Effect of hygrothermal aging on moisture diffusion and tensile behavior of CFRP composite laminates

Carbon Fiber Reinforced Polymer (CFRP) composites are widely used in aircraft structures, because of their superior mechanical and lightweight properties. CFRP composites are often exposed to hygrothermal environments in service. Temperature and moisture can affect the material properties of composites. In order to make clear the moisture diffusion behavior and the properties degradation of composites, the TG800/E207 composite laminates with four stacking sequences [0]₁₆, [90]₁₆, [±45]_4s, and [(+45/0/0/–45)_s]_s are designed and manufactured. Moisture absorption tests are carried out at 80 ℃, 90 %RH. It is shown that the moisture absorption curves of composite laminates present a three-stage. A modified Fickian model was proposed to capture the diffusion behavior of TG800/E207 composite laminates. The relationships among the non-Fickian parameters, the environmental parameters and the stacking sequences of CFRP were correlated and compared. Results showed that the modified Fickian curve is sensitive to the diffusivity of Stage I and Stage II. Compared with unaged specimens, the maximum tensile stress for [0]₁₆, [90]₁₆, [±45]_4s, and [(+45/0/0/–45)_s]_s decreased by 14.94 %, 28.15 %, 11.96 %, and 26.36 %, respectively. The strains at failure for [0]₁₆, [90]₁₆, [±45]_4s, and [(+45/0/0/–45)_s]_s decreased by 55.38 %, 62.65 %, 46.41 %, and 31.71 %, respectively. The elastic modulus for [0]₁₆, [90]₁₆, [±45]_4s, and [(+45/0/0/–45)_s]_s increased by 90.93 %, 94.57 %, 49.22 %, and 8.22 %, respectively. [90]₁₆ sample has the minimum saturated moisture content and the maximum strength degeneration.     

Improving surface integrity when drilling CFRPs and Ti-6Al-4V using sustainable lubricated liquid carbon dioxide

In the quest for decreasing fuel consumption and resulting gas emissions in the aeronautic sector, lightweight materials such as Carbon Fiber Reinforced Polymers (CFRPs) and Ti-6Al-4V alloys are being used. These materials, with excellent weight-to-strength ratios, are widely used for structural applications in aircraft manufacturing. To date, several studies have been published showing that the use of metalworking fluids (MWFs), special tool geometries, or advanced machining techniques is required to ensure a surface quality that meets aerospace component standards. Conventional MWFs pose a number of environmental and worker health hazards and also degrade the mechanical properties of CFRPs due to water absorption in the composite. Therefore, a transition to more environmentally friendly cooling/lubrication techniques that prevent moisture problems in the composite is needed. This research shows that lubricated LCO₂ is a viable option to improve the quality of drilled CFRP and titanium aerospace components compared to dry machining, while maintaining clean work areas. The results show that the best combination of tool geometry and cooling conditions for machining both materials is drilling with Brad point drills and lubricated LCO₂. Drilling under these conditions resulted in a 90 % improvement in fiber pull-out volume compared to dry machined CFRP holes. In addition, a 33 % reduction in burr height and a 15 % improvement in surface roughness were observed compared to dry drilling of titanium.     

基于碳纳米管薄膜的复合材料层间增韧

通过浮动催化化学气相沉积法制备连续碳纳米管薄膜，并将其原位沉积到单向碳纤维织物表面，手工铺层后借助真空辅助树脂传递模塑成型（VARTM）工艺制备碳纳米管-碳纤维/环氧树脂复合材料层压板，研究不同面密度的碳纳米管薄膜对层压板Ⅱ型层间断裂韧性的影响。结果表明，随着碳纳米管薄膜面密度的增加，层压板Ⅱ型层间断裂韧性先逐渐提高，当碳纳米管薄膜面密度为9.64 g/m²时，层压板Ⅱ型层间断裂韧性最佳，与原始层压板相比提高了94%。碳纳米管通过桥接树脂裂纹、从树脂中拔出等方式提高层间断裂韧性。当碳纳米管面密度超过临界值时，会引起树脂浸润困难，导致增韧效果降低。     

Preparation of CF/Ni-Fe/CNT/silicone layered rubber for aircraft sealing and electromagnetic interference shielding applications

