CN113702512A - Reference block for nondestructive testing of functional honeycomb composite material and preparation method thereof - Google Patents
Reference block for nondestructive testing of functional honeycomb composite material and preparation method thereof Download PDFInfo
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- CN113702512A CN113702512A CN202111104751.4A CN202111104751A CN113702512A CN 113702512 A CN113702512 A CN 113702512A CN 202111104751 A CN202111104751 A CN 202111104751A CN 113702512 A CN113702512 A CN 113702512A
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- 239000002131 composite material Substances 0.000 title claims abstract description 50
- 238000009659 non-destructive testing Methods 0.000 title claims abstract description 16
- 238000002360 preparation method Methods 0.000 title claims abstract description 14
- 230000007547 defect Effects 0.000 claims abstract description 96
- 239000011248 coating agent Substances 0.000 claims abstract description 68
- 238000000576 coating method Methods 0.000 claims abstract description 68
- 239000010410 layer Substances 0.000 claims abstract description 59
- 239000012792 core layer Substances 0.000 claims abstract description 46
- 238000000034 method Methods 0.000 claims abstract description 33
- 239000011230 binding agent Substances 0.000 claims abstract description 25
- 230000008569 process Effects 0.000 claims abstract description 21
- 229920001343 polytetrafluoroethylene Polymers 0.000 claims description 108
- 239000004810 polytetrafluoroethylene Substances 0.000 claims description 105
- -1 polytetrafluoroethylene Polymers 0.000 claims description 102
- 239000012790 adhesive layer Substances 0.000 claims description 51
- 238000005498 polishing Methods 0.000 claims description 16
- 229920000049 Carbon (fiber) Polymers 0.000 claims description 12
- 239000004917 carbon fiber Substances 0.000 claims description 12
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 claims description 12
- 238000005507 spraying Methods 0.000 claims description 12
- 239000003822 epoxy resin Substances 0.000 claims description 9
- 229920000647 polyepoxide Polymers 0.000 claims description 9
- 238000001514 detection method Methods 0.000 abstract description 41
- 238000012360 testing method Methods 0.000 abstract description 18
- 239000011162 core material Substances 0.000 abstract description 6
- 238000004451 qualitative analysis Methods 0.000 abstract description 6
- 238000004445 quantitative analysis Methods 0.000 abstract description 6
- 239000004033 plastic Substances 0.000 description 35
- 230000035945 sensitivity Effects 0.000 description 10
- 239000000853 adhesive Substances 0.000 description 8
- 230000001070 adhesive effect Effects 0.000 description 8
- 239000011092 plastic-coated paper Substances 0.000 description 8
- 239000011208 reinforced composite material Substances 0.000 description 8
- 239000004809 Teflon Substances 0.000 description 5
- 229920006362 Teflon® Polymers 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 5
- 238000005520 cutting process Methods 0.000 description 5
- 229920005989 resin Polymers 0.000 description 5
- 239000011347 resin Substances 0.000 description 5
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 229910052799 carbon Inorganic materials 0.000 description 4
- 238000012795 verification Methods 0.000 description 4
- 239000000956 alloy Substances 0.000 description 3
- 229910045601 alloy Inorganic materials 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000004593 Epoxy Substances 0.000 description 2
- 230000002159 abnormal effect Effects 0.000 description 2
- 230000009286 beneficial effect Effects 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000012966 insertion method Methods 0.000 description 2
- 238000012545 processing Methods 0.000 description 2
- 238000002310 reflectometry Methods 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 229920006231 aramid fiber Polymers 0.000 description 1
- 230000007797 corrosion Effects 0.000 description 1
- 238000005260 corrosion Methods 0.000 description 1
- 230000007123 defense Effects 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000002349 favourable effect Effects 0.000 description 1
- 238000010438 heat treatment Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 238000004519 manufacturing process Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/22—Details, e.g. general constructional or apparatus details
- G01N29/30—Arrangements for calibrating or comparing, e.g. with standard objects
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N29/00—Investigating or analysing materials by the use of ultrasonic, sonic or infrasonic waves; Visualisation of the interior of objects by transmitting ultrasonic or sonic waves through the object
- G01N29/04—Analysing solids
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
- G01N2291/00—Indexing codes associated with group G01N29/00
- G01N2291/02—Indexing codes associated with the analysed material
- G01N2291/023—Solids
- G01N2291/0231—Composite or layered materials
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- General Health & Medical Sciences (AREA)
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Abstract
The application relates to a reference block for nondestructive testing of functional honeycomb composite materials and a preparation method thereof. The preparation method comprises the following steps: a) presetting first artificial defects between the binder layer and the skin and between the binder layer and the honeycomb core layer in the process of preparing the honeycomb composite material to obtain a middle reference block; b) and in the process of preparing the functional coating on the surface of the skin of the middle reference block, presetting a second artificial defect between the skin and the functional coating to obtain the reference block. The functional coating is arranged on the contrast test block prepared according to the method, and the artificial defects are pre-buried between the functional coating and the honeycomb core material, so that the detection capability of the ultrasonic detection equipment can be comprehensively verified, the ultrasonic detection equipment inspected by the contrast test block is used for detecting the functional honeycomb composite material, qualitative and quantitative analysis can be carried out on the defects at different positions, and the quality of an actual product is guaranteed.
