WO1997033009A1 - Titane renforce a l'aide d'un composite matriciel a base d'aluminium - Google Patents
Titane renforce a l'aide d'un composite matriciel a base d'aluminium Download PDFInfo
- Publication number
- WO1997033009A1 WO1997033009A1 PCT/US1997/003171 US9703171W WO9733009A1 WO 1997033009 A1 WO1997033009 A1 WO 1997033009A1 US 9703171 W US9703171 W US 9703171W WO 9733009 A1 WO9733009 A1 WO 9733009A1
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- WIPO (PCT)
- Prior art keywords
- metal
- matrix composite
- metal matrix
- monolithic
- reinforced part
- Prior art date
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- 239000011159 matrix material Substances 0.000 title claims abstract description 55
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 title claims description 66
- 229910052782 aluminium Inorganic materials 0.000 title claims description 62
- 239000002131 composite material Substances 0.000 title claims description 48
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 title claims description 32
- 239000010936 titanium Substances 0.000 title claims description 31
- 229910052719 titanium Inorganic materials 0.000 title claims description 31
- 239000011156 metal matrix composite Substances 0.000 claims abstract description 80
- 229910001092 metal group alloy Inorganic materials 0.000 claims abstract description 73
- 239000000463 material Substances 0.000 claims abstract description 61
- 239000002184 metal Substances 0.000 claims abstract description 57
- 238000000034 method Methods 0.000 claims abstract description 24
- 239000000835 fiber Substances 0.000 claims description 75
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 32
- 229910001069 Ti alloy Inorganic materials 0.000 claims description 18
- 229910052742 iron Inorganic materials 0.000 claims description 16
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 claims description 15
- 239000000919 ceramic Substances 0.000 claims description 14
- 230000003014 reinforcing effect Effects 0.000 claims description 11
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 8
- 229910052802 copper Inorganic materials 0.000 claims description 8
- 239000010949 copper Substances 0.000 claims description 8
- 229910052594 sapphire Inorganic materials 0.000 claims description 4
- 230000002708 enhancing effect Effects 0.000 claims description 3
- 229910052593 corundum Inorganic materials 0.000 claims 2
- 229910001845 yogo sapphire Inorganic materials 0.000 claims 2
- 229910052751 metal Inorganic materials 0.000 description 23
- 229910045601 alloy Inorganic materials 0.000 description 11
- 239000000956 alloy Substances 0.000 description 11
- 238000004519 manufacturing process Methods 0.000 description 8
- 150000002739 metals Chemical class 0.000 description 8
- 230000008569 process Effects 0.000 description 8
- 239000012535 impurity Substances 0.000 description 6
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 5
- 238000013459 approach Methods 0.000 description 5
- 238000005266 casting Methods 0.000 description 5
- 238000000576 coating method Methods 0.000 description 5
- 238000009715 pressure infiltration Methods 0.000 description 5
- 229910052710 silicon Inorganic materials 0.000 description 5
- 239000010703 silicon Substances 0.000 description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 5
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 4
- NRTOMJZYCJJWKI-UHFFFAOYSA-N Titanium nitride Chemical compound [Ti]#N NRTOMJZYCJJWKI-UHFFFAOYSA-N 0.000 description 4
- 229910000765 intermetallic Inorganic materials 0.000 description 4
- 239000010959 steel Substances 0.000 description 4
- 229910001209 Low-carbon steel Inorganic materials 0.000 description 3
- 238000006243 chemical reaction Methods 0.000 description 3
- 239000011248 coating agent Substances 0.000 description 3
- 229910002804 graphite Inorganic materials 0.000 description 3
- 239000010439 graphite Substances 0.000 description 3
- 238000012545 processing Methods 0.000 description 3
- 239000011253 protective coating Substances 0.000 description 3
- 230000002787 reinforcement Effects 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 230000007704 transition Effects 0.000 description 3
- 229910052723 transition metal Inorganic materials 0.000 description 3
- 150000003624 transition metals Chemical class 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- 229910052786 argon Inorganic materials 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 238000011109 contamination Methods 0.000 description 2
- 239000012153 distilled water Substances 0.000 description 2
- 238000005516 engineering process Methods 0.000 description 2
- -1 from SiO. Chemical compound 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 230000000737 periodic effect Effects 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 238000002360 preparation method Methods 0.000 description 2
