JP2013505857A - セラミックマトリックスを有する複合材料部品およびその製造方法 - Google Patents
セラミックマトリックスを有する複合材料部品およびその製造方法 Download PDFInfo
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- JP2013505857A JP2013505857A JP2012530305A JP2012530305A JP2013505857A JP 2013505857 A JP2013505857 A JP 2013505857A JP 2012530305 A JP2012530305 A JP 2012530305A JP 2012530305 A JP2012530305 A JP 2012530305A JP 2013505857 A JP2013505857 A JP 2013505857A
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- 239000011159 matrix material Substances 0.000 title claims abstract description 121
- 239000000919 ceramic Substances 0.000 title claims abstract description 79
- 239000002131 composite material Substances 0.000 title claims abstract description 7
- 238000000034 method Methods 0.000 title claims description 27
- 238000004519 manufacturing process Methods 0.000 title claims description 22
- 239000000463 material Substances 0.000 claims abstract description 63
- 239000000835 fiber Substances 0.000 claims abstract description 21
- 230000002787 reinforcement Effects 0.000 claims abstract description 8
- 230000001902 propagating effect Effects 0.000 claims abstract description 7
- 230000001131 transforming effect Effects 0.000 claims abstract description 5
- 230000007704 transition Effects 0.000 claims abstract description 5
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 50
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 44
- 238000000151 deposition Methods 0.000 claims description 33
- 238000005229 chemical vapour deposition Methods 0.000 claims description 24
- 230000008021 deposition Effects 0.000 claims description 20
- 238000006243 chemical reaction Methods 0.000 claims description 15
- 239000002245 particle Substances 0.000 claims description 15
- 239000002243 precursor Substances 0.000 claims description 15
- 239000007788 liquid Substances 0.000 claims description 11
- 239000010936 titanium Substances 0.000 claims description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 8
- 230000015572 biosynthetic process Effects 0.000 claims description 8
- 229910052799 carbon Inorganic materials 0.000 claims description 8
- 239000000725 suspension Substances 0.000 claims description 8
- 229910010293 ceramic material Inorganic materials 0.000 claims description 6
- 239000000470 constituent Substances 0.000 claims description 5
- 229910052582 BN Inorganic materials 0.000 claims description 4
- PZNSFCLAULLKQX-UHFFFAOYSA-N Boron nitride Chemical compound N#B PZNSFCLAULLKQX-UHFFFAOYSA-N 0.000 claims description 4
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 claims description 4
- 239000004327 boric acid Substances 0.000 claims description 4
- 239000002296 pyrolytic carbon Substances 0.000 claims description 4
