Oxide/oxide composite 3D weaving and binder-free SPS
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Solution Overview
Problem
Oxide/oxide composite materials prepared by existing methods exhibit limited mechanical characteristics, particularly low shear strength, due to cracks in the matrix and nonuniform composition gradients, which are exacerbated by the use of organic binders and pressure gradient methods like resin transfer molding or submicrometer powder suction (SPS).
Innovation Solution
A method involving three-dimensional weaving of refractory oxide fibers with specific weaves (interlock, multi-plain, multi-satin, multi-serge) and fiber volume fractions (40% to 51%) to limit matrix block sizes, combined with the SPS technique, which eliminates the need for organic binders and ensures uniform infiltration and sintering of refractory oxide particles to form a crack-free matrix.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If organic binder is added to the suspension to prevent preform expansion during drying, then the cohesion of the system is improved, but the suspension behavior changes from Newtonian to shear-thinning, leading to nonuniform composition and poor flow control
Solution Approach 1:
The patent removes the organic binder component from the suspension system entirely. By extracting this problematic element, the suspension maintains Newtonian behavior and uniform flow characteristics without requiring binders for cohesion, thus preventing both the expansion issue and the composition nonuniformity simultaneously
Solution Approach 2:
The patent modifies the suspension composition by eliminating organic binders and adjusting the inorganic filler content and particle size distribution. This parameter change maintains system stability through inorganic mechanisms rather than organic binders, preserving both cohesion and uniform composition
2Strength
If high volume percentage of fillers is used in the suspension to achieve high mechanical characteristics in a single impregnation step, then the mechanical properties are improved, but the flow of suspension becomes difficult to control, leading to composition gradients and uncontrolled pores
Solution Approach 1:
The patent segments the filler particle size into multiple distributions (e.g., fine, medium, coarse particles) within the suspension. This segmentation allows high total filler content while maintaining flow control, as different sized particles pack and flow differently, preventing aggregation and maintaining uniform distribution throughout the impregnation process
Solution Approach 2:
The patent optimizes the suspension parameters by controlling particle size distribution, shape, and surface characteristics of the inorganic fillers. These parameter changes enable high filler volume percentages while maintaining Newtonian flow behavior and preventing composition gradients during impregnation
3Volume of moving object
If pressure gradient methods like RTM or SPS are used to penetrate suspension into thick fiber textures, then the impregnation depth is improved, but cracks form in the matrix during drying, leading to expansion and reduced mechanical properties
Solution Approach 1:
The patent extracts the organic binder component that causes crack formation during drying. By using only inorganic fillers in a binder-free suspension, the dried matrix does not undergo the expansion and cracking that occurs with organic binder removal, thereby maintaining mechanical integrity while achieving deep impregnation through pressure gradient methods
Solution Approach 2:
The patent changes the chemical composition parameters of the suspension by eliminating organic components and using only inorganic fillers. This parameter change fundamentally alters the drying behavior, preventing crack formation and matrix expansion while maintaining the ability to achieve deep impregnation through controlled pressure gradients
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
The approach results in oxide/oxide composite materials with improved mechanical properties, including a modulus of elasticity between 120 GPa and 170 GPa, breaking deformation of at least 0.35%, and breaking stress greater than 250 MPa, while maintaining material uniformity and preventing cracks.
Implementation Method 1
establishing a pressure difference to force the slip to pass through the fiber texture
Implementation Method 2
sintering the submicrometer powder of refractory oxide particles in order to form a refractory oxide matrix in the preform
Data Source
AI summary
A part made of oxide/oxide composite material includes fiber reinforcement constituted by a plurality of warp yarn layers and of weft yarn layers interlinked by three-dimensional weaving, with the spaces present between the reinforcing yarns being filled with a refractory oxide matrix. The fiber reinforcement presents a weave selected from the following weaves: interlock; multi-plain; multi-satin; and multi-serge, with warp and weft thread counts lying in the range 4 yarns/cm to 20 yarns/cm. The fiber reinforcement also presents a fiber volume fraction lying in the range 40% to 51%.