热塑性复合材料在线成型设备研究进展
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摘要
热压罐成型技术已经成为制备超大尺寸航天飞行器的技术瓶颈,在线成型技术成为非热压罐成型技术的研究重点。然而,在线成型技术制备的热塑性复合材料性能只能达到传统热压罐成型技术的80%。消除与热压罐成型复合材料性能20%差距的关键在于突破在线成型设备中热辅助铺放头的设计制造技术,从工艺装备方面消除或降低影响热塑性复合材料性能的不利因素。本文介绍了在线成型设备的研究和发展过程,比较了两种主流热辅助铺放头即燃气辅助铺放头和激光辅助铺放头的优势和劣势。结合前期的实验结果,提出了激光辅助铺放头的技术指标,并对国内在线成型设备的发展前景进行了展望。
Autoclave technologies are becoming the technical bottlenecks to manufacture very large aerospace crafts. On the other hand, on-line consolidation technologies are becoming the research priorities in the field of out-of autoclave process. However, the properties of the thermoplastic composites generated from the on-line consolidation technologies are 80% of the properties generated from the autoclave technologies. The solution to eliminate the 20% gap between the on-line consolidation and the autoclave technologies is making breakthroughs on manufacturing heat-assisted placement heads. As a result, we can eliminate or decrease the disadvantage effect on the properties of the thermoplastic composites from manufacturing sides. This paper introduced the researches and developments of the processing equipment for thermoplastic composites. We compared the advantages and disadvantages of the main heat-assisted placement heads, namely gas-assisted placement heads and laser-assisted placement heads. Based on the results from previous experiments, we proposed the technical indexes of the laser-assisted placement heads and then summed up the practical problems need to be solved for the on-line consolidation technologies.
Autoclave technologies are becoming the technical bottlenecks to manufacture very large aerospace crafts. On the other hand, on-line consolidation technologies are becoming the research priorities in the field of out-of autoclave process. However, the properties of the thermoplastic composites generated from the on-line consolidation technologies are 80% of the properties generated from the autoclave technologies. The solution to eliminate the 20% gap between the on-line consolidation and the autoclave technologies is making breakthroughs on manufacturing heat-assisted placement heads. As a result, we can eliminate or decrease the disadvantage effect on the properties of the thermoplastic composites from manufacturing sides. This paper introduced the researches and developments of the processing equipment for thermoplastic composites. We compared the advantages and disadvantages of the main heat-assisted placement heads, namely gas-assisted placement heads and laser-assisted placement heads. Based on the results from previous experiments, we proposed the technical indexes of the laser-assisted placement heads and then summed up the practical problems need to be solved for the on-line consolidation technologies.
引文
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[28] Lawrence J.A high power diode laser-based technique for the bonding of composite patches to aluminium alloys on various military aircraft[J].Journal of Laser Applications,2006,18(2):151-155.
[29] Stokes-Griffin C M,Compston P.In situ consolidation of thermoplastic prepreg tape using automated tape placement technology:potential and possibilities[J].Composites Part A,2015,75:104-115.
[30] Moore S G,Dillon A K.Fiber placement system and method with modulated laser scan heating:US 10016932[P/OL].2018-07-10[2018-08-22].http://www.freepatentsonline.com/10016932.html.
[31] Franz E.Laying head,fibre placement device and method:US 9772295[P/OL].2017-09-2[2018-08-22].http://www.freepatentsonline.com/9772295.html.
[32] Moore S G,Dillon A K,Burg A G.Laser-reflective compaction roller and associated fiber placement system and method:US20160332434[P/OL].2016-11-17[2018-08-22].http://www.freepatentsonline.com/y2016/0332434.html.
[33] Coiffier C C,Sibois H,Lefebure P.Future for high performance thermoplastic composites and aircraft helicopters[C]//Proceeding of JEC Composites.Paris:2005.
[34] Schledjewski R,Miaris A.Thermoplastic tape placement by means of diode laser heating[C]//International SAMPE Conference.Baltimore:2009.
