CN103068565A - 具有复合材料-金属接头的复合材料结构以及制造其的方法 - Google Patents

具有复合材料-金属接头的复合材料结构以及制造其的方法 Download PDF

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CN103068565A
CN103068565A CN2011800395871A CN201180039587A CN103068565A CN 103068565 A CN103068565 A CN 103068565A CN 2011800395871 A CN2011800395871 A CN 2011800395871A CN 201180039587 A CN201180039587 A CN 201180039587A CN 103068565 A CN103068565 A CN 103068565A
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metal
composite
sheet metal
fiber
flaggy
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CN103068565B (zh
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K·H·格瑞斯
G·E·乔格森
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Boeing Co
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Boeing Co
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Abstract

复合材料结构包括层压的纤维增强树脂板层和金属片的堆叠组。树脂板层与金属片的边缘交叉，以形成将树脂板层与金属片连接的复合材料-金属接头。

Description

具有复合材料-金属接头的复合材料结构以及制造其的方法
技术领域
一般而言，本公开内容涉及复合材料结构，具体而言，涉及纤维增强树脂层压板层，并且更具体地涉及具有复合材料-金属(composite-to-metal)接头的混合复合材料。
背景技术
粘合技术通常用于组装复合材料结构。在复合材料结构还需要紧固件的应用中，可能需要增加围绕紧固件的结构的局部厚度或规格(gauge)以便承受传输经过紧固件接头的负荷。随着所述结构的局部厚度增加，紧固件可能需要延长，从而对结构增加重量。此外，该结构的局部厚度增加可增加通过紧固件接头的负荷路径的偏心率，这可能将不期望的弯曲负荷置于紧固件上。
上述问题的一种解决方案由将金属配件附接到紧固件区域中的复合材料结构组成。这些金属配件可以由钛或可基本上不与接触其的碳纤维增强复合材料发生化学反应的类似金属形成。然而，钛配件可能相对较贵，特别是当必须使其形成复杂形状时。
因此，需要复合树脂-金属接头，其可用于将基本上全金属配件与基本上全复合树脂结构连接，其相对便宜且易于制造，并且其可以承受紧固件连接点周围传输的负荷。还需要复合树脂-金属接头，其基本上避免全金属配件和全复合树脂结构之间的化学反应。
发明内容
公开的实施方式提供了混合型复合材料结构，其包括可用于将基本上全金属配件与基本上全复合树脂结构连接的纤维增强树脂复合材料-金属接头。该接头提供复合材料与金属结构之间的过渡，其适合用在更高性能的应用中，比如航天运载工具。这种从基本上全复合材料到基本上全金属材料的过渡可以降低或消除腐蚀的可能性和/或由于偏心率造成的问题。在复合材料结构的铺叠(lay-up)期间，金属片被一些复合材料板层替换，并且从复合材料板层到金属片的过渡出现在交错的位置，以便提供从复合材料部分到金属部分的足够负荷转移。交错的过渡造成复合材料板层和金属片之间的交叉(interleaving)并且产生多个接合缝，其可以减少接头中裂缝或脱胶(disbond)的发生和/或蔓延。金属片之间放置的粘合剂将金属片粘接和组合为接近实心的金属配件。
根据一个公开的实施方式，提供了复合材料结构，其包括一叠层压的纤维增强树脂板层和一叠金属片。金属片具有边缘，其与纤维增强树脂板层的边缘交叉，以形成连接纤维增强树脂板层与金属片的复合材料-金属接头。
