CN107602142B - Preparation method of integrated integral composite material air rudder - Google Patents
Preparation method of integrated integral composite material air rudder Download PDFInfo
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- CN107602142B CN107602142B CN201710677374.0A CN201710677374A CN107602142B CN 107602142 B CN107602142 B CN 107602142B CN 201710677374 A CN201710677374 A CN 201710677374A CN 107602142 B CN107602142 B CN 107602142B
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Abstract
The preparation method of the integrated integral composite material air rudder comprises the steps of stacking and paving at least three pieces of carbon cloth, directly sewing carbon fiber yarns in one dimension, calcining at 1310 +/-10 ℃ after dipping in polycarbosilane solution, carrying out thermal curing reaction to obtain a ceramic product, carrying out heat treatment at 1610 +/-10 ℃ to remove impurities to obtain a rough blank, cutting the rough blank by a diamond cutter to form a fine blank, and grinding and finish machining to prepare the integrated integral composite material air rudder, so that the defects of difficult die manufacturing, easy glue accumulation and slag removal, easy size over-tolerance, poor process stability, poor ablation resistance and the like of a small-sized quartz fiber composite rudder are overcome; the defect that the cost of the traditional three-dimensional five-direction woven C/SiC air rudder is high is overcome; the target of zero ablation can be achieved, and the flight control precision can be effectively improved in an auxiliary mode.
Description
Technical Field
The invention belongs to the technical field of aircraft air rudder (wing) preparation, and particularly relates to a preparation method of an integrated integral composite material air rudder.
Background
The aircraft is exposed to a severe pneumatic heating environment, the air rudder (wing) is used as a control component, serious ablation threat is faced, the front edge and the shape of the rudder are easy to generate certain changes, and deviation of control precision can be caused.
The traditional air rudder generally adopts quartz fiber, and when a mold forming mode is used, glue is easy to gather, the front edge strength is low, ablation is easy, and the rudder shaft needs extra protective measures; the traditional three-dimensional five-way woven C/SiC air rudder at present has the defects of complex process and high cost, the product cost is increased, and the application range of the air rudder is limited.
Disclosure of Invention
The invention provides a preparation method of an integrated integral composite material air rudder, which is used for researching and producing key parts of an aircraft and can solve the problems that the front edge of the traditional quartz air rudder is low in strength and easy to ablate, and a rudder shaft needs extra protective measures; the defects that the traditional three-dimensional five-direction weaving and needling C/SiC air rudder is complex in process and high in cost, and meanwhile, the air rudder is low in strength and complex in process in the traditional needling process are overcome.
The specific technical scheme adopted for realizing the purpose of the invention is as follows:
the preparation method of the integrated integral composite material air vane comprises the steps of stacking and paving at least three carbon cloth sheets, sewing the carbon fiber yarns in one dimension, immersing the carbon fiber yarns in polycarbosilane solution, calcining the carbon fiber yarns at 1310 +/-10 ℃ for thermal curing reaction to obtain a ceramic product, performing heat treatment at 1610 +/-10 ℃ for removing impurities to obtain an air vane rough blank with the size of 1.3-1.5 times of the proportion, cutting by a diamond cutter, grinding and finish machining to prepare the integrated integral composite material air vane, wherein:
(1) the thickness of the single carbon cloth is 0.1 mm-0.2 mm;
(2) the sewing density is 2-5 needles/square centimeter;
(3) repeating the dipping, calcining and thermal curing reaction for more than 10 times;
(4) carrying out primary heat treatment to remove impurities;
(5) carrying out successive micro-cutting processing on the air vane blank by adopting a diamond cutter, wherein the cutting amount is about 10 +/-3 microns/time, and forming an air vane fine blank with the size of 1.1-1.2 times of the proportion;
(6) and (4) grinding and finely processing the fine blank of the air vane for many times, wherein the grinding amount is less than 10 microns/time until the requirements on the appearance and the size of the air vane are met.
The inspection and acceptance adopts X-ray, microwave and ultrasonic flaw detection methods, and the hollow (or bubble) surface in the air rudder is subjected toThe product is larger than 1cm2The product of (1) is prohibited from use.
