CN106553397A - 一种纤维/金属层结构复合材料及其制备方法 - Google Patents
一种纤维/金属层结构复合材料及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种纤维/金属层结构复合材料及其制备方法,涉及功能复合材料制造领域。所述纤维/金属层结构复合材料由纤维树脂层和金属层交替组成,其中还可添加橡胶层;树脂中添加有修复剂微胶囊和催化剂,还可添加微米级强度增强颗粒。其制备方法包括将纤维经树脂浸润制成纤维树脂层;将金属板材经表面处理后制成金属层;将纤维树脂层与金属层交替铺放于模具型腔内;将模具型腔内的层结构经加温、加压和固化处理。本发明将纤维树脂复合材料、金属、橡胶的优点相结合,具有较强的设计性;所设计的材料比强度高、耐疲劳、耐腐蚀、高阻尼等突出特点的功能复合材料,一定程度上满足航空航天、国防、轨道交通、汽车等领域对新材料的迫切需求。
Description
技术领域
本发明公开了一种纤维/金属层结构复合材料及其制备方法,涉及功能复合材料制造技术,属于材料学领域。
背景技术
伴随着航空、航天等领域科学技术的发展,火箭、载人飞船、空间站等航天器相继发射成功,其对使用的材料性能提出轻量化、耐高温、易修复等新的要求。复合材料因其具有比强度高、疲劳性能好等优点广泛应用于航空、航天领域。遗憾的是,在外太空的陨石撞击、离子辐射等复杂工况作用下,航天器使用的复合材料会出现破损现象,相关材料破损的发生,使得维修成本高昂,人工修复较为困难。因此,如何实现材料自修复已经成为航空、航天领域迫切需要解决的技术难题。
发明内容
为解决航空、航天材料复杂工况下,存在的“破损后维修成本高、人工修复困难”等技术难题,本发明公开了一种纤维/金属层结构复合材料及其制备方法,其中:
纤维/金属层结构复合材料的特征在于:所述层结构复合材料由纤维树脂层4和金属层5交替组成;所述纤维树脂层4为被树脂浸润的纤维,所述树脂中添加有修复剂微胶囊2和催化剂3。所述修复剂微胶囊2的内部修复剂为环戊二烯二聚体的脲醛树脂;所述催化剂3为格拉布催化剂。所述树脂中还添加有微米级强度增强颗粒8。所述微米级强度增强颗粒8为金刚石或氮化硼。所述层结构复合材料还设有橡胶层7;所述橡胶层7、纤维树脂层4与金属层5相互交替设置。
纤维/金属层结构复合材料的制备方法的特征在于:
步骤一:将纤维经树脂浸润制成纤维树脂层4;步骤二:将金属板材经表面处理后制成金属层5;步骤三:将纤维树脂层4与金属层5交替铺放于模具型腔内;步骤四:将模具型腔内的层结构经加温、加压和固化处理,制成层结构复合材料。
步骤一中所述树脂为热固性树脂或热塑性树脂;步骤一中所述树脂中添加修复剂微胶囊2与催化剂3;所述修复剂微胶囊2的内部修复剂为环戊二烯二聚体的脲醛树脂,所述催化剂3为40-50微米的格拉布催化剂;步骤三中所述纤维树脂层4与金属层5的层结构间添加橡胶层7;纤维树脂层4、金属层5以及橡胶层7交替铺放于模具型腔内;步骤四中所述固化处理所采用的固化剂成分为聚醚胺(PEA)或异佛尔酮二胺(IPDA)。
所述的树脂中还添加有微米级强度增强颗粒8;所述微米级强度增强颗粒8为金刚石或氮化硼。
步骤一中,所述纤维的材质为碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、凯夫拉纤维、麻纤维或木纤维中的至少一种;所述纤维的结构形式为短纤维、长纤维、连续纤维丝9或纤维织物10中的至少一种;所述金属板材的材质为铝合金、钛合金、铝锂合金或镁合金中的至少一种;所述橡胶层7的材质为硅橡胶、丁基橡胶或丁腈橡胶中的至少一种。
步骤二中,对金属板材的表面处理为:先采用有机溶剂或氢氧化钠与碳酸钠的混合液或酸性溶液对金属板材表面进行净化处理;然后通过机械处理的方式提高金属表面活性能。
与现有技术相比,本发明的有益效果在于:
本发明创造性地解决了航空、航天材料复杂工况下,存在的“破损后维修成本高、人工修复困难”等技术难题,本发明通过纤维、树脂、修复剂、催化剂、金属板、橡胶的种类、体积分数、铺排角度等参数优选,能够制备出纤维/金属层结构复合材料,实验结果表明:本发明制备的纤维/金属层结构复合材料及其制备方法,实现了材料微裂纹的自我修复;较金属材料,其减重达到15%-20%,提高疲劳性能3-10倍,增加阻尼性能30%-50%。本发明为航空、航天领域迫切需要解决的“材料自修复技术难题”提供了解决方案,一定程度上满足了航空、航天、国防、轨道交通、汽车等领域对自修复材料的迫切需求。
