JP7481256B2 - セラミックマトリックス複合体を製造する方法 - Google Patents
セラミックマトリックス複合体を製造する方法 Download PDFInfo
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- JP7481256B2 JP7481256B2 JP2020539741A JP2020539741A JP7481256B2 JP 7481256 B2 JP7481256 B2 JP 7481256B2 JP 2020539741 A JP2020539741 A JP 2020539741A JP 2020539741 A JP2020539741 A JP 2020539741A JP 7481256 B2 JP7481256 B2 JP 7481256B2
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- 238000000034 method Methods 0.000 title claims description 57
- 239000011153 ceramic matrix composite Substances 0.000 title claims description 19
- 238000004519 manufacturing process Methods 0.000 title description 6
- 239000002002 slurry Substances 0.000 claims description 85
- 239000002904 solvent Substances 0.000 claims description 85
- 239000011159 matrix material Substances 0.000 claims description 63
- 239000002245 particle Substances 0.000 claims description 63
- 239000011230 binding agent Substances 0.000 claims description 50
- 239000007787 solid Substances 0.000 claims description 47
- 239000000835 fiber Substances 0.000 claims description 38
- KFZMGEQAYNKOFK-UHFFFAOYSA-N Isopropanol Chemical compound CC(C)O KFZMGEQAYNKOFK-UHFFFAOYSA-N 0.000 claims description 33
- 230000008595 infiltration Effects 0.000 claims description 23
- 238000001764 infiltration Methods 0.000 claims description 23
- 238000002347 injection Methods 0.000 claims description 23
- 239000007924 injection Substances 0.000 claims description 23
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 17
- 229910052574 oxide ceramic Inorganic materials 0.000 claims description 16
- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 claims description 13
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 12
- BLRPTPMANUNPDV-UHFFFAOYSA-N Silane Chemical group [SiH4] BLRPTPMANUNPDV-UHFFFAOYSA-N 0.000 claims description 11
- 238000009835 boiling Methods 0.000 claims description 11
- 229910000077 silane Inorganic materials 0.000 claims description 11
- 238000009826 distribution Methods 0.000 claims description 10
- 238000001802 infusion Methods 0.000 claims description 10
- 238000005245 sintering Methods 0.000 claims description 9
- 229910001233 yttria-stabilized zirconia Inorganic materials 0.000 claims description 7
- 238000010438 heat treatment Methods 0.000 claims description 6
- 239000000377 silicon dioxide Substances 0.000 claims description 6
- 235000012239 silicon dioxide Nutrition 0.000 claims description 6
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 6
