CN110588014A - 2.5D composite material spray pipe expansion section and co-curing forming method thereof - Google Patents
2.5D composite material spray pipe expansion section and co-curing forming method thereof Download PDFInfo
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- CN110588014A CN110588014A CN201910827949.1A CN201910827949A CN110588014A CN 110588014 A CN110588014 A CN 110588014A CN 201910827949 A CN201910827949 A CN 201910827949A CN 110588014 A CN110588014 A CN 110588014A
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/30—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core
- B29C70/34—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation
- B29C70/342—Shaping by lay-up, i.e. applying fibres, tape or broadsheet on a mould, former or core; Shaping by spray-up, i.e. spraying of fibres on a mould, former or core and shaping or impregnating by compression, i.e. combined with compressing after the lay-up operation using isostatic pressure
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/04—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising reinforcements only, e.g. self-reinforcing plastics
- B29C70/28—Shaping operations therefor
- B29C70/54—Component parts, details or accessories; Auxiliary operations, e.g. feeding or storage of prepregs or SMC after impregnation or during ageing
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- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
- F02K—JET-PROPULSION PLANTS
- F02K9/00—Rocket-engine plants, i.e. plants carrying both fuel and oxidant therefor; Control thereof
- F02K9/97—Rocket nozzles
Abstract
The invention discloses a 2.5D composite material spray pipe expansion section and a co-curing forming method thereof, belonging to the technical field of solid rocket engines, wherein the 2.5D composite material spray pipe expansion section comprises an ablation layer, a laying layer, a heat insulation layer, a composite material shell, a reinforcing rib and an internal carbon needle, and the co-curing forming method comprises the following steps: forming a laying layer on the outer surface of the ablation layer, and radially implanting carbon needles to ensure that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer; assembling the preformed composite shell and the uncured heat insulation layer, radially implanting carbon needles to enable the carbon needles to penetrate through the composite shell and be inserted into the heat insulation layer, and connecting the composite shell with the heat insulation layer; the laying layer, the heat insulation layer, the composite shell and the reinforcing ribs are preformed from inside to outside in sequence and are finally integrally co-cured and formed. The invention effectively enhances the interlayer binding force of the expansion section of the spray pipe, avoids generating internal gaps, reduces the damage of fibrous tissues and improves the structural stability and the use reliability of products.
Description
Technical Field
The invention relates to the technical field of solid rocket engines, in particular to a 2.5D composite material nozzle expansion section and a co-curing forming method thereof.
Background
The nozzle expanding section is a key part of the solid rocket engine, and the use reliability and safety of the engine are directly determined by the performance of the nozzle expanding section. The nozzle expansion section generally includes an ablation layer, a thermal insulation layer, a composite shell and a reinforcing rib. The existing nozzle expansion section manufacturing process has the following defects:
1. two-dimensional winding is adopted for forming, and the ablation layer is easy to fall off from the layer under the high-speed flushing of high-temperature and high-pressure airflow;
2. the composite shell and the heat insulation layer are assembled after being independently cured, so that an internal gap is generated in the structure;
3. the composite shell is connected with the thermal insulation layer through bolts, and the screw holes greatly damage fibrous tissues and damage the internal structure of the product;
4. by adopting staged curing, after repeated heating, microcracks and even cracks are easily generated in the product due to different thermal expansion coefficients, and the use reliability and safety of the product are seriously threatened.
Disclosure of Invention
Aiming at the technical problems, the invention provides a 2.5D composite material spray pipe expansion section and a co-curing forming method thereof.
In order to achieve the purpose, the technical scheme provided by the invention is as follows:
the invention firstly provides a 2.5D composite material spray pipe expansion section which comprises an ablation layer, a laying layer, a heat insulation layer, a composite material shell, reinforcing ribs and internal carbon needles, and is formed by co-curing through the following steps: forming a laying layer on the outer surface of the ablation layer, and radially implanting carbon needles to ensure that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer; assembling the preformed composite shell and the uncured heat insulation layer, radially implanting carbon needles to enable the carbon needles to penetrate through the composite shell and be inserted into the heat insulation layer, and connecting the composite shell with the heat insulation layer; the laying layer, the heat insulation layer, the composite shell and the reinforcing ribs are preformed from inside to outside in sequence and are finally integrally co-cured and formed.
