CN113619243A - 一种抗烧蚀轻质承载u型罩体及其制备方法 - Google Patents

一种抗烧蚀轻质承载u型罩体及其制备方法 Download PDF

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CN113619243A
CN113619243A CN202110660855.7A CN202110660855A CN113619243A CN 113619243 A CN113619243 A CN 113619243A CN 202110660855 A CN202110660855 A CN 202110660855A CN 113619243 A CN113619243 A CN 113619243A
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resistant
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许晓洲
柯红军
谢永旺
汪东
尹先鹏
李娜
王国勇
李丽英
张昊
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Aerospace Research Institute of Materials and Processing Technology
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Abstract

本发明提出一种抗烧蚀轻质承载U型罩体及其制备方法。U型罩体最外面为热防护抗烧蚀层，最里面为结构承载层，结构承载层还可设置具有一定宽度和高度的加强筋条增加承载能力，热防护层和结构承载层之间采用耐高温硅橡胶进行粘接。本发明采用热防护抗烧蚀层与结构承载层相互配合的方法，热防护层采用耐烧蚀纤维增强酚醛树脂体系，结构承载层采用碳纤维增强树脂基体系，承载层与热防护层相互配合可以在结构减重的基础上实现U型罩体的耐烧蚀性能和力学性能的平衡。

Description

一种抗烧蚀轻质承载U型罩体及其制备方法
技术领域
本发明涉及一种抗烧蚀轻质承载U型罩体及其制备方法，属于耐烧蚀复合材料技术领域。
背景技术
随着航天航空技术的发展，对飞行器提出了高飞行速度、远航程和高有效载荷的要求。随着飞行器飞行速度增加，飞行器表面存在强烈的气动加热，导致表面驻点温度升高。而当飞行速度增加时则驻点温度与飞行速度的马赫数平方成正相关增加。
传统飞行器发动机整流罩主要采用金属材料，并在金属材料表面加上抗烧蚀涂层，利用烧蚀层防热，金属层提供承载来协同实现。然而金属材料密度大，不利于高飞行速度、远航程和高有效载荷的需求，传统的结构树脂基复合材料又通常难以直接暴露在500℃以上使用。因此，飞行器罩体的研发一直受到限制。
发明内容
本发明的目的在于克服现有技术不足，提供一种抗烧蚀轻质承载U型罩体及其制备方法。
本发明的技术解决方案：
一种抗烧蚀轻质承载U型罩体，包括最外层的热防护抗烧蚀层、最内层的结构承载层和中间层的耐高温粘接层，所述热防护抗烧蚀层为耐烧蚀纤维增强酚醛树脂层，所述结构承载层为碳纤维增强树脂基复合材料。
进一步地，所述热防护抗烧蚀层采用的耐烧蚀纤维是一种不燃纤维且具有隔热性能；耐烧蚀纤维种类为本领域常用的具有耐烧蚀性能的纤维，如玻璃纤维、高硅氧纤维和芳纶纤维等。
