JP2017533829A - セラミックプリフォームおよび方法 - Google Patents
セラミックプリフォームおよび方法 Download PDFInfo
- Publication number
- JP2017533829A JP2017533829A JP2017540539A JP2017540539A JP2017533829A JP 2017533829 A JP2017533829 A JP 2017533829A JP 2017540539 A JP2017540539 A JP 2017540539A JP 2017540539 A JP2017540539 A JP 2017540539A JP 2017533829 A JP2017533829 A JP 2017533829A
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- JP
- Japan
- Prior art keywords
- ceramic
- preform
- ceramic preform
- reinforcing fibers
- fiber
- 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.)
- Granted
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- 239000000919 ceramic Substances 0.000 title claims abstract description 202
- 238000000034 method Methods 0.000 title claims abstract description 49
- 150000001875 compounds Chemical class 0.000 claims abstract description 70
- 239000011156 metal matrix composite Substances 0.000 claims abstract description 63
- 229910052751 metal Inorganic materials 0.000 claims abstract description 47
- 239000002184 metal Substances 0.000 claims abstract description 47
- 239000012783 reinforcing fiber Substances 0.000 claims abstract description 30
- 238000004519 manufacturing process Methods 0.000 claims abstract description 18
- 239000000835 fiber Substances 0.000 claims description 85
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 51
- 239000002245 particle Substances 0.000 claims description 32
- 239000000203 mixture Substances 0.000 claims description 30
- 229910000323 aluminium silicate Inorganic materials 0.000 claims description 28
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 claims description 28
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 23
- 239000008119 colloidal silica Substances 0.000 claims description 21
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 claims description 19
- 229910010271 silicon carbide Inorganic materials 0.000 claims description 19
- 239000011230 binding agent Substances 0.000 claims description 18
- 229920002472 Starch Polymers 0.000 claims description 15
- 238000010438 heat treatment Methods 0.000 claims description 15
- 239000008107 starch Substances 0.000 claims description 15
- 235000019698 starch Nutrition 0.000 claims description 15
- 238000004512 die casting Methods 0.000 claims description 11
- 229910000838 Al alloy Inorganic materials 0.000 claims description 10
- 239000000463 material Substances 0.000 claims description 9
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- 239000012153 distilled water Substances 0.000 claims description 7
- 238000003825 pressing Methods 0.000 claims description 7
- 239000000654 additive Substances 0.000 claims description 6
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- 230000000996 additive effect Effects 0.000 claims description 4
- 239000007864 aqueous solution Substances 0.000 claims description 3
- 238000005406 washing Methods 0.000 claims description 2
- 230000004580 weight loss Effects 0.000 claims description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 claims 4
- 229910004298 SiO 2 Inorganic materials 0.000 claims 4
- 239000000084 colloidal system Substances 0.000 claims 1
- 239000000377 silicon dioxide Substances 0.000 claims 1
- 238000003756 stirring Methods 0.000 claims 1
- 239000000243 solution Substances 0.000 description 15
- 239000012210 heat-resistant fiber Substances 0.000 description 13
- 241000758789 Juglans Species 0.000 description 10
- 235000009496 Juglans regia Nutrition 0.000 description 10
- 229910052782 aluminium Inorganic materials 0.000 description 10
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 10
- 238000009472 formulation Methods 0.000 description 10
- 235000020234 walnut Nutrition 0.000 description 10