To meet the needs of preventing information leakage in space engineering and military industry, an efficient method was introduced to obtain layered electromagnetic shielding sealing rubber. The carbon fiber, Ni-Fe coating, and Carbon NanoTube (CNT) were combined by chemical plating and in-situ polymerization to obtain a lightweight (0.14 g/cm²) and thin (1 mm thick) Carbon fiber Fabric (CF)/Ni-Fe/CNT/silicone layered electromagnetic shielding composites. The layered material obtained by adjusting the electroless plating time exhibited a high Shielding Efficiency (SE) of 60.2–85.5 dB in the range of 0–4800 MHz, which can be used for aviation electromagnetic shielding. Carbon fibers and carbon nanotubes mainly attenuated electromagnetic waves through absorption loss, while the nickel-iron alloy coating through reflection loss interacted with the magnetic vector of incident ElectroMagnetic (EM) radiation and magnetic dipoles, therefore, the EM Interference (EMI) shielding composite attenuated EM waves with the “absorption-reflection-absorption” cooperative interaction. Moreover, the flexible fabric substrate adhered with silicone rubber possessed a breaking elongation of 52.3%, which can be utilized as a good sealing material. Simultaneously, the outstanding exothermicity (67.2 °C under the applied voltage of 5 V) makes it possible to be applied in electric heating area. The electromagnetic shielding composites prepared in this paper have good potential in the fields of precision electronic equipment and aviation systems.     

Effects of fiber orientation on tool wear evolution and wear mechanism when cutting carbon fiber reinforced plastics

The aim of the present paper is to reveal the influence of different fiber orientations on the tool wear evolution and wear mechanism. Side-milling experiments with large-diameter milling tools are conducted. A finite element (FE) cutting model of carbon fiber reinforced plastics (CFRP) is established to get insight into the cutting stress status at different wear stages. The results show that different fiber orientations bring about distinct differences in the extent, profile and mechanism of tool wear. Severer wear occurs when cutting 45° and 90° plies, followed by 0°, correspondingly, the least wear is obtained when θ = 135° (θ represents the orientation of fibers). Moreover, the worn profiles of cutting tools when θ = 0° and 45° are waterfall edge, while round edge occurs when θ = 135° and a combined shape of waterfall and round edge is obtained when θ = 90°. The wear mechanisms under different fiber orientations are strongly dependent on the cutting stress distributions. The evolution of tool wear profile is basically consistent with the stress distribution on the tool surface at different wear stages, and the extent of tool wear is determined by the magnitude of stress on the tool surface. Besides, the worn edges produce an actual negative clearance angle, which decreases the actual cutting thickness and leads to compressing and bending failure of fibers beneath the cutting region as well as low surface qualities.     

可自展开碳纤维增强复合材料杆的制备与性能

采用T300碳纤维/环氧树脂预浸料制备了具有双凸透镜状构型的柔性铰链和圆管,通过金属法兰将铰链和圆管胶接组装得到可自展开碳纤维增强复合材料杆。研究了复合材料铰链的展开力矩和复合材料杆的固有频率及重复展开性能。结果表明:复合材料铰链的初始展开力矩为372.8 N·mm,功重比为13.3 W/kg,可自展开复合材料杆的一阶固有频率为4.25 Hz,重复指向精度为0.08°。     

Wetting behavior of AgCu-4.5Ti filler reinforced by carbon nanotubes on C/C composite

The effect of Carbon Nanotubes (CNTs) content on the wettability of AgCu-4.5Ti + x CNTs (wt%) composite filler alloys on C/C composite was investigated. The results show that the added CNTs reacted with element Ti in the filler and produced the dispersed fine in situ synthesized TiC particles, which increased the consumption of element Ti and provided the nucleus for the growth of Ti-Cu compounds simultaneously. The above effects of introducing CNTs, inhibited the formation of Ti-Cu compounds, also changed the distribution of compounds, which dramatically influenced the interfacial microstructure and characteristics of wetting behavior. The increase of CNTs content refined and dispersed coarse Ti-Cu compounds, decreased the initial spreading temperature, and improved the wettability, but high content of CNTs (more than 0.3wt%) decreased the wettability of the filler alloy. The wetting interfacial microstructure of corresponding composite filler alloys were analyzed by Scanning Electron Microscope (SEM), Energy Dispersive X-ray Spectrometer (EDS) and Transmission Electron Microscope (TEM), which consisted of TiC, TiCu, TiCu₂ and TiCu₄ compound. The typical wetting behavior of AgCu-4.5Ti + 0.3wt% CNTs composite filler on C/C composite was divided into four stages. The effect mechanism of CNTs content on the wetting behavior was proposed.     

