CN111454073A - High-heat-conductivity, strong-bonding and ablation-resistant ultrahigh-temperature ceramic matrix composite and preparation method thereof - Google Patents
High-heat-conductivity, strong-bonding and ablation-resistant ultrahigh-temperature ceramic matrix composite and preparation method thereof Download PDFInfo
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Abstract
本发明涉及一种高导热、强结合、耐烧蚀的超高温陶瓷基复合材料及其制备方法,所述超高温陶瓷基复合材料的制备方法包括:(1)选取碳纤维编织成碳纤维预制体,所述碳纤维的热导率>40W/m·K;(2)采用化学气相渗透法在碳纤维预制体中碳纤维表面沉积界面层;(3)通过溶胶凝胶法、浆料浸渍法、前驱体浸渍裂解法向碳纤维预制体中引入碳源和陶瓷相,再结合反应熔渗法实现致密化,得到所述高导热、强结合、耐烧蚀的超高温陶瓷基复合材料。
The invention relates to an ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance and a preparation method thereof. The thermal conductivity of the carbon fiber is more than 40W/m·K; (2) the interface layer is deposited on the surface of the carbon fiber in the carbon fiber preform by chemical vapor infiltration; (3) by the sol-gel method, the slurry impregnation method, and the precursor impregnation method The carbon source and the ceramic phase are introduced into the carbon fiber preform by the pyrolysis method, and then combined with the reactive infiltration method to achieve densification, and the ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance is obtained.
Description
技术领域technical field
本发明涉及一种提高纤维增强陶瓷基复合材料耐烧蚀性能的方法,具体涉及一种高导热、强结合、耐烧蚀的超高温陶瓷基复合材料的制备方法,属于超高温陶瓷基复合材料制备技术领域。The invention relates to a method for improving the ablation resistance of a fiber-reinforced ceramic matrix composite material, in particular to a method for preparing an ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance, belonging to the ultra-high temperature ceramic matrix composite material Preparation technology field.
背景技术Background technique
作为高超声速飞行器研制的关键技术之一,热结构是保障飞行器在极端环境安全服役的基石,其工作环境复杂严苛,因此对高温结构材料提出了严峻挑战。要适应极端服役环境,必须攻克热结构材料高强韧、耐超高温、近零烧蚀难题。连续纤维增强超高温陶瓷基复合材料(Ceramic Matrix Composites)从根本上克服了陶瓷材料固有的脆性,同时具有轻质、耐超高温、抗氧化烧蚀、可设计性强等优点,成为高超声速飞行器热防护、热结构的重要候选材料。As one of the key technologies in the development of hypersonic aircraft, thermal structure is the cornerstone to ensure the safe service of aircraft in extreme environments. Its working environment is complex and severe, so it poses severe challenges to high-temperature structural materials. In order to adapt to the extreme service environment, it is necessary to overcome the problems of high strength and toughness, ultra-high temperature resistance and near-zero ablation of thermal structural materials. Continuous fiber reinforced ultra-high temperature ceramic matrix composites (Ceramic Matrix Composites) fundamentally overcome the inherent brittleness of ceramic materials, and at the same time have the advantages of light weight, ultra-high temperature resistance, oxidation ablation resistance, and strong designability, becoming a hypersonic aircraft. Important candidate material for thermal protection, thermal structure.
高温抗氧化烧蚀是应用在极端服役环境下的超高温陶瓷基复合材料最为关键的性能参数。High temperature oxidation and ablation resistance is the most critical performance parameter of ultra-high temperature ceramic matrix composites used in extreme service environments.
发明内容SUMMARY OF THE INVENTION
为此,本发明的目的在于提供一种高导热、强结合、耐烧蚀的超高温陶瓷基复合材料及其制备方法,主要是通过提高超高温陶瓷基复合材料热导率、基体结合强度来提高材料的耐烧蚀性能。Therefore, the purpose of the present invention is to provide an ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance and a preparation method thereof, mainly by improving the thermal conductivity and matrix bonding strength of the ultra-high temperature ceramic matrix composite material. Improve the ablation resistance of the material.
一方面,本发明提供了一种高导热、强结合、耐烧蚀的超高温陶瓷基复合材料的制备方法,包括:On the one hand, the present invention provides a preparation method of an ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance, comprising:
(1)选取碳纤维编织成碳纤维预制体,所述碳纤维的热导率>40W/m·K;(1) Select carbon fibers to be woven into carbon fiber preforms, and the thermal conductivity of the carbon fibers is greater than 40W/m·K;
(2)采用化学气相渗透法在碳纤维预制体中碳纤维表面沉积界面层;(2) using chemical vapor infiltration method to deposit an interface layer on the surface of carbon fiber in the carbon fiber preform;
(3)通过溶胶凝胶法、浆料浸渍法、前驱体浸渍裂解法向碳纤维预制体中引入碳源和陶瓷相,再结合反应熔渗法实现致密化,得到所述高导热、强结合、耐烧蚀的超高温陶瓷基复合材料。(3) introducing a carbon source and a ceramic phase into the carbon fiber preform by a sol-gel method, a slurry impregnation method, and a precursor impregnation cracking method, and then combined with a reactive infiltration method to achieve densification to obtain the high thermal conductivity, strong bonding, Ablation-resistant ultra-high temperature ceramic matrix composites.
