WO2020038313A1 - 一种金属基碳纤维复合材料及陶瓷的制备方法 - Google Patents
一种金属基碳纤维复合材料及陶瓷的制备方法 Download PDFInfo
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- the invention relates to the field of composite material preparation, in particular to a metal-based carbon fiber composite material and a method for preparing ceramics.
- Metal-based carbon fiber composites have broad application prospects in the fields of aerospace, biomaterials and civil industry due to their excellent properties such as high specific strength, high specific modulus and good toughness. Compared with metal materials, it has a high specific modulus. Amount and specific strength; Compared with ceramics, it has high toughness and impact resistance.
- metal carbonization, carburization, and electrochemical corrosion occur when carbon fibers and metals are compounded.
- ceramic materials are a class of inorganic non-metallic materials made from natural or synthetic compounds through shaping and high-temperature sintering. It has the advantages of high melting point, high hardness, high wear resistance, and oxidation resistance. It can be used as a structural material and a tool material. Since ceramics also have some special properties, it can also be used as a functional material. Ceramic material is the material with the best stiffness and the highest hardness among engineering materials, and its hardness is mostly above 1500HV. Ceramics have higher compressive strength, but lower tensile strength, poor plasticity and toughness.
- Ceramic materials generally have a high melting point (mostly above 2000 ° C) and have excellent chemical stability at high temperatures; the thermal conductivity of ceramics is lower than that of metal materials, and ceramics are also good thermal insulation materials. At the same time, the linear expansion coefficient of ceramics is lower than that of metals. When temperature changes, ceramics have good dimensional stability. Ceramic materials are not easily oxidized at high temperatures, and have good corrosion resistance to acids, alkalis, and salts. In order to improve the abrasion resistance of the metal, a ceramic coating is applied on the metal substrate. However, due to the large physical and chemical properties of ceramic and metal, it is difficult to directly connect them, mainly because the thermal expansion coefficients of the two differ greatly. The joint is prone to generate large residual thermal stress.
- the present invention provides a method for preparing a metal-based carbon fiber composite material and a ceramic, so as to improve the bonding strength of the carbon fiber and the metal matrix, and improve the hardness, compressive strength and heat resistance of the ceramic.
- a first aspect of the present invention provides a method for preparing a metal-based carbon fiber composite material, including the following steps:
- the shaped carbon fiber is heated to the melting point of the metal, and after the metal is melted and mixed, it is cooled to room temperature and discharged, and the metal-based carbon fiber composite material is prepared.
- the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material.
- the step of placing carbon fibers in an electrolyte for electroplating is to place carbon fibers in an electroplating bath containing a nickel-containing electrolyte, wherein, in the nickel-containing electrolyte, the mass percentage of nickel Above 25%, the diameter of the carbon fiber is 0.1-0.3mm.
- the step of shaping the electroplated carbon fiber includes:
- Non-electroplated metal fiber is used to reinforce the shaped carbon fiber.
- the electroplated carbon fiber is shaped by using a tool made of ceramic.
- the ceramic is one or more combinations of alumina, zirconium carbide, and boron nitride.
- the step of heating the shaped carbon fiber to the melting point of the metal and cooling the metal to room temperature after the metal is melted and mixed includes: after the metal is heated and melted, the surface of the electroplated carbon fiber and the non-electroplated carbon fiber have metal and metal After sticking together, after cooling to room temperature, the metal solidifies.
- a second aspect of the present invention provides a method for preparing a ceramic using a metal-based carbon fiber composite material, including the following steps:
- Ceramics are sintered on the surface of the metal-based carbon fiber composite material subjected to anodization.
- the ceramic is yttria-stabilized zirconia.
- the step of sintering ceramics on the surface of the metal-based carbon fiber composite material subjected to anodization includes: spraying yttria-stabilized zirconia powder on the surface of the metal-based carbon fiber composite material and performing hot isostatic Pressure sintering.
- the step of hot isostatic sintering includes: increasing the temperature from room temperature 25 ° C to 1400-1800 ° C at a speed of 1-5 ° C / min at 1-3Mpa; Pressure, heat preservation time is 0.5-3 hours, heat preservation pressure is 3-6Mpa; after heat preservation and pressure preservation, under the pressure of 1-3Mpa, the temperature is reduced to room temperature 25 ° C at a speed of 3-7 ° C / min.
