EP4323326A1 - Corps moulé composite constitué d?une céramique mixte liée par réaction infiltrée avec du silicium - Google Patents

Corps moulé composite constitué d?une céramique mixte liée par réaction infiltrée avec du silicium

Info

Publication number
EP4323326A1
EP4323326A1 EP21721875.9A EP21721875A EP4323326A1 EP 4323326 A1 EP4323326 A1 EP 4323326A1 EP 21721875 A EP21721875 A EP 21721875A EP 4323326 A1 EP4323326 A1 EP 4323326A1
Authority
EP
European Patent Office
Prior art keywords
weight
molding according
proportion
composite molding
silicon
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.)
Pending
Application number
EP21721875.9A
Other languages
German (de)
English (en)
Inventor
Lars Schnetter
Philipp Gingter
Clara MINAS-PAYAMYAR
Fabian Heinz
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.)
Schunk Ingenieurkeramik GmbH
Original Assignee
Schunk Ingenieurkeramik GmbH
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 Schunk Ingenieurkeramik GmbH filed Critical Schunk Ingenieurkeramik GmbH
Publication of EP4323326A1 publication Critical patent/EP4323326A1/fr
Pending legal-status Critical Current

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    • C04B41/45Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
    • C04B41/50Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
    • C04B41/5093Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with elements other than metals or carbon
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00Layered products essentially comprising ceramics, e.g. refractory products
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    • B33ADDITIVE MANUFACTURING TECHNOLOGY
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    • B33Y10/00Processes of additive manufacturing
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B33ADDITIVE MANUFACTURING TECHNOLOGY
    • B33YADDITIVE MANUFACTURING, i.e. MANUFACTURING OF THREE-DIMENSIONAL [3-D] OBJECTS BY ADDITIVE DEPOSITION, ADDITIVE AGGLOMERATION OR ADDITIVE LAYERING, e.g. BY 3-D PRINTING, STEREOLITHOGRAPHY OR SELECTIVE LASER SINTERING
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    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/30Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
    • C04B2237/32Ceramic
    • C04B2237/36Non-oxidic
    • C04B2237/365Silicon carbide
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2237/00Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
    • C04B2237/50Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
    • C04B2237/70Forming laminates or joined articles comprising layers of a specific, unusual thickness
    • C04B2237/704Forming laminates or joined articles comprising layers of a specific, unusual thickness of one or more of the ceramic layers or articles

