JPWO2013146514A1 - 無機繊維結合型セラミックスの製造方法 - Google Patents
無機繊維結合型セラミックスの製造方法 Download PDFInfo
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- JPWO2013146514A1 JPWO2013146514A1 JP2014507775A JP2014507775A JPWO2013146514A1 JP WO2013146514 A1 JPWO2013146514 A1 JP WO2013146514A1 JP 2014507775 A JP2014507775 A JP 2014507775A JP 2014507775 A JP2014507775 A JP 2014507775A JP WO2013146514 A1 JPWO2013146514 A1 JP WO2013146514A1
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- inorganic fiber
- inorganic
- temperature
- fiber
- pressing
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- 239000000919 ceramic Substances 0.000 title claims abstract description 150
- 239000012784 inorganic fiber Substances 0.000 title claims abstract description 86
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 24
- 229910052799 carbon Inorganic materials 0.000 claims abstract description 69
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims abstract description 62
- 239000000843 powder Substances 0.000 claims abstract description 62
- 238000003825 pressing Methods 0.000 claims abstract description 53
- 239000000126 substance Substances 0.000 claims abstract description 30
- 238000005979 thermal decomposition reaction Methods 0.000 claims abstract description 27
- 239000002344 surface layer Substances 0.000 claims abstract description 23
- 239000012298 atmosphere Substances 0.000 claims abstract description 14
- 239000011261 inert gas Substances 0.000 claims abstract description 9
- 239000000835 fiber Substances 0.000 claims description 40
- 238000000034 method Methods 0.000 claims description 35
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 18
- 239000000463 material Substances 0.000 claims description 18
- 239000000203 mixture Substances 0.000 claims description 14
- 229910004298 SiO 2 Inorganic materials 0.000 claims description 11
- 239000000155 melt Substances 0.000 claims description 7
- 238000002844 melting Methods 0.000 claims description 7
- 230000008018 melting Effects 0.000 claims description 7
- 239000011521 glass Substances 0.000 claims description 4
- 239000011882 ultra-fine particle Substances 0.000 claims description 4
- 229910021488 crystalline silicon dioxide Inorganic materials 0.000 claims description 3
- 239000011248 coating agent Substances 0.000 claims description 2
- 238000000576 coating method Methods 0.000 claims description 2
- 230000001965 increasing effect Effects 0.000 abstract description 12
- 230000007547 defect Effects 0.000 abstract description 11
- 239000007789 gas Substances 0.000 description 41
- 238000000197 pyrolysis Methods 0.000 description 24
- 230000000052 comparative effect Effects 0.000 description 21
- 238000012360 testing method Methods 0.000 description 20
- 238000013001 point bending Methods 0.000 description 13
- 239000002131 composite material Substances 0.000 description 10
- 238000007731 hot pressing Methods 0.000 description 10
- 238000000465 moulding Methods 0.000 description 10
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 7
- 239000004744 fabric Substances 0.000 description 5
- 125000006850 spacer group Chemical group 0.000 description 5
- 239000011800 void material Substances 0.000 description 5
- 238000005452 bending Methods 0.000 description 4
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- 238000009413 insulation Methods 0.000 description 4
- 230000002093 peripheral effect Effects 0.000 description 4