根据另一个实施方式，提供了混合树脂-金属结构，其包括复合树脂部分、金属部分以及树脂部分和金属部分之间的过渡段。树脂部分包括纤维增强树脂的层压板层，并且金属部分包括粘合的金属片。过渡段包括在所述层压板层和金属片之间交错的重叠。
根据另一个实施方式，提供了混合复合材料金属部件。该部件包括纤维增强复合材料的铺叠，其终止于界面位置。在界面位置处，与复合材料相同厚度的金属板层延续至部件的金属边缘，并且重复铺叠，其中复合材料-金属界面从已有的界面位置朝向部件的边缘交错。结构粘合剂层置于金属板层之间，其中下一个金属-复合材料界面与部件边缘错开，以产生嵌套拼接，并且继续交错的界面堆叠——其产生嵌套的接头片(tab)——直至部件的全部厚度，其中复合材料板层都没有完全延伸至部件的边缘。
根据又另一个实施方式，提供了制造复合材料结构的方法。该方法包括形成具有复合材料部分和金属部分的多板层复合材料铺叠，并且在复合材料部分和金属部分之间形成复合材料-金属接头。该方法进一步包括将铺叠压实和固化。
根据进一步的实施方式，提供了生产混合金属部件的方法。该方法包括铺设至少一个纤维增强复合材料板层，其终止于界面位置；和铺设相邻的金属板层，其中金属板层与相邻纤维增强复合材料板层的厚度基本相同。重复铺设复合材料板层和相邻金属板层的步骤以形成复合材料-金属界面，其从已有界面位置朝向所述部件的边缘交错。该方法进一步包括在金属板层之间铺设结构粘合剂层，并且重复复合材料和金属板层铺叠，其中下一个金属-复合材料界面与部件边缘错开，以产生嵌套拼接。
9.混合复合树脂-金属结构，包括：
复合树脂部分，其包括纤维增强树脂的层压板层；
金属部分，其包括粘合的金属片；以及
过渡段，其在所述复合树脂部分和所述金属部分之间，所述过渡段包括在所述层压板层和所述金属片之间交错的重叠。
10.权利要求9所述的混合复合树脂-金属结构，其中：
所述层压板层和所述金属片分层排列，并且
每个层包括基本上边对边对接的一个所述金属片和多个所述纤维增强树脂板层。
11.权利要求10所述的混合复合树脂-金属结构，其中每个层中所述板层的厚度基本上等于所述层中所述金属片的厚度。
20.生产混合金属部件的方法，包括：
铺设至少一个纤维增强复合材料板层，其终止于界面位置；
铺设相邻的金属板层，其中所述金属板层与所述相邻的纤维增强复合材料板层的厚度相同；
重复所述铺设复合材料板层和相邻的金属板层的步骤以形成复合材料-金属界面，其从已有的界面位置朝向所述部件的边缘交错；
在所述金属板层之间铺设结构粘合剂层；和
重复所述复合材料和金属板层铺叠，其中下一个金属-复合材料界面与所述部件边缘错开，以产生嵌套拼接。
21.权利要求20所述的方法，进一步包括：
继续所述复合材料和金属板层的交错界面堆叠以产生嵌套接头片，直至所述部件的全部厚度，其中复合材料板层都没有完全延伸至所述部件的边缘。
22.权利要求21所述的方法，进一步包括：
真空袋加工所述部件以去除所述铺叠中的空气空隙；并且将铺叠的部件固化。
23.混合复合树脂-金属航空器结构，包括：
多个层压的层，其形成纤维增强的全复合材料部分、全金属部分、以及将所述复合材料部分与所述金属部分连接的混合复合材料-金属指形接头，
所述层中的每个都包括多个复合树脂板层和钛金属片，其中所述板层和所述金属片彼此边对边对接排列，在所述层中形成复合材料-金属过渡点，并且其中所述层中的过渡点相对于彼此交错以形成所述指形接头；和
在所述金属片之间用于将所述金属片组合的粘合剂层，并且
其中每个所述层中的板层的厚度基本上等于一个片和粘合剂层的组合厚度。
24.制造混合复合树脂-金属航空器结构的方法，包括：
形成铺叠，其包括纤维增强的全复合材料部分、全金属部分以及将所述复合材料部分与所述金属部分连接的混合复合材料-金属指形接头；形成所述铺叠，包括铺叠多个层，其中每个层通过将多个复合树脂板层与钛金属片边对边对接而形成，在所述层中形成复合材料-金属过渡点；
在所述金属片之间放置粘合剂层n以将所述金属部分组合；
通过将所述层中的过渡点相对于彼此交错，在所述复合材料部分和所述金属部分之间形成接头；
将所述铺叠压实；并且
将所述铺叠固化。
12.权利要求9所述的混合复合树脂-金属结构，其中所述交错的重叠在所述复合树脂部分和所述金属部分之间形成复合材料-金属指形接头。
13.权利要求9所述的混合复合树脂-金属结构，进一步包括在每个所述金属片之间的粘合剂层，用于将所述片粘合在一起并且将所述金属部分组合。
