CN116547253A - 一种由短纤维增强的金属基体或陶瓷基体复合材料制成的空心部件的制造方法 - Google Patents

一种由短纤维增强的金属基体或陶瓷基体复合材料制成的空心部件的制造方法 Download PDF

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Publication number
CN116547253A
CN116547253A CN202180071534.1A CN202180071534A CN116547253A CN 116547253 A CN116547253 A CN 116547253A CN 202180071534 A CN202180071534 A CN 202180071534A CN 116547253 A CN116547253 A CN 116547253A
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raw material
sacrificial core
metal matrix
green body
matrix composite
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阿诺·德莱霍泽
埃里克·布永
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Safran Ceramics SA
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Safran Ceramics SA
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Abstract

本发明涉及一种制造由陶瓷基复合材料或金属基复合材料制成的中空部件的方法，包括以下步骤：准备至少包含短纤维和陶瓷基体或金属基体前体装料的原材料(30)，在注射成型设备(20)的模腔(23)中定位牺牲芯(10)，所述模腔的尺寸大于所述牺牲芯的尺寸，通过将原材料注射成型到所述牺牲芯(10)和所述模腔的内壁之间的自由空间(230)中来成形原材料(30)，以获得包括所述牺牲芯和成形的原材料的生坯，从所述注射成型设备(20)中取出所述生坯，通过所述生坯的快速烧结使原材料(30)致密化，以便将装料转化为陶瓷基体或金属基体，去除或除去所述牺牲芯(10)以获得由陶瓷基体或金属基体复合材料制成的中空部件(60)；其中，在注入原材料之前，在所述牺牲芯上包覆柔性石墨片、喷涂沉积的石墨层或氮化硼漆层。