- the present invention provides a method for preparing a metal-based carbon fiber composite material and a ceramic.
- the method for preparing the metal-based carbon fiber composite material includes: electroplating carbon fibers into an electrolyte; sculpting the electroplated carbon fibers, A carbon fiber having a predetermined shape is obtained; the shaped carbon fiber is heated to a melting point of the metal, and is cooled to room temperature after the metal is melted and mixed, and then discharged to obtain the metal-based carbon fiber composite material.
- the method for preparing the ceramic includes anodizing the surface of the metal-based carbon fiber composite material; sintering the ceramic on the surface of the metal-based carbon fiber composite material after the anodization.
- the preparation method of metal-based carbon fiber composite material realizes the effective combination of metal nickel and carbon fiber.
- the metal-based carbon fiber composite material prepared by the method of the present invention effectively fuses carbon fiber and metal substrate, forms an organic whole, and improves carbon fiber. Bonding strength with metal substrate;
- the method for preparing ceramics using the metal-based carbon fiber composite material realizes the connection between the metal material and the ceramic.
- the metal-based carbon fiber composite material has extremely high hardness and compressive strength, good heat resistance, and high temperature resistance. It can keep the shape and size unchanged, and can resist the erosion of high temperature jet.
- FIG. 1 is a flowchart of a method for preparing a metal-based carbon fiber composite material according to the present invention
- FIG. 2 is a flowchart of a method for preparing a metal-based carbon fiber composite ceramic according to the present invention
- FIG. 3 is a flow chart of a method for preparing a Tesla turbine disk by using the metal-based carbon fiber composite ceramic preparation method of the present invention
- FIG. 4 is a schematic structural diagram of a Tesla turbine disk prepared by using the metal-based carbon fiber composite ceramic preparation method of the present invention.
- a method 100 for preparing a metal-based carbon fiber composite material, as shown in FIG. 1, includes the following steps:
- Step 110 The carbon fiber is electroplated in an electrolyte
- Step 120 Shape the carbon fibers after plating to obtain carbon fibers of a predetermined shape
- Step 130 The shaped carbon fiber is heated to the melting point of the metal, and after the metal is melted and mixed, it is cooled to room temperature and discharged, and the metal-based carbon fiber composite material is obtained.
- the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material.
- the step 110 includes electroplating the carbon fibers in a plating bath containing a nickel-containing electrolyte, wherein, in the nickel-containing electrolyte, the mass percentage of nickel is greater than 25%, and the diameter of the carbon fibers is 0.1-0.3 mm. , Preferably 0.2 mm.
- the step 120 includes:
- Shape the carbon fiber after plating use the tooling to shape the carbon fiber after plating, the meaning of the shape is to shape the carbon fiber into a predetermined shape.
- the tooling material needs to be resistant to high temperatures, difficult to deform, and difficult to react with metals, and is preferably made of ceramics, which is one or more combinations of alumina, zirconium carbide, and boron nitride.
- the method further comprises the step of using a non-plated metal carbon fiber to reinforce the shaped carbon fiber.
- the step 130 includes: after the metal is melted (when the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material, the heating temperature is greater than 1000 ° C), all carbon fiber surfaces have metal and the metal is stuck together, and cooled to After room temperature, the metal solidified.
- the metal-based carbon fiber composite material prepared by the above method realizes the effective combination of metal nickel and carbon fiber, effectively fuses the carbon fiber and the metal substrate, forms an organic whole, and improves the bonding strength of the carbon fiber and the metal matrix.
- a second aspect of the present invention provides a method 200 for preparing ceramics using a metal-based carbon fiber composite material. As shown in FIG. 2, the method includes the following steps:
- Step 210 The carbon fiber is electroplated in an electrolyte
- Step 220 Shape the electroplated carbon fibers to obtain carbon fibers of a predetermined shape
- Step 230 heating the shaped carbon fiber to the melting point of the metal, cooling to room temperature after the metal is melted and mixed, and discharging, to obtain the metal-based carbon fiber composite material;
- Step 240 Anodize the surface of the metal-based carbon fiber composite material.
- the effect of the anodization can make the interface between the metal (nickel) and the high-temperature ceramics better, and form a transition surface.
- An oxide layer is formed on the surface;
- Step 250 Sinter a high-temperature-resistant ceramic on the surface of the metal-based carbon fiber composite material subjected to anodization to obtain the ceramic.
