JP2011173784A - セラミックマトリクス複合体物品を製造する方法及びその方法により形成された物品 - Google Patents
セラミックマトリクス複合体物品を製造する方法及びその方法により形成された物品 Download PDFInfo
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Abstract
【解決手段】セラミック複合体構造10の製造方法は、熱硬化性樹脂、適切な硬化剤、セラミック成分、炭素質固体成分及び任意に使用される適切な溶剤を含む適切な前駆物質スラリ組成を補強材料に含浸させる110。熱硬化性樹脂の例は、ポリエステル、ビニルエステル、エポキシ樹脂、ビスマレイミド樹脂及びポリイミド樹脂を含む。炭素質固体成分は熱分解時に適切な量の炭素チャーを生成する。溶剤除去のため、硬化前にプレフォームは乾燥されてもよく、これにより70体積%までの固体を含む加工用材料が形成される。複合体物品の形成のために、プレフォームは、硬化120、熱分解130、且つ溶融ケイ素を浸透される140。熱硬化性樹脂は、加工性、未加工強度及び相対的に短時間である硬化サイクルを考慮して選択される。
【選択図】図2
Description
12 エーロフォイル部分
14 ダブテール
16 後縁部分
18 前縁部分
100 ステップ:補強材料を提供する
102a 点線
102b 破線
104 ステップ:補強材料を整形する
110 ステップ:補強材料をスラリ組成物と接触させる
120 ステップ:熱硬化性樹脂を硬化させる
130 ステップ:熱分解する
140 ステップ:メルト溶浸
Claims (10)
- 適切な補強材料を提供すること(100)と;
熱硬化性樹脂、適切な硬化剤、セラミック成分、炭素質固体成分及び任意に使用される適切な溶剤を含み、前記熱硬化性樹脂は、ポリエステル、ビニルエステル、エポキシ樹脂、ビスマレイミド樹脂及びポリイミド樹脂から選択された少なくとも1つの樹脂であり、且つ前記炭素質固体成分は、熱分解時に適切な量の炭素を生成する前駆物質スラリ組成物を提供することと;
加工用材料を形成するために、前記補強材料に前記前駆物質スラリ組成物を含浸させる(110)ことと;
前記溶剤が存在している場合、前記溶剤のほぼすべてを除去するために前記加工用材料を乾燥させることとから成り、乾燥後の前記加工用材料は、前記セラミック成分、樹脂チャー生成物及び前記炭素質固体成分より導出された約70体積%までの固体を含むことを特徴とする方法。 - 前記加工用材料を乾燥させた後又は乾燥させる前に、前記加工用材料をニアネットシェイプのプレフォームに整形すること(102a、102b)を更に含む請求項1記載の方法。
- 前記ニアネットシェイプのプレフォームの中で適切な硬化条件の下で前記熱硬化性樹脂を硬化させることにより、硬化プレフォームを形成すること(120)を更に含む請求項2記載の方法。
- 前記硬化プレフォームを熱分解することにより前記炭素チャーを生成し且つ多孔質プレフォームを形成すること(130)と;
前記多孔質プレフォームに溶融ケイ素を浸透させることにより、セラミック複合体構造を形成すること(140)とを更に含む請求項3記載の方法。 - 前記前駆物質スラリ組成物を提供することは、約48体積%のアセトン、約16体積%の前記炭素質固体成分、約9体積%の前記セラミック成分及び残余成分としての前記熱硬化性樹脂及び前記適切な硬化剤を提供することを含む請求項1記載の方法。
- 前記加工用材料は単方向性テープである請求項1記載の方法。
- 前記前駆物質スラリ組成物を提供することは、分散剤、濃厚化剤、架橋モノマー、低プロファイル添加剤及び染料から選択された適切な量の1つ以上の添加剤を提供することを含む請求項1記載の方法。
- 前記前駆物質スラリ組成物を提供することは、15分未満で硬化可能な熱硬化性樹脂を提供することを含む請求項1記載の方法。
- 前記前駆物質スラリ組成物を提供することは、グラファイト粒子、グラファイト薄片、グラファイトホイスカー、非晶質炭素、単結晶炭素又は多結晶炭素、炭化植物繊維、ランプブラック、微粉砕石炭、木炭、炭化ポリマー繊維又はフェルトより成る群から前記炭素質固体成分として少なくとも1つの物質を選択することを含む請求項1記載の方法。
- 前記加工用材料を整形することは、複数のプレプレグプライを形成することを含み且つ前記方法は、
未硬化プライスタックを形成するために前記プレプレグプライを積み重ねることと;
前記熱硬化性樹脂及び前記適切な硬化剤を含むマトリクス材料から形成された被覆プライによって前記スタックの外側のプライの各々を被覆することと;
15分未満の総硬化時間にわたり適切な硬化条件の下で前記スタックを圧縮硬化させることと;
前記硬化スタックを熱分解することにより前記炭素チャーを生成し且つ多孔質プレフォームを形成することと;
前記多孔質プレフォームに溶融ケイ素を浸透させることによりセラミック複合体構造を形成することとを含む請求項2記載の方法。
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US28974409P | 2009-12-23 | 2009-12-23 | |
US61/289,744 | 2009-12-23 | ||
US12/827,821 | 2010-06-30 | ||
US12/827,821 US8899939B2 (en) | 2009-12-23 | 2010-06-30 | Process for producing a ceramic matrix composite article and article formed thereby |
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Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
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JP2013241327A (ja) * | 2012-04-27 | 2013-12-05 | General Electric Co <Ge> | 溶融浸潤(melt−infiltrated)セラミックマトリックス複合材物品を製造する方法 |
JP2016069272A (ja) * | 2014-09-24 | 2016-05-09 | ロールス−ロイス コーポレイション | セラミックマトリクス複合材物品の製造方法 |
JP2017024978A (ja) * | 2015-07-13 | 2017-02-02 | ロールス−ロイス ハイ テンプレチャー コンポジッツ,インコーポレイティド | セラミックマトリックス複合材物品の製造方法 |
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US20130167374A1 (en) * | 2011-12-29 | 2013-07-04 | General Electric Company | Process of producing ceramic matrix composites and ceramic matrix composites formed thereby |
RU2487850C1 (ru) * | 2012-01-11 | 2013-07-20 | Открытое Акционерное Общество "Уральский научно-исследовательский институт композиционных материалов" | Способ изготовления изделий из углерод-карбидокремниевого материала |
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Also Published As
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US20110150663A1 (en) | 2011-06-23 |
CA2726177C (en) | 2018-09-25 |
EP2338861A2 (en) | 2011-06-29 |
CA2726177A1 (en) | 2011-06-23 |
US8899939B2 (en) | 2014-12-02 |
EP2338861A3 (en) | 2013-06-05 |
JP5898840B2 (ja) | 2016-04-06 |
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