进一步地，所述结构承载层选用的树脂基体没有特殊种类的限制，其耐温等级根据使用工况条件确定，可以选择环氧树脂，双马树脂或者聚酰亚胺等耐高温结构树脂；耐高温粘接剂要求耐热等级在200℃以上。
进一步地，所述热防护抗烧蚀层的厚度为5～20mm，厚度越大其耐烧蚀性能就越好，但重量也越大，总厚度太高，会影响飞行器的有效载荷；所述结构承载层的厚度为1～8mm，厚度越大其力学性能就越好，但重量也越大，总厚度太高，也会影响飞行器的有效载荷。本领域技术人员根据具体的烧蚀性能和结构承载性能的要求，选择防热烧蚀层和结构承载层的厚度。
进一步地，所述热防护抗烧蚀层采用的酚醛树脂没有特殊的种类限制，其耐温等级根据使用工况的温度确定，可以选择钡酚醛、硼酚醛、钼酚醛等中的一种或几种。
进一步地，所述耐高温粘接层优选为耐高温硅橡胶粘接剂层。
进一步地，所述结构承载层中含有加强筋条以增强承载能力和抗变形能力。
一种抗烧蚀轻质承载U型罩体的制备方法，通过以下步骤实现：
第一步，制备U型罩体带加强筋条结构承载层：
A1.1、根据相应的工况应用需求选择环氧树脂，双马树脂或者聚酰亚胺等耐高温树脂，之后通过热熔法或者湿法工艺制备碳纤维预浸料，得到相应的树脂基碳纤维预浸料；
A1.2、将A1.1得到的树脂基碳纤维预浸料按照带加强筋条结构承载层的结构尺寸进行剪裁得到大面积蒙皮矩形预浸料以及分断蒙皮矩形预浸料，将分断蒙皮预浸料首先铺层到U型金属阳模上(金属阳模上带有凹陷可放置加强筋条的区域)，之后加上单向加强筋条预浸料，然后铺层大面积蒙皮，之后再进行热压罐固化脱模得到带加强筋条结构承载层；固化工艺根据采用的树脂基体种类而定。
第二步，制备热防护抗烧蚀层：
A2.1、将酚醛树脂通过热熔法制备耐烧蚀纤维预浸料；
A2.2、将A2.1得到的耐烧蚀纤维预浸料按照U型罩体结构尺寸在U型金属阴模上进行铺层，之后再进行热压罐固化脱模得到热防护抗烧蚀层，热防护抗烧蚀层也可以将A2.1得到的耐烧蚀纤维预浸料通过斜叠缠绕工艺缠绕好毛坯，之后再转移至U型金属阴模固化；
第三步，将第一和二步中的得到的带加强筋条结构承载层和热防护抗烧蚀层按照抗烧蚀轻质承载U型罩体的尺寸进行加工打孔、去边和打磨得到可粘接用的结构承载层和热防护抗烧蚀层；
第四步，将第三步得到的可粘接用的结构承载层和热防护抗烧蚀层采用耐高温粘接剂进行粘接，得到抗烧蚀轻质承载U型罩体。
环氧树脂、双马树脂和聚酰亚胺等树脂预浸料和酚醛树脂纤维预浸料或者预浸料热熔法和湿法工艺制备为本领域公知技术，在此就不一一赘述。
本发明采用的耐高温树脂基碳纤维预浸料中的碳纤维可为T300级、T700级或者T1000级单向纤维或者纤维布，按照U型罩体需要进行调节，且每层厚度为0.1～1.4mm，单向预浸料的厚度优选0.125mm、纤维布的厚度优选0.2mm。
本发明采用的耐烧蚀纤维预浸料每层厚度为0.1～0.4mm，优选0.2mm。
本发明采用的耐高温粘接剂，其耐温等级在200℃以上，通常为可以为RTV-2、RTV-400或者其余耐热性和粘接性能良好的粘接剂，粘接层厚度为0.1～1mm，优选为0.3mm。
本发明与现有技术相比的有益效果：
(1)本发明的U型罩体采用的是轻质的具有不同功能层结构的复合结构，重量比采用金属材料的低。热防护抗烧蚀层与结构承载层相互配合，可以在结构减重的基础上实现U型罩体的耐烧蚀性能和力学性能的平衡。
