单晶硅电火花线切割表面损伤层形成机理

 为了研究单晶硅电火花线切割(WEDM)表面损伤层的损伤形式和形成机理,以电火花线切割加工后的单晶硅表面为研究对象,采用表面形貌观察分析及择优腐蚀方法研究了单晶硅经过电火花线切割后的加工表面.研究结果表明单晶硅经电火花放电加工后表面损伤形式分为4种:热损伤、应力损伤、热与应力综合作用损伤及电解/电化学腐蚀损伤.热损伤使得硅表面形成多晶或非晶硅;应力损伤使硅表面产生裂纹;热与应力综合作用会产生小孔效应,且随着放电功率密度的增加,小孔会明显增多;电解/电化学作用会加快损伤区域及杂质元素富集区域的腐蚀.     

Fabrication of Nanostructured Electroforming Copper Layer by Means of an Ultrasonic-assisted Mechanical Treatment

Electroformed copper layer with nanostructure is obtained using a subsequent mechanical treatment under the conditions of ultrasonic vibration according to the demand of high performance material in aeronautics. The microstructure of the electroformed copper layer is observed by optical microscope (OM), scanning electron microscope (SEM) and transmission electron microscope (TEM). The tensile strength is evaluated with a tensile tester. It is found that bulk crystal of electroformed copper's surface layer is changed to nanocrystals (about 10 nm in size) after the ultrasonic-assisted mechanical treatment (UMT) but the whole monocrystalline structure still remains. The tensile strength exhibited by the new copper layer is two times better than the regular electroformed copper layer, while the fracture strain remains constant. In addition, the strengthening mechanism of UMT process is proved to be dislocation strengthening mechanism.     

硅烷偶联剂改性Al2 O3p/TDE-85 的力学性能

利用硅烷偶联剂对Al2O3颗粒进行表面改性,制备了Al2O3颗粒增强的TDE-85树脂基复合材料,研究了表面改性对其力学性能的影响,采用差热分析仪测定复合材料的固化反应温度,并计算了固化反应活化能。利用扫描电子显微镜分析了拉伸断口形貌。研究发现,当Al2O3用量为2wt%时,固化反应速度较快,硅烷偶联剂用量为4wt%时,冲击强度为13.2 kJ/m2;拉伸强度为65.2 MPa;弹性模量为2.66 GPa;最大伸长率为3.35%,此时对Al2O3颗粒的表面改性综合效果最好。     

高能机械加工表面纳米化40Cr钢组织结构与力学性能

利用超声高能机械加工处理工艺在40Cr钢表面制备了纳米晶表面层。采用SEM,TEM和纳米压痕技术等分析了表面纳米晶层的组织结构与力学性能。实验结果表明,表面是由分布均匀的纳米级铁素体和纳米级渗碳体晶粒构成的复合纳米结构,过渡区由纳米级的渗碳体晶粒和粗晶铁素体晶粒构成。表面平均晶粒尺寸为3nm。随着深度的增加,晶粒尺寸逐渐增大。表面硬度高达8GPa,为基体硬度的3倍,随着深度的增加,硬度迅速降低。表面层弹性模量为252GPa,与基体十分接近。     

硅橡胶/双酚A-苯胺型苯并噁嗪树脂耐烧蚀复合材料的制备与烧蚀结构的研究

苯并噁嗪树脂具有优异的成炭和抗高温氧化性能,是新一代的耐烧蚀树脂。以双酚A-苯胺型苯并噁嗪树脂为耐烧蚀树脂,采用1H-NMR、DSC和转矩流变仪研究其成环率和加工性能;以硅橡胶为耐烧蚀基体,采用熔融共混方法制备了硅橡胶苯并噁嗪树脂耐烧蚀复合材料。进行力学和氧乙炔焰烧蚀检测,利用FT-IR、Raman和SEM研究复合材料综合性能和烧蚀结构。结果表明:苯并噁嗪树脂能够明显提高硅橡胶复合材料的耐烧蚀性能,当树脂添加量为20份时,复合材料具有较好的耐烧蚀和力学性能;该复合材料经过氧乙炔焰烧蚀后,烧蚀层形成表面陶瓷层、裂解炭化层和基体层。表面陶瓷层主要由SiO_2,SiC和C组成,裂解炭化层的主要组由C,SiO_2,SiC以及炭化彻底的碳和炭化不完全的有机结构组成。     

单晶硅纳米加工机理的分子动力学研究

对内部无缺陷的单晶硅的纳米切削过程进行了分子动力学模拟.通过模拟结果,对单晶硅纳米切削中的切屑形成过程和加工表面的形成过程做出了合理的解释.并用第一原理应力计算方法对单晶硅纳米切削过程中的脆塑转变的可行性进行了研究.     

