Continuous fiber reinforced metal matrix composite component near net shape forming enclosure and method

Abstract

This invention proposes a near-net-shape forming sleeve and method for continuous fiber reinforced metal matrix composite components. The technical solution employs solid-powder coupled hot pressing, designing a special structure sleeve composed of a preform with wound long fibers, powder, a mold core, a sleeve cylinder, end caps, and a pressure block. Vacuum hot pressing achieves powder densification, diffusion bonding between the powder and the preform, and composite formation between the continuous fibers and the metal matrix. The technical solution proposed in this invention provides a simplified solution to the technical challenge of near-net-shape forming of complex continuous fiber reinforced metal matrix composite components.

Description

Technical Field

[0001] This invention relates to the field of composite materials technology, and more specifically to a package and method for near-net-shape forming of continuous fiber reinforced metal matrix composite components. Background Technology

[0002] With the development of aerospace equipment technology, the design of its components is becoming more complex and integrated, and increasingly demanding higher performance. Typical components such as turbine blade rings and casings have complex structures and high service strength requirements, which poses a great challenge to the corresponding materials and forming technologies. Continuous fiber reinforced composite materials can achieve high strength and toughness in specific directions, which is an important means to solve this problem.

[0003] In the prior art, patent document CN103561890A discloses a method for manufacturing integral turbine engine components using diffusion bonding technology. This method utilizes hot isostatic pressing (HIP) to diffusely bond multiple layers of metal wires wound on a mandrel into a single unit. Patent document US2007 / 0051455A1 discloses a method for preparing aero-turbine turbine components by hot isostatic pressing of a bundle of coated filaments wound perpendicular to a rotating body within a sheath. Patent document US8065799B2 discloses a method for preparing turbine disks by pre-embedding fibers between two forging blanks and then hot isostatic pressing them within a sheath. Patent document CN104532171A discloses a method for preparing continuous fiber-reinforced aluminum matrix composites by hot isostatic pressing of a carbon fiber preform pre-embedded in a powder sheath. The existing methods for forming continuous fiber-reinforced metal matrix composite components are still not suitable for near-net-shape forming of complex structures. Current forming methods are limited, processes are complex, and processing removal is significant. The applicability of the forming process to the component structure is also limited, thus restricting its application scope. Summary of the Invention

[0004] To address the problems existing in the prior art, a package and method for near-net-shape forming of continuous fiber reinforced metal matrix composite components are provided.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] This invention proposes a near-net-shape forming sleeve for continuous fiber reinforced metal matrix composite components, comprising a cylindrical central preform; an outer mold core, which is an L-shaped rotating body; the central preform is disposed within the outer mold core; and a pressure block; the pressure block, outer mold core, and central preform cooperate to form a powder cavity for holding powder; the outer surface of the outer mold core has an edge preform powder cavity; the outer layer of the outer mold core is provided with a cylindrical wall; an upper end cap is provided above the pressure block, outer mold core, and central preform; and a lower end cap is provided at the bottom of the outer mold core and central preform. The upper end cap, lower end cap, and cylindrical wall constitute the outer shell of the sleeve.

[0007] Preferably, the upper end cover is provided with a protrusion, which is located above the pressure block and can drive the pressure block to move up and down; the protrusion is an annular shape with a frustum-shaped cross-section.

[0008] Preferably, the outer surface of the central preform has a groove, and long fibers are wrapped and filled in the groove. The continuous long fibers are evenly distributed and fixed in position on the preform to avoid displacement or shearing of the continuous long fibers during the forming process.

[0009] Preferably, the long fibers are one or more of the following: boron fibers plated with a base metal, carbon fibers, silicon carbide fibers, tungsten wires, molybdenum wires, and tungsten-core silicon carbide fibers.

[0010] Preferably, the central preform and powder material are one or more of the following: titanium alloy, aluminum-titanium alloy, Ti2AlNb alloy (a transition metal titanium alloy with added aluminum and niobium), nickel-based alloy, and stainless steel.