(2)本发明的U型罩体由复合材料制备，防热层和承载层厚度以及材料可根据需要调节，各功能层更好的发挥各自作用，可设计性强。
附图说明
图1为U型罩体结构示意图；其中：1-结构承载层，2-耐高温粘接层，3-热防护抗烧蚀层，4-加强筋条。
具体实施方式
下面结合具体实施例对本发明作进一步阐述，但本发明并不限于以下实施例。
本发明如图1所示，由热防护抗烧蚀层作为最外层和结构承载层作为内层组成，两层之间采用耐高温粘接剂粘接。其中热防护抗烧蚀层采用耐烧蚀纤维酚醛树脂材料，其中耐烧蚀纤维是一种不燃纤维且具有隔热性能；结构承载层选用的树脂基体没有特殊种类的限制，其耐温等级根据使用工况条件确定，可以选择环氧树脂，双马树脂或者聚酰亚胺等耐高温结构树脂；耐高温粘接剂要求耐热等级在200℃以上。
实施例1：
一种抗烧蚀轻质承载U型罩体结构：
外层热防护抗烧蚀层的厚度为15mm，热防护抗烧蚀层采用玻璃纤维布增强酚醛树脂；结构承载层采用1mm的T1000碳纤维增强双马树脂；U型罩体总厚度为15.3mm。
第一步，制备U型罩体带加强筋条的结构承载层：
A1.1、双马树脂通过热熔法工艺制备T1000碳纤维单向预浸料，得到相应的T1000/双马树脂预浸料；
A1.2、将A1.1得到的T1000/双马树脂预浸料按照带U型罩体加强筋条结构承载层的结构尺寸进行剪裁得到大面积蒙皮矩形预浸料以及分断蒙皮矩形预浸料，将分断蒙皮矩形预浸料首先铺层到U型金属阳模上，之后加上单向加强筋条预浸料，然后铺层大面积蒙皮，之后再进行热压罐固化脱模得到U型罩体带加强筋条结构承载层，其中大面积蒙皮铺层按照[45/0/-45/90/90/-45/0/45]角度均衡对称铺层；
改性双马树脂为固化工艺为100℃保温1小时，然后160℃加压固化2小时，最后在250℃固化4小时，冷却后脱模得到U型罩体带加强筋条的结构承载层。
第二步，制备热防护抗烧蚀层：
A2.1、将酚醛树脂通过热熔法制备耐烧蚀玻璃纤维布预浸料，得到耐烧蚀纤维布预浸料；
A2.2、将A2.1得到的耐烧蚀玻璃纤维布预浸料按照U型罩体结构尺寸进行剪裁得到预浸料，进行铺层得到15mm左右的预浸料铺层件，之后进行热压罐固化脱模得到热防护抗烧蚀层；
酚醛树脂固化工艺为90℃保温1h，然后130℃加压固化2h对整体结构进行固化。
第三步，将第一步和第二步中的得到的结构承载层和热防护抗烧蚀层按照U型罩体结构尺寸进行加工打孔、去边和打磨，得到可粘接用的结构承载层和热防护抗烧蚀层。
第四步，将第三步得到的可粘接用的结构承载层和热防护抗烧蚀层采用耐高温硅橡胶RTV-2进行粘接，得到抗烧蚀轻质承载U型罩体结构。
本实施例通过石英灯辐射加热实验测试，当外防热层温度为700℃时，最里层结构承载层温度为83℃，且无脱粘现象。
实施例2：
一种抗烧蚀轻质承载U型罩体结构：
外层热防护抗烧蚀层的厚度为5mm，热防护抗烧蚀层采用高硅氧纤维布增强酚醛树脂；结构承载层采用8mm的T700碳纤维增强聚酰亚胺树脂；U型罩体总厚度为13.3mm。
第一步，制备U型罩体带加强筋条的结构承载层，
A1.1、聚酰亚胺树脂通过湿法工艺制备T700碳纤维单向预浸料，得到相应的T700/聚酰亚胺树脂预浸料；