本发明人发现,材料热导率和基体结合强度是影响超高温陶瓷基复合材料抗氧化烧蚀性能的关键因素。而且,在烧蚀过程中,进一步研究得到当高热导率复合材料的热导率大于15W/m·K时,其基本可以将烧蚀区的热量迅速传递到材料各部分,避免热量聚集,降低烧蚀区表面温度从而降低烧蚀损伤。同时,考虑到材料热导率与材料的组成、结构密切相关。为此,本公开首次通过选用高热导率(热导率>40W/m·K)的碳纤维构建具有高热导率碳纤维预制体,再结合反应熔渗方法制备高致密超高温陶瓷基复合材料,使复合材料在后续烧蚀过程中可以迅速将热量传输到材料各部分,避免热量聚集,降低烧蚀表面温度;同时,还能提高复合材料基体结合强度,降低烧蚀过程中材料发生层状剥蚀的风险,为提高纤维增强超高温陶瓷基复合材料耐烧蚀性能提供了新的解决方法。而且,本发明不采用碳热还原过程,在避免多次高温热处理对碳纤维造成损伤的同时,保证了碳纤维纤维仍然具有高热导性能。The inventors found that the thermal conductivity of the material and the bonding strength of the matrix are the key factors affecting the anti-oxidative ablation performance of the ultra-high temperature ceramic matrix composite material. Moreover, during the ablation process, further studies have shown that when the thermal conductivity of the high thermal conductivity composite material is greater than 15W/m·K, it can basically transfer the heat in the ablation zone to all parts of the material quickly, avoiding heat accumulation and reducing heat. The surface temperature of the ablation zone reduces the ablation damage. At the same time, considering that the thermal conductivity of the material is closely related to the composition and structure of the material. For this reason, the present disclosure for the first time constructs carbon fiber preforms with high thermal conductivity by selecting carbon fibers with high thermal conductivity (thermal conductivity>40W/m·K), and then combines the reaction infiltration method to prepare high-density and ultra-high temperature ceramic matrix composites. In the subsequent ablation process, the composite material can quickly transfer heat to all parts of the material, avoid heat accumulation, and reduce the temperature of the ablation surface; at the same time, it can also improve the bonding strength of the composite material matrix and reduce the layered exfoliation of the material during the ablation process. It provides a new solution for improving the ablation resistance of fiber-reinforced ultra-high temperature ceramic matrix composites. Moreover, the present invention does not use a carbothermic reduction process, which ensures that the carbon fiber still has high thermal conductivity while avoiding damage to the carbon fiber caused by multiple high-temperature heat treatments.
较佳的,所述碳纤维预制体为2维纤维预制体、2.5维纤维预制体、或3维纤维预制体。Preferably, the carbon fiber preform is a 2-dimensional fiber preform, a 2.5-dimensional fiber preform, or a 3-dimensional fiber preform.
较佳的,所述碳纤维预制体中碳纤维的含量为10~70vol%。Preferably, the carbon fiber content in the carbon fiber preform is 10-70 vol%.
较佳的,所述界面层为PyC层、BN层、SiC界面层中的至少一层;所述界面层的总厚度为0.01~5μm。Preferably, the interface layer is at least one of a PyC layer, a BN layer, and a SiC interface layer; the total thickness of the interface layer is 0.01-5 μm.
较佳的,所述碳源为酚醛树脂、聚乙烯吡咯烷酮、蔗糖、碳粉中的至少一种。Preferably, the carbon source is at least one of phenolic resin, polyvinylpyrrolidone, sucrose, and carbon powder.
较佳的,所述陶瓷相为SiC、TaC、ZrC、ZrB2、HfC、HfB2中的至少一种。Preferably, the ceramic phase is at least one of SiC, TaC, ZrC, ZrB 2 , HfC, and HfB 2 .
较佳的,所述反应熔渗法所用原料为Si、Zr、Hf、ZrSi2、HfSi2中的至少一种。Preferably, the raw material used in the reactive infiltration method is at least one of Si, Zr, Hf, ZrSi 2 and HfSi 2 .
较佳的,在引入碳源和陶瓷相后,再于保护气氛、600~1000℃下进行裂解;优选地,所述保护气氛为惰性气氛。Preferably, after the carbon source and the ceramic phase are introduced, the pyrolysis is carried out in a protective atmosphere at 600-1000°C; preferably, the protective atmosphere is an inert atmosphere.
