CN107804041B - 一种隔热隐身耐高温进气道及其制备方法 - Google Patents
一种隔热隐身耐高温进气道及其制备方法 Download PDFInfo
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Abstract
本发明提出一种隔热隐身耐高温进气道，该进气道从内而外由透波层、隔热隐身层、电磁屏蔽层和低发射率涂层组成。透波层由连续氧化物增强氧化物基复合材料构成；隔热隐身层为经匹配优化设计的隔热芯层与电磁周期结构吸波层交替排列形成的多层复合材料，隔热芯层为陶瓷纤维毡增强气凝胶复合材料隔热芯层，电磁周期结构吸波层由高温电磁周期结构单元图案组成；电磁屏蔽层由碳纤维构成，其外表面喷涂低红外发射率涂层。该隔热隐身耐高温进气道具有隔热效果好、吸波频段宽、低频吸波性能好的优点，同时具备一定的红外隐身性能，可应用于高速飞行器，解决剧烈气动加热条件下飞行器进气道隔热、雷达及红外隐身问题。
Description
技术领域
本发明属于飞行器隐身技术领域，具体涉及一种隔热隐身耐高温进气道及其制备方法，该进气道同时具有雷达隐身及红外隐身功能。
背景技术
高速飞行器进气道内侧多为弹/机设备，其工作温度不高于80℃，而进气道内表面气动加热温度会高达几百摄氏度，需采取防隔热措施保证设备正常工作。同时，进气道是高速飞行器前向重要散射辐射源，急亟需采取隐身措施降低其RCS，同时抑制其红外辐射，提高高速飞行器隐身突防性能。
中国专利《一种进气道防隔热装置》(申请号：CN201320616014.7)公布了一种基于气凝胶和陶瓷材料的进气道防隔热装置，其不足之处在于，该装置只满足了高速飞行器进气道的隔热需求，没有考虑进气道隐身性能需求；中国专利《一种双层耐高温隔热吸波复合材料的制备方法》(申请号：CN201611259844.3)公布了一种基于多孔结构陶瓷纤维材料的耐高温隔热吸波复合材料，其不足之处在于，该材料采用隔热陶瓷基体上涂覆吸波涂料的简单组合，其雷达吸波效果有限，且吸波涂料密度大，只适用于地面建筑，难以在飞行器上应用。
发明内容
针对上述不足，本发明公开了一种隔热隐身耐高温进气道及其制备方法。该进气道采用气凝胶复合隔热芯层与电磁周期结构吸波层交替排列，解决了进气道有限厚度空间下隔热隐身一体化的需求，通过调整隔热芯层中的电损耗吸收剂含量形成渐变介质，与电磁周期结构吸波层结合设计解决吸波带宽展开及低频吸波的难题；隔热芯层隔绝了进气道内表面气动加热产生的热量向外表面的传递，降低了进气道外表面温度，配合低发射率贵金属薄膜涂层，实现对红外辐射的有效抑制，对进气道雷达隐身效果影响较小，同时实现了雷达、红外性能；本发明同时公开了上述隔热隐身耐高温进气道的制备方法，并提出了预制孔-缝合-致密化工艺实现进气道成型，保证了进气道的结构和性能稳定性。具体技术方案如如下：
一种隔热隐身耐高温进气道，该高温进气道由透波层、隔热吸波层、电磁屏蔽层和低红外发射率涂层组成。
透波层由连续氧化物增强氧化物基复合材料构成，具备防热、承载及透波的功能。
隔热吸波层为隔热芯层和电磁周期结构吸波层交替叠加形成。隔热芯层采用陶瓷纤维毡增强气凝胶复合材料体系，起隔热作用；同时在隔热吸波结构中充当隔离层，并且通过调整隔热芯层的介电常数形成渐变介质，实现阻抗匹配及带宽调节，从而实现宽频、低频吸波效果。此外，隔热芯层降低了进气道内表面向外表面传热，通过降低外表面温度实现抑制进气道外表面的红外辐射的功能。
