MXPA98001313A - Infiltrated ceramic lining with pre-ceram polymer resins - Google Patents

Abstract

This invention relates to making cast metal parts with ceramic linings (12) for automobiles. The present invention solves the problems of overexposure of metal parts subjected to increased temperatures and ismodalized in a method to form a ceramic liner (10), (12) for a part comprising the steps of forming a liner of a ceramic material containing pores, filling the pores with a pre-ceramic polymer resin, and igniting the saturated liner with a pre-ceramic polymer resin at a temperature and for a time that converts the resin to a ceramic within the pores The liner (12) can be mechanically bonded, adhesively bonded, or a metal part can be cast onto the liner (1).

Description

INFILTRATED CERAMIC LINING WITH PRE-CERAMIC POLYMER RESINS TECHNICAL FIELD This invention relates to the manufacture of cast metal parts with automotive ceramic liners and, more particularly, to (1) a method for forming a metal part having a rupture-resistant ceramic liner comprising the steps of , forming a metal part having a matching surface to receive the liner, forming a liner of a ceramic material containing pores, filling the pores with a pre-ceramic polymer resin (hereinafter used interchangeably with the term ceramic resin derived from polymer), ignite the liner saturated with pre-ceramic polymer resin at a temperature that converts the resin to a ceramic within the pores, and bond the ceramic liners to the matching surface of the metal part , (2) to methods for achieving the same result comprising the steps of forming a lining of a ceramic material containing pores, filling the pores with a polyester resin. pre-ceramic fixture ignite the saturated liner of pre-ceramic polymer resin at a temperature and for a time that converts the resin to a ceramic within the pores, place the liner inside a mold for the metal part with the the matching surface of the liner facing a mold portion that will be occupied by the metal that will form the part; and, filling the mold with molten metal to form the part with a molten ceramic insert in its integral place, and (3) a method for forming fiber reinforced ceramic matrix composite parts (FRCMC) and linings, which comprise the steps of forming a preform in the configuration of the part from the fibers of a generic fiber system (hereinafter used interchangeably and with the term reinforcement fibers) can be used in matrix composite materials. fiber-reinforced ceramic, placing the preform in a cavity of a mold that has the shape of the part, forcing a ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturate the preform, heat the mold to a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the saturated preform with ceramic resin derived from liquid polymer, to a part of the to the polymer composite, removing the polymer composite part of the mold, and igniting the polymer composite part in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the resin of ceramic derived from polymer to a resin so that the part of polymer composite material is transformed to a fiber-reinforced ceramic matrix composite part BACKGROUND OF THE INVENTION The operating temperatures of automobiles and similar internal combustion engines have increased for several reasons, such as for improved combustion efficiency and a reduction in the fuel to air ratio (ie, fuel-air combustion engines), for the purposes of reducing the pollutants emitted that result from the most complete burning of the fuel. Accordingly, there has been a corresponding need to protect metal parts subjected to these increased temperatures. An obvious aspect treated with limited success in the prior art is to line the metal part with ceramic. Thus, for example, there is a multiple of exhaust 10 with a monolithic ceramic liner 12 as shown in Figure 1, and a power head 14 with a ceramic liner 12 as presented in Figure 2, the prior art being known in the art. the prior art can be better understood with reference to Figure 3 As seen in the enlarged drawing, the monolithic ceramic material of the liner 12 as used in the prior art, is a porous material having a multitude of pores 16 therethrough. Thus, the liner 12 of the prior art is quite delicate with a nominal erosion resistance, and easily breaks if the part falls, it is struck or otherwise it is subjected to great force. If the liner 12 of the power head 14 is broken and a part falls into the operating engine, the interior of the engine cylinder will probably be heavily marked by the hard ceramic edges striking. For both the power head 14 and the exhaust manifold 10, any gap or rupture in the ceramic liner will eventually occur by damaging or destroying the underlying unprotected metal. A crack through the exhaust manifold 10 or through the power head 14 typically requires the complete replacement of the part. Also, the lining of a part with the monolithic ceramic material according to the prior art can be a delicate process, costly and time consuming So, it is an object of the present invention to provide a ceramic liner for an automotive internal combustion engine part or the like, which hardens to resist breakage and erosion. It is another object of the present invention to provide a method for applying a ceramic liner to an automotive internal combustion engine part or the like, which is simple, inexpensive, and to be quickly assembled in order not to impact with the It is a further object of the present invention to provide a method for applying a ceramic liner to an automotive internal combustion engine part or the like, wherein the liner is cast into the interior of the automobile. part, as part of the molding process A further object of the present invention is to provide a method for creating preforms of fiber-reinforced ceramic matrix composite for use in the lining of automobile internal combustion engine parts and to be part of the automobile internal combustion engine Other objects and benefits of this invention will be apparent from the following description ion when read along with accompanying drawings that accompany it DESCRIPTION OF THE INVENTION The above objects have been achieved in a first aspect of the present invention through the method of forming a metal part having a rupture-resistant ceramic liner, comprising the steps of forming a metal part having a surface coincident to receive the liner, form a liner of a ceramic material containing pores, fill the pores of a pre-ceramic polymer resin ignite the saturated liner of pre-ceramic polymer resin at a temperature and for a time ( designated by the resin manufacturer) which converts the resin to a ceramic within the pores, and, joining the ceramic liner to the matching surface of the metal part In one embodiment, the step of forming the lining of a material of ceramic that contains pores, comprises emptying an inexpensive, non-combustible cement slurry, to a lining-shaped mold, igniting the molded mud material for a time and at a temperature that converts it to a manageable pre-ceramic form, remove the pre-ceramic form from the mold and ignite the pre-ceramic form for a time and at a temperature which converts it into a ceramic form that contains pores formed by degassing. And the step of filling the pores with a polymer-derived ceramic resin comprising placing the liner within a batch containing a liquid pre-ceramic polymer resin, until the pores are saturated with the resin. Preferably, the resin is a silicon-carboxyl resin (sold by Alhed-Signal under the trade name Blackglas) In a second embodiment, the step of forming the lining of a ceramic material, containing pores, comprises placing a fiber preform within a mold with Liner form to occupy 30% to 60% of the mold volume, force a liquid pre-ceramic polymer resin through the preform to fill the remaining volume of the mold with liquid pre-ceramic polymer