CN114953617A - Ceramic-fiber-metal super-hybrid laminate and preparation method thereof - Google Patents
Ceramic-fiber-metal super-hybrid laminate and preparation method thereof Download PDFInfo
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- B32B9/005—Layered products comprising a layer of a particular substance not covered by groups B32B11/00 - B32B29/00 comprising one layer of ceramic material, e.g. porcelain, ceramic tile
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Abstract
The invention relates to a ceramic-fiber-metal super-hybrid laminate and a preparation method thereof, the laminate comprises a ceramic plate of which the surface is to be protected, a thermoplastic fiber reinforced resin prepreg layer laid on the inner side of the ceramic plate, a thermosetting fiber reinforced resin prepreg and a metal plate alternately laid structure, wherein the thermosetting fiber reinforced resin prepreg on the outermost layer is laid on the inner side of the thermoplastic fiber reinforced resin prepreg layer, and micron-scale or nano-scale holes are processed on the metal plate and the ceramic plate. The structural style that changes the direct and external environment contact of outer metal of traditional fibre metal laminate, the surperficial metal sheet that will protect replaces into the ceramic plate, the weight of ceramic plate is less than the metal sheet, has reached more lightweight purpose to a certain extent, and the heat resistance of pottery is showing stronger than ordinary metal and alloy simultaneously, and it effectively promotes the heat resistance of laminate to place it outermost to it, and the pottery can utilize to receive the broken characteristics that absorb the impact energy behind the impact, in order to reach the purpose of protection plywood inner structure.
Description
Technical Field
The invention belongs to the technical field of plate composite materials, and particularly relates to a ceramic-fiber-metal super-hybrid laminate and a preparation method thereof.
Background
With the high-speed development of aerospace technology, the spacecraft enters space, human beings increasingly explore the space, and the requirements on light composite materials with heat resistance, impact resistance and easy repair are more and more urgent. Fiber Metal Laminates (FMLs) are super-hybrid composite materials obtained by alternately laying Fiber reinforced resin prepregs and Metal sheets after necessary interface treatment and curing at a certain temperature and pressure. Due to the unique composition of FMLs, the composite material combines the performance advantages of metal and fiber composite materials, has high specific stiffness and specific strength, excellent fatigue resistance and high damage tolerance, draws wide attention of people, and has wide application prospect in the aerospace field.
The FMLs have greatly improved performance compared with a common metal plate, the service environment of an aerospace aircraft is severe, and under the ultrahigh-temperature environment, the heat resistance of the outer metal or alloy plate is insufficient and the laminate can be seriously damaged due to high-temperature melting. The airplane may collide with flying birds during high-speed flight, and the impact resistance of the laminate is insufficient, so that the laminate is broken in a large area. The outermost layer of the fiber metal laminate is metal, so that the fiber metal laminate has conductivity and can be subjected to lightning strike and difficult repair.
Disclosure of Invention
In order to solve the problems, the invention provides a novel ceramic-fiber-metal super-hybrid laminate and a preparation method thereof.
The technical scheme of the invention is as follows:
the utility model provides a novel super mixed plywood of pottery-fibre-metal, this plywood is including treating the ceramic plate of protection surface, the structure of laying in the inboard thermoplastic fiber reinforced resin prepreg layer of ceramic plate, thermosetting fiber reinforced resin prepreg and the metal sheet is laid in turn, and outmost thermosetting fiber reinforced resin prepreg is laid in the inboard of thermoplastic fiber reinforced resin prepreg layer, all processes out micron order or nanometer hole on metal sheet and the ceramic plate. The micron-scale or nano-scale holes can be obtained by processing through anodic oxidation equipment, and the arrangement mode of the holes is random, so that the interface bonding performance of metal and thermosetting fiber reinforced resin prepreg, ceramic and thermoplastic fiber reinforced resin prepreg is better. The thermoplastic fiber reinforced resin prepreg and the thermosetting fiber reinforced resin prepreg both have specific curing curves, require corresponding temperature, pressure and vacuum degree, and are laminated and cured at certain temperature, pressure and vacuum degree in sequence after the laying is well arranged to obtain the laminate. The outermost layer of a traditional fiber metal laminate is metal, and the metal/fiber prepreg is laid according to an n +1/n structure.
The expansion coefficient of the thermoplastic fiber reinforced resin prepreg layer is between that of the thermosetting fiber reinforced resin prepreg and that of the ceramic plate.
The thickness of the thermoplastic fiber reinforced resin prepreg is less than 2/3 of the thickness of the thermosetting fiber reinforced resin prepreg among the metal layers and is more than 1/3 of the thickness of the thermosetting fiber reinforced resin prepreg among the metal layers.
