航空发动机用耐高温热塑性树脂基复合材料及其服役条件下结构、缺陷及性能演变机理

In order to realize the target of lightweight aero-engine, and to dissolve the problems of the poor impact toughness and insufficient high temperature performance of thermosetting composites for aeroengine fan stator blades and casing, this project will focus on the design and preparation series of high strength, high toughness phthalazinone-containing poly(aryl ether) resins and the corresponding fiber-reinforced composites with different heat resistance grades (200-300 oC and 350 oC). The high performance matrix resins can be controllably prepared with low cost by tuning the molecular structure of polymer backbone and optimizing the polymerization process. The processing technology of the fiber-reinforced thermoplastic resin based composite prepregs will be optimized. And the matching relationship between matrix resin and fiber of prepregs and composites will be studied. Moreover, the processing technologies of composite, including thermal forming, welding and so on, will be studied. We will systematically study the structure and defect evolution mechanism of composite materials under preparation and service conditions, and establish methods for defect control. The relationship between structure, preparing process and properties of the heat-resistant thermoplastic resin matrix composites will be clarified. Finally, lightweight, heat-resistant, high performance, phthalazinone-based thermoplastic resin matrix composites will be obtained to meet the performance requirements of aero-engine fan casings and stator blades. It’ll provide experimental and theoretical basis for the development of aeroengine technology, and solve the major strategic demand for the aero engine technological progress and industrial development in China.

为了实现航空发动机轻量化的目标，针对航空发动机风扇静子叶片和机匣用热固性复合材料冲击韧性欠佳、高温性能不足等问题，设计、制备具有不同耐温等级（200-300 ℃和350 ℃）、高强、高韧系列含二氮杂萘酮联苯结构聚芳醚基体树脂及复合材料。通过调节聚合物主链的分子结构，优化聚合工艺，实现高性能基体树脂的低成本、可控制备；优化新型热塑性树脂基复合材料预浸带制备工艺，研究基体树脂与纤维匹配关系，研究复合材料的热成型、焊接等加工技术。系统研究复合材料在制造和服役条件下的结构和缺陷的演变机理，建立缺陷的调控方法，阐明耐高温热塑性树脂基复合材料结构、制备工艺与性能关系，获得满足航空发动机风扇机匣和静子叶片性能要求的轻质、耐高温、高性能含二氮杂萘酮联苯结构聚芳醚热塑性树脂基复合材料，为航空发动机相关零部件的设计提供实验和理论依据，解决我国航空发动机技术进步和产业发展的重大战略需求。

分别设计、合成了三个系列具有不同耐热等级的杂萘联苯结构聚芳醚树脂，玻璃化转变温度最高可达368 ℃，同时具有良好的溶解性和力学性能；研究聚合物化学结构对溶液流变性能、熔体流变性能的影响规律，进而研究聚合物的合成工艺和结构优化调控方法，实现树脂基体分子结构可控性和聚合工艺的稳定性。采用溶液浸渍工艺制备预浸带。系统地研究预浸带的制备工艺以及树脂溶液的化学流变特性，进而建立粘度-时间-温度关系流变特性关系式，确定最佳浸胶液配方和浓度。优化了预浸工艺，控制预浸带挥发份、面密度和单层厚度，并系统分析预浸带缺陷及其造成原因。.研究不同的预浸带的工艺参数对单向层合板的力学性能影响；进而探明预浸带的缺陷形成机理和对模压工艺的遗传特性；研究模压工艺对复合材料内部缺陷形成机理和综合性能的影响；并通过在层间加入负载纳米氧化锌的静电纺丝膜等手段提高复合材料的层间性能，结果表明，复合材料层压板的层间韧性显著提升（Ⅱ型层间断裂韧性值提升至2.62 kJ/m2，增幅达112%），研究了静电纺丝膜分子结构对单向层合板抗分层性能的影响规律。.搭建了电阻焊接工艺原理验证平台，研究了碳纤维增强杂萘联苯结构聚芳醚树脂基复合材料的电阻焊成型工艺仿真、成型工艺、缺陷和性能，通过对加热元件和焊接面的表面处理，显著提升的复合材料之间的焊接强度（拉剪强度最高可达48MPa）。