GB2175893A - Fibre-reinforced ceramic materials - Google Patents

Fibre-reinforced ceramic materials Download PDF

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Publication number
GB2175893A
GB2175893A GB08508573A GB8508573A GB2175893A GB 2175893 A GB2175893 A GB 2175893A GB 08508573 A GB08508573 A GB 08508573A GB 8508573 A GB8508573 A GB 8508573A GB 2175893 A GB2175893 A GB 2175893A
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GB
United Kingdom
Prior art keywords
slip
preform
ceramic
silicon
silicon nitride
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB08508573A
Inventor
Andrew Robert Baker
David Charles Evans
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
AE PLC
Original Assignee
AE PLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by AE PLC filed Critical AE PLC
Priority to GB08508573A priority Critical patent/GB2175893A/en
Priority to PCT/GB1986/000189 priority patent/WO1986005774A1/en
Priority to EP86902441A priority patent/EP0217902A1/en
Publication of GB2175893A publication Critical patent/GB2175893A/en
Withdrawn legal-status Critical Current

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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02F—CYLINDERS, PISTONS OR CASINGS, FOR COMBUSTION ENGINES; ARRANGEMENTS OF SEALINGS IN COMBUSTION ENGINES
    • F02F7/00—Casings, e.g. crankcases or frames
    • F02F7/0085—Materials for constructing engines or their parts
    • F02F7/0087—Ceramic materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22D—CASTING OF METALS; CASTING OF OTHER SUBSTANCES BY THE SAME PROCESSES OR DEVICES
    • B22D19/00—Casting in, on, or around objects which form part of the product
    • B22D19/14—Casting in, on, or around objects which form part of the product the objects being filamentary or particulate in form
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0006—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects the reinforcement consisting of aligned, non-metal reinforcing elements
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    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2203/00—Non-metallic inorganic materials
    • F05C2203/08—Ceramics; Oxides
    • F05C2203/0804—Non-oxide ceramics
    • F05C2203/083—Nitrides
    • F05C2203/0843—Nitrides of silicon
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2203/00—Non-metallic inorganic materials
    • F05C2203/08—Ceramics; Oxides
    • F05C2203/0865—Oxide ceramics
    • F05C2203/0895—Zirconium oxide
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F05—INDEXING SCHEMES RELATING TO ENGINES OR PUMPS IN VARIOUS SUBCLASSES OF CLASSES F01-F04
    • F05C—INDEXING SCHEME RELATING TO MATERIALS, MATERIAL PROPERTIES OR MATERIAL CHARACTERISTICS FOR MACHINES, ENGINES OR PUMPS OTHER THAN NON-POSITIVE-DISPLACEMENT MACHINES OR ENGINES
    • F05C2253/00—Other material characteristics; Treatment of material
    • F05C2253/16—Fibres

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Mechanical Engineering (AREA)
  • Composite Materials (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Dispersion Chemistry (AREA)
  • Combustion & Propulsion (AREA)
  • General Engineering & Computer Science (AREA)
  • Ceramic Products (AREA)
  • Pistons, Piston Rings, And Cylinders (AREA)
  • Manufacture Of Alloys Or Alloy Compounds (AREA)

Abstract

A method for manufacturing a fibre reinforced ceramic material which comprises forming a preform (11) of ceramic fibres, placing the preform in a porous mould (12, 13) and applying a ceramic slip (14) to the preform in the mould. The slip material (14) is then caused to impregnate the preform (11) by applying a pressure differential thus forming an impregnated preform (15). This is then removed from the mould (12, 13), the slip liquid is driven off and the preform is heat treated. The ceramic fibres and the slip material may include alumina, kaowool, silicon carbide, silicon nitride and/or zirconia.

