CN114318323A - Method for repairing local damage of aircraft skin surface in situ through cold spraying - Google Patents
Method for repairing local damage of aircraft skin surface in situ through cold spraying Download PDFInfo
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- CN114318323A CN114318323A CN202111507473.7A CN202111507473A CN114318323A CN 114318323 A CN114318323 A CN 114318323A CN 202111507473 A CN202111507473 A CN 202111507473A CN 114318323 A CN114318323 A CN 114318323A
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Abstract
The invention relates to the technical field of remanufacturing and repairing, in particular to a method for repairing local damage on the surface of an aircraft skin in situ by cold spraying, which comprises the following steps: polishing microcracks and surface corrosion areas discovered by nondestructive inspection to completely remove damage defects, and manually polishing to form a groove around the periphery of the defects; secondly, performing sand blasting pretreatment before spraying on the polished area to be sprayed; and thirdly, based on portable cold spraying equipment, adopting 2024 aluminum alloy powder similar to skin materials as raw materials, and manually repairing the damaged area, wherein the repairing coating area is higher than the peripheral undamaged skin. The method has the advantages of wider application range, better repairing effect of the skin structure, capability of meeting the requirement of in-situ repair of skin damage in most areas on the airplane, quick and simple repairing process, capability of ensuring the repairing effect, and capability of solving the problems that the aerodynamic appearance of the airplane is damaged and the weight of the airplane is obviously increased by the traditional repairing method.
Description
Technical Field
The invention relates to the technical field of remanufacturing and repairing, in particular to a method for repairing local damage on the surface of an aircraft skin in situ through cold spraying.
Background
The aircraft skin is a layer of aluminum alloy metal plate on the surface of the aircraft, which forms the appearance of the aircraft and has the functions of maintaining the aerodynamics and transferring loads. In the taking off and landing and flying processes of the airplane, the skin is subjected to the action of external pressure which continuously changes, and the skin is exposed in the natural environment for a long time, so that the surface of the skin is easy to generate damage defects such as fatigue cracks, pitting corrosion or local corrosion. Meanwhile, in the process of repairing the airplane, damage defects such as indentation and deformation may occur on the surface of the skin due to improper protection. Aiming at the skin damage, the traditional skin repairing mode is grinding, patching and the like, the original aerodynamic appearance of the airplane can be damaged by the repairing mode, and the weight of the airplane is obviously increased after the repairing mode, so that the flying performance of the airplane is influenced.
The cold spraying technology is an important remanufacturing and repairing technical means, the heat input in the repairing process is low, the rapid deposition of light metal materials such as aluminum, magnesium, zinc and the like can be realized, the thickness of the prepared coating can reach the centimeter level or even the decimeter level, and the cold spraying technology is suitable for repairing the damage in various local small ranges. The invention aims to solve the problems that: and repairing local damages such as cracks, pitting corrosion and the like on the surface of the airplane by adopting a cold spraying remanufacturing and repairing technology. When the damage is repaired, the original aerodynamic appearance of the airplane is maintained, the skin does not have obvious weight increase, and the influence of the skin repairing process on the performance of the airplane is reduced.
CN101448976B "method for repairing damaged outer skin areas on aircraft", wherein there is a possibility of repairing damage to plating layers which adhere to the outer skin of a passenger aircraft and which keep the outer skin in an undamaged state from corrosion. By this method, the plating can be reproduced in the existing damaged area without the accompanying rework. However, in the method, the skin repair needs to be carried out by adopting a fixed spraying distance and a fixed moving speed, manual spraying by operators is difficult, most skin areas on the airplane are complex curved surfaces, and the whole skin plate cannot be detached due to damage of local areas during actual repair, so that the method is more suitable for the detachable skin repair with a simple shape and cannot be suitable for the most on-board skin repair. Secondly, the raw material used in the method is pure aluminum or near-aluminum powder with the aluminum content of more than 90 percent, while the material of the aircraft skin is mostly 2-series aluminum alloy such as 2A12 and 2B06, the powder used in the method has large difference with the matrix, the difference of hardness, thermal expansion coefficient, self-corrosion potential and the like is large, and the coating hardness of the component is generally below 65HV, so that the repaired area is easy to generate secondary abrasion. In addition, the method does not specifically provide the treatment requirement on the damaged area before cold spraying repair aiming at the technical characteristics of cold spraying.
