Method of Producing Carbon Fiber Reinforced Ceramic Matrix Composites

Inactive Publication Date: 2008-06-19
DACC
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  • Abstract
  • Description
  • Claims
  • Application Information

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Benefits of technology

[0033]The method of producing carbon fiber reinforced ceramic matrix composites according to the present invention as shown above has the effect of improving the properties of carbon fiber reinforced ceramic matrix composites, and it is poss

Problems solved by technology

Up to now, fiber reinforced ceramic matrix composites have been produced with a variety of manufacturing processes, however, in most cases, they cause mechanical and/or chemical impact damages to fibers during the manufacturing processes.
In this process, however, high-priced raw materials and manufacturing equipment are employed, its manufacturing process is complicated, and lots of process time more than several hundred hours is required, and therefore its application is extremely restricted to high-tech industries, such as aerospace, or the like.
As described above, however, the carbon fiber reinforced resin composite produced by mixing with liquid-phase carbon precursors is more effective than existing chemical vapor infiltration processes in terms of manufacturing cost, but it is difficult to prevent the reaction of liquid-phase silicon against carbon fibers due to some difficulties in forming a uniform carbon fiber protective layer, and thereby rapidly reducing mechanical properties of carbon fiber reinforced ceramic matrix composites.
To solve such a problem, as disclosed in Korean Patent Application No. 1999-7008146, as well as U.S. Pat. No. 6,079,525, U.S. Pat. No. 6,030,913, and U.S. Pat. No. 6,231,791, the carbon fiber reinforced ceramic matrix composite is produced by iterative impregnation of liquid organic bind

Method used

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  • Method of Producing Carbon Fiber Reinforced Ceramic Matrix Composites
  • Method of Producing Carbon Fiber Reinforced Ceramic Matrix Composites
  • Method of Producing Carbon Fiber Reinforced Ceramic Matrix Composites

Examples

Experimental program
Comparison scheme
Effect test

first embodiment

[0066]A mixture comprising 30 wt % carbon fibers that have been cut out in the size of 30 mm, 40 wt % phenol resin, 5 wt % carbon powder, and 5 wt % silicon carbide powder is prepared and stacked alternately with carbon fabrics in the form of 20 wt % satin weave to produce a green body. The produced green body is placed in a mold, and then cured while being pressurized at a pressure 2 MPa for 10 minutes to produce a carbon fiber reinforced resin composite.

[0067]The carbon fiber reinforced resin composite is subjected to thermal treatment in inert gas atmosphere. Furthermore, pyrolytic carbon is deposited in a condition of rapid thermal gradient chemical vapor infiltration process to produce a carbon fiber reinforced carbon composite.

[0068]The produced carbon fiber reinforced carbon composite is stacked on silicon powder, and heated at 1,550° C. in vacuum atmosphere, and infiltrated with liquid-phase silicon to produce a carbon fiber reinforced ceramic matrix composite. Here, physica...

second embodiment

[0069]A mixture comprising 55 wt % carbon fibers that have been cut out in the size of 30 mm, 35 wt % phenol resin, 5 wt % carbon powder, and 5 wt % silicon carbide powder is prepared to produce a green body. Stacking alternately with carbon fabrics is not implemented in the second embodiment. The produced green body is placed in the mold, and then cured while being pressurized at a pressure 2 MPa for 10 minutes to produce a carbon fiber reinforced resin composite.

[0070]The carbon fiber reinforced resin composite is subjected to thermal treatment in inert gas atmosphere. Furthermore, pyrolytic carbon is deposited in a condition of rapid thermal gradient chemical vapor infiltration process to produce a carbon fiber reinforced carbon composite.

[0071]The produced carbon fiber reinforced carbon composite is stacked on silicon powder, and heated at 1,550° C. in vacuum atmosphere, and infiltrated with liquid-phase silicon to produce a carbon fiber reinforced ceramic matrix composite. Here...

third embodiment

[0072]320K oxyphene carbon fiber is wound around a mandrel to produce unidirectional carbon mats, and the carbon mats produced by this method are stacked together. For stacking method, they are stacked alternately by a method of 0 / +60 / −60°.

[0073]At least two layers are stacked together, and then punched using a needle to reinforce every layer in the z-direction, and the process is reiterated to produce a felt preform having 30 mm in thickness. This felt preform is produced at approximately 45% of oxyphene fiber volume ratio, where the thickness of a layer is approximately 0.9 mm, and the fiber ratio in the z-direction is approximately 10%.

[0074]The produced preform is subjected to thermal treatment at 1,700° C. in vacuum atmosphere to remove the impurities of the preform.

[0075]Pyrolytic carbon is deposited on the produced carbon felt preform in a condition of rapid thermal gradient chemical vapor infiltration process to produce a carbon fiber reinforced carbon composite.

[0076]The pr...

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Abstract

The present invention relates to a method of producing carbon fiber reinforced ceramic matrix composites, the method of producing carbon fiber reinforced ceramic matrix composites according to the present invention is characterized in that the method comprises the steps of: producing a carbon fiber reinforced resin composite that is molded with a mixture in which carbon fibers and polymer precursors containing carbon are mixed; producing a carbon fiber reinforced carbon composite by depositing pyrolytic carbon during a rapid thermal gradient chemical vapor infiltration process while increasing the deposition speed in a direction from the inside to the outside by performing a thermal treatment on said carbon fiber reinforced resin composite at high temperature; and infiltrating liquid-phase silicon into the pores of said carbon fiber reinforced carbon composite. The method of producing carbon fiber reinforced ceramic matrix composites according to the present invention as described above has the effect of improving the properties of carbon fiber reinforced ceramic matrix composites, and it is possible to deposit a pyrolytic carbon layer at a deposition speed 5-10 times faster than other conventional chemical vapor infiltration processes, thereby showing a remarkably improved effect in terms of manufacturing process, time, and cost.

Description

TECHNICAL FIELD[0001]The present invention relates to a method of producing carbon fiber reinforced ceramic matrix composites, maintaining excellent mechanical strength at high temperature as well as having excellent properties in corrosion resistance, thermal resistance, friction and abrasion under a severe environment, such as heat, chemical erosion, etc.BACKGROUND ART[0002]Fiber reinforced ceramic matrix composites are lightweight materials having excellent mechanical and thermal properties at high temperature. With these properties, fiber reinforced ceramic matrix composites are applicable to friction and abrasion materials, such as brake disks, and pads for aircraft or ground transport means, and also to ultrahigh thermal resistant materials, such as ceramic engines, and rocket nozzle parts, which require mechanical strength, corrosion resistance, and thermal resistance. Fiber reinforced ceramic matrix composites have been studied to overcome the drawbacks to monolithic ceramic...

Claims

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Application Information

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IPC IPC(8): D01F9/12C04B35/80C04B35/565C04B35/83C04B38/00
CPCC04B35/565C04B2235/614C04B35/806C04B35/83C04B38/0032C04B2111/00362C04B2111/26C04B2111/28C04B2235/48C04B2235/5248F16D69/023F16D2200/0047C04B35/573C04B38/0058C04B38/0067C04B38/068C04B35/80
Inventor LIM, DONG WONPARK, HONG SIKCHO, DAE HYUNSHIN, HYUN KYU
Owner DACC
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