Description

SPECIFICATION Fibre reinforced ceramics The present invention relates to fibre reinforced ceramic materials, their uses and methods for their manufacture.
Fibre reinforced ceramic materials are known in themselves and it is an object of the present invention to provide an improved method of manufacturing such materials. It is a further object of the invention to provide such a material having superior strength and heat insulating properties at possibly lower specific weights.
According to the invention a method for manufacturing a fibre reinforced ceramic material comprises forming a pre-form of ceramic fibres, tape or mat, applying a ceramic slip to the pm-form, causing the slip material to impregnate the pre-form by applying a pressure differential, and driving off the slip liquid.
The term "ceramic slip" is used in this context to refer to a slurry of ceramic material finely dispersed in a liquid carrier medium.
The ceramic fibres are preferably of alumina, (such as that sold under the Trade Mark SAF FIL), kaowool, silicon carbide, silicon nitride or zirconia. They may of course comprise a combination of some of these materials. The slip material may also comprise one or more of these materials and may incorporate yttrium oxide (Y203), magnesium oxide (MgO), chromium oxide (cur203), tungsten trioxide (W03), cerium dioxide (CeO2), silica (SiO2) and/or magnesium carbonate (MgCO3) (which would convert to MgO). A preferred slip composition might be 109two Y203, 3% MgCO3, 2% W02, 1.5% SiO2, the balance being silicon nitride or zirconia, or alternatively the W03 might be replaced by Cur203.
In a similar alternative composition, the silicon nitride is replaced by silicon powder which is converted to silicon nitride at a later stage by a method known as the reaction bonding process.
Preferably, the preform is located within a mould, for example of plaster for the slip impregnation step. The pressure differential applied may be in the form of a high pressure applied to the slip to force it into the preform, or alternatively a pressure below ambient may be applied to the preform to draw the slip into the interstices. Naturally, a combination of these alternatives may be used.
Preferably, the slip liquid is water.
Fibre reinforced ceramic materials made in accordance with the invention tend to be very strong, light in weight and highly resistant to suddent impacts, particularly when silicon nitride and/or zirconia are used.
It is a further object of the invention to attach a fibre reinforced ceramic material to a metal backing.
Preferably, therefore, the thickness of the preform and the amount of slip applied are arranged so that the preform is impregnated over a part only of its thickness, leaving a portion unfilled, and a molten metal is then applied under pressure to the unfilled portion to impregnate it and allowed to solidify (a socalled "squeeze-casting" process).
The present invention extends to such a ceramic/metal fibre reinforced composite material. The molten metal used can be varied to suit the intended use: a typical piston material (such as the alloy sold under the Trade Mark Lo-Ex) might be used to produce a piston with an insulating crown of fibre reinforced ceramic material which is tenaciously bonded to the piston alloy through the fibres. Similarly by using suitable nickel or cobalt alloys, gas turbine engine components such as blades may be produced having highly chemical and heat resistant ceramic surfaces strongly bonded to the blade alloy through ceramic fibres.
The invention may be carried into practice in various ways and two embodiments will now be described by way of example with reference to the accompanying drawings, in which: Figures 1 to 3 are schematic illustrations of three successive stages according to a first embodiment of the present invention for manufacturing a ceramic fibre reinforced material; Figures 4 to 8 are five similar successive stages according to a second embodiment for manufacturing a piston with a ceramic fibre reinforced crown; Figures 9 and 10 are two similar stages according to a third embodiment for producing a piston with a ceramic fibre reinforced crown with a combustion bowl, and Figure 11 is a cutaway isometric sketch of a part of a further embodiment.
Referring firstly to Figs. 1 to 3, a preform 11 made up of a bundle of silicon nitride fibres having a diameter of between 1 and 5 micrometers and a length 100 to 1000 times their diameter is located in a mould 12 having a plaster base 13. The fibres may be heid in position using a binding agent. A slip 14, comprising an aqueous slurry of 10% Y203, 3% MgCO3, 2% W03, 1.5% SiO2, the balance being silicon powder, is then placed in the mould 12 above the preform 11. The slip material has a particle size in the range 2-10,um.
Pressure is applied to the inside of the mould 12 so that the slip material is forced into the interstices of the preform 11 and the water is absorbed by the mould base 13. The ceramic preform body 15 so formed is then removed from the mould 12 and allowed to dry in air for 24 hours, after which it is heated to 380"C in air for 12 hours which converts the MgCO3 to MgO. The preform 15 is then heated to 1 1000C in argon for 5 hours, after which the temperature is raised to 1400"C under an atmosphere of nitrogen at 1 bar pressure in order to convert the silicon to silicon nitride (Si3N4).Final full densification of the silicon nitride so formed may be achieved by further heating in a nitrogen atmosphere at 1750"C. Any binding agent present in the preform will be removed during one of the heating steps.
Referring now to Figs. 4 to 8, a method is illustrated for manufacturing a piston with a crown of a fibre reinforced ceramic material.
A similar procedure to that described with reference to Figs. 1 to 3 is followed initially though the preform 21 is somewhat thicker and the amount of slip 14 used is somewhat less. Thus, after the pressurising step, the preform 21 is impregnated with the slip material to a part only of its thickness as shown at 22 in Fig. 6, so that the upper part of the preform remains porous.
The impregnated preform is then subjected to heat treatment as in the previous embodiment and placed in a piston mould 23 and, after any machining that may be necessary, a molten piston alloy 24 is introduced as shown in Fig. 7. The piston 25 is formed by a squeeze castin step in which a high pressure of perhaps 200 to 300 tons is applied to the alloy while it is allowed to solidify. This causes the piston alloy 24 to impregnate the remaining porous portion of the preform 21 as shown at 27 in Fig. 8. The finished piston 25 having a crown 26 of fibre reinforced ceramic material is then removed from the mould 23.
The fibre reinforced material may have the form shown, or may have a re-entrant form to give mechanical retention in the piston body.
In the embodiment shown in Figs. 9 and 10 a preform 31 is located in a mould 32 and a ceramic slip material 33 is located in an upper cavity 34 above the preform 31. The space 35 beneath the preform 31 is then subjected to a pressure reduction. The slip material impregnates the preform 31 to the desired degree and the pressure reduction is then removed.
The part-impregnated preform is removed and partially sintered. It is then machined to shape to form a bowl 36 as shown in Fig. 10 and fully sintered. The finished preform is then case into the piston by the squeeze-casting method of the previous embodiment. Some support of the bowl 36 may be required during the squeeze casting step.
In another embodiment shown in Fig. 11, it may be required to have fibre ends protruding both axially and radially from the finished preform 41 in order to increase the keying effect when squeeze casting the finished preform into a piston. In such a case a preform of interlocking fibres extending both axially and radially is used together with an outer cylindrical tube 44 having comb-like axial teeth 45 which surrounds the preform inside the mould 42. The radially extending fibres 46 are bent down and trapped between the teeth 45, the base 43 and the mould wall 42. When the preform is released from the mould, the ends of the radially extending fibres remain protruding from the preform.

