Experimental analysis of drilling fiber reinforced composites

In comparison with metals, long-fiber reinforced composites have a layered structure, with different properties throughout their thickness. When drilling such structures, internal defects like delamination occur, caused by the drilling loads and their uneven distribution among the plies. The current experimental analysis is focused towards determining the cutting loads distribution (axial and tangential) along the work-piece thickness and tool radius by analyzing the thrust and torque curves when drilling with 3 different drills carbon-fiber (CFRP) and glass-fiber (GFRP) reinforced composite plates. A wide range of cutting parameters is tested. The highest loads are found at the tool tip in the vicinity of the chisel edge for all cases. It is also found that the maximum load per ply varies mainly with the axial feed rate and tool geometry, while the spindle speed has little or no influence. The analysis is useful for selecting the cutting parameters for delamination free drilling and also for conducting drill geometry optimizations.     

Drilling of long fiber reinforced thermoplastics—Influence of the cutting edge on the machining results

The cutting edge has a large impact on the performance of a cutting tool when drilling fiber reinforced plastics (frp). Delamination, burrs and defects at hole entry and exit pose a challenge when drilling frp. Within the presented work the influence of the cutting edge on drilled hole quality when machining long fiber reinforced thermoplastics is investigated. Major influencing determinants on the machining results when drilling long fiber reinforced thermoplastics are feed force and fiber separation. The interdependencies between cutting edge radius, feed forces and fiber separation are described in a phenomenological model.     

Preparation of three-dimensional braided carbon fiber reinforced mullite composites from a sol with high solid content

To prepare the three-dimensional braided carbon fiber reinforced mullite (3D C/mullite) composites, an Al₂O₃-SiO₂ sol with a solid content of 20% (mass fraction) and an Al₂O₃/SiO₂ mass ratio of 2:1 was selected as the raw material. Characteristics and mullitization of the sol were analyzed throughly. It is found that the formation of mullite is basically completed at 1300 °C and the gel powders exhibit favorable sintering shrinkage. The 3D C/mullite composites without interfacial coating were fabricated through the route of vacuum impregnation-drying-heat treatment. Satisfied mechanical properties with a flexural strength of 241.2 MPa and a fracture toughness of 10.9 MPa·m^1/2 are obtained although the total porosity reaches 26.0%. Oxidation resistances of the composites at 1200, 1400 and 1600 °C were investigated. Due to the further densification of matrix, the 3D C/mullite composites show tiny mass loss and their mechanical properties are well retained after oxidation at 1600 °C for 30 min.     

The effect of plasma spraying power on the structure and mechanical properties of hydroxyapatite deposited onto carbon/carbon composites

This paper deals with the effect of plasma spraying power on hydroxyapatite (HA) coatings on carbon/carbon composites (C/C composites). The microstructure and phase composition of the as-sprayed coatings have been examined by scanning electron microscopy (SEM) and X-ray diffraction (XRD), respectively. The shear strength of the HA coatings–C/C substrates was detected on a RGD-5 tensile testing machine. Results indicate that the melting extent and the shear strength of the coatings were evidently improved with the increasing of spraying power. Moreover, the amount of decomposed phases is increased and the content of crystalline HA of coatings was slightly changed. Observation of fracture surfaces shows that carbon fiber bundles can bond well with HA coatings using 40 kW spraying power.     

Shielding performance of metal fiber composites

Metal fibers have been applied to construct composites with desirable electromagnetic interference shiel ding effectiveness and mechanical properties. Copper and stainless steel fibers were prepared with micro-saw fiberpulling combined cutting method. The cross section of the fibers is hook-like, which is beneficial to the improvement of bonding strength. Cement-based composites with copper and stainless steel fibers were fabricated and their electromagnetic shielding effectiveness was measured in the frequency range of 1 - 5 GHz. The results show that the electromagnetic interference shielding effectiveness of those composites is enhanced by the addition of metal fibers,which functions mainly due to the absorption. At some frequencies, 20 dB or more difference is obtained between the materials with and without metal fibers.     

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.     

