CN108860656B - Cold spraying reinforcement repairing method for cracks of aluminum alloy structural part of airplane - Google Patents
Cold spraying reinforcement repairing method for cracks of aluminum alloy structural part of airplane Download PDFInfo
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- B64—AIRCRAFT; AVIATION; COSMONAUTICS
- B64F—GROUND OR AIRCRAFT-CARRIER-DECK INSTALLATIONS SPECIALLY ADAPTED FOR USE IN CONNECTION WITH AIRCRAFT; DESIGNING, MANUFACTURING, ASSEMBLING, CLEANING, MAINTAINING OR REPAIRING AIRCRAFT, NOT OTHERWISE PROVIDED FOR; HANDLING, TRANSPORTING, TESTING OR INSPECTING AIRCRAFT COMPONENTS, NOT OTHERWISE PROVIDED FOR
- B64F5/00—Designing, manufacturing, assembling, cleaning, maintaining or repairing aircraft, not otherwise provided for; Handling, transporting, testing or inspecting aircraft components, not otherwise provided for
- B64F5/40—Maintaining or repairing aircraft
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Abstract
The invention relates to a method for repairing airplane parts, in particular to a method for repairing cracks of an airplane aluminum alloy structural member by cold spraying reinforcement, which comprises the following steps: (1) dismantling; (2) preliminary cleaning; (3) plugging; (4) cleaning; (5) an air gun; (6) spraying; (7) polishing; (8) removing the shielding object; (9) removing dust; (10) sampling; the reinforcing is carried out in a spraying block mode, and compared with the traditional reinforcing corner box, the redundant quality is greatly reduced, and the airplane weight increment caused by repair is relieved; the repairing process is lossless, and the fatigue weak point caused by the perforation of the airplane matrix is avoided; the repair cycle is greatly reduced, the reinforcing corner box repair needs a plurality of long-term procedures such as appearance design, machining, on-machine check, on-machine assembly and the like, the reinforcing repair of the spraying block only needs appearance design, protection, spraying and polishing, and the cycle can be shortened by more than 50%; fourthly, the special-shaped spray gun can be used for reinforcing complex structural members in the aircraft fuel tank.
Description
Technical Field
The invention relates to a method for repairing airplane parts, in particular to a method for repairing cracks of an airplane aluminum alloy structural member by cold spraying reinforcement.
Background
The cold spraying technology is mainly based on the aerodynamic principle, utilizes high-pressure gas to carry powder particles, forms supersonic airflow after being accelerated by a spray gun, impacts a substrate under the complete solid state, and deposits on the surface of the substrate to form a compact coating through the strong plastic deformation of the powder particles. Has the following characteristics: firstly, the powder particles are low in heating temperature and do not need to be heated to a molten state in the spraying process, the thermal stress is not generated, the bonding strength is high, and the influence on a matrix is basically avoided; secondly, the coating with any thickness can be sprayed theoretically, and low-melting-point materials with good shaping property such as aluminum, magnesium, copper, zinc and the like can be prepared; thirdly, portable equipment can be developed for operation according to construction conditions, and the coating is compressive stress, so that the fatigue strength is improved; fourthly, the repairing process has no mechanical damage to the matrix, and the fatigue weak point caused by the perforation of the matrix of the airplane is completely avoided. Because of flameless operation, the method can be used for on-board repair operation of an oil tank area, achieves the purpose of prolonging the crack propagation life of the structural part and solves the repair problem. The technology is generally used for repairing the dimension and the appearance of the part and preparing the coating.
The key bearing structural part of the airplane is made of 7B04 high-strength aluminum alloy, cracks with a certain length appear at specific parts of a plurality of airplanes after the airplane is in service for a period of time, the structural part is positioned in an oil tank, the space is narrow, and the conventional welding repair or metal part reinforcement repair method cannot repair the structural part. The structural member is a main bearing member of the airplane, is mainly used for installing and fixing a main landing gear and transmitting ground load to an airplane body structure, and the airplane is scrapped when cracks are not repaired.