Description
Technical Field
The application relates to the technical field of honeycomb composite materials, in particular to a reference block for nondestructive testing of functional honeycomb composite materials and a preparation method thereof.
Background
The honeycomb composite material is also called a honeycomb sandwich plate and mainly comprises a skin, a honeycomb core layer and a binder layer. The honeycomb composite material has unique mechanical properties such as high strength-weight ratio, good fatigue resistance and the like, so that the honeycomb composite material has increasingly wide application in aerospace force bearing structures.
In the traditional honeycomb composite material, the skin mainly adopts a structure of resin coating composite alloy plates. In order to achieve light weight of the component, the skin in the prior art is also of a structure using a carbon fiber reinforced composite material, i.e., a carbon fiber reinforced composite material. The carbon fiber reinforced composite material has the advantages of light weight and high strength, and the corrosion resistance of the carbon fiber reinforced composite material is also excellent.
During the processing and service of honeycomb composites, defects are easily formed, such as: gaps are easily formed between the skin and the honeycomb core material, poor bonding is caused, the mechanical property of the honeycomb core material is seriously influenced, and hidden troubles are caused for the use of the honeycomb composite material. At present, the nondestructive testing method for the honeycomb composite material has various methods, wherein the ultrasonic testing is applied more. The detection precision and sensitivity of the detection equipment are very important for the detection result. Therefore, before nondestructive testing, in order to verify the detection capability of the detection equipment, a reference block is generally required to be prepared, that is, artificial defects are pre-embedded at a preset position in the honeycomb composite material, and then the detection equipment is used for detecting the reference block, so that the detection precision and sensitivity of the detection equipment can be obtained, and further, a powerful guarantee is provided for subsequent accurate detection.
At present, the reference block adopts a structure of a skin, a honeycomb core layer and a binder, and artificial defects are pre-embedded between the binder and the skin and between the binder and the honeycomb core layer. Recently, with the appearance and application of functional honeycomb composite materials, the existing reference block has certain limitations. The functional honeycomb composite material is formed by adding a functional coating on the surface of the existing honeycomb composite material, so that new characteristics are given to the composite material. For example: the functional honeycomb composite material is widely applied to various industrial systems including aerospace and civil fields. If a coating with wave absorbing and wave transmitting functions is added on the surface of the skin, the functional honeycomb composite material can be applied to the field of national defense and military industry. The functional honeycomb composite material is detected by using ultrasonic detection equipment tested by the conventional reference block, the sensitivity is often low due to the detection sensitivity check result, the debonding defect between the coating and the composite material is not considered, and the problems of missed detection, inconformity between an abnormal area and the actual situation and the like are easily caused.
Disclosure of Invention
In order to solve or partially solve the problems in the related art, the application provides a reference block for nondestructive testing of functional honeycomb composite materials and a preparation method thereof.
Firstly, the application provides a preparation method of a reference block for nondestructive testing of functional honeycomb composite materials, which comprises the following steps:
a) presetting first artificial defects between the binder layer and the skin and between the binder layer and the honeycomb core layer in the process of preparing the honeycomb composite material to obtain a middle reference block;
b) and in the process of preparing the functional coating on the surface of the skin of the middle reference block, presetting a second artificial defect between the skin and the functional coating to obtain the reference block.
Further, the step b) is specifically as follows:
b1) arranging a plurality of second artificial defects at preset positions on the surface of the skin of the middle reference block, wherein the second artificial defects are polytetrafluoroethylene sheets;
b2) and spraying functional coating on the surface of the skin on which the polytetrafluoroethylene sheet is arranged to obtain a reference block.
Further, the step b1) is specifically as follows:
b11) taking a first template with the same size as the surface of the skin, and forming a first positioning hole in the first template, wherein the position and the size of the first positioning hole correspond to the preset position and the size of a polytetrafluoroethylene sheet positioned between the skin and the functional coating;
b12) placing the first template on the surface of the skin, and placing a corresponding polytetrafluoroethylene sheet into the first positioning hole;
b13) and placing a fixture on the polytetrafluoroethylene sheet, and removing the first template.
Further, the template is a paper template or a plastic paper template.
Further, the polytetrafluoroethylene sheet is formed by stacking two or more polytetrafluoroethylene sheets.
Further, a step of pretreating the skin is further included between the step b), specifically:
polishing the surface of the skin for the first time;
coating epoxy resin on the surface of the skin;
and polishing the surface of the skin for the second time.
Further, the sizes of the second artificial defects on the same layer are phi 4-phi 12; and/or the number of the first artificial defects on the same layer is a plurality, and the size of the first artificial defects is phi 6-phi 12.
Secondly, the application also provides a reference block for nondestructive testing of the functional honeycomb composite material, wherein first artificial defects are preset between the adhesive layer and the skin and between the adhesive layer and the honeycomb core layer; which presets a second artificial defect between the functional coating and the skin.
Further, the first artificial defect is formed by stacking two or more layers of polytetrafluoroethylene sheets, and the total thickness is not more than 0.1 mm; and/or the presence of a gas in the gas,
the second artificial defect is formed by stacking two or more layers of polytetrafluoroethylene sheets, and the total thickness of the two or more layers of polytetrafluoroethylene sheets is not more than 0.05 mm.
