CN105482723B - 接头组件及其检查方法 - Google Patents

接头组件及其检查方法 Download PDF

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CN105482723B
CN105482723B CN201510598664.7A CN201510598664A CN105482723B CN 105482723 B CN105482723 B CN 105482723B CN 201510598664 A CN201510598664 A CN 201510598664A CN 105482723 B CN105482723 B CN 105482723B
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joint assembly
control particles
parts
adhesive layer
control
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CN105482723A (zh
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P·克罗瑟斯
L·赫里斯托祖卢
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Boeing Co
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    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
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    • B29C66/73921—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of at least one of the parts being a thermoplastic characterised by the materials of both parts being thermoplastics
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Abstract

本发明名称为接头组件及其检查方法。提供接头组件(218)。接头组件(218)包括第一零件(202)和第二零件(204)，第一零件包括第一粘合表面(206)和第二零件包括连接至第一粘合表面(206)的第二粘合表面(208)，这样使得在其间限定粘合层。第一和第二零件零件(202，204)中至少一个包括多个对照颗粒(222，224)，当向第一和第二零件(202，204)施加预定量的热和压力时，所述对照颗粒扩散穿过粘合层。

Description

接头组件及其检查方法
技术领域
本公开内容的领域一般涉及复合接头，以及更具体地，涉及复合接头无损粘合强度检验技术。
背景技术
至少一些已知的航空器零件可以由非金属复合材料——诸如碳纤维增强聚合物(CFRP)——的多层层压结构制造。复合材料一般具有高的强度-重量比并且可以以各种形状和尺寸形成。为了减轻航空器的重量，复合材料可以与金属材料诸如铝、钛和/或钢结合使用。减轻整体重量一般有助于增加航空器的燃料效率。
由复合材料制造的至少一些已知的航空器零件可以与粘合剂材料粘合在一起。虽然粘合剂材料在将零件粘合在一起上一般是有效的，但在航空器的使用寿命期间可能发生脱胶。例如，在长时间使用航空器后可能发生脱胶和/或在飞行期间当异物撞击材料时可能导致脱胶。在定期维护期间，这样的脱胶可能难以检测，并且可能难以通过目测检查来检测。
而且，检验在制造部件期间已经在零件之间形成合格的粘合是困难且昂贵的。例如，至少一种已知的检验粘合强度的方法包括在与形成部件相同的条件下使用相同的过程形成过程检验试样(coupon)。然后通过破坏试验评估过程检验试样的强度，如果试样的粘合强度比预定阀值大，则部件通过验收以便使用。然而，形成和评估过程检验试样是耗时且繁重的任务，其仅提供在零件之间形成的粘合的间接粘合强度检验。
发明内容
在一方面，提供接头组件。接头组件包括第一零件和第二零件，第一零件包括第一粘合表面和第二零件包括连接至第一粘合表面的第二粘合表面，这样使得在其间限定粘合层(bond line)。第一和第二零件中至少一个包括多个对照颗粒(contrast particle)，当向第一和第二零件施加预定量的热和压力时所述对照颗粒扩散穿过粘合层，其中所述第一和第二零件中至少一个包括多个对照颗粒，当向所述第一和第二零件施加预定量的热和压力时所述对照颗粒扩散穿过粘合层。有利地，第一零件包括多个由第一材料制造的第一对照颗粒，和所述第二零件包括由不同于第一材料的第二材料制造的多个第二对照颗粒。优选地，当施加预定量的热和压力时，多个第一和第二对照颗粒彼此混杂(intersperse)。有利地，当通过无损验伤技术评估时，多个对照颗粒由能够检测的第一材料制造。优选地，接头组件包括第一和第二零件，第一和第二零件包括多个对照颗粒，其中多个对照颗粒由第一材料制造，第一材料不同于用于制造所述第一和第二零件的第二材料，这样使得当通过无损检查技术评估时，测定第一和第二材料之间的差异。有利地，第一和第二零件由热塑材料制造，其中所述多个对照颗粒的对照颗粒具有小于大约100纳米的尺寸。