Description

一种由短纤维增强的金属基体或陶瓷基体复合材料制成的空 心部件的制造方法
技术领域
本发明涉及制造由金属基复合材料或陶瓷基复合材料制成的空心部件的一般领域。
背景技术
陶瓷(CMC)基复合材料或金属(MMC)基复合材料包括由陶瓷基体或金属基体致密化的纤维增强材料。这些材料在刚度和耐高温性方面具有高水平的性能。
本发明的应用领域是制造涡轮发动机的热部分中使用的中空部件，例如涡轮的部件、涡轮发动机的尾部部件或辅助喷嘴部件。更具体地，本发明可用于生产分配器或中空涡轮机叶片。
涡轮级包括属于定子的定叶片或分配器和随后的属于转子的动叶片。分配器的第一级通常是空心的，以便将常规线路空气从涡轮外部径向输送到内部，从而为轮毂提供空气以确保其增压和吹扫以及可能的冷却。该空气的一部分可用于冷却分配器。
此外，动叶片也可以是中空的，以供冷却空气通过。中空部件的使用还允许减少涡轮机的质量。
文献US2020270180公开了一种用于制造中空CMC部件的方法，包括围绕芯形成纤维预制件、加固预制件以及去除芯。
在文献US2020270180中，纤维预制件是通过在芯周围覆盖纤维结构或通过编织包括用于插入芯的中空区域的预制件而用连续纤维形成的。
文献US2020270180中描述的解决方案使用由连续纤维编织的层或结构，这些纤维本质上具有保持力或内聚力，允许这些纤维在固结之前围绕芯成形。
文献US2020270180中公开的解决方案不能转换为由短纤维制造中空CMC部件，根据定义，短纤维是不连续的并且不能编织在一起形成相干(coherent structure)的纤维结构。
短纤维允许获得小尺寸的部件。短纤维还允许直接制造或接近净形的复合材料部件。
因此，希望有一种解决方案能够制造由具有短纤维的CMC或MMC制成的中空部件。
发明专利内容
因此，本发明的目的在于克服上述缺点，提出一种制造由陶瓷基体或金属基体复合材料制成的中空部件的方法，包括以下步骤：
准备至少包含短纤维和陶瓷基体前体或金属基体前体装料的原材料，
在注入成型设备的模腔中定位牺牲芯，所述模腔的尺寸大于所述牺牲芯的尺寸，
通过将所述原材料注射成型到所述牺牲芯和所述模腔的内壁之间的自由空间中来成形原材料，以获得包括所述牺牲芯和成形的原材料的生坯，
从所述注射成型设备中取出所述生坯，
通过所述生坯的快速烧结使原材料致密化，以便将装料转化为陶瓷基体或金属基体，
去除或除去所述牺牲芯以获得由陶瓷基复合材料或金属基复合材料制成的中空部件。
本发明的制造方法有利地将牺牲芯的使用与注射成型技术和通过快速烧结致密化技术结合。事实上，牺牲芯在成形步骤中既用作反模具，以用于限定要形成的腔体和最终部件(“净形状”)的形状和尺寸，又用作参与烧结基体前体装料的颗粒的导体。
本发明的方法允许制造由具有短纤维增强的CMC或MMC复合材料制成的中空部件，甚至用于小尺寸和/或具有复杂几何形状的部件。
根据本发明方法的第一方面，牺牲芯具有能够在致密化步骤之后从致密化的原材料脱模的几何形状。在这种情况下，牺牲芯在注入原材料的步骤之前可以包覆柔性石墨片、喷涂沉积的石墨层或涂有氮化硼涂料层，以促进其机械去除。
根据本发明方法的第二方面，牺牲芯通过化学处理去除。这允许使用具有无法脱模的复杂几何形状(底切(undercut))的芯，并可以形成具有任何形状空腔的部件。
根据本发明方法的第三方面，牺牲芯由以下材料之一制成：石墨、氧化锆和氧化铝。
根据本发明方法的第四方面，原材料包括陶瓷基体前体装料和选自以下材料之一的材料制成的短纤维：碳、碳化硅和氧化铝。
根据本发明方法的第五方面，原材料包括金属基体前体装料和选自以下材料之一的材料制成的短纤维：碳化硅和氧化铝。可将金属装料(通常为硅)进一步添加到原材料中以促进最终致密化。
根据本发明的方法的第六方面，在注入原材料之前在牺牲芯上沉积至少一个扩散阻挡层。这能够避免牺牲芯的材料与原材料中用于形成基体的材料之间可能的化学相互作用。
根据本发明的方法的第七方面，原材料还包含粘合剂，该方法还包括在原材料致密化之前或期间对原材料脱脂的步骤。这允许消除最终部件的复合材料中有机材料的存在。
附图说明
图1是示出根据本发明制造由具有短纤维增强的陶瓷基复合材料或金属基复合材料制成的中空部件的方法的步骤的流程图，
图2是根据本发明一个实施例的牺牲芯的示意性立体图，
图3是示出根据本发明的一个实施例的注射成型设备中牺牲芯的定位的示意性分解立体图，
图4是图3设备关闭后的剖视图，
图5是图3的设备关闭后的另一个剖视图，
图6是示出了从图3、图4和图5的设备中取出生坯的示意性分解立体图，
图7是放置了图6的生坯的闪蒸烧结设备的示意性截面图，
图8是在去除牺牲芯之后由具有短纤维增强的陶瓷基复合材料或金属基复合材料制成的中空部件的示意性立体图。
具体实施方式
如图1所示，根据本发明的制造由陶瓷基复合材料(CMC)或金属基复合材料(MMC)制成的部件的方法开始于生产牺牲芯10(步骤S1，图2)。根据本发明，牺牲芯由与本发明方法的制造步骤兼容的材料和所需的最终材料制成，芯的材料优选地与部件的复合材料具有热化学兼容性。牺牲芯的组成材料还具有机械和热性能，使其能够承受如下所述部件制造过程中所用的压力和温度。牺牲芯也可以是导电的以在闪蒸烧结步骤SPS期间参与生坯的加热。牺牲芯材料还必须易于去除或能够在不损坏最终部件的情况下去除。为此目的并且以非限制性方式，牺牲芯可以由石墨、氧化铝或氧化锆制成。
如图2中所示，牺牲芯10包括主体11，其具有对应于将在最终CMC或MMC部件中形成的中空或空腔的几何形状和尺寸。芯10还包括定位销或加长件12，其从主体11延伸并且旨在促进牺牲芯在注射成型设备中保持就位，如下所述。牺牲芯可以通过机加工或本领域技术人员已知的其他任何方式获得。
下一步骤包括准备原材料(也称为“原料”)(步骤S2)，原材料至少包含有短纤维和陶瓷基前体装料或金属基前体装料。原材料还可以包含粘合剂，就是这里描述的示例中的情况。
