Cf/Al复合材料异形件预制体制备及其力学性能研究

目的解决铝基复合材料异形件形状特征复杂,对良好的抗拉和抗剪切等使用性能有较高要求,制备难度较大等问题。方法提出了"铺层-缠绕-缝合"碳纤维异形件预制体制备方法,设计了直接式缝合、插销式缝合、整体式缝合3种成形方案,通过理论计算分析不同方案预制体的力学性能;在此基础上,采用液固高压成形Cf/Al复合材料异形件,并通过断口形貌、微观组织以及致密度的分析,解释了其力学性能提升的原因。结果根据较佳的预制体成形方法,成功制备了预制体和复合材料异形件;异形件内部未发现气孔、微裂纹等缺陷,Cf/Al复合材料拉伸强度达278MPa,较基体提高了114%。结论整体缝合法为较佳的预制体成形方案,可使构件具有较高的连接强度和定位精度;复合材料内部浸渗良好,致密度达98.59%,故该复合材料的力学性能较铝合金基体提升较多。     

Cf/Mg 复合材料异形件成形装置设计与实验研究

为实现Cf/Mg复合材料异形件的近净成形,在分析金属基复合材料液态浸渗制备技术的基础上,提出了真空压力浸渗-液固挤压制备Cf/Mg复合材料新工艺,并设计了相应的成形装置.利用设计的装置开展2D碳毡增强镁基复合材料异形件的制备研究.在熔炼温度为760~820℃,预制体预热温度为570~610℃,浸渗气压0.5 MPa和挤压载荷10~30 MPa等工艺参数下,成功制备出Cf/Mg复合材料异形制件.对复合材料制件进行宏观尺寸测量及扫描电镜(SEM)观察发现,制件外形完整,与设计一致;制件内部组织致密、纤维分布均匀;预制体在制备过程中没有发生明显的变形和破坏.     

碳纤维预制体结构对CVI-GSI C/C-SiC复合材料微观结构与力学性能的影响EI

采用不同面密度和丝束大小的碳纤维布,通过不同z向缝合方式编织了两种碳布叠层结构的碳纤维预制体,再经化学气相渗透法(chemical vapor infiltration,CVI)与气相渗硅法(gaseous silicon infiltration,GSI)联用制备了C/C-SiC复合材料。研究了碳纤维预制体结构对CVI-GSI C/C-SiC复合材料微观结构与力学性能的影响。结果表明,由纤维体积分数与C/C素坯密度都相同的预制体所制备的两种复合材料的密度、各相组成、结构与性能均大不相同。较小的碳纤维丝束(1K)和碳布面密度(92 g/m^(2)),以及锁式缝合留下的较大孔隙为GSI反应中Si蒸气的渗透提供了更加充足的通道,最终制备的T1复合材料孔隙率低、结构均匀、性能更高,其弯曲强度、模量和断裂韧度分别为300.97 MPa,51.75 GPa,11.32 MPa·m^(1/2)。初始预制体结构和C/C中间体结构的综合调控是CVI-GSI联用工艺制备高性能C/C-SiC复合材料的关键。     

碳纤维预制体结构对CVI-GSIC/C-SiC复合材料微观结构与力学性能的影响

采用不同面密度和丝束大小的碳纤维布，通过不同z向缝合方式编织了两种碳布叠层结构的碳纤维预制体，再经化学气相渗透法(chemical vapor infiltration, CVI)与气相渗硅法(gaseous silicon infiltration, GSI)联用制备了C/C-SiC复合材料。研究了碳纤维预制体结构对CVI-GSI C/C-SiC复合材料微观结构与力学性能的影响。结果表明，由纤维体积分数与C/C素坯密度都相同的预制体所制备的两种复合材料的密度、各相组成、结构与性能均大不相同。较小的碳纤维丝束(1K)和碳布面密度(92 g/m²),以及锁式缝合留下的较大孔隙为GSI反应中Si蒸气的渗透提供了更加充足的通道，最终制备的T1复合材料孔隙率低、结构均匀、性能更高，其弯曲强度、模量和断裂韧度分别为300.97 MPa, 51.75 GPa, 11.32 MPa·m^1/2。初始预制体结构和C/C中间体结构的综合调控是CVI-GSI联用工艺制备高性能C/C-SiC复合材料的关键。     