The thermosetting fiber reinforced resin prepreg is an epoxy resin material, the thermal expansion coefficient of the epoxy resin is 50 x 10 < -6 >/DEG C-60 x 10 < -6 >/DEG C, the thermal expansion coefficient of the ceramic material is 4 x 10 < -6 >/DEG C-13 x 10 < -6 >/DEG C, the difference between the thermal expansion coefficient of the thermoplastic fiber reinforced resin prepreg and the thermal expansion coefficient of the ceramic material is not more than the difference between the thermal expansion coefficient of the thermoplastic fiber reinforced resin prepreg and the thermal expansion coefficient of the thermosetting fiber reinforced resin prepreg, so that the deformation of the ceramic and the thermosetting fiber reinforced resin prepreg is synchronous as much as possible, and the phenomenon that the ceramic is damaged from internal stress due to brittleness is avoided;
the ceramic material is at least one of magnesia ceramic, alumina ceramic, steatite ceramic, silicon carbide ceramic, silicon oxide ceramic or silicon nitride ceramic;
the thermoplastic fiber reinforced resin prepreg is at least one of polyimide resin, polyethylene resin, polypropylene resin, polyphenylene sulfide resin, polyether ether ketone resin or polyetherimide resin;
the fiber is at least one of aramid fiber, glass fiber or carbon fiber;
the metal plate is made of light metal material and comprises at least one of aluminum alloy, titanium alloy and magnesium alloy.
The structure of the ceramic-fiber-metal super-hybrid laminate is as follows: 2/2/n +1/n structural lay-up arrangement, where the first 2 represents two ceramic layers, the second 2 is 2 thermoplastic fibre reinforced resin prepreg layers, n represents a total of n metal layers, and n +1 represents the number of layers of thermosetting fibre reinforced resin prepreg layers, where the surface to be protected has only two surfaces;
or the structure of the ceramic-fiber-metal super-hybrid laminate is as follows: 1/1/n/n structural lay-up arrangement, where the first 1 represents a ceramic layer, the second 1 is a thermoplastic fibre reinforced resin prepreg layer, the first n represents the number of layers of thermosetting fibre reinforced resin prepreg layer and the second n represents a total of n metal layers, where the surface to be protected has only one surface.
A method for preparing the ceramic-fiber-metal super-hybrid laminate comprises the steps of preparing a ceramic plate into a required shape in a mould in advance, forming a metal plate into the required shape, ensuring that a fiber layer is soft without forming in advance,
then carrying out surface treatment on the ceramic plate and the metal plate which are prepared into required shapes by laser processing, sand blasting or other processing methods meeting the requirements on size and precision, so that micron/nanometer holes are formed on the surfaces of the ceramic plate and the metal plate;
paving a ceramic plate and a thermoplastic fiber reinforced resin prepreg in a mould in sequence, vacuumizing according to a curing curve of the thermoplastic fiber reinforced resin prepreg, heating to the upper limit of the temperature of the curing curve of the thermoplastic fiber reinforced resin prepreg, and cooling and curing to obtain the whole ceramic plate with the thermoplastic prepreg;
then paving the whole ceramic plate with the thermoplastic prepreg, the thermosetting fiber reinforced resin prepreg and metal plate alternate structure and the whole ceramic plate with the thermoplastic prepreg in a mould in sequence, and then vacuumizing, heating, pressurizing and curing according to the temperature curve of the thermosetting resin; the thermosetting fiber reinforced resin prepreg and the metal plate are alternately laid by a layer of thermosetting fiber reinforced resin prepreg, a layer of metal plate and a layer of thermosetting fiber reinforced resin prepreg; paving the whole ceramic plate with the thermoplastic prepreg, the thermosetting fiber reinforced resin prepreg, the metal plate, the thermosetting fiber reinforced resin prepreg, … … and the whole ceramic plate with the thermoplastic prepreg in sequence, vacuumizing according to the temperature curve of the thermosetting resin, and heating, pressurizing and curing; if only one metal plate is provided, the position of the ellipsis has no content, if a plurality of metal plates are provided, several layers of metal and thermosetting fiber reinforced resin prepregs are arranged in an alternating structure, and the whole ceramic plate with the thermoplastic prepregs is arranged on the surface of the laminate to be protected.
The metal plate is processed into a part with a specific shape by shot peening, roll bending, stamping or hydro-forming; the ceramic plate is prepared by processing ceramic powder into a blank with a specific shape by means of isostatic pressing, injection molding or extrusion molding, and then sintering the blank to obtain a part with a specific shape;
if the parts processed by the metal plate and the parts processed by the ceramic plate are bent parts, after the curing is finished, ultrasonic vibration with the frequency of 20-60Hz and the amplitude of 10-60 mu m is applied to the whole part by using an ultrasonic vibration platform, and the pressure is kept at 0.1-5 MPa for 30s, so that the residual stress of the parts is released, and the high-precision ceramic-fiber-metal super-hybrid laminate is obtained. The pressure maintained during ultrasonic vibration is now close to the pressure used during the previous curing.
