JP7187369B2 - セラミックス基複合材料の製造方法 - Google Patents
セラミックス基複合材料の製造方法 Download PDFInfo
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- JP7187369B2 JP7187369B2 JP2019057453A JP2019057453A JP7187369B2 JP 7187369 B2 JP7187369 B2 JP 7187369B2 JP 2019057453 A JP2019057453 A JP 2019057453A JP 2019057453 A JP2019057453 A JP 2019057453A JP 7187369 B2 JP7187369 B2 JP 7187369B2
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- oxygen
- zirconia sol
- zirconia
- composite material
- matrix composite
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- 239000011153 ceramic matrix composite Substances 0.000 title claims description 186
- 238000004519 manufacturing process Methods 0.000 title claims description 76
- MCMNRKCIXSYSNV-UHFFFAOYSA-N Zirconium dioxide Chemical compound O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 792
- 239000010410 layer Substances 0.000 claims description 362
- 239000001301 oxygen Substances 0.000 claims description 244
- 229910052760 oxygen Inorganic materials 0.000 claims description 244
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 claims description 242
- 239000000463 material Substances 0.000 claims description 185
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 123
- 239000000835 fiber Substances 0.000 claims description 112
- 229920000642 polymer Polymers 0.000 claims description 108
- 238000010304 firing Methods 0.000 claims description 105
- 238000007581 slurry coating method Methods 0.000 claims description 73
- 239000011159 matrix material Substances 0.000 claims description 70
- 239000011247 coating layer Substances 0.000 claims description 57
- 239000012298 atmosphere Substances 0.000 claims description 55
- 239000002002 slurry Substances 0.000 claims description 47
- 238000010438 heat treatment Methods 0.000 claims description 45
- 239000002759 woven fabric Substances 0.000 claims description 45
- 238000005470 impregnation Methods 0.000 claims description 39
- 239000002243 precursor Substances 0.000 claims description 20
- 239000000919 ceramic Substances 0.000 claims description 19
- 239000011148 porous material Substances 0.000 claims description 15
- 239000011261 inert gas Substances 0.000 claims description 14
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 13
- 239000004814 polyurethane Substances 0.000 claims description 11
- 229920002635 polyurethane Polymers 0.000 claims description 11
- 239000000843 powder Substances 0.000 claims description 11
- 239000011248 coating agent Substances 0.000 claims description 9
- 238000000576 coating method Methods 0.000 claims description 9
- 239000002904 solvent Substances 0.000 claims description 6
- 239000004744 fabric Substances 0.000 claims description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 4
- 229910052799 carbon Inorganic materials 0.000 claims description 4
- 239000002270 dispersing agent Substances 0.000 claims description 3
- 238000002474 experimental method Methods 0.000 description 63
- 238000000034 method Methods 0.000 description 58
- 238000010586 diagram Methods 0.000 description 29
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- 238000006243 chemical reaction Methods 0.000 description 16
