CN110981520A - Preparation method of ceramic matrix composite material component with abradable coating and component - Google Patents
Preparation method of ceramic matrix composite material component with abradable coating and component Download PDFInfo
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Abstract
The invention belongs to the field of surface treatment of ceramic matrix composites, and relates to a preparation method of a ceramic matrix composite component with an abradable coating and the component, which solve the problems of poor mechanical property, short service life of the component with weak oxidation resistance and poor thermal matching property of the abradable coating and the ceramic matrix composite of the existing ceramic matrix composite component with the abradable coating.
Description
Technical Field
The invention belongs to the field of surface treatment of ceramic matrix composites, and particularly relates to a surface passivation treatment method for processing a groove on the surface of a ceramic matrix composite, which improves the binding force and durability between a surface coating of the ceramic matrix composite and a substrate of the ceramic matrix composite.
Background
The continuous fiber toughened silicon carbide ceramic matrix composite material is an ideal high-temperature structural material, comprises a C/SiC ceramic matrix composite material and a SiC/SiC ceramic matrix composite material, has excellent performances of high temperature resistance, high specific strength, low density, ablation resistance, high specific modulus, oxidation resistance and the like, is a light composite material with integrated structure bearing and harsh environment resistance, and has great application potential in the fields of weapon equipment such as aeroengines, satellite attitude control engines, hypersonic ramjets, solid rocket engines and the like.
The SiC/SiC ceramic matrix composite can work for a long time in a high-temperature environment under the condition of little or no cooling, can improve the working temperature of blades, combustion chambers and spray pipes of an aircraft engine by hundreds of degrees centigrade, and obviously improves the efficiency and the thrust of the engine. In order to solve the problem of strength damage caused by direct contact abrasion due to overhigh hardness of the ceramic matrix composite when an engine rotor part works, an abradable coating needs to be prepared on the surface of the ceramic matrix composite to avoid the strength damage.
In the conventional metal material, in order to improve the bonding strength between the coating and the material, a sand blasting process is performed on the surface of the material before the coating is sprayed, so that the surface roughness of the material is improved. Aiming at the surface treatment of the ceramic matrix composite, if a sand blasting process is adopted, the bonding force between the coating and the matrix can be increased; however, in the sand blasting process, the SiC layer on the surface of the ceramic matrix composite is damaged, so that the fibers are exposed, the mechanical property and the oxidation resistance of the material are affected, and the service life of the member is reduced. Meanwhile, due to the existence of the difference of the thermal expansion coefficients of the coating and the ceramic matrix composite, the thermal matching performance is poor.
Disclosure of Invention
In order to solve the problems of poor mechanical property, weak oxidation resistance, short service life and poor thermal matching between the abradable coating and the ceramic matrix composite existing in the existing ceramic matrix composite component with the abradable coating, the invention provides a preparation method of the ceramic matrix composite component with the abradable coating and the component; the grooves and the blind holes with a certain number are processed on the surface of the ceramic matrix composite material substrate, so that the binding force between the abradable coating and the ceramic matrix composite material substrate is enhanced, the abradable coating and the ceramic matrix composite material substrate are connected more tightly, the durability is higher, the mechanical property and the oxidation resistance of the component are further improved, and the service life of the component is further prolonged.
The invention provides a preparation method of a ceramic matrix composite component with an abradable coating, which comprises the following steps:
step 1.1, weaving carbon fibers into two-dimensional plain cloth; placing a plurality of layers of two-dimensional plain cloth in a laminated manner; sewing a plurality of layers of two-dimensional plain cloth together along the lamination direction by using carbon fibers to obtain a carbon fiber prefabricated body;
step 1.2, clamping the carbon fiber preform obtained in the step 1.1 by using a graphite mold, placing the carbon fiber preform in a CVI deposition furnace, and depositing a pyrolytic carbon interface layer PyC by adopting a chemical vapor deposition method;
step 1.3, depositing a SiC matrix on the carbon fiber preform treated in the step 1.2 by adopting a CVI (chemical vapor infiltration) process, and after the process is repeated for multiple times, releasing the graphite mold to obtain a ceramic matrix composite flat plate;
step 1.4, processing the thickness of the ceramic matrix composite flat plate to a set thickness by adopting a surface grinding machine to obtain a ceramic matrix composite substrate;
step 2.1, machining grooves and blind holes;
fixing the ceramic matrix composite substrate on a positioning tool, and processing a plurality of grooves and blind holes with set depths along the surface of the ceramic matrix composite substrate;
2.2, depositing a SiC matrix by adopting a CVI (chemical vapor infiltration) process;
depositing a SiC matrix on the ceramic matrix composite substrate processed in the step 2.1 by adopting a CVI (chemical vapor infiltration) process to finally obtain the surface-modified ceramic matrix composite substrate;
and uniformly spraying a coating with a set thickness on the surface of the ceramic matrix composite substrate after surface modification.