这里的短纤维具有介于50mm和100mm之间的长度。短纤维允许直接制造净形或近净形的CMC或MMC部件。在MMC部件的情况下，短纤维允许具有各向同性或横向各向同性增强，这允许提高部件的金属基体的抗蠕变性。这提高了MMC部件在高温下的刚性，同时降低了其密度，从而提高了特定的机械性能。
在制造空心CMC部件的情况下，原材料包括陶瓷基体前体装料和由选自以下材料之一的材料制成的短纤维：碳、碳化硅、氧化铝、莫来石和氧化镁。陶瓷基体前体装料由耐火陶瓷颗粒粉末组成，例如碳化硅颗粒、氮化硼(Si3N4)颗粒或陶瓷粉末的任意混合物。
在制造空心MMC部件的情况下，原材料包括金属基体前体装料和由选自以下材料之一的材料制成的短纤维：碳化硅和氧化铝。金属基体前体装料由金属颗粒粉末组成，具体是钛合金、镍合金或铝合金颗粒。
粘合剂由至少一种聚合物粘合剂组成，例如聚乙二醇(PEG)、硬脂酸、聚丙烯或基于聚甲醛(POM)的制剂。
该方法继续将牺牲芯10定位在注射成型设备20的模腔23中，如图4所示(步骤S3)。更具体地，注射成型设备20包括具有压印210的第一半壳21和具有压印220的第二半壳22。当设备20通过接合两个半壳21和22而闭合时(如图4和图5)所示，压印210和压印220限定了尺寸大于牺牲芯10的尺寸的模腔23，以便在芯的外表面和模腔的壁之间提供注入空间。壳体211和221也分别从压印210和220延伸。壳体211和221旨在与牺牲芯10的加长件12配合，以便将芯保持在模腔中的适当位置，从而在芯和压印210、220的壁之间形成用于原材料的注入空间230(图4和图5)。根据目标部件的材料的最终厚度来确定注入空间230的尺寸，特别考虑到烧结和任何脱脂对部件的几何变化的影响。
然后通过注射成型技术将原材料成型(步骤S4)。更具体地，当注射成型设备20在牺牲芯10位于其内部的情况下关闭时，在步骤S2中准备的原材料30经由注入口30注入到牺牲芯10和模腔23的内壁之间的自由空间230中(图4和5)。
一旦原材料的注入完成，就获得生坯40，也称为“生坯体”，包括在外表面上涂覆有一层成形原材料30的牺牲芯10(图6)。
然后将生坯40从注射成型设备中取出(脱模)(图6，步骤S5)。
当原材料包含粘合剂时，在将生坯放置在快速烧结设备中的步骤之前执行原材料脱脂步骤，以从待制造的复合材料中去除有机材料(步骤S6)。脱脂步骤可以通过溶剂途径、惰性气体下的热途径、或这两种途径的组合等来进行。脱脂也可以通过在闪蒸烧结前进行适当处理而直接在闪蒸烧结设备中原位进行。
将生坯40放置在闪蒸烧结设备或SPS(“火花等离子烧结”)50中(图7，步骤S7)。传统热压和闪蒸烧结之间的区别在于，热源不是外部的，而是通过电极施加的电流(直流-脉冲直流-或交流)通过导电模具。“闪蒸烧结”包括使用设备在机械应力下的热处理，来封装生坯。热量的施加是通过电流尽可能靠近生坯部件通过的焦耳效应来实现的，这允许快速关闭孔隙并非常快速地达到最大致密化率(在晶粒之间形成键而没有完全融合晶粒)。这种由材料扩散产生的焊缝伴随着致密化，也就是说孔隙率水平的降低和硬化赋予成形原材料内聚力。闪蒸烧结设备50允许使原材料30经受直流电流(通常为0-25V，1-20kA)的脉冲(3.3ms)，同时在从环境温度到2500℃的温度范围内施加数十MPa(高达300MPa)的压力。闪蒸烧结通常在真空下进行，但也可以在惰性气氛(氮气、氩气)下进行。
为此目的，闪蒸烧结设备50包括由诸如石墨的导电材料制成的两个半壳51和52形成的模具。两个半壳51和52之间限定了模腔，该模腔可以具有复杂的形状，其尺寸根据要生产的最终部件的尺寸来限定。牺牲芯在这里起到反模的作用，以确保最终部件内壁的致密化。
设备50包括第一和第二电极55和56，它们一方面连接到电流发生器57，另一方面分别通过第一活塞53和第二活塞54连接到模具的半壳51和52。在形成具有复杂几何形状的部件的情况下，可以使用关键设备。发生器57发出电流I，其循环通过设备50，即电极56和57、活塞53和54以及半壳51和52，以及原材料30的装料和牺牲芯10。在烧结过程中，活塞53和54进一步对半壳51和52施加机械应力P。
致密化循环的参数，即主要是电流强度、施加的机械应力值和处理环境的性质，由原材料的待烧结元素的性质定义并且是本领域技术人员众所周知的。根据定义的热循环(升温/降温斜率、阶段等)控制电流。必要时也可以控制机械应力(释放/施加应力)。
所使用的模具优选由石墨制成并且通过石墨片或通过本领域技术人员已知的任何其他方式与粉末分离以避免任何粘附，例如具体是通过喷涂沉积的石墨层或氮化硼涂料层。
一旦原材料通过围绕牺牲芯10的闪蒸烧结而被致密化(步骤S8)，从设备50中取出所获得的预制件。下一步骤包括去除或消除牺牲芯(步骤S9)。如果其几何形状允许，也就是说如果芯没有底切，则可以机械地去除芯。为了便于机械拆卸，在对原材料进行注射成型的步骤之前，可以在牺牲芯上包裹或涂覆柔性石墨片、喷涂石墨层或氮化硼涂料层。
牺牲芯也可以通过热化学处理去除。例如，在石墨牺牲芯的情况下，可以通过热化学氧化处理来消除，例如，如果部件的材料允许，在400℃和600℃之间的温度下在空气中进行。
在去除或消除牺牲芯之后，获得由用短纤维增强的陶瓷基复合材料或金属基复合材料制成的部件60，该部件包括内部凹槽61，其形状和尺寸由牺牲芯10限定。
为了避免在制造方法中基体和待制造部件的纤维(如果后者未被保护)和牺牲芯之间可能发生的化学作用，可以在注入原材料之前在芯的外表面形成扩散阻挡层。作为非限制性示例，扩散阻挡层可以由氮化硼层组成。在金属基底的情况下，可以沉积氧化铝或钨作为阻挡层。
本发明的方法允许容易且可重复地生产由具有短纤维陶瓷基体(CMC-FC)的复合材料制成的中空部件，纤维被涂有中间相并且任选地涂有中间相或短纤维金属基体的保护层材料(MMC-FC)，即使对于小部件也是如此，这对于连续纤维来说是不可能的。本发明特定但非排他性地应用于制造小型燃气轮机的空心部件中，例如用于涡轮分配器级的出口导叶或“OGV”。

