GB2216143A - Composite material and method for manufacturing it - Google Patents
Composite material and method for manufacturing it Download PDFInfo
- Publication number
- GB2216143A GB2216143A GB8904104A GB8904104A GB2216143A GB 2216143 A GB2216143 A GB 2216143A GB 8904104 A GB8904104 A GB 8904104A GB 8904104 A GB8904104 A GB 8904104A GB 2216143 A GB2216143 A GB 2216143A
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- United Kingdom
- Prior art keywords
- binder
- silicon
- fibres
- filaments
- mixture
- Prior art date
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
- C04B35/63404—Polymers obtained by reactions only involving carbon-to-carbon unsaturated bonds
- C04B35/63416—Polyvinylalcohols [PVA]; Polyvinylacetates
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped 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
- C04B35/58—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/584—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
- C04B35/591—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride obtained by reaction sintering
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/515—Shaped 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
- C04B35/58—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides
- C04B35/584—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride
- C04B35/593—Shaped 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 borides, nitrides, i.e. nitrides, oxynitrides, carbonitrides or oxycarbonitrides or silicides based on silicon nitride obtained by pressure sintering
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/6303—Inorganic additives
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/632—Organic additives
- C04B35/634—Polymers
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/626—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B
- C04B35/63—Preparing or treating the powders individually or as batches ; preparing or treating macroscopic reinforcing agents for ceramic products, e.g. fibres; mechanical aspects section B using additives specially adapted for forming the products, e.g.. binder binders
- C04B35/638—Removal thereof
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/622—Forming processes; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/64—Burning or sintering processes
- C04B35/645—Pressure sintering
- C04B35/6455—Hot isostatic pressing
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/71—Ceramic products containing macroscopic reinforcing agents
- C04B35/78—Ceramic products containing macroscopic reinforcing agents containing non-metallic materials
- C04B35/80—Fibres, filaments, whiskers, platelets, or the like
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- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Ceramic Products (AREA)
Description
r) r)4 Composite material and method for manufacturinq it The present
invention relates to a composite material comprising silicon nitride.
Because of their favorable ratios of strength and modulus of elasticity to specific qravitv, hichstrenqth ceramic_composite materials are of interest for industrial mechanical engineering. In particular, materials comprisinq silicon nitride are of considerable imDortance because of the chemical and thermal stability of this material.
The present invention provides ceramic material comvrising a silicon nitride matrix containing fibres and/or filaments of silicon carbide. At least some of the fibres and/or filaments may be in the form of a fabric, which may be woven or unwoven.
The invention also Drovides a method of manufacturing a ceramic material which comr)rises forming a body from fibres and/or filaments of silicon carbide, introducina a mixture of silicon nowder and a binder into cavities in the formed body, allowinq or causing the binder to harden, thermally decomDosina the binder in the absence of oxygen, and nitriding the silicon to form silicon nitride, and a ceramic material made by the method. Preferably, the body is formed by winding the fibres and/or filaments on a 1k former and/or on another layer of the said fibres and/or filaments.
The invention more particularly provides a method for manufacturing a ceramic composite material having a silicon nitride matrix, which comprises mixing silicon powder with a binder, winding a body from fibres or filaments or fabrics of silicon carbider introducing the mixture of silicon powder and binder into the cavities of the wound body, allowing the binder to harden, thermally decomposing the binder in the absence of oxygen and treating the resulting body in a nitrogen atmosphere at temperatures of 1,400 to 1,5000C and converting the silicon into silicon nitride at the same time.
The diameter of the SiC fibres is not critical, but diameters of 0.1 to 0. 01 mm are preferred. The particle size of the silicon powder should be as small as Possible so that it is able to Penetrate into the cavities of the formed body. The Proportion by volume of SiC fibre is 10 to 50, Preferably 20 to 40 % of the final material. The mixture of silicon powder and binder may, if necessary, be introduced into the cavities of the body under Pressure.
The nature of the binder is not critical. 4 water-soluble polymer, for example, polyvinyl alcohol or phenolformaldehyde resins, may if desired be used. Advantageously, a liquid binder is used. Preferably, the binder used yields only small quantities of carbon during pyrolysis. The carbon vroduced during pyrolysis may react with the silicon powder at the nitriding temperature to form new silicon carbide, but as complete a conversion as possible of the silicon to silicon nitride is preferred since this involves an increase in volume, i.e. the body produced contains only small vroDortions of pores.
The thermal decomposition of the binder preferably takes place at a temperature not exceeding 600 0 C. Aromatic binders require temperatures of up to 1,000 0 C and yield a particularly large amount of elementary carbon.
When the body is built up from a plurality of layers, in order to achieve a good impregnation of the body with the mixture of silicon r)owder and binder, it is advantageous to ar)ply the mixture to the body after the production of each laver.
The manner in which the binder is hardened is not critical. Thus, for example, hardening by drying or by chemical reaction (for example, polymerization of a reactive starting material)is possible. The mixture mav therefore, if desired, also contain a hardener for the binder.