Claims (14)

1. A method for manufacturing a fibre reinforced ceramic material which comprises: forming a pre-form of ceramic fibres, tape or mat; applying a ceramic slip to the preform; causing the slip material to impregnate the pre-form by applying a pressure differential, and driving off the slip liquid; the term "ceramic slip" being used in this context to refer to a slurry of ceramic material finely dispersed in a liquid carrier medium.
2. A method as claimed in Claim 1 in which the ceramic fibres are of alumina, kaowool, silicon carbide, silicon nitride and/or zirconia.
3. A method as claimed in Claim 1 or Claim 2 in which the slip material incorporates alumina, kaowool, silicon carbide, silicon nitride and/or zirconia.
4. A method as claimed in Claim 3 in which the slip material further comprises yttrium oxide, magnesium oxide, chromium oxide, tungsten trioxide, cerium dioxide, silicon dioxide and/or magnesium carbonate.
5. A method as claimed in Claim 4 in which the slip composition is 10% yttrium oxide, 3% magnesium carbonate, 2% tungsten trioxide, and 1.5% silicon dioxide, the balance being silicon nitride or zirconia.
6. A method as claimed in Claim 4 in which the slip composition is 10% yttrium oxide, 3% magnesium carbonate, 2% tungsten trioxide, and 1.5% silicon dioxide, the balance being silicon powder which is subsequently converted to silicon nitride by a method known as the reaction bonding process.
7. A method as claimed in any preceding claim in which the pre-form is located within a plaster mould for the slip impregnation step.
8. A method as claimed in any preceding claim in which the pressure differential applied is in the form of a high pressure applied to the slip to force it into the preform.
9. A method as claimed in any preceding claim in which the slip liquid is water.
10. A method as claimed in any preceding claim in which the preform is heat treated in an inert atmosphere after the slip liquid has been driven off.
11. A method as claimed in any preceding claim in which the preform is heat treated in an atmosphere of nitrogen after the slip liquid has been driven off.
12. A method as claimed in any preceding claim in which the thickness of the preform and the amount of slip applied are arranged so that the preform is impregnated over a part only of its thickness, leaving a portion unfilled, and a molten metal is then applied under pressure to the unfilled portion to impregnate it and the molten metal is then allowed to soli dify.
13. A method for manufacturing a fibre ring for ceramic material substantially as herein described with reference to and as shown in Figs. 1 to 3 of the accompanying drawings.
14. A method for manufacturing a piston with a ceramic fibre reinforced crown substantially as herein specifically described with reference to and as shown in Figs. 4 to 8 or Figs. 9 and 10 or Fig. 11 of the accompanying drawngs.
GB08508573A 1985-04-02 1985-04-02 Fibre-reinforced ceramic materials Withdrawn GB2175893A (en)

