Process for producing fiber reinforced composite

• US 5,876,659 A
• Filed: 07/24/1997
• Issued: 03/02/1999
• Est. Priority Date: 06/25/1993
• Status: Expired due to Fees

• Current Assignee: Hitachi, Ltd.
• Original Assignee: Hitachi, Ltd.
• Inventors: Yasutomi, Yoshiyuki, Kikuchi, Shigeru, Maeda, Kunihiro, Saito, Yukio
• Primary Examiner(s): Fiorilla, Christopher A.
• Application Number:
  US08/898,462
• Time in Patent Office: 586 Days
• Field of Search: 264/640, 264/638, 164/461, 164/97, 164/91
• US Class Current: 264/638
• CPC Class Codes: B22F 2998/00 Supplementary information concerning processes or compositions relating to powder metallurgy
• CPC Class Codes: B22F 2999/00 Aspects linked to processes or compositions used in powder metallurgy
• CPC Class Codes: B22F 3/1039 by reaction B22F3/001, B22F3/23 take precedence
• CPC Class Codes: C04B 2235/3205 Alkaline earth oxides or oxide forming salts thereof, e.g. beryllium oxide
• CPC Class Codes: C04B 2235/3217 Aluminum oxide or oxide forming salts thereof, e.g. bauxite, alpha-alumina
• CPC Class Codes: C04B 2235/3224 Rare earth oxide or oxide forming salts thereof, e.g. scandium oxide
• CPC Class Codes: C04B 2235/3225 Yttrium oxide or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3232 Titanium oxides or titanates, e.g. rutile or anatase
• CPC Class Codes: C04B 2235/3244 Zirconium oxides, zirconates, hafnium oxides, hafnates, or oxide-forming salts thereof
• CPC Class Codes: C04B 2235/3409 Boron oxide, borates, boric acids, or oxide forming salts thereof, e.g. borax
• CPC Class Codes: C04B 2235/3418 Silicon oxide, silicic acids, or oxide forming salts thereof, e.g. silica sol, fused silica, silica fume, cristobalite, quartz or flint glass constituents C04B2235/36
• CPC Class Codes: C04B 2235/3463 Alumino-silicates other than clay, e.g. mullite
• CPC Class Codes: C04B 2235/3804 Borides
• CPC Class Codes: C04B 2235/3813 Refractory metal borides
• CPC Class Codes: C04B 2235/3817 Carbides
• CPC Class Codes: C04B 2235/3821 Boron carbides
• CPC Class Codes: C04B 2235/3826 Silicon carbides
• CPC Class Codes: C04B 2235/3839 Refractory metal carbides
• CPC Class Codes: C04B 2235/3843 Titanium carbides
• CPC Class Codes: C04B 2235/3847 Tungsten carbides
• CPC Class Codes: C04B 2235/386 : Boron nitrides
• CPC Class Codes: C04B 2235/3865 : Aluminium nitrides
• CPC Class Codes: C04B 2235/3886 : Refractory metal nitrides, e.g. vanadium nitride, tungsten nitride
• CPC Class Codes: C04B 2235/3891 : Silicides, e.g. molybdenum disilicide, iron silicide
• CPC Class Codes: C04B 2235/40 : Metallic constituents or additives not added as binding phase
• CPC Class Codes: C04B 2235/401 : Alkaline earth metals
• CPC Class Codes: C04B 2235/402 : Aluminium
• CPC Class Codes: C04B 2235/404 : Refractory metals
• CPC Class Codes: C04B 2235/421 : Boron
• CPC Class Codes: C04B 2235/422 : Carbon
• CPC Class Codes: C04B 2235/428 : Silicon
• CPC Class Codes: C04B 2235/441 : Alkoxides, e.g. methoxide, tert-butoxide
• CPC Class Codes: C04B 2235/483 : Si-containing organic compounds, e.g. silicone resins, (poly)silanes, (poly)siloxanes or (poly)silazanes
• CPC Class Codes: C04B 2235/5216 : Inorganic
• CPC Class Codes: C04B 2235/5224 : Alumina or aluminates
• CPC Class Codes: C04B 2235/5236 : Zirconia
• CPC Class Codes: C04B 2235/524 : Non-oxidic, e.g. borides, carbides, silicides or nitrides
• 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 2235/526 : characterised by the length of the fibers
• CPC Class Codes: C04B 2235/5264 : characterised by the diameter of the fibers
• CPC Class Codes: C04B 2235/5268 : Orientation of the fibers
• CPC Class Codes: C04B 2235/5276 : Whiskers, spindles, needles or pins
• CPC Class Codes: C04B 2235/5296 : with a defined aspect ratio, e.g. indicating sphericity spherical constituents C04B2235/528
• CPC Class Codes: C04B 2235/5445 : submicron sized, i.e. from 0,1 to 1 micron
• CPC Class Codes: C04B 2235/6021 : Extrusion moulding
• CPC Class Codes: C04B 2235/6027 : Slip casting
• CPC Class Codes: C04B 2235/604 : Pressing at temperatures other than sintering temperatures
• CPC Class Codes: C04B 2235/616 : Liquid infiltration of green bodies or pre-forms
• CPC Class Codes: C04B 2235/6567 : Treatment time
• CPC Class Codes: C04B 2235/658 : Atmosphere during thermal treatment
• CPC Class Codes: C04B 2235/6582 : Hydrogen containing atmosphere
• CPC Class Codes: C04B 2235/77 : Density
• CPC Class Codes: C04B 2235/80 : Phases present in the sintered or melt-cast ceramic products other than the main phase
• CPC Class Codes: C04B 2235/85 : Intergranular or grain boundary phases
