碳/铝复合材料板带铸轧控制成型及力学行为研究
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摘要
碳纤维增强铝基复合材料轻质高强，在航空、航天、电子、汽车以及先进武器系统等领域得到了广泛应用。目前制备纤维增强铝基复合材料的方法有液态金属浸渍法、加压铸造法、扩散粘接法、粉末冶金法和超声波焊接法等。本论文提出了一种集液态浸渍、凝固和轧制于一体，浸润、凝固的同时承受轧制变形的碳纤维增强铝基复合材料板带铸轧控制成型方法，控制碳纤维与铝的结合状况，提高铝基复合材料板带的力学性能。
1、碳纤维与铝液间的浸润性及界面结合强度是得到高性能复合材料的前提条件。表面镀镍的碳纤维可以有效提高碳纤维与金属液间的浸润性，而且可以避免高温状态下金属铝与碳纤维发生界面反应，生成脆性相。为此，对碳纤维表面镀镍和镀镍碳纤维在高温下的力学性能进行研究，探究镍层对碳纤维力学性能的影响规律。研究结果表明：表面镀镍处理对碳纤维束的抗拉强度影响很小，镀镍碳纤维束可以保持原有碳纤维束的高拉伸强度；高温状态下镀镍碳纤维与氧发生反应，形成蜂窝状结构，导致抗拉强度减小。因而在碳/铝复合材料制备过程中，采取吹惰性气体进行保护，以避免高温时碳纤维与氧直接接触。利用自行设计的实验装置，制备了碳纤维包覆铝基复合材料，其最大抗拉强度达到1200MPa。
2、建立连续纤维与液态铝复合成型的多场耦合分析模型，探究铝液流动行为对纤维增强铝基复合材料成型过程的影响规律。首先，对镀镍碳纤维包覆铝基复合材料热型连铸过程进行数值模拟，得到拉坯速度和换热系数对热型连铸成型过程中铝液的温度场、凝固场和速度场的影响规律。结果表明：换热系数为4000W·m-2·K-1时，最大拉速为1.32m/min；当拉速为1.2m/min时，随着换热系数增大，同一点处的温度值逐渐下降，但当换热系数超过6000W·m-2·K-1时，温度下降的幅度变小。其次，对双向纤维增强铝基复合材料板带铸轧成型过程进行数值模拟，得到了拉速和换热系数对铝基复合材料板带铸轧成型过程的影响规律。结果表明：在铸轧区内，铝液温度快速下降，温度值快速达到固相线以下，流动速度变得很小；随着拉速增大，速度变化剧烈程度增大，铝液凝固速度变小，在同一点处的温度值增大，液相率增大；随着换热系数的增大，温度值逐渐减小，凝固速度加快，在同一点处的温度值逐渐减小，液相率逐渐降低。
3、建立了单向纤维增强和双向纤维增强复合材料的单胞模型，采用均匀化方法分别对单向纤维增强和双向纤维增强复合材料的等效弹性性能进行预测。首先，对玻璃/环氧单向纤维增强复合材料等效弹性性能进行预测，并与现有的计算结果比较，验证了均匀化方法预测单向纤维增强复合材料等效弹性性能的正确性。其次，采用均匀化方法，对不同纤维含量的单向碳纤维增强铝基复合材料的等效弹性性能进行预测，并对NASA经验公式进行修正，得到单向碳纤维增强铝基复合材料等效弹性性能的预测公式。最后，将单向碳纤维增强铝基复合材料的等效弹性常数作为双向碳纤维增强铝基复合材料单胞中纤维束的材料参数，采用均匀化方法预测双向纤维增强铝基复合材料的等效弹性性能。结果表明：随着纤维体积含量的增大，横向拉伸模量逐渐增大，剪切模量逐渐减小。
Carbon fiber reinforced aluminum matrix composite（sCFRAMC）, with thecharacteristics of light weight and high strength, have been widely used in thefields of aviation, aerospace, electronics, automobiles and advanced weaponsystems. At present, the preparation methods of fiber reinforced aluminummatrix composites include liquid metal impregnation method, pressure castingmethod, diffusion bonding method, powder metallurgy method and ultrasonicwelding method, etc.. A new controlled forming method is put forward. Itcombines the liquid dipping, solidification and rolling deformation, which canimprove the mechanical properties of aluminum matrix composite plate bycontrolling the binding condition between the carbon fiber and the aluminum.
The infiltration and interfacial bonding strength between carbon fiber andaluminum liquid are the precondition of gaining high performance composites.Carbon fiber with Ni coating can not only improve effectively the infiltrationbetween carbon fiber and metal fluid, but also avoid producing brittle phase dueto interface reaction between aluminum liquid and carbon fiber. Therefore, thenickel-plated on the surface of carbon fiber and the mechanical properties ofnickel-plated carbon fiber under the condition of high temperature are studied toexplore the effect of Nickel lay on carbon fiber’mechanical properties. Theresults show that the effect of nickel-plated surface treatment on the tensilestrength of the carbon fiber bundle is small, and carbon fiber bundles withNi-coating can maintain their high tensile strength of carbon fiber bundles.Under the high temperature, the carbon fiber reacts with oxygen, and formhoneycomb structure, which gradually decreases the tensile strength. Thus, inthe preparation process of CFRAMC, the way of blowing inert gas is adopted toensure that carbon fiber is isolated from oxygen. Then, the unidirectionalCFRAMC is prepared at the self-designed experimental apparatus, and itsmaximum tensile strength is up to1200MPa.
