CN111196063B - 一种径向负梯度泡沫铝夹芯板及其制备方法 - Google Patents
一种径向负梯度泡沫铝夹芯板及其制备方法 Download PDFInfo
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Abstract
本发明属金属材料结构设计技术领域，提供一种径向负梯度泡沫铝夹芯板。为层状结构，自下而上依次为下板层、径向负梯度泡沫铝芯层和上板层；上层板和下层板内表面用胶粘或焊接与径向梯度泡沫铝芯层的顶部和底部连接固定；径向负梯度泡沫铝芯层为若干径向负梯度泡沫铝单胞在平面内依次排列组成，单胞之间的接触部位焊接或二次发泡连接；负梯度泡沫铝单胞的密度以正方形形心出发，沿半径方向逐渐增加。结构合理、性能优异，密度低、比刚度大、比强度高、稳定性好、抗冲击性、电磁屏蔽、阻尼特性优良、低热导率和电导率、绝热、隔音，在化工、冶金、机械、建筑土木、高速汽车、船舶、包装运输、航空航天、军事防护等工程材料领域具有广阔的应用前景。
Description
技术领域
本发明属于金属材料结构设计技术领域，具体涉及一种径向负梯度泡沫铝夹芯板及其制备方法；该径向负梯度泡沫铝夹芯板适用于建筑土木、航空航天、高速列车船舶、风机叶片等工程材料领域。
背景技术
泡沫铝是在纯铝或铝合金中加入添加剂经过发泡工艺后制成的，它同时兼有金属和气泡特征，是一种具有复杂细观结构的新型多功能材料，具有比强度高、比刚度高和能量吸收好等特性。梯度泡沫材料指的是其成分或结构逐渐变化而使相应的材料力学性能发生变化的一种材料。梯度泡沫材料种类较多，例如层级梯度或连续梯度结构，以及体积含量、形状、方向等存在梯度的情况，其力学性能具有良好的可设计性，因此受到了广泛的关注。
泡沫铝夹芯板是由外面板层和泡沫铝内芯构成的金属材料，它不仅宏观上具有夹芯结构的复合特征，而且在充分发挥泡沫铝材料自身特点的同时，解决了单一泡沫铝强度较低，难于连接等问题。泡沫铝夹芯板具有密度低、比刚度大、比强度高、稳定性好、抗冲击、电磁屏蔽、阻尼特性优良、热导率和电导率低、绝热、隔音等特点，在电子、通讯、化工、治金、机械、建筑、汽车、船舶、包装运输、航空航天技术、军事防护等领域都具有广阔的应用前景。
常见的泡沫铝夹芯板使用均匀泡沫铝作为夹层板的芯材，目前均匀泡沫铝夹层板在设计理论和制造技术上也已较为成熟，能够制备出来的内芯填充物均采用均匀泡沫铝加工成形。然而，均匀泡沫铝夹芯板强度较低，限制并影响了其在承力结构上的推广应用，且从轻量化的角度而言，夹层板中的均匀泡沫芯层并不是最优的，因此有必要设计一种优化的内芯结构以及制备方法来满足泡沫铝夹芯板的应用需求。
发明内容
为了解决现有技术存在的不足，本发明提供了一种径向负梯度泡沫铝夹芯板及其制备方法。所制备的径向负梯度泡沫铝夹芯板结构合理、性能优良。通过对泡沫铝芯层设计合理的密度分布形状，不仅具有质量小、吸能效率高的特点，还使其与相同横截面积同等高度的均匀泡沫铝夹芯板相比在抗压、抗弯强度方面均有较大增加，增强了泡沫铝芯层的力学性能，有效提高了泡沫铝夹芯板承受面外载荷时的保护效果。
本发明解决技术问题所采用的技术方案为：一种径向负梯度泡沫铝夹芯板，所述径向负梯度泡沫铝夹芯板为层状结构，自下而上，依次为下板层、径向负梯度泡沫铝芯层和上板层；其中：上层板和下层板内表面采用胶粘或焊接，平行、对称与径向负梯度泡沫铝芯层的顶部和底部连接固定；径向负梯度泡沫铝芯层为若干径向负梯度泡沫单胞在平面内依次排列组合得到。
所述的径向负梯度泡沫铝单胞形状为正方体或长方体，单胞密度变化所在面为正方形，从正方形心处至正方形边界处密度逐渐增加；密度变化所在面的垂直方向为单胞轴向方向，泡沫铝密度均匀；V为泡沫铝单胞的总体积，将泡沫铝密度变化面沿径向分为N份，V i 分别表示第i份的体积，ρ i为第i份的相对密度。以将密度变化区域分为三层为例，中心层密度为ρ 1，中间层密度为ρ 2，最外层密度为ρ 3，则ρ 1<ρ 2<ρ 3。