- 125000002091 cationic group Chemical group 0.000 description 9
- 229920002261 Corn starch Polymers 0.000 description 8
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- 239000001866 hydroxypropyl methyl cellulose Substances 0.000 description 7
- 229920003088 hydroxypropyl methyl cellulose Polymers 0.000 description 7
- UFVKGYZPFZQRLF-UHFFFAOYSA-N hydroxypropyl methyl cellulose Chemical compound OC1C(O)C(OC)OC(CO)C1OC1C(O)C(O)C(OC2C(C(O)C(OC3C(C(O)C(O)C(CO)O3)O)C(CO)O2)O)C(CO)O1 UFVKGYZPFZQRLF-UHFFFAOYSA-N 0.000 description 7
- 235000010979 hydroxypropyl methyl cellulose Nutrition 0.000 description 7
- 238000012545 processing Methods 0.000 description 7
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 6
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 6
- 239000011777 magnesium Substances 0.000 description 6
- 229910052749 magnesium Inorganic materials 0.000 description 6
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 5
- 229910045601 alloy Inorganic materials 0.000 description 5
- 239000000956 alloy Substances 0.000 description 5
- 238000002485 combustion reaction Methods 0.000 description 5
- 230000008595 infiltration Effects 0.000 description 5
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- 239000001923 methylcellulose Substances 0.000 description 5
- 239000010936 titanium Substances 0.000 description 5
- 229910052719 titanium Inorganic materials 0.000 description 5
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000005245 sintering Methods 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
- 229910052799 carbon Inorganic materials 0.000 description 3
- 229910052742 iron Inorganic materials 0.000 description 3
- 229910052720 vanadium Inorganic materials 0.000 description 3
- 229910052726 zirconium Inorganic materials 0.000 description 3
- 229910001018 Cast iron Inorganic materials 0.000 description 2
- 229920003091 Methocel™ Polymers 0.000 description 2
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 2
- 230000002776 aggregation Effects 0.000 description 2
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- 239000003575 carbonaceous material Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
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- 239000011521 glass Substances 0.000 description 2
- 238000003621 hammer milling Methods 0.000 description 2
- 238000003754 machining Methods 0.000 description 2
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 2
- 238000009740 moulding (composite fabrication) Methods 0.000 description 2
- 150000003839 salts Chemical class 0.000 description 2
- 239000010703 silicon Substances 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000012546 transfer Methods 0.000 description 2
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 2
- 241000083700 Ambystoma tigrinum virus Species 0.000 description 1
- 229910052580 B4C Inorganic materials 0.000 description 1
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 244000068645 Carya illinoensis Species 0.000 description 1
- 235000009025 Carya illinoensis Nutrition 0.000 description 1
- 229910000881 Cu alloy Inorganic materials 0.000 description 1
- 229920002907 Guar gum Polymers 0.000 description 1
- CPLXHLVBOLITMK-UHFFFAOYSA-N Magnesium oxide Chemical compound [Mg]=O CPLXHLVBOLITMK-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- 240000007594 Oryza sativa Species 0.000 description 1
- 235000007164 Oryza sativa Nutrition 0.000 description 1
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- 229910001315 Tool steel Inorganic materials 0.000 description 1
- 230000002745 absorbent Effects 0.000 description 1
- 239000002250 absorbent Substances 0.000 description 1