In the maintenance enterprises of aviation equipment, when cracks are found in the repair process of airplane bearing aluminum alloy structural parts, the airplane bearing aluminum alloy structural parts are all high-strength aluminum alloys, the weldability is poor, welding repair is generally not carried out, and the structural parts in a fuel tank area cannot be welded. The superficial crack treatment mode is to polish and remove cracks, and the deeper or longer cracks are reinforced by utilizing a metal reinforcing corner box, and the reinforcing mode has certain defects: firstly, the metal reinforced corner box has larger mass, and the weight of the airplane is seriously increased; secondly, the base body needs to be perforated and riveted or screwed, and a weak area exists; thirdly, the processing technology of the reinforced corner box is complex, the repair cycle is long, and the production schedule is severely restricted. In addition, if the crack is in a narrow space area, a surface state complex area, an oil tank area or a large load area, the traditional reinforcing mode of the reinforcing corner box is not suitable for being adopted or has higher difficulty in repair.
Disclosure of Invention
In order to solve the problems, the invention provides a cold spraying reinforcement repairing method for cracks of an aluminum alloy structural part of an airplane.
A cold spraying reinforcement repairing method for cracks of an aluminum alloy structural part of an airplane comprises the following specific steps:
(1) dismantling: removing the accessories on the spraying path;
(2) primary cleaning: primarily cleaning the interior of the spraying area by using acetone and removing oil stains;
(3) plugging: plugging the pipeline by adopting a plug and a plugging cap;
(4) cleaning: carefully cleaning, sandblasting and roughening and cleaning a to-be-sprayed area by using acetone;
(5) an air gun: medium-pressure cold spraying equipment and a customized special-shaped spray gun are adopted, and high-purity helium is used as carrier gas;
(6) spraying: respectively spraying 7075 aluminum alloy spraying blocks on two sides of the cracked structural part in a lossless manner by using a special process through a cover on the surface or the side surface of an upper wall plate of the airplane to form two reinforcing patches;
(7) polishing: polishing and modifying the surface of the cold spraying reinforcing patch to ensure smooth and flat surface and smooth transition, wherein the surface roughness is not inferior to Ra3.2 mu m;
(8) removing the shielding materials: a dust collector is adopted to remove dust and particle impurities in the oil tank;
(9) removing dust: then cleaning the interior with acetone to remove residual dust;
(10) sampling: after fuel oil is added into the oil tank, sampling is carried out to test the oil pollution degree not to exceed the specified index.
And (3) the preliminary cleaning in the step (3) is to adopt a glass fiber adhesive tape which is temperature resistant, has good viscosity and does not drop adhesive, and is assisted with a special HM-109 sealant in an aircraft fuel tank to fill pores, so that the spraying area is comprehensively protected.
The process parameters of the step (4) are as follows:
sand blasting equipment: portable sand blasting equipment;
consumable material: brown corundum sand;
sand blasting pressure: 0.8 MPa;
surface roughness: ra7 μm.
The process parameters of the step (6) are as follows:
cold spraying equipment: medium pressure cold spray equipment;
carrier gas: 99.999% helium;
powder material: 7075 aluminum powder;
specification of powder: (1-50) mu m;
heating temperature: above 300 ℃;
spraying pressure: (0.7 to 3.5) MPa.
The invention has the beneficial effects that: the cold spraying technology is innovatively used for replacing the traditional reinforcing technology of the reinforcing corner box, and a layer of coating block close to the matrix material is sprayed on the surface of the structural member, so that the crack of the matrix is reinforced, and the service life of the airplane is prolonged; the invention reinforces by the way of the spraying block, compared with the traditional reinforcing corner box, the invention greatly reduces the redundant quality and relieves the airplane weight gain caused by repair; the repairing process is lossless, and the fatigue weak point caused by the perforation of the airplane matrix is avoided; the repair cycle is greatly reduced, the reinforcing corner box repair needs a plurality of long-term procedures such as appearance design, machining, on-machine check, on-machine assembly and the like, the reinforcing repair of the spraying block only needs appearance design, protection, spraying and polishing, and the cycle can be shortened by more than 50%; fourthly, the special-shaped spray gun can be used for reinforcing complex structural members in the aircraft fuel tank.
Drawings
The invention is further illustrated with reference to the following figures and examples.
FIG. 1 is a schematic perspective view of the present invention;
FIG. 2 is a schematic perspective view of a cold spray reinforcing patch according to the present invention;
FIG. 3 is a schematic cross-sectional view of the patch of the present invention;
FIG. 4 is a schematic view of a main view of the patch position according to the present invention;
FIG. 5 is an enlarged view of section I of FIG. 4 according to the present invention;
FIG. 6 is a schematic perspective view of a metal reinforcing angle box for bolt butt joint according to the present invention;
FIG. 7 is a schematic perspective view of a metal reinforced angle box and a butt bolt according to the present invention.