resin, ignite the mold for a while and at a temperature that converts it to a manageable pre-ceramic shape, remove the pre-ceramic form from the mold, and ignite the pre-ceramic form for a time that converts The liquid pre-ceramic polymer resin is formed into a pore-containing ceramic matrix composite formed by degassing. Preferably, the liquid pre-ceramic polymer resin is a silicon-carboxyl resin, for example Blackglas. The above objects have also been achieved in a second aspect of the present invention through the method of forming a metal part having a rupture resistant ceramic liner, comprising the steps of forming a lining of a ceramic material containing pores, filling the pores with a pre-ceramic polymer resin, igniting the liner saturated with the pre-ceramic polymer resin at a temperature and for a time (as designated by the resin manufacturer) that converts the resin to a ceramic inside the pores, place the lining inside a mold for the metal part with the matching surface of the liner facing towards a portion of the mold that will be occupied by the metal that will form the part, and, fill the mold with molten metal to form the part As with the first aspect the step of forming the lining of a ceramic material containing pores can comprise any aspect described above AND the step filling the pores with a polymer-derived ceramic resin again comprises placing the liner in a bath comprising a liquid pre-ceramic polymer resin until the pores are saturated with the resin; ignite the liner saturated with pre-ceramic polymer resin at a temperature and for a time that converts the resin into a ceramic within the pores. In all cases where the pores formed by degassing are filled, it is preferred to repeat the procedure pore filling and reheating several times to virtually and completely remove the pores of the final product In another aspect of the present invention, a method for making a car part of a fiber reinforced ceramic matrix composite comprising the steps of forming a preform in the part configuration from the fibers of a generic fiber system that is employed is described. in fiber-reinforced ceramic matrix composite materials, placing the preform in a mold cavity having the shape of the part, forcing a ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturating the preform, heating the mold at a temperature and for a time associated with the polymer-derived ceramic ream which transforms the saturated preform with polymer-derived ceramic resin to a part of polymer composite material, removing the polymer composite part from the polymer. mold, and ignite the polymer composite part in an inert atmosphere and at a temperature and for a time associated with the polymer-derived ceramic resin, which transforms the polymer-derived ceramic resin into a ceramic, whereby the polymer composite part is transformed to a fiber-reinforced ceramic matrix composite part. Preferably, the method includes also the steps of submerging the composite material part of ceramic matrix reinforced with fiber containing pores, formed by degassing during ignition to a ceramic resin bath derived from liquid polymer, to fill the pores with the derived ceramic resin of liquid polymer, ignite the fiber-reinforced ceramic matrix composite part in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin that transforms the polymer-derived ceramic resin into the pores at a ceramic, and repeat this procedure until the pore density within the fiber-reinforced ceramic matrix composite part is less than a preset percentage offering maximum strength to the part The preferred method can also be adapted to form hollow parts such as motor manifolds using the steps of forming a first preform into the configuration of an inner portion of the manifold from fibers of a generic fiber system that can be employed in fiber-reinforced ceramic matrix composite materials, placing the first preform into a cavity of a first mold having the shape of the lower portion of the multiple; forcing a ceramic resin derived from liquid polymer through the cavity to fill the cavity and saturating the first preform, heating the first mold at a temperature and for a time associated with the polymer-derived ceramic resin, which forms the first preform saturated with ceramic resin derived from liquid polymer to a first part of polymer composite material; remove the first part of polymer composite from the mold; forming a second preform in the configuration of an upper portion of the manifold through fibers of the generic fiber system; placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold; forcing the polymer resin derived from liquid polymer through the cavity to fill the cavity and saturate the second preform; heating the second mold at a temperature and for a time associated with the polymer-derived ceramic resin, which forms the second preform saturated with ceramic resin with liquid polymer to a second part of polymer composite, removing the second part of material polymer composite of the mold, fixing the first part of polymer composite and the second part of polymer composite together along matching edges to form the manifold as a hollow duct-shaped part; and igniting the polymer composite composite in an inert atmosphere at a temperature and for a time associated with the polymer-derived ceramic resin that transforms the polymer-derived ceramic resin into a resin so that the composite material polymer is transformed to a composite fiber-reinforced ceramic matrix composite and the upper portion and lower portion are fused together along the matching edges. The pores formed by degassing are preferably sealed in the manner described above to give a maximum resistance to the resulting manifold and seal any leak that may exist along the matching edges. When the manifold is an exhaust manifold that will be filled internally with a ceramic foam catalyst substrate structure, the procedure and the required tools can be greatly simplified by the previous step of placing the second preform in a cavity of a second mold. having the shape of the upper portion of the manifold further including the steps of placing the first preform as part of the wall defining the cavity of the second mold, and placing the structure of the ceramic foam catalyst substrate in the first preform, whereby the first preform and the ceramic foam catalyst substrate structure in combination, are part of the cavity of the second wall BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 is a simplified cross-sectional view of a car exhaust manifold lined with monolithic ceramic of the prior art. Figure 2 is a simplified cross section of a car power head lined with monolithic ceramic of the prior art. Figure 3 is an enlarged simplified drawing of the monolithic ceramic material employed in the prior art of Figures 1 and 2, depicting the pores contained therein. Figure 4 is a simplified cross section of a first step for making a car part lined with ceramic according to the present invention in a first aspect. Figure 5 is a simplified cross-section of a second step for making a car part lined with ceramic according to the present invention. Figure 6 is a simplified cross-sectional view of a third step to be a car part lined with ceramic according to the present invention. Figure 7 is a simplified cross section of a third step for making a car part lined with ceramic according to the present invention in a second aspect. Figure 8 is a simplified cross section of a fourth step for making a car part lined with ceramic according to the present invention in a second aspect. Figure 9 is a functional block diagram of the basic steps for making preforms of fiber reinforced ceramic matrix composite material for use in the practice of the present invention in a preferred aspect. Figure 10 is a functional block diagram of the steps added to the preferred embodiment of the present invention.