薄层化碳布缝合碳/碳复合材料制备与性能

为获得高性能、低成本碳/碳复合材料,以商用级T700大丝束薄层化碳纤维展宽平纹布和航空航天级T300小丝束碳纤维缎纹布为原材料制备缝合预制体,采用化学气相沉积工艺方法制备了一系列缝合碳/碳复合材料,对材料的气相致密化特征、微观结构特征和力学性能进行了测试与分析。研究结果表明,碳布规格和缝合间距对材料气相致密化效果和力学性能有较大影响。当选用T700-12 K、展宽16 mm大丝束纤维编织的面密度100 g/m2的平纹布为原材料且预制体缝合间距为5 mm×5 mm时,制备的密度为1.781 g/cm3薄层化碳布缝合碳/碳复合材料表现出良好的气相沉积工艺适应性和优异的力学性能,材料拉伸强度、压缩强度、弯曲强度和层间剪切强度高达342.9 MPa、285.5 MPa、328.4 MPa和15.2 MPa。通过商用级大丝束薄层化碳纤维的应用,大幅降低了高性能碳/碳复合材料的原材料成本,且制备的碳/碳复合材料性能达到了国际先进水平。      

两种碳纤维增强Cf/BN-Si3N4复合材料性能对比

采用XRD,XPS和SEM对T300和T700两种碳纤维的物相结构、表面成分以及表面形貌进行了分析.分别以两种碳纤维编织件为增强体,采用先驱体浸渍一裂解(PIP)工艺制备了Cf/BN-Si3N4复合材料,并对其力学性能和微观结构进行分析.结果表明,两种碳纤维的石墨化程度、表面活性均相近,表面形貌差别很大.两种纤维增强的复合材料密度相当,但力学性能以及断裂行为有明显区别.与T300碳纤维增强的复合材料相比,T700增强的复合材料弯曲强度更高,弹性模量略低,具有更好的韧性.碳纤维表面状态的差异是纤维与基体的结合强弱以及复合材料力学性能不同的主要原因.     

三维编织复合材料研究及应用现状

正三维编织复合材料是利用编织技术,把经向、纬向及法向的纤维束(或纱线)编织成一个整体,即为预成型结构件(简称"预制体"),然后以预制体作为增强材料进行树脂浸渍固化而形成的复合材料结构。由于增强纤维在三维空间多向分布,阻止或减缓了冲击载荷作用下复合材料层间裂纹的扩展,使得复合材料层间性能大大提升。因此,三维编织复合材料较普通层合复合材料具有更高的冲击损伤容限和断裂韧性。三维编织技术可按实际     

碳纤维增强铜基复合材料(Cf/Cu)中碳纤维表面改性与结合界面性能的研究现状

本文简述了影响碳纤维与铜基体结合强度的重要因素以及改善方法,并对碳纤维增强铜基复合材料(Cf/Cu)的制备以及碳纤维与铜基体的结合问题进行了展望.     

增强毡C/C复合材料的结构和性能

设计了两种不同结构的预制体,即碳布 碳毡(1#预制体)、无纬布 碳毡(2#预制体),经化学气相沉积(CVD)与浸渍树脂相结合的致密化工艺制备出了高密度的增强毡C/C复合材料.结果表明:1#、2#预制体制备的C/C材料表现出了良好的力学性能,其拉伸强度分别达61.25MPa和53.12MPa,其中2#材料的拉伸破坏表现出了假塑性.结合材料的微观形貌研究了预制体结构、界面对C/C复合材料拉伸性能的影响.     

T300碳纤维热处理对Cf/SiC复合材料性能的影响

以聚碳硅烷先驱体浸渍裂解工艺制备T300碳纤维增强3D Cf/SiC复合材料,研究了T300碳纤维预先热处理对材料性能的影响.结果表明,热处理能够弱化Cf/SiC复合材料中纤维-基体界面结合,减少碳纤维在复合过程的损伤,显著提高复合材料性能.纤维经热处理后制备的Cf/SiC复合材料弯曲强度和断裂韧性分别从未经处理的154MPa,4.8MPa·m1/2提高到437MPa,20.4 MPa·m1/2.     

Experimental and theoretical studies of the elastic behavior of knitted-fabric composites

This paper presents experimental and theoretical studies of the elastic behavior of knitted-fabric composites. In the experimental studies, two types of weft-knit preforms based upon plain-stitch and rib-stitch fabrics were first fabricated and fabric composites were consolidated by using a hand lay-up process. Tensile and rail shear tests were performed, and Young's moduli along the warp and weft directions and shear modulus determined. In order to correlate the preform microstructure with composite elastic properties, geometric models for plain-stitch and rib-stitch fabric composites were developed. Modeling of the elastic behavior was conducted by using an averaging method. The predicted elastic constants are in reasonably good agreement with experimental values. Finally, the limitation and potential of knitted-fabric composites are discussed.     

