RU2421429C2 - Composite multilayer materials, methods of making cowling, cut off half-sphere, shell, half-shell and apparatus for realising said methods - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: invention relates to the technology of producing composite materials and methods of making housing elements of aircraft and space-rocket articles. Disclosed is a multilayer composite material which contains carbon-carbon layers and/or carbon-metal layers, joined by intermediate porous layers of carbonised carbon and comprising mainly carbon-carbon and carbon-metal parts of the composite material. Each of the carbon-carbon layers (K) on both sides of are coated with layers of carbonitride compounds of titanium and silicon (T), and inner intermediate porous layers of the carbonised carbon (E) contain copper-titanium layers (M). The carbon-metal part of the composite material contains aluminium-lithium (A) and magnesium-lithium layers (B,C,F), reinforced with carbon fibre (D), inner porous layers of carbonised carbon with copper-titanium surface layers, heated or cooled with inert gas using plasma heating or a gas-liquid medium based on an inert gas. The invention also discloses methods and devices for making a cowling, a cut off half-sphere, a shell and a half-shell using the disclosed composite material.

EFFECT: achieving good specific strength characteristics, brittle fracture resistance, heat resistance, erosion resistance, high reflecting and absorption capacity of the composite material, which significantly lowers weight, increases resistance to heat and meterorite effects, increases reliability of aerospace articles.

21 cl, 2 tbl, 27 dwg

Description

The invention relates to a technology for creating composite materials (KM) and methods for manufacturing body elements of aerospace products. Known carbon-metal composite material (KM) based on aluminum-lithium and magnesium-lithium alloys, reinforced with carbon fiber, a method and apparatus for the manufacture of shell-type products (RF Patent No. 2171311, Bull. No. 21-2001).

However, the use of a known composite material at high speeds in air requires thermal protection.

Known carbon-carbon KM with an outer outer layer of titanium carbonitride compounds, a method and apparatus for the manufacture of shell type products (RF Patent No. 2228917, Bull. No. 14-2004).

In the known composite material, the level of heat resistance and tightness is not high enough.

A known method and device for hot pressing products from KM, allowing to form the product in the form of a truncated hemisphere (RF Patent No. 2212341, Bull. No. 26-2003).

In the known method and device, it is difficult to form on the inner surface of various structural elements such as boss, fitting, etc.

A known method and device for plasma spraying of powder using the effect of superplastic state of the sprayed surface (RF Patent No. 2199604, Bull. No. 6-2003).

However, with plasma spraying, insufficiently high speeds of the sprayed powder develop, which reduces the contact strength and does not completely remove the residual porosity of the sprayed layer.

Known siliconized graphite obtained by impregnating graphite blanks with liquid silicon (see Tuchinsky LI Composite materials obtained by the method of impregnation. - M .: Metallurgy, 1986, S. 190-194).

However, siliconized graphite has a low level of strength properties.

A known method and device for centrifugal casting of metal, including flask, rotation mechanism and gating system. (Polytechnical Dictionary. Edited by I.I. Artobolsky, Soviet Encyclopedia, 1976, p. 259).

The disadvantages of the known method and device are:

- active oxidation of the surface of the formed casting;

- the difficulty of obtaining ultrafine casting thickness.

A known method of forming a casting with synthetic carbides (RF Patent No. 2080206, bull. No. 15-1997), including the introduction of synthetic carbides into the melt and pulling the casting from it up. However, in a similar manner it is difficult to obtain a casting in the form of a thin-walled shell.

The closest analogue is KM, a method of manufacturing a shell type shell and a device for its implementation from it (Application No. 20022132948/02, Decision of the Federal State Institution FIPS, dated January 30, 2007).

KM includes carbon-metal (RF Patent No. 2171311) and carbon-carbon (RF Patent No. 2228917) parts connected by an intermediate layer of carbonized carbon and the outer outer layer of titanium carbonitride compounds.

The method of forming titanium carbonitride compounds includes plasma gas-dynamic spraying of titanium in a nitrogen medium using a Venturi-type nozzle.

Products made from the well-known KM have an insufficiently high level of heat resistance.

In addition, with plasma gas-dynamic spraying of the initial powder using a Venturi-type nozzle, insufficiently high flow rates develop.

An object of the present invention is to provide carbon-carbon and carbon-metal or only carbon-carbon composite materials with outer and inner layers of carbonitride titanium and silicon compounds, inner intermediate porous layers of carbonized carbon with copper-titanium surface layers and cooled by an inert gas-liquid flow or heated with an inert gas, the development of methods for manufacturing products such as cylindrical, conical shells, truncated hemispheres ery and other elements, shells and half-shells with increased indicators of specific strength, heat resistance, heat resistance, heat resistance, resistance to brittle fracture, reflective and absorbing abilities, accuracy of geometric parameters, as well as devices for implementing the methods.

The technical result obtained as a result of the implementation of the invention is to reduce the mass and increase the reliability of the structures of aerospace products.

The problem is achieved by manufacturing semi-finished products from carbon-metal and carbon-carbon or only carbon-carbon CM with inner intermediate porous layers of carbonized carbon and copper-titanium surface layers cooled by a gas-liquid flow based on an inert gas or heated by an inert gas, external external and the inner layers of carbonitride compounds of titanium and silicon carbon-carbon part of the CM.

In the carbon-metal and carbon-carbon CM, the layers are arranged in the following sequence: the outer outer layer of the titanium and silicon carbonitride compounds, → the carbon-carbon layer, → the titanium and silicon carbonitride compound layer, → the copper-titanium layer, → the porous carbonized carbon layer, → a copper-titanium layer, → a layer of carbonitride titanium and silicon compounds, → a carbon-carbon layer, → a layer of carbonitride titanium and silicon compounds, → a copper-titanium layer, → a porous layer of carbonized carbon, → me nano-titanium layer, → aluminum-magnesium-lithium layer reinforced with carbon fiber → copper-titanium layer, → porous layer of carbonized carbon, → copper-titanium layer, → aluminum-magnesium-lithium layer reinforced with carbon fiber, → copper titanium layer, → a porous layer of carbonized carbon, → a copper-titanium layer, → an aluminum-magnesium-lithium layer reinforced with carbon fiber.