Disclosure of Invention
The invention provides a method for repairing local damage on the surface of an aircraft skin in situ by cold spraying, aiming at the conditions that the original aerodynamic appearance of the aircraft is damaged by the traditional skin repairing mode, the weight of the repaired aircraft is obviously increased, and the flight performance of the aircraft is influenced. The repaired skin has the same appearance as the original appearance and similar weight, no step difference exists between the damaged part and the undamaged part, the original aerodynamic appearance of the airplane is ensured, and the problems that the aerodynamic appearance of the airplane is damaged and the weight of the airplane is obviously increased by the traditional repairing method are solved.
The technical problem to be solved by the invention is realized by adopting the following technical scheme:
a method for repairing local damage of an aircraft skin surface in situ by cold spraying comprises the following steps:
polishing microcracks and surface corrosion areas discovered by nondestructive inspection to completely remove damage defects, and manually polishing to form a groove around the periphery of the defects;
secondly, performing sand blasting pretreatment before spraying on the polished area to be sprayed;
based on SST-PX type portable cold spraying equipment, 2024 aluminum alloy powder close to skin materials is used as raw materials, damaged areas are manually repaired, and the repairing coating areas are higher than the surrounding undamaged skins;
removing the protective adhesive tape, and polishing the coating shape by adopting an electric polishing tool, a file and abrasive paper until the surface is smooth and has no pit and the repaired area has no step difference;
fifthly, using 0.5-0.8% of alodine solution to carry out antiseptic treatment on the damaged positions of the anodized layer on the surface of the repaired part, and drying;
detecting flaws of the repaired part by adopting visual inspection and dye penetrant inspection, and observing whether flaws and craters exist;
and (seventhly), evaluating the microstructure and microhardness of the repaired area, the bonding strength of the coating and the anticorrosion effect of the coating.
Preferably, the bevel angle in step (one) is 120-150 °.
Preferably, the specific process of the sand blasting pretreatment before spraying in the step (two) is as follows:
(a) firstly, protecting the periphery of a sand blasting area by adopting a high-temperature resistant protective adhesive tape;
(b) cleaning with acetone to remove various oil stains and impurities;
(c) adopting a portable sand blasting machine, and having the following technological parameters: the method comprises the following steps of (1) coarsening a region to be sprayed to obtain a surface with the roughness of about Ra6.0-Ra8.0 by using brown corundum sand of 60-80 meshes, sand blasting pressure of 0.3-0.6 MPa, sand blasting distance of 150-250 mm, sand blasting angle of 90 degrees +/-20 degrees, sand yield of 1-2 kg/min and sand blasting linear velocity of 20-150 mm/s;
(d) and blowing the sand blasting surface by using compressed air to remove floating sand.
Preferably, the spraying process parameters in the step (three) are as follows: the spraying pressure is 170-190 psi; the gas heating temperature is 470-490 ℃; the powder feeding rate is 10 g-20 g; the spraying distance is 10 mm-35 mm; the spraying angle is 90 degrees +/-20 degrees; the spraying linear speed is 10 mm/s-300 mm/s; the process gas is nitrogen with a purity of not less than 99.9%.
Preferably, the surface roughness of the coating after polishing in the step (IV) is not less than Ra0.8.
Preferably, the method for evaluating the microstructure and the microhardness in the step (seven) is as follows: by adopting the same spraying process, a coating sample piece is prepared, the sample piece is evaluated, and whether the microstructure and the microhardness of the sample piece meet the requirements or not is judged.
Preferably, the coating bonding strength evaluation in step (seven): and spraying three groups of sample pieces with cold spraying bonding strength by using the same spraying process according to the standard of GB/T8642-2002 'determination of tensile bonding strength of thermal spraying', evaluating the sample pieces, and judging whether the bonding strength of the sample pieces meets the requirements.
Preferably, the anticorrosive effect of the coating in the step (seven) is evaluated: refer to HB5362-86 "Corrosion resistance quality inspection of Metal protective layer for aircraft in general" and GJB/T150.11A-2009 "environmental test method for military Equipment laboratory part 11: salt spray test, three groups of cold spraying corrosion resistance sample pieces are sprayed by the same spraying process, the sample pieces are evaluated, and whether the corrosion resistance effect of the sample pieces meets the requirements or not is judged.
The invention has the beneficial effects that:
compared with the prior art, the method has the advantages of wider application range, better repairing effect of the skin structure, capability of meeting the requirements of in-situ repairing of skin damage in most areas on the airplane, quick and simple repairing process, capability of ensuring the repairing effect, and capability of solving the problems that the aerodynamic appearance of the airplane is damaged and the weight of the airplane is obviously increased by the traditional repairing method.