Further, the process conditions for depositing the pyrolytic carbon interface layer PyC by the CVI method in step 1.2 are as follows:
depositing at 900-1100 ℃ and under the atmosphere pressure of 0.2-0.3 KPa, introducing propylene and argon at a certain flow rate, depositing for 50-60 h, and naturally cooling.
Further, the process conditions for depositing the SiC matrix on the carbon fiber preform processed in step 1.2 by adopting the CVI process in step 1.3 are as follows:
depositing at 900-1200 ℃ and under the atmosphere pressure of 2-2.5 KPa, introducing hydrogen and argon at a certain flow rate, and bubbling CH3SiCl3And (MTS) is carried into a CVI deposition furnace, hydrogen and MTS form a certain molar mass ratio, and the temperature is naturally reduced after 50-100 h of deposition.
Further, step 2.2 adopts a CVI process to deposit the SiC substrate on the ceramic matrix composite substrate processed in step 2.1 under the following process conditions:
placing the ceramic matrix composite substrate processed in the step 2.1 in a CVI deposition furnace, introducing hydrogen and argon at a certain flow rate at the deposition temperature of 900-1200 ℃ and the atmosphere pressure of 2-2.5 KPa, and bubbling CH3SiCl3(MTS) carry-in CVI depositionIn the furnace, hydrogen and MTS form a certain molar mass ratio, and the temperature is naturally reduced after 50-100 h of deposition.
Further, in order to verify the effect, the following steps are further included between step 1 and step 2:
step a, processing a ceramic matrix composite substrate test piece;
placing the ceramic matrix composite substrate on a numerical control processing table, selecting a cutter, and processing the ceramic matrix composite substrate into a test piece with a set shape along the lamination direction;
step b, machining grooves and blind holes;
fixing a test piece on a positioning tool, and uniformly processing a plurality of grooves and blind holes with set depths along the surface of the test piece;
step c, depositing a SiC matrix;
depositing a SiC matrix on the test piece prepared in the step b by adopting the CVI process in the step 2.2, and repeating the process for at least 2 times to finally obtain the surface-modified ceramic matrix composite test piece;
step d, preparing a coating;
uniformly spraying a coating with a set thickness on the surface of the ceramic matrix composite test piece after surface modification;
and e, verifying the performance of the test piece prepared in the step d.
Further, in order to test the performance of the test piece conveniently, the test piece is circular in shape.
Further, the graphite mold comprises an upper-layer plate-shaped mold, a lower-layer plate-shaped mold and a clamping mechanism, and a plurality of through holes are formed in the upper-layer plate-shaped mold and the lower-layer plate-shaped mold.
Further, the thickness of the ceramic matrix composite substrate is 3.5 mm;
processing a groove on the surface of the ceramic matrix composite material substrate or the surface of the test piece by using a diamond thread cutter; processing a blind hole on the surface of the ceramic matrix composite or the surface of a test piece by using a diamond drill;
the depth of the grooves and the blind holes is 0.4mm, and the grooves are parallel to each other; the blind holes are uniformly distributed along the circumferential direction of the surface of the test piece or the ceramic matrix composite material substrate;
the thickness of the coating was 1 mm.
Further, step 2.2 the process of depositing the SiC matrix using CVI method is repeated at least 2 times.
