JP5267729B2 - SiC被覆SiC繊維結合型セラミックス - Google Patents
SiC被覆SiC繊維結合型セラミックス Download PDFInfo
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Description
第1工程においては、前駆重合体である金属元素含有有機ケイ素重合体を調整する。第1工程において用いられるポリシランは、例えば「有機ケイ素化合物の化学」化学同人(1972年)に記載の方法に従い、ナトリウムを用いて1種類以上のジクロロシランを脱塩素反応させることにより得られる鎖状又は環状の重合体であり、その数平均分子量は、通常300〜1000である。このポリシランは、ケイ素の側鎖として、水素原子、低級アルキル基、フェニル基又はシリル基を有することができるが、何れの場合も、ケイ素原子に対する炭素原子の割合がモル比で1.5以上であることが必要である。この条件を満足しないと、繊維中の炭素の全てが不融化の際に導入された酸素と共に、焼結に至るまでの昇温過程で炭酸ガスとして脱離し、繊維間の境界炭素層が形成されないので好ましくない。
第2工程においては、金属元素含有有機ケイ素重合体の紡糸繊維を得る。前駆重合体である金属元素含有有機ケイ素重合体を溶融紡糸及び乾式紡糸のようなそれ自体公知の方法によって紡糸し、紡糸繊維を得ることができる。
第3工程においては、紡糸繊維を酸素含有雰囲気中50〜170℃で加熱して不融化繊維を調製する。不融化の目的は、紡糸繊維を構成するポリマー間に酸素原子による橋かけ点を形成させて、後続の無機化工程において不融化繊維が溶融せず、かつ隣接する繊維同士が融着しないようにすることである。酸素含有雰囲気を構成するガスとしては、空気、酸素、オゾンが例示される。不融化温度は50〜170℃であり、不融化時間は不融化温度に依存するが、通常、数分〜30時間である。不融化繊維中の酸素の含有量は8〜16重量%になるようにコントロールすることが望ましい。この酸素の大部分は、次工程の無機化後も繊維中に残存し、最終の焼結に至るまでの昇温過程において、無機繊維中の余剰炭素をCOガスとして脱離させる重要な働きをする。なお、酸素含有量が8重量%より少ない場合は、無機繊維中の余剰炭素が必要以上に残存し、昇温過程においてSiC結晶の回りに偏析して安定化するためβ−SiC結晶同士が粒界第2相を介すことなく焼結することを阻害し、また、16重量%よりも多い場合は、無機繊維中の余剰炭素が完全に脱離して繊維間の境界炭素層が生成しない。これらは、いずれも得られる材料の力学的特性に悪影響を及ぼす。
第4工程においては、不融化繊維を、連続式又は回分式で、アルゴンのような不活性ガス雰囲気中、1000〜1700℃の範囲内の温度で加熱処理して、無機化する。
第3工程で得られた不融化繊維、又は第4工程で得られた無機化繊維を所定の形状、例えば、織物、繊維を一方向に配向したシート、繊維束、又はチョップ状短繊維の少なくとも1種類の形状よりなる予備成形体を所定形状のカーボンダイス中に配置して、真空、不活性ガス、還元ガス及び炭化水素のうち少なくとも1種からなる雰囲気中で、1700〜2200℃の範囲で加熱する。加熱した後、100〜1000kg/cm2の範囲の圧力で加圧処理することによって、(A)SiC繊維結合型セラミックスを製造することができる。加熱後、予備成形体の表面部の炭素をCOやSiOガスとして排出させるために、その温度で一定時間保持した後に加圧処理を行うことが好ましい。保持する時間は、予備成形体の大きさや種類、及び昇温速度などによって決定される。
第3工程で得られた不融化繊維、又は第4工程で得られた無機化繊維を所定の形状、例えば、織物、繊維を一方向に配向したシート、繊維束、又はチョップ状短繊維の少なくとも1種類の形状よりなる予備成形体に形成し、その表面の少なくとも一部を粉末状及びポーラス状の少なくとも一方の形状の無機物質に接するように所定形状のカーボンダイス中に配置して、真空、不活性ガス、還元ガス及び炭化水素のうち少なくとも1種からなる雰囲気中で、1700〜2200℃の範囲で加熱する。加熱した後、100〜1000kg/cm2の範囲の圧力で加圧処理することによって、(B)傾斜構造SiC繊維結合型セラミックスを製造することができる。加熱後、予備成形体の表面部の炭素をCOやSiOガスとして排出させるために、その温度で一定時間保持した後に加圧処理を行うことが好ましい。保持する時間は、予備成形体の大きさや種類、及び昇温速度などによって決定される。
IHI製のアーク加熱方式のエロージョン試験装置を用いて、ノズル径75mm、ノズルからの距離35mm、燃焼ガス(模擬空気)の流量50L/min、電流180Aの条件で200秒実施した。この条件における加熱率をガートンゲージで実測したところ、2.6MW/m2であった。サンプルの表面温度は、燃焼ガスが噴射しているノズル上部に取り付けた覗き窓に放射温度計を設置して、サンプルの斜め上から測定した。
まず、窒素ガス気流下にナトリウム400gを含有する無水キシレンを加熱環流させながら、ジメチルジクロロシラン1Lを滴下し、引き続き10時間加熱環流し沈殿物を生成させた。この沈殿をろ過し、メタノール、次いで水で洗浄して、白色のポリジメチルシラン420gを得た。次に、ジフェニルジクロロシラン750g、及びホウ酸124gを窒素ガス雰囲気下にn−ブチルエーテル中、100〜120℃で加熱し、生成した白色樹脂状物をさらに真空中400℃で1時間加熱処理することによって、フェニル基含有ポリボロシキサン530gを得た。
