EP3687957A2 - Procédé de fabrication d'éléments géométriques complexes contenant du carbone ou du carbure de silicium - Google Patents

Procédé de fabrication d'éléments géométriques complexes contenant du carbone ou du carbure de silicium

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Publication number
EP3687957A2
EP3687957A2 EP18782379.4A EP18782379A EP3687957A2 EP 3687957 A2 EP3687957 A2 EP 3687957A2 EP 18782379 A EP18782379 A EP 18782379A EP 3687957 A2 EP3687957 A2 EP 3687957A2
Authority
EP
European Patent Office
Prior art keywords
component
coke
carbon
green body
silicon carbide
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
EP18782379.4A
Other languages
German (de)
English (en)
Inventor
Oswin Oettinger
Dominik RIVOLA
Philipp Modlmeir
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
SGL Carbon SE
Original Assignee
SGL Carbon SE
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by SGL Carbon SE filed Critical SGL Carbon SE
Publication of EP3687957A2 publication Critical patent/EP3687957A2/fr
Withdrawn legal-status Critical Current

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    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/56Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides
    • C04B35/565Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbides or oxycarbides based on silicon carbide
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/522Graphite
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    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B35/00Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
    • C04B35/515Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics
    • C04B35/52Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite
    • C04B35/528Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components
    • C04B35/532Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on non-oxide ceramics based on carbon, e.g. graphite obtained from carbonaceous particles with or without other non-organic components containing a carbonisable binder
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/02Composition of constituents of the starting material or of secondary phases of the final product
    • C04B2235/50Constituents or additives of the starting mixture chosen for their shape or used because of their shape or their physical appearance
    • C04B2235/54Particle size related information
    • C04B2235/5418Particle size related information expressed by the size of the particles or aggregates thereof
    • C04B2235/5427Particle size related information expressed by the size of the particles or aggregates thereof millimeter or submillimeter sized, i.e. larger than 0,1 mm
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/602Making the green bodies or pre-forms by moulding
    • C04B2235/6026Computer aided shaping, e.g. rapid prototyping
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/608Green bodies or pre-forms with well-defined density
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/614Gas infiltration of green bodies or pre-forms
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/60Aspects relating to the preparation, properties or mechanical treatment of green bodies or pre-forms
    • C04B2235/616Liquid infiltration of green bodies or pre-forms
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    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/74Physical characteristics
    • C04B2235/77Density
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/95Products characterised by their size, e.g. microceramics
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    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2235/00Aspects relating to ceramic starting mixtures or sintered ceramic products
    • C04B2235/70Aspects relating to sintered or melt-casted ceramic products
    • C04B2235/96Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
    • C04B2235/9607Thermal properties, e.g. thermal expansion coefficient