所述的径向负梯度泡沫铝芯层材质为闭孔泡沫纯铝或泡沫铝合金。
径向负梯度泡沫铝单胞利用线切割技术，将泡沫材料切割后拼接组合焊接或粘接得到；或利用中国专利CN 101418391 B中离心沉积法生产制备得到。径向负梯度泡沫铝单胞之间的接触部位通过焊接或二次发泡连接。
所述的上层板、下层板形状、尺寸相同，厚度小于梯度泡沫芯层高度；上层板和下层板为金属或非金属材质；上、下层面板为同种或异种材料。所述径向梯度泡沫铝芯层轴向方向与面板所在平面方向平行；面板材料和芯材在连接前均用砂纸对其表面进行打磨，清洗去除油污和锈迹。
所述的径向梯度泡沫铝单胞的加工方法。选取不同密度的闭孔泡沫铝，利用线切割技术将泡沫材料切割，得到设计尺寸的圆柱形、圆环形等形状，按照密度大小拼接组合。以将密度变化区域分为三层为例，中心层为圆柱形状，密度为ρ 1；中间层为圆环形状，密度为ρ 2；最外层为内部切除圆柱后的正方体或长方体，密度为ρ 3，则ρ 1<ρ 2<ρ 3；按照密度及形状顺序，焊接或粘接得到径向梯度泡沫铝单胞；或利用中国专利CN 101418391 B中制备梯度多孔材料的方法，将基体粉末与致孔剂混合，然后加入无水乙醇，制备悬浮液；然后将悬浮液倒入模具中，然后进行离心沉积；离心沉积后烘干，脱模后取出粗坏，再放入石墨模具中烧结，得坯料；去除坯料中的致孔剂，即得径向负梯度泡沫铝单胞。
所述的径向梯度泡沫铝内芯由一定数量径向负梯度泡沫铝单胞在平面内依次排列，通过焊接或二次发泡连接而成，单胞之间面连接处密度相同，为单胞密度最大区域。
所述径向梯度泡沫铝芯层轴向方向与面板所在平面平行。
所述的面板材料和芯材在连接前均用砂纸对其表面进行打磨，清洗去除油污和锈蚀。
所述的径向负梯度泡沫铝夹芯板采用焊接将径向梯度泡沫铝芯体与面板焊接而成，或在面板与径向梯度泡沫铝内芯接触面上均匀涂覆一层胶粘剂，静置或于温度不高于70℃烘箱中固化得到。
所述的胶粘剂为聚氨酯或环氧脂类。
为了增加芯层的抗冲击、能量吸收效果，所述梯度泡沫铝单胞与上下面板连接处密度较大，胞元较多。当夹芯板受到冲击力时，冲击力通过面板传递到泡沫层，连接处强度更大能够抵抗传递过来的冲击力，起抗震缓冲作用，提高载荷状态时能量吸收，减少对夹芯板的破坏。
为了保持材料密度较小并提高抗弯能力，所述单胞中心密度较小，胞元较少。通过结构密度分布，使离中心越近处密度越小来保持单胞的平均密度，同时增加了上下侧壁处泡沫铝相对于中性轴的惯性矩，增强芯层的抗弯能力。
为了加强弯曲强度，所述单胞连接处密度较大，等同于加强筋。加强筋的存在增强了夹芯板结构的面内强度和弯曲强度，使得它相比常见的泡沫铝夹芯板具有更大的抗弯能力；
为了保持结构的稳定性，所述单胞连接部位组合后构成了一个稳固的新型结构。其作用是当夹芯板处于均布冲击加载作用下时，使梯度泡沫成为一个整体来承受夹芯板可能承受的全部载荷，产生大变形并吸收了大量能量。
与现有技术相比，本发明径向负梯度泡沫铝夹芯板上下面板用来直接承受外部载荷，径向负梯度泡沫铝芯层用来承受面板传递的载荷。上下面板内部布置一定数量的梯度泡沫铝能够增加夹芯板抵抗面外压缩的能力，通过塑性变形吸收能量，是性能优越的缓冲吸能结构。
通过对泡沫铝芯层设计合理的密度分布，使梯度泡沫单胞与上下面板连接处密度较大、单胞中心密度较小、单胞连接处密度较大。这种结构密度分布设计使梯度泡沫铝芯层夹芯板在充分发挥泡沫金属夹芯自身轻质、高效吸能等优点的同时，增强了泡沫铝芯层的抗压、抗弯强度力学性能，有效提高了泡沫铝夹芯板承受面外载荷时的保护效果。