- 238000013022 venting Methods 0.000 description 2
- 238000004804 winding Methods 0.000 description 2
- 229910018191 Al—Fe—Si Inorganic materials 0.000 description 1
- 229920000049 Carbon (fiber) Polymers 0.000 description 1
- 229910000975 Carbon steel Inorganic materials 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- WHXSMMKQMYFTQS-UHFFFAOYSA-N Lithium Chemical compound [Li] WHXSMMKQMYFTQS-UHFFFAOYSA-N 0.000 description 1
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 1
- 101100293261 Mus musculus Naa15 gene Proteins 0.000 description 1
- ATJFFYVFTNAWJD-UHFFFAOYSA-N Tin Chemical compound [Sn] ATJFFYVFTNAWJD-UHFFFAOYSA-N 0.000 description 1
- HCHKCACWOHOZIP-UHFFFAOYSA-N Zinc Chemical compound [Zn] HCHKCACWOHOZIP-UHFFFAOYSA-N 0.000 description 1
- 230000004075 alteration Effects 0.000 description 1
- 229910052787 antimony Inorganic materials 0.000 description 1
- WATWJIUSRGPENY-UHFFFAOYSA-N antimony atom Chemical compound [Sb] WATWJIUSRGPENY-UHFFFAOYSA-N 0.000 description 1
- 229910052797 bismuth Inorganic materials 0.000 description 1
- JCXGWMGPZLAOME-UHFFFAOYSA-N bismuth atom Chemical compound [Bi] JCXGWMGPZLAOME-UHFFFAOYSA-N 0.000 description 1
- 239000004917 carbon fiber Substances 0.000 description 1
- 239000010962 carbon steel Substances 0.000 description 1
- 230000015556 catabolic process Effects 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229910017052 cobalt Inorganic materials 0.000 description 1
- 239000010941 cobalt Substances 0.000 description 1
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 1
- 239000000084 colloidal system Substances 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 239000000356 contaminant Substances 0.000 description 1
- 238000005520 cutting process Methods 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 238000006731 degradation reaction Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
- 239000010432 diamond Substances 0.000 description 1
- 238000001035 drying Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 239000002657 fibrous material Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000007689 inspection Methods 0.000 description 1
- 229910052747 lanthanoid Inorganic materials 0.000 description 1
- 150000002602 lanthanoids Chemical class 0.000 description 1
- 239000007788 liquid Substances 0.000 description 1
- 229910052744 lithium Inorganic materials 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 229910052749 magnesium Inorganic materials 0.000 description 1
- 239000011777 magnesium Substances 0.000 description 1
- WPBNNNQJVZRUHP-UHFFFAOYSA-L manganese(2+);methyl n-[[2-(methoxycarbonylcarbamothioylamino)phenyl]carbamothioyl]carbamate;n-[2-(sulfidocarbothioylamino)ethyl]carbamodithioate Chemical compound [Mn+2].[S-]C(=S)NCCNC([S-])=S.COC(=O)NC(=S)NC1=CC=CC=C1NC(=S)NC(=O)OC WPBNNNQJVZRUHP-UHFFFAOYSA-L 0.000 description 1
- 230000013011 mating Effects 0.000 description 1
- 238000010310 metallurgical process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 238000012856 packing Methods 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 239000012783 reinforcing fiber Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 238000005204 segregation Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
- 229910010271 silicon carbide Inorganic materials 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 238000010257 thawing Methods 0.000 description 1
- 229910052720 vanadium Inorganic materials 0.000 description 1
- GPPXJZIENCGNKB-UHFFFAOYSA-N vanadium Chemical compound [V]#[V] GPPXJZIENCGNKB-UHFFFAOYSA-N 0.000 description 1
- 230000003313 weakening effect Effects 0.000 description 1
- 238000003466 welding Methods 0.000 description 1
- 229910052725 zinc Inorganic materials 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/08—Making alloys containing metallic or non-metallic fibres or filaments by contacting the fibres or filaments with molten metal, e.g. by infiltrating the fibres or filaments placed in a mould
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C47/00—Making alloys containing metallic or non-metallic fibres or filaments
- C22C47/02—Pretreatment of the fibres or filaments
- C22C47/06—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element
- C22C47/062—Pretreatment of the fibres or filaments by forming the fibres or filaments into a preformed structure, e.g. using a temporary binder to form a mat-like element from wires or filaments only
- C22C47/068—Aligning wires
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F2998/00—Supplementary information concerning processes or compositions relating to powder metallurgy
Definitions
- the present invention relates to hybrid parts incorporating titanium and aluminum matrix composites. More particularly, the invention relates to parts having separate regions of titanium and an aluminum matrix composite wherein the separate regions share an interface.
