TR2022003994T2 - MANUFACTURE OF MULTI-LAYER CERAMIC STRUCTURES FROM CONTINUOUS FILAMENTS WITH DIFFERENT COMPOSITIONS - Google Patents
MANUFACTURE OF MULTI-LAYER CERAMIC STRUCTURES FROM CONTINUOUS FILAMENTS WITH DIFFERENT COMPOSITIONSInfo
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Abstract
Mevcut buluş, çok katmanlı RF - geçirgen yapılar hazırlamak için farklı bileşime sahip sürekli seramik filamentlerin sarılması yolu ile çoklu seramik katmanların oluşturulduğu bir metottur. Metotta, belirli dielektrik sabitleri ve örgü sayısı / kalınlığı olan katmanlar oluşturmak için farklı sürekli seramik filamentler örülmektedir. Aynı ya da farklı dielektrik özelliklere sahip katmanlar, arzu edilen mekanik, ısıl ve elektriksel isterleri karşılamak üzere bir sandviç yapı tasarımı oluşturmaktadır.The present invention is a method in which multiple ceramic layers are formed by winding continuous ceramic filaments with different compositions to prepare multilayer RF-transparent structures. In the method, different continuous ceramic filaments are woven to form layers with specific dielectric constants and mesh number/thickness. Layers with the same or different dielectric properties form a sandwich structure design to meet the desired mechanical, thermal and electrical requirements.
Description
TARIFNAME FARKLI BILESIME SAHIP SUREKLI FILAMENTLERDEN çOK KATMANLI SERAMIK YAPILARIN IMAL EDILMESI Teknik Alan Mevcut bulus, çok katmanli RF - geçirgen yapilar hazirlamak için farkli bilesime sahip olan sürekli seramik filamentlerin sarilmasi yolu ile çoklu seramik katmanlarin olusturuldugu bir metottur. DESCRIPTION MULTI-LAYERS OF CONTINUOUS FILAMENTS OF DIFFERENT COMPOSITIONS MANUFACTURE OF CERAMIC STRUCTURES Technical Field The present invention uses different compositions to prepare multilayer RF-transparent structures. multiple ceramic layers by winding continuous ceramic filaments It is a method by which .
Arka plan Hipersonik füzelerdeki gelismis radar sistemleri, geleneksel radom teknolojisinde kullanilan malzemeleri ve üretim tekniklerini etkilemektedir. Yüksek sicakliklara, termomekanik yüklere ve agresif çevresel faktörlere dayanirken birden fazla hedefi radar Ile etkili ve hizli bir sekilde tespit etme Ihtiyaci, üst düzey füze radar muhafazalarinin gelistirilmesini gerektirmektedir. Background Advanced radar systems in hypersonic missiles are more common in traditional radome technology. It affects the materials used and production techniques. high temperatures, Multiple targets while withstanding thermomechanical loads and aggressive environmental factors Need to detect effectively and quickly with radar, high-end missile radar requires improvement of their conservation.
Elyaf ile güçlendirilmis seramik matris kompozit (FR-GMC), yukarida yer verilen endiselerin çogunu ele almak Için umut verici bir çözümdür. Bu kompozitler, daha sonra seramik bir süspansiyon ile emprenye edilen elyaf [1, 2] gibi filamentler kullanilarak 2D (dokuma, atkili örme, örgü, çözgülü örme) ya da 3D (3D dokuma, 3D spacer) kumaslar hazirlanarak üretilir. Seramik elyaf, uygulamaya bagli olarak oksit olabilecegi gibi oksit bazli olmayabilir de [3 - 5]. Fiber reinforced ceramic matrix composite (FR-GMC) It is a promising solution to address many of the concerns. These composites were later 2D using filaments such as fiber impregnated with a ceramic suspension [1, 2] (woven, weft knitted, knitted, warp knitted) or 3D (3D woven, 3D spacer) fabrics It is prepared and produced. Ceramic fiber may be oxide or oxide depending on the application. It may not be based [3 - 5].
Füze radomlarini gelistirmek için CMC teknolojisi, son yillarda önemli bir ivme kazanmis durumdadir. US Pat. No. 5,738,750 sayili belge, petegin her iki tarafinda Silika esasli reçine (agirlikça %35) ile emdirilmis Silika elyaftan (agirlikça %65) olusan kuvars kumasi yiginlari ile petek yapinin kaplandigi çok katmanli radom katmanlari gelistirme metodunu açiklamaktadir. Inorganik reçine ya polisilikon ya da polISIlozan olup, pirolizden sonra sirasi ile Silika ya da silisyum nitrüre dönüstürülür. Bununla birlikte, bu katmanlarin birlestirilmesi ile radom seklinin nasil olusturulduguna dair net bir tariften açikça bahsedilmemistir. CMC technology to develop missile radomes has gained significant momentum in recent years. is in a winning position. US Pat. No. Document No. 5,738,750, on both sides of the honeycomb Consisting of silica fiber (65% by weight) impregnated with silica-based resin (35% by weight). multi-layered radome layers covered with a honeycomb structure with stacks of quartz fabric Explains the development method. Inorganic resin is either polysilicon or polyISILOSAN After pyrolysis, it is converted into silica or silicon nitride. With this However, it is clear how the radome shape is formed by combining these layers. A recipe is not explicitly mentioned.
