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CN102825898A - 用于制造复合表面的方法 - Google Patents

用于制造复合表面的方法 Download PDF

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CN102825898A
CN102825898A CN201210198080.7A CN201210198080A CN102825898A CN 102825898 A CN102825898 A CN 102825898A CN 201210198080 A CN201210198080 A CN 201210198080A CN 102825898 A CN102825898 A CN 102825898A
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synusia
matrix composite
ceramic
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H.C.罗伯茨三世
R.A.布里廷厄姆
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General Electric Co
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Abstract

本发明涉及用于制造复合表面的方法。一种用于制造复合物(10)的方法包括：对外部层片(14)打孔以产生通过外部层片(14)的穿孔(22)，以及将填料材料(24)插入穿孔(22)中。该方法进一步包括将外部层片(14)层压到内部层片(30)上。

Description

用于制造复合表面的方法
技术领域
本发明大体涉及用于制造复合表面的方法。本发明的具体实施例可产生具有间断陶瓷表面轮廓的层压式层片组件。
背景技术
陶瓷基质复合物通常用于高温应用中，因为它们有低重量和高耐热性。用于燃气轮机发动机的护罩包括用于与邻近的支承结构接合的安装特征，以固持护罩节段。在陶瓷基质复合物和金属结构之间的安装特征在固持特征内包括接合容差，以容许在护罩节段和支承结构之间有不同的热增长。护罩通常由陶瓷基质复合物制成或涂覆有陶瓷基质复合物，陶瓷基质复合物比超合金轻，并且还可经受与热气路径相关联的高温环境。护罩附连到外部壳体上的容差可导致护罩有不合需要的运动或振动。因此，机械阻尼器可布置成抵靠着护罩，以减小或防止护罩的振动。通常由(但不限于)金属制成的机械阻尼器用作抵靠着护罩的质量体，并且在机械阻尼器和护罩之间产生的摩擦会减小或防止护罩的相对运动。
随着时间的过去，护罩中的陶瓷材料和机械阻尼器之间的持续接触可对机械阻尼器具有磨蚀作用。具体而言，温度变化、压力变化、振动和其它动态力可使陶瓷材料磨蚀或腐蚀机械阻尼器的邻近的金属表面。机械阻尼器的磨蚀或腐蚀会降低机械阻尼器的效果，从而需要增加维护和检查，以避免过早失效和/或意外停机。
减小与机械阻尼器接触的陶瓷材料的表面面积是降低机械阻尼器上的腐蚀性磨损的一个方法。例如，以前减小与机械阻尼器接触的陶瓷材料的表面面积的尝试已经集中在制造之后移除陶瓷表面中的局部区域和/或对陶瓷构件和/或机械阻尼器应用磨损抑制材料。但是，在制造之后移除局部化区域中的陶瓷材料难以实现。例如，可能不可接近陶瓷构件的一部分来在制造之后进行加工，并且意外地过量地移除陶瓷材料可损害构件，从而导致有额外的昂贵的修理。应用呈涂层形式的磨损抑制材料可由于能够成功地将磨损抑制材料结合到陶瓷构件和/或机械阻尼器上而复杂化。一旦被结合，因为陶瓷构件和机械阻尼器之间的接触压力的循环加载的原因，磨损抑制材料将有扩大的损坏，并且与热气路径相关联的高温可破坏结合强度，从而导致结合的寿命有限。
因此，用于制造降低陶瓷材料和匹配的金属表面之间的磨损的复合表面的改进的方法将是有用的。
发明内容