In the carbon-carbon CM, the layers are arranged in the following sequence: the outer outer layer of the titanium and silicon carbonitride compounds, → the carbon-carbon layer, → the layer of titanium and silicon carbonitride compounds, → the copper-titanium layer, → the porous carbonized carbon layer, → copper-titanium layer, → layer of titanium and silicon carbonitride compounds, → carbon-carbon layer, → layer of titanium and silicon carbonitride compounds, → copper-titanium layer, → porous carbonized carbon layer, → copper-titanium layer, → layer ith carbonitride titanium and silicon compounds, → carbon-carbon layer, → outer inner layer of titanium and silicon carbonitride compounds.

Methods of forming and manufacturing semi-finished products from CM in the form of cylindrical and conical shells, truncated hemispheres and other elements, shells or half shells consist of several stages and include: the formation of a carbon-metal semi-finished product from aluminum-magnesium-lithium alloys reinforced with carbon fiber; the formation of carbon-carbon semi-finished product with the outer layers of titanium and silicon carbonitride compounds; the formation of an intermediate semi-finished product of carbonized porous carbon with outer copper-titanium layers; plasma and gas-dynamic spraying on the external contacting surfaces of semi-finished lithium or a polymer binder; Assembly of a multilayer prefabricated shell by putting one on top of another or laying one truncated hemisphere into another in a stamp block; the formation of a bonding layer based on lithium or carbonized carbon by diffusion welding or carbonization of a polymer binder under tension.

In order to form a porous through layer of carbonized carbon, the polymer binder is heated and evacuated while it is flushed with an inert gas by means of artificial leakage.

In order to ensure the dissipation of high-energy thermal effects, KM contains highly heat-conducting copper, copper-silver or silver layers that are in contact with other layers of KM.

The assembly of the shell from carbon-metal and carbon-carbon shells and truncated hemispheres is carried out in the following sequence: plasma spraying on the outer surface of the lithium frame, assembly, welding of adjacent shells, truncated hemispheres and frames on the outer inner layer, → plasma spraying on the surface of the lithium weld zone , laying of rings of porous carbonized carbon with surface copper-titanium layers, diffusion welding of contacting surfaces, welding of external metal gaps, → plasma spraying of lithium, laying half rings of carbon-metal KM, diffusion welding of contacting surfaces and electron beam or laser welding of gaps, → plasma spraying of lithium, laying half rings of porous carbon, diffusion welding of contacting surfaces and welding of external metal gaps, → plasma spraying of lithium, laying of half rings made of carbon-metal KM, diffusion welding of contacting surfaces and electron beam or laser welding of gaps, → plasma deposited lithium spraying, laying of porous carbon half rings, diffusion welding of contacting surfaces and electron beam or laser welding of external metal gaps, → gas-dynamic spraying of a polymer binder, laying of carbon-carbon half rings with surface layers of titanium and silicon carbonitride compounds, voltage carbonization of a polymer binder the formation in the gap by plasma spraying of the inner layer of titanium and silicon carbonitride compounds, the formation of carbon-carbon in the gap native layer by gas-dynamic spraying of a polymeric binder, laying carbon fiber followed by carbonization and graphitization by plasma heating of a polymeric binder, plasma spraying of the outer layer of carbonitride titanium and silicon compounds, → gas-dynamic spraying of a polymeric binder, laying of half rings of porous carbon with surface copper-titanium layers, energized carbonization of the polymer binder, electron beam or laser welding of copper-titanium external layers, → gas-dynamic spraying of a polymer binder, laying carbon-carbon semicircles with surface layers of titanium and silicon carbonitride compounds, energized polymer binder, the formation of an inner layer of titanium and silicon carbonitride compounds in the gap by plasma spraying, the formation of a carbon-carbon layer in the gap by gas-dynamic spraying a polymer binder, laying carbon fiber, followed by carbonization and graphitization by plasma heating of the polymer vyazuyuschego forming by plasma spraying the outer layer of titanium carbonitride and silicon compounds.

The shell is assembled from carbon-carbon and carbon-metal shells, truncated hemispheres, frames are welded on the inside of the metal part, an intermediate porous layer of carbonized carbon is formed on the outside of the metal part of the welded zone, and carbon-carbon half rings are glued followed by carbonization of the polymer binder under tension with the outer and inner layers of titanium and silicon carbonitride compounds, as well as an intermediate porous layer of carbonized carbon.

In order to increase the strength properties of the joint, the size of the half rings is made in such a way that the half rings overlap the joint gaps of the previous half rings with similar layers of CM adjacent shells or shells and a truncated hemisphere.

The assembly of a half-shell consisting of a truncated hemisphere, a cylindrical shell in the form of a nozzle of the Loval or Venturi type and a multilayer carbon-carbon composite material, includes: forming a carbon-carbon layer with a titanium hermetic coating in the form of a conjugated cylindrical shell and a shell in the form of a nozzle of the type Lovalya or Venturi followed by high-temperature nitriding of the titanium coating and plasma high-speed spraying of silicon carbides, silicon in a nitrogen atmosphere on the outer surface the possibility of precision workpiece, as well as by centrifugal casting of molten silicon and silicon carbides on the inner outer surface of the precision workpiece with subsequent high-temperature nitriding of silicon.

Then, cylindrical and conical conjugated carbon-carbon shells with outer surface layers of titanium and silicon carbonitride compounds are put on the outer external surface of the formed precision workpiece, the gap between the outer surface of the precision workpiece and the shells is filled with polymer binder by vacuum absorption and by blowing with an inert gas by artificial leakage and simultaneous carbonization of the polymer binder intermediate layer.

The gaps between the shells are filled with particles of titanium and silicon carbonitride compounds, a carbon fiber and a polymer binder with its simultaneous carbonization and graphitization.

The conjugated shells are again put on, an intermediate porous layer is formed in the gap, the shells are interconnected and a surface layer of carbonitride titanium and silicon compounds is formed.

A truncated hemisphere is attached to the cylindrical shell and, accordingly, layers of titanium and silicon carbonitride compounds, carbon-carbon layers and intermediate porous layers of carbonized carbon are formed in the gap.