- the present invention relates to structures employing materials which combine the advantages of monolithic metals and metallic alloys with those of composites.
- the present invention relates to metallic alloy components having at least a portion reinforced by a metal matrix composite (MMC) material in which the matrix metal of the MMC is a different metal than that of the metallic monolith forming the remainder of the part.
- MMC metal matrix composite
- the invention further relates to materials having an interface between a monolithic metal or metallic alloy and an MMC, as well as to methods for fabricating parts of materials having such an interface.
- the invention comprises a monolithic segment which comprises a first metal or metallic alloy, and a reinforcing segment which comprises a metal matrix composite material.
- the monolithic segment substantially encapsulates the metal matrix composite material.
- the metal matrix composite material comprises at least one ceramic fiber contained within a matrix which comprises a second metal or metallic alloy.
- the metal or metallic alloy which forms the monolithic segment differs from the metal or metallic alloy which. forms the matrix of the composite material.
- the term "substantially encapsulates" is intended to mean that the metal matrix composite material has a substantial portion, although not necessarily all, of its external surface surrounded by the monolithic segment.
- the fabricated part is a tube having a monolithic metal interior and exterior with a metal matrix composite positioned between the interior and exterior walls.
- Such tubes can be made by the process comprising the steps of: a) providing a cylindrical sleeve of a first monolithic material, the sleeve having an outer diameter; b) providing at least one preform comprising at least one tow of a ceramic fiber; c) wrapping said at least one preform around the cylindrical sleeve; d) providing a cylindrical jacket of a second monolithic material, the jacket having an inner diameter that is greater than the outer diameter of the sleeve; e) inserting the sleeve wrapped with the preform into the jacket; f) infiltrating said at least one preform with a matrix of a metal or metallic alloy, the metal or metallic alloy being different that each of the first and second monolithic materials.
- inventive materials may be used in a wide variety of industries, they offer particular advantages in the aerospace industry.
- turbine engine blades i.e., fan blades, compressor blades
- fan frames i.e., fan frames, rods and tubing.
- the materials may be configured in a manner in which the metal matrix composite is completely encapsulated within a metal or metallic alloy, or alternatively, the part can be configured in a manner such that it has an MMC component in one section and a metal or metallic alloy in another section.
- the MMC may be a rod-like insert within a cylindrical aperture formed in the leading edge of the blade, or, in the second instance, the blade may be formed of MMC with a root of a metal such as titanium alloy.
- the MMC comprises continuous fibers of polycrystalline 0.-AI 2 O3 contained within a matrix of elemental aluminum or an alloy of elemental aluminum containing up to about 2% by weight copper, and the monolithic metal comprises titanium alloy.
- the titanium part is fabricated, and then used as a mold for the MMC insert.
- the process for forming the MMC is substantially simplified because it can be made in situ. No additional tooling is required, and the insert does not have to be machined or otherwise fabricated.