- the metal-based carbon fiber composite material is a nickel-based carbon fiber composite material
- the ceramic is yttria-stabilized zirconia YSZ.
- the steps 210-230 are the same as the method for preparing the aforementioned metal-based carbon fiber composite material.
- the step 250 includes: spraying yttria-stabilized zirconia powder on the surface of the metal-based carbon fiber composite material, and then performing hot isostatic sintering.
- the specific process is: increasing the temperature from room temperature 25 ° C at a speed of 1-5 ° C / min (preferably 3 ° C / min) to 1400-1800 ° C (preferably 1600 ° C) at 1-3Mpa;
- the holding time is 0.5-3 hours (preferably 1 hour) and the holding pressure is 3-6Mpa.
- the temperature is reduced at a speed of 3-7 ° C / minute (preferably 5 ° C / minute) under the pressure of 1-3Mpa.
- heating or cooling rate If the heating or cooling rate is too fast, it will cause the components to shrink and phase change unevenly, resulting in a large amount of internal stress, which will cause the ceramic to crack; if the insulation pressure and time are not enough, it will also cause the components to shrink and phase change unevenly, resulting A large amount of internal stress causes the ceramic to crack.
- the method for preparing ceramics by using the metal-based carbon fiber composite material realizes the connection between the metal material and the ceramic.
- the metal-based carbon fiber composite material has extremely high hardness and compressive strength, good heat resistance, and can be used at high temperatures. Keeping the shape and size unchanged, it can resist the erosion of high-temperature jets.
- a third aspect of the present invention provides a method 300 for manufacturing a Tesla turbine disk.
- the Tesla turbine disk is provided with positioning holes 410 and exhaust holes 420.
- the rotating shaft passes through the positioning holes 410 of the same structure of the Tesla turbine disk 400 and has the same features as the several structures.
- the Sierra turbine disk 400 is fixedly connected.
- the exhaust hole 420 is disposed near the positioning block 410. Further preferably, there are several, preferably three, exhaust holes 420, which are all distributed on the surface of the Tesla turbine disk 400.
- the method 300 for manufacturing a Tesla turbine disk includes the following steps:
- Step 310 Place the carbon fibers in a nickel-containing electrolyte for electroplating
- Step 320 Wound the electroplated carbon fiber on a mandrel to form a disc-shaped carbon fiber; the mandrel needs to be resistant to high temperatures, difficult to deform, and difficult to react with metals, and is preferably made of ceramics to make the mandrel.
- the ceramic is one or more combinations of alumina, zirconium carbide and boron nitride;
- Step 330 The disc-shaped carbon fiber and the mandrel are heated together to the melting point of nickel, the metallic nickel is melted and adhered, and then cooled to room temperature to obtain a nickel-based carbon fiber composite material of the Tesla turbine disc;
- Step 340 Remove the mandrel and machine an exhaust hole on the nickel-based carbon fiber composite material of the Tesla turbine disc by machining.
- the exhaust hole is disposed near the positioning hole of the turbine disc, and the exhaust There may be several holes, preferably three, evenly distributed on the surface of the turbine disk;
- Step 350 Anodize the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk
- Step 360 Sinter ceramics on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disc that has been anodized to obtain a ceramic material of the Tesla turbine disc.
- the ceramic is yttria-stabilized zirconia YSZ;
- Step 370 Polish using a diamond abrasive to obtain the Tesla turbine disk.
- the Tesla turbine disk made by the above-mentioned method for manufacturing a Tesla turbine disk has extremely high hardness and compressive strength, good heat resistance, can maintain the shape and size unchanged at high temperatures, and can resist the erosion of high-temperature jets. When the disc size is large, it is not easy to deform, which realizes the universal application of Tesla turbine discs.
- carbon fibers are put into a nickel-containing electrolyte for electroplating; the electrolyte contains 500 g / L of nickel sulfate; 70 g / L of nickel chloride; 40 g / L of boric acid; and 0.1 g / L of sodium lauryl sulfate.
- the nickel sulfate is a main salt
- boric acid is a buffering agent
- nickel chloride is an anti-passivation agent
- sodium lauryl sulfate is a dispersant.
- Experimental conditions pH value is 3 ⁇ 4; temperature is 25 °C; plating time is 1 ⁇ 12min; current density is 0.1 ⁇ 0.5A / dm2.
