复合材料与被修航空铝合金结构件的性能匹配性研究
|
摘要
本文采用碳纤维、碳-玻混杂纤维复合材料作为增强体，环氧树脂E-44作为基体，分别按照单向、正交和准各向同性三种不同的铺层方式制成复合材料作为补片材料，采用胶接固化工艺修补中心带孔的航空铝合金板，修补前对航空铝合金构件表面采取了刷涂KH-560硅烷偶联剂、浸涂KH-560硅烷偶联剂、刷涂KH-560后刷涂SY-D9防腐底胶三种不同的腐蚀防护方案。
利用激光导热仪、拉伸试验机与高分辨电子显微镜等检测手段研究了复合材料补片与被修补航空铝合金结构件的热匹配性、力学性能匹配性；观察了补片-铝合金界面腐蚀形貌，定性分析了腐蚀产物与腐蚀机理。以有限元分析为基础，通过力学性能测试，探讨了不同类型的复合材料补片对中心开孔铝合金板的修复效果。
研究结果表明(1)采用碳-玻混杂纤维复合材料(准各向同性铺层)作为补片胶接修补中心开孔的铝合金构件是可行的，与碳纤维复合材料相比，热膨胀系数由1.01×10~(-6)K~(-1)提高到3.41×10~(-6)K~(-1)，与铝合金热膨胀系数相差最小。承载能力恢复到完好板的80％，能满足胶接修补的需要。(2)采用碳纤维／环氧树脂复合材料修补铝合金结构件，在大气环境下，对修补件进行挂片试验，通过SEM,TEM,HRTEM分析表征，结果表明：在铝合金表面，沿着纤维轴向发生了较为严重的点蚀和缝隙腐蚀，腐蚀产物为氧化铝。(3)在铝合金表面刷涂硅烷偶联剂KH-560和SY-D9底胶能有效抑制铝合金表面的腐蚀，并且将疲劳寿命由未采取防腐措施的的6400次提高到20000次。
In this study, patch composite materials were fabricated through employing carbon fiber or carbon-glass fiber as reinforcement material and employing E-44 epoxy resin as matrix under three different plying models such as unidirection. orthotropic and quasi-isotropy. The aeronautic aluminium alloy components accompanyed with a inner hole were brushed coating or immersed coating with K.H-560 silane coupling agent, or SY-D9 adhesive followed by KH-560 to protect the metal surface from corrosion.
Laser thermo-conductor, high resolution TEM were used to investigate the thermo or mechnical matching between composite patch and aluminium alloy components.The interface inside the fixing region were observed directly by SEM or TEM and thereby the corrosion mechanism was analyzed. Under finite element programme, via examining the mechanical property, the repairing effect from different types of composite patchs on the aluminium sheets with a center hole were also studied.
It were shown that carbon mixed with glass fibers (under quasi-isotropy plying) used as patch to repair aluminium sheets with a center hole could meet the demond of bonding-repair.Compared with carbon fiber composite, the thermo-expansion coefficient was increased from 1.01×10-6K-1 to 3.41×10-6K-1, mostly approaching the thermo-expansion coefficient of aluminium alloy. It was found from the Cf/epoxy working at atmosphere examination, by SEM, TEM and HRTEM, that along axis dirction of the fiber dot corrision and aperture corrision cooured onside the skin of the aluminium sheet and the corrision product was aluminium oxide.
Coating KH560 silane coupling agent and SY-D9 adhesive onside the aluminium skin could effectly control the corrsion and increase the fatigue life-span from 6400
time to 20000 times.