14.权利要求9所述的混合复合树脂-金属结构，其中每个所述金属片是钛合金。
15.混合复合材料-金属部件，包括：
纤维增强复合材料的铺叠，其终止于界面位置，其中与所述复合材料相同厚度的金属板层延续至部件的金属边缘，并且重复铺叠，其中复合材料-金属界面从已有的界面位置朝向部件边缘交错，并且包括在所述金属板层之间的结构粘合剂层，其中下一个所述金属-复合材料界面与所述部件边缘错开，以产生嵌套拼接，并且继续所述交错的界面堆叠——其产生嵌套的接头片——直至部件的全部厚度，其中所述复合材料板层都没有完全延伸至所述部件的边缘。
附图简述
图1是具有复合材料-金属接头的复合材料结构的截面图图示。
图2是包括复合材料-金属接头的复合材料结构的透视图图示。
图3是图2中指定为图3的区域的透视图图示。
图4是接头的截面图图示，更好地显示复合材料板层和金属片之间的交叉。
图5是图4中所示接头的两个单独层的截面图图示，也显示施加薄膜粘合剂在金属片上。
图6是通过图5中所示的两个层形成的接头的一部分的放大截面图图示。
图7是用于制造具有图2-4中所示的复合材料接头的复合材料结构的方法的宽泛流程图图示。
图8是显示图7中所示方法的额外细节的流程图图示。
图9是用于制造具有图2-4中所示的复合材料接头的复合材料结构的另一方法的流程图。
图10是航空器生产和维护方法的流程图图示。
图11是航空器的框图图示。
详述
首先参考图1，混合复合材料结构20包括复合树脂部分22，其通过包括复合材料-金属接头26的过渡段25连接到金属部分24。在图示的实例中，复合材料结构20是基本上平的复合材料片，然而，取决于应用，结构20可具有一个或多个弯曲、弧面(contour)或其它几何特征。例如，复合材料结构20可以构成航空器内和/或外成型的蒙皮(未显示)，其借助搭接接头(lap joint)30和经过蒙皮20进入框架28的紧固件32固定到航空器的框架28部分。
框架28可包括复合材料、金属或其它刚性材料，并且结构20的金属部分24可以用作刚性金属配件24，其适于在框架28和复合材料部分20之间转移一定范围的负荷和多种类型的加载。如下面将更详细讨论的，金属部分24可以包括任意各种金属，比如但不限于钛，其基本上不与复合材料部分20和结构28发生反应并可相容。在一个实际的实施方式中，例如但不限于，复合树脂部分22可以包括碳纤维增强环氧树脂，金属部分24可以包括钛合金，并且框架28可以包括铝合金或复合材料。过渡段25和接头26强度足以承载复合树脂部分22和金属部分24之间通常范围和类型的负荷，包括但不限于张力、弯曲、扭曲和剪切负荷。虽然图示的过渡段25和接头26在全复合树脂部分22和全金属部分24之间形成，但也可能使用其连接两种不同的复合材料结构(未显示)或两种不同的金属结构(未显示)。
参考图1-4，复合材料板层35的铺叠终止于下文称作过渡点39的界面位置39，其中基本上与复合材料板层35相同厚度的金属片或板层37延续至金属部分24的金属边缘24a，并且重复铺叠，其中复合材料-金属界面39从已有的界面位置39朝向金属边缘24a交错，并且包括在金属板层37之间的结构金属粘合剂层45(参见图5和6)，其中下一个金属-复合材料界面39与部件边缘24a错开，以产生嵌套拼接27。继续该交错的界面堆叠——其产生嵌套的接头片29(参见图3)——直至混合复合材料结构20的全部厚度，其中复合材料板层35都没有完全延伸至全金属部分24的金属边缘24a。
现在还参考图2-4，结构20的复合材料部分22包括纤维增强树脂板层35的层压堆叠34，并且结构20的金属部分24包括金属片或板层37的堆叠36，其粘合在一起以形成基本上组合的金属结构。如图5和6中所示，复合材料板层35和金属片37以层38排列。每个层38包括与一个金属片37基本上边对边对接的一个或多个复合材料板层35。因此，每个层38在点39处从复合材料即复合树脂板层35过渡到金属即金属片37。
过渡点39根据预定的铺叠计划相对于彼此交错，使得板层35和金属片37在过渡段25(图1)中彼此重叠。过渡点39的交错产生多个接合缝，其可以减少接头26中裂缝或脱胶的发生和/或蔓延。过渡点39的交错还产生复合材料板层35和金属片37在接头26内交叉的形式，其在全复合材料部分22和全金属部分24之间形成嵌套拼接27。该嵌套拼接27也可以称为指形粘接26、指形接头26或多梯级搭接接头26。相邻的过渡点39在结构20的面内方向上彼此间隔开，以便获得粘合的接头26，其展现最佳的性能特点，包括强度和对脱胶以及不一致(inconsistency)比如裂缝蔓延的抗性。在图示的实例中，形成接头26的嵌套拼接27为双指形接头26的形式，其中过渡点39从最大重叠的大致中心点55在相对方向上交错。然而，其它接头构型也是可能的，其包括但不限于单指形接头，其中多个过渡点39在单个方向上交错。
