国外空天往返飞行器用先进树脂基复合材料研究与应用进展

杨智勇; 张东; 顾春辉; 赵锐霞; 左小彪; 仝凌云; 尚呈元; 孙宏杰

doi:10.13801/j.cnki.fhclxb.20220325.004

国外空天往返飞行器用先进树脂基复合材料研究与应用进展

doi: 10.13801/j.cnki.fhclxb.20220325.004

1.
航天材料及工艺研究所，北京 100076
2.
中国运载火箭技术研究院　空天业务部，北京 100076

基金项目: 国防基础科研计划项目(JCKY2019203-WDZC006)

详细信息

通讯作者:
杨智勇，博士，高级工程师，研究方向为树脂基结构复合材料及工艺　E-mail: yzy512007@163.com

中图分类号: TB332
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出版历程
- 收稿日期: 2022-01-10
- 修回日期: 2022-02-25
- 录用日期: 2022-03-19
- 网络出版日期: 2022-03-29
- 刊出日期: 2022-07-30

Research and application of advanced resin matrix composites for aerospace shuttle vehicles abroad

1.
Aerospace Research Institute of Materials & Processing Technology, Beijing 100076, China
2.
Department of Aerospace Research and Exploration, China Academy of Launch Vehicle Technology, Beijing 100076, China

Funds: NIU Wen, YE Lei, LI Wenjie, et al.USA Defence Advaced Research projects Agency (DARPA) launches XS-1 aerospace vehicle program[J]Aerodynamic Missile Jounal, 2014, (11): 25-29(in Chinese).

摘要

摘要: 先进树脂基复合材料技术是空天往返飞行器轻量化结构系统设计与研制的重要基础支撑。本文首先阐述了国外空天往返飞行器用先进树脂基复合材料类型及性能，典型轻质复合材料结构制造工艺应用及发展情况，然后介绍了世界主要国家空天往返飞行器的复合材料结构研制应用进展情况，包括美国X系列飞行器、日本HOPE-X空天飞行器的复合材料应用情况，最后介绍了飞行器复合材料结构的技术发展趋势。
- 空天往返飞行器 /
- 复合材料 /
- 结构 /
- 制造工艺 /
- 研制 /
- 应用
Abstract: Advanced resin matrix composite technology is an important basic support for the design and manufacture of lightweight structural system of aerospace shuttle vehicles. Firstly, the type and properties of advanced resin matrix composites used in foreign aerospace vehicles, the manufacturing technology, application and development of typical lightweight composite structure were described. And then the vehicular composite structures manufacture and application in major countries were introduced, including the composite application of “X Series” vehicles in USA and HOPE-X vehicles in Japan. Finally, the technical development trend of aircraft composite structure was introduced.
- aerospace shuttle vehicle /
- composite /
- structure /
- process /
- manufacture /
- application

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图 1 树脂基复合材料的树脂基体发展演变：环氧树脂

Figure 1. Development and evolution of resin matrix of resin matrix composites: Epoxies

RFI—Resin film infiltration

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图 2 树脂基复合材料的树脂基体发展演变：耐中温和高温树脂

Figure 2. Development and evolution of resin matrix of resin matrix composites: Intermediate and high temperature resistant resins

ATF—Advanced tactic fighter; PETI—Phenylethynyl terminated polyimide; BMI—Bismaleimide; HSCT—High speed civil transport; LARC—Langley research center; CASTS—Composites for advanced space transportation systems

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图 3 碳纤维复合材料在空天飞行器机身上的应用结构形式

Figure 3. Application of carbon fiber composite on the fuselage of aerospace vehicle

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图 4 典型贮箱间结构组成分布

Figure 4. Typical intertanks structural lay-out

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图 5 飞行器结构复合材料制造技术发展演变

Figure 5. Evolution of aero structural composites fabrication technology

ACT—Advanced composite technology; QC—Quality control; JSF—Joint strike fighter; HSCT—High speed civil transport; RLV—Reusable launch vehicles

