CN113787734B - Carbon fiber reinforced aluminum alloy laminate member forming process and forming die - Google Patents
Carbon fiber reinforced aluminum alloy laminate member forming process and forming die Download PDFInfo
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- CN113787734B CN113787734B CN202111078528.7A CN202111078528A CN113787734B CN 113787734 B CN113787734 B CN 113787734B CN 202111078528 A CN202111078528 A CN 202111078528A CN 113787734 B CN113787734 B CN 113787734B
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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
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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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- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
The invention discloses a forming process of a carbon fiber reinforced aluminum alloy laminate member, and provides a process route of 'soft die forming of an aluminum alloy outer plate → surface treatment of an aluminum alloy outer plate forming piece → paving of carbon fiber cloth and upper and lower aluminum alloy outer plate forming pieces → composite pressing of a carbon fiber reinforced aluminum alloy laminate pre-forming piece → heating and melting of a metal connecting agent → mould unloading' for forming the fiber metal laminate member. The invention also discloses a forming die for the carbon fiber reinforced aluminum alloy laminate member.
Description
Technical Field
The invention belongs to the technical field of plate member forming, relates to a carbon fiber reinforced aluminum alloy laminate member forming technology, and particularly relates to a carbon fiber reinforced aluminum alloy laminate member forming process and a forming die.
Background
The term (a) explains:
fiber metal laminates (FMLs for short): the sandwich material is formed by sequentially paving a metal thin plate, a fiber material and a connecting agent and then curing under the conditions of specific temperature and pressure.
The components are as follows: the parts with thin wall characteristics are prepared by stamping and processing plates or pipes serving as original blanks.
And (3) die forming: putting a certain amount of prepreg into a mold cavity at a forming temperature, and then closing and pressurizing a rigid male mold and a rigid female mold to form and cure the prepreg.
Solid particulate media forming techniques (modes): carrying out soft die forming on the plate by using the solid particles to replace a rigid male die; wherein, the solid particle medium is micro-particles with strong pressure bearing capacity and good flow property.
Mechanical alloying: mechanical Alloying (MA) is also called high-energy ball milling, and refers to a powder preparation technique in which metal or alloy powder is subjected to long-term violent impact and collision between powder particles and grinding balls in a high-energy ball mill, so that the powder particles are repeatedly subjected to cold welding and fracture, and atoms in the powder particles are diffused, thereby obtaining alloyed powder.
Soldering flux: the flux and the soldering flux used in the soldering process can remove oxides on the surfaces of the base metal and the soldering flux and protect the base metal and the soldering flux; and can reduce oxidation in the heating process, improve the wetting capacity of the brazing filler metal to the base metal, and effectively dissolve or destroy oxide films on the surfaces of weldments and the brazing filler metal.
(II) technical background:
in light weight design and manufacture, material design and structural design are two basic ideas for realizing light weight. In the aspect of material design, high-quality light alloy materials (such as aluminum alloy, magnesium alloy and titanium alloy) are widely applied, and composite materials are receiving wide attention due to unique properties of the composite materials. In the aspect of structural design, the thin-wall structural part has an obvious light weight effect and is a preferred structure in light weight design. The fiber metal layer plate material has the characteristics of both a metal material and a fiber reinforced composite material, the weight of the fiber metal layer plate member is reduced by more than 25% compared with an isometric aluminum alloy member, the cost is only about 1/3 of the isometric fiber reinforced composite material member, and the fiber metal layer plate member also has good service performances such as high strength, high damage tolerance, corrosion resistance and the like, and has wide application prospects and development potentials in various fields such as aerospace, automobile manufacturing, rail transit, hardware and electronics and the like.
At present, the forming mode of the fiber metal laminate mainly has two process ideas: the first method is to respectively form and process metal and fiber, lay the metal and the fiber layer by layer after surface treatment, bond the metal and the fiber into a fiber metal laminate by a connection mode, and then cure the fiber metal laminate by an autoclave process to prepare a target structural member; the second method is to bond the metal plate and the fiber layer into a fiber metal laminate, and then to process the laminate into the target part by using the traditional plastic forming process (such as stamping forming). The key point of the first forming idea is that an autoclave process is used for curing, but the autoclave investment cost is high, and the production cost for small components with small batch size is too high; and the hydraulic forming process has great difficulty in liquid sealing under the conditions of high temperature and high pressure, and the poor chemical and physical stability of a liquid medium under the high temperature condition brings great potential safety hazards to the process. The second forming idea can exert the advantages of convenience and high efficiency of the traditional stamping process, and an autoclave process, a hot die pressing process and a rolling process are usually adopted, but the large-curvature laminate member is difficult to form through secondary processing, and the forming quality of the large-curvature laminate member is still greatly different from that of the traditional metal plate stamping.
At present, the preparation technology of the fiber metal laminate is relatively mature, but the fiber metal laminate prepared by the existing preparation technology generally belongs to semi-finished materials and usually needs secondary processing to prepare usable parts. The traditional metal stamping processing needs to utilize the plastic deformation of a metal material, but the plasticity of the metal material and the plasticity of a fiber material are different, and the fiber in the existing fiber metal laminate/pipe has almost no plasticity, so that the deformation of each layer of the composite laminate/pipe in the secondary processing is difficult to coordinate, the defects of folds, layering, splitting and the like are easily caused, a huge problem is brought to the secondary processing of the product, the application field of the composite laminate component which is more wide in trend is limited to a great extent, and the application value can only be realized in a few scenes. Therefore, the preparation technology of the laminate member is developed on the basis, and the popularization of the fiber metal laminate member to more application scenes is of great significance.