另一方面,本发明还提供了一种根据上述制备方法制备的高导热、强结合、耐烧蚀的超高温陶瓷基复合材料,所述超高温陶瓷基复合材料中各相呈弥散分布或连续分布形式。On the other hand, the present invention also provides an ultra-high temperature ceramic matrix composite material with high thermal conductivity, strong bonding and ablation resistance prepared according to the above preparation method, wherein each phase in the ultra-high temperature ceramic matrix composite material is dispersed or continuous. distribution form.
较佳的,所述超高温陶瓷基复合材料的开口气孔率低于10%,热导率大于15W/m·K,层间结合强度大于40MPa。Preferably, the open porosity of the ultra-high temperature ceramic matrix composite material is less than 10%, the thermal conductivity is greater than 15 W/m·K, and the interlayer bonding strength is greater than 40 MPa.
较佳的,在热流密度为4.02MW/m2的等离子火焰下烧蚀60秒后,所述超高温陶瓷基复合材料的线烧蚀率低于10μm/s。Preferably, the linear ablation rate of the ultra-high temperature ceramic matrix composite material is lower than 10 μm/s after being ablated under a plasma flame with a heat flux density of 4.02 MW/m 2 for 60 seconds.
有益效果:Beneficial effects:
本发明通过使用高导热的碳纤维作为增强体、构建高导热的碳纤维预制体、结合反应熔渗原位反应方法提高基体致密度、结合强度和热导率,从而提高超高温陶瓷基复合材料抗烧蚀性能。使用本发明制备的超高温陶瓷基复合材料在烧蚀过程中,可以迅速地将烧蚀区的热量传输到材料各部分,减少热量聚集,降低烧蚀表面温度。同时,较高的基体结合强度,降低了烧蚀过程中材料发生层状剥蚀的风险,有效提高材料耐烧蚀性能。The invention improves the density, bonding strength and thermal conductivity of the matrix by using carbon fibers with high thermal conductivity as reinforcements, constructing carbon fiber preforms with high thermal conductivity, and combining reactive infiltration in situ reaction methods, thereby improving the burning resistance of ultra-high temperature ceramic matrix composites. corrosion performance. During the ablation process of the ultra-high temperature ceramic matrix composite material prepared by the invention, the heat in the ablation zone can be rapidly transferred to each part of the material, the heat accumulation is reduced, and the temperature of the ablation surface is lowered. At the same time, the higher bonding strength of the substrate reduces the risk of layered erosion of the material during the ablation process, and effectively improves the ablation resistance of the material.
附图说明Description of drawings
图1为本发明中超高温陶瓷基复合材料的制备路线图;Fig. 1 is the preparation route diagram of the ultra-high temperature ceramic matrix composite material in the present invention;
图2为实施例1制备的高导热、强结合超高温陶瓷基复合材料,经碳热还原制备的复合材料和传统复合材料的热导率-温度曲线,从图中可知从室温到1200℃,三种材料的热导率随温度升高均有小幅降低,但高导热、强结合超高温陶瓷基复合材料的热导率始终远高于其他两种复合材料;Figure 2 shows the thermal conductivity-temperature curve of the high thermal conductivity, strong bonding ultra-high temperature ceramic matrix composite material prepared in Example 1, the composite material prepared by carbothermic reduction and the traditional composite material. The thermal conductivity of the three materials decreases slightly with the increase of temperature, but the thermal conductivity of the high thermal conductivity and strong bonding ultra-high temperature ceramic matrix composites is always much higher than that of the other two composites;
图3为实施例1制备的高导热、强结合超高温陶瓷基复合材料(a)、经碳热还原制备的复合材料(b)和传统超高温陶瓷基复合材料(c)在热流密度为4.02MW/m2的等离子火焰下烧蚀60秒后的光学照片,从图中可知高导热、强结合超高温陶瓷基复合材料的烧蚀中心无明显损伤,但另外两种复合材料烧蚀中心有明显烧蚀坑。Figure 3 shows the high thermal conductivity, strong bonding ultra-high temperature ceramic matrix composite material (a) prepared in Example 1, the composite material prepared by carbothermic reduction (b) and the traditional ultra-high temperature ceramic matrix composite material (c) at a heat flux density of 4.02 Optical photo after ablation for 60 seconds under MW/m 2 plasma flame, it can be seen from the figure that the ablation center of the high thermal conductivity and strong bonding ultra-high temperature ceramic matrix composite has no obvious damage, but the ablation center of the other two composite materials has Obvious ablation pits.
具体实施方式Detailed ways
以下通过下述实施方式进一步说明本发明,应理解,下述实施方式仅用于说明本发明,而非限制本发明。The present invention is further described below through the following embodiments, and it should be understood that the following embodiments are only used to illustrate the present invention, but not to limit the present invention.
在本发明中,基于提高超高温陶瓷基复合材料热导率、基体结合强度的角度出发,从而实现提高材料耐烧蚀性能,具体来说提供了一种高导热、强结合、耐烧蚀的超高温陶瓷基复合材料的制备方法。In the present invention, based on the perspective of improving the thermal conductivity and the bonding strength of the ultra-high temperature ceramic matrix composite material, the ablation resistance of the material is improved, and specifically, a high thermal conductivity, strong bonding, and ablation resistance is provided. Preparation method of ultra-high temperature ceramic matrix composite material.