Definitions

  • the present invention relates to a method for producing a complex geometric component containing carbon or silicon carbide, the component produced by this method and its use.
  • Complex geometric components containing carbon, graphite or silicon carbide can be produced by means of an additive manufacturing process, the 3D printing process.
  • a densification with resin (WO 2017/089494, DE 10 2015 222338) or pitch (WO 2015/038260) is performed.
  • the resin with which the step of densification takes place serves merely as a carbon donor. With such a component, there are no special requirements in terms of strength.
  • a component containing carbon or graphite, which has higher strengths, can be prepared by first densifying with, for example, phenolic resin, then graphitizing, and then again impregnating with a resin.
  • Impregnation with the phenolic resin and graphitization provide an electrically conductive network in the component.
  • the operating temperature of this component is given by the last resin impregnation. If, on the other hand, a subsequent densification with pitch occurs, it becomes liquid again during the pyrolysis or carbonization, so that bleeding (running out) of the pitch occurs from the carbon body produced by means of 3D printing. Furthermore, it will come to a sagging of the pitch due to gravity. As a result, the carbon-based or graphite-based component is inhomogeneous and has significant density gradients from top to bottom. Bleeding also significantly changes the outer contour of the structure, which requires reworking.
  • the object of the present invention is therefore to provide a method for producing a complex geometric component containing carbon or silicon carbide, with which a largely homogeneous component with good mechanical properties and high final contour proximity can be produced.
  • this object is achieved by a method for producing a complex geometric component comprising carbon or silicon carbide comprising the following steps:
  • Silicon carbide which has been produced by means of a 3D printing process
  • the green body based on carbon or silicon carbide in step a) is produced by means of a 3D printing process.
  • the production of such a green body can be carried out according to the methods described in WO 2017/089494.
  • a powdered composition having a grain size (d50) between 3 ⁇ and 500 ⁇ , preferably between 50 ⁇ and 350 ⁇ , more preferably between 100 ⁇ and 250 ⁇ comprising at least 50 wt .-% coke, preferably at least 80 wt. -%, more preferably at least 90 wt .-% and particularly preferably at least 95 wt .-% coke, and a liquid binder provided.
  • a planar deposition of a layer of the pulverulent composition followed by local deposition of droplets of the liquid binder on this layer.
  • These steps are repeated until the desired one Form of the component is made, wherein in the individual steps, an adaptation of the steps takes place to the desired shape of the component.
  • at least partial curing or drying of the binder wherein the
  • the abovementioned pulverulent composition may be both a powder of primary particles and a granulate.
  • the term "d50" is understood to mean that 50% of the particles are smaller than the stated value The d50 value was determined with the aid of the laser granulometric method (ISO 13320) using a measuring device from Sympatec GmbH with associated evaluation software has been.
  • the following is to be understood as obtaining a green body having the desired shape of the component.
  • the green body Immediately after the curing or drying of the binder, the green body is still surrounded by a powder bed of loose particles of the powdered composition. The green body must therefore be removed from the powder bed or separated from the loose, non-solidified particles.
  • This is referred to in the literature on 3D printing as "unpacking" of the printed component, which can be followed by a (fine) cleaning of the green body, in order to remove adhering particles however, the type of unpacking is not particularly limited, and any known methods can be used.
  • Green body in step a) using coke preferably selected from the group consisting of acetylene coke, flexioks, fluid coke, petroleum coke, shot coke, coal tar coke, coke of carbonated ion exchange beads and any mixtures thereof, more preferably selected from the group consisting of acetylene coke, flexikoks, Fluid coke, shot coke, coke of carbonated ion exchange beads and any mixtures thereof.
  • coke preferably selected from the group consisting of acetylene coke, flexioks, fluid coke, petroleum coke, shot coke, coal tar coke, coke of carbonated ion exchange beads and any mixtures thereof.
  • Green coke is a coke, which still contains volatile constituents. These volatiles are almost no longer present in the calcined or carbonized coke, this coke undergoes a temperature treatment of typically 700 ° C to 1400 ° C.
  • the terms calcined or carbonized are understood as synonyms.
  • Graphitized coke is obtained by treating the coke at a temperature of normally more than 2000 ° C to 3000 ° C.
  • the coke may be admixed with a liquid activator, such as, for example, a liquid sulfuric acid activator.
  • a liquid activator such as, for example, a liquid sulfuric acid activator.
  • the curing time and the necessary temperature for curing the binder can be reduced, on the other hand, the dust development of the powdered composition is reduced.
  • the amount of activator is 0.05% to 3.0% by weight, more preferably 0.1% to 1.0% by weight, based on the total weight of coke and activator.
  • the powdery composition sticks together and the flowability is reduced; If less than 0.05% by weight, based on the total weight of coke and activator, the amount of activator capable of reacting with the binder, more specifically the resin component of the binder, is too small to provide the desired advantages above to reach.
  • Suitable binders are, for example, phenolic resins,
  • binders should be like this be that after carbonation stable bodies can be obtained.
  • the binder should either have a sufficiently high carbon yield or an Si-containing inorganic yield when using organic binders after pyrolysis.
  • thermoplastic binders such as pitch, it may be necessary to carbonize the entire powder bed to decompose it and ultimately crosslink it.
  • PAN polyacrylonitrile
  • the binder phenolic resins, furan resins or polyimides are resins and polymers with a comparatively high carbon yield. They belong to the class of binders which are converted by curing into a non-fusible binder system.
  • cellulose, starch or sugar preferably in the present case as solution, can also be used as binder.
  • These binders only need to be dried, which is inexpensive.
  • silicates or silicon-containing polymers as binders, preferably present as a solution, has the advantage that these binders also only have to be cured. They form SiC when carbonated.