Enhanced ultrasonic total focusing imaging of CFRP corner with ray theory-based homogenization technique

Ultrasonic testing is effective in defect characterization and quality assurance of Carbon Fiber Reinforced Plastic (CFRP) components in the aerospace industry. Due to the coupling between complex shape and elastic anisotropy, the Phased Array Ultrasonic Testing (PAUT) and time-based Total Focusing Method (TFM) face significant challenges in the calculation of wave propagation. A wave velocity distribution model is established for a multidirectional convex corner of CFRP based on a homogenization theory and the above coupling effects are also incorporated. A ray-tracing method is proposed based on Dijkstra’s shortest path search algorithm. The predicted time of flight ensures that this technique, the homogenized TFM, could synthesize a high-quality focused image by post-processing on the full matrix capture data. Experiments on a laminate with three ?1.5 mm Side-Drilled Holes (SDHs) in different circumferential directions confirm a successful homogenized TFM imaging that all SDHs can be effectively detected. As compared to the isotropic scenario, the maximum positioning error is reduced to 0.12, 0.08, and 0.38 mm, and the Signal-to-Noise Ratios (SNRs) are increased by 2.1, 1.1, and 11.8 dB, respectively. It is suggested that the ray-tracing assisted TFM technique can effectively improve the imaging of corners in CFRP components.     

Effects of surface topography and specimen thickness on high-speed raindrop impact damage of CFRP laminates

Raindrop impact erosion has been observed since early days of aviation, and can be catastrophic for exposed materials during supersonic flight. A single impact waterjet apparatus is established for mimicking drop impacts at the velocities between 350 m/s and 620 m/s. Carbon Fiber Reinforced Polymer(CFRP) laminates with three different surface morphologies and specimen thicknesses are tested here. A central region with no visible damage has been noticed, surrounded by a “failure ring” with common...     

Leakage and wear characteristics of carbon seals for aero-engines

Experimental investigation has been performed to study the leakage and wear characteristics of carbon seal working at high circumferential speed. To expand the scope of application, two newly designed carbon seals were compared: #1 Carbon Seal (CS1) with the inner diameter of 136 mm and including 4 segments, #2 Carbon Seal (CS2) with the inner diameter of 212 mm and including 6 segments. Air leakage tests were firstly conducted in the Medium-speed Seal Test Rig. The pressure ratio changed from 1.04 to 2.02 with the rotating speed varying from 0 to 18300 r/min. Of paramount concern was the durability test, including 300 h running time accumulated by three different working conditions, which was separately implemented on each carbon seal. The morphology variation of the friction surface, wear and leakage were recorded. Results indicated that the leakage monotonously increases with the pressure ratio and decreases with the rotating speed. Comparing with CS1, more typical features exist on the friction surface of CS2, which are generated by more severe wear. Continually, leakage characteristics deteriorate. Furthermore, fitted formula has been educed for the life prediction of carbon seal, which could provide some supports for aero-engine design.     

Improved creep aging response in Al-Cu alloy by applying pre-aging before pre-straining

The improvement of post-form properties without compromising creep formability has been a critical issue in creep age forming of aluminum alloy component. A pretreatment process incorporating artificial pre-aging at 165 °C for 6 h/12 h/24 h followed by pre-strain(3%–9%)has been developed. This method not only evidently improves the strength but also accelerates the creep deformation during creep aging of an Al-Cu alloy. A strength increase of 50 MPa with a slight decrease of ductility relative t...     

Temperature effect on buckling properties of ultra-thin-walled lenticular collapsible composite tube subjected to axial compression

This paper seeks to outline the temperature effect on the buckling properties of ultra-thin-walled lenticular collapsible composite tube(LCCT) subjected to axial compression.The buckling tests of the LCCT specimens subjected to axial compression were carried out on INSTRON-500 N servo-hydraulic machine in dry state and at the temperatures of 25 C, 100 C and 80 C. The load–displacement curves and buckling initiation loads were measured and the buckling initiation mechanism was discussed from experimental observations. Experiments show that the buckling initiation load, on average, is only about 2.2% greater at the low temperature of 80 C than at the room temperature of 25 C due to the material hardening, demonstrating an insignificant increase in the buckling initiation load, whereas it is about 19.5% lower at the high temperature of 100 C than at the room temperature owing to the material softening, implying a significant decrease in the buckling initiation load. The failure mode of the LCCT in axial compression tests at three different temperatures can be reckoned to be characteristic of the buckling initiation and propagation around the central region until rupture. The finite element(FE) model is presented to simulate the buckling initiation mechanism based on the eigenvalue-based methodology. Good correlation between experimental and numerical results is achieved.     