In order to further increase the strength properties, heat resistance and heat resistance of CM, the latter is cooled by a gas-liquid flow of inert gas through porous intermediate layers of carbonized carbon, followed by recirculation of the inert gas in a closed loop, liquefying and spraying it.

In order to rationally use an inert gas, it is fed and stored in a gaseous, liquid, and solid state.

In order to maintain a given temperature regime of the carbon-metal part of CM inert porous layers recycle inert gas heated in a plasma torch or cooled by a gas-liquid medium based on an inert gas.

To form the outer layer of silicon carbonitride compounds, silicon carbide powder is first fed into the nozzle openings after a critical section of the plasma sprayer, then silicon powder, and gas-forming nitrogen is used as the plasma-forming medium.

To ensure high contact strength and reduce residual porosity of the sprayed layer, the speed of the sprayed particle stream is increased by using the nozzle circuit of a plasma sprayer in the form of a Loval or Venturi type nozzle, and the sprayed powder is introduced through holes in the nozzle loop located after the critical section.

To form a cylindrical or conical shells and a truncated hemisphere or other boss elements, protrusions, fints, etc. on the inner surface of the metal part of the semi-finished products by extruding the metal, the working surface of the split mandrel or die has corresponding recesses for forming various structural elements on the inner surface of the semi-finished products in the process diffusion welding of metal layers in the conditions of its superplastic state.

The system of recirculation and regeneration (cooling, liquefaction and formation) of a gas-liquid medium based on an inert gas includes: a liquefaction unit, pipelines, gas cooling panels, manifolds for the formation of a gas-liquid medium, storage tanks for liquefied gas, shut-off and control valves, control unit.

The inert gas recycle heating system includes: a plasma heating unit, pipelines, a heater, a control unit.

Table 1 shows the expected technical and operational characteristics of the created composite materials (KM).

The invention is illustrated by drawings, which depict: figure 1 is a cross section of a multilayer carbon-carbon and carbon-metal CM; figure 2 is a cross section of a carbon-carbon KM; figure 3 - diagram of the assembly and welding of the shell of carbon-carbon and carbon-metal KM; 4 is a diagram of a device for impregnation, degassing, diffusion welding or carbonization of a semi-finished shell type; 5 is a diagram of a device for impregnation, degassing, diffusion welding or carbonization of a semi-finished product such as a truncated hemisphere; 6 is a diagram of a device for graphitization and gas high-temperature nitriding of a carbonized semi-finished product such as a shell or a truncated hemisphere; 7 is a diagram of a centrifugal casting device of a silicon melt and silicon carbides on the inner outer surface of the shell type; Fig. 8 is a section through a sprue channel of a centrifugal casting device; Fig.9, 10, 11, 12 - graphs of degassing, impregnation and diffusion welding of the carbon-metal composition of semi-finished products such as shell or truncated hemisphere; Fig.13, 14, 15, 16 - graphs of degassing, impregnation and carbonization of the carbon-carbon composition of semi-finished products such as shell or truncated hemisphere; Fig.17, 18, 19, 20 - graphs of the processes of graphitization and high-temperature nitriding of semi-finished products such as shell or truncated hemisphere; Fig is a graph of centrifugal casting on the inner surface of the shell of a silicon melt and silicon carbides; Fig is a graph of the process of high temperature nitriding of the surface layer of silicon semi-finished type shell or truncated hemisphere; Fig is a diagram of the preliminary welding of semi-finished products such as shells and a truncated hemisphere; Fig is a diagram of a device for diffusion welding, energized carbonization, electron beam or laser plasma welding of half rings in the welded zone of the shell and half shell; Fig is a diagram of a gas-dynamic spraying of a polymer binder; Fig is a diagram of a plasma gas-dynamic spraying of carbonitride compounds of silicon and titanium.

Carbon-metal KM (figure 1) includes:

A - aluminum-lithium alloy (Al-Li);

B — magnesium-lithium alloy (Mg-Li) with the structure of an (α + β) solid solution;

C - magnesium-lithium alloy (Mg-Li) with the structure of α-solid solution;

D is carbon fiber;

F - magnesium-lithium alloy (Mg-Li) with the structure of a β-solid solution;

E is a porous layer of carbonized carbon;

M - copper-titanium layer;

T is the outer outer layer of carbonitride compounds of titanium, silicon.

Figure 2 presents:

Carbon-carbon KM (Fig.1, 2) includes:

K - carbon fabric;

D is carbon fiber;

T - layer of carbonitride compounds of titanium and silicon;

E is a porous layer of carbonized carbon;

M - copper-titanium layer.

A method of manufacturing a multilayer shell or a truncated hemisphere includes the manufacture of individually shells and truncated hemispheres, one of carbon-metal KM, the second (intermediate) of porous carbonized carbon with a surface titanium-copper layer, the third of carbon-carbon KM with an outer layer of titanium carbonitride compounds and silicon, subsequent assembly, diffusion welding of the contacting surfaces, or carbonization of the binder component.

A method and device for manufacturing a shell of carbon-metal KM based on aluminum-magnesium-lithium alloys reinforced with carbon fiber are presented in figures 1, 4, 9.

A method and device for manufacturing a shell of carbon-carbon KM with an outer layer of titanium carbonitride compounds are presented in figures 1, 2, 4, 6, 11, 13, 17.

A method and device for manufacturing a truncated hemisphere of carbon-carbon KM or carbon-metal KM are presented in figures 1, 2, 5, 6, 10, 11, 12, 14, 15, 16, 18, 19, 20.

A method and device for manufacturing a shell or a truncated hemisphere of carbonized porous carbon with an outer copper-titanium layer include forming on the mandrel or die a titanium layer, a polymer binder layer followed by its carbonization, simultaneous evacuation and artificial leakage of an inert gas, as well as plasma spraying of copper powder on a titanium surface Figs. 1, 2, 4, 5, 13, 14, 15, 16, 27.

The method and device for forming the surface layer of titanium carbonitride compounds include feeding titanium powder into the plasma torch, and nitrogen gas is used as the plasma-forming medium. Figure 1, 2, 27.

In a similar manner, a surface layer of silicon carbonitride compounds is formed.

