含紧固件复合材料层压板雷击后损伤及力学性能退化试验

以含金属紧固件编织结构碳纤维/环氧树脂复合材料层压板为研究对象,通过人工模拟雷电流试验,并结合目视观察、超声损伤扫描、微米X射线三维成像及高倍显微镜等损伤检测手段,对其在雷电流直接效应作用下的损伤模式、机制及特征进行了分析,同时,采用材料力学性能试验系统,对其雷击后的静拉伸承载能力退化程度进行了评估。研究结果表明：由金属紧固件引起的"雷电流分散效应"导致含紧固件复合材料层压板雷击损伤以分层损伤为主,且损伤沿层压板整个厚度方向分布;雷击损伤的产生存在一个雷电流强度门槛值,当雷电流强度小于该值时,层压板不会出现损伤;紧固孔周围的雷击损伤在静拉伸过程中会产生"应力分散效应",导致含紧固件层压板静拉伸承载能力随雷击峰值电流的增加先提高后下降。     

含紧固件碳纤维增强树脂复合材料在雷电流A分量下的损伤特性

为深入分析雷电环境下含紧固件碳纤维增强树脂（CFRP）复合材料的损伤机制及尺寸对损伤面积的影响规律,对两种不同尺寸含紧固件CFRP进行雷电损伤试验和仿真研究。根据热电耦合理论在ABAQUS中建立含紧固件CFRP的热-电耦合模型,得到单一雷电流A分量作用下CFRP的温度场分布规律;雷电损伤试验中采用超声C扫描方法评估试件损伤特性。试验和仿真结果表明:此雷击条件下,雷电流通过紧固件扩散到CFRP层合板整个厚度,试件在雷电流峰值不太大的情况下损伤面积较小,但随电流峰值的增大,损伤面积剧增、分层损伤严重。电流相近情况下不同尺寸的含紧固件CFRP的损伤分层、损伤形态及面积相近,尺寸对试件的损伤特性影响较小。试验和仿真研究为CFRP的结构设计提供一定的仿真和试验数据支撑。      

雷电流组合波形下碳纤维/环氧树脂基复合材料层压板雷击损伤试验

为了评估碳纤维/环氧树脂基复合材料位于不同飞机雷击分区下的雷击损伤程度及损伤特征,采用A+B、D+B+C和A+B+C+D 3种不同的雷电流波形组合,对两类不同尺寸复合材料层压板试验件（Type1和Type2）进行了模拟雷电流冲击试验,通过目视损伤观察和超声损伤扫描,分析评估了复合材料位于飞机1A区、2A区及1B区时的雷击损伤程度及特征,同时还对含铜网防护碳纤维/环氧树脂基复合材料层压板在不同雷击分区下的雷击防护效果进行了评估。结果表明：不同雷击分区下,碳纤维/环氧树脂基复合材料在雷电流作用下的损伤模式基本一致,包括纤维断裂、基体烧蚀及分层损伤;对于相同类型试验件,1B区对应雷击损伤程度最严重,其次为2A区,1A区损伤程度最小;在相同雷击分区下,长宽比较小的Type1型试验件雷击损伤程度大于长宽比较大的Type2型试验件;0.25 mm厚铜网能够有效对碳纤维/环氧树脂基复合材料进行雷击防护,位于1A区、2A区及1B区的含防护与无防护Type2型试件,前者雷击损伤程度较后者分别下降88.9%、53.9%和68.7%。     

碳纤维增强树脂复合材料在多重连续雷电流冲击下的损伤特性

通过对比碳纤维增强树脂复合材料（CF/EP）层合板在单一雷电流脉冲及不同组合及时序的多重雷电流分量作用下的雷击损伤特性,探索多重连续雷电流分量在CF/EP层合板上的散流过程与作用机制。研究发现CF/EP层合板在雷电流脉冲作用下出现纤维断裂、烧蚀、树脂热解、铺层分离等严重雷击损伤。在雷电流A、B、C及D分量连续作用下,CF/EP损伤面积达到2 790 mm2,损伤深度约1.28 mm。在多重连续雷电流脉冲作用下,CF/EP的雷电损伤深度主要与雷电流A、B及D分量的冲击力效应及介质击穿效应有关,而持续时间长、转移电荷量大的雷电流C分量的热效应对损伤面积的贡献接近40%。CF/EP层合板雷击损伤特性与雷电流分量的组合及作用时序关系密切,雷电流分量单独作用时造成的CF/EP雷击损伤效果与处于多重连续脉冲序列中时所造成的雷击损伤效果有很大差异。对CF/EP在多重连续雷电流作用下损伤效应的研究能够加深对雷电作用过程的理解,并为CF/EP雷电直接效应机制研究及试验方法的建立及完善提供实验和理论依据。      