US Pat. No. 7,118,802 sayili belgede 8+ Mach hizinda uçan bir füze radomu için isterler açiklanmaktadir. Onerilen yapi, yük tasiyan bir kolloid emdirilmis FR-CMC tabakasindan ve bir isi yalitim tabakasindan olusmaktadir. Kolloid, agirlikça % 40 - 50 kati madde yüklemesine (alümina ya da Silika) sahip bir seramik süspansiyon iken, yalitim tabakasi, seramik parçaciklar ile dolu % 45 açikliga sahip bir köpüktür. US Pat. No. Document No. 7,118,802 for a missile radome flying at Mach 8+ requirements are explained. The proposed structure is FR-CMC impregnated with a load-bearing colloid. It consists of a layer and a thermal insulation layer. Colloid, 40 - 50% by weight is a ceramic suspension with solids loading (alumina or Silica), The insulation layer is a 45% open foam filled with ceramic particles.
Katmanlar, yüksek sicaklikta kararli bir yapistirici ile yapistirilir. Daha önce bahsedilmis olan patente benzer bir sekilde, bu belgede de radar muhafazanin bu ayri katmanlar kullanilarak nasil sekillendirildigine dair net bir açiklama bulunmamaktadir. The layers are bonded with a high temperature stable adhesive. mentioned before Similar to the previous patent, this document also describes the radar housing as having these separate layers. There is no clear explanation as to how it is shaped using .
Genis bantli HARM anti-radyasyon füzesinin yapisi [7] 'de çizilmistir. Bu modele göre, 3 mm kalinliginda, düsük dielektrik petek yapisi, daha ince, yüksek dielektrik tabakalar arasina sandviçlenmistir. Açik literatürde açiklanan bilgilere benzer bir sekilde, genis bantli radomun nasil Insa edildigine dair hiçbir açiklama yoktur. The structure of the broadband HARM anti-radiation missile is drawn in [7]. According to this model, 3 mm thick, low dielectric honeycomb structure, thinner, high dielectric layers sandwiched between. Similar to the information described in the open literature, extensive There is no explanation of how the band radome is constructed.
Seramik genis bantli füze radomlarin imal edilmesi, malzeme ve üretim teknolojilerinin seçimi konusunda bazi kisitlamalar getirmektedir. Süper/ hipersonik füze radomlarina yönelik malzemeler yillardir iyi bilinmesine ragmen, yüksek Mach sayilarinda uçan genis bantli radomlari gelistirmek için üst düzey teknolojilerin benimsenmesi nispeten yenidir. Sonuç olarak, fonksiyonel derecelendirme ya da genis bant özelligini uygulayan sandviç yapilar ile hazirlanan seramik genis bantli radomlarin imal edilmesi hakkinda sinirli bilgi bulunmaktadir. Manufacturing of ceramic broadband missile radomes, materials and production technologies It imposes some restrictions on selection. Super/hypersonic missile radomes Although materials for flying at high Mach numbers have been well known for years, The adoption of high-end technologies to develop broadband radomes is relatively is new. As a result, implementing functional grading or broadband feature About the manufacturing of ceramic broadband radomes prepared with sandwich structures There is limited information available.
Daha önceki çabalar çogunlukla dar i' tek bantta çalisan büyük, tek katmanli seramik radomlari sekillendirmeye odaklanmaktadir. Kalip sistemi ile birlikte kaliplama (US Pat. ve ardindan kimyasal buharla kaplama (CVD) (US Pat. No. 4,358,772 sayili belge), tekniklerden bazilaridir. Previous efforts have mostly relied on large, single-layer ceramics operating in a narrow single band. focuses on shaping radomes. Molding with molding system (US Pat. and then chemical vapor deposition (CVD) (US Pat. No. 4,358,772), are some of the techniques.
Bu bilgilere ve deneyimlerimize dayanarak, seramik genis bant radomlarin imalatindaki ilerlemeyi engelleyen faktörler, seramik malzemenin kirilgan dogasi ve çok katmanli yapinin ayri ayri seramik katmanlari arasindaki CTE (Isil Genlesme Katsayisi) uyumsuzlugu olup, bunun da pisirme sirasinda mikro çatlaklara ve katman ayrisimina yol açmasidir. Based on this information and our experience, in the manufacture of ceramic broadband radomes Factors hindering progress are the fragile nature of the ceramic material and the multilayer CTE (Coefficient of Thermal Expansion) between individual ceramic layers of the structure incompatibility, which causes microcracks and layer separation during firing. is to lead.