Figure 11 is a detailed cross-section of a mold used in the preferred embodiment of the present invention to make fiber-reinforced ceramic matrix composite preform cylinder sleeves. Figure 12 is a detailed cross-section of a mold used in the preferred embodiment of the present invention for making fiber-reinforced ceramic matrix composite preform pistons. Figure 13 is a detailed cross-section of a mold used in the preferred embodiment of the present invention for making cylinder head liners. fiber reinforced ceramic matrix composite preform Figure 14 is a simplified cross-section of a mold used in the preferred embodiment of the present invention to be half of a composite fiber-reinforced ceramic matrix composite. 15 is a simplified cross section of a mold used In the preferred embodiment of the present invention to be the matching half of a multiple of fiber-reinforced ceramic matrix composite Figure 16 is a simplified cross-section showing how the two halves of the manifold produced in the Figures 14 and 15, are connected and fused together during ignition. Figure 17 is a simplified cross-section of a mold used in the preferred embodiment of the present invention to be the matching half of a multiple of reinforced ceramic matrix composite. fiber when the first half and a ceramic foam core are used as part of the mold to reduce the necessary tools.

BEST MODE FOR CARRYING OUT THE INVENTION In accordance with one aspect of the present invention, the typical prior art ceramic liner, as described above, is resistant against rupture by making it as a composite material of polymer-derived ceramic matrix (CMC). In a CMC derived from conventional polymer, a generic fiber system is worn through a pre-ceramic polymer resin. The mixture is then turned on at a temperature and for a time recommended by the supplier of the material, in order to convert the resin to a ceramic material, thus forming the part of a fiber reinforced ceramic matrix composite material (FRCMC). In this aspect of the invention, the porous, low resistance ceramic material is replaced by the fiber system in the following manner. One technique for lining a metal part with ceramic is to take a mold 18 having a matching surface 20 configured to fix the metal part as shown in Figure 4. After molding, the resulting lining 12 is then fixed to the part of metal in its intended position and mechanically is held or joins in place using commercially available high temperature adhesives or the like. To use this aspect according to the present invention, the liner 12 is cast in the usual manner as presented in FIG. Figure 4, using such a cement mud material, but not limited to, that commercially available under the name of Ceramacast by AREMCO. The cast liner 12 is ignited in a usual manner as taught with the manufacturer, to form the ceramic liner Low Resistance 12"In accordance with the present invention, the ceramic liner 12 'is then immersed in a container 22 containing a bath of a resin Pre-ceramic polymer 24 The preferred resin 24 is a silicon-carboxyl resin of pre-ceramic polymer (sold by Allied Signal under the trade name of Blackglas) The Blackglas resin has a viscosity substantially equal to that of water this way, it easily penetrates and fills the pores. 16 Many liquid resin materials have a more or less viscosity of the honey type. Such resins can not fill the pores 16 and, therefore, do not obtain the objects of the present invention. When the resin 24 has saturated the pores 16 of the ceramic liner 12 ', the liner 12' is again ignited at a temperature and for a time as taught by the resin manufacturer, which converts the ream 24 to a ceramic within the pores 16, thus creating the CMC liner 12"The CMC liner 12" can then be attached to its matching portion 26 as presented in Figure 6. In an alternative aspect as presented in Figures 7 and 8, the procedure it is greatly simplified and the resulting surface between the liner 12"and its associated part 26 is reinforced by melting the metal part 26 directly on / around the pre-existing reinforced liner 12 'C'. The liner 12 is first cast as in Figure 4 After of the steps described above with respect to Figure 5 of the ignition of the liner 12 to form the liner 12 ', fill the pores 16 with resin 24, and ignite the liner 12' to create the liner CMC 12", the liner CMC 12" is placed inside a compatible mold 30 for melting the metal 32 for the part 26 as shown in Figure 7 facing the space of the mold 30 which will be occupied by the metal The mold 30 is then filled with molten metal 32 as presented in Figure 8 to form part 26 with liner 12"firmly held in place within metal 32, when metal 32 cools and hardens. Since the liner 12"is a hardened CMC, it is able to withstand the temperatures of the metal molding process without being damaged by the same. Having described two alternative methods for improving the strength of ceramic auto parts linings and for melting the liners directly on metal automobile parts, a preferred resin transfer molding (RTM) method and apparatus for forming automotive parts or liners therefor of a ceramic matrix composite according to a preferred embodiment of the present invention will now be described in detail A functional block diagram of the basic aspect steps of RTM is presented in Figure 9 The first step is to form a preform configured from the generic fiber system that will be used after, it is inserted into a preform mold and the mold is sealed. In a preferred aspect, the generic fiber system occupies 30% up to 60% of the internal volume of the mold as an alternative but not preferred aspect, the mold can be filled with crumbled generic fiber at the same packing density by volume. Then, a pre-ceramic polymer resin is forced through the fibers to fill the remaining internal volume of the mold. The preferred resin is the silicon-carboxyl polymer resin. pre-ceramic previously described, sold by Allied Signal under the trade name of Blackglas This is due to its low viscosity that allows it to be