附图说明:
图1是纤维/金属层结构复合材料的结构示意图,其中:
图1a为修复剂微胶囊未被裂纹穿破的裂纹扩展状态示意图;
图1b为裂纹扩展穿破微胶囊状态示意图;
图1c为穿破的微胶囊释放的修复液与催化剂发生交联聚合状态示意图;
图1d为加入橡胶层的结构示意图;
图1e为加入橡胶层和微米级强度增强颗粒的结构示意图。
图2是选用不同外层材料的纤维/金属层结构复合材料的结构示意图,其中:
图2a为纤维树脂层为外层材料时结构示意图;
图2b为橡胶层为外层材料时结构示意图;
图2c为纤维树脂层和金属层分别为外层材料时结构示意图;
图2d为橡胶层和金属层分别为外层材料时结构示意图;
图2e为橡胶层和纤维树脂层分别为外层材料时结构示意图。
图3为采用连续纤维时纤维/金属层结构复合材料的结构示意图,其中:
图3a为采用连续纤维丝时纤维/金属层结构复合材料的结构示意图;
图3b为采用正交铺排的连续纤维丝时纤维/金属层结构复合材料的示意图;
图3c为采用连续纤维织物时纤维/金属层结构复合材料的示意图。
图中:
1-短纤维; 2-修复剂胶囊; 3-催化剂; 4-纤维树脂层;
5-金属层; 6-裂纹; 7-橡胶层; 8-微米级强度增强颗粒;
9-连续纤维丝; 10-连续纤维织物。
具体实施方式:
下面结合说明书附图,举例说明具有自修复功能的纤维/金属层结构复合材料制备方法实施方式:
如图1a所示,本发明公开了一种纤维/金属层结构复合材料,由纤维树脂层4和金属层5交替组成;纤维树脂层4为被树脂浸润的短纤维1,所述树脂为热固性树脂或热塑性树脂,且在树脂中添加有修复剂微胶囊2和催化剂3,其中:修复剂微胶囊2内部修复液为环戊二烯二聚体的脲醛树脂(DCPD),催化剂3为40-50微米的格拉布催化剂(Grubbs);所述金属层5的材质为铝合金、钛合金、铝锂合金或镁合金等中至少一种。如图1b所示,当本发明所述纤维/金属层结构复合材料受到外部作用力后,裂纹6扩展并穿破修复剂微胶囊2;接下来,如图1c所示,被穿破的修复剂微胶囊2释放出内部修复液,并与外部催化剂3发生交联聚合,实现了纤维/金属层结构复合材料的自修复过程。
此外,为满足航空、航天等领域对低阻尼系数及高强度的材料特性需求,如图1d所示,本发明在纤维树脂层4与金属层5的层合结构中还添加有橡胶层7,所述橡胶层7材质为硅橡胶、丁基橡胶或丁腈橡胶等中至少一种;如图1e所示,在纤维树脂层4中还添加了微米级强度增强颗粒8,以提高材料的强度,所述微米级强度增强颗粒8为金刚石或氮化硼等。本发明最终有效解决了航空、航天材料复杂工况下,存在的“破损后维修成本高、人工修复困难”等技术难题。
为充分发挥本发明所述的纤维/金属层结构复合材料的可设计性,交替铺放的纤维树脂层4、橡胶层7、金属层5可以按需求进行铺排,即金属层5、纤维树脂层4或橡胶层7均可以单独作为复合材料的两面外层材料,如图1e、2a和2b所示;当然,也可选择金属层5、纤维树脂层4或橡胶层7中的任意两种分别作为复合材料的两面外层材料,即纤维树脂层4和金属层5、橡胶层7和金属层5、橡胶层7和纤维树脂层4也均可以分别作为复合材料的两面外层材料,如图2c、2d、2e所示;上述设计充分满足了航空、航天、国防、轨道交通、汽车等领域不同工况需求。
为进一步提高本发明纤维/金属层结构复合材料的强度及各向同性,所述树脂纤维层4中的纤维除采用短纤维1(如图1a所示)的结构形式以外,还可以采用长纤维、连续纤维丝9(如图3a、3b所示)或连续纤维织物10(如图3c所示)中至少一种,且纤维的排列形式也可根据实际情况进行调整,如图3a所示为单一方向排列的连续纤维丝9,如图3b所示为采用正交铺排的连续纤维丝9;此外,纤维的材质可以为碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、凯夫拉纤维、麻纤维、木纤维等中的一种或多种。
结合上述技术方案,本发明还提供了一种纤维/金属层结构复合材料的制备方法,具体制备过程如下:
步骤一:制备纤维树脂层4:
将纤维放入添加有修复剂微胶囊2、催化剂3和微米级强度增强颗粒8的树脂中充分浸润;其中:所选用的纤维材质为碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、凯夫拉纤维、麻纤维或木纤维等中至少一种;所选纤维的结构形式为短纤维、长纤维、连续纤维丝9或纤维织物10;所采用的修复剂微胶囊2中的修复剂为环戊二烯二聚体的脲醛树脂(DCPD);所采用的催化剂3为格拉布催化剂(Grubbs);所采用的微米级强度增强颗粒8为金刚石或氮化硼等。
步骤二:制备金属层5:
先采用丙酮或乙醇等有机溶剂、氢氧化钠和碳酸钠等混合液、稀硝酸等酸性溶液对金属板表面净化处理;之后,借助抛光、喷砂等机械处理手段对净化后的金属板表面进行处理,提高金属表面的活性能,其中:金属板材质为铝合金、钛合金、铝锂合金或镁合金等中至少一种。
步骤三:将制备好的纤维树脂层4和制备好的金属层5以层结构交替铺放于模具型腔内;在此步骤中,可根据实际需要添加橡胶层7,所述橡胶的材质为硅橡胶、丁基橡胶或丁腈橡胶等中至少一种;纤维树脂层4、金属层5和橡胶层7以层结构交替铺排,且无需固定次序,所述纤维树脂层4、金属层5或橡胶层7均可作为外层材料。
步骤四:将已交替铺排好的层结构经50-300℃温度范围加温、1-30MP加压、4-20小时固化,实现纤维/金属层结构复合材料制备;此过程中所选用的固化剂主要成分为聚醚胺(PEA)或异佛尔酮二胺(IPDA)等。
Claims (10)
1.一种纤维/金属层结构复合材料,其特征在于:所述层结构复合材料由纤维树脂层(4)和金属层(5)交替组成;所述纤维树脂层(4)为被树脂浸润的纤维,所述树脂中添加有修复剂微胶囊(2)和催化剂(3)。
2.根据权利要求1所述的一种纤维/金属层结构复合材料,其特征在于:所述修复剂微胶囊(2)的内部修复剂为环戊二烯二聚体的脲醛树脂;所述催化剂(3)为格拉布催化剂。
3.根据权利要求1所述的一种纤维/金属层结构复合材料,其特征在于:所述树脂中还添加有微米级强度增强颗粒(8)。
4.根据权利要求3所述的一种纤维/金属层结构复合材料,其特征在于:所述微米级强度增强颗粒(8)为金刚石或氮化硼。
5.根据权利要求1-4中任一项所述的一种纤维/金属层结构复合材料,其特征在于:所述层结构复合材料还设有橡胶层(7);所述橡胶层(7)、纤维树脂层(4)与金属层(5)相互交替设置。
6.一种纤维/金属层结构复合材料的制备方法,其特征在于:
步骤一:将纤维经树脂浸润制成纤维树脂层(4);
步骤二:将金属板材经表面处理后制成金属层(5);
步骤三:将纤维树脂层(4)与金属层(5)交替铺放于模具型腔内;
步骤四:将模具型腔内的层结构经加温、加压和固化处理,制成层结构复合材料。
7.根据权利要求6所述的一种纤维/金属层结构复合材料制备方法,其特征在于:
步骤一中所述树脂为热固性树脂或热塑性树脂;
步骤一中所述树脂中添加修复剂微胶囊(2)与催化剂(3);所述修复剂微胶囊(2)的内部修复剂为环戊二烯二聚体的脲醛树脂,所述催化剂(3)为40-50微米的格拉布催化剂;
步骤三中所述纤维树脂层(4)与金属层(5)的层结构间添加橡胶层(7);纤维树脂层(4)、金属层(5)以及橡胶层(7)交替铺放于模具型腔内;
步骤四中所述固化处理所采用的固化剂成分为聚醚胺或异佛尔酮二胺。
8.根据权利要求6或7所述的一种纤维/金属层结构复合材料制备方法,其特征在于:所述的树脂中还添加有微米级强度增强颗粒(8);所述微米级强度增强颗粒(8)为金刚石或氮化硼。
9.根据权利要求6所述的一种纤维/金属层结构复合材料制备方法,其特征在于:
步骤一中,所述纤维的材质为碳纤维、玻璃纤维、玄武岩纤维、芳纶纤维、凯夫拉纤维、麻纤维或木纤维中的至少一种;所述纤维的结构形式为短纤维、长纤维、连续纤维丝或纤维织物中的至少一种;所述金属板材的材质为铝合金、钛合金、铝锂合金或镁合金中的至少一种;所述橡胶层的材质为硅橡胶、丁基橡胶或丁腈橡胶中的至少一种。
10.根据权利要求6所述的纤维/金属层结构复合材料制备方法,其特征在于:步骤二中,对金属板材的表面处理为:先采用有机溶剂或氢氧化钠与碳酸钠的混合液或酸性溶液对金属板材表面进行净化处理;然后通过机械处理的方式提高金属表面活性能。
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