电磁周期结构吸波层采用玻璃相为粘接相，贵金属氧化物为导电相的电阻浆料通过丝网印刷工艺印制高温电磁周期结构单元图案构成，通过调整图案形状、尺寸和方阻与隔热芯层进行匹配优化设计，可实现对吸波强度、频段及带宽的调控，实现高温下的低频宽带的吸波功能。
电磁屏蔽层由碳纤维构成，起到电磁屏蔽反射衬底的作用。电磁屏蔽层外表面喷涂低红外发射率贵金属薄膜涂层，配合隔热层的作用，降低进气道外表面红外辐射。
本发明还提供了一种该隔热隐身耐高温进气道的制备方法，包括以下步骤：
第一步：制备隔热芯层
采用溶胶-凝胶工艺制备湿凝胶。根据匹配设计要求，加入SiC纤维搅拌均匀，将陶瓷纤维毡作为增强体浸渍到湿凝胶中，采用超临界干燥工艺制备出纤维毡增强气凝胶隔热复合材料。采用高温热处理移除残余有机物和碳杂质，并进行疏水处理减少材料表面羟基和吸附水，最后根据进气道模型外形进行机械加工及表面封孔处理获得隔热芯层。
第二步：制备吸波功能层
以玻璃为粘接相，以锰酸锶镧材料等钙钛矿结构材料或钨、钼、锰、钌等金属材料氧化物中的一种为导电相，制备高温电阻浆料。根据设计要求，采用丝网印刷-烧结工艺在对应的隔热芯层表面上印制高温电磁周期结构单元图案，获得电磁周期结构吸波层，并在隔热芯层上制备预制孔。
第三步：制备透波层和电磁屏蔽层
进行氧化物纤维透波层和碳纤维电磁屏蔽层的编织，采用纤维浸渍裂解工艺(PIP)制备粗坯，待编织件具备足够的硬度、韧性后，根据进气道外形进行机械加工获得透波层及电磁屏蔽层，在透波层上制备预制孔，方便后续缝合。
第四步：整体成型及喷涂低发射率涂层
将制备好的气凝胶复合隔热芯层和电磁周期结构吸波功能层按照设计要求层铺，上下外表面分别铺设透波层和电磁屏蔽层，采用氧化物陶瓷纤维纱线缝合工艺制备出一体化复合材料预成型体；采用PIP工艺对透波层织物及缝合纱线进行致密化，同时利用液相先驱体的粘接性能进一步提升各功能层间的结合强度。根据进气道外形进行精确机械加工工艺，采用磁控溅射技术在电磁屏蔽层外表面喷涂低发射率贵金属薄膜涂层，获得隔热隐身耐高温进气道。
本发明与现有技术相比的有益效果：
与现有的技术相比，本发明所涉及的隔热隐身耐高温进气道，具有隔热效果好、吸波频段宽、低频吸波性能好的优点，同时具备一定的红外隐身性能，制备方法有效可行，可以应用于高速飞行器进气道隐身设计，解决高速飞行器隔热隐身一体化难题。
附图说明
本发明共有3幅附图
图1为本发明隔热隐身耐高温进气道截面示意图；
图2为本发明隔热隐身耐高温进气道结构横断面示意图；
图3为三层电磁周期结构单元示意图。
具体实施方式
为解决高速飞行器进气道隔热性能以及红外、雷达隐身性能，本发明提出一种具有良好防隔热功能、低频宽带吸波及红外隐身功能的多功能层高温进气道及其制备方法。采用纤维毡增强气凝胶复合材料作为进气道隔热芯层，加入SiC纤维形成渐变介质，同时在隔热芯层中引入电磁周期结构吸波层，实现有限厚度空间内的隔热和宽频吸波一体化。通过隔热芯层厚度、介电常数，以及周期结构单元图案、尺寸及方阻的渐变设计，实现展宽吸波频带和低频吸波的目标。在进气道外表面喷涂低发射率贵金属薄膜涂层降低发射率，采用气凝胶隔热控制进气道外表面温度，降低进气道外表面红外辐射。采用隔热芯层表面印制电磁周期结构层，并应用预制孔-缝合-致密化工艺确保层合进气道的结构和性能稳定性。
以下结合具体实施例对本方案做进一步说明。
实施例1：(两层隔热芯层，一层电磁周期结构)
第一步：制备隔热芯层
