腐蚀条件下飞机结构使用寿命的评定与监控

本文提出了一种对腐蚀条件下飞机结构使用寿命进行评定和监控的方法，该方法以室温大气环境的寿命评定结论为基础，考虑地面停放预腐蚀和空中环境中腐蚀疲劳的影响而对使用寿命进行修正，并针对歼击机的使用特点而进行工程简化，简化方案已在两种歼击机的关键部位中实施。     

Investigation on a Sol-gel Coating Containing Inhibitors on 2024-T3 Aluminum Alloy

For a long time, chromate incorporated conversion coatings have been drawn special attention in corrosion protection of air-craft-used aluminum alloys. However,ever-increasing environmental pressures requires that non-chromate conversion coatings be developed because of the detrimental carcinogenic effects of the chromate compounds. In recent years, the sol-gel coatings doped with inhibitors were developed to replace chromate conversion coatings, and showed real promise. A sol-gel coating was prepared and its anti-corrosion behavior was investigated using the potentiodynamic scanning (PDS) and the electrochemical impedance spectroscopy (EIS). It is found that the sol-gel coating obtained by the hydrolysis and condensation of 3-glycidoxypropyltrimethoxysilane (GPTMS) and tetramethoxysilane (TMOS) is prone to form defects if cured at the room temperature, whereas if cured at a higher temperature (100 ℃), these flaws can be avoided. Furthermore, it can be seen that addition of anti-foam agents and surfactants will reduce the faults if cured at the room temperature. Effects of the corrosion inhibitors, CeCl3 and mercaptobenzothiazole (MBT), in the sol-gel coatings on 2024-T3 aluminum alloy were also investigated. Results show that the corrosion resistance of the sol-gel coatings containing CeCl3 proves to be better than that of the pure and MBT added sol-gel coatings by the electrochemical methods.     

Electrolytic Passivation of Nitinol Shape Memory Alloy in Different Electrolytes

The corrosion behavior of the nitinol alloy was studied in various corrosion media of different Cl^- ion concentrations. The results demonstrate that the Cl^- ion concentration has significant influences on the corrosion behavior of the nitinol alloy. In order to enhance the corrosion resistance, protective films were generated on the surface of the nitinol alloy by means of the electrochemical passivation method, for which five different electrolytic solutions were investigated. The surface analysis indicates full growth of all samples passivated in the different electrolytic solutions with layers, however, showing different morphological features. Without any defects like micro-cracks and pores, the surface of the samples passivated in the molybdate solution turns out smoother and denser than those passivated in other solutions. It is shown that the electro-chemical passivation will reduce Ni content but increase Ti content in the surface, reaching the Mole ratio of Ti：Ni = 9.01：1 on the outermost surface. Potentiodynamic polarization test demonstrates that the samples electrochemically passivated in the molybdate solution present a significant increase in breakdown potential due to titanium enrichment on the outermost surface.     

构件打磨深度对疲劳寿命的影响

按照飞机结构修理手册的规定,腐蚀损伤的允许打磨深度不超过构件厚度的10%。疲劳寿命计算和试验结果表明,从疲劳强度角度考虑,如果损伤部位修理不能利用原紧固件孔安装紧固件,并且又只能采用非对称铆接修理,则打磨深度在总厚度的10%～20%时,较合理的修理仍是通过打磨清除腐蚀,然后恢复涂层。     

飞机结构搭接件腐蚀三维裂纹扩展特性分析

通过对某型退役飞机分解检查,发现搭接件在腐蚀产物的膨胀作用下产生了裂纹。采用20节点等参奇异元,运用三维有限元法分析含半椭圆裂纹的飞机结构搭接件的应力应变状态,通过计算裂纹前缘典型部位的应力强度因子,预测了裂纹的扩展趋势,分析了其危害性。结果表明,搭接件半椭圆形裂纹以较小的形状比(a/b)扩展,在较长阶段内并不会扩展到外表面。所以裂纹具有隐蔽性,对飞机安全构成潜在的威胁。     