forced through and saturated in a high volume density of the generic fiber preform. The stronger the density of the fiber, the stronger the part will be. In this way, to use a resin of higher viscosity, the packing density of the fibers could be greatly reduced, resulting in a corresponding reduction in the strength of the part. The preform impregnated with resin inside the mold, is then heated to one level and for a sufficient time to polimepzar the resin saturating the fiber preform. Then the preform is like an unglazed ceramic porcelain so that it does not have its full strength but can be handled. The polymer preform is removed from the mold and then ignited at a temperature and for a time as established by the resin manufacturer in order to form the polymer as a resin. The part or liner in its basic form, is thus formed as a ceramic matrix composite material preferably having about 50-60% by volume of the fiber content therein. The ignition process, which converts the polymer to ceramic, causes the formation of pores due to the degassing that occurs during the ignition procedure. The resulting ceramic part is approximately 70% solid and 30% pores formed by degassing. In this respect, it is very similar to the monolithic ceramic previously used to line automotive parts. The parts of fiber-reinforced ceramic composite are, of course, much stronger than the monolithic parts due to the high fiber content. However, the same technique can be used to make the parts even stronger. According to the preferred embodiment of the present invention, which is just what was done in what is presented in Figure 10 The ceramic preform is immersed in the Blackglas liquid resin (or equivalent) The water type viscosity of the resin causes it to fill 30% of the pores in the part then it is ignited once more during the time and at the temperature indicated by the resin manufacturer. This causes the resin within 30% of pores to be c Onverted to ceramic But, the ignition procedure causes 30% of 30% of the volume to be degassed. In this way, the part is once again submerged in the liquid resin and ignited for a third time. This procedure can be repeated until a desired level of pore removal is obtained. The resulting part is approximately 95% -98% of ceramic and fibers without any of the degassed pores. In this manner, it is of maximum strength. An RTM mold 34 for making cylinder sleeves of fiber reinforced ceramic matrix composite according to the above-described process is presented in Figure 11. The mold 34 includes a base / portion of mandrel tool 36 defining the bottom and cylindrical center of the mold Two semi-cylindrical half portions 38 define the internal volume of the sleeve mold in combination with the mandrel tool base / portion 36 A top cap tool 40 encloses and seals the mold, the sleeve fiber preform 42 slides over the cylindrical center of the mandrel tool base / portion 36 The two half portions 38 are placed around the preform 42 and the top cap tool 40 is put in place All the mold 34 is then held together through the past pins 44 and notches 46 The internal mold volume occupied by the preform 42 is connected through a series of feed holes 48 to a resin reservoir at 50. The top cap tool 40 contains a series of drain holes 52. connecting the internal mold volume to a vacuum source at 54 Due to the water type consistency of the resin, the internal leak between the components must be avoided through O-shaped rings 56, as necessary With the mold 34 closed and sealed with the preform 42 in place the vacuum source 54 is activated to create a vacuum and the path to the resin reservoir 50 is opened Resin 58 under pressure is forced into the mold 34 and through the preform 42 from the combined pressure and the vacuum of the vacuum source 54 until the preform 42 is fully saturated with the resin 58 The complete mold 34 is then heated to polimepzar the ream 58 The mold 34 is then disassembled by inverting the above-described procedure to release the pre-formed preform 42 from the mold 34 Figure 12 represents a model 34 'used to produce a piston, the which is all of ceramic composite matrix material according to an RTM method. The preform 42 'is of a piston shape having cylindrical side walls and a closed lid. The diagonal base mandrel tool portion 36 has a modified central portion as shown which conforms to the internal shape of the piston preform 42 '. Unlike this the mold 34' and how to use it are as described above for the mold 34 of Figure 11 For a generally flat object such as a liner for a cylinder head, a mold 34"as shown in Figure 13 can be used. In this case the mandrel portion is not necessary. In this way, the mold 34"comprises a base tool portion 36 'in combination with a lid tool portion 40'. Also more holes 48 and 52 may be required to obtain full saturation of the preform 42" A type Fully enclosed ductwork of the part such as a manifold may be made in accordance with the same RTM method of the present invention. Various aspects for making the part are described in Figures 14-17. In Figures 14 and 15, two can be seen. molds 34 '", each producing half of the manifold The mold 34'" of Figure 14 produces the upper half and the mold 34 '"of Figure 15 produces the lower half according to the procedure described above The two halves of 42 'polimepzadas preforms are then "fixed by jumps" together as shown in Figure 16 When subsequently ignited to make a ceramic to the resin the two lateral joints are fused together uniting yes the two preforms 42 '"in a single ceramic part. In the case of an exhaust manifold incorporating a ceramic foam 60 as a catalyst substrate, the foam configured in combination with the lower half preform 42 '"can be used as part of the mold 34" "thus greatly simplifying the application Mold Cap Tool 40"As Well as the Assembly Procedure Having thus described the present invention in general terms, three specific examples of parts will now be described to be developed and tested by the inventors of the present invention.