- 239000002994 raw material Substances 0.000 description 4
- 239000012300 argon atmosphere Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 238000010438 heat treatment Methods 0.000 description 3
- 229910010272 inorganic material Inorganic materials 0.000 description 3
- 239000011147 inorganic material Substances 0.000 description 3
- 230000013011 mating Effects 0.000 description 3
- 239000002759 woven fabric Substances 0.000 description 3
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 2
- LFQSCWFLJHTTHZ-UHFFFAOYSA-N Ethanol Chemical compound CCO LFQSCWFLJHTTHZ-UHFFFAOYSA-N 0.000 description 2
- 239000011230 binding agent Substances 0.000 description 2
- 230000002950 deficient Effects 0.000 description 2
- 239000000284 extract Substances 0.000 description 2
- 239000012530 fluid Substances 0.000 description 2
- 238000007689 inspection Methods 0.000 description 2
- 239000012212 insulator Substances 0.000 description 2
- 238000010030 laminating Methods 0.000 description 2
- 150000001247 metal acetylides Chemical class 0.000 description 2
- 230000001590 oxidative effect Effects 0.000 description 2
- 230000001629 suppression Effects 0.000 description 2
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 239000005354 aluminosilicate glass Substances 0.000 description 1
- 229910052786 argon Inorganic materials 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000006243 chemical reaction Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 239000002178 crystalline material Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 238000000354 decomposition reaction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000002708 enhancing effect Effects 0.000 description 1
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- 239000002657 fibrous material Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
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- 238000005470 impregnation Methods 0.000 description 1
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- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 1
- 239000003921 oil Substances 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 239000012466 permeate Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 230000000644 propagated effect Effects 0.000 description 1
- 239000011226 reinforced ceramic Substances 0.000 description 1
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- 230000000007 visual effect Effects 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
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- B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
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Abstract
Description
本実施形態に係る無機繊維結合型セラミックスの製造方法は、原料となる積層物をセラミックス粉末で囲むようにカーボンダイスにセットしプレスする第一プレス工程、及び第一プレス工程よりも高い温度でプレスする第二プレス工程を備える。
成形した無機繊維結合型セラミックスの端部と中央部の表面欠陥の状態を検査するために、精密機械部品の検査に用いる蛍光探傷試験を実施した。蛍光探傷試験の方法は以下のとおりである。まず、平面研削盤により、成形した無機繊維結合型セラミックスの表面を0.5〜1mm程度研削した後、浸透液の浸透を妨げる付着物や油脂類などの汚れなどをエタノールで洗浄し、70℃で乾燥させた。次に、浸透液(スーパーグロー蛍光浸透探傷剤、OD−2800 III)を刷毛塗りし、10分程度放置した後、浸透液を流水で軽く洗浄し、現像液(スーパーグロー、DN−600P)を極僅か噴霧した。そして、5分程度、放置した後、指示模様が明瞭に識別できる紫外線強度(800μW/cm2以上)をもつ紫外線照射装置を用い、直ちに暗所で波長330〜360nmの紫外線を照射し、表面を目視により観察し、写真撮影を行った。
第二プレス工程後の無機繊維結合型セラミックスより、幅4mm、高さ3mm、長さ40mmの4点曲げ試験片を採取し、材料試験機を用いて、上部支点間距離10mm、下部支点間距離30mm、クロスヘッド速度0.5mm/minで4点曲げ試験を実施し、成形した無機繊維結合型セラミックスの端部から中央部までの曲げ強度を測定した。