Hot deformation behavior and strain compensation constitutive model of equiaxed fine grain diffusion-welded micro-duplex TC4 titanium alloy

In this work, two-stage diffusion bonding of micro-duplex TC4 titanium alloy was carried out to study the flow behavior and constitutive models of the bonding joint and the base metal after the same thermal cycling during the hot forming process. Microstructure and mechanical properties test were used to verify the good quality of the equiaxed fine grain diffusion-welded TC4 alloy. Quasi-static tensile experiment was carried out at temperatures ranging from 750–900 °C and strain rates of 0.0001–0.1 s⁻¹. The joint showed the weak dynamic recovery at strain rates of 0.01–0.1 s⁻¹ and temperatures of 750–850 °C. At strain rates of 0.0001–0.001 s⁻¹ and temperatures of 850–900 °C, the flow stress of joint presented steady-state characteristics. Different deformation conditions lead to the remarkable difference of dynamic softening performance between the joint and heat-treated base metal, but the flow stress in elastic and strain hardening stages exhibited similar behavior. The strain compensated Arrhenius-type constitutive models of TC4 joint and heat-treated base metal were developed respectively. The fifth-order polynomial functions between the material property correlation coefficients and strain were obtained. The models have shown good correlation, with correlation coefficient values of 0.984 and 0.99. The percentage average absolute relative error for the models were found to be 10% and 9.46%, respectively.     

Interfacial characteristics in CNTs-AgCuTi systems

AgCuTi-based composite fillers reinforced with Carbon Nanotubes（CNTs） were prepared by mechanical ball milling and ultrasonic agitation. The morphological features, chemical components, and melting characteristics of the composite fillers with different content of CNTs addition were investigated using Field Emission Scanning Electron Microscopy（FESEM）, XRay Diffraction（XRD） and a Differential Scanning Calorimeter（DSC）. After being heated at 900 ℃, the microstructure of the composite fillers was ...     

Through-thickness heterogeneity in creep properties of friction stir welding 7B50-T7451 aluminum alloy thick plate joint: Experiments and modeling

Through-thickness heterogeneity in creep properties of 7B50-T7451 aluminum alloy Friction Stir Welding(FSW) joints was investigated. Creep tests for three slices of the FSW joint were conducted at the temperature of 150–200 °C and applied stress of 60–225 MPa. The theta projection method was used to predict creep curves and minimum creep rate. The results show that the minimum creep rate increases and creep rupture life decreases with the increase of creep temperature and applied stress. Creep p...     

一维和二维电热除冰相变传热特性的参数影响分析

基于飞机电热除冰过程冰层融化的特征,开展了一维和二维电热除冰相变传热特性数值计算研究和参数影响分析,重点考虑了加热模式、冷却时间、加热功率和加热单元间隔等参数对冰层相变传热的影响。采用了基于焓-多孔介质方法的热焓模型,将计算区域看作是包括多层材料和冰、水及其混合区的多孔介质,采用了结构化网格拓扑结构对计算区域进行划分,采用了有限体积方法对控制方程组进行离散,采用线性插值的方法获得混合区的物性参数,耦合能量方程和液态水体积分数公式,迭代求解了计算域的温度分布,获得了不同材料间界面温度的变化,重点分析了冰-保护层界面的温度变化。基于二维电热除冰模型的冰-保护层界面温度不均匀特征,提出了耦合考虑冰-保护层界面热点和冷点温度的冰脱落温度判断准则。研究表明:高功率的周期性加热模式要优于低功率的连续性加热模式,采用合理的冷却时间和加热功率,可获得更低的能量消耗和更好的除冰效果。合理设置加热单元间隔可以提高周期性的除冰效率,但也会形成冷点和热点,造成冰-保护层界面温度分布的不均匀。冰-保护层界面的冷点类似于锚点,即使此刻热点的冰已经融化,整个冰层也无法脱落和剥离。因此,冰脱落的判断要耦合考虑界面热点和冷点的温度特征。      