The invention also provides a ceramic matrix composite component with an abradable coating, which is characterized in that: the ceramic matrix composite material comprises a ceramic matrix composite material substrate and a wear-resistant coating coated on the surface of the ceramic matrix composite material substrate, wherein a plurality of parallel grooves and a plurality of blind holes uniformly distributed along the circumferential direction are formed on the surface of the ceramic matrix composite material substrate, which is in contact with the wear-resistant coating.
The invention has the beneficial effects that:
1. according to the invention, the surface of the ceramic matrix composite substrate is processed with a certain number of grooves and blind holes, so that the contact area between the coating and the substrate is increased, the thermal stress between the coating and the substrate is reduced, the bonding force between the material and the surface coating is improved, and the coating and the substrate material are connected more tightly.
2. According to the invention, after the groove is machined, SiC deposition is carried out, the exposed area of the machined fiber is reduced, the fiber is protected against oxidation, and the contact area between the abradable pattern layer and the component is further increased.
Drawings
FIG. 1 is a schematic structural view of a ceramic matrix composite test piece with grooves and blind holes machined on the surface thereof according to the present invention;
FIG. 2 is a graph of stress response of a coating region of an experimental sample;
FIG. 3 is a graph of stress response for a coated area of a control sample;
FIG. 4 is a schematic structural view of a graphite jig;
the reference numbers in the figures are: 1-ceramic matrix composite substrate, 2-groove, 3-blind hole;
31-upper plate-shaped die, 32-lower plate-shaped die and 33-clamping mechanism.
Detailed Description
The invention is further described with reference to the following figures and specific embodiments.
Example one
This example prepares ceramic matrix composite test pieces with abradable coatings by the following procedure:
(1.1) selecting T300-1K carbon fiber (including but not limited to the brand), weaving the carbon fiber into two-dimensional plain cloth, adopting 25 layers of two-dimensional plain cloth with the size of 240mm multiplied by 150mm, needling and connecting the 25 layers of two-dimensional plain cloth by 1K carbon fiber at the sewing distance of 5mm multiplied by 5mm along the thickness direction, and sewing the 25 layers of two-dimensional plain cloth together, thereby obtaining the volume density of 0.70g/cm3And the carbon fiber preform with the carbon fiber volume fraction of 40.0-42.0%.
(1.2) clamping the carbon fiber preform by using a graphite mold, placing the carbon fiber preform in a CVI deposition furnace, and depositing a pyrolytic carbon interface layer (PyC) by adopting a vapor deposition method. Specifically, the graphite jig has a structure as shown in fig. 4, and includes an upper plate-shaped mold 31, a lower plate-shaped mold 32, and a clamping mechanism 33, wherein the upper plate-shaped mold 31 and the lower plate-shaped mold 32 are provided with a plurality of through holes, so as to ensure sufficient contact between the gas and the carbon fiber preform. When in use, the carbon fiber preform is placed between the upper plate-like mold 31 and the lower plate-like mold 32 and clamped by the clamping mechanism 33.
The technology for depositing the pyrolytic carbon interface layer (PyC) by adopting the CVI method comprises the following steps:
depositing at 900-1100 ℃ and under the atmosphere pressure of 0.2-0.3 KPa, introducing propylene and argon at a certain flow rate, depositing for 50-60 h, and naturally cooling.
(1.3) depositing a SiC matrix on the carbon fiber preform subjected to the heat treatment in the step (1.2) by adopting a CVI (chemical vapor infiltration) process, repeating the process for 6 times, releasing the graphite mold, and finally obtaining the carbon fiber preform with the volume density of 1.8g/cm3The SiC/SiC composite material flat plate;
the specific process comprises the following steps: the deposition temperature is 900-1200 ℃, the atmosphere pressure is 2-2.5 KPa, hydrogen and argon are introduced at a certain flow rate, MTS is brought into a CVI deposition furnace in a bubbling mode, the hydrogen and the MTS form a certain molar mass ratio, and the deposition is carried out for 50-100 hours and then the temperature is naturally reduced.
