摘要
先进复合材料(Advanced Composite Materials, ACMs)由于其自身优异的比强度、比模量和抗腐蚀、抗磨、抗疲劳等性能,已经成为飞机的四大结构用材料之一。但在复合材料固化成型过程中,因为增强纤维和树脂的热膨胀系数的不匹配性以及树脂聚合反应等原因,往往在复合材料中容易产生固化残余应力,而固化残余应力会明显降低复合材料的性能并增大其组装的困难,因此高效的无损检测技术监测复合材料的固化过程显得特别重要,同时内置传感器对复合材料的结构健康状态进行实时监测也是复合材料结构无损检测技术的重要发展趋势。在众多传感器中,布拉格光栅(Fiber Bragg Grating, FBG)传感器作为一种抗磁、抗电性能优越的传感器,对材料最小扰动的方式被置入到复合材料中,从而监测碳纤维预浸料的整个热压罐固化成型过程。
本论文首先对FBG传感器的应力灵敏系数、温度灵敏系数以及在高低温度下的热稳定性等性能都做了全面细致地研究工作,结果表明,具有不同中心波长的FBG传感器的应力灵敏系数、温度灵敏系数和在高低温下的热稳定性都较相近,并与理论分析值基本一致。当将含金属套管的FBG传感器和裸栅FBG传感器同时置于环氧树脂中,从两根FBG传感器的信号图中不仅能够很容易地辨别出树脂固化反应的凝胶点和玻璃化转变温度出现的时间,还能计算出固化反应的放热量和冷却后的固化收缩量,并且还发现固化过程中的热释放过程是一个极其缓慢的过程。
随后在单向层合板热压罐的固化工艺中,针对能够影响固化残余应力大小的第二升温时间、第二保温时间、冷却方式、固化压力和泄压温度等五个不同的固化工艺条件设计出了田口正交试验,并同时将FBG传感器埋置在预浸料的中间层以便对固化的全过程进行监测。将得到的正交试验结果经过田口软件分析,找出了固化试验中的重要因子以及它们之间的交互作用。随后设计出的重要因子间的优化试验,找到了适合本固化试验的最佳固化工艺条件和-6.49MPa最小的固化残余应力,发现不同的固化工艺条件对固化残余应力有着显著的影响,而即使埋置在同一铺层间不同方向上的两个FBG传感器也展示出了完全不同的信号变化。
其次文中还对不同铺层顺序和不同铺层厚度的固化行为和固化残余应大小进行了研究。首先通过分析FBG传感器监测得到的正交和准各向同性铺层中的固化信号,重点研究了不同铺层在降温过程中的固化行为。其次还对对称铺层和非对称两种铺层的固化行为进行了比较,找到了对称铺层和非对称铺层在固化过程中影响FBG传感器信号的一般规律。最后通过X衍射法对FBG传感器测得的残余应力进行验证,由于X衍射法要求对试样表面进行打磨处理,这将会释放部分固化残余应力,因此X衍射法比FBG传感器测得的残余应力值小但基本趋势是一致的。
同时还对具有不同固化残余应力值的复合材料单向层合板试样进行了层间剪切强度测试,并将测试的剪切强度数据按照一定的步骤进行了数据处理后发现：四种固化条件下的B基准剪切强度值与由FBG传感器监测得到的固化残余应力值之间具有近似曲线的关系,表明当残余应力值大于14MPa时,固化残余应力越大,对剪切强度的影响越大；当残余应力值小于8MPa时,固化残余应力越小,对剪切强度的影响也越小。
最后,由于不锈钢模具的热容较大,在固化过程的降温阶段将会在层合板的上、下表面形成一定的温度梯度,因此本论文采用对流边界条件用ANSYS有限元软件对对称和非对称铺层的固化过程进行了数值模拟。将模拟得到的固化结果与光栅FBG传感器监测试验结果进行对比后发现,不同铺层顺序和不同铺层厚度的预浸料在固化后的变化趋势与试验结果基本一致。
Since the advanced composite materials have excellent specific strength, specific stiffness, anti-corrosion, anti-abrasion and fatigue resistance, they have taken the first place in the four structure materials of aircraft. However, the curing residual stresses, which is always, during the curing process of composite material, induced by the mismatch of thermal expansion coefficients between reinforced fiber and resin, the shrinkage in the resin polymerization reaction or other reasons, can reduce the performance of composite materials and increase their assemble difficulty. So it is very meaningful to monitor the curing process of composite materials with efficient non-destructive testing technology. To monitor the health condition of composite structure using built-in sensors method is also an important development trend of composite structure non-destructive testing technology. Among numerous sensors, the optical fiber grating (FBG) sensor, which is a superior sensor with magnetic and electrical resistance, can be embedded in the composite materials with little interference to monitor the whole autoclave curing process of prepreg.
