JP2007039319A - 炭素繊維強化SiC系複合材及び摺動材 - Google Patents
炭素繊維強化SiC系複合材及び摺動材 Download PDFInfo
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Abstract
【解決手段】炭素繊維強化炭素複合材に、金属Siを溶融含浸させて得られる炭素繊維強化SiC系複合材において、該炭素繊維強化炭素複合材に用いられる炭素繊維がピッチ系炭素短繊維であり、前記ピッチ系炭素短繊維の繊維が二次元ランダムに配向していることを特徴とする炭素繊維強化SiC系複合材。炭素繊維強化炭素複合材は、嵩密度1.2〜1.7g/cm3、気孔率15〜40vol%、体積当たりの炭素繊維含有率20〜50vol%であることが好ましい。
【選択図】図1
Description
本発明に係る炭素繊維強化SiC系複合材の製造方法に用いられるC/C複合材は、補強炭素繊維としてピッチ系炭素繊維を用いたものである。
C/C複合材を製造するには、好ましくは、該短繊維束を乾式又は湿式で解繊、分散し、繊維が二次元ランダムに配向したシート(以下「二次元ランダムシート」と称す場合がある。)を作製し、マトリックス物質をこのシートの炭素繊維短繊維間に充填させる。
C/C複合材を製造するには、まず上述のようにして製造された二次元ランダムシートに、不活性ガス雰囲気中で加熱されることにより炭化する樹脂及び/又はピッチを含浸させた後、乾燥する。この樹脂及び/又はピッチとしては特に制限はないが、通常フェノール樹脂、フラン樹脂、或いは石油系、石炭系ピッチ等が使用される。好ましくは取り扱い性の観点から、フェノール樹脂である。含浸されるマトリックスはアルコール、アセトン、アントラセン油等の溶媒に溶解、または分散して適正な粘度に調整されることが好ましい。
嵩密度(BD)
本発明で用いるC/C複合材の嵩密度BDは、好ましくは1.2g/cm3以上、更に好ましくは1.4g/cm3以上、一方、好ましくは1.7g/cm3以下である。BDが1.2g/cm3以上では、金属Siと反応する炭素マトリックスが少なくなく、SiC化が進み易く、その結果、炭素繊維が金属Siと反応しにくい。従って、十分な引張強度を付与しやすい傾向にある。また、BDが1.7g/cm3以下では、金属Siの溶融含浸の際、金属Siが含浸されやすくなるため、金属Si、SiとCとの反応で生成したSiC、未反応のCとの熱膨張差による、クラック等の発生を抑制しやすい傾向にある。
本発明で用いるC/C複合材の気孔率Vvは、好ましくは15vol%以上、一方、好ましくは40vol%以下、更に好ましくは30%以下である。Vvが30%よりも多いと、炭素マトリックスが不足し、炭素繊維がSiと反応し易くなる傾向にある。Vvが15%よりも少ないと、気孔が少ないところからSiの含浸が不十分となり、SiCの生成が不足する傾向にある。
本発明で用いるC/C複合材の体積中の炭素繊維の体積含有率Vfは、好ましくは20%以上50%以下である。Vfが20%よりも低いと、炭素繊維が少なく、SiC−C/C複合材の強度が不足するおそれがある。Vfが50%よりも高いと、炭素マトリックスが不足したり、気孔が不足するおそれがある。上記の通り、炭素マトリックスが不足すると、炭素繊維がSiと反応し易くなる傾向にある。気孔が不足すると、SiCの生成が不足する傾向にある。
本発明のSiC−C/C複合材は、C/C複合材に、金属Siを溶融含浸させてなるものである。
1本のフィラメント直径10μm、フィラメント数12000本、弾性率20ton/mm2のピッチ系炭素繊維を30mm長に切断したものをランダムウェバーにて開繊し、ピッチ系炭素短繊維が二次元ランダムに配向したシート(目付170g/m2)を得た。このシートに、エタノールで希釈したフェノール樹脂を含浸させた後、乾燥してフェノール樹脂含浸シートを作製した。このシートを金型内で積層し、250℃にて加圧成形して、体積当りの炭素繊維の体積含有率Vfが約50%の成形体を得た。
実施例1において、ピッチの含浸・炭化プロセス回数を変えることにより嵩密度の異なるC/C複合材となるようにしたこと以外は同様にして表1に示す物性のC/C複合材を得た。なお、含浸・炭化プロセスの回数は、実施例2では2回、実施例3では0回である。このC/C複合材を用いて同様にしてSiC−C/C複合試験片を作製し、同様に引張試験を実施して、結果を表1に示した。実施例2,3で得られたSiC−C/C複合材は、良好な耐酸化性、耐熱性を有することが認められた。
実施例1において、成形時の圧力を低くすることにより、C/C複合材の体積当たりの炭素繊維含有率Vfを小さくしたこと、およびピッチの含浸・炭化プロセス回数を7回に変えたこと以外は同様にして表1に示す物性のC/C複合材を得た。このC/C複合材を用いて同様にしてSiC−C/C複合試験片を作製し、同様に引張試験を実施して、結果を表1に示した。実施例4で得られたSiC−C/C複合材は、良好な耐酸化性、耐熱性を有することが認められた。