The shell body is assembled from several shells, frames and truncated hemispheres by diffusion, electron beam or laser and plasma welding.

A method and apparatus for assembling a shell from KM include assembling shells, frames, truncated hemispheres from KM containing carbon-metal and carbon-carbon parts, an intermediate layer of a carbonized polymer binder, and an outer layer of titanium carbonitride compounds. Figure 1, 23, 26, 27.

In the proposed method and device, a lithium layer is deposited on the contact surface of the frame by plasma spraying, shells, truncated hemispheres are assembled, welded to the inner surface of adjacent shells or shells and truncated hemispheres, shells and truncated hemispheres are welded to the inner outer metal layer K of carbon. Figure 3, layer 1 (1); Fig.23.

Previously, on the end parts of the shells, the truncated hemisphere and half rings according to FIG. 3, adjacent surfaces of the CM layers for welding are formed so that the welds of subsequent adjacent layers do not coincide.

They are applied by plasma spraying to the outer outer surface of the welded zone of lithium, and half-rings of porous carbonized carbon with outer copper-titanium surface layers are laid (glued). Figure 3, layer 2 (2).

The semi-finished shell is moved to the device (Fig.24, 25), diffusion welding of the inner outer surface of the half rings with the outer outer surface of the welded zone is performed. Figure 3, layer 1 (1), 2 (2). A tight cathode-ray or laser welding of gaps of adjacent external outer copper-titanium layers is performed.

The semi-finished shell is moved to the device (Fig. 23), plasma sprayed onto the outer outer surface of the half rings of Fig. 3, layer 2, (2) lithium, the half rings of Fig. 3, layer 1, (3) of carbon-metal are laid (glued) KM.

The semi-finished shell is moved to the device (Figs. 24, 25), diffusion welding of adjacent surfaces is carried out, and the gaps are sealed. Figure 3, layer 1, (3).

The semi-finished shell is moved to the device (FIG. 23), applied to the outer surface of the half rings of FIG. 3, layer 1, (3) lithium, the half rings of FIG. 3, layer 2, (2) are laid (glued).

The semi-finished shell is moved to the device (Fig.24, 25), diffusion welding of adjacent surfaces and hermetic welding of gaps are performed. Figure 3, layer 2, (4).

Move the semi-finished shell into the device (Fig.23), apply a layer of lithium and lay the half rings of Fig.3, layer 1, (5).

The semi-finished shell is moved to the device (Figs. 24, 25), diffusion welding and welding of gaps are performed. Figure 3, layer 1, (5).

The semi-finished shell is moved into the device (Fig. 23), lithium is applied and the half rings are laid, Fig. 3, layer 2, (6).

The semi-finished shell is moved to the device (Figs. 24, 25), diffusion welding of adjacent surfaces and electron beam or laser hermetic welding of gaps of adjacent surfaces of the outer copper-titanium layers are performed. Figure 3, layer 2, (6).

The shell semi-finished product is moved to the device (Fig. 23), a polymer binder is applied to the outer external surface of the welded zone, carbon-carbon KM half rings are laid (glued) with the outer surface layer of titanium and silicon carbonitride compounds, Fig. 3, layer 3, (7 )

The shell semi-finished product is moved to the device (Figs. 24, 25), the polymer binder is carbonized under tension, gas-dynamic and plasma formation in the gap of layers of titanium and silicon carbonitride compounds, a carbon-carbon layer is produced, Fig. 3, layer 3, (7 )

The semi-finished shell is moved to the device (Fig. 23), a polymer binder is applied to the surface of the welded zone, half-rings of porous carbonized carbon with outer copper-titanium layers are laid (glued), Fig. 3, layer 2, (8).

The shell semi-finished product is moved to the device (Figs. 24, 25), the polymer binder is carbonized under voltage, electron-beam or laser welding of the gaps of adjacent external outer copper-titanium layers is performed, Fig. 3, layer 2, (8).

The shell semi-finished product is moved to the device (Fig. 23), a layer of polymer binder is applied to the surface of the welded zone, half-rings of carbon-carbon KM are placed (glued) with the outer layer of titanium and silicon carbonitride compounds, Fig. 3, layer 3, (9).

The shell semi-finished product is moved to the device (Figs. 24, 25), the polymer binder is carbonized under tension, gas-dynamic and plasma formation in the gap of layers of titanium and silicon carbonitride compounds, a carbon-carbon layer is produced, Fig. 3, layer 3, (9 )

Table 2 shows the process flow diagram for manufacturing the shell or half-shell body from the proposed CMs.

The device (Fig.24, 25) for electron beam or laser diffusion welding, as well as voltage carbonization includes a screw press 1 with a given speed of movement and loading, a screw beam 2, a rolling roller 3, infrared emitters 4, electron beam or laser welding head 5, gas-dynamic nozzle 6, plasma spray 7.

Shell 8 includes: shells 9, truncated hemispheres 10, carbon-carbon half rings 11 with surface layers of carbonitride titanium and silicon compounds, half rings 12 of porous carbon with outer copper-titanium layers, half rings 13 of carbon-metal KM, frames 14 of carbon metal KM.

The mechanism of rotation and horizontal movement of the shell 8 includes: rollers 15 (with drives) of horizontal movement of the shell 8, rollers 16 (with drives) of rotation of the shell 8.

The rollers 15, 16 have a coating on the working surface, eliminating damage to the surface of the shell, for example polyurethane.

The mechanism for moving and loading the beam 2 includes: el. drive 17, screw 18, nut 19, split suspension 20.

The mechanism for replacing the rolling roller 3 on the screw crosshead 2 includes: a drive 21, fixing guides 22 of the rolling roller 3, a detachable sleeve 23, a process hatch 24.

The device (Fig.24, 25) also includes a housing 25, a pipe 26 connecting to a vacuum pumping system, a loading hatch with a cover 27.

The design of the device includes a control system, a vacuum system and power supply of the device as a whole (not shown in the drawing).

The shell 8 (Fig.24, 25) of the shells 9 and truncated hemispheres 10 are pre-welded on the stand (Fig.23) along the outer inner layer 13 of the carbon-metal KM, the frame is welded 14, sprayed onto the surface of the welding zone of lithium and installed (glued) half rings 12 of porous carbon with outer copper-titanium surface layers.