Further, the skin is made of carbon fiber reinforced composite materials.
The technical scheme provided by the application can comprise the following beneficial effects:
the functional coating is arranged on the contrast test block prepared according to the method, and the artificial defects are pre-buried between the functional coating and the honeycomb core material, so that the detection capability of the ultrasonic detection equipment can be comprehensively verified, the ultrasonic detection equipment inspected by the contrast test block is used for detecting the functional honeycomb composite material, qualitative and quantitative analysis can be carried out on the defects at different positions, and the quality of an actual product is guaranteed.
Drawings
The foregoing and other objects, features and advantages of the application will be apparent from the following more particular descriptions of exemplary embodiments of the application, as illustrated in the accompanying drawings wherein like reference numbers generally represent like parts throughout the exemplary embodiments of the application.
FIG. 1 is a schematic structural diagram of a reference block for nondestructive testing of functional honeycomb composite provided in an embodiment of the present application;
FIG. 2 is a schematic diagram of the structure of an integrated template in another embodiment of the present application;
description of the reference numerals
1-Honeycomb core layer
2-adhesive layer
3-covering
4-functional coating
5-Integrated form
S1-Polytetrafluoroethylene sheet
S2-Polytetrafluoroethylene sheet
S3-Polytetrafluoroethylene sheet
Detailed Description
Embodiments of the present application will be described in more detail below with reference to the accompanying drawings. While embodiments of the present application are illustrated in the accompanying drawings, it should be understood that the present application may be embodied in various forms and should not be limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the application. As used in this application and the appended claims, the singular forms "a", "an", and "the" are intended to include the plural forms as well, unless the context clearly indicates otherwise. It should also be understood that the term "and/or" as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items.
It should be understood that although the terms "first," "second," "third," etc. may be used herein to describe various information, these information should not be limited to these terms. These terms are only used to distinguish one type of information from another. For example, first information may also be referred to as second information, and similarly, second information may also be referred to as first information, without departing from the scope of the present application. Thus, a feature defined as "first" or "second" may explicitly or implicitly include one or more of that feature. In the description of the present application, "a plurality" means two or more unless specifically limited otherwise.
In order to solve the above problems, embodiments of the present application provide a reference block for nondestructive testing of a functional honeycomb composite material and a preparation method thereof, which can more accurately verify the precision and sensitivity of an ultrasonic testing device in detecting a functional honeycomb composite material product.
First, an embodiment of the present invention provides a method for preparing a reference block for nondestructive testing of a functional honeycomb composite, including the following steps:
a) presetting first artificial defects between the binder layer and the skin and between the binder layer and the honeycomb core layer in the process of preparing the honeycomb composite material to obtain a middle reference block;
b) and in the process of preparing the functional coating on the surface of the skin of the middle reference block, presetting a second artificial defect between the skin and the functional coating to obtain the reference block.
In the preparation process, the step a) is a process for presetting first artificial defects between the adhesive layer and the skin and between the adhesive layer and the honeycomb core layer, and is used for detecting the detection precision and sensitivity of ultrasonic equipment to gaps between the adhesive layer and the skin and between the adhesive base layer and the honeycomb core layer. And step b) is a process of presetting a second artificial defect between the skin and the functional coating, and the second artificial defect is used for detecting the detection precision and sensitivity of the ultrasonic equipment to the gap between the functional coating and the skin. The reason that the detection sensitivity and the precision are low when the functional honeycomb composite material is detected by using the ultrasonic equipment detected by the conventional reference block is that: in the process of preparing the coating, a spraying mode is often adopted, gaps can be generated in the process, the coating is usually thin, and therefore the gaps between the coating and the skin cannot be accurately detected through the ultrasonic equipment verified by the existing test block. Based on this, the reference block provided by the embodiment of the application increases the second artificial defect between the skin and the functional coating, so that the detection capability of the ultrasonic equipment is verified more comprehensively, and further qualitative and quantitative analysis of the defects of different positions of the product is realized, and the quality of the actual product is ensured.
In the step a), the first artificial defect can adopt a blade insertion method or a polytetrafluoroethylene sheet is placed; the latter is preferred because: the polytetrafluoroethylene has excellent high temperature resistance, can resist the high temperature of 200 ℃ in an autoclave, is not easy to deform to generate folds, is usually very thin, has large difference between acoustic impedance and composite material, has high sound pressure reflectivity, and can effectively simulate the defects of layering and debonding. Further, the polytetrafluoroethylene sheet may be formed by stacking two or more polytetrafluoroethylene sheets, whereby the thickness of the artificial defect can be adjusted by increasing or decreasing the number of layers of the polytetrafluoroethylene sheets. The thickness of the first artificial defect is preferably not more than 0.1mm, more preferably not more than 0.05 mm. In this example, the first artificial defect is formed by the stacking of two sheets of teflon, the thickness of a single sheet of teflon being 0.01 mm. In addition, first artificial defects of different sizes are preferably provided on the same layer to verify the detection sensitivity of the ultrasonic apparatus to defects of different sizes. Specifically, the number of the first artificial defects on the same layer is several, and the size range is preferably phi 6 to phi 12. In this embodiment, the first artificial defects of three sizes are set on the same layer, i.e., phi 12, phi 10, and phi 6, respectively.
