CN117105647A - 一种纤维增强陶瓷基透波构件及其制备方法 - Google Patents
一种纤维增强陶瓷基透波构件及其制备方法 Download PDFInfo
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Abstract
本发明提出一种纤维增强陶瓷基透波构件及其制备方法,涉及航天透波材料领域,通过方法改进和材料改进,直接在模具内编织耐高温陶瓷纤维网格布,并在纤维网格布上注入热膨胀系数匹配的耐高温浆料制成基体,能够克服热膨胀应力导致的开裂问题,能够提高所制备的构件的强度和韧性,而且能够制备不同的异形透波构件,尤其适用于飞行器透波构件如天线罩、天线窗的制备。
Description
技术领域
本发明涉及航天透波材料领域,尤其涉及一种纤维增强陶瓷基透波构件及其制备方法。
背景技术
在航空领域,均质陶瓷材料如熔融石英陶瓷材料、氮化硅陶瓷材料由于其优异的介电性能,可用于飞行器透波构件(如天线罩、天线窗)的制备,但因为材料的脆性较大,均质陶瓷在透波构件的应用受到了较大的限制。目前,通常采用的做法是采用均质陶瓷材料或纤维增强陶瓷基复合材料制成透波构件,然而均质陶瓷材料有着脆性大、稳定性差的缺点。而最成熟的纤维增强陶瓷基复合材料石英纤维增强陶瓷基复合材料,例如石英纤维增强二氧化硅陶瓷基复合材料),其存在耐温较低、成本高、制备工艺复杂、生产周期长及批生产困难等缺点,上述因素限制了飞行器透波构件的低成本化及批量生产。
发明内容
本发明的目的在于克服现有技术中的不足,提供一种纤维增强陶瓷基透波构件及其制备方法,通过方法改进和材料改进,直接在模具内编织耐高温陶瓷纤维网格布,并在纤维网格布上注入热膨胀系数匹配的耐高温浆料制成基体,能够克服热膨胀应力导致的开裂问题,能够提高所制备的构件的强度和韧性,而且能够制备不同的异形透波构件,尤其适用于飞行器透波构件如天线罩、天线窗的制备。
为实现上述目的,本发明采用的技术方案如下:
一种纤维增强陶瓷基透波构件的制备方法,包括以下步骤:
(1)根据需要制备的构件的坯体形状,设计和制造模具的阴模和阳模;
(2)采用仿形定位工装在阴模内编织基于耐高温陶瓷纤维的纤维网格布,自网格上牵引纤维并固定至阴模的内型面;
(3)纤维网格布固定后,装配阳模并密封模具,选用与耐高温陶瓷纤维的热膨胀系数匹配的耐高温陶瓷浆料并向模具内注入浆料,通过成型工艺制成构件湿坯;
(4)将构件湿坯干燥充分后进行高温烧结,得到构件坯体,精加工后得到纤维增强陶瓷基透波构件。
进一步地,所述阴模的内型面与构件坯体的外型面随形。
进一步地,所述阴模采用石膏、多孔树脂、金属材料中的一种或几种制成。
进一步地,所述纤维网格布在阳模的外型面和阴模的内型面之间连接,或者仅在阴模的内型面上连接。
进一步地,所述纤维网格布采用氧化铝纤维、氮化硅纤维、氮化硼纤维、硅硼氮纤维材料中的一种或几种制成。
进一步地,所述成型工艺为注凝成型或注浆成型中的一种。
进一步地,所述阳模采用随形阳模或占位阳模;对于注凝成型工艺,所述阳模为随型阳模,其外型面与构件坯体的内型面随形;对于注浆成型工艺,阳模为占位阳模。
进一步地,所述阳模采用金属、尼龙、陶瓷、树脂、木材材料的一种或几种制成。
进一步地,所述耐高温陶瓷浆料采用熔融石英陶瓷、氧化铝、氮化硅材料中的一种或几种制成。
进一步地,所述高温烧结时间为150-270min,高温烧结温度为1200-1800℃。
一种纤维增强陶瓷基透波构件,由上述方法制备得到。
