Method of Producing Carbon Fiber Reinforced Ceramic Matrix Composites

Abstract

The present invention relates to a method of producing carbon fiber reinforced ceramic matrix composites, the method of producing carbon fiber reinforced ceramic matrix composites according to the present invention is characterized in that the method comprises the steps of: producing a carbon fiber reinforced resin composite that is molded with a mixture in which carbon fibers and polymer precursors containing carbon are mixed; producing a carbon fiber reinforced carbon composite by depositing pyrolytic carbon during a rapid thermal gradient chemical vapor infiltration process while increasing the deposition speed in a direction from the inside to the outside by performing a thermal treatment on said carbon fiber reinforced resin composite at high temperature; and infiltrating liquid-phase silicon into the pores of said carbon fiber reinforced carbon composite. The method of producing carbon fiber reinforced ceramic matrix composites according to the present invention as described above has the effect of improving the properties of carbon fiber reinforced ceramic matrix composites, and it is possible to deposit a pyrolytic carbon layer at a deposition speed 5-10 times faster than other conventional chemical vapor infiltration processes, thereby showing a remarkably improved effect in terms of manufacturing process, time, and cost.

Description

TECHNICAL FIELD[0001]The present invention relates to a method of producing carbon fiber reinforced ceramic matrix composites, maintaining excellent mechanical strength at high temperature as well as having excellent properties in corrosion resistance, thermal resistance, friction and abrasion under a severe environment, such as heat, chemical erosion, etc.BACKGROUND ART[0002]Fiber reinforced ceramic matrix composites are lightweight materials having excellent mechanical and thermal properties at high temperature. With these properties, fiber reinforced ceramic matrix composites are applicable to friction and abrasion materials, such as brake disks, and pads for aircraft or ground transport means, and also to ultrahigh thermal resistant materials, such as ceramic engines, and rocket nozzle parts, which require mechanical strength, corrosion resistance, and thermal resistance. Fiber reinforced ceramic matrix composites have been studied to overcome the drawbacks to monolithic ceramic...

AI Technical Summary

Benefits of technology

[0033]The method of producing carbon fiber reinforced ceramic matrix composites according to the present invention as shown above has the effect of improving the properties of carbon fiber reinforced ceramic matrix composites, and it is possible to deposit a pyrolytic carbon layer at a deposition speed 5-10 times faster than other conventional chemical vapor infiltration processes, thereby providing a remarkably improved effect in terms of manufacturing process, time, and cost.

Problems solved by technology

Up to now, fiber reinforced ceramic matrix composites have been produced with a variety of manufacturing processes, however, in most cases, they cause mechanical and / or chemical impact damages to fibers during the manufacturing processes.

In this process, however, high-priced raw materials and manufacturing equipment are employed, its manufacturing process is complicated, and lots of process time more than several hundred hours is required, and therefore its application is extremely restricted to high-tech industries, such as aerospace, or the like.

As described above, however, the carbon fiber reinforced resin composite produced by mixing with liquid-phase carbon precursors is more effective than existing chemical vapor infiltration processes in terms of manufacturing cost, but it is difficult to prevent the reaction of liquid-phase silicon against carbon fibers due to some difficulties in forming a uniform carbon fiber protective layer, and thereby rapidly reducing mechanical properties of carbon fiber reinforced ceramic matrix composites.

To solve such a problem, as disclosed in Korean Patent Application No. 1999-7008146, as well as U.S. Pat. No. 6,079,525, U.S. Pat. No. 6,030,913, and U.S. Pat. No. 6,231,791, the carbon fiber reinforced ceramic matrix composite is produced by iterative impregnation of liquid organic binders or by changing the composition of the mixture, but it is impossible to prevent the reduction in mechanical properties caused by carbon fiber erosion and to improve friction and abrasion characteristics at high temperature.

This process has remarkably improved an aspect of fiber protection, but it is difficult to produce carbon fiber reinforced ceramic matrix composites having a complicated shape due to difficulty in combining different carbon fiber reinforced ceramic matrix composites into a structured body.

In particular, the manufacturing process is complicated and required more than several hundred hours for the manufacturing time, and therefore it caused an increase in the manufacturing cost.

Examining the overall problems related to the production technologies of carbon fiber reinforced ceramic matrix composites in most cases a process of producing a carbon fiber reinforced carbon composite that is employed for producing carbon fiber reinforced ceramic matrix composites still has some difficulties in terms of its production cost and technologies.

For example, conventional chemical vapor in-filtration process has excellent characteristics as a fiber protective layer; but it is not adequate for producing carbon fiber reinforced carbon composites due to its high-cost raw materials and manufacturing process difficulties.

Images