And (1.4) processing the thickness of the composite material flat plate to 3.5mm by adopting a surface grinding machine to obtain the ceramic matrix composite material matrix.
(2.1) processing a ceramic matrix composite substrate test piece;
placing the ceramic matrix composite substrate flat plate obtained in the step 1 on a numerical control machining table, and machining a disc-shaped test piece with the diameter of 25mm by using a diamond cutter with the diameter of 8 mm;
(2.2) machining the groove and the blind hole;
bonding a disc-shaped test piece on a positioning tool, uniformly processing 12 grooves with the depth of 0.4mm along the surface of the test piece by using a diamond threading tool with the thickness of 1mm and the angle of 45 degrees, wherein the grooves are mutually parallel and the width of the groove is 2 mm; then, uniformly processing 36 blind holes with the depth of 0.4mm along the circumferential direction by using a 1.5mm diamond drill bit;
(2.3) depositing a SiC matrix;
depositing the prepared disc-shaped test piece on the SiC matrix by adopting a CVI method, and repeating the process for 2 times to finally obtain the SiC matrix with the volume density of 2.0g/cm3The SiC/SiC composite material matrix test piece after surface modification.
and uniformly spraying a coating with the thickness of 1mm on the surface of the SiC/SiC composite material matrix test piece with the modified surface by adopting a plasma spraying method to form a test piece with an abradable coating.
The depth, thickness and other data mentioned above can be changed according to actual requirements.
And (3) verifying the effect of the test piece with the abradable coating by adopting a computer simulation mode:
experimental sample model: the processed test piece model with the abradable coating is obtained;
control sample model:
the processing procedure of the control sample was: and (3) directly and uniformly spraying a coating with the thickness of 1mm on the surface of the disc-shaped test piece processed in the step 2.1.
Introducing the experimental sample model and the control sample model into workbench19.2, defining a base material as a rigid body, endowing the abradable coating material with properties, constraining the lower bottom surface of the sample, loading 1000N acting force on the upper bottom surface of the sample, analyzing the stress response of the coating region of the experimental sample, wherein the stress response of the coating region of the experimental sample is shown in FIG. 2; the control sample coating area stress response is shown in fig. 3; through the comparison and calculation results of the stress cloud charts, it is obvious that the stress value of each test piece is obviously changed due to the fact that the contact area between the test piece and the abradable part is increased after the experimental sample is processed, and the maximum stress 2.4607MPa and the large-area stress 2.0079MPa are concentrated in the stress of the test piece in the graph 2; FIG. 3 shows that the large-area stress is 2.23MPa, and the stress state is obviously improved in FIG. 2.
Example two
This example prepares a ceramic matrix composite component with an abradable coating by the following process:
step 1.1, selecting T300-1K carbon fibers (including but not limited to the brand), and weaving the carbon fibers into two-dimensional plain cloth; after laminating 25 layers of two-dimensional plain cloth with the size of 240mm multiplied by 150mm, the 25 layers of two-dimensional plain cloth are sewed together by 1K carbon fiber along the laminating direction to obtain the two-dimensional plain cloth with the volume density of 0.70g/cm3And the carbon fiber preform with the carbon fiber volume fraction of 40.0-42.0%.
Step 1.2, clamping the carbon fiber preform obtained in the step 1.1 by using a graphite mold, placing the carbon fiber preform in a CVI deposition furnace, and depositing a pyrolytic carbon interface layer PyC by adopting a vapor deposition method; the technology for depositing the pyrolytic carbon interface layer (PyC) by adopting the CVI method comprises the following steps: depositing at 900-1100 ℃ and under the atmosphere pressure of 0.2-0.3 KPa, introducing propylene and argon at a certain flow rate, depositing for 50-60 h, and naturally cooling.
Step 1.3, depositing a SiC matrix on the carbon fiber preform treated in the step 1.2 by adopting a CVI (chemical vapor infiltration) process, and after the process is repeated for multiple times, releasing the graphite mold to finally obtain the carbon fiber preform with the volume density of 1.8g/cm3The ceramic matrix composite flat plate of (1);
the specific process comprises the following steps: the deposition temperature is 900-1200 ℃, the atmosphere pressure is 2-2.5 KPa, hydrogen and argon are introduced at a certain flow rate, MTS is brought into a CVI deposition furnace in a bubbling mode, the hydrogen and the MTS form a certain molar mass ratio, and the deposition is carried out for 50-100 hours and then the temperature is naturally reduced.
