CA2056789C - A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite material article - Google Patents

A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite material article

Info

Publication number
CA2056789C
CA2056789C CA002056789A CA2056789A CA2056789C CA 2056789 C CA2056789 C CA 2056789C CA 002056789 A CA002056789 A CA 002056789A CA 2056789 A CA2056789 A CA 2056789A CA 2056789 C CA2056789 C CA 2056789C
Authority
CA
Canada
Prior art keywords
yarn
fibers
discontinuous fibers
covering
covering yarn
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA002056789A
Other languages
French (fr)
Other versions
CA2056789A1 (en
Inventor
Pierre Olry
Dominique Coupe
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Safran Aircraft Engines SAS
Original Assignee
Societe Europeenne de Propulsion SEP SA
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Societe Europeenne de Propulsion SEP SA filed Critical Societe Europeenne de Propulsion SEP SA
Publication of CA2056789A1 publication Critical patent/CA2056789A1/en
Application granted granted Critical
Publication of CA2056789C publication Critical patent/CA2056789C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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Classifications

    • DTEXTILES; PAPER
    • D02YARNS; MECHANICAL FINISHING OF YARNS OR ROPES; WARPING OR BEAMING
    • D02GCRIMPING OR CURLING FIBRES, FILAMENTS, THREADS, OR YARNS; YARNS OR THREADS
    • D02G3/00Yarns or threads, e.g. fancy yarns; Processes or apparatus for the production thereof, not otherwise provided for
    • D02G3/02Yarns or threads characterised by the material or by the materials from which they are made
    • D02G3/16Yarns or threads made from mineral substances
    • D02G3/18Yarns or threads made from mineral substances from glass or the like

Abstract

A fibrous preform is formed from a yarn composed of long discontinuous fibers made of a refractory material or its precursor. the discontinuous fibers are disposed parallel to one another without twist, and theintegrity of the yarn is achieved by a covering yarn made of a fugitive material. The fibrous preform is intended to be densified by a matrix material for the manufacture of a composite material article. The covering yarn is eliminated before the preform is densified by the matrix material.

Description

2~678g A process for the n~nl-f~chlre of a fibrous preform formed of refractory fibers for producing a composite material article 1. Field of the Invention The invention relates to the m~nufacture of fibrous preforms fommed 5 of refractory fibers for producing composite material articles. The invention also relates to a composite yam suitable for the manufacture of such preforms.
Refractory fibers are understood to encompass carbon fibers and ceramic fibers. Among the latter are carbide, nitride or refractory oxide fibers, such as those made of silicon carbide or silicon nitride, or boron carbide, 10 alumina, etc..
Precursors of refractory fibers are understood to mean fibers in a state prior to a refractory state, the transition to the latter state usually being obtained by heat treatment. For example, a precursor of carbon would be pre-oxidized polyacrylonitrile (PAN), or pitch, while a precursor of silicon carbide1S would be polycarbosilane (PCS).
One particular application of the present invention is in the manufacture of composite material components composed of a refractory fibrous preform that is densified by a matrix. Densification consists in the deposition or infiltration of the matrix material into the porosity of the preform 20 throughout the volume thereof.
2. Prior art Various processes are known for obtaining a preform made of refractory fibers. One classical process consists in superposing plies composed of two-dimensional fibrous texture, usually a cloth, the plies being in some 25 cases bound together, e.g. by needling.
One difficulty encountered with known refractory fibers resides in their poor ability to undergo textile forming operation, such as weaving, notably in the case of ceramic fibers, and especially as regards needling.
One way of overcoming this difficulty consists in conducting all the 30 necessary textile-forming operations on yarns whose constituent fibcrs are inthe precursor state, where they are more apt to undergo these operations. The transformation of the precursor into a refractory material is thcn performed after carrying the textile operations.
Another way of overcoming this difficulty, when needling 35 superposed plies of a carbon fiber cloth, consists in interposing layers of felt 2 ~ 8 between the plies. When using a cloth formed from yarns in which the cohesion of the carbon fibers is ensured by twisting the penetration of the yams by the needling action has more the effect of breaking the fibers than detaching the fibers to allow implantation across the plies. Accordingly, the interposed felt s layers are provided to serve as a source of fibers capable of being drawn along by the needling action.
A further problem encountered in the manufacture of composite material articles concems the accessibility of the intemal pores of the preform during dcnsification.
Different densification techniques are known, such as resin dcnsification and chemical vapor deposition or infiltration.
Rcsin densification consists in impregnating the preform with a liquid containing a precursor of the material forming the matrix and then transforming thc precursor, usually through a heat treatment. Usually the 15 prccursor is a polymer which is cured and pyrolysed to obtain the matrix matcrial. Thc process including impregnation, curing and pyrolysis may be carricd out scveral times.
Chcmical vapor deposition or infiltration involves placing the prcform in an enclosure into which a gaseous flow is introduced under 20 prcdctcrmined temperature and pressure conditions. The gaseous flow thus forms thc matrix material upon contact with the fibers of the preform, though a dccomposition of one or several its constituents, or by a reaction between its constitucnts.
Whatever the technique used, it is impossible in practice to obtain a 25 complete densification of the preform. The reason is that some of the volumesthat the yarns define between themselves include "dead" volumes. These "dead" volumes cannot be densified, even if a chemical vapor infiltration process is used, their restricted access, if at all ~resent, becoming rapidly obtructed.
Summary of the invention with objects It is an object of an aspect of the present invention to provide a process for the manufacture of a fibrous prefol,-l of refractory fibers which may include the carrying out of different types of textile operations, including nee~ling.