Mechanistic force modeling for milling of carbon fiber reinforced polymers with double helix tools

Carbon fiber reinforced polymers (CFRP) have emerged as the material of choice to satisfy increasing demand for lighter aircrafts. Machinability characteristics of CFRPs are quite different than those of metals; therefore, special tool designs have been developed for CFRP machining. The double helix end mill design compresses the upper and lower sides of the laminate using opposite helix angles that eliminate delamination. A mechanistic force model for double helix tools is developed based on milling force data obtained on flat end mills. The proposed model can be used to improve double helix tool designs and to optimize milling process parameters.     

连续SiC纤维增强钛基复合材料界面反应研究

针对连续SiC纤维增强钛基复合材料界面反应速率、反应产物进行了研究.采用基体-纤维涂覆法和热等静压工艺,制备了连续W芯SiC纤维增强TC17复合材料.对复合材料进行不同温度、不同时间热暴露,通过SEM、TEM、EDS,表征分析了界面反应层厚度、界面处化学成分及界面反应产物类型.结果表明:C涂层能有效保护SiC纤维;界面反应层处的主要元素为Ti和C;制备状态试样的界面反应产物为TiC1-x,靠近C涂层的TiC1-x晶粒较细小,靠近基体TiC1-x晶粒较粗大;高温热暴露使界面反应加剧,反应层厚度增加,反应层的生长符合抛物线规律,反应的动力学参数为频率因子k0=1.33×10-3m·s-1/2,反应激活能Q=243.22 kJ·mol-1.     

化学镀表面改性石英纤维复合材料与因瓦合金的真空钎焊

采用化学镀镍方法对石英纤维复合材料进行了表面改性,研究了镀镍工艺对改善石英纤维复合材料焊接性的作用.结果表明,采用Ag-Cu共晶箔片对化学镀镍改性的石英纤维复合材料与因瓦合金在830℃保温10min进行真空钎焊后,形成由(Cu,Ni),Ni(s,s),Ag(s,s)等固溶组织及Ni元素与石英纤维间钉扎作用共同构成的界面连接结构,此时接头室温抗剪强度达到29MPa;这也说明,镀镍层通过扩散反应发挥了增强复合材料表面结构、实现致密冶金连接的作用.     

Microstructures and wear resistance of large WC particles reinforced surface metal matrix composites produced by plasma melt injection

Large WC particles (− 840 μm-+ 420 μm) reinforced surface metal matrix composites (SMMCs) were produced using plasma melt injection (PMI) process on a Q235 (similar to ASTM A570 Gr. A) low carbon steel substrate. Microstructures of the SMMC were observed using scanning electron microscope (SEM), and the composition was determined with energy dispersion spectroscopy (EDS). Phases were analyzed with X-ray diffraction. Micro-hardness of the SMMC was tested. Wear losses of the SMMC layer were evaluated under dry friction conditions and compared with those of the substrate material. The results show that the large WC particles are caught by crystallized metal and stay in the upper part of the SMMC layer, and there is only a little melting on the outer surface. No sinking down of WC particles occurs. The SMMC layer is well bonded to the substrate, and the interface is crack free. The wear resistance of the Q235 substrate is greatly improved with large WC particles injected.     

针刺整体毡C/C复合材料整体喉衬烧蚀分析

采用针刺整体毡炭／炭（C／C）复合材料整体喉衬进行小型固体火箭发动机地面点火实验，结合扫描电镜（SEM）及能谱分析（EDS），分别对烧蚀后整体喉衬收敛部位、喉径部位和扩张部位的烧蚀形貌进行分析。结果表明：在较高压强（12～14MPa）条件下，针刺整体毡C／C复合材料整体喉衬烧蚀均匀，烧蚀型面光滑、烧蚀率低，但因轴向纤维少及轴向强度较低，接近喉径部位的收敛部位和喉径部位易产生分层；不同部位的烧蚀形貌不同，是由于整体喷管中的燃气温度、组分浓度和速度所致。     

