Research progress and challenges in manufacturing fiber reinforced ceramic matrix composites using direct ink writing technology
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摘要: 先进陶瓷及其复合材料凭借优异的性能已被广泛应用于航空航天领域,目前采用三维打印技术实现这类材料的快速低成本制备成为核心问题。与传统工艺相比,现有三维打印陶瓷材料普遍面临着脆性特征明显及损伤容限能低的问题,因此纤维复合陶瓷材料的三维打印技术成为研究热点。综述了近年来国内外基于墨水直写技术制备纤维强韧陶瓷基复合材料的技术路线及特点,围绕这类材料的组成成分、工艺路径与力学性能的关系,综合分析了不同陶瓷墨水的设计、纤维引入的方式、致密化工艺的选择、打印构件关键性能之间的有机联系,指出了当前的主要问题并对未来研究方向进行了展望。Abstract: Advanced ceramics and composites have been widely used in aerospace applications because of their excellent performance, at present, the use of three-dimensional (3D) printing technology to achieve rapid, efficient, and low-cost preparation of such materials has become a central issue. Compared with the traditional process, the 3D printing of ceramic materials is generally faced with the problem of their inherent brittleness and low damage tolerance. Therefore, the incorporation of fiber reinforcements in printed parts to overcome the challenges of poor fracture toughness of advanced ceramics has become a hot topics and frontier. Here, we systematically summarize recently developed direct ink writing (DIW) technologies for printing fiber reinforced ceramic matrix composites (FRCMC), focus on the relationship between the processing, structure, and properties of DIW-FRCMCs, comprehensively analyze the ceramic ink design process, the fiber introduction method, the densification technologies and the important properties of the printed parts. In the last, the important issues were pointed out and future research directions were prospected.
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图 7 陶瓷先驱体墨水的DIW打印成型:(a) 打印工艺流程;(b) 打印结构的厚度变化;(c) PCS先驱体墨水黏度和剪切速率;(d) BPCS先驱体墨水黏度与剪切速率[27,40-41]
Figure 7. DIW printing molding of ceramic precursor ink: (a) printing process flow; (b) the thickness variation of the printing structure; (c) PCS precursor ink viscosity and shear rate; (d) viscosity and shear rate of BPCS precursor ink[27,40-41]
图 10 短切纤维复合材料的DIW打印成型:(a) 短切纤维体积分数和长度范围;(b) 分散剂对纤维分布影响;(c) 构件的尺寸偏差比;(d) 核壳结构复合长丝共同挤出示意图[16,19,36,40,47-48]
Figure 10. DIW printing forming of short cut fiber composite materials: (a) volume fraction and length range of short cut fibers; (b) the effect of dispersants on fiber distribution; (c) the dimensional deviation ratio of components; (d) schematic diagram of co-extrusion of core-shell structure composite filament[16,19,36,40,47-48]
图 11 DIW工艺中连续纤维的加入方式:(a) 连续纤维的表面上浆过程;(b) 斜插式喷嘴设计;(c) 折角式喷嘴设计;(d) 无折角喷嘴设计;(e) 超声辅助设计
Figure 11. Addition method of continuous fibers in DIW process: (a) surface sizing process of continuous fibers; (b) design of oblique insertion nozzle; (c) design of angled nozzles; (d) non angled nozzle design; (e) ultrasound assisted design
图 12 连续纤维复合材料的DIW打印成型:(a) 多核打印系统示意图;(b) 多核墨水的流速分布;(c) 螺杆旋转输运连续纤维;(d) 超声辅助纤维分离技术[20,35,51]
Figure 12. DIW printing molding of continuous fiber composite: (a) schematic diagram of multi-core printing system; (b) flow rate distribution of multi-core ink; (c) continuous fiber of screw rotation; (d) ultrasonic assisted fiber separation technology[20,35,51]
图 17 纤维强韧化机制:(a) 短切纤维核壳结构;(b) 高取向短切纤维裂纹扩展示意图;(c) 连续纤维核壳结构;(d) 连续纤维裂纹扩展示意图[20,36,47,52]
Figure 17. Fiber strong toughness mechanism: (a) short cut fiber core shell structure; (b) schematic diagram of high orientation short cut fiber crack expansion; (c) continuous fiber core shell structure; (d) schematic diagram of continuous fiber crack expansion[20,36,47,52]
表 1 DIW制造陶瓷/陶瓷复材研究中的构件性能
Table 1. The mechanical properties of ceramic composite materials manufacturing using the DIW technique
Ceramic phase Enhanced phase Slurry design Fiber extrusion
methodDensification
processFracture
toughness/
(MPa·m½)Bending
strength/MPaTensile
strength/MPaRef. SiC Ceramic powder Sintering 27.3 [27] SiC Continuous carbon fiber Ceramic powder Angle deviation Sintering 219 [35] SiC Short carbon fiber Ceramic powder Co-extrusion
17.5 vol%PIP 2.71 123 [36] PMSSQ Short carbon fiber Ceramic precursor Pre-impregnation
33 vol%Pyrolysis [40] Al2O3 Modified precursor Sintering 156.6 [45] SiC Short carbon fiber Ceramic powder Pre-impregnation
17.5 vol%CVI、LSI 5.82 274 [47] SiC Short carbon fiber Ceramic powder Pre-impregnation
20 vol%LSI、Carbonization 253.63 53.68 [48] SiC Continuous carbon fiber Ceramic powder No angle deviation PIP 3.77 146 [51] ZrB2
SiCContinuous carbon fiber Ceramic powder No angle deviation Low temperature hot pressing 10.04 388.3 [20] SiC Continuous carbon fiber Ceramic powder Angle deviation Sintering 232 [50] PCS Ceramic precursor PIP、CVI 129.7 [53] PCS Short silicon carbide fiber Ceramic precursor Pre-impregnation
10 vol%Pyrolysis 102.2 [19] ZrB2 Short carbon fiber Ceramic powder Fiber prefabricated
components
1 wt%CVI、SI、RMI [49] Notes: PMSSQ is Polymethylsilsesquioxane; PCS is Polycarbosilane; PIP is Precursor infiltration pyrolysis process; CVI is Chemical vapor infiltration process; LSI is Liquid silicon infiltration process; SI is Slurry impregnation process; RMI is Reactive melt infiltration process. -
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