以下示例性地说明超高温陶瓷基复合材料的制备方法,如图1所示。The following exemplarily illustrates the preparation method of the ultra-high temperature ceramic matrix composite material, as shown in FIG. 1 .
纤维选取。使用高导热碳纤维作为增强纤维。具体来说,采用高导热碳纤维(热导率大于40W/m·K)为增强体,可以提高复合材料整体的热导率。Fiber selection. High thermal conductivity carbon fibers are used as reinforcing fibers. Specifically, high thermal conductivity carbon fibers (thermal conductivity greater than 40 W/m·K) are used as reinforcements, which can improve the overall thermal conductivity of the composite material.
编织纤维预制体。将碳纤维编织成碳纤维预制体。该纤维预制体可为2维、2.5维或3维编织体,优选3维的编织体作为碳纤维预制体。在可选的实施方式中,碳纤维预制体中碳纤维的体积含量为10~70vol%的碳纤维,优选碳纤维含量为20~50vol%,可以更好地吸收或浸渍碳源和部分陶瓷相(或其陶瓷前驱体)。Woven fiber preform. Weaving carbon fibers into carbon fiber preforms. The fiber preform can be a 2-dimensional, 2.5-dimensional or 3-dimensional braid, preferably a 3-dimensional braid as the carbon fiber preform. In an optional embodiment, carbon fibers with a volume content of carbon fibers in the carbon fiber preform of 10 to 70 vol%, preferably 20 to 50 vol% of carbon fibers, can better absorb or impregnate the carbon source and part of the ceramic phase (or its ceramics). Precursor).
界面层的制备。在碳纤维预制体中采用化学气相渗透法沉积PyC层、BN层、SiC界面层、(PyC/SiC)n、或(BN/SiC)n多层复合界面(n≥1)。该界面层的厚度可为0.01~5μm,其在后续制备过程中可以进一步防止碳纤维受到损伤,从而避免热导率的降低。Preparation of the interface layer. The PyC layer, BN layer, SiC interface layer, (PyC/SiC) n , or (BN/SiC) n multilayer composite interface (n≥1) were deposited in the carbon fiber preform by chemical vapor infiltration. The thickness of the interface layer can be 0.01-5 μm, which can further prevent the carbon fibers from being damaged in the subsequent preparation process, thereby avoiding the reduction of thermal conductivity.
在碳纤维预制体中引入碳源和部分陶瓷相。具体方法包括但不仅限于溶胶凝胶法、浆料浸渍法、前驱体浸渍裂解法等。其中,引入的碳源可为有机碳源或/和无机碳源,例如酚醛树脂、聚乙烯吡咯烷酮、蔗糖、碳粉。其中,陶瓷相可为SiC、TaC、ZrC、ZrB2、HfC、HfB2等。在引入陶瓷相时可选用陶瓷相对应的陶瓷粉体、或者是陶瓷相对应的有机前驱体(主要指SiC前驱体如聚碳硅烷等)。作为一个真空浸渍的示例,抽真空后(真空度可为0-10Pa),可将碳纤维预制体浸渍于含有碳源和部分陶瓷相的浆料中,保持0.5~2小时后进行干燥。其中,浆料中碳源的含量可为5~30wt%。浆料中陶瓷相(或陶瓷相对应有机前驱体)的含量可为30~80wt%。浆料所用有机溶剂可为乙醇、丙酮、汽油、二甲苯等。The carbon source and part of the ceramic phase are introduced into the carbon fiber preform. Specific methods include, but are not limited to, sol-gel method, slurry impregnation method, precursor impregnation cracking method, and the like. Wherein, the introduced carbon source can be an organic carbon source or/and an inorganic carbon source, such as phenolic resin, polyvinylpyrrolidone, sucrose, carbon powder. The ceramic phase may be SiC, TaC, ZrC, ZrB 2 , HfC, HfB 2 or the like. When the ceramic phase is introduced, a ceramic powder corresponding to the ceramic, or an organic precursor corresponding to the ceramic (mainly refers to a SiC precursor such as polycarbosilane, etc.) can be used. As an example of vacuum impregnation, after vacuuming (the degree of vacuum can be 0-10 Pa), the carbon fiber preform can be impregnated in the slurry containing the carbon source and part of the ceramic phase, kept for 0.5-2 hours, and then dried. Wherein, the content of the carbon source in the slurry may be 5-30 wt %. The content of the ceramic phase (or the organic precursor corresponding to the ceramic) in the slurry may be 30-80 wt %. The organic solvent used in the slurry can be ethanol, acetone, gasoline, xylene and the like.