Compared with the prior art, the invention has the beneficial effects that:
the ceramic-fiber-metal super-hybrid laminate changes the structural form that the outer layer metal of the traditional fiber metal laminate is directly contacted with the external environment, replaces the surface metal plate to be protected with the ceramic plate, the weight of the ceramic plate is less than that of the metal plate, the aim of lighter weight is achieved to a certain extent, meanwhile, the heat resistance of the ceramic is obviously better than that of common metal and alloy, the ceramic is placed on the outermost layer, the heat resistance of the laminate is effectively improved, and the ceramic can be broken after being impacted to absorb the impact energy, so that the aim of protecting the internal structure of the laminate is achieved. Therefore, the heat-resistant composite material is applied to the aerospace field such as the spacecraft, can enhance the heat resistance of the skin parts of the spacecraft, and enables the spacecraft to work in a higher-temperature environment; when an airplane collides with a bird or other objects, the characteristics that the ceramic on the outer layer has poor toughness, and most of impact energy can be absorbed by the ceramic which is broken and falls off when being impacted can be utilized, so that the impact force on the fiber and metal in the airplane can be effectively reduced, and the inner structure of the airplane can be protected; when the airplane flies at high altitude, the insulating property of the ceramic can effectively prevent the airplane from being struck by lightning; the recycling of the ceramic and the recycling of the thermoplastic resin can also play a role in saving resources and reducing the maintenance cost.
The ceramic has higher heat resistance than metal and alloy thereof, can effectively improve the heat resistance of the laminate when being arranged on the outer layer, is applied to a rocket and an airship, and can improve the heat resistance of the rocket and the airship when the shell and the atmosphere generate heat through violent friction when the rocket enters and exits the atmosphere and the airship returns to the atmosphere (at the moment, the surface to be protected is the surface contacting with the atmosphere); by utilizing the characteristic that most impact energy can be absorbed by breaking and falling off when the ceramic is impacted, the impact force on internal fibers and metal is effectively reduced, and the internal structure of the ceramic is protected.
In the invention, the surface metal is replaced by ceramic, the impact resistance of the laminate can be increased to a greater extent by utilizing the characteristic that the ceramic is broken by impact and absorbs impact energy, the melting point of the ceramic is basically more than 2000 ℃ and higher than the melting points of metal and alloy thereof, and the heat resistance of the laminate is improved.
Drawings
FIG. 1 is a schematic representation of the structure of a ceramic-fiber-metal super-hybrid laminate 2/2/2/1 according to the present invention.
Fig. 2 is a schematic representation of the structure of the ceramic-fiber-metal ultra-hybrid laminate 2/2/3/2 of the present invention.
Fig. 3 is a schematic representation of the construction of a ceramic-fiber-metal super-hybrid laminate bend 2/2/2/1 of the present invention.
Fig. 4 is a schematic representation of the construction of a ceramic-fiber-metal super hybrid laminate tubular member 1/1/1/1 according to the present invention.
FIG. 5 is a schematic view of the holes of the ceramic-fiber-metal super-hybrid laminate according to the present invention after surface processing.
In the figure: 1 a ceramic layer; 2 thermoplastic fiber reinforced resin prepreg layer; 3 thermosetting fiber reinforced resin prepreg layer; 4, a metal layer; 5 surface holes.
Detailed Description
The following embodiments are intended to more clearly illustrate the technical solutions of the present invention and should not be taken as a basis for limiting the scope of the present invention.
The existing fiber metal laminate is generally prepared and then formed into a required shape firstly, but the ceramic forming performance is poor, so that the ceramic plate is required to be prepared into the required shape in advance in a mould, the metal plate is formed into a specific shape in a stamping forming mode and the like, a fiber layer is soft and is not required to be formed in advance, and then the ceramic plate with the required shape, the prepreg and the metal plate with the required shape are sequentially subjected to layering, heating, pressurizing and curing. When the prepreg between the ceramic layer and the metal layer is arranged, a thermoplastic fiber reinforced resin prepreg between the existing thermosetting fiber reinforced resin prepreg and the selected ceramic layer is added.