Bulusun Kisa Açiklamasi Mevcut bulus, çok katmanli RF - geçirgen yapilar hazirlamak için farkli bilesimdeki sürekli seramik filamentlerin sarilmasi yolu ile çoklu seramik katmanlarin olusturuldugu bir metottur. Elyaf, sirasi ile örnegin Si02 ve AI203 gibi düsük ve yüksek dielektrik sabitli seramiklerden seçilir. Birden fazla katman önceden belirlenmis bir sandviç tasarima göre yapilandirildiktan sonra, yapi sargi yüzeyinden (örn. mandrel) çikarilir, ayri bir düzenekte reçine ile emdirilir ve pisirilir. Brief Description of the Invention The present invention uses materials of different composition to prepare multilayer RF-transparent structures. Multiple ceramic layers are formed by winding continuous ceramic filaments. It is a method. Fibers have low and high dielectric constants, such as SiO2 and Al2O3, respectively. Selected from ceramics. Multiple layers into a predetermined sandwich design Once configured according to the structure, the structure is removed from the winding surface (e.g. mandrel), placed in a separate It is impregnated with resin and baked in the mechanism.
Bu bulusta ele alindigi gibi seramik genis bantli f'uze radomlarinin seramik elyaf ag yapilar ile imal edilmesi asagidaki ayirt edici özelliklere sahiptir: Dogasi geregi kirilgan seramik malzeme, bükülebilir ve esnek olan sürekli seramik elyaf ile bir mandrel üzerinde sekillendirilir. As discussed in this invention, ceramic broadband missile radomes are made of ceramic fiber mesh. Manufactured with structures has the following distinctive features: The inherently brittle ceramic material is a continuous material that is bendable and flexible. It is shaped on a mandrel with ceramic fiber.
Filamentler, elyaf, elyaf demetleri ve kumaslar arasindan seçilebilir. Filaments can be selected from fibres, fiber bundles and fabrics.
Filamentler (bu noktadan itibaren elyaf olarak adlandirilir) 'örnegin SiOz, AI203, SIC ya da bunlarin karisik bilesimleri gibi bir dizi oksit ya da oksit olmayan Elyaflar saf seramik, organik araç eklenmis ya da PDC (Polimerden Türetilmis Seramik) menseli olabilir ve bunlar, baglayicinin uzaklastirilmasi ve pisirme isleminden sonra saf seramige dönüstürül'ur. Filaments (from this point on called fibres) 'e.g. SiOz, Al2O3, A range of oxides and non-oxides, such as SIC or mixed combinations thereof The fibers can be pure ceramic, organic vehicle added or PDC (Polymer Derived) may originate from ceramics) and these may be caused by binder removal and firing After the process, it is converted into pure ceramic.
Organik ve sentetik yapidaki elyaf (pamuk, Aramid, Kevlar, poliakrilonitril ve benzeri) ayrica, pisirme sirasinda yapida gözeneklilik (düsük dielektrik bölgeler) olusturan kurban katmanlar olarak da kullanilabilir. Organic and synthetic fibers (cotton, Aramid, Kevlar, polyacrylonitrile and etc.), as well as porosity (low dielectric regions) in the structure during firing. It can also be used as sacrificial layers.
Elyaf, Örnegin mandrel gibi bir destek `üzerine x, y ve 2 yönlerinde dolanabilir, sarilabilir ya da örülebilir olup, islemler bu noktadan itibaren `örme olarak adlandirilmistir. The fiber can be wound in x, y and 2 directions on a support such as a mandrel, It can be wrapped or knitted, and from this point onwards the processes are called `knitting'. has been named.
Yapinin her bir katmani, belirli bir dielektrik sabiti sergileyen spesifik bilesime sahip olan sürekli seramik elyafin örülmesi ile olusturulur. Katmanlar, yeterli genis bant RF performansini garanti etmek için belirli tasarimlarda (örnegin A / B 1' C/ D tipi sandviç gibi) örülmüst'ür. Each layer of the structure has a specific composition that exhibits a certain dielectric constant. It is created by knitting continuous ceramic fibers. Layers, enough To ensure broadband RF performance, certain designs (e.g. A/ B 1' is knitted like a C/D type sandwich).
Kalibin 'üzerindeki örgülü tabakalar kaliptan bir sepet olarak çikarilir ve vakum ya da basinç altinda tanimlanmis bilesime sahip bir reçine ile emprenye edilir ve yas (green) durumda bile gerçek boyuta yakin sekilli bir yapi elde edilir. Bu ayni zamanda sinterlenmis gövdeler için tipik isleme sürelerini hizlandiran yas islemeye imkan vermektedir. The mesh layers on the mold are removed from the mold as a basket and vacuum or impregnated with a resin of defined composition under pressure and even in the green state, a structure shaped like the real size is obtained. This age, which also accelerates typical processing times for sintered bodies. It allows processing.
Matrisi olusturan yalnizca bir tür bulamaç (reçine) kullanilir. Bu nedenle de, katmanlar arasinda reçine uyusmazligina yönelik endise bulunmamaktadir. Only one type of slurry (resin) is used to form the matrix. For this reason, There is no concern for resin incompatibility between layers.