本发明径向负梯度泡沫铝夹芯板结构合理、性能优异，同时具有良好的密度低、比刚度大、比强度高、稳定性好、抗冲击性、电磁屏蔽、阻尼特性优良、低热导率和电导率、绝热、隔音等特点，在化工、治金、机械、建筑土木、高速汽车、船舶、包装运输、航空航天、军事防护等工程领域都具有广阔的应用前景。
附图说明
图1为径向负梯度泡沫铝夹芯板示意图；图中：1-上面板；2-径向负梯度泡沫铝芯层；3-径向负梯度泡沫铝单胞；4-下面板；
图2为径向负梯度泡沫铝单胞示意图。
具体实施方式
下面结合附图及实施例对本发明作进一步详细说明。
实施例1：
首先，选取不同密度的闭孔泡沫铝，利用电火花线切割机将泡沫材料切割得到相同体积大小的圆柱形、圆环形等形状，按照密度大小拼接组合。以将密度变化区域分为三层为例，中心层为圆柱形状，密度为ρ 1；中间层为圆环形状，密度为ρ 2；最外层为内部切除圆柱后的正方体或长方体，密度为ρ 3，则ρ 1<ρ 2<ρ 3；按照密度及形状顺序，焊接或粘接得到径向梯度泡沫铝单胞3。径向梯度泡沫铝单胞孔隙率沿径向由内向外逐渐变化，从90%减至50%。
然后，将一定数量径向负梯度泡沫铝单胞3在平面内依次排列，单胞之间面接触部位焊接得到径向梯度泡沫铝芯层2。
最后，用砂纸对上、下面板1、4和梯度泡沫铝内芯2表面进行打磨，清洗去除油污和锈迹。上、下面板1、4可采用金属材料，如为铝、镁、钢、钛或铜等；也可采用非金属材料，如塑料板、玻璃钢板等制作；面板1、4可采用同种材科，也可采用异种材料。在面板1、4与径向梯度泡沫铝内芯2接触面处焊接或涂覆一层胶粘剂静置于不高于70℃烘箱中固化得到径向负梯度泡沫铝夹芯板。
实施例2：首先，利用中国专利CN 101418391 B中制备梯度多孔材料的方法，将基体粉末与致孔剂混合，然后加入无水乙醇，制备悬浮液；然后将悬浮液倒入模具中，然后进行离心沉积；离心沉积后烘干，脱模后取出粗坏，再放入石墨模具中烧结，得坯料；去除坯料中的致孔剂，即得径向负梯度泡沫铝单胞3。径向梯度泡沫铝密度孔隙率沿径向由内向外逐渐变化，从80%减至10%，孔隙尺寸为30～480µm；
然后，将一定数量径向负梯度泡沫铝单胞3在平面内依次排列，单胞之间面接触部位焊接得到径向梯度泡沫铝芯层2。
最后，用砂纸对上、下面板1、4和梯度泡沫铝内芯2表面进行打磨，清洗去除油污和锈迹。上、下面板1、4可采用金属材料，如为铝、镁、钢、钛或铜等；也可采用非金属材料，如塑料板、玻璃钢板等制作；面板1、4可采用同种材科，也可采用异种材料。在面板1、4与径向梯度泡沫铝内芯2接触面处焊接或涂覆一层胶粘剂静置于不高于70℃烘箱中固化得到径向负梯度泡沫铝夹芯板。
实施例3：首先，选取不同密度的闭孔泡沫铝，利用电火花线切割机将泡沫材料切割得到相同体积大小的圆柱形、圆环形等形状，按照密度大小拼接组合。以将密度变化区域分为三层为例，中心层为圆柱形状，密度为ρ 1；中间层为圆环形状，密度为ρ 2；最外层为内部切除圆柱后的正方体或长方体，密度为ρ 3，则ρ 1<ρ 2<ρ 3；按照密度及形状顺序，焊接或粘接得到径向梯度泡沫铝单胞3。径向梯度泡沫铝密度为孔隙率沿径向由内向外逐渐变化，从90%减至50%。
然后，将一定数量径向负梯度泡沫铝单胞3在平面内依次排列，单胞之间面接触部位处放置同等面积大小的泡沫铝合金，实现全密封包覆，并在两端施加适当压力，通过火焰枪加热进行二次发泡连接得到径向梯度泡沫铝芯层2。工艺参数：加热温度为800～850℃，保温时间为300～600s。
最后，用砂纸对上、下面板1、4和梯度泡沫铝内芯2表面进行打磨，清洗去除油污和锈迹。上、下面板1、4可采用金属材料，如为铝、镁、钢、钛或铜等；也可采用非金属材料，如塑料板、玻璃钢板等制作；面板1、4可采用同种材科，也可采用异种材料。在面板1、4与径向梯度泡沫铝内芯2接触面处焊接或涂覆一层胶粘剂静置于不高于70℃烘箱中固化得到径向负梯度泡沫铝夹芯板。