[0011] Preferably, the preparation method of the central preform is one of the following three: forging billet, casting billet, hot isostatic pressing powder compact.

[0012] The present invention also proposes a near-net-shape forming method for continuous fiber reinforced metal matrix composite components using the above-mentioned encapsulation, specifically including the following steps:

[0013] S1: Fill the powder cavity with the raw material powder;

[0014] S2: Vacuum electron beam welding is used for the sleeve wall, upper end cap, and lower end cap;

[0015] S3: Perform hot pressing on the welded sheath;

[0016] S4: After hot pressing, the outer casing and excess base material are removed by mechanical processing;

[0017] S5: Chemical etching treatment is performed to obtain the shaped component.

[0018] Preferably, in step S1, the raw material powder is atomized spherical powder with an average particle size of 50-150 μm.

[0019] Preferably, in step S2, the vacuum degree of vacuum electron beam welding is no greater than 1×10⁻⁶. -3 Pa.

[0020] Preferably, in step S3, the pressure of the hot pressing treatment is 100-500 MPa, the hot pressing temperature is 1 / 2 to 3 / 4 of the melting point temperature of the powder, and the hot pressing time is 2-5 h.

[0021] The beneficial effects of this invention are:

[0022] First, a preform is introduced into the encapsulation, and grooves are cut into the preform to achieve uniform distribution and fixation of continuous long fibers on the preform, preventing displacement or shearing of the continuous long fibers during the forming process. Second, by combining vacuum encapsulation with hot pressing, powder densification, diffusion bonding between powder and preform, and composite forming between continuous fibers and metal matrix can be achieved simultaneously. Third, the precision of the internal cavity structure of the part is ensured by the mold core, thereby obtaining high-performance, precise, and complex components. Attached Figure Description

[0023] The above and / or additional aspects and advantages of the present invention will become apparent and readily understood from the description of the embodiments taken in conjunction with the following drawings, in which:

[0024] Figure 1 This is a schematic diagram of the near-net-shape forming sleeve for a continuous fiber reinforced metal matrix composite component as described in Example 1;

[0025] Figure 2 This is a schematic cross-sectional view of the near-net-shape forming sleeve for a continuous fiber reinforced metal matrix composite component as described in Example 1;

[0026] Figure 3 This is a schematic diagram of the outer mold core structure for near-net-shape forming of a continuous fiber reinforced metal matrix composite component as described in Example 1;

[0027] Figure 4 This is a schematic diagram of the encapsulation structure after filling for near-net-shape forming of a continuous fiber reinforced metal matrix composite component as described in Example 1;

[0028] Figure 5 This is a schematic diagram of the encapsulation structure after hot pressing for near-net-shape forming of a continuous fiber reinforced metal matrix composite component as described in Example 1.

[0029] Figure 6 This is a schematic diagram of a continuous fiber reinforced metal matrix composite component after near-net-shape forming using a casing, as described in Example 1.

[0030] Figure 7 This is a schematic diagram of the cross-section of a continuous fiber reinforced metal matrix composite component after near-net-shape forming using a casing, as described in Example 1.

[0031] Explanation of reference numerals in the attached figures:

[0032] 1. Upper end cap; 2. Cylinder wall; 3. Lower end cap; 4. Outer mold core; 5. Central preform; 6. Press block; 7. Powder cavity; 8. Edge preform powder cavity; 9. Groove; 10. Titanium alloy powder; 11. Edge preform; 12. Silicon carbide fiber. Detailed Implementation

[0033] Embodiments of the present invention are described in detail below. Examples of these embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and are only used to explain the present invention, and should not be construed as limiting the present invention.

