CN114920572A - Woven carbon fiber reinforced ceramic core, preparation method thereof and corresponding investment casting method - Google Patents
Woven carbon fiber reinforced ceramic core, preparation method thereof and corresponding investment casting method Download PDFInfo
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- 229920000049 Carbon (fiber) Polymers 0.000 title claims abstract description 44
- 239000004917 carbon fiber Substances 0.000 title claims abstract description 44
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 title claims abstract description 41
- 239000011226 reinforced ceramic Substances 0.000 title claims abstract description 12
- 238000000034 method Methods 0.000 title claims description 35
- 238000002360 preparation method Methods 0.000 title claims description 17
- 238000005495 investment casting Methods 0.000 title claims description 12
- 239000000919 ceramic Substances 0.000 claims abstract description 132
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 63
- 239000011159 matrix material Substances 0.000 claims abstract description 47
- 239000002657 fibrous material Substances 0.000 claims abstract description 33
- 239000002002 slurry Substances 0.000 claims description 28
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 27
- 235000015895 biscuits Nutrition 0.000 claims description 21
- 239000004744 fabric Substances 0.000 claims description 21
- 239000010410 layer Substances 0.000 claims description 19
- 238000003825 pressing Methods 0.000 claims description 14
- 238000005245 sintering Methods 0.000 claims description 14
- 230000007704 transition Effects 0.000 claims description 10
- 238000004519 manufacturing process Methods 0.000 claims description 9
- 238000000137 annealing Methods 0.000 claims description 8
- 238000005266 casting Methods 0.000 claims description 7
- 238000001125 extrusion Methods 0.000 claims description 7
- 239000002184 metal Substances 0.000 claims description 7
- 239000000377 silicon dioxide Substances 0.000 claims description 7
- 238000000465 moulding Methods 0.000 claims description 6
- 239000002356 single layer Substances 0.000 claims description 6
- 238000002347 injection Methods 0.000 claims description 3
- 239000007924 injection Substances 0.000 claims description 3
- 238000006243 chemical reaction Methods 0.000 claims description 2
- 238000004321 preservation Methods 0.000 claims description 2
- 239000002994 raw material Substances 0.000 claims description 2
- 239000003518 caustics Substances 0.000 claims 1
- 238000001802 infusion Methods 0.000 claims 1
- 239000000243 solution Substances 0.000 claims 1
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 15
- 229910052710 silicon Inorganic materials 0.000 description 15
- 239000010703 silicon Substances 0.000 description 15
- 238000009941 weaving Methods 0.000 description 11
- 238000010438 heat treatment Methods 0.000 description 10
- 230000008569 process Effects 0.000 description 9
- 239000000835 fiber Substances 0.000 description 6
- 239000000843 powder Substances 0.000 description 6
- 239000003513 alkali Substances 0.000 description 5
- 239000000463 material Substances 0.000 description 5
- 239000000758 substrate Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 238000002156 mixing Methods 0.000 description 4
- 239000011224 oxide ceramic Substances 0.000 description 4
- 239000004014 plasticizer Substances 0.000 description 4
- 230000002787 reinforcement Effects 0.000 description 4
- 229910052814 silicon oxide Inorganic materials 0.000 description 4
- 238000000498 ball milling Methods 0.000 description 3
- 238000001816 cooling Methods 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000003993 interaction Effects 0.000 description 3
- QNRATNLHPGXHMA-XZHTYLCXSA-N (r)-(6-ethoxyquinolin-4-yl)-[(2s,4s,5r)-5-ethyl-1-azabicyclo[2.2.2]octan-2-yl]methanol;hydrochloride Chemical group Cl.C([C@H]([C@H](C1)CC)C2)CN1[C@@H]2[C@H](O)C1=CC=NC2=CC=C(OCC)C=C21 QNRATNLHPGXHMA-XZHTYLCXSA-N 0.000 description 2
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 description 2
- 230000008859 change Effects 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- 238000002474 experimental method Methods 0.000 description 2
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- 238000001746 injection moulding Methods 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 230000001590 oxidative effect Effects 0.000 description 2
- 238000007711 solidification Methods 0.000 description 2
- 230000008023 solidification Effects 0.000 description 2
- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000008358 core component Substances 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000011049 filling Methods 0.000 description 1
- 230000004927 fusion Effects 0.000 description 1
- 230000006872 improvement Effects 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000002844 melting Methods 0.000 description 1
- 239000011812 mixed powder Substances 0.000 description 1