- MCMNRKCIXSYSNV-UHFFFAOYSA-N ZrO2 Inorganic materials O=[Zr]=O MCMNRKCIXSYSNV-UHFFFAOYSA-N 0.000 claims description 5
- 239000008119 colloidal silica Substances 0.000 claims description 5
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 3
- -1 aluminum silicates Chemical class 0.000 claims description 2
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- 150000004756 silanes Chemical group 0.000 claims 1
- 239000000203 mixture Substances 0.000 description 7
- 230000000704 physical effect Effects 0.000 description 7
- 239000000919 ceramic Substances 0.000 description 6
- 239000000126 substance Substances 0.000 description 6
- YKTSYUJCYHOUJP-UHFFFAOYSA-N [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] Chemical group [O--].[Al+3].[Al+3].[O-][Si]([O-])([O-])[O-] YKTSYUJCYHOUJP-UHFFFAOYSA-N 0.000 description 5
- 239000002131 composite material Substances 0.000 description 5
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- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 3
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- 229910010293 ceramic material Inorganic materials 0.000 description 3
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- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 2
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 2
- 238000013459 approach Methods 0.000 description 2
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 239000000463 material Substances 0.000 description 2
- 229910052863 mullite Inorganic materials 0.000 description 2
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 2
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Description
(1)所望の形のプリフォームへの、繊維のレイアップ及び固定;
(2)マトリックス材料の浸透;並びに
(3)最終機械加工、及び、要求される場合には、被覆又は含浸等をして空隙を減少させるさらなる処理、
からなる。
・(浸透されたサブミクロンサイズの粒子に起因して)しばしば酸化物プリプレグが乏しい形状追従性を有し、しばしば乏しい流動特性を有するので、酸化物CMCプリプレグを用いて複雑な形をレイアップすることは非常に困難な場合がある。
・鋭い半径又は鋭いエッジの周りにプライを形成すること、とりわけ軸外れプライを使用することは、プライ中にしわ又は他の異常を引き起こさずに達成することが非常に困難である場合がある。
・とりわけ軸外れプライを使用する場合、複雑な部品のためのプライキットは非常に大規模である(多数の異なるサイズ及び外形のプライ)場合がある。これは組み立てに時間がかかる場合があり、人的なレイアップの誤りをもたらす場合がある。
・プライのレイアップ、真空袋詰め及びオートクレーブサイクルは、時間がかかり、かつ多くの人手を要する場合がある。
・追加のスラリー浸透は、外表面を封鎖し、CMCのアクセスできない内部空隙を作り出す場合がある。すなわち、後の処理サイクルにおいて、CMCの中央に、スラリー粒子が満足には浸透しない場合がある。CMC外表面は低空隙率であるとともに高密度となり、依然として多孔性の領域を有するCMCの中央へ、マトリックスを浸透させない場合がある。機械加工等の追加の処理工程が、内部の多孔性の領域をアクセス可能にするのに、必要となる場合がある。
・浴中の追加のスラリー浸透は、所望しない位置におけるマトリックスの発達をもたらす場合があり、それは酸化物CMCの寸法公差を維持するために最終機械加工を必要とする。