The existing well developed laminate member forming process includes roll bending forming process, hot press forming process and stamping forming process. The roll bending forming process has two problems of low forming quality and rebound deformation of a component; the hot-press forming process is easy to generate defects of interface delamination, pores and the like, and laminate peeling can be generated seriously; the press forming process cannot form a small bending radius on a thicker fiber metal laminate, and only can avoid layering and fiber debonding by selecting the process of bonding and curing after the thinnest laminate is pressed step by step. In the actual process, the composite laminate member with large curvature and a complex structure cannot be formed due to low fiber elongation.
Disclosure of Invention
The invention aims to provide a forming process and a forming die for a carbon fiber reinforced aluminum alloy laminate member, which are used for solving the problems of difficulty in secondary processing of fiber metal and limited use scene in the prior art, and provides a process route for forming the fiber metal laminate member, namely soft die forming of an aluminum alloy outer plate → surface treatment of an aluminum alloy outer plate forming piece → paving of carbon fiber cloth and upper and lower aluminum alloy outer plate forming pieces → composite pressing of a carbon fiber reinforced aluminum alloy laminate plate → heating and melting of a metal connecting agent → mould unloading.
In order to achieve the purpose, the invention provides the following scheme:
the invention provides a forming process of a carbon fiber reinforced aluminum alloy laminate member, which comprises the following steps:
carrying out solid particle medium soft die forming on the aluminum alloy outer plate blank so as to respectively form an upper layer aluminum alloy outer plate forming piece and a lower layer aluminum alloy outer plate forming piece, wherein the upper layer aluminum alloy outer plate forming piece and the lower layer aluminum alloy outer plate forming piece are completely the same in forming shape;
performing surface treatment on the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece;
coating metal connecting agents on two side surfaces of the carbon fiber cloth, the lower surface of the upper-layer aluminum alloy outer plate forming piece and the upper surface of the lower-layer aluminum alloy outer plate forming piece, and sequentially laminating and arranging the lower-layer aluminum alloy outer plate forming piece, the carbon fiber cloth and the upper-layer aluminum alloy outer plate forming piece from bottom to top to form a carbon fiber reinforced aluminum alloy laminate preform;
performing composite pressing on the carbon fiber reinforced aluminum alloy laminate preformed piece by adopting a solid particle medium soft die forming mode (technology) to form a carbon fiber reinforced aluminum alloy laminate component, and continuously maintaining the application of pressure to the carbon fiber reinforced aluminum alloy laminate component so as to enable the metal connecting agent to completely infiltrate the carbon fibers;
heating and preserving heat of the carbon fiber reinforced aluminum alloy laminate member while continuously applying pressure to the carbon fiber reinforced aluminum alloy laminate member;
cooling the carbon fiber reinforced aluminum alloy laminate member after heat preservation; and after cooling, unloading the carbon fiber reinforced aluminum alloy laminate member, and taking out the carbon fiber reinforced aluminum alloy laminate member.
Optionally, the surface treatment comprises:
polishing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece;
scrubbing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece by using acetone to remove surface grease;
soaking the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece in a sodium hydroxide (NaOH) solution to remove a surface oxidation film;
and washing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece with distilled water, and actinically treating in a nitric acid water solution until the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece are white and bright and then are taken out, and drying is carried out after washing with distilled water.
Optionally, the surface treatment is performed on the upper surface and the lower surface of the upper-layer aluminum alloy outer plate forming piece and the upper surface and the lower surface of the lower-layer aluminum alloy outer plate forming piece.
Optionally, nitric acid (HNO) is used as described above 3 ) After the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece are subjected to deoxidation treatment, phosphoric acid anodic oxidation treatment can be further performed on the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece.
Optionally, the preparation method of the metal connecting agent comprises the following steps:
carrying out mechanical alloying treatment on metal powder, wherein the metal powder is mixed powder of aluminum powder, silicon powder and zinc powder;
the metal powder after mechanical alloying treatment is mixed with glycol solution and AlF 3 And (4) mixing the-KF and the KCI brazing flux to prepare metal connecting agent slurry.
Optionally, the metal powder is subjected to mechanical alloying treatment in a stainless steel vacuum ball milling tank; 1-1.5% of stearic acid or 1.5-3% of absolute ethyl alcohol is added into the stainless steel vacuum ball-milling tank to prevent the metal powder from cold welding in the mechanical alloying process.
Optionally, performing solid particle medium soft mold forming on the lower aluminum alloy outer plate blank by adopting a hydraulic press loading male die manner to form the lower aluminum alloy outer plate forming piece; and then replacing the female die, and carrying out solid particle medium soft die forming on the upper layer aluminum alloy outer plate blank by adopting a mode of loading the male die by a hydraulic press so as to form the upper layer aluminum alloy outer plate forming piece.
Optionally, the carbon fiber reinforced aluminum alloy laminate preform is formed outside a die for composite pressing.