A1.2、将A1.1得到的T700/聚酰亚胺树脂预浸料按照带U型罩体加强筋条的结构承载层的结构尺寸进行剪裁得到大面积蒙皮矩形预浸料以及分断蒙皮矩形预浸料，将分断蒙皮矩形预浸料首先铺层到U型金属阳模上，之后加上单向加强筋条预浸料，然后铺层大面积蒙皮，之后再进行热压罐固化脱模得到U型罩体带加强筋条结构承载层，其中大面积蒙皮铺层按照[45/0/-45/90]8S角度均衡对称铺层；
聚酰亚胺树脂为固化工艺为200℃保温3小时，然后310℃-350℃之间加压，升温到380℃固化3h，冷却后脱模得到U型罩体带加强筋条的结构承载层。
第二步，制备热防护抗烧蚀层：
A2.1、将酚醛树脂通过热熔法制备高硅氧纤维布预浸料，得到耐烧蚀纤维布预浸料；
A2.2、将A2.2得到的高硅氧纤维布预浸料按照U型罩体结构尺寸进行剪裁得到预浸料，进行铺层得到5mm左右的预浸料铺层件，之后进行热压罐固化脱模得到热防护抗烧蚀层；
酚醛树脂固化工艺为90℃保温1小时，然后130℃加压固化2小时对整体结构进行固化。
第三步，将第一步和第二步中的得到的结构承载层和热防护抗烧蚀层按照U型罩体结构尺寸进行加工打孔、去边和打磨，得到可粘接用的结构承载层和热防护抗烧蚀层。
第四步，将第三步得到的可粘接用的结构承载层和热防护抗烧蚀层采用耐高温硅橡胶RTV-400进行粘接，得到抗烧蚀轻质承载U型罩体结构。
本实施例通过石英灯辐射加热实验测试，当外防热层温度为700℃时，最里层结构承载层温度为203℃，且无脱粘现象。
实施例3：
一种抗烧蚀轻质承载U型罩体结构：
外层热防护抗烧蚀层的厚度为20mm，热防护抗烧蚀层采用高硅氧纤维布增强酚醛树脂；结构承载层采用3mm的T300碳纤维增强环氧树脂；U型罩体总厚度为23.3mm。
第一步，制备U型罩体带加强筋条的结构承载层：
A1.1、环氧树脂通过热熔法工艺制备T700碳纤维单向预浸料，得到相应的T700/环氧树脂预浸料；
A1.2、将A1.1得到的T700/环氧树脂预浸料按照U型罩体带加强筋条的结构承载层的结构尺寸进行剪裁得到大面积蒙皮矩形预浸料以及分断蒙皮矩形预浸料，将分断蒙皮矩形预浸料首先铺层到U型金属阳模上，之后加上单向加强筋条预浸料，然后铺层大面积蒙皮，之后再进行热压罐固化脱模得到U型罩体带加强筋条结构承载层，其中大面积蒙皮铺层按照[45/0/-45/90]3S角度均衡对称铺层；
环氧树脂固化工艺为90℃保温30分钟，然后升温到110℃加压，之后升温到130℃固化2小时，冷却后脱模得到U型罩体带加强筋条的结构承载层。
第二步，制备热防护抗烧蚀层，
A2.1、将酚醛树脂通过热熔法制备高硅氧纤维布预浸料，得到耐烧蚀纤维布预浸料；
A2.2、将A2.1得到的高硅氧纤维布预浸料按照U型罩体结构尺寸进行剪裁得到预浸料，进行铺层得到20mm左右的预浸料铺层件，之后进行热压罐固化脱模得到热防护抗烧蚀层；
酚醛树脂固化工艺为90℃保温1小时，然后130℃加压固化2小时对整体结构进行固化。
第三步，将第一步和第二步中的得到的结构承载层和热防护抗烧蚀层按照U型罩体结构尺寸进行加工打孔、去边和打磨得到可粘接用的结构承载层和热防护抗烧蚀层。
第四步，将第三步得到的可粘接用的结构承载层和热防护抗烧蚀层采用耐高硅橡胶RTV-2进行粘接，得到抗烧蚀轻质承载U型罩体结构。
本实施例通过石英灯辐射加热实验测试，当外防热层温度为700℃时，最里层结构承载层温度为52℃，且无脱粘现象。
本发明未详细说明部分为本领域技术人员公知技术。
