CN111039687B - 一种连续纤维增强陶瓷基复合材料无伤制孔方法 - Google Patents

一种连续纤维增强陶瓷基复合材料无伤制孔方法 Download PDF

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CN111039687B
CN111039687B CN201911297763.6A CN201911297763A CN111039687B CN 111039687 B CN111039687 B CN 111039687B CN 201911297763 A CN201911297763 A CN 201911297763A CN 111039687 B CN111039687 B CN 111039687B
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王启明
谢巍杰
邱海鹏
陈明伟
王岭
刘善华
关宏
赵禹良
王晓猛
张冰玉
罗文东
马新
刘时剑
梁艳媛
李秀倩
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Abstract

本发明是一种连续纤维增强陶瓷基复合材料无伤制孔方法，该方法通过纤维铺放模板设计与制备、连续纤维铺放、基体填充、无伤制孔等过程控制，实现在制孔的同时保持连续纤维增强陶瓷基复合材料结构完整性，与现有减材加工制孔方法相比，不会对连续纤维造成破坏损伤且避免了加工引起的其它缺陷损伤，能够使含孔结构的连续纤维增强陶瓷基复合材料的力学性能提升10％～60％。

Description

一种连续纤维增强陶瓷基复合材料无伤制孔方法
技术领域
本发明是一种连续纤维增强陶瓷基复合材料无伤制孔方法，属于陶瓷基复合材料的制备技术领域。
背景技术
连续纤维增强陶瓷基复合材料具有陶瓷材料耐高温、抗氧化、耐磨损、耐腐蚀等优点，同时因连续纤维的增强增韧作用而具有优异的抗外部冲击载荷性能。连续纤维增强陶瓷基复合材料凭借良好的高温稳定性和高温力学性能，在先进航空发动机热端部件、先进飞行器热防护***等领域得到越来越广泛的应用。
连续纤维增强陶瓷基复合材料在实际应用中通常需要制孔，如用于连接的装配孔、用于冷却的气膜孔等。目前常用的制孔方式为采用减材加工方式在完整材料上制孔，如机械加工钻削制孔、激光制孔、水切割制孔、线切割制孔等，以上方式均会造成材料中的连续纤维受到破坏损伤，从而使材料力学性能降低，进而影响构件整体使用性能。如何实现制孔的同时保持连续纤维增强陶瓷基复合材料结构的完整性，是连续纤维增强陶瓷基复合材料应用领域亟待解决的问题。
发明内容
本发明正是针对上述现有技术状况而设计提供了一种连续纤维增强陶瓷基复合材料无伤制孔方法，其目的是实现在制孔的同时不对连续纤维增强陶瓷基复合材料结构造成损伤，从而提升了含孔结构的连续纤维增强陶瓷基复合材料的力学性能。
本发明的技术解决方案是：
该种连续纤维增强陶瓷基复合材料无伤制孔方法的步骤如下：
步骤一、依据孔的尺寸、形状及位置要求，进行纤维铺放模板的设计与制备，纤维铺放模板在需要制孔的相应位置设置预填物，预填物具有与孔对应的尺寸、形状、位置等特征；
步骤二、将连续纤维依照预设参数铺设于纤维铺放模板上，预设参数包含纤维走向、纤维体积分数、纤维预制体厚度，需要制孔的位置由预填物占据而被纤维绕过，得到连续纤维预制体；
步骤三、在连续纤维预制体的孔隙中填充陶瓷基体，完成连续纤维增强陶瓷基复合材料的致密化；
步骤四、将纤维铺放模板与预填物脱除，完成无伤制孔。
在一种实施中，所述纤维铺放模板具有与连续纤维增强陶瓷基复合材料构件结构特征相适应的型面，兼具为连续纤维增强陶瓷基复合材料定型的功能，纤维铺放模板以及预填物的形状、位置、尺寸在连续纤维铺放与基体填充过程中保持不变，纤维铺放模板以及预填物的理化性能稳定，材质选用石墨、陶瓷、高温合金、高聚物。
在一种实施中，所述纤维铺放模板对预填物的约束保证预填物在连续纤维铺放与陶瓷基体填充过程中的精准定位，约束方式可采用一体成型、榫接、粘接、焊接。
在一种实施中，所述孔的截面形状为圆孔和异型孔，孔径不小于0.1mm。
在一种实施中，所述连续纤维为碳纤维、碳化硅纤维、氮化物纤维或氧化物纤维。
在一种实施中，所述连续纤维铺设方式为铺丝、铺带、铺层、机织或手工编织，连续纤维预制体结构为单向带、2D铺层、2.5D织物或3D织物。
在一种实施中，所述陶瓷基体为碳化硅、氮化物陶瓷或氧化物陶瓷。
在一种实施中，所述纤维铺放模板与预填物从连续纤维增强陶瓷基复合材料的脱除方式为直接剥离、减材加工。
本发明具有的优点和有益效果是：
第一，本发明提供的连续纤维增强陶瓷基复合材料无伤制孔方法通过纤维铺放模板设计与制备、连续纤维铺放、基体填充、无伤制孔等过程控制，实现在制孔的同时保持连续纤维增强陶瓷基复合材料结构完整性，与现有减材加工制孔方法相比，不会对连续纤维造成破坏损伤且避免了加工引起的其它缺陷损伤，能够使含孔结构的连续纤维增强陶瓷基复合材料的力学性能提升10％～60％。
第二，本发明提供的连续纤维增强陶瓷基复合材料无伤制孔方法，孔的形状与方向具有很强的设计性，尤其为异型孔的制备提供了一种高效低成本的解决方案，且制孔精度因不受加工条件限制而大幅提升。
本发明还适用于其它连续纤维增强复合材料的制孔。
附图说明：
图1为实施例中纤维铺放模板示意图，其中，a：正等侧图，b：俯视图；
图2为实施例中连续纤维铺放示意图；
图3为实施例中基体填充示意图；
图4为实施例中无伤制孔示意图。
具体实施方式：
以下结合附图和下述实施方案对本发明做进一步的详细说明：
参见附图1～4所示，本实施例中，该种连续碳化硅纤维增强碳化硅陶瓷基复合材料平板构件的尺寸为100mm×50mm×5mm，中央含1个直径为6mm的直孔5，该种连续纤维增强陶瓷基复合材料无伤制孔方法的步骤如下：
步骤一、依据孔5的尺寸、形状及位置要求，进行纤维铺放模板1的设计与制备，纤维铺放模板1的尺寸为100mm×50mm×10mm，纤维铺放模板1在中央设置预填物2，预填物2的直径为6mm、厚度为5mm，纤维铺放模板1和预填物2由高纯石墨一体成型；
步骤二、将连续碳化硅纤维3依照预设参数铺设于纤维铺放模板1上，纤维铺设方式为单向铺丝，纤维走向沿构件长度方向，纤维体积分数为40％，纤维预制体厚度为5mm，需要制孔5的位置由预填物2占据而被连续碳化硅纤维3绕过；
步骤三、采用先驱体浸渍裂解工艺，对连续碳化硅纤维预制体进行热解炭界面层制备，以聚碳硅烷为浸渍剂，经过浸渍-裂解循环完成致密化，在连续碳化硅纤维预制体的孔隙中填充碳化硅陶瓷基体4，完成连续碳化硅纤维增强碳化硅陶瓷基复合材料6的致密化；
步骤四、将纤维铺放模板1与预填物2从连续碳化硅纤维增强碳化硅陶瓷基复合材料6上直接剥离，完成孔5的无伤制备，得到含孔5结构的连续碳化硅纤维增强碳化硅陶瓷基复合材料6。