- 239000000203 mixture Substances 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 230000035939 shock Effects 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 238000000352 supercritical drying Methods 0.000 description 1
- 230000009466 transformation Effects 0.000 description 1
- 238000005303 weighing Methods 0.000 description 1
Classifications
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- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/02—Sand moulds or like moulds for shaped castings
- B22C9/04—Use of lost patterns
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22C—FOUNDRY MOULDING
- B22C9/00—Moulds or cores; Moulding processes
- B22C9/10—Cores; Manufacture or installation of cores
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- 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
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/14—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on silica
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- 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
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- C—CHEMISTRY; METALLURGY
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- 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
- C04B2235/3826—Silicon carbides
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- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- 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
- C04B2235/5248—Carbon, e.g. graphite
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- 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
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E30/00—Energy generation of nuclear origin
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Abstract
The invention provides a woven carbon fiber reinforced ceramic core, which comprises a ceramic matrix and a reinforcing structure, wherein the reinforcing structure is positioned in the ceramic matrix, the reinforcing structure is coated on the ceramic matrix, the reinforcing structure is formed by fiber materials which are at least partially overlapped, the reinforcing structure reinforces the ceramic matrix, and the comprehensive performance of the ceramic core is improved.
Description
Technical Field
The invention relates to a woven carbon fiber reinforced ceramic core, a preparation method thereof and a corresponding investment casting method, in particular to a ceramic core for investment casting for preparing a gas turbine blade, a preparation method thereof and a corresponding investment casting method.
Background
The development of a gas turbine involves the cross fusion of various technologies such as structure, material, control, precision manufacturing and the like, and is known as an industrial crown. With the rapid development of the gas turbine industry, the use requirement of a hot-end core component of the gas turbine, namely a turbine hollow blade, is continuously improved. Ceramic cores are commonly adopted at home and abroad to form a complex inner cavity structure in the turbine blade to improve the cooling efficiency of the turbine blade, so that the service temperature of the turbine blade is improved. Therefore, the ceramic core becomes a core part for investment casting of the hollow turbine blade, and the manufacturing level of the ceramic core has important significance on the quality, the manufacturing cost, the product yield and the like of the hollow blade.
Silicon-based ceramic cores are one of the most widely used ceramic core types today. And the silicon dioxide of the silicon-based ceramic core can generate crystal form transformation in the sintering process, cristobalite is separated out from the matrix, and microcracks are generated along with the volume effect, so that the strength of the ceramic core is reduced. If the ceramic core cannot bear thermal shock of high-temperature molten metal in the blade casting process, the core may deviate or even break, core deviation, core exposure and core breakage in the investment casting process are caused, and the yield is reduced. Meanwhile, the ceramic core is not easy to remove in the blade, and the core needs to be removed by an alkali liquor corrosion method, and cannot be completely removed.
For example, patent document CN109622894B discloses a method for manufacturing a ceramic core with a quartz glass rod, comprising in sequence the following steps: step 1, preparing ceramic core slurry; step 2, pressing a ceramic core biscuit, wherein the weak connection part of the ceramic core biscuit is made of a quartz glass rod; step 3, loading the ceramic core biscuit into a pot and molding; step 4, sintering the ceramic core; between step 2 and step 3, the following steps are also included: and a heat insulation layer or/and an easily-melting layer is/are wrapped on the periphery of the quartz glass rod. By adopting the method, the quartz glass rod is subjected to local heat treatment in the sintering process of the ceramic core, so that cracks caused by volume change due to phase change of the quartz glass rod are greatly reduced or even eliminated, and the strength of the quartz glass rod is improved.