利用激光导热仪、拉伸试验机与高分辨电子显微镜等检测手段研究了复合材料补片与被修补航空铝合金结构件的热匹配性、力学性能匹配性；观察了补片-铝合金界面腐蚀形貌，定性分析了腐蚀产物与腐蚀机理。以有限元分析为基础，通过力学性能测试，探讨了不同类型的复合材料补片对中心开孔铝合金板的修复效果。
研究结果表明(1)采用碳-玻混杂纤维复合材料(准各向同性铺层)作为补片胶接修补中心开孔的铝合金构件是可行的，与碳纤维复合材料相比，热膨胀系数由1.01×10~(-6)K~(-1)提高到3.41×10~(-6)K~(-1)，与铝合金热膨胀系数相差最小。承载能力恢复到完好板的80％，能满足胶接修补的需要。(2)采用碳纤维／环氧树脂复合材料修补铝合金结构件，在大气环境下，对修补件进行挂片试验，通过SEM,TEM,HRTEM分析表征，结果表明：在铝合金表面，沿着纤维轴向发生了较为严重的点蚀和缝隙腐蚀，腐蚀产物为氧化铝。(3)在铝合金表面刷涂硅烷偶联剂KH-560和SY-D9底胶能有效抑制铝合金表面的腐蚀，并且将疲劳寿命由未采取防腐措施的的6400次提高到20000次。
In this study, patch composite materials were fabricated through employing carbon fiber or carbon-glass fiber as reinforcement material and employing E-44 epoxy resin as matrix under three different plying models such as unidirection. orthotropic and quasi-isotropy. The aeronautic aluminium alloy components accompanyed with a inner hole were brushed coating or immersed coating with K.H-560 silane coupling agent, or SY-D9 adhesive followed by KH-560 to protect the metal surface from corrosion.
Laser thermo-conductor, high resolution TEM were used to investigate the thermo or mechnical matching between composite patch and aluminium alloy components.The interface inside the fixing region were observed directly by SEM or TEM and thereby the corrosion mechanism was analyzed. Under finite element programme, via examining the mechanical property, the repairing effect from different types of composite patchs on the aluminium sheets with a center hole were also studied.
It were shown that carbon mixed with glass fibers (under quasi-isotropy plying) used as patch to repair aluminium sheets with a center hole could meet the demond of bonding-repair.Compared with carbon fiber composite, the thermo-expansion coefficient was increased from 1.01×10-6K-1 to 3.41×10-6K-1, mostly approaching the thermo-expansion coefficient of aluminium alloy. It was found from the Cf/epoxy working at atmosphere examination, by SEM, TEM and HRTEM, that along axis dirction of the fiber dot corrision and aperture corrision cooured onside the skin of the aluminium sheet and the corrision product was aluminium oxide.
Coating KH560 silane coupling agent and SY-D9 adhesive onside the aluminium skin could effectly control the corrsion and increase the fatigue life-span from 6400
time to 20000 times.
引文
[1] Baker AA. Repair of cracked or defective metallic aircraft-components with advanced fibre composites±an overview of Australian work. Comp Structure 1984; 2:153±81.
[2] Baker A A. Fiber composite repair of cracked metallic aircraft component-practical and basic aspects [J]..Composites, 1987, 18(4): 293～307.
[3] Jones R, Callinan R J. Bonded repairs to surface flaws [A]. In: Proceedings of the sixth International Fracture Conference [C]. New Delhi, India: 1984, 3517～3522.
[4] 陈绍杰．复合材料研究与应用的概况．沈阳：航空工业部第六○一研究所，1986：8～9
[5] 陈绍杰等．复合材料结构修理指南．北京：航空工业出版社，2001：110～113。
[6] Turaga V.R.S. Umamaheswar, Ripudaman Singh. Modelling of a patch repair to a thin cracked sheet. Engineering Fracture Mechanics 62 (1999) 267±289
[7] A. Mahadesh Kumar, S.A. Hakeem. Optimum design of symmetric composite patch repair to centre cracked metallic sheet. Composite Structures 49 (2000):285～292.
[8] Mary A.Mahler. Bonded Composite repair of Composite Structures. Los Angeles, USA, 1999.
[9] 徐建新．损伤铝合金结构的复合材料胶接修补技术研究[D]．南京：南京航空航天大学，1996．
[10] 金观昌．电子错位散斑干涉术用于无损检测的探讨[J]．实验力学，1992，7
[11] 陈金根．复合材料制品的超声检测[J]．无损探伤，1995，6：1～8．
[12] Bossi RH, Coopride K K. X-ray computed tomography of composite [A]. In: Proc 36th International SAMPE Symp[C]. 1996: 224～239.