幾つかの実施態様において、この処理で使用される注入スラリーは、酸化物セラミック材料、マトリックスバインダー(「バインダー」)及び溶媒を含み、酸化物セラミック材料は酸化アルミニウム粒子又はイットリア安定化ジルコニア(YSZ又はZrO2)を含む。スラリー中の粒子は、典型的には、1nm~1000nmの粒度分布を有するサブミクロンの粉砕された粒子である。ある実施態様において、粒子は二酸化ケイ素であってよく、特定の実施態様において、コロイダルシリカ粒子であってよい。スラリーは、50wt%~85wt%の固体及び15wt%~50wt%の溶媒を有することができる。55wt%~85wt%の固体及び15wt%~45wt%の溶媒を有するスラリーは、50wt%~54wt%の固体を使用するよりも、より良い時間効率であることができる。60wt%~75wt%の固体及び25wt%~40wt%の溶媒を有するスラリーを使用できることが期待される。特定の実施において、酸化アルミニウムスラリーは、75wt%~81wt%の固体及び19wt%~25wt%の溶媒を有する。
2D織物乾燥繊維(又はプリプレグ)レイアップ、3次元(3D)織物プリフォーム、ピンガイド繊維配置によって作り出されたプリフォーム、編組プリフォーム、又は他のプリフォームは、酸化アルミニウム繊維を用いて製造することができる。2D構造は、0°/90°、0°/-45°/90°/45°又はそれらの任意の組み合わせを含むラミネート構造プライレイアップスケジュールを有することができる。「0°/90°」レイアップスケジュールは、連続層中で、専断的な基準面に関して、0°と90°の間で縦糸が互い違いになることを意味する。「0°/-45°/45°/90°」レイアップスケジュールは、連続層中で、専断的な基準面に関して、前記縦糸の角を提供する。同様に、0°/-60°/90°/60°レイアップを使用することができる。
図1は、酸化物CMCを製造するための本方法を実施するために使用することができる、マトリックス浸透系の単純化した図を例示している。系は、マトリックススラリーを提供するためのマトリックス入口105、並びにプリフォーム(図示されていない)からマトリックススラリー及び特にスラリーの溶媒を除去するためのマトリックス出口110を含む。プリフォームは注入ツール115の空洞中に配置され、空洞はプリフォームに対して補完する形状を有する。空洞をさらすことを可能とするために、注入ツールは、プリフォームを収容するための少なくとも2つの部品中にある。
図2は、本開示によって酸化物CMCを製造する方法についてのフローチャート200を例示している。2D織物ラミネートレイアップ、3D織物プリフォーム、ピンガイド繊維配置によって作り出されたプリフォーム、編組プリフォーム又は他のプリフォーム(一般に「プリフォーム」)は、当業者にとって公知の技術によって調製される210。
本発明の実施形態としては、以下の実施形態を挙げることができる。
(付記1)
セラミックマトリックス複合体を製造する方法であって、
溶媒、マトリックスバインダー及び固体粒子を有するスラリーをプリフォームに浸透させること;
マトリックスバインダーを硬化させずに、少なくとも幾らかの溶媒を除去すること;並びに
プリフォームの所望の特性が達成されるまで、浸透及び溶媒の除去を繰り返すこと、
を含み、所望の特性は、密度、空隙率及び繊維体積率からなる群から選択される少なくとも1つである、方法。
(付記2)
少なくとも幾らかの溶媒を除去することが、溶媒とマトリックスバインダー間の化学的又は物理的性質における違いを利用することを含む、付記1に記載の方法。
(付記3)
化学的又は物理的性質が沸点温度である、付記2に記載の方法。
(付記4)
化学的又は物理的性質が蒸気圧である、付記2に記載の方法。
(付記5)
スラリーをプリフォームに浸透させること;
溶媒の沸点より高く、マトリックスバインダーの沸点より低い温度にプリフォームを加熱して、溶媒を蒸発させること;及び
蒸発した溶媒を排出すること、
を含む、付記3に記載の方法。
(付記6)
溶媒がイソプロピルアルコール又はアセトンであり;
マトリックスバインダーがケイ酸アルミニウム又はシランであり;
固体粒子が酸化物セラミック材料である、
付記5に記載の方法。
(付記7)
固体粒子が1nm~1000nmの粒度分布を有する、付記6に記載の方法。
(付記8)
スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、付記7に記載の方法。
(付記9)
スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、付記8に記載の方法。
(付記10)
酸化物セラミック材料が、酸化アルミニウム、二酸化ジルコニウム及びイットリア安定化ジルコニアからなる群から選択される、付記8に記載の方法。
(付記11)
所望の特性が達成された後にスラリーを硬化すること;及び
プリフォームを焼結すること、
を含む、付記1に記載の方法。
(付記12)
溶媒が水であり;
マトリックスバインダーがケイ酸アルミニウム又はシランであり;
固体粒子が二酸化ケイ素である、
付記5に記載の方法。
(付記13)
固体粒子が1nm~1000nmの粒度分布を有する、付記12に記載の方法。
(付記14)
スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、付記13に記載の方法。
(付記15)
スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、付記14に記載の方法。
(付記16)
固体粒子がコロイダルシリカである、付記12に記載の方法。
(付記17)
所望の特性が達成された後にスラリーを硬化すること;及び
プリフォームを焼結すること、
を含む、付記12に記載の方法。
(付記18)
固体粒子が1nm~1000nmの粒度分布を有する、付記1に記載の方法。
(付記19)
スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、付記1に記載の方法。
(付記20)
スラリーが、55wt%~85wt%の固体粒子及び15wt%~45wt%の溶媒を有する、付記19に記載の方法。
(付記21)
スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、付記20に記載の方法。
(付記22)
プリフォームの様式が、2次元(2D)乾燥繊維(又はプリプレグ)レイアップ、2D織物のラミネートレイアップ、ピンガイド繊維配置によって作り出されたプリフォーム、3次元(3D)織物プリフォーム及び編組プリフォームからなる群から選択される、付記1に記載の方法。
Claims (20)
- セラミックマトリックス複合体を製造する方法であって、
注入ツールに空洞を設けること
注入ツールの空洞中にプリフォームを配置すること;
注入ツールの空洞中で、溶媒、マトリックスバインダー及び固体粒子を有するスラリーをプリフォームに浸透させること;
注入ツールを加熱して、それによって、溶媒の沸点より高く、マトリックスバインダーの沸点より低い温度にプリフォームを加熱して、溶媒を蒸発させ、蒸発した溶媒を排出することによって、マトリックスバインダーを完全には硬化させずに、少なくとも幾らかの溶媒を除去すること;
得られたプリフォームが所望の特性を達成するまで、浸透及び溶媒の除去を繰り返すこと;並びに
所望の特性が達成された後に、注入ツール及びプリフォームを、プリフォーム中のマトリックスバインダーを完全に硬化するのに十分な温度に加熱することによって、注入ツール中のマトリックスバインダーを硬化すること、
を含み、所望の特性は、密度及び空隙率からなる群から選択される少なくとも1つであり、
溶媒が、イソプロピルアルコール、アセトン及び水からなる群から選択され、
マトリックスバインダーが、シラン及びケイ酸アルミニウムからなる群から選択され、
固体粒子が、酸化物セラミック材料及び二酸化ケイ素からなる群から選択される、方法。 - 少なくとも幾らかの溶媒を除去することが、溶媒とマトリックスバインダー間の蒸気圧における違いを利用することを含む、請求項1に記載の方法。
- 少なくとも幾らかの溶媒を除去することが、真空を適用することを含む、請求項1に記載の方法。
- 溶媒がイソプロピルアルコール又はアセトンであり;
マトリックスバインダーがシランであり;
固体粒子が酸化物セラミック材料である、
請求項1に記載の方法。 - 固体粒子が1nm~1000nmの粒度分布を有する、請求項4に記載の方法。
- スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、請求項5に記載の方法。
- スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、請求項6に記載の方法。
- 酸化物セラミック材料が、酸化アルミニウム、二酸化ジルコニウム及びイットリア安定化ジルコニアからなる群から選択される、請求項6に記載の方法。
- プリフォームを焼結することを含む、請求項1に記載の方法。
- 溶媒が水であり;
マトリックスバインダーがシランであり;
固体粒子が二酸化ケイ素である、
請求項1に記載の方法。 - 固体粒子が1nm~1000nmの粒度分布を有する、請求項10に記載の方法。
- スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、請求項11に記載の方法。
- スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、請求項12に記載の方法。
- 固体粒子がコロイダルシリカである、請求項10に記載の方法。
- プリフォームを焼結することを含む、請求項10に記載の方法。
- 固体粒子が1nm~1000nmの粒度分布を有する、請求項1に記載の方法。
- スラリーが、50wt%~85wt%の固体粒子及び15wt%~50wt%の溶媒を有する、請求項1に記載の方法。
- スラリーが、55wt%~85wt%の固体粒子及び15wt%~45wt%の溶媒を有する、請求項17に記載の方法。
- スラリーが、75wt%~81wt%の固体粒子及び19wt%~25wt%の溶媒を有する、請求項18に記載の方法。
- プリフォームの様式が、2次元(2D)乾燥繊維(又はプリプレグ)レイアップ、2D織物のラミネートレイアップ、ピンガイド繊維配置によって作り出されたプリフォーム、3次元(3D)織物プリフォーム及び編組プリフォームからなる群から選択される、請求項1に記載の方法。
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WO2019143768A1 (en) | 2019-07-25 |
RU2020123783A (ru) | 2022-02-21 |
US20190225552A1 (en) | 2019-07-25 |
CA3088532A1 (en) | 2019-07-25 |
CN111615504A (zh) | 2020-09-01 |
BR112020014259A2 (pt) | 2020-12-01 |
JP2021511278A (ja) | 2021-05-06 |
MX2020007134A (es) | 2020-12-03 |
RU2020123783A3 (ja) | 2022-03-10 |
EP3740462A1 (en) | 2020-11-25 |
KR20200111171A (ko) | 2020-09-28 |
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