- the diameter of the carbon fiber was 0.2 mm. After electroplating, nickel-based carbon fibers were obtained.
- the electroplated nickel-based carbon fiber is wound on a mandrel to form a disc-shaped carbon fiber; the mandrel is selected from alumina, zirconium carbide, or boron nitride.
- the disc-shaped carbon fiber and the mandrel are heated together to a temperature above the melting point of nickel, and the heating temperature is 1500 ° C, and the temperature is maintained for 10-45 minutes, preferably 30 minutes. After the metal nickel is melted and adhered, it is cooled to room temperature to obtain the Tesla turbine Plate of nickel-based carbon fiber composite material.
- the mandrel is removed, and three uniformly distributed exhaust holes are machined on the nickel-based carbon fiber composite material of the Tesla turbine disk.
- Anodizing is performed on the surface of the nickel-based carbon fiber composite material of the Tesla turbine disk.
- the specific process is: anodizing the nickel-based carbon fiber composite material in an external magnetic field, and the strength of the external magnetic field is 20-60mT.
- the cathode and electrolyte are ammonium salts, the concentration of the electrolyte is 1-15%, the temperature of the electrolyte is 0-50 ° C, the applied current density is 0.5-10mA / cm2, and the residence time of the nickel-based carbon fiber composite material in the electrolyte It is 1-2 minutes; then it is taken out for washing and drying to obtain an anodized nickel-based carbon fiber composite material.
- hot isostatic pressing is performed for sintering.
- the specific process is: at 1-3Mpa, the temperature is increased from room temperature 25 ° C to 1600 ° C at a rate of 3 ° C / min. After maintaining the temperature for 1 hour, the temperature is 3-6Mpa, and under the pressure of 1-3Mpa, Cool down to 25 °C at room temperature at a rate of 5 °C / min;
- the nickel-based carbon fiber composite material is polished by using a diamond polishing liquid to prepare the Tesla turbine disk.