- the resulting part combines the toughness, machineability, repairability, and existing knowledge base of conventional monolithic parts with the high strength, stiffness, and low density of MMCs. Additionally, since the MMC is used only where it is specifically needed, the cost of the resulting part is substantially less than if the entire part was fabricated of MMC.
- FIG. 1 depicts a rod having an MMC insert.
- FIG. 4 is a schematic representation of one cross section of the blade of FIG. 3.
- FIG. 5 is a schematic representation of another cross section of the blade of FIG. 3.
- FIGS. 6a and 6b are schematic representations of a tube incorporating an MMC core. Detailed Description of the Invention Materials
- the present invention relates to parts having a monolithic metal or metallic alloy in combination with a metal matrix composite (MMC) material.
- the materials are selected such that the metal or metal alloy which forms the monolithic segment of the part is of a different metal or metallic alloy than that used as the matrix of the MMC materials. Due to the use of different metals or metallic alloys, an interface exists between the monolithic segment of the part and the reinforcing MMC segment.
- the part is formed of a titanium alloy monolith and an aluminum matrix composite.
- the titanium alloy Ti-6A1-4V has been found to be particularly useful. Of course, the invention is not intended to be limited as such, since numerous other titanium alloys could be used as well.
- the preferred fiber reinforced aluminum matrix composites contain continuous fibers of polycrystalline 01-AI2O3 encapsulated within either a matrix of substantially pure elemental aluminum or an alloy of pure aluminum with up to about 2% copper by weight.
- the preferred fibers have equiaxed grains, with a grain size of less than about 100 nm, and a fiber diameter in the range of about 1-50 micrometers. A fiber diameter in the range of about 5-25 micrometers is preferred with a range of about 5-15 micrometers being most preferred.
- Preferred composite materials have a fiber density of between about 3.90-3.95 grams per cubic centimeter. Among the preferred fibers are those described in U.S. Patent No. 4,954,462 (Wood et al.).
- Alumina fibers are available commercially under the designation "NEXTEL” 610 CERAMIC FIBERS” from the 3M Company, St. Paul, MN.
- the encapsulating matrix is selected to be such that it does not react chemically with the fiber material, thereby eliminating the need to provide a protective coating on the fiber exterior.
- the percentage of fibers contained in the fiber may be selected to suit the strength and/or weight requirements of the part ultimately being fabricated. In one embodiment, the fibers comprise about 30-70 % by weight of the composite material. In a preferred embodiment, the fibers comprise about 40-60 % by weight of the composite material.
- the term "polycrystalline” means a material having predominantly a plurality of crystalline grains in which the grain size is less than the diameter of the fiber in which the grains are present.
- the term “continuous” is intended to mean a fiber having a length which is relatively infinite when compared to the fiber diameter. In practical terms, such fibers have a length on the order of about 15 cm to at least several meters, and may even have lengths on the order of kilometers or more. In the preferred embodiments, the use of a matrix comprising either substantially pure elemental aluminum, or an alloy of elemental aluminum with up to about 2% by weight copper has been shown to produce successful composites.
- substantially pure elemental aluminum As used herein the terms “substantially pure elemental aluminum”, “pure aluminum” and “elemental aluminum” are interchangeable and are intended to mean aluminum containing less than about 0.05% impurities by weight. Such impurities typically comprise first row transition metals (titanium, vanadium, chromium, manganese, iron, cobalt, nickel, and zinc) as well as second and third row metals and elements in the lanthanide series. In one preferred embodiment, the terms are intended to mean aluminum having less than about 0.03% iron by weight, with less than about 0.01% iron by weight being most preferred.
- Minimizing the iron content is desirable because iron is a common contaminant of aluminum, and further, because iron and aluminum combine to form brittle intermetallic compounds (e.g., AljFe, AfeFe, etc.). It is also particularly desirable to avoid contamination by silicon (such as from SiO., which can be reduced to free silicon in the presence of molten aluminum) because silicon, like iron, forms a brittle phase, and because silicon can react with the aluminum (and any iron which may be present) to form brittle Al-Fe-Si intermetallic compounds. The presence of brittle phases in the composite is undesirable, as such phases tend to promote fracture in the composite when subjected to stress.