下面在以下描述中阐述了本发明的各方面和优点，或者根据描述，本发明的各方面和优点可为显而易见的，或者可通过实践本发明来学习本发明的各方面和优点。
本发明的一个实施例是一种用于制造复合物的方法。该方法包括：对外部层片打孔以产生通过外部层片的穿孔；以及将填料材料插入穿孔中。该方法进一步包括将外部层片层压到内部层片上。
在另一个实施例中，一种用于制造复合物的方法包括：形成外部复合层片；以及从外部复合层片移除一部分以产生通过外部复合层片的穿孔。该方法进一步包括：用填料材料填充外部复合层片中的穿孔的至少一部分；以及将外部复合层片层压到内部层片上。
在又一个实施例中，一种用于制造复合物的方法包括：形成外部层片；从外部层片移除一部分，以在外部层片上产生间断表面；以及对间断表面应用填料材料。该方法进一步包括将外部层片层压到内部层片上。
在审阅说明书之后，本领域普通技术人员将更好地理解这样的实施例和其它实施例的特征和各方面。
附图说明
在说明书的剩余部分中特别阐述了针对本领域技术人员的本发明的完整和能够实施的公开，包括其最佳模式，说明书参照了附图，其中：
图1是根据本发明的一个实施例经处理以产生间断表面轮廓的单个层片的透视图；
图2是图1中显示的单个层片的透视图，对间断表面轮廓添加了填料材料；以及
图3是根据本发明的一个实施例的层压式层片组件的透视图。
部件列表：
10单个层片
12间断表面
14陶瓷基质复合物
16复合层片的部分
18压机
20叉齿
22穿孔
24填料材料
26平准器
28层压式层片组件
30内部层片。
具体实施方式
现在将详细参照本发明的目前的实施例，在附图中示出了实施例的一个或多个实例。详细描述使用数字和字母名称来指示图中的特征。图和描述中相同或相似的名称用来指示本发明的相同或相似的部件。
以阐明本发明而非限制本发明的方式来提供各个实例。事实上，将对本领域技术人员显而易见的是，可在本发明中作出修改和变型，而不偏离本发明的范围或精神。例如，示出或描述成一个实施例的一部分的特征可用于另一个实施例上，以产生又一个实施例。因而，意图的是本发明覆盖在所附权利要求及其等效方案的范围内的这样的修改和变型。
本发明的多种实施例包括用于制造复合材料的方法，该复合材料在复合物的外部表面上具有局部化间断表面。在特定实施例中，多个层或层片的陶瓷基质复合物、金属基质复合物和/或有机基质复合物可层压在一起，局部化间断表面在层压件的外部表面上。因此，该方法产生期望的间断表面，而不需要在制造之后的加工或其它处理来实现期望的表面特征。
图1提供根据本发明的一个实施例的单个层片10的透视图，单个层片10经处理以在层片10的至少一部分上面产生间断表面12。在这个特定实施例中，单个层片10包括陶瓷基质复合物14，但是本发明的备选实施例可结合金属基质复合物和/或有机基质复合物。陶瓷基质复合物14可作为外部复合层片结合在多层层压复合物中，因为其有低重量和高耐热性。陶瓷基质复合物14可包括硅基材料，例如氧化硅(SiO2)、碳化硅(SiC)或氮化硅(Si3N4)，但是本发明的备选实施例可包括基于碳化钨(WC)、氧化锆(ZrO2)，碳化硼(B4C)或本领域中已知的其它陶瓷的陶瓷基质复合物14。另外，陶瓷基质复合物14可在整个陶瓷基质中包括碳增强纤维、陶瓷增强纤维、金属增强纤维、有机增强纤维、无机增强纤维和/或玻璃增强纤维。备选地或另外，可对陶瓷基质添加具有薄的氮化硼涂层的陶瓷增强纤维。增强纤维可编织或纺织到陶瓷基质中，以产生大约0.001英寸至0.020英寸的期望层片10厚度。但是，层片10的实际厚度取决于任何增强纤维的存在和大小以及陶瓷基质复合物14所意图的用途，并且不限制本发明，除非在权利要求中特别叙述。
如图1中显示，该方法包括移除复合层片10的部分16，以产生间断表面12。部分16可使用本领域已知的用于完成层片的任何技术来移除。例如，可使用旋转式钻机、放电机或激光钻机来钻通层片10或对层片10打孔，以精确地烧蚀或移除层片10的部分16，以在层片10上产生得到的间断表面12。备选地，如图1中显示的那样，具有凸出的叉齿20的压机18可在层片10上面滚动，以在层片10中产生凹陷或穿孔22。凹陷或穿孔22可具有大于大约0.01英寸和小于大约2.5英寸的直径和间隔。凹陷或穿孔22的具体大小和间隔可由本领域的普通技术人员以最少的试验来确定，以实现期望尺寸的间断表面12，而不过度地弱化层片10的强度，并且凹陷和穿孔22的精确大小和间隔不限制本发明，除非权利要求中特别叙述。