Wherein, the laying layer is formed by laying carbon cloth/phenolic cyanate on the outer surface of the ablation layer.
The ablation layer is formed by winding carbon cloth/phenolic aldehyde cyanate, and the initial winding surface of the ablation layer is the outer molding surface of the mold.
The heat insulation layer is formed by winding high silica cloth/phenolic aldehyde cyanate, and the initial winding layer surface of the heat insulation layer is the outer molding surface of the laying layer.
Preferably, the carbon needle is prepared from epoxy resin or phenolic resin through a pultrusion process, the fiber volume content of the carbon needle is 50% -70%, and the curing degree of the carbon needle is 70% -90%.
Preferably, the implantation method of the carbon needle is an ultrasonic hammer implantation method, the carbon needle is pre-inserted into the auxiliary foam plate, and the target carbon needle is implanted by using an ultrasonic hammer.
The invention also provides a co-curing molding method of the 2.5D composite material nozzle expansion section, which comprises the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer;
s3, implanting carbon needles into the laying layer and the ablation layer by using an ultrasonic hammer, so that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer;
s4, winding the high silica cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a heat insulation layer;
s5, laying by adopting T700/cyanate, and preforming the composite shell;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting carbon needles by using an ultrasonic hammer, and enabling the carbon needles to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer;
s7, using polystyrene foam as the internal support of the annular rib, laying carbon cloth or phenolic cyanate, and forming an annular reinforcing rib on the surface of the ablation layer extending to the outside of the laying layer along the length direction;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging, wherein the curing temperature range is 70-170 ℃, the curing time is 3-50h, and the curing pressure is 3-6 MPa.
Preferably, the width of the cloth tape in the step S1 is selected to be in the range of 50-120mm, and the winding thickness is in the range of 15-30 mm.
Preferably, the thickness of the laid layer in step S2 ranges from 10 to 40 mm.
Preferably, in the step S3, the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50% -70%, the curing degree is 70% -90%, the diameter range of the carbon needle is 0.1-1.2mm, the implantation depth is 5-70mm, the implantation density is 2mm × 2mm-12mm × 12mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 600-1000mm towards the inner side of the thermal insulation layer.
Preferably, the insulation layer winding thickness in step S4 ranges from 10 to 50 mm.
Preferably, the prepreg of the step S5 has a thickness ranging from 0.1 to 0.5mm, a ply angle ranging from 0 to 180 degrees, and a lay-up thickness ranging from 20 to 40 mm.
Preferably, the carbon needle of step S6 is made of epoxy resin or phenolic resin by pultrusion process, the fiber volume content is 50% -70%, the curing degree is 70% -90%, the diameter range of the carbon needle is 0.1-1.2mm, the implantation depth is 35-60mm, and the implantation density is 2mm × 2mm-15mm × 15 mm.
Preferably, the 2.5D composite material nozzle expansion section co-curing forming method comprises the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 85mm, and the winding thickness is 25 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 12 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter of the carbon needle is 0.3mm, the implantation depth is 37mm, the implantation density is 7mm multiplied by 7mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 700mm towards the inner side of the thermal insulation layer;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 40 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.2mm, the laying angle is 50 degrees, and the laying thickness is 30 mm;
s6, assembling a preformed composite shell and an uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter range of the carbon needle is 0.3mm, the implantation depth is 41mm, and the implantation density is 10mm multiplied by 10 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying the carbon cloth/phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 160 ℃, the curing time is 45h, and the curing pressure is 4 MPa.
