CFRP/金属异种材料激光连接工艺的研究现状

树脂基碳纤维增强复合材料（CFRP）作为新型轻质结构复合材料,广泛应用于航空航天器件的零部件中。CFRP与航空常用金属传统连接主要有胶接和机械连接,但具有一定的局限性。激光连接技术具有能量密度高,可控性好等特点,可用于复合材料和金属的连接。本文针对当前树脂基CFRP与金属（铝合金、钛合金、钢等）激光连接接头成形机理以及接头缺陷进行了综述,同时分析了焊接工艺、组织结构优化以及焊前金属表面处理对接头成形的调控,并对CFRP/金属激光连接的发展趋势提出了展望。     

Al2O3P/6061Al复合材料瞬间液相扩散连接

用纯金属作中间层TLP连接颗粒增强铝基复合材料,接头存在增强相偏聚区,是接头力学性能的薄弱区域.控制增强相偏聚区是改善接头力学性能的一种有效途径.文中尝试用Cu,Al金属复合中间层TLP连接Al2O3P/6061Al复合材料,探讨了其接头的显微结构和力学性能特点.结果表明,用Cu,Al金属复合中间层能够控制接头增强相偏聚,改善接头抗剪强度.在连接温度600℃,保温时间60min的工艺条件下,10 μm Al/10 μm Cu/10 μm Al复合中间层接头增强相偏聚明显下降,接头抗剪强度110 MPa;1.5 μm Cu/10 μm Al/1.5 μm Cu复合中间层接头无明显的增强相偏聚,接头抗剪强度123 MPa.     

蓝宝石与Invar合金超快激光选区微焊接接头组织和性能

采用飞秒激光选区微焊接技术制备了蓝宝石/Invar合金异质材料接头，研究了激光功率对接头密封性、宏微观形貌和剪切性能的影响.采用扫描电子显微镜、能谱分析仪和激光共聚焦显微镜等表征了接头界面焊接缺陷与元素分布的规律以及接头断裂行为.结果表明，蓝宝石和Invar合金分别经过非线性吸收和线性吸收作用，材料发生了熔化、混合和扩散，形成了犬牙交错的连接界面，说明界面存在着冶金结合和机械咬合双重作用.接头抗剪强度随激光功率单调增加，当激光功率为10.19 W时，最大抗剪强度为145.3 MPa.蓝宝石/Invar合金接头的断裂形式主要为解理性断裂，两侧断口均有Fe,Ni,Al和O元素，进一步说明了超快激光促进了两种材料在界面的冶金反应.     

时效处理对铝合金A6061与碳纤维增强热塑性复合材料激光连接接头的影响

采用激光直接连接技术对铝合金(A6061)与碳纤维增强热塑性复合材料(Carbon Fiber Reinf-orced Thermal Plastic,CFRTP)进行连接,以接头抗拉强度作为评价指标,确定连接参数的影响规律及最优连接工艺.采用时效处理的方法提高接头连接强度,研究时效处理参数对拉伸强度的影响,揭示最优工...     

树脂基CFRP/金属异种材料激光连接工艺研究现状

树脂基碳纤维增强复合材料(CFRP)作为新型轻质结构复合材料,广泛应用于航空航天器件的零部件中。CFRP与航空常用金属传统连接主要有胶接和机械连接,但具有一定的局限性。激光连接技术具有能量密度高,可控性好等特点,可用于复合材料和金属的连接。本文针对当前树脂基CFRP与金属(铝合金、钛合金、钢等)激光连接接头成形机理以及接头缺陷进行了综述,同时分析了焊接工艺、组织结构优化以及焊前金属表面处理对接头成形的调控,并对CFRP/金属激光连接的发展趋势提出了展望。     

Cf/SiC复合材料与304不锈钢钎焊接头组织与性能

采用Ti-Zr-Be活性钎料作为连接层,在一定工艺参数下真空钎焊C_f/SiC复合材料和304不锈钢.利用SEM,EDS,XRD和俄歇谱仪分析接头微观组织结构,利用剪切试验检测接头力学性能,分析了工艺参数对接头抗剪强度的影响.结果表明,在复合材料附近形成ZrC+TiC+Be₂C/Ti-Si反应层,连接层中主要包含FeZr₂,锆基固溶体,BeTi,Ti-Zr固溶体等反应产物,304不锈钢附近形成FeTi/αFe反应层.在连接温度为950℃,连接时间为60min时,接头室温抗剪强度最高为109.3 MPa,断裂位置为C_f/SiC复合材料与中间层连接界面靠近复合材料端.     