实施例4：首先，利用中国专利CN 101418391 B中制备梯度多孔材料的方法，将基体粉末与致孔剂混合，然后加入无水乙醇，制备悬浮液；然后将悬浮液倒入模具中，然后进行离心沉积；离心沉积后烘干，脱模后取出粗坏，再放入石墨模具中烧结，得坯料；去除坯料中的致孔剂，即得径向负梯度泡沫铝单胞3。径向梯度泡沫铝密度孔隙率沿径向由内向外逐渐变化，从80%减至10%，孔隙尺寸为30～480 µm；
然后，将一定数量径向负梯度泡沫铝单胞3在平面内依次排列，单胞之间面接触部位处放置同等面积大小的泡沫铝合金，实现全密封包覆，并在两端施加适当压力，通过火焰枪加热进行二次发泡连接得到径向梯度泡沫铝芯层2。工艺参数：加热温度为850℃，保温时间为320～600s。
最后，用砂纸对上、下面板1、4和梯度泡沫铝内芯2表面进行打磨，清洗去除油污和锈迹。上、下面板1、4可采用金属材料，如为铝、镁、钢、钛或铜等；也可采用非金属材料，如塑料板、玻璃钢板等制作；面板可采用同种材科，也可采用异种材料。在面板1、4与径向梯度泡沫铝内芯2接触面处焊接或涂覆一层胶粘剂静置于不高于70℃烘箱中固化得到径向负梯度泡沫铝夹芯板。
Claims (7)
1.一种径向负梯度泡沫铝夹芯板，其特征在于：所述径向负梯度泡沫铝夹芯板为层状结构，从下而上，依次为下板层、径向负梯度泡沫铝芯层和上板层；其中：上层板和下层板内表面采用胶粘或焊接，平行、对称地与径向负梯度泡沫铝芯层的顶部和底部连接固定；径向负梯度泡沫铝芯层为若干径向负梯度泡沫铝单胞在平面内依次排列组合得到；
所述的径向负梯度泡沫铝单胞形状为正方体或长方体，单胞密度变化所在面为正方形，从正方形形心处至正方形边界处密度逐渐增加；密度变化所在面的垂直方向为单胞轴向方向，泡沫铝密度均匀；V为泡沫铝单胞的总体积，将泡沫铝密度变化面沿径向分为N份，V i 分别表示第i份的体积，ρ i为第i份的相对密度；以将密度变化区域分为三层为例，中心层密度为ρ 1，中间层密度为ρ 2，最外层密度为ρ 3，则ρ 1<ρ 2<ρ 3；
所述径向负梯度泡沫铝芯层轴向方向与面板所在平面方向平行。
2.根据权利要求1所述的一种径向负梯度泡沫铝夹芯板，其特征在于：所述的径向负梯度泡沫铝芯层材质为闭孔泡沫纯铝或泡沫铝合金。
3.根据权利要求1所述的一种径向负梯度泡沫铝夹芯板，其特征在于：径向负梯度泡沫铝单胞利用线切割技术，将泡沫材料切割后拼接组合焊接或粘接得到；或利用离心沉积法生产制备得到。
4.根据权利要求1所述的一种径向负梯度泡沫铝夹芯板，其特征在于：径向负梯度泡沫铝单胞之间的接触部位通过焊接或二次发泡连接。
5.根据权利要求1所述的一种径向负梯度泡沫铝夹芯板，其特征在于：所述上层板、下层板形状、尺寸相同，厚度小于梯度泡沫芯层高度；上层板和下层板为金属或非金属材质；两侧面板为同种或异种材料。
6.根据权利要求1所述的一种径向负梯度泡沫铝夹芯板，其特征在于：面板材料和芯材在连接前均用砂纸对其表面进行打磨，清洗去除油污和锈迹。
7.制备权利要求1所述的一种径向负梯度泡沫铝夹芯板的方法，其特征在于：径向梯度泡沫铝单胞的加工方法为：选取不同密度的闭孔泡沫铝，用线切割技术将泡沫材料切割，得到设计尺寸的圆柱形、圆环形，按照密度大小拼接组合；以将密度变化区域分为三层，中心层为圆柱形状，密度为ρ 1；中间层为圆环形状，密度为ρ 2；最外层为内部切除圆柱后的正方体或长方体，密度为ρ 3，则ρ 1<ρ 2<ρ 3；按照密度及形状顺序，焊接或粘接得到径向梯度泡沫铝单胞；
径向负梯度泡沫铝夹芯板采用焊接将径向梯度泡沫铝芯体与面板焊接而成，或在面板与径向梯度泡沫铝内芯接触面上均匀涂覆一层聚氨酯或环氧脂类胶粘剂，静置或于温度不高于70℃烘箱中固化得到。
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