US-12623973-B2 - Ceramic matrix composite and method for manufacturing same

US12623973B2US 12623973 B2US12623973 B2US 12623973B2US-12623973-B2

Abstract

Provided is a method for manufacturing a ceramic matrix composite including a matrix and reinforcing fibers provided in the matrix. The method includes infiltrating a fiber body with powder of a ceramic material that becomes a part of the matrix. The fiber body is constituted by the reinforcing fibers. The method includes arranging, in a liquid material for the matrix, the fiber body infiltrated with the powder. The method includes heating the fiber body in this state, thereby bringing the liquid material into a film-boiling state such that ceramic derived from the liquid material is generated as a part of the matrix in the fiber body.

Inventors

Yuki Kubota
Michimasa UDA
Haruhiko SOEDA
Takuya Aoki

Assignees

IHI AEROSPACE CO., LTD.
JAPAN AEROSPACE EXPLORATION AGENCY

Dates

Publication Date: 20260512
Application Date: 20211203
Priority Date: 20201204

Claims (7)

1 . A method for manufacturing a ceramic matrix composite including a matrix and reinforcing fibers provided in the matrix, the method comprising: a step (A) of infiltrating a fiber body with powder of a ceramic material that becomes a part of the matrix, the fiber body being constituted by the reinforcing fibers; a step (B) of arranging, in a liquid material for the matrix, the fiber body infiltrated with the powder; and a step (C) of heating the fiber body in a state where the fiber body is arranged in the liquid material, thereby bringing the liquid material into a film-boiling state such that ceramic derived from the liquid material is generated as a part of the matrix in the fiber body, wherein the step (C) includes: a step (C1) of heating the fiber body, thereby bringing the liquid material into the film-boiling state such that the ceramic is generated in the fiber body; a step (C2) of cooling the fiber body until a temperature of the fiber body becomes equal to or lower than a low-side target temperature lower than a boiling point of the liquid material; and repeating the step (C1) and the step (C2) in the state where the fiber body is arranged in the liquid material, wherein the repeating the step (C1) and the step (C2) includes: raising the temperature of the fiber body by heating the fiber body at the step (C1); starting the step (C2) at a timing that the temperature of the fiber body becomes equal to or higher than a high-side target temperature in course of raising the temperature of the fiber body at the step (C1); lowering the temperature of the fiber body by cooling the fiber body at the step (C2); and starting the step (C1) again at a timing that the temperature of the fiber body becomes equal to or lower than the low-side target temperature in course of lowering the temperature of the fiber body at the step (C2).
2 . The method for manufacturing the ceramic matrix composite according to claim 1 , wherein: the step (A) includes: a step (A1) of producing slurry by mixing the powder with a liquid; a step (A2) of burying the fiber body in the slurry in a slurry vessel; and a step (A3) of evacuating inside gas of the slurry vessel, thereby causing the fiber body to be infiltrated with the slurry including the powder.
3 . The method for manufacturing the ceramic matrix composite according to claim 1 , wherein: the step (A) uses the powder having a median diameter equal to or larger than 1 μm and equal to or smaller than 20 μm.
4 . The method for manufacturing the ceramic matrix composite according to claim 1 , wherein: the step (A) uses, as the powder, mixed powder in which powder having a median diameter of 5 μm and powder having a median diameter of 17 μm are mixed with each other.
5 . The method for manufacturing the ceramic matrix composite according to claim 1 , wherein: the step (B) includes arranging the fiber body and a heated body inside a treatment vessel that holds the liquid material; and the step (C1) includes induction-heating the heated body, thereby heating the fiber body.
6 . The method for manufacturing the ceramic matrix composite according to claim 5 , wherein: the step (C1) includes causing alternating current is caused to flow through a coil arranged outside of the treatment vessel, thereby causing the coil to generates an alternating magnetic field such that the heated body is induction-heated by the alternating magnetic field and heats the fiber body, and the treatment vessel is formed of a non-electroconductive material.
7 . The method for manufacturing the ceramic matrix composite according to claim 5 , wherein: the step (B) includes: attaching the fiber body to the heated body by an attachment tool; and suspending the attachment tool, the fiber body, and the heated body so as not to contact with an inner surface of the treatment vessel.