石英纤维复合材料与因瓦合金的胶接辅助钎焊连接分析

通过表面涂覆活性胶改性的方法,实现了石英纤维复合材料与因瓦合金的胶接辅助钎焊连接.结果表明,含有钛的液态活性胶在焊接加热过程中与石英纤维复合材料表面纤维发生反应,并通过Ag-Cu共晶钎料层、铜中间层与因瓦合金获得致密连接,接头产生TiO,TiC,CuTi,Fe2Ti等化合物,其结构可表示为QFSC/TiO+Si+TiC+Cu(s,s)/CuTi+Cu(s,s)+Ag(s,s)/Cu(s,s)+Ag(s,s)+Fe2Ti/Invar.由不同钎焊温度接头的剪切性能对比试验得出,在850℃保温15min时的接头抗剪强度达到最大值44MPa.表面涂覆活性胶对钎料润湿的促进作用、活性金属元素Ti与复合材料纤维的化学反应及接头焊缝区产生的化合物生成相是影响连接性能的主要因素.     

纤维增强热塑性树脂复合材料与激光连接研究进展

为研究碳纤维增强复合材料和铝合金搭接激光焊接过程的温度变化规律,文中以6061铝合金和碳纤维增强尼龙66复合材料(CF/PA66)为研究对象,建立了基于热传导的有限元模型,使用SYSWELD软件对两种材料搭接激光焊接过程进行数值模拟,并通过试验验证了模型的准确性;在此基础上研究了激光功率、焊接速度、搭接宽度、冷却条件、工装导热条件对接头温度场的影响规律;研究发现, CF/PA66树脂熔化区域随着激光功率的增大而增加,随冷却速度的增大而减小,同种工艺参数下材料搭接尺寸对界面树脂最大熔化宽度无影响,水冷条件能够显著降低CF/PA66树脂熔化量,导热材料热导率越大,对PA66树脂熔化量的降低作用越显著.

     

Developments in the non-traditional machining of particle reinforced metal matrix composites

The non-traditional machining of particulate reinforced metal matrix composites is relatively new. However, researchers seem to pay more attention in this field recently as the traditional machining of particulate reinforced metal matrix composites is very complex. This research investigates different non-traditional machining, such as electro-discharge, laser beam, abrasive water jet, electro-chemical and electro-chemical discharge machining of this composite materials. The machining mechanism, material removal rate/machining speed and surface finish have been analysed for every machining process. This analysis clearly shows that vaporisation, melting, chemical dissolution and mechanical erosion are the main material removal mechanisms during non-traditional machining. The thermal degradation and the presence of reinforcement particles mainly damage the machined surface. The understanding of electro-discharge, laser beam and abrasive water jet machining is more developed than that of electro-chemical and electro-chemical discharge machining for particulate reinforced MMC.     

TiB2/Cu复合材料用于电火花加工电极的可行性探讨

从分析电火花加工对电极材料的基本要求入手，结合TiB2／Cu复合材料在目前制备工艺条件下所获得的电学、力学性能等特性，采用对比研究的方法，探讨将其作为电火花加工电极材料的可行性。     

An experimental bone defect healing with hydroxyapatite coating plasma sprayed on carbon/carbon composite implants

Hydroxyapatite coatings with proper thickness were coated on fusion-cage-like carbon fiber reinforced carbon composite implants for bone tissue reconstruction by the plasma spraying technique. Autogenously bone filled fusion-cage-like implants were grafted in hybrid goats' tibia for 328 days. By means of X-ray photography, histological observation and scanning electron microscopy, the biological behaviors of the coating were compared with the pure carbon fiber reinforced carbon composites and the bone defect healing effect of the implants was evaluated. The results indicated that hydroxyapatite coating has more obvious osteoconductive effect than the pure carbon fiber reinforced carbon composites with surface bioinert. The calcium and phosphorus ions leached from HA provide a suitable biological mineralization environment that accelerates the metabolism of bone, the osteoblast differentiation and collagen synthesis. The coating can significantly speed up the bone defect healing process and improve the surface bioactivity of carbon fiber reinforced carbon composites.     