~`

aos~78q It is an object of an aspect of the present invention to provide a process for the manufacture of fibrous prcfolllls having practically no "dead"
volumes and therefore capable of being easily densified.

Other aspects of this invention are as follows:

A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite m~ttori~l article, said process comprising the steps of:
providing a yarn comprising:
discontinuous fibers made of a refractory m~teri~l or a precursor thereof, with the discontinuous fibers being disposed parallel to one another, without twist, and a covering yarn made of a fugitive material over the discontinuous fibers to provide integrity to the yarn;
forming a fibrous plcfol-ll from said yarn composed of parallel discontinuous fibers and a covering yarn; and elimin~ting said covering yarn to allow said discontinuous fibers to loosen within the bulk of said prefoll".

A composite yarn comprising:
discontinuous fibers made of one of a refractory m~teri~l or precursor of said refractory m~teri~l, said discontinuous fibers being disposed in a parallel relationship without twist; and a covering yarn disposed over the discontinuous fibers to provide integrity to the composite yarn and made of a fugitive material, said covering yarn having a denier less than one tenth of a denier of the discontinuous fibers.

a~5G? 189 ,, ~
3a Preferably, the covering yam has a low denier compared with that of the assembly of discontinuous fibers in order not to leave too important voids within the preform after elimin~tion of the covering yam. The denier of the covcring-yam is preferably less than one tenth of that of the assembly of discontinuous fibers.
The covering yam is made of a fugitive material which is to be understood as encompassing any material capable of being eliminatcd without leaving any residue, and without causing an altcration of thc rcfractory fibcrs.For instance, the fugitive material can be a soluble polymcr, such as PVA
(polyvinyl alcohol), or a polymer capable of being totally eliminated by a heat treatment, such as polyvinyl acetate or polyethylene.
The step of providing a yam in the process according to thc invention involves obtaining discontinuous fibcrs, prcfcrably long discontinuous fibers, that are parallel to onc another and madc of a rcfractory material or a precursor thereof. Such a step may be achieved c.g. by controllcd stretch-brcaking of a multi-filament tow cable, as describcd in document FR-A-2 608 641, whcrcby fîbers having an average length of bctwccn 100 and 120 mm (about 4 to 5 inches) can be obtained.
In the aforementioncd document, the fibers are transformcd into a yam by a twist carried out on a standard spinning apparatus.
In contrast, the fibcrs that make up the yam used in the present invcntion are left parallel to each other, and not t~visted, the integrity of the yam -3~
4 2~5~189 being achieved by covering the fibers with a covering yam. This covering can be obtained by means of a known yam covering machine, such as the "Parafil"
machine produced by Spindelfabrik Suessen of Germany.
The covering of the yam provides the necessary resistance in view S of the textile operations, and weaving in particular.
After elimin~tion of the covering yam, the presence of discontinuous parallel fibers in an untwisted state allows the needling to be conducted by taking some of these fibers with the needles, without relying on a felt-like texture to provide the fibers susceptible of being drawn along by the needles.
Accordingly, the process according to the present invention may be used in all applications that require textile operations on the yarn, such as needling and weaving.
The process according to the invention has the added advantage of making it possible to eliminate the "dead" volumes that are not completely densifiable. Indeed, once the preform has been made and the covering yam elimin~ted, the loosened fibers have a tendency to occupy the available volumes as a result of a "swelling" of the yam. This enables the porosity of thepreform to be more easily and more uniformly accessible to the matrix material.
This results in a more complete densification and a reduced inhomogeneity of the composite material.
When the yam used for producing a preform is made of a precursor of the intended refractory material, the transformation of the precursor into a refractory material is conducted after the preform is produced and after 2s elimin~tion of the covering yam. When the covering yam is made of a material capable of being eliminated by heat, the elimin~tion can be obtained during a raising in temperature carried out in view of transforming the precursor by a heat treatment.
Detailed description of the preferred embodiments The specific examples explaining the manufacture of fibrous preforms according to the present invention that now follow are given purely as a non-limiting indication.
Example 1: Manufacture of a preform made of carbon fibers.
A two-dimensional (2D) texture is formed by weaving a yam made of non-twisted pre-oxidized PAN (polyacrylonitrile) fibers covered with a 2~7~