The multi-field coupling model of composite forming for continuous fiberand liquid aluminum is established to explore the effect of the flow behavior of liquid aluminum on fiber-reinforced aluminum matrix composites formingprocess. Firstly, the numerical simulations about heated mold continuous castingprocess of plated-nickel’ carbon fibers coated aluminum matrix have beenperformed. The effects of the casting speed and the heat transfer coefficient onthe temperature field, solidification field and velocity field of molten aluminumin the composites forming process are given. The results show when the heattransfer coefficient is4000W m-2K-1, the maximum casting speed is1.32m/min;at the casting speed of1.2m/min, the temperature decreases gradually at thesame point with the increase of the heat transfer coefficient, however, the changeof the temperature becomes smaller when the heat transfer coefficient exceeds6000W m-2K-1. Secondly, the numerical simulations about strip cast-rollingforming process of bi-directional fiber reinforced aluminum matrix compositeshave been performed. The effects of the casting speed and the heat transfercoefficient on strip cast-rolling forming process of aluminum matrix compositesare obtained. The results show that the temperature of the liquid aluminumdecreases rapidly, the temperature reaches quickly below the solid phasetemperature, and the flow velocity becomes small in the cast-rolling zone; withthe increase of the casting speed, the speed changes more violently, the rate ofsolidification of molten aluminum becomes small, and both the temperature andthe liquid phase ratio values increase gradually at the same point; with theincrease of the heat transfer coefficient, the temperature decreases gradually, therate of solidification of molten aluminum becomes faster, while the temperatureand the liquid phase ratio decrease gradually at the same point.
A unit cell models are set up for unidirectional fiber reinforced(UDFR) andbi-directional fiber reinforced(BDFR) composites. The equivalent elasticproperties of UDFR and BDFR composites are predicted respectively byhomogenization method. Firstly, the equivalent elastic properties of glass/epoxyUDFR composites are predicted. Through comparing with existing calculationresults, the correctness of this homogenization method is verified. Secondly, byhomogenization method, equivalent elastic properties of UDFR aluminummatrix composites are also predicted. Through revising NASA empirical formula, the predicting formula of unidirectional CFRAMC are gained. Finally,taking UDFR aluminum matrix composites equivalent elastic constants as thematerial parameters of the fiber bundles in BDFR aluminum matrix composite,the equivalent elastic properties of BDFR aluminum matrix composites arepredicted by homogenization method. The results show that with the increase ofthe fiber volume content, the transverse tensile modulus increase gradually andthe shear modulus decrease gradually.
1、碳纤维与铝液间的浸润性及界面结合强度是得到高性能复合材料的前提条件。表面镀镍的碳纤维可以有效提高碳纤维与金属液间的浸润性，而且可以避免高温状态下金属铝与碳纤维发生界面反应，生成脆性相。为此，对碳纤维表面镀镍和镀镍碳纤维在高温下的力学性能进行研究，探究镍层对碳纤维力学性能的影响规律。研究结果表明：表面镀镍处理对碳纤维束的抗拉强度影响很小，镀镍碳纤维束可以保持原有碳纤维束的高拉伸强度；高温状态下镀镍碳纤维与氧发生反应，形成蜂窝状结构，导致抗拉强度减小。因而在碳/铝复合材料制备过程中，采取吹惰性气体进行保护，以避免高温时碳纤维与氧直接接触。利用自行设计的实验装置，制备了碳纤维包覆铝基复合材料，其最大抗拉强度达到1200MPa。
2、建立连续纤维与液态铝复合成型的多场耦合分析模型，探究铝液流动行为对纤维增强铝基复合材料成型过程的影响规律。首先，对镀镍碳纤维包覆铝基复合材料热型连铸过程进行数值模拟，得到拉坯速度和换热系数对热型连铸成型过程中铝液的温度场、凝固场和速度场的影响规律。结果表明：换热系数为4000W·m-2·K-1时，最大拉速为1.32m/min；当拉速为1.2m/min时，随着换热系数增大，同一点处的温度值逐渐下降，但当换热系数超过6000W·m-2·K-1时，温度下降的幅度变小。其次，对双向纤维增强铝基复合材料板带铸轧成型过程进行数值模拟，得到了拉速和换热系数对铝基复合材料板带铸轧成型过程的影响规律。结果表明：在铸轧区内，铝液温度快速下降，温度值快速达到固相线以下，流动速度变得很小；随着拉速增大，速度变化剧烈程度增大，铝液凝固速度变小，在同一点处的温度值增大，液相率增大；随着换热系数的增大，温度值逐渐减小，凝固速度加快，在同一点处的温度值逐渐减小，液相率逐渐降低。
3、建立了单向纤维增强和双向纤维增强复合材料的单胞模型，采用均匀化方法分别对单向纤维增强和双向纤维增强复合材料的等效弹性性能进行预测。首先，对玻璃/环氧单向纤维增强复合材料等效弹性性能进行预测，并与现有的计算结果比较，验证了均匀化方法预测单向纤维增强复合材料等效弹性性能的正确性。其次，采用均匀化方法，对不同纤维含量的单向碳纤维增强铝基复合材料的等效弹性性能进行预测，并对NASA经验公式进行修正，得到单向碳纤维增强铝基复合材料等效弹性性能的预测公式。最后，将单向碳纤维增强铝基复合材料的等效弹性常数作为双向碳纤维增强铝基复合材料单胞中纤维束的材料参数，采用均匀化方法预测双向纤维增强铝基复合材料的等效弹性性能。结果表明：随着纤维体积含量的增大，横向拉伸模量逐渐增大，剪切模量逐渐减小。
Carbon fiber reinforced aluminum matrix composite（sCFRAMC）, with thecharacteristics of light weight and high strength, have been widely used in thefields of aviation, aerospace, electronics, automobiles and advanced weaponsystems. At present, the preparation methods of fiber reinforced aluminummatrix composites include liquid metal impregnation method, pressure castingmethod, diffusion bonding method, powder metallurgy method and ultrasonicwelding method, etc.. A new controlled forming method is put forward. Itcombines the liquid dipping, solidification and rolling deformation, which canimprove the mechanical properties of aluminum matrix composite plate bycontrolling the binding condition between the carbon fiber and the aluminum.
