多孔碳陶瓷化改进反应熔渗法制备陶瓷基复合材料研究进展

doi:10.15541/jim20230608

无机材料学报 ›› 2024, Vol. 39 ›› Issue (6): 623-633.DOI: 10.15541/jim20230608

多孔碳陶瓷化改进反应熔渗法制备陶瓷基复合材料研究进展

赵日达(), 汤素芳()

中国科学院金属研究所, 前沿材料研究部, 沈阳 110016

收稿日期:2023-12-31 修回日期:2024-02-27 出版日期:2024-06-20 网络出版日期:2024-02-26
通讯作者: 汤素芳, 研究员. E-mail: sftang@imr.ac.cn
作者简介:赵日达(1995-), 男, 博士, 助理研究员. E-mail: rdzhao16s@imr.ac.cn
基金资助:
国家自然科学基金(52272075);国家自然科学基金(U20A20242)

Research Progress of Ceramic Matrix Composites Prepared by Improved Reactive Melt Infiltration through Ceramization of Porous Carbon Matrix

ZHAO Rida(), TANG Sufang()

Frontier Materials Division, Institute of Metal Research, Chinese Academy of Sciences, Shenyang 110016, China

Received:2023-12-31 Revised:2024-02-27 Published:2024-06-20 Online:2024-02-26
Contact: TANG Sufang, professor. E-mail: sftang@imr.ac.cn
About author:ZHAO Rida (1995-), male, PhD, assistant professor. E-mail: rdzhao16s@imr.ac.cn
Supported by:
National Natural Science Foundation of China(52272075);National Natural Science Foundation of China(U20A20242)

摘要/Abstract

摘要：

连续纤维增强陶瓷基复合材料具有高强韧、耐氧化的特性, 现已成为航空航天领域重要的高温结构候选材料。反应熔渗法可实现陶瓷基复合材料的大规模、短周期和低成本制备, 是目前最具有商业化前景的技术之一。然而, 传统反应熔渗法制得陶瓷基复合材料存在着基体碳残留、纤维刻蚀等问题, 导致材料力学与氧化-烧蚀性能不佳。为突破传统碳基体陶瓷化程度低的局限性, 相关研究人员采用碳基体孔结构构筑方法, 通过多孔碳基体取代传统熔渗预制体中致密碳基体, 以促进碳基体的陶瓷化转变及反应熔体的消耗, 进而实现陶瓷基复合材料的性能优化。本综述介绍了采用多孔碳陶瓷化策略制备SiC陶瓷、SiC/SiC复合材料、C/SiC复合材料及超高温陶瓷基复合材料的相关研究进展, 并且通过与传统反应熔渗法对比, 验证了多孔碳陶瓷化策略的优势, 同时总结了相关多孔碳基体制备方法的发展演变过程, 最后针对先进陶瓷基复合材料的基础理论与工艺技术需求, 对多孔碳陶瓷化改进反应熔渗法的未来发展方向进行了展望。

关键词: 陶瓷基复合材料, 反应熔渗法, 多孔碳陶瓷化, 综述

Abstract:

Owing to the high strength/toughness and excellent anti-oxidation ability, continuous fiber reinforced ceramic matrix composites have become the preferred candidates for high temperature structural materials in aerospace field. Reactive melt infiltration can achieve the large-scale, short-cycle and low-cost production of ceramic matrix composites, which has been widely considered to be one of the most promising technologies from a commercial perspective. However, the mechanical and anti-oxidation/ablation properties of obtained composites prepared by conventional reactive melt infiltration are not satisfactory due to the existence of residual carbon and corroded fibers. In order to address the problems, relevant researchers constructed porous carbon matrix to replace conventional densified structure to promote its ceramic transformation and the consumption of reactive melt, thus achieving the improved performance of ceramic matrix composites. This paper reviewed the research progress about the preparation of SiC ceramics, SiC/SiC composites, C/SiC composites, and ultra-high temperature ceramic matrix composites by porous carbon ceramization strategy. Besides, the superiority of the method was verified compared to conventional reactive melt infiltration. The development of preparation methods for porous carbon matrix was also summarized. Finally, in term of the requirements of basic theory and technology for advanced ceramic matrix composites, the prospect for the future development of improved reactive melt infiltration to prepared ceramic matrix composites was discussed.

Key words: ceramic matrix composite, reactive melt infiltration, porous carbon ceramization, review

中图分类号:

TM285

赵日达, 汤素芳. 多孔碳陶瓷化改进反应熔渗法制备陶瓷基复合材料研究进展[J]. 无机材料学报, 2024, 39(6): 623-633.

ZHAO Rida, TANG Sufang. Research Progress of Ceramic Matrix Composites Prepared by Improved Reactive Melt Infiltration through Ceramization of Porous Carbon Matrix[J]. Journal of Inorganic Materials, 2024, 39(6): 623-633.

