JP6248090B2 - セラミック複合材料部品の製造方法 - Google Patents
セラミック複合材料部品の製造方法 Download PDFInfo
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- 238000004519 manufacturing process Methods 0.000 title claims description 26
- 239000000919 ceramic Substances 0.000 title description 18
- 239000002131 composite material Substances 0.000 title description 3
- 238000000034 method Methods 0.000 claims description 41
- 239000000463 material Substances 0.000 claims description 37
- 230000002787 reinforcement Effects 0.000 claims description 33
- 229910010293 ceramic material Inorganic materials 0.000 claims description 13
- 239000012779 reinforcing material Substances 0.000 claims description 13
- 239000002243 precursor Substances 0.000 claims description 11
- 230000001681 protective effect Effects 0.000 claims description 5
- 238000005470 impregnation Methods 0.000 claims description 4
- 230000002093 peripheral effect Effects 0.000 claims description 2
- 230000003014 reinforcing effect Effects 0.000 claims 2
- 238000009966 trimming Methods 0.000 claims 2
- 239000004744 fabric Substances 0.000 claims 1
- 239000011153 ceramic matrix composite Substances 0.000 description 33
- 239000011159 matrix material Substances 0.000 description 19
- 239000000835 fiber Substances 0.000 description 13
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 11
- 229910010271 silicon carbide Inorganic materials 0.000 description 11
- 239000007789 gas Substances 0.000 description 10
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 229910052710 silicon Inorganic materials 0.000 description 4
- 239000010703 silicon Substances 0.000 description 4
- 239000000567 combustion gas Substances 0.000 description 3
- 238000013461 design Methods 0.000 description 2
- 238000010304 firing Methods 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 239000012783 reinforcing fiber Substances 0.000 description 2
- MTPVUVINMAGMJL-UHFFFAOYSA-N trimethyl(1,1,2,2,2-pentafluoroethyl)silane Chemical compound C[Si](C)(C)C(F)(F)C(F)(F)F MTPVUVINMAGMJL-UHFFFAOYSA-N 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910000676 Si alloy Inorganic materials 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 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
- 238000013459 approach Methods 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 239000012700 ceramic precursor Substances 0.000 description 1
- 230000000295 complement effect Effects 0.000 description 1
- 238000007596 consolidation process Methods 0.000 description 1
- 238000001816 cooling Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 238000012938 design process Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 238000005495 investment casting Methods 0.000 description 1
- 238000010248 power generation Methods 0.000 description 1
- 239000011226 reinforced ceramic Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910000601 superalloy Inorganic materials 0.000 description 1
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/282—Selecting composite materials, e.g. blades with reinforcing filaments
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F01—MACHINES OR ENGINES IN GENERAL; ENGINE PLANTS IN GENERAL; STEAM ENGINES
- F01D—NON-POSITIVE DISPLACEMENT MACHINES OR ENGINES, e.g. STEAM TURBINES
- F01D5/00—Blades; Blade-carrying members; Heating, heat-insulating, cooling or antivibration means on the blades or the members
- F01D5/12—Blades
- F01D5/28—Selecting particular materials; Particular measures relating thereto; Measures against erosion or corrosion
