CN107253861A - 一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法 - Google Patents
一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法 Download PDFInfo
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Abstract
一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,它涉及一种制备SiC陶瓷轮机叶轮的方法。本发明是为了目前3D打印技术制备的SiC陶瓷强度低和致密度低的技术问题。本发明:一、建轮机叶轮的三维模型;二、三维模型的分层处理;三、制备陶瓷粉末;四、层层打印,制备陶瓷坯体;五、清除多余粉末;六、热固化;七、脱脂;八、化学气相渗透致密化。本发明设计了SLS与CVI法相结合的工艺,工艺简单、材料设备成本低,并且制备周期短,余料可以再次利用,致密度高,强度高,且不受陶瓷颗粒种类和零件形状的限制,可制备各种高强度耐高温的陶瓷部件。本发明应用于制备SiC陶瓷轮机叶轮。
Description
技术领域
本发明属涉及一种制备SiC陶瓷轮机叶轮的方法。
背景技术
SiC陶瓷具有优良的力学性能,高的抗弯强度、优良的抗氧化性、良好的耐腐蚀性、高的抗磨损以及低的摩擦系数,而且高温力学性能(强度、抗蠕变性等)是已知陶瓷材料中最佳的。热压烧结、无压烧结、热等静压烧结的材料,其高温强度可一直维持到1600℃,是陶瓷材料中高温强度最好的材料。因而用SiC制造航天器可以说是物尽其用。
目前陶瓷材料成型方法主要有挤压成型、注射成型、等静压成型、流延成型等,这些方法在制备过程都需要模具,一旦设计尺寸改变或者调整将需要重新设计并制造模具,而制造模具成本较高,周期较长。而且受到模具的复杂程度限制,这些工艺适合制备形状简单的制品。
随着工业的发展,这些传统的工艺已经不能满足高科技产品的需求。3D打印快速成型技术是近年来快速发展的一种新型成型工艺,该工艺利用计算机软件设计构件,通过软件分层离散和数控成型***,利用激光束、热熔喷嘴等方式将金属粉末、陶瓷粉末、塑料、组织细胞等特殊材料进行逐层堆积粘结,最终叠加成型,制造出实体产品。该工艺与传统成型方法相比,具有以下特点:(1)可以制备形状复杂的高科技产品;(2)制备过程无需模具,省钱省时周期短;(3)可以轻易通过计算机软件改变设计尺寸及形状,大大缩短新产品开发时间;(4)可制备结构微小的电子陶瓷制品等优点。因此,近年来快速成型技术受到广泛的关注,尤其航天领域备受关注。目前3D打印术主要有立体光刻造型技术(SLA)、选择性激光烧结(SLS)、分层实体制造(LOM)、三维打印(3DP)等,其中可应用于选择性激光烧结技术的材料更广泛。
然而,目前现有陶瓷的3D打印制备还仅限于初步成形,对其强度的进一步提升研究有限,陶瓷的抗拉强度为5MPa~20MPa,孔隙率为45%~60%,强度低,致密度低,导致陶瓷3D打印产品并未得到很好的应用。
发明内容
本发明是为了目前3D打印技术制备的SiC陶瓷强度低和致密度低的技术问题,而提供一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法。
本发明的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法是按以下步骤进行的:
一、用计算机构建轮机叶轮的三维模型,然后将三维模型转换为STL格式文件;
二、将步骤一的STL格式文件导入SLS的3D打印机,通过SLS的3D打印机的分层处理软件对三维模型进行分层处理;
三、将SiC粉末和树脂粉末加入混合机中混合8h~24h,得到粒径均匀的陶瓷粉末;所述的树脂粉末和SiC粉末的质量比为1:(15~20);
四、将步骤三得到的粒径均匀的陶瓷粉末加入到步骤二的SLS的3D打印机的料筒中,铺平粉末,然后将SLS的3D打印机的工作箱加热至温度为40℃~45℃,通过SLS的3D打印机的激光头根据步骤二的分层处理得到的数据由下至上层层打印,得到陶瓷坯体;所述的层层打印中每层的厚度为0.05mm~0.2mm;
五、打开3D打印机的工作箱门,在室温下静置20min~60min,取出陶瓷坯体后清除多余粉末;
六、将步骤五清除多余粉末后的陶瓷坯体用玻璃珠包埋,然后放入恒温干燥箱中,在温度为200℃的条件下热固化3h,自然冷却至室温,清理掉陶瓷坯体表面的玻璃珠;