[13] Ferraro P, Stetson K A. On the holographic detection of core-to-skin disbonds in composite sandwich structures [J]. J Mater Eval, 1994, 61(12): 1376～1381.
[14] Qin Y W, Bao N K. Infrared thermography to its application in the NDT of
sandwich structures [J]. Optics and Laser in Eng, 1996, 21(2-3): 205～211
[15] 陈金龙．双材料界面粘接质量定量检测的相移错位散斑技术[J]．复合材料学报，2001，18(1)：128～130．
[16] Chiu WK, Galea SC, Koss LL, Rajic N. Damage detection in bonded repairs using PZT material. Smart Mater Structure, 1999
[17] L. Koh, et al. Smart-structure for composite repair. Composite Structure, 1999, 47:745～752.
[18] Erdogan F, Arin K. A sandwich plate with a part through and a debonding crack [J]. Engineer Fracture Mechanics, 1972, 4(2): 449～458.
[19] Rose L R F. An application of the inclusion analogy for bonded reinforcement [J]. Int Journal of Solids and Structures, 1981,17:827～838.
[20] Davis M J., Bond, D A. The Importance of Failure Mode Identification in Adhesive Bonded Aircraft Structures and Repairs, Proc. of ICCM12.
[21] Jones R, et al. Crack-patching: analysis and design [J]. J Sructure Mechanics, 1982, 10(2):177～190.
[22] Sun C T, Klug J, Arendt C. Analysis of cracked aluminum plates repaired with bonded composites patches [J]. AIAA Journal, 1996,34(2):369～374.
[23] 白金译．复合材料胶接修理参数优化分析．西北工业大学硕士论文，2000．
[24] Molent L, Callinan R J, Jones R. Design of an all boron/epoxy doubler reinforcement for the F-111 wing pivot fitting; structure aspects [J]. Composite Structure, 1989,11:57～83.
[25] Adhesive Bonded Patch Repair of Damaged Composite Laminate, Imperial College, London, 1996.
[26] 乔新主编．波音飞机复合材料结构修理教程．北京：中国民航出版社，1996．
[27] Ratwani M M, Kan H P, Fitagerald J H, et al. Experimental investigations of fiber composite reinforcement of cracked metallic structures [Z]. ASTM STP787, Philadelphia, USA: ASTM, 1982: 541～558.
[28] Sandow F A, Cannon R K. Composite repair of cracked aluminum alloy aircraft structure [R]. AD-A190514.
[29] Denny J J, Mall S. Characterization of disbond effects on fatigue crack growth
behavior in aluminum plate with bonded composite patch [J]. Engineering Fracture Mechanics, 1997,57(5): 507～525.
[30] M. Hunt. Electronic Packing[J]. Material Engineering, 1991, 108(2):25
[31] C. zwwbent. Metal matrix composites for electronic packing[J]. The Journal of the Minerals Metals Materials Society, 1992, 44(7):15-23
[32] Schapery. R. A. Thermal expension coefficients of composite Materials, 1968, 2:380-384
[33] Rosen. B. W. Hasin. Z. Effect thermal expansion coefficients and specific heats of composite materials[J]. J. Engineering Science, 1970, 8:157-173
[34] Alawi H, Saleh I E. Fatigue crack growth retardation by bonding patches [J]. Engineering Fracture Mechanics, 1992,42(5): 86
[35] Bogetti T A, Gillespie,Jr J W. Process-induced stress and deformation in thick-section thermoset composite laminates.Journal of Composite Materials, 1992,26(5):626～660
[36] Loos A C,Springer G S,Curing of epoxy matrix composites.Journal of Composite Materials, 1983,17:135～169
[37] Tsai S W. Coposites design(4 th Edition).Think Composites, 1988,Section 10:1～134
