Disclosure of Invention
The invention aims to provide a method and a device for repairing the damage of a thermoplastic composite material, which are used for solving the problems in the prior art, so that the impact damage of the thermoplastic composite material can be quickly repaired, and the applicability of the thermoplastic composite material is greatly improved.
In order to achieve the purpose, the invention provides the following scheme: the invention provides a method for repairing damage of a thermoplastic composite material, which comprises the following steps:
determining the damage condition: determining the impact damage position and the damage area of the thermoplastic composite material;
selecting a tool: selecting two heating flat plates which are matched with the shape of the area to be repaired on the thermoplastic composite material, cleaning the heating flat plates, and smearing a release agent on the surface of the joint of the heating flat plates and the thermoplastic composite material;
selecting a demoulding material: preparing a demolding material with a structure larger than a to-be-repaired area on the thermoplastic composite material;
heating and repairing: placing and covering the demolding material on the thermoplastic composite material at the position of the area to be repaired, covering and pressing one heating flat plate on one side of the demolding material far away from the area to be repaired, placing the other heating flat plate on one side of the thermoplastic composite material far away from the demolding material and corresponding to the position of the area to be repaired, heating the two heating flat plates to be above the melting temperature of the thermoplastic composite material, applying required repairing pressure to the two heating flat plates, enabling the two heating flat plates to clamp the thermoplastic composite material and the demolding material and keeping the required repairing pressure for required time, then keeping the required repairing pressure, cooling the heating flat plates to be at the required temperature, withdrawing the heating flat plates, and cleaning the demolding material on the thermoplastic composite material;
checking and repairing: and carrying out nondestructive testing on the repaired thermoplastic composite material, and checking the repairing effect.
Preferably, the thermoplastic composite comprises a resin matrix filled with reinforcement fibers for enhancing its structural strength.
Preferably, the reinforcement fibers include, but are not limited to, carbon fibers, glass fibers, basalt fibers, and aramid fibers.
Preferably, the resin matrix includes, but is not limited to, PEEK, PAEK, PPS thermoplastic resin.
Preferably, the detection process in the steps of determining the damage condition and checking and repairing is nondestructive detection, and the nondestructive detection adopts ultrasonic scanning detection or ray detection or acoustic emission detection.
Preferably, in the step of selecting the demolding material, the area of the demolding material is more than 150% of the area of the region to be repaired, and the demolding material covers the region to be repaired.
Preferably, in the heating repairing step, the heating temperature of the heating flat plate is 10 to 25 ℃ higher than the melting temperature of the thermoplastic composite material.
Preferably, in the heating repair step, the required repair pressure is 1MPa < P < 5MPa.
Preferably, in the heat-repairing step, the time required is 15min to 60min.
The device comprises an upper loading arm and a lower loading arm which are hinged, wherein one end of the upper loading arm is hinged with an upper support, the other end of the upper loading arm is connected with a hook, a lower support is fixed at one end of the lower loading arm corresponding to the upper support, an electric telescopic rod is hinged at one end of the lower loading arm corresponding to the hook, the end part of the electric telescopic rod is connected with the hook, heating flat plates capable of covering an area to be repaired are arranged on one sides of the upper support and the lower support close to each other respectively, and the two heating flat plates are clamped on the surfaces of the two sides of the area to be repaired.
Compared with the prior art, the invention has the following technical effects:
firstly, through confirming the damage condition, selecting a tool, selecting a demolding material, heating, repairing, checking, repairing and other repairing steps, the low-speed impact damage of the thermoplastic composite material can be effectively repaired, the application capability of the thermoplastic composite material is improved, the surface quality of the thermoplastic composite material in the repairing process can be guaranteed, the appearance of the thermoplastic composite material is greatly maintained, and the emergency use requirement is met.