For another example, patent document CN108299001B discloses a method for forming a silicon-based ceramic core, and in particular, a two-step method for preparing a silicon-based ceramic core: firstly, preparing a silicon oxide core rough blank by an injection molding process; the second step is that: nanometer and submicron-grade particles are introduced into the rough blank by combining sol-gel with a supercritical drying process, so that the comprehensive performance of the silicon-based ceramic core is enhanced. Compared with the process for preparing the silicon-based ceramic core by using the injection molding mode alone, the process has the advantages of higher controllability, smaller shrinkage rate of the prepared product, more uniform structure of the product and higher strength, and can greatly improve the yield of the silicon-based ceramic core.
However, none of the above prior art completely solves the above problems of the silicon-based ceramic core.
Disclosure of Invention
The invention mainly aims to provide a woven carbon fiber reinforced ceramic core, a preparation method thereof and a corresponding investment casting method, so as to solve the problems in the prior art.
In order to achieve the above object, according to one aspect of the present invention, there is provided a woven carbon fiber reinforced ceramic core comprising a ceramic substrate and a reinforcing structure, characterized in that the reinforcing structure is located inside the ceramic substrate, the ceramic substrate covers the reinforcing structure, the reinforcing structure is composed of at least partially overlapped fiber materials including carbon fibers, and the reinforcing structure reinforces the ceramic substrate so that the strength of the ceramic core 1550 ℃ is not lower than 25 MPa.
Further, the reinforcing structure is a two-dimensional structure composed of at least partially overlapped fiber materials, and the two-dimensional structure is a sheet-shaped, layered or net-shaped structure with the length and width dimensions being significantly larger than the thickness dimension.
Further, the reinforcing structure is woven from a fibrous material.
Further, the reinforcing structure is a fiber fabric made of fiber materials through two-dimensional weaving.
Further, the reinforcing structure is a single-layer fiber fabric formed by 2 × 2 two-dimensional weaving.
Further, the ceramic matrix includes a silica matrix.
Further, the volume fraction of the fibrous material in the ceramic core is 30-60%.
Further, an interface transition layer exists on an interface between the reinforcing structure and the ceramic matrix, and the interface transition layer is generated by chemical reaction between the reinforcing structure and the ceramic matrix.
Further, the interface transition layer comprises SiC.
Further, the porosity of the ceramic core is 20-40%.
In order to achieve the above object, according to another aspect of the present invention, there is provided a method for manufacturing the above woven carbon fiber reinforced ceramic core, comprising a slurry preparation step, a biscuit pressing step and a sintering step,
in the slurry preparation step, raw materials of the ceramic substrate are mixed to prepare slurry;
in the biscuit pressing step, pressing the slurry to obtain a biscuit;
sintering the green body to form the ceramic core in the sintering step;
characterized in that a reinforcing structure preparation step is also included before the biscuit pressing step,
in the reinforcing structure preparing step, preparing fiber materials to form the reinforcing structure, in which the fiber materials are at least partially overlapped;
in the biscuit pressing step, the reinforcing structure is pressed together with the slurry into the biscuit.
Further, the biscuit pressing step comprises a slurry injecting step, a reinforcing structure immersing step and an extrusion forming step,
in the slurry injecting step, injecting the slurry in a molten state into a mold in a heat preservation state;
in the reinforcing structure immersing step, immersing the reinforcing structure in the slurry in an insulated state in the mold;
in the extrusion molding step, the mold is closed, and the slurry and the reinforcing structure are extruded.
Further, in the sintering step, the temperature of the green body is raised, so that a part of the reinforcing structure is gasified, and the ceramic core is obtained.
In order to accomplish the above object, according to another aspect of the present invention, there is provided an investment casting method using the above ceramic core, comprising a casting step and a releasing step,
in the casting step, pouring a metal melt into a ceramic mold, wherein the metal melt is cooled to form a product, and the ceramic mold comprises a ceramic core and a ceramic shell matched with the ceramic core;
in the demolding step, the ceramic mold and the product are removed;
characterized by further comprising a low-temperature annealing step performed after the demolding step, wherein the product is heated in the low-temperature annealing step so that all of the reinforcing structures remaining inside the product are vaporized.
