Method of preparing carbon fiber reinforced carbon-silicon carbide composite part

Patent metadata

Field	Value
Publication number	US-11021402-B2
Application number	US-201916503613-A
Country	US
Kind code	B2
Filing date	Jul 4, 2019
Priority date	Apr 13, 2017
Publication date	Jun 1, 2021
Grant date	Jun 1, 2021

Abstract

A method of preparing a C/C-SiC composite part, including: preparing, using a solvent evaporation process, carbon fiber composite powders coated with a phenol resin; according to a three-dimensional model of a to-be-prepared part, forming a green part corresponding to the to-be-prepared part using the carbon fiber composite powders and a 3D printing technology; densifying the green part to yield a C/C porous body having a density of 0.7 to 1.1 g/cm3 and an open porosity of 30 to 50%; and siliconizing the C/C porous body under vacuum, removing excess silicon to yield a primary carbon fiber reinforced carbon-silicon carbide (C/C-SiC) body, densifying the primary C/C-SiC body, to obtain a final C/C-SiC composite part.

First claim

What is claimed is:

1. A method, comprising:
(a) preparing, using a solvent evaporation process, carbon fiber composite powders coated with a phenol resin;
(b) according to a three-dimensional model of a to-be-prepared part, forming a green part corresponding to the to-be-prepared part using the carbon fiber composite powders and a 3D printing technology;
(c) densifying the green part to yield a C/C porous body having a density of 0.7 to 1.1 g/cm 3 and an open porosity of 30 to 50%; and
(d) siliconizing the C/C porous body under vacuum, removing excess silicon to yield a primary carbon fiber reinforced carbon-silicon carbide (C/C-SiC) body, densifying the primary C/C-SiC body, to obtain a final C/C-SiC composite part.

2. The method of claim 1 , wherein the solvent evaporation process in (a) is carried out as follows:
(a1) dissolving a thermoplastic phenol resin comprising 7-10 wt. % of a curing agent in an organic solvent, adding carbon fiber powders to the organic solvent to yield a dispersed solution; where a volume ratio of the carbon fiber powders to the phenolic resin is (2-8):(2-8); and
(a2) distilling the dispersed solution and crystallizing to yield a powder aggregate, and drying, grinding and sieving the powder aggregate to yield the carbon fiber composite powders.

3. The method of claim 2 , wherein the carbon fiber powders in (a1) has a diameter of 6 to 10 μm and a length of 50 to 200 μm.

4. The method of claim 1 , wherein a particle size of the carbon fiber composite powders is between 10 and 150 μm.

5. The method of claim 3 , wherein a particle size of the carbon fiber composite powders is between 10 and 150 μm.

6. The method of claim 1 , wherein the 3D printing technology in (b) is a powder bed-based 3D printing technique including selective laser sintering (SLS) technique and three-dimensional printing (3DP) technique.

7. The method of claim 5 , wherein the 3D printing technology in (b) is a powder bed-based 3D printing technique including selective laser sintering (SLS) technique and three-dimensional printing (3DP) technique.

8. The method of claim 1 , wherein densifying the green part in (c) comprises impregnation, curing and carbonization; the impregnation is carried out under vacuum or under negative pressure, and the impregnation liquid is a thermosetting phenolic resin or a furan resin liquid having a dynamic viscosity of less than 50 mPa·s, or an alcohol solution of a thermosetting phenolic resin having a dynamic viscosity of less than 20 mPa·s.

9. The method of claim 7 , wherein densifying the green part in (c) comprises impregnation, curing and carbonization; the impregnation is carried out under vacuum or under negative pressure, and the impregnation liquid is a thermosetting phenolic resin or a furan resin liquid having a dynamic viscosity of less than 50 mPa·s, or an alcohol solution of a thermosetting phenolic resin having a dynamic viscosity of less than 20 mPa·s.

10. The method of claim 1 , wherein the densifying the C/C porous body in (d) comprises depositing SiC in pores formed in the process of removal of silicon by a chemical vapor infiltration method.

11. The method of claim 9 , wherein the densifying the C/C porous body in (d) comprises depositing SiC in pores formed in the process of removal of silicon by a chemical vapor infiltration method.

12. A carbon fiber reinforced carbon-silicon carbide (C/C-SiC) composite part produced by the method of claim 1 .

Assignees

• Univ Huazhong Science Tech

Inventors

• Yan Chunze
• Zhu Wei
• Fu Hua
• Xu Zhongfeng
• Shi Yusheng
• Li Chenhui
• Wu Jiamin
• Wen Shifeng
• Li Zhaoqing

Classifications

• C04B35/565 Primary

  based on silicon carbide · CPC title

• B33Y10/00 Primary

  Processes of additive manufacturing · CPC title

• C04B35/80

  Fibres, filaments, whiskers, platelets, or the like · CPC title

• C04B35/573

  obtained by reaction sintering {or recrystallisation} · CPC title

• C04B2235/616

  Liquid infiltration of green bodies or pre-forms · CPC title