Secondly, the upper loading arm and the lower loading arm are driven to rotate through the electric telescopic rod, the upper support and the lower support are driven to be matched with each other, the two heating flat plates are clamped on two sides of a region to be repaired and can reach the corresponding temperature for melting materials, the two heating flat plates customized according to the shape of the thermoplastic composite material are used as an auxiliary material, the thermoplastic composite material resin matrix can have certain flow, the defects of cracks, layering and the like in the composite material are filled under the effect of repairing pressure, the internal damage of the thermoplastic composite material is repaired, the mechanical property of the thermoplastic composite material is recovered to the maximum degree, the thermoplastic composite material can meet the using requirement, and the repairing effects of quick detachment, quick repair, stable shape and reliable quality can be achieved.
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 derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.
The invention aims to provide a method and a device for repairing damage of a thermoplastic composite material, which are used for solving the problems in the prior art, so that impact damage of the thermoplastic composite material can be quickly repaired, and the applicability of the thermoplastic composite material is greatly improved.
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.
As shown in fig. 1 to 5, the present embodiment provides a method for repairing damaged thermoplastic composite material, especially for repairing damaged high-performance thermoplastic composite material, including the following steps:
and (3) determining the damage condition: determining the impact damage position and the damage area of the thermoplastic composite material;
selecting a tool: selecting two heating flat plates which are matched with the shape of an area to be repaired on the thermoplastic composite material, cleaning the heating flat plates, and smearing a release agent on the surface of the joint of the heating flat plates and the thermoplastic composite material; preferably, the cleaning agent adopted in the cleaning operation is a mold cleaning agent which can remove impurities and chemical residues on the working surface of the repair tool, the release agent is a high-temperature release agent, the temperature resistance level of the release agent is higher than the processing temperature, the high temperature resistance level ensures that the release agent does not lose efficacy in the repair process, the composite material can be smoothly released, and the composite material has high surface quality;
selecting a demoulding material: preparing a demoulding material with a structure larger than a to-be-repaired area on the thermoplastic composite material; preferably, the temperature resistance grade of the heating plate is higher than the repairing temperature of the thermoplastic composite material, the heating plate completely covers an impact damage area of the thermoplastic composite material, the demolding material and the demolding agent are cooperatively used, a good demolding effect and high surface quality can be obtained, specifically, after repairing is avoided through the demolding material, the heating plate cannot be sufficiently separated from the thermoplastic composite material, the surface of the thermoplastic composite material is damaged under the influence of the heating plate, the heating plate can be contacted with the thermoplastic composite material through the demolding material, in the demolding process, the heating plate can be rapidly separated from the thermoplastic composite material through the demolding material, and the demolding agent is arranged between the heating plate and the demolding material, so that the phenomenon that the demolding material is adhered to the heating plate in the molding process and influences on cleaning of a subsequent heating plate are avoided; preferably, the demolding material adopts a polyimide film and high-temperature demolding cloth, the thermoplastic composite material is attached to the polyimide film, the polyimide film is attached to the high-temperature demolding cloth, and the high-temperature demolding cloth is attached to the heating flat plate;