- F01D5/284—Selection of ceramic materials
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
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- C04B2235/00—Aspects relating to ceramic starting mixtures or sintered ceramic products
- C04B2235/65—Aspects relating to heat treatments of ceramic bodies such as green ceramics or pre-sintered ceramics, e.g. burning, sintering or melting processes
- C04B2235/658—Atmosphere during thermal treatment
- C04B2235/6581—Total pressure below 1 atmosphere, e.g. vacuum
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
- C04B2237/32—Ceramic
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
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- C04B2237/32—Ceramic
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/30—Composition of layers of ceramic laminates or of ceramic or metallic articles to be joined by heating, e.g. Si substrates
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- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/60—Forming at the joining interface or in the joining layer specific reaction phases or zones, e.g. diffusion of reactive species from the interlayer to the substrate or from a substrate to the joining interface, carbide forming at the joining interface
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/61—Joining two substrates of which at least one is porous by infiltrating the porous substrate with a liquid, such as a molten metal, causing bonding of the two substrates, e.g. joining two porous carbon substrates by infiltrating with molten silicon
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/76—Forming laminates or joined articles comprising at least one member in the form other than a sheet or disc, e.g. two tubes or a tube and a sheet or disc
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- C04B2237/00—Aspects relating to ceramic laminates or to joining of ceramic articles with other articles by heating
- C04B2237/50—Processing aspects relating to ceramic laminates or to the joining of ceramic articles with other articles by heating
- C04B2237/86—Joining of two substrates at their largest surfaces, one surface being complete joined and covered, the other surface not, e.g. a small plate joined at it's largest surface on top of a larger plate
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
- F05D—INDEXING SCHEME FOR ASPECTS RELATING TO NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES, GAS-TURBINES OR JET-PROPULSION PLANTS
- F05D2300/00—Materials; Properties thereof
- F05D2300/60—Properties or characteristics given to material by treatment or manufacturing
- F05D2300/603—Composites; e.g. fibre-reinforced
- F05D2300/6033—Ceramic matrix composites [CMC]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02T—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO TRANSPORTATION
- Y02T50/00—Aeronautics or air transport
- Y02T50/60—Efficient propulsion technologies, e.g. for aircraft
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/2419—Fold at edge
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Composite Materials (AREA)
- Turbine Rotor Nozzle Sealing (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
- Compositions Of Oxide Ceramics (AREA)
Description
12 ダブテール
14 プラットホーム
16 翼形部
18 シャンク
20 チップシュラウド
22 シール歯
24 第1組の強化材含有プライ
26 第2組の強化材含有プライ
28 第3組の強化材含有プライ
30 無強化材プライ
32 凹面
34 凸面
36 インサートプライ
36A 無強化材プライ
38 開口
40 追加インサートプライ断片
42 プリプレグプライ