By adopting the technical scheme, the technical effects are as follows:
(1) the one-dimensional sewing process of the low-cost carbon cloth with the thickness of 0.1-0.2 mm is used for replacing the traditional three-dimensional five-way woven C/SiC fiber or needling process and is used as an air vane forming mode, so that the process is simplified, and the cost is reduced; firstly, determining the density of a one-dimensional sewing needle according to the strength index of an air vane, wherein the general sewing density is 2-5 needles/square centimeter, and the shearing strength of the air vane with the sewing density of 3 needles/square centimeter can reach 430MPa at present;
(2) an integrated forming mode is selected, and the traditional composite air rudder heat-proof sleeve, the rudder core and the rudder shaft are respectively processed, formed and assembled:
the specific blank thermosetting process comprises the following steps: firstly, after the stitching compression amount is estimated, the carbon cloth is directly tiled in a multilayer mode, the carbon fiber yarns are stitched in a one-dimensional direct manner in a normal mode, and the stitching density of the periphery of a blank can be enhanced by 1 needle per square centimeter according to the requirement to obtain a rough blank; then dipping by polycarbosilane solution, calcining at 1310 +/-10 ℃ to obtain a ceramic product (the ceramic yield is about 55%), and repeating the dipping, calcining and thermal curing process for 10 times; finally, carrying out primary heat treatment at 1610 +/-10 ℃ to remove impurities and obtain a fine blank, wherein the density, porosity and strength of the obtained fine blank for sewing are superior to those of the blank adopting a knitting or needling process.
(3) Selecting a diamond cutter, and cutting the air vane blank to obtain the air vane, which specifically comprises the following steps: the method adopts a diamond cutter to carry out successive micro-processing on the air vane blank, the cutting amount is about 10 +/-3 microns/time, and the main processing process is as follows:
firstly, a control surface is determined as a machining reference surface of each complex profile of the air rudder,
secondly, the front edge and the rudder shaft are determined as preferential processing positions, the processing amount of each time is set to be less than 10 microns,
and finally, grinding the blank of the air vane for multiple times to form the air vane finally.
The carbon cloth air rudder adopting a one-dimensional normal sewing mode replaces a traditional molded quartz fiber air rudder and a universal three-dimensional five-way woven or needled C/SiC fiber air rudder; the zero-ablation air rudder which can be used for a long time under the environment of 1500 ℃ and 0.6MPa pressure is prepared by the one-dimensional normal carbon cloth sewing matched manufacturing and forming and the ultrasonic flaw detection method.
The advantages of the invention are embodied in that:
1) the heat-proof material and the process abandon the traditional mould pressing, weaving or needling quartz fiber and general three-dimensional five-way weaving C/SiC fiber; the low-cost carbon cloth is used for one-dimensional normal sewing; the ablation resistance and the low-cost manufacture of the air vane are ensured;
2) directly sewing the blank in one dimension in an integrated way, repeating the process of soaking and calcining at 1300 ℃ for 10 times to produce a ceramic object, and carrying out the process of heat-treating the blank at 1600 ℃ for one time, wherein the density, porosity and strength of the blank are all superior to those of the blank adopting a weaving or needling process;
3) the size of each component blank is slightly larger (such as 12 percent larger) than the size of a formal product, so that enough allowance is ensured during mechanical processing, then a diamond cutter is used for processing from outside to inside, the problems of front edge glue accumulation and strength uniformity are solved, and the front edge is ensured to have enough strength and ablation resistance;
4) during machining, a cutter is adopted for successive micro machining (such as 10 +/-3 microns of cutting amount per time), so that the uniformity of the strength of the whole rudder and better surface finish are ensured;
5) the synchronous integral manufacturing mode is adopted, so that a heat-proof sleeve, a rudder core and a rudder shaft which are required to be manufactured independently in the traditional air rudder are omitted, the strength of the whole rudder is ensured, and the heat-proof problem of the rudder shaft is solved;
6) preferentially processing to ensure the processing quality of the front edge of the rudder and the rudder shaft;
7) the acceptance inspection adopts an ultrasonic flaw detection method to ensure that the area of a cavity (or bubble) in the air rudder is more than 1cm2The product is forbidden to fly, and the ground electric arc wind tunnel test and the multiple flight test show that: the air vane has ablation resistance close to zero ablation of more than 300s under the environment that the temperature is more than 1500 ℃ and the atmospheric pressure of the front edge reaches 0.6 MPa.
Drawings
FIG. 1 is a flow chart of the integrated monolithic composite air vane manufacturing process of the present invention.
Detailed Description
The structure of the present invention will be described in further detail with reference to fig. 1 and examples.
The preparation method of the air rudder comprises the following steps:
(1) and manufacturing the air vane blank by using a low-cost carbon cloth one-dimensional normal sewing process.
The compactness of the air vane of the one-dimensional normal carbon cloth sewing process is superior to that of a mould pressing, weaving or needling air vane adopting a blank curing process, and the front edge of the air vane needs to have the characteristic of zero ablation under the environment of more than 1500 ℃ and the atmospheric pressure of 0.6 MPa.