Optionally, while continuously applying pressure to the carbon fiber reinforced aluminum alloy laminate member, placing the carbon fiber reinforced aluminum alloy laminate member in an atmosphere protection furnace for heating, so that the metal connecting agent in the carbon fiber reinforced aluminum alloy laminate member is heated and melted, and the carbon fiber cloth is bonded with the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece; wherein:
the heating temperature in the atmosphere protection furnace is 420-520 ℃, and the combination time of the metal connecting agent is 30-120 min; the pressure applied to the carbon fiber reinforced aluminum alloy laminate member is 20MPa to 30 MPa.
Optionally, the temperature rise rate in the atmosphere protection furnace is 3-5 ℃/min.
Optionally, the temperature rise rate in the atmosphere protection furnace is 1.5 ℃/min
Optionally, the process of melting and bonding the metal connecting agent can realize solution treatment of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece. The aluminum alloy outer plate forming piece can be subjected to solution treatment according to the heat treatment process parameters of the solution temperature of 480 ℃ and the solution time of 30 min.
Optionally, the solid particles adopted when the carbon fiber reinforced aluminum alloy laminate preform is subjected to composite pressing are silica particles or ceramic particles with the diameter of 0.3-0.6 mm.
Meanwhile, the invention provides a carbon fiber reinforced aluminum alloy laminate member forming die, which is used for performing solid particle medium soft die forming on an aluminum alloy outer plate blank, performing composite pressing on a carbon fiber reinforced aluminum alloy laminate preformed piece and performing melting combination on a metal connecting agent on a carbon fiber reinforced aluminum alloy laminate member, and comprises the following steps:
the female die comprises a plurality of female die bodies which have different shapes and can be replaced mutually;
the male die is positioned above the female die and is used for being matched with a solid particle medium and the corresponding female die body, and soft die forming can be performed on the aluminum alloy outer plate blank and composite pressing can be performed on the carbon fiber reinforced aluminum alloy laminate preformed piece;
the blank pressing assembly is arranged on the female die body and can fix the edges of the aluminum alloy outer plate blank and the carbon fiber reinforced aluminum alloy laminate preformed piece in the processes of soft die forming of the aluminum alloy outer plate blank and composite pressing of the carbon fiber reinforced aluminum alloy laminate preformed piece;
the fastening assembly comprises a fastening bolt, a fastening top plate, a fastening sliding plate, a fastening spring, a fastening bracket and a fastening base which are sequentially arranged from top to bottom; the female die is arranged above the fastening base; the fastening bracket is fixedly arranged above the fastening base and is positioned on the periphery of the female die; the fastening sliding plate is slidably sleeved on the fastening support and is positioned above the male die; the fastening spring is sleeved on the fastening bracket, and two ends of the fastening spring are respectively abutted against the fastening sliding plate and the fastening base; the fastening top plate is fixed at the top end of the fastening support, the fastening bolt penetrates through the fastening top plate and is in threaded connection with the fastening top plate, and the fastening bolt can push the fastening sliding plate to move downwards to press the male die.
Optionally, the binder assembly includes a binder ring and a binder bolt for fixing the binder ring.
Compared with the prior art, the invention has the following technical effects:
the invention provides a forming process of a carbon fiber reinforced aluminum alloy laminate member, which provides a process route of 'soft die forming of an aluminum alloy outer plate → surface treatment of an aluminum alloy outer plate forming piece → paving of carbon fiber cloth and upper and lower aluminum alloy outer plate forming pieces → composite pressing of a carbon fiber reinforced aluminum alloy laminate pre-forming piece → heating melting of a metal connecting agent → mould unloading' for forming the fiber metal laminate member, can develop a delicate composite forming process according to the plastic property and metallurgical bonding property of different series of aluminum alloys, realizes the composite forming integrated preparation scheme of the laminate member, is particularly suitable for preparing the fiber metal laminate member with the special-shaped cross section, solves the problem of difficult secondary processing of the fiber metal laminate member, expands the application range of the fiber metal composite material, provides reference for forming the fiber metal composite material with the complex shape, and can be used for forming a large curvature, a large curvature and a large curvature, The forming of the carbon fiber reinforced aluminum alloy composite laminate member with a complex structure solves the problem of forming the laminate member while compounding parts.
In addition, the forming process of the carbon fiber reinforced aluminum alloy laminate member provided by the invention performs the metal plate blank firstly, so that the quality of the formed laminate member can be ensured; the design can replace the forming die of different cavity shapes, reduce the product investment, is suitable for the member production of large curvature of small batch; the solid particles are used as pressure transmission medium, and the heat-transfer medium has the advantages of uniform heat transfer and pressure transmission, heat resistance, easy sealing and the like. Meanwhile, the solid particle medium forming technology is suitable for the production of small-batch components, the solid particle medium can provide reliable laminate bonding pressure and resin curing pressure for the composite pressing process in all directions, and the particle medium is convenient to load, easy to seal and strong in heat resistance; secondly, the scheme of preforming the metal component and then compositely pressing the fiber layer and the metal layer avoids the problem of coordinated deformation of the metal layer and the fiber layer, can effectively avoid various problems in laminate forming, and has strong practicability.
