航空用铝锂合金结构选择性增强工艺与裂纹抑制机理研究
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摘要
摘要：现代民用客机日益向着大型化方向发展,安全、舒适、经济、环保成为飞机设计的基本要求。要达到经济、环保的要求,除了开发环保、高效的发动机外,飞机结构轻型化也是一个非常重要途径；在轻量化的同时,提高飞机构件的疲劳性能,对飞机的安全性起着决定性作用,各国科研工作者也一直致力于开发新型低密度材料及解决结构疲劳问题的研究。在结构设计方面,提出了许多新的飞机设计方法来提高结构安全性,在减轻结构重量的同时提高构件的疲劳寿命,选择性增强技术就是其中之一。
本文在国家大飞机专项重点项目“铝锂合金综合设计技术研究”的资助下,以新一代铝锂合金(Al-Li-S-4)为研究对象,开展了铝锂合金结构选择性增强工艺及裂纹抑制机理的研究。通过理论计算、实验研究及有限元仿真等方法,研究了铝锂合金连接(胶接)机理与胶接工艺,制备了铝锂合金选择性增强构件并开展了构件的内应力、裂纹扩展的实验及仿真研究,为大飞机的机身选择性增强结构设计、制造提供理论支持与工艺参数,以提高我国飞机设计制造水平。论文的主要研究内容及如下：
(1)在技术上突破了铝锂合金胶接性能的关键工艺：铝锂合金表面处理工艺,确定了最优的处理工艺参数。
通过正交实验的方法,对表面处理工艺进行了优化,使之适合铝锂合金。探索出该合金的最佳表面处理工艺,大大提高了该材料的胶接连接性能,为胶接连接的铝锂合金选择性增强结构提供制备工艺。
(2)基于边界层理论,利用商用有限元分析软件Marc.MSC建立混合失效的内聚力模型,对胶接边界应力奇异性进行了分析,提出了改进的胶接接头奇异点应力计算公式,对估算铝锂合金胶接接头端部的应力峰值提供了更为精确的计算方法；在此基础上,系统研究了铝锂合金胶接接头几何、物理参数(材料的厚度、接头长度、胶接剂的弹性模量、胶接剂厚度等)对接头内应力的影响,为选择性增强结构的胶接工艺改进提供理论上的支持。
(3)利用有限元方法,建立热残余应力模型,研究了铝锂合金选择性增强构件由于高温固化时产生的热残余应力大小及其影响区域。并采用理论计算、实验研究相结合的方法验证了建立的有限元模型的有效性。
(4)采用实验的方法研究了两种材料做增强板(钛合金、GLARE复合板)的选择性增强构件的裂纹扩展速率；并研究了不同几何尺寸的钛合金增强板对铝锂合金选择性增强结构试样裂纹扩展速率的影响；此外,对钛合金板螺栓与胶接混合增强构件的裂纹扩展速率做了研究；同时对增强材料与铝锂合金的匹配关系、连接方式做了初步的探讨,为选择性增强结构的设计方法提供了有效的参考。
(5)采用实验数据与有限元分析相结合的方法研究了裂纹尖端应力与裂纹扩展速率及裂纹长度之间的关联关系,揭示了选择性增强构件裂纹抑制机理；在经典疲劳裂纹扩展模型公式(Paris公式)的基础上,利用实验数据,改进了经典公式适用于铝锂合金选择性增强结构特征构件的疲劳裂纹扩展速率公式,并通过实验结果验证了该公式在预测选择性增强构件裂纹扩展速率的有效性。
Abstract:Modern aircraft is becoming large-scale device. Safety, comfort, pursuing aircraft reduction operating costs and environmental-friendly are the aims of designers. In order to reaching the goal, light-aircraft is one of important ways besides environmental-friendly and high-efficieny engineer. On the other hand, it becomes important that how to improve safety and fatigue property of aircraft. Researchers in the world are studying new lighter materials and fatigue of material since plane born at the beginning of the last century. A lot of design ideas were put up to improve fatigue life of structure. Selective reinforcement structure is one of important technologies.