Metal flow hysteresis behavior and shape control strategy during porthole die extrusion of micro heat pipe

The shape control strategy of micro grooves is still unclear and challenging during the porthole die extrusion of grooved micro heat pipe (MHP). Through the simulation and experiment of porthole die extrusion of a MHP profile, the metal flow hysteresis behavior within micro features and the effect of ram speed and extrusion temperature on it and the resulting forming integrity was elucidated. Innovatively, Taguchi design and variance analysis (ANOVA) were introduced to determine their influence magnitude on the metal flow uniformity calculated by simulation results. The main findings are given below. The metal flow hysteresis derives from part feature size effect. The negligible friction-affected area during conventional extrusion severely slows down the metal flow within micro features during the MHP profile extrusion, which is due to the surge in the area ratio of the friction-affected area to the region in which it is located. Neither ram speed nor extrusion temperature can change the distribution of the friction-affected area. However, increasing ram speed multiplies the metal flow hysteresis and severely reduces the forming integrity, whereas extrusion temperature has little effect. Following this strategy, batch extrusion of the profile with micro-grooved width of 0.27 ± 0.02 mm was achieved in industrialized conditions.     

Investigation on surface integrity of electron beam melted Ti-6Al-4 V by precision grinding and electropolishing

Electron beam melting (EBM), as an excellent Additive Manufacturing (AM) technology, enables the printing of Ti-6Al-4 V alloy for a wide range of applications such as aerospace and biomechanical industries. It improves functionality and integrity of components and negates complexities in assembly processes. However, due to the poor surface and sub-surface integrity represented by the rough surface finish and low dimensional accuracy, achieving a favorable surface condition is quite challenging. Therefore, post processing becomes essential for these electron beam melted (EBM-ed) Ti-6Al-4 V alloys. Being the most common technique to improve such parts, milling of Ti-6Al-4 V alloy is very challenging and resulting tool wear issues, due to its unique material properties. Thus, this paper presents a comprehensive study on the surface integrity of EBM-ed Ti-6Al-4 V parts processed by precision grinding and electropolishing, aiming to qualitatively and quantitatively clarify the interrelation between process parameters and processed surface quality. The surface and subsurface characteristics such as profile accuracy, surface roughness, microstructure, defective layer and residual stress before and after post processing were compared and evaluated. The results show that by precision grinding, the profile accuracy was improved from over 300 µm PV to 7 µm PV, while surface roughness (R_a) was reduced from 30 µm to about 2 µm. The layer with partially melt particles was removed, but introduced a deformed subsurface layer with more residual stress. Then by applying electropolishing, the residual stress was released and the deformed layer was removed. In addition, R_a was further reduced to 0.65 µm. The research can serve as a reference for the integration of post machining processes with AM.     

GCr15钢离子注入表面改性研究

对航空轴承用钢ＧＣｒ１５进行了硼离子、氮离子及其复合注入试验。利用扫描电镜和Ｘ射线衍射仪对注入层的组织结构进行了分析，并测试了注入层的硬度、耐磨性、耐蚀性。结果表明：ＧＣｒ１５离子注入层形成了多种弥散相和非晶相，表层的残余奥氏体含量也有所减少。表层的硬度、耐磨性以及耐蚀性经离子注入后明显增加。     

Improving profile accuracy and surface quality of blisk by electrochemical machining with a micro inter-electrode gap

Electrochemical machining (ECM) has emerged as an important option for manufacturing the blisk. The inter-electrode gap (IEG) distribution is an essential parameter for the blisk precise shaping process in ECM, as it affects the process stability, profile accuracy and surface quality. Larger IEG leads to a poor localization effect and has an adverse influence on the machining accuracy and surface quality of blisk. To achieve micro-IEG (<50 μm) blisk finishing machining, this work puts forward a novel variable-parameters blisk ECM strategy based on the synchronous coupling mode of micro-vibration amplitude and small pulse duration. The modelling and simulation of the blisk micro-IEG machining have been carried out. Exploratory experiments of variable-parameters blisk ECM were carried out. The results illustrated that the IEG width reduced with the progress of variable parameter process. The IEG width of the blade’s concave part and convex part could be successfully controlled to within 30 μm and 21 μm, respectively. The profile deviation for the blade’s concave surface and convex surface are 49 μm and 35 μm, while the surface roughness reaches R_a = 0.149 μm and R_a = 0.196 μm, respectively. The profile accuracy of the blisk leading/trailing edges was limited to within 91 μm. Compared with the currently-established process, the profile accuracy of the blade’s concave and convex profiles was improved by 50.5 % and 53.3 %, respectively. The surface quality was improved by 53.2 % and 50.9 %, respectively. Additionally, the machined surface was covered with small corrosion pits and weak attacks of the grain boundary due to selective dissolution. Some electrolytic products were dispersed on the machined surface, and their components were mainly composed of the carbide and oxide products of Ti and Nb elements. The results indicate that the variable-parameters strategy is effective for achieving a tiny IEG in blisk ECM, which can be used in engineering practice.     