The forming die provided by the invention is reasonable in structural arrangement and convenient to disassemble and assemble, can be used for implementing various forming processes of the laminated plate members including the forming process of the carbon fiber reinforced aluminum alloy laminated plate member, and is particularly suitable for preparing the fiber metal laminated plate member with the special-shaped section.
Drawings
In order to more clearly illustrate the embodiments of the present invention or the technical solutions in the prior art, the drawings needed in the embodiments will be briefly described below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings without creative efforts.
FIG. 1 is a schematic flow chart of a forming process of a carbon fiber reinforced aluminum alloy laminate member according to an embodiment of the present invention;
FIG. 2 is a schematic structural diagram of a soft mold forming process of an aluminum alloy outer plate blank according to an embodiment of the present invention;
FIG. 3 is a schematic view of a state structure of a composite pressing process according to an embodiment of the present invention;
FIG. 4 is a schematic structural diagram of a carbon fiber reinforced aluminum alloy laminate member forming mold according to an embodiment of the present invention.
Wherein the reference numbers are: a male die 1; a solid particulate medium 2; preforming the blank holder 3; an aluminum alloy outer plate blank 4; a female die 5 for forming the aluminum alloy outer plate blank; an upper aluminum alloy outer panel forming member 6; a carbon fiber cloth 7; a lower aluminum alloy outer panel forming member 8; a fastening bolt 9; fastening the top plate 10; a thrust bearing 11; fastening the sliding plate 12; a fastening bracket 13; a fastening spring 14; a blank holder assembly 15; a gasket 16; a carbon fiber reinforced aluminum alloy laminate preform 17; securing the base 18.
Detailed Description
The technical solutions in the embodiments of the present invention will be clearly and completely described below with reference to the drawings in the embodiments of the present invention, and it is obvious that the described embodiments are only a part of the embodiments of the present invention, and not all of the embodiments. All other embodiments, which can be obtained by a person skilled in the art without making any creative effort based on the embodiments in the present invention, belong to the protection scope of the present invention.
The invention aims to provide a forming process of a carbon fiber reinforced aluminum alloy laminate member, which aims to solve the problems of difficulty in secondary processing of fiber metal and limited use scene in the prior art, and provides a process route of 'soft die forming of an aluminum alloy outer plate → surface treatment of an aluminum alloy outer plate forming piece → paving of carbon fiber cloth and upper and lower aluminum alloy outer plate forming pieces → composite pressing of a carbon fiber reinforced aluminum alloy laminate pre-forming piece → heating and melting of a metal connecting agent → mould unloading' for forming the fiber metal laminate member.
The invention also aims to provide a forming die which can be used for implementing the forming process of the carbon fiber reinforced aluminum alloy laminate member.
In order to make the aforementioned objects, features and advantages of the present invention comprehensible, embodiments accompanied with figures are described in further detail below.
Example one
As shown in fig. 1 to 3, the present embodiment provides a forming process of a carbon fiber reinforced aluminum alloy laminate member, which specifically includes the following process routes:
s1) aluminum alloy outer plate blank preforming: and sequentially placing the aluminum alloy outer plate blank 4, the preformed blank holder 3, the solid particle medium 2 and the male die 1 on the aluminum alloy outer plate blank forming female die 5, closing the die, and loading the male die 1 by using a hydraulic machine to form an aluminum alloy outer plate formed piece. In this embodiment, the aluminum alloy outer plate blank 4 has two layers, the lower aluminum alloy outer plate blank is formed first, after the lower aluminum alloy outer plate formed piece 8 is formed, another die having the same shape as that of the die for forming the lower aluminum alloy outer plate formed piece 8 is replaced, the upper aluminum alloy outer plate blank is placed on the newly replaced die, and the hydraulic press is used again to load the male die 1 to form the upper aluminum alloy outer plate formed piece 6. The upper aluminum alloy outer plate forming member 6 and the lower aluminum alloy outer plate forming member 8 are both formed by soft molding using a solid particle medium, and the preformed shapes of the two members are completely the same, but since the carbon fiber reinforced aluminum alloy laminate preform (i.e., the carbon fiber reinforced aluminum alloy laminate preform 17 described below) to be formed subsequently has a certain thickness, the upper aluminum alloy outer plate forming member 6 and the lower aluminum alloy outer plate forming member 8 have the same formed shape but different formed areas, and the formed area of the upper aluminum alloy outer plate forming member 6 is slightly smaller than that of the lower aluminum alloy outer plate forming member 8, which is also a reason for forming another plate blank after replacing the aluminum alloy outer plate blank forming die 5. Since the present embodiment is directed to the composite pressing of a sheet material, the upper aluminum alloy outer panel formed piece 6 and the lower aluminum alloy outer panel formed piece 8 located on both sides of the whole carbon fiber reinforced aluminum alloy laminate preform (hereinafter, referred to as a carbon fiber reinforced aluminum alloy laminate preform 17) are located on the outermost layers, and therefore, both may be collectively referred to as an aluminum alloy outer panel formed piece (both may be referred to as an aluminum alloy outer slab before forming).