Tüm katmanlarda bir reçinenin kullanilmasi, katmanlar boyunca homojen bilesimin tek bir matrisini temsil ettiginden dolayi, CTE uyumsuzluguna bagli kusur riskini ortadan kaldirir. o Reçine bilesimi saf seramik ya da inorganik tabanli olabilir ve bu, oksidasyon ya da piroliz yolu ile sinterleme üzerine seramige dönüstürülür. 0 Yeni yapi, elyaflar arasi alani dolduran inorganik reçine sebebi ile çok daha toktur. Bu kompozit yapi, saf seramik gövdede oldugu gibi ani ve yikici kirilma yerine, yapinin çalisma kosullari altinda kademeli olarak bozulmasina yardimci o Nihai yapi, geleneksel teknikler ile düsük üretkenlige yol açan karmasik ve zaman alan süreçleri önleyen gerçege yakin boyutta sekle sahiptir. Using one resin in all layers ensures homogeneous due to CTE mismatch, since it represents a single matrix of the composition eliminates the risk of defects. o The resin composition may be pure ceramic or inorganic based and this may be subjected to oxidation or It is converted into ceramic upon sintering via pyrolysis. 0 The new structure is much more durable due to the inorganic resin filling the interfiber space. is full. This composite structure prevents sudden and destructive breakage, as in the pure ceramic body. instead, it helps the structure gradually deteriorate under operating conditions. o The final structure is complex and complex with traditional techniques leading to low productivity. It has a life-like shape that prevents time-consuming processes.
Sekillerin Kisa Açiklamasi Sekil 1, dielektrik sabitinin Erin > ati oldugu farkli elyaflari kullanan sandviç yapilari göstermektedir. Brief Description of Figures Figure 1, sandwich structures using different fibers where the dielectric constant Erin > ati shows.
Sekil 2, dielektrik sabitinin Erin > EU oldugu farkli kumaslari kullanan sandviç yapilari göstermektedir. Figure 2, sandwich structures using different fabrics where the dielectric constant is Erin > EU shows.
Detayli Açiklama Elyaf ile güçlendirilmis seramik matris kompozitler (FR-GMC), yigin seramiklere kiyasla gelistirilmis tokluk ve hasar toleransina sahip gelismis ve istege göre uyarlanabilir malzemelerdir [6]. Genel olarak, takviye edici elyaf inorganik ve organik elyaf olarak siniflandirilabilir [4]. Organik elyaf çogunlukla karbon ve polimer elyaf iken, inorganik elyaf ayrica metalik olmayan ve metalik elyaf olarak ayrilabilir. Seramik elyaflar, cam / mineral ve tek kristal elyaflar ile birlikte metalik olmayan inorganik elyaf ailesine aittir CMC uygulamasi için elyaf malzeme seçimi büyük önem tasimaktadir. Yüksek Mach sayili uçuslar sirasinda radom malzemesi üzerindeki sicakliklarin 1.000 ”C'ye kadar çiktigi ve bunun da elyaf malzeme seçimini sinirladigi bilinmektedir. Polimer ve cam elyaflar sirasi ile 500 T) ve 700 cC bozulma sicakl iklarina sahip olup, bu da onlarin daha yüksek sicakliklarda CMC'lerde etkin kullanimlarini sinirlamaktadir [6]. Bu nedenle de, seramik elyaflar, yüksek sicakliklara ve yüksek hizlarda mekanik / termomekanik yüklere maruz kalan havada tasinan bilesenler için yüksek performansli CMC'leri desteklemek için dogru seçim olarak ortaya çikmaktadir. Detailed Description Fiber-reinforced ceramic matrix composites (FR-GMC) are more durable compared to bulk ceramics. Advanced and customizable with improved toughness and damage tolerance materials [6]. In general, reinforcing fibers are divided into inorganic and organic fibers. can be classified [4]. While organic fiber is mostly carbon and polymer fiber, inorganic fiber can also be divided into non-metallic and metallic fiber. Ceramic fibers, glass / belongs to the family of non-metallic inorganic fibers along with mineral and single crystal fibers Fiber material selection is of great importance for CMC application. High Mach Temperatures on the radome material can reach up to 1,000°C during scheduled flights. It is known that it grows and this limits the choice of fiber materials. polymer and glass fibers have distortion temperatures of 500 T) and 700 cC, respectively, which makes them limiting their effective use in CMCs at higher temperatures [6]. This For this reason, ceramic fibers can withstand high temperatures and high speeds mechanically/ High performance for airborne components subjected to thermomechanical loads It emerges as the right choice to support CMCs.