• CPC Class Codes: C04B 2235/94 : Products characterised by their shape
• CPC Class Codes: C04B 2235/96 : Properties of ceramic products, e.g. mechanical properties such as strength, toughness, wear resistance
• CPC Class Codes: C04B 2235/9615 : Linear firing shrinkage
• CPC Class Codes: C04B 35/01 : based on oxide ceramics
• CPC Class Codes: C04B 35/053 : Fine ceramics
• CPC Class Codes: C04B 35/117 : Composites
• CPC Class Codes: C04B 35/185 : Mullite 3Al2O3-2SiO2
• CPC Class Codes: C04B 35/488 : Composites
• CPC Class Codes: C04B 35/5611 : based on titanium carbides
• CPC Class Codes: C04B 35/5622 : based on zirconium or hafnium carbides
• CPC Class Codes: C04B 35/563 : based on boron carbide
• CPC Class Codes: C04B 35/565 : based on silicon carbide
• CPC Class Codes: C04B 35/571 : obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/575 : obtained by pressure sintering
• CPC Class Codes: C04B 35/58014 : based on titanium nitrides, e.g. TiAlON
• CPC Class Codes: C04B 35/58028 : based on zirconium or hafnium nitrides
• CPC Class Codes: C04B 35/58064 : based on refractory borides
• CPC Class Codes: C04B 35/58071 : based on titanium borides
• CPC Class Codes: C04B 35/58078 : based on zirconium or hafnium borides
• CPC Class Codes: C04B 35/581 : based on aluminium nitride
• CPC Class Codes: C04B 35/583 : based on boron nitride
• CPC Class Codes: C04B 35/584 : based on silicon nitride
• CPC Class Codes: C04B 35/589 : obtained from Si-containing polymer precursors or organosilicon monomers
• CPC Class Codes: C04B 35/62847 : with oxide ceramics
• CPC Class Codes: C04B 35/62849 : Silica or silicates
• CPC Class Codes: C04B 35/62852 : Alumina or aluminates
• CPC Class Codes: C04B 35/62855 : Refractory metal oxides
• CPC Class Codes: C04B 35/6286 : Carbides
• CPC Class Codes: C04B 35/62863 : Silicon carbide
• CPC Class Codes: C04B 35/62865 : Nitrides
• CPC Class Codes: C04B 35/62868 : Boron nitride
• CPC Class Codes: C04B 35/62871 : Silicon nitride
• CPC Class Codes: C04B 35/62873 : Carbon
• CPC Class Codes: C04B 35/62878 : with boron or silicon
• CPC Class Codes: C04B 35/62886 : by wet chemical techniques
• CPC Class Codes: C04B 35/62897 : Coatings characterised by their thickness
• CPC Class Codes: C04B 35/6316 : Binders based on silicon compounds
• CPC Class Codes: C04B 35/6325 : based on organo-metallic compounds
• CPC Class Codes: C04B 35/645 : Pressure sintering
• CPC Class Codes: C04B 35/76 : Fibres, filaments, whiskers, platelets, or the like
• 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: C04B 41/009 : characterised by the material treated
• CPC Class Codes: C04B 41/5006 : Boron compounds
• CPC Class Codes: C04B 41/5027 : Oxide ceramics in general; Specific oxide ceramics not covered by C04B41/5029 - C04B41/5051
• CPC Class Codes: C04B 41/5031 : Alumina
• CPC Class Codes: C04B 41/5035 : Silica
• CPC Class Codes: C04B 41/5041 : Titanium oxide or titanates
• CPC Class Codes: C04B 41/5042 : Zirconium oxides or zirconates; Hafnium oxides or hafnates
• CPC Class Codes: C04B 41/5049 : Zinc or bismuth oxides
• CPC Class Codes: C04B 41/87 : Ceramics
• CPC Class Codes: C22C 47/025 : Aligning or orienting the fibres
• CPC Class Codes: C22C 47/04 : by coating, e.g. with a protective or activated covering
• CPC Class Codes: C22C 47/06 : by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
• CPC Class Codes: C22C 47/068 : Aligning wires
• CPC Class Codes: C22C 47/08 : by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould C22C47/16 takes precedence
• CPC Class Codes: C22C 47/14 : by powder metallurgy, i.e. by processing mixtures of metal powder and fibres or filaments
• CPC Class Codes: C22C 47/20 : by subjecting to pressure and heat an assembly comprising at least one metal layer or sheet and one layer of fibres or filaments
• CPC Class Codes: F01D 5/282 : Selecting composite materials, e.g. blades with reinforcing filaments
• CPC Class Codes: F01D 5/284 : Selection of ceramic materials
• CPC Class Codes: F01D 5/3007 : of axial insertion type
• CPC Class Codes: F01D 5/3084 : the blades being made of ceramics
• CPC Class Codes: F01D 5/3092 : Protective layers between blade root and rotor disc surfaces, e.g. anti-friction layers F01D5/288 takes precedence
• CPC Class Codes: F05D 2300/6033 : Ceramic matrix composites [CMC]
• CPC Class Codes: F05D 2300/6034 : Orientation of fibres, weaving, ply angle
• CPC Class Codes: F23R 2900/00018 : Manufacturing combustion chamber liners or subparts
• CPC Class Codes: F23R 3/007 : constructed mainly of ceramic components
• CPC Class Codes: Y02T 50/60 : Efficient propulsion technologies, e.g. for aircraft