复合材料板层35可以包括纤维增强树脂，比如但不限于，碳纤维环氧树脂，其形式可以是单向的预浸带或织物。其它的纤维增强是可能的，包括玻璃纤维，并且使用非预浸材料可以是可能的。复合材料板层35可以具有预定的纤维取向，并且根据预定的板层计划铺叠，以满足期望的性能规格。如之前所述，粘合的片37可以包括金属比如钛，其适用于预期的应用。在图示的实例中，金属片37的堆叠36具有总厚度t1，其一般基本上等于板层35的层压的堆叠34的厚度t2。然而，在图示的实例中，在堆叠37的相对侧上，t2略微大于t1数个外包板层43的厚度。
图5和6图示说明图2-4所示的接头26的两个邻接层38的细节。在该实例中，每个层38包括具有集体总厚度T1的四个板层35。相邻层38的单个金属片37借助于结构粘合剂层45粘合在一起，结构粘合剂层45可以包括商业薄膜粘合剂或者其它形式的合适的粘合剂，其在铺叠过程期间置于金属片36之间。
图5中表示为T2的每个金属片37和一个粘合剂层45的组合厚度基本等于层38中复合材料板层35的厚度T1。虽然图中没有显示，粘合剂的薄膜可置于板层35之间以增加层间粘合强度。在一个实际的实施方式中，可使用钛合金金属片37，其中每个具有大约0.0025英寸的厚度，薄膜粘合剂45可以是大约0.005英寸厚，并且可以在每个具有大约0.30英寸的集体总厚度的层38中使用四个复合材料碳纤维环氧树脂板层35。取决于应用，使用除钛以外的金属是可能的。相邻过渡点39之间的距离、并因此层38之间重叠的长度、以及复合材料板层35的厚度和数量与金属片37的厚度将取决于具体应用的要求，包括待传输经过接头26的负荷的类型和大小，以及可能的其它性能规格。
分别在复合材料部分22和金属部分24(图1)的两种不同材料之间的接头26的不同层38使得结构20非常适合于使用嵌入式或悬挂式(mounted)传感器(未显示)进行粘合质量的非破坏性评估。超声结构波(未显示)可以在金属部分24的边缘、复合材料部分22或过渡段25中引入结构20。这些超声波行进经过相当于由金属37片和复合材料板层35与金属片37之间的界面(未显示)形成的波导。出于分析接头26中接合缝状态的目的，放置在结构20中的基于MEMS(微电子机械)的传感器、薄压电传感器(未显示)或其它变换器可用于接收超声结构波。
现参考图7，如65所示，制造复合材料结构20的一种方法包括形成多层复合材料铺叠。形成铺叠包括在步骤67铺叠复合树脂部分22，并且在69铺叠金属部分24。形成铺叠的步骤65进一步包括在铺叠的复合树脂部分和金属部分之间形成复合材料-金属接头，在71显示。
图8图示说明图7中所示方法的额外细节。在步骤40开始，将单个金属片37修整成期望的尺寸和/或形状。然后在42，通过适当方法制备金属片37的表面，该方法可包括用溶剂清洁片37、将其干燥等等，而后在44，通过以由预先定义的板层计划(未显示)确定的顺序铺叠金属片36和复合材料板层35而组装铺叠，该计划包括在每个层38中的板层35和金属片36之间的过渡点39的预定交错。
在铺叠过程期间，金属片37如同板层按顺序排列成铺叠，更如同在传统铺叠过程中复合材料板层按顺序排列成铺叠。如步骤46所示，可在金属片37之间引入粘合剂，以便将其粘合在一起成为组合的金属结构。类似地，虽然没有在图8中显示，但可在单独的复合材料板层35之间引入粘合胶，以便增加这些板层35之间的粘合强度。接下来，在48，可以使用任意数种已知的压实技术比如真空装袋将铺叠压实，而后在步骤50使用高压釜或非高压釜固化方法将铺叠固化。在步骤52，如果需要，可以修整和/或检查固化的复合材料结构20。
图9图示说明了制造混合复合材料部件20的方法的又另一个实施方式。该方法开始于步骤73，其中将至少一个终止于界面位置39的复合材料板层35铺设在合适的铺叠工具(未显示)上。在75，铺叠相邻的金属板层37，其基本与相邻的复合材料板层35的厚度相同。如77所示，重复铺叠过程，其中复合材料-金属界面39从已有的界面位置39朝向部件20的金属边缘24a交错。在79，在金属板层37之间铺设结构粘合剂层45。继续地重复步骤73-79，以产生嵌套拼接27和形成嵌套接头片29的交错界面堆叠，直至混合部件20的全部厚度，其中复合材料板层35都没有完全延伸至部件20的金属边缘24a。虽然图9中没有显示，但完成的铺叠进行真空装袋加工以去除空隙，并且随后使用任何合适的固化方法进行固化。