PVA (poly vinyl alcohol) yam. The characteristics of the 2D cloth are as follows:
- yield of the pre-oxidized PAN yarn :500 tex - yield of the PVA covering yam :45 dtex - weavingcontexture :8satin - count of warp directions :10/cm - count of weft directions :10/cm - weight :1050 g/m2 After weaving, the cloth is washed in a bath of water at 80-C for a period of 10 mn and then dried. The PVA covering yam is completely dissolved and the fibers forming the pre-oxidized PAN yam expand within the cloth, allowing the latter to be needled directly, without need for a felt layer.
Several layers are then superposed and needled to form a fibrous preform. The latter is then submitted to a thermal treatment (carbonisation) to transform the pre-oxidized PAN into carbon. A fibrous preform composed of carbon fibers is obtained. The above-described cloth makes it possible to obtain a needled preform in which the volume ratio of the carbon fibers is around 30% (percentage of the preform's apparent volume effectively occupied by the fibers).
The carbon fiber preform can then be densified by a material composing the matrix, such as carbon or ceramic, in order to produce the desired composite material article with a carbon fiber reinforcement. The densification is obtained by resin densification or by chemical vapor infiltration. The swelling of the yams within the fibrous texture, resulting from 2s the relaxation of the untwisted fibers after elimin~tion of the covering yam, prevents the formation of "dead" volumes within the preform and consequently contributes to a more complete and homogeneous densification.
Example 2: Manufacture of a preform made of ceramic fibers.
A texture is formed by a multi-layer weaving of a yam composed of untwisted silicon carbide (SiC) fibers covered with a PVA yam. The characteristics of the cloth are as follows:
- yield of the SiC yam :330 tex - yield of the PVA covering yarn :45 dtex - weaving contexture :Interlock 3s - number of layers : 5 6 ~os67as - count of warp directions : 40/cm - count of weft directions : 30/cm - thickness of cloth : 3 mm After weaving, the texture is soaked in a bath of water at 80-C for a 5 period of 15 mim1tes and then dried. It is observed that the PVA yarn is dissolved and that the SiC fibers expand within the texture. The fiber volume ratio of in the woven texture as indicated above is around 30%.
As explained with reference to example 1, the resulting texture is particularly suitable to be subsequently densified.
lo The invention is not limited to the above examples.
A preform made of carbon fibers may be manufactured starting directly from carbon fibers, including high strength carbon fibers.
Also, a preform made of ceramic fibers, such as SiC fibers may be manufactured starting from a SiC precursor, such as polycarbosilane (PCS).

Claims (11)

1. A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite material article, said process comprising the steps of:
providing a yarn comprising:
discontinuous fibers made of a refractory material or a precursor thereof, with the discontinuous fibers being disposed parallel to one another, without twist, and a covering yarn made of a fugitive material over the discontinuous fibers to provide integrity to the yarn;
forming a fibrous preform from said yarn composed of parallel discontinuous fibers and a covering yarn; and eliminating said covering yarn to allow said discontinuous fibers to loosen within the bulk of said preform.
2. A process according to Claim 1, wherein said covering yarn has a denier less than one tenth of that of the assembly of discontinuous fibers.
3. A process according to Claim 1, wherein the discontinuous fibers are obtained by a controlled stretch breaking process.
4. A process according to Claim 1, wherein said covering yarn is made of a soluble polymer.
5. A process according to Claim 1, wherein said covering yarn is made of a material capable of being eliminated by heat.
6. A process according to Claim 1, wherein said yarn is essentially composed of discontinuous fibers made of a precursor of a refractory material, and the transformation of said precursor into said refractory material is carried out after the step of eliminating said covering yarn.
7. A process according to Claim 1, further comprising a needling step carried out on said fibrous preform after the step of eliminating said covering yarn.
8. A composite yarn comprising:
discontinuous fibers made of one of a refractory material or precursor of said refractory material, said discontinuous fibers being disposed in a parallelrelationship without twist; and a covering yarn disposed over the discontinuous fibers to provide integrity to the composite yarn and made of a fugitive material, said covering yarn having a denier less than one tenth of a denier of the discontinuous fibers.
9. The composite yarn according to Claim 8, wherein said refractory material, is selected from carbon and ceramics.
10. The composite yarn according to Claim 8, wherein said fugitive material is a soluble polymer.
11. The composite yarn according to Claim 8, wherein said fugitive material is capable of being eliminated by heat.
CA002056789A 1990-12-03 1991-12-02 A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite material article Expired - Lifetime CA2056789C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR909015128A FR2669940B1 (en) 1990-12-03 1990-12-03 WIRE FORMED FROM REFRACTORY FIBERS OR PRECURSORS THEREOF AND ITS APPLICATION TO THE MANUFACTURE OF PARTS OF COMPOSITE MATERIAL.
FR15128 1990-12-03