[35] Schledjewski R.Thermoplastic tape placement process in-situ consolidation is reachable[J].Plastic Rubber Composite,2009,38(9-10):379-386.
[36] 唐邦铭.热塑性预浸带缠绕工艺参数及加热方式对成型质量及内应力的影响[J].复合材料学报,1999,16(2):21-28.
[37] 宋清华,肖军,文立伟,等.热塑性复合材料自动纤维铺放装备技术[J].复合材料学报,2016,33(6):1214-1222.
[38] 咸梦蝶,闫宝瑞,信春玲,等.热塑性复合材料自动铺放成型工艺[J].塑料,2017,46(5):66-80.
[39] 宋清华,肖军,文立伟,等.热塑性复合材料自动铺放过程中温度场研究[J].材料工程,2018,46 (1):83-91.
[40] 宋清华,肖军,文立伟,等.自动铺放成型热塑性复合材料的非等温结晶动力学研究[J].材料工程,2018,46(4):120-126.
[2] Tierney J,Gillespie J W JR.Modeling of heat transfer and void dynamics for the thermoplastic composite tow placement process[J].Journal of Composite Materials,2003,37(19):1745-1768.
[3] Hergenrother P M.The use,design,synthesis,and properties of high performance/high temperature resistant polymers:An overview[J].High Performance Polymers Journal,2003,15(1):3-45.
[4] 马全胜,王宝铭.复合材料用高性能热塑性树脂最新进展[J].玻璃钢/复合材料,2017(3):25-30.
[5] Matthias P C.On-line consolidation of thermoplastic composites[J].Journal of Thermoplastic Composite Materials,1998,16(5):433-455.
[6] Brulotte X G,Hubert P,Hojjati M.Aspects of in-situ consolidation of thermoplastic laminates manufactured by automated tape placement[C]//International SAMPE Conference.Long Beach:2011.
[7] Steeg M,Schledjewski R,Schlarb A K.Automation implementation and process development of thermoplastic tape placement for 3-dimensional parts[J].SAMPE Journal,2006,42(5):18-24.
[8] Nicodeau C,Cinquin J,Regnier G.In situ consolidation process optimization for thermoplastic matrix composites[C]//International SAMPE Conference.Long Beach:2006.
[9] Tierney J,Gillespie J W.Modeling of in situ strength development for the thermoplastic composite tow placement process[J].Journal of Composite Materials,2006,40(16):1487-1506.
[10] Lamontia M A,Gruber M B,Tierney J J.Modeling the accudyne thermoplastic in situ ATP process[C]//30th International SAMPE Europe Conference.Paris:2009.
[11] Qureshi Z,Swait T,Scaife R.In situ consolidation of thermoplastic prepreg tape using automated tape placement technology:potential and possibilities[J].Composites Part B,2014,66:255-267.
[12] Mazumdar S K,Hoa S V.Determination of manufacturing conditions for hot-gas-aided thermoplastic tape winding[J].Journal of Thermoplastic Composite Materials,1996,9(1):35-53.
[13] Yousefpour A,Hojjati M,Immarigeon J P.Fusion bonding/welding of thermoplastic composites[J].Journal of Thermoplastic Composite Materials,2004,17(4):303-341.
[14] Brzeski M,Holschuh R,Schledjewaki R.Effect of tool temperature on laminate properties during in situ consolidation placement process[C]//International SAMPE Conference.Seatle:2010.
[15] Lamontia M A.Heated head automated tape and ribbon placement and dry material forms development[R].Report to the Boeing Company and NASA-LaRC,submitted by Lamontia Technical Services,Purchase Contract JV9446,1999.
[16] Claudel S,Repellin A,Jaguenaud L.Advanced and affordable thermoplastic based composite tank for cryogenic fluid storage[C]//International SAMPE Conference.Seatle:2010.
[17] Mazundar S K,Hoa S V.Manufacturing of non-axisymmetric thermoplastic composite parts by tape winding technique[J].Advanced Manufacturing Processes,2012,10(1):47-56.