- the nickel-based carbon fiber composite material obtained through the above method has a tensile strength of 4 to 7 Gpa and a tensile modulus of 400 to 700 Gpa.
- the present invention provides a method for preparing a metal-based carbon fiber composite material and a ceramic.
- the method for preparing the metal-based carbon fiber composite material includes: electroplating carbon fibers into an electrolyte; sculpting the electroplated carbon fibers, A carbon fiber having a predetermined shape is obtained; the shaped carbon fiber is heated to a melting point of the metal, and is cooled to room temperature after the metal is melted and mixed, and then discharged to obtain the metal-based carbon fiber composite material.
- the method for preparing the ceramic includes anodizing the surface of the metal-based carbon fiber composite material; sintering the ceramic on the surface of the metal-based carbon fiber composite material after the anodization.
- the metal-based carbon fiber composite material prepared by the method has higher bonding strength between carbon fiber and metal matrix, and the ceramic material has higher hardness, compressive strength and heat resistance.
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Abstract
一种金属基碳纤维复合材料及陶瓷的制备方法,所述金属基碳纤维复合材料的制备方法包括:将碳纤维放入电解液中电镀;对电镀后的碳纤维造型,得到预定形状的碳纤维;将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复合材料。所述陶瓷的制备方法包括将所述金属基碳纤维复合材料表面进行阳极氧化;在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷。所述方法制得的金属基碳纤维复合材料具有较高的碳纤维与金属基体的结合强度,陶瓷材料具有较高的硬度、抗压强度和耐热性。
Description
本发明涉及复合材料制备领域,具体涉及一种金属基碳纤维复合材料及陶瓷的制备方法。
金属基碳纤维复合材料因具有高比强度、高比模量和韧性好等优良性能,在航空航天,生物材料和民用工业领域具有广阔的应用前景,与金属材料相比,它具有高的比模量和比强度;与陶瓷相比,具有高的韧性和耐冲击性能。但由于碳纤维表面惰性大、表面能低,缺乏有化学活性的化学键,反应活性低,与基体的结合力差,表面存在较多的缺陷,直接影响了复合材料的力学性能,限制了碳纤维高性能的发挥。复合材料制造过程中,碳纤维与金属复合时会发生金属碳化、渗碳及电化学腐蚀现象。现有技术中对碳纤维金属化方法做了很多有效的尝试和探索,但现有的方法都存在一定的缺陷,金属化后的碳纤维的质量参差不齐,普适性补强,因此寻求一种最大限度地提高碳纤维与基体间的界面结合强度的制备方法是非常必要的。
此外,陶瓷材料是用天然或合成化合物经过成形和高温烧结制成的一类无机非金属材料。它具有高熔点、高硬度、高耐磨性、耐氧化等优点,可用作结构材料、刀具材料,由于陶瓷还具有某些特殊的性能,又可作为功能材料。陶瓷材料是工程材料中刚度最好、硬度最高的材料,其硬度大多在1500HV以上。陶瓷的抗压强度较高,但抗拉强度较低,塑性和韧性很差。陶瓷材料一般具有高的熔点(大多在2000℃以上),且在高温下具有极好的化学稳定性;陶瓷的导热性低于金属材料,陶瓷还是良好的隔热材料。同时陶瓷的线 膨胀系数比金属低,当温度发生变化时,陶瓷具有良好的尺寸稳定性。陶瓷材料在高温下不易氧化,并对酸、碱、盐具有良好的抗腐蚀能力。为了提高金属的耐磨性,会在金属基体上涂覆一层陶瓷涂层,但是由于陶瓷与金属的理化性质差异较大,很难直接连接,主要因为两者的热膨胀系数差异较大,在连接处易产生很大的残余热应力。