The material of the skin in the reference block is selected according to the detection object, and a resin alloy composite structure or a carbon fiber reinforced composite material can be adopted. The specific process of step a) may be the same as the process of preparing the existing reference block. For a reference block adopting the carbon fiber reinforced composite material skin, a tiny gap is easily generated in a non-artificial defect arrangement area in the processing process, and the detection of ultrasonic equipment is interfered. For this reason, for the reference block using the carbon fiber reinforced composite skin, in order to reduce the gap between the skin and the adhesive layer, step a) preferably includes the steps of:
a1) the carbon fiber reinforced resin prepreg is alternately paved according to paving modes of 0 degrees, 45 degrees, 90 degrees and-45 degrees, and a vacuum bag is arranged;
a2) placing the bagged skin in an autoclave for curing;
a3) cutting the skin after demolding to obtain the skin with a preset shape and size; for example, the machining in this embodiment results in a 350 x 200 rectangular skin; then, polishing the adhesive joint surface;
a4) the honeycomb core layer and the skin are glued through the binder layer, polytetrafluoroethylene sheets are arranged between the binder layer and the skin in advance and between the binder layer and the honeycomb core layer, and the honeycomb core layer and the skin are placed in an autoclave for curing after bagging, so that a middle comparison test block is obtained.
The accuracy of the first artificial defect preset position influences the detection accuracy of the ultrasonic verification device, and the higher the accuracy of the first artificial defect preset position is, the more beneficial the detection accuracy of the ultrasonic verification device is. In order to improve the accuracy of the preset position of the first artificial defect, the step a) of arranging the polytetrafluoroethylene sheet between the adhesive layer and the skin and between the adhesive layer and the honeycomb core layer in advance preferably includes the following steps:
taking a second template and a third template which have the same size as the surface of the skin; a second positioning hole is formed in the second template, and the position and the size of the second positioning hole correspond to the preset position and the size of the polytetrafluoroethylene sheet located between the honeycomb core layer and the binder layer; a third positioning hole is formed in the third template, and the position and the size of the third positioning hole correspond to the preset position and the size of the polytetrafluoroethylene sheet located between the adhesive layer and the skin;
placing a second template on the surface of the honeycomb core layer, and placing a corresponding polytetrafluoroethylene sheet in a second positioning hole; removing the template;
placing an adhesive layer on the surface of the honeycomb core layer;
placing a third template on the surface of the adhesive layer, and placing a corresponding polytetrafluoroethylene sheet in a third positioning hole; removing the template;
and placing a skin on the surface of the adhesive layer.
The template adopted in the steps is preferably a paper template or a plastic paper template, more preferably a plastic paper template, and the plastic paper template has proper adhesive force with the adhesive layer and the honeycomb core layer, so that the template is favorably positioned and is convenient to remove.
The intermediate reference block obtained in the above manner can also be directly used for detecting ultrasonic equipment, and the ultrasonic equipment detected by the intermediate reference block is used for carrying out nondestructive detection on the common honeycomb composite material.
In the step b), the second artificial defect can adopt a blade insertion method or a polytetrafluoroethylene sheet; the latter is preferred because: the polytetrafluoroethylene has excellent high temperature resistance, can resist the high temperature of 200 ℃ in an autoclave, is not easy to deform to generate folds, is usually very thin, has large difference between acoustic impedance and composite material, has high sound pressure reflectivity, and can effectively simulate the defects of layering and debonding. Further, the polytetrafluoroethylene sheet is formed by stacking two or more polytetrafluoroethylene sheets, whereby the thickness of the artificial defect can be adjusted by increasing or decreasing the number of layers of the polytetrafluoroethylene sheets. The thickness of the second artificial defect is preferably not more than 0.05mm, more preferably not more than 0.03 mm. In this example, the second artificial defect is formed by the stacking of two sheets of teflon, the thickness of a single sheet of teflon being 0.01 mm. In addition, second artificial defects of different sizes are preferably provided on the same layer to verify the detection sensitivity of the ultrasonic equipment to defects of different sizes. Specifically, the size range of the first artificial defects on the same layer is preferably from phi 4 to phi 12. In this embodiment, the same layer is provided with the second artificial defects of three sizes, i.e., phi 12, phi 10, and phi 6, respectively. In another preferred embodiment, four sizes of second artificial defects are provided on the same layer, phi 12, phi 10, phi 6 and phi 4 respectively. In addition, considering that the gap between the skin and the functional coating is small in the actual production process, second artificial defects with three sizes, namely phi 10, phi 6 and phi 4, can also be arranged on the same layer.
The step b) may specifically be:
b1) arranging a plurality of second artificial defects at preset positions on the surface of the skin of the middle reference block, wherein the second artificial defects are polytetrafluoroethylene sheets;
b2) and spraying functional coating on the surface of the skin on which the polytetrafluoroethylene sheet is arranged to obtain a reference block.
