ZTM陶瓷/纤维编织体微波连接及其弹性行为研究
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摘要
针对高温密封材料在现代工业和航天前沿领域的重要需求，利用ZTM（氧化锆增韧莫来石）致密陶瓷的气密与承载作用和铝硅纤维编织体的压缩-回弹特性，设计ZTM陶瓷/铝硅纤维编织体组合方式，获得了具有气密-热密综合功能的耐高温弹性密封组件。在基础材料制备和特性分析基础上，选择微波连接实现了耐温属性差异较大材料的可靠连接，进一步研究了连接组件在不同载荷和温度条件下的压缩-回弹规律，并对相关机理进行了分析。
采用粉体压制、常规烧结，制备了ZTM陶瓷基体，该材料具有随温度升高强度不降低的特性。选用体积分数为45%、编织角为45o的铝硅三维四向纤维编织体呈现压缩-回弹特性，该材料在980℃即开始析晶，在1000℃以下可以安全使用，超过1100℃，纤维将发生析晶、变形、收缩、熔融等结构和性能的改变。
利用微波选择性加热的特点，进行了耐温属性差异较大的ZTM陶瓷/纤维体的微波连接研究。通过对微米级粒径的Al-Si合金粉体微波的升温特性、氧化特性、物相分析的研究，设计了Al-Si合金、Al_2O_3、SiO_2和ZrO_2作为中间层组分的微波连接相材料，在2kW/60min微波处理条件下实现了ZTM陶瓷/铝硅纤维编织体的连接。
研究表明，Al-Si粉吸波能力强、熔融温度低，在微波处理条件下，迅速升温并且发生熔融，同时自身发生氧化反应，并与其它组分结合形成莫来石。微波反应过程中，中间层材料与ZTM发生传热、粘结、质点扩散，在较高温度下实现有效连接；而疏松结构铝硅纤维体，吸波能力相对较差，在950℃左右，熔融的Al-Si合金与纤维体界面的玻璃质纤维发生化学反应，实现了纤维体与中间层的低温连接。
研究了不同温度、载荷条件下组件的压缩回弹规律。结果表明：在0.1MPa压力下，组件在室温至600℃表现为弹性性能，可实现100%回弹；随压力增大，组件的高温回弹能力逐渐降低。在1MPa载荷、400℃以下组件仍可实现完全回弹，而1000℃时组件回弹率仅为30%。材料的压缩回弹机理表现为弹性回弹、滞弹性回弹和弹塑性回弹。获得了组件在不同温度条件下的极限载荷、不同压强条件的回弹特点和材料弹性失效机理，为组件在高温密封中的可靠应用提供了理论依据。
In order to meet the urgent requirements of high-temperature sealing materials inmodern industries and aerospace frontier field, an elastic sealing component withexcellent gas and thermal sealing functions at elevated temperatures was prepared bymicrowave joining the ZTM ceramics and alumina silica fiber braids, considering thegas sealing and bearing capacity of ZTM (zirconia toughened mullite) ceramics andcompressive and resilient properties of alumina silica fiber braids. Based on basicmaterials preparation and performance analysis, a high quality joining was realizedbetween ZTM and fiber braids in spite of their different temperature resistanceproperties. The compressive and resilient properties of joining components underdifferent loadings and temperatures were investigated, and the relative mechanismswere analyzed.
The ZTM ceramics prepared by pressing process and conventional sinteringrevealed an excellent high-temperature strength which did not decrease withtemperature increasing. The fiber braids with three dimensions, four directions,45%volume fraction and45oweaving angle used in this experiment presented excellentcompressive and resilient properties. It was showed that the crystallizationtemperature of the fiber braids was about980oC and the crystallization, deformation,shrinkage or fusion would happen over1100oC. Therefore, the components could beused safely below1000oC.
The process of microwave joining ZTM ceramics and fiber braids was studied.Through studying the temperature-rising characteristics, oxidization properties andphases analysis of micron level Al-Si alloy powders, an interface layer, includingpowders of Al-Si alloys、Al_2O_3、SiO_2and ZrO_2, was designed based on the microwaveselective heating characteristics. As a result, ZTM ceramics and fiber braids werejoined successfully with a microwave treating under2kW/60min.
The results showed that the Al-Si alloy powders were heated rapidly, melt, oxidized,and finally formed mullite with other components due to their strong absorbingmicrowave ability. The interlayer and ZTM ceramics were joined effectively at hightemperature by heat-transmission, bonding and particles diffusion. However, fiberbraids had a relatively loose structure and weak microwave-absorbing ability. They were joined to the interlayer at low temperature about950oC owing to the chemicalreaction between molten Al-Si alloys and vitreous fiber at fiber braids interface.
The compressive and resilient rules of component materials were studied underdifferent loads and temperatures. The results indicated that the materials were elasticunder0.1MPa between room temperature and600oC, and the resilient rates were100%. The resilience of materials at elevated temperature decreased with pressureincreasing. Under1MPa load, the materials were still full resilience below400oC,but the resilience-rate only retained30%at1000oC. The compressive and resilientmechanisms of joining materials were elastic resilience, anelasticity resilience andelastic-plastic resilience. The ultimate load at different temperatures, resiliencecharacteristics under different pressures, and elastic failure mechanism of materialswere analyzed, which provided a theory basis for the reliable application ofcomponent materials at elevated temperature.