Drawings
The invention is further illustrated with reference to the following figures and examples:
FIG. 1 is a schematic view of a defect grinding groove in the present invention;
FIG. 2 is a microstructure view of a 2024 aluminum alloy coating according to the present invention.
Detailed Description
In order to make the technical means, the creation features, the achievement purposes and the effects of the invention easy to understand, the invention is further explained in the following with the accompanying drawings and the embodiments.
A method for repairing local damage of an aircraft skin surface in situ by cold spraying comprises the following steps:
polishing the damaged area to remove the damage
And (2) polishing the damaged areas such as microcracks, surface corrosion and the like found by nondestructive inspection to completely remove the damaged defects, manually polishing the damaged areas around the peripheries of the defects to form grooves, wherein the angles of the grooves on the periphery are as close as possible, and the angle of the groove is 120-150 degrees as shown in figure 1, so as to ensure the spraying angle and the coating quality of the cold spraying process.
(II) pretreatment before cold spraying
Before cold spraying, the polished area to be sprayed needs to be subjected to sand blasting treatment. Firstly, the periphery of the sand blasting area is protected by adopting a high-temperature resistant protective adhesive tape so as to prevent the skin on the periphery of the area to be repaired from being damaged by sand blasting. And then acetone is used for cleaning to remove various oil stains and impurities. And finally, adopting a portable sand blasting machine, roughening the area to be sprayed by using 60-80-mesh brown corundum sand, 0.3-0.6 MPa of sand blasting pressure, 150-250 mm of sand blasting distance, 90 +/-20-degree sand blasting angle, 1-2 kg/min of sand output and 20-150 mm/s of sand blasting linear velocity to obtain a surface with the roughness of about Ra6.0-Ra8.0, and finally blowing the sand blasting surface by using compressed air to remove floating sand. Before spraying, the sand-blasting surface can not be touched to prevent pollution.
(III) Cold spray coating
Based on SST-PX type portable cold spraying equipment, 2024 aluminum alloy powder close to skin materials is used as raw materials, and spraying process parameters are as follows: spraying pressure: 170 psi-190 psi; the gas heating temperature is 470-490 ℃; the powder feeding rate is 10 g-20 g; the spraying distance is 10 mm-35 mm; spraying angle: 90 ° ± 20 °; spraying line speed: 10 mm/s-300 mm/s; nitrogen with the purity not less than 99.9 percent is used as the process gas.
And (3) manually repairing the damaged area by an operator according to the process, wherein the repaired coating area is higher than the skin which is not damaged at the periphery, and a margin is left for polishing the coating.
(IV) coating profile sanding
And removing the protective adhesive tape, and polishing the coating by adopting an electric polishing tool, a file, sand paper and the like, wherein the polished surface of the coating is smooth and has no surface defects such as pits and the like. The polished coating profile is as same as the skin profile as possible, and the repaired area has no step difference so as to ensure the original aerodynamic appearance of the airplane. The surface roughness of the coating after polishing is not inferior to Ra0.8.
(V) surface anticorrosion treatment of repaired part
And (3) carrying out antiseptic treatment on the damaged positions of the anodized layer on the surface of the repaired part by using 0.5-0.8% of alodine solution, and drying.
(VI) repair Performance evaluation
The repaired coating performance was evaluated using the following method:
the first method comprises the following steps: and (3) flaw detection is carried out on the repaired part by adopting a visual inspection and dye penetrant inspection method, the repaired coating has no defects such as cracks, pressing pits and the like through the visual inspection and the dye penetrant inspection, and the skin quality inspection is qualified.
And the second method comprises the following steps: preparing a coating sample by adopting the same spraying process, and evaluating the microstructure and microhardness of the sample; the microscopic property test result of the coating shows that as shown in figure 2, the porosity of the coating is lower than 0.5%, the interface inclusion level is about 5%, and the microstructure property of the coating is excellent according to the relevant requirements of American military standard MIL-STD-3021 material deposition cold spraying.
And the third is that: with reference to the GB/T8642-2002 'determination of tensile bonding strength of thermal spraying', three groups of cold spraying bonding strength sample pieces are sprayed by the same spraying process, and the bonding strength of the cold spraying coating is evaluated; the microhardness is between 120HV0.05 and 130HV0.05, and is similar to the surface hardness of the aircraft skin; the bonding strength detection result of the coating shows that the bonding strength of the coating is more than 60MPa, so that the coating and the skin matrix are tightly bonded, and the use requirement is met.
