理腔室时在丝束上形成中间相的装置。
具体实施方式
该方法开始于通过进行气相沉积用中间相涂覆丝束(图1中的步骤S10)。
丝束可以包含陶瓷纤维，例如，氮化物或碳化物纤维，如碳化硅纤维。在另一变体中，丝束可以包含碳纤维。在一个示例中，丝束包含碳化硅纤维，以原子百分比计，其氧含量小于或等于1％。该丝束的示例由NGS公司以商品名“Hi-Nicalon-S”提供，由供应商UBE以商品名“Tyranno SA3”提供，或由供应商COI Ceramics以商品名“Sylramic i-BN”提供。一种丝束包含多根纤维，例如，至少一百根纤维，典型地500根纤维。
中间相用于减缓丝束纤维因初始在基质内开始的裂纹而断裂。例如，脆化-释放(embrittlement-release)中间相可以包含层状结构的材料，当裂纹到达中间相时，能够通过原子尺度的局部脱胶(un-bonding)来耗散断裂能，从而使裂纹在中间相内偏转。中间相是可包含单层或多层的涂层。中间相可以包含如下材料的一个或多个层：氮化硼BN、硅掺杂氮化硼BN(Si)(硅的质量含量为5％至40％，并且余量为氮化硼)、热解碳PyC、或硼掺杂碳碳化硼(硼的原子含量为5％至20％，余量为碳)。中间相的厚度可以大于或等于10纳米(nm)，例如，可以为10nm至1000nm。以已知的方式，可以优选在形成中间相之前对丝束纤维进行表面处理，以消除存在于纤维上的胶料(sizing)和氧化物表面层，例如二氧化硅SiO2。
用于用气相沉积所形成的中间相来涂覆丝束的方法和装置是已知的，同时这些丝束在拉紧的情况下输送通过处理腔室。关于这方面，例如，可以参考文献FR 3 044 022，其内容通过参考全文纳入本文。
用于在丝束2上形成中间相的合适装置1的示例的简要描述参考图2在下文中提供。
装置1包括：处理腔室4，用于涂覆的多根丝束2由传送体系6驱动输送通过该处理腔室，此处所述输送体系包括第一组滑轮6a和第二组滑轮6b。各组6a或6b包含一个或多个滑轮。在涂覆期间，丝束2由传送体系6从入口端5a输送到出口端5b。传送体系6构造成使丝束2沿着传送轴Y输送通过处理腔室4。在所示示例中，传送轴Y与装置1的纵轴X平行。拉紧滑轮6a和6b之间的丝束2，并且拉紧入口端5a和出口端5b之间的丝束2。由于所施加的张力，丝束2的纤维铺开，导致丝束2的更均匀填充和纤维的单独涂覆。在用中间相进行涂覆期间，可以将丝束2连续输送通过处理腔室4。在该情况下，丝束2在被输送通过处理腔室4时不会停止。
由中间相涂覆的丝束2可以不是互连的(特别是丝束2并未被织造、针织或编织在一起)。丝束2可能并未经过任何纺织操作，并且在用中间相涂覆期间可能不会形成纤维结构。
中间相通过将气相10通过入口孔7注入处理腔室4中以在丝束2上形成中间相而获得。该中间层可以通过化学气相沉积(CVD)形成。中间相可以与丝束纤维接触而形成。未反应的任意气相与反应的副产物一起通过出口孔8(箭头11)泵出。装置1还包括加热体系，其构造成对处理腔室4进行加热以进行气相沉积。加热体系可以通过感应或辐射加热来加热处理腔室4。当形成PyC中间相时，气相10可以包含一种或多种气态烃，例如，选自甲烷、乙烷、丙烷和丁烷。在一个变体中，气相10可以包括用于陶瓷材料的气态前体，例如，三氯化硼BCl3和氨NH3的组合。为了制备给定的中间相，选择待使用的前体以及处理腔室4中所施加的压力和温度条件形成了本领域技术人员公知常识的一部分。
多层中间相可以通过如下制备：串联放置该类型的多个单元，各单元包括用于注入气相的装置和用于去除残留气相的装置。
一旦丝束2已涂覆有中间相，该方法继续进行所涂覆丝束的三维编织以形成待制备部件的纤维预制件(图1中的步骤S20)。