Example 1: Manufacture of a FRCMC cylinder sleeve 1. Manufacture or purchase a cylindrical preform of the required size (there are a number of vendors in the United States that sell fiber preforms for composite applications) of fibers such as, but not limited to, alumina, Altex, Nextel 312, Nextel 440, Nextel 510, Nextel 550, silicon nitride, silicon carbide, HPZ, graphite, carbon and peat. The preform must be made so that when it is loaded into the mold tool, I take between 30% and 60% of the open volume inside the closed tool In the example, the preform has been constructed by hand by the inventors 2 The preform is then applied a fiber contact surface coating, for a better industry practice. The assignee of this application, Northrop Corporation, currently has a number of patents on the application of contact surface coatings, including U.S. Patent No. 5,034,181, entitled APPARATUS FOR METHOD OF MANUFACTURING PREFORMS, the U.S. Patent. No. 5,110,771, entitled METHOD OF FORMING A PRECRACKED FIBER COATING FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES; U.S. Patent No. 5,275,984, entitled FIBER COATING OF UNBONDED MULTI-LAYERS FOR TOUGHING CERAMIC FIBER-MATRIX COMPOSITES; U.S. Patent No. 5,162,271, entitled METHOD OF FORMING A DUCTILE FIBER COATING FOR TOUGHENING NON-OXIDE CERAMIC MATRIX COMPOSITES; and U.S. Patent No. 5,221, 578, entitled WEAK FRANGIBLE FIBER COATING WITH UNFILLED PORES FOR TOUGHENING CERAMIC FIBER-MATRIX COMPOSITES. The teachings of which are incorporated herein by reference. Also, Allied Signal or Synterials are commercial companies, which will apply a contact surface coating as a purchasing service. In the example, the contact surface coating was applied by the inventors as described in the co-pending application referenced above 3. The cylindrical preform was then placed on the mandrel portion of the tool and the mold was closed and sealed around the same. It should be noted that in some cases such as with volume preforms with high fiber content, a hydraulic press or the like may be necessary to close the mold. 4 The lower feed holes in the mold should be connected via a flexible pipe with a valve to a container containing Blackglas resin. The upper ventilation hole was connected through a flexible transparent pipe with a valve to a vacuum source. Both valves Initially, they were opened to allow the resin to be sucked through the mold. The container with the Blackglas resin was priced above 1 0545 Kg / crt.2, that is, above atmospheric pressure, to create a positive pressure that tends to force the resin through the mold When the resin flows through the mold without any air bubble present in the pipe on the vacuum side (outlet) both valves close 6 The mold with the enclosed preform and the resin mixture then heated through the next cycle A) Ambient ramp at 65 5 ° C to 2 7 ° / m? nuto B) Maintain at 65 5 ° C for 30 minutes C) Ram pa to 1 7 ° / m to 148 8 ° CD) Hold at 1488 ° C for 60 minutes E) Cool to 1 2 ° / m until the temperature is below 60 ° C for the demoulding of the It should be noted that there is a variety of warming cycle definitions which will create a useful product and the foregoing is by way of example only and not intended to be exclusive. 7 After cooling the mold the mold was disassembled and the component of polymer composite material was removed from the pyrolysis mold NOTE: The above seven steps intensify a resin transfer molding (RTM) aspect to prepare the polymer composite. Other applicable aspects to create the same part are manual placementStretch extrusion, filament winding, cam placement, or short fiber injection. These are valid techniques for manufacturing polymer composite material to be included within the scope and spirit of the present invention and the appended claims. These various techniques do not claim to be inventive of the present inventors in and for themselves and only the total method that is being described and claimed is novel for these inventors and their application. 8. The polymer composite component was then pyrolyzed. In this regard, the manufacture of a sealable container, such as a stainless steel box, capable of withstanding 1037.7 ° C for the pyrolysis cycle in a normal furnace is required. In an alternative, if available an inert gas oven can be used. The box must have two pipe connections, one on the underside and one on the top to allow the box to be flooded with an inert gas. In this example, the sleeve was placed in the box, the box was placed in a normal oven, the stainless steel pipe was connected to the bottom connector of the box and to a supply of high purity argon. Any equivalent inert gas can be used, of course. The argon is allowed to flow into the box, and out of the upper vent at a rate of 5-10 SCFH for the entire heating cycle, thus ensuring that the sleeve is fully bathed in an argon environment. The furnace was closed and ignited at the following base: A) Ramp at 148.8 ° C at 223 ° / hour B) Ramp at 482.2 ° C at 43 ° C / hour C) Ramp at 760 ° C at 20 ° C / hour D) Ramp at 871.1 ° C at 50 ° / hour E) Maintain at 871.1 ° C for 4 hours F) Ramp at 25 ° C at -125 ° / hour Again, there is a variety of heating schedules different from this, given in a way example only, which will produce usable hardware. 9. After cooling, the sleeve was removed from the furnace and box and immersed in a Blackglas resin bath for a sufficient time to allow air to be removed from the sleeve (typically 5 minutes or more). An additional step of vacuum infiltration can also be used for this step. 10. Step 8 was repeated. 11. Step 9 was repeated. Step 8 was repeated. 13. Step 9 was repeated. Step 8 was repeated. 15. Step 9 was repeated. 16. Step 8 was repeated. 17. The sleeve is now ready for pre-use coating application machining. The sleeve was ground (commercial grade diamond cutting stones recommended) to an internal diameter, which was 0.01016 cm and 0.11778 cm above the dimension of the finished sleeve hole dimension. If the sleeve is intended to be used in a two-stroke engine, the consumption and exhaust positions must be cut at the same time using conventional machining practices (recommended commercial grade diamond-coated grinding tools). After finishing the machining procedures, all sharp edges on the inner surface of the sleeve must be cut using a diamond paper. 18. The sleeve was then placed in an oven for a time and at a suitable temperature to ensure the "burn" of any of the cutting lubricants used in the machining process. (Typically 2 hours @ 371.1 ° C, but it is dependent on the lubricant). 19. The sleeve is now ready for the application of the wear lining as described in copending application serial number PCT / US96 / 11771 filed on the date thereof, entitled REDUCING WEAR BEATWEEN STRUCTURAL FIBER REIFORCED CERAMIC MATRIX COMPOSITE AUTOMOTIVE ENGINE PARTS IN SLIDING CONTACTING RELATIONSHIP. In a first embodiment for coating the sleeve surface with a wear-resistant coating, a woven mat of woven or non-woven fabric is used. In this embodiment, the contact surfaces of the composite component of ceramic matrix reinforced with structural fiber was covered with an erosion resistant coating, which is hermetically joined to the wear surface of the FRCMC structures. For this purpose, the erosion-resistant coating preferably comprises Mulite (ie alumina silicate AI2SÍ4), alumina (ie AI2SÍ3), or an equivalent, applied through a plasma spray generally in accordance with well-known techniques. those experts in the field. The erosion resistant coating is applied as follows. Prior to the application of the erosion resistant coating, all holes for spark plugs, valves, piston pins, etc. were machined. Commercial grade diamond cutting tools are recommended for this purpose. Any other machination