Further, in the demolding step, the ceramic core inside the product is corroded by alkali liquor, so that the ceramic matrix in the ceramic core is removed from the product, and at least part of the reinforcing structure still remains inside the product.
By applying the technical scheme of the invention, at least the following beneficial effects are obtained:
1. the invention improves the comprehensive performance of the ceramic core and solves the problems of over-large size shrinkage, low room temperature and high temperature strength, large high temperature deflection and the like of the silicon-based ceramic core.
2. The ceramic core has high porosity, the matrix of the ceramic core can be easily corroded by alkali liquor, and the demoulding efficiency is high.
3. The residual carbon fiber framework of the ceramic core in the demoulding step can be completely removed in a mode of oxidizing into gas in the low-temperature annealing treatment process of the blade, so that the problem that the ceramic core is not easy to completely remove is solved.
4. Experiments prove that the prepared silicon-based ceramic core can be applied to hollow directional/single crystal blades prepared under the condition of directional solidification at the temperature of more than 1550 ℃.
Detailed Description
It should be noted that the embodiments and features of the embodiments may be combined with each other without conflict. The present invention will be described in detail with reference to examples.
The invention is described in further detail below with reference to specific examples, which are not to be construed as limiting the scope of the invention as claimed.
Example 1
The two-dimensional woven carbon fiber reinforced ceramic core is characterized by comprising a reinforced matrix and a silicon oxide ceramic matrix, wherein the reinforced matrix is a supporting framework formed by a two-dimensional woven carbon fiber fabric, and a SiC transition interface layer is arranged between the surface of carbon fiber and the ceramic matrix. The number of layers of the carbon fiber fabric is 1, the volume fraction of the carbon fiber fabric is about 30%, and the thickness of the single-layer carbon fiber braided fabric is 5 mm.
It should be noted that the forming manner of the reinforcing structure is not limited to the weaving method used in the embodiment, and other overlapping methods may be used as long as the fiber materials are partially overlapped to cause interaction between different fibers, so as to form the reinforcing structure. The fiber material and matrix material used are not limited to those described in this embodiment, and any fiber material known to those skilled in the art to provide reinforcement, or any material capable of forming a ceramic core matrix, may be used in the practice of the present invention.
The term "partially overlapped" as used herein refers to a method of weaving at least a portion of the fiber materials so that the fiber materials interact with each other to form a reinforced structure.
The preparation process mainly comprises the following steps:
s1, preparing a reinforced structure:
and (3) preparing a carbon fiber framework by two-dimensionally weaving the carbon fiber into a 1 x 1 rhombic structure.
S2, powder mixing:
and (2) filling the required quartz glass powder and zirconia balls into a ball milling tank for ball milling according to the mass ratio of 1:2, wherein the rotating speed of the ball mill is 200r/min, and the ball milling time is 10 h. And drying the uniformly mixed powder for 12 hours.
S3, slurry preparation:
weighing a certain amount of plasticizer, putting the plasticizer into a mixing barrel at the temperature of 90 ℃, adding dried powder into the mixing barrel in batches after the plasticizer is completely melted, and stirring under high vacuum. 0.1 percent of oleic acid is added in the mixing process. After the powder is completely added, the mixture is continuously and uniformly stirred for 4 hours under vacuum, and the slurry with the powder uniformly dispersed in the plasticizer can be obtained.
S4, biscuit pressing:
the biscuit is pressed by adopting an extrusion molding method, which can be divided into a slurry injection step, a reinforced structure immersion step and an extrusion molding step.
S4-1, slurry injection step:
the ceramic core slurry in the molten state was poured into a mold (mold temperature was maintained at 40 ℃).
S4-2, a reinforced structure immersion step:
the pre-made carbon fiber cloth was immediately immersed into the ceramic slurry.
S4-3, extrusion forming:
and (3) operating a press to mold, carrying out extrusion molding on the ceramic slurry, cooling the mold to 30 ℃, and then opening the mold to finally obtain the ceramic core biscuit.