Seramik elyaf, oksit ya da oksit olmayan seramikler olarak siniflandirilir. Ilk grupta yer alanlar, yüksek çevresel stabilite sergileyen ancak sinirli yüksek sicaklik sünme performansi sergileyen alümina (AI203) esasli elyaflardir. Bu tür elyafin alümina bilesimi, % 10 ila % 100'e kadar bir aralik içinde seçilebilir. Oksit olmayan seramik elyaflar çogunlukla SiC'dir ve zayif kimyasal stabilite ile birlesen mükemmel isil sünme davranisina sahiptir. Bu elyafin SiC kismi, çalisma isterlerine bagli olarak % 10 ila % 100 araliginda degisebilir. Her iki elyaf sinifi için, kristaline, morfoloji, malzeme boyunca homojenite ve yüzey özellikleri, sahadaki CMC performansini etkileyen önemli özelliklerdir. Elyaf kaplama, elyaf ile matris arasinda zayif bir arayüz saglamak sureti ile yapinin hasar toleransini belirleyen bir diger kritik faktördür [4, 6]. Ceramic fibers are classified as oxide or non-oxide ceramics. Place in the first group areas that exhibit high environmental stability but limited high temperature creep They are alumina (Al203) based fibers that exhibit high performance. This type of fiber has alumina The composition can be selected within a range from 10% to 100%. Non-oxide ceramic fibers are mostly SiC and have excellent thermal creep combined with poor chemical stability. It has the behavior. The SiC portion of this fiber is 10 to 10% depending on operating requirements. It may vary within the range of 100. For both fiber classes, crystalline, morphology, material Homogeneity and surface properties throughout the field are important factors affecting CMC performance in the field. are features. Fiber coating provides a weak interface between the fiber and the matrix. It is another critical factor that determines the damage tolerance of the structure [4, 6].
Iki fiber türü arasindaki seçim, büyük ölçüde matrisin tipine ya da elyaf ag yapiyi dolduran inorganik reçineye baglidir. Oksit elyaf ideal olarak oksit matris ile (oksit kompozit) ve oksit olmayan ise oksit olmayan matris ile (oksit olmayan kompozit) kullanilmalidir. Bununla birlikte, ayrica ara karisimlar da, daha yeni uygulamalara yol açacak sekilde, farkli isleme teknikleri vasitasi ile hazirlanir. The choice between the two fiber types depends largely on the type of matrix or fiber network structure. It depends on the inorganic resin filling it. Oxide fiber is ideally combined with an oxide matrix (oxide composite) and if non-oxide, with non-oxide matrix (non-oxide composite) should be used. However, intermediate mixtures also lead to newer applications. It is prepared through different processing techniques in a way that it will open.
Oksit kompozitlere gelince, düsük konsantrasyonlarda SIOz ve B203 ile harmanlanmis saf AI203 ya da AI203 ile hazirlanan elyaf, CMC'nin oksidasyonunu ve alkalin direncini önemli ölçüde artirmaktadir [3, 4]. Oksit olmayan kompozitler için, C ya da BN ile kaplanmis SiC elyafi, SiC matris kompozitin yüksek sicaklik deformasyonuna dayanmasina olanak tanir [4]. AI203 ve SiC seramiklerinin elyaf ve yigin formlari arasindaki karsilastirma Tablo 1'de sunulmustur. Elyafin dökmeye göre önemli ölçüde üstün gerilme mukavemeti, zorlu çevresel kosullar altinda bu elyafin dikkate alinmasi için belirtmeye deger niteliktedir. As for oxide composites, blended with low concentrations of SIO2 and B203 Fiber prepared with pure Al203 or Al203 prevents the oxidation and alkaline resistance of CMC. increases significantly [3, 4]. For non-oxide composites, with C or BN coated SiC fiber resists high temperature deformation of SiC matrix composite. allows it to endure [4]. Fiber and bulk forms of AI203 and SiC ceramics The comparison between them is presented in Table 1. Significantly lower fiber content compared to bulk superior tensile strength makes this fiber a consideration under harsh environmental conditions It is worth mentioning for.
Tablo 1: Seramik elyaf ile yigin seramik özelliklerinin karsilastirilmasi Malzeme Birim AI203 SiC Mukavemeti Katsayisi Sicakligi a: Nextel 610, b: Kyocera A601D (> 99 %) c: Nippon Carbon Hi-Nicalon “8” (99,8 %), d: Kyocera SC211 *: Tek filament S %1 gerinim / 69 MPal 1.000 saat **z Tek filament 500 MPa/1.000 saat +: tahmini Ozetlemek gerekirse, seramik elyaf, yigin seramiklerin hasar toleransini gelistirirken tokluk saglamaktadir. Ornegin ergitilmis silika, Magnezyum Alüminyum Silikat, Lityum Alüminyum Silikat, Si3N4, SiAION, AI203 gibi malzemelerden yigin seramik olarak üretilen süper f hipersonik füze radomlar, kirilgan yapilari nedeni ile ekstrem kosullar altinda yikimsal is görmezlik ile sonuçlanma riskini tasimaktadir. Bu seramiklerin üretiminde kullanilan örnegin çamur döküm, cam eriyik döküm, sicak kaliplama gibi teknikler, sekillendirme, kurutma, pisirme ve isleme adimlarinda seramigin kirilmasi nedeni ile düsük verime sahiptir. Table 1: Comparison of ceramic fiber and bulk ceramic properties Material Unit AI203 SiC Strength Coefficient temperature a: Nextel 610, b: Kyocera A601D (> 99 %) c: Nippon Carbon Hi-Nicalon “8” (99.8%), d: Kyocera SC211 *: Monofilament S 1% strain / 69 MPal 1,000 hours **z Single filament 500 MPa/1,000 hours +: estimated To summarize, ceramic fiber improves the damage tolerance of bulk ceramics It provides satiety. For example, fused silica, Magnesium Aluminum Silicate, Lithium As bulk ceramics from materials such as Aluminum Silicate, Si3N4, SiAION, AI203 The produced super f hypersonic missile radomes are suitable for extreme conditions due to their fragile structure. It carries the risk of resulting in catastrophic disability. These ceramics used in production such as mud casting, glass melt casting, hot molding breaking of ceramics during the techniques, shaping, drying, firing and processing steps Because of this, it has low efficiency.