采用粉体压制、常规烧结，制备了ZTM陶瓷基体，该材料具有随温度升高强度不降低的特性。选用体积分数为45%、编织角为45o的铝硅三维四向纤维编织体呈现压缩-回弹特性，该材料在980℃即开始析晶，在1000℃以下可以安全使用，超过1100℃，纤维将发生析晶、变形、收缩、熔融等结构和性能的改变。
利用微波选择性加热的特点，进行了耐温属性差异较大的ZTM陶瓷/纤维体的微波连接研究。通过对微米级粒径的Al-Si合金粉体微波的升温特性、氧化特性、物相分析的研究，设计了Al-Si合金、Al_2O_3、SiO_2和ZrO_2作为中间层组分的微波连接相材料，在2kW/60min微波处理条件下实现了ZTM陶瓷/铝硅纤维编织体的连接。
研究表明，Al-Si粉吸波能力强、熔融温度低，在微波处理条件下，迅速升温并且发生熔融，同时自身发生氧化反应，并与其它组分结合形成莫来石。微波反应过程中，中间层材料与ZTM发生传热、粘结、质点扩散，在较高温度下实现有效连接；而疏松结构铝硅纤维体，吸波能力相对较差，在950℃左右，熔融的Al-Si合金与纤维体界面的玻璃质纤维发生化学反应，实现了纤维体与中间层的低温连接。
研究了不同温度、载荷条件下组件的压缩回弹规律。结果表明：在0.1MPa压力下，组件在室温至600℃表现为弹性性能，可实现100%回弹；随压力增大，组件的高温回弹能力逐渐降低。在1MPa载荷、400℃以下组件仍可实现完全回弹，而1000℃时组件回弹率仅为30%。材料的压缩回弹机理表现为弹性回弹、滞弹性回弹和弹塑性回弹。获得了组件在不同温度条件下的极限载荷、不同压强条件的回弹特点和材料弹性失效机理，为组件在高温密封中的可靠应用提供了理论依据。
In order to meet the urgent requirements of high-temperature sealing materials inmodern industries and aerospace frontier field, an elastic sealing component withexcellent gas and thermal sealing functions at elevated temperatures was prepared bymicrowave joining the ZTM ceramics and alumina silica fiber braids, considering thegas sealing and bearing capacity of ZTM (zirconia toughened mullite) ceramics andcompressive and resilient properties of alumina silica fiber braids. Based on basicmaterials preparation and performance analysis, a high quality joining was realizedbetween ZTM and fiber braids in spite of their different temperature resistanceproperties. The compressive and resilient properties of joining components underdifferent loadings and temperatures were investigated, and the relative mechanismswere analyzed.
The ZTM ceramics prepared by pressing process and conventional sinteringrevealed an excellent high-temperature strength which did not decrease withtemperature increasing. The fiber braids with three dimensions, four directions,45%volume fraction and45oweaving angle used in this experiment presented excellentcompressive and resilient properties. It was showed that the crystallizationtemperature of the fiber braids was about980oC and the crystallization, deformation,shrinkage or fusion would happen over1100oC. Therefore, the components could beused safely below1000oC.
The process of microwave joining ZTM ceramics and fiber braids was studied.Through studying the temperature-rising characteristics, oxidization properties andphases analysis of micron level Al-Si alloy powders, an interface layer, includingpowders of Al-Si alloys、Al_2O_3、SiO_2and ZrO_2, was designed based on the microwaveselective heating characteristics. As a result, ZTM ceramics and fiber braids werejoined successfully with a microwave treating under2kW/60min.
The results showed that the Al-Si alloy powders were heated rapidly, melt, oxidized,and finally formed mullite with other components due to their strong absorbingmicrowave ability. The interlayer and ZTM ceramics were joined effectively at hightemperature by heat-transmission, bonding and particles diffusion. However, fiberbraids had a relatively loose structure and weak microwave-absorbing ability. They were joined to the interlayer at low temperature about950oC owing to the chemicalreaction between molten Al-Si alloys and vitreous fiber at fiber braids interface.
The compressive and resilient rules of component materials were studied underdifferent loads and temperatures. The results indicated that the materials were elasticunder0.1MPa between room temperature and600oC, and the resilient rates were100%. The resilience of materials at elevated temperature decreased with pressureincreasing. Under1MPa load, the materials were still full resilience below400oC,but the resilience-rate only retained30%at1000oC. The compressive and resilientmechanisms of joining materials were elastic resilience, anelasticity resilience andelastic-plastic resilience. The ultimate load at different temperatures, resiliencecharacteristics under different pressures, and elastic failure mechanism of materialswere analyzed, which provided a theory basis for the reliable application ofcomponent materials at elevated temperature.
引文
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