The thermosetting fiber reinforced resin prepreg can be an epoxy resin material, the thermal expansion coefficient of the epoxy resin is generally 50 x 10 < -6 >/DEG C-60 x 10 < -6 >/DEG C, the thermal expansion coefficient of the ceramic material is 4 x 10 < -6 >/DEG C-13 x 10 < -6 >/DEG C, and the thermoplastic fiber reinforced resin prepreg with the low expansion coefficient between the two materials is added, and the difference between the thermal expansion coefficient of the thermoplastic fiber reinforced resin prepreg and the thermal expansion coefficient of the ceramic material is not more than the difference between the thermal expansion coefficient of the thermoplastic fiber reinforced resin prepreg and the thermal expansion coefficient of the thermosetting fiber reinforced resin prepreg, this makes it possible to synchronize the deformation of the ceramic and thermosetting fiber-reinforced resin prepregs as much as possible, and to avoid the occurrence of a phenomenon in which the ceramic is damaged from the inside due to brittleness.
The ceramic material can be magnesia ceramic, alumina ceramic, steatite ceramic, silicon carbide ceramic, silica ceramic, silicon nitride ceramic and other ceramics with higher thermal expansion coefficient, high temperature resistance and impact absorption performance, and the magnesia ceramic and the steatite ceramic are preferably used, and the thermal expansion coefficient is 13 x 10 (-6)/DEG C. The ceramic material needs to be made of high-temperature-resistant and impact-absorbing ceramic, a plate with enough size can be obtained by designing a die with enough size, different processing modes are selected for the ceramic plate according to different shapes and materials, and the specific preparation process can be realized according to the prior art.
The thermoplastic fiber reinforced resin prepreg can be polyimide resin (the thermal expansion coefficient is 20-30 x 10 < -6 >/DEG C), polyethylene resin, polypropylene resin, polyphenylene sulfide resin, polyether ether ketone resin, polyether imide resin and the like, and the fibers are made of fiber materials capable of realizing the reinforcement effect of the laminate, such as aramid fibers, glass fibers, carbon fibers and the like. The thermal expansion coefficient of the thermoplastic fiber reinforced resin prepreg is between that of the thermosetting and ceramic materials. This transition layer is closer to the coefficient of thermal expansion of the ceramic and its presence can serve to protect the ceramic.
The metal plate material can be aluminum alloy, titanium alloy, magnesium alloy and other light metal materials. The structure of the novel ceramic-fiber-metal super-hybrid laminate provided by the invention can be as follows: 2/2/n +1/n structural lay-up arrangement, where the first 2 represents two ceramic layers, the second 2 is 2 thermoplastic fibre reinforced resin prepreg layers, n represents a total of n metal layers, and n +1 represents the number of thermosetting fibre reinforced resin prepreg layers, where the surface to be protected has only two surfaces. The fiber laying angle is 0 degree, 90 degrees, +/-45 degrees and the like, the specific arrangement of the laying structure is flexibly changed according to different part structures, and the specific laying angle is determined by the type of the processed part and the load type borne by the service space environment. The structure of the ceramic-fiber-metal super-hybrid laminate can be further characterized in that the ceramic layer/the thermoplastic fiber reinforced resin prepreg layer/the thermosetting fiber reinforced resin prepreg layer/the metal layer: 1/1/n/n (see fig. 4), where the first 1 represents a ceramic layer, the second 1 is a thermoplastic fiber reinforced resin prepreg layer, the first n represents the number of layers of thermosetting fiber reinforced resin prepreg layer, and the second n represents a total of n metal layers, where the surface to be protected has only one surface.
The ceramic-fiber-metal super-hybrid laminate changes the structural form that the outermost layer of the traditional fiber metal laminate is metal, and improves the heat resistance and the shock resistance of the traditional fiber metal laminate by utilizing the characteristics of the super heat resistance of ceramic and the capability of absorbing impact energy during crushing. According to the laminated board provided by the invention, the ceramic thin plate is arranged on the outermost side, so that the ceramic is directly contacted with the external environment, the external environment is isolated from the fiber reinforced resin prepreg layer and the metal layer by the ceramic plate, and the heat resistance of the whole laminated board is improved by utilizing the high temperature resistance of the ceramic. Meanwhile, the characteristics that the outermost layer of ceramic can absorb energy when being broken by impact are utilized, most of the impact energy can be taken away by the broken ceramic, and the purpose of protecting the fiber and the metal layer from being damaged is achieved, so that the impact resistance of the laminate is improved. After the outermost layer of ceramic is broken, the residual ceramic on the surface can be knocked off, so that the resource can be recycled, and pollution can not be caused.