Compared with the prior art, the invention has the technical effects that:
according to the invention, carbon cloth/phenolic aldehyde cyanate is laid outside the ablation layer, the carbon needles are implanted by using an ultrasonic hammer, and the carbon needles are implanted in the 2D winding surface in the radial direction on the basis of the existing 2D winding to form a semi-3D composite material spray pipe expansion section, namely a 2.5D composite material spray pipe expansion section, so that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer, the interlayer binding force is effectively enhanced, and interlayer falling is avoided; the composite shell is preformed and then co-cured with the uncured heat insulation layer, so that an internal gap is prevented from being generated in the structure; the composite shell is connected with the heat insulation layer by carbon needles, the diameter of each carbon needle is 0.1-1.2mm, and the damage of a screw hole to a fibrous tissue is effectively reduced; the product ablation layer, the laying layer, the heat insulation layer, the composite shell, the reinforcing ribs and the internal carbon needles adopt a co-curing process, so that microcracks and even cracks caused by different thermal expansion coefficients in the product after repeated temperature rise of staged curing are avoided, and the structural stability and the use reliability of the product are improved.
Drawings
In order to more clearly illustrate the embodiments of the present application or technical solutions in the prior art, the drawings needed to be used in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments described in the present invention, and other drawings can be obtained by those skilled in the art according to the drawings.
Fig. 1 is a schematic structural diagram of a 2.5D composite nozzle expansion segment according to an embodiment of the present invention, in which 1 is an ablation layer, 2 is a laying layer, 3 is a thermal insulation layer, 4 is a composite shell, 5 is a reinforcing rib, and 6 is a carbon needle.
FIG. 2 is a schematic view of the range of the ablation layer carbon needle radial implantation according to an embodiment of the present invention.
Fig. 3 is a schematic view of a radial implantation range of the carbon needle of the composite shell according to an embodiment of the present invention.
Detailed Description
In order to make the technical solutions of the present invention better understood by those skilled in the art, the present invention will be further described in detail with reference to the following embodiments and the accompanying drawings. The following examples are used to illustrate the present invention, but do not limit the scope of the invention.
Example 1
The 2.5D composite material nozzle expansion section provided by the invention comprises an ablation layer 1, a laying layer 2, a heat insulation layer 3, a composite material shell 4, a reinforcing rib 5 and an internal carbon needle 6 as shown in figure 1. The outer diameter of the inlet end of the expansion section of the spray pipe in the embodiment is phi 1500mm, the outer diameter of the outlet end of the expansion section of the spray pipe is phi 5000mm, and the length of the expansion section of the spray pipe is 4900 mm. The 2.5D composite material nozzle expansion section is prepared by adopting a method comprising the following steps:
s1, selecting a cloth belt or phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of the cloth belt is 50mm, and the winding thickness is 15 mm;
s2, laying the carbon cloth or the phenolic cyanate prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 10 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50%, the curing degree is 75%, the diameter of the carbon needle is 0.1mm, the implantation depth is 5mm, the implantation density is 2mm multiplied by 2mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 600mm to the inner side of the thermal insulation layer, as shown in figure 2;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 10 mm;
s5, laying by adopting T700 or cyanate, preforming the composite shell, wherein the thickness of the prepreg is 0.1mm, the laying angle is 0 degree, and the laying thickness is 20 mm;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, as shown in figure 3, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50%, the curing degree is 70%, the diameter range of the carbon needle is 0.1mm, the implantation depth is 35mm, and the implantation density is 2mm multiplied by 2 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying the carbon cloth/phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2, as shown in FIG. 1;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 70 ℃, the curing time is 50h, and the curing pressure is 3 MPa.