The shell 8 is installed on the drive rollers 15 and introduced into the device (Fig.24, 25). Close the loading hatches with lids 27, turn on the vacuum system and vacuum to a predetermined vacuum the working volume of the device (Fig.24, 25)

The half rings 12 are heated with infrared emitters 4 and, using the kneading roller 3, diffusion welding of the inner outer surfaces of the half rings 12 with the surface of the welded zone of the outer outer layer 13 of the carbon-metal CM is performed.

Using a welding head 5, hermetic welding of the gaps of the outer copper-titanium layers of the half rings 12 is carried out.

In a similar way, diffusion welding and welding of gaps of half rings 13 of carbon-metal KM and half rings 12 of porous carbonized carbon with outer copper-titanium layers with similar layers of shells 9 are performed.

Before assembly and welding of carbon-carbon half rings 11, a polymer binder is applied to the surface of the welded zone with a nozzle 30 (FIG. 23). Collect (glue) the half rings 11 to the surface of the welded zone and move the shell 8 into the device (Fig.24, 25).

Using infrared emitters 4, the polymer binder is heated with its simultaneous evacuation and carbonization under voltage using a rolling roller 3.

The gaps are filled with a polymeric binder by a gas-dynamic nozzle 6, using infrared emitters 4 and a knurling roller 3, the polymeric binder is carbonized and the carbonized polymeric binder is graphitized in the gap with a welding head 5.

In the process of carbonization and graphitization of a polymer binder in the working volume of the device (Fig.24, 25) maintain a predetermined vacuum (vacuum).

Using a plasma sprayer 7, an outer surface layer of carbonitride titanium and silicon compounds is formed.

The sheath 8 is moved to the device (Fig. 23), a layer of polymer binder is applied, half rings 12 of porous carbonized carbon with a surface titanium-copper layer are laid (glued) and the sheath is transferred to the device (Figs. 24, 25).

In the device (Fig. 24, 25), welding of the gaps of adjacent copper-titanium layers is made and the semi-finished product is moved by the shell 8 into the device (Fig. 23).

A layer of polymer binder is applied, carbon-carbon half rings are laid (glued) and the semi-finished shell 8 is transferred to the device (Figs. 24, 25).

Carry out carbonization under tension of the polymer binder of the contacting surfaces of the semirings 11, the formation of layers of carbonitride compounds of titanium and silicon, the carbon-carbon layer in the gap.

When forming a welded joint of the shell 9, a truncated hemisphere 10 of the shell 8, the welded zone of the shell 8 is moved to the service area of the rolling roller 3.

Replacement of the rolling roller 4 is carried out as follows: the detachable sleeve 23 is engaged, the drive 21 is turned on and the rolling roller 3 is brought out using the fixing guides 22 into the replacement zone of the rolling roller 3, the process door 24 is opened and the rolling roller 3 is replaced.

A method of manufacturing a multilayer half-shell, consisting of a truncated hemisphere, a cylindrical shell, a shell in the form of a nozzle of the Loval or Venturi type and a multilayer CM with outer inner layers of carbonitride compounds of titanium and silicon, intermediate porous layers of carbonized carbon and copper-titanium layers, includes:

- the formation on a detachable mandrel of a carbon-carbon carbonized layer with a titanium hermetic coating in the form of a Loval nozzle or a Venturi nozzle (Fig.2, 4, 13);

- graphitization of the carbonized carbon-carbon binder layer and high temperature nitriding of the titanium coating (Fig.6, 17);

- plasma high-speed spraying on the outer surface of the semi-finished silicon carbide and silicon carbides in a nitrogen medium (Fig.17);

- centrifugal casting of molten silicon and silicon carbides on the inner surface of the semi-finished product, followed by high-temperature nitriding (Fig. 7, 6, 21, 22);

- applying to the outer surface of the semi-finished product a polymer binder, assembling (donning) cylindrical and conical shells made of carbonized porous carbon with outer copper-titanium layers, hermetic welding of the outer outer and adjacent copper-titanium layers, carbonization of the polymer binder under tension (Figure 2, 4 , 13, 24, 25);

- applying a polymeric binder to the outer surface of the semi-finished product, assembling (donning) cylindrical and conical shells made of carbon-carbon KM with the outer layers of carbonitride titanium and silicon compounds, carbonization of the polymeric binder, plasma welding with the formation of the carbon-carbon layer, outer layers of titanium carbonitride compounds and silicon in the weld zone of adjacent shells (Fig.2, 4, 13, 24, 25, 27);

- applying to the outer surface of the semi-finished product a polymer binder, assembling (donning) shells of carbonized porous carbon with outer copper-titanium layers, carbonization of the polymer binder, welding of external adjacent copper-titanium layers (Figs. 2, 4, 13, 24, 25);

- drawing on the outer surface of the semi-finished product a polymeric binder, assembling (putting on) shells of cylindrical and conical shells of carbon-carbon KM with outer layers of carbonitride titanium and silicon compounds, carbonization of a polymer binder, plasma welding with the formation of a carbon-carbon layer, outer layers of carbonitride titanium compounds and silicon in the weld zone of adjacent shells (Fig.2, 4, 13, 24, 25, 26, 27). Similarly, the formation of a multilayer truncated hemisphere of carbon-carbon KM with outer and inner layers of carbonitride titanium and silicon compounds, intermediate inner layers of carbonized porous carbon with copper-titanium surface layers and subsequent welding of the cylindrical part of the semi-finished product and the truncated hemisphere (Figure 2, 5 , 13, 24, 25, 26, 27).

The device (Fig.7, 8) includes a chamber 1 of centrifugal casting of the melt on the inner surface of the semifinished product 10, a ladle furnace 11, a dispenser-degasser 12, a gating system 13.

The centrifugal casting chamber 1 includes clamping clips 2 for fixing the processed semi-finished product 10, a rotation drive 3 of the fixing clip 2, a heater 4 for the heating system of the semi-finished product body 10, a container 5 for draining excess melt, drives 6 for horizontal and vertical movement of chamber 1.