[0034] Example 1

[0035] Reference Appendix Figures 1-7 This embodiment proposes a near-net-shape forming cladding for continuous fiber reinforced metal matrix composite components, including a cylindrical titanium alloy central preform 5, which is manufactured by a forging process; and an outer mold core 4, which is a rotating body with an L-shaped cross-section. The structure of the outer mold core 4 is as follows: Figure 3 As shown; the central preform 5 is disposed within the outer mold core 4; it also includes a pressing block 6; the pressing block 6, the outer mold core 4, and the central preform 5 cooperate to form a powder cavity 7 for holding powder in the cavity; the outer surface of the outer mold core 4 has an edge preform powder cavity 8, the purpose of which is to obtain an edge preform 11 during the molding process; the outer layer of the outer mold core 4 is provided with a cylindrical wall 2, and an upper end cover 1 is provided above the pressing block 6, the outer mold core 4, and the central preform 5; a lower end cover 3 is provided at the bottom of the outer mold core 4 and the central preform 5, and the upper end cover 1, the lower end cover 3, and the cylindrical wall 2 form a casing shell, the structural schematic diagram of the casing surface is shown below. Figure 1 As shown in the diagram, the internal structure of the casing is as follows: Figure 2 As shown.

[0036] The upper cover 1 is provided with a protrusion, which is located above the pressure block 6 and can drive the pressure block 6 to move up and down. The protrusion is an annular shape with a frustum-shaped cross section.

[0037] The outer surface of the central preform 5 has a groove 9, and silicon carbide fiber 12 is wrapped and filled in the groove 9.

[0038] This embodiment also proposes a near-net-shape forming method for continuous fiber reinforced metal matrix composite components using the above-mentioned encapsulation, specifically including the following steps:

[0039] S1: Fill the powder cavity 7 with raw titanium alloy powder 10. The titanium alloy raw material powder is atomized spherical powder with an average particle size of about 100μm. The encapsulation structure after filling the powder is as follows: Figure 4 As shown;

[0040] S2: Vacuum electron beam welding is used for the sleeve wall 2, upper end cap 1, and lower end cap 3; the vacuum degree of vacuum electron beam welding is 1×10⁻⁶. -3 Pa;

[0041] S3: The welded sheath is hot-pressed at 300 MPa for 3.5 hours. The hot-pressing temperature is half the melting point of the titanium alloy. During the hot-pressing process, the upper cover 1 drives the pressure block 6 to press down the titanium alloy powder 10. Figure 5 As shown;

[0042] S4: After hot pressing, the outer casing and excess base material are removed by mechanical processing;

[0043] S5: Chemical etching treatment is performed to obtain shaped components, such as... Figure 6 and Figure 7 As shown, it can be observed that silicon carbide fibers 12 reinforce the component within the component.

[0044] Example 2

[0045] This embodiment proposes a near-net-shape forming cladding for continuous fiber reinforced metal matrix composite components, including a cylindrical aluminum-titanium alloy central preform 5, which is formed by forging; an outer mold core 4, which is an L-shaped rotating body; the central preform 5 is disposed within the outer mold core 4; a pressure block 6; the pressure block 6, the outer mold core 4, and the central preform 5 cooperate to form a powder cavity 7 for holding powder in a cavity; the outer surface of the outer mold core 4 has edge preform powder cavities 8; the outer layer of the outer mold core 4 is provided with a cylindrical wall 2; an upper end cap 1 is provided above the pressure block 6, the outer mold core 4, and the central preform 5; a lower end cap 3 is provided at the bottom of the outer mold core 4 and the central preform 5; the upper end cap 1, the lower end cap 3, and the cylindrical wall 2 constitute the outer shell of the cladding. A schematic diagram of the cladding surface is shown below. Figure 1 As shown in the diagram, the internal structure of the casing is as follows: Figure 2 As shown.

[0046] The upper cover 1 is provided with a protrusion, which is located above the pressure block 6 and can drive the pressure block 6 to move up and down. The protrusion is an annular shape with a frustum-shaped cross section.

[0047] The outer surface of the central preform 5 has a groove 9, and carbon fiber is wrapped and filled in the groove 9.