- brittle phases may cause the matrix to fracture even before the reinforcing ceramic fibers fracture, resulting in composite failure.
- transition metal i.e., Groups IB through VlilB of the periodic table
- Iron and silicon have been particularly specified herein as a result of their commonality as impurities in metallurgical processes.
- Each of the first row transition metals described above is relatively soluble in molten aluminum and, as noted, can react with the aluminum to form brittle intermetallic compounds.
- metal impurities such as tin, lead, bismuth, antimony and the like do not form compounds with aluminum, and are virtually insoluble in molten aluminum.
- those impurities tend to segregate to the fiber/matrix interface, thereby weakening the composite strength at the interface. Although such segregation may aid longitudinal strength of the ultimate composite by contributing to a global load sharing domain (discussed below), the presence of the impurities ultimately results in a substantial reduction in the transverse strength of the composite due to decohesion at the fiber/matrix interface.
- Elements from Groups LA and UA of the periodic table tend to react with the fiber and drastically decrease the strength of the fiber in the composite.
- Magnesium and lithium are particularly undesirable elements in this regard, due, in part, to the length of time the fibers and the metal must be maintained at high temperatures during processing or in use.
- references to "substantially pure elemental aluminum”, “pure aluminum”, and “elemental aluminum” as used herein, are intended to apply to the matrix material rather than to the reinforcing fibers, since the fibers will likely include domains of iron (and possibly other) compounds within their grain structure. Such domains typically are remnants of the fiber manufacturing process and have, at most, negligible effect on the overall characteristics of the resulting composite material, since they tend to be relatively small and fully encapsulated within the grains of the fiber. As such, they do not interact with the composite matrix, and thereby avoid the drawbacks associated with matrix contamination. Formed Parts
- FIG. 1 A rod formed of a titanium alloy reinforced with an aluminum matrix composite is shown schematically in FIG. 1.
- the rod 10 has a core 12 formed from an aluminum matrix composite surrounded by a jacket 14 of monolithic titanium alloy. An interface 16 exists between the core 12 and the jacket 14.
- the rod was produced using a tube of Ti-6A1-4V alloy.
- a cylindrical preform of alumina fibers (“NEXTEL 610 CERAMIC FIBERS") was made with an outer diameter corresponding to the inner diameter of the tube. The cylindrical preform was inserted into the titanium tube. The tube and preform were then inserted into a pressure casting unit and the preform was infiltrated with aluminum to form the structure shown in FIG. 1. The details of the process are given below in Example 1.
- the fan blade 20 includes a monolithic body 22, a monolithic root 24, and a reinforcing segment 26.
- the monolithic body 22 and root 24 are formed of, for example, a titanium alloy
- the reinforcing segment 26 is formed of an MMC which comprises, for example, continuous fibers of polycrystalline ⁇ -Al 2 0 3 contained within a matrix of elemental aluminum or an alloy of elemental aluminum containing up to about 2% copper.
- FIGS. 3-5 are schematic representations of a fan blade 30 having an MMC blade body 32 and a monolithic metal or metallic alloy root 34.
- the blade body 32 and the root 34 meet at an interface 36 (shown in phantom) which joins the two dissimilar metals together.
- the attachment between the blade body 32 and the root 34 across the interface 36 may be strengthened by increasing the surface area of the interface 36.
- the root 34 may have an extension segment 38 which extends into a recess in the blade body 32.
- the blade may be configured such that an extension segment projects from the blade body and is encapsulated by a recess in the root.
- One approach for the fabrication of such parts is to machine the titanium root in two halves which match at a parting plane. Pockets or recesses would be machined into the mating surfaces in order to allow the alumina fiber preform to be inserted.
- a preform of alumina fibers in the shape of the blade can be made separately and then placed between the machined titanium root pieces. This assembly can then be placed into a pressure infiltration mold and cast using ordinary processing.
- the titanium may require titanium-nitride or other surface coatings to minimize reaction between the titanium and molten aluminum.