Step 1.4, processing the thickness of the ceramic matrix composite flat plate to 3.5mm by adopting a surface grinding machine to obtain a ceramic matrix composite substrate;
step 2.1, machining the groove and the blind hole;
fixing the ceramic matrix composite substrate on a positioning tool, and processing a plurality of grooves with set depths along the surface of the ceramic matrix composite substrate; the grooves may be 0.4mm deep and 2mm wide, with the grooves being parallel to one another. Then, uniformly processing 36 blind holes with the depth of 0.4mm along the circumferential direction by using a 1.5mm diamond drill bit;
2.2, depositing a SiC matrix by adopting a CVI (chemical vapor infiltration) process;
depositing a SiC matrix on the ceramic matrix composite substrate processed in the step 2.1 by adopting a CVI process, and repeating the process for 2 times to finally obtain the ceramic matrix composite substrate with the volume density of 2.0g/cm3The surface-modified ceramic matrix composite substrate of (1);
and uniformly spraying a coating with the thickness of 1mm on the surface of the ceramic matrix composite substrate after surface modification.
The depth, thickness and other data mentioned above can be changed according to actual requirements.
By the preparation method, the binding force between the ceramic matrix composite substrate and the coating is increased, the reduction of the oxidation resistance and mechanical property of the material due to the surface treatment mode is reduced, and a member with better mechanical property and oxidation resistance is obtained. The component structure can be seen in fig. 1: the ceramic matrix composite material comprises a ceramic matrix composite material matrix 1 and a wear-resistant coating coated on the surface of the ceramic matrix composite material matrix, wherein the surface of the ceramic matrix composite material matrix, which is in contact with the wear-resistant coating, is provided with a plurality of parallel grooves 2 and a plurality of blind holes 3 arranged along the circumferential direction.
Claims (10)
1. A method of making a ceramic matrix composite component having an abradable coating, comprising the steps of:
step 1, preparing a ceramic matrix composite substrate;
step 1.1, weaving carbon fibers into two-dimensional plain cloth; placing a plurality of layers of two-dimensional plain cloth in a laminated manner; sewing a plurality of layers of two-dimensional plain cloth together along the lamination direction by using carbon fibers to obtain a carbon fiber prefabricated body;
step 1.2, clamping the carbon fiber preform obtained in the step 1.1 by using a graphite mold, placing the carbon fiber preform in a CVI deposition furnace, and depositing a pyrolytic carbon interface layer PyC by adopting a chemical vapor deposition method;
step 1.3, depositing a SiC matrix on the carbon fiber preform treated in the step 1.2 by adopting a CVI (chemical vapor infiltration) process, and after the process is repeated for multiple times, releasing the graphite mold to obtain a ceramic matrix composite flat plate;
step 1.4, processing the thickness of the ceramic matrix composite flat plate to a set thickness by adopting a surface grinding machine to obtain a ceramic matrix composite substrate;
step 2, modifying the surface of the ceramic matrix composite substrate;
step 2.1, machining grooves and blind holes;
fixing the ceramic matrix composite substrate on a positioning tool, and processing a plurality of grooves and blind holes with set depths along the surface of the ceramic matrix composite substrate;
2.2, depositing a SiC matrix by adopting a CVI (chemical vapor infiltration) process;
depositing a SiC matrix on the ceramic matrix composite substrate processed in the step 2.1 by adopting a CVI (chemical vapor infiltration) process to finally obtain the surface-modified ceramic matrix composite substrate;
step 3, preparing a coating;
and uniformly spraying a coating with a set thickness on the surface of the ceramic matrix composite substrate after surface modification.