Bu patentin odak noktasi, seramik elyaf takviyeli CMC'Ierin hazirlanma metodudur. Bu metot izlenmek sureti ile, seramik elyaflar ve bu elyaflar ile uyumlu olan inorganik reçineler, örnegin ses alti, süpersonik ve hipersonik hizlarda uçan askeri ve sivil uygulamalar için radomlar, mikrodalga geçirgen koruyucular, kapaklar ve burunlar gibi havadan tasinan yapilarin hazirlanmasi için kullanilabilir. Istenilen frekanslarda malzeme uyumlulugu ve RF-geçirgenligi saglandigi sürece mevcut elyaf ve reçinelerin kombine edilmesi bakimindan herhangi bir kisitlama bulunmamaktadir. Buna ilave olarak, metot hem genis, hem de dar ve tek bantli radomlar olusturmak için uygulanabilir niteliktedir. Elyafin tipi ve çapi, örgü tipi, elyaf açikligi ve tabaka basina kalinligi, bulamaç malzeme bilesimi, arzu edilen elektromanyetik performansa göre tasarlanmistir. Buna ilave olarak, eger seramik elyaf ardisik katmanlar halinde 15° - 1350 arasinda bir açisal dogrultuda sarilacak olursa yapisal bütünlükte önemli ölçüde iyilesme elde edilebilir. The focus of this patent is the method of preparation of ceramic fiber reinforced CMCs. This ceramic fibers and inorganic materials compatible with these fibers, by following the method resins, such as military and civilian aircraft flying at subsonic, supersonic and hypersonic speeds such as radomes, microwave-permeable shields, covers and noses for applications It can be used for the preparation of airborne structures. at desired frequencies existing fibers and resins as long as material compatibility and RF-permeability are ensured. There are no restrictions regarding combination. In addition to this Generally, the method can be used to create both wide, narrow and single-band radomes. is applicable. Fiber type and diameter, weave type, fiber gauge and per layer thickness, slurry material composition, and the desired electromagnetic performance. is designed. In addition, if the ceramic fiber is deposited in successive layers at 15° - If it is wrapped in an angular direction between 1350 and 1350, the structural integrity will be significantly reduced. recovery can be achieved.
Bu bulusta, sürekli seramik elyaflar, genis bant radomun çoklu katmanlarini olusturmak için kullanilmaktadir. Her bir katmanin dielektrik sabiti, elyaf malzeme, onun kalinligi ve bulamaç malzeme ile tanimlanir. Radomun genis bant özelligi, düsük ve yüksek dielektrik sabitinde degisen bu tür ayri ayri katmanlari degistirerek optimize edilebilir. In this invention, continuous ceramic fibers are used to form multiple layers of broadband radome. It is used for. The dielectric constant of each layer depends on the fiber material, its thickness and The slurry is defined by the material. Radome's broadband feature, low and high can be optimized by varying such individual layers varying in dielectric constant.