LY12-CZ铝合金预腐蚀及疲劳损伤研究

对实验室环境下LY12-CZ铝合金进行了预腐蚀及疲劳寿命与剩余强度的预测研究。在不同的温度及不同的腐蚀天数条件下,对试验件进行预腐蚀,按ASTMG34-1标准人工产生腐蚀坑,获得了腐蚀损伤数据,随后进行疲劳试验,初步建立了腐蚀损伤与疲劳寿命降低之间的关系。在试验研究基础上,用AFGROW软件模拟腐蚀损伤及腐蚀坑深度的不同对试件疲劳寿命和剩余强度产生的影响,建立了预测含腐蚀损伤试件的疲劳寿命与剩余强度的有效的工程方法。     

基于模糊可靠性的飞机结构腐蚀疲劳寿命评定

腐蚀和腐蚀疲劳大大降低了LY12CZ铝合金的材料性能,严重地威胁着飞机的结构完整性和使用安全。飞机结构失效过程与所受的载荷、材料特性、服役的腐蚀环境等因素有关,由于各因素联合作用,失效过程损伤机理相当复杂,既有随机性又有模糊性。针对目前腐蚀疲劳寿命评估的常规概率方法的缺陷,基于通过对海军航空部队调研得到的飞机实际使用载荷谱,提出更合理、更贴近实际情况的模糊可靠性评估方法。讨论了蚀孔形状比和各模糊因素对结构寿命的影响规律,研究结果表明该模糊可靠性方法可以应用于飞机结构的腐蚀疲劳寿命评估。     

Ce在钛合金阳极化中作用的研究

 研究了 Ce元素在钛合金阳极氧化中的作用。通过对普通工艺和稀土工艺之间氧化膜微观形貌的对比,讨论了 Ce元素对氧化膜完整性的影响。利用能谱分析,说明了 Ce元素加入可以使钛合金表面氧化较为充分,并且 Ce元素参与了氧化膜的组成。采用局部成分分析法确定了膜层的横向分布范围。对氧化膜截面的SEM图进行分析,讨论了 Ce元素对钛合金阳极氧化膜厚度的影响。利用动电位扫描,对普通氧化膜和稀土氧化膜的耐点蚀性进行了比较,表明 Ce盐的加入可以提高钛合金氧化膜抗点蚀的能力。     

复合材料布带缠绕成型压力控制技术

复合材料布带缠绕成型过程中的压力波动会影响制品的致密度和均匀度,同时会造成缠绕制品的界面强度及纤维体积分数不一致。芯模的圆度误差和安装误差会导致压力波动,气体的可压缩性、比例阀的死区效应、阀的流量非线性、气缸摩擦力及测量噪声会对缠绕压力控制造成非线性干扰。因此,设计了自适应灰色预测模糊PID控制器,通过对气缸输出缠绕压力的灰色预测,正确反映了压力信号的变化趋势,为模糊PID控制的推理提供了可靠依据。同时,采用两个独立的模糊推理系统来调节预测控制的步长和步长自整定算法的比例因子。仿真分析和实验结果表明：相比于传统PID控制,采用自适应灰色预测模糊PID控制使缠绕压力的稳态误差减小了62%,超调量减小了80%,有效提高了复合材料缠绕成型压力控制系统的稳定性。     

1420 铝锂合金锻件开裂原因分析与控制

某产品用1420 铝锂合金锻件在存放过程中发生开裂。本文通过对失效锻件进行形貌观察以及

断口、金相和力学性能分析,结合此锻件的制造工艺,分析认为:此锻件的开裂属于延迟开裂;锻件小端转角区

(R 区)存在较大的应力,淬火水冷阶段在R 区内表面形成微小表层裂纹;长期的存放过程中,锻件表面受到腐

蚀,发生应力腐蚀;微裂纹在残余应力及应力腐蚀的作用下缓慢扩展直至发生失稳扩展形成宏观贯穿裂纹,致

使锻件开裂。通过车光锻件内外表面及车光后的荧光检查,有效地预防了此类开裂故障的发生。