- titanium root is machine a one-piece titanium root and wrap the alumina fiber preform around it. This assembly can then be placed into the pressure infiltration mold and processed as described in the Examples. Again, it is preferred that the titanium root be tapered in thickness (i.e., full width at the root end and tapering to narrow at the outboard end) to allow gradual load transition.
- FIGS. 6a and 6b are schematic representations of a tube 40 incorporating an MMC core 42 between an inner sleeve 44 and an outer jacket 46.
- the inner sleeve and the outer jacket are formed of a metal or metallic alloy which is different from that which comprises the matrix material of the MMC.
- Such tubular constructions are well-suited for numerous industrial applications including landing gear support tubes and the like for the aerospace industry. A detailed discussion of such tubes and their fabrication is given below in Example 2.
- This example illustrates the preparation of a titanium tube reinforced with an aluminum matrix composite.
- a commercially available Ti-6A1-4V, titanium alloy rod was machined into a tube 10 cm long, with an outer diameter of 2.4 cm (0.9 in) and an inner diameter of 1.4 cm (0.57 in).
- a preform of alumina fiber tows (“NEXTEL 610 CERAMIC FIBERS”) was fashioned into a cylinder, 1.4 cm (0.57 in) and 10 cm (4 in) long.
- the preform was made by first level winding a layer of individual tow of fiber onto a four-sided drum (10.5 in (27 cm) per side) to form a mat. Distilled water was added to the tow as it was wound to provide some integrity to the mat. The mat was then slit parallel to the axis of the drum and removed. They are then rolled into a round cylinder of the required dimensions. Once rolled, the fiber preform was forced into the titanium alloy tube. This fiber preform was sufficient to result in a final composite core with approximately 50% fibers by volume.
- the tube and the preform were placed into a pressure infiltration casting apparatus.
- the tube was placed into an airtight vessel and positioned at the bottom of an evacuable chamber.
- Pieces of aluminum metal were loaded into the chamber on a support plate above the mold. Small holes (approx. 2.54 mm in diameter) were present in the support plate to permit passage of molten aluminum to the tube below.
- the chamber was closed and the chamber pressure was reduced to 3 milliTorr (0.4 Pa) to evacuate the air from the mold and the chamber.
- the aluminum metal was heated to 720 °C. and the tube, with the fiber preform in it, were heated to at least 670 °C. The aluminum melted at this temperature but remained on the plate above the tube.
- the power to the heaters was turned off, and the chamber was pressured by filling with argon to a pressure of 8.96 MPa (1300 psi).
- the molten aluminum immediately flowed through the holes in the support plate and into the mold.
- the temperature was allowed to drop to 600 °C. before venting the chamber to the atmosphere. After the chamber had cooled to room temperature, the tube was removed from the chamber.
- the resulting tube was examined by cutting off one end with a diamond abrasive wheel saw. Upon inspection, it was determined that the fiber preform was infiltrated with aluminum matrix material, and that an interface between the aluminum matrix composite and the titanium tube was clearly evident.
- a structural tube section had a length of 21 cm (8 in).
- the structural tube section was fabricated from titanium alloy inner and outer tubes with an aluminum matrix composite between.
- the inner titanium tube changed in thickness at each end to provide a transition from a hybrid (titanium outer jacket and inner sleeve containing MMC in between) in the center of the structural tube to all metal (titanium) at its ends.
- a hybrid titanium outer jacket and inner sleeve containing MMC in between
- the hybrid, structural tube was made by first machining an inner titanium sleeve, and an outer titanium jacket.
- the inner tube was 8.00 inches (20.32cm) long and had a constant inner diameter of 3.259 inches (8.28cm).
- the outer diameter was 3.656 inches (9.29cm) at the ends and for a distance of 0.50 inches (1.27cm) in from each end.
- Each side of the drum was 8.00 inches (20.32cm) long (parallel to axis of drum) and 8.36 inches (21 23cm) wide.
- the corners of the drum had a radius of approximately 1-inch (2.54cm) forming a transition between each of the four sides.