发明内容
为解决上述问题,本发明提供了一种金属基碳纤维复合材料及陶瓷的制备方法,以提高碳纤维与金属基体的结合强度、以及提高陶瓷的硬度、抗压强度和耐热性。
具体由下列技术方案实现:
本发明的第一方面提供了一种金属基碳纤维复合材料的制备方法,包括如下步骤:
将碳纤维放入电解液中电镀;
对电镀后的碳纤维造型,得到预定形状的碳纤维;
将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复合材料。
在一些具体实施例中,所述金属基碳纤维复合材料为镍基碳纤维复合材料。
在一些具体实施例中,所述将碳纤维放入电解液中电镀的步骤为将碳纤维放入装有含镍电解液的电镀池中电镀,其中,所述含镍电解液中,镍的质量百分比大于25%,碳纤维的直径为0.1-0.3mm。
在一些具体实施例中,所述对电镀后的碳纤维造型的步骤包括:
对经过电镀后的碳纤维造型;
使用非电镀金属的碳纤维对所述造型后的碳纤维加固。
在一些具体实施例中,采用工装对电镀后的碳纤维造型,所述工装由陶 瓷制成。
在一些具体实施例中,所述陶瓷为氧化铝、碳化锆和氮化硼的一种或多种组合。
在一些具体实施例中,将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温的步骤包括:加热金属熔化后,电镀金属的碳纤维和非电镀金属的碳纤维表面均有金属且金属粘连在一起,冷却至室温后,金属凝固。
本发明的第二方面提供了一种使用金属基碳纤维复合材料制备陶瓷的方法,包括如下步骤:
使用如前所述的金属基碳纤维复合材料的制备方法制备金属基碳纤维复合材料;
在所述金属基碳纤维复合材料表面进行阳极氧化;
在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷。
在一些具体实施例中,所述陶瓷为氧化钇稳定氧化锆。
在一些具体实施例中,所述在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷的步骤包括:将氧化钇稳定氧化锆粉末喷洒至所述金属基碳纤维复合材料表面后进行热等静压烧结。
在一些具体实施例中,所述热等静压烧结的步骤包括:在1-3Mpa下,将温度从室温25℃开始以1-5℃/分钟的速度上升至1400-1800℃;然后保温保压,保温时间为0.5-3小时、保温压力为3-6Mpa;保温保压后,在1-3Mpa的压力下,以3-7℃/分钟的速度降温到室温25℃。
综上所述,本发明提供了一种金属基碳纤维复合材料及陶瓷的制备方法,所述金属基碳纤维复合材料的制备方法包括:将碳纤维放入电解液中电镀;对电镀后的碳纤维造型,得到预定形状的碳纤维;将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复 合材料。所述陶瓷的制备方法包括将所述金属基碳纤维复合材料表面进行阳极氧化;在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷。
本发明的上述技术方案具有如下有益的技术效果:
1、金属基碳纤维复合材料的制备方法,实现了金属镍和碳纤维的有效结合,通过本发明方法制得的金属基碳纤维复合材料,使碳纤维与金属基材发生有效融合,形成有机整体,提高碳纤维与金属基体的结合强度;
2、使用所述金属基碳纤维复合材料制备陶瓷的方法,实现了在金属材料与陶瓷的连接,该金属基碳纤维复合材料制备陶瓷具有极高的硬度和抗压强度,耐热性好,在高温下可以保持形状尺寸不变,能够抵御高温射流的侵蚀。
图1是本发明金属基碳纤维复合材料制备的方法流程图;
图2是本发明金属基碳纤维复合材料陶瓷制备的方法流程图;
图3是使用本发明金属基碳纤维复合材料陶瓷制备方法制备特斯拉涡轮盘的方法流程图;
图4是使用本发明金属基碳纤维复合材料陶瓷制备方法制备的特斯拉涡轮盘的结构示意图。
为使本发明的目的、技术方案和优点更加清楚明了,下面结合具体实施方式并参照附图,对本发明进一步详细说明。应该理解,这些描述只是示例性的,而并非要限制本发明的范围。此外,在以下说明中,省略了对公知结构和技术的描述,以避免不必要地混淆本发明的概念。
一种金属基碳纤维复合材料的制备方法100,如图1所示,包括如下步骤:
步骤110、将碳纤维放入电解液中电镀;
步骤120、对电镀后的碳纤维造型,得到预定形状的碳纤维;
步骤130、将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复合材料。
所述金属基碳纤维复合材料为镍基碳纤维复合材料。
