CN113387714A - 一种飞机碳刹车盘非摩擦面损伤修复方法 - Google Patents
一种飞机碳刹车盘非摩擦面损伤修复方法 Download PDFInfo
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Abstract
本发明公开了一种飞机碳刹车盘非摩擦面损伤修复的方法,包括损伤部位去除、修补材料裁剪、修补材料抗氧化改性、胶接固化和高温热处理五个过程。本发明在不影响修补材料的力学性能的基础上,对修补材料进行抗氧化改性,提高了损伤修复区域的抗氧化能力,避免了再次进行防氧化涂层制备。本发明专利只针对非摩擦面损伤进行修复,对C/C复合材料本身的机械、摩擦磨损、导热性能影响小。
Description
技术领域
本发明涉及一种飞机碳刹车盘非摩擦面损伤修复方法,属于材料修复技术领域。
背景技术
碳/碳复合材料因其独特的高温摩擦性能而成为飞机刹车盘材料,飞机碳刹车盘因维护不当、外物磕碰作用导致非摩擦面边缘磕伤、掉块、材质酥松、氧化层脱落等损伤故障。通过对飞机碳刹车盘非摩擦面损伤修复可以避免过度损伤造成费用昂贵的换件,延长碳刹车盘的维修周期。
碳基体在370℃就开始氧化,高于500℃时迅速氧化,而飞机碳刹车盘在正常降落时温度一般在700℃以下,在中止起飞等极限条件下时可瞬间达到1000℃,因此碳刹车盘需要良好的抗热震性能和抗氧化性能。碳刹车盘损伤后,氧化气体极易在碳刹车盘修补区域发生氧化,在表面形成孔隙后,氧化气体渗透进入内部不断与碳反应,导致致密结构变疏松,导致力学性能迅速降低。因此对修复的碳刹车盘进行防氧化保护十分必要。
申请号为CN202010029059.9的中国专利公开了一种碳碳复合材料的修补方法,包括以下步骤:第一步,检查产品破损程度:在自然光照明下检查产品受损程度,在光线不足的情况下可以人工补光;第二步,配制粘接剂;第三步,修补区域表面处理;第四步,选择及裁剪增强材料;第五步,涂胶修补;第六步,固化;第七步,打磨表面处理;第八步,碳化处理;第九步,高温纯化处理;第十步,成品检验。该方法未对修复区域进行防氧化处理,而修复的碳/碳在高温使用时易氧化失效。
申请号为CN201410034500.7的中国专利公开了一种碳/碳复合材料抗氧化用铼/铱涂层表面缺陷的修复方法,该修复方法包括在带有铼涂层的碳/碳复合材料上浸润刷涂饱和可溶性钴盐溶液形成钴化合物层,钴化合物层经氢气还原形成金属钴层,将得到的带有金属钴层和铼涂层的碳/碳复合材料置于Ar气气氛中进行高温处理,使金属钴熔化弥合铼涂层表面缺陷并与铼固溶形成铼/钴合金涂层,然后在铼/钴合金涂层上沉积铼涂层,再在铼涂层上沉积铱涂层,得到带有缺陷修复后铼/铱涂层的碳/碳复合材料。
发明内容
本发明所要解决的技术问题是:现有通用修复方法稳定性较差,修复效果欠佳的问题,提供一种更适用于飞机碳刹车盘非摩擦面损伤专用的修复方法。
为了解决上述技术问题,本发明提供了一种飞机碳刹车盘非摩擦面损伤修复的方法,包括以下步骤:
步骤1)、损伤部位去除:目视检查碳刹车盘非摩擦面的损伤情况,确定损伤去除范围,并划线,损伤去除范围比受损区域边缘宽,去除范围为圆形或椭圆形,去除最深深度为受损最深深度,划定损伤区域后,用打磨工具对损伤区域进行打磨,打磨为斜坡状,在打磨面上加工出流胶槽,在将打磨后损伤碳刹车置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
步骤2)、修补材料裁剪:先用机械加工的方式在报废的碳刹车盘切割下体积大于待修复碳刹车盘损伤去除区域的修补材料,再将修补材料打磨至与损伤去除区域相当;在修补材料的粘接面上加工流胶槽,将打磨后的修补材料置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