[0048] This embodiment also proposes a near-net-shape forming method for continuous fiber reinforced metal matrix composite components using the above-mentioned encapsulation, specifically including the following steps:

[0049] S1: Fill the powder cavity 7 with raw aluminum-titanium alloy powder. The raw aluminum-titanium alloy powder is atomized spherical powder with an average particle size of about 150μm.

[0050] S2: Vacuum electron beam welding is used for the sleeve wall 2, upper end cap 1, and lower end cap 3; the vacuum degree of vacuum electron beam welding is 5×10⁻⁶. -4 Pa;

[0051] S3: The welded sheath is hot-pressed at 100MPa for 5 hours, and the hot-pressing temperature is 3 / 4 of the melting point of the aluminum-titanium alloy.

[0052] S4: After hot pressing, the outer casing and excess base material are removed by mechanical processing;

[0053] S5: Chemical etching treatment is performed to obtain the shaped component.

[0054] Although embodiments of the invention have been shown and described, those skilled in the art will understand that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.

Claims

1. A near-net-shape forming sleeve for continuous fiber reinforced metal matrix composite components, characterized in that, The device includes a cylindrical central preform; an outer mold core, which is an L-shaped rotating body; the central preform is disposed within the outer mold core; and a pressing block; the pressing block, outer mold core, and central preform cooperate to form a powder cavity for holding powder; the outer surface of the outer mold core has an edge preform powder cavity; the outer layer of the outer mold core is provided with a cylindrical wall; an upper end cover is provided above the pressing block, outer mold core, and central preform; a lower end cover is provided at the bottom of the outer mold core and central preform; the upper end cover, lower end cover, and cylindrical wall form a casing. The outer surface of the central preform has grooves, and long fibers are wrapped and filled in the grooves. The upper end cover is provided with a protrusion, which is located above the pressure block and can drive the pressure block to move up and down; the protrusion is an annular shape with a frustum-shaped cross-section.

2. The near-net-shape forming sleeve for a continuous fiber reinforced metal matrix composite component according to claim 1, characterized in that, The long fibers are one or more of the following: boron fibers, carbon fibers, silicon carbide fibers, tungsten wires, and molybdenum wires, which are coated with a base metal.

3. The near-net-shape forming sleeve for a continuous fiber reinforced metal matrix composite component according to claim 1, characterized in that, The central preform and powder material are one or more of titanium alloy, nickel-based alloy, and stainless steel.

4. The near-net-shape forming sleeve for a continuous fiber reinforced metal matrix composite component according to claim 1, characterized in that, The preparation method of the central preform is one of the following three: forging billet, casting billet, or hot isostatic pressing powder compact.

5. A near-net-shape forming method for a continuous fiber-reinforced metal matrix composite component using the enclosure described in any one of claims 1 to 4, characterized in that, Specifically, the following steps are included: S1: Fill the powder cavity with the raw material powder; S2: Vacuum electron beam welding is used for the sleeve wall, upper end cap, and lower end cap; S3: Perform hot pressing on the welded sheath; S4: After hot pressing, the outer casing and excess base material are removed by mechanical processing; S5: Chemical etching treatment is performed to obtain the shaped component.

6. The near-net-shape forming method for continuous fiber reinforced metal matrix composite components according to claim 5, characterized in that, In step S1, the raw material powder is atomized spherical powder with an average particle size of 50~150μm.

7. The near-net-shape forming method for continuous fiber reinforced metal matrix composite components according to claim 5, characterized in that, In step S2, the vacuum level of vacuum electron beam welding is no greater than 1×10⁻⁶. -3 Pa.

8. The near-net-shape forming method for continuous fiber reinforced metal matrix composite components according to claim 5, characterized in that, In step S3, the pressure of hot pressing is 100~500MPa, the hot pressing temperature is 1 / 2~3 / 4 of the melting point temperature of the powder, and the hot pressing time is 2~5h.

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