Katman olusturma kavrami ve islemi Sekil 1'de gösterilmekte ve asagidaki sekilde açiklanmaktadir: 0 A tipi sandviç için: 1inci (en içteki) ve 3üncü (en distaki) katmanlar, daha düsük sargi sayisina (Ef_h) sahip daha yüksek dielektrik sabitli seramik elyaflar ile meydana getirilebilirken, ortadaki elyaf daha yüksek sarma sayisina (EU) sahip düsük dielektrik sabitli malzemeden yapilmistir. 0 B tipi sandviç için: linci (en içteki) ve 3üncü (en distaki) katmanlar, daha yüksek sargi sayisina (EU) sahip daha düsük dielektrik sabitli seramik elyaflar ile meydana getirilebilirken, ortadaki elyaf daha düsük sarma sayisina (Ef_h) sahip yüksek dielektrik sabitli malzemeden yapilmistir. 0 C tipi sandviç için: 1inci, 3'ünc'u ve 5inci katmanlar, daha düsük sarma sayisina (erin) sahip olan daha yüksek dielektrik sabitli seramik elyaflar ile meydana getirilebilirken, 2nci ve 4üncü elyaflar daha yüksek sarma sayisina (EU) sahip olan düsük dielektrik sabitli malzemeden yapilmistir. 0 D-sandviç için: 1inci, Süncü ve 5inci katmanlar, daha yüksek sarma sayisina (asçi) sahip olan daha düsük dielektrik sabitli seramik elyaflar ile meydana getirilebilirken, 2nci ve 4üncü elyaflar daha düsük sarma sayisina (Ef_h) sahip olan yüksek dielektrik sabitli malzemeden yapilmistir. The concept and process of creating layers is shown in Figure 1 and is described below. It is explained: 0 For type A sandwich: 1st (innermost) and 3rd (outermost) layers, lower with ceramic fibers with higher dielectric constant and higher number of turns (Ef_h) while the fiber in the middle has a higher winding count (EU). It is made of low dielectric constant material. 0 For type B sandwich: 1st (innermost) and 3rd (outermost) layers, higher with ceramic fibers with lower dielectric constant and number of turns (EU) while the fiber in the middle has a lower winding number (Ef_h). It is made of material with high dielectric constant. 0 For type C sandwich: 1st, 3rd and 5th layers with lower number of wraps It is formed by ceramic fibers with higher dielectric constant (erin). while the 2nd and 4th fibers have a higher winding count (EU). It is made of material with low dielectric constant. 0 For D-sandwich: 1st, 3rd and 5th layers require higher number of wraps (cook) It is formed by ceramic fibers with lower dielectric constant. while the 2nd and 4th fibers have a lower winding number (Ef_h). It is made of material with high dielectric constant.
Alternatif olarak, elyafa bir alternatif olarak sandviç seramik yapilari olusturmak için seramik kumaslar da ayrica kullanilabilir. Kumaslar elyaftan daha genistir ve bu nedenle de imalat sürecini hizlandirirlar. Kumaslarin elyafin yerini almasi durumunda, katmanlar Sekil 2'de gösterildigi gibi farkli tasarim alternatifleri kapsaminda yapilabilirler. Alternatively, to create sandwich ceramic structures as an alternative to fibres. Ceramic fabrics can also be used. Fabrics are wider than fiber and this Therefore, they speed up the manufacturing process. If fabrics replace fiber, layers within the scope of different design alternatives as shown in Figure 2. They can be done.
Sürekli elyaf mandrel üzerine sarildiktan ve arzu edilen genis bant performansini karsilayan yapiya ait tüm katmanlar istiflendikten sonra, yapi mandrelden çikarilir. Bu, temel olarak, belirli bir tasarima göre örülmüs yogun bir elyaf ag yapi ile olusturulan, süzdürmeye hazir bir sepettir. Bulamaç süzdürme, bulamacin elyaflar arasi bosluklari doldurdugu bir islemdir. Bu islem en iyi sekilde, elyaf sepetin, bulamaç ile dolu özel bir hazne içine yerlestirildigi durumda vakum altinda gerçeklestirilebilir. Bir yapilanmada, üzerine örülme islemi yapilmadan önce bir destek yüzeyi (örnegin mandrel), islemin sonunda örülmüs yapinin rahatça çikarilmasini kolaylastirmak için yapismayan bir kimyasal ile kaplanir. After the continuous fiber is wound on the mandrel and achieves the desired broadband performance After all layers of the corresponding structure are stacked, the structure is removed from the mandrel. This, Basically, it is created with a dense fiber mesh structure knitted according to a specific design, It is a basket ready to drain. Slurry leaching, the interfiber spaces of the slurry It is a process that is filled out. This process is best done in a special container where the fiber basket is filled with slurry. It can be performed under vacuum when placed in the chamber. In a structure, Before the knitting process is carried out, a support surface (e.g. mandrel) At the end, there is a non-stick coating to facilitate easy removal of the knitted structure. coated with chemicals.
Ikinci bir alternatif olarak sepet, bulamaç ile beslenen, yapismaz yüzeye sahip paslanmaz çelikten mamul disi ve erkek kaliplarin arasina yerlestirilebilir ve bu kaliplar tarafindan desteklenebilir. Her iki metotta da vakum, bulamaci optimize edilmis reoloji ile elyaflar arasindaki açik alanin içine hareket ettiren kapali hazne ya da kaliplarda uygulanir. As a second alternative, the basket is fed with slurry and has a non-stick surface. It can be placed between male and female molds made of stainless steel and these molds Can be supported by. In both methods, vacuum, slurry optimized rheology in closed chambers or molds that move the fibers into the open space between the fibers. is applied.
Farkli bir metotta sepet, akiskanligi az olan yogun bulamaç ile dolu bir kap içine daldirilabilir. Yapi daha sonra karsi taraftan bulamaç olmaksizin (iç taraf) vakuma maruz birakilir, bu da bulamaci elyaflar arasindaki açikliklarin içine çeker. In a different method, the basket is placed in a container filled with dense slurry with low fluidity. submersible. The structure is then vacuumed without slurry from the opposite side (inner side). is exposed, which draws the slurry into the gaps between the fibres.
