Manufacturing method for ceramic-based composite material
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Solution Overview
Problem
The PIP method for producing ceramic matrix composites requires repeated infiltration, drying, and sintering steps, leading to prolonged manufacturing time and decreased strength due to fiber bundle deterioration.
Innovation Solution
A manufacturing method involving a green body formation step, followed by a densification step that includes multiple infiltration, drying, steam treatment, and sintering steps, with the steam treatment under saturation water vapor pressure to enhance polymer infiltration efficiency and reduce the need for repeated sintering, along with an interface coating formation step using a sizing agent heated under nitrogen to modify the fiber bundle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the PIP method is used to produce ceramic matrix composite by repeating infiltration, drying, and sintering steps, then the desired strength characteristics are achieved, but the manufacturing time is prolonged
Solution Approach 1:
The patent introduces a steam treatment step that changes the physical-chemical parameters of the green body by exposing it to saturation water vapor at controlled temperatures (30-200°C). This parameter change enhances polymer infiltration efficiency and allows the process to achieve desired strength characteristics with fewer repeated cycles, thereby reducing manufacturing time while maintaining strength requirements
Solution Approach 2:
The steam treatment acts as an intermediary step between drying and sintering. By introducing this intermediate treatment, the patent improves polymer infiltration into the green body structure, which reduces the number of repeated infiltration-drying-sintering cycles needed, thus shortening manufacturing time while achieving the required strength characteristics
2Reliability
If the sintering step is repeated a plurality of times to achieve desired characteristics, then the ceramic matrix composite is formed, but decreased strength occurs due to deterioration of fiber bundles
Solution Approach 1:
The steam treatment serves as an intermediary that improves polymer infiltration efficiency, allowing the process to achieve desired characteristics with fewer sintering repetitions. This reduces thermal exposure to fiber bundles, preventing strength deterioration while still achieving the required material characteristics
Solution Approach 2:
The steam treatment is performed as a preliminary action before the final sintering step. By pre-treating the green body with saturation water vapor, the patent enhances polymer infiltration and prepares the structure for more effective sintering, reducing the need for repeated high-temperature exposure that would deteriorate fiber bundles
3Manufacturing precision
If multiple infiltration and sintering steps are performed to increase polymer infiltration, then the matrix density is improved, but the manufacturing complexity and time increase
Solution Approach 1:
The patent introduces steam treatment as a parameter change that occurs within the existing process framework. By controlling temperature and humidity parameters during steam treatment, the patent achieves improved polymer infiltration and matrix density without adding significant process complexity, as the steam treatment can be integrated into the existing drying step infrastructure
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 shortens manufacturing time, maintains strength by reducing heat-induced fiber bundle deterioration, and increases polymer infiltration efficiency without requiring extensive facilities, while also simplifying the process by eliminating the need for multiple sintering steps.
Implementation Method 1
a steam treatment step of leaving the dried green body under a saturation water vapor pressure to form a treated green body
Implementation Method 2
a sintering step of sintering the treated green body
Implementation Method 3
a drying step of drying the infiltrated green body to form a dried green body
Data Source
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AI summary
Provided is a ceramic-based composite material manufacturing method which is unlikely to result in strength deterioration and with which it is possible to shorten manufacturing time. This manufacturing method is for a ceramic-based composite material having a woven fabric that has multiple fiber bundles and having a matrix that is disposed in the gaps between the fiber bundles, the manufacturing method comprising: a base body formation step for forming a base body by calcining the woven fabric impregnated with a polymer that is a precursor to the matrix; and a densification step for further impregnating the base body with a polymer and calcining same. The densification step comprises: a second impregnation step for further impregnating the base body with a polymer so as to form an impregnated base body; a drying step for drying the impregnated base body so as to form a dried base body; a steam treatment step for leaving the dried base body under saturation water vapor pressure so as to form a treated base body; and a calcination step for calcining the treated base body.