七、将步骤六中清理掉玻璃珠后的陶瓷坯体用SiC颗粒包埋,放入高温真空炉进行脱脂,自然冷却至室温,得到SiC陶瓷轮机叶轮;所述的脱脂的温度为600~800℃,保温时间为30min~60min;
八、将步骤七得到的SiC陶瓷轮机叶轮进行化学气相渗透致密化60h~80h,自然冷却至室温,得到高强度耐高温SiC陶瓷轮机叶轮;
所述的化学气相渗透致密化的过程为:将步骤七得到的SiC陶瓷轮机叶轮放入气相沉积炉中,然后通入反应气体进行沉积,沉积温度为1050℃~1100℃,炉压为1KPa~20KPa;所述的反应气体为H2和三氯甲基硅烷的混合气体,H2和三氯甲基硅烷的摩尔比为1~10。
步骤一所述的STL为光固化立体造型术。
本发明的有益效果:
本发明设计了选择性激光烧结(SLS)与CVI法(化学气相渗透法)相结合的工艺,本发明工艺简单、材料设备成本低,并且制备周期短,余料可以再次利用,最终部件的抗拉强度为150MPa~200MPa,孔隙率为12%~18%,致密度高,强度高,且不受陶瓷颗粒种类和零件形状的限制,可制备各种高强度耐高温的陶瓷部件,所制备的陶瓷经过后处理可应用于制造轮机叶轮。
具体实施方式
具体实施方式一:本实施方式为一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,具体是按以下步骤进行的:
一、用计算机构建轮机叶轮的三维模型,然后将三维模型转换为STL格式文件;
二、将步骤一的STL格式文件导入SLS的3D打印机,通过SLS的3D打印机的分层处理软件对三维模型进行分层处理;
三、将SiC粉末和树脂粉末加入混合机中混合8h~24h,得到粒径均匀的陶瓷粉末;所述的树脂粉末和SiC粉末的质量比为1:(15~20);
四、将步骤三得到的粒径均匀的陶瓷粉末加入到步骤二的SLS的3D打印机的料筒中,铺平粉末,然后将SLS的3D打印机的工作箱加热至温度为40℃~45℃,通过SLS的3D打印机的激光头根据步骤二的分层处理得到的数据由下至上层层打印,得到陶瓷坯体;所述的层层打印中每层的厚度为0.05mm~0.2mm;
五、打开3D打印机的工作箱门,在室温下静置20min~60min,取出陶瓷坯体后清除多余粉末;
六、将步骤五清除多余粉末后的陶瓷坯体用玻璃珠包埋,然后放入恒温干燥箱中,在温度为200℃的条件下热固化3h,使得树脂更加均匀附着在SiC颗粒表面,自然冷却至室温,清理掉陶瓷坯体表面的玻璃珠;
七、将步骤六中清理掉玻璃珠后的陶瓷坯体用SiC颗粒包埋,放入高温真空炉进行脱脂,自然冷却至室温,得到SiC陶瓷轮机叶轮;所述的脱脂的温度为600~800℃,保温时间为30min~60min;
八、将步骤七得到的SiC陶瓷轮机叶轮进行化学气相渗透致密化60h~80h,自然冷却至室温,得到高强度耐高温SiC陶瓷轮机叶轮;
所述的化学气相渗透致密化的过程为:将步骤七得到的SiC陶瓷轮机叶轮放入气相沉积炉中,然后通入反应气体进行沉积,沉积温度为1050℃~1100℃,炉压为1KPa~20KPa;所述的反应气体为H2和三氯甲基硅烷的混合气体,H2和三氯甲基硅烷的摩尔比为1~10。
具体实施方式二:本实施方式与具体实施方式一不同的是:步骤三所述的SiC粉末的粒径为10μm~70μm。其他与具体实施方式一相同。
具体实施方式三:本实施方式与具体实施方式一或二不同的是:步骤三所述的树脂粉末的粒径为5μm。其他与具体实施方式一或二相同。
具体实施方式四:本实施方式与具体实施方式一至三之一不同的是:步骤三所述的树脂粉末为环氧树脂粉末。其他与具体实施方式一至三之一相同。
具体实施方式五:本实施方式与具体实施方式一至四之一不同的是:步骤六中所述的玻璃珠的粒径为0.5mm。其他与具体实施方式一至四之一相同。
具体实施方式六:本实施方式与具体实施方式一至五之一不同的是:步骤七中所述的SiC颗粒的粒径为100μm~200μm。其他与具体实施方式一至五之一相同。
具体实施方式七:本实施方式与具体实施方式一至六之一不同的是:步骤三中所述的树脂粉末和SiC粉末的质量比为1:19。其他与具体实施方式一至六之一相同。
用以下试验对本发明进行验证:
试验一:本试验为一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,具体是按以下步骤进行的:
一、用计算机构建轮机叶轮的三维模型,然后将三维模型转换为STL格式文件;
二、将步骤一的STL格式文件导入SLS的3D打印机,通过SLS的3D打印机的分层处理软件对三维模型进行分层处理;
三、将SiC粉末和树脂粉末加入混合机中混合8h~24h,得到粒径均匀的陶瓷粉末;所述的树脂粉末和SiC粉末的质量比为1:19;