heating and repairing: placing and covering a demoulding material on a to-be-repaired area on a thermoplastic composite material, covering and pressing a heating flat plate on one side of the demoulding material far away from the to-be-repaired area, placing another heating flat plate on one side of the thermoplastic composite material far away from the demoulding material and corresponding to the to-be-repaired area, heating the two heating flat plates to be above the melting temperature of the thermoplastic composite material, applying required repairing pressure on the two heating flat plates, enabling the two heating flat plates to clamp the thermoplastic composite material and the demoulding material tightly and keep the required repairing pressure for required time, then keeping the required repairing pressure, cooling the heating flat plates to be at required temperature, removing the heating flat plates, and cleaning the demoulding material on the thermoplastic composite material; heating a heating flat plate to a temperature above the melting temperature of the thermoplastic composite material, applying required repair pressure for a required time, then maintaining the repair pressure and cooling to the required temperature, wherein the required heating temperature can enable a resin matrix of the thermoplastic composite material to have certain flow, and filling the defects of cracks, layering and the like in the composite material under the action of the repair pressure, so that the internal damage of the thermoplastic composite material is repaired, the mechanical property of the thermoplastic composite material is recovered to the maximum extent, and the thermoplastic composite material meets the use requirement;
preferably, in the heating and repairing step, the heating temperature (namely, the repairing temperature) of the heating flat plate is 10-25 ℃ higher than the melting temperature of the thermoplastic composite material, the required repairing pressure is 1MPa to less than P to less than 5MPa, and the required time is 15-60 min; specifically, the repairing temperature T, the repairing pressure P and the repairing pressure T are adjusted finely along with the thickness of the thermoplastic composite material, when the thickness h of the thermoplastic composite material is less than 3mm, the repairing temperature T is more than the melting temperature Tm of the thermoplastic composite material and is (10-15 ℃), the repairing pressure is more than 1MPa and less than P and less than 2MPa, and the repairing pressure is more than 1MPa and less than T and less than 30min after 15min; when the thickness is more than 3mm and less than 5mm, the repairing temperature T is more than the melting temperature Tm of the thermoplastic composite material and is (15-20 ℃), the repairing pressure is more than 2MPa and less than 3MPa, and more than 30min and less than T and 45min; when the thickness is more than 5mm and less than h and less than 8mm, the repair temperature T is more than the melting temperature Tm of the thermoplastic composite material and is (20-25 ℃), the repair pressure is more than 3MPa and less than 5MPa, and more than 45min and less than T and less than 60min, the repair process can select proper repair conditions according to the thickness of the composite material, the proper temperature can enable the resin matrix of the composite material to have certain flow, and the defects of cracks, layering and the like in the composite material are filled under the action of the repair pressure, so that the internal damage of the thermoplastic composite material is repaired, the mechanical property of the thermoplastic composite material is recovered to the maximum extent, and the thermoplastic composite material meets the use requirement;
checking and repairing: and carrying out nondestructive testing on the repaired thermoplastic composite material, and checking the repairing effect.
Preferably, the thermoplastic composite material comprises a resin matrix, the resin matrix is filled with reinforcement fibers for enhancing the structural strength of the resin matrix, and the composite material of the resin matrix and the reinforcement fibers can adapt to complex service environments and meet the use requirements of most structures. Preferably, the reinforcement fibers include, but are not limited to, carbon fibers, glass fibers, basalt fibers, aramid fibers. And preferably, the resin matrix includes, but is not limited to, PEEK, PAEK, PPS thermoplastic resin, so that the entire resin matrix has excellent mechanical properties.
Further, the detection process in the steps of determining the damage condition and checking and repairing is nondestructive detection, and the nondestructive detection adopts ultrasonic scanning detection or ray detection or acoustic emission detection to detect the flaw and detect the repaired thermoplastic composite material so as to ensure the repairing effect of the thermoplastic composite material. Preferably, the nondestructive testing method is ultrasonic scanning, the ultrasonic scanning equipment has the advantage of portability, the damage position and the damage area of the composite material can be detected, and the use requirement of rapid detection can be met.
In the step of selecting the demoulding material, the area of the demoulding material is more than 150% of the area to be repaired, and the demoulding material covers the area to be repaired.
In the heating and repairing step, the heating temperature of the heating flat plate is 10-25 ℃ higher than the melting temperature of the thermoplastic composite material.
In the heating repairing step, the required repairing pressure is more than 1MPa and less than 5MPa.
In the heat-repairing step, the time required is 15min to 60min.