采用溶胶-凝胶工艺制备SiO2湿凝胶。根据根据匹配设计要求，按隔热层从内向外SiC纤维占隔热层体积占比分别为0.05％和2％的顺序，加入SiC纤维(介电实部为3～12，虚部为0～18)搅拌均匀。将SiO2纤维毡作为增强体浸渍到湿凝胶中，采用超临界干燥工艺制备出介电常数从内向外逐渐增大的SiO2纤维毡增强SiO2气凝胶隔热复合材料。对SiO2气凝胶隔热复合材料进行500℃空气气氛高温热处理移除残余有机物和碳杂质，并进行疏水处理减少材料表面羟基和吸附水，最后根据进气道模型外形进行机械加工，并进行表面封孔处理获得隔热芯层，从内到外厚度分别为7.3mm和9.5mm。
第二步：制备电磁周期结构吸波层
根据设计要求，以玻璃为粘接相，以钨、钼、锰、钌等贵金属氧化物材料为导电相，制备高温电阻浆料(导电桨体烧结后方阻为50Ω/sq)，采用丝网印刷-烧结工艺在第一步获得的第二层隔热芯层(9.5mm)内表面上印制设计好的圆形结构单元图案(边长10mm，间距2mm和边长15mm，间距5mm)，并在1100℃～1200℃的温度下进行烧结，获得两层电磁周期结构吸波层，并在隔热芯层上制备预制孔。
第三步：制备透波层和电磁屏蔽层
采用SiO2纤维(介电常数实部1.5～7，损耗角正切0.1～0.4)、T300碳纤维进行透波层和电磁屏蔽层的编织，采用纤维浸渍裂解工艺(PIP)制备粗坯，待编织件具备足够的硬度、韧性后，根据进气道外形进行机械加工获得透波层和电磁屏蔽层，厚度分别为2.3mm和0.9mm。
第四步：整体成型及喷涂低发射率涂层
将制备好的印有或没有电磁周期结构吸波层的SiO2气凝胶复合隔热芯层按照设计要求层铺，内外表面分别铺设透波层及电磁屏蔽层，采用SiO2纤维纱线缝合工艺制备出一体化复合材料预成型体。采用PIP工艺对透波层织物及缝合纱线进行致密化，待进气道不增重后停止。根据进气道外形进行精确机械加工工艺，采用磁控溅射技术在电磁屏蔽层外表面喷涂低发射率贵金属金薄膜涂层，获得隔热隐身耐高温进气道。
实施例2：(三层隔热芯层，两层电磁周期结构)
第一步：制备隔热芯层
采用溶胶-凝胶工艺制备Al2O3湿凝胶。根据根据匹配设计要求，按隔热层从内向外，SiC纤维占隔热层体积占比分别为0.01％，0.2％和5％的顺序，加入SiC纤维(介电实部为3～12，虚部为0～18)搅拌均匀。将Al2O3纤维毡作为增强体浸渍到湿凝胶中，采用超临界干燥工艺制备出介电常数从内向外逐渐增大的Al2O3纤维毡增强Al2O3气凝胶隔热复合材料。对Al2O3气凝胶隔热复合材料进行高温热处理移除残余有机物和碳杂质，并进行疏水处理减少材料表面羟基和吸附水，最后根据进气道模型外形进行机械加工，并进行表面封孔处理获得隔热芯层，从内到外厚度分别为6.2mm，12.1mm和8.4mm。
第二步：制备电磁周期结构吸波层
根据设计要求，按方阻由内向外逐渐增大的顺序，以玻璃为粘接相，以钨、钼、锰、钌等贵金属氧化物材料为导电相，制备高温电阻浆料(导电桨体烧结后方阻为70Ω/sq和20Ω/sq)，采用丝网印刷-烧结工艺在第一步获得的第二、三层隔热芯层内表面上印制设计好的正方形结构单元图案(第二层：边长10mm，间距2mm，方阻70Ω/sq；第二层：边长15mm，间距5mm，方阻20Ω/sq)，并在1100℃～1200℃的温度下进行烧结，获得两层电磁周期结构吸波层，并在隔热芯层上制备预制孔。
第三步：制备透波层和电磁屏蔽层
