CN108215346A - 一种碳纤维增强耐高温复合材料管及其制备方法 - Google Patents
一种碳纤维增强耐高温复合材料管及其制备方法 Download PDFInfo
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Abstract
本发明公开了一种碳纤维增强耐高温复合材料管及其制备方法,属于复合材料管领域,由内到外依次包括不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层,其中:所述高温隔热复合材料层在不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成;所述轴向强度层在高温隔热复合材料层外采用碳纤维与耐高温树脂复合而成,所述碳纤维采用轴向排布结构;所述最外刚性层采用二维编织结构的高模量碳纤维增强耐高温树脂浸渍复合而成。本发明自重较轻,且耐高温,加工过程尺寸稳定性好。
Description
技术领域
本发明涉及复合材料管技术领域,特别是指一种碳纤维增强耐高温复合材料管及其制备方法。
背景技术
高温环境下的结构材料是现代工业生产设备以及军工设备或航空航天器中重要的承载部件,其中高温环境下的高速气流冲蚀和磨损是影响设备和部件寿命以及稳定性的主要情况,高温气相和固相冲蚀主要是小且松散的流动粒子冲击材料表面产生破坏,例如航空发动机的粉尘和沙粒对发动机材料表面的冲蚀,高温气流物料对高温管路的冲蚀,发电厂的微尘煤灰气体对换热器管道的冲蚀等。现代高温耐热材料不仅要求耐热性,而且要求低密度、密封性以及高温的综合力学强度。传统的材料采用特种金属,自身的刚度和强度较差,生产成本高而且耐热性较差。为了解决这一问题,新型的多种材质综合运用的复合结构是解决这一问题的主要方法。
发明内容
本发明提供一种一种碳纤维增强耐高温复合材料管及其制备方法,其自重较轻,且耐高温,加工过程尺寸稳定性好。
为解决上述技术问题,本发明提供技术方案如下:
一方面,本发明提供一种碳纤维增强耐高温复合材料管,由内到外依次包括不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层,其中:
所述高温隔热复合材料层在不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成;
所述轴向强度层在高温隔热复合材料层外采用碳纤维与耐高温树脂复合而成,所述碳纤维采用轴向排布结构;
所述最外刚性层采用二维编织结构的高模量碳纤维增强耐高温树脂浸渍复合而成。
进一步的,所述不锈钢内层的厚度为2-5mm,所述高温隔热复合材料层的厚度为2-5mm,所述轴向强度层的厚度为4-5mm,所述最外刚性层的厚度为4-5mm。
另一方面,本发明还提供一种上述碳纤维增强耐高温复合材料管的制备方法,包括:
步骤1:不锈钢内层的制备:采用特种合金钢制备不锈钢内层,特种合金钢为310S奥氏体铬镍不锈钢、800N8800镍铁铬合金或600N06600镍铬系镍基合金;
步骤2:高温隔热复合材料层的制备:在步骤1制备的不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织高温隔热复合材料层预制体结构浸渍改性树脂复合而成,采用改性树脂在-0.06~-0.1MPa真空度浸渍高温隔热复合材料层预制体,固化一定时间成型;
步骤3:轴向强度层的制备:在步骤2得到的高温隔热复合材料层的表面采用碳纤维轴向排布结构在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,加热固化一定时间成型;
步骤4:最外刚性层的制备:在步骤2得到的轴向强度层的表面采用高模量碳纤维二维编织结构,在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,热固化成型。
进一步的,步骤2中,高温隔热复合材料层的碳纤维为T300、T700、T800、T1000或T1200;
陶瓷纤维为碳化硅纤维、氧化铝纤维、碳化硼纤维或氮化硼纤维。
进一步的,步骤2中,预制体结构采用三维四向、三维五向、三维七向或2.5维结构。
进一步的,步骤2中,改性树脂为酚醛树脂、呋喃树脂或环氧树脂;
改性树脂中添加隔热石英或氧化铝陶瓷空心球进行隔热改性,空心球的比例为5-20%。
进一步的,步骤2中,空心球为混级球或分级球,所述混级球的粒径为0.2-5mm,所述分级球的粒径分别为0.2-1mm、1-2mm、2-3mm、3-5mm。