Example 2
The 2.5D composite material nozzle expansion section provided by the invention comprises an ablation layer 1, a laying layer 2, a heat insulation layer 3, a composite material shell 4, a reinforcing rib 5 and an internal carbon needle 6 as shown in figure 1. The outer diameter of the inlet end of the expansion section of the spray pipe is phi 1600mm, the outer diameter of the outlet end of the expansion section of the spray pipe is phi 5200mm, and the length of the expansion section of the spray pipe is 5000 mm. The 2.5D composite material nozzle expansion section is prepared by adopting a method comprising the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 70mm, and the winding thickness is 20 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 12 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50%, the curing degree is 70%, the diameter of the carbon needle is 0.2mm, the implantation depth is 15mm, the implantation density is 4mm multiplied by 4mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 600mm to the inner side of the thermal insulation layer, as shown in figure 2;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 20 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.2mm, the laying angle is 15 degrees, and the laying thickness is 25 mm;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, as shown in figure 3, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50%, the curing degree is 70%, the diameter range of the carbon needle is 0.2mm, the implantation depth is 35mm, and the implantation density is 5mm multiplied by 5 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying carbon cloth or phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2, as shown in FIG. 1;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 100 ℃, the curing time is 45h, and the curing pressure is 4 MPa.
Example 3
The 2.5D composite material nozzle expansion section provided by the invention comprises an ablation layer 1, a laying layer 2, a heat insulation layer 3, a composite material shell 4, a reinforcing rib 5 and an internal carbon needle 6 as shown in figure 1. The external diameter of the inlet end of the expansion section of the spray pipe is phi 1600mm, the external diameter of the outlet end of the spray pipe is phi 5500mm, and the length of the spray pipe is 5100 mm. The 2.5D composite material nozzle expansion section is prepared by adopting a method comprising the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 85mm, and the winding thickness is 25 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 12 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter of the carbon needle is 0.3mm, the implantation depth is 37mm, the implantation density is 7mm multiplied by 7mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 700mm to the inner side of the thermal insulation layer, as shown in figure 2;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 40 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.2mm, the laying angle is 50 degrees, and the laying thickness is 30 mm;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, as shown in figure 3, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter range of the carbon needle is 0.3mm, the implantation depth is 41mm, and the implantation density is 10mm multiplied by 10 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying carbon cloth or phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2, as shown in FIG. 1;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 160 ℃, the curing time is 45h, and the curing pressure is 4 MPa.
Example 4
The 2.5D composite material nozzle expansion section provided by the invention comprises an ablation layer 1, a laying layer 2, a heat insulation layer 3, a composite material shell 4, a reinforcing rib 5 and an internal carbon needle 6 as shown in figure 1. The outer diameter of the inlet end of the expansion section of the spray pipe is phi 1700mm, the outer diameter of the outlet end of the expansion section of the spray pipe is phi 5600mm, and the length of the expansion section of the spray pipe is 5300 mm. The 2.5D composite material nozzle expansion section is prepared by adopting a method comprising the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 100mm, and the winding thickness is 25 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 35 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 65%, the curing degree is 85%, the diameter of the carbon needle is 0.8mm, the implantation depth is 55mm, the implantation density is 9mm multiplied by 9mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 800mm to the inner side of the thermal insulation layer, as shown in figure 2;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a heat insulation layer, wherein the winding thickness of the heat insulation layer is 45 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.5mm, the laying angle is 75 degrees, and the laying thickness is 35 mm;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, as shown in figure 3, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 65%, the curing degree is 85%, the diameter range of the carbon needle is 0.8mm, the implantation depth is 50mm, and the implantation density is 12mm multiplied by 12 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying carbon cloth or phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2, as shown in FIG. 1;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 160 ℃, the curing time is 5 hours, and the curing pressure is 6 MPa.