Bu metotlarin tamaminda, elyaf yapinin bütünlügü dikkatli bir sekilde izlenmeli ve vakumun neden oldugu olasi bir deformasyona karsi korunmalidir. Daha fazla islem kabilinden, elyaflar matris tarafindan tanimlanan konturu takip ettiginden, yapi üzerinde hiçbir zararli etki olmaksizin, pisirilen yapilarin islenmesi de ayrica düsünülebilir ve uygulanabilir. In all of these methods, the integrity of the fiber structure must be carefully monitored and It must be protected against possible deformation caused by vacuum. More transactions on the structure, as the fibers follow the contour defined by the matrix. Processing of fired structures without any detrimental effects can also be considered and applicable.
Bulamaç emdirilmis elyaf ag yapisi dikkatli bir sekilde kurutulur ve baglayici uzaklastirilir. Tüm isil islem, yapi üzerinde örnegin çatlak baslatma ve yayilma, kirilma, sarkma, siskinlik, çökme gibi geri dönüsü olmayan etkiler yaratma potansiyeline sahip oldugundan dolayi, baglayicinin uzaklastirilmasi ve sinterleme profilleri dikkatlice optimize edilmelidir. Bu nedenle de, ham maddelerin islemden önce bilesimleri ve reolojik ve termo-mekanik davranislari açisindan dikkatli bir sekilde karakterize edilmelidir. The slurry impregnated fiber web is carefully dried and the binder is removed. All heat treatment results in crack initiation and propagation, fracture, It has the potential to cause irreversible effects such as sagging, swelling and collapse. Therefore, binder removal and sintering profiles should be carefully should be optimized. For this reason, the composition and composition of raw materials before processing carefully characterized in terms of their rheological and thermo-mechanical behavior. should be done.
Açiklanan bulus, sürekli oksit / oksit olmayan elyaflar ve bu elyaflar ile uyumlu bulamaçlar için uygulanabilir. Baska bir deyis ile, malzemelerin uyumlulugunu ve nihai yapinin performansini garanti etmek için elyaf - bulamaç çifti birlikte tanimlanmalidir. The disclosed invention provides continuous oxide/non-oxide fibers and is compatible with these fibers. Applicable to slurries. In other words, the compatibility of the materials and the final The fiber – slurry pair must be defined together to guarantee the performance of the structure.
Elyaflar, matrisin sicaklik stabilite araligi, düsük CTE, düsük dielektrik sabiti ve kaybi ve yüksek isil - stabilite ve mekanik mukavemet ile karsilastirilabilir bir sinterleme sicakligina sahip olmalidir. Bundan baska olarak, bu özelliklerin korunmasi i' sicaklik dalgalanmalari ile hafifçe sapmasi beklenir. Bu isterlerin çogu, onlarca yildir ticari füze radomlarinda kullanilan ergimis silika sisteminde optimize edilebilir. Bu nedenle de, polisilikon, polisilozan, polikarbosilan içeren PDC esasli bulamaçlar, seçilen elyaflar ile kullanilmak üzere aday bulamaçlardir. Alternatif olarak, ayrica, çesitli bilesimlerde alümina gibi malzemeler içeren bulamaçlar, yukarida bahsedilen elyaf - bulamaç özellikleri eslestigi sürece kullanilabilir. The fibers are characterized by the temperature stability range of the matrix, low CTE, low dielectric constant and loss and Comparable sintering with high thermal stability and mechanical strength It must have temperature. Furthermore, the preservation of these properties requires temperature It is expected to deviate slightly with fluctuations. Many of these requirements have been in commercial missile development for decades. It can be optimized in the fused silica system used in radomes. For this reason, PDC based slurries containing polysilicon, polysiloxane, polycarbosilane, with selected fibers are candidate slurries to be used. Alternatively, also in various compositions slurries containing materials such as alumina, the above-mentioned fiber - slurry It can be used as long as its features match.
Ornegin ergimis silika, Magnezyum Alüminyum Silikat, Lityum Alüminyum Silikat, Si3N4, SiAION, Al203 gibi mevcut radom malzemeleri için elyaf seçimi sinirlidir. Tüm ticari ürünler arasinda, AI203 ve SiC, sirasi ile oksit ve oksit olmayan elyaflar için ticari olarak temin edilebilir adaylardir. Bunlarin ilki, çesitli uygulamalardaki isterleri karsilamak için farkli bilesimler halinde üretilirken, ikincisi yüksek sicakliklarda yari iletken olmasina dair bildirilen karakterinden dolayi bir radar muhafaza malzemesi olmak için tam olarak uygun degildir.For example, fused silica, Magnesium Aluminum Silicate, Lithium Aluminum Silicate, Si3N4, Fiber selection for existing radome materials such as SiAION, Al2O3 is limited. All commercial Among the products, Al2O3 and SiC are commercially available for oxide and non-oxide fibers, respectively. are available candidates. The first of these is to meet the requirements in various applications. While they are produced in different compositions, the latter is semiconductor at high temperatures. It is fully suitable as a radar housing material due to its reported character of not suitable.
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