采用Al2O3纤维(介电常数实部5～8，损耗角正切0.1～0.3)、T700碳纤维进行透波层和电磁屏蔽层的编织，采用纤维浸渍裂解工艺(PIP)制备粗坯，待编织件具备足够的硬度、韧性后，根据进气道外形进行机械加工获得透波层和电磁屏蔽层，厚度分别为2.5mm和0.8mm。
第四步：整体成型及喷涂低发射率涂层
将制备好的印有或没有电磁周期结构吸波层的Al2O3气凝胶复合隔热芯层按照设计要求层铺，内外表面分别铺设透波层及电磁屏蔽层，采用Al2O3纤维纱线缝合工艺制备出一体化复合材料预成型体。采用PIP工艺对透波层织物及缝合纱线进行致密化，待进气道不增重后停止。根据进气道外形进行精确机械加工工艺，采用磁控溅射技术在电磁屏蔽层外表面喷涂低发射率贵金属铂薄膜涂层，获得隔热隐身耐高温进气道。
实施例3：(四层隔热芯层，三层电磁周期结构)
第一步：制备隔热芯层
采用溶胶-凝胶工艺制备SiN湿凝胶。根据根据匹配设计要求，按隔热层从内向外，SiC纤维占隔热层体积占比分别为0.01％，0.2％、2％和4.5％的顺序，加入SiC纤维(介电实部为3～12，虚部为0～18)搅拌均匀。将SiN纤维毡作为增强体浸渍到湿凝胶中，采用超临界干燥工艺制备出介电常数从内向外逐渐增大的SiN纤维毡增强SiN气凝胶隔热复合材料。对SiN气凝胶隔热复合材料进行高温热处理移除残余有机物和碳杂质，并进行疏水处理减少材料表面羟基和吸附水，最后根据进气道模型外形进行机械加工，并进行表面封孔处理获得隔热芯层，从内到外厚度分别为4.5mm，8.9mm、8.7mm和5.3mm。
第二步：制备电磁周期结构吸波层
根据设计要求，按方阻由内向外逐渐增大的顺序，以玻璃为粘接相，以钨、钼、锰、钌等贵金属氧化物材料为导电相，制备高温电阻浆料(导电桨体烧结后方阻为200Ω/sq、90Ω/sq和10Ω/sq)，采用丝网印刷-烧结工艺在第一步获得的第二、三和四层隔热芯层内表面上印制设计好的结构单元图案(第二层：正方形，边长10mm，间距2mm，方阻200Ω/sq；第二层：圆形，直径25mm，间距5mm，方阻90Ω/sq；第三层：正方形，边长50mm，间距8mm，方阻10Ω/sq)，并在1100℃～1200℃的温度下进行烧结，获得三层电磁周期结构吸波层，并在隔热芯层上制备预制孔。
第三步：制备透波层和电磁屏蔽层
采用SiN纤维(介电常数实部4～9，损耗角正切0.01～0.4)、T700碳纤维进行透波层和电磁屏蔽层的编织，采用纤维浸渍裂解工艺(PIP)制备粗坯，待编织件具备足够的硬度、韧性后，根据进气道外形进行机械加工获得透波层和电磁屏蔽层，厚度分别为2.1mm和0.5mm。
第四步：整体成型及喷涂低发射率涂层
将制备好的印有或没有电磁周期结构吸波层的SiN气凝胶复合隔热芯层按照设计要求层铺，内外表面分别铺设透波层及电磁屏蔽层，采用SiN纤维纱线缝合工艺制备出一体化复合材料预成型体。采用PIP工艺对透波层织物及缝合纱线进行致密化，待进气道不增重后停止。根据进气道外形进行精确机械加工工艺，采用磁控溅射技术在电磁屏蔽层外表面喷涂低发射率贵金属钯薄膜涂层，获得隔热隐身耐高温进气道。
本发明的制备方法有很多途径，以上所述仅是本发明的优选实施方式，应当指出，对于本技术领域的普通技术人员来说，在不脱离本发明原理的前提下，还可以作出若干改进，这些改进也应视为本发明的保护范围。
Claims (6)
1.一种隔热隐身耐高温进气道，其特征在于，该进气道从内而外由透波层(1)、隔热隐身层(2)、电磁屏蔽层(3)和低发射率涂层(4)组成，
所述透波层(1)为连续氧化物纤维增强氧化物基复合材料；
所述隔热隐身层(2)由隔热芯层(5)和电磁周期结构吸波层(6)交替排布组成，