纤维预制件用于形成待制备部件的纤维增强件。纤维预制件可以通过在多层经线丝束和多层纬线丝束之间的三维织造来获得。所述纤维预制件也可通过三维织造制造成单一件。三维织造可通过使用“互锁”织造进行，即每层纬线丝束与多层经线丝束互连的织造物，其中，相同纬列中的所有丝束在织造平面中具有相同移动。经线和纬线之间的作用可以互换，并且这种互换应当视为同样由权利要求涵盖。当然，使用其他类型的3D织造不会超出本发明的范围。各种合适的制造技术见述于文件WO 2006/136755，其通过引用全文纳入本文。
以已知方式，可以优选在用胶料组合物织造之前对经涂覆丝束进行处理以避免织造期间破坏中间相的风险，所述胶料组合物包含线性聚硅氧烷。该胶料组合物的示例公开于文献US 2017/073854中，其内容通过参考全文纳入本文。避免破坏中间相的任意风险的另一种解决方案是使用织布机形成预制件，所述织布机具有与由钼制成的与丝束接触的元件。该类型的织布机公开于文献FR 3045679中，其内容通过参考全文纳入本文。
在形成3D织造预制件之后，通过CVI在纤维预制件的孔中和中间相上形成包含碳化硅的固结相(图1中的步骤S30)。固结相可以与中间相接触而形成。通过CVI获得的固结相不含有游离硅，并且杨氏模量大于或等于350GPa。例如，固结相的杨氏模量可以为350GPa至450GPa，例如350GPa至420GPa。如上所述，该固结相提供了具有所需高温下抗蠕变性的部件。固结相包含碳化硅，其任选地掺杂有自修复材料，例如硼B或碳化硼B4C。
固结相的厚度可以大于或等于500nm，例如，为1微米(μm)至30μm。固结相的厚度足以使纤维预制件固结，即，使得预制件的丝束充分地连接在一起，从而能够在无需支撑工具帮助的情况下在保持其形状的同时对预制件进行处理。
在形成固结相之后且开始任选的补充致密化(supplemental densification)(图1中的步骤S40)之前，固结纤维预制件的剩余体积孔隙率可以小于或等于45％，例如可以为30％至35％。固结的纤维预制件(或CMC部件)中的固结相的体积分数可以大于或等于5％。在一个示例中，固结相的该体积分数为10％至30％。
在形成固结相之后，可以进行补充致密化步骤以终止预制件的致密化(步骤S40)。在补充致密化步骤S40期间所形成的陶瓷基质相形成于固结相上，并且可以与固结相接触。
在一个实施方式中，该补充致密化步骤对应于通过浆料浇铸渗透+熔体渗透技术的致密化。在该情况下，可以将陶瓷和/或碳粉引入到固结的纤维预制件的孔中。为此，固结的预制件可以用含有悬浮在液体介质(例如水)中的粉末的浆料进行浸渍。粉末可以通过过滤保留在预制件中，所述过滤可在抽吸或压力的帮助下进行。优选使用由平均尺寸(D50)小于或等于5μm、甚至小于或等于2μm的颗粒组成的粉末。在用熔融组合物进行渗透前，粉末存在于固结的纤维预制件的孔中。粉末可以包含碳化硅颗粒。除了碳化硅颗粒之外或替代碳化硅颗粒，一些其它材料(例如，碳、碳化硼、硼化硅、氮化硅)的颗粒可以存在于纤维预制件的孔中。
随后，含有颗粒的固结的纤维预制件由含有硅的熔融组合物进行渗透。该组合物本身可以对应于熔融硅或对应于还包含一种或多种其他元素(例如钛、钼、硼、铁或铌)的熔融态的硅合金。在熔融组合物中硅的重量含量可以大于或等于50％，例如，大于或等于75％，例如，大于或等于90％。
当然，使用补充致密化步骤S40的其它类型技术不会超出本发明的范围。例如，补充致密化步骤可以已知方式通过CVI或通过聚合物渗透与热解(PIP)技术进行。在一个示例中，用于形成固结相的CVI技术可以继续进行以使得纤维预制件完全致密化。在该情况下，CMC部件的所有陶瓷基质可以通过CVI获得。
术语"在……至……范围内"应理解为包括端值。