复合材料雷击放电效应三维数值模拟

建立长空气间隙及复合材料层合板三维有限元模型,采用棒-板长间隙正极性流注生长概率模型为基于经典流注理论的随机放电模型。计算空气间隙区域内各网格点电位,列出电极周围所有流注待发展路径,计算每条流注待发展路径的生长时间,确定具有最小生长时间路径为优先选择路径。流注到达复合材料层合板后选流注与板交叉点作为雷击附着点进行复合材料层合板雷击直接效应分析,获得复合材料层合板在雷电压作用下电势、温度及热应力分布。计算结果表明,流注瞬间产生的高电势、温度及热应力主要沿顶层电导率最大方向对称扩展,所研究的初步结果可作为定性描述;为准确模拟复合材料的雷击放电效应过程,需进一步考虑复合材料的雷击烧蚀及热力学等破坏机理。     

碳纤维增强银粉改性树脂复合材料的雷击损伤效应

针对碳纤维增强树脂(CFRP)复合材料中树脂电阻大,在雷电流作用下会产生大量焦耳热造成雷击损伤的短板,探索通过增强基体的导电性来解决这一问题。为实现对CFRP复合材料的改性,在其环氧树脂浆料中加入了以Ag粉为主的导电填料,使改性CFRP复合材料层合板沿厚度方向的电导率提高217.30倍。采用不同峰值的单一雷电流D分量分别对改性及未改性CFRP复合材料层合板试件进行雷击损伤实验,通过损伤区域超声C扫描图像、试件残余温度场和仿真热解损伤的对比,分析基体改性对CFRP复合材料雷击损伤的防护机制。结果表明:通过Ag粉改性能有效提高CFRP复合材料层合板的电导率,且在厚度方向上的改性效果最佳;在峰值电流分别为20 kA、40 kA和60 kA的条件下,改性CFRP复合材料层合板的损伤面积分别下降87.28%、77.82%和88.59%,损伤深度分别增加147.06%、130.65%和119.72%;以损伤体积为最终指标,则Ag粉改性基体能有效降低CFRP复合材料的雷击损伤,其防护机制是通过减少雷电流作用下的高温区域面积和升温幅度来降低热解和爆炸冲击实现。      

雷击冲击力作用下复合材料层合板动力学响应及损伤特性

采用基于连续介质损伤理论（CDM）的复合材料三维渐进损伤分析模型,以ABAQUS有限元分析软件为平台,结合VUMAT子程序,对雷击冲击力作用下的复合材料层合板进行了三维动力学分析,研究了雷击冲击力作用下层合板的动力学响应及损伤特性。结果表明,在雷击冲击力作用下,层合板做降幅振荡运动,冲击力做功与层合板内能和动能相互转换,同时伴随着黏性耗散能,冲击力做功大小可用雷电流库伦量与作用积分的函数表示;层合板损伤由外力做功大小决定,对于同种材料,基体、纤维及分层损伤分别存在不同的损伤能量临界值,当冲击力做功大于该值,层合板会产生对应的损伤;在相同边界支持条件下,冲击力总功最大值决定了不同损伤类型损伤状态变量的大小,与波形参数和峰值电流无关。     

不同防护形式复合材料板雷击损伤分区特性

基于A+B+C+D 4种标准雷电流波形的联合作用,开展了不同防护形式复合材料板雷击试验。考虑放电通道物理特性,分析放电通道与复合材料表面间的作用过程,将复合材料表面损伤区域分解成初始附着区、附着传导区、附着扩展区、二次附着区和扫掠损伤区,并对未防护基准件、局部喷铝、全喷铝防护件及铜网防护件4类板的各区域进行了损伤特性分析。结果表明:复合材料表面损伤是强电磁场条件下放电通道热电物理特性与复合材料表面热电特性及电荷分布的共同作用结果;复合材料表面铝层喷涂方式、厚度以及均匀程度均影响表面损伤的对称性和损伤分区特性;铜网防护造成复合材料板表面粗糙使得表面损伤分区复杂;表面电荷累积特性和分布的均匀程度直接影响二次附着区和扫掠损伤区的分布;复合材料表面雷击损伤包括纤维升华、断裂、起毛,基体炭化熔融、烧蚀,材料分层、剥落以及防护材料的熔融汽化和断裂等。分析结果可以用于复合材料雷击防护定性设计。     

含雷击热-力耦合损伤复合材料层压板拉伸剩余强度预测

为了对含雷击热-力耦合损伤复合材料层压板的剩余强度进行预测,基于连续介质损伤力学法(CDM)和唯象分析法,建立了表征复合材料雷击热-力耦合损伤的刚度矩阵渐进损伤退化模型。基于该模型,通过ABAQUS有限元仿真软件,建立了含雷击热-力耦合损伤的复合材料层压板结构三维模型。结合UMAT子程序,完成了拉伸载荷下的剩余强度预测。结果表明:通过与试验对比,仿真结果与试验结果取得了良好的一致性。本文所建立模型,能够有效进行含雷击热-力耦合损伤复合材料层压板结构拉伸剩余强度预测。     