According to the ceramic-fiber-metal super-hybrid laminate, a layer of thermoplastic fiber reinforced resin prepreg is added between the ceramic and the thermosetting fiber reinforced resin prepreg, and the ceramic layer is protected by utilizing the characteristic that the thermal expansion coefficient of the thermoplastic resin is close to that of the ceramic. After the ceramic falls off the surface of the thermoplastic resin, the surface of the thermoplastic resin is cleaned and heated and melted under proper conditions, so that the resource recycling can be realized. The insulating ceramic is arranged on the outermost layer, and the problems that the airplane is struck by lightning when flying at high altitude and the like can be effectively prevented. The thickness of the thermoplastic fiber reinforced resin prepreg is less than 2/3 of the thickness of the thermosetting fiber reinforced resin prepreg among the metal layers and is more than 1/3 of the thickness of the thermosetting fiber reinforced resin prepreg among the metal layers.
The ceramic plate on the outer surface of the invention is obtained by different processing methods according to the shape of a target part, firstly, the surface of the ceramic plate which is prepared into the required shape is cleaned necessarily, and then the surface of the ceramic plate which is prepared into the required shape is processed by laser processing, sand blasting or other processing methods meeting the requirements of size and precision, so that micron/nanometer holes are formed on the surface of the ceramic plate. The surface of the metal plate inside needs to be sequentially subjected to alkali washing, acid washing and anodic oxidation treatment.
The invention needs to pre-form the metal plate and the ceramic plate into the required part shape before the layer is solidified, the metal plate is processed into the part, the bent part and the like with the specific shape by shot forming, roll bending forming, press forming, hydraulic forming and the like, the ceramic plate is processed into the blank with the specific shape by the methods of isostatic pressing, injection forming, extrusion forming and the like, and then is processed into the part, the bent part and the like with the specific shape by sintering treatment.
According to the invention, because the curing modes of the thermosetting resin and the thermoplastic resin are different, and the curing temperature of the thermoplastic resin is higher than that of the thermosetting resin, if the thermosetting prepreg is cured firstly, the cured thermosetting prepreg is damaged due to high temperature when the thermoplastic prepreg is cured, so that the thermoplastic resin needs to be cured firstly. In a specific mould, sequentially laying a ceramic plate and a thermoplastic fiber reinforced resin prepreg, vacuumizing according to the curing curve of the thermoplastic fiber reinforced resin prepreg, heating to a certain temperature (according to the curing curve of the thermoplastic resin), cooling and curing to obtain the whole ceramic plate with the thermoplastic prepreg. Then paving the whole ceramic plate with the thermoplastic prepreg, the thermosetting fiber reinforced resin prepreg, the metal plate, the thermosetting fiber reinforced resin prepreg and the whole ceramic plate with the thermoplastic prepreg in a specific mould, vacuumizing according to the temperature curve of the thermosetting resin, heating, pressurizing and curing, thus obtaining the laminate structure with only one metal layer, arranging several layers of alternating structures of the metal and thermosetting fiber reinforced resin prepregs, and arranging the whole ceramic plate with the thermoplastic prepreg on the surface of the laminate to be protected.
Example 1
This example produces a flat laminate:
preparing a magnesium oxide ceramic plate: taking magnesium oxide ceramic raw material powder, adding a proper amount of ceramic catalyst and sintering aid (yttrium oxide, aluminum oxide and titanium oxide), adding a proper amount of water, carrying out ball milling by using a ball mill to obtain plate blank slurry, putting the slurry into a specific mould, carrying out isostatic pressing forming to prepare a ceramic plate, putting the ceramic plate into a high-temperature furnace, carrying out degreasing and sintering, wherein the sintering temperature is 1500 ℃, the heat preservation time is 4 hours, cooling to obtain a ceramic plate, and then carrying out glazing treatment and decontamination treatment on the ceramic plate.
Processing a micropore hole: referring to fig. 5, the holes are processed on the surface of the ceramic by sand blasting, laser processing or other processing methods capable of processing the holes, so that the interface bonding performance of the ceramic and the fiber prepreg is better, and the holes are randomly distributed.
Pretreating a metal plate: and (3) carrying out alkali washing, acid washing decontamination and anodic oxidation treatment on the metal plate.
Preparing a flat plate laminate: paving a magnesia ceramic plate and a carbon fiber reinforced polyether-ether-ketone resin prepreg (a thermoplastic fiber reinforced polyether-ether-ketone resin prepreg) in a mould meeting the size requirement in sequence, vacuumizing according to the curing curve of the carbon fiber reinforced polyether-ether-ketone resin prepreg, heating to 390 ℃ from room temperature at the heating rate of 5 ℃/min, preserving heat for 20min, and then naturally cooling and curing to obtain the whole ceramic plate with the thermoplastic prepreg, wherein the magnesia ceramic plate is arranged outside the carbon fiber reinforced polyether-ether-ketone resin prepreg;
then, paving the whole ceramic plate with the thermoplastic prepreg, the thermosetting fiber reinforced resin prepreg layer 3, the metal layer 4, the thermosetting carbon fiber reinforced epoxy resin prepreg and the whole ceramic plate with the thermoplastic prepreg in a specific mould in sequence, wherein the thermosetting fiber reinforced resin prepreg layer adopts the thermosetting carbon fiber reinforced epoxy resin prepreg, vacuumizing is performed according to the temperature curve of the thermosetting carbon fiber reinforced epoxy resin prepreg, heating is performed from room temperature to 150 ℃ at the heating rate of 3 ℃/min, the temperature is kept for 30nim, and the pressure of 0.1-5 MPa is applied for curing, so that the structure of the ceramic layer/thermoplastic fiber reinforced resin prepreg layer/thermosetting fiber reinforced resin prepreg layer/metal layer 2/2/2/1 is obtained.