Claims (9)

1.一种制造CMC部件的方法，所述方法至少包括：
-多根丝束通过输送通过处理腔室而被中间相涂覆，其中，气相被注入处理腔室，所述丝束在其输送期间拉紧，并且中间相由所注入的气相通过气相沉积形成；
-通过使用涂覆有中间相的丝束进行三维织造形成纤维预制件；以及
-通过化学气相渗透对纤维预制件进行处理以在中间相上形成固结相来形成固结纤维预制件，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa，其中固结相的体积分数为5％至30％，
其中，所述方法还包括：通过用包含硅的熔融组合物进行渗透，在固结相上形成碳化硅基质相来使固结纤维预制件致密化，其中，碳和/或陶瓷颗粒在渗透前就存在于固结预制件的孔隙中，或者固结纤维预制件的致密化通过聚合物渗透与热解技术进行。
2.如权利要求1所述的方法，其中，固结相的杨氏模量大于或等于375GPa。
3.如权利要求1所述的方法，其中，固结纤维预制件的剩余体积孔隙率为25％至45％。
4.如权利要求1所述的方法，其中，所述中间相通过至少一层以下材料层形成：氮化硼、掺杂有硅的氮化硼、热解碳或硼掺杂碳。
5.如权利要求1所述的方法，其中，丝束包含碳化硅纤维，其氧含量以原子百分比计小于或等于1％。
6.一种CMC部件，其至少包含：
-包含多根丝束的3D织造的纤维增强件，所述丝束具有各自涂覆有中间相的多根纤维；以及
-使纤维增强件致密且位于中间相上的固结相，所述固结相包含碳化硅并且杨氏模量大于或等于350GPa，所述固结相不含游离硅，其中固结相的体积分数为5％至30％，
其中，部件还包括位于固结相上的碳化硅基质相，所述碳化硅基质相的剩余体积孔隙率小于或等于8％。
7.如权利要求6所述的CMC部件，其中，固结相的杨氏模量大于或等于375GPa。
8.如权利要求6或7中任一项所述的CMC部件，其中，所述中间相通过至少一层以下材料层形成：氮化硼、掺杂有硅的氮化硼、热解碳或硼掺杂碳。
9.如权利要求6至8中任一项所述的CMC部件，其中，丝束包含碳化硅纤维，其氧含量以原子百分比计小于或等于1％。
CN202080027459.4A 2019-04-05 2020-03-30 制造cmc部件的方法 Active CN113748096B (zh)

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
US201962829863P 2019-04-05 2019-04-05
US62/829,863 2019-04-05
FRFR1911064 2019-10-07
FR1911064A FR3101629B1 (fr) 2019-10-07 2019-10-07 Procédé de fabrication d'une pièce en CMC
PCT/EP2020/058929 WO2020201202A1 (fr) 2019-04-05 2020-03-30 Procede de fabrication d'une piece en cmc

Publications (2)

Publication Number Publication Date
CN113748096A CN113748096A (zh) 2021-12-03
CN113748096B true CN113748096B (zh) 2023-05-23

Family

ID=69375478

Family Applications (1)

Application Number Title Priority Date Filing Date
CN202080027459.4A Active CN113748096B (zh) 2019-04-05 2020-03-30 制造cmc部件的方法

Country Status (2)