碳纤维复合材料/钛合金激光连接界面微织构调控工艺研究

碳纤维增强热塑性复合材料（CFRTP）与钛合金复合结构的高质量连接是实现飞机轻量化以及高强度制造的关键。采用激光高速旋转焊接技术进行CFRTP/钛合金复合结构的连接,通过在钛合金表面制备不同尺寸网格型微织构研究了界面状态对CFRTP/钛合金接头强度的影响规律。结果表明,钛合金表面微织构的制备可以显著提升接头强度,且不同线间距下的微织构对接头的强度有直接影响,线间距越小,接头强度越高;在CFRTP与钛合金微织构中间添加PA树脂层,有利于提高接头强度。     

Be/Al/Be激光焊接接头显微组织分析

铝为过渡材料,运用激光焊接技术实现了铍与铍激光熔焊连接.采用扫描电镜(SEM)、金相显微镜(OM)、微控电子万能试验压力机及微区X射线衍射仪(XRD)对焊接接头的显微组织、剪切断口形貌、力学性能及相结构进行了试验研究.结果表明,Be/Al/Be激光焊接接头为铝与铍形成类似复合材料的双相组织,接头抗剪强度介于铝和铍的抗剪强度之间,随着焊缝组织铍含量增加,接头抗剪强度呈上升趋势、焊接接头断裂形式由塑性断裂向脆性断裂转变、断口形貌由韧窝断口向准解理断口过渡,焊缝中的金属化合物是导致焊缝失效断裂的主要原因.     

镀Cr层对低碳钢与CFRP接头力学性能的影响

以低碳钢与碳纤维增强树脂基复合材料CFRP激光连接接头为研究对象,采用表面电镀工艺在低碳钢表面镀Cr,分析了镀Cr层对低碳钢与CFRP接头剪切强度的影响。结果表明,镀Cr低碳钢与CFRP激光连接接头发生断裂的位置是CFRP内部,断裂后的CFRP依旧粘连着低碳钢基体,镀Cr层的存在明显提高了接头的剪切强度。     

Cf/SiC复合材料与钛合金(Ti-Zr-Cu-Ni)+W复合钎焊分析

在适当的工艺参数下,用(Ti-Zr-Cu-Ni)+W复合钎料真空钎焊Cf/SiC复合材料与钛合金,采用SEM,EDS和XRD分析接头组织结构,利用剪切试验检测接头的力学性能.结果表明,钎焊时复合钎料中的钛、锆与Cf/SiC复合材料反应,在Cf/SiC复合材料与连接层界面生成Ti3SiC2,Ti5Si3和少量TiC(ZrC)化合物的混合反应层,在连接层与钛合金界面形成Ti-Cu化合物扩散层.增强相钨粉能有效缓解接头的残余热应力,提高接头力学性能,在连接温度930℃,保温时间20 min的工艺条件下,增强相钨粉含量为15%(体积分数)时,接头抗剪强度最高为166 MPa.     

Interface Characterization in Fiber-Reinforced Polymer–Matrix Composites

A novel methodology is presented and applied to measure the shear interface strength of fiber-reinforced polymers. The strategy is based in fiber push-in tests carried out on the central fiber of highly-packed fiber clusters with hexagonal symmetry, and it is supported by a detailed finite element analysis of the push-in test to account for the influence of hygrothermal residual stresses, fiber constraint and fiber anisotropy on the interface strength. Examples of application are presented to determine the shear interface strength in carbon and glass fiber composites reinforced with either thermoset or thermoplastic matrices. In addition, the influence of the environment (either dry or wet conditions) on the interface strength in C/epoxy composites is demonstrated.     