実施例1において、C/C複合材の炭素繊維としてPAN系炭素繊維を用いたこと以外は同様にして表1に示す物性のC/C複合材を得、このC/C複合材を用いて同様にしてSiC−C/C複合試験片を作製し、同様に引張試験を実施して、結果を表1に示した。
C/C複合材の炭素繊維としてPAN系炭素繊維を用い、この炭素繊維を一方向のプリプレグとして、0°/90°でニードリングを打ちながら積層したプリフォームを得、このプリフォームにマトリックスとしてピッチを含浸、焼成することを3回繰り返して、表1に示す物性のC/C複合材を得た。このC/C複合材を用いて、実施例1と同様にして金属Siの溶融含浸によるSiC化を行ってSiC−C/C複合試験片を作製し、同様に引張試験を実施して、結果を表1に示した。
図2,3からも分かるように、PAN系炭素繊維を使用した比較例1のSiC−C/C複合試験片では、図3の丸で囲んだ部分では、炭素繊維と、含浸されたSiが反応しており、ピッチ系炭素繊維を使用した実施例1のSiC−C/C複合試験片に比べ、マトリックス由来の炭素だけでなく、炭素繊維そのものも部分的にSiと反応してSiC化されているようにみえる。そして、この炭素繊維のSiC化が、強度が発現しなかった理由と考えられる。これに対して、図2の実施例1のSiC−C/C複合試験片では、炭素繊維は、Siと反応しておらず、炭素繊維以外のマトリックス由来の炭素と反応しており、このような炭素繊維のSiC化はなされていない。
Claims (14)
- 炭素繊維強化炭素複合材(以下、C/C複合材という。)に金属Siを溶融含浸させて得られる炭素繊維強化SiC系複合材において、
該C/C複合材の炭素繊維がピッチ系炭素繊維の短繊維(以下、ピッチ系炭素短繊維という。)であり、該ピッチ系炭素短繊維が該炭素繊維強化SiC系複合材中において二次元ランダムに配向していることを特徴とする炭素繊維強化SiC系複合材。 - 請求項1において、該短繊維の長さが10〜50mmであることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1又は2において、該C/C複合材は、前記ピッチ系炭素短繊維が二次元ランダムに配向しているシートを積層してなる積層体を含むことを特徴とする炭素繊維強化SiC系複合材。
- 請求項3において、該シートは、短繊維束を解繊及び/又は分散させて繊維を二次元ランダムに配向させたシートであることを特徴とする炭素繊維強化SiC系複合材。
- 請求項3又は4において、該シートの目付が10〜500g/m2であることを特徴とする炭素繊維強化SiC系複合材。
- 請求項3ないし5のいずれか1項において、前記積層体は、樹脂及び/又はピッチを含浸させた前記シートを複数枚積層した後、加圧成形し、次いで不活性ガス雰囲気中で焼成したプリフォームであることを特徴とする炭素繊維強化SiC系複合材。
- 請求項6において、前記C/C複合材は、該プリフォームに樹脂、タール及びピッチの少なくとも1種の含浸材を含浸させた後、不活性ガス雰囲気中で加熱して含浸材を炭化させる含浸・炭化プロセスを少なくとも1回行うことにより形成されたものであることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし7のいずれか1項において、金属Si溶融含浸前の前記C/C複合材の嵩密度が1.2〜1.7g/cm3であることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし8のいずれか1項において、金属Si溶融含浸前の前記C/C複合材の気孔率が15〜40vol%であることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし9のいずれか1項において、金属Si溶融含浸前の前記C/C複合材の体積当たりの炭素繊維含有率が20〜50vol%であることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし10のいずれか1項において、金属Si溶融含浸前の前記C/C複合材は、マトリックスとしてピッチ由来の炭素を含有することを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし11のいずれか1項において、マトリックスとして炭素、炭化珪素、および珪素を含有することを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし12のいずれか1項において、引張強度が50MPa以上であることを特徴とする炭素繊維強化SiC系複合材。
- 請求項1ないし13のいずれか1項に記載の炭素繊維強化SiC系複合材を用いた摺動材。
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