进一步地,所述纤维增强陶瓷基透波构件为飞行器用的天线罩或天线窗,最大尺寸可达米级,壁厚为2-12mm,构件结构为规则结构或三维空间异型结构。
本发明的技术方案的优点如下:
本发明提供的方法制备了一种均质陶瓷基体夹陶瓷纤维网格布的材料结构。在高温下,陶瓷纤维和浆料的热膨胀系数不一致会产生应力,当这些应力超过了材料的强度时,材料就会破裂或失效。因此,本发明通过采用耐高温浆料如熔融石英陶瓷、氧化铝、氮化硅等材料制成均质陶瓷基体,采用氧化铝纤维、氮化硅纤维、氮化硼纤维、硅硼氮纤维等耐高温陶瓷纤维材料制成纤维网格布,利用耐高温陶瓷纤维与耐高温陶瓷浆料的热膨胀系数相匹配,可以降低热膨胀过程中的压力的产生,能够避免在热膨胀过程中产生应力而导致透波构件的破裂或失效,可以显著提高透波构件的性能和寿命,尤其是在高温和变温环境下使用的情况下,提高透波构件的耐久性和可靠性。
此外,为了保证制备的构件在高温烧结过程中不会因为基体与纤维网格布热膨胀系数不同而导致损坏,陶瓷纤维与浆料材料的烧结温度需匹配。本发明方法能够直接在阴模上铺覆纤维网格布,所用的陶瓷纤维较少,纤维网格布编织成本远低于纤维预制体编织成本,因此能够降低制备成本,能够制备不同的异形透波构件,尤其适用于飞行器透波构件如天线罩、天线窗的制备。
附图说明
所包括的附图用来提供对本发明实施例的进一步的理解,其构成了说明书的一部分,用于例示本发明的实施例,并与文字描述一起来阐释本发明的原理。显而易见地,下面描述中的附图仅仅是本发明的一些实施例,对于本领域普通技术人员来讲,在不付出创造性劳动的前提下,还可以根据这些附图获得其他的附图。
图1为本发明一实施例中制备纤维增强陶瓷基透波构件的示意图;
附图标记说明:
101:阳模;
102:纤维网格布;
103:阴模;
104:耐高温陶瓷浆料。
具体实施方式
需要说明的是,在不冲突的情况下,本申请中的实施例及实施例中的特征可以相互组合。下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。以下对至少一个示例性实施例的描述实际上仅仅是说明性的,决不作为对本发明及其应用或使用的任何限制。基于本发明中的实施例,本领域普通技术人员在没有作出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。
需要注意的是,这里所使用的术语仅是为了描述具体实施方式,而非意图限制根据本申请的示例性实施方式。如在这里所使用的,除非上下文另外明确指出,否则单数形式也意图包括复数形式,此外,还应当理解的是,当在本说明书中使用术语“包含”和/或“包括”时,其指明存在特征、步骤、操作、器件、组件和/或它们的组合。
除非另外具体说明,否则在这些实施例中阐述的部件和步骤的相对布置、数字表达式和数值不限制本发明的范围。同时,应当明白,为了便于描述,附图中所示出的各个部分的尺寸并不是按照实际的比例关系绘制的。对于相关领域普通技术人员已知的技术、方法和设备可能不作详细讨论,但在适当情况下,所述技术、方法和设备应当被视为授权说明书的一部分。在这里示出和讨论的所有示例中,任何具体值应被解释为仅仅是示例性的,而不是作为限制。因此,示例性实施例的其它示例可以具有不同的值。应注意到:相似的标号和字母在下面的附图中表示类似项,因此,一旦某一项在一个附图中被定义,则在随后的附图中不需要对其进行进一步讨论。
本发明提供一实施例提供一种纤维增强陶瓷基透波构件的制备方法,以制备锥型结构的构件为例,图1是制备示意图,在制备过程中涉及阳模101、纤维网格布102、阴模103和浆料104。该方法的具体步骤包括:
(1)根据需要制备的构件的坯体形状,设计和制造模具的阳模101和阴模103;
(2)采用仿形定位工装在阴模103内编织基于耐高温陶瓷纤维的纤维网格布102,自网格上牵引纤维并固定至阴模103内型面;
(3)纤维网格布固定后,装配阳模101并密封模具,选用与耐高温陶瓷纤维的热膨胀系数匹配的耐高温陶瓷浆料并向模具内注入,通过成型工艺制成构件湿坯;
(4)将构件湿坯干燥充分后进行高温烧结,得到构件坯体,精加工后得到纤维增强陶瓷基透波构件。
作为一种优选的实施方式,阴模103的内型面与构件坯体的外型面随形,在本实施例中为锥型。
作为一种优选的实施方式,阴模103采用具备一定强度的材料制成,例如采用石膏、多孔树脂、金属等材料等材料,其中石膏、多孔树脂因吸水性好多用于注浆成型工艺,如金属这类传热性好的材料多用于注凝成型工艺。在本实施例中,阴模103采用铝合金材料制成。
作为一种优选的实施方式,阳模101的外型面可以与构件坯体内型面随形,在本实施例中为锥型,也可以仅为占位阳模。对于注凝成型工艺,阳模101采用随型阳模;而对于注浆成型工艺,阳模101采用占位阳模。在本实施例中,阳模101采用随型阳模。
作为一种优选的实施方式,阳模101可以采用金属、尼龙、陶瓷、树脂、木材等材料制成。在本实施例中,阳模101采用铝合金制成。
作为一种优选的实施方式,纤维网格布102可在阳模101外型面和阴模103内型面之间连接,此时模具应为开阖结构,也可以仅在阴模103内型面上连接。
作为一种优选的实施方式,纤维网格布102采用氧化铝纤维、氮化硅纤维、氮化硼纤维、硅硼氮纤维等耐高温陶瓷纤维材料编织而成。在本实施例中,纤维网格布102采用硅硼氮纤维编织而成。
作为一种优选的实施方式,耐高温陶瓷浆料104采用熔融石英陶瓷、氧化铝、氮化硅等均质陶瓷材料,材料的选择一方面能够制造既能耐高温又能透波的构件,另一方面使形成的基体与纤维网格布之间热膨胀系数匹配,避免构件坯体开裂。在本实施例中,耐高温陶瓷浆料104采用氮化硅陶瓷材料制成。
作为一种优选的实施方式,耐高温陶瓷浆料104中根据需求添加有机物分散剂,但不应损坏热膨胀系数匹配的作用。
作为一种优选的实施方式,成型工艺采用注凝成型工艺或注浆成型工艺,本实施例中采用注凝成型工艺制成氮化硅陶瓷复合材料。
作为一种优选的实施方式,高温烧结时间为150-270min,高温烧结温度为1200-1800℃。烧结参数依据坯体厚度及产品技术要求进行调整。在本实施例中,高温烧结时间为150mm,高温烧结温度为1800℃。
本发明提供另一实施例,与上述第一个实施例基本相同,不同之处在于,阴模101采用多孔树脂材料制成,纤维网格布102采用氮化硼纤维编织而成,阳模103采用尼龙制成的占位阳模,耐高温陶瓷浆料104采用氧化铝陶瓷材料制成,并采用注浆成型工艺制成的氧化铝陶瓷复合材料,高温烧结时间需210min,高温烧结温度1550℃。
本发明还提供又一实施例,与上述第一个实施例基本相同,不同之处在于,烧结高温烧结时间需270min,高温烧结温度1200℃。
实验测试:
以下表1所示为材料线膨胀性能测试数据,本发明制备的纤维增强陶瓷基透波构件(具体为均质陶瓷材料熔融石英陶瓷)的热膨胀系数在400℃时不足0.8×10-6/℃,氮化硅复相陶瓷也仅为2.8×10-6/℃,远低于氧化铝纤维(8.4×10-6℃)及氮化硼纤维(6.5×10-6℃)的线膨胀系数。因此在材料烧结及使用过程中,均质陶瓷基体由于与纤维网格布受热膨胀不一致,而被其膨胀破坏。因此,需采用线膨胀系数较为接近的均质陶瓷浆料和纤维网格布。