S2) surface treatment of an aluminum alloy outer plate forming piece: the surface treatment is carried out on the bonding surfaces of the upper aluminum alloy outer plate forming piece 6 and the lower aluminum alloy outer plate forming piece 8, and the loose oxide layer on the surface of the aluminum plate is removed mainly through polishing treatment and chemical treatment so as to increase the adhesive force of the metal matrix to the connecting agent and improve the interface bonding strength. First, the upper and lower surfaces of the upper aluminum alloy outer plate molded article 6 and the upper and lower surfaces of the lower aluminum alloy outer plate molded article 8 may be polished with 800#, 1000#, 1500#, and 2000# sandpaper in this order. Then carrying out chemical treatment steps of alkali washing, acid washing and drying: firstly, scrubbing the upper and lower surfaces of an upper layer aluminum alloy outer plate forming piece 6 and the upper and lower surfaces of a lower layer aluminum alloy outer plate forming piece 8 by using acetone to remove surface grease; then placing the upper-layer aluminum alloy outer plate forming piece 6 and the lower-layer aluminum alloy outer plate forming piece 8 in a 25g/L sodium hydroxide solution at the temperature of (60 +/-5) DEG C for soaking for 3min to remove the surface oxide film; then washing the surfaces of the upper-layer aluminum alloy outer plate forming piece 6 and the lower-layer aluminum alloy outer plate forming piece 8 with distilled water for 2-5 min: and performing photochemical treatment in a nitric acid aqueous solution of 200 g/L-300g/L for 5min, neutralizing alkali liquor, taking out the aluminum alloy outer plate forming piece 6 at the upper layer and the aluminum alloy outer plate forming piece 8 at the lower layer after the surfaces are white and bright, washing with distilled water for 2-5min, and drying. In actual practice, the surface treatment may be performed only on the lower surface of the upper aluminum alloy outer panel formed piece 6 and only on the upper surface of the lower aluminum alloy outer panel formed piece 8, and the operation method may be the same as described above.
S3) material layer laying stage: in order to facilitate the layer laying of the carbon fiber cloth 7, the layer laying process is carried out outside the aluminum alloy outer plate blank forming female die 5, namely, the carbon fiber reinforced aluminum alloy laminate preformed piece 17 is formed outside the die. After the prepared slurry of the metal connecting agent is uniformly coated on the lower surface of the upper-layer aluminum alloy outer plate forming piece 6 and the upper surface of the lower-layer aluminum alloy outer plate forming piece 8 which are subjected to surface treatment and the surfaces of the two sides of the cut carbon fiber cloth 7, the lower-layer aluminum alloy outer plate forming piece 8, the carbon fiber cloth 7 and the upper-layer aluminum alloy outer plate forming piece 6 are sequentially arranged in a laminated mode from bottom to top to form a carbon fiber reinforced aluminum alloy laminate pre-forming piece 17, and the carbon fiber reinforced aluminum alloy laminate pre-forming piece is placed into a die to be subjected to composite pressing. The step comprises a preparation process of the metal connecting agent, namely, the preparation of metal connecting agent slurry is carried out before the material layer is paved, and the method mainly comprises the following steps: mixing aluminum powder, silicon powder and zinc powder according to a certain weight ratio to form mixed metal powder, placing the mixed metal powder into a stainless steel vacuum ball milling tank, placing stainless steel grinding balls with the diameter of 5mm, the diameter of 10mm and the diameter of 15mm in different proportions in the tank, and ball milling the mixed metal powder for 30-50 hours by adopting a high-energy ball mill under the protection of argon atmosphere at the conditions of the rotating speed of 300-400 r/min and the ball powder ratio of 15: 1-20: 1 to fully mix the metal powder so as to complete mechanical alloying treatment on the metal powder. In order to prevent cold welding phenomenon, 1 to 1.5 mass percent of stearic acid or 1.5 to 3 mass percent of absolute ethyl alcohol can be added into the ball milling tank. The metal powder after mechanical alloying is mixed with glycol solution and AlF 3 And (4) mixing the-KF and KCI brazing flux to prepare slurry for convenient coating.
S4) carrying out composite pressing on carbon fiber reinforced aluminum alloy laminate preformed pieces: firstly, die filling is carried out, namely, the carbon fiber reinforced aluminum alloy laminate preformed piece 17 which is well laid is placed into the aluminum alloy outer plate blank forming female die 5, in order to prevent the laminate from slipping in the composite press forming process, the edge of the laminate can be compacted by using a blank holder, solid particle media 2 are poured into the laminate and filled with all corner parts in the carbon fiber reinforced aluminum alloy laminate preformed piece 17 as far as possible, and then the male die 1 is covered. And then, carrying out composite pressing on the carbon fiber reinforced aluminum alloy laminate preformed piece 17 by adopting a mode of loading a male die by a hydraulic machine and a mode (technology) of soft die forming of a solid particle medium to form the carbon fiber reinforced aluminum alloy laminate member.
S5) heating and melting stage of the metal connecting agent: after the carbon fiber reinforced aluminum alloy laminate preform 17 is subjected to composite pressing, the hydraulic press is unloaded, and the fastening assembly can be reused to continuously provide the pressure of 20-30 MPa for the male die 1. And meanwhile, the assembled forming die and the fastening assembly are placed into an atmosphere protective furnace filled with protective atmosphere for heating and melting, the heating rate in the furnace is 3-5 ℃/min, the heating temperature is 420-520 ℃, and the bonding time of the metal connecting agent slurry is 30-120 min. Meanwhile, the solution treatment of 6 series or 7 series aluminum alloy plates, namely the upper aluminum alloy outer plate forming piece 6 and the lower aluminum alloy outer plate forming piece 8, can be realized in the heat preservation stage.