described later is also done at this point. After finishing the machining procedures if any, all the sharp edges on the surface of the part are removed using diamond paper. If the part has been machined, it is placed in an oven for a suitable time and temperature to ensure the "burning" of any of the cutting lubricants used in the machining process. (Typically 2 hours at 371.1 ° C, but it is dependent on the lubricant). The key is that the erosion-resistant coating is bonded to the FRCMC structure. If the surface of the FRCMC structure is not properly separated, the erosion resistant coating can simply become flaky and provide no long-term protection. In the preferred aspect, the surface of the FRCMC structure is lightly cleaned by blasting blasting to form small mounds within the ceramic matrix of the FRCMC structure. It is also believed that light cleaning with a shot blasting jet exposes lint or filaments on the exposed fiber of the generic fiber system, which the erosion resistant coating can hold and adhere to. The blast cleaning of typical blasting shot that has proved successful is a grit size of 100 @ 1,406 kg / cm2. According to a second possible aspect, the surface of the FRCMC structure can be provided with a series of thin slotsShallow, regularly spaced, thin "thread" similar to a notch or bolt, where the erosion-resistant coating can be mechanically locked. Essentially, the surface is classified to provide a rigid surface instead of a smooth surface. The depth, width and separation of the grooves is not critical and can be determined for each part or component without undue experimentation. In general, the grooves must be closely spaced in order to minimize any large smooth areas of the surface, where there is a potential for the erosion-resistant coating to lose its adhesion and flake off. In this way, an over-grooving of the over-grooving of the surface may be preferable with the exception that over-grooving requires the application of the additional wear material to provide a smooth wear surface after final milling. . The grooves must be shallow in order to provide a mechanical seal area for the erosion-resistant coating without reducing the structural strength of the underlying FRCMC structure to any appreciable degree. After surface preparation, the part is cleaned using dry compressed cleaning air and then loaded into a suitable support accessory for the plasma spray process. Direct air blowers are used to cool the opposite side of the part during the application of the erosion resistant coating. The erosion-resistant coating sprayed in plasma is then applied using a deposition rate set at 5 grams per minute or more. The speed of the support fixture, the movement of the plasma gun through the surface and the width of the spray are set to obtain a pole spray pattern loaded with 50% overlap. The spray gun is fixed relative to the surface by spraying from 0.254 cm to 7.62 cm away. The particle sizes used for this purpose vary from 170 to 400 meshes. Sufficient material is applied to allow finishing machining. After the application of the erosion-resistant coating, the coated surface is smoothed with diamond paper or an appropriately shaped tool (diamond tools of commercial grade recommended) to obtain the final surface contour. In an alternative embodiment, the erosion-resistant material in powder form can be dispersed within the matrix material (i.e., the resin) before forming the component for improved wear resistance. Alternatively, the plasma sprayed coating can be applied and then the part with the erosion-resistant coating then bonded can be further re-infiltrated with the pre-ceramic polymer resin and then converted to a ceramic state, the result is a hardening of the coating essentially incorporating the coating to the composite or mixed ceramic matrix composite formed from the combination of FRCMC and a monolithic wear coating reinforced with ceramic matrix integrally bonded through the common ceramic matrix. The sleeve was cleaned by blasting blasting using a shot and a suitable pressure to remove any loose matrix material exposing the fibers with CMC. (Typically, shot of 100 @ 1,406 kg / cm2). . the sleeve was then cleaned using dry compressed cleaning air 21 The sleeve was then loaded into a rotating table fixture, which rotated the sleeve around its centerline for the plasma spray process 22. Air blowers were used. direction to cool the outside of the sleeve, while minimizing any air blowing through the ports, where applicable. 23. The plasma spray wear coating was then applied using a deposition rate set at 5 grams per minute or more The table rotation speed, the axial movement speed of the plasma gun (inside and outside the sleeve) , and the width of the spray was set to obtain a pole spray pattern loaded with an overlap of fifty %. The spray gun was fixed relative to the sprayed surface from 0 254 cm to 762 cm away. The particle sizes used for this procedure ranged from 170 to 400 mesh. Sufficient material was applied to achieve a subdivided hole component. 24 After application of the wear liner, the sleeve was ground (commercial grade diamond stones recommended) to obtain the final sleeve hole. At this point, the sleeve was ready for installation in an engine block.

Example 2: Manufacture of a FRCMC piston 1. A CMC piston was formed using RTM according to the same procedure as that of the cylinder sleeve of Example 1 steps 1 to 16. 2. The component is now ready for the machining of application of pre-wear coating. The piston was machined (recommended commercial grade diamond cut stones) yet external contour, which had a sub-dimension between 0.01016 and 0.1778 cm than the outer dimension finished piston. After finishing the machining procedures, all sharp edges on the surface of the piston were removed using diamond paper. 3. The piston was then placed in an oven for a time and at a suitable temperature to ensure "burning" of any of the cutting lubricants used in the machining process (typically 2 hours @ 371.1 ° C, but is dependent on the lubricant ). 4. The piston is now ready for the application of the wear lining substantially as described in Example 1, with the exception that the sleeve was coated against wear on its internal surface, ie in sliding contact with the piston, while the piston was coated against wear on its outer surface, i.e. in sliding contact with the piston. sleeve. The outer surface of the piston is cleaned by blasting blasting blast using a shot and pressure suitable to remove any loose matrix material and expose the fibers within CMC. (Typically shot of 100 @ 5. The piston is then cleaned using dry compressed cleaning air 6. The piston was then loaded into a rotating table attachment for the plasma spray process 7. Direct air blowers were used to cool the inside of the piston 8. After the coating was applied against wear sprayed with plasma using a deposition speed set at 5 grams per minute or more.The speed of rotation of the table, the speed of axial movement of the pistol Plasma (above and below the piston) and the spray width were set to obtain a pole spray pattern loaded with 50% overlap The spray gun was fixed relative to the sprayed surface from 0.254 to 7.62 cm away The particle sizes used for this procedure ranged from 170 to 400 mesh, both the piston jacket and the upper part were coated. achieve an oversizing of the external piston diameter. 9. After the application of wear coating, the piston was changed (recommended commercial grade diamond tools) to achieve the final external piston contour, cutting ring grooves using a diamond cutting wheel, and any of the Additional machining requirements as a function of the piston design. The completed piston is now ready to be installed on an engine.