Fig. 1 is a schematic view of a laminate structure with only one metal layer, and the structure sequentially includes, from outside to inside, a ceramic layer 1, a thermoplastic fiber reinforced resin prepreg layer 2, a thermosetting fiber reinforced resin prepreg layer 3, a metal layer 4, a thermosetting fiber reinforced resin prepreg layer 3, a thermoplastic fiber reinforced resin prepreg layer 2, and a ceramic layer 1.
Fig. 2 is a schematic diagram of a laminate structure having two metal layers, which includes, from outside to inside, a ceramic layer 1, a thermoplastic fiber-reinforced resin prepreg layer 2, a thermosetting fiber-reinforced resin prepreg layer 3, a metal layer 4, a thermosetting fiber-reinforced resin prepreg layer 3, a thermoplastic fiber-reinforced resin prepreg layer 2, and a ceramic layer 1. The thickness of the thermosetting fiber reinforced resin prepreg layer positioned between the two metal layers is twice that of the thermoplastic fiber reinforced resin prepreg layer, and the thickness of the thermosetting fiber reinforced resin prepreg layer positioned between the metal layers and the thermoplastic fiber reinforced resin prepreg layer is equal to that of the thermoplastic fiber reinforced resin prepreg layer.
After the flat plate laminate is prepared, forming processes such as stretching, bending and the like are not needed (the flat plate laminate is prepared, and the shape and the size are just needed), so the problem that the laminate is damaged in the forming process due to poor toughness of the outer layer ceramic is solved.
Example 2
The ceramic-fiber-metal super-hybrid laminate of the embodiment is used for preparing parts with larger curvature, and the larger the curvature is, the larger the bending degree is. The specific process is as follows:
preparing a ceramic plate meeting curvature requirements: taking ceramic raw material powder, adding a binder according to a certain proportion, uniformly mixing, applying an injection molding process, putting the uniformly mixed raw materials into an injection device, injecting the raw materials into a mold at a certain injection pressure to form a ceramic blank, putting the ceramic blank into a high-temperature furnace for degreasing and sintering, wherein the sintering temperature is 1500 ℃, the heat preservation time is 4 hours, cooling to obtain a ceramic curved surface part with a required shape, and glazing and decontaminating.
Processing a micropore hole: the holes are machined on the surface of the ceramic by sand blasting, laser machining or other machining methods capable of machining the holes.
Metal plate pretreatment: and (3) carrying out alkali washing, acid washing decontamination and anodic oxidation treatment on the aluminum alloy metal plate meeting the curvature requirement.
Preparing a large-curvature laminate: referring to fig. 3, paving ceramic plates and carbon fiber reinforced polyether ether ketone resin prepregs which meet curvature requirements in sequence in a mold, vacuumizing according to a curing curve of the carbon fiber reinforced polyether ether ketone resin prepregs, heating from room temperature to 390 ℃ at a heating rate of 5 ℃/min, preserving heat for 20min, and then naturally cooling and curing to obtain the whole ceramic plate with the magnesium oxide ceramic plate outside and the thermoplastic prepregs inside the carbon fiber reinforced polyether ether ketone resin prepregs;
then paving the whole ceramic plate with the thermoplastic prepreg, the thermosetting carbon fiber reinforced epoxy resin prepreg, the metal plate, the thermosetting carbon fiber reinforced epoxy resin prepreg and the whole ceramic plate with the thermoplastic prepreg in a specific mould, wherein the curvatures of all layers are consistent after paving, the edge sections of all layers are flush, vacuumizing according to the temperature curve of the thermosetting carbon fiber reinforced epoxy resin prepreg, heating to 150 ℃ from room temperature at the heating rate of 3 ℃/min, preserving heat for 30min and applying the pressure of 0.1-0.5 MPa for curing;
after the solidification is finished, an ultrasonic vibration platform is utilized to apply ultrasonic vibration with the frequency of 20-60Hz and the amplitude of 10-60 mu m to the whole part, and the pressure is kept at 0.1-0.5 MPa for 30s, so that the residual stress of the part is released, and the high-precision part is obtained. The aging treatment is carried out on the part, so that the residual stress of the part can be eliminated, and the problem that the integral precision of the part is not enough due to the rebound of metal because the metal bending part has the residual stress is solved.