- 230000006978 adaptation Effects 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 238000004220 aggregation Methods 0.000 description 1
- 230000032683 aging Effects 0.000 description 1
- 239000005359 alkaline earth aluminosilicate glass Substances 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 239000005354 aluminosilicate glass Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- INAHAJYZKVIDIZ-UHFFFAOYSA-N boron carbide Chemical compound B12B3B4C32B41 INAHAJYZKVIDIZ-UHFFFAOYSA-N 0.000 description 1
- 239000006229 carbon black Substances 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000002041 carbon nanotube Substances 0.000 description 1
- 229910021393 carbon nanotube Inorganic materials 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000007906 compression Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000008602 contraction Effects 0.000 description 1
- 230000010485 coping Effects 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000010891 electric arc Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000012467 final product Substances 0.000 description 1
- 239000012530 fluid Substances 0.000 description 1
- 239000003365 glass fiber Substances 0.000 description 1
- 229910021389 graphene Inorganic materials 0.000 description 1
- 229910002804 graphite Inorganic materials 0.000 description 1
- 239000010439 graphite Substances 0.000 description 1
- 239000000665 guar gum Substances 0.000 description 1
- 235000010417 guar gum Nutrition 0.000 description 1
- 229960002154 guar gum Drugs 0.000 description 1
- 239000010903 husk Substances 0.000 description 1
- 238000002347 injection Methods 0.000 description 1
- 239000007924 injection Substances 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052748 manganese Inorganic materials 0.000 description 1
- 239000011572 manganese Substances 0.000 description 1
- 239000011159 matrix material Substances 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
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- 239000011368 organic material Substances 0.000 description 1
- 238000000643 oven drying Methods 0.000 description 1
- 230000000704 physical effect Effects 0.000 description 1
- 239000000047 product Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 239000011226 reinforced ceramic Substances 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 235000009566 rice Nutrition 0.000 description 1
- 238000007873 sieving Methods 0.000 description 1
- RMAQACBXLXPBSY-UHFFFAOYSA-N silicic acid Chemical compound O[Si](O)(O)O RMAQACBXLXPBSY-UHFFFAOYSA-N 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 235000012239 silicon dioxide Nutrition 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 229910052572 stoneware Inorganic materials 0.000 description 1
- 239000000230 xanthan gum Substances 0.000 description 1
- 229920001285 xanthan gum Polymers 0.000 description 1
- 235000010493 xanthan gum Nutrition 0.000 description 1
- 229940082509 xanthan gum Drugs 0.000 description 1
Classifications
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/0081—Casting in, on, or around objects which form part of the product pretreatment of the insert, e.g. for enhancing the bonding between insert and surrounding cast metal
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
- B22D19/00—Casting in, on, or around objects which form part of the product
- B22D19/02—Casting in, on, or around objects which form part of the product for making reinforced articles
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
- C04B35/56—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
- C04B35/565—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
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- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