2 SiC繊維結合型セラミックス
3 SiC被覆層とSiC繊維結合型セラミックスの境界
Claims (3)
- 酸素(O)0.01〜1重量%、並びに2A族、3A族及び3B族の金属原子のうち少なくとも1種以上の金属原子が含有された主にSiCの焼結構造からなる無機繊維、及びその繊維間に形成され、炭素(C)を主成分とする厚さ1〜100nmの境界層が含まれたSiC繊維結合型セラミックスの表面がSiCを主成分とする被覆層によって被覆されていることを特徴とするSiC被覆SiC繊維結合型セラミックス。
- 酸素(O)0.01〜1重量%、並びに2A族、3A族及び3B族の金属原子のうち少なくとも1種以上の金属原子が含有された主にSiCの焼結構造からなる無機繊維、及びその繊維間に形成され、炭素(C)を主成分とする厚さ1〜100nmの境界層が含まれた母材と、主にSiCを主成分とするセラミックス構造からなり、前記母材の表面の少なくとも一部に形成された表面部と、前記表面部と前記母材の間に介在し、前記母材の構造から表面部の構造に徐々に且つ連続的に変化する傾斜構造となっている境界部とを含むSiC繊維結合型セラミックスの表面がSiCを主成分とする被覆層によって被覆されていることを特徴とするSiC被覆SiC繊維結合型セラミックス。
- 化学的、並びに物理的に研磨することなくSiC被覆後の表面粗さが、Rmax=10μm以下であり、かつSiC被覆層の膜厚のバラツキが50μm以下であることを特徴とする請求項1又は2記載のSiC被覆SiC繊維結合型セラミックス。
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JPS6487581A (en) * | 1987-09-30 | 1989-03-31 | Kyocera Corp | Production of ceramics material |
JPH0551268A (ja) * | 1991-08-21 | 1993-03-02 | Sumitomo Electric Ind Ltd | 繊維強化傾斜機能材料 |
JP2002104892A (ja) * | 2000-07-24 | 2002-04-10 | Ube Ind Ltd | セラミックス複合材料 |
WO2008035590A1 (en) * | 2006-09-20 | 2008-03-27 | Ube Industries, Ltd. | SiC FIBER BONDED CERAMIC AND PROCESS FOR PRODUCTION OF THE SAME |
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JPS584732B2 (ja) | 1976-09-30 | 1983-01-27 | 財団法人特殊無機材料研究所 | 耐加水分解性、耐熱性に優れたボロシロキサンポリマ−の製造方法 |
JPS5350299A (en) | 1976-10-18 | 1978-05-08 | Tokushiyu Muki Zairiyou Kenkiy | Process for preparing inorganic polymer whose main chain contains si b and o as elemental component |
JPH11171658A (ja) * | 1997-12-05 | 1999-06-29 | Ube Ind Ltd | 結晶性炭化ケイ素系繊維強化セラミック複合材料 |
JP3969106B2 (ja) * | 2001-02-05 | 2007-09-05 | 宇部興産株式会社 | 高耐熱性無機繊維結合セラミックス接合体及びその接合方法 |
JP4707854B2 (ja) * | 2001-03-08 | 2011-06-22 | 独立行政法人科学技術振興機構 | 高強度SiC繊維/SiC複合材料の製造方法 |
JP2003252694A (ja) * | 2002-03-01 | 2003-09-10 | Chokoon Zairyo Kenkyusho:Kk | SiC繊維複合化SiC複合材料 |
JP4753568B2 (ja) | 2004-11-24 | 2011-08-24 | 川崎重工業株式会社 | SiC系繊維強化セラミックス複合材料耐環境コーティングおよびその製造方法 |
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JPS6487581A (en) * | 1987-09-30 | 1989-03-31 | Kyocera Corp | Production of ceramics material |
JPH0551268A (ja) * | 1991-08-21 | 1993-03-02 | Sumitomo Electric Ind Ltd | 繊維強化傾斜機能材料 |
JP2002104892A (ja) * | 2000-07-24 | 2002-04-10 | Ube Ind Ltd | セラミックス複合材料 |
WO2008035590A1 (en) * | 2006-09-20 | 2008-03-27 | Ube Industries, Ltd. | SiC FIBER BONDED CERAMIC AND PROCESS FOR PRODUCTION OF THE SAME |
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