具体的,所述步骤110包括将碳纤维放入装有含镍电解液的电镀池中电镀,其中,所述含镍电解液中,镍的质量百分比大于25%,碳纤维的直径为0.1-0.3mm,优选0.2mm。
具体的,所述步骤120包括:
对经过电镀后的碳纤维造型;采用工装对电镀后的碳纤维造型,造型的含义为将碳纤维塑造成预定的形状。所述工装材料需耐高温、不易变形、很难与金属发生反应,优选由陶瓷制成,所述陶瓷为氧化铝、碳化锆和氮化硼的一种或多种组合。
优选地,还可包括使用非电镀金属的碳纤维对所述造型后的碳纤维加固的步骤。
具体的,所述步骤130包括:加热金属熔化后(所述金属基碳纤维复合材料为镍基碳纤维复合材料时,加热温度大于1000℃),所有碳纤维表面均有金属且金属粘连在一起,冷却至室温后,金属凝固。
由上述方法制得的金属基碳纤维复合材料,实现了金属镍和碳纤维的有效结合,使碳纤维与金属基材发生有效融合,形成有机整体,提高了碳纤维与金属基体的结合强度。
本发明的第二方面提供了一种使用金属基碳纤维复合材料制备陶瓷的方法200,如图2所示,包括如下步骤:
步骤210、将碳纤维放入电解液中电镀;
步骤220、对电镀后的碳纤维造型,得到预定形状的碳纤维;
步骤230、将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,得到所述金属基碳纤维复合材料;
步骤240、在所述金属基碳纤维复合材料表面进行阳极氧化,阳极氧化所起的作用可以让金属(镍)和高温陶瓷的相接面融合更好,形成一个过渡面,在金属(镍)的表面形成氧化层;
步骤250、在经过阳极氧化的所述金属基碳纤维复合材料表面烧结耐高温陶瓷,得到所述陶瓷。
具体的,所述金属基碳纤维复合材料为镍基碳纤维复合材料,所述陶瓷为氧化钇稳定氧化锆YSZ。所述步骤210-230与前述金属基碳纤维复合材料的制备方法相同。
所述步骤250包括:将氧化钇稳定氧化锆粉末喷洒至所述金属基碳纤维复合材料表面后进行热等静压烧结。具体过程为:在1-3Mpa下,将温度从室温25℃开始以1-5℃/分钟(优选3℃/分钟)的速度上升至1400-1800℃(优选1600℃);然后保温保压,保温时间为0.5-3小时(优选1小时)、保温压力为3-6Mpa;保温保压后,在1-3Mpa的压力下,以3-7℃/分钟(优选5℃/分钟)的速度降温到室温25℃。如果升温或降温速度过快,会导致各组分收缩及相变不均匀,产生大量内应力,导致陶瓷开裂;如果保温压力和时长不足,同样会导致各组分收缩及相变不均匀,产生大量内应力,导致陶瓷开裂。
使用所述金属基碳纤维复合材料制备陶瓷的方法,实现了在金属材料与陶瓷的连接,该金属基碳纤维复合材料制备陶瓷具有极高的硬度和抗压强度,耐热性好,在高温下可以保持形状尺寸不变,能够抵御高温射流的侵蚀。
本发明的第三方面提供了一种特斯拉涡轮盘的制造方法300。所述特斯拉涡轮盘如图4所示,设置有定位孔410和排气孔420,转轴穿过若干结构相同的特斯拉涡轮盘400的定位孔410并与所述若干结构相同的特斯拉涡轮盘400固定连接。
优选的,所述排气孔420设置在靠近定位块410处。进一步优选,所述排气孔420有若干个,优选3个,均布于特斯拉涡轮盘400表面。
所述特斯拉涡轮盘的制造方法300,如图3所示,包括如下步骤:
步骤310、将碳纤维放置在含镍电解液中电镀;
步骤320、将电镀后的碳纤维缠绕在芯轴上形成盘状碳纤维;所述芯轴需耐高温、不易变形、很难与金属发生反应,优选由陶瓷制成,制成所述芯轴的所述陶瓷为氧化铝、碳化锆和氮化硼的一种或多种组合;
步骤330、将盘状碳纤维和芯轴一起加热到镍的熔点,使金属镍融化并粘连后冷却至室温,制得所述特斯拉涡轮盘的镍基碳纤维复合材料;
步骤340、拆除芯轴,通过机加工的方式在所述特斯拉涡轮盘的镍基碳纤维复合材料上加工排气孔,所述排气孔设置在靠近涡轮盘定位孔处,所述排气孔可以设置有若干个,优选3个,均布于涡轮盘表面;
步骤350、在所述特斯拉涡轮盘的镍基碳纤维复合材料表面进行阳极氧化;
步骤360、在经过阳极氧化的所述特斯拉涡轮盘的镍基碳纤维复合材料表面烧结陶瓷,得到特斯拉涡轮盘的陶瓷材料;所述陶瓷为氧化钇稳定氧化锆YSZ;
步骤370、使用金刚石研磨液抛光,制得所述特斯拉涡轮盘。
由上述特斯拉涡轮盘的制造方法制得的特斯拉涡轮盘具有极高的硬度和抗压强度,耐热性好,在高温下可以保持形状尺寸不变,能够抵御高温射流的侵蚀,圆盘尺寸大时不易变形,实现了特斯拉涡轮盘的普及应用。
下面通过具体的实施例对本发明进行进一步地说明。
实施例1:
使用镍基碳纤维复合材料陶瓷制备特斯拉涡轮盘的制备方法:
首先,将碳纤维放入含镍电解液中进行电镀;所述电解液中含硫酸镍500g/L;氯化镍70g/L;硼酸40g/L;十二烷基硫酸钠0.1g/L。其中所述硫酸镍为主盐,硼酸为缓冲剂,氯化镍为防钝化剂,十二烷基硫酸钠为分散剂。实验条件:pH值为3~4;温度为25℃;电镀时间为1~12min;电流密度为0.1~0.5A/dm2。碳纤维的直径为0.2mm。电镀后得到镍基碳纤维。