- UGACIEPFGXRWCH-UHFFFAOYSA-N [Si].[Ti] Chemical compound [Si].[Ti] UGACIEPFGXRWCH-UHFFFAOYSA-N 0.000 claims description 3
- 239000000126 substance Substances 0.000 claims description 3
- 230000008595 infiltration Effects 0.000 claims description 2
- 238000001764 infiltration Methods 0.000 claims description 2
- 230000000149 penetrating effect Effects 0.000 claims 1
- 239000010410 layer Substances 0.000 description 99
- 239000011153 ceramic matrix composite Substances 0.000 description 19
- 239000007789 gas Substances 0.000 description 15
- 239000005055 methyl trichlorosilane Substances 0.000 description 14
- JLUFWMXJHAVVNN-UHFFFAOYSA-N methyltrichlorosilane Chemical compound C[Si](Cl)(Cl)Cl JLUFWMXJHAVVNN-UHFFFAOYSA-N 0.000 description 14
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- 238000001000 micrograph Methods 0.000 description 6
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- ATUOYWHBWRKTHZ-UHFFFAOYSA-N Propane Chemical compound CCC ATUOYWHBWRKTHZ-UHFFFAOYSA-N 0.000 description 2
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- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000005388 borosilicate glass Substances 0.000 description 1
- 239000007833 carbon precursor Substances 0.000 description 1
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- 239000003795 chemical substances by application Substances 0.000 description 1
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- 230000001590 oxidative effect Effects 0.000 description 1
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- 239000001294 propane Substances 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
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- 229910052719 titanium Inorganic materials 0.000 description 1
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Abstract
【選択図】図3
Description
本発明は、セラミックマトリックスを有する複合材料部品に関し、特に航空用エンジンまたはロケットエンジンのための部品に関するが、これらに限定されない。
したがって、本発明は、腐食性環境において、少なくとも1000℃まで、さらには少なくとも1200℃までの高温での使用に対するより長い寿命を有するCMC部品を提供することを目的とする。
第1伝播様式に従って前記中間相に隣接した2つのセラミックマトリックス層の1つを横切る方向に前記中間相に到達するクラックを転換させて、前記クラックの前記伝播が第2伝播様式に従って前記中間相に沿って続くようにすることを促進できる材料からできた第1相、および
前記第2伝播様式に従って前記中間相に沿って伝播する前記クラックを転換させて、前記クラックの前記伝播が転換して前記第1伝播様式に従って前記中間相に隣接したその他のセラミックマトリックス層を通って続くようにすることを促進できる、前記中間相内に分布した分離性接触パッドから成る第2相
を含むCMC部品によって達成される。
第1伝播様式に従って前記中間相に隣接した2つのセラミックマトリックス層の1つを横切る方向に前記中間相に到達するクラックを転換させて、前記クラックの前記伝播が第2伝播様式に従って前記中間相に沿って続くようにすることを促進できる材料からできた第1相、および
前記第2伝播様式に従って前記中間相に沿って伝播する前記クラックを転換させて、前記クラックの前記伝播が転換して前記第1伝播様式に従って前記中間相に隣接したその他のセラミックマトリックス層を通って続くようにすることを促進できる、前記中間相内に分布した分離性接触パッドから成る第2相
から作られる方法によって達成される。
−中間相に達するクラックの様式Iから様式IIへの転換を促進することが可能なクラック−転換材料から作られる第1剥離相、および
−中間相に沿って様式IIで伝播するクラックの様式Iへの方向転換(Redirection)を促進することが可能な分離性接触パッド(図2には図示されない)から作られる第2相。
(a)製造すべき部品に対応した形状を有する繊維性予成形品であって、炭素またはセラミック繊維からできた予成形品を作る、