Definitions

  • the invention relates to a composite molding made from a reaction-bonded mixed ceramic infiltrated with silicon.
  • reaction-bonded SiC reaction-bonded SiC
  • RB B4C reaction-bonded B4C
  • combinations of these materials RBSiC/B4C
  • silicon carbide, and especially boron carbide provide the lightest protection solutions, they also generate the highest costs. For this reason, these materials are preferably used in the field of aircraft protection and personal protection. In the area of personal protection/body protection, monoliths (one-piece protective elements) are used in particular.
  • sintered materials typically offer an option for lighter protection elements than reaction-bonded materials, but in most cases the reaction-bonded materials offer better value for money.
  • RB B4C can also be used successfully with a proportion of RBSiC for various threat classes such as NIJ4 and ammunition types with hardened steel cores. These materials dominate the market in Europe but also in Asian countries such as Korea.
  • a silicon-infiltrated boron carbide is known from US Pat. No. 3,857,744, which uses a grain size of “600 grit to 120 grit”. A grain size of ⁇ 110 pm is therefore typically used.
  • the B4C share here is significantly greater than 50% by weight. However, it has been shown that high B4C proportions lead to poorer performance compared to WC/Co ammunition, since the boron carbide is amorphized.
  • the object of the invention is therefore to create an improved composite shaped body, which consists of a reaction-bonded SiC/B4C material, which has an optimized price-performance ratio and can also be used against the important tungsten carbide ammunition.
  • a ceramic body is hereby created, in particular for use as ballistic protection, based on a metal-ceramic composite material which contains Si, SiC and coarse-grained B4C.
  • the material properties are determined by the raw material recipe, the shaping process and the siliconization process.
  • the composite moldings produced in this way typically have an optimized density, high hardness and are particularly suitable for ballistic protection applications due to the special microstructure.
  • the microstructure can be achieved with a reaction-bonded silicon-infiltrated Influence mixed ceramics by the formation of secondary silicon carbide.
  • the type and amount of carbon additive are decisive for the formation of secondary silicon carbide and thus for the formation of the binding bridges that determine the strength of the material.
  • the siliconization process in which molten silicon penetrates the porous molded body, is significantly influenced by the pore structure.
  • the large B4C grains in combination with a proportion that is not too high prevent amorphization, with the SiC matrix being stabilized.
  • the selected size of the primary grains of B4C also has a stabilizing effect with the SiC matrix.
  • the formation of secondary silicon carbide and the binding bridges produced with it can be influenced.
  • a smaller amount of SiC formed during the infiltration for example >5% by weight and ⁇ 25% by weight and an Si content ⁇ 20% by weight, is advantageous.
  • the material seems to develop a kind of functional deformability at the B4C level, with a ceramic that is hardly deformable per se.
  • a low Si content and a higher SiC content can be advantageous.
  • a remaining Si content of ⁇ 15% by weight is particularly advantageous.
  • a material with a B4C content of between 30-40% by weight, a proportion of secondary SiC of 15-25% by weight and an Si content ⁇ 15% by weight and a primary particle size of the B4C>100 ⁇ m is particularly preferred .
  • slip casting reaches its limits here, as cracks and large-scale deformation can occur more frequently. This also applies to isostatically pressed material, since the density gradients in isostatic pressing also increase with size and volume.
  • powder bed-based 3D printing has turned out to be a suitable manufacturing method for very large components.
  • Powder bed printing is a very efficient manufacturing method, particularly for the material according to the invention—coarse B-iC combined with fine SiC.
  • the large dimensions are required in particular in the aviation sector, e.g. as protective components for seats or large panels.
  • the coarse crystallites of B4C obviously offer the advantage of high efficiency in printing, and it has also surprisingly turned out that the large components produced in this way are significantly more homogeneous than products that are produced by casting, die casting or isostatic pressing. Compared to isostatic pressing and subsequent green processing, powder bed printing also offers considerable cost advantages, since no machining (milling of the green body) is necessary and significantly less material has to be used.
  • 3D powder bed printing it is thus possible with 3D powder bed printing to produce large components such as seat shells and backrests from the composite molding according to the invention. Thanks to the near-netshape approach, these offer additional options for weight savings in addition to the pure savings through the material, since material only has to be used where it is actually required according to the application.