S6) demolding: and after the heat preservation of the carbon fiber reinforced aluminum alloy laminate preformed piece 17 is finished in the atmosphere protection furnace, waiting for the cooling of the mold to the normal temperature. After cooling, the fastening assembly is unloaded, and the solid particle medium 2 and the carbon fiber reinforced aluminum alloy laminate member formed by pressing are taken out. And finally, trimming the edge of the carbon fiber reinforced aluminum alloy laminate member to obtain the final part.
In this embodiment, the temperature increase rate in the protective furnace in the above-described step S5) is preferably set to 1.5 ℃/min depending on the type of material and the thickness of the plate member.
In this embodiment, in step S4), the carbon fiber reinforced aluminum alloy laminate preform 17 is subjected to composite press forming by using a solid particle medium forming technique. Wherein, the solid particle medium 2 can be preferably silica particles or ceramic particles with the diameter of 0.3-0.6 mm, and the particles can enter the gaps of the die in the pressurizing process, but the solid particles can finally play a sealing role due to the mutual friction effect.
In the embodiment, when the female die 5 and the male die 1 for forming the aluminum alloy outer plate blank adopt the special-shaped structures as shown in fig. 2 and 3, the preparation of the carbon fiber reinforced aluminum alloy laminate with the special-shaped section is realized, and the application range of the fiber metal laminate is expanded. The curing pressure is kept by utilizing a pressure self-locking device (namely a fastening assembly), so that the curing device is simple and convenient; the fusion metal connecting agent is fused and combined and subjected to solution treatment in the composite pressing process, the preparation technology of the aluminum alloy low-temperature deformation heat treatment and the carbon fiber reinforced aluminum alloy laminate member is ingeniously integrated, the use strength of the composite member is improved, and the forming preparation of the high-quality composite laminate member is realized.
In this example, a solid particulate media soft mold forming technique was applied during the composite compaction process. The solid particle medium has uniform heat transfer and pressure transfer, is heat-resistant, is easy to seal, and has fluidity, particles at the position with overlarge pressure flow to the position with lower pressure to prevent overload, and simultaneously, the fluidity is utilized to improve the forming precision of fine parts and avoid the problem of difficulty in filling special-shaped section parts in die forming.
The embodiment designs a composite forming integrated process scheme of a fiber reinforced metal laminate member, which is characterized by comprising the steps of 'soft die forming of an aluminum alloy outer plate → surface treatment of an aluminum alloy outer plate forming piece → paving and pasting of carbon fiber cloth and upper and lower aluminum alloy outer plate forming pieces (containing metal connecting agent slurry preparation) → composite pressing of a carbon fiber reinforced aluminum alloy laminate pre-forming piece → heating and melting of a metal connecting agent in an atmosphere protection furnace and aluminum alloy solution treatment → die unloading'. The scheme of pre-forming and then composite pressing avoids the problem of coordinated deformation of the metal layer and the fiber layer, can effectively avoid the problems of fiber layer fracture and the like in laminate forming, and improves the application range of the carbon fiber reinforced aluminum alloy member.
In the embodiment, the composite member is placed in the heating furnace at a certain temperature, the specific temperature ensures that the fiber layers and the aluminum alloy member are fully combined, and meanwhile, no matter the upper and lower aluminum alloy plate blanks adopt 7 series aluminum alloy plates or 6 series aluminum alloy plates, the solid solution temperature can be reached, and the use of the composite member is ensured.
The embodiment adopts the solid particle medium forming technology to realize the composite pressing of the laminate member, compared with hydraulic forming, the composite pressing has the advantages of no need of sealing, no pollution, recyclable solid particle medium and accordance with the requirements of low carbon and environmental protection; the granular medium soft mold forming process has the advantages of uniform heat transfer and pressure transfer, good sealing performance and the like. Because only different forming dies with cavities of different shapes need to be replaced, the product investment is reduced, and the method can be used for producing small-batch large-curvature components.