步骤3)、修补材料抗氧化改性:
步骤3.1):将Al2O3、B2O3、TiO2、ZrB2粉末混合,搅拌均匀;
步骤3.2):在硅酸钠水溶液中加入四硼酸锂,搅拌,得到稳定溶液,然后加入步骤3.1)得到的混合粉末,充分搅拌均匀得到改性液;
步骤3.3):将步骤3.2)得到的改性液倒入浸渍罐中,将修补材料完全浸渍在改性液中,然后抽真空,进行真空浸渍;
步骤3.4):将浸渍后的修补材料晾干后在80-120℃烘箱中固化2-4h;
步骤4)、胶接固化:将粘接剂涂刷在待修复碳刹车盘非摩擦面以及修补材料的粘接面上,将修补材料粘接至损伤去除区域,用夹具夹紧,清理溢出的多余粘接剂,再放入烘箱中固化,固化后拆除真空袋后,打磨平整修理区域;
步骤5)、热处理:对步骤4)得到的碳刹车盘放入预抽真空充N2保护的热解炉内加热并保温,然后随炉冷却至室温,得到修复好的碳刹车盘。
优选地,所述步骤1)中斜坡状的斜度在1:15-1:20之间。
3.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤3.1)中Al2O3、B2O3、TiO2、ZrB2粉末混合前分别放入球磨机中球磨12小时,然后过325目筛,再置于120℃烘箱中6小时。
优选地,所述步骤3.1)中Al2O3、B2O3、TiO2、ZrB2粉末的重量比为1:1.2:0.8:0.5。
优选地,所述步骤3.2)中四硼酸锂的加入量为硅酸钠水溶液质量的1-6%,混合粉末的加入量为硅酸钠水溶液质量的10%;所述硅酸钠水溶液的模数为2.8-3.2。
优选地,所述步骤3.3)中真空浸渍的压力为40-60kPa,时间为1-4h。
优选地,所述步骤4)中粘接剂的配制方法为:将树脂在有机溶剂中混合,再加入无机填料、催化剂、固化剂,搅拌,得到粘接剂。
更优选地,所述树脂为有机硅树脂和环氧树脂中的至少一种;所述无机填料为铝、碳化硼和玻璃粉中的至少一种。
优选地,所述步骤4)中固化的工艺参数为:以5℃/min升温至120-160℃保温3h。
优选地,所述步骤5)中热解炉内加热到700℃,保温2h。
本发明与现有技术相比的有益效果在于:本发明在不影响修补材料的力学性能的基础上,提高了损伤修复区域的抗氧化能力,对修补材料进行抗氧化改性,该方法可以提前对修补材料进行基体抗氧化处理,提高修理效率,采用修补材料基体改性的方式,避免了再次进行防氧化涂层制备时耗时长、工艺复杂、花费高昂以及防氧化涂层与碳/碳复合材料之间热膨胀系数不匹配问题。本发明专利只针对非摩擦面损伤进行修复,对C/C复合材料本身的机械、摩擦磨损、导热性能影响小。
本发明通过挖补方式对飞机碳刹车盘非摩擦面进行修复,以报废碳刹车盘作为修补材料,同时对修补材料进行抗氧化改性,避免了抗氧化涂层与碳/碳复合材料之间的热膨胀系数匹配,提高了碳刹车修理质量。
具体实施方式
为使本发明更明显易懂,兹以优选实施例,作详细说明如下。
实施例1
一种飞机碳刹车盘非摩擦面损伤修复的方法,包括损伤部位去除、修补材料裁剪、修补材料抗氧化改性、胶接固化和高温热处理五个过程,具体工艺步骤为:
(1)损伤部位去除:目视检查碳刹车盘非摩擦面损伤,确定损伤去除范围,并划线,损伤去除范围比受损区域边缘宽,去除范围为圆形或椭圆形,去除最深深度为受损最深深度,划定损伤区域后,用打磨工具对损伤区域进行打磨,打磨为斜坡状,斜度在1:15-1:20之间,在打磨面上加工出流胶槽,在将打磨后损伤碳刹车置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