Example 5
The 2.5D composite material nozzle expansion section provided by the invention comprises an ablation layer 1, a laying layer 2, a heat insulation layer 3, a composite material shell 4, a reinforcing rib 5 and an internal carbon needle 6 as shown in figure 1. The external diameter of the inlet end of the expansion section of the spray pipe is phi 1800mm, the external diameter of the outlet end of the expansion section of the spray pipe is phi 6000mm, and the length of the expansion section of the spray pipe is 5500 mm. The 2.5D composite material nozzle expansion section is prepared by adopting a method comprising the following steps:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 120mm, and the winding thickness is 30 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 40 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 70%, the curing degree is 90%, the diameter of the carbon needle is 1.2mm, the implantation depth is 70mm, the implantation density is 12mm multiplied by 12mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 1000mm to the inner side of the thermal insulation layer, as shown in figure 2;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 50 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.5mm, the laying angle is 90 degrees, and the laying thickness is 40 mm;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, as shown in figure 3, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 70%, the curing degree is 90%, the diameter range of the carbon needle is 1.2mm, the implantation depth is 60mm, and the implantation density is 15mm multiplied by 15 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying carbon cloth or phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2, as shown in FIG. 1;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 170 ℃, the curing time is 3h, and the curing pressure is 6 MPa.
In the embodiment, the co-curing molding method for the expansion section of the 2.5D composite material spray pipe is realized, carbon cloth or phenolic cyanate prepreg is laid outside an ablation layer, and a carbon needle is implanted by using an ultrasonic hammer, so that the interlayer bonding force is effectively enhanced; the composite shell is preformed and then co-cured with the uncured heat insulation layer, so that an internal gap is avoided; the composite shell is connected with the heat insulation layer by carbon needles, the diameter of each carbon needle is 0.1-1.2mm, and damage to fibrous tissues is effectively reduced; the product ablation layer, the laying layer, the heat insulation layer, the composite shell, the reinforcing ribs and the internal carbon needles adopt a co-curing process, so that the structural stability and the use reliability of the product are improved.
Claims (9)
1. The 2.5D composite material spray pipe expansion section is characterized by comprising an ablation layer, a laying layer, a heat insulation layer, a composite material shell, reinforcing ribs and internal carbon needles, and is formed by co-curing through the following steps: forming a laying layer on the outer surface of the ablation layer, and radially implanting carbon needles to ensure that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer; assembling the preformed composite shell and the uncured heat insulation layer, radially implanting carbon needles to enable the carbon needles to penetrate through the composite shell and be inserted into the heat insulation layer, and connecting the composite shell with the heat insulation layer; the laying layer, the heat insulation layer, the composite shell and the reinforcing ribs are preformed from inside to outside in sequence and are finally integrally co-cured and formed.
2. The 2.5D composite nozzle expansion segment of claim 1, wherein the lay-up layer is formed by laying carbon cloth/phenolic cyanate ester on the outer surface of the ablation layer.
3. The 2.5D composite nozzle extension of claim 2, wherein the ablation layer is woven with a tape/phenolic cyanate wrap and the initial winding surface of the ablation layer is the outer mold surface.
4. The 2.5D composite nozzle flare according to claim 2, wherein the insulation layer is wound from high silica cloth/phenolic cyanate ester and the initial wound layer surface of the insulation layer is the outer laying surface.
5. The 2.5D composite nozzle expansion segment of claim 1, wherein the carbon needle is prepared from epoxy or phenolic resin by a pultrusion process, the fiber volume content of the carbon needle is 50% -70%, and the curing degree is 70% -90%.
6. The 2.5D composite nozzle expansion segment of claim 1, wherein the carbon needle implantation method is an ultrasonic hammer implantation method, wherein the carbon needle is pre-inserted onto an auxiliary foam plate, and the target carbon needle is implanted by an ultrasonic hammer.
7. The 2.5D composite nozzle flare co-cure molding process of any one of claims 1 to 6, comprising the steps of:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer;
s3, implanting carbon needles into the laying layer and the ablation layer by using an ultrasonic hammer, so that the carbon needles penetrate through the laying layer and are inserted into the ablation layer to reach the molding surface of the ablation layer;
s4, winding the high silica cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a heat insulation layer;
s5, laying by adopting T700/cyanate, and preforming the composite shell;
s6, assembling the preformed composite shell and the uncured heat insulation layer, implanting carbon needles by using an ultrasonic hammer, and enabling the carbon needles to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer;
s7, using polystyrene foam as an internal support of the annular rib, laying the carbon cloth/phenolic cyanate, and forming an annular reinforcing rib on the surface of the ablation layer extending to the outside of the laying layer along the length direction;
and S8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after the packaging is finished.