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- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/62605—Treating the starting powders individually or as mixtures
- C04B35/62685—Treating the starting powders individually or as mixtures characterised by the order of addition of constituents or additives
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- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating 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
- C04B41/51—Metallising, e.g. infiltration of sintered ceramic preforms with molten metal
- C04B41/515—Other specific metals
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- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/80—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only ceramics
- C04B41/81—Coating or impregnation
- C04B41/85—Coating or impregnation with inorganic materials
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C32/00—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ
- C22C32/0047—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents
- C22C32/0052—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides
- C22C32/0063—Non-ferrous alloys containing at least 5% by weight but less than 50% by weight of oxides, carbides, borides, nitrides, silicides or other metal compounds, e.g. oxynitrides, sulfides, whether added as such or formed in situ with carbides, nitrides, borides or silicides as the main non-metallic constituents only carbides based on SiC
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/06—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
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- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
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- C22C47/062—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
- C22C47/068—Aligning wires
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- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
- C22C47/12—Infiltration or casting under mechanical pressure
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- C22C49/00—Alloys containing metallic or non-metallic fibres or filaments
- C22C49/02—Alloys containing metallic or non-metallic fibres or filaments characterised by the matrix material
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- C22C49/06—Aluminium
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
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- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
- F16D65/02—Braking members; Mounting thereof
- F16D65/12—Discs; Drums for disc brakes
- F16D65/125—Discs; Drums for disc brakes characterised by the material used for the disc body
- F16D65/126—Discs; Drums for disc brakes characterised by the material used for the disc body the material being of low mechanical strength, e.g. carbon, beryllium; Torque transmitting members therefor
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
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- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00241—Physical properties of the materials not provided for elsewhere in C04B2111/00
- C04B2111/00362—Friction materials, e.g. used as brake linings, anti-skid materials
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- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00905—Uses not provided for elsewhere in C04B2111/00 as preforms
- C04B2111/00913—Uses not provided for elsewhere in C04B2111/00 as preforms as ceramic preforms for the fabrication of metal matrix comp, e.g. cermets
- C04B2111/00931—Coated or infiltrated preforms, e.g. with molten metal
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- C04B2235/50—Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