The mixture of binder and silicon powder preferably contains 10 to 40, preferably 15 to 25% by volume of silicon powder.
4 It is Darticularly preferable if water-soluble polyvinyl alcohol admixed with boric acid or boron trioxide is used as binder. The addition of boric aeld or boric trioxide makes it possible to process the sic fibres better since the flexibility increases. In addition, the adhesion between the fibres and the silicon nitride matrix in the final composite body, which is of considerable importance for the mechanical properties of the body, is improved.
When the body is thick enough, for example, after a sufficient number of layers of Sic fibres have been built up (in Darticular, more than 3 layers of SiC fibres), the binder of the green body is allowed to harden (for example, by hardening in a drying oven). This is followed by a careful thermal decomoosition of the binder resin in a protective gas or in vacuo so that the silicon metal and the Sic fibres are not oxidized. This is followed by the nitriding of the silicon to form silicon nitride.
At the end of nitriding, a reaction bonded silicon nitride (RBSN) body is produced which has a defined Sic structure. It may be further compacted by hot isostatic pressing. If the binder already contains a sintering aid (for example, yttrium oxide), the RBSN body may also be further compacted by post-sintering.
The composite material of the invention contains filaments, fibres or fabric of silicon carbide in a silicon nitride matrix. The proportion by weight of silicon carbide in the composite material is advantageously about 10 to 50, preferably 20 to 40 The remainder is essentially silicon nitride (Si 3 N 4) Advantageously, the filaments and/or fibres of silicon carbide are arranged in parallel wound layers. The mechanical stability of the wound body is particularly high if the filaments or fibres are arranged parallel to each other when manufacturing the wound bodv.
The method of the invention makes it possible to manufacture tubes havinq a composite structure which withstand high internal pressures at hiqh temperatures.
Claims (25)
1. A ceramic material comprising a silicon nitride matrix containing fibres and/or filaments of silicon carbide.
2. A material as claimed in claim 1, wherein at least some of the fibres and/or filaments-are in the form of a fabric.
3. A material as claimed in claim 1 or claim 2, wherein the proportion of silicon carbide is 10 to 50 % by weight.
4. A material as claimed in any one of claims 1 to 3, wherein the fibres and/or filaments are arranged in r)arallel wound layers.
S. A material as claimed in any one of claims 1 to 4, which is in the form of a tube.
6. A material as claimed in claim 1 substantially as described herein.
7. A method of manufacturing a ceramic material which comprises forming a body from fibres and/or filaments of silicon carbide, introducing a mixture of silicon powder and a binder into cavities in the formed body, allowing or causing the binder to harden, thermally decomDosing the binder in the absence of oxygen, and nitriding the silicon to form silicon nitride.
8. A method as claimed in claim 7, wherein at least some of the fibres and/or filaments are in the form of a fabric.
9. A method as claimed in claim 7 or claim 8, wherein the body is formed by winding the fibres and/or filaments on a former and/or on another layer of the said fibres and/or filaments.
10. A method as claimed in any one of claims 7 to 9, wherein the body is built up from sur)erimt)osed layers of the fibres and/or filaments and wherein each layer has the silicon r)owder/binder mixture apiDlied thereto.
11. A method as claimed in any one of claims 7 to 10, wherein the silicon vowder/binder mixture also comprises a hardener for the binder.
12. A method as claimed in any one of claims 7 to 11, wherein the silicon powder/binder mixture contains 15 to 25% by volume of silicon vowder.
8
13. A method as claimed in any one of claims 7 to 12, wherein the binder is hardened by drying.
14. A method as claimed in any one of claims 7 to 13, wherein the binder comprises polyvinyl alcohol.
15. A method as claimed in claim 14, wherein the binder contains boron trioxide or boric acid.
16. A method as claimed in any one of claims 7 to 15, wherein thermal decomposition of the binder is effected at a temr)erature not exceeding 600 0 C.
17. A method as claimed in any one of claims 7 to 16, wherein nitridina of the silicon is effected by heating the body at a temperature of from 1400 to 1500 0 C in an atmosphere of nitrogen.
18. A method as claimed in any one of claims 7 to 17, wherein, after nitriding, the body is compacted.
19. A method as claimed in claim 18, wherein compacting is effected by hot isostatic pressing.
20. A method as claimed in claim 18, wherein the binder contains a sintering agent and compacting is effected by sintering.
21. A method as claimed in any one of claims 7 to 20, wherein the body is in the form of a tube.
22. A method for manufacturing a ceramic composite material having a silicon nitride matrix, which comprises mixing silicon powder with a binder, winding a body from fibres or filaments or fabrics of silicon carbide, introducing the mixture of silicon powder and binder into the cavities of the wound body, allowing the binder to harden, thermally decomposing the binder in the absence of oxygen and treating the resulting body in a nitrogen atmoslohere at temperatures of 1,400 to 1, 500 0 C and convertinq the silicon into silicon nitride at the same time.