The accuracy of the preset position of the second artificial defect influences the detection accuracy of the ultrasonic verification device, and the higher the accuracy of the preset position of the second artificial defect is, the more favorable the detection accuracy of the ultrasonic verification device is. The polytetrafluoroethylene sheet is thin and light in weight, and is easy to displace in the arrangement process and the subsequent spraying process of the functional coating, so that the detection precision is influenced. Therefore, in order to improve the accuracy of the preset position of the second artificial defect, it is more preferable that step b1) is specifically:
b11) taking a first template with the same size as the surface of the skin, and forming a first positioning hole in the first template, wherein the position and the size of the first positioning hole correspond to the preset position and the size of a polytetrafluoroethylene sheet positioned between the skin and the functional coating;
b12) placing the first template on the surface of the skin, and placing the corresponding polytetrafluoroethylene sheet in the first positioning hole;
b13) and placing a fixture on the polytetrafluoroethylene sheet, and removing the first template.
The first template is arranged to position the polytetrafluoroethylene sheet in the process of placing the second artificial defect, a paper template or a plastic paper template is preferably adopted as the template adopted in the step, a plastic paper template is more preferably adopted, and a proper adhesive force is provided between the plastic paper template and the skin, so that the template can be positioned conveniently, and the template can be removed conveniently.
The function of placing a fixture on the polytetrafluoroethylene sheet is as follows: in the spraying process, pressure is applied to the polytetrafluoroethylene sheet to prevent the polytetrafluoroethylene sheet from displacing. It will be appreciated by those skilled in the art that the fixture serves only to prevent the ptfe sheet from moving during the spraying process, and that after one or two primer coats are applied, the ptfe sheet is fixed in position and the fixture is removed for subsequent spraying.
The specific form of the fixture can be as follows:
scheme I: the fixture is a conical body, the size of the bottom surface of the conical body is smaller than that of the polytetrafluoroethylene sheet, the bottom surface of the conical body is provided with a polytetrafluoroethylene coating, and the top of the conical body is provided with a pull ring. The bottom is provided with a polytetrafluoroethylene coating for preventing the polytetrafluoroethylene from being adhered when a heavy object is removed, and the pull ring at the top is convenient for manually or mechanically removing the fixed object.
Scheme II: the fixture is provided with a plurality of supporting legs, and the supporting legs can rotate along the vertical surface. When the fixing device is used, the fixing device is placed on the surface of the polytetrafluoroethylene sheet, downward pressure is applied to the fixing device, and the supporting legs are outwards expanded to positions close to the edge of the polytetrafluoroethylene sheet, so that the polytetrafluoroethylene sheet is fixed. When the fixture needs to be removed, the fixture is directly lifted upwards.
Scheme III: the fixed object is a sleeve structure, the inner cylinder is slidably sleeved in the outer cylinder, and the tail end of the inner cylinder, namely one end which is not contacted with the polytetrafluoroethylene sheet, is provided with a pull ring or a handle. When the device is used, the fixture is placed on the surface of the polytetrafluoroethylene sheet, when the fixture needs to be removed, the pull ring or the handle of the inner cylinder is lifted upwards, the inner cylinder leaves the polytetrafluoroethylene sheet firstly, and then the outer cylinder leaves the polytetrafluoroethylene sheet.
In the non-artificial defect layout area, micro-gaps are also easily generated in the process of spraying the functional coating, which can interfere with the detection of the ultrasonic equipment. In order to reduce the gap between the skin and the functional coating, the method further comprises a step of pretreating the skin between the step b), specifically:
polishing the surface of the skin for the first time;
coating epoxy resin on the surface of the skin, and curing at normal temperature;
and polishing the surface of the skin for the second time.
The first polishing of the surface of the skin is performed firstly: the method comprises the steps of preliminarily reducing holes on the surface of the skin, then filling the holes by coating epoxy resin, and polishing for the second time after curing at normal temperature, so that the smooth and non-porous surface of the skin can be basically realized, and the probability of defects in a non-artificial area between the skin and a functional coating is reduced.
In the above scheme, if the first artificial defect and/or the second artificial defect are made of the polytetrafluoroethylene sheet, the polytetrafluoroethylene sheet is preferably subjected to heating pretreatment before being placed, so that the material is temporarily hardened and is not easily deformed during placement.
Please refer to fig. 1, the following is a preferred embodiment of the present application:
a preparation method of a reference block for nondestructive testing of functional honeycomb composite materials comprises the following steps:
a1) the carbon fiber reinforced resin prepreg is alternately paved according to paving modes of 0 degrees, 45 degrees, 90 degrees and-45 degrees, and a vacuum bag is arranged;
a2) placing the bagged skin in an autoclave for curing;
a3) cutting the skin after demolding to obtain 350 x 200 rectangular skin 3; then, polishing the adhesive joint surface;
a4) taking a second plastic paper passing template and a third plastic paper passing template which have the same size as the surface of the skin 3, and forming three second positioning holes with the sizes of phi 12, phi 10 and phi 6 on the second plastic paper passing template, wherein the positions of the second positioning holes correspond to the preset positions and sizes of polytetrafluoroethylene sheets S1 between the honeycomb core layer 1 and the adhesive layer 2; three third positioning holes with the sizes of phi 12, phi 10 and phi 6 are formed in the third plastic paper passing template, and the position and the size of each third positioning hole correspond to the preset position and the size of a polytetrafluoroethylene sheet S2 positioned between the adhesive layer 2 and the skin 3;
placing the second plastic paper passing template on the upper surface of the honeycomb core layer 1, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm into the second positioning holes, and removing the second plastic paper passing template;
arranging an adhesive layer 2 on the surface of the honeycomb core layer 1;
placing the third plastic paper passing template on the surface of the adhesive layer 2, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm in a third positioning hole, and removing the third plastic paper passing template;
and arranging a skin 3 on the surface of the adhesive layer 2.