Country Link
CN (1) CN113748096B (zh)
FR (1) FR3101629B1 (zh)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20230407532A1 (en) * 2022-06-16 2023-12-21 Raytheon Technologies Corporation Particle-imbedded serving yarn for cmc applications

Family Cites Families (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
FR2887601B1 (fr) 2005-06-24 2007-10-05 Snecma Moteurs Sa Piece mecanique et procede de fabrication d'une telle piece
US10047015B2 (en) * 2012-01-20 2018-08-14 Free Form Fibers, Llc High strength ceramic fibers and methods of fabrication
FR3018083B1 (fr) 2014-02-28 2016-04-08 Safran Ceram Fil ensime destine a subir une operation textile
FR3044022B1 (fr) 2015-11-19 2020-12-04 Herakles Dispositif pour le revetement d'un ou plusieurs fils par un procede de depot en phase vapeur
FR3045679B1 (fr) 2015-12-21 2019-05-03 Safran Ceramics Metier a tisser avec element en molybdene
US9850174B2 (en) * 2016-03-23 2017-12-26 General Electric Company Ceramic matrix composites having monomodal pore size distribution and low fiber volume fraction
CN106064951B (zh) * 2016-06-08 2019-05-14 中国人民解放军国防科学技术大学 C/C-SiC复合材料及其制备方法和应用
FR3053328B1 (fr) * 2016-06-29 2022-01-21 Herakles Procede de fabrication d'une piece en materiau composite a matrice ceramique

Also Published As

Publication number Publication date
FR3101629A1 (fr) 2021-04-09
CN113748096A (zh) 2021-12-03
FR3101629B1 (fr) 2022-06-17

Similar Documents

Publication Publication Date Title
JP5541659B2 (ja) 熱構造複合材部品の製造方法およびそれによって得られる部品
US9784217B2 (en) Low-thickness thermostructural composite material part, and manufacture method
RU2519116C2 (ru) Способ изготовления детали сложной формы из композиционного материала
US8039053B2 (en) Method for making a part of composite material with ceramic matrix and resulting part
US9611180B2 (en) Method for manufacturing a part made of CMC
RU2668431C2 (ru) Способ получения деталей из композитного материала путем пропитки композицией с низкой температурой плавления
JP4659372B2 (ja) セラミックマトリクス複合材料から多孔性部品を製造する方法
JP5539386B2 (ja) セラミック繊維の処理方法
CN108602724B (zh) 一种用陶瓷基质复合材料制造部件的方法
JP2017137231A (ja) セラミック繊維を加工処理する方法
JP6301261B2 (ja) Ｃｍｃ材料部品
WO2014137478A1 (en) Methods for reducing the process-induced shrinkage in a laminated ceramic matrix composite, and articles made therefrom
CN109476552B (zh) 复合材料部件
US11236022B2 (en) Filament winding apparatus and method for ceramic matrix composites
CN113748096B (zh) 制造cmc部件的方法
US20200181029A1 (en) A method of fabricating a part out of ceramic matrix composite material
KR102153918B1 (ko) 화학기상증착을 이용한 SiC 나노와이어 균일 성장에 의한 고밀도의 탄화규소 복합체 제조 방법 및 이의 의해 제조된 탄화규소 복합체
US20220177374A1 (en) A method of fabricating a cmc part
CN111971262A (zh) 复合材料部件的制造方法
EP4292995A2 (en) Particle-imbedded serving yarn for cmc applications
JP2013112561A (ja) 平滑表面を有するセラミックス基複合部材およびその製造方法
CN118434699A (zh) 制造由SiC/SiC复合材料制成的部件的方法
CN116547129A (zh) 由具有至少部分地陶瓷基质的复合材料制成的叶片
CN111107983A (zh) 制造具有传感器的复合材料部件的方法
JPH11343176A (ja) セラミックス複合材料の製造方法

Legal Events

Date Code Title Description
PB01 Publication
PB01 Publication
SE01 Entry into force of request for substantive examination
SE01 Entry into force of request for substantive examination
GR01 Patent grant
GR01 Patent grant