以上公开的本发明的具体实施例，其目的在于帮助理解本发明的内容并据以实施，本领域的普通技术人员可以理解，在不脱离本发明的精神和范围内，各种替换、变化和修改都是可能的。本发明不应局限于本说明书的实施例所公开的内容，本发明的保护范围以权利要求书界定的范围为准。

Claims (10)

1.一种抗烧蚀轻质承载U型罩体，其特征在于，包括最外层的热防护抗烧蚀层、最内层的结构承载层和中间层的耐高温粘接层，所述热防护抗烧蚀层为耐烧蚀纤维增强酚醛树脂层，所述结构承载层为碳纤维增强树脂基复合材料。
2.根据权利要求1所述的抗烧蚀轻质承载U型罩体，其特征在于：所述热防护抗烧蚀层的总厚度为5～20mm，所述结构承载层的厚度为1～8mm，热防护抗烧蚀层和结构承载层厚度根据实际工况要求进行选择。
3.根据权利要求1所述的抗烧蚀轻质承载U型罩体，其特征在于：所述结构承载层选用的树脂基体为耐高温结构树脂，其耐温等级根据使用工况条件确定；所述耐高温结构树脂为环氧树脂、双马树脂或者聚酰亚胺。
4.根据权利要求1所述的抗烧蚀轻质承载U型罩体，其特征在于：所述热防护抗烧蚀层采用的酚醛树脂其耐温等级根据使用工况条件确定，所述酚醛树脂为钡酚醛、硼酚醛、钼酚醛中的一种或几种。
5.根据权利要求1或2所述的抗烧蚀轻质承载U型罩体，其特征在于：所述热防护抗烧蚀层采用的耐烧蚀纤维为玻璃纤维、高硅氧纤维、芳纶纤维中的一种。
6.根据权利要求1所述的抗烧蚀轻质承载U型罩体，其特征在于：所述耐高温粘接层为耐高温硅橡胶粘接剂层。
7.根据权利要求1所述的抗烧蚀轻质承载U型罩体，其特征在于：所述结构承载层中含有加强筋条以增强承载能力和抗变形能力。
8.一种抗烧蚀轻质承载U型罩体的制备方法，其特征在于，包括以下步骤：
第一步，制备带加强筋条的结构承载层：根据相应的工况应用需求选择耐高温树脂，通过热熔法或者湿法工艺制备碳纤维预浸料，得到相应的树脂基碳纤维预浸料；将树脂基碳纤维预浸料按照带加强筋条结构承载层的结构尺寸进行剪裁得到大面积蒙皮矩形预浸料以及分断蒙皮矩形预浸料，将分断蒙皮预浸料首先铺层到U型金属阳模上，之后加上单向加强筋条预浸料，然后铺层大面积蒙皮，之后再进行热压罐固化脱模得到带加强筋条的结构承载层；
第二步，制备热防护抗烧蚀层：将酚醛树脂通过热熔法制备耐烧蚀纤维预浸料；将耐烧蚀纤维预浸料按照U型罩体结构尺寸在U型金属阴模上进行铺层，之后再进行热压罐固化脱模得到热防护抗烧蚀层；或者将耐烧蚀纤维预浸料通过斜叠缠绕工艺缠绕好毛坯，之后再转移至U型金属阴模固化，得到热防护抗烧蚀层；
第三步，将第一步和第二步中的得到的带加强筋条的结构承载层和热防护抗烧蚀层按照抗烧蚀轻质承载U型罩体的尺寸进行加工打孔、去边和打磨，得到可粘接用的结构承载层和热防护抗烧蚀层；
第四步，将第三步得到的可粘接用的结构承载层和热防护抗烧蚀层采用耐高温粘接剂进行粘接，得到抗烧蚀轻质承载U型罩体。
9.根据权利要求8所述的抗烧蚀轻质承载U型罩体的制备方法，其特征在于：所述结构承载层采用的碳纤维预浸料中的碳纤维为T300级、T700级或者T1000级单向纤维，按照U型罩体结构承载层结构设计要求进行调节，且每层厚度为0.1～1.4mm。
10.根据权利要求8所述的抗烧蚀轻质承载U型罩体的制备方法，其特征在于：所述耐高温粘接层，其耐温等级在200℃以上，厚度为0.1～1mm。
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