This paper was funded through major project of state major project 'Research on the integrated design technology of aluminum lithium alloy'. Research work went on the crack inhibition mechanism of the aluminum lithium alloy by theoretical calculation, experiment and finite element simulation methods. The work is mainly including bonding technology, optimization of bonding methods and research of selective reinforcement structure, which including internal stress, crack propagation mechanism. This will offer the reference for aircraft structure design and manufacture of China. The main content includes:
(1) Key process of aluminum alloy bonding is broken through in technical field. The optimized parameters are determined to handle surface of the alloy.
Anodization process are optimized by orthogonal experimental method; The aim is to explore the best alloy surface treatment technology improving bonding properties to fit the alloy studied in paper; this will provide a process for selective reinforcement structure of aluminum lithium alloy.
(2) Cohesive zone model of mixed failure on the bonding specimens is founded by commercial analysis software MARC.MSC, basing on the boundary layer theory. Singularity of stress on the bonding edge of bonding sample are analyzed and put forward optimized formula to improve bonding joint stress calculation estimating the joint edge peak stress. On base of these analyses, parameters of material and dimension (thickness, length of overlap, elastic modulus and thickness of adhesive, and so on) were researched, all these work will provide useful reference for improving bonding process.
(3) Thermal residual stress of aluminum lithium alloy selective reinforcement structure during curing is studied by finite element model method, and theoretical calculation and experimental methods is used to verify the validity of the finite element method.
(4) Crack growth rate of aluminum lithium alloy selective reinforcement structure with two different reinforced patches (Titanium alloy and GLARE composite plate) under varied cyclical loading is studied. Effect on crack growth rate of reinforced plate dimensions of Ti alloy plates was researched. In addition, crack growth rate of selective reinforcement structure by titanium alloy bolted and bonding was studied. At the same time, preliminary study was carried out on the relationship of matching between aluminum alloy and reinforced plate, connective mode. All these work will provide effective reference to the selective reinforcement design.
(5) Experimental data and finite element method are used to study relationship between crack growth rate of crack, crack length and stress of crack tip in selective reinforcement strength structure in this paper. The mechanism of crack inhibition in reinforcement structure was revealed. A new formula was put forward based on the classical Paris formula which fit selective reinforcement structure fatigue crack propagation in this paper, using the method of experiment and finite element method, and validity of the predicting formula is verified by experimental results.
本文在国家大飞机专项重点项目“铝锂合金综合设计技术研究”的资助下,以新一代铝锂合金(Al-Li-S-4)为研究对象,开展了铝锂合金结构选择性增强工艺及裂纹抑制机理的研究。通过理论计算、实验研究及有限元仿真等方法,研究了铝锂合金连接(胶接)机理与胶接工艺,制备了铝锂合金选择性增强构件并开展了构件的内应力、裂纹扩展的实验及仿真研究,为大飞机的机身选择性增强结构设计、制造提供理论支持与工艺参数,以提高我国飞机设计制造水平。论文的主要研究内容及如下：
(1)在技术上突破了铝锂合金胶接性能的关键工艺：铝锂合金表面处理工艺,确定了最优的处理工艺参数。
通过正交实验的方法,对表面处理工艺进行了优化,使之适合铝锂合金。探索出该合金的最佳表面处理工艺,大大提高了该材料的胶接连接性能,为胶接连接的铝锂合金选择性增强结构提供制备工艺。
(2)基于边界层理论,利用商用有限元分析软件Marc.MSC建立混合失效的内聚力模型,对胶接边界应力奇异性进行了分析,提出了改进的胶接接头奇异点应力计算公式,对估算铝锂合金胶接接头端部的应力峰值提供了更为精确的计算方法；在此基础上,系统研究了铝锂合金胶接接头几何、物理参数(材料的厚度、接头长度、胶接剂的弹性模量、胶接剂厚度等)对接头内应力的影响,为选择性增强结构的胶接工艺改进提供理论上的支持。
(3)利用有限元方法,建立热残余应力模型,研究了铝锂合金选择性增强构件由于高温固化时产生的热残余应力大小及其影响区域。并采用理论计算、实验研究相结合的方法验证了建立的有限元模型的有效性。
(4)采用实验的方法研究了两种材料做增强板(钛合金、GLARE复合板)的选择性增强构件的裂纹扩展速率；并研究了不同几何尺寸的钛合金增强板对铝锂合金选择性增强结构试样裂纹扩展速率的影响；此外,对钛合金板螺栓与胶接混合增强构件的裂纹扩展速率做了研究；同时对增强材料与铝锂合金的匹配关系、连接方式做了初步的探讨,为选择性增强结构的设计方法提供了有效的参考。