碳纤维/环氧复合材料典型铺层的热膨胀系数及其复合计算

本文采用当前我国飞机上使用的国产碳纤维复合材料制成七类典型铺层层压板,精确测定上述各类典型结构的各不同方向或不同铺层角的热膨胀系数,为材料研究和应用设计提供一整套可靠的实测数据。同时利用这些实测数据,对膨胀系数复合公式进行验算,得到很好的一致性。应用这些复合公式,可对各种铺层碳纤维复合材料各不同方向的热膨胀系数进行计算,以及设计出各种热膨胀系数(包括零膨胀系数)的碳纤维复合材料。     

Lightning Strike Ablation Damage Characteristic Analysis for Carbon Fiber/Epoxy Composite Laminate with Fastener

In order to analyze the lightning strike ablation damage characteristic of composite laminate with fastener, based on the energy-balance relationship in lightning strike, mathematical analysis model of ablation damage of composite laminate with fastener was constructed. According to the model, an effective three dimensional thermal-electrical coupling analysis finite element model of composite laminate with fastener suffered from lightning current was established based on ABAQUS, and lightning strike ablation damage characteristic was analyzed. Analytical results reveal that lightning current could conduct through the thickness direction of the laminate due to the existence of metallic fastener, and then distribute to all layers, finally conducted in-the-plane of each layer, conductive ability of different layup orientations depend on potential distribution and in-the-plane electrical conductivity along potential gradient declining direction; different potential boundaries correspond to different potential distribution in each layer, and result in conductive ability of different layup orientations was changed, then caused different lightning strike ablation damage distribution. According to the investigation in this paper, we can recognize the lightning strike ablation damage characteristic of composite laminate with fastener qualitatively.     

Lightning Strike Ablation Damage Influence Factors Analysis of Carbon Fiber/Epoxy Composite Based on Coupled Electrical-Thermal Simulation

According to the mathematical analysis model constructed on the basis of energy-balance relationship in lightning strike, and accompany with the simplified calculation strategy of composite resin pyrolysis degree dependent electrical conductivity, an effective three dimensional thermal-electrical coupling analysis finite element model of composite laminate suffered from lightning current was established based on ABAQUS, to elucidate the effects of lighting current waveform parameters and thermal/electrical properties of composite laminate on the extent of ablation damage. Simulated predictions agree well with the composite lightning strike directed effect experimental data, illustrating the potential accuracy of the constructed model. The analytical results revealed that extent of composite lightning strike ablation damage can be characterized by action integral validly, there exist remarkable power function relationships between action integral and visual damage area, projected damage area, maximum damage depth and damage volume of ablation damage, and enhancing the electrical conductivity and specific heat of composite, ablation damage will be descended obviously, power function relationships also exist between electrical conductivity, specific heat and ablation damage, however, the impact of thermal conductivity on the extent of ablation damage is not notable. The conclusions obtained provide some guidance for composite anti-lightning strike structure-function integration design.     

Experimental and Numerical Simulation Analysis of Typical Carbon Woven Fabric/Epoxy Laminates Subjected to Lightning Strike

To clarify the evolution of damage for typical carbon woven fabric/epoxy laminates exposed to lightning strike, artificial lightning testing on carbon woven fabric/epoxy laminates were conducted, damage was assessed using visual inspection and damage peeling approaches. Relationships between damage size and action integral were also elucidated. Results showed that damage appearance of carbon woven fabric/epoxy laminate presents circular distribution, and center of the circle located at the lightning attachment point approximately, there exist no damage projected area dislocations for different layers, visual damage territory represents maximum damage scope; visible damage can be categorized into five modes: resin ablation, fiber fracture and sublimation, delamination, ablation scallops and block-shaped ply-lift; delamination damage due to resin pyrolysis and internal pressure exist obvious distinguish; project area of total damage is linear with action integral for the same type specimens, that of resin ablation damage is linear with action integral, but no correlation with specimen type, for all specimens, damage depth is linear with logarithm of action integral. The coupled thermal–electrical model constructed is capable to simulate the ablation damage for carbon woven fabric/epoxy laminates exposed to simulated lightning current through experimental verification.     

Lightning ablation suppression of aircraft carbon/epoxy composite laminates by metal mesh

Three-dimensional finite element (FE) models of carbon/epoxy composite laminates with copper mesh and aluminum mesh protection were established subjected to lightning strike, in which different mesh spacing was selected. Effectiveness of numerical method was verified and impulse current waveforms with different current peaks were applied according to aircraft lightning zones. Thermal-electrical material parameters varying with temperature were added into numerical models. Element deletion method was used to deal with lightning ablation elements of composite structures. The results show that ablation area and depth of composite laminates with metal mesh protection are significantly smaller, which proves good protection effectiveness of metal meshes on anti-lightning strike. The denser the mesh spacing, the better the anti-lightning strike will be. Protection of composite laminates with copper mesh has better effects than that of aluminum mesh. Considering the effect of mesh spacing variation on composite structural weight and anti-lightning strike, the ideal mesh spacing was obtained.