Systems and methods for carbon-carbon materials incorporating yttrium and zirconium compounds
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Solution Overview
Problem
Carbon composite materials used in aircraft brake components exhibit varying wear characteristics, leading to short product lives and frequent maintenance due to inadequate wear resistance.
Innovation Solution
A method involving the infiltration of carbon structures with a ceramic preparation containing yttrium oxides and zirconium oxides, followed by heat treatment to form ceramic particles like zirconium oxycarbide, zirconium carbide, yttrium oxycarbide, and yttrium carbide, which are then integrated into the carbon composite material to enhance wear resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If carbon fiber composite materials are used in brake components, then the components achieve lightweight design and basic friction performance, but the wear resistance is insufficient leading to short product life
Solution Approach 1:
The patent applies composite materials by combining carbon fiber composite base material with ceramic particles (zirconium carbide, yttrium carbide, zirconium oxycarbide, yttrium oxycarbide) to create a multi-phase composite structure. The ceramic particles are dispersed throughout the carbon matrix to provide enhanced wear resistance while maintaining the lightweight characteristics of carbon composites.
Solution Approach 2:
The patent applies local quality by creating regions with different material properties within the brake component. Ceramic particles are strategically distributed in high-wear areas to provide localized wear protection, while the carbon matrix maintains overall structural integrity and friction characteristics.
2Reliability
If ceramic particles are added to carbon composite to improve wear resistance, then the wear characteristics improve, but the manufacturing process complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-coating ceramic particles with carbon before infiltration. This pre-coating step prepares the ceramic particles for better integration into the carbon matrix during subsequent CVI processing, reducing manufacturing complications that would arise from direct infiltration of uncoated ceramics.
Solution Approach 2:
The patent uses carbon coating as an intermediary layer between the ceramic particles and the carbon matrix. This intermediate carbon layer facilitates better bonding and integration of the ceramic particles into the carbon composite structure, simplifying the overall manufacturing process by improving interfacial compatibility.
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 integration of these ceramic particles improves the wear resistance of carbon composite materials in aircraft brake components, extending their lifespan and reducing maintenance needs.
Implementation Method 1
densifying the carbon structure by chemical vapor infiltration (CVI)
Implementation Method 2
heat treating the carbon structure to form a plurality of ceramic particles in the carbon structure
Data Source
AI summary
A method of treating a carbon structure is provided. The method may include the step of infiltrating the carbon structure with a ceramic preparation comprising yttrium oxides and zirconium oxides. The carbon structure may be densified by chemical vapor infiltration (CVI) and heat treated to form yttrium oxycarbides and/or carbides and zirconium oxycarbides and/or carbides. Heat treating the carbon structure may comprise a temperature ranging from 1000° C. to 1600° C.