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- 229920005989 resin Polymers 0.000 description 14
- 239000011347 resin Substances 0.000 description 14
- 230000000694 effects Effects 0.000 description 12
- 238000007254 oxidation reaction Methods 0.000 description 11
- 238000005245 sintering Methods 0.000 description 10
- 238000012545 processing Methods 0.000 description 9
- 230000003647 oxidation Effects 0.000 description 8
- 230000015572 biosynthetic process Effects 0.000 description 6
- 238000011156 evaluation Methods 0.000 description 6
- 238000005755 formation reaction Methods 0.000 description 6
- 239000007789 gas Substances 0.000 description 6
- 238000012360 testing method Methods 0.000 description 6
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- 239000002131 composite material Substances 0.000 description 5
- 239000002994 raw material Substances 0.000 description 5
- 238000010030 laminating Methods 0.000 description 4
- 239000002245 particle Substances 0.000 description 4
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 3
- 229910052863 mullite Inorganic materials 0.000 description 3
- 125000004043 oxo group Chemical group O=* 0.000 description 3
- 238000009941 weaving Methods 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000009833 condensation Methods 0.000 description 2
- 230000005494 condensation Effects 0.000 description 2
- 239000000203 mixture Substances 0.000 description 2
- 230000004048 modification Effects 0.000 description 2
- 238000012986 modification Methods 0.000 description 2
- 150000002926 oxygen Chemical class 0.000 description 2
- 238000000197 pyrolysis Methods 0.000 description 2
- 238000009864 tensile test Methods 0.000 description 2
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910018516 Al—O Inorganic materials 0.000 description 1
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 1
- ZAMOUSCENKQFHK-UHFFFAOYSA-N Chlorine atom Chemical compound [Cl] ZAMOUSCENKQFHK-UHFFFAOYSA-N 0.000 description 1
- 239000004962 Polyamide-imide Substances 0.000 description 1
- 239000005062 Polybutadiene Substances 0.000 description 1
- 239000004743 Polypropylene Substances 0.000 description 1
- 241000220317 Rosa Species 0.000 description 1
- 229910018557 Si O Inorganic materials 0.000 description 1
- 230000003213 activating effect Effects 0.000 description 1
- 229910000323 aluminium silicate Inorganic materials 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 238000001354 calcination Methods 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 239000012700 ceramic precursor Substances 0.000 description 1
- 239000000460 chlorine Substances 0.000 description 1
- 229910052801 chlorine Inorganic materials 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 238000006297 dehydration reaction Methods 0.000 description 1
- HNPSIPDUKPIQMN-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Al]O[Al]=O HNPSIPDUKPIQMN-UHFFFAOYSA-N 0.000 description 1
- 238000007598 dipping method Methods 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 238000006011 modification reaction Methods 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 230000001590 oxidative effect Effects 0.000 description 1