- the tow was wound with a tension of 20 pounds (9.08 kg) and distilled water was added to the tow as it was placed on the drum to allow denser packing and to allow the tow to be frozen.
- the tows were wrapped at a spacing of 0.050 cm. After the drum was wrapped with ten layers of fibers, it was placed in the freezer at minus 17 °C for over two hours. The drum was then removed and additional water sprayed on the fiber surface, then it was placed back in the freezer for over 15 minutes.
- the second preform was placed so that its edge matched the free edge of the first piece.
- the seam between the two was rolled with a hand-held rubber roller to blend the edges together.
- the second preform was wrapped around and compacted like the first. This sequence was repeated until the lay-up was the full thickness (i.e., nine layers of preforms). This resulted in a final fiber volume percent in the finished composite portion of greater than 50 percent.
- the outer tube was slid over the inner tube to complete the preform assembly. It was critical that the inner tube/preform assembly remained frozen so that the outer tube could slide over without shaving off or disrupting the preform.
- One end of the inner tube was placed in a bath of liquid nitrogen during the assembly to ensure that the preforms remained frozen.
- a hydraulic press was used to press the outer tube down over the inner tube to ensure that the assembly process was straight and aligned (to prevent binding).
- the completed inner-tube/preform/outer-tube assembly was then placed in a drying oven at 100 °C for 2 hours followed by 1 hour at 200 °C to dry out the water.
- the assembly was then placed in a vacuum chamber and a vacuum of at least 10"4 Torr was applied.
- the assembly was then removed from the vacuum chamber, sealed in a plastic bag, and transferred to the pressure infiltration casting unit.
- the inner-tube/preform/outer-tube assembly Prior to placement in the casting unit, the inner-tube/preform/outer-tube assembly was placed inside a low-carbon steel tube with the bottom end sealed by welding in a 0.134 inch (0.34cm) thick carbon steel bottom.
- This low-carbon steel tube and bottom are referred to as the can.
- the 0.062 inch (0.16cm) diameter holes in the inner titanium tube were at the top of this assembly (opposite the bottom of the can).
- the joint between the steel tube and the steel bottom was air tight.
- the steel tube was 18.00 inches (45.72cm) long with a maximum inner diameter of 3.986 inches (10.12cm) and an outer diameter of 4.250 inches (10.80cm).
- the inner surface of the low carbon steel tube and bottom were painted with a protective coating to prevent a reaction between molten aluminum and the iron in the steel.
- the protective coating was a water-based colloidal graphite (Commercially available from Acheson Colloids Company under the trade designation "AQUADAG").
- the can with the titanium tubes and preform inside, was then placed into a pressure infiltration casting apparatus. In this apparatus, the tube was placed into an airtight vessel and positioned at the bottom of an evacuable chamber. Pieces of aluminum metal were loaded into the top of the can, on a support plate above the mold.
- the support plate was a 3.911 inch (9.93cm) diameter piece of graphite, one-quarter inch (0.64cm) thick.
- the power to the heaters was turned off, and the chamber was pressured by filling with argon to a pressure of 8.96 MPa (1300 psi).
- the molten aluminum immediately flowed through the holes in the support plate and into the mold.
- the temperature was allowed to drop to 600 °C before venting the chamber to the atmosphere.
- the assembly was removed from the chamber and the tube was removed from the can.
- the tube was examined by ultrasonic scanning radially at all points and was found to be intact (i.e., no disbonds were apparent between the titanium tubes and infiltrated composite).
- Example 2 Fabrication of a Tube with Titanium Nitride Coating Two more tubes were made as described in Example 2, except that the inner surfaces of the outer tubes and the outer surfaces of the inner tubes were coated with titanium nitride by reactive cathodic arc coating in order to reduce the reaction between the molten aluminum and the titanium alloy during processing. Satisfactory results were obtained using a coating thickness having a minimum on the order of approximately 1 micron.
- the titanium nitride coatings were applied by Vergason Technology Inc. (Van Ethen, NY).