S5, sintering:
burying the corrected biscuit in alpha-Al with grain size of about 100 meshes 2 O 3 Powder in a sagger. The thickness of the filler on the top of the core biscuit is not less than 25mm, and then the core biscuit is placed into a box-type resistance furnace for sintering. A sintering system: heating to 300 ℃ at a heating rate of 0.1-3 ℃/min, preserving heat for 100-200 min, heating to 600 ℃ at a heating rate of 0.1-3 ℃/min, preserving heat for 100-200 min, heating to 900 ℃ at a heating rate of 0.1-3 ℃/min, preserving heat for 100-200 min, heating to 1200 ℃ at a heating rate of 0.1-3 ℃/min, preserving heat for 200-300 min, and cooling to room temperature along with the furnace to obtain the silicon-based ceramic core.
The silica-based ceramic core prepared by the embodiment has the advantages of good surface quality, high molding rate, 37.13% of porosity, 23.78MPa of room-temperature strength, 36.54MPa of high-temperature strength and 0.41mm of high-temperature deflection.
Example 2
The two-dimensional woven carbon fiber reinforced ceramic core is characterized by comprising a reinforced matrix and a silicon oxide ceramic matrix, wherein the reinforced matrix is a supporting framework formed by a two-dimensional woven carbon fiber fabric, and a SiC transition interface layer is arranged between the surface of carbon fiber and the ceramic matrix. The number of the carbon fiber fabric layers is 1, the volume fraction of the carbon fiber fabric layers is about 30%, and the thickness of the single-layer carbon fiber braided fabric is 5 mm.
It should be noted that the forming manner of the reinforcing structure is not limited to the weaving method used in the embodiment, and other overlapping methods may be used as long as the fiber materials are partially overlapped to cause interaction between different fibers, so as to form the reinforcing structure. The fiber material and matrix material used are not limited to those described in this embodiment, and any fiber material known to those skilled in the art to provide reinforcement, or any material capable of forming a ceramic core matrix, may be used in the practice of the present invention.
The term "partially overlapped" as used herein means that at least a portion of the fiber materials are woven so as to interact with each other to form a reinforcing structure.
The preparation process mainly comprises the following steps:
s1, preparing a reinforced structure:
the carbon fiber skeleton is prepared by two-dimensionally weaving a 2 x 2 conventional structure with carbon fibers.
Steps S2 to S5 in this example are the same as in example 1.
The silica-based ceramic core prepared by the embodiment has the advantages of good surface quality, high molding rate, 30.17% of porosity, 28.36MPa of room-temperature strength, 39.52MPa of high-temperature strength and 0.23mm of high-temperature deflection.
Example 3
The two-dimensional woven carbon fiber reinforced ceramic core is characterized by comprising a reinforced matrix and a silicon oxide ceramic matrix, wherein the reinforced matrix is a supporting framework formed by two-dimensional woven carbon fiber fabrics, and a SiC transition interface layer is arranged between the surface of carbon fiber and the ceramic matrix. The number of layers of the carbon fiber fabric is 2, the volume fraction of the carbon fiber fabric is about 60%, and the thickness of the single-layer carbon fiber braided fabric is 5 mm.
It should be noted that the forming method of the reinforcing structure is not limited to the weaving method used in the embodiment, and other overlapping methods may be used as long as the fiber materials are partially overlapped, so that different fibers interact with each other to form the reinforcing structure. The fiber material and matrix material used are not limited to those described in this embodiment, and any fiber material known to those skilled in the art to provide reinforcement, or any material capable of forming a ceramic core matrix, may be used in the practice of the present invention.
The term "partially overlapped" as used herein means that at least a portion of the fiber materials are woven so as to interact with each other to form a reinforcing structure.
The preparation process mainly comprises the following steps:
s1, preparing a reinforced structure:
and (3) preparing a carbon fiber framework by two-dimensionally weaving the carbon fiber into a 1 x 1 rhombic structure.
Steps S2 to S5 in this example are the same as in example 1.
The silica-based ceramic core prepared by the embodiment has the advantages of good surface quality, high molding rate, 26.82% of porosity, 26.93MPa of room-temperature strength, 38.62MPa of high-temperature strength and 0.35mm of high-temperature deflection.