2. The method for preparing a ceramic matrix composite component with an abradable coating according to claim 1, wherein the process conditions for depositing the pyrolytic carbon interface layer PyC in step 1.2 by CVI are as follows:
depositing at 900-1100 ℃ and under the atmosphere pressure of 0.2-0.3 KPa, introducing propylene and argon at a certain flow rate, depositing for 50-60 h, and naturally cooling.
3. The method for preparing a ceramic matrix composite component with an abradable coating according to claim 2, wherein the process conditions for depositing the SiC matrix on the carbon fiber preform treated in step 1.2 using the CVI process in step 1.3 are as follows:
depositing at 900-1200 ℃ and under the atmosphere pressure of 2-2.5 KPa, introducing hydrogen and argon at a certain flow rate, and bubbling CH3SiCl3And (3) carrying the hydrogen into a CVI deposition furnace, forming a certain molar mass ratio of the hydrogen to MTS, and naturally cooling after 50-100 h of deposition.
4. The method of making a ceramic matrix composite component with an abradable coating of claim 3, wherein step 2.2 uses a CVI process to deposit a SiC substrate on the ceramic matrix composite substrate processed in step 2.1 under the following process conditions:
placing the ceramic matrix composite substrate processed in the step 2.1 in a CVI deposition furnace, introducing hydrogen and argon at a certain flow rate at the deposition temperature of 900-1200 ℃ and the atmosphere pressure of 2-2.5 KPa, and bubbling CH3SiCl3And (3) carrying the hydrogen into a CVI deposition furnace, forming a certain molar mass ratio of the hydrogen to MTS, and naturally cooling after 50-100 h of deposition.
5. The method for preparing a ceramic matrix composite component having an abradable coating of claim 1, further comprising, between step 1 and step 2, the steps of:
step a, processing a ceramic matrix composite substrate test piece;
placing the ceramic matrix composite substrate on a numerical control processing table, selecting a cutter, and processing the ceramic matrix composite substrate into a test piece with a set shape along the lamination direction;
step b, machining grooves and blind holes;
fixing a test piece on a positioning tool, and uniformly processing a plurality of grooves and blind holes with set depths along the surface of the test piece;
step c, depositing a SiC matrix;
depositing a SiC matrix on the test piece prepared in the step b by adopting the CVI process in the step 2.2, and repeating the process for at least 2 times to finally obtain the surface-modified ceramic matrix composite test piece;
step d, preparing a coating;
uniformly spraying a coating with a set thickness on the surface of the ceramic matrix composite test piece after surface modification;
and e, verifying the performance of the test piece prepared in the step d.
6. The method of making a ceramic matrix composite component having an abradable coating of claim 5, wherein: the test piece is circular in shape.
7. The method of making a ceramic matrix composite component with an abradable coating of any one of claims 1-6, wherein: the graphite mould comprises an upper-layer plate-shaped mould, a lower-layer plate-shaped mould and a clamping mechanism, wherein a plurality of through holes are formed in the upper-layer plate-shaped mould and the lower-layer plate-shaped mould.
8. The method of making a ceramic matrix composite component having an abradable coating of claim 7, wherein: the thickness of the ceramic matrix composite substrate is 3.5 mm;
processing a groove on the surface of the ceramic matrix composite material substrate or the surface of the test piece by using a diamond thread cutter; processing a blind hole on the surface of the ceramic matrix composite or the surface of a test piece by using a diamond drill;
the depth of the grooves and the blind holes is 0.4mm, and the grooves are parallel to each other; the blind holes are uniformly distributed along the circumferential direction of the surface of the test piece or the ceramic matrix composite material substrate;
the thickness of the coating was 1 mm.
9. The method of making a ceramic matrix composite component having an abradable coating of claim 8, wherein: and 2.2, repeating the process of depositing the SiC matrix by adopting a CVI method for at least 2 times.
10. A ceramic matrix composite component having an abradable coating, characterized by: the ceramic matrix composite material comprises a ceramic matrix composite material substrate and a wear-resistant coating coated on the surface of the ceramic matrix composite material substrate, wherein a plurality of parallel grooves and a plurality of blind holes uniformly distributed along the circumferential direction are formed on the surface of the ceramic matrix composite material substrate, which is in contact with the wear-resistant coating.
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