Publications (2)

Publication Number Publication Date
CA2056789A1 CA2056789A1 (en) 1992-06-04
CA2056789C true CA2056789C (en) 1999-01-05

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Application Number Title Priority Date Filing Date
CA002056789A Expired - Lifetime CA2056789C (en) 1990-12-03 1991-12-02 A process for the manufacture of a fibrous preform formed of refractory fibers for producing a composite material article

Country Status (6)

Country Link
US (1) US5228175A (en)
EP (1) EP0489637B1 (en)
JP (1) JP2854178B2 (en)
CA (1) CA2056789C (en)
DE (1) DE69108530T2 (en)
FR (1) FR2669940B1 (en)

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EP0495570B1 (en) * 1991-01-16 1999-04-28 Sgl Carbon Composites, Inc. Silicon carbide fiber reinforced carbon composites
US6465100B1 (en) * 1993-06-15 2002-10-15 Alliant Techsystems Inc. Densification of composite preforms by liquid resin infiltration assisted by rigid-barrier actinic gelation
JP2755361B2 (en) * 1993-06-30 1998-05-20 徹 糸井 Method for manufacturing multiple woven fabrics
FR2734581B1 (en) * 1995-05-24 1997-08-14 Europ Propulsion HYBRID YARN FOR MANUFACTURING FIBROUS PREFORMS OF COMPOSITE MATERIAL PARTS AND PROCESS FOR PREPARING THE SAME
US5952075A (en) * 1997-09-08 1999-09-14 Fiberite, Inc. Needled near netshape carbon preforms having polar woven substrates and methods of producing same
US6248417B1 (en) * 1997-09-08 2001-06-19 Cytec Technology Corp. Needled near netshape carbon preforms having polar woven substrates and methods of producing same
FR2770233B1 (en) * 1997-10-27 2000-01-14 Messier Bugatti PROCESS FOR MANUFACTURING CARBON FIBER PREFORMS
DE10061028A1 (en) * 2000-12-08 2002-06-20 Eads Deutschland Gmbh Process for producing multilayer TFP preforms using fusible fixing threads
US6820406B2 (en) 2001-05-14 2004-11-23 Cargill, Incorporated Hybrid yarns which include plant bast fiber and thermoplastic fiber, reinforcement fabrics made with such yarns and thermoformable composites made with such yarns and reinforcement fabrics
US20030157323A1 (en) * 2001-05-14 2003-08-21 Mikhail Khavkine Hybrid yarns which include oil seed flax plant bast fiber and other fibers and fabrics made with such yarns
US6833399B2 (en) 2001-09-21 2004-12-21 Cargill, Limited Flowable flax bast fiber and flax shive blend useful as reinforcing agent
JP4568912B2 (en) * 2004-03-22 2010-10-27 株式会社クレハ Isotropic pitch-based carbon fiber spun yarn, composite yarn and fabric using the same, and production method thereof
FR2902802B1 (en) * 2006-06-21 2008-12-12 Snecma Propulsion Solide Sa FIBROUS REINFORCING STRUCTURE FOR A PIECE OF COMPOSITE MATERIAL AND PART COMPRISING THE SAME
PL2532775T3 (en) * 2011-06-07 2013-12-31 Climatex Ag Textile substrate of multiple different disposable and/or recyclable materials, use of such a textile substrate and method for processing such a textile substrate
US10648106B2 (en) * 2012-03-05 2020-05-12 Goodrich Corporation Systems and methods for reduced crimp carbon fiber helical fabric
ITUB20152386A1 (en) 2015-07-22 2017-01-22 Freni Brembo Spa SHAPED MATERIAL AND MANUFACTURING PROCEDURE
JP6652000B2 (en) * 2016-06-29 2020-02-19 株式会社豊田自動織機 Preform for fiber reinforced composite material and fiber reinforced composite material
JP6620771B2 (en) * 2017-02-08 2019-12-18 株式会社豊田自動織機 Fiber structure and fiber reinforced composite

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GB2021660B (en) * 1978-04-26 1982-09-22 Tba Industrial Products Ltd Cored staple-fibre yarns
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Also Published As

Publication number Publication date
DE69108530D1 (en) 1995-05-04
JPH0586534A (en) 1993-04-06
EP0489637B1 (en) 1995-03-29
FR2669940B1 (en) 1994-10-21
DE69108530T2 (en) 1995-12-21
CA2056789A1 (en) 1992-06-04
US5228175A (en) 1993-07-20
JP2854178B2 (en) 1999-02-03
FR2669940A1 (en) 1992-06-05
EP0489637A1 (en) 1992-06-10

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