  • Protective panels produced in this way can easily assume dimensions of 1m 2 and more, so that entire protective elements such as doors, tailgates, floor elements and other structural components of a vehicle or aircraft can be produced from a single structure.
  • the large elements facilitate integration and avoid joints that can otherwise present weak points in the shot. It is known that at triple points (the point where 3 corners of a ballistic tile meet) ballistic performance decreases by up to 30%. Due to the high homogeneity of the material resulting from 3D printing, however, very large components with an envelope volume > 200 x 200 x 200mm 3 or even large areas > 500 x 500mm 2 can be realized without any problems.
  • FIG. 1 schematically shows a section of a micrograph.
  • the invention relates to a composite molded body made from a reaction-bonded mixed ceramic infiltrated with silicon, the structure of which is determined by primary grains of crystalline B4C grains with an average grain size d50 > 100 pm and ⁇ 500 pm and a proportion of > 10% by weight and ⁇ 50% by weight %.
  • the structure is also determined by primary grains of silicon carbide with d50 ⁇ 100 pm and a proportion of > 10% by weight and ⁇ 50% by weight.
  • the primary grains are siliconized and connected by secondary silicon carbide with a proportion of >5% by weight and ⁇ 25% by weight, in a silicon matrix with a free metallic silicon content of >1% by weight and
  • ⁇ 20% by weight 1 shows an example of a micrograph according to the invention.
  • the percentages by weight are percentages by weight.
  • the invention thus relates to a reaction-bonded SiC/B4C with a B4C content
  • a stable support matrix for the primary crystals B4C and SiC can be created in this way and the resistance to projectiles, for example, can be increased.
  • a composite molding with a B4C content between 30% by weight and 40% by weight and an Si content ⁇ 15% by weight and a primary particle size of the B4C >200 ⁇ m is particularly preferred.
  • the primary grains of silicon carbide are present with d50 ⁇ 40 pm, in particular ⁇ 10 pm.
  • the density gradient can be ⁇ 2%.
  • the composite molding can also contain boron dissolved within the metallic silicon in a proportion of between >0.05 and ⁇ 5% by weight.
  • the micrograph of Fig. 1 shows the B4C content primary grains 1, free, metallic silicon 2 and a penetrating composite of fine-grained, primary and secondary silicon carbide 3.
  • the composite shaped body can be produced by pressure slip casting, which includes the production of a slip with SiC/B4C particles as well as colloidal carbon and organic auxiliaries.
  • the resulting green body is then contacted with liquid silicon and infiltrated at temperatures between 1500°C and 1700°C.
  • the silicon reacts with the carbon to form secondary SiC.
  • the shaping takes place by 3D printing, since this enables the realization of complex products, such as seat shells and backrests, for aeronautical applications.
  • the ceramics produced in this way in combination with polymers (PE, aramid, etc.) as well as carbon fibres, glass fibers and/or metals, offer particularly efficient protection against WC/Co ammunition, in particular against ammunition types M993 and M995.
  • the invention also relates to the use of the composite molding as a ballistic protection.
  • the composite molding is preferably covered with one or more layers of a backing material.
  • a backing material can be pressed with the mixed ceramic according to the invention.
  • the backing material can also preferably be formed from several layers of one or more plastics, for example polyethylene, aramid, etc., carbon fibers, glass fibers, metal, for example aluminum, steel, etc., combinations of these materials and/or connecting material, for example adhesive foils.
  • a body armor plate from the composite molded body according to the invention, for which purpose pressure slip casting is used.
  • an aqueous suspension consisting of colloidal carbon with an average particle size of less than 1 ⁇ m in a proportion of 10% by weight, fine-grained silicon carbide with an average particle size of 5-1 ⁇ m in a proportion of 50% by weight and coarse-grained B4C an average particle size of 120 pm with a proportion of 40% by weight.
  • 18% by weight of water and 1% by weight of organic auxiliaries wetting agents, liquefaction auxiliaries, binders
  • the slip is then cast on a die-casting machine using a porous plastic mold based on polymethyl methacrylate at a slip pressure of 40 bar to form a multiply curved plate with the dimensions 350 ⁇ 275 ⁇ 9 mm.
  • the shard formed in this way is then dried in a circulating air drying chamber and converted via reaction firing to a ceramic plate based on a reaction-bonded composite material, consisting essentially of SiC and B4C as well as free Si.
  • the composite molded body thus obtained forms a body protection plate which can be used as a monolithic insert of a ballistic body armor vest.
