Preparation and properties of high specific strength carbon/carbon composites based on carbon fiber/carbon foam preforms
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摘要: 碳/碳复合材料以其优异的性能广泛应用于航空航天、武器装备等领域，但碳纤维预制体成本高等因素限制了碳/碳复合材料的发展。碳泡沫具有三维网状结构，其韧带表现出与碳纤维相似的性质，可以作为增强相制备新型碳/碳复合材料。本文以酚醛树脂作为碳源，NaCl作为造孔剂，制备出不同碳纤维体积含量(0vol%、1vol%、3vol%、5vol%、7vol%)的碳泡沫作为碳/碳复合材料预制体，利用热梯度化学气相渗积(TG-CVI)快速致密化技术制备碳/碳复合材料，考察了碳纤维含量对碳纤维/碳泡沫预制体及其致密化后密度、微观结构和力学性能的影响。结果表明，随着碳纤维含量的增加，碳纤维/碳泡沫预制体中的微裂纹数量显增加，密度由0.51 g/cm3逐渐降低至0.31 g/cm3，抗压强度由51.30 MPa下降至1.30 MPa，抗弯强度由42.53 MPa下降至6.32 MPa。致密化之后碳/碳复合材料抗压强度与抗弯强度显著提升，最高分别为183.67 MPa和123.46 MPa，其密度为1.09 g/cm3，因此具有高比强度。致密化后复合材料的热导率从0.298 W/(m·K)(致密化前)增大到2.484 W/(m·K)，提升了734%，这是由于致密化后碳纤维与热解碳形成了三维导热网络。Abstract: Carbon/carbon composites has been widely used in aerospace, weaponry and other fields with their excellent properties. However, the development of carbon/carbon composites has been limited by the high cost of carbon fiber preforms. Carbon foam has a three-dimensional network structure, and its ligaments show similar properties to carbon fibers, which can be used as the reinforcing phase to prepare carbon/carbon composites. In this paper, carbon foams with different carbon fiber volume contents (0vol%, 1vol%, 3vol%, 5vol%, 7vol%) were prepared as carbon/carbon composites preforms by using phenolic resin as the carbon source and NaCl as the pore-forming agent, and the carbon/carbon composites were prepared by using the rapid densification technique of thermal gradient chemical vapour infiltration (TG-CVI), which investigated the effects of carbon fiber content on the carbon fiber/carbon foam preform and its density, microstructure and mechanical properties after densification. The effects of carbon fiber content on the density, microstructure and mechanical properties of the carbon fiber/carbon foam preform and its densification were investigated. The results showed that with the increase of carbon fiber content, the number of microcracks in the carbon fiber/carbon foam precast body increased significantly, the density gradually decreased from 0.51 g/cm3 to 0.31 g/cm3, and the compressive strength decreased from 51.30 MPa to 1.30 MPa, flexural strength decreased from 42.53 MPa to 6.32 MPa. The compressive and flexural strengths of the carbon/carbon composites were significantly increased after densification, up to 183.67 MPa and 123.46 MPa, respectively, while the density was 1.09 g/cm3, resulting in high specific strength. The thermal conductivity of the composites increased from 0.298 W/(m·K) (before densification) to 2.484 W/(m·K), an increase of 734%, which was attributed to the formation of a three-dimensional thermal conductivity network between the carbon fibers and pyrolytic carbon after densification.
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图 2 碳纤维/碳泡沫致密化前后微观形貌SEM图像
Figure 2. SEM images of carbon fiber/carbon foam before and after densification
图 3 碳纤维/碳泡沫致密化前后XRD图谱
Figure 3. XRD pattern of carbon fiber/carbon foam before and after densification
图 4 碳纤维/碳泡沫致密化前后的拉曼图谱
Figure 4. Raman pattern of carbon fiber/carbon foam before and after densification
图 5 碳纤维/碳泡沫致密化前后的密度和抗弯强度
Figure 5. Density and flexural strength of carbon fiber/carbon foam before and after densification
图 6 碳纤维/碳泡沫致密化前后的密度、抗弯强度与比压缩强度
Figure 6. Density, compressive strength and specific compressive strength of carbon fiber/carbon foam before and after densification
图 7 碳纤维/碳泡沫致密化前后应力-应变曲线图
Figure 7. Stress-strain curves of carbon fiber/carbon foam before and after densification
图 8 碳纤维/碳泡沫致密化前后压缩断口形貌
Figure 8. SEM images of compression sections of carbon fiber/carbon foam before and after densification
图 9 碳纤维/碳泡沫致密化前后的热导率
Figure 9. Thermal conductivity of carbon fiber/carbon foam before and after densification;
表 1 碳纤维/碳泡沫致密化前的密度、残碳率与体积收缩率
Table 1. Density, residual carbon rate and volume shrinkage of carbon fiber/carbon foam before deposition
Sample CF CF1%Cf CF3%Cf CF5%Cf CF7%Cf Density/(g·cm−3) 0.51 0.59 0.46 0.42 0.31 Residual carbon rate/% 49.1 50.3 52.1 54.7 56.8 Volume shrinkage/% 46.3 42.1 22.8 18.4 13.7 
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