Method for manufacturing a part made of a composite material
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for manufacturing composite materials, such as oxide/oxide or ceramic matrix composites, fail to produce parts with high matrix volume ratios and varying mechanical properties across the thickness of the material.
Innovation Solution
A method involving successive impregnations with slips containing particles of different sizes and chemical natures, followed by a third impregnation and liquid phase elimination using a porous material to control matrix volume and surface characteristics, ensuring uniform distribution and improved surface finish.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single impregnation with uniform particles is used, then the manufacturing process is simple, but the matrix volume ratio cannot be optimized and mechanical properties cannot vary in thickness
Solution Approach 1:
The impregnation process is divided into multiple sequential steps, each introducing particles of different sizes and/or chemical natures. The first impregnation introduces larger particles, the second introduces smaller particles to fill interstices, and optionally a third impregnation introduces surface particles. This segmentation allows precise control of matrix volume ratio and property gradients through the material thickness.
Solution Approach 2:
Different regions of the composite material are given different properties by controlling particle distribution. The core contains a mixture of first and second particles, while the surface region contains primarily third particles. This local quality variation enables optimized mechanical properties in different zones of the material.
2Manufacturing precision
If conventional single-stage impregnation is used, then production is efficient, but high matrix volume ratio and property variation are not achieved
Solution Approach 1:
Particles are introduced into the fibrous texture in a predetermined sequence before final consolidation. The first particles are introduced and distributed, then second particles are introduced to fill interstices, and third particles are introduced for surface modification. This preliminary action ensures optimal particle distribution and matrix volume ratio before sintering.
Solution Approach 2:
Smaller second particles are nested within the interstices between larger first particles, creating a hierarchical structure that maximizes matrix volume ratio. This nesting approach allows efficient space utilization and controlled property gradients without requiring excessive material or process complexity.
3Quantity of substance
If particles of the same size are used, then the impregnation process is simple, but interstices cannot be fully filled and matrix volume ratio is limited
Solution Approach 1:
The particle size parameter is varied across different impregnation stages. First particles have a larger average size, while second particles have a smaller average size designed to fill the interstices between first particles. This parameter change enables complete filling of the fibrous texture and achieves high matrix volume ratios.
4Manufacturing precision
If surface particles are not separately introduced, then the process is simpler, but surface quality and microporosity are not optimized
Solution Approach 1:
The surface region is given special attention through a dedicated third impregnation step that introduces particles specifically for surface quality optimization. These third particles have different characteristics (size and/or chemical nature) from core particles, creating a tailored surface layer with improved properties and reduced microporosity.
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 allows for precise control of matrix volume ratio and surface quality, resulting in composite parts with enhanced mechanical properties and reduced microporosity, suitable for applications like turbomachine blades.
Implementation Method 1
the drainage through the part made of porous material of the liquid phase of the slip that has passed through the fibrous texture, the refractory particles being retained inside said texture by said part made of porous material
Implementation Method 2
the injection of a compression fluid into the compaction chamber, the fluid exerting pressure on the membrane to force the slip through the fibrous texture
Implementation Method 3
an impermeable membrane deformable placed opposite a second face of the fibrous texture, said membrane separating the impregnation chamber from a compaction chamber
Implementation Method 4
The loaded preform thus obtained is then subjected to sintering in order to form a refractory oxide matrix in the preform
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a method for manufacturing a part made of composite material, said method including the following steps: a step of forming a fibrous texture (10) from refractory fibres; a first impregnation step of impregnating the fibrous texture (10) with a first slurry (150) containing first refractory particles (151); a step of removing the liquid phase (152) from the first slurry (151) so as to allow only the first refractory particles (151) to remain inside said texture; a second impregnation step of impregnating the fibrous texture (20) with a second slurry (160) containing second refractory particles (161); a step of removing the liquid phase (162) from the second slurry (160) such as to allow only the second refractory particles (161) to remain inside said texture and to obtain a fibrous preform (30) filled with the first and second refractory particles (151, 161); and a step of sintering the first and second refractory particles (151, 161) in the fibrous preform (30) so as to form a refractory matrix inside said preform.