  • the composite molding consists, for example, of a material obtained comprising coarse-grained B4C with a proportion of 31% by weight, fine-grained primary SiC with a proportion of 41% by weight, fine-grained secondary SiC with a proportion of 17% by weight and free, metallic silicon with a proportion of 11% by weight.
  • a vehicle protection panel from the composite molding according to the invention, for which purpose uniaxial compression molding is used.
  • an aqueous suspension is prepared according to the composition described in Example 1 and processed further by means of a spray-drying process to give pressed granules. Only the composition of the organic auxiliaries has to be adjusted and a pressing auxiliaries added.
  • the granulate is then poured into a square carbide mold and pressed at a pressure of 1700 bar.
  • the blank obtained in this way is then subjected to reaction firing, from which a ceramic plate based on a reaction-bonded composite material, consisting essentially of SiC and B4C as well as free Si, is produced, with an edge length of 50mm and a wall thickness of 9mm.
  • the composite molded body obtained in this way forms a polygonal protective panel which can be used for the efficient lining of large areas in vehicle protection.
  • the grains are selectively solidified at the points specified by a CAD model on which they are based, by adding an organic binder drop by drop, preferably furan resin, which is applied via inkjet print heads.
  • the CAD model used here which corresponds to the final component geometry, allows complex structures to be created. Following these two sub-steps, the construction area level is lowered by a previously defined layer thickness, which in this case is 300 pm. This sequence of steps is repeated iteratively until the layer-by-layer implementation of the CAD model is complete.
  • the complex-shaped preform obtained in this way has a Porosity of 45 vol .-% and is then infiltrated with an aqueous dispersion consisting of 30 wt .-% colloidal carbon and a dispersing agent and a wetting agent.
  • a ceramic preform with a complex shape is obtained in this way, consisting of 87% by weight of the original SiC—E C powder mixture and 13% by weight of colloidal carbon.
  • this ratio changes to 79/21% by weight, after a possible third impregnation step to 76/24% by weight.
  • the complex-shaped preform obtained in this way is converted into a ceramic body based on a reaction-bonded composite material, consisting essentially of SiC and B4C as well as free Si, by means of a reaction firing.
  • the material obtained in this way consists, for example, of coarse-grained B4C with a proportion of 15% by weight, fine-grained primary SiC with a proportion of 45% by weight, fine-grained secondary SiC with a proportion of 24% by weight and free metallic material Si with a proportion of 15% by weight.
  • the complex-shaped preliminary body obtained in this way can be used as the basic element of a ballistic helmet for head protection, with the production using the 3D printing process described here allowing the production of an ergonomic, potentially individualized helmet geometry.
  • weight-optimized seat shells for use in various aircraft can be obtained in this way.
  • the seat shell produced in this way has a size of approx. 300 x 300mm, a wall thickness of 9mm and a height of 200mm and is ergonomically shaped.
  • the associated backrest has a length of 500mm, a width of 300mm and a height of 100mm and is also ergonomically shaped. Such large components can be produced without cracks. Processing using subtractive processes is no longer necessary.
  • the composite molding according to the invention is produced by means of a powder-bed-based 3D printing process, the mixing ratio in this case being 50% by weight SiC and 50% by weight B4C.
  • the material obtained in this way consists, for example, of coarse-grained B4C with a proportion of 26% by weight, fine-grained primary SiC with a proportion of 35% by weight, fine-grained secondary SiC with a proportion of 24% by weight, and free metallic silicon with a proportion of 15% by weight.
  • the side element produced in this way has dimensions of 1200 mm x 800 mm x 9 mm, for example.
  • protection means no penetration by the projectile with a back face deformation of 39mm in the test.
  • the general rule for the backing is that it can be formed from aramid fiber fabrics, polyethylene (PE), carbon fiber fabrics, glass fiber fabrics and/or a mixture thereof.
  • the backing can preferably be attached to the mixed ceramic on one or both sides to be appropriate. In general, it is therefore the case that with a surface weight of preferably ⁇ 32 kg/m 2 1 shot of M995 with a tungsten carbide core can preferably be stopped.
  • protection means no penetration by the projectile with a back face deformation of 29 mm in the 1st shot and 37 mm in the 2nd shot in the test.
  • the general rule for the backing is that it can be formed from aramid fiber fabrics, polyethylene (PE), carbon fiber fabrics, glass fiber fabrics and/or a mixture thereof.
  • the backing can preferably be attached to the mixed ceramic on one or both sides. In general, it is therefore the case that with a basis weight of preferably ⁇ 40 kg/m 2 , 2 shots of M995 with a tungsten carbide core can preferably be stopped at a distance of 100 mm.