所述电磁屏蔽层(3)由高导电率碳纤维构成；
所述低发射率涂层(4)为贵金属薄膜层构成；
所述隔热芯层(5)为掺杂有SiC纤维的陶瓷纤维毡增强气凝胶复合材料构成，其中SiC纤维占隔热芯层(5)体积含量的0.01％～5％，SiC纤维的相对介电实部为3～12，虚部为0～18，且调整后各隔热芯层(5)的介电常数由内向外逐渐增大，形成渐变介质，所述的气凝胶导热系数小于0.09W/m·k；
所述电磁周期结构吸波层(6)为在隔热芯层(5)表面喷涂的电磁周期结构单元图案，所述的结构单元图案为正方形、圆形、长条形、十字形中的一种或多种组合，图案尺寸按照吸波频段的不同而变化，周期结构单元尺寸为10mm～50mm，厚度为10μm～100μm，方阻分布在10Ω/□～200Ω/□之间，各层方阻从内到外逐渐变小。
2.一种如权利要求1所述的隔热隐身耐高温进气道，其特征在于，所述透波层(1)为连续SiO2纤维增强SiO2基复合材料或者连续Al2O3纤维增强Al2O3基复合材料中的一种。
3.一种如权利要求1所述的隔热隐身耐高温进气道，其特征在于，所述电磁屏蔽层(3)高电导率碳纤维的体积电阻率小于10-1Ω·cm。
4.一种如权利要求1所述的隔热隐身耐高温进气道，其特征在于，所述低发射率膜层(4)中的贵金属为金、铂和钯中的一种，膜层的特征厚度为5nm～100nm。
5.一种如权利要求1所述的隔热隐身耐高温进气道，其特征在于，所述隔热芯层(5)的陶瓷纤维毡增强气凝胶复合材料为SiO2纤维毡增强SiO2气凝胶、Al2O3纤维毡增强Al2O3气凝胶及SiN纤维毡增强SiN气凝胶中的一种。
6.一种如权利要求1～5任一项所述的隔热隐身耐高温进气道的制备方法，其特征在于，包括以下工艺步骤：
第一步：制备隔热芯层(5)
采用溶胶-凝胶工艺制备湿凝胶，根据匹配设计要求，加入SiC纤维搅拌均匀，将陶瓷纤维毡作为增强体浸渍到湿凝胶中，采用超临界干燥工艺制备出纤维毡增强气凝胶隔热复合材料，采用高温热处理移除残余有机物和碳杂质，并进行疏水处理减少材料表面羟基和吸附水，最后根据进气道模型外形进行机械加工及表面封孔处理获得隔热芯层(5)；
第二步：制备隔热隐身层(2)
以玻璃为粘接相，以钙钛矿结构材料或金属材料氧化物中的一种为导电相，制备高温电阻浆料，根据设计要求，采用丝网印刷-烧结工艺在对应的隔热芯层(5)表面上印制高温电磁周期结构单元图案，获得电磁周期结构吸波层(6)，并在隔热芯层(5)上制备预制孔；
第三步：制备透波层(1)和电磁屏蔽层(3)
进行氧化物纤维透波层和碳纤维电磁屏蔽层的编织，采用纤维浸渍裂解工艺PIP制备粗坯，待编织件具备足够的硬度、韧性后，根据进气道外形进行机械加工获得透波层(1)及电磁屏蔽层(3)，在透波层(1)上制备预制孔，方便后续缝合；
第四步：整体成型及喷涂低发射率涂层(4)
将制备好的气凝胶复合隔热芯层(5)和电磁周期结构吸波层(6)按照设计要求层铺，上下外表面分别铺设透波层(1)和电磁屏蔽层(3)，采用氧化物陶瓷纤维纱线缝合工艺制备出一体化复合材料预成型体；采用PIP工艺对透波层(1)织物及缝合纱线进行致密化，同时利用液相先驱体的粘接性能进一步提升各功能层间的结合强度，根据进气道外形进行精确机械加工工艺，采用磁控溅射方法在电磁屏蔽层(3)外表面喷涂低发射率涂层(4)，获得隔热隐身耐高温进气道。
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