Effects of yarn size and Z-yarn density on the interlaminar shear properties of two Z-reinforced 3D C/SiC composites

This work investigated the effects of yarn size and Z-yarn density on the interlaminar shear strength (ILSS) of two 3D C/SiC composites fabricated by chemical vapor infiltration. They were the 3D needled (3DN) composite and the 3D stitched (3DS) plain woven composite, respectively. For 3DN C/SiC, short-cut fiber lamina was confirmed as the initial facture source. Large yarn size resulted into the occurrence of 0° non-woven fiber lamina fracture source and increased the crack extending paths. The ILSS of textile preforms indicates ILSS of their composites. The existing knowledge had displayed that increasing Z-yarn density increased the ILSS of 3DN carbon fiber preform. Thus the ILSS of 3DN C/SiC increased with increasing yarn size and Z-yarn density. For 3DS C/SiC, the interlaminar region was considered as the initial fracture source and caused the matrix crack sources in the weft and warp yarn. Large yarn size alleviated SiC densification effect of preform while high Z-yarn density enhanced Z-pinning effect and SiC densification effect of interlaminar region. Thus the ILSS of 3DS C/SiC decreased with increasing yarn size and decreasing Z-yarn density.     

Hierarchical composites reinforced with robust short sisal fibre preforms utilising bacterial cellulose as binder

A novel robust non-woven sisal fibre preform was manufactured using a papermaking process utilising nanosized bacterial cellulose (BC) as binder for the sisal fibres. It was found that BC provides significant mechanical strength to the sisal fibre preforms. This can be attributed to the high stiffness and strength of the BC network. Truly green non-woven fibre preform reinforced hierarchical composites were prepared by infusing the fibre preforms with acrylated epoxidised soybean oil (AESO) using vacuum assisted resin infusion, followed by thermal curing. Both the tensile and flexural properties of the hierarchical composites showed significant improvements over polyAESO and neat sisal fibre preform reinforced polyAESO. These results were corroborated by the thermo-mechanical behaviour of the (hierarchical) composites, which showed an increased storage modulus and enhanced fibre–matrix stress transfer. Micromechanical modelling was also performed on the (hierarchical) composites. By using BC as binder for short sisal fibres, added benefits such as the high Young’s modulus of BC, enhanced fibre–fibre and fibre–matrix stress transfer can be utilised in the resulting hierarchical composites.     

Fabrication of particulate aluminium-matrix composites by liquid metal infiltration

Aluminium-matrix composites were fabricated by liquid metal infiltration of porous particulate reinforcement preforms, using AlN, SiC and Al₂O₃ as the particles. The quality of the composites depended on the preform fabrication technology. In this work, this technology was developed for high-volume fraction (up to 75%) particulate preforms, which are more sensitive to the preform fabrication process than lower volume fraction whisker/fibre preforms as their porosity and pore size are much lower. The technology developed used an acid phosphate binder (with P/Al molar ratio=23) in the amount of 0.1 wt% of the preform, in contrast to the much larger binder amount used for whisker preforms. The preforms were made by filtration of a slurry consisting of the reinforcement particles, the binder and carrier (preferably acetone), and subsequent baking (preferably at 200 °C) for the purpose of drying. Baking in air at 500 °C instead of 200 °C caused the AlN preforms to oxidize, thereby decreasing the thermal conductivity of the resulting Al/AlN composites. The reinforcement-binder reactivity was larger for AlN than SiC, but this reactivity did not affect the composite properties due to the small binder amount used. The Al/AlN composites were superior to the Al/SiC composites in the thermal conductivity and tensile ductility. The Al/Al₂O₃ composites were the poorest due to Al₂O₃ particle clustering.     

“离位”增韧预成型体压缩特性

针对"离位"增韧预成型体的液态成型工艺性,研究了两种不同结构形式增韧层"离位"增韧预成型体的厚度压缩特性。分别采用多孔薄膜结构增韧层、高孔隙率无纺布结构增韧层与碳纤维织物交替铺层制备"离位"增韧预成型体,采用力学试验机测试其厚度压缩特性。实验结果表明,预成型体压缩过程中,在相同压力水平下,增韧层的引入会降低预成型体的纤维体积分数;不同压力水平下,预成型体的压缩行为与增韧层结构形式有关。此外,采用织物预成型体厚度压缩本构模型,对"离位"增韧预成型体的压缩厚度进行了预测,通过模型预测值与实验值的比较,确定了模型中的经验指数k=2时,两者吻合较好。     

The displacive compensation of porosity (DCP) method for fabricating dense, shaped, high-ceramic-bearing bodies at modest temperatures