在可选的实施方式中,在引入碳源和部分陶瓷相后,可进行干燥和裂解过程,目的在于使得有机碳源或陶瓷相前驱体(主要指SiC前驱体如聚碳硅烷等)发生裂解分别形成无机碳和陶瓷相。而且,本发明中为了避免损伤高导热碳纤维,不采用超高温陶瓷前驱体及高温碳热还原过程,同时也优化了制备的过程。In an optional embodiment, after the introduction of the carbon source and part of the ceramic phase, a drying and cracking process may be performed, in order to make the organic carbon source or ceramic phase precursor (mainly SiC precursor such as polycarbosilane, etc.) cracked Inorganic carbon and ceramic phases are formed, respectively. Moreover, in the present invention, in order to avoid damage to the high thermal conductivity carbon fiber, the ultra-high temperature ceramic precursor and the high temperature carbothermic reduction process are not used, and the preparation process is also optimized.
最后结合反应熔渗原位反应方法完成材料致密化过程。其反应熔渗原料可为Si、Zr、Hf、ZrSi2、HfSi2中。反应熔渗的气氛可为惰性气氛等。对于不同的反应熔渗原料其反应温度和时间可适当调整。例如,当反应熔渗原料可为Si时,反应熔渗温度可为1450~1600℃。Zr对应的反应熔渗温度可为1850~2000℃。Hf对应的反应熔渗温度可为2250~2500℃。ZrSi2对应的反应熔渗温度可为1620~2000℃。HfSi2对应的反应熔渗温度可为1680~2000℃。而且,反应熔渗过程降低了复合材料的气孔率、提高复合材料基体致密度,可以降低热传输过程中的声子散射,提高材料热导率。同时,反应熔渗过程也提高复合材料基体结合强度,进一步可以降低材料在烧蚀过程中发生层状剥离的风险(被高速气流剥蚀的风险),提升材料的耐烧蚀性能。Finally, the material densification process is completed by combining the reactive infiltration in-situ reaction method. The reactive infiltration raw materials can be Si, Zr, Hf, ZrSi 2 , and HfSi 2 . The atmosphere of the reactive infiltration may be an inert atmosphere or the like. For different reaction infiltration raw materials, the reaction temperature and time can be adjusted appropriately. For example, when the reactive infiltration raw material may be Si, the reactive infiltration temperature may be 1450-1600°C. The reaction infiltration temperature corresponding to Zr can be 1850-2000°C. The reaction infiltration temperature corresponding to Hf may be 2250-2500°C. The reaction infiltration temperature corresponding to ZrSi 2 can be 1620-2000°C. The corresponding reaction infiltration temperature of HfSi 2 can be 1680-2000°C. Moreover, the reactive infiltration process reduces the porosity of the composite material and increases the density of the composite material matrix, which can reduce the phonon scattering during the heat transfer process and improve the thermal conductivity of the material. At the same time, the reactive infiltration process also improves the bonding strength of the composite matrix, which can further reduce the risk of laminar peeling of the material during the ablation process (risk of being ablated by high-speed airflow), and improve the ablation resistance of the material.
在本发明中,采用闪射法导热仪(德国NETZSCH LFA467 HT)测得超高温陶瓷基复合材料在1200℃下的热导率大于15W·m-1·K-1。In the present invention, the thermal conductivity of the ultra-high temperature ceramic matrix composite material measured at 1200° C. is greater than 15W·m −1 ·K −1 by using a flash thermal conductivity meter (NETZSCH LFA467 HT, Germany).
在本发明中,采用阿基米德排水法测得超高温陶瓷基复合材料的开口气孔率小于10vol%,优选开口气孔率小于5vol%。In the present invention, the open porosity of the ultra-high temperature ceramic matrix composite material measured by the Archimedes drainage method is less than 10 vol%, preferably the open porosity is less than 5 vol%.
在本发明中,采用层间剪切测试法测得超高温陶瓷基复合材料的层间结合强度大于40MPa。In the present invention, the interlaminar bonding strength of the ultra-high temperature ceramic matrix composite material measured by the interlaminar shear test method is greater than 40 MPa.
在本发明中,所制备超高温陶瓷基复合材料在烧蚀过程中,可以迅速将烧蚀区的热量传输到材料各部分,减少热量聚集,降低材料表面温度。采用等离子焰(瑞士PlasmerJet,A-2000,Sulzer Metco)测得超高温陶瓷基复合材料在热流密度为4.02MW/m2的等离子火焰下(~2200℃)的线烧蚀率低于10μm/s,优选低于1μm/s。In the present invention, during the ablation process of the prepared ultra-high temperature ceramic matrix composite material, the heat in the ablation zone can be rapidly transferred to each part of the material, thereby reducing heat accumulation and lowering the surface temperature of the material. The linear ablation rate of ultra-high temperature ceramic matrix composites measured by plasma flame (PlasmerJet, A-2000, Sulzer Metco, Switzerland) under plasma flame with heat flux density of 4.02MW /m2 (~2200℃) is less than 10μm/s , preferably below 1 μm/s.
