Manufacturing method for ceramic matrix composite

Patent metadata

Field	Value
Publication number	US-11447424-B2
Application number	US-201716313108-A
Country	US
Kind code	B2
Filing date	Dec 6, 2017
Priority date	Dec 7, 2016
Publication date	Sep 20, 2022
Grant date	Sep 20, 2022

Abstract

A manufacturing method for a ceramic matrix composite, having a woven fabric that has multiple fiber bundles and having a matrix that is disposed in the gaps between the fiber bundles, includes: a green body formation step for forming a green body by sintering the woven fabric infiltrated with a polymer that is a precursor to the matrix; and a densification step for further infiltrating the green body with a polymer and sintering same. The densification step includes: a second infiltration step for further infiltrating the green body with a polymer so as to form an infiltrated green body; a drying step for drying the infiltrated green body so as to form a dried green body; a steam treatment step for leaving the dried green body under saturation water vapor pressure so as to form a treated green body; and a sintering step for sintering the treated green body.

First claim

The invention claimed is:

1. A manufacturing method for a ceramic matrix composite having a woven fabric that has a plurality of fiber bundles containing one of first components selected from alumina, mullite, and SiC and a matrix containing one of second components selected from alumina, mullite, and SiC and is disposed in a gap between the plurality of fiber bundles, the method comprising:
a green body formation step of forming a green body by infiltrating the woven fabric with a polymer blend including a polymer having —Al—O— linkage and a polymer having —Al—O—Si—O linkage as a precursor of the matrix and performing sintering; and
a densification step of further infiltrating the green body with the polymer blend and performing sintering,
wherein the densification step includes
an infiltration step of further infiltrating the green body with the polymer blend to form an infiltrated green body,
a drying step of drying the infiltrated green body to form a dried green body,
after the drying step, a steam treatment step of leaving the dried green body under a saturation water vapor pressure to increase infiltration of the polymer blend into the dried green body by intermolecular condensation of adjacent oxo groups in the polymer blend and intramolecular condensation of the oxo groups in the polymer blend to form a crosslink containing —Al—O—Al— linkages and a three-dimensional network, thereby, forming a treated green body,
a first determination step of determining whether or not the steam treatment is sufficiently progressing in the treated green body, and
a sintering step of sintering the treated green body,

after the steam treatment step, in response to the steam treatment being determined not sufficiently performed in the first determination step, the infiltration step, the drying step, and the steam treatment step are repeated, and in the sintering step, the treated green body for which the infiltration step, the drying step, and the steam treatment step have been repeated a plurality of times is calcined.

2. The manufacturing method for a ceramic matrix composite according to claim 1 ,
wherein the steam treatment step is carried out under saturation water vapor at 30° C. to 200° C.

3. The manufacturing method for a ceramic matrix composite according to claim 1 ,
wherein the woven fabric has a sizing agent that covers a periphery of the plurality of fiber bundles, and
the method further comprises an interface coating formation step of forming an interface coating on the plurality of fiber bundles by heating the woven fabric under a nitrogen atmosphere to modify the sizing agent, before the green body formation step.

4. The manufacturing method for a ceramic matrix composite according to claim 3 ,
wherein the sizing agent is at least one selected from the group consisting of polyurethane, epoxy resin, modified epoxy resin, phenol resin, polyimide resin, and polyamide resin.

Assignees

• Mitsubishi Heavy Ind Aero Engines Ltd

Inventors

• Nishikawa kosuke
• Fukushima Akira
• Nogami Ryoma
• Tamugi Azusa

Classifications

• C04B2235/5228

  Silica and alumina, including aluminosilicates, e.g. mullite · CPC title

• C04B2235/616

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

• C04B35/80 Primary

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

• C04B35/18

  rich in aluminium oxide · CPC title

• D06M15/59

  Polyamides; Polyimides · CPC title