(b)繊維上に繊維/マトリックス脆化軽減中間相層であって、おそらく繊維性予成形品を製造する前に形成することが可能な中間相層を形成する、
(c)セラミックマトリックス層を形成する、
(d)セラミックマトリックス層上に中間相を形成する、
(e)セラミックマトリックス層を形成する、および
(f)おそらく1回以上工程(c)から(e)を繰り返す。
−剥離相の材料の粒子のまたは剥離相の材料の先駆材料を液体担体に含む懸濁液の準備、
−懸濁液によるマトリックス層120の含浸、および
−固体担体を除去し、マトリックス層120の表面に分散した単離された粒子を残す、ここで、粒子は層120の表面空隙に固定されるものの、常に余剰の空隙は存在しており、粒子は、製造しようとする中間相の厚さを超えないように選択されたサイズを有している。
アッセンブリー:SiC/SiC+PyC中間相/SiC/SiC+PyC中間相/SiCをシリコン基体上に製造した:
ここにおいて、
−SiC層は、周知の様式でCVIにより得られた化学量論的層であり、MTS+H2気相から、約1000℃の温度にて、約5kPaの圧力下で、H2割合とMTS割合との間の比率αを約6として得られた;
−SiC+PyC中間相はMTS+H2気相からCVIにより得られ、層状構造を有する第1剥離相PyCおよびPyC微結晶からできた第2相が生じており、条件は、比率αが1未満となるように選択されたこと以外は、化学量論的SiCの取得のための条件と同じである。
例1と同様の方法を使用したが、それぞれの中間相の製造の際に、0.25にほぼ近い比率αおよび5分間の期間を使用し、0.3ミクロンにほぼ等しい厚さを有し、70%at.のPyCを含み、残りはSiC微結晶により形成されたSiC+PyC中間相を得た。
例1と同様の方法を使用したが、それぞれの中間相の製造の際に、0.5にほぼ近い比率αおよび5分間の期間を使用し、0.2ミクロンにほぼ等しい厚さを有し、60%at.のPyCを含み、残りはSiC微結晶により形成されたSiC+PyC中間相を得た。
SiC+Si(Siが高度に富化された非化学両論的SiC)団塊は、SiC基体上にCVDにより形成し、ガス状MTS+H2+HCl相を使用し、約1000℃の温度で、約5kPaの圧力下で、比率αおよびδはそれぞれ約8および約0.5に等しい値とし、堆積時間は約30分として形成した。
アッセンブリー:SiC/(SiC+Si)+PyC中間相/SiCをシリコン基体上に得た:
ここにおいて、
−SiC層は、例1のようなCVIにより得た化学両論的SiC層である;
−(SiC+Si)+PyC中間相は、分離したSiC+Si団塊のCVD堆積、その後の連続的PyC層のCVI堆積により得た。
−剥離相の材料の粒子のまたは剥離相の材料の先駆材料を液体担体に含む懸濁液の準備、
−懸濁液によるマトリックス層120の含浸、および
−液体担体を除去し、マトリックス層120の表面に分散した単離された粒子を残す、ここで、粒子は層120の表面空隙に固定されるものの、常に余剰の空隙は存在しており、粒子は、製造しようとする中間相の厚さを超えないように選択されたサイズを有している。
Claims (15)
- セラミックマトリックスを有し、2つの隣接したセラミックマトリックス層の間に位置するクラック転換マトリックス中間相を有する複数のセラミック層から成るマトリックスによって緻密化された繊維強化材を含む複合材料部品であって、前記中間相(10;110;210)は、
第1伝播様式に従って前記中間相に隣接した2つのセラミックマトリックス層の1つを横切る方向に前記中間相に到達するクラックを転換させて、前記クラックの前記伝播が第2伝播様式に従って前記中間相に沿って続くようにすることを促進できる材料からできた第1相(12;112;211)、および
前記第2伝播様式に従って前記中間相に沿って伝播する前記クラックを転換させて、前記クラックの前記伝播が転換して前記第1伝播様式に従って前記中間相に隣接したその他のセラミックマトリックス層を通って続くようにすることを促進できる、前記中間相内に分布した分離性接触パッド(14;114;214)から成る第2相
を含むことを特徴とする複合材料部品。 - 前記第2相を構成する前記分離性接触パッドは、2つのセラミックマトリックス層の間を局地的に埋める役割を果たすことを特徴とする請求項1に記載の部品。
- 前記分離性接触パッドはセラミックから作られていることを特徴とする請求項2に記載の部品。
- 前記分離性接触パッドは、2つの隣接したセラミックマトリックス層の1つと一体に形成されていることを特徴とする請求項3に記載の部品。
- 前記分離性接触パッドは、前記中間相の表面の20%から80%を占めることを特徴とする請求項1から4の何れか1項に記載の部品。
- 前記中間相の前記第1相の前記材料は、熱分解炭素PyC、窒化ホウ素BN、ホウ酸ドープ炭素BCおよびMAX相、特にチタンシリコン炭化物Ti3SiC2から成る群から選択されることを特徴とする請求項1から5の何れか1項に記載の部品。
- 前記中間相は、0.01ミクロンから2ミクロンの厚さを有することを特徴とする請求項1から6の何れか1項に記載の部品。
- 繊維性予成形品の製造、および2つの隣接したセラミックマトリックス層の間に位置するクラック−転換中間相を有する複数のセラミック層から成るマトリックスによる前記繊維性予成形品の緻密化を含み、前記中間相は、
第1伝播様式に従って前記中間相に隣接した2つのセラミックマトリックス層の1つを横切る方向に前記中間相に到達するクラックを転換させて、前記クラックの前記伝播が第2伝播様式に従って前記中間相に沿って続くようにすることを促進できる材料からできた第1相、および
前記第2伝播様式に従って前記中間相に沿って伝播する前記クラックを転換させて、前記クラックの前記伝播が転換して前記第1伝播様式に従って前記中間相に隣接したその他のセラミックマトリックス層を通って続くようにすることを促進できる、前記中間相内に分布した分離性接触パッドから成る第2相
から作られる、セラミックマトリックスを有する複合材料部品の製造方法。 - 前記中間相は、前記第1相および前記第2相の化学蒸着浸透による共堆積により作られることを特徴とする請求項8に記載の方法。
- 前記中間相は、前記第1相の前記材料の連続層のセラミックマトリックス層上に化学蒸着浸透堆積を行い、前記堆積した層の前記材料を局所的に除去して不連続層を形成すること、およびそのように形成された空間に前記第2相を構成する材料を堆積することにより充填することにより作られることを特徴とする請求項8に記載の方法。