下面进一步列举实施例以详细说明本发明。同样应理解,以下实施例只用于对本发明进行进一步说明,不能理解为对本发明保护范围的限制,本领域的技术人员根据本发明的上述内容作出的一些非本质的改进和调整均属于本发明的保护范围。下述示例具体的工艺参数等也仅是合适范围中的一个示例,即本领域技术人员可以通过本文的说明做合适的范围内选择,而并非要限定于下文示例的具体数值。The following further examples are given to illustrate the present invention in detail. It should also be understood that the following examples are only used to further illustrate the present invention, and should not be construed as limiting the protection scope of the present invention. Some non-essential improvements and adjustments made by those skilled in the art according to the above content of the present invention belong to the present invention. scope of protection. The specific process parameters and the like in the following examples are only an example of a suitable range, that is, those skilled in the art can make selections within the suitable range through the description herein, and are not intended to be limited to the specific numerical values exemplified below.
实施例1Example 1
一种高导热、强结合、耐烧蚀超高温陶瓷基复合材料的制备方法,其具体步骤是:A preparation method of a high thermal conductivity, strong bonding, ablation resistant ultra-high temperature ceramic matrix composite material, the specific steps are:
(1)纤维选取:选用热导率为60W/m·K的高导热碳纤维作为复合材料增强体;(1) Fiber selection: select high thermal conductivity carbon fiber with thermal conductivity of 60W/m K as the composite material reinforcement;
(2)编织碳纤维预制体:采用2维缝合方式制备碳纤维预制体,该预制体中碳纤维体积含量为~30vol%;(2) Braided carbon fiber preform: a carbon fiber preform is prepared by 2-dimensional stitching, and the volume content of carbon fiber in the preform is ~30 vol%;
(3)界面层制备:采用化学气相渗透法在上述预制体纤维表面沉积PyC/SiC复合界面层。沉积的PyC/SiC复合界面层的总厚度为~0.5μm;(3) Preparation of interface layer: A PyC/SiC composite interface layer was deposited on the surface of the above-mentioned preform fiber by chemical vapor infiltration method. The total thickness of the deposited PyC/SiC composite interface layer is ~0.5 μm;
(4)引入陶瓷基体:使用酚醛树脂、聚乙烯吡咯烷酮作为碳源,乙醇为溶剂,与粒径为1~3μm的ZrC粉体混合为浆料。ZrC粉体占浆料的60wt%,碳源占10wt%。在真空度为-0.07MPa~-0.10MPa的条件下浸渍(3)中碳纤维预制体,浸渍时间为2小时。将所得碳纤维预制体在80℃下干燥6h后,再在800℃、Ar保护气氛下裂解。最后在1500℃、1~10Pa的条件下渗Si,完成材料致密化,得到Cf/ZrC-SiC复合材料。(4) Introduction of ceramic matrix: use phenolic resin and polyvinylpyrrolidone as carbon source, ethanol as solvent, and mix with ZrC powder with particle size of 1-3 μm to form slurry. ZrC powder accounts for 60wt% of the slurry, and carbon source accounts for 10wt%. The carbon fiber preform in (3) is impregnated under the condition that the vacuum degree is -0.07MPa~-0.10MPa, and the impregnation time is 2 hours. The obtained carbon fiber preform was dried at 80 °C for 6 h, and then cracked at 800 °C under an Ar protective atmosphere. Finally, Si was infiltrated under the conditions of 1500 ℃ and 1-10 Pa to complete the densification of the material, and the C f /ZrC-SiC composite material was obtained.
上述所得Cf/ZrC-SiC复合材料的开口气孔率~5vol%,层间结合强度为50MPa,1200℃以下材料热导率大于15W·m-1·K-1(如图2所示)。材料在热流密度4.02MW/m2等离子烧蚀60s(烧蚀中心温度~2250℃),烧蚀中心无明显损伤(如图3所示),线烧蚀率仅为0.06μm/s。The open porosity of the obtained C f /ZrC-SiC composite material is ~5vol%, the interlayer bonding strength is 50MPa, and the thermal conductivity of the material below 1200°C is greater than 15W·m -1 ·K -1 (as shown in Figure 2). The material was plasma ablated for 60s at a heat flux density of 4.02MW/m 2 (the temperature of the ablation center was ~2250℃), and the ablation center had no obvious damage (as shown in Figure 3), and the linear ablation rate was only 0.06μm/s.
实施例2Example 2
与实施例1中步骤类似,所不同的是:步骤(2)中碳纤维的排布方式为3维针刺形式,XYZ取向的纤维比例为10:10:1。碳纤维预制体中碳纤维含量为~40vol%。Similar to the steps in Example 1, the difference is that: in step (2), the carbon fibers are arranged in a 3-dimensional acupuncture form, and the ratio of XYZ-oriented fibers is 10:10:1. The carbon fiber content in the carbon fiber preform was -40 vol%.
所得Cf/ZrC-SiC复合材料的开口气孔率~4vol%,层间结合强度为50MPa,1200℃以下材料热导率大于20W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2100℃),线烧蚀率为0.03μm/s。The open porosity of the obtained C f /ZrC-SiC composite material is ~4vol%, the interlayer bonding strength is 50MPa, and the thermal conductivity of the material below 1200℃ is greater than 20W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2100℃), the linear ablation rate was 0.03μm/s.