钢纤维增强有色金属基复合材料综述

有色金属基复合材料相对于传统有色金属材料而言,具有更好的抗氧化性、高耐热性、高比强度、高比模量、耐磨损和高使用寿命。在有色金属基复合材料的众多的增强体中,非金属纤维(C/C、SiC)与金属基质结合界面的相容性是制约金属基复合材料性能的关键问题,而金属纤维与金属基质之间良好的相容性能够有效改善金属材料的性能。金属纤维增强有色金属基复合材料的制备工艺主要有扩散粘结法、液态渗透法、压力铸造法、涂层热压法、双辊轧制法。 本文主要总结了钢纤维增强有色金属基(Al、Mg、Cu、Zn和Zr)复合材料的制备方法、微观组织、界面特征和机械性能,指出了钢纤维增强有色金属基复合材料进一步研究发展所需要解决的问题。     

硼硅玻璃与可伐合金的激光熔接工艺

对硼硅玻璃与可伐合金的激光直接熔接工艺进行了研究,得到了最佳工艺参数。通过对可伐合金表面进行光纤激光毛化处理,提高了玻璃-金属接头的可靠性。通过扫描电镜、能谱分析等方法对接头界面微观组织及断口形貌进行了观察与分析,对接头的压剪强度进行了测试。结果表明,在激光扫描速度一定时,激光功率越大,反应产物成分越接近Fe₂SiO₄;在激光功率为650W,扫描速度为15mm/s时,接头压剪强度达到最大值5.8MPa;在此激光工艺参数下,经过激光毛化后的可伐合金与玻璃的接头强度最高可达12。9MPa,比未毛化的接头强度提高了122.4%。     

石墨烯金属基复合材研究进展

本文详细叙述了石墨烯及其衍生物等增强相的应用范畴及适用区别以及比较了金属基复合材料的不同制备方法,分析传统的制备方法之间的分类特点及应用方向,重点提出了工艺步骤灵活、可控性极高的新型制备石墨烯增强金属基复合材料的方法—激光增材制造技术。深入讨论了石墨烯及其衍生物作为增强相,给金属基复合材料中带来的力学、摩擦学、电学、金属耐腐蚀等性能方面的改变,比较了石墨烯及衍生物作为增强相对铝、镁、镍、铜、钛等金属基复合材料性能提高及改善程度和在不同金属基复合材料中仍存在的增强相各种团聚、分散问题与金属基体的界面结合等及目前提出的处理方案,最后提出制备石墨烯金属基复合材料未来发展方向及新型制备技术仍存在的实际问题。     

Dissimilar materials joining of metal/carbon fibre reinforced plastic by resistance spot welding

ABSTRACT

Dissimilar materials joining of metal to carbon fibre reinforced plastic (CFRP), which consisted of PA6, modified polypropylene (PP) or polyphenylene sulphide (PPS) as matrix polymer with short carbon fibre, was performed using series resistance spot welding (series-RSW). The metal plate was placed on CFRP plate as the lap joint, and electrodes of series-RSW were pressed only on the metal plate side. The metal around the electrode was heated by electrical resistance heating, and the thermoplastic near the interface was slightly melted by the heat conduction from heated metal. The objectives of this research are to confirm the possibility of direct joining of CFRP and metal, and to investigate the effects of the heat input during series-RSW, silane-coupling treatment and chemical structure of matrix plastics on the joint properties.

The direct joint formations of SUS304 to CFRP (PA6) and CFRP (PP) were accomplished, and CFRP (PPS) was not. The joining area, which corresponding to the melted area of CFRP, enlarged with increasing the welding current and welding time, therefore, the tensile shear fracture load also increased. The silane-coupling treatment for metal surface was highly effective to increase the joining strength. The maximum tensile shear strength of about 13 MPa was obtained for SUS304/CFRP (PA6) joint.     