[18] Agarwal V,Mccullough R L,Schultz J M.The thermoplastic laser assisted consolidation process-mechanical and microstructure characterization[J].Journal of Thermoplastic Composite Materials,1996(9):365-380.
[19] Duley W W,Mueller R E.CO2 Laser welding of polymers[J].Polymer Engineering and Science,1992,32(9):582-585.
[20] Benatar A,Gutowski T G.A review of methods for fusion bonding thermoplastic composites[J].SAMPE Journal,1987,23:33-39.
[21] Bullock D E,Boyce J.On-line consolidation of thermoplastic matrix composite tape using ultrasonic heating[C]//International SAMPE Conference.Anaheim:1994.
[22] Labeas G N,Watiti V B,Katsiropoulos C V.Thermomechanical simulation of infrared heating diaphram forming process for thermoplastic parts[J].Journal of Thermoplastic Composite Materials,2008,21:353-370.
[23] Costa A P D,Botelho E C,Costa M L.A review of welding technologies for thermoplastic composites in aerospace applications[J].Journal of Aerospace Technology and Management,2012,4(3):255-265.
[24] Barer I D,Allaer K ,Jacques S.Interlaminar behavior of infrared welded joints of carbon fabric reinforced polyphenylene sulfide[J].Polymer Composites,2012,33(7):1105-1113.
[25] Phillips W M.Torch for welding thermoplastic material:U.S.2372737[P].1945-04-03.
[26] Howie I,Roderic D,Gillespie J W.Adjustable hot gas torch nozzle:US5626471[P/OL].1997-05-06[2018-08-22].http://www.freepatentsonline.com/5626471.html.
[27] Whitney J,William R.Hot gas thermoplastic welding apparatus:US3080910[P/OL].1963-03-12 [2018-08-22].http://www.freepatentsonline.com/3080910.html.
[28] Lawrence J.A high power diode laser-based technique for the bonding of composite patches to aluminium alloys on various military aircraft[J].Journal of Laser Applications,2006,18(2):151-155.
[29] Stokes-Griffin C M,Compston P.In situ consolidation of thermoplastic prepreg tape using automated tape placement technology:potential and possibilities[J].Composites Part A,2015,75:104-115.
[30] Moore S G,Dillon A K.Fiber placement system and method with modulated laser scan heating:US 10016932[P/OL].2018-07-10[2018-08-22].http://www.freepatentsonline.com/10016932.html.
[31] Franz E.Laying head,fibre placement device and method:US 9772295[P/OL].2017-09-2[2018-08-22].http://www.freepatentsonline.com/9772295.html.
[32] Moore S G,Dillon A K,Burg A G.Laser-reflective compaction roller and associated fiber placement system and method:US20160332434[P/OL].2016-11-17[2018-08-22].http://www.freepatentsonline.com/y2016/0332434.html.
[33] Coiffier C C,Sibois H,Lefebure P.Future for high performance thermoplastic composites and aircraft helicopters[C]//Proceeding of JEC Composites.Paris:2005.
[34] Schledjewski R,Miaris A.Thermoplastic tape placement by means of diode laser heating[C]//International SAMPE Conference.Baltimore:2009.
[35] Schledjewski R.Thermoplastic tape placement process in-situ consolidation is reachable[J].Plastic Rubber Composite,2009,38(9-10):379-386.
[36] 唐邦铭.热塑性预浸带缠绕工艺参数及加热方式对成型质量及内应力的影响[J].复合材料学报,1999,16(2):21-28.
[37] 宋清华,肖军,文立伟,等.热塑性复合材料自动纤维铺放装备技术[J].复合材料学报,2016,33(6):1214-1222.
[38] 咸梦蝶,闫宝瑞,信春玲,等.热塑性复合材料自动铺放成型工艺[J].塑料,2017,46(5):66-80.
[39] 宋清华,肖军,文立伟,等.热塑性复合材料自动铺放过程中温度场研究[J].材料工程,2018,46 (1):83-91.
[40] 宋清华,肖军,文立伟,等.自动铺放成型热塑性复合材料的非等温结晶动力学研究[J].材料工程,2018,46(4):120-126.