Claims (3)

1.一种连续纤维增强陶瓷基复合材料无伤制孔方法，其特征在于：该方法的步骤如下：
步骤一、依据孔的尺寸、形状及位置要求，进行纤维铺放模板的设计与制备，纤维铺放模板在需要制孔的相应位置设置预填物，预填物具有与孔对应的尺寸、形状、位置特征；
所述纤维铺放模板具有与连续纤维增强陶瓷基复合材料构件结构特征相适应的型面，兼具为连续纤维增强陶瓷基复合材料定型的功能，纤维铺放模板以及预填物的形状、位置、尺寸在连续纤维铺放与基体填充过程中保持不变，为此，采用一体成型来保证纤维铺放模板对预填物的约束在连续纤维铺放与陶瓷基体填充过程中的精准定位，纤维铺放模板以及预填物的理化性能稳定，材质选用石墨；
步骤二、将连续纤维依照预设参数铺设于纤维铺放模板上，连续纤维铺设方式为铺丝、铺带、铺层、机织或手工编织，连续纤维预制体结构为单向带、2D铺层、2.5D织物、3D织物，预设参数包含纤维走向、纤维体积分数、纤维预制体厚度，需要制孔的位置由预填物占据而被纤维绕过，得到连续纤维预制体；
所述无伤制孔的截面形状为圆孔和异型孔，孔径不小于0.1mm；
步骤三、在连续纤维预制体的孔隙中填充碳化硅陶瓷基体，完成连续纤维增强陶瓷基复合材料的致密化；
步骤四、将纤维铺放模板与预填物脱除，完成无伤制孔。
2.根据权利要求1所述的连续纤维增强陶瓷基复合材料无伤制孔方法，其特征在于：所述连续纤维为碳纤维、碳化硅纤维、氮化物纤维或氧化物纤维。
3.根据权利要求1所述的连续纤维增强陶瓷基复合材料无伤制孔方法，其特征在于：所述纤维铺放模板与预填物从连续纤维增强陶瓷基复合材料的脱除方式为直接剥离、减材加工。
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