JP2012504091A - 耐熱構造複合材料でつくられる部品の製造方法 - Google Patents
耐熱構造複合材料でつくられる部品の製造方法 Download PDFInfo
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Abstract
【選択図】 なし
Description
本発明は耐熱構造複合材料部品、特には航空の分野または宇宙の分野における使用のための部品を作製することに関する。このような部品の例はガスタービン航空機用エンジン用のアフターボディー部材、たとえば多流式エンジンのミキサもしくは補助ノズルまたはセントラルボディーまたは「プラグ」である。
・繊維プリフォームを、炭素前駆体またはセラミック前駆体、一般には溶媒によって任意に希釈された樹脂を含有した団結組成物で含浸された炭素またはセラミックのヤーン(またはトウ)からつくり出す工程;
・炭素前駆体またはセラミック前駆体を熱分解によって変化させる工程;およびその後
・プリフォームを化学気相浸透(CVI)によって緻密にする工程。
本発明の1つの目的は、液体技術による団結とCVIによる緻密化とを関連付けながらも、力学的ポテンシャルが非常に高まった耐熱構造複合材料部品を作製する方法を提案することにある。
・団結組成物は低ポロシティーのヤーン内またはトウ内の空間に浸透しにくく、それによりこれら空間の大部分をCVI緻密化のために開放しおよびその結果各ヤーンまたはトウにおいて高度な機械的特性を有する「ミニ複合材」を得ることを可能にする;および
・熱分解からの固体残留物はフィラーの存在により強化され、それによりそれの機械的特性およびそれの緻密化容量が増加する。
本発明の方法の実施を、CMCタイプの耐熱構造複合材料からつくり出される部品の製造に関して、図1を参照しながら以下に説明する。
・プリフォーム中でのセラミック残留物の体積パーセントが3%ないし10%の範囲内、好ましくは3%ないし6%の範囲内にある;および
・プリフォーム中でのセラミック粉末の体積パーセントが0.5%ないし5%の範囲内、好ましくは0.5%ないし3%の範囲内にある。
・繊維テクスチャプライを成形部材上に掛ける(付形する);
・複数のプライを重ね合わせて掛ける,これらは繊維プリフォームが多様な厚さを示す場合には同様の大きさを有する必要はない,;および
・繊維テクスチャパネルを切り出して、これらパネルを成形部材上にそれらの縁部を隣接させた状態、場合によってはそれらの縁部を互いに重ね合わせた状態で据える。
・団結組成物中のセラミック前駆体のより少ない量;および
・CVIによって得られるセラミックマトリックスのために利用可能なヤーン内部のより大きな体積
で有効な団結を得ることができる点を特徴とする。
・団結組成物中に含有されるセラミック前駆体残留物を強化する機能を提供しおよびそれにより団結容量を向上させる;および
・団結組成物、特にはそれが含有するセラミック前駆体がヤーン内の空間(ヤーンの内部体積)へと浸透するのがより困難なことを確実にする;しかしながら、この目的のためには、上述したように、団結組成物をフィルタリングするヤーンの効果を避けるのに、固体フィラーの粒径が比較的小さいことが必要である。
C繊維の繊維テクスチャを、日本の供給業者Tenaxから「NM5 Roving HTS Fibers」という名称で供給されているC繊維ヤーンの多層3D製織によってつくった。得られたC織物は約4ミリメートル(mm)の厚さを示した。それらを減圧下で約1600℃の温度で約30分(min)間にわたって熱処理した。
・B4C粉末またはSiC粉末をポリエチレンイミンからなる分散剤とこの分散剤用の溶媒(エタノール)との混合物中に分散させ;
・ポリシロキサン樹脂用の溶媒、具体的にはメチルエチルケトン(MEK)を添加し;および
・ポリシロキサン樹脂を添加する。
−1:辛うじて良好な団結
0:優れた団結
+1:非常に優れた団結
+2:プリフォームが非常に堅く、団結は有効であるが、過度であると見なされうる。
CMC部品を以下のようにつくった。
・SiC粉末をポリエチレンイミンからなる分散剤混合物とこの分散剤用の溶媒(エタノール)とに分散させ;
・ポリシロキサン樹脂用の溶媒、具体的にはMEKを添加し;および
・ポリシロキサン樹脂を3/10の希釈比で添加する。
比較として、手順は、従来技術のように、固体フィラーを何ら含んでおらずそれによりプリフォーム中の12%の体積割合に相当する体積を占有する団結固体相を残す団結組成物を使用した以外、例2と同様であった。
Claims (9)
- 耐熱構造複合材料部品を作製する方法であって、ヤーンまたはトウから繊維プリフォームを形成することと、前記繊維プリフォームをその形状で団結させることと、その後団結された前記繊維プリフォームを化学気相浸透によって緻密にすることとを含み、前記団結を、前記繊維プリフォームの前記ヤーンまたはトウに炭素前駆体またはセラミック前駆体を含有する団結組成物を含浸させることと、前記炭素前駆体またはセラミック前駆体を熱分解によって変化させることとによって行い、ここで、平均粒径が200ナノメートル未満の粉末の形態にある耐熱性固体フィラーをさらに含有しかつ熱分解後に団結固体相を残す団結組成物が使用され、前記団結固体相では、前記前駆体に由来する炭素またはセラミックが前記プリフォームの見かけ体積の3%ないし10%に相当する体積を占めおよび前記固体フィラーがプリフォームの見かけ体積の0.5%ないし5%に相当する体積を占めることを特徴とする方法。
- 前記プリフォーム中での前記前駆体に由来する前記団結相の前記炭素またはセラミックの体積パーセントが3%ないし6%の範囲内にあることを特徴とする請求項1に記載の方法。
- 前記プリフォーム中での前記団結相の前記固体フィラーの体積パーセントが0.5%ないし3%の範囲内にあることを特徴とする請求項1または2に記載の方法。
- 使用される前記固体フィラーが200ナノメートル未満の平均粒径を示すことを特徴とする請求項1ないし3のいずれか1項に記載の方法。
- ヤーンまたはトウから形成された繊維テクスチャに型合わせを行い、これに前記団結組成物を含浸させることによって前記繊維プリフォームをつくることを特徴とする請求項1ないし4のいずれか1項に記載の方法。
- 前記団結組成物中の前記炭素前駆体またはセラミック前駆体が樹脂であり、前記樹脂を予備硬化させた後に前記繊維プリフォームに型合わせを行うことを特徴とする請求項5に記載の方法。
- セラミックマトリックス複合材料からつくり出される部品を製作するための請求項1ないし6のいずれか1項に記載の方法であって、前記固体フィラーがSiC、TiC、B4C、およびBNから選択される少なくとも1種の化合物の粉末を含むことを特徴とする方法。
- 前記団結組成物での含浸に先立ち、前記ヤーンまたはトウの前記繊維に対する化学気相浸透によって相間を形成することを特徴とする請求項1ないし7のいずれか1項に記載の方法。
- 前記団結組成物での含浸に先立ち、前記ヤーンまたはトウの前記繊維に対する化学気相浸透によって第1の相間層を形成し、前記繊維プリフォームの団結の後であって団結された前記繊維プリフォームの緻密化の前に第2の相間層を形成することを特徴とする請求項1ないし7のいずれか1項に記載の方法。
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FR0856530 | 2008-09-29 | ||
FR0856530A FR2936517B1 (fr) | 2008-09-29 | 2008-09-29 | Procede de fabrication de pieces en materiau composite thermostructural |