The ladle furnace includes a vacuum tight loading gate 14, a heater 35, a heated channel-hole 15 with a stopper 16, a seat ring-base 17, a pipe with valves 18.19 for evacuation and inert gas inlet.

The dispenser-vacuum device 12 includes a seat ring 21 with a tight seal 22, an intermediate chamber 20 with nozzles, a vacuum shutter 50 and a valve 51 for evacuating and filling inert gas, a crucible body 23, a filler neck 25 with a vacuum-tight shutter 26, an inclined bottom 24 of the crucible 23 s slotted flat channel-hole 27 and a hole 28 in the base of the inclined part of the bottom 24, blocked by a stop 29, a pipe with valves 33, 34 for supplying a gas degassing mixture, a high pressure pipe 30 with a vacuum shutter 31 and a valve 32 for evacuation and inert gas inlet, heater 35.

The gate system 13 is made of composite carbon-carbon material 36 (Fig. 8) and includes a flat channel-hole 27 with an inner working layer of titanium carbonitride compounds.

In addition, the carbon-carbon part of the gate system 13 is enclosed (Figs. 7, 8) in a heat-insulated 37 heated by a heater 35 and a water-cooled case 38 having a nozzle with a shutter 39, valve 40 for evacuating and filling the system with inert gas.

The gate system 13 (Fig. 7) includes a joint 8, allowing you to change the angle of the output channel 7 of the gate system 13 using the drive 9.

The gate system 13 (Fig. 8) includes a unit for freezing the liquid metal stream and consists of a metal jacket body 41 and nozzles with valves 42, (Figs. 7, 8) 43 for supplying a gas-liquid medium based on liquid nitrogen and nitrogen gas removal.

At the exit, a flat channel-hole 27 is communicated by side channels through nozzles with valves 44 for supplying a controlled gas medium to the wall layer (wall - liquid melt) to stabilize a flat stream of liquid metal.

The device operates as follows (Fig.7, 8, 21).

The liquid melt of silicon and silicon carbides is poured into the ladle furnace 11, the shutter 14 is closed, the working volume of the ladle furnace 11 is evacuated through the nozzle and the vacuum shutter 18, when the specified vacuum is reached, the heater 35 is turned on and the liquid melt is heated to the specified temperature. When the melt reaches the required temperature, the vacuum shutter 18 is closed, valve 19 is opened and the free volume of the ladle furnace 11 is filled with inert gas.

The ladle furnace 11 is moved and installed with the seat ring-base 17 on the seal 22 of the seat ring 21 of the dispenser-vacuum device.

Open the gates 50, 26 and vacuum dispenser-vacuum 12 to a predetermined vacuum. The gate channel is frozen, for which purpose (Figs. 7, 8), a gas-liquid medium based on liquid nitrogen is supplied to the jacket body 41 through the valve 42 and gaseous nitrogen is removed through the valve 43, having previously evacuated and filled with an inert gas the internal idle volume of the gate system 13. The stopper 16 of the channel-openings 15, the ladle furnace 11 is opened and the crucible23 of the dispenser-vacuum unit 12 is filled with molten liquid.

Close the channel-hole 15 with the stopper 16, open the shutter 31, close the shutter 26, turn on the heater 35, open the leakage valves 33, 34 and through the pipe 30 degass the liquid metal in the dispenser-vacuum 12.

Download the semi-finished product 10 into the chamber 1 (Fig. 7) of centrifugal casting and fix it in the clips 2, attach the chamber 1 to the chamber of the dispenser-vacuum chamber 12, set the movable channel-tray 7 at a predetermined angle to the inner outer surface of the semi-finished product 10 using the drive unit 9 joints 8, seal the docking connector of the chambers 1, 12, turn on the synchronous rotation drives 3, open the vacuum shutters 51, 56 and vacuum the chambers 1, 12 to a predetermined vacuum, close the vacuum shutters 54, 56, open the valves 55, 57 and fill the chambers 1, 12 inert ha zom, include a heater 4 for heating the outer surface of the semi-finished product 10.

Upon completion of the process of degassing liquid metal in the metering unit 12, the shutter 31 is closed, the gating system heaters 35 are turned on, the freezing medium supply valves 42 are closed (Fig. 8), the stabilizing gas mixture supply valve 44 is opened, the valve 32 is opened and above the surface of the liquid melt in the dispenser-vacuum 12 create an inert gas overpressure.

The liquid melt through the heated flat channel-hole 27 of the gating system 13 falls on the inner surface of the semi-finished product 10. Unused residual liquid melt flows into the tank 5.

Upon completion of the process of forming a surface layer based on silicon and silicon carbides, excess pressure is removed in the dispenser-vacuum device 12 and a gas-liquid medium based on liquid nitrogen is supplied to the jacket body 41 (Figs. 7, 8), the supply of a stabilizing gas medium is turned off, the actuators 6 , undock the chamber 1 and unload the semi-finished product 10.

Compared with the known analogues, the proposed composite materials and methods for manufacturing products such as shells, truncated hemispheres, half shells allow to obtain a higher level of specific strength, heat resistance, heat resistance, heat resistance, accuracy of geometric parameters and other indicators, and the proposed device for implementing the claimed methods will require significantly less capital investments and costs.

Claims (21)