A novel process is introduced for the fabrication of dense, shaped ceramic/metal composites of high ceramic content: the Displacive Compensation of Porosity (DCP) method. In this process, a metallic liquid is allowed to infiltrate and undergo a displacement reaction with a porous oxide preform. Unlike other displacement-reaction-based processes (e.g., the C⁴, RMP, and AAA processes), a larger volume of oxide is generated than is consumed, so that composites with relatively high ceramic contents can be fabricated. Bar- and disk-shaped MgO/Mg-Al composites were produced by the infiltration and reaction of molten Mg with porous Al₂O₃ preforms at 1000 °C. By varying the relative density of the preforms (from 53.3 to 71.0% of theoretical), the magnesia content of the final composites could be adjusted from 70.4 to 85.6 vol %. Because the increase in oxide volume associated with the conversion of alumina into magnesia was accommodated by the prior pore volume of the preforms, the composites retained the shapes and dimensions (to within a few percent) of the starting preforms. The MgO/Mg-Al composites were lightweight (2.94–3.30 g/cm³), dense (97.7–99.0% of theoretical), and resistant to hydration. Bar-shaped MgO/Mg-Al composites exhibited average flexural strength and indentation toughness values of 244 MPa and 5.4 MPa · m^1/2, respectively.     

Role of Mg and Mg+Si as external dopants in production of pure Al–SiC metal matrix composites by pressureless infiltration

Abstract

Metal matrix composites have been produced by pressureless infiltration of pure Al into Mg doped SiC preforms after 1 h at 900°C. Aluminium has been found to infiltrate preforms containing between 2 and 14 wt-%Mg, however Al did not infiltrate a preform containing 1 wt-%Mg. Preforms doped with 1 wt-%Mg and Si did result in infiltration. Increasing the Mg content or increasing the Si content in the preform resulted in more extensive infiltration. The effect of Mg and Mg mixed with Si on pressureless infiltration of pure Al, microstructure of MMC as well as mechanical properties are discussed. Although the dopant was uniformly distributed throughout the preform microstructural analysis and hardness measurements indicate that the resultant composite may not be uniform due to infiltration inwards from the edge to the centre of preform.     

预制体结构对针刺石英纤维/环氧树脂复合材料导热性能的影响

为了探索预制体结构对针刺石英纤维/环氧树脂复合材料导热性能的影响,采用逐层针刺技术和树脂传递模塑工艺制作了针刺石英纤维/环氧树脂复合材料。利用瞬态热线法测量了环氧树脂和不同预制体结构的针刺石英纤维/环氧树脂复合材料的导热性能。结果表明:随着纤维体积分数的提高,针刺石英纤维/环氧树脂复合材料的导热性能得到了提升。其中,用石英纤维短切毡增强环氧树脂的导热性能比环氧树脂提高了35.9%。当针刺石英纤维/环氧树脂复合材料中的无纬布纤维平行于热线时,采用石英纤维短切毡与石英纤维无纬布共同增强的2种针刺石英纤维/环氧树脂复合材料的导热性能分别比环氧树脂提高了45.5%和46.4%;而当无纬布纤维垂直于热线时,导热性能比环氧树脂分别提高了56.4%和61.8%。针刺石英纤维/环氧树脂复合材料的导热性能不仅受石英纤维体积分数影响,也受到预制体中无纬布纤维体积分数和取向的影响。      

压铸法制造SiCw/Al复合材料的渗透过程分析

本文深入分析了用压铸法制造SiCw/Al复合材料过程中液态铝渗入SiC晶须预制块中的渗透过程。通过理论计算得到液态铝渗入晶须预制块的临界渗透压不超过2MPa。对不同晶须含量的预制块所进行的模拟渗透过程的压缩试验结果表明,随外力的增加,预制块被压缩的程度增大,从而使预制块的晶须相对含量增大。通过对渗透过程的分析,认为液态铝渗透晶须预制块需要一定时间,因此当外力以较大的速度达到最大值时,液态铝不能完全渗入预制块中,这时预制块将被压缩,导致所得复合材料晶须相对含量提高。研究结果表明,复合材料晶须体积分数主要取决于预制块晶须体积分数和复合压力。      

非连续增强相预制块的研究进展

采用压力浸渗方法制备非连续增强复合材料需要高质量的预制块。综述了湿压法制备非连续增强相预制块所用粘结剂的种类和特性、预制块烘干方式对粘结剂分布的影响，以及湿压法制备预制块技术的研究进展；对目前预制块制备技术的发展方向进行了展望。