在另一方面，提供接头组件。接头组件包括第一零件和第二零件，第一零件包括第一粘合表面和第二零件包括配置为连接至所述第一粘合表面第二粘合表面。接头组件还包括放置在第一和第二粘合表面之间的粘合剂层(layer of adhesive)，这样使得第一粘合层被限定在该层和第一粘合表面之间，并且使得第二粘合层被限定在该层和第二粘合表面之间。粘合剂层包括多个对照颗粒，当向第一和第二零件施加预定量的热和压力时所述对照颗粒扩散穿过第一和第二粘合层中至少一个。
在又另一个方面，提供检查接头组件的方法。该方法包括通过无损检查技术评估接头组件，获得接头组件的图像，并基于图像中对照颗粒的位置检验接头组件中零件之间的粘合形成。当向零件施加预定量的热和压力时，对照颗粒从第一位置扩散进入零件中至少一个。
附图说明
图1为示例性航空器生产和使用方法的流程图。
图2为示例性航空器的方框图。
图3为图解形成示例性接头组件的一系列过程步骤的示意性流程图。
图4为图解形成可选的接头组件的一系列过程步骤的示意性流程图。
图5为检查接头组件的示例性方法的流程图。
具体实施方式方式
本文描述的实施方式涉及接头组件和其检查方法。更具体地，本文描述的方法能够直接检验接头组件中零件之间的粘合形成，其中通过在粘合界面处扩散在热塑材料中形成粘合。经由无损检查(NDI)技术通过评估接头组件提供直接的检验，并且接头组件包括分散在其中的对照颗粒，当通过NDI技术评估时，所述对照颗粒能够检测。例如，对照颗粒最初位于零件自身中或位于放置在零件之间的粘合剂层中。当施加预定量的热和压力时，诸如传统用于形成接头组件的量的热和压力，对照颗粒扩散穿过在零件之间限定的粘合层。对照颗粒在完成的接头组件中的位置由NDI评估确定，并且当对照颗粒位于组件的相邻零件内时(即，当出现扩散时)，确认合格的粘合检验。
参考附图，公开内容的实施方式可在航空器制造和使用方法100(图1所示)的上下文中并通过航空器102(图2所示)描述。在生产前期间，可以在制造过程期间使用包括航空器102的规格和设计104数据，并且可以采购106与机身相关联的其它材料。在生产期间，在航空器102进入其验收和交付过程112之前，进行航空器102的零件和子组件制造108和系统集成110。一旦机身验收成功满足并完成，航空器102可被投入使用114。在由客户使用中，为航空器102安排周期性的、常规的以及定期维护和保养116，其包括例如任何修改、重新配置和/或整修。在可选的实施方式中，制造和使用方法100可通过除航空器以外的平台执行。
与航空器制造和/或使用100相关联的每个部分和过程可由系统集成商、第三方和/或操作者(如，客户)执行或完成。出于该描述的目的，系统集成商可包括但不限于任何数量的航空器制造商和主系统分包商；第三方可包括但不限于任何数量的商户、分包商和供应商；以及操作者可以为航空公司、租赁公司、军事实体、服务组织等。
如图2所示，通过方法100生产的航空器102可包括具有多个系统120的机身118和内部122。高级系统120的实例包括一个或多个推进系统124、电力系统126、液压系统128和/或环境系统130。可包括任何数量的其它系统。
本文体现的装置和方法可以在方法100的任何一个或多个阶段期间采用。例如，对应于零件和子组件生产过程108的零件或子组件可以以类似于在航空器102投入使用114时生产的零件或子组件的方式制作或制造。同样，在生产阶段108和110期间，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，例如，通过大幅地加快航空器102的组装和/或降低航空器102的组装成本。类似地，在航空器102保养和维护时，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，例如，在定期维护和保养116期间。
如本文所使用，术语“航空器”可包括但不限于仅包括飞机、无人机(UAV)、滑翔机、直升机、和/或通过空域航行的任何其他物体。进一步，在可选的实施方式中，本文描述的航空器制造和使用方法可用于任何制造和/或使用操作。
图3为图解形成示例性接头组件200的一系列过程步骤的示意性流程图。在示例性实施方式中，接头组件200包括第一零件202和第二零件204。第一零件202包括第一粘合表面206以及第二零件204包括连接至第一粘合表面206的第二粘合表面208，这样使得粘合层210在其间限定。而且，第一零件202和第二零件和204中至少一个包括分散在其中的多个对照颗粒。具体地，在一个实施方式中，第一零件202包括分散在其中的多个第一对照颗粒212，以及第二零件204包括分散在其中的多个第二对照颗粒214。如将在下面更详细描述的，当向第一零件202和第二零件204施加预定量的热和压力216时，对照颗粒212和214扩散穿过粘合层210。
第一零件202和第二零件204可由使接头组件200实现如本文描述功能的任何材料制造。用于制造零件202和204的示例性材料包括热塑材料，诸如但不限于碳纤维增强聚合物。如此，在形成零件202和204期间，由热塑材料制造零件202和204实现在其中分散对照颗粒212和214。