速率检测中新型定角脉冲产生电路

介绍了一种用于转台速率检测的新型定角脉冲产生电路,详细说明了其工作原理和性能,并给出了实测结果。     

Ti/Al/Ti_(46)Zr_(26)Cu_(17)Ni_(11)非晶层状复合材料界面相组成

利用DSC对真空甩带法制得的Ti_(46)Zr_(26)Cu_(17)Ni_(11)非晶薄带进行热分析,据此选择在693 K(T_g),753 K(T_g~T_(x1)),813 K(T_(x1))下对非晶合金进行不同时间真空热处理,分析非晶晶化行为,并以Ti_(46)Zr_(26)Cu_(17)Ni_(11)非晶合金、TA2和纯Al为原材料,利用Gleeble-3500热模拟试验机在873 K/10 MPa/8 h下制备层状复合材料,采用SEM、TEM、显微硬度计并结合热力学和元素扩散理论对界面层相组成、析出次序和性能进行研究。结果表明:Ti_(46)Zr_(26)Cu_(17)Ni_(11)非晶玻璃转变温度T_g=720 K,初始晶化温度T_(x1)=788 K;非晶晶化首先生成亚稳相I相,随后进一步析出三元或四元Laves相和Ti Ni相;热压后,纯Al和非晶晶化层间界面由薄层Al_3Ni和晶粒细小结构均匀的Al3(Ti0.6Zr0.4)层组成,界面平直无缺陷,总厚度与纯Ti、纯Al间界面层厚度比约为6.5∶1;Al_3(Ti_(0.6)Zr_(0.4))和Al_3Ti硬度相近,分别为(564.20±10.46)HV和(579.83±15.26)HV,但Al_3(Ti_(0.6)Zr_(0.4))层塑性更好。     

改性废胶粉/天然橡胶的制备及性能

以丙烯酰胺(AM)为接枝单体,采用紫外光(UV)接枝的方法对废胶粉进行接枝改性,研究了废胶粉接枝改性的最佳条件。将最佳改性条件下的废胶粉与天然橡胶制成复合材料,研究了复合材料的力学性能、热空气老化性能及微观形貌。结果表明:废胶粉紫外光接枝改性的最佳条件为废胶粉目数为100目,AM用量为8%,BP用量为5%,光照时间为4 min。当改性废胶粉添加量为10%时,复合材料的拉伸强度、邵尔A硬度均有所提高;复合材料的抗热氧老化性能得到改善。微观形貌分析表明:改性废胶粉在NR中的分散性得到了改善,相容性得到了提高。     

PAN基碳纤维表面液相氧化改性研究

利用拉曼光谱(Raman),红外光谱(IR)和扫描电镜(SEM)对经过KClO3/H2SO4液相改性处理的碳纤维(CF)表面结构进行了研究,并初步讨论了微观结构对碳纤维单丝力学性能的影响.结果表明:纤维表面的沟槽随改性处理时间增加逐渐加深;表面处理的刻蚀作用会使晶粒边界活性增大,石墨微晶变小;改性处理能够增加CF表面活性官能团(羧酸(-C=O)和酚羟基(-OH)),降低碳纤维表面惰性;表面处理后纤维的力学性能均有所下降,液相氧化处理60min和120min后,拉伸强度分别降低约15％和50％.     

Multi-sensor control for precise assembly of optical components

In order to perform an optical assembly accurately, a multi-sensor control strategy is developed which includes an attitude measurement system, a vision system, a loss measurement system and a force sensor. A 3-DOF attitude measuring method using linear variable differential transformers （LVDT） is designed to adjust the relation of position and attitude between the spher- ical mirror and the resonator. A micro vision feedback system is set up to extract the light beam and the diaphragm, which can achieve the coarse positioning of the spherical mirror in the optical assembly process. A rapid self-correlation method is presented to analyze the spectrum signal for the fine positioning. In order to prevent the damage of the optical components and realize sealing of the resonator, a hybrid force-position control is constructed to control the contact force of the optical components. The experimental results show that the proposed multi-sensor control strategy succeeds in accomplishing the precise assembly of the optical components, which consists of parallel adjustment, macro coarse adjustment, macro approach, micro fine adjustment, micro approach and optical contact. Therefore, the results validate the multi-sensor control strategy.     