The infiltration and interfacial bonding strength between carbon fiber andaluminum liquid are the precondition of gaining high performance composites.Carbon fiber with Ni coating can not only improve effectively the infiltrationbetween carbon fiber and metal fluid, but also avoid producing brittle phase dueto interface reaction between aluminum liquid and carbon fiber. Therefore, thenickel-plated on the surface of carbon fiber and the mechanical properties ofnickel-plated carbon fiber under the condition of high temperature are studied toexplore the effect of Nickel lay on carbon fiber’mechanical properties. Theresults show that the effect of nickel-plated surface treatment on the tensilestrength of the carbon fiber bundle is small, and carbon fiber bundles withNi-coating can maintain their high tensile strength of carbon fiber bundles.Under the high temperature, the carbon fiber reacts with oxygen, and formhoneycomb structure, which gradually decreases the tensile strength. Thus, inthe preparation process of CFRAMC, the way of blowing inert gas is adopted toensure that carbon fiber is isolated from oxygen. Then, the unidirectionalCFRAMC is prepared at the self-designed experimental apparatus, and itsmaximum tensile strength is up to1200MPa.
The multi-field coupling model of composite forming for continuous fiberand liquid aluminum is established to explore the effect of the flow behavior of liquid aluminum on fiber-reinforced aluminum matrix composites formingprocess. Firstly, the numerical simulations about heated mold continuous castingprocess of plated-nickel’ carbon fibers coated aluminum matrix have beenperformed. The effects of the casting speed and the heat transfer coefficient onthe temperature field, solidification field and velocity field of molten aluminumin the composites forming process are given. The results show when the heattransfer coefficient is4000W m-2K-1, the maximum casting speed is1.32m/min;at the casting speed of1.2m/min, the temperature decreases gradually at thesame point with the increase of the heat transfer coefficient, however, the changeof the temperature becomes smaller when the heat transfer coefficient exceeds6000W m-2K-1. Secondly, the numerical simulations about strip cast-rollingforming process of bi-directional fiber reinforced aluminum matrix compositeshave been performed. The effects of the casting speed and the heat transfercoefficient on strip cast-rolling forming process of aluminum matrix compositesare obtained. The results show that the temperature of the liquid aluminumdecreases rapidly, the temperature reaches quickly below the solid phasetemperature, and the flow velocity becomes small in the cast-rolling zone; withthe increase of the casting speed, the speed changes more violently, the rate ofsolidification of molten aluminum becomes small, and both the temperature andthe liquid phase ratio values increase gradually at the same point; with theincrease of the heat transfer coefficient, the temperature decreases gradually, therate of solidification of molten aluminum becomes faster, while the temperatureand the liquid phase ratio decrease gradually at the same point.
A unit cell models are set up for unidirectional fiber reinforced(UDFR) andbi-directional fiber reinforced(BDFR) composites. The equivalent elasticproperties of UDFR and BDFR composites are predicted respectively byhomogenization method. Firstly, the equivalent elastic properties of glass/epoxyUDFR composites are predicted. Through comparing with existing calculationresults, the correctness of this homogenization method is verified. Secondly, byhomogenization method, equivalent elastic properties of UDFR aluminummatrix composites are also predicted. Through revising NASA empirical formula, the predicting formula of unidirectional CFRAMC are gained. Finally,taking UDFR aluminum matrix composites equivalent elastic constants as thematerial parameters of the fiber bundles in BDFR aluminum matrix composite,the equivalent elastic properties of BDFR aluminum matrix composites arepredicted by homogenization method. The results show that with the increase ofthe fiber volume content, the transverse tensile modulus increase gradually andthe shear modulus decrease gradually.
引文
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