(5)采用实验数据与有限元分析相结合的方法研究了裂纹尖端应力与裂纹扩展速率及裂纹长度之间的关联关系,揭示了选择性增强构件裂纹抑制机理；在经典疲劳裂纹扩展模型公式(Paris公式)的基础上,利用实验数据,改进了经典公式适用于铝锂合金选择性增强结构特征构件的疲劳裂纹扩展速率公式,并通过实验结果验证了该公式在预测选择性增强构件裂纹扩展速率的有效性。
Abstract:Modern aircraft is becoming large-scale device. Safety, comfort, pursuing aircraft reduction operating costs and environmental-friendly are the aims of designers. In order to reaching the goal, light-aircraft is one of important ways besides environmental-friendly and high-efficieny engineer. On the other hand, it becomes important that how to improve safety and fatigue property of aircraft. Researchers in the world are studying new lighter materials and fatigue of material since plane born at the beginning of the last century. A lot of design ideas were put up to improve fatigue life of structure. Selective reinforcement structure is one of important technologies.
This paper was funded through major project of state major project 'Research on the integrated design technology of aluminum lithium alloy'. Research work went on the crack inhibition mechanism of the aluminum lithium alloy by theoretical calculation, experiment and finite element simulation methods. The work is mainly including bonding technology, optimization of bonding methods and research of selective reinforcement structure, which including internal stress, crack propagation mechanism. This will offer the reference for aircraft structure design and manufacture of China. The main content includes:
(1) Key process of aluminum alloy bonding is broken through in technical field. The optimized parameters are determined to handle surface of the alloy.
Anodization process are optimized by orthogonal experimental method; The aim is to explore the best alloy surface treatment technology improving bonding properties to fit the alloy studied in paper; this will provide a process for selective reinforcement structure of aluminum lithium alloy.
(2) Cohesive zone model of mixed failure on the bonding specimens is founded by commercial analysis software MARC.MSC, basing on the boundary layer theory. Singularity of stress on the bonding edge of bonding sample are analyzed and put forward optimized formula to improve bonding joint stress calculation estimating the joint edge peak stress. On base of these analyses, parameters of material and dimension (thickness, length of overlap, elastic modulus and thickness of adhesive, and so on) were researched, all these work will provide useful reference for improving bonding process.
(3) Thermal residual stress of aluminum lithium alloy selective reinforcement structure during curing is studied by finite element model method, and theoretical calculation and experimental methods is used to verify the validity of the finite element method.
(4) Crack growth rate of aluminum lithium alloy selective reinforcement structure with two different reinforced patches (Titanium alloy and GLARE composite plate) under varied cyclical loading is studied. Effect on crack growth rate of reinforced plate dimensions of Ti alloy plates was researched. In addition, crack growth rate of selective reinforcement structure by titanium alloy bolted and bonding was studied. At the same time, preliminary study was carried out on the relationship of matching between aluminum alloy and reinforced plate, connective mode. All these work will provide effective reference to the selective reinforcement design.
(5) Experimental data and finite element method are used to study relationship between crack growth rate of crack, crack length and stress of crack tip in selective reinforcement strength structure in this paper. The mechanism of crack inhibition in reinforcement structure was revealed. A new formula was put forward based on the classical Paris formula which fit selective reinforcement structure fatigue crack propagation in this paper, using the method of experiment and finite element method, and validity of the predicting formula is verified by experimental results.
引文
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