Ceramic matrix composite manufacturing method and ceramic matrix composite

Patent metadata

Field	Value
Publication number	US-12151981-B2
Application number	US-202017442992-A
Country	US
Kind code	B2
Filing date	Feb 28, 2020
Priority date	Mar 25, 2019
Publication date	Nov 26, 2024
Grant date	Nov 26, 2024

Abstract

A ceramic matrix composite manufacturing method includes: forming a zirconia-sol containing layer that contains zirconia sol, on fabric having an interface layer formed on a periphery of each of a plurality of ceramic-made fibers; impregnating the fabric having the zirconia-sol containing layer formed, with a polymer as a precursor, to form a body; supplying oxygen to the polymer included in the body; heating the body in an inert gas atmosphere to cause a reaction of the polymer to form a matrix; and heating the body in an oxygen atmosphere to remove the interface layer, after supplying the oxygen and heating the body in the inert gas atmosphere, to generate a ceramic matrix composite in which the matrix is interposed between the fibers.

First claim

The invention claimed is:

1. A ceramic matrix composite manufacturing method comprising:
forming a zirconia-sol containing layer that contains zirconia sol, on fabric having an interface layer formed on a periphery of each of a plurality of ceramic-made fibers;
impregnating the fabric having the zirconia-sol containing layer formed, with a polymer as a precursor, to form a body;
supplying oxygen to the polymer included in the body;
heating the body in an inert gas atmosphere to cause a reaction of the polymer to form a matrix; and
heating the body in an oxygen atmosphere to remove the interface layer so that a vacancy is formed between the fibers and the matrix and a zirconia-containing layer is formed in vacancy-facing area by a given thickness from a surface of the matrix facing the vacancy, after supplying the oxygen and heating the body in the inert gas atmosphere, to generate a ceramic matrix composite in which the matrix is interposed between the fibers.

2. The ceramic matrix composite manufacturing method according to claim 1 , wherein
forming the zirconia-sol containing layer includes
forming a zirconia sol interface layer covering a periphery of the interface layer; and
applying alumina slurry to the fabric having the zirconia sol interface layer formed, to form an alumina slurry coating layer.

3. The ceramic matrix composite manufacturing method according to claim 1 , wherein forming the zirconia-sol containing layer includes applying alumina slurry that contains the zirconia sol to the fabric, to form an alumina slurry coating layer that contains the zirconia sol.

4. The ceramic matrix composite manufacturing method according to claim 1 , wherein
forming the zirconia-sol containing layer includes
forming a zirconia sol interface layer that covers a periphery of the interface layer; and
applying alumina slurry that contains the zirconia sol to the fabric, to form an alumina slurry coating layer that contains the zirconia sol.

5. The ceramic matrix composite manufacturing method according to claim 1 , wherein heating the body in the inert gas atmosphere is performed after supplying the oxygen.

6. The ceramic matrix composite manufacturing method according to claim 1 , wherein
supplying the oxygen includes supplying oxygen to the polymer by heating the body in an oxygen atmosphere, and
a heating temperature of the body used at supplying the oxygen is lower than heating temperatures used at heating the body in the inert gas atmosphere and heating the body in the oxygen atmosphere.

7. The ceramic matrix composite manufacturing method according to claim 6 , wherein the heating temperature of the body used at supplying the oxygen is equal to or higher than 200 degrees Celsius and lower than 600 degrees Celsius.

8. The ceramic matrix composite manufacturing method according to claim 1 , wherein
supplying the oxygen includes supplying oxygen to the polymer by keeping the body in a water vapor atmosphere, and
a temperature of the water vapor used at supplying the oxygen is lower than a heating temperature used at heating the body in the inert gas atmosphere and heating the body in the oxygen atmosphere.

9. The ceramic matrix composite manufacturing method according to claim 8 , wherein a temperature of the water vapor used at supplying the oxygen is equal to or higher than 80 degrees Celsius and lower than 200 degrees Celsius.

10. The ceramic matrix composite manufacturing method according to claim 1 , wherein the polymer contains a ceramic made of a same material as that of the fibers.

11. The ceramic matrix composite manufacturing method according to claim 1 , wherein the interface layer is a layer including carbon as a main component.

Assignees

• Mitsubishi Heavy Ind Aero Engines Ltd

Inventors

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

Classifications

• C04B35/80

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

• C04B2235/661

  Multi-step sintering · CPC title

• C04B2235/6583

  Oxygen containing atmosphere, e.g. with changing oxygen pressures · CPC title

• C04B2235/616

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

• C04B2235/5252

  having a specific pre-form · CPC title