本公开内容的实施方式可用于多种潜在的应用，特别是在运输产业中，包括，例如，航空航天、船舶和汽车应用。因此，现参考图10和11，本公开内容的实施方式可用在图10所示的航空器制造和维护方法60和图11所示的航空器62的情况中。公开的实施方式的航空器应用可以包括，例如，各种结构性复合部件和组件，特别是在组装过程中需要使用紧固件的那些。在生产前期间，示例性方法60可以包括航空器62的规格和设计64以及材料采购66。在生产期间，发生航空器62的部件和子组件的制造68以及系统整合70。其后，航空器62可经受认证和交付72以便投入使用74。在消费者使用的同时，航空器62安排进行日常维修和保养76(其还可以包括改进、重新配置、整修等等)。
方法60的每个过程可以通过系统整合人员、第三方和/或操作人员(例如，消费者)执行或实施。出于该描述的目的，系统整合人员可以包括但不限于诸多航空器制造商和主要系统转包商；第三方可以非限制性地包括诸多销售商、转包商和供应商；以及操作者可以是航空公司、租赁公司、军事实体、服务组织等。
如图11所示，通过示例性方法60生产的航空器62可以包括具有多个系统80的机体78和内部82。高水平系统82的实例包括一个或多个推进系统84、电力系统86、液压系统88和环境系统90。可以包括任意数量的其它系统。公开的方法可用于制造用在机体78或内部82中的部件、结构和组件。虽然显示航空航天的实例，但本公开内容的原理还可适用于各种其它的工业，比如于船舶和汽车工业。
可以在生产和维护方法60的任意一个或多个阶段期间利用本文实施的系统和方法。例如，对应于生产过程68的部件、结构和组件可以以与使用航空器62时生产的部件、结构和组件类似的方式构造或制造。另外，例如通过大幅加快航空器62的装配或减少航空器62的成本，可以在生产阶段68和70期间利用一个或多个装置实施方式、方法实施方式或其组合。类似地，当航空器62在使用中，例如但不限于，用于维修和保养76时，可以利用一个或多个装置实施方式、方法实施方式或其组合。
虽然本公开内容的实施方式已经关于某些示例性的实施方式进行了描述，但应当理解特定实施方式是出于说明而非限制的目的，本领域技术人员将想到其它变型。

Claims (12)

1.复合材料结构，包括：
纤维增强树脂板层的层压堆叠；以及
金属片的堆叠，所述金属片具有与所述纤维增强树脂板层的边缘交叉的边缘，以形成将所述纤维增强树脂板层与所述金属片连接的复合材料-金属接头。
2.权利要求1所述的复合材料结构，其中：
所述纤维增强树脂板层和金属片的堆叠分层排列，其中每个所述层包括金属片和至少一个所述纤维增强树脂板层。
3.权利要求2所述的复合材料结构，其中每个所述层中的所述纤维增强树脂板层的厚度大体等于所述层中所述金属片的厚度。
4.权利要求2所述的复合材料结构，其中：
每个所述层中的所述纤维增强树脂板层和所述金属片具有基本对接的边缘，形成树脂-金属过渡点。
5.权利要求4所述的复合材料结构，其中所述层的所述过渡点相对于彼此交错。
6.权利要求2所述的复合材料结构，其中所述层在所述树脂板层的堆叠和所述金属片的堆叠之间形成纤维增强树脂-复合材料指形接头。
7.权利要求1所述的复合材料结构，进一步包括：
在相邻的所述金属片之间的粘合剂层，用于将所述片粘合在一起。
8.权利要求1所述的复合材料结构，其中：
所述金属片是钛合金，并且
所述板层的所述纤维增强包括碳。
9.制造复合材料结构的方法，包括：
形成具有纤维增强复合树脂部分和金属部分的多层复合材料铺叠，包括在所述铺叠的所述复合树脂部分和所述金属部分之间形成复合材料-金属接头。
10.权利要求9所述的方法，其中形成所述铺叠包括通过将至少一个纤维增强复合树脂板层和一个金属片以彼此基本上边对边对接放置，形成每个所述层，以在所述层中的所述纤维增强复合树脂和所述金属之间形成过渡点。
11.权利要求10所述的方法，其中形成所述铺叠包括将所述层中的所述过渡点相对于彼此交错。
12.权利要求10所述的方法，进一步包括：
通过在所述金属片之间放置粘合剂层而将所述金属部分组合。
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