And placing the bag in an autoclave for curing to obtain a middle reference block.
b10) Polishing the surface of the skin 3 of the middle reference block for the first time; coating epoxy resin on the surface of the skin 3, and curing at normal temperature; and then, the surface of the skin 3 is polished for the second time to be in a smooth and non-porous state.
b11) Taking a first plastic-coated paper template with the same size as the surface of the skin 3, and forming three first positioning holes with the sizes of phi 12, phi 10 and phi 6 on the first plastic-coated paper template, wherein the position and the size of each first positioning hole correspond to the preset position and the size of a polytetrafluoroethylene sheet S3 positioned between the skin 3 and the functional coating 4;
b12) placing the first plastic paper template on the surface of the skin 3, and placing a corresponding polytetrafluoroethylene sheet in the first positioning hole; each of the sheets was formed by stacking two sheets of 0.01mm thick polytetrafluoroethylene.
b13) And placing a fixture on the polytetrafluoroethylene sheet S3, and removing the paper template.
b2) And spraying a functional coating on the surface of the skin 3 on which the polytetrafluoroethylene sheet S3 is arranged, and curing to obtain a functional coating 4, thereby obtaining a reference block, wherein the structure of the reference block is shown in FIG. 1.
In addition, in order to save raw materials and simplify the operation, the first plastic paper passing template, the second plastic paper passing template and the third plastic paper passing template in the above steps can be combined on one integrated template 5, as shown in fig. 2, the positioning holes of each layer are all arranged on one integrated template 5 according to the position and size, and the polytetrafluoroethylene sheets of different layers only need to be placed into the corresponding positioning holes.
According to the method, the functional coating is arranged on the contrast test block, and the artificial defects are pre-buried between the functional coating and the honeycomb core material, so that the detection capability of the ultrasonic detection equipment can be comprehensively verified, the functional honeycomb composite material is detected by the ultrasonic detection equipment which is detected by the contrast test block, qualitative and quantitative analysis can be performed on the defects at different positions, and the quality of actual products is guaranteed.
Correspondingly, the application also provides a reference block for nondestructive testing of the functional honeycomb composite material, wherein first artificial defects are preset between the binder layer and the skin and between the binder layer and the honeycomb core layer; which presets a second artificial defect between the functional coating and the skin. The reference block can be prepared as described above.
Specifically, referring to fig. 1, the reference block includes:
a honeycomb core layer 1;
the honeycomb core layer 1 is connected with the skin 3 through the binder layer 2;
the surface of the skin 3 is provided with a functional coating 4;
first artificial defects are preset between the adhesive layer 2 and the skin 3 and between the adhesive layer 2 and the honeycomb core layer 1;
a second artificial defect is preset between the functional coating 4 and the skin 3.
The skin can adopt a resin alloy composite structure, and can also adopt a carbon fiber reinforced composite material, such as a carbon fiber-epoxy composite material. The latter is preferably used. The honeycomb core layer can adopt aramid fiber honeycomb or aluminum honeycomb. The adhesive layer may be an epoxy layer.
As a preferred version of the present application, the above-mentioned first artificial defect is formed by stacking two or more polytetrafluoroethylene sheets, preferably with a total thickness not exceeding 0.1 mm; and/or the presence of a gas in the gas,
the second artificial defect is formed by stacking two or more polytetrafluoroethylene sheets, and the total thickness is not more than 0.05 mm.
In this embodiment, each of the first and second artificial defects is formed by stacking two 0.01mm thick sheets of ptfe.
In addition, the size of a plurality of second artificial defects on the same layer is preferably phi 4-phi 12; and/or the first artificial defects on the same layer are a plurality of ones with the size of phi 6-phi 12.
The application provides a reference block is provided with functional coating to pre-buried artificial defect between functional coating and the honeycomb core, the detectability of ultrasonic testing equipment that from this can be more comprehensive, the ultrasonic testing equipment who has used to inspect through this reference block detects functional honeycomb combined material, can carry out qualitative and quantitative analysis to the defect of different positions, thereby guarantees the quality of actual product.
The reference block and the preparation method thereof provided by the present application are described below with reference to specific examples.
Example 1
1. The carbon fiber-epoxy resin prepreg is crossly paved according to paving modes of 0 degrees, 45 degrees, 90 degrees and-45 degrees, and a vacuum bag is formed;
2. placing the bagged skin in an autoclave for curing;
3. cutting the skin after demolding to obtain 350 × 200 rectangular skin; then, polishing the adhesive joint surface;
4. taking a plastic-coated paper template with the same size as the surface of the skin, wherein the plastic-coated paper template is provided with six rows of positioning hole groups as shown in figure 2, each row of positioning hole groups comprises three positioning holes with the sizes of phi 12, phi 10 and phi 6 respectively, the position of the first row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the functional coating and the upper adhesive layer, the position of the second row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the upper skin, the position of the third row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the honeycomb core layer, the position of the fourth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the honeycomb core layer and the lower adhesive layer, and the position of the fifth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the lower adhesive layer and the lower skin, and the position of the sixth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the lower skin and the lower functional coating.