The carbon fiber reinforced aluminum alloy laminate member forming die related in the embodiment can be used for the processes of carrying out solid particle medium soft die forming on an aluminum alloy outer plate blank, carrying out composite pressing on a carbon fiber reinforced aluminum alloy laminate pre-forming piece and carrying out metal connecting agent melting and bonding on a carbon fiber reinforced aluminum alloy laminate member. As shown in figures 1-4, the carbon fiber reinforced aluminum alloy laminate member forming mold mainly comprises an aluminum alloy outer plate blank forming female mold 5, a male mold 1, a blank pressing assembly and a fastening assembly. The aluminum alloy outer plate blank forming die 5 comprises a plurality of die bodies which have different shapes and can be replaced mutually. The male die 1 is used for being matched with the solid particle medium 2 and the corresponding female die body, and can perform soft die forming on the upper and lower layer plate blanks of the aluminum alloy and perform composite pressing on the carbon fiber reinforced aluminum alloy laminate preformed piece. The edge pressing assembly 15 is arranged on the female die body and can fix the edges of the upper layer plate blank, the lower layer plate blank and the carbon fiber reinforced aluminum alloy plate shell laminate preformed piece in the soft die preformed and composite pressing stages. The fastening assembly comprises a fastening bolt 9, a fastening top plate 10, a fastening sliding plate 12, a fastening spring 14, a fastening bracket 13 and a fastening base 18 which are sequentially arranged from top to bottom; the female die body is arranged above the fastening base 18; the bottom end of the fastening bracket 13 is fixedly arranged above the fastening base 18, and the fastening bracket 13 is positioned on the periphery of the female die body; the fastening sliding plate 12 is slidably sleeved on the fastening bracket 13, and the fastening sliding plate 12 is positioned above the male die 1; the fastening spring 14 is sleeved on the fastening bracket 13, and two ends of the fastening spring 14 are respectively abutted against or connected with the lower surface of the fastening sliding plate 12 and the upper surface of the fastening base 18; the fastening top plate 10 is fixed at the top end of the fastening bracket 13, the fastening bolt 9 penetrates through the fastening top plate 10 and is in threaded connection with the fastening top plate 10, and the fastening bolt 9 can push the fastening sliding plate 12 to move downwards to press the convex die 1.
As shown in fig. 4, the fastening assembly is sleeved outside the composite pressing mold, and the upper surface of the fastening sliding plate 12 is further provided with a thrust bearing 11. The composite pressing die after die filling is placed in a fastening base 18, a fastening support 13, a fastening spring 14, a fastening sliding plate 12, a thrust bearing 11, a fastening top plate 10 and a fastening bolt 9 are sequentially installed, pressure is applied to the thrust bearing 11 by rotating the fastening bolt 9, so that pressure is applied to the fastening sliding plate 12, further pressure is applied to a male die 1, a metal connecting agent in the carbon fiber cloth 7 is fully melted and infiltrates carbon fibers, and infiltration and combination effects on micropores on the surface of aluminum alloy are improved. The fastening spring 14 can adjust the applied pressure to avoid overhigh pressure; at the same time, the clamping spring 14 also serves to reset the clamping slide 12.
In this embodiment, binder assembly 15 includes a binder ring and binder bolts for securing the binder ring. As shown in fig. 4, a gasket 16 is also provided between the blankholder of the blankholder assembly 15 and the aluminium alloy outer blank-forming die 5 to ensure that the blankholder exerts a firm and smooth pressure on the edge of the sheet material.
In this embodiment, since the forming mold includes a plurality of types of die bodies that have different shapes and can be replaced with each other, the male mold 1 can be correspondingly configured to have a plurality of shapes and specifications for different shapes and specifications of different die bodies. Here, the punch 1 is used to press the solid particulate medium 2, so in order to ensure uniform force transmission of the punch 1 to the solid particulate medium 2, it is preferable to provide the bottom surface of the punch 1 as a flat surface. The forming surface of the female die body can be irregular wavy or zigzag, and the like, and can be used for preparing various carbon fiber reinforced aluminum alloy laminates with special-shaped sections.
The carbon fiber reinforced aluminum alloy laminate member forming die is reasonable in structural arrangement and convenient to disassemble and assemble, can be used for implementing various laminate member forming processes including the carbon fiber reinforced aluminum alloy laminate member forming process, and is particularly suitable for preparing special-shaped section fiber metal laminate members.
It will be evident to those skilled in the art that the invention is not limited to the details of the foregoing illustrative embodiments, and that the present invention may be embodied in other specific forms without departing from the spirit or essential attributes thereof. The present embodiments are therefore to be considered in all respects as illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than by the foregoing description, and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein, and any reference signs in the claims are not intended to be construed as limiting the claim concerned.
The principle and the implementation mode of the invention are explained by applying a specific example, and the description of the embodiment is only used for helping to understand the method and the core idea of the invention; meanwhile, for a person skilled in the art, according to the idea of the present invention, the specific embodiments and the application range may be changed. In view of the above, the present disclosure should not be construed as limiting the invention.
Claims (8)
1. A carbon fiber reinforced aluminum alloy laminate member forming process is characterized by comprising the following steps:
carrying out solid particle medium soft die forming on the aluminum alloy outer plate blank to respectively form an upper layer aluminum alloy outer plate forming piece and a lower layer aluminum alloy outer plate forming piece, wherein the upper layer aluminum alloy outer plate forming piece and the lower layer aluminum alloy outer plate forming piece are completely the same in forming shape;
performing surface treatment on the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece;
coating metal connecting agents on two side surfaces of the carbon fiber cloth, the lower surface of the upper-layer aluminum alloy outer plate forming piece and the upper surface of the lower-layer aluminum alloy outer plate forming piece, and sequentially laminating and arranging the lower-layer aluminum alloy outer plate forming piece, the carbon fiber cloth and the upper-layer aluminum alloy outer plate forming piece from bottom to top to form a carbon fiber reinforced aluminum alloy laminate preform; preparation of the Metal connecting agentThe method comprises the following steps: carrying out mechanical alloying treatment on metal powder, wherein the metal powder is mixed powder of aluminum powder, silicon powder and zinc powder, and then mixing the metal powder after the mechanical alloying treatment with glycol solution and AlF 3 -KF-KCI brazing flux is mixed to prepare metal connecting agent slurry;
carrying out composite pressing on the carbon fiber reinforced aluminum alloy laminate preformed piece in a solid particle medium soft die forming mode to form a carbon fiber reinforced aluminum alloy laminate component, and continuously keeping applying pressure to the carbon fiber reinforced aluminum alloy laminate component to enable the metal connecting agent to completely infiltrate carbon fibers;
heating and preserving heat of the carbon fiber reinforced aluminum alloy laminate member while continuously applying pressure to the carbon fiber reinforced aluminum alloy laminate member;
cooling the carbon fiber reinforced aluminum alloy laminate member after heat preservation; and after cooling, unloading the carbon fiber reinforced aluminum alloy laminate member, and taking out the carbon fiber reinforced aluminum alloy laminate member.