Example 3
The ceramic-fiber-metal super-hybrid laminate of the embodiment is used for preparing a tubular member, and referring to fig. 4, the inside of the tubular member is not in contact with the atmosphere and does not need protection, so that the ceramic plate is not arranged inside the tubular member, the outer surface of the tubular member can be in contact with the atmosphere to generate friction to be a surface needing protection, and the ceramic surface is arranged on the outer surface of the tubular member. The preparation process comprises the following steps:
preparing a ceramic tubular part meeting the size requirement: taking ceramic raw material powder, adding a proper amount of water, a binder and a lubricant, uniformly mixing to obtain pug, applying an extrusion forming method, putting the pug into an extruder, pushing a piston by using a hydraulic press at a proper speed, extruding a plasticized blank from a specific tubular extrusion nozzle in vacuum to form a ceramic tubular blank, putting the ceramic tubular blank into a high-temperature furnace for degreasing and sintering, wherein the sintering temperature is 1500 ℃, the heat preservation time is 4 hours, cooling to obtain a ceramic tubular part, and glazing and decontaminating.
Processing a micropore hole: and machining the holes on the surface of the ceramic tubular part by sand blasting, laser machining or other machining methods capable of machining the holes.
Pretreating a metal pipe: and (3) carrying out alkali washing, acid washing decontamination and anodic oxidation treatment on the metal pipe fitting.
Preparing a tubular piece laminate: referring to fig. 4, firstly, sequentially laying a ceramic tubular part and a carbon fiber reinforced polyether-ether-ketone resin prepreg in a specific mold, vacuumizing according to a curing curve of the carbon fiber reinforced polyether-ether-ketone resin prepreg, heating from room temperature to 390 ℃ at a heating rate of 5 ℃/min, preserving heat for 20min, and then naturally cooling and curing to obtain a ceramic tube whole with the ceramic tubular part outside and the carbon fiber reinforced polyether-ether-ketone resin prepreg inside and provided with the thermoplastic prepreg;
when the tubular piece is prepared, because the pressure can not be directly applied to the tubular piece from the outside, the pressure is applied to the metal layer in the tubular piece by using an air pressure bulging technology;
laying layers in a specific mould according to the sequence of the whole ceramic pipe with the thermoplastic prepreg, the thermosetting carbon fiber reinforced epoxy resin prepreg and the metal pipe, sealing two ends of the tubular part after laying layers and leaving an inflation inlet, conveying gas through the inflation inlet, applying air pressure of 0.1-5 MPa to the interior of the tubular part, heating the tubular part to 150 ℃ from room temperature at the heating rate of 3 ℃/min according to the temperature curve of the thermosetting carbon fiber reinforced epoxy resin prepreg, and curing at the heat preservation pressure of 30 nim. The tubular part also has the problem of springback caused by residual stress, so the residual stress of the part also needs to be eliminated by aging treatment, after the solidification is finished, the ultrasonic vibration platform is utilized to apply ultrasonic vibration with the frequency of 20-60Hz and the amplitude of 10-60 mu m to the whole part, and the pressure is kept at 0.1-5 MPa for 30s, so that the residual stress of the part is released, and the high-precision part is obtained.
Nothing in this specification is said to apply to the prior art.
Claims (9)
1. The ceramic-fiber-metal super-hybrid laminate is characterized by comprising a ceramic plate with a surface to be protected, a thermoplastic fiber reinforced resin prepreg layer paved on the inner side of the ceramic plate, a thermosetting fiber reinforced resin prepreg and a metal plate alternately paved structure, wherein the thermosetting fiber reinforced resin prepreg on the outermost layer is paved on the inner side of the thermoplastic fiber reinforced resin prepreg layer, and micron-scale or nano-scale holes are machined in the metal plate and the ceramic plate.
2. The ceramic-fiber-metal super-hybrid laminate of claim 1, wherein the coefficient of expansion of the thermoplastic fiber-reinforced resin prepreg layer is between the coefficient of expansion of the thermoset fiber-reinforced resin prepreg and the coefficient of expansion of the ceramic plate.
3. The ceramic-fiber-metal superhybrid laminate of claim 1, wherein the thickness of the thermoplastic fiber-reinforced resin prepreg is less than 2/3 the thickness of the thermosetting fiber-reinforced resin prepreg between metal layers and greater than 1/3 the thickness of the thermosetting fiber-reinforced resin prepreg between metal layers.
