Ultra-Refractory C/C Composite with Self-Healing Matrix
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Solution Overview
Problem
Current ultra-refractory ceramic materials used in aerospace applications lack sufficient resistance to thermal shocks, erosion, and ablation, with traditional methods for producing fiber-reinforced composites being costly and time-consuming, and existing materials like SiC-based composites experiencing degradation at high temperatures.
Innovation Solution
A process involving the infiltration of carbon fiber preforms with a ceramic suspension containing ZrB2, Si3N4, SiC, and WC, followed by vacuum drying and sintering, to produce ultra-refractory composite materials with high tenacity and self-healing properties, optimized for low porosity and enhanced mechanical performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If chemical vapor infiltration (CVI) techniques are used to produce ultra-refractory ceramic matrix composites, then the material achieves good densification and closed pores, but the production cost increases and production time lengthens
Solution Approach 1:
The patent replaces the complex chemical vapor infiltration process with a simpler slurry infiltration method followed by vacuum drying and sintering. This substitution of the infiltration mechanism achieves comparable densification (residual porosity < 5%) while dramatically reducing production time and cost, making the process more suitable for industrial applications
Solution Approach 2:
The patent modifies the infiltration parameters by using a liquid slurry phase instead of gaseous precursors, and employs vacuum drying at controlled temperatures to achieve optimal porosity reduction. The sintering parameters are also optimized to achieve full densification without requiring the extended processing times of CVI methods
2Reliability
If conventional ceramic materials like SiC are used, then they provide good oxidation resistance below 1600°C, but they soften and form vapors at temperatures above 1600°C
Solution Approach 1:
The patent creates a composite material system combining ultra-refractory ceramic phases (ZrB2, HfB2, ZrC, HfC, TaC) with carbon fiber reinforcement. This composite structure provides both high-temperature stability (maintaining mechanical properties up to 2000°C) and oxidation resistance, overcoming the limitations of conventional single-phase ceramics
Solution Approach 2:
The patent introduces a multi-phase matrix composition where different ceramic phases are distributed throughout the material to provide localized functionality. The ultra-refractory phases provide high-temperature structural stability while maintaining oxidation resistance, allowing the material to perform reliably in extreme thermal environments
3Reliability
If carbon fiber reinforcement is added to ultra-refractory ceramic matrices, then thermal shock resistance improves, but the material becomes susceptible to severe erosion
Solution Approach 1:
The patent develops a multi-component composite system where carbon fibers provide thermal shock resistance through their high fracture toughness, while the ultra-refractory ceramic matrix (ZrB2, HfB2, etc.) provides erosion resistance. The synergistic combination of these materials allows the composite to withstand both thermal shocks and erosive environments simultaneously
Solution Approach 2:
The patent addresses the erosion susceptibility of carbon fibers by embedding them within an ultra-refractory ceramic matrix that protects the fibers from direct erosive attack. The matrix acts as a protective barrier, converting the potential weakness of carbon fibers into a strength through the protective effect of the surrounding ceramic phase
4Productivity
If vacuum bag infiltration of carbon fibers with ceramic suspensions is used, then production cost decreases and production time shortens, but residual porosity increases compromising high-temperature performance
Solution Approach 1:
The patent replaces the vacuum bag infiltration method with slurry infiltration followed by vacuum drying and sintering. This process substitution achieves superior densification (residual porosity < 5%) while maintaining the production efficiency and cost benefits of the simpler infiltration approach, eliminating the porosity problem associated with vacuum bag methods
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The resulting composite materials exhibit high flexural strength, low porosity, and self-healing capabilities, enabling their use in extreme temperature conditions without significant erosion or degradation, thus addressing the limitations of existing materials.
Implementation Method 1
infiltrating said at least one preform with a ceramic suspension
Implementation Method 2
drying the composite material under vacuum
Implementation Method 3
consolidated by sintering with or without the application of gas or mechanical pressure
Implementation Method 4
The majority of the processes developed employ chemical vapor infiltration (CVI) techniques, primarily with C vapors, in order to close open pores and favor the in situ formation of an SiC phase
Data Source
Figure 1~2
Figure 3
AI summary
The present invention relates to a process for the production of fiber- reinforced composite materials with an ultra-refractory, high tenacity, high ablation resistant matrix with self-healing properties, prepared from highly sinterable slurries. The composite material is produced using techniques of infiltration and drying at ambient pressure or under vacuum, and consolidated by sintering with or without the application of gas or mechanical pressure.