46 隙間
Claims (15)
- 第1の領域と、第1の領域よりも第2の領域の幾何学的形状を複雑にする1以上の軸外幾何学的特徴要素を有する1以上の第2の領域とを含む部品の製造方法であって、
部品の第1の領域を、セラミック材料前駆体中に強化材を含有するプライであって、少なくとも第2の組のプライと第3の組のプライの間に少なくとも第1の組のプライを含んでいるプライで形成する工程と、
第2及び第3の組のプライの少なくとも一部を分断及び/又はトリミングして、第2の領域に隙間を導入する工程と、
第2の組のプライ及び第3の組のプライの各々の折り曲げられた遠位端部が部品の第1の領域内の第1の組のプライに対して横断方向に配向するように、第2の組のプライ及び第3の組のプライの各々の遠位端部を第1の組のプライから離れるように折り曲げる工程と、
第2の領域における第2及び第3の組のプライの分断部分及び/又は隣接トリム部分の間の隙間を、隙間を埋める寸法及び形状の追加インサートプライ断片で埋める工程と、
第2の組のプライの折り曲げられた遠位端部の少なくとも幾つかの間及び第3の組のプライの折り曲げられた遠位端部の少なくともいくつかの間に、第4の組のプライを挟み込む工程と、次いで
第1の組のプライと第2及び第3の組のプライのうち第1の組のプライから離れるように折り曲げられなかった部分とが部品の第1の領域を画成し、かつ第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとが部品の第2の領域を画成するように、第1、第2、第3及び第4の組のプライを合体及び硬化させる工程と
を含む方法。 - 部品が、部品の少なくとも第3の領域であって、第1、第2、第3及び第4の組のプライを合体及び硬化させる前に第5の組のプライで形成された少なくとも第3の領域をさらに含むように製造され、当該方法が、
セラミック材料前駆体中に強化材を含有する第5の組のプライを形成する工程と、
第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成される部品の第2の領域の表面に第5の組のプライを適用する工程であって、第2及び第3の組のプライの各々の折り曲げられた遠位端部の上に重なる第1の部分と、第1の領域と整列して、第2及び第3の組のプライの折り曲げられた遠位端部に対して横断方向に配向した第2の部分とをもつように、第5の組のプライを折り曲げる、工程と
をさらに含む、請求項1記載の方法。 - 第2及び第3の組のプライの折り曲げられた遠位端部によって形成される部品の第2の領域と、第5の組のプライの第1及び第2の部分によって形成される部品の第3の領域との間に画成される隙間を埋めることをさらに含む、請求項2記載の方法。
- 部品の第1の領域が、部品の第1の領域の第2及び第3の組のプライの最外層で画成される表面に重層された1組以上の無強化材プライをさらに含んでおり、無強化材プライが第2及び第3の組のプライに存在する強化材を含んでいない、請求項1記載の方法。
- 無強化材プライの遠位端部を第1の領域の第1の組のプライから離れるように折り曲げて、無強化材プライの折り曲げられた遠位端部を第1の組のプライに対して横断方向に配向せしめ、第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成される部品の第2の領域の最外面に重層させることをさらに含む、請求項4記載の方法。
- 第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成される部品の第2の領域の最外面に重層された1組以上の保護プライをさらに含んでおり、保護プライが第2及び第3の組のプライに存在する強化材を含んでいない、請求項1記載の方法。
- 第1の組のプライの遠位端部が、第2の組のプライ、第3の組のプライ又はそれらの組合せと同じ配向で折り曲げられる、請求項1記載の方法。
- 第4の組のプライが、部品の第1の領域で画成される外周形状と対応する寸法及び形状の開口を含む、請求項1記載の方法。
- 第2及び第3の組のプライが、部品の第1の領域に凹面及び凸面を画成するように形成される、請求項1記載の方法。
- 第1、第2、第3及び第4の組のプライが、布材料の溶融含浸を含むプリプレグ法で形成されたプリプレグプライである、請求項1記載の方法。
- 部品が翼形部品であり、翼形部品の第1の領域が翼形部であり、翼形部品の第2の領域がチップシュラウドである、請求項1記載の方法。
- 翼形部と、翼形部よりもチップシュラウドの幾何学的形状を複雑にする1以上の軸外幾何学的特徴要素を有するチップシュラウドと、1以上のシール歯とを備えるタービンブレードの製造方法であって、
タービンブレードの翼形部を、セラミック材料前駆体中に強化材を含有するプライであって、少なくとも第2の組のプライと第3の組のプライの間に少なくとも第1の組のプライを含んでいるプライで形成する工程と、
第2及び第3の組のプライの層の少なくとも一部を分断及び/又はトリミングしてチップシュラウドに隙間を導入する工程と、
第2の組のプライ及び第3の組のプライの各々の折り曲げられた遠位端部がタービンブレードの翼形部内の第1の組のプライに対して横断方向に配向するように、第2の組のプライ及び第3の組のプライの各々の遠位端部を第1の組のプライから離れるように折り曲げる工程と、
チップシュラウドにおける第2及び第3の組のプライの分断部分及び/又は隣接トリム部分の間の隙間を、隙間を埋める寸法及び形状の追加インサートプライ断片で埋める工程と、
第2の組のプライの折り曲げられた遠位端部間及び第3の組のプライの折り曲げられた遠位端部間に第4の組のプライを挟み込む工程と、
タービンブレードの少なくともシール歯を、セラミック材料前駆体中に強化材を含有する第5の組のプライで形成する工程であって、第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成される表面に第5の組のプライを適用して、第2及び第3の組のプライの各々の折り曲げられた遠位端部の上に重なる第1の部分と、翼形部と整列して第2及び第3の組のプライの折り曲げられた遠位端部に対して横断方向に配向した第2の部分とをもつように、第5の組のプライを折り曲げる工程と、次いで
第1の組のプライと第2及び第3の組のプライのうち第1の組のプライから離れるように折り曲げられなかった部分とがタービンブレードの翼形部を画成し、第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとがタービンブレードのチップシュラウドを画成し、かつ第5の組のプライがタービンブレードのシール歯を画成するように、第1、第2、第3、第4及び第5の組のプライを合体及び硬化させる工程と
を含む方法。 - タービンブレードの翼形部が、第2及び第3の組のプライの最外層で画成されるタービンブレードの翼形部の表面に重層された1組以上の無強化材プライをさらに含んでおり、無強化材プライが第2及び第3の組のプライに存在する強化材を含んでいない、請求項12記載の方法。
- 無強化材プライの遠位端部を翼形部の第1の組のプライから離れるように折り曲げて、無強化材プライの折り曲げられた遠位端部を第1の組のプライに対して横断方向に配向せしめ、第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成されるタービンブレードのチップシュラウドの最外面に重層させることをさらに含む、請求項13記載の方法。
- 第2及び第3の組のプライの折り曲げられた遠位端部とそれらの間に挟み込まれた第4の組のプライとで画成されるタービンブレードのチップシュラウドの最外面に重層された1組以上の保護プライをさらに含んでおり、保護プライが第2及び第3の組のプライに存在する強化材を含んでいない、請求項12記載の方法。
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