- 前記中間相は、前記第1相の構成材料または前記材料の先駆物質のセラミックマトリックス層上に不連続堆積を行い、互いに離れたパッチを形成すること、および前記第2相を構成する材料を堆積することにより前記パッチ間の空間を埋めることにより作られることを特徴とする請求項8に記載の方法。
- 前記不連続堆積は、前記第1相の前記構成材料または前記材料の先駆物質の粒子を液体担体中に懸濁し、前記懸濁物に前記セラミックマトリックス層を浸透させ、前記液体担体を除去し、前記セラミックマトリックス層の表面に分散した粒子を得ることにより行われることを特徴とする請求項11に記載の方法。
- 前記不連続堆積は、前記第1相の前記材料の先駆材料により形成され、前記先駆材料の変換は、次のセラミックマトリックス層の形成の際に、気相との化学反応により行われることを特徴とする請求項10または11に記載の方法。
- 前記空間の前記充填は、次のセラミックマトリックス層の形成の間におけるセラミック材料の堆積により行われることを特徴とする請求項10から13の何れか1項に記載の方法。
- 前記中間相は、前記第2相の前記分離性接触パッドを形成する団塊のセラミックマトリックス層上における形成、および前記第1相を構成する材料の層の堆積により作られることを特徴とする請求項8に記載の方法。
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EP4353701A2 (en) | 2013-11-26 | 2024-04-17 | RTX Corporation | Gas turbine engine component coating with self-healing barrier layer |
US9470603B2 (en) * | 2014-04-25 | 2016-10-18 | Teledyne Scientific & Imaging, Llc | Morphing ceramic composite components for hypersonic wind tunnel |
US10501378B2 (en) * | 2015-02-24 | 2019-12-10 | United Technologies Corporation | Conformal composite coatings and methods |
CA2939288A1 (en) * | 2015-08-28 | 2017-02-28 | Rolls-Royce High Temperature Composites, Inc. | Ceramic matrix composite including silicon carbide fibers in a ceramic matrix comprising a max phase compound |
US10801108B2 (en) * | 2017-08-28 | 2020-10-13 | Raytheon Technologies Corporation | Method for fabricating ceramic matrix composite components |
CN108585907B (zh) * | 2018-05-03 | 2021-09-14 | 中国航发北京航空材料研究院 | 一种Cr2AlC改性的自愈合碳化硅陶瓷基复合材料的制备方法 |
CN109608217B (zh) * | 2018-12-13 | 2021-09-03 | 湖南泽睿新材料有限公司 | 一种含MAX相界面层的SiCf/SiC复合材料的制备方法 |
US11506383B2 (en) * | 2020-10-09 | 2022-11-22 | Pratt & Whitney Canada Corp | Combustor liner and method of operating same |
DE102022202475A1 (de) | 2022-03-11 | 2023-09-14 | Fraunhofer-Gesellschaft zur Förderung der angewandten Forschung eingetragener Verein | Mehrlagiger Werkstoffverbund, Bauteil umfassend den mehrlagigen Werkstoffverbund, Verfahren zu deren Herstellung und deren Verwendung |
FR3141167A1 (fr) * | 2022-10-21 | 2024-04-26 | Safran Ceramics | Procédé de fabrication d’une pièce en matériau composite à matrice céramique |
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CN102470630A (zh) | 2012-05-23 |
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JP5722330B2 (ja) | 2015-05-20 |
RU2012114237A (ru) | 2013-11-10 |
WO2011036358A1 (fr) | 2011-03-31 |
FR2950622A1 (fr) | 2011-04-01 |
FR2950622B1 (fr) | 2011-10-21 |
KR101701545B1 (ko) | 2017-02-01 |
EP2483073B1 (fr) | 2015-04-08 |
EP2483073A1 (fr) | 2012-08-08 |
CN102470630B (zh) | 2014-09-10 |
US20120164430A1 (en) | 2012-06-28 |
KR20120079834A (ko) | 2012-07-13 |
BR112012000853A2 (pt) | 2016-03-01 |
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