Example 4
The two-dimensional woven carbon fiber reinforced ceramic core is characterized by comprising a reinforced matrix and a silicon oxide ceramic matrix, wherein the reinforced matrix is a supporting framework formed by a two-dimensional woven carbon fiber fabric, and a SiC transition interface layer is arranged between the surface of carbon fiber and the ceramic matrix. The number of the carbon fiber fabric layers is 2, the volume fraction of the carbon fiber fabric layers is about 60%, and the thickness of the single-layer carbon fiber braided fabric is 5 mm.
It should be noted that the forming manner of the reinforcing structure is not limited to the weaving method used in the embodiment, and other overlapping methods may be used as long as the fiber materials are partially overlapped to cause interaction between different fibers, so as to form the reinforcing structure. The fiber material and matrix material used are not limited to those described in this embodiment, and any fiber material known to those skilled in the art to provide reinforcement, or any material capable of forming a ceramic core matrix, may be used in the practice of the present invention.
The term "partially overlapped" as used herein means that at least a portion of the fiber materials are woven so as to interact with each other to form a reinforcing structure.
The preparation process mainly comprises the following steps:
s1, preparing a reinforced structure:
the carbon fiber skeleton is prepared by two-dimensionally weaving a 2 x 2 conventional structure with carbon fibers.
Steps S2 to S5 in this example are the same as in example 1.
The silica-based ceramic core prepared by the embodiment has the advantages of good surface quality, high molding rate, 24.33% of porosity, 30.61MPa of room-temperature strength, 42.17MPa of high-temperature strength and 0.15mm of high-temperature deflection.
Comparative example
The comparative example, in which the other preparation process and the main process parameters were the same as in example 1, was a ceramic core without carbon fibers, i.e., a pure silicon-based ceramic core.
TABLE 1 comparison of Performance parameters of inventive examples 1-4 and comparative examples
| Sample (I) | Porosity (%) | Strength at room temperature (MPa) | High temperature Strength (MPa) | High temperature deflection (mm) |
| Example 1 | 37.13 | 23.78 | 36.54 | 0.41 |
| Example 2 | 30.17 | 28.36 | 39.52 | 0.23 |
| Example 3 | 26.82 | 26.93 | 38.62 | 0.35 |
| Example 4 | 24.33 | 30.61 | 42.17 | 0.15 |
| Comparative example | 26.83 | 13.06 | 22.96 | 1.28 |
From the above table, compared with a pure silicon-based ceramic core, the addition of the reinforcing structure provides a high-temperature framework structure for the ceramic core, the porosity is improved, and simultaneously, the ceramic core keeps better room-temperature and high-temperature strength and lower high-temperature deflection, and is easy to remove. Example 2 the overall performance is optimal.
Example 5
According to another aspect of the present invention, there is provided an investment casting method using the above ceramic core, comprising a casting step and a releasing step,
in the casting step, pouring a metal melt into a ceramic mold, wherein the metal melt is cooled to form a product, and the ceramic mold comprises a ceramic core and a ceramic shell matched with the ceramic core;
in the demolding step, the ceramic mold and the product are removed, specifically, the ceramic core inside the product is corroded by alkali liquor, so that the ceramic matrix in the ceramic core is removed from the product, and at least part of the reinforcing structure still remains inside the product;
further comprising a low-temperature annealing step of heating the product so that all of the reinforcing structures remaining inside the product are vaporized, the low-temperature annealing step being performed after the demolding step.
From the above description, it can be seen that the above-described embodiments of the present invention achieve the following technical effects:
1. the invention improves the comprehensive performance of the ceramic core and solves the problems of over-large size shrinkage, low room temperature and high temperature strength, large high temperature deflection and the like of the silicon-based ceramic core.
2. The ceramic core has high porosity, the matrix of the ceramic core can be easily corroded by alkali liquor, and the demoulding efficiency is high.
3. The residual carbon fiber framework of the ceramic core in the demoulding step can be completely removed in a mode of oxidizing into gas in the low-temperature annealing treatment process of the blade, so that the problem that the ceramic core is not easy to completely remove is solved.
4. Experiments prove that the prepared silicon-based ceramic core can be applied to hollow directional/single crystal blades prepared under the condition of directional solidification at the temperature of more than 1550 ℃.
