Method For Producing A Composite Including A Ceramic Matrix

• US 20140084521A1
• Filed: 01/23/2012
• Published: 03/27/2014
• Est. Priority Date: 03/07/2011
• Status: Active Grant

• Current Assignee: Commissariat a L'Energie Atomique (AES Corporation)
• Original Assignee: Cedric Sauder
• Inventors: Sauder, Cdric, Lorrette, Christophe
• Granted Patent: US 9,145,338 B2
• Time in Patent Office: Days
• US Class Current: 264/640
• CPC Class Codes: B28B 23/0006 the reinforcement consisting of aligned, non-metal reinforcing elements
• CPC Class Codes: B28B 7/342 which are at least partially destroyed, e.g. broken, molten, before demoulding; Moulding surfaces or spaces shaped by, or in, the ground, or sand or soil, whether bound or not; Cores consisting at least mainly of sand or soil, whether bound or not
• CPC Class Codes: C04B 2235/5244 Silicon carbide
• CPC Class Codes: C04B 2235/5248 Carbon, e.g. graphite
• CPC Class Codes: C04B 2235/5252 having a specific pre-form
• CPC Class Codes: C04B 2235/6028 Shaping around a core which is removed later
• CPC Class Codes: C04B 2235/614 Gas infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/616 Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 35/565 based on silicon carbide
• CPC Class Codes: C04B 35/80 Fibres, filaments, whiskers, platelets, or the like
• CPC Class Codes: C04B 35/83 Carbon fibres in a carbon matrix
• CPC Class Codes: G21C 21/02 Manufacture of fuel elements or breeder elements contained in non-active casings
• CPC Class Codes: G21C 3/07 characterised by their material, e.g. alloys
• CPC Class Codes: Y02E 30/30 Nuclear fission reactors

Abstract

A method for producing a part made of ceramic matrix and ceramic fibres composite material. It comprises: the formation of a fibrous preform by intertwining threads constituted of ceramic material fibres on a contact surface of a support element reproducing the internal and/or external shape of the part to be produced; the partial densification of the fibrous preform at a temperature below the melting temperature of the material of the support element and below the melting temperature of the material of the fibres of the preform, said partial densification resulting in a consolidated fibrous preform comprising a matrix volume fraction above 5% and at the most equal to 40% of the matrix volume of the part to be produced; the removal of the support element from the consolidated fibrous preform by chemical attack of the contact surface of the material of the support element; the densification of the consolidated preform, carried out at a temperature below the melting temperature of the fibres of said preform.

Claims

1. A Method for producing a part made of ceramic material matrix and ceramic material fibres composite material, the method comprising the following successive steps:

formation of a fibrous preform by intertwining threads constituted of ceramic material fibres on a contact surface of a support element reproducing the internal and/or external shape of the part to be produced;

partial densification of the fibrous preform at a temperature below the melting temperature of the material of the support element and below the melting temperature of the material of the fibres of the preform, said partial densification resulting in a consolidated fibrous preform comprising a matrix volume fraction above 5% and at the most equal to 40% of the matrix volume of the part to be produced;

removal of the support element from the consolidated fibrous preform by chemical attack of the contact surface of the material of the support element;

densification of the consolidated preform, carried out at a temperature below the melting temperature of the fibres of said preform.

2. The method according to claim 1, wherein the fibrous preform consolidated at the partial densification step comprises a matrix volume fraction at the most equal to 30% of the matrix volume of the part to be produced.

3. The method according to claim 2, wherein the fibrous preform consolidated at the partial densification step comprises a matrix volume fraction at the most equal to 20% of the matrix volume of the part to be produced.

4. The method according to claim 3, wherein the fibrous preform consolidated at the partial densification step comprises a matrix volume fraction at the most equal to 10% of the matrix volume of the part to be produced.

5. The method according to claim 1, wherein the support element is made of silica, preferably made of silica glass.

6. The method according to claim 1, wherein the support element is made of alumina.

7. The method according to claim 1, wherein the support element is made of zirconium oxide.

8. The method according to claim 1, wherein the support element comprises a core that is made of a metal able to withstand the densification temperature of the preform and which is covered with a layer of silica, silica glass, alumina or zirconium oxide.

9. The method according to claim 5, wherein the chemical attack of the support element is obtained using an acid, preferably hydrofluoric acid, or a base.

10. The method according to claim 8, wherein the chemical attack of the support element is obtained by carrying out the chemical attack of the layer of silica, silica glass, alumina or zirconium oxide present on the core using an acid, preferably hydrofluoric acid, or a base.

11. The method according to claim 1, wherein the support element is a hollow element.

12. The method according to claim 1, wherein the support element has an axis of revolution or is of flat shape.

13. The method according to claim 1, wherein the fibres are made of a material selected from carbon and silicon carbide.

14. The method according to claim 1, wherein the matrix is made of a material selected from carbon and silicon carbide.

15. The method according to claim 1, wherein the part made of composite material is a composite material cladding for a gas cooled or sodium cooled fast reactor or for a pressurised water reactor.

16. The method according to claim 1, wherein the part made of composite material is a hexagonal composite material tube for a gas cooled or sodium cooled fast reactor or for a pressurised water reactor.