3D-Printed SiC Molding for Complex SiC–Si Components
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Solution Overview
Problem
Existing methods struggle to produce SiC-Si composite components with complex shapes while maintaining favorable mechanical properties.
Innovation Solution
A method involving 3D printing to create a first molded body with SiC particles, followed by impregnating pores with carbon particles and reacting with metallic Si to form a SiC-Si composite component, ensuring the carbon particles have a smaller average diameter than the pore diameter and controlling Si content between 5% to 40% by mass.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If a 3D printing method is used to produce a SiC—Si composite component with a complex shape, then the shape complexity is improved, but the mechanical properties deteriorate
Solution Approach 1:
The patent applies preliminary action by filling the pores of the 3D-printed molded body with carbon particles before the final reactive sintering process. This preliminary filling of pores with carbon particles (which will later react with Si to form SiC) prepares the structure in advance to ensure dense packing and good mechanical properties in the final product, while maintaining the complex shape achieved through 3D printing
Solution Approach 2:
The patent changes parameters by controlling the particle size distribution of carbon particles (using particles with average diameter of 1/10 to 1/100 of the pore diameter) and Si content (5-40 mass%), and by optimizing the reactive sintering conditions. These parameter changes ensure that the final composite component achieves both complex shape fidelity and favorable mechanical properties
2Quantity of substance
If the carbon particles have a smaller average diameter than the pore diameter, then the porosity is reduced, but the manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by establishing specific relationships between carbon particle size and pore diameter (average particle diameter of 1/10 to 1/100 of the pore diameter), and by controlling Si content (5-40 mass%). These quantified parameter changes systematically reduce porosity while maintaining manufacturing feasibility through the reactive sintering process
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 enables the production of SiC-Si composite components with improved mechanical strength, low porosity, and high bulk density, suitable for complex and large-sized shapes.
Implementation Method 1
forming a second molded body, in which the first molded body and a dispersion containing carbon particles are brought into contact so that the pores are impregnated with the carbon particles
Implementation Method 2
forming a SiC—Si composite component by carrying out that the second molded body is impregnated with a metallic Si and is reactively sintered
Data Source
AI summary
The present invention relates to a method of producing a SiC—Si composite component. The method includes preparing a first molded body containing SiC particles by a 3D printing method, wherein the first molded body has a first average pore diameter M1;forming a second molded body, in which the first molded body and a dispersion containing carbon particles are brought into contact so that the pores are impregnated with the carbon particles, wherein the carbon particles have a secondary particle having an average particle diameter M2, and the carbon particles satisfy the following formula:M2≤M1/10; andforming a SiC—Si composite component by carrying out that the second molded body is impregnated with a metallic si and is reactively sintered;wherein the content of Si is in the range of 5% by mass to 40% by mass in the SiC—Si composite component.