[38] 李顺林．复合材料力学引论．上海．海交通大学出版社，1986，161～172
[39] 航空航天部科学技术研究院，复合材料设计手册，北京：航空工业出版社，1990．36～141
[36] 李金桂主编 腐蚀和腐蚀控制手册 国防工业出版社306-309
[37] V.Subramanian and W.J.van Ooij. Corrosion, 1998, 54(3): 204
[38] Nie Tang. Modification of Polymer-Metal Interface for Corrosion Improvement, Ph. D Thesis, University of Cincinnati, 1996
[39] 廖子龙 底胶及与不同表面处理胶接接头的适应性[]“北京粘接学会第三届学术年会”1990
[40] L.T. Drzal, SAMPE J., 19(5), 7(1983)
[41] E.P. Plueddeman, Interface in Polymer Matrix Composites, Aademic Press, 1994
[42] G. Riess, M. Bourdeaux, B. Brie, C. Jouquet, Interional Conference on Carbon
Fibers, Their Place in Modem Technology, London, Paper, No.8, 1974
[43]J. Chang, J. P. Bell and R. Toseph, SAMPLE Q., 18(3),39(1987)
[44]R. V. Subramanian and A. S. Crasto, Poly. Comps.,9,3(1988)
[45]A. S. Crasto, S. H. Qwn and R. V. Subramanian, Poly, comps.,9,3(1988)
[46]Stltant. J. N, Mcgarry. F. J. Poly. Eng. Sci., 1973, 13:29
[47]Yee. SA. F., Pearson. R. A. J. Mater. Sci, 1986, 21.2462
[48]邢素丽，铝合金构件战伤的复合材料快速修补，国防科学技术大学研究生院学位论文，50
[2] Baker A A. Fiber composite repair of cracked metallic aircraft component-practical and basic aspects [J]..Composites, 1987, 18(4): 293～307.
[3] Jones R, Callinan R J. Bonded repairs to surface flaws [A]. In: Proceedings of the sixth International Fracture Conference [C]. New Delhi, India: 1984, 3517～3522.
[4] 陈绍杰．复合材料研究与应用的概况．沈阳：航空工业部第六○一研究所，1986：8～9
[5] 陈绍杰等．复合材料结构修理指南．北京：航空工业出版社，2001：110～113。
[6] Turaga V.R.S. Umamaheswar, Ripudaman Singh. Modelling of a patch repair to a thin cracked sheet. Engineering Fracture Mechanics 62 (1999) 267±289
[7] A. Mahadesh Kumar, S.A. Hakeem. Optimum design of symmetric composite patch repair to centre cracked metallic sheet. Composite Structures 49 (2000):285～292.
[8] Mary A.Mahler. Bonded Composite repair of Composite Structures. Los Angeles, USA, 1999.
[9] 徐建新．损伤铝合金结构的复合材料胶接修补技术研究[D]．南京：南京航空航天大学，1996．
[10] 金观昌．电子错位散斑干涉术用于无损检测的探讨[J]．实验力学，1992，7
[11] 陈金根．复合材料制品的超声检测[J]．无损探伤，1995，6：1～8．
[12] Bossi RH, Coopride K K. X-ray computed tomography of composite [A]. In: Proc 36th International SAMPE Symp[C]. 1996: 224～239.
[13] Ferraro P, Stetson K A. On the holographic detection of core-to-skin disbonds in composite sandwich structures [J]. J Mater Eval, 1994, 61(12): 1376～1381.
[14] Qin Y W, Bao N K. Infrared thermography to its application in the NDT of
sandwich structures [J]. Optics and Laser in Eng, 1996, 21(2-3): 205～211
[15] 陈金龙．双材料界面粘接质量定量检测的相移错位散斑技术[J]．复合材料学报，2001，18(1)：128～130．
[16] Chiu WK, Galea SC, Koss LL, Rajic N. Damage detection in bonded repairs using PZT material. Smart Mater Structure, 1999
[17] L. Koh, et al. Smart-structure for composite repair. Composite Structure, 1999, 47:745～752.
[18] Erdogan F, Arin K. A sandwich plate with a part through and a debonding crack [J]. Engineer Fracture Mechanics, 1972, 4(2): 449～458.
[19] Rose L R F. An application of the inclusion analogy for bonded reinforcement [J]. Int Journal of Solids and Structures, 1981,17:827～838.
[20] Davis M J., Bond, D A. The Importance of Failure Mode Identification in Adhesive Bonded Aircraft Structures and Repairs, Proc. of ICCM12.