1. Composite multilayer carbon-carbon and carbon-metal materials, carbon-carbon or carbon-metal materials, including a carbon-carbon part with an outer outer layer of titanium carbonitride compounds, an intermediate porous carbonized carbon layer and a carbon-metal part with aluminum outer layers lithium alloy, inner layers of magnesium-lithium alloys, hardened with carbon fiber, characterized in that the outer layer of titanium carbonitride compounds is coated with a layer silicon carbonitride compounds, the carbon-carbon part contains the inner layers of titanium and silicon carbonitride compounds, the inner intermediate layers of porous carbonized carbon with surface copper-titanium layers, the carbon-metal part contains the outer aluminum-lithium layers and the inner magnesium-lithium layers reinforced with carbon fiber and intermediate porous layers of carbonized carbon with surface copper-titanium layers. 2. The composite material according to claim 1, characterized in that during operation the carbon-carbon part is cooled by a gas-liquid stream based on an inert gas and the carbon-metal part is cooled or heated by an inert gas through intermediate porous layers of carbonized carbon. 3. The composite multilayer carbon-carbon and carbon-metal material according to claim 1, characterized in that the layers are arranged in the following sequence: an outer carbon-carbon layer with surface layers of titanium and silicon carbonitride compounds, an intermediate porous layer of carbonized carbon with surface copper titanium layers, a carbon-carbon layer with surface layers of carbonitride compounds of titanium and silicon, an intermediate porous layer of carbonized carbon with surface copper ethane layers, a carbon-metal layer with surface aluminum-lithium layers and inner magnesium-lithium layers reinforced with carbon fiber, an intermediate porous layer of carbonized carbon with surface copper-titanium layers, a carbon-metal layer with surface aluminum-lithium layers and inner magnesium- carbon fiber hardened lithium layers, an intermediate porous carbonized carbon layer with surface copper-titanium layers, carbon-metal with th with the surface of aluminum-lithium layers and internal magnesium-lithium layers reinforced with carbon fiber. 4. Composite materials according to claim 1, characterized in that the number of layers and the thickness of the composite material is determined from the conditions of the specified performance characteristics. 5. Composite materials according to claim 1, characterized in that they further include copper-silver-titanium layers. 6. Composite materials according to claim 1, characterized in that they further include silver-titanium layers. 7. Composite carbon-carbon or carbon-metal materials according to claim 1, characterized in that the carbon-carbon part with the outer and inner layers of carbonitride compounds of titanium and silicon, inner intermediate porous layers of carbonized carbon with surface copper-titanium layers cooled by gas-liquid an inert gas flow, as well as a carbon-metal part with outer aluminum-lithium and inner magnesium-lithium layers reinforced with carbon fiber, and between GOVERNMENTAL carbonized porous carbon layers with surface layers of copper and titanium that are cooled or heated inert gas, is used independently in product design. 8. The composite carbon-carbon material according to claim 1, characterized in that the layers are arranged in the following sequence: a carbon-carbon layer with surface layers of carbonitride titanium and silicon compounds, a porous carbonized carbon layer with surface copper-titanium layers, a carbon-carbon layer with surface layers of titanium and silicon carbonitride compounds, an intermediate porous carbonized carbon layer with surface copper-titanium layers, a carbon-carbon layer with surface layers mi carbonitride compounds of titanium and silicon. 9. The composite carbon-metal material according to claim 1, characterized in that the layers are arranged in the following sequence: an aluminum-lithium layer, a magnesium-lithium layer strengthened by a carbon fiber, an aluminum-lithium layer, an intermediate porous layer of carbonized carbon with surface copper titanium layers, aluminum-lithium layer, carbon-fiber reinforced magnesium-lithium layers, aluminum-lithium layer, intermediate porous carbonized carbon layer with surface copper-titanium layers holes, aluminum-lithium layer, magnesium-lithium layers reinforced with carbon fiber, aluminum-lithium layer. 10. The method of forming and manufacturing a multilayer precise blank of a shell or a truncated hemisphere of carbon-carbon composite material according to claim 1 or 8 with outer and inner layers of carbonitride compounds of titanium and silicon, as well as intermediate porous layers of carbonized carbon with surface copper-titanium layers, including assembly, impregnation, pressing, carbonization, graphitization and high temperature nitriding of the outer titanium layer, characterized in that they form an accurate shell blank or truncated hemispheres with outer titanium and inner carbon-carbon layers, high-temperature nitriding form the outer outer layers of titanium carbonitride compounds and plasma spraying in nitrogen medium layers of silicon carbonitride compounds, form an accurate blank of a shell or a truncated hemisphere with a porous layer of carbonized carbon and surface carbon honey titanium layers by carbonization of the polymer binder by vacuum and artificial inert gas leakage, as well as orostnym plasma spraying the surface layers of copper, successively collect accurate multilayered preform or truncated hemispherical shells fill gaps polymeric binder and its carbonized. 11. The method according to claim 10, characterized in that a high-speed plasma stream is formed by feeding the source material after the critical section of the nozzle in the following sequence: silicon carbide powder, silicon powder. 12. A method of forming and manufacturing a multilayer precision blank of a shell or a truncated hemisphere of a carbon-metal composite material with aluminum-magnesium-lithium layers reinforced with carbon fiber, as well as intermediate porous layers of carbonized carbon with surface copper-titanium layers, including assembly, impregnation, pressing, diffusion welding, characterized in that a shell or a truncated hemisphere is formed of aluminum-magnesium-lithium alloys reinforced with carbon fiber window, form a shell or a truncated hemisphere with a porous layer of carbonized carbon and surface copper-titanium layers, sequentially collect a multilayer accurate preparation of shells or truncated hemispheres, fill the gaps with lithium and perform diffusion welding. 13. The method according to p. 12, characterized in that on the outer inner metal surface of the multilayer precision billet shell or truncated hemisphere form bosses, protrusions, fittings and other elements by extruding metal into recesses on the outer working surface of the mandrel or die during diffusion welding layers of metal in a superplastic state. 