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- F16D—COUPLINGS FOR TRANSMITTING ROTATION; CLUTCHES; BRAKES
- F16D65/00—Parts or details
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Abstract
Description
本願は、2014年10月20日に出願され、“Ceramic Preform and Method”と題された米国仮特許出願第62/066,057号に対する優先権を主張するものであり、その全体は、参照により本明細書中に援用される。
Claims (24)
- セラミックプリフォームを作製する方法であって、
強化用繊維を個々のストランドに分離するように、強化用繊維の塊をほぐすステップと、
前記強化用繊維の分離されたストランドと、セラミック粒子と、放出多孔性生成構成要素と、デンプンと、低温有機結合剤と、コロイド状シリカと、水とを含む、セラミック化合物を調製するステップと、
前記セラミックプリフォームを作成するように、前記セラミック化合物を所望の形状に形成するステップと、
を含む、方法。 - 前記セラミック化合物は、約41重量%〜約47重量%のセラミック粒子と、約9重量%〜約15重量%の強化用繊維と、約4.5重量%〜約5.5重量%の放出多孔性生成構成要素と、約3重量%〜約4重量%のデンプンと、約1.5重量%〜約2重量%の低温有機結合剤と、約4.5重量%〜約11重量%のコロイド状シリカと、約17重量%〜約38重量%の水とを含む、請求項1に記載の方法。
- 前記強化用繊維は、アルカリ土類アルミノケイ酸塩強化用繊維であり、前記セラミック粒子は、炭化ケイ素粒子である、請求項2に記載の方法。
- 前記強化用繊維は、約38重量%〜約43重量%のSiO2と、約18重量%〜約23重量%のAl2O3と、約23重量%〜約28重量%のCaO+MgOとを含む、アルカリ土類アルミノケイ酸塩強化用繊維である、請求項1に記載の方法。
- 前記強化用繊維は、約40重量%〜約50重量%のSiO2と、約10重量%〜約16重量%のAl2O3と、約20重量%〜約35重量%のCaO+MgOとを含む、アルカリ土類アルミノケイ酸塩強化用繊維である、請求項1に記載の方法。
- 前記ほぐすステップは、
前記強化用繊維の塊を容器の中へ配置し、蒸留水と、1.0〜2.0重量%濃度におけるアルキルアミノアミド添加剤とから成る、水溶液を添加するステップと、
前記容器の内容物を攪拌するステップと、
前記水溶液を傾瀉するステップと、
残留添加物を除去するように水で前記強化用繊維を洗浄するステップと、
前記洗浄水を傾瀉するステップと、
ほぐれた繊維懸濁液を形成するように、約14重量%〜約27重量%の第1の水を前記洗浄された強化用繊維に添加するステップと、
を含む、請求項1に記載の方法。 - 前記セラミック化合物を調製するステップは、
前記セラミック化合物の乾燥粉末を混合するステップであって、前記乾燥粉末は、前記セラミック粒子と、放出多孔性生成構成要素と、デンプンと、低温有機結合剤とを含む、ステップと、
第1の混合物を形成するように、前記混合乾燥粉末および前記ほぐれた繊維懸濁液をともに混合するステップと、
第2の混合物を形成するように、前記コロイド状シリカおよび約3.5重量%〜約9重量%の第2の水をともに混合するステップと、
前記セラミック化合物を形成するように、前記第1および第2の混合物をともに混合するステップと、
を含む、請求項6に記載の方法。 - 前記セラミック化合物を押圧および圧延するステップをさらに含む、請求項1に記載の方法。
- 前記セラミック化合物は、ブレーキディスク金属マトリクス複合材料で使用するためのディスクまたはリングのいずれか一方として形成される、請求項1に記載の方法。
- 前記セラミックプリフォームからの前記水の除去による重量損失割合が約20パーセント〜約70パーセントになるまで、オーブンの中で前記セラミックプリフォームを乾燥させるステップと、
前記セラミックプリフォームから前記放出多孔性生成構成要素、前記デンプン、および前記低温有機結合剤を除去するために十分な温度で前記セラミックプリフォームを熱処理するステップと、
前記コロイド状シリカによって作成されるセラミック結合を密閉するために十分な温度で前記セラミックプリフォームを熱処理するステップと、
をさらに含む、請求項1に記載の方法。 - 前記強化用繊維は、3.5ミクロンを上回る直径を有する、請求項1に記載の方法。
- 前記強化用繊維の前記直径は、5〜6ミクロンである、請求項11に記載の方法。
- ブレーキディスク金属マトリクス複合材料で使用するためのディスクまたはリングのいずれか一方として形成される、セラミック化合物を含む、セラミックプリフォームであって、前記セラミック化合物は、約41重量%〜約47重量%のセラミック粒子と、3.5ミクロンを上回る直径を有する、約9重量%〜約15重量%のアルカリ土類アルミノケイ酸塩強化用繊維と、約4.5重量%〜約5.5重量%の放出多孔性生成構成要素と、約3重量%〜約4重量%のデンプンと、約1.5重量%〜約2重量%の低温有機結合剤と、約4.5重量%〜約11重量%のコロイド状シリカと、約17重量%〜約38重量%の水とを含む、セラミックプリフォーム。
- 前記セラミック粒子は、炭化ケイ素粒子である、請求項13に記載のセラミックプリフォーム。
- 前記アルカリ土類アルミノケイ酸塩強化用繊維は、約38重量%〜約43重量%のSiO2と、約18重量%〜約23重量%のAl2O3と、約23重量%〜約28重量%のCaO+MgOとを含む、請求項13に記載のセラミックプリフォーム。
- 前記アルカリ土類アルミノケイ酸塩強化用繊維は、約40重量%〜約50重量%のSiO2と、約10重量%〜約16重量%のAl2O3と、約20重量%〜約35重量%CaO+MgOとを含む、請求項13に記載のセラミックプリフォーム。
- 前記アルカリ土類アルミノケイ酸塩強化用繊維の前記直径は、5〜6ミクロンである、請求項13に記載のセラミックプリフォーム。
- 前記セラミックプリフォームは、前記ブレーキディスク金属マトリクス複合材料の制動面の少なくとも一部を備える、請求項13に記載のセラミックプリフォーム。
- 金属マトリクス複合材料を作製する方法であって、
予熱温度まで請求項13に記載のセラミックプリフォームを加熱するステップと、
ダイカスト金型の型穴の中に前記セラミックプリフォームを配置するステップと、
金属が前記セラミックプリフォームに浸潤して前記ブレーキディスク金属マトリクス複合材料を形成するように、溶解金属を前記型穴に導入するステップであって、前記予熱温度は、前記溶解金属の温度を上回る、ステップと、
を含む、方法。 - 前記溶解金属は、直接スクイズ鋳造プロセスを使用して、前記型穴に導入される、請求項19に記載の方法。
- 前記溶解金属は、高温性能アルミニウム合金である、請求項19に記載の方法。
- 前記セラミックプリフォームは、前記ブレーキディスク金属マトリクス複合材料の制動面の少なくとも一部を備える、請求項19に記載の方法。
- ブレーキディスク金属マトリクス複合材料を形成するように溶解高温性能アルミニウム合金が浸潤した請求項13に記載のセラミックプリフォームを備える、金属マトリクス複合材料。
- 前記セラミックプリフォームは、前記ブレーキディスク金属マトリクス複合材料の制動面の少なくとも一部を備える、請求項23に記載の金属マトリクス複合材料。
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Also Published As
Publication number | Publication date |
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JP6672319B2 (ja) | 2020-03-25 |
WO2016064430A1 (en) | 2016-04-28 |
US9714686B2 (en) | 2017-07-25 |
CN107000249A (zh) | 2017-08-01 |
EP3209471A4 (en) | 2018-06-27 |
US20160108980A1 (en) | 2016-04-21 |
EP3209471A1 (en) | 2017-08-30 |
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