مهندسی مکانیک مدرس

مهندسی مکانیک مدرس

بهینه‌سازی چالش‌های ساخت قطعات خام کامپوزیت SiC-Al2O3-YSZ در فرآیند پرس‌گرم خوراک سرامیکی

نوع مقاله : مقاله پژوهشی

نویسندگان
دانشکده مهندسی مکانیک و انرژی، دانشگاه شهید بهشتی، تهران، تهران
چکیده
کاربید سیلیسیوم به‏دلیل ویژگی‌های استثنایی خود در اشکال خالص و کامپوزیتی اهمیت حیاتی دارد، اما ساخت قطعات سرامیکی مبتنی بر آن همچنان با چالش‌هایی روبه‌رو است. این پژوهش با هدف غلبه بر این موانع، به بررسی و بهینه‌سازی فرآیند ترکیبی «قالب‏گیری پرس‌گرم خوراک سرامیکی» که تلفیقی از پرس‌گرم تک‌جهته و قالب‌گیری تزریقی است، می‏پردازد. با ترکیب دو روش فوق، استفاده از مواد اولیه SiC، Al2O3، YSZ و چسب پلیمری، چالش‌های ساخت قطعه خام کامپوزیتی شناسایی و راهکارهای مؤثر ارائه شده ‏است. طراحی قالب دارای پیچ‌های هدایت‌شونده، پوشش‌دهی دو مرحله‌ای و آماده‌سازی پودر خوراک با دستگاه خردکن، مراحل کلیدی بودند. با بهره‌گیری از روش طراحی آزمایش، شرایط بهینه فرآیند برمبنای متغیرهای دما، فشار و زمان پرس تعیین گردید. نتایج نشان داد که دما به‌عنوان عامل اصلی، با کنترل رفتار رئولوژیکی چسب و تسهیل بازآرایی ذرات، بیشترین تأثیر را بر تراکم و سختی قطعه دارد. داده‏های آزمون سختی نشان داد بهترین شرایط برای انجام پرس‏گرم، اعمال دمای °C۱۲۰ ، فشار bar ۱۸۵ و زمان min ۲۷ است. بررسی ریزساختار نیز یکنواختی توزیع تقویت‌کننده و انسجام ناشی از چسب را در شرایط بهینه تأیید می‌کند. همچنین تحلیل اندازه ذرات (دامنه توزیع: 37/1 میکرومتر؛ شیب توزیع: 96/3) حاکی از مناسب بودن این پودر برای فرآیند قالب‌گیری است.
کلیدواژه‌ها
موضوعات

عنوان مقاله English

Optimization Challenges in Manufacturing SiC-Al2O3-YSZ Composite Green Parts via Ceramic-Feedstock Warm Pressing Process

نویسندگان English

Mohammad Keshavarzi
عسل حسینی منزه
Faculty of Mechanical and Energy Engineering, Shahid Beheshti University, Tehran, Iran
چکیده English

This research presents an investigation into the optimization of ceramic-feedstock warm-pressing for the fabrication of SiC-based composites. The process integrates uniaxial warm-pressing with injection molding, employing SiC, Al2O3, YSZ, and a polymer binder. Critical challenges encountered during green body production were meticulously identified, leading to the proposal of effective solutions. Significant process advancements involved designing a mold with guide screws, implementing a dual-stage coating technique, and utilizing a pulverizer for feedstock powder preparation. Through Design of Experiments (DOE), the optimal warm-pressing parameters were determined, revealing that temperature is the primary factor controlling the binder’s rheological behavior and facilitating particle rearrangement. Hardness test data indicated that the optimal conditions for warm-pressing were 120°C, 185 bar, and 27 minutes. Microstructural examination corroborated the uniform distribution of reinforcements and the cohesive strength imparted by the binder. Furthermore, particle size analysis (distribution range: 1.37 μm; distribution slope: 3.96) indicates the suitability of this powder for the molding process.

کلیدواژه‌ها English

Silicon Carbide Feedstock
Ceramic Composite
Uniaxial Warm-Pressing
Molding
Design of Experiments (DOE)
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