[21] Jones R, et al. Crack-patching: analysis and design [J]. J Sructure Mechanics, 1982, 10(2):177～190.
[22] Sun C T, Klug J, Arendt C. Analysis of cracked aluminum plates repaired with bonded composites patches [J]. AIAA Journal, 1996,34(2):369～374.
[23] 白金译．复合材料胶接修理参数优化分析．西北工业大学硕士论文，2000．
[24] Molent L, Callinan R J, Jones R. Design of an all boron/epoxy doubler reinforcement for the F-111 wing pivot fitting; structure aspects [J]. Composite Structure, 1989,11:57～83.
[25] Adhesive Bonded Patch Repair of Damaged Composite Laminate, Imperial College, London, 1996.
[26] 乔新主编．波音飞机复合材料结构修理教程．北京：中国民航出版社，1996．
[27] Ratwani M M, Kan H P, Fitagerald J H, et al. Experimental investigations of fiber composite reinforcement of cracked metallic structures [Z]. ASTM STP787, Philadelphia, USA: ASTM, 1982: 541～558.
[28] Sandow F A, Cannon R K. Composite repair of cracked aluminum alloy aircraft structure [R]. AD-A190514.
[29] Denny J J, Mall S. Characterization of disbond effects on fatigue crack growth
behavior in aluminum plate with bonded composite patch [J]. Engineering Fracture Mechanics, 1997,57(5): 507～525.
[30] M. Hunt. Electronic Packing[J]. Material Engineering, 1991, 108(2):25
[31] C. zwwbent. Metal matrix composites for electronic packing[J]. The Journal of the Minerals Metals Materials Society, 1992, 44(7):15-23
[32] Schapery. R. A. Thermal expension coefficients of composite Materials, 1968, 2:380-384
[33] Rosen. B. W. Hasin. Z. Effect thermal expansion coefficients and specific heats of composite materials[J]. J. Engineering Science, 1970, 8:157-173
[34] Alawi H, Saleh I E. Fatigue crack growth retardation by bonding patches [J]. Engineering Fracture Mechanics, 1992,42(5): 86
[35] Bogetti T A, Gillespie,Jr J W. Process-induced stress and deformation in thick-section thermoset composite laminates.Journal of Composite Materials, 1992,26(5):626～660
[36] Loos A C,Springer G S,Curing of epoxy matrix composites.Journal of Composite Materials, 1983,17:135～169
[37] Tsai S W. Coposites design(4 th Edition).Think Composites, 1988,Section 10:1～134
[38] 李顺林．复合材料力学引论．上海．海交通大学出版社，1986，161～172
[39] 航空航天部科学技术研究院，复合材料设计手册，北京：航空工业出版社，1990．36～141
[36] 李金桂主编 腐蚀和腐蚀控制手册 国防工业出版社306-309
[37] V.Subramanian and W.J.van Ooij. Corrosion, 1998, 54(3): 204
[38] Nie Tang. Modification of Polymer-Metal Interface for Corrosion Improvement, Ph. D Thesis, University of Cincinnati, 1996
[39] 廖子龙 底胶及与不同表面处理胶接接头的适应性[]“北京粘接学会第三届学术年会”1990
[40] L.T. Drzal, SAMPE J., 19(5), 7(1983)
[41] E.P. Plueddeman, Interface in Polymer Matrix Composites, Aademic Press, 1994
[42] G. Riess, M. Bourdeaux, B. Brie, C. Jouquet, Interional Conference on Carbon
Fibers, Their Place in Modem Technology, London, Paper, No.8, 1974
[43]J. Chang, J. P. Bell and R. Toseph, SAMPLE Q., 18(3),39(1987)
[44]R. V. Subramanian and A. S. Crasto, Poly. Comps.,9,3(1988)
[45]A. S. Crasto, S. H. Qwn and R. V. Subramanian, Poly, comps.,9,3(1988)
[46]Stltant. J. N, Mcgarry. F. J. Poly. Eng. Sci., 1973, 13:29
[47]Yee. SA. F., Pearson. R. A. J. Mater. Sci, 1986, 21.2462
[48]邢素丽，铝合金构件战伤的复合材料快速修补，国防科学技术大学研究生院学位论文，50