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Abstract
Cette invention concerne une pièce qui est faite d'un métal ou d'un alliage de métaux, et qui est renforcée à l'aide d'un matériau composite matriciel métallique. Ces matériaux sont choisis de manière à ce que le métal ou l'alliage métallique dont est faite la pièce, soient différents du métal ou de l'alliage métallique utilisés pour la matrice du composite matriciel métallique. Cette invention concerne également un procédé de formation de telles pièces.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US61277496A | 1996-03-07 | 1996-03-07 | |
US08/612,774 | 1996-03-07 |
Publications (1)
Publication Number | Publication Date |
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WO1997033009A1 true WO1997033009A1 (fr) | 1997-09-12 |
Family
ID=24454609
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1997/003171 WO1997033009A1 (fr) | 1996-03-07 | 1997-02-28 | Titane renforce a l'aide d'un composite matriciel a base d'aluminium |
Country Status (1)
Country | Link |
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WO (1) | WO1997033009A1 (fr) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
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EP3991883A1 (fr) * | 2020-10-27 | 2022-05-04 | Safran | Procédé de fabrication d'une aube pour turbomachine |
EP3991882A1 (fr) * | 2020-10-27 | 2022-05-04 | Safran | Procédé de fabrication d'une aube pour turbomachine |
Citations (4)
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GB1309519A (en) * | 1971-03-17 | 1973-03-14 | Pfizer | Process for producing a clad reinforced composite |
US4053011A (en) * | 1975-09-22 | 1977-10-11 | E. I. Du Pont De Nemours And Company | Process for reinforcing aluminum alloy |
US4570316A (en) * | 1983-05-20 | 1986-02-18 | Nippon Piston Ring Co., Ltd. | Method for manufacturing a rotor for a rotary fluid pump |
EP0369931A1 (fr) * | 1988-11-10 | 1990-05-23 | Lanxide Technology Company, Lp. | Procédé pour la production de corps macrocomposites et les corps macrocomposites ainsi obtenus |
-
1997
- 1997-02-28 WO PCT/US1997/003171 patent/WO1997033009A1/fr active Application Filing
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB1309519A (en) * | 1971-03-17 | 1973-03-14 | Pfizer | Process for producing a clad reinforced composite |
US4053011A (en) * | 1975-09-22 | 1977-10-11 | E. I. Du Pont De Nemours And Company | Process for reinforcing aluminum alloy |
US4570316A (en) * | 1983-05-20 | 1986-02-18 | Nippon Piston Ring Co., Ltd. | Method for manufacturing a rotor for a rotary fluid pump |
EP0369931A1 (fr) * | 1988-11-10 | 1990-05-23 | Lanxide Technology Company, Lp. | Procédé pour la production de corps macrocomposites et les corps macrocomposites ainsi obtenus |
Cited By (8)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
EP3991883A1 (fr) * | 2020-10-27 | 2022-05-04 | Safran | Procédé de fabrication d'une aube pour turbomachine |
EP3991882A1 (fr) * | 2020-10-27 | 2022-05-04 | Safran | Procédé de fabrication d'une aube pour turbomachine |
WO2022090116A1 (fr) * | 2020-10-27 | 2022-05-05 | Safran | Procédé de fabrication d'une aube pour turbomachine |
WO2022090115A1 (fr) * | 2020-10-27 | 2022-05-05 | Safran | Procédé de fabrication d'une aube pour turbomachine |
CN116507436A (zh) * | 2020-10-27 | 2023-07-28 | 赛峰公司 | 用于制造涡轮发动机轮叶的方法 |
CN116635177A (zh) * | 2020-10-27 | 2023-08-22 | 赛峰公司 | 制造用于涡轮发动机的叶片的方法 |
US11980934B2 (en) | 2020-10-27 | 2024-05-14 | Safran | Method for manufacturing a turbine engine vane |
US12398645B2 (en) | 2020-10-27 | 2025-08-26 | Safran | Method for manufacturing a blade for a turbomachine |
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