And fourthly: refer to HB5362-86 "Corrosion resistance quality inspection of Metal protective layer for aircraft in general" and GJB/T150.11A-2009 "environmental test method for military Equipment laboratory part 11: salt spray test, three groups of cold spraying corrosion resistance sample pieces are sprayed by the same spraying process, and the repaired alodine corrosion resistance effect is evaluated; salt spray tests prove that the surface corrosion resistance of the repaired skin meets the requirements of HB5362-86 inspection of corrosion resistance quality of metal protective layers commonly used for airplanes.
Compared with the traditional aircraft skin repairing method, the cold spraying repairing method maintains the original aerodynamic shape of the aircraft, has no obvious weight increase, and solves the problems that the aerodynamic shape of the aircraft is damaged and the weight increase of the aircraft is obvious in the traditional repairing method.
The invention provides a method for remanufacturing and repairing skin local damage by cold spraying, which can be manually completed by an operator and provides parameters such as wider spraying distance, moving speed of a spray gun, spraying angle and the like. The portable spraying equipment can be moved to any area needing to be repaired, the method can meet the requirement of in-situ repair of skin damage in most areas on the airplane on the premise of not removing the skin, and the repaired skin can maintain the original appearance and reduce the weight increment of the airplane after traditional repair. The 2024 aluminum alloy powder with the characteristics similar to those of the base material is used as the raw material, and complete spraying parameters are provided, so that the repaired coating has the characteristics similar to those of the skin, cannot become the weak point of the skin structure, and is suitable for repairing the local structural damage of the skin. The invention can effectively reduce the frequency of skin renewal and the maintenance cost of the airplane.
The foregoing shows and describes the general principles, essential features, and advantages of the invention. It will be understood by those skilled in the art that the present invention is not limited to the embodiments described above, which are merely illustrative of the principles of the invention, but that various changes and modifications may be made without departing from the spirit and scope of the invention, which fall within the scope of the invention as claimed. The scope of the invention is defined by the appended claims and equivalents thereof.
Claims (9)
1. A method for repairing local damage of an aircraft skin surface in situ by cold spraying is characterized by comprising the following steps: the method comprises the following steps:
polishing microcracks and surface corrosion areas discovered by nondestructive inspection to completely remove damage defects, and manually polishing to form a groove around the periphery of the defects;
secondly, performing sand blasting pretreatment before spraying on the polished area to be sprayed;
based on SST-PX type portable cold spraying equipment, 2024 aluminum alloy powder close to skin materials is used as raw materials, damaged areas are manually repaired, and the repairing coating areas are higher than the surrounding undamaged skins;
removing the protective adhesive tape, and polishing the coating shape by adopting an electric polishing tool, a file and abrasive paper until the surface is smooth and has no pit and the repaired area has no step difference;
fifthly, using 0.5-0.8% of alodine solution to carry out antiseptic treatment on the damaged positions of the anodized layer on the surface of the repaired part, and drying;
detecting flaws of the repaired part by adopting visual inspection and dye penetrant inspection, and observing whether flaws and craters exist;
and (seventhly), evaluating the microstructure and microhardness of the repaired area, the bonding strength of the coating and the anticorrosion effect of the coating, and judging whether the use requirement is met.
2. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: the bevel angle in the step (I) is 120-150 degrees.
3. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: the specific process of the sand blasting pretreatment before the spraying in the step (II) is as follows:
(a) firstly, protecting the periphery of a sand blasting area by adopting a high-temperature resistant protective adhesive tape;
(b) cleaning with acetone to remove various oil stains and impurities;
(c) carrying out sand blasting by adopting a portable sand blasting machine;
(d) and blowing the sand blasting surface by using compressed air to remove floating sand.
4. The cold spray in-situ repair method for the local damage of the surface of the aircraft skin according to claim 3, wherein the method comprises the following steps: the parameters of the sand blasting process are as follows: the brown corundum sand is 60-80 meshes, the sand blasting pressure is 0.3-0.6 MPa, the sand blasting distance is 150-250 mm, the sand blasting angle is 90 +/-20 degrees, the sand output is 1-2 kg/min, the sand blasting linear velocity is 20-150 mm/s, and the area to be sprayed is coarsened to obtain the surface with the roughness of about Ra6.0-Ra8.0.
5. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: the spraying process parameters in the step (III) are as follows: the spraying pressure is 170-190 psi; the gas heating temperature is 470-490 ℃; the powder feeding rate is 10 g-20 g; the spraying distance is 10 mm-35 mm; the spraying angle is 90 degrees +/-20 degrees; the spraying linear speed is 10 mm/s-300 mm/s; the process gas is nitrogen with a purity of not less than 99.9%.
6. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: and (IV) polishing to ensure that the surface roughness of the coating is not less than Ra0.8.
7. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: the method for evaluating the microstructure and the microhardness in the step (VII) comprises the following steps: by adopting the same spraying process, a coating sample piece is prepared, the sample piece is evaluated, and whether the microstructure and the microhardness of the sample piece meet the requirements or not is judged.
8. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: and (5) evaluating the bonding strength of the coating in the step (seven): and spraying three groups of sample pieces with cold spraying bonding strength by using the same spraying process according to the standard of GB/T8642-2002 'determination of tensile bonding strength of thermal spraying', evaluating the sample pieces, and judging whether the bonding strength of the sample pieces meets the requirements.
9. The cold spraying in-situ repair method for the local damage of the surface of the aircraft skin according to claim 1, wherein the method comprises the following steps: and (seventhly), evaluating the anticorrosive effect of the coating: refer to HB5362-86 "Corrosion resistance quality inspection of Metal protective layer for aircraft in general" and GJB/T150.11A-2009 "environmental test method for military Equipment laboratory part 11: salt spray test, three groups of cold spraying corrosion resistance sample pieces are sprayed by the same spraying process, the sample pieces are evaluated, and whether the corrosion resistance effect of the sample pieces meets the requirements or not is judged.
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Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
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| CN115074719A (en) * | 2022-06-25 | 2022-09-20 | 上海海鹰机械厂 | Composite repairing method for cracks around holes of ordnance casting integral part based on cold spraying additive |
| CN115255805A (en) * | 2022-08-04 | 2022-11-01 | 湖北超卓航空科技股份有限公司 | Method for quickly repairing notch fault of aircraft wing fuel tank skin |
| CN115255804A (en) * | 2022-08-04 | 2022-11-01 | 湖北超卓航空科技股份有限公司 | Rapid repairing method for aircraft fuel tank skin hole fault |
| CN115488331A (en) * | 2022-08-30 | 2022-12-20 | 国营芜湖机械厂 | Cold spraying powder for outer barrel of landing gear and spraying method applying powder |
| CN116840250A (en) * | 2023-09-01 | 2023-10-03 | 北京地铁车辆装备有限公司 | Closed maintenance method for stainless steel roof and vehicle body |
| WO2024078291A1 (en) * | 2022-10-12 | 2024-04-18 | 中车青岛四方机车车辆股份有限公司 | Method and device for repairing damage of mounting surface of axle box body |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN115074719A (en) * | 2022-06-25 | 2022-09-20 | 上海海鹰机械厂 | Composite repairing method for cracks around holes of ordnance casting integral part based on cold spraying additive |
| CN115255805A (en) * | 2022-08-04 | 2022-11-01 | 湖北超卓航空科技股份有限公司 | Method for quickly repairing notch fault of aircraft wing fuel tank skin |
| CN115255804A (en) * | 2022-08-04 | 2022-11-01 | 湖北超卓航空科技股份有限公司 | Rapid repairing method for aircraft fuel tank skin hole fault |
| CN115488331A (en) * | 2022-08-30 | 2022-12-20 | 国营芜湖机械厂 | Cold spraying powder for outer barrel of landing gear and spraying method applying powder |
| CN115488331B (en) * | 2022-08-30 | 2023-09-26 | 国营芜湖机械厂 | Landing gear outer cylinder cold spraying powder and spraying method using same |
| WO2024078291A1 (en) * | 2022-10-12 | 2024-04-18 | 中车青岛四方机车车辆股份有限公司 | Method and device for repairing damage of mounting surface of axle box body |
| CN116840250A (en) * | 2023-09-01 | 2023-10-03 | 北京地铁车辆装备有限公司 | Closed maintenance method for stainless steel roof and vehicle body |
| CN116840250B (en) * | 2023-09-01 | 2024-01-26 | 北京地铁车辆装备有限公司 | Closed maintenance method for stainless steel roof and vehicle body |
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