进一步的,步骤2中,高温隔热复合材料层的制备过程中固化温度为120-150℃,固化时间为1-4小时。
进一步的,步骤3中,碳纤维为T300、T700、T800、T1000或T1200,耐高温树脂为酚醛树脂、呋喃树脂或环氧树脂;
固化温度为120-150℃,固化时间为1-4小时。
进一步的,步骤4中,高模量碳纤维为M35J、M40J、M45J、M55J或M60J,耐高温树脂为酚醛树脂、呋喃树脂或环氧树脂;
固化温度为120-150℃,固化时间为1-4小时。
本发明具有以下有益效果:
本发明的碳纤维增强耐高温复合材料管及其制备方法,由内到外依次包括不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层,本发明由多层多材质层状结构、多种碳纤维排布组合而成,高温隔热复合材料层在不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成,具有较好的耐高温性和隔热性;轴向强度层和最外刚性层中均通过耐高温树脂浸渍而成,加工过程尺寸稳定,四层结构有机组合,有效综合了材料的强度和刚度,解决了金属材质的高温刚性不足,加工过程尺寸不稳定的问题,同时自重较轻。
附图说明
图1为本发明的碳纤维增强耐高温复合材料管的整体结构示意图,其中,1-不锈钢内层,2-高温隔热复合材料层,3-轴向强度层,4-最外刚性层。
具体实施方式
为使本发明要解决的技术问题、技术方案和优点更加清楚,下面将结合附图及具体实施例进行详细描述。
一方面,本发明提供一种碳纤维增强耐高温复合材料管,如图1所示,由内到外依次包括不锈钢内层1、高温隔热复合材料层2、轴向强度层3和最外刚性层4,其中:
高温隔热复合材料层2在不锈钢内层1表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成;
轴向强度层3在高温隔热复合材料层外采用碳纤维与耐高温树脂复合而成,碳纤维采用轴向排布结构;
最外刚性层4采用二维编织结构的高模量碳纤维增强耐高温树脂浸渍复合而成。
本发明的碳纤维增强耐高温复合材料管,由内到外依次包括不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层,本发明由多层多材质层状结构、多种碳纤维排布组合而成,高温隔热复合材料层在不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成,具有较好的耐高温性和隔热性;轴向强度层和最外刚性层中均通过耐高温树脂浸渍而成,加工过程尺寸稳定,四层结构有机组合,有效综合了材料的强度和刚度,解决了金属材质的高温刚性不足,加工过程尺寸不稳定的问题,同时自重较轻。
进一步的,不锈钢内层1的厚度为2-5mm,高温隔热复合材料层2的厚度为2-5mm,轴向强度层3的厚度为4-5mm,最外刚性层4的厚度为4-5mm,其各层厚度也可以根据产品要求灵活调整,并不限于上述尺寸范围。
另一方面,本发明还提供一种上述的碳纤维增强耐高温复合材料管的制备方法,包括:
步骤1:不锈钢内层1的制备:采用特种合金钢制备不锈钢内层,特种合金钢为310S奥氏体铬镍不锈钢、800N8800镍铁铬合金或600N06600镍铬系镍基合金;
步骤2:高温隔热复合材料层2的制备:在步骤1制备的不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织高温隔热复合材料层预制体结构浸渍改性树脂复合而成,采用改性树脂在-0.06~-0.1MPa真空度浸渍高温隔热复合材料层预制体,固化一定时间成型;
步骤3:轴向强度层3的制备:在步骤2得到的高温隔热复合材料层的表面采用碳纤维轴向排布结构在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,加热固化一定时间成型;
步骤4:最外刚性层4的制备:在步骤2得到的轴向强度层的表面采用高模量碳纤维二维编织结构,在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,热固化成型。
下面结合具体实施例进行进一步说明本制备方法的特征和细节,但所列过程和数据并不意味着对本发明范围的限制。
实施例1:
一种耐高温多层多材质层状结构碳纤维复合材料管,包括:不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层;
采用310S奥氏体铬镍不锈钢制备厚度5mm的不锈钢内层;
