A method of fabricating a composite material part by self-propagating high temperature synthesis

Patent metadata

Field	Value
Publication number	US-2018044249-A1
Application number	US-201515326881-A
Country	US
Kind code	A1
Filing date	Jul 16, 2015
Priority date	Jul 17, 2014
Publication date	Feb 15, 2018
Grant date	—

Abstract

A method of fabricating a part made of ceramic matrix composite material, the method includes fabricating the part by forming a ceramic matrix in the pores of a fiber structure, the ceramic matrix being formed by self propagating high temperature synthesis from a powder composition present in the pores of the fiber structure,

First claim

1 . A method of fabricating a part made of ceramic matrix composite material, the method comprising the following step:
a) fabricating the part by forming a ceramic matrix in the pores of a fiber structure, the ceramic matrix being formed by self propagating high temperature synthesis from a powder composition present in the pores of the fiber structure; the matrix formed during step a) comprising a majority by weight:
of Si 2 N 2 O formed by self propagating high temperature synthesis by chemical reaction between a silicon powder, a silica powder, and a gaseous phase comprising the element N; or
of phases of TiN and of TiB 2 , these compounds being formed by self propagating high temperature synthesis by chemical reaction between a powder comprising titanium, a powder comprising boron, and a gaseous phase comprising the element N.

2 . A method according to claim 1 , wherein, prior to step a), a preliminary step b) is performed of densifying the fiber structure by a method other than the method of self propagating high temperature synthesis.

3 . A method according to claim 1 , wherein an additional step c) of densifying the part is performed after step a).

4 .- 8 . (canceled)

9 . A method according to claim 1 , wherein the following steps are performed before step a):
inserting at least a first powder into the pores of the fiber structure; and then inserting at least a second powder different from the first into the pores of the fiber structure; a ceramic matrix of composition that varies on going towards the outside surface of the part being obtained after step a).

10 . A method according to claim 1 , comprising a step of forming an environmental and/or thermal barrier, the environmental and/or thermal barrier being present after step a) over all or some of an outside surface of the part.

11 .- 12 . (canceled)

13 . A method according to claim 1 , wherein the matrix formed during step a) comprises a majority by weight of Si 2 N 2 O formed by self propagating high temperature synthesis by chemical reaction between a silicon powder, a silica powder, and a gaseous phase comprising the element N, and wherein a powder comprising boron is present in the pores of the fiber structure prior to step a), and during step a) the powder comprising boron forms a BN phase by a nitriding reaction with the gaseous phase.

14 . A part made of ceramic matrix composite material, the part comprising:
a reinforcing fiber structure; and a ceramic matrix comprising a majority by weight of Si 2 N 2 O present in the pores of the fiber structure, the matrix presenting a content by weight of residual free silicon that is less than or equal to 5%.

15 . (canceled)

16 . A part according to claim 14 , wherein the matrix comprises crystalline Si 2 N 2 O at a content by weight greater than or equal to 70%.

17 . A turbine engine including a part according to claim 14 .

18 . A method of fabricating a part made of ceramic matrix composite material, the method comprising the following step:
a) fabricating the part by forming a ceramic matrix in the pores of a fiber structure, the ceramic matrix being formed by self propagating high temperature synthesis from a powder composition present in the pores of the fiber structure; the matrix formed during step a) comprising a majority by weight:
of TiC and of SiC, these compounds being formed by self propagating high temperature synthesis by chemical reaction between a powder comprising titanium, a powder comprising silicon, and a powder comprising carbon; or
of AlN formed by self propagating high temperature synthesis by chemical reaction between a powder comprising aluminum, a carbon powder, and a gaseous phase comprising the element N.

19 . A method according to claim 18 , wherein, prior to step a), a preliminary step b) is performed of densifying the fiber structure by a method other than the method of self propagating high temperature synthesis.

20 . A method according to claim 18 , wherein an additional step c) of densifying the part is performed after step a).

21 .- 25 . (canceled)

26 . A method according to claim 18 , wherein the following steps are performed before step a):
inserting at least a first powder into the pores of the fiber structure; and then inserting at least a second powder different from the first into the pores of the fiber structure; a ceramic matrix of composition that varies on going towards the outside surface of the part being obtained after step a).

27 . A method according to claim 10 , further comprising a step of forming an environmental and/or thermal barrier, the environmental and/or thermal barrier being present after step a) over all or some of an outside surface of the part.

28 .- 29 . (canceled)

30 . A method of fabricating a part made of ceramic matrix composite material, the method comprising the following step:
a) fabricating the part by forming a ceramic matrix in the pores of a fiber structure, the ceramic matrix being formed by self propagating high temperature synthesis from a powder composition present in the pores of the fiber structure; the matrix formed during step a) comprising a majority by weight:
of phases of BN and of Ti—C—N, these compounds being formed by self propagating high temperature synthesis by chemical reaction between a powder comprising titanium, a powder comprising boron and carbon, and a gaseous phase comprising the element N; or
of phases of Al 2 O 3 and of SiC, these compounds being formed by self propagating high temperature synthesis by chemical reaction between a powder comprising silicon and oxygen, a powder comprising aluminum, and a powder comprising carbon; or
of a SiAlON type compound formed by self propagating high temperature synthesis by chemical reaction between a silicon powder, a silica powder, a powder comprising aluminum, and a gaseous phase comprising the element N.

31 . A method according to claim 30 , wherein, prior to step a), a preliminary step b) is performed of densifying the fiber structure by a method other than the method of self propagating high temperature synthesis.

32 . A method according to claim 30 , wherein an additional step c) of densifying the part is performed after step a).

33 .- 37 . (canceled)

38 . A method according to claim 30 , wherein the following steps are performed before step a):
inserting at least a first powder into the pores of the fiber structure; and then inserting at least a second powder different from the first into the pores of the fiber structure; a ceramic matrix of composition that varies on going towards the outside surface of the part being obtained after step a).

39 . A method according to claim 30 , further comprising a step of forming an environmental and/or thermal barrier, the environmental and/or thermal barrier being present after step a) over all or some of an outside surface of the part.

40 .- 41 . (canceled)

Assignees

• Safran Ceram
• Centre Nat Rech Scient

Inventors

• Taillet Brice
• Pailler Rene
• Teyssandier Francis
• Philippe Eric
• Bouillon Eric

Classifications

• C04B2235/5244

  Silicon carbide · CPC title

• F01D25/005

  Selecting particular materials · CPC title

• C04B35/62807

  Silica or silicates · CPC title

• C04B35/80 Primary

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

• F05D2300/6033

  Ceramic matrix composites [CMC] · CPC title