The device comprises an upper loading arm and a lower loading arm which are hinged, wherein one end of the upper loading arm is hinged with an upper support, the other end of the upper loading arm is connected with a hook, a lower support is fixed at one end of the lower loading arm corresponding to the upper support, an electric telescopic rod is hinged at one end of the lower loading arm corresponding to the hook, the end part of the electric telescopic rod is connected with the hook, heating flat plates capable of covering an area to be repaired are arranged on one sides of the upper support and the lower support, which are close to each other, respectively, and the two heating flat plates are clamped on the surfaces of two sides of the area to be repaired. The upper support is connected with the lower loading arm through a pin hole structure, the lower support is fixed on the upper loading arm, so that the loading arm can uniformly apply pressure on the template, the two heating flat plates are customized according to the shape of the damaged area of the thermoplastic composite material, and can be quickly disassembled and replaced; the heating rods are positioned at the openings of the two heating flat plates and can apply stable temperature through the temperature control system; the electric telescopic rod is connected with the upper loading arm and the lower loading arm through the hooks, pressure can be applied to the lower template, the two heating flat plates can be replaced by the tool for meeting the repairing requirements of composite materials with different shapes, and the damage of different positions can be repaired by prolonging the loading force arm.
As a preferred embodiment of the present invention, impact damage repair at 25J energy is provided if faced with a 150mm by 100mm by 4.5mm flat sheet of carbon fiber reinforced PAEK thermoplastic composite.
The method comprises the following steps: carrying out nondestructive testing on the impacted carbon fiber reinforced PAEK thermoplastic composite material by adopting an ultrasonic scanning microscope, and determining that the damage area of the composite material is about 5.4cm 2 The internal damage shape is an ellipse;
step two: selecting a flat plate tool with the shape consistent with that of the thermoplastic composite material repairing area;
step three: cleaning a flat plate tool for repairing impact damage of the thermoplastic composite material by using sand paper and a mould cleaning agent, and smearing a release agent;
step four: cutting the demolding material with the area larger than 150% of the impact damage area of the composite material, and enabling the demolding material to completely cover the damage area of the thermoplastic composite material;
step five: the thermoplastic composite material is attached to a demolding material, and the demolding material is attached to a flat tool coated with a demolding agent;
step six: raising the temperature of the flat plate tool to 340 ℃; and applying a pressure of 2 MPa; maintaining the temperature and pressure for 30min;
step seven: and 4, carrying out nondestructive testing on the repaired thermoplastic composite material by adopting an ultrasonic scanning microscope, and checking the repairing effect.
According to the repairing method, the impact damage of the carbon fiber reinforced PAEK thermoplastic composite material flat plate with the thickness of 150mm multiplied by 100mm multiplied by 4.5mm under the energy of 25J can be repaired well.
As a preferred embodiment of the present invention, if a carbon fiber reinforced PEEK thermoplastic composite flat plate of 150mm × 100mm × 5mm is faced, the impact damage is repaired under 30J energy.
The method comprises the following steps: carrying out nondestructive testing on the impacted carbon fiber reinforced PEEK thermoplastic composite material by adopting an ultrasonic scanning microscope, and determining that the damage area of the composite material is about 5.6cm 2 Inside, ofThe shape of the lesion is elliptical;
step two: selecting a flat plate tool with the shape consistent with that of the thermoplastic composite material repairing area;
step three: cleaning a flat tool for repairing impact damage of the thermoplastic composite material by using abrasive paper and a mold cleaning agent, and smearing a release agent;
step four: cutting the demoulding material with the area larger than 150% of the impact damage area of the composite material, and enabling the demoulding material to completely cover the damage area of the composite material;
step five: bonding a thermoplastic composite material with a demolding material, and bonding the demolding material with a flat tool coated with a demolding agent;
step six: raising the temperature of the flat plate tool to 390 ℃; and applying a pressure of 4 MPa; maintaining the temperature and pressure for 45min;
step seven: and carrying out nondestructive testing on the repaired thermoplastic composite material by adopting an ultrasonic scanning microscope, and inspecting the repairing effect.
According to the repairing method, the impact damage of the carbon fiber reinforced PEEK thermoplastic composite material flat plate with the diameter of 150mm multiplied by 100mm multiplied by 5mm under the energy of 30J can be repaired to be good.
The adaptation according to the actual needs is within the scope of the invention.
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. Any reference sign in a claim should not 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.