  • the fraction of the binder in the green body is preferably 1, 0 to 35.0% by weight, preferably 1.0 to 10.0% by weight and most preferably 1.5 to 5.0% by weight, based on the total weight of the green body.
  • the binders are the same binders used for 3D coke printing become.
  • the SiC used is used in the form of a powder which preferably has a particle size (d50) between 50 ⁇ m and 500 ⁇ m, preferably between 60 ⁇ m and 350 ⁇ m, more preferably between 70 ⁇ m and 300 ⁇ m, particularly preferably between 75 ⁇ m and 200 ⁇ m ,
  • d50 particle size between 50 ⁇ m and 500 ⁇ m, preferably between 60 ⁇ m and 350 ⁇ m, more preferably between 70 ⁇ m and 300 ⁇ m, particularly preferably between 75 ⁇ m and 200 ⁇ m
  • the laser granulometric method ISO 13320
  • Carbon are described in DE 19646094 or WO 2013/104685.
  • CVI method for example, a method which works isothermally and isobarically ("classical CVI method") as in DE 19646094 or a method in which high pressures and a short residence time of the gas take place, the so-called “rapid CVI method” according to WO 2013/104685 be used.
  • the conventional CVI process or the rapid CVI process is used in step b) of the process according to the invention.
  • the chemical vapor infiltration according to step b) is carried out using a carbon-containing gas, preferably natural gas, methane gas or propane gas, more preferably natural gas.
  • the chemical vapor infiltration according to step b) of the process is carried out at a temperature between 950 ° C and 1400 ° C, preferably at a temperature between 1100 ° C and 1300 ° C.
  • the chemical vapor infiltration according to step b) is carried out at a pressure of 5 mbar-50 mbar, preferably at a pressure of 15 mbar-30 mbar.
  • a gassing time of 100 to 400 hours, preferably 150 to 350 hours is carried out.
  • an impregnating agent selected from the group consisting of a phenolic resin, a furan resin, a sugar solution, a cellulose solution, a starch solution or a pitch, preferably a phenolic resin , a furan resin or pitch.
  • a carbonization step takes place.
  • carbonization is the thermal
  • the carbonization may be carried out by heating to temperatures in the range of 500 ° C - 1100 ° C, preferably 800 ° C to 1000 ° C, under inert gas atmosphere (e.g., under argon or nitrogen atmosphere) followed by holding time.
  • inert gas atmosphere e.g., under argon or nitrogen atmosphere
  • the above-mentioned impregnation step and the carbonization step may be performed more than once.
  • a graphitization step may also be carried out, wherein this graphitization step is carried out in a temperature range of 2000 ° C - 3000 ° C, preferably in a temperature range 2400 ° C - 2800 ° C. It is also included here that the above-mentioned impregnation step (s) and carbonation step (s) take place before step b).
  • Another object of the present invention is a complex geometric component, which has been produced by the process according to the invention.
  • the component according to the invention may comprise carbon, graphite or silicon carbide.
  • the component according to the invention comprising carbon has a density of more than 1.3 g / cm 3 and the component according to the invention comprising graphite has a density of greater than 1.4 g / cm 3 , preferably greater than 1.5 g / cm 3 ,
  • the component according to the invention comprising graphite has a thermal conductivity of more than 30 W / m-K, preferably more than 40 W / m-K.
  • the thermal conductivity was determined according to DIN 51908.
  • This component according to the invention also has a bending strength of more than 10 MPa, preferably of more than 15 MPa. The strength was determined according to the 3-point bending method according to DIN 51902.
  • Another object of the present invention is the use of the components according to the invention for chemical apparatus construction, as a casting core or as a casting mold, preferably as a casting mold having undercuts or
  • FIG. 1 shows a microsection of a component according to the invention
  • Inventive Examples 1 and 2 coke powder type green Flexikoks down sieved with 0.1 mm and sieved upwards with 0.4 mm was first with 0.35 wt .-% of a sulfuric acid liquid activator for phenolic resin, based on the total weight of Coke and activator, added and processed with a 3D-pressure powder bed machine.
  • a Rackel unit places on a flat powder bed a thin Kokspulverlage (about 0.26 mm height) and a kind of ink jet printing unit prints an alcoholic phenolic resin solution according to the desired component geometry on the
  • the green body was subjected to a furan resin dip impregnation and also cured at 140 ° C.
  • the resin consisted of 10 parts of furfuryl alcohol and a part of maleic anhydride as a hardener.
  • the green bodies were heated slowly under nitrogen atmosphere to 900 ° C and thereby carbonized. The density was thereby increased to 1.1 g / cm 3 .
  • the open porosity was about 30%. This measure made the handling of the body more robust.
  • the body was subjected to gas phase infiltration with a natural gas / argon mixture.
  • the process temperature was at 1200 ° C, the process pressure at 50 mbar pressure and the gassing time at 300 hours.
  • the final density of the bodies was 1.37 g / cm 3 and the body had an open porosity of about 12%.
  • Part of the samples were characterized physically and mechanically (Examples 1 .1); another part of the samples was heated to 2600 ° C in a graphitizing oven. These samples were also of an analogous characterization subjected (Example 1 .2).
  • the graphitization treatment resulted in a small geometric fading, so that the final density of the test specimens increased to 1.51 g / cm 3 .
  • Tables 1 and 2 The properties of the test specimens according to the comparative example are summarized in Tables 1 and 2.
  • Type designation 9905 DL used.
  • the bodies were first impregnated with the phenolic resin under vacuum pressure and then carbonized after curing at 140 ° C. under a nitrogen atmosphere at 900 ° C. After the first liquid resin compaction with phenolic resin and subsequent carbonization, the density was 1.28 g / cm 3 and the open porosity was about 22%. The post-compression process with the phenolic resin was repeated twice more, so that at the end the carbonized bodies had a density of 1.39 g / cm 3 . The open porosity was 1 1%.
  • Some of the samples were characterized analogously to Example 1 .1 (see Table Example 2.1). Another part was graphitized analogously to Example 1 .2 at 2600 ° C and finally characterized (see Table Examples 2.2). In addition, a graphitized sample was subjected to microscopic examination.
  • 3D printed carbon bodies can be obtained by both
  • Liquid resin as well as over the gas phase are densified with carbon, so that densities of about 1 .4 g / cm 3 can be achieved.
  • the bending strength level of the samples with vapor deposition is significantly better, which suggests a better binding of the pyrocarbon by vapor deposition to the coke grains.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Ceramic Products (AREA)
  • Carbon And Carbon Compounds (AREA)