实施例3Example 3
与实施例1中步骤类似,所不同的是:步骤(3)采用化学气相渗透法在纤维表面沉积(PyC/SiC)3多层复合界面层,总厚度为~3μm。Similar to the steps in Example 1, the difference is that: in step (3), chemical vapor infiltration is used to deposit a (PyC/SiC) 3 multi-layer composite interface layer on the fiber surface, with a total thickness of ~3 μm.
所得Cf/ZrC-SiC复合材料的气孔率~6vol%,层间结合强度为55MPa,1200℃以下材料热导率大于18W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2200℃),线烧蚀率为0.06μm/s。The porosity of the obtained C f /ZrC-SiC composite material is ~6vol%, the interlayer bonding strength is 55MPa, and the thermal conductivity of the material below 1200°C is greater than 18W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2200℃), the linear ablation rate was 0.06μm/s.
实施例4Example 4
与实施例1中步骤类似,所不同的:是步骤(4)使用蔗糖作为浆料碳源,碳源占浆料15~30wt%。Similar to the steps in Example 1, the difference is that in step (4), sucrose is used as the carbon source of the slurry, and the carbon source accounts for 15-30 wt% of the slurry.
所得Cf/ZrC-SiC复合材料(碳源占浆料15wt%)的气孔率~4vol%,层间结合强度为50MPa,1200℃以下材料热导率大于20W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2100℃),线烧蚀率为0.06μm/s。The obtained C f /ZrC-SiC composite material (carbon source accounts for 15wt% of the slurry) has a porosity of ~4vol%, an interlayer bonding strength of 50MPa, and a thermal conductivity below 1200°C greater than 20W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2100℃), the linear ablation rate was 0.06μm/s.
实施例5Example 5
与实施例1中步骤类似,所不同的是:步骤(4)前驱体浆料采用1-3μm的ZrB2粉体与聚碳硅烷的混合物,ZrB2粉体占混合前驱体浆料的40~80wt%。Similar to the steps in Example 1, the difference is: in step (4), the precursor slurry adopts a mixture of 1-3 μm ZrB 2 powder and polycarbosilane, and the ZrB 2 powder accounts for 40-40% of the mixed precursor slurry. 80wt%.
所得Cf/ZrB2-SiC复合材料(ZrB2粉体占混合前驱体浆料的60wt%)的气孔率~4vol%,层间结合强度为60MPa,1200℃以下材料热导率大于15W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2200℃),线烧蚀率为0.03μm/s。The obtained C f /ZrB 2 -SiC composite material (ZrB 2 powder accounts for 60wt% of the mixed precursor slurry) has a porosity of ~4vol%, the interlayer bonding strength is 60MPa, and the thermal conductivity of the material below 1200°C is greater than 15W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2200℃), the linear ablation rate was 0.03μm/s.
实施例6Example 6
与实施例1中步骤类似,所不同的是:步骤(4)前驱体浆料中采用1~3μm的ZrB2和1~3μm的ZrC混合粉体作为陶瓷填料,混合粉体占混合前驱体浆料的40~80wt%,ZrB2和ZrC的质量比为1:1。Similar to the steps in Example 1, the difference is: in step (4), the mixed powder of ZrB 2 of 1-3 μm and ZrC of 1-3 μm is used as the ceramic filler in the precursor slurry, and the mixed powder accounts for the mixed precursor slurry. The mass ratio of ZrB 2 and ZrC is 1:1.
所得Cf/ZrB2-ZrC-SiC复合材料(混合粉体占混合前驱体浆料的70wt%)的气孔率~4vol%,层间结合强度为55MPa,1200℃以下材料热导率大于17W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2200℃),线烧蚀率为0.03μm/s。The obtained C f /ZrB 2 -ZrC-SiC composite material (mixed powder accounts for 70wt% of the mixed precursor slurry) has a porosity of ~4vol%, the interlayer bonding strength is 55MPa, and the thermal conductivity of the material below 1200°C is greater than 17W· m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2200℃), the linear ablation rate was 0.03μm/s.
实施例7Example 7
与实施例1中步骤类似,所不同的是:步骤(4)中使用ZrSi2在1700℃,1~10Pa的条件下为对材料进行反应熔渗致密化。Similar to the steps in Example 1, the difference is that: in step (4), ZrSi 2 is used to perform reactive infiltration and densification of the material under the conditions of 1700° C. and 1-10 Pa.
所得Cf/ZrC-SiC复合材料的气孔率~5vol%,层间结合强度为53MPa,1200℃以下材料热导率大于20W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2100℃),线烧蚀率为0.03μm/s。The porosity of the obtained C f /ZrC-SiC composite material is ~5vol%, the interlayer bonding strength is 53MPa, and the thermal conductivity of the material below 1200°C is greater than 20W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2100℃), the linear ablation rate was 0.03μm/s.