(2)修补材料裁剪:先用机械加工的方式在报废的碳刹车盘切割下体积大于待修复碳刹车盘损伤去除区域的修补材料,再对待修补材料打磨至与损伤去除区域相当,在修补材料的粘接面上加工流胶槽,将打磨后的修补材料置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
(3)修补材料抗氧化改性:
①粉末处理:将Al2O3、B2O3、TiO2、ZrB2粉末分别放入球磨机中球磨12h,然后过325目筛,在置于120℃烘箱中6h得到处理好的粉末,将上诉粉末按1:1.2:0.8:0.5的比例放入搅拌机中搅拌均匀;
②溶液配制:硅酸钠水溶液中加入1wt%四硼酸锂,在以1000rmp的转速搅拌4h制备得到稳定溶液,在加入①中10wt%混合好的粉末,充分搅拌均匀得到改性液;
③浸渍:将②得到的改性液倒入浸渍罐中,在将修补材料完全浸渍在改性液中,然后抽真空至40kPa,浸渍4h;
④固化:将浸渍后的修补材料凉干后在80℃烘箱中固化4h;
(4)胶接固化:将配置好的粘接剂涂刷在待修复碳刹车盘以及修补材料的粘接面上,将修补材料粘接至损伤去除区域,用夹具夹紧,清理溢出的多余粘接剂,在放入烘箱中固化,固化工艺参数为:以5℃/min升温至250℃保温3h,固化后拆除夹具,打磨平整修理区域;
(5)高温热处理:对(4)处理后的带修复碳刹车盘放入预抽真空充N2保护的热解炉内,加热到500℃保温4h,然后随炉冷却至室温,得到修复后的碳刹车盘。
实施例2
一种飞机碳刹车盘非摩擦面损伤修复的方法,包括损伤部位去除、修补材料裁剪、修补材料抗氧化改性、胶接固化和高温热处理五个过程,具体工艺步骤为:
(1)损伤部位去除:目视检查碳刹车盘非摩擦面损伤,确定损伤去除范围,并划线,损伤去除范围比受损区域边缘宽,去除范围为圆形或椭圆形,去除最深深度为受损最深深度,划定损伤区域后,用打磨工具对损伤区域进行打磨,打磨为斜坡状,斜度在1:15-1:20之间,在打磨面上加工出流胶槽,在将打磨后损伤碳刹车置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
(2)修补材料裁剪:先用机械加工的方式在报废的碳刹车盘切割下体积大于待修复碳刹车盘损伤去除区域的修补材料,再对待修补材料打磨至与损伤去除区域相当,在修补材料的粘接面上加工流胶槽,将打磨后的修补材料置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
(3)修补材料抗氧化改性:
①粉末处理:将Al2O3、B2O3、TiO2、ZrB2粉末分别放入球磨机中球磨12小时,然后过325目筛,在置于120℃烘箱中6h得到处理好的粉末,将上诉粉末按1:1.2:0.8:0.5的比例放入搅拌机中搅拌均匀;
②溶液配制:硅酸钠水溶液中加入6wt%四硼酸锂,在以1000rmp的转速搅拌4h制备得到稳定溶液,在加入①中10wt%混合好的粉末,充分搅拌均匀得到改性液;
③浸渍:将②得到的改性液倒入浸渍罐中,在将修补材料完全浸渍在改性液中,然后抽真空至60kPa,浸渍1h;
④固化:将浸渍后的修补材料凉干后在120℃烘箱中固化2h;
(4)胶接固化:将配置好的粘接剂涂刷在待修复碳刹车盘以及修补材料的粘接面上,将修补材料粘接至损伤去除区域,用夹具夹紧,清理溢出的多余粘接剂,在放入烘箱中固化,固化工艺参数为:以5℃/min升温至250℃保温3h,固化后拆除夹具,打磨平整修理区域;
(5)高温热处理:对(4)处理后的带修复碳刹车盘放入预抽真空充N2保护的热解炉内,加热到700℃保温2h,然后随炉冷却至室温,得到修复后的碳刹车盘。
Claims (10)
1.一种飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,包括以下步骤:
步骤1)、损伤部位去除:目视检查碳刹车盘非摩擦面的损伤情况,确定损伤去除范围,并划线,损伤去除范围比受损区域边缘宽,去除范围为圆形或椭圆形,去除最深深度为受损最深深度,划定损伤区域后,用打磨工具对损伤区域进行打磨,打磨为斜坡状,在打磨面上加工出流胶槽,在将打磨后损伤碳刹车置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
步骤2)、修补材料裁剪:先用机械加工的方式在报废的碳刹车盘切割下体积大于待修复碳刹车盘损伤去除区域的修补材料,再将修补材料打磨至与损伤去除区域相当;在修补材料的粘接面上加工流胶槽,将打磨后的修补材料置于超声清洗仪中清洗,清洗后置于真空干燥烘箱中干燥;
步骤3)、修补材料抗氧化改性:
步骤3.1):将Al2O3、B2O3、TiO2、ZrB2粉末混合,搅拌均匀;
步骤3.2):在硅酸钠水溶液中加入四硼酸锂,搅拌,得到稳定溶液,然后加入步骤3.1)得到的混合粉末,充分搅拌均匀得到改性液;
步骤3.3):将步骤3.2)得到的改性液倒入浸渍罐中,将修补材料完全浸渍在改性液中,然后抽真空,进行真空浸渍;
步骤3.4):将浸渍后的修补材料晾干后在80-120℃烘箱中固化2-4h;
步骤4)、胶接固化:将粘接剂涂刷在待修复碳刹车盘非摩擦面以及修补材料的粘接面上,将修补材料粘接至损伤去除区域,用夹具夹紧,清理溢出的多余粘接剂,再放入烘箱中固化,固化后拆除真空袋后,打磨平整修理区域;
步骤5)、热处理:对步骤4)得到的碳刹车盘放入预抽真空充N2保护的热解炉内加热并保温,然后随炉冷却至室温,得到修复好的碳刹车盘。
2.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤1)中斜坡状的斜度在1:15-1:20之间。
3.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤3.1)中Al2O3、B2O3、TiO2、ZrB2粉末混合前分别放入球磨机中球磨12小时,然后过325目筛,再置于120℃烘箱中6小时。
4.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤3.1)中Al2O3、B2O3、TiO2、ZrB2粉末的重量比为1:1.2:0.8:0.5。
5.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤3.2)中四硼酸锂的加入量为硅酸钠水溶液质量的1-6%,混合粉末的加入量为硅酸钠水溶液质量的10%;所述硅酸钠水溶液的模数为2.8-3.2。
6.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤3.3)中真空浸渍的压力为40-60kPa,时间为1-4h。
7.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤4)中粘接剂的配制方法为:将树脂在有机溶剂中混合,再加入无机填料、催化剂、固化剂,搅拌,得到粘接剂。
8.如权利要求7所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述树脂为有机硅树脂和环氧树脂中的至少一种;所述无机填料为铝、碳化硼和玻璃粉中的至少一种。
9.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤4)中固化的工艺参数为:以5℃/min升温至120-160℃保温3h。
10.如权利要求1所述的飞机碳刹车盘非摩擦面损伤修复的方法,其特征在于,所述步骤5)中热解炉内加热到700℃,保温2h。
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