Detailed Description
In order to make the technical means, the creation characteristics, the achievement purposes and the effects of the invention easy to understand, the invention is further explained below.
As shown in fig. 1 to 7, a cold spray repair method for cracks of an aluminum alloy structural member of an airplane specifically comprises the following steps:
(1) dismantling: removing the accessories on the spraying path;
(2) primary cleaning: primarily cleaning the interior of the spraying area by using acetone and removing oil stains;
(3) plugging: plugging the pipeline by adopting a plug and a plugging cap;
(4) cleaning: carefully cleaning, sandblasting and roughening and cleaning a to-be-sprayed area by using acetone;
(5) an air gun: medium-pressure cold spraying equipment and a customized special-shaped spray gun are adopted, and high-purity helium is used as carrier gas;
(6) spraying: respectively spraying 7075 aluminum alloy spraying blocks on two sides of the cracked structural part in a lossless manner by using a special process through a cover on the surface or the side surface of an upper wall plate of the airplane to form two reinforcing patches;
(7) polishing: polishing and modifying the surface of the cold spraying reinforcing patch to ensure smooth and flat surface and smooth transition, wherein the surface roughness is not inferior to Ra3.2 mu m;
(8) removing the shielding materials: a dust collector is adopted to remove dust and particle impurities in the oil tank;
(9) removing dust: then cleaning the interior with acetone to remove residual dust;
(10) sampling: after fuel oil is added into the oil tank, sampling is carried out to test the oil pollution degree not to exceed the specified index.
The initial cleaning in the step (3) is to adopt a glass fiber adhesive tape which is temperature resistant, has good viscosity and does not fall off glue, and to assist a special HM-109 sealant in an aircraft fuel tank to fill pores, so as to comprehensively protect a spraying area.
The structural member reinforcement is realized by adopting a nondestructive process method aiming at the cracks of the airplane structural member, the crack propagation rate is avoided or controlled, and the fatigue life of the structural member is prolonged; meanwhile, a protection method of an area where the cracks of the aircraft structural member are located is researched, and the pollution of powder generated by cold spraying on an aircraft fuel system is prevented.
The invention innovatively uses a cold spraying technology to replace the traditional reinforcing technology of the reinforcing corner box, and realizes the reinforcement of matrix cracks and prolongs the service life of an airplane by spraying a layer of coating blocks close to matrix materials on the surface of a structural member.
The process parameters of the step (4) are as follows:
sand blasting equipment: portable sand blasting equipment;
consumable material: brown corundum sand;
sand blasting pressure: 0.8 MPa;
surface roughness: ra7 μm.
The invention reinforces by the way of the spraying block, compared with the traditional reinforcing corner box, the invention greatly reduces the redundant quality and relieves the airplane weight gain caused by repair; the repairing process is lossless, and the fatigue weak point caused by the perforation of the airplane matrix is avoided; the repair cycle is greatly reduced, the reinforcing corner box repair needs a plurality of long-term procedures such as appearance design, machining, on-machine check, on-machine assembly and the like, the reinforcing repair of the spraying block only needs appearance design, protection, spraying and polishing, and the cycle can be shortened by more than 50%; fourthly, the special-shaped spray gun can be used for reinforcing complex structural members in the aircraft fuel tank.
The process parameters of the step (6) are as follows:
cold spraying equipment: medium pressure cold spray equipment;
carrier gas: 99.999% helium;
powder material: 7075 aluminum powder;
specification of powder: (1-50) mu m;
heating temperature: above 300 ℃;
spraying pressure: (0.7 to 3.5) MPa.