聚氯乙烯包覆处理竹纤维对其增强摩擦材料摩擦学性能的影响

采用聚氯乙烯(PVC)包覆法处理竹原纤维,并将其应用于增强树脂基摩擦材料。通过定速摩擦试验、表面形貌观察及能谱分析、热失重分析等方法探讨PVC包覆处理竹纤维对其增强摩擦材料摩擦学性能的影响。结果表明,竹纤维经过PVC包覆处理后,能显著提高摩擦材料的整体摩擦学性能,尤其是中高温的摩擦因数。PVC溶液质量浓度为20 g/L,处理时间为20 min,材料具有良好的综合摩擦磨损性能。PVC包覆处理后竹纤维表面可形成一层均匀的PVC复合界面膜,使复合材料中竹纤维和树脂基体的界面黏结性能得到改善,令竹纤维在较高温度下仍然能对基体起到增强作用,提高了材料的摩擦磨损性能。     

Compressive strength of carbon nanotubes grown on carbon fiber reinforced epoxy matrix multi-scale hybrid composites

The characteristics of interface between fiber reinforcement and matrix have a strong influence on the properties of a composite material. Multiwalled carbon nanotubes were grown on carbon fibers by catalytic decomposition of acetylene using thermal chemical vapor deposition technique at 700 °C to modify the fiber surface. Unidirectional multi-scale composites were fabricated using these carbon nanotubes grown fibers with epoxy matrix. As the nanotubes were directly grown on the fibers they get strongly attached with the fibers thus modifying their surface condition which in turn alters the fiber/matrix interface. Modification of the fiber/matrix interface is therefore expected to change the properties of composites. The compressive strengths of these composites were measured which showed a significant enhancement of 43% and 94% in the longitudinal and transverse compressive strengths respectively as compared to composites made of carbon fibers which underwent a similar thermal cycle but without carbon nanotubes growth. The morphology of CNTs grown on carbon fibers was examined at nano-level using HRTEM which showed growth of carbon nanotubes with different morphology and diameter ranging from 5-50 nm.     

Aging behavior of Al2O3 short fiber reinforced Al-Cu alloy composites

Al2O3 short fiber reinforced AI-Cu composites containing 1%, 3%, 5% and 7% Cu were fabricated by a squeeze casting technique. The as-cast Al2O3/Al-Cu composites were solution treated at 535 ℃ and then aged at 170, 190 and 210 ℃, respectively. Age hardening behavior of the Al2O3/Al-Cu composites was analyzed by measuring the hardness of the samples at different aging temperatures and aging time. Microstructures of the composites were observed by transmission electron microscope（TEM）. The results indicate that the hardness of the Al2O3/Al-Cu composites containing 7% Cu is much higher than that containing 1%-5% Cu because of the large amount of CuAl2 precipitant in the Al2O3/Al-Cu composite. With the increase of Cu content from 1% to 7%, the time needed for the appearance of peak hardness shortened, indicating that the addition of Cu can accelerate the kinetic of CuAl2 precipitation in the Al2O3/Al-Cu composites. The Al2O3/Al-Cu composite containing 7% Cu shows the highest increment of hardness by aging treatment. Therefore, in order to get a higher peak hardness, the Al2O3/Al-Cu composites need more Cu addition as compared with the un-reinforced Al-Cu alloys.     

W-Cu composites reinforced by copper coated graphene prepared using infiltration sintering and spark plasma sintering: A comparative study

In order to solve problems of significant interfacial reactions and agglomeration in graphene reinforced WCu composites, powders of copper coated graphene (Cu@Gr) were pre-mechanically mixed with tungsten and copper powders, and then graphene doped WCu composites were sintered using two different methods, e.g., spark plasma sintering (SPS) and infiltration sintering. Microstructural analysis showed that the doped Cu@Gr powder can effectively inhibit the interfacial reaction between graphene and tungsten, prevent the segregation of graphene, and evenly distribute the copper in the binder phase. When the mixed concentration of Cu@Gr was 0.45 wt%, uniform distributions of W phase and Cu phase were obtained in the composite, and the mechanical properties and conductivity of this composite achieved their best results. When the doping content was further increased to 0.8%, WC phase was found in all alloys, thus resulting in poor mechanical and physical properties. Comparing the microstructures produced using these two methods, the composites prepared using the infiltration sintering method showed network distribution of copper phase and segregation of copper, whereas the composites prepared using the SPS method showed network skeleton phase of tungsten. Although the SPS process was performed in a much shorter time, the mechanical properties of the composites sintered using the SPS process did not show much differences with those sintered using the infiltration sintering method.