Abstract

Fiber bundle reinforced composite material useful for various high temperature structural members having excellent strength, toughness and resistance to oxidation and a process for producing the same. The fiber bundle reinforced composite material is reinforced with fiber bundles each having a plurality of continuous inorganic fibers bundled with medium such as carbon, being oriented in one, two or three directions, or randomly in the matrix which is reinforced with nano-sized particles precipitated. The fiber bundle reinforced composite material has a desired orientation of fibers and enables production of fiber bundle reinforced composite members having excellent strength and toughness.

Claims

1. A process for producing a fiber bundle reinforced ceramic or metal matrix composite material comprising:

a) impregnating more than one plurality of inorganic fibers oriented in one direction with at least one of precursors capable of forming at least one selected from the group consisting of C, SiC, TiC, BN, Si₃ N₄, B₄ C, SiO₂, TiO₂, Al₂ O₃, B₂ O₃ and Ta₂ O₅ ;

b) heating the impregnated fibers to form solidified inorganic fiber bundles;

c) mixing the fiber bundles with either;

1) a slurry of ceramic components;

or

2) a molten metal;

d) extruding the mixture to shape; and

e) drying the shape and sintering the dried shape if the mixture comprises (1) to provide said ceramic matrix composite material, or cooling the shape to solidification if the mixture comprises (2) to provide said metal matrix composite material.

2. The process for producing a fiber bundle reinforced composite material according to claim 1, wherein said ceramic matrix comprises a powder of at least one metal selected from the group consisting of Si, Al, Cr, Ti, Zr, Mg, B, Y, W, Nb, V, Sc, La, Hf, Mo, Ce, Yb, Er, Ho and Dy, or a powdery mixture of said metal powder and particles of at least one ceramic selected from the group consisting of nitrides, carbides, oxides, carbonitrides, oxynitrides, borides, intermetallic compounds of Si, Al, Cr, Ti, Zr, Mg, B, Y, W, Nb, V, Sc, La, Hf, Mo, Ce, Yb, Er, Ho and Dy, and said sintering is in situ precipitation sintering in a reactive gaseous atmosphere of at least one selected from the group consisting of nitriding, carbiding, carbonitriding, oxidizing, and oxynitriding atmospheres.

3. The process for producing a fiber bundle reinforced composite material according to claim 1, wherein said inorganic fiber bundles have a diameter of 0.05 mm to 10.0 mm.

4. The process for producing a fiber bundle reinforced composite material according to claim 1, wherein said inorganic fiber bundles are coated on the surfaces thereof with at least one selected from the group consisting of SiC, Si₃ N₄, SiO₂, C, TiC, B₄ C, BN, TiN, AlN, TiO₂, ZrO₂, Al₂ O₃, ZnO, MgO, B₂ O₃, and Ta₂ O₅.

5. The process for producing a fiber bundle reinforced composite material according to claim 1, wherein after sintering through precipitation reaction, the composite material is subjected to at least one treatment selected from the group consisting of non-pressurized high temperature treatment, pressurized high temperature treatment and chemical vapor infiltration.

6. The process for producing a fiber bundle reinforced composite material according to claim 1, wherein at least one sintering aid is mixed in the starting materials, or impregnated into the sintered body after sintering through precipitation reaction.