在不锈钢内层表面采用T300碳纤维混杂碳化硅纤维,混杂比例为1:1,采用三维四向制备高温隔热复合材料层预制体,采用添加比在5%的粒径为0.2mm的混级石英陶瓷空心球改性酚醛树脂在-0.06MPa范围真空度浸渍高温隔热复合材料层预制体,在120℃热固化,固化时间为1小时制备厚度2mm的高温隔热复合材料层;
在高温隔热复合材料层表面选用T800碳纤维轴向排布结构在-0.1MPa真空度下真空导入浸渍酚醛树脂,在150℃热固化,固化时间为2小时制备厚度4mm的轴向强度层;
在轴向强度层表面采用M35J高模量碳纤维的平纹编织结构,在-0.1MPa真空度下真空导入浸渍呋喃树脂,在150℃热固化,固化时间为4小时制备厚度4mm的表面刚性层。
实施例2:
一种耐高温多层多材质层状结构碳纤维复合材料管,包括:不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层;
采用800N8800镍铁铬合金制备厚度2mm的不锈钢内层;
在不锈钢内层表面采用T1200碳纤维混杂碳化硅纤维,混杂比例为3:1,采用2.5维结构制备高温隔热复合材料层预制体,采用添加比在10%的粒径为0.2mm分级石英陶瓷空心球改性环氧树脂在-0.1MPa范围真空度浸渍高温隔热复合材料层预制体,在130℃热固化,固化时间为3小时制备厚度4mm的高温隔热复合材料层;
在高温隔热复合材料层表面选用T300碳纤维轴向排布结构在-0.1MPa真空度下真空导入浸渍酚醛树脂,在135℃热固化,固化时间为2.5小时制备厚度5mm的轴向强度层;
在轴向强度层表面采用M60J高模量碳纤维的缎纹编织结构,在-0.1MPa真空度下真空导入浸渍环氧树脂,在120℃热固化,固化时间为3小时制备厚度5mm的表面刚性层。
实施例3:
一种耐高温多层多材质层状结构碳纤维复合材料管,包括:不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层;
采用600N06600镍铬系镍基合金制备厚度4mm的不锈钢内层;
在不锈钢内层表面采用T800碳纤维混杂碳化硼纤维,混杂比例为3:1,采用三维七向制备高温隔热复合材料层预制体,采用添加比在10%的粒径为0.2mm的混级氧化铝陶瓷空心球改性酚醛树脂在-0.1MPa范围真空度浸渍高温隔热复合材料层预制体,在150℃热固化,固化时间为2小时制备厚度5mm的高温隔热复合材料层;
在高温隔热复合材料层表面选用T700碳纤维轴向排布结构在-0.1MPa真空度下真空导入浸渍环氧树脂,在140℃热固化,固化时间为2小时制备厚度4.5mm的轴向强度层;
在轴向强度层表面采用M55J高模量碳纤维的斜纹编织结构,在-0.1MPa真空度下真空导入浸渍呋喃树脂,在135℃热固化,固化时间为2小时制备厚度5mm的表面刚性层。
实施例4:
一种耐高温多层多材质层状结构碳纤维复合材料管,包括:不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层;
采用310S奥氏体铬镍不锈钢制备厚度2mm的不锈钢内层;
在不锈钢内层表面采用T1200碳纤维混杂氧化铝纤维,混杂比例为1:1采用2.5维结构制备高温隔热复合材料层预制体,采用添加比在12%的粒径为0.3mm的混级石英陶瓷空心球改性酚醛树脂在-0.06MPa范围真空度浸渍高温隔热复合材料层预制体,在128℃热固化,固化时间为2.5小时制备厚度3mm的高温隔热复合材料层;
在高温隔热复合材料层表面选用T1200碳纤维轴向排布结构在-0.1MPa真空度下真空导入浸渍环氧树脂,在120℃热固化,固化时间为4小时制备厚度5mm的轴向强度层;
在轴向强度层表面采用M60J高模量碳纤维的缎纹编织结构,在-0.1MPa真空度下真空导入浸渍酚醛树脂,在150℃热固化,固化时间为4小时制备厚度5mm的表面刚性层。
在本发明中,制备方法的条件不同,得到的碳纤维增强耐高温复合材料管的性能会有不同,为更好地证明本发明的性能,构建如下对比例1:
对比例1:
取与实施例4中管的整体厚度、内径、长度均相同的耐高温铝合金管。
将实施例1-实施例4以及对比例1进行自重对比,并将实施例1-4以及对比例1中的管在空气中进行马丁耐热试验,得到耐热温度,结果见表1:
表1
检验项目 | 实施例1 | 实施例2 | 实施例3 | 实施例4 | 对比例1 |
自重,kN/m3 | 18.8 | 18.2 | 17.4 | 17.2 | 39.2 |
耐热温度,℃ | 421 | 414 | 411 | 423 | 139 |