Placing the plastic paper template on the upper surface of the honeycomb core layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm into corresponding positioning holes, and removing the plastic paper template; arranging an adhesive layer on the surface of the honeycomb core layer; placing the plastic paper template on the surface of the adhesive layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm in corresponding positioning holes, and removing the plastic paper template; arranging a skin on the surface of the adhesive layer; and placing the bag in an autoclave for curing to obtain a middle reference block.
5. Polishing the surface of the skin of the middle reference block for the first time; coating epoxy resin on the surface of the skin, and curing at normal temperature; and then, polishing the surface of the skin for the second time to a smooth and nonporous state.
6. Taking a plastic paper template, placing the plastic paper template on the surface of the skin, and placing corresponding polytetrafluoroethylene sheets in corresponding positioning holes; each of the sheets was formed by stacking two sheets of 0.01mm thick polytetrafluoroethylene.
7. And (4) placing a fixed object on the polytetrafluoroethylene sheet, and removing the paper template.
8. And spraying a functional coating on the surface of the skin on which the polytetrafluoroethylene sheet is arranged, and curing to obtain a functional coating, thereby obtaining a reference block, wherein the structure of the reference block is shown in figure 1.
The comparative test block prepared in this example was provided with the following artificial defects, where a represents a defect size of φ 12, b represents a defect size of φ 10, and c represents a defect size of φ 6:
between the honeycomb core layer and the upper binder layer: 1a, 1b, 1c
Between the honeycomb core layer and the lower binder layer: 2a, 2b, 2c
Between the upper bonding layer and the upper skin; 3a, 3b, 3c
Between the lower adhesive layer and the lower skin: 4a, 4b, 4c
Between the upper skin and the upper functional coating: 5a, 5b, 5c
Between the lower skin and the lower functional coating: 6a, 6b, 6c
Comparative example 1
1. The carbon fiber-epoxy resin prepreg is crossly paved according to paving modes of 0 degrees, 45 degrees, 90 degrees and-45 degrees, and a vacuum bag is formed;
2. placing the bagged skin in an autoclave for curing;
3. cutting the skin after demolding to obtain 350 × 200 rectangular skin; then, polishing the adhesive joint surface;
4. taking a plastic-coated paper template with the same size as the surface of the skin, wherein the plastic-coated paper template is provided with six rows of positioning hole groups as shown in figure 2, each row of positioning hole groups comprises three positioning holes with the sizes of phi 12, phi 10 and phi 6 respectively, the position of the first row of positioning holes corresponds to the preset position (not used in the embodiment) of the polytetrafluoroethylene sheet between the functional coating and the upper adhesive layer, the position of the second row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the upper skin, the position of the third row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the honeycomb core layer, the position of the fourth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the honeycomb core layer and the lower adhesive layer, and the position of the fifth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the lower adhesive layer and the lower skin, the location of the sixth row of locating holes corresponds to the pre-set location of the teflon sheet between the lower skin and the lower functional coating (not used in this embodiment).
Placing the plastic paper template on the upper surface of the honeycomb core layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm into corresponding positioning holes, and removing the plastic paper template; arranging an adhesive layer on the surface of the honeycomb core layer; placing the plastic paper template on the surface of the adhesive layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm in corresponding positioning holes, and removing the plastic paper template; arranging a skin on the surface of the adhesive layer; and placing the bag in an autoclave for curing to obtain a reference block.
The reference block prepared in this example was provided with the following artificial defects:
between the honeycomb core layer and the upper binder layer: 7a, 7b, 7c
Between the honeycomb core layer and the lower binder layer: 8a, 8b, 8c
Between the upper bonding layer and the upper skin; 9a, 9b, 9c
Between the lower adhesive layer and the lower skin: 10a, 10b, 10c
Comparative example 2
1. The carbon fiber-epoxy resin prepreg is crossly paved according to paving modes of 0 degrees, 45 degrees, 90 degrees and-45 degrees, and a vacuum bag is formed;
2. placing the bagged skin in an autoclave for curing;
3. cutting the skin after demolding to obtain 350 × 200 rectangular skin; then, polishing the adhesive joint surface;
4. taking a plastic-coated paper template with the same size as the surface of the skin, wherein the plastic-coated paper template is provided with six rows of positioning hole groups as shown in figure 2, each row of positioning hole groups comprises three positioning holes with the sizes of phi 12, phi 10 and phi 6 respectively, the position of the first row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the functional coating and the upper adhesive layer, the position of the second row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the upper skin, the position of the third row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the upper adhesive layer and the honeycomb core layer, the position of the fourth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the honeycomb core layer and the lower adhesive layer, and the position of the fifth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the lower adhesive layer and the lower skin, and the position of the sixth row of positioning holes corresponds to the preset position of the polytetrafluoroethylene sheet between the lower skin and the lower functional coating.
Placing the plastic paper template on the upper surface of the honeycomb core layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm into corresponding positioning holes, and removing the plastic paper template; arranging an adhesive layer on the surface of the honeycomb core layer; placing the plastic paper template on the surface of the adhesive layer, placing two layers of polytetrafluoroethylene sheets with the thickness of 0.01mm in corresponding positioning holes, and removing the plastic paper template; arranging a skin on the surface of the adhesive layer; and placing the bag in an autoclave for curing to obtain a middle reference block.