無機繊維として、繊維径8.5μmのチラノ繊維(登録商標:宇部興産株式会社製)を用いて繻子織物を作製し、80×80mm角に切断した後、1000℃の空気中で20時間保持して無機繊維部、及び表面層から構成される被覆無機繊維からなる織物シートを得た。この被覆無機繊維の表面にはa=0.06に相当する平均約510nmの均一な表面層が形成されていた。ここでaとは、被覆無機繊維の表面層の厚さをTμm、無機繊維の直径をDμmとした場合、a=T/Dである。そして、この繻子織物シートを100枚積層し、有機バインダーで固めた積層物を作製した。この積層物中の被覆無機繊維の無機繊維部は、主にSi、Ti、C及びOを含む非晶質物質、並びにβ−SiC、TiC及びCを含む結晶質超微粒子と、SiO2及びTiO2を含む非晶質物質との集合体の混合物で構成され、表面層は、主にSi及びO、Tiを含む非晶質物質で構成されていた。
図1に、本実施例の第一プレス工程と第二プレス工程のプレスに用いたダイスの写真を示す。図1(a)は、4つのパーツからなるダイスの上面図、図1(b)は、ダイスを分割したときの1つのパーツの斜視図、図1(c)は、図1(b)の1つのパーツの斜視図の点線部を拡大した写真である。ダイスは、図1(a)に示すように4つのパーツで1つのダイスを形成し、4つのパーツはそれぞれ分割できるようになっている。その1つのパーツの斜視図が図1(b)であり、パーツの内側は、プレスに用いられると、パンチ棒、積層物、セラミック粉末等が接し、熱分解により発生したガスの影響により、内側表面が損傷する。その損傷した代表的なダイスを図1(c)に示した。本実施例で用いたダイスは、本来であれば、無機繊維結合型セラミックス成形体の作製が困難なダイス表面が損傷した内寸が90×90mm角のカーボンダイスである。ダイス内部の表面には、熱分解により発生したガスの影響で形成された凹凸のある様子が観察された。
次に、実施例1と同様の手順で積層物をカーボンダイスにセットして、温度1400℃、圧力40MPaで第一プレス工程のプレスを行い、引き続き圧力を保持した状態で温度1850℃に昇温し1時間保持することによって第二プレス工程のプレスを行い、実施例2に係る無機繊維結合型セラミックスを得た。その他の条件は、実施例1と同様である。積層物を囲んでいるアルミナは、第二プレス工程後の冷却された室温では、繊維結合型セラミックスとアルミナとの熱膨張差により、亀裂が入っており、また、アルミナ粉末と積層物の間にカーボンシートを挟んでいた為、アルミナの角をプラスチックハンマー等で軽く叩くと容易に除去できた。
繊維径8.5μmのチラノ繊維(登録商標:宇部興産株式会社製)からなる繻子織物を180×180mm角に切断した後、実施例1と同様にして繻子織物シートを500枚積層した積層物を作製した。カーボンダイスとしては、本来であれば無機繊維結合型セラミックス成形体の作製が困難なダイス表面の損傷した内寸が190×190mm角の大型のカーボンダイスを用いた。カーボンダイスへの積層物のセット方法は実施例1と同様であるが、アルミナ粉末は実施例1に比べて隙間の容積が大きいため、積層物の下に500g、積層物(180×180mm)とダイス(190×190mm)の隙間に80g、積層物の上に500g入れた。この状態でアルゴン雰囲気下、温度1400℃、圧力40MPaで第一プレス工程のプレスを行った。引き続き、圧力を保持した状態で温度1750℃、保持時間2時間の条件で第二プレス工程のプレスを行い、実施例1より大きな実施例3に係る無機繊維結合型セラミックスを得た。
繊維径8.5μmのチラノ繊維(登録商標:宇部興産株式会社製)からなる繻子織物を89×89mm角に切断した後、1000℃の空気中で20時間処理して無機繊維部、及び表面層から構成される被覆無機繊維の織物シートを得た。この被覆無機繊維の表面には実施例と同様にa=0.06に相当する平均約510nmの均一な表面層が形成されていた。次に、実施例1と同様に本来であれば無機繊維結合型セラミックス成形体の作製が困難なダイス表面の損傷した内寸が90×90mm角のカーボンダイスを用いてホットプレスを実施した。ダイスへの積層物のセット方法を図2(b)を用いて説明する。まず、下パンチ棒10をセットしたカーボンダイス1(カーボン製モールド)の側面に、カーボンシート6を配置した。次に、セットした下パンチ棒10の上に厚さ5mmのCC複合材料製スペーサー5を置き、その上に厚さ0.2mmのカーボンシート6を敷いて、織物シートを100枚積層し有機バインダーで固めた積層物7を配置した。そして、その上にカーボンシート6を敷いて、さらに、カーボンシート6上にCC複合材料製スペーサー5を置き、最後に上パンチ棒4をセットした。積層物をカーボンダイスにセットした状態を図2(b)に示す。そして、実施例1と同様にアルゴン雰囲気下、圧力40MPa、温度1750℃、保持時間1時間の条件でホットプレス成形を行い、比較例1に係る無機繊維結合型セラミックスを得た。
次に、比較例1と同様の手順で積層物をカーボンダイスにセットして、温度1850℃でホットプレス成形を行い、比較例2に係る無機繊維結合型セラミックスを得た。その他の条件は、比較例1と同様である。
3 積層物をセットする位置
4 上パンチ棒
5 CC複合材製スペーサー
6 カーボンシート
7 積層物
8 アルミナ粉末
9 CC複合材製モールド
10 下パンチ棒
12 ボイド
Claims (7)
- 熱分解開始温度が1900℃以下の無機繊維からなる無機繊維部と、該無機繊維どうしを結合するための無機物質からなる表面層とにより構成される被覆無機繊維の成形体を積層した積層物を、セラミックス粉末で囲むようにカーボンダイスにセットし、不活性ガス雰囲気中、1000〜1800℃の温度及び5〜50MPaの圧力でプレスする第一プレス工程、及び
該第一プレス工程で得られたセラミックス被覆積層物を、不活性ガス雰囲気中、1600〜1900℃の温度でかつ前記第一プレス工程よりも高い温度及び5〜100MPaの圧力でプレスする第二プレス工程、
を備えることを特徴とする無機繊維結合型セラミックスの製造方法。 - 前記無機繊維部は、
(a)Si、M、C及びOを含む非晶質物質(MはTi又はZrを示す。)、
(b)β−SiC、MC及びCを含む結晶質超微粒子と、SiO2及びMO2を含む非晶質物質との集合体(Mは(a)と同様である。)、又は
(c)上記(a)と上記(b)との混合物
を含有する無機質物質で構成され、
前記表面層は、
(d)Si及びO、場合によりMを含む非晶質物質(MはTi又はZrを示す。)、
(e)結晶質のSiO2及び/又はMO2を含む結晶質物質(Mは(d)と同様である。)、又は
(f)上記(d)と上記(e)との混合物
を含有する無機質物質で構成されていることを特徴とする請求項1記載の無機繊維結合型セラミックスの製造方法。 - 前記表面層の厚さT(単位μm)が、T=aD(ここで、aは0.023〜0.090の範囲内の数値であり、Dは無機繊維部の繊維径(単位μm)である。)であることを特徴とする請求項1又は2記載の無機繊維結合型セラミックスの製造方法。
- 前記セラミックス粉末が、アルミナ粉末であることを特徴とする請求項1記載の無機繊維結合型セラミックスの製造方法。
- 前記セラミックス粉末が、1800℃以下で溶融する無機物質と、前記第二プレス工程のプレス温度より溶融温度の高い無機物質との混合物を含むことを特徴とする請求項1記載の無機繊維結合型セラミックスの製造方法。
- 前記1800℃以下で溶融する無機物質が、SiO2を主成分とするガラスであり、前記第二プレス工程のプレス温度より溶融温度の高い無機物質が、炭素又はBNであることを特徴とする請求項5記載の無機繊維結合型セラミックスの製造方法。
- 前記第一プレス工程及び第二プレス工程の雰囲気圧力が、0.01〜1MPaであることを特徴とする請求項1記載の無機繊維結合型セラミックスの製造方法。
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