Description

TECHNICAL FIELD The present invention relates to a ceramic matrix composite and a method for manufacturing the same. BACKGROUND ART A ceramic matrix composite is a composite that includes ceramic as a matrix, and reinforcing fibers provided in the matrix. Examples of the ceramic includes silicon carbide. The ceramic matrix composites are used as high-temperature structural members in rocket engines, aircraft jet engines, and the like. The matrix is formed on the reinforcing fibers (i.e., a fiber body that is, for example, a woven or knitted fabric of the reinforcing fibers) by a method of chemical vapor impregnation (CVI), polymer impregnation of pyrolysis (PIP), metal melt infiltration (MI), or the like. The fiber body is also called a preform. In the CVI method, a reactive gas is caused to flow through a heated fiber body, and a reactant consequent on the reactive gas is deposited as a matrix in pores in the fiber body. In the PIP method, a fiber body is impregnated with a polymer such as polycarbosilane, and the impregnation polymer is burned to form a matrix. In the MI method, a powder material (e.g., powder of silicon carbide or carbon) is made to be contained in an inside of a fiber body, and then, a melted metal component (e.g., metallic silicon) is caused to flow into the fiber body so that a matrix (e.g., the matrix of silicon carbide and metallic silicon) is formed. Patent Literature 1 and Non-Patent Literatures 1 and 2 describe techniques related to a part of the embodiment of the present application. CITATION LIST Patent Literatures Patent Literature 1: JP2017-1912APatent Literature 2: CN102795871A Non-Patent Literatures Non-Patent Literature 1: C. Besnarda et al. “Synthesis of hexacelsian barium aluminosilicate by film boiling chemical vapour process”, Journal of the European Ceramic Society 40 (2020) 3494-3497Non-Patent Literature 2: Masanori SHIMIZU et al. “Crystallization Behavior and Change in Surface Area of Alkoxide-Derived Mullite Precursor Powders with Different Compositions”, Journal of the Ceramic Society of Japan 105 [2] 131-135 (1997)Non-Patent Literature 3: Takesi Nakamura et al, “Development of CMC Nozzle”, IHI Engineering Review, Vol. 48 No. 3 (2008-9)Non-Patent Literature 4: Min Mei et al. “Preparation of C/SiC composites by pulse chemical liquid-vapor deposition process”, Materials Letters 82 (2012) 36-38 SUMMARY OF INVENTION Technical Problem The above-described PIP method, CVI method, and MI method have respective problems. The PIP method and the CVI method require a long time for forming a high-density matrix, which causes an increase in cost. The MI method enables a high-density matrix to be formed in a relatively short time, but metal remains in it, and the metal causes a decline in heat resistance and oxidation resistance. For this reason, a technique of combining the respective methods has been proposed. For example, the CVI method and the PIP method are combined, or the CVI method, the powder infiltration, and the PIP method are combined, so that a processing period can be shortened to ⅓ (Non-Patent Literature 3). A film boiling method has been proposed (Patent Literature 2 and Non-Patent Literature 4). The film boiling method enables a matrix to be formed at a speed 50 times or more faster than that in processing of the CVI method alone. According to the conventional film boiling method, a formation speed of the matrix is high, but densification is insufficient. In view of the above, an object of the present invention is to provide a technique that aims at maximizing an advantageous effect of a film boiling method, and can form a high-density matrix in a short time, using the film boiling method, in a method for manufacturing a ceramic matrix composite. Solution to Problem In order to accomplish the above-described abject, a method according to the present invention is a method for manufacturing a ceramic matrix composite including a matrix and reinforcing fibers provided in the matrix, the method including: a step (A) of infiltrating a fiber body with powder of a ceramic material that becomes a part of the matrix, the fiber body being constituted by the reinforcing fibers;a step (B) of arranging, in a liquid material for the matrix, the fiber body infiltrated with the powder,a step (C) of heating the fiber body in a state where the fiber body is arranged in the liquid material, thereby bringing the liquid material into a film-boiling state such that ceramic derived from the liquid material is generated as a part of the matrix in the fiber body. Advantageous Effects of Invention According to the present invention, in the case of using a film boiling method, powder infiltration is combined with it. Thereby, an effect of the film boiling method is maximized, and a high density is achieved in a short time. In a film boiling method, when a fiber body includes large pores, such pores are not sufficiently charged with a matrix, regardless of the same level of a porosity. As