纤维-铝合金复合层板构件制备成形一体化技术基础研究

In order to realize weight reduction and enhance effective carrying capacity, it’s very urgent to use Fiber Aluminum Laminates (FALs) components during manufacturing new heavy lift launch vehicles and wide body aircrafts. The traditional forming method of these parts is making FALs firstly and then carrying out forming processes. However, two serious problems are difficult to overcome including delaminating and wrinkling. To solve these defects, an integrated method of manufacturing with forming of FALs is proposed in this project, combining gas forming and curing in one operation. The fiber composite layer and aluminum alloy layer were placed with each other according to a certain rule. Then the layers were put into forming die and heated to curing temperature. Hot gas forming process was conducted with the curing going on. Finally a FALs component could be obtained after cooling. The emphasis was put on the variation and distribution of stress and strain during the gas forming/curing integrated process. The plastic deformation behavior of FALs components during the hybrid process was analyzed. The coordinate deformation mechanism of normal non-homogeneous sheet based on interface features was revealed. The control of mechanical property and deformation mechanism of curved surface shells under thermal mechanical coupling condition were clarified. The defects during forming and curing and corresponding prevention method were discussed. Systematic research on integration of manufacturing and forming was carried out to provide theoretical support for the application of hybrid process in aerospace industry.

新一代重型运载火箭和宽体客机迫切需要采用纤维-铝合金复合层板构件实现轻量化，提高有效运载能力。传统成形方法为先制备纤维-铝合金复合层板再成形，存在层间剥离与失稳起皱等缺陷难以克服。为解决上述难题，本项目提出纤维-铝合金复合层板构件制备成形一体化技术，基本原理是按一定规则分层铺设纤维复合材料与铝合金板，然后在模具内加热至固化温度，在纤维复合材料固化的同时进行热态气压成形，获得纤维-铝合金复合层板构件。通过分析复合层板气压/固化复合工艺应力应变分布特征与塑性变形规律，研究厚向非均质板材层间界面协调变形规律，揭示热力耦合条件下层板曲面件的性能调控机制与变形机理，探讨缺陷形成机制与防止方法，为制备成形一体化技术在航空航天领域的应用提供理论基础。

新一代重型运载火箭和宽体客机迫切需要采用纤维-铝合金复合层板构件实现轻量化，提高有效运载能力。传统成形方法为先制备纤维-铝合金复合层板再成形，存在层间剥离与失稳起皱等缺陷难以克服。为解决上述难题，本项目提出纤维-铝合金复合层板构件制备成形一体化技术，基本原理是按一定规则分层铺设纤维复合材料与铝合金板，然后在模具内加热至固化温度，在纤维复合材料固化的同时进行热态气压成形，获得纤维-铝合金复合层板构件。理论研究方面：建立了纤维金属层板变形过程中的应力应变计算模型；通过工艺仿真获得了复合层板气压/固化复合工艺应力应变分布特征与塑性变形规律，分析了厚向非均质板材层间界面协调变形规律。实验研究方面：获得了工艺参数对纤维金属层板力学性能影响规律；建立了热气压制备成形一体化专用装置，开展了碳纤维复合材料复杂零件热气压成形的可行性验证，探讨了缺陷形成机制与防止方法，分析了其性能变化规律，建立了考虑铺层角度和厚度的复合材料构件应力响应模型；揭示了热力耦合条件下层板曲面件的性能调控机制与变形机理。研究表明，本项目技术方案能够同时提高纤维金属层板成形效率和强度，在航空航天、汽车等领域具有较好的应用前景。