4. The ceramic-fiber-metal super-hybrid laminate according to claim 1, wherein the thermosetting fiber-reinforced resin prepreg is an epoxy resin material, the epoxy resin has a thermal expansion coefficient of 50 x 10 (-6)/DEG C to 60 x 10 (-6)/DEG C, the ceramic material has a thermal expansion coefficient of 4 x 10 (-6)/DEG C to 13 x 10 (-6)/DEG C, and the difference between the thermal expansion coefficient of the thermoplastic fiber-reinforced resin prepreg and the thermal expansion coefficient of the ceramic material is not greater than the difference between the thermal expansion coefficient of the thermoplastic fiber-reinforced resin prepreg and the thermal expansion coefficient of the thermosetting fiber-reinforced resin prepreg;
the ceramic material is at least one of magnesia ceramic, alumina ceramic, steatite ceramic, silicon carbide ceramic, silicon oxide ceramic or silicon nitride ceramic;
the thermoplastic fiber reinforced resin prepreg is at least one of polyimide resin, polyethylene resin, polypropylene resin, polyphenylene sulfide resin, polyether ether ketone resin or polyetherimide resin;
the fiber is at least one of aramid fiber, glass fiber or carbon fiber;
the metal plate is made of light metal material and comprises at least one of aluminum alloy, titanium alloy and magnesium alloy.
5. The ceramic-fiber-metal super-hybrid laminate according to claim 1, wherein the micro-or nano-scale pores are obtained by processing and processing through an anodic oxidation device, and the arrangement of the pores is random; the thermoplastic fiber reinforced resin prepreg and the thermosetting fiber reinforced resin prepreg both have specific curing curves, require corresponding temperature, pressure and vacuum degree, and are laminated and cured in sequence after the laying is well arranged to obtain the laminate.
6. The ceramic-fiber-metal super-hybrid laminate according to claim 1, wherein the structure of the ceramic-fiber-metal super-hybrid laminate is as follows: 2/2/n +1/n structural lay-up arrangement, where the first 2 represents two ceramic layers, the second 2 is 2 thermoplastic fibre reinforced resin prepreg layers, n represents a total of n metal layers, and n +1 represents the number of layers of thermosetting fibre reinforced resin prepreg layers, where the surface to be protected has only two surfaces;
or the structure of the ceramic-fiber-metal super-hybrid laminate is as follows: 1/1/n/n structural lay-up arrangement, where the first 1 represents a ceramic layer, the second 1 is a thermoplastic fibre reinforced resin prepreg layer, the first n represents the number of layers of thermosetting fibre reinforced resin prepreg layer and the second n represents a total of n metal layers, where the surface to be protected has only one surface.
7. A method of making a ceramic-fiber-metal super-hybrid laminate according to claim 1, wherein the ceramic plate and the metal plate are previously formed into a desired shape,
then, carrying out surface treatment on the ceramic plate and the metal plate which are prepared into the required shapes through laser processing or sand blasting processing, so that micron/nanometer holes are formed on the surfaces of the ceramic plate and the metal plate;
paving a ceramic plate and a thermoplastic fiber reinforced resin prepreg in a mould in sequence, vacuumizing according to a curing curve of the thermoplastic fiber reinforced resin prepreg, and heating to the upper limit of the temperature of the curing curve of the thermoplastic fiber reinforced resin prepreg for cooling and curing to obtain the whole ceramic plate with the thermoplastic prepreg;
and then layering the whole ceramic plate with the thermoplastic prepreg, the thermosetting fiber reinforced resin prepreg and metal plate alternating structure and the whole ceramic plate with the thermoplastic prepreg in a mould in sequence, and then vacuumizing, heating, pressurizing and curing according to the temperature curve of the thermosetting resin.
8. The method of making a ceramic-fiber-metal super-hybrid laminate according to claim 7, wherein the metal sheet is formed into a part having a specific shape by shot peening, roll bending, press forming or hydroforming; the ceramic plate is prepared by processing ceramic powder into a blank with a specific shape by means of isostatic pressing, injection molding or extrusion molding, and then sintering the blank to obtain a part with a specific shape;
if the parts processed by the metal plate and the parts processed by the ceramic plate are bent parts, after the curing is finished, ultrasonic vibration with the frequency of 20-60Hz and the amplitude of 10-60 mu m is applied to the whole part by using an ultrasonic vibration platform, and the pressure is kept at 0.1-5 MPa for 30s, so that the residual stress of the parts is released, and the high-precision ceramic-fiber-metal super-hybrid laminate is obtained.
9. Use of a ceramic-fiber-metal ultra-hybrid laminate according to any one of claims 1 to 6 or obtained by the preparation method according to any one of claims 7 to 8, in spacecraft, aeronautical aircraft, rocket or spacecraft.
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