第一对照颗粒212和第二对照颗粒214可由使接头组件200实现如本文中所描述功能的任何材料制造。具体地，例如，在一个实施方式中，第一对照颗粒212由第一材料制造，以及第二对照颗粒214由在至少一个特征诸如材料或尺寸上不同于第一材料的第二材料制造。基于当通过无损检查技术评估接头组件200时材料是否能够检测，选择用于制造第一对照颗粒212和第二对照颗粒214的材料。例如，如果实施的无损检查技术为涡流试验，则对照颗粒212和214由诸如石墨烯的导电材料制造。
而且，如上面所描述的，第一和第二材料在至少一个特征上不同，这样使得当通过无损检查技术评估时，可以确定第一对照颗粒212和第二对照颗粒214之间的差异。如此，如将在下面更详细描述的，基于对照颗粒212和对照颗粒214在接头组件200中的位置，可以检验第一零件202和第二零件204之间的粘合形成。在可选的实施方式中，第一零件202和第二零件204中只有一个包括对照颗粒，这样使得当对照颗粒扩散穿过粘合层210时，检测粘合形成。
第一对照颗粒212和第二对照颗粒214也可为使接头组件200实现如本文中所描述功能的任何尺寸。例如，在示例性实施方式中，对照颗粒212和214具有小于大约100纳米的尺寸，这样使得当施加热和压力216时，对照颗粒212和214容易地扩散穿过粘合层210。而且，利用该尺寸的颗粒利于减少对用于制造第一零件202和第二零件204的材料的机械性质的改造。
在一系列过程步骤中，第一粘合表面206和第二粘合表面208被连接在一起，并且向基本上形成单一结构的第一零件202和第二零件204施加热和压力216。热和压力216利于软化零件202和204的热塑材料，这样使得对照颗粒212和214的至少一些扩散穿过粘合层210。如此，可以基于对照颗粒212和214在接头组件200中的位置检验零件202和204之间的粘合形成。更具体地，基于对照颗粒212和214在接头组件200内的位置处的预定体积内的浓度或任一对照颗粒212和214分别扩散进入相对的零件202和204的距离，检验粘合形成。
图4为图解形成可选的接头组件218的一系列过程步骤的示意型流程图。在示例性实施方式中，接头组件218包括第一零件202和第二零件204，并且粘合表面206和208被间接连接在一起。在粘合表面206和208之间放置粘合剂层220，这样使得在层220和第一粘合表面206之间限定第一粘合层222，以及在层220和第二粘合表面208之间限定第二粘合层224。而且，与接头组件200(图3所示)不同，第一零件202和第二零件204不包括分散在其中的对照颗粒212和214。而是，如将在下面更详细描述的，粘合剂层220包括多个对照颗粒226，当向第一零件202和第二零件204施加预定量的热和压力216时，多个对照颗粒226扩散穿过第一粘合层222和第二粘合层224的至少一个。
粘合剂层220包括树脂基体228和分散在其中的对照颗粒226。树脂基体228可以为使接头组件218实现如本文中描述功能的任何材料。在示例性实施方式中，树脂基体228由不同于用于制造对照颗粒226的第一材料的第三材料制造，这样使得当通过无损检查技术评估时，可以确定其间的差异。
在一系列过程步骤中，粘合剂层220被放置在第一零件202和第二零件204之间，并且向其施加热和压力216。热和压力216利于软化零件202和204的热塑材料，并且利于固化粘合剂层220。随着层220固化，分散在其中的对照颗粒226扩散穿过第一粘合层222和第二粘合层224中至少一个。如此，基于对照颗粒226在接头组件218中的位置可以检验零件202和204之间的粘合形成。更具体地，基于对照颗粒226扩散进入零件202和204中每个的距离检验粘合形成。
图5为检查接头组件诸如接头组件200或218(图3和4所示)的示例性方法300的流程图。在示例性实施方式中，方法300包括通过无损检查技术评估302接头组件，和获得304接头组件的图像。示例性非检查技术包括但不限于涡流试验、层析x射线摄影法、太赫兹成像技术或x射线成像技术。在一个实施方式中，沿接头组件的零件之间限定的粘合层诸如粘合层210、222或224评估302接头组件。
方法300还包括基于图像中对照颗粒的位置检验306接头组件中零件之间的粘合形成。当向零件施加预定量的热和压力时，对照颗粒从第一位置扩散进入至少一个零件。例如，当评估接头组件200时，第一位置位于零件202和204中一个内，以及当评估接头组件218时，第一位置位于粘合剂层220内。在一个实施反式中，在检验接头组件中零件的粘合形成之前，检验图像的分辨率大于预定图像质量阀值。如果分辨率小于预定图像质量阀值，则获得随后的图像直到获得了合适的图像。
如上面所描述，检验306粘合形成包括确定接头组件的位置处对照颗粒的浓度或对照颗粒扩散进入至少一个零件的距离中至少一个。而且，检验306粘合形成包括确定用于制造多个对照颗粒的第一材料和用于制造零件的第二材料之间的差异，或如果第一材料和第二材料被用于制造零件，则确定两者之间的差异。
书面描述使用实例以公开各种实施方式，包括最佳模式，并且还使本领域技术人员能够实践各种实施方式，包括制造和使用任何设备或系统以及执行任何合并的方法。公开内容的可取得专利权的范围由权利要求限定，并且可包括本领域技术人员想到的其它实例。如果其它实例具有不同于权利要求的文字语言的结构要素，或如果它们包括与权利要求的文字语言无实质区别的等效结构要素，则这样的其它实例旨在权利要求的范围内。