PCT/FR2009/051804 WO2010034937A2 (fr) | 2008-09-29 | 2009-09-23 | Procede de fabrication de pieces en materiau composite thermostructural. |
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FR2983193B1 (fr) * | 2011-11-30 | 2014-05-09 | Snecma Propulsion Solide | Procede de fabrication de piece en materiau cmc |
EP2807133A4 (en) * | 2012-01-26 | 2016-06-01 | Us Gov Sec Navy | FIRE-RESISTANT METAL CERAMICS AND MANUFACTURING METHOD THEREFOR |
US8815381B2 (en) | 2012-01-26 | 2014-08-26 | The United States Of America, As Represented By The Secretary Of The Navy | Formation of boron carbide-boron nitride carbon compositions |
WO2013165538A1 (en) * | 2012-05-01 | 2013-11-07 | The Government Of The Usa, As Represented By The Secretary Of The Navy | Formation of boron carbide-boron nitride carbon compositions |
CN103113123B (zh) * | 2013-02-04 | 2014-03-12 | 西安交通大学 | 一种SiCf/SiC陶瓷基复合材料涡轮叶片的制备方法 |
FR3004712B1 (fr) * | 2013-04-19 | 2015-05-08 | Herakles | Procede de fabrication de materiau composite a matrice carbure |
FR3015976A1 (fr) * | 2013-12-27 | 2015-07-03 | Commissariat Energie Atomique | Procede de fabrication d'une piece en materiau composite cf/sic a partir d'une suspension colloidale et piece ainsi obtenue |
FR3026675B1 (fr) * | 2014-10-02 | 2016-11-11 | Mbda France | Procede pour la realisation d'une piece monolithique composite thermostructurale a double paroi et piece obtenue |
US9975815B2 (en) | 2015-02-26 | 2018-05-22 | General Electric Company | Methods for forming ceramic matrix composite articles |
US11072565B2 (en) | 2015-02-27 | 2021-07-27 | General Electric Company | Ceramic matrix composite structures with controlled microstructures fabricated using chemical vapor infiltration (CVI) |
FR3059679B1 (fr) * | 2016-12-07 | 2021-03-12 | Safran Ceram | Outillage de conformation et installation pour l'infiltration chimique en phase gazeuse de preformes fibreuses |
IT201700089373A1 (it) * | 2017-08-03 | 2019-02-03 | Petroceramics S P A | Materiale composito fibro-rinforzato pre-impregnato e materiale composito ceramico fibro-rinforzato, ottenuto per formatura e successiva pirolisi di detto materiale pre-impregnato |
US10829418B2 (en) * | 2017-11-27 | 2020-11-10 | United Technologies Corporation | Method of densifying a ceramic matrix composite using a filled tackifier |
US10829419B2 (en) * | 2017-11-27 | 2020-11-10 | United Technologies Corporation | Method of densifying a ceramic matrix composite using a filled tackifier |
FR3084445B1 (fr) * | 2018-07-25 | 2021-01-22 | Safran Aircraft Engines | Fabrication d'une chambre de combustion en materiau composite |
US11046615B2 (en) * | 2018-12-19 | 2021-06-29 | Raytheon Technologies Corporation | Self-healing matrix for a ceramic composite |
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WO2010034937A2 (fr) | 2010-04-01 |
FR2936517B1 (fr) | 2011-07-29 |
KR101568453B1 (ko) | 2015-11-11 |
KR20110066914A (ko) | 2011-06-17 |
FR2936517A1 (fr) | 2010-04-02 |
WO2010034937A3 (fr) | 2010-05-20 |
EP2340238B1 (fr) | 2018-04-18 |
EP2340238A2 (fr) | 2011-07-06 |
JP5405578B2 (ja) | 2014-02-05 |
CN102164875A (zh) | 2011-08-24 |
US8529995B2 (en) | 2013-09-10 |
US20110200748A1 (en) | 2011-08-18 |
CN102164875B (zh) | 2014-03-19 |
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