由表1可知,本发明的碳纤维增强耐高温复合材料管与对比例1相比,其自重较轻,不到耐高温铝合金管自重的一半,但是其耐热温度明显提高,其中,实施例4的效果最为明显,可见,本发明在自重较小的前提下实现了耐高温性能更好的碳纤维复合材料管。
以上所述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,在不脱离本发明所述原理的前提下,还可以作出若干改进和润饰,这些改进和润饰也应视为本发明的保护范围。
Claims (10)
1.一种碳纤维增强耐高温复合材料管,其特征在于,由内到外依次包括不锈钢内层、高温隔热复合材料层、轴向强度层和最外刚性层,其中:
所述高温隔热复合材料层在不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织预制体结构浸渍改性树脂复合而成;
所述轴向强度层在高温隔热复合材料层外采用碳纤维与耐高温树脂复合而成,所述碳纤维采用轴向排布结构;
所述最外刚性层采用二维编织结构的高模量碳纤维增强耐高温树脂浸渍复合而成。
2.根据权利要求1所述的碳纤维增强耐高温复合材料管,其特征在于,所述不锈钢内层的厚度为2-5mm,所述高温隔热复合材料层的厚度为2-5mm,所述轴向强度层的厚度为4-5mm,所述最外刚性层的厚度为4-5mm。
3.一种权利要求1-2任一所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,包括:
步骤1:不锈钢内层的制备:采用特种合金钢制备不锈钢内层,特种合金钢为310S奥氏体铬镍不锈钢、800N8800镍铁铬合金或600N06600镍铬系镍基合金;
步骤2:高温隔热复合材料层的制备:在步骤1制备的不锈钢内层表面采用碳纤维和陶瓷纤维混杂编织高温隔热复合材料层预制体结构浸渍改性树脂复合而成,采用改性树脂在-0.06~-0.1MPa真空度浸渍高温隔热复合材料层预制体,固化一定时间成型;
步骤3:轴向强度层的制备:在步骤2得到的高温隔热复合材料层的表面采用碳纤维轴向排布结构在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,加热固化一定时间成型;
步骤4:最外刚性层的制备:在步骤2得到的轴向强度层的表面采用高模量碳纤维二维编织结构,在-0.06~-0.1MPa真空度下真空导入浸渍耐高温树脂,热固化成型。
4.根据权利要求3所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤2中,高温隔热复合材料层的碳纤维为T300、T700、T800、T1000或T1200;
陶瓷纤维为碳化硅纤维、氧化铝纤维、碳化硼纤维或氮化硼纤维。
5.根据权利要求4所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤2中,预制体结构采用三维四向、三维五向、三维七向或2.5维结构。
6.根据权利要求5所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤2中,改性树脂为酚醛树脂、呋喃树脂或环氧树脂;
改性树脂中添加隔热石英或氧化铝陶瓷空心球进行隔热改性,空心球的比例为5-20%。
7.根据权利要求6所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤2中,空心球为混级球或分级球,所述混级球的粒径为0.2-5mm,所述分级球的粒径分别为0.2-1mm、1-2mm、2-3mm、3-5mm。
8.根据权利要求7所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤2中,高温隔热复合材料层的制备过程中固化温度为120-150℃,固化时间为1-4小时。
9.根据权利要求3所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤3中,碳纤维为T300、T700、T800、T1000或T1200,耐高温树脂为酚醛树脂、呋喃树脂或环氧树脂;
固化温度为120-150℃,固化时间为1-4小时。
10.根据权利要求3所述的碳纤维增强耐高温复合材料管的制备方法,其特征在于,步骤4中,高模量碳纤维为M35J、M40J、M45J、M55J或M60J,耐高温树脂为酚醛树脂、呋喃树脂或环氧树脂;
固化温度为120-150℃,固化时间为1-4小时。
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