Method for manufacturing part made of composite material
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Solution Overview
Problem
Existing methods for fabricating thermostructural composite materials, such as oxide/oxide and ceramic matrix composites, fail to control the matrix volume fraction and mechanical properties, particularly in the thickness direction of the material.
Innovation Solution
A method involving multiple impregnations with slips containing refractory particles of varying sizes and chemical natures, followed by sintering, to control the matrix volume fraction and properties, with the use of a porous material to drain the liquid phase without disturbing the particle distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single impregnation with slip containing refractory particles is performed, then the manufacturing process is simple, but the matrix volume fraction cannot be optimized and mechanical properties cannot be controlled in the thickness direction
Solution Approach 1:
The impregnation process is divided into multiple sequential steps, each introducing particles of specific size ranges. The first impregnation introduces larger particles (0.5-5 μm), the second introduces medium particles (0.1-1 μm), and the third introduces finer particles (0.01-0.1 μm). This segmentation allows precise control over matrix volume fraction and mechanical properties in the thickness direction by controlling particle distribution at different depths.
Solution Approach 2:
Different regions of the preform receive different particle sizes and concentrations through the sequential impregnation process. The surface regions receive finer particles while deeper regions receive coarser particles, creating local variations in matrix quality that optimize both surface finish and bulk mechanical properties.
2Manufacturing precision
If multiple impregnations with different particle sizes are performed, then matrix volume fraction and mechanical properties can be controlled, but the process time increases
Solution Approach 1:
The fiber preform is prepared in advance with a specific architecture and porosity distribution optimized for sequential impregnation. The preform structure is designed to facilitate uniform particle distribution during each impregnation step, reducing the number of cycles needed and optimizing the efficiency of each subsequent impregnation.
Solution Approach 2:
The impregnation process parameters are systematically varied across the three steps: particle size distribution, slip concentration, and impregnation pressure are adjusted for each step. This parameter optimization ensures that each impregnation step is highly efficient and contributes maximally to the final matrix volume fraction and property distribution.
3Ease of manufacture
If larger particles are used in the slip, then the impregnation is easier, but micropores remain and matrix density is reduced
Solution Approach 1:
The impregnation process uses a nested particle size approach where larger particles are introduced first to establish the basic matrix framework, then medium particles fill the interstices between larger particles, and finally finer particles fill remaining voids. This nested structure ensures complete pore elimination while maintaining impregnation efficiency at each stage.
Solution Approach 2:
Different particle sizes are strategically distributed to different regions: larger particles provide structural framework in the bulk, while progressively finer particles are introduced to fill voids and improve density. The surface regions receive the finest particles to achieve both high density and good surface finish.
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 the optimization of matrix volume fraction and mechanical properties, reducing micropores and achieving a high matrix volume fraction, as well as improving the surface shape of the final part by using finer particles on the surface.
Implementation Method 1
a part made of porous material for draining the liquid phase of the slip that has impregnated the fiber texture, the refractory particles being retained inside said texture by said part made of porous material
Implementation Method 2
sintering the first and second refractory particles present in the fiber preform in order to form a refractory matrix in said preform
Data Source
AI summary
A method of fabricating a part out of composite material, includes forming a fiber texture from refractory fibers; impregnating the fiber texture for a first time with a first slip containing first refractory particles; eliminating the liquid phase from the first slip so as to leave within the texture only the first refractory particles; impregnating the fiber texture for a second time with a second slip containing second refractory particles; eliminating the liquid phase from the second slip so as to leave within the texture only the second refractory particles and obtain a fiber preform filled with the first and second refractory particles; and sintering the first and second refractory particles present in the fiber preform in order to form a refractory matrix in the preform.