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • General Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Ceramic Products (AREA)
  • Producing Shaped Articles From Materials (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)

Abstract

La présente invention concerne un corps moulé composite fabriqué à partir d'une céramique mixte liée par réaction, infiltrée avec du silicium, dont la structure est déterminée par des grains primaires de grains cristallins de B4C (1) ayant une taille de grain moyenne d50 > 100 µm et < 50 µm et une proportion de > 10 % en poids et < 50 % en poids, également déterminée par des grains primaires d'un carbure de silicium plus fin ayant d50 < 70 µm et une proportion de > 10 % en poids et < 50 % en poids, et les grains primaires sont silicifiés (3) par du carbure de silicium formé secondairement ayant une proportion de > 5 % en poids et < 25 % en poids, dans une matrice de silicium ayant une teneur en silicium métallique libre (2) de > 1 % en poids et < 20 % en poids.
EP21721875.9A 2021-04-16 2021-04-16 Corps moulé composite constitué d?une céramique mixte liée par réaction infiltrée avec du silicium Pending EP4323326A1 (fr)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
PCT/EP2021/059908 WO2022218540A1 (fr) 2021-04-16 2021-04-16 Corps moulé composite constitué d'une céramique mixte liée par réaction infiltrée avec du silicium

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EP4323326A1 true EP4323326A1 (fr) 2024-02-21

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EP21721875.9A Pending EP4323326A1 (fr) 2021-04-16 2021-04-16 Corps moulé composite constitué d?une céramique mixte liée par réaction infiltrée avec du silicium
EP22168592.8A Pending EP4074676A1 (fr) 2021-04-16 2022-04-14 Corps moulé composite à partir d'une céramique mixte liée par réaction, infiltrée au silicium

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US (1) US20240158311A1 (fr)
EP (2) EP4323326A1 (fr)
JP (1) JP2024516957A (fr)
KR (1) KR20230169966A (fr)
AU (1) AU2021440327A1 (fr)
CA (1) CA3214362A1 (fr)
DE (1) DE112021007519A5 (fr)
IL (1) IL307727A (fr)
WO (1) WO2022218540A1 (fr)

Family Cites Families (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3765300A (en) * 1967-05-22 1973-10-16 Carborundum Co Dense carbide composite for armor and abrasives
US3857744A (en) 1970-01-19 1974-12-31 Coors Porcelain Co Method for manufacturing composite articles containing boron carbide
JPS5914026B2 (ja) 1976-02-27 1984-04-02 ヘキスト・アクチ−エンゲゼルシヤフト 2−カルボアルコキシアミノ−ベンズイミダゾリル−5(6)−スルホン酸−フェニルエステル化合物
EP0372708A1 (fr) * 1988-11-10 1990-06-13 United Kingdom Atomic Energy Authority Procédé de production d'un corps à base de carbure de silicium
US6609452B1 (en) 2000-01-11 2003-08-26 M Cubed Technologies, Inc. Silicon carbide armor bodies, and methods for making same
US8128861B1 (en) 2000-07-21 2012-03-06 M Cubed Technologies, Inc. Composite materials and methods for making same
WO2005079207A2 (fr) 2003-11-25 2005-09-01 M Cubed Technologies, Inc. Corps composites en carbure de bore et leurs procedes de fabrication
US20110009255A1 (en) 2005-12-22 2011-01-13 Coorstek, Inc. Boron-silicon-carbon ceramic materials and method of making
KR101190561B1 (ko) * 2008-04-04 2012-10-16 토토 가부시키가이샤 복합 재료 및 그의 제조 방법
DE102017217321A1 (de) * 2017-09-28 2019-03-28 Sgl Carbon Se Keramisches Bauteil
US11364654B2 (en) * 2018-12-17 2022-06-21 Ut-Battelle, Llc Indirect additive manufacturing process for producing SiC—B4C—Si composites

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WO2022218540A1 (fr) 2022-10-20
AU2021440327A1 (en) 2023-10-12
KR20230169966A (ko) 2023-12-18
EP4074676A1 (fr) 2022-10-19
IL307727A (en) 2023-12-01
JP2024516957A (ja) 2024-04-18
CA3214362A1 (fr) 2022-10-20
DE112021007519A5 (de) 2024-04-04
US20240158311A1 (en) 2024-05-16

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