The above description is only a preferred embodiment of the present invention and is not intended to limit the present invention, and various modifications and changes may be made by those skilled in the art. Any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the protection scope of the present invention.
Claims (15)
1. The woven carbon fiber reinforced ceramic core comprises a ceramic matrix and a reinforcing structure, and is characterized in that the reinforcing structure is located inside the ceramic matrix, the ceramic matrix wraps the reinforcing structure, the reinforcing structure is made of fiber materials which are at least partially overlapped, the fiber materials comprise carbon fibers, and the reinforcing structure reinforces the ceramic matrix, so that the strength of the ceramic core at 1550 ℃ is not lower than 25 MPa.
2. The ceramic core of claim 1, wherein the reinforcing structure is a two-dimensional structure of at least partially overlapping fibrous material, the two-dimensional structure being a sheet, layer, or mesh structure having a length and width dimension substantially greater than a thickness dimension.
3. The ceramic core as recited in claim 2, wherein the reinforcing structure is woven from a fibrous material.
4. The ceramic core of claim 3 wherein the reinforcing structure is a fabric of fibrous material woven in two dimensions.
5. The ceramic core of claim 4 wherein the reinforcing structure is a single layer of 2 x 2 two-dimensional weave-forming fabric.
6. The ceramic core as claimed in any one of claims 1 to 5, wherein the ceramic matrix comprises a silica matrix.
7. The ceramic core as claimed in any of claims 1-5, wherein the fibrous material has a volume fraction of 30% to 60% in the ceramic core.
8. The ceramic core as claimed in any one of claims 1 to 5, wherein an interfacial transition layer is present at an interface between the reinforcing structures and the ceramic matrix, the interfacial transition layer being formed by a chemical reaction between the reinforcing structures and the ceramic matrix.
9. The ceramic core of claim 8, wherein the interfacial transition layer comprises SiC.
10. The ceramic core as claimed in any one of claims 1 to 5, wherein the porosity of the ceramic core is 20 to 40%.
11. A method of making a ceramic core as claimed in any one of claims 1 to 10, comprising a slurry preparation step, a green body pressing step and a sintering step,
in the slurry preparation step, raw materials of the ceramic matrix are mixed to prepare slurry;
in the biscuit pressing step, pressing by using the slurry to obtain a biscuit;
sintering the green body to form the ceramic core in the sintering step;
characterized in that a reinforcing structure preparation step is also included before the biscuit pressing step,
in the reinforcing structure preparing step, preparing fibrous materials to form the reinforcing structure in which the fibrous materials at least partially overlap;
in the biscuit pressing step, the reinforcing structure is pressed into the biscuit together with the slurry.
12. The method of making a ceramic core as recited in claim 11, wherein the green body pressing step includes a slurry injection step, a reinforcing structure infusion step, and a press forming step,
in the slurry injecting step, injecting the slurry in a molten state into a mold in a heat preservation state;
in the reinforcing structure immersing step, immersing the reinforcing structure in the slurry in an insulated state in the mold;
in the extrusion molding step, the mold is closed, and the slurry and the reinforcing structure are extruded.
13. The method of making a ceramic core according to claim 11, wherein in the sintering step, the greenbody is heated to vaporize a portion of the reinforcing structure to provide the ceramic core.
14. An investment casting method using the ceramic core according to any one of claims 1 to 10, comprising a casting step and a mold releasing step,
in the casting step, pouring a metal melt into a ceramic mold, wherein the metal melt is cooled to form a product, and the ceramic mold comprises a ceramic core and a ceramic shell matched with the ceramic core;
in the demolding step, the ceramic mold and the product are removed;
characterized by further comprising a low-temperature annealing step performed after the demolding step, wherein the product is heated in the low-temperature annealing step so that all of the reinforcing structures remaining inside the product are vaporized.
15. The investment casting method of claim 14, wherein during the de-molding step, the ceramic core is etched within the product using a caustic solution to remove the ceramic matrix of the ceramic core from the product, at least a portion of the reinforcing structures remaining within the product.
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