SiCp增强Al基复合材料的真空扩散焊接

采用真空扩散焊接方法研究了同质及异质ＳｉＣｐ增强Ａｌ基复合材料的连接特性,考察了ＳｉＣｐ体积分数变化及插入中间合金层对同质及异质Ａｌ合金基复合材料真空扩散焊接质量及接头性能的影响。研究结果表明,无论同质还是异质Ａｌ合金基复合材料,真空扩散焊接头的强度均随ＳｉＣｐ体积分数的增加而降低;获得满意的异质ＳｉＣｐ增强Ａｌ合金基复合材料的真空扩散焊连接远比同质材料时困难。研究结果还表明,无论同质还是异质Ａｌ     

Al-Mg系自生纤维增强铝基复合材料组织与性能

为解决金属基复合材料中外加增强体与基体间异质界面对材料性能带来的不利影响，提出一种基于粉末冶金技术的原位复合新工艺，并制备出自生金属间化合物纤维增强铝基复合材料。研究结果表明，原位生成的金属间化合物纤维均匀分布在基体中，并平行于材料制备时的挤出方向；原位复合材料的增强效果明显，屈服强度比外加复合材料和基体分别高出28％和95．7％，断裂强度则相应提高了20．6％和88．5％；原位复合材料的强化机制主要是基体和增强体间界面结合良好，既能发挥基体的塑韧性，又能有效发挥自生增强体的强度优势，材料的断裂机制为自生纤维脆性断裂和劈裂。本研究同时表明，此方法工艺简单，成本低廉，且效率高，容易实现产业化。     

Forming induced interface structures for manufacturing hybrid metal composites

The performance of hybrid metal composite parts strongly depends on the properties of the mechanical interface between the two components as well as on the deformation behavior. A combination of different joining mechanisms (e.g. adhesive bonding, mechanical form-fit) offers enhanced interface performance. This paper shows a novel interface concept based on form-fit elements induced by forming. Compared to other joining methods, the forming induced interface structure provides improved strength as well as energy absorption. Shear tests show an increase of up to 40% in shear strength and up to 78% in fracture energy compared to non-structured adhesive bondings.     

外加颗粒增强表层复合材料制备方法

按照采用热源和陶瓷增强颗粒的添加方式,对外加颗粒增强表层复合材料的制备方法分类.详细介绍了堆焊、激光熔覆、激光熔射、等离子熔化-注射等颗粒增强表层复合材料的制备方法,并分析了各种制备技术的优缺点.堆焊特点是基体与表层为冶金结合,效率高.激光熔覆可以实现输入的准确控制,冷却速度快,热畸变小.但是堆焊和激光熔覆过程都存在裂纹问题.激光熔射不受基体可焊性限制,可制备颗粒增强相连续分布的表层,避免裂纹的形成.等离子熔化-注射技术与激光熔射技术类似,可以制备出增强相体积分数从0～100%连续变化的梯度复合材料.避免由于增强颗粒分布不均引起的裂纹,实现低投入、低成本运行.     

Hybrid joining process for carbon fiber reinforced thermosetting plastic and metallic thin sheets by chemical bonding and plastic deformation

A new joining process for thin metallic and continuous carbon fiber reinforced thermosetting plastic (CFRP) sheets is proposed. This joining process is a hybrid of chemical bonding and plastic deformation, usable for ultra-lightweight structures. In contrast to conventional joining methods, such as rivet joining with an adhesive, the proposed method does not require any additional components and can eliminate holes that would cut the continuous carbon fibers and cause stress concentration. Hence, a smaller weight and a higher joining quality can be attained, especially for thin sheets. Aiming at making comparison and demonstrating the applicability of the proposed hybrid joining method, two thermosetting CFRP sheets with different laminates were used as lap adherends in the experiment. The effects of the deformation temperature, the use of a dummy sheet and the relative positions of the sample and dummy sheet on the joining quality were systematically investigated and optimized. The optimal hybrid joint shows high-quality bonding without delamination or adhesive failure. The tensile shear test of single-lap A2017P-CFRP hybrid joints manufactured under optimal experimental conditions indicates that, compared with adhesive bonding and conventional rivet joining with an adhesive, the proposed joining method has obvious superiority in terms of tensile shear load, slip displacement and absorption energy.