实施例8Example 8
与实施例1中步骤类似,所不同的是:步骤(4)中使用Zr在1900℃,1~10Pa的条件下对材料进行反应熔渗致密化。Similar to the step in Example 1, the difference is: in step (4), Zr is used to carry out reactive infiltration and densification of the material at 1900° C. and 1-10 Pa.
所得复合材料的气孔率~5vol%,层间结合强度为50MPa,1200℃以下材料热导率大于17W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2100℃),线烧蚀率为0.04μm/s。The porosity of the obtained composite material is ~5vol%, the interlayer bonding strength is 50MPa, and the thermal conductivity of the material below 1200°C is greater than 17W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2100℃), the linear ablation rate was 0.04μm/s.
实施例10Example 10
与实施例1中步骤类似,所不同的是:步骤(4)中使用HfSi2在1700℃,1~10Pa的条件下对材料进行反应熔渗致密化。Similar to the steps in Example 1, the difference is that: in step (4), HfSi 2 is used to carry out reactive infiltration and densification of the material under the conditions of 1700° C. and 1-10 Pa.
所得复合材料的气孔率~4vol%,层间结合强度为53MPa,1200℃以下材料热导率为大于18W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2150℃),线烧蚀率为0.03μm/s。The porosity of the obtained composite material is ~4vol%, the interlayer bonding strength is 53MPa, and the thermal conductivity of the material below 1200°C is greater than 18W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2150℃), the linear ablation rate was 0.03μm/s.
对比例1Comparative Example 1
与实施例1中步骤类似,所不同的是:步骤(4)首先使用有机Zr前驱体(PZC)和碳作为浆料在1~10Pa下真空浸渍纤维,先于800℃、Ar保护气氛下裂解,后1700℃下碳热还原2小时,再使用Si反应熔渗致密化。Similar to the steps in Example 1, the difference is: in step (4), the organic Zr precursor (PZC) and carbon are used as the slurry to impregnate the fibers under vacuum at 1 to 10 Pa, and then cracked at 800 ° C under Ar protective atmosphere. , followed by carbothermic reduction at 1700 °C for 2 hours, and then infiltration and densification using Si reaction.
所得Cf/ZrC-SiC复合材料的气孔率~5vol%,层间结合强度为35MPa,1200℃以下材料热导率小于10W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2600℃),线烧蚀率为30μm/s。The porosity of the obtained C f /ZrC-SiC composite material is ~5vol%, the interlayer bonding strength is 35MPa, and the thermal conductivity of the material below 1200°C is less than 10W·m -1 ·K -1 . After the material was ablated by 4.02MW/m 2 plasma for 60s (ablation center temperature~2600℃), the linear ablation rate was 30μm/s.
对比例2Comparative Example 2
传统超高温陶瓷基复合材料的制备:Preparation of traditional ultra-high temperature ceramic matrix composites:
步骤1:选取常规三维针刺碳纤维为纤维增强体;Step 1: Select conventional three-dimensional acupuncture carbon fiber as fiber reinforcement;
步骤2:采用化学气相渗透法在上述预制体纤维表面沉积PyC/SiC复合界面层,厚度~0.5μm;Step 2: using chemical vapor infiltration method to deposit a PyC/SiC composite interface layer on the surface of the above-mentioned prefabricated fibers, with a thickness of ~0.5 μm;
步骤3:使用有机Zr前驱体(PZC)和聚碳硅烷前驱体在0~10Pa真空度下真空浸渍步骤2中所得材料,并保持1h;Step 3: use organic Zr precursor (PZC) and polycarbosilane precursor to vacuum impregnate the material obtained in step 2 under a vacuum of 0-10Pa, and keep it for 1h;
步骤4:在800-1200℃,氩气气氛下保温2h,裂解步骤3中所得材料;Step 4: Incubate at 800-1200°C under an argon atmosphere for 2h, and crack the material obtained in step 3;
步骤5:在1500-1800℃,氩气气氛下碳热还原2h;Step 5: Carbothermal reduction under argon atmosphere at 1500-1800°C for 2h;
步骤6:重复步骤3~步骤5,直至获得致密的Cf/ZrC-SiC复合材料。Step 6: Repeat steps 3 to 5 until a dense C f /ZrC-SiC composite material is obtained.
所得Cf/ZrC-SiC复合材料的气孔率~15vol%,层间结合强度为32MPa,1200℃以下材料热导率小于5W·m-1·K-1。材料在4.02MW/m2等离子烧蚀60s后(烧蚀中心温度~2800℃),线烧蚀率为41μm/s。The porosity of the obtained C f /ZrC-SiC composite material is ~15vol%, the interlayer bonding strength is 32MPa, and the thermal conductivity of the material below 1200°C is less than 5W·m -1 ·K -1 . After the material was ablated by plasma at 4.02MW/m 2 for 60s (ablation center temperature~2800℃), the linear ablation rate was 41μm/s.
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