表1均质陶瓷及纤维材料线膨胀系数
备注:同一材料体系,均质陶瓷与纤维线膨胀系数基本一致,此处不进行单独区分。
为了便于描述,在这里可以使用空间相对术语,如“在……之上”、“在……上方”、“在……上表面”、“上面的”等,用来描述如在图中所示的一个器件或特征与其他器件或特征的空间位置关系。应当理解的是,空间相对术语旨在包含除了器件在图中所描述的方位之外的在使用或操作中的不同方位。例如,如果附图中的器件被倒置,则描述为“在其他器件或构造上方”或“在其他器件或构造之上”的器件之后将被定位为“在其他器件或构造下方”或“在其他器件或构造之下”。因而,示例性术语“在……上方”可以包括“在……上方”和“在……下方”两种方位。该器件也可以其他不同方式定位(旋转90度或处于其他方位),并且对这里所使用的空间相对描述作出相应解释。
此外,需要说明的是,使用“第一”、“第二”等词语来限定零部件,仅仅是为了便于对相应零部件进行区别,如没有另行声明,上述词语并没有特殊含义,因此不能理解为对本发明保护范围的限制。
以上仅为本发明的优选实施例而已,并不用于限制本发明,对于本领域的技术人员来说,本发明可以有各种更改和变化。凡在本发明的精神和原则之内,所作的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。
Claims (10)
1.一种纤维增强陶瓷基透波构件的制备方法,其特征在于,包括以下步骤:
(1)根据需要制备的构件的坯体形状,设计和制造模具的阴模和阳模;
(2)采用仿形定位工装在阴模内编织基于耐高温陶瓷纤维的纤维网格布,自网格上牵引纤维并固定至阴模的内型面;
(3)纤维网格布固定后,装配阳模并密封模具,选用与耐高温陶瓷纤维的热膨胀系数匹配的耐高温陶瓷浆料并向模具内注入浆料,通过成型工艺制成构件湿坯;
(4)将构件湿坯干燥充分后进行高温烧结,得到构件坯体,精加工后得到纤维增强陶瓷基透波构件。
2.如权利要求1所述的方法,其特征在于,所述阴模的内型面与构件坯体的外型面随形。
3.如权利要求1所述的方法,其特征在于,所述阴模采用石膏、多孔树脂、金属材料中的一种或几种制成。
4.如权利要求1所述的方法,其特征在于,所述成型工艺为注凝成型或注浆成型中的一种;和/或,所述高温烧结时间为150-270min,高温烧结温度为1200-1800℃。
5.如权利要求4所述的方法,其特征在于,所述阳模采用随形阳模或占位阳模;对于注凝成型工艺,所述阳模为随型阳模,其外型面与构件坯体的内型面随形;对于注浆成型工艺,阳模为占位阳模。
6.如权利要求1或4所述的方法,其特征在于,所述阳模采用金属、尼龙、陶瓷、树脂、木材材料的一种或几种制成。
7.如权利要求1所述的方法,其特征在于,所述纤维网格布在阳模的外型面和阴模的内型面之间连接,或者仅在阴模的内型面上连接。
8.如权利要求1所述的方法,其特征在于,所述纤维网格布采用氧化铝纤维、氮化硅纤维、氮化硼纤维、硅硼氮纤维材料中的一种或几种制成;和/或,所述耐高温陶瓷浆料采用熔融石英陶瓷、氧化铝、氮化硅材料中的一种或几种制成。
9.一种纤维增强陶瓷基透波构件,其特征在于,由权利要求1-8任一项所述的方法制备得到。
10.如权利要求9所述的纤维增强陶瓷基透波构件,其特征在于,该构件为飞行器用的天线罩或天线窗,最大尺寸可达米级,壁厚为2-12mm,构件结构为规则结构或三维空间异型结构。
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