图2提供图1中显示的单个层片10的透视图，对间断表面12增加了填料材料24。在未处理时，陶瓷基质复合物14中的凹陷或穿孔22可易于有回填，并且对凹陷或穿孔22添加填料材料24因而会取代被移除部分16中的一些或全部，以防止陶瓷基质复合物14中的回填。另外，对陶瓷基质复合物14添加的填料材料24在其余的制造过程期间保持间断表面12，而不破坏层片10的完整性。填料材料24可包括任何非结合性的浆糊、凝胶、半固体或可注射到凹陷或穿孔22中或以别的方式对间断表面12应用的其它材料。例如，填料材料24可包括氮化硼、石墨、聚四氟乙烯、微气球结构或适于预期的环境的事实上任何其它非结合性润滑剂。填料材料24可注射或应用到单独的穿孔22上，使得填料材料24部分地或完全地填充凹陷或穿孔22。例如，如图2中显示的那样，可将一层填料材料24应用到层片10上，以完全地填充间断表面12中的凹陷或穿孔22。如果期望，则可被拉动跨过层片10的平准器(level)26可从层片10移除在凹陷或穿孔22的外部的过量的填料材料24。
图3提供根据本发明的一个实施例的层压式层片组件28的透视图。如显示的那样，单个层片10可附连或层压到一个或多个内部层片30上，以产生层压式层片组件28。内部层片30可包括陶瓷基质复合物、金属基质复合物或有机基质复合物中的一个或多个。对于本文考虑的应用，多种层片10、30可形成为单维度或多维度编织织物，并且对该多种层片10、30进行制造、层压和成形以形成期望的构件的方法不意图限制本发明。例如，单独的层片10、30可单独地形成为层压到衬底上的带层，以产生期望的构件。
因而本文描述的制造方法提供了优于现有的在制造之后的加工技术的若干技术和商业优点。例如，在形成系统构件之前从单个层片10移除部分16允许对单个层片10的整个表面区域有不受限制的接近，以容许将间断表面12精确地定位在期望位置处，而没有意外损害系统构件的内部层片28的风险。另外，间断表面12的精确布置不受系统构件的最终形状、位置或可接近性限制。
本书面描述使用实例来公开本发明，包括最佳模式，并且还使本领域任何技术人员能够实践本发明，包括制造和使用任何装置或系统，以及执行任何结合的方法。本发明的可授予专利的范围由权利要求限定，并且可包括本领域技术人员想到的其它实例。如果这样的其它实例包括不异于权利要求的字面语言的结构元素，或者如果这样的其它实例包括与权利要求的字面语言无实质性差异的等效结构元素，则它们意图处于权利要求的范围之内。

Claims (6)

1. 一种用于制造复合物(10)的方法，包括：
a.对外部层片(14)打孔，以产生通过所述外部层片的穿孔(22)；
b.将填料材料(24)插入所述穿孔(22)中；以及
c.将所述外部层片(14)层压到内部层片(30)上。
2. 根据权利要求1所述的方法，其特征在于，所述方法进一步包括用陶瓷基质复合物形成所述外部层片(14)。
3. 根据权利要求1所述的方法，其特征在于，所述打孔包括钻通所述外部层片(14)，以产生通过所述外部层片(14)的所述穿孔(22)。
4. 根据权利要求1所述的方法，其特征在于，所述方法进一步包括用润滑剂填充所述外部层片(14)中的所述穿孔(22)的至少一部分。
5. 根据权利要求1所述的方法，其特征在于，所述方法进一步包括用氮化硼或聚四氟乙烯中的至少一个填充所述外部层片(14)中的所述穿孔(22)的至少一部分。
6. 根据权利要求1所述的方法，其特征在于，所述层压包括将所述外部层片(14)层压到陶瓷基质复合物、金属基质复合物或有机基质复合物中的至少一个上。
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