2. The carbon fiber reinforced aluminum alloy laminate member forming process as claimed in claim 1, wherein the surface treatment includes:
polishing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece;
scrubbing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece by using acetone to remove surface grease;
soaking the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece in a sodium hydroxide solution to remove a surface oxidation film;
and washing the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece with distilled water, and actinically treating in a nitric acid water solution until the surfaces of the upper-layer aluminum alloy outer plate forming piece and the lower-layer aluminum alloy outer plate forming piece are white and bright and then are taken out, and drying is carried out after washing with distilled water.
3. The process for forming a carbon fiber reinforced aluminum alloy laminate member according to claim 1, wherein the metal powder is subjected to mechanical alloying treatment in a stainless steel vacuum ball mill tank; stearic acid with the mass fraction of 1-1.5% or absolute ethyl alcohol with the mass fraction of 1.5-3% is added into the stainless steel vacuum ball milling tank, so that the cold welding phenomenon of the metal powder in the mechanical alloying process is prevented.
4. The forming process of the carbon fiber reinforced aluminum alloy laminate member according to claim 1 or 2, wherein the lower aluminum alloy outer plate blank is subjected to solid particle medium soft mold forming by loading a male mold by a hydraulic press to form the lower aluminum alloy outer plate forming piece; and then replacing the female die, and carrying out solid particle medium soft die forming on the upper layer aluminum alloy outer plate blank by adopting a mode of loading the male die by a hydraulic press so as to form the upper layer aluminum alloy outer plate forming piece.
5. The carbon fiber reinforced aluminum alloy laminate member forming process as claimed in claim 1 or 2, wherein the carbon fiber reinforced aluminum alloy laminate preform is formed outside a mold for composite pressing.
6. The carbon fiber reinforced aluminum alloy laminate member forming process as claimed in claim 1, wherein the carbon fiber reinforced aluminum alloy laminate member is placed in an atmosphere protection furnace and heated while continuing to apply pressure to the carbon fiber reinforced aluminum alloy laminate member, so that the metal connecting agent in the carbon fiber reinforced aluminum alloy laminate member is heated and melted, and the adhesion of the carbon fiber cloth to the upper layer aluminum alloy outer plate forming piece and the lower layer aluminum alloy outer plate forming piece is realized; wherein:
the heating temperature in the atmosphere protection furnace is 420-520 ℃, and the combination time of the metal connecting agent is 30-120 min; the pressure applied to the carbon fiber reinforced aluminum alloy laminate member is 20 MPa-30 MPa.
7. The forming process of the carbon fiber reinforced aluminum alloy laminate member as claimed in claim 1, wherein the solid particles used in the composite pressing of the carbon fiber reinforced aluminum alloy laminate preform are silica particles or ceramic particles having a diameter of 0.3 to 0.6 mm.
8. The carbon fiber reinforced aluminum alloy laminate member forming process as claimed in claim 1, which is carried out using a carbon fiber reinforced aluminum alloy laminate member forming die comprising:
the female die comprises a plurality of female die bodies which have different shapes and can be replaced mutually;
the male die is positioned above the female die and is used for being matched with a solid particle medium and the corresponding female die body, and soft die forming can be performed on the aluminum alloy outer plate blank and composite pressing can be performed on the carbon fiber reinforced aluminum alloy laminate preformed piece;
the blank pressing assembly is arranged on the female die body and can fix the edges of the aluminum alloy outer plate blank and the carbon fiber reinforced aluminum alloy laminate preformed piece in the processes of soft die forming of the aluminum alloy outer plate blank and composite pressing of the carbon fiber reinforced aluminum alloy laminate preformed piece;
the fastening assembly comprises a fastening bolt, a fastening top plate, a fastening sliding plate, a fastening spring, a fastening bracket and a fastening base which are sequentially arranged from top to bottom; the female die is arranged above the fastening base; the fastening bracket is fixedly arranged above the fastening base and is positioned on the periphery of the female die; the fastening sliding plate is slidably sleeved on the fastening bracket and is positioned above the male die; the fastening spring is sleeved on the fastening bracket, and two ends of the fastening spring are respectively abutted against the fastening sliding plate and the fastening base; the fastening top plate is fixed at the top end of the fastening support, the fastening bolt penetrates through the fastening top plate and is in threaded connection with the fastening top plate, and the fastening bolt can push the fastening sliding plate to move downwards to press the male die.
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