Claims (8)

1.一种制造由陶瓷基复合材料或金属基复合材料制成的中空部件(60)的方法，包括以下步骤：
准备至少包含短纤维和陶瓷基前体装料或金属基前体装料的原材料(30)，
在注射成型设备(20)的模腔(23)中定位牺牲芯(10)，所述模腔的尺寸大于所述牺牲芯的尺寸，
通过将原材料注射成型到所述牺牲芯(10)和所述模腔的内壁之间的自由空间(230)中来成形原材料(30)，以获得包括所述牺牲芯和成形的原材料的生坯(40)，
从所述注射成型设备(20)中取出所述生坯(40)，
通过所述生坯(40)的快速烧结使原材料(30)致密化，以便将装料转化为陶瓷基体或金属基体，
去除或除去所述牺牲芯(10)以获得由陶瓷基复合材料或金属基复合材料制成的中空部件(60)；其中，在注入原材料之前，所述牺牲芯包覆柔性石墨片、喷涂沉积的石墨层或氮化硼漆层。
2.根据权利要求1所述的方法，其中，所述牺牲芯(10)具有能够在所述致密化步骤之后从致密化的原材料脱模的几何形状。
3.根据权利要求1或2所述的方法，其中，所述牺牲芯(10)由以下材料之一制成：石墨、氧化锆和氧化铝。
4.根据权利要求1至3中任一项所述的方法，其中，所述原材料(30)包括陶瓷基体前体装料和选自以下材料之一制成的短纤维：碳、碳化硅和氧化铝。
5.根据权利要求1至3中任一项所述的方法，其中，所述原材料(30)包括金属基体前体装料和选自以下材料之一制成的短纤维：碳化硅和氧化铝。
6.根据权利要求1至5中任一项所述的方法，其中，在注入所述原材料(30)之前，在所述牺牲芯(10)上沉积至少一层扩散阻挡层。
7.根据权利要求1至6中任一项所述的方法，其中，所述原材料还包含粘合剂，所述方法还包括在所述原材料致密化之前或期间对所述原材料(30)进行脱脂的步骤。
8.根据权利要求7所述的方法，其中，在用于所述生坯(40)的闪蒸烧结的设备(50)内执行所述原材料(30)的脱脂步骤。
CN202180071534.1A 2020-10-20 2021-10-12 一种由短纤维增强的金属基体或陶瓷基体复合材料制成的空心部件的制造方法 Pending CN116547253A (zh)

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