Process for manufacturing a composite friction component

Patent metadata

Field	Value
Publication number	US-11530727-B2
Application number	US-201816756335-A
Country	US
Kind code	B2
Filing date	Oct 16, 2018
Priority date	Oct 19, 2017
Publication date	Dec 20, 2022
Grant date	Dec 20, 2022

Abstract

A process for manufacturing a friction component made of composite material, includes the densification of a fibrous preform of carbon yarns by a matrix including at least pyrocarbon and at least one ZrOxCy phase, where 1≤x≤2 and 0≤y≤1, the matrix being formed by chemical vapor infiltration at least from a first gaseous precursor of pyrocarbon and a second gaseous precursor including zirconium, the second precursor being an alcohol or a C1 to C6 polyalcohol modified by linking the oxygen atom of at least one alcohol function to a group of formula —Zr—R3, the substituents R being identical or different, and R being selected from: —H, C1 to C5 carbon chains and halogen atoms.

First claim

The invention claimed is:

1. A process for manufacturing a friction component of composite material, comprising:
densification of a fibrous preform of carbon yarns by a matrix comprising at least pyrocarbon and at least one ZrO x C y phase, where 1≤x≤2 and 0≤y≤1, the matrix being formed by chemical vapor infiltration at least from a first gaseous precursor of pyrocarbon and a second gaseous precursor comprising zirconium, said second precursor being an alcohol or a C 1 to C 6 polyalcohol, which alcohol or a C 1 to C 6 polyalcohol is modified by linking the oxygen atom of at least one alcohol function to a group of formula —Zr—R 3 , the substituents R being identical or different, and R being selected from: —H, C 1 to C 5 carbon chains and halogen atoms.

2. The process claimed in claim 1 , wherein the densification comprises:
a first densification cycle in which a first pyrocarbon matrix phase is formed from the first precursor,
a second densification cycle, carried out after the first cycle, in which a second matrix phase comprising the ZrO x C y phase is formed at least from the second precursor, and
a third densification cycle, carried out after the second cycle, in which a third pyrocarbon matrix phase is formed from a third gaseous pyrocarbon precursor, identical or different from the first precursor.

3. The process claimed in claim 1 , wherein the densification comprises at least the formation of a co-deposition of the pyrocarbon phase and the ZrO x C y phase from a gaseous mixture of a gaseous pyrocarbon precursor and the second precursor.

4. The process as claimed in claim 1 , wherein R is selected from: —H, C 1 to C 3 carbon chains and halogen atoms.

5. The process as claimed in claim 1 , wherein at least one substituent R is a C 1 to C 5 or C 1 to C 3 carbon chain or a halogen atom.

6. The process as claimed in claim 1 , wherein the process further comprises a deoxygenation heat treatment of the ZrO x C y phase formed.

7. The process as claimed in claim 1 , wherein the ZrO x C y phase, optionally deoxygenated, is present, in the final component, in a mass content of between 0.5% and 25%.

8. The process claimed in claim 7 , wherein the ZrO x C y phase, optionally deoxygenated, is present, in the final component, in a mass content of between 2% and 10%.

9. The process as claimed in claim 1 , wherein the friction component is a brake disc.

10. The process as claimed in claim 1 , wherein the C 1 to C 6 polyalcohol is modified by linking the oxygen atom of each alcohol function to said group of formula —Zr—R 3 .

Assignees

• Safran Ceram
• Centre Nat Rech Scient

Inventors

• Bouillon Eric
• Delehouze Arnaud
• Lorriaux Amandine
• Maille Laurence

Classifications

• C23C16/26

  Deposition of carbon only · CPC title

• C23C16/56

  After-treatment · CPC title

• C04B2235/79

  Non-stoichiometric products, e.g. perovskites (ABO3) with an A/B-ratio other than 1 · CPC title

• C04B2235/5256

  Two-dimensional, e.g. woven structures · CPC title

• F16D69/023 Primary

  Composite materials containing carbon and carbon fibres or fibres made of carbonizable material · CPC title