Example 3: Fabrication of an FRCMC Head / Head Liner 1. A CMC cylinder head liner and a CMC cylinder head were formed using RTM according to the same procedure as that of the cylinder sleeve of Example 1 for Steps 1 to 16 of it. 2. The components are now ready for the machining of the pre-wear coating application. At this time, and before the application of the wear lining, all holes (spark plugs, valves, etc.) were machined, (recommended commercial grade diamond cutting tools). After the completion of the machining procedures, all the sharp edges of the head surface / headliner were removed using diamond paper. 3. The head / head liner was placed in an oven for a time and at a temperature suitable to ensure "burn-in" of any of the cutting lubricants used in the machining process. (Typically 2 hours @ 371.1 ° C, but it is dependent on the lubricant). 4. The side of the combustion chamber of the head / headliner was cleaned with blasting shot blasting using appropriate shot and pressure to remove any loose matrix material and expose the fibers within the CMC. (Typically shot of 100 @ 1,406 kg / cm2). 5. The head / headliner were cleaned using dry compressed cleaning air. 6. The head / headliner was then loaded into a support fitting for the plasma spray procedure. 7. Direct air blowers were used to cool the side of the chamber without combustion of the head / headliner. 8. The plasma sprayed wear coating was then applied using a deposition rate set at 5 grams per minute or more. The lateral velocity of the support fixture the vertical movement speed of the plasma gun (above and below the surfaces), and the spray width were set to obtain a pole spray pattern loaded with 50% overlap. The spray gun was fixed in relation to the sprayed surface from .254 to 7.62 cm away. The particle sizes used for this procedure varied from 170 to 400 meshes. Sufficient material was applied to allow finishing machining. 9. After application of the wear liner, the head combustion chamber / headliner area was made smooth with diamond paper or an appropriately shaped tool (recommended commercial grade diamond tools) to achieve the final internal contour . In the case of the cylinder head, the matching block surface of the head was also machined flat at this point and was ready to be used. 10. In the case of the head liner, the component was then joined inside its metal mat. Of course, it could also have been cast on the metal mat. After installation with its mat, the matching block surface of the headliner is also machined flat. The metal cylinder head lined with ceramic was then ready to be used.

Claims (21)

1. CLAIMS 1. A method for forming a ceramic lining resistant to erosion and rupture for a part, comprising the steps of: a) forming a lining of a molten monolithic ceramic material, containing pores; b) filling the pores with a pre-ceramic polymer resin; and c) igniting the liner filled with the pre-ceramic polymer resin for a time and at a temperature sufficient to convert the polymer resin to a ceramic, within the pores, thereby forming a reinforced ceramic composite. The method according to claim 1, wherein the step of forming a liner of a ceramic material containing pores comprises: a) pouring a ceramic material of mud cement into a mold; and b) igniting the mud material for a time and at a temperature sufficient to compress the mud material to a porous ceramic liner. The method according to claim 1, wherein the step of filling the pores with a pre-ceramic polymer resin comprises: placing the liner in a container containing a liquid pre-ceramic polymer resin having a viscosity substantially equal to that of water, until the pores are saturated with the resin. The method according to claim 1, wherein the step of filling the pores with a pre-ceramic polymer resin comprises. Place the liner in a bath containing a silicon-carboxyl ream. A method for forming a metal part having a rupture and erosion resistant ceramic liner comprising the steps of a) forming a metal part having a combination surface to receive the liner, b) forming a lining of a molten monolithic ceramic material containing pores, c) filling the pores with a pre-ceramic polymer resin, d) igniting the saturated liner with the pre-ceramic polymer resin for a time and at temperatures sufficient to convert the resin to a ceramic, inside the pores, thus forming a composite material of reinforced ceramic, and e) joining the ceramic lining to the combination surface of the metal part 6. The method according to claim 5, further characterized in that the step of forming the liner of a ceramic material containing pores comprises: a) emptying a cement mud material into a mold; and b) igniting the mud material for a time and at a temperature sufficient to compress the mud material to a porous ceramic liner 7. The method according to claim 5 wherein the step of filling the pores with a polymer resin of Pre-ceramic comprises: placing the liner in a container containing a liquid pre-ceramic polymer resin having a viscosity substantially equal to that of water until the pores are saturated with the resin The method according to claim 5 , wherein the step of filling the pores with a pre-ceramic polymer resin comprises: placing the liner in a container containing the silicon-carboxyl resin 9. A method for forming a metal part having a ceramic liner Resistant to rupture comprising the steps of: a) forming a lining of a molten monolithic ceramic material containing pores, b) filling the pores with a pre-ce polymer resin dynamic c) igniting the saturated liner with the pre-ceramic polymer resin for a time and at a temperature sufficient to convert the polymer resin to a ceramic within the pores thereby forming a reinforced ceramic composite material; d) placing the liner inside the mold for the metal part with the matching surface of the liner facing towards a portion of the mold that will be occupied by the metal forming the part; and e) filling the mold with molten metal to form the part in combination with the liner 10. The method according to claim 9, wherein the step for forming the lining of a ceramic material contains pores comprising a) emptying a material Mud ceramic cement in a mold; and b) igniting the mud material for a time and at a temperature sufficient to compress the mud material to a porous ceramic liner. The method according to claim 9, wherein the step of filling the pores with a polymer resin of Pre-ceramic comprises: placing the liner in a bath containing a liquid pre-ceramic polymer resin having a viscosity substantially equal to that of water until the pores are saturated with the resin 12. The method according to claim 9, wherein the step of filling the pores with a pre-ceramic polymer resin comprises: placing the liner in a bath comprising the silicon-carboxyl resin. 13. An exhaust manifold lined with ceramic, non-brittle, erosion resistant, heat resistant, for an internal combustion engine comprising: a) a metal manifold that defines an exhaust gas conduit having walls internal and b) the inner walls of the conduit being lined with a ceramic material having pores wherein the pores contain a pre-ceramic polymer resin in a ceramic state. 14. The non-brittle, erosion-resistant, heat-resistant ceramic exhaust manifold according to claim 13 wherein: the pre-ceramic polymer resin comprises the silicon-carboxyl resin in its ceramic state. 