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GB08508573A GB2175893A (en) 1985-04-02 1985-04-02 Fibre-reinforced ceramic materials
PCT/GB1986/000189 WO1986005774A1 (en) 1985-04-02 1986-04-02 Fibre reinforced ceramics
EP86902441A EP0217902A1 (en) 1985-04-02 1986-04-02 Fibre reinforced ceramics

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Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2230259A (en) * 1989-04-14 1990-10-17 Gen Electric Fibre reinforced composite member
US5488017A (en) * 1989-04-14 1996-01-30 General Electric Company Fibert reinforced ceramic matrix composite member
WO1998024737A1 (en) * 1996-12-02 1998-06-11 Saint-Gobain Industrial Ceramics, Inc. Silicon carbide reinforced silicon carbide composite
US5780126A (en) * 1996-07-17 1998-07-14 Minnesota Mining & Manufacturing Filter material
US5849375A (en) * 1996-07-17 1998-12-15 Minnesota Mining & Manufacturing Company Candle filter

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EP0280830A1 (en) * 1987-03-02 1988-09-07 Battelle Memorial Institute Method for producing metal or alloy casting, composites reinforced with fibrous or particulate materials
JP2667858B2 (en) * 1987-04-20 1997-10-27 株式会社日立製作所 Manufacturing method of high temperature superconducting material
JPH029777A (en) * 1988-03-02 1990-01-12 Honda Motor Co Ltd Fiber reinforced ceramic molded body and production thereof
GB2230258B (en) * 1989-04-14 1993-10-20 Gen Electric Consolidated member and method and preform for making
FR2671797B1 (en) * 1991-01-18 1994-02-25 Propulsion Ste Europeenne METHOD FOR DENSIFICATION OF A POROUS SUBSTRATE BY A MATRIX CONTAINING CARBON.
FR2677641B1 (en) * 1991-06-17 1994-01-28 Propulsion Ste Europeenne PROCESS FOR THE PREPARATION OF PARTS OF COMPOSITE MATERIAL WITH AN ALUMINA MATRIX.
US20110027603A1 (en) * 2008-12-03 2011-02-03 Applied Nanotech, Inc. Enhancing Thermal Properties of Carbon Aluminum Composites
CN109053188A (en) * 2018-09-28 2018-12-21 中国人民解放军国防科技大学 A kind of preparation method of ZrO2 base high temperature resistant composite material

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GB1131426A (en) * 1965-03-26 1968-10-23 Morgan Refractories Ltd Improvements in or relating to fibrous insulating materials
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GB2106433B (en) * 1981-09-22 1985-11-06 Ae Plc Squeeze casting of pistons
EP0107919A1 (en) * 1982-10-01 1984-05-09 The British Ceramic Research Association Limited Silicon nitride ceramic bodies
FR2547577B1 (en) * 1983-06-20 1989-12-15 Aerospatiale COMPOSITE REFRACTORY MATERIAL REINFORCED WITH REFRACTORY FIBERS AND MANUFACTURING METHOD THEREOF
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GB1016105A (en) * 1961-11-01 1966-01-05 Wood Conversion Co Integrated ceramic bodies
GB1131426A (en) * 1965-03-26 1968-10-23 Morgan Refractories Ltd Improvements in or relating to fibrous insulating materials
GB1302462A (en) * 1970-06-17 1973-01-10

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2230259A (en) * 1989-04-14 1990-10-17 Gen Electric Fibre reinforced composite member
GB2230259B (en) * 1989-04-14 1993-11-17 Gen Electric Fibre reinforced ceramic matrix composite member and method for making
US5488017A (en) * 1989-04-14 1996-01-30 General Electric Company Fibert reinforced ceramic matrix composite member
US5601674A (en) * 1989-04-14 1997-02-11 General Electric Company Fiber reinforced ceramic matrix composite member and method for making
US5780126A (en) * 1996-07-17 1998-07-14 Minnesota Mining & Manufacturing Filter material
US5849375A (en) * 1996-07-17 1998-12-15 Minnesota Mining & Manufacturing Company Candle filter
WO1998024737A1 (en) * 1996-12-02 1998-06-11 Saint-Gobain Industrial Ceramics, Inc. Silicon carbide reinforced silicon carbide composite
US6245424B1 (en) 1996-12-02 2001-06-12 Saint-Gobain Industrial Ceramics, Inc. Silicon carbide reinforced silicon carbide composite

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EP0217902A1 (en) 1987-04-15

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