图/表 12

图1 用于制备(a-d) SiC[24⇓⇓-27], (e) SiC/SiC[33], (f, g) C/SiC[31,39]及(h) C/SiC-ZrC[18]的多孔碳典型形貌

Fig. 1 Typical morphologies of porous carbon for preparation of (a-d) SiC[24⇓⇓-27], (e) SiC/SiC[33], (f, g) C/SiC[31,39] and (h) C/SiC-ZrC[18]

图2 通过相分离法制备多孔碳的示意图[49]

Fig. 2 Schematic illustration of preparation for porous carbon by phase separation[49]

表1 多孔碳的碳源、密度、中位孔径及生成陶瓷的密度与硅含量

Table 1 Carbon sources, densities and median pore diameters of porous carbon, densities and Si content of obtained ceramics

Carbon source	Density of porous carbon/(g·cm^-3)	Median pore diameter of porous carbon/nm	Density of ceramic/ (g·cm^-3)	Si content/% (in mass)	Ref.
Furfuryl alcohol	/	1000	/	/	[25]
Furfuryl alcohol	0.86	1300	/	/	[26]
Furfuryl	0.74	2580	3.04	17.6	[49]
	0.65	1940	2.81	34.7
	0.58	670	3.01	/
	0.90	40	3.07	/
Phenol formaldehyde	0.79	2363	2.10	13.0	[43]
	0.79	1552	2.81	12.0
	0.74	1226	2.88	16.0
	0.74	642	2.91	14.0
	0.73	190	2.93	16.0
Phenol formaldehyde	0.72	39.9	2.92	20.0	[27]
	0.72	39.9	3.07	15.4
	0.79	28.8	3.08	12.2
	0.78	38.7	2.95	3.1
Phenol formaldehyde	0.90	20.1	2.90	3.6	[2]

图3 (a) RMI过程中生成的陶瓷层示意图和(b)预制体孔径随渗透时间的变化曲线[33]

Fig. 3 (a) Schematic illustration of ceramic layer generated during the RMI and (b) curves of preforms pore radius vs infiltration time[33]

图4 溶胶-凝胶法制备多孔树脂的示意图[34]

Fig. 4 Schematic illustration of formation of porous resin obtained by Sol-Gel[34]

图5 不同C/SiC复合材料的XRD图谱[39]

Fig. 5 XRD patterns of different C/SiC composites[39]

图6 (a)双壁碳纳米管液硅熔渗模型示意图, (b)液硅熔渗高度(H)与融渗时间(t)之间的对应关系和(c)液硅在内径2 nm双壁碳纳米管模型中的毛细熔渗行为[51]

Fig. 6 (a) Schematic illustration of liquid Si infiltration in double-walled carbon nanotubes, (b) relationship between infiltration height (H) and infiltration time (t) for liquid Si infiltration, and (c) capillary infiltration behavior of liquid Si into a double-walled carbon nanotubes with an inner tube diameter of 2 nm[51]

图7 C/ZrC-C预制体的(a)界面结构和(b)基体形貌[54]

Fig. 7 Microstructures of (a) interface and (b) matrix in the C/ZrC-C preform[54]

图8 多孔C/C的(a, b)微观结构与(c)孔径分布曲线, (d) C/C- SiC-(ZrxHf1-x)C的截面形貌[35]

Fig. 8 (a, b) Microstructures and (c) pore size distribution curves of the porous C/C, and (d) cross-sectional micrograph of the C/C-SiC-(ZrxHf1-x)C[35]

图9 (a) C/SiC-HfC与(b, c) SiC-HfC基体截面形貌, (d) HfC晶粒直径分布及其平均直径[18]

Fig. 9 Cross-sectional morphologies of (a) C/SiC-HfC and (b, c) SiC-HfC matrix, and (d) grain diameter distribution of HfC and its mean diameter[18]

图10 传统RMI与多孔碳陶瓷化改进RMI制得陶瓷基复合材料的(a)弯曲强度与(b)2200 ℃线烧蚀率对比[18,33⇓-35,39]

Fig. 10 Comparison of (a) flexural strength and (b) 2200 ℃ linear ablation rates of ceramic matrix composites obtained by conventional RMI and improved RMI through ceramization of porous carbon matrix[18,33⇓-35,39]

表2 多孔预制体的基体制备方法、中位孔径、孔径分布范围及所生成陶瓷基复合材料的弯曲强度

Table 2 Preparation methods of porous matrix in preform, median pore diameters and predominant pore size ranges of preform, and flexural strength of the obtained ceramic matrix composites

Preform	Preparation method of porous matrix	Median pore diameter/nm	Predominant pore size range/nm	Ceramic matrix composites	Flexural strength/MPa	Ref.
C/SiC-C	Phase separation	1800	500-10000	C/SiC-Si	/	[31]
SiC/BN_x/SiN_x/C	Phase separation	/	1000-4500	SiC/_BN_x_/SiN_x_/SiC-Si	/	[30]
C/B₄C-C	Sol-Gel	39800	25000-75000	C/ZrB₂-SiC-ZrC	231	[56]
C/B₄C-Al₂O₃-C	Sol-Gel	/	10-10000	C/B₄C-Al₂O₃-SiC-Si	300	[57]
C/ZrC-C	Carbothermal reduction	/	4-130000	C/ZrC-SiC-ZrSi₂	380	[54]
C/C	Phase separation	41.6	10-80	C/SiC	218	[39]
SiC/SiC-C	Phase separation	/	100-5000	SiC/SiC-Si	201	[33]
C/C	Phase separation	1300	100-5200	C/C-SiC-(Zr_xHf₁₋_x)C	/	[35]
SiC/SiC-C	Sol-Gel	/	500-10000	SiC/SiC-Si	809	[34]
C/C	Phase separation	/	10-130	C/SiC-ZrC	288	[2,18]
C/C	Phase separation	/	10-130	C/SiC-HfC	251	[2,18]

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多孔碳陶瓷化改进反应熔渗法制备陶瓷基复合材料研究进展

Research Progress of Ceramic Matrix Composites Prepared by Improved Reactive Melt Infiltration through Ceramization of Porous Carbon Matrix

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