15. A cylinder head lined with non-brittle, erosion-resistant, heat-resistant ceramic for an internal combustion engine comprising: a) a metal cylinder head having a surface facing the cylinder; and b) the surface facing the cylinder of the centered cylinder head lined with a ceramic material having pores wherein the pores contain a pre-ceramic polymer resin in a ceramic state. 16. The heat-resistant, non-brittle, erosion resistant, ceramic-lined cylinder head according to claim 15, wherein the pre-ceramic polymer resin comprises a silicon-carboxyl resin in its ceramic state . 17. A car part of fiber-reinforced ceramic matrix composite material derived by a) forming a fiber preform in the shape of the part from reinforcing fibers that are used in reinforced ceramic matrix composite materials with fiber, b) placing the preform in a cavity of a mold having the shape of the part; c) force a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the preform; d) heat the mold for a time and at a temperature sufficient to transform the preform saturated with the pre-polymer resin; - liquid ceramic to a part of polymer composite, e) removing the part of the polymer composite from the mold, and f) igniting the part of the polymer composite in an inert atmosphere for a time and at a temperature sufficient to transform the resin of pre-ceramic polymer, whereby the polymer composite part is transformed to a fiber-reinforced ceramic matrix composite part. 18. The automobile part according to claim 17 and after step (f) thereof is further derived by: g) immersing the fiber reinforced matrix composite part containing pores formed by degassing during ignition in a bathing the liquid pre-ceramic polymer resin to fill the pores with liquid pre-ceramic polymer resin; h) igniting the fiber-reinforced ceramic matrix composite part in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin in the pores to a ceramic; and i) repeating steps (g) and (h) until the pore density within the part of the ceramic matrix composite material reinforced with final fiber is less than a preset percentage offering maximum strength to part 19. A multiple of fiber-reinforced ceramic matrix composite material engine derived by: a) making a first preform in a configuration of a lower portion of the manifold from reinforcing fibers that can be employed in fiber-reinforced ceramic matrix composite materials; b) placing the first preform in a cavity of a first mold having the shape of the lower portion of the manifold; c) forcing a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the first preform; d) heating the first mold for a time and at a temperature sufficient to transform the first preform saturated with the liquid pre-ceramic polymer resin to a first part of polymer composite material, e) remove the first part of polymer composite material of the mold; f) forming a second preform in a configuration of an upper portion of the manifold from the reinforcing fibers, g) placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold; h) forcing the liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the second preform; i) heating the second mold for a time and at a temperature sufficient to transform the second preform saturated with the liquid pre-ceramic polymer resin to a second part of polymer composite material, j) remove the second part of polymer composite material of the mold; k) fixing the first part of the polymer composite and the second part of the polymer composite together along the coinciding edges to form the manifold as a part configured as a hollow conduit; Y I) igniting the polymer composite manifold in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin to a ceramic so that the polymer composite material manifold is transformed to a manifold of composite material of ceramic matrix reinforced with fiber and the upper portion and the lower portion are fused together along the coinciding edges. 20. The engine manifold according to the claim 19, and after step (I) thereof is further derived by: m) submerging the fiber reinforced ceramic matrix composite manifold containing pores formed by degassing upon ignition to a bath of the pre-polymer resin. - liquid ceramic to fill the pores with liquid pre-ceramic polymer resin; n) igniting the fiber reinforced ceramic matrix composite manifold in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin into the pores of a ceramic; and o) repeating steps (m) and (n) until the pore density within the fiber reinforced ceramic matrix composite manifold is less than a preset percentage providing maximum strength to the part. 21. A method for making a fiber reinforced ceramic matrix composite motor manifold, comprising the steps of: a) forming a first preform into a configuration of a lower portion of the manifold from the reinforcing fibers that can be used in fiber-reinforced ceramic matrix composite materials; b) placing the first preform in a cavity of a first mold having the shape of the lower portion of the manifold; c) forcing a liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the first preform; d) heating the first mold for a time and at a temperature sufficient to transform the first preform saturated with the liquid pre-ceramic polymer resin to a first part of the polymer composite material; e) removing the first part of polymer composite material from the mold; f) forming a second preform in a configuration of an upper portion of the manifold from reinforcing fibers; g) placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold; h) forcing the liquid pre-ceramic polymer resin through the cavity to fill the cavity and saturate the second preform; i) heating the second mold for a time and at a temperature sufficient to transform the second preform saturated with the liquid pre-ceramic polymer resin to a second part of polymer composite material; j) removing the second part of polymer composite material from the mold; k) fixing the first part of polymer composite and the second part of polymer composite together along coinciding edges to form the manifold as a hollow duct part, i) igniting the polymer composite composite manifold in an inert atmosphere for a time and at a temperature sufficient to transform the pre-ceramic polymer resin to a ceramic so that the polymer composite composite is transformed to a fiber reinforced ceramic matrix composite manifold and the upper portion and the lower portion are fused together along the coinciding edges; wherein the manifold is an exhaust manifold internally filled with a ceramic foam catalyst substrate structure and prior to step (g) placing the second preform in a cavity of a second mold having the shape of the upper portion of the manifold , further including the steps of: f1) placing the first preform as part of a wall defining the second mold cavity; and f2) placing the ceramic foam catalyst substrate structure in the first preform whereby the first preform and the ceramic foam catalyst substrate structure in combination form part of the cavity of the second wall. 21. An exhaust manifold lined with non-brittle, erosion resistant, heat-resistant ceramic for an internal combustion engine comprising: a metal manifold defining an exhaust gas conduit having internal walls; and the inner walls of the duct having a melted monolithic ceramic liner with pores saturated with a silicon-carboxyl resin in a ceramic state.