In order to ensure that the whole rudder has good thermal strength, the one-dimensional normal sewing density of the carbon cloth is generally between 3 needles/square centimeter, and the carbon cloth is integrally and synchronously manufactured (a heat-proof sleeve, a rudder shaft and a rudder core which are required by the traditional quartz woven air rudder are omitted) to form a primary blank of the air rudder.
(2) The 1300 ℃ impregnation calcination was repeated 10 times.
(3) And (3) carrying out a heat treatment curing process at 1600 ℃ once to remove impurities to obtain an air vane rough blank with the size of 1.3-1.5 times of the proportion.
(4) A diamond cutter is selected, blanks with the proportion size of 1.1-1.2 times (preferably 1.12) are machined in a micro mode (the chip quantity is about 10 micrometers/time) one by one, and the machining quality of the front edge and the rotating shaft of the rudder is preferentially ensured, so that the problem of forming of the complex molded surface of the front edge of the rudder is solved, the uniformity of strength and proper surface smoothness are ensured, and the method specifically comprises the following steps:
firstly, a control surface is determined as a machining reference surface of each complex profile of the air rudder.
In order to facilitate the processing of the cambered surface of the front edge of the rudder and the internal thread in the rotating shaft and facilitate the processing of a cutter, a control surface which is large in area and easy to clamp is selected as a processing reference surface;
secondly, determining the front edge and the rotating shaft as preferential processing positions, and setting the processing amount of each time to be less than 10 microns; the two key parts on the air vane have the best thermal strength and ablation resistance; in order to reduce the rejection rate caused by excessive processing and ensure that the air rudder has good surface roughness, the processing amount is determined to be less than 10 microns each time.
And grinding the blank of the air vane for multiple times to finally form the air vane.
(5) Finally, X-ray or microwave flaw detection is adopted during product inspection, and the area of the cavity (air bubble) is larger than 1cm2Is prohibited for use in flying.
While the above examples illustrate specific embodiments of the invention, those of ordinary skill in the art, in light of the present disclosure, will be able to practice the invention in a variety of specific embodiments.
Claims (2)
1. The preparation method of the integrated integral composite material air rudder comprises the steps of stacking and paving at least three carbon cloth sheets, sewing the carbon fiber yarns in one dimension directly, immersing the carbon fiber yarns in polycarbosilane solution, calcining at 1310 +/-10 ℃ for thermal curing reaction to obtain ceramic products, carrying out heat treatment at 1610 +/-10 ℃ for removing impurities to obtain rough blanks, cutting the rough blanks by a diamond cutter to form fine blanks, and grinding and finish machining to prepare the integrated integral composite material air rudder, wherein:
(1) the thickness of the single carbon cloth is 0.1 mm-0.2 mm;
(2) the sewing density is 2-5 needles/square centimeter;
(3) repeating the dipping, calcining and thermal curing reaction for 10 times;
(4) carrying out primary heat treatment to remove impurities to obtain an air vane rough blank with the size of 1.3-1.5 times of the proportion;
(5) carrying out successive micro-cutting processing on the air vane blank by adopting a diamond cutter, wherein the cutting amount is 10 +/-3 microns/time, and forming an air vane fine blank with the size of 1.1-1.2 times of the proportion;
(6) and (4) grinding and finely processing the fine blank of the air vane for multiple times, wherein the grinding amount is less than 10 microns/time until the requirements on the appearance and the size of the air vane are met.
2. The method for preparing the integrated composite material air vane as claimed in claim 1, wherein the acceptance is performed by using X-ray,The area of the inner cavity or bubble of the air vane is more than 1cm2The product of (1) is prohibited from use.
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| CN108248139B (en) * | 2018-01-22 | 2023-06-23 | 山东大学 | Three-dimensional braided carbon-carbon composite material plate and preparation method thereof |
| CN108995792B (en) * | 2018-07-30 | 2020-04-24 | 上海机电工程研究所 | Air rudder with composite material structure |
| CN112361894B (en) * | 2020-10-12 | 2022-05-31 | 中国运载火箭技术研究院 | Air rudder for rocket |
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| JP6559473B2 (en) * | 2015-06-10 | 2019-08-14 | 株式会社Ｉｈｉエアロスペース | Method for producing silicon carbide composite |
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| CN102249721A (en) * | 2011-05-20 | 2011-11-23 | 中国人民解放军国防科学技术大学 | Method for preparing carbon-fiber-reinforced silicon carbide composite material |
| CN102795871A (en) * | 2012-05-14 | 2012-11-28 | 中国人民解放军国防科学技术大学 | Method for quickly preparing C/SiC ceramic matrix composite material |
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