CFRP三维铣削仿真模型的建立及层间损伤分析

碳纤维增强树脂基复合材料(CFRP)具有层间结合强度低、各向异性等特点,切削过程中易产生层间损伤。为了对CFRP铣削加工过程中的层间应力、层间损伤进行研究,建立了复合材料三维铣削仿真模型。该模型在结构上采用等效均质建模,层内单元利用VUMAT子程序建立了三维Hashin起始失效准则以及损伤演化过程模型,层间采用Cohesive单元连接以模拟层间损伤的产生及扩展。通过与实验切削力数值的比较,验证了仿真模型的准确性。利用该模型分析了切削力、层间应力及层间损伤随纤维方向角(0°、45°、90°、135°)的变化规律。结果表明:铣削过程加工损伤主要集中在近工件表面。铣削力、层间应力、层间损伤受纤维方向角的影响,纤维方向角为90°与135°时,轴向铣削力较大,层间应力与层间损伤均随纤维方向角的增加而增大,纤维方向角为135°时,层间应力最大,层间损伤最严重。     

Microstructure,thermophysical property and ablation behavior of high thermal conductivity carbon/carbon composites after heat-treatment

Uni-directional carbon/carbon composites with high thermal conductivity are suitable to supply continuous thermal protection for future reentry vehicles since they could reduce surface temperature and ablation rates simultaneously in harsh environments. In this work, the high thermal conductivity carbon/carbon composites were prepared by chemical vapor infiltration. After heat-treatment, both their open porosity and internal friction increase due to the fiber/matrix thermal expansion mismatch; while their thermal conductive performance become better due to more complete carbon structure. With raising heat-treatment temperature from 1800 °C to 2450 °C, the mass and linear ablation rates of C/C composites with fibers vertical to the oxyacetylene torch for 60 s decrease from 0.66 mg/s and 2.95 μm/s to 0.51 mg/s and 2.05 μm/s respectively. The improved ablation resistance is resulted from the increased thermal conductivity from 282 to 508 W/(m·K) and more carbon fibers exposed to the flame during ablation, which have better oxidation resistance than those of carbon matrix. While such ablation rates become larger for composites with fibers parallel to the flame, from 1.02 mg/s and 3.73 μm/s to 1.28 mg/s and 5.01 μm/s respectively since the ablation occurred more easily through gaps at the fiber/matrix interfaces, which become larger and are always exposed to the flame for this case.     

基于零厚度内聚力单元单向碳纤维增强树脂基复合材料微观切削机理研究

为探究碳纤维复合材料(CFRP)微观切削机理,通过有限元法,采用零厚度内聚力单元模拟界面相,碳纤维建模呈圆柱状并随机分布于基体中,以此来真实反应CFRP的微观结构。通过对各组成相设置不同的材料本构、材料失效和演化准则,对4种典型角度(0°、45°、90°、135°)进行直角切削仿真,探究不同纤维角度下单向碳纤维增强树脂基复合材料(UD-CFRP)在切削过程中的微观切削机理。结果表明:不同纤维角度下CFRP的微观破坏形式不同,切削0°CFRP时破坏主要以界面开裂和纤维折断为主,切削45°和90°CFRP时主要是刀具的侵入破坏,切削135°CFRP时则发生纤维的断裂和沿纤维方向的裂纹,纤维断裂点在刀刃下方。最后,通过实验验证了微观模型的准确性。     

CFRP铣削有限元模型建立及切削力仿真分析

为探索碳纤维增强树脂基复合材料(CFRP)铣削加工过程中切削力与工艺参数之间的映射关系,建立CFRP铣削加工有限元仿真模型并对切削力进行分析。基于ABAQUS软件通过定义材料属性、材料失效模型、纤维铺层数和纤维方向建立了CFRP铣削加工二维有限元仿真模型,并对该模型进行了实验验证。基于该模型,分析了切削力与纤维方向角、铣削速度、每齿进给量和刀具前角等工艺参数之间的映射关系。仿真结果表明:纤维方向角从0°增大到90°,切削力呈现降低趋势,而纤维方向角从90°增大到180°,切削力呈现增大趋势。随着切削速度和每齿进给量的增大,切削力随之增大,而随着刀具前角增大,切削力随之减小。