5. Taking the plastic paper template, placing the plastic paper template on the surface of the skin, and placing corresponding polytetrafluoroethylene sheets in corresponding positioning holes; each of the sheets was formed by stacking two sheets of 0.01mm thick polytetrafluoroethylene.
6. And (4) placing a fixed object on the polytetrafluoroethylene sheet, and removing the paper template.
7. And spraying a functional coating on the surface of the skin on which the polytetrafluoroethylene sheet is arranged, and curing to obtain a functional coating, thereby obtaining a reference block, wherein the structure of the reference block is shown in figure 1.
The reference block prepared in this example was provided with the following artificial defects:
between the honeycomb core layer and the upper binder layer: 11a, 11b, 11c
Between the honeycomb core layer and the lower binder layer: 12a, 12b, 12c
Between the upper bonding layer and the upper skin; 13a, 13b, 13c
Between the lower adhesive layer and the lower skin: 14a, 14b, 14c
Between the upper skin and the upper functional coating: 15a, 15b, 15c
Between the lower skin and the lower functional coating: 16a, 16b, 16c
Taking ultrasonic A scanning detection equipment of three different manufacturers, and numbering the equipment in sequence of A1, A2 and A3;
taking ultrasonic phased array detection equipment of three different manufacturers, and numbering the equipment in sequence as B1, B2 and B3;
the test blocks of example 1, comparative example 1 and comparative example 2 were tested using the above six devices, and the test results are shown in table 1, where the abnormal defect points in table 1 are the defect points detected in the non-artificial defect area.
TABLE 1 ultrasonic equipment test results
According to the content, the contrast test block provided by the application can be used for verifying the detection capability of the ultrasonic detection equipment more comprehensively, the ultrasonic detection equipment inspected by the contrast test block is used for detecting the functional honeycomb composite material, and qualitative and quantitative analysis can be carried out on the defects at different positions, so that the quality of an actual product is ensured.
Having described embodiments of the present application, the foregoing description is intended to be exemplary, not exhaustive, and not limited to the disclosed embodiments. Many modifications and variations will be apparent to those of ordinary skill in the art without departing from the scope and spirit of the described embodiments. The terminology used herein is chosen in order to best explain the principles of the embodiments, the practical application, or improvements made to the technology in the marketplace, or to enable others of ordinary skill in the art to understand the embodiments disclosed herein.
Claims (10)
1. A preparation method of a reference block for nondestructive testing of functional honeycomb composite materials is characterized by comprising the following steps:
a) presetting first artificial defects between the binder layer and the skin and between the binder layer and the honeycomb core layer in the process of preparing the honeycomb composite material to obtain a middle reference block;
b) and in the process of preparing the functional coating on the surface of the skin of the middle reference block, presetting a second artificial defect between the skin and the functional coating to obtain the reference block.
2. The preparation method according to claim 1, wherein the step b) is specifically:
b1) arranging a plurality of second artificial defects at preset positions on the surface of the skin of the middle reference block, wherein the second artificial defects are polytetrafluoroethylene sheets;
b2) and spraying functional coating on the surface of the skin on which the polytetrafluoroethylene sheet is arranged to obtain a reference block.
3. The preparation method according to claim 2, wherein the step b1) is specifically:
b11) taking a first template with the same size as the surface of the skin, and forming a first positioning hole in the first template, wherein the position and the size of the first positioning hole correspond to the preset position and the size of a polytetrafluoroethylene sheet positioned between the skin and the functional coating;
b12) placing the first template on the surface of the skin, and placing a corresponding polytetrafluoroethylene sheet into the first positioning hole;
b13) and placing a fixture on the polytetrafluoroethylene sheet, and removing the first template.
4. The method of claim 3, wherein the template is a paper template or a overmolded paper template.
5. The method of claim 3, wherein the polytetrafluoroethylene sheet is formed by stacking two or more polytetrafluoroethylene sheets.
6. The method according to claim 3, further comprising a step of pre-treating the skin between steps b), in particular:
polishing the surface of the skin for the first time;
coating epoxy resin on the surface of the skin;
and polishing the surface of the skin for the second time.
7. The method according to claim 3, wherein the size of the second artificial defects on the same layer is phi 4-phi 12; and/or the number of the first artificial defects on the same layer is a plurality, and the size of the first artificial defects is phi 6-phi 12.
8. A reference block for nondestructive testing of functional honeycomb composite materials is characterized in that first artificial defects are preset between an adhesive layer and a skin and between the adhesive layer and a honeycomb core layer; which presets a second artificial defect between the functional coating and the skin.
9. The reference block of claim 7, wherein the first artificial defect is formed by a stack of two or more layers of polytetrafluoroethylene sheets, the total thickness not exceeding 0.1 mm; and/or the presence of a gas in the gas,
the second artificial defect is formed by stacking two or more layers of polytetrafluoroethylene sheets, and the total thickness of the two or more layers of polytetrafluoroethylene sheets is not more than 0.05 mm.
10. The reference block of claim 7, wherein the skin is a carbon fiber reinforced composite.
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