8. The 2.5D composite nozzle flare co-cure molding process of claim 7, comprising the steps of:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the selection range of the width of a cloth belt is 50-120mm, and the winding thickness range is 15-30 mm;
s2, laying the carbon cloth or the phenolic cyanate prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness range of the laying layer is 10-40 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50% -70%, the curing degree is 70% -90%, the diameter range of the carbon needle is 0.1-1.2mm, the implantation depth is 5-70mm, the implantation density is 2mm multiplied by 2mm-12mm multiplied by 12mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 600 plus 1000mm to the inner side of the thermal insulation layer;
s4, winding the high silica cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness range of the thermal insulation layer is 10-50 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness range of the prepreg is 0.1-0.5mm, the laying angle is 0-180 degrees, and the laying thickness range is 20-40 mm;
s6, assembling a preformed composite shell and an uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 50% -70%, the curing degree is 70% -90%, the diameter range of the carbon needle is 0.1-1.2mm, the implantation depth is 35-60mm, and the implantation density is 2mm multiplied by 2mm-15mm multiplied by 15 mm;
s7, using polystyrene foam as an internal support of the annular rib, laying the carbon cloth/phenolic cyanate, and forming an annular reinforcing rib on the surface of the ablation layer extending to the outside of the laying layer along the length direction;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging, wherein the curing temperature range is 70-170 ℃, the curing time is 3-50h, and the curing pressure is 3-6 MPa.
9. The 2.5D composite nozzle flare co-cure molding process of claim 8, comprising the steps of:
s1, selecting carbon cloth/phenolic cyanate ester prepreg to wind an ablation layer, wherein the width of a cloth belt is 85mm, and the winding thickness is 25 mm;
s2, laying the carbon cloth/phenolic cyanate ester prepreg on the outer surface of the ablation layer to form a laying layer, wherein the thickness of the laying layer is 12 mm;
s3, implanting a carbon needle into the laying layer and the ablation layer by using an ultrasonic hammer, enabling the carbon needle to penetrate through the laying layer and be inserted into the ablation layer to reach the molding surface of the ablation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter of the carbon needle is 0.3mm, the implantation depth is 37mm, the implantation density is 7mm multiplied by 7mm, and the implantation starting position of the carbon needle is that the edge of the thermal insulation layer extends 700mm towards the inner side of the thermal insulation layer;
s4, winding high silica cloth/phenolic cyanate ester prepreg on the outer molding surface of the ablation layer to form a thermal insulation layer, wherein the winding thickness of the thermal insulation layer is 40 mm;
s5, laying by adopting T700/cyanate ester, preforming the composite shell, wherein the thickness of the prepreg is 0.2mm, the laying angle is 50 degrees, and the laying thickness is 30 mm;
s6, assembling a preformed composite shell and an uncured heat insulation layer, implanting a carbon needle by using an ultrasonic hammer, enabling the carbon needle to penetrate through the composite shell and be inserted into the heat insulation layer to connect the composite shell and the heat insulation layer, wherein the carbon needle is made of epoxy resin or phenolic resin through a pultrusion process, the fiber volume content is 60%, the curing degree is 75%, the diameter range of the carbon needle is 0.3mm, the implantation depth is 41mm, and the implantation density is 10mm multiplied by 10 mm;
s7, using polystyrene foam as an internal support of the annular ribs, laying the carbon cloth/phenolic cyanate, and forming annular reinforcing ribs on the surface of the ablation layer extending to the outside of the laying layer along the length direction, wherein the number of the annular reinforcing ribs is 2;
s8, carrying out integral vacuum packaging on the ablation layer, the laying layer, the heat insulation layer, the reinforcing ribs and the internal carbon needles, and carrying out co-curing after packaging is finished, wherein the curing temperature range is 160 ℃, the curing time is 45h, and the curing pressure is 4 MPa.
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