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
- 230000001706 oxygenating effect Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 229920001515 polyalkylene glycol Polymers 0.000 description 1
- 229920006122 polyamide resin Polymers 0.000 description 1
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- 229920001225 polyester resin Polymers 0.000 description 1
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- 239000012779 reinforcing material Substances 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- LIVNPJMFVYWSIS-UHFFFAOYSA-N silicon monoxide Inorganic materials [Si-]#[O+] LIVNPJMFVYWSIS-UHFFFAOYSA-N 0.000 description 1
- 238000004544 sputter deposition Methods 0.000 description 1
- 238000003786 synthesis reaction Methods 0.000 description 1
- 238000005979 thermal decomposition reaction Methods 0.000 description 1
- 229920006337 unsaturated polyester resin Polymers 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 229920001567 vinyl ester resin Polymers 0.000 description 1
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Description
図1は、第1の実施形態に係るセラミックス基複合材料の製造システム1のブロック図である。第1の実施形態に係るセラミックス基複合材料の製造システム1は、PIP(Polymer Impregnation and Pyrolysis)法の処理に供する素体100-1を形成し、この形成した素体100-1をPIP法によって処理することで、第1の実施形態に係るセラミックス基複合材料103-1を製造するシステムであり、第1の実施形態に係るセラミックス基複合材料103-1の製造方法を実施するシステムである。
図11は、第2の実施形態に係るジルコニアゾル含有層形成ステップS13の詳細を示すフローチャートである。第2の実施形態に係るセラミックス基複合材料103-2の製造方法は、第2の実施形態に係るセラミックス基複合材料103-1の製造方法において、ジルコニアゾル含有層形成ステップS13を変更したものである。第2の実施形態に係るセラミックス基複合材料103-2の製造方法は、他の構成については、第1の実施形態に係るセラミックス基複合材料103-1の製造方法と同様である。第2の実施形態に係るセラミックス基複合材料103-2の製造方法及びセラミックス基複合材料103-2の説明では、第1の実施形態に係るセラミックス基複合材料103-1の製造方法及びセラミックス基複合材料103-1と同様の構成に第1の実施形態と同一の符号群を用い、その詳細な説明を省略する。
図14は、第3の実施形態に係るジルコニアゾル含有層形成ステップS13の詳細を示すフローチャートである。第3の実施形態に係るセラミックス基複合材料103-3の製造方法は、第3の実施形態に係るセラミックス基複合材料103-1の製造方法及びセラミックス基複合材料103-2の製造方法において、ジルコニアゾル含有層形成ステップS13を変更したものである。第3の実施形態に係るセラミックス基複合材料103-3の製造方法は、他の構成については、第1の実施形態に係るセラミックス基複合材料103-1の製造方法及び第2の実施形態に係るセラミックス基複合材料103-2の製造方法と同様である。第3の実施形態に係るセラミックス基複合材料103-3の製造方法及びセラミックス基複合材料103-3の説明では、第1の実施形態に係るセラミックス基複合材料103-1の製造方法及びセラミックス基複合材料103-1、並びに、第2の実施形態に係るセラミックス基複合材料103-2の製造方法及びセラミックス基複合材料103-2と同様の構成に、第1の実施形態並びに第2の実施形態と同一の符号群を用い、その詳細な説明を省略する。
実験1として、上記したセラミックス基複合材料の製造システム1を用いて、第1の実施形態から第3の実施形態に係るジルコニアゾル含有層形成ステップS13を実行することなく、すなわち、ジルコニアゾル含有層24-1,24-2,24-3を形成することなく、その他の処理である上記したそれぞれの処理である裁断ステップS10、界面層形成ステップS12、積層ステップS14、含浸ステップS16、酸素供給ステップS18、不活性焼成ステップS20及び酸素焼成ステップS22の各処理のみを実行して、セラミックス基複合材料を製造した。なお、実験1では、断面の直径が約10μmの繊維22を有する繊維束21による織布20を採用した。
実験2として、実験1において、界面層形成ステップS12と積層ステップS14との間で、第1の実施形態に係るジルコニアゾル含有層形成ステップS13を追加で実行して、ジルコニアゾル含有層24-1を形成して、第1の実施形態に係るセラミックス基複合材料103-1を製造した。実験2では、ジルコニアゾル含有層形成ステップS13におけるジルコニアゾル界面層形成ステップS13-1において、粒径が1μm程度のジルコニア粉末を含み、第1ジルコニア含有率が5質量%であるクロルフリーの水性ゾルであるジルコニアゾルを使用した。実験2では、その他の条件は、実験1と同じとした。実験2において、実験1と同じ形状及び同じサイズの試験片を作成して、実験1と同様の方法で引張強度保持率の評価を行った。実験2は、引張強度保持率が78%との評価結果が得られた。
実験3として、実験1において、界面層形成ステップS12と積層ステップS14との間で、第2の実施形態に係るジルコニアゾル含有層形成ステップS13を追加で実行して、ジルコニアゾル含有層24-2を形成して、第2の実施形態に係るセラミックス基複合材料103-2を製造した。実験3では、ジルコニアゾル含有層形成ステップS13におけるジルコニアゾル含有アルミナスラリー塗布ステップS13-3において、粒径が1μm程度のジルコニア粉末を含むクロルフリーの水性ゾルであるジルコニアゾルを含有し、第2ジルコニア含有率が1質量%となるアルミナスラリーを使用した。実験3では、その他の条件は、実験1と同じとした。実験3において、実験1と同じ形状及び同じサイズの試験片を作成して、実験1と同様の方法で引張強度保持率の評価を行った。実験3は、引張強度保持率が90%との評価結果が得られた。