14. The method of forming and assembling a shell-type housing consisting of multilayer shells, truncated hemispheres of carbon-carbon and carbon-metal composite material, porous carbonized carbon with surface copper-titanium layers, as well as frames of carbon-metal composite material, including welding metal parts, applying a polymer binder to the surface of the welded zone, laying half rings of carbon-carbon composite material, filling polymer gaps m binder, carbonization, graphitization of the binder with the simultaneous formation of the outer layer of titanium carbonitride compounds, characterized in that the formation and assembly of the shell type shell is carried out in the following sequence: plasma spraying on the outer surface of the lithium frame, assembly, welding of adjacent shells, truncated hemispheres along the outer inner layer and welding of frames, plasma spraying on the surface of the welded zone of lithium, laying of half rings of porous carbonized carbon from the surface and copper-titanium layers, diffusion welding of contacting surfaces and welding of external metal gaps, plasma spraying of lithium, laying of half rings of carbon-metal composite material, diffusion welding of contacting surfaces and welding of gaps, plasma spraying of lithium, laying of half rings of porous carbon with surface copper titanium layers, diffusion welding of contacting surfaces and welding of external metal gaps, gas-dynamic spraying of a polymer binder o, laying carbon-carbon semicircles with surface layers of titanium and silicon carbonitride compounds, energizing a polymer binder, forming an internal layer of titanium and silicon carbonitride compounds in a gap by plasma spraying, forming a carbon-carbon layer in a gap by gas-dynamic spraying of a polymer binder, laying a carbon fibers, followed by carbonization and graphitization by plasma heating of the polymer binder, formation in the gap by plasma spraying of nar a thin layer of carbonitride titanium and silicon compounds, gas-dynamic spraying of a polymer binder, laying of porous carbon half rings with surface copper-titanium layers, carbonization of a polymer binder under tension, welding of copper-titanium outer and adjacent layers, gas-dynamic spraying of a polymer binder, laying of carbon-carbon half rings with surface layers of titanium and silicon carbonitride compounds, carbonization under tension of a polymer binder, formation in the gap of a plasma by spraying the inner layer of titanium and silicon carbonitride compounds, forming a carbon-carbon layer in the gap by gas-dynamic spraying of a polymer binder, laying a carbon fiber followed by carbonization and graphitization by plasma heating of a polymer binder, forming an outer layer of titanium and silicon carbonitride compounds in a plasma spraying gap. 15. The method according to 14, characterized in that each subsequent half-rings-layers overlap the butt gaps of the previous half-rings-layers with similar layers of the composite material of adjacent shells or shells with a truncated hemisphere. 16. A method of forming and assembling a half-shell type housing consisting of a truncated hemisphere, a frame, a cylindrical shell and a shell in the form of a nozzle of a multilayer carbon-carbon composite material and outer and inner layers of carbonitride compounds of titanium and silicon, inner layers of porous carbonized carbon with surface copper -titanium layers, including the formation of a shell and a truncated hemisphere of a carbon-carbon composite material with a surface outer layer of carbonitride x titanium compounds, characterized in that they form on a detachable mandrel a carbon-carbon layer with a titanium hermetic coating in the form of a mating cylindrical shell and a shell in the form of a nozzle, followed by high-temperature nitriding of the titanium coating and plasma high-speed deposition of silicon and silicon carbides in a nitrogen medium on the outer surface precision workpieces, and also form the inner surface layer of silicon carbonitride compounds by centrifugal casting of molten silicon and carbides on the inner the surface of the precision workpiece followed by high-temperature nitriding of silicon, then a layer of polymer binder is applied to the external surface of the formed precision workpiece by gas-dynamic spraying, cylindrical, conical shells and half rings of porous carbonized carbon with a surface of copper-titanium coating are put on, the polymer binder is carbonized and the outer and adjacent copper-titanium layers, gas-dynamic spraying is applied to the outer surface of the formed polymer binder, put on cylindrical, conical shells and half rings of carbon-carbon composite material with surface layers of titanium and silicon carbonitride compounds, carry out carbonization of the polymer binder, form layers of titanium, silicon, carbonitride and carbon-carbon layers in the gap by plasma and gas dynamic spraying , by gas-dynamic spraying, a polymer binder is applied to the outer surface of the formed precision blank, cylindrical, clear shells and half rings of porous carbonized carbon with surface copper-titanium layers, carry out carbonization of the polymer binder and welding of the outer and adjacent copper-titanium layers, apply a polymer binder on the outer surface of the formed precision workpiece, put on cylindrical, conical shells and half rings of carbon -carbon composite material with surface layers of carbonitride compounds of titanium and silicon, carry out the carbonization of the polymer bond layers, the layers of titanium and silicon carbonitride compounds and a carbon-carbon layer are formed in the gap by plasma and gas-dynamic spraying, a polymer binder is applied to the outer surface of the frame, a truncated hemisphere, a cylindrical shell and a shell in the form of a nozzle are assembled on the frame, layers of titanium carbonitride compounds , silicon and carbon-carbon layer, a polymer binder is applied to the surface of the welded zone, half rings of porous carbon with outer surface copper-titanium are laid layers, carbonize the polymer binder, weld the outer surface copper-titanium layers, apply a polymer binder to the outer surface of the weld, lay half rings of the carbon-carbon composite material with the surface layers of titanium and silicon carbonitride compounds, carbonize the polymer binder, form layers of carbonitride compounds in the gap titanium, silicon and carbon-carbon layer, a polymer binder is applied, half rings of porous carbon with outer surface are laid copper-titanium layers, carbonize the polymer binder, weld the surface copper-titanium layers, apply the polymer binder, lay the half rings of the carbon-carbon composite material with the surface layers of carbonitride titanium and silicon compounds, carbonize the polymer binder, form layers of titanium and silicon crabitride compounds in the gap and carbon-carbon layer. 17. A device for assembling a shell, half-shell of carbon-metal and carbon-carbon or carbon-carbon and carbon-metal composite materials, including a press, a sealed chamber, a vacuum system, a welding manipulator, a semi-finished product moving mechanism, characterized in that it contains infrared heaters-emitters, high-speed gas-dynamic and plasma sprayers, screw press with a given speed of loading and moving the traverse with a knurled roller, rotation mechanism of the semi-finished product and shells, the mechanism for replacing the rolling roller. 18. The device according to 17, characterized in that the replacement mechanism of the rolling roller comprises a screw crosshead, a drive with a detachable clutch, locking guides of the rolling roller, a process hatch with a sealed cover, hermetic seals of the crosshead shaft. 19. The device according to 17, characterized in that the mechanism of rotation and movement of the semi-finished shell contains rollers with drives of horizontal movement and rotation, hermetic seals of the shafts of the drives. 20. The device according to 17, characterized in that the rollers for rotation and movement of the semi-finished shell have a coating on the working surface, eliminating damage to the surface of the shell. 21. A device for centrifugal casting of molten silicon and silicon carbides, including a ladle furnace, a vacuum shutter, an intermediate chamber with a heater, a dispenser-vacuumator, a sprue channel with a liquid metal freezing system, characterized in that it contains an autonomous movable centrifugal casting chamber, horizontal drives and vertical movement of the chamber, evacuation and inert gas inlet system, prefabricated product heating system, movable joint assembly of the outlet part of the gate channel with the mechanism of changing the angle of inclination.

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