Virtual flight test of pitch and roll attitude control based on circulation control of tailless flying wing aircraft without rudders

Circulation Control(CC) realizes rudderless flight control by driving compressed air jet to generate a virtual rudder surface, which significantly improves low detectability. The layout plan of combined control rudder surface is proposed based on the tailless flying wing aircraft. The closed-loop jet actuator system and stepless rudder surface switching control strategy are used to quantitatively study the control characteristics of circulation actuator for pitch and roll attitude through 3-DOF ...     

Random copolymer membrane coated PBO fibers with significantly improved interfacial adhesion for PBO fibers/cyanate ester composites

Poly(p-phenylene-2,6-benzobisoxazole) (PBO) fibers possess excellent dielectric, mechanical properties and heat resistance. However, the surface of PBO fibers is smooth and highly chemical inert, resulting in poor interfacial compatibility to polymer matrix, which severely limits its wider application in high-performance fiber-reinforced resin matrix composites. In this work, random copolymers (P(S-co-BCB-co-MMA)) containing benzocyclobutene in the side-chain were synthesized by reversible addition-fragmentation chain transfer (RAFT) polymerization, which were then utilized to form dense random copolymer membrane on the surface of PBO fibers by thermally cross-linking at 250 °C (PBO@P fibers). Four kinds of synthesized P(S-co-BCB-co-MMA) with different number-average molar mass (M_n) were well controlled and possessed narrow dispersity. When the M_n was 32300, the surface roughness of PBO@P fibers was increased from 11 nm (PBO fibers) to 39 nm. In addition, PBO@P fibers presented the optimal interfacial compatibility with bisphenol A cyanate (BADCy) resins. And the single fiber pull-out strength of PBO@P fibers/BADCy micro-composites was 4.5 MPa, increasing by 45.2% in comparison with that of PBO fibers/BADCy micro-composites (3.1 MPa). Meantime, PBO@P fibers still retained excellent tensile strength (about 5.1 GPa). Overall, this work illustrates a simple and efficient surface functionalization method, which would provide a strong theoretical basis and technical support for controlling the surface structure & chemistry of inert substrates.     

从双层到多层带有微结构的硅硅直接键合技术研究

通过理论分析和实验验证对多层带有微结构的硅硅直接键合技术进行了研究.采用的硅片表面活化处理方法是亲水湿法,采用的键合工艺流程是先将硅片在键合机中进行预键合,再使用退火炉进行高温退火.其中预键合参数对多层键合成功与否起到决定性的作用,为节约实验时间,针对3个主要预键合参数（温度、压力、时间）的选取进行了详细的正交实验分析.使用项目组自制的硅硅键合分析软件对键合片的红外图像进行处理分析,计算键合率.采用实验得到的最佳预键合工艺参数,多层键合的键合率达到了86.6527%.      

Fabrication and Life Prediction of SSiC Ceramic Joint Joined with Silicon Resin YR3370

Joints between sintered silicon carbide （SSiC） were produced using a polysiloxane silicon resin YR3370 （GE Toshiba Silicones） as joining material. Samples were heat treated in a 99.99% nitrogen flux at temperatures ranging from 1 100 ℃ to 1 300 ℃. Three point bending strength of the joint reached the maximum of 179 MPa as joined at 1 200℃. The joining layer is continuous, homogeneous and densified and has a thickness of 2 μm -5μm. The joining mechanism is that the amorphous silicon oxycarbide （SixOyCz） ceramic pyrolyzed from silicon resin YR3370 acts as an inorganic adhesive to SSiC substrate, which means the formation of the continuous Si-C bond structure between SixOyCz structure and SSiC substrate. Life prediction of the ceramic joint can be realized through the measurement of the critical time of the joint after the cyclic loading test.     

磁过滤直流真空阴极弧制备类金刚石膜的结构和力学性能研究

采用磁过滤直流真空阴极弧沉积技术在硅片、不锈钢片基体上制备了类金刚石(DLC)膜。检测结果表明,膜中存在着微米级的大颗粒分布,膜厚为290nm,sp3键的含量为62.23%。所制备的薄膜具有典型的DLC膜Raman光谱特征,耐磨性能优良,膜与基体的结合性能良好。