Firstly, the stress sensitive coefficient, the temperature sensitive coefficient and the thermal stability performances at high and low temperature of FBG sensors had been thoroughly studied in this paper. The results showed that the stress sensitive coefficient, the temperature sensitive coefficient and the thermal stability performances at high and low temperature of FBG sensors with different central wavelength were very similar, and they were all consistent with the theoretical analysis value. When the FBG sensor encapsulated by metal casing and the naked one were put into the epoxy resin, the gel point and glass transition temperature of resin curing reaction could be easily and immediately identified from two signals of FBG sensors, and the curing reaction heat with the curing shrinkage after cooling could be also calculated. Besides, it was found that the heat release of curing process was very slow.
Secondly, in the unidirectional laminate autoclave curing process, a Taguchi orthogonal test was designed according to five different curing conditions (including the second heating time, the second holding time, the cooling mode, the curing pressure and the temperature of pressure releasing), which could affect the curing residual stresses. And the FBG sensors were embedded into the middle of prepreg in order to monitor the whole process of curing. After the results of orthogonal test were analyzed by Taguchi soft, the important factor in the curing test and interaction between them could be obtained. Subsequently, in terms of the optimal test of important factor, the optimum curing condition fitting to this test and the minimal residual stresses (-6.49MPa) had also been found. In addition, different curing conditions had great influence on curing residual stresses. Even the two FBG sensors at same layer of different direction showed different signal changes.
Thirdly, this paper had researched on curing behavior and curing residual stresses of different ply sequences and different thickness. In the beginning, the curing behaviors of orthogonal and quasi isotropic layers at cooling stage were mainly studied by means of analyzing the curing signals which were monitored by FBG sensors. Subsequently, the paper compared the curing behaviors of symmetric and asymmetric laminate, and found out the general rule that how symmetric and asymmetric laminate affected the FBG sensors.
Finally, X ray diffraction method was used to verify the residual stresses measured by FBG sensors. Since the surface of specimens in X ray diffraction method required to be polished, it would release part of curing residual stresses. The value measured by X ray diffraction method was less than that measured by FBG sensors, but the general trend was still the same.
Meanwhile, interlaminar shear strength of the unidirectional composite laminate specimens with different curing residual stress had been tested, and the test data was processed according by certain steps subsequently. The results revealed that the relationship between B benchmark shear strength value under four curing conditions and curing residual stresses monitored by FBG sensors was an approximate curve. That was a great impact on the shear strength when the curing residual stress monitored by FBG sensors was more than14MPa. However, when the curing residual stresses monitored by FBG sensors were less than8MPa, the impact was very little.
Finally, the heat capacity of stainless steel mold was relatively large, which led to a certain temperature gradient between the upper and lower surface of the laminate during the cooling stage of curing process. The curing process of symmetric and asymmetric layers were simulated with the convection boundary condition by ANSYS finite element software. The simulation results obtained were compared with the test results monitored by FBG sensors, which showed that changing trend of cured prepreg with different stacking sequence and different layer thickness was consistent with test results.
引文
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