四、将步骤三得到的粒径均匀的陶瓷粉末加入到步骤二的SLS的3D打印机的料筒中,铺平粉末,然后将SLS的3D打印机的工作箱加热至温度为40℃,通过SLS的3D打印机的激光头根据步骤二的分层处理得到的数据由下至上层层打印,得到陶瓷坯体;所述的层层打印中每层的厚度为0.1mm;
五、打开3D打印机的工作箱门,在室温下静置40min,取出陶瓷坯体后清除多余粉末;
六、将步骤五清除多余粉末后的陶瓷坯体用玻璃珠包埋,然后放入恒温干燥箱中,在温度为200℃的条件下热固化3h,使得树脂更加均匀附着在SiC颗粒表面,自然冷却至室温,清理掉陶瓷坯体表面的玻璃珠;
七、将步骤六中清理掉玻璃珠后的陶瓷坯体用SiC颗粒包埋,放入高温真空炉进行脱脂,自然冷却至室温,得到SiC陶瓷轮机叶轮;所述的脱脂的温度为700℃,保温时间为40min;
八、将步骤七得到的SiC陶瓷轮机叶轮进行化学气相渗透致密化70h,自然冷却至室温,得到高强度耐高温SiC陶瓷轮机叶轮;
所述的化学气相渗透致密化的过程为:将步骤七得到的SiC陶瓷轮机叶轮放入气相沉积炉中,然后通入反应气体进行沉积,沉积温度为1100℃,炉压为10KPa;所述的反应气体为H2和三氯甲基硅烷的混合气体,H2和三氯甲基硅烷的摩尔比为8。
步骤三所述的SiC粉末的粒径为40μm;步骤三所述的树脂粉末的粒径为5μm,具体是环氧树脂粉末;步骤六中所述的玻璃珠的粒径为0.5mm;步骤七中所述的SiC颗粒的粒径为100μm。
本试验制备的高强度耐高温SiC陶瓷轮机叶轮的抗拉强度为150MPa~200MPa,孔隙率为12%~18%,致密度高,且强度高。
Claims (7)
1.一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法是按以下步骤进行的:
一、用计算机构建轮机叶轮的三维模型,然后将三维模型转换为STL格式文件;
二、将步骤一的STL格式文件导入SLS的3D打印机,通过SLS的3D打印机的分层处理软件对三维模型进行分层处理;
三、将SiC粉末和树脂粉末加入混合机中混合8h~24h,得到粒径均匀的陶瓷粉末;所述的树脂粉末和SiC粉末的质量比为1:(15~20);
四、将步骤三得到的粒径均匀的陶瓷粉末加入到步骤二的SLS的3D打印机的料筒中,铺平粉末,然后将SLS的3D打印机的工作箱加热至温度为40℃~45℃,通过SLS的3D打印机的激光头根据步骤二的分层处理得到的数据由下至上层层打印,得到陶瓷坯体;所述的层层打印中每层的厚度为0.05mm~0.2mm;
五、打开3D打印机的工作箱门,在室温下静置20min~60min,取出陶瓷坯体后清除多余粉末;
六、将步骤五清除多余粉末后的陶瓷坯体用玻璃珠包埋,然后放入恒温干燥箱中,在温度为200℃的条件下热固化3h,自然冷却至室温,清理掉陶瓷坯体表面的玻璃珠;
七、将步骤六中清理掉玻璃珠后的陶瓷坯体用SiC颗粒包埋,放入高温真空炉进行脱脂,自然冷却至室温,得到SiC陶瓷轮机叶轮;所述的脱脂的温度为600~800℃,保温时间为30min~60min;
八、将步骤七得到的SiC陶瓷轮机叶轮进行化学气相渗透致密化60h~80h,自然冷却至室温,得到高强度耐高温SiC陶瓷轮机叶轮;
所述的化学气相渗透致密化的过程为:将步骤七得到的SiC陶瓷轮机叶轮放入气相沉积炉中,然后通入反应气体进行沉积,沉积温度为1050℃~1100℃,炉压为1KPa~20KPa;所述的反应气体为H2和三氯甲基硅烷的混合气体,H2和三氯甲基硅烷的摩尔比为1~10。
2.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤三所述的SiC粉末的粒径为10μm~70μm。
3.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤三所述的树脂粉的粒径为5μm。
4.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤三所述的树脂粉末为环氧树脂粉末。
5.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤六中所述的玻璃珠的粒径为0.5mm。
6.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤七中所述的SiC颗粒的粒径为100μm~200μm。
7.根据权利要求1所述的一种SLS/CVI制备高强度耐高温SiC陶瓷轮机叶轮的方法,其特征在于步骤三中所述的树脂粉末和SiC粉末的质量比为1:19。
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