C/C-SiC Composite Part Fabrication via 3D Printing and Solvent Evaporation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for preparing carbon fiber reinforced carbon-silicon carbide (C/C-SiC) composite materials face inefficiencies in forming complex parts, particularly due to high porosity and residual silicon content, which affect the material's performance and structural integrity.
Innovation Solution
A method involving solvent evaporation to prepare uniform carbon fiber composite powders coated with phenol resin, followed by 3D printing and densification processes, including siliconization under vacuum to reduce residual silicon and achieve high-density, low-porosity C/C-SiC composite parts.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If molding process is used to prepare C/C porous preforms, then preparation process is simple and cost is low, but efficiency in fabricating complex parts is poor and near net shape formation fails
Solution Approach 1:
The patent changes the manufacturing approach from traditional molding to 3D printing technology, fundamentally altering the process parameters and capabilities to enable complex part fabrication while maintaining preparation simplicity
Solution Approach 2:
The patent introduces 3D printing technology that adds dimensional capability to the manufacturing process, enabling the creation of complex three-dimensional structures with heat dissipation passages that cannot be achieved by conventional molding
2Ease of manufacture
If mechanical mixed powder is used for SLS process, then silicon carbide blank can be formed, but high porosity and residual silicon affect material performance
Solution Approach 1:
The patent changes the powder preparation method from mechanical mixing to solvent evaporation process, which fundamentally alters the powder characteristics to achieve uniform particle size, appropriate morphology, and controlled composition that reduce porosity and residual silicon content
Solution Approach 2:
The patent performs preliminary actions in the powder preparation stage by using solvent evaporation to pre-form uniform particles with controlled characteristics before 3D printing, which prevents porosity and residual silicon issues during subsequent processing
3Adaptability or versatility
If 3D printing technology is used to form complex structures, then design freedom increases and near net shape is achieved, but surface finishing requirements increase due to powder bed limitations
Solution Approach 1:
The patent optimizes powder parameters including particle size distribution, morphology, and surface characteristics through solvent evaporation process, which improves surface finish quality while maintaining the design freedom benefits of 3D printing
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
This method enables the production of C/C-SiC composite parts with reduced residual silicon, high density, and adjustable porosity, closely approaching the final shape, thus enhancing high-temperature mechanical properties and reducing design time and costs.
Implementation Method 1
distilling the dispersed solution and crystallizing to yield a powder aggregate
Implementation Method 2
siliconized by vacuum infiltration and sintering
Data Source
Figure 1
AI summary
Disclosed is a method for preparing a C/C-SiC composite material part and a product thereof. The method comprises the following steps: (a) preparing a carbon fibre/phenolic resin composite powder by a solvent evaporation method; (b) according to a three-dimensional model of the part, moulding the carbon fibre composite powder into an initial moulded blank by means of a 3D printing process; (c) subjecting the initial moulded blank to a primary densification treatment to obtain a C/C porous body; (d) subjecting the C/C porous body to a molten siliconizing reaction, a high-temperature desilication and a secondary densification, to obtain the final C/C-SiC part. By means of the method, a C/C-SiC composite material part with a complex structure can be moulded, with a short production cycle and low costs, and the resulting C/ C-SiC composite material part has a low residual silicon content and excellent performance.