Ceramic Matrix Composite Melt Infiltration Path Formation
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Solution Overview
Problem
The formation of ceramic matrix composites using the melt-infiltrated method is hindered by the presence of carbon or silicon carbide fillers, which fragment impregnation paths, leading to incomplete impregnation with molten silicon and potential defects such as voids or cracks, and unreacted silicon residues.
Innovation Solution
A method involving the stacking of fiber layers impregnated with base resin, forming a matrix layer with impregnation paths perpendicular to the stacking direction, and impregnating the laminate with molten metal or alloy to react and form a continuous impregnation path for uniform impregnation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If a matrix slurry containing a large amount of filler (carbon or silicon carbide) is used, then the ceramic matrix composite can be formed with appropriate filler content, but the impregnation path is fragmented by the filler, making it difficult to form an appropriate impregnation path and leading to incomplete impregnation with molten silicon
Solution Approach 1:
The invention creates impregnation paths in advance through carbonization of the laminate before molten silicon impregnation. This preliminary action ensures continuous pathways are established prior to filler addition, allowing molten silicon to flow through the entire structure without being blocked by filler particles.
Solution Approach 2:
The invention segments the impregnation process into distinct stages: first creating continuous carbon-based impregnation paths through carbonization, then introducing molten silicon along these pre-formed paths. This segmentation allows the filler to be present without disrupting the impregnation flow, as the pathways are already established.
2Productivity
If pores formed by the pore-forming agent are large, then pore formation is promoted, but unreacted silicon that has not reacted with carbon may be left even after impregnation with molten silicon, reducing the strength of the formed ceramic matrix composite
Solution Approach 1:
The invention ensures continuous reaction by maintaining impregnation paths that allow molten silicon to penetrate throughout the entire laminate structure. The continuous carbonization process and sustained molten silicon flow ensure complete reaction throughout, preventing unreacted silicon residues even in large pores.
3Device complexity
If an impregnation path is not formed appropriately, then the process can be simpler, but impregnation with molten silicon stops halfway and some areas are left not impregnated, causing defects such as voids or cracks
Solution Approach 1:
The invention performs preliminary carbonization to create continuous impregnation paths before molten silicon impregnation. This advance preparation ensures that pathways are established throughout the entire structure, guaranteeing complete impregnation without requiring complex real-time path formation mechanisms.
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 approach prevents defects in the ceramic matrix composite formation by ensuring complete impregnation with molten silicon, thereby enhancing the composite's strength and integrity.
Implementation Method 1
forming an impregnation path in the matrix layer entirely in an in-plane direction perpendicular to a direction of the stacking in the laminate by carbonizing the formed laminate
Implementation Method 2
impregnating, with the molten metal or alloy, the laminate in which the impregnation path has been formed
Data Source
Figure 1~2
Figure 3
AI summary
A method of forming a ceramic matrix composite with being impregnated with molten metal includes: stacking a plurality of fiber layers that are layers of reinforced fibers impregnated with base resin to form a laminate in which a matrix layer containing fibers extending in a direction of impregnation with the molten metal is disposed between the fiber layers; forming an impregnation path in the matrix layer entirely in an in-plane direction perpendicular to a direction of the stacking in the laminate by carbonizing the formed laminate; and impregnating, with the molten metal, the laminate in which the impregnation path has been formed.