実験4として、実験3において、ジルコニアゾル含有層形成ステップS13におけるジルコニアゾル含有アルミナスラリー塗布ステップS13-3において使用したアルミナスラリーについて、第2ジルコニア含有率を3質量%に変更した。実験4では、その他の条件は、実験3と同じとした。実験4において、実験1と同じ形状及び同じサイズの試験片を作成して、実験1と同様の方法で引張強度保持率の評価を行った。実験4は、引張強度保持率が64%との評価結果が得られた。
実験5として、実験1において、界面層形成ステップS12と積層ステップS14との間で、第3の実施形態に係るジルコニアゾル含有層形成ステップS13を追加で実行して、ジルコニアゾル含有層24-3を形成して、第3の実施形態に係るセラミックス基複合材料103-3を製造した。実験5では、ジルコニアゾル含有層形成ステップS13におけるジルコニアゾル界面層形成ステップS13-1において、実験2と同様のジルコニアゾルを使用した。また、実験5では、ジルコニアゾル含有層形成ステップS13におけるジルコニアゾル含有アルミナスラリー塗布ステップS13-3において、実験3と同様のジルコニアゾルを含有するアルミナスラリーを使用した。実験5では、その他の条件は、実験1と同じとした。実験5において、実験1と同じ形状及び同じサイズの試験片を作成して、実験1と同様の方法で引張強度保持率の評価を行った。実験5は、引張強度保持率が104%との評価結果が得られた。
10-1,11-1 繊維層
20 織布
21 繊維束
22 繊維
23 界面層
24-1,24-2,24-3 ジルコニアゾル含有層
25-1,25-2,25-3 ジルコニア含有層
26 ジルコニアゾル界面層
27 アルミナスラリー塗布層
28 ジルコニアゾル含有アルミナスラリー塗布層
30 ポリマー
31 酸素含有ポリマー
32 マトリクス
33 空孔
100-1,100-2,100-3 素体
101-1,101-2,101-3 酸素含有素体
102-1,102-2,102-3 不活性焼成素体
103-1,103-2,103-3 セラミックス基複合材料
Claims (9)
- 複数のセラミックス製の繊維の周囲に、前記周囲を覆う界面層が形成された織布に、ジルコニアゾルを含有するジルコニアゾル含有層を形成するジルコニアゾル含有層形成ステップと、
前記ジルコニアゾル含有層を形成した前記織布に、前駆体としてのポリウレタン系ポリマーを含浸して素体を形成する含浸ステップと、
前記素体に含まれる前記ポリウレタン系ポリマーに酸素を供給する酸素供給ステップと、
前記素体を不活性ガス雰囲気下で加熱することで、前記ポリウレタン系ポリマーを反応させてマトリクスを形成する不活性焼成ステップと、
前記酸素供給ステップ及び前記不活性焼成ステップの後に、前記素体を酸素雰囲気下で加熱することで、前記界面層を除去して前記繊維と前記マトリクスとの間に空孔を形成するとともに前記マトリクスにおいて前記空孔と対向する空孔側対向領域にジルコニア含有層を形成し、前記繊維同士の間に前記マトリクスが配置されるセラミックス基複合材料を生成する酸素焼成ステップと、
を有し、
前記ジルコニアゾル含有層形成ステップは、
前記織布に、前記ジルコニアゾルを含むアルミナスラリーを塗布して前記ジルコニアゾルを含有するアルミナスラリー塗布層を形成するジルコニアゾル含有アルミナスラリー塗布ステップと、
を有し、
前記ジルコニアゾルを含有するアルミナスラリーは、前記アルミナスラリーのうち溶媒や分散剤等を除く溶質部分の全体の質量を100質量%としたときのジルコニア粉末の含有量が0.01質量%以上5質量%以下である、セラミックス基複合材料の製造方法。 - 複数のセラミックス製の繊維の周囲に、前記周囲を覆う界面層が形成された織布に、ジルコニアゾルを含有するジルコニアゾル含有層を形成するジルコニアゾル含有層形成ステップと、
前記ジルコニアゾル含有層を形成した前記織布に、前駆体としてのポリウレタン系ポリマーを含浸して素体を形成する含浸ステップと、
前記素体に含まれる前記ポリウレタン系ポリマーに酸素を供給する酸素供給ステップと、
前記素体を不活性ガス雰囲気下で加熱することで、前記ポリウレタン系ポリマーを反応させてマトリクスを形成する不活性焼成ステップと、
前記酸素供給ステップ及び前記不活性焼成ステップの後に、前記素体を酸素雰囲気下で加熱することで、前記界面層を除去して前記繊維と前記マトリクスとの間に空孔を形成するとともに前記マトリクスにおいて前記空孔と対向する空孔側対向領域にジルコニア含有層を形成し、前記繊維同士の間に前記マトリクスが配置されるセラミックス基複合材料を生成する酸素焼成ステップと、
を有し、
前記ジルコニアゾル含有層形成ステップは、
前記界面層の周囲を覆うジルコニアゾル界面層を形成するジルコニアゾル界面層形成ステップと、
前記織布に、前記ジルコニアゾルを含むアルミナスラリーを塗布して前記ジルコニアゾルを含有するアルミナスラリー塗布層を形成するジルコニアゾル含有アルミナスラリー塗布ステップと、
を有し、
前記ジルコニアゾルを含有するアルミナスラリーは、前記アルミナスラリーのうち溶媒や分散剤等を除く溶質部分の全体の質量を100質量%としたときのジルコニア粉末の含有量が0.01質量%以上5質量%以下である、セラミックス基複合材料の製造方法。 - 前記不活性焼成ステップを、前記酸素供給ステップの後に行う、請求項1または請求項2に記載のセラミックス基複合材料の製造方法。
- 前記酸素供給ステップにおいて、酸素雰囲気下において前記素体を加熱することで、前記ポリウレタン系ポリマーに酸素を供給し、
前記酸素供給ステップにおける前記素体の加熱温度は、前記不活性焼成ステップ及び前記酸素焼成ステップでの加熱温度より低い、請求項1から請求項3のいずれか1項に記載のセラミックス基複合材料の製造方法。 - 前記酸素供給ステップにおける前記素体の加熱温度は、200℃以上、600℃未満である、請求項4に記載のセラミックス基複合材料の製造方法。
- 前記酸素供給ステップにおいて、水蒸気雰囲気下で前記素体を保持することで、前記ポリウレタン系ポリマーに酸素を供給し、
前記酸素供給ステップにおける前記水蒸気の温度は、前記不活性焼成ステップ及び前記酸素焼成ステップでの加熱温度より低い、請求項1から請求項3のいずれか1項に記載のセラミックス基複合材料の製造方法。 - 前記酸素供給ステップにおける前記水蒸気の温度は、80℃以上、200℃未満である、請求項6に記載のセラミックス基複合材料の製造方法。
- 前記ポリウレタン系ポリマーは、前記繊維と同じ材料のセラミックスを含む、請求項1から請求項7のいずれか1項に記載のセラミックス基複合材料の製造方法。
- 前記界面層は、炭素を主成分とする層である、請求項1から請求項8のいずれか1項に記載のセラミックス基複合材料の製造方法。
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