将电镀后的镍基碳纤维缠绕在芯轴上形成盘状碳纤维;所述芯轴选自氧化铝、碳化锆或氮化硼。
将盘状碳纤维和芯轴一起加热到镍的熔点以上,加热温度为1500℃,保持10-45分钟,优选30分钟,使金属镍融化并粘连后冷却至室温,制得所述特斯拉涡轮盘的镍基碳纤维复合材料。
拆除芯轴,通过机加工的方式在所述特斯拉涡轮盘的镍基碳纤维复合材料上加工3个均匀分布的排气孔。
在所述特斯拉涡轮盘的镍基碳纤维复合材料表面进行阳极氧化,具体过程为:将镍基碳纤维复合材料在外加磁场中进行阳极氧化处理,外加磁场的强度为20-60mT,以石墨为阴极,电解质为铵盐,电解液的浓度为1-15%,电解液的温度为0-50℃,施加的电流密度为0.5-10mA/cm2,镍基碳纤维复合材料在电解液中停留的时间为1-2分钟;然后取出进行清洗干燥得到表面经过阳极氧化的镍基碳纤维复合材料。
将YSZ粉末喷洒至所述镍基碳纤维复合材料表面后进行热等静压烧结。具体过程为:在1-3Mpa下,将温度从室温25℃开始以3℃/分钟的速度上升至1600℃,在保持保温1小时、保温压力3-6Mpa后,在1-3Mpa的压力下,以5℃/分钟的速度降温到室温25℃;
使用金刚石研磨液对所述镍基碳纤维复合材料进行抛光,制得所述特斯拉涡轮盘。
经过上述方法制得的镍基碳纤维复合材料具有的拉伸强度为4~7Gpa,拉伸模量为400~700Gpa。
综上所述,本发明提供了一种金属基碳纤维复合材料及陶瓷的制备方法,所述金属基碳纤维复合材料的制备方法包括:将碳纤维放入电解液中电镀;对电镀后的碳纤维造型,得到预定形状的碳纤维;将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复合材料。所述陶瓷的制备方法包括将所述金属基碳纤维复合材料表面进行阳极氧化;在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷。所述方法制得的金属基碳纤维复合材料具有较高的碳纤维与金属基体的结合强 度,陶瓷材料具有较高的硬度、抗压强度和耐热性。
应当理解的是,本发明的上述具体实施方式仅仅用于示例性说明或解释本发明的原理,而不构成对本发明的限制。因此,在不偏离本发明的精神和范围的情况下所做的任何修改、等同替换、改进等,均应包含在本发明的保护范围之内。此外,本发明所附权利要求旨在涵盖落入所附权利要求范围和边界、或者这种范围和边界的等同形式内的全部变化和修改例。
Claims (10)
- 一种金属基碳纤维复合材料的制备方法,其特征在于,包括如下步骤:将碳纤维放入电解液中电镀;对电镀后的碳纤维造型,得到预定形状的碳纤维;将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温,出料,即制得所述金属基碳纤维复合材料。
- 根据权利要求1所述的金属基碳纤维复合材料的制备方法,其特征在于,所述金属基碳纤维复合材料为镍基碳纤维复合材料。
- 根据权利要求2所述的金属基碳纤维复合材料的制备方法,其特征在于,所述将碳纤维放入电解液中电镀的步骤为将碳纤维放入装有含镍电解液的电镀池中电镀,其中,所述含镍电解液中,镍的质量百分比大于25%,碳纤维的直径为0.1-0.3mm。
- 根据权利要求1-3任一项所述的金属基碳纤维复合材料的制备方法,其特征在于,所述对电镀后的碳纤维造型的步骤包括:对电镀后的碳纤维造型;使用非电镀金属的碳纤维对所述造型后的碳纤维加固。
- 根据权利要求4所述的金属基碳纤维复合材料的制备方法,其特征在于,采用工装对电镀后的碳纤维造型,所述工装由陶瓷制成。
- 根据权利要求5所述的金属基碳纤维复合材料的制备方法,其特征在于,所述陶瓷为氧化铝、碳化锆和氮化硼的一种或多种组合。
- 根据权利要求4所述的金属基碳纤维复合材料的制备方法,其特征在于,将造型后的碳纤维加热至金属熔点,待金属熔化混合后冷却至室温的步骤包括:加热金属熔化后,电镀金属的碳纤维和非电镀金属的碳纤维表面均有金属且金属粘连在一起,冷却至室温后,金属凝固。
- 一种使用金属基碳纤维复合材料制备陶瓷的方法,其特征在于,包括如下步骤:使用如权利要求1-7任一项所述的金属基碳纤维复合材料的制备方法制备金属基碳纤维复合材料;在所述金属基碳纤维复合材料表面进行阳极氧化;在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷。
- 根据权利要求8所述的使用金属基碳纤维复合材料制备陶瓷的方法,其特征在于,所述陶瓷为氧化钇稳定氧化锆。
- 根据权利要求9所述的使用金属基碳纤维复合材料制备陶瓷的方法,其特征在于,所述在经过阳极氧化的所述金属基碳纤维复合材料表面烧结陶瓷的步骤包括:将氧化钇稳定氧化锆粉末喷洒至所述金属基碳纤维复合材料表面后进行热等静压烧结。
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