23. A method as claimed in claim 7, carried out substantially as described herein.
24. A ceramic material whenever made by a method as claimed in any one of claims 7 to 23.
25. Any novel feature described herein or any novel combination of herein described features.
Published 1989 atThe Patent Offiee, State House, 86."71 HighHolborn, London WCIR4TP. Further copies maybe obtainedfrom The Patent Office. Wes Branch, St Mary Cray, Orpington, Rent BR5 3RD. Printed by Multiplex techniques IUL St Mary Cray, Kent, Con. 1/87
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| DE3805641A DE3805641A1 (en) | 1988-02-24 | 1988-02-24 | COMPOSITE MATERIAL AND METHOD FOR THE PRODUCTION THEREOF |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| GB8904104D0 GB8904104D0 (en) | 1989-04-05 |
| GB2216143A true GB2216143A (en) | 1989-10-04 |
| GB2216143B GB2216143B (en) | 1991-05-01 |
Family
ID=6347980
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB8904104A Expired - Fee Related GB2216143B (en) | 1988-02-24 | 1989-02-23 | Composite material and method for manufacturing it |
Country Status (3)
| Country | Link |
|---|---|
| JP (1) | JPH01257167A (en) |
| DE (1) | DE3805641A1 (en) |
| GB (1) | GB2216143B (en) |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5698332A (en) * | 1992-11-12 | 1997-12-16 | The Dow Chemical Company | Substrate coated with composition of non-cyclic polyanhydride and co-reactant resin |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2011863A1 (en) * | 1968-05-22 | 1970-03-13 | Nat Res Dev | Prodn of ceramic articles from silicon nitride by flame - spraying |
| FR2329611A1 (en) * | 1975-10-27 | 1977-05-27 | Res Inst Iron Steel | PROCESS FOR THE PREPARATION OF COMPOSITE MATERIALS REINFORCED BY CONTINUOUS SILICON CARBIDE FIBERS |
| EP0209320A1 (en) * | 1985-07-10 | 1987-01-21 | Hitachi, Ltd. | Fiber-reinforced ceramics |
| EP0240177A2 (en) * | 1986-03-17 | 1987-10-07 | Sumitomo Electric Industries Limited | Ceramic compact, in particular based on silicon nitride and ceramic fibres and process for its production |
| WO1988006147A1 (en) * | 1987-02-16 | 1988-08-25 | Aerospatiale Societe Nationale Industrielle | Compound ceramic material with reinforcement filaments, and process for the manufacture of same |
| WO1988007029A1 (en) * | 1987-03-17 | 1988-09-22 | Max-Planck-Gesellschaft Zur Förderung Der Wissensc | Process for the hot isostatic compression of silicon nitride bodies reinforced with carbide fibres and carbide whiskers |
-
1988
- 1988-02-24 DE DE3805641A patent/DE3805641A1/en not_active Withdrawn
-
1989
- 1989-02-22 JP JP1040420A patent/JPH01257167A/en active Pending
- 1989-02-23 GB GB8904104A patent/GB2216143B/en not_active Expired - Fee Related
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| FR2011863A1 (en) * | 1968-05-22 | 1970-03-13 | Nat Res Dev | Prodn of ceramic articles from silicon nitride by flame - spraying |
| FR2329611A1 (en) * | 1975-10-27 | 1977-05-27 | Res Inst Iron Steel | PROCESS FOR THE PREPARATION OF COMPOSITE MATERIALS REINFORCED BY CONTINUOUS SILICON CARBIDE FIBERS |
| EP0209320A1 (en) * | 1985-07-10 | 1987-01-21 | Hitachi, Ltd. | Fiber-reinforced ceramics |
| EP0240177A2 (en) * | 1986-03-17 | 1987-10-07 | Sumitomo Electric Industries Limited | Ceramic compact, in particular based on silicon nitride and ceramic fibres and process for its production |
| WO1988006147A1 (en) * | 1987-02-16 | 1988-08-25 | Aerospatiale Societe Nationale Industrielle | Compound ceramic material with reinforcement filaments, and process for the manufacture of same |
| WO1988007029A1 (en) * | 1987-03-17 | 1988-09-22 | Max-Planck-Gesellschaft Zur Förderung Der Wissensc | Process for the hot isostatic compression of silicon nitride bodies reinforced with carbide fibres and carbide whiskers |
Non-Patent Citations (2)
| Title |
|---|
| JP61091063 * |
| JP63312925 * |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5698332A (en) * | 1992-11-12 | 1997-12-16 | The Dow Chemical Company | Substrate coated with composition of non-cyclic polyanhydride and co-reactant resin |
Also Published As
| Publication number | Publication date |
|---|---|
| GB2216143B (en) | 1991-05-01 |
| GB8904104D0 (en) | 1989-04-05 |
| JPH01257167A (en) | 1989-10-13 |
| DE3805641A1 (en) | 1989-09-07 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| PCNP | Patent ceased through non-payment of renewal fee |
Effective date: 19930223 |