In the figure, 1 is a crack position, 2 is a cold spraying reinforcing patch, 3 is a force bearing structural part, 4 is a bolt, 5 is a metal reinforcing corner box, 6 is a base material, 7 is a crack, a 7B04 material which is the same as an airplane structural part is adopted to process a test piece, and a groove is formed in one side of the test piece for generating the crack. In order to verify the repairing effect of the cold spraying on the existing cracks, the cold spraying reinforcement is carried out after the test piece naturally forms the cracks on the test piece in a loading mode of a testing machine. The influence of cold spraying reinforcement on the crack extension life is inspected by comparing the loading cycle times of different test pieces in the process from the crack to the damage, and the reinforcement effect of cold spraying on the existing crack is verified. Test results show that the 7075 aluminum alloy can be subjected to cold spraying reinforcement on a 7B04 high-strength aluminum alloy matrix to obtain a fatigue gain effect of more than 200%, crack faults of key parts of an airplane are solved, the safety of the airplane is ensured, the service life of the airplane is prolonged, and the method has high economic benefits.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (1)
1. A cold spraying reinforcement repairing method for cracks of an aluminum alloy structural part of an airplane is characterized by comprising the following steps: the method comprises the following specific steps:
(1) dismantling: removing the accessories on the spraying path;
(2) primary cleaning: primarily cleaning the interior of the spraying area by using acetone and removing oil stains; the preliminary cleaning is to adopt a glass fiber adhesive tape which is temperature resistant, has good viscosity and does not fall off adhesive, and is assisted with a special HM-109 sealant in an airplane oil tank to fill pores, so as to comprehensively protect a spraying area;
(3) plugging: plugging the pipeline by adopting a plug and a plugging cap;
(4) cleaning: carefully cleaning, sandblasting and roughening and cleaning a to-be-sprayed area by using acetone; the specific process parameters are as follows: sand blasting equipment: portable sand blasting equipment; consumable material: brown corundum sand; sand blasting pressure: 0.8 MPa; surface roughness: ra7 μm;
(5) an air gun: medium-pressure cold spraying equipment and a customized special-shaped spray gun are adopted, and high-purity helium is used as carrier gas;
(6) spraying: respectively spraying 7075 aluminum alloy spraying blocks on two sides of the cracked structural part in a lossless manner by using a special process through a cover on the surface or the side surface of an upper wall plate of the airplane to form two reinforcing patches; the specific process parameters are as follows: cold spraying equipment: medium pressure cold spray equipment; carrier gas: 99.999% helium; powder material: 7075 aluminum powder; specification of powder: (1-50) mu m; heating temperature: above 300 ℃; spraying pressure: (0.7-3.5) MPa;
(7) polishing: the surface of the cold spraying reinforcing patch is polished and shaped to ensure smooth and flat surface, smooth transition and surface roughness
Not inferior to Ra3.2 μm;
(8) removing the shielding materials: a dust collector is adopted to remove dust and particle impurities in the oil tank;
(9) removing dust: then cleaning the interior with acetone to remove residual dust;
(10) sampling: after fuel oil is added into the oil tank, sampling is carried out to test the oil pollution degree not to exceed the specified index.
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| CN201810848871.7A CN108860656B (en) | 2018-07-28 | 2018-07-28 | Cold spraying reinforcement repairing method for cracks of aluminum alloy structural part of airplane |
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| CN201810848871.7A CN108860656B (en) | 2018-07-28 | 2018-07-28 | Cold spraying reinforcement repairing method for cracks of aluminum alloy structural part of airplane |
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Families Citing this family (7)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN109735839A (en) * | 2019-01-14 | 2019-05-10 | 西安建筑科技大学 | A kind of method that fatigue crack is repaired in cold spraying |
| CN110918416B (en) * | 2019-12-09 | 2021-11-19 | 中国航空工业集团公司沈阳飞机设计研究所 | Main bearing part repairing method based on three-dimensional material increase |
| CN111703587B (en) * | 2020-06-08 | 2022-11-01 | 国营四达机械制造公司 | Method for repairing crack corrosion fault of electric heating leading edge skin of airplane |
| CN112265652B (en) * | 2020-09-10 | 2023-05-26 | 大连长丰实业总公司 | Maintenance method of aircraft pipe joint |
| CN112522695B (en) * | 2020-10-06 | 2023-02-28 | 湖北超卓航空科技股份有限公司 | Method for repairing fatigue crack by cold spraying |
| CN112475300B (en) * | 2020-11-25 | 2023-05-09 | 中国航空工业集团公司沈阳飞机设计研究所 | Jet flow additive repairing process method for aluminum alloy base material |
| CN113002022B (en) * | 2021-03-25 | 2022-03-08 | 南京工程学院 | Fiber reinforced resin matrix composite material repairing method |
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| CN203698676U (en) * | 2014-03-07 | 2014-07-09 | 中国科学院金属研究所 | On-site repair device for aircraft skin surfaces |
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