Claims (10)

1.检查接头组件(200)的方法，所述接头组件包括：
第一零件(202)，其包括第一粘合表面(206)；和
第二零件(204)，其包括被配置为连接至所述第一粘合表面(206)的第二粘合表面(208)，使得在其之间限定粘合层(210)，
其中所述第一零件(202)包括在其中分散的由第一材料制造的多个第一对照颗粒(212)，和第二零件(204)包括在其中分散的由不同于所述第一材料的第二材料制造的多个第二对照颗粒(214)，其中当通过无损检查技术评估时，所述第一材料和所述第二材料能够被检测，当向所述第一零件(202)和所述第二零件(204)施加预定量的热和压力时，所述第一对照颗粒(212)和所述第二对照颗粒(214)扩散穿过粘合层(210)；
所述方法包括：
通过无损检查技术评估所述接头组件(200)；
获得所述接头组件(200)的图像；和
基于所述图像中对照颗粒(212，214)的位置，通过检验所述第一对照颗粒(212)和所述第二对照颗粒(214)扩散穿过粘合层(210)来检验所述接头组件(200)中零件(202，204)之间的粘合形成。
2.根据权利要求1所述的方法，其中在检查的接头组件(200)中，当通过无损检查技术评估时，所述第一对照颗粒(212)和所述第二对照颗粒(214)由能够检测的材料制造。
3.根据权利要求2所述的方法，其中所述第一对照颗粒(212)由第一材料制造和所述第二对照颗粒(214)由在至少一个特征上不同于所述第一材料的第二材料制造。
4.根据权利要求3所述的方法，其中所述特征指材料或尺寸。
5.根据权利要求1所述的方法，其中在检查的接头组件(200)中，所述第一零件和第二零件(202，204)由热塑材料制造。
6.根据权利要求1所述的方法，其中在检查的接头组件(200)中，所述第一对照颗粒(212)和所述第二对照颗粒(214)具有小于100纳米的尺寸。
7.根据权利要求1所述的方法，进一步包括检验所述图像的分辨率大于预定图像质量阀值。
8.根据权利要求1所述的方法，其中检验粘合形成包括确定所述第一对照颗粒(212)和所述第二对照颗粒(214)在所述接头组件(200)内的所述位置处的浓度或所述第一对照颗粒(212)和所述第二对照颗粒(214)扩散进入所述零件(202，204)中至少一个的距离中的至少一个。
9.根据权利要求1所述的方法，进一步包括当所述第一对照颗粒(212)和所述第二对照颗粒(214)扩散穿过所述粘合层(210)时，验证所述接头组件(200)以便使用。
10.根据前述权利要求中任一项所述的方法，进一步包括以下步骤：
提供所述第一零件(202)、所述第二零件(204)和所述粘合层(210)；
施加所述预定量的热和压力至所述第一零件和第二零件(202，204)。
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