Abstract

La présente invention concerne un procédé de fabrication d'un élément géométrique complexe contenant du carbone ou du carbure de silicium, l'élément fabriqué selon de procédé et son utilisation.
EP18782379.4A 2017-09-28 2018-09-28 Procédé de fabrication d'éléments géométriques complexes contenant du carbone ou du carbure de silicium Withdrawn EP3687957A2 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
DE102017217358.0A DE102017217358A1 (de) 2017-09-28 2017-09-28 Verfahren zur Herstellung von komplexen geometrischen Bauteilen enthaltend Kohlenstoff oder Siliziumkarbid
PCT/EP2018/076544 WO2019063831A2 (fr) 2017-09-28 2018-09-28 Procédé de fabrication d'éléments géométriques complexes contenant du carbone ou du carbure de silicium

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Publication Number Publication Date
EP3687957A2 true EP3687957A2 (fr) 2020-08-05

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US (1) US20200223757A1 (fr)
EP (1) EP3687957A2 (fr)
CN (1) CN111148728A (fr)
DE (1) DE102017217358A1 (fr)
WO (1) WO2019063831A2 (fr)

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GB2571514A (en) * 2018-01-24 2019-09-04 Univ Limerick Improvements relating to carbon fibre precursors
IL302254A (en) 2020-10-21 2023-06-01 Arkema France Actinically curable compositions for carbon-bonded ablative composites and additive manufacturing method of such compositions
CN114478012A (zh) * 2021-12-29 2022-05-13 宁波伏尔肯科技股份有限公司 一种碳部件制造方法及其制造的碳部件

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DE102015223240A1 (de) * 2015-11-24 2017-05-24 Sgl Carbon Se Kohlenstoff-Metall Verbundwerkstoff
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WO2019063831A2 (fr) 2019-04-04
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US20200223757A1 (en) 2020-07-16
DE102017217358A1 (de) 2019-03-28

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