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图 6 X-33飞行器内部结构

Figure 6. Internal structure of X-33 aerospace vehicle

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图 7 X-33飞行器复合材料结构

Figure 7. Composite structure of X-33 aerospace vehicle

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图 8 X-33飞行器液氢贮箱内部结构及材料组成

Figure 8. Internal structure and material composition of X-33 aerospace vehicle LH2 tank

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图 9 X-37B飞行器

Figure 9. X-37B aerospace vehicle

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图 10 X-37B飞行器结构碳纤维复合材料组件示意图

Figure 10. Schematic diagram of carbon fiber composite components of X-37B aerospace vehicle structure

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图 11 装配中的X-37B飞行器机身

Figure 11. X-37B vehicle fuselage in assembly

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图 12 成功试验后运回的X-37B飞行器

Figure 12. X-37B vehicle returned after successful proof tests

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图 13 HOPE-X飞行器机身结构胶接

Figure 13. Fuselage structure bonding of HOPE-X vehicle

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图 14 HOPE-X飞行器结构组装

Figure 14. HOPE-X vehicle structural assembly

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图 15 IXV飞行器复合材料结构

Figure 15. IXV composite structure

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图 16 英国SKYLON飞行器

Figure 16. British SKYLON vehicle

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图 17 俄罗斯МРКН飞行器

Figure 17. Russian МРКН vehicle

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表 1 国外空天往返飞行器用典型树脂基复合材料信息

Table 1. Typical resin matrix composites for foreign aerospace shuttle vehicles

No.	Type	Grade	Reinforcement	Resin	T_g/℃	Typical mechanical properties
No.	Type	Grade	Reinforcement	Resin	T_g/℃	σ/MPa	Ε/GPa	τ/MPa	C_AI/MPa
1	CFRP	T300/934	T300(FA)	934	210	628	63	83	−
2	CFRP	T300/LTM45EL	UD	LTM45	210 (Post treatment at 175℃)	1338	128	79	−
3	CFRP	IM7/977-2	IM-7(UD)	977-2	205	2606	169	112	254
4	CFRP	IM7/8552	IM-7(UD)	8552	201	2648	162	139	214
5	CFRP	IM7/5250-4	IM-7(UD)	5250-4	288	2618	162	139	248
6	CFRP	IM7/5260	IM-7(UD)	5260	274	2691	165	159	345
7	CFRP	T650/5250-4	T650(FA)	5250-4	273	910	72	−	−
8	GFRP	F50-HRP	GF	PF	−	−	−	−	−
9	CFRP	IM7/PETI-5	IM-7(UD)	PETI-5	270 (Post treatment at 350℃)	1913	170	99	320
Notes: CFRP—Carbon fiber reinforced resin matrix composites; GFRP—Glass fiber reinforced resin matrix composites; GF—Glass fiber; PF—Phenol formaldehyde resin; σ—Tensile strength; E—Tensile modulus; τ—Shear strength of the short beam; C_AI—Compression strength after impacting; FA—Fabric; UD—Unidirectional band; F50-HRP—Grade of GFRP; T_g—Glass transition temperature: PETI-5—Polyimide resin; IM-7—Carbon fiber: LTM45—Epoxy resin.

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表 2 国外空天往返飞行器典型复合材料结构及其制造方案

Table 2. Typical composite structure and manufacturing process for foreign aerospace shuttle vehicles

No.	Segment	Frame name	Structural style	Manufacturing materials	Manufacturing process	Application
1	Wing	Wing full size test piece	Honeycomb sandwich structure	IM7/5250-4+ HRH-327 GF/PI honeycomb	Bonding curing process	Reusable vehicle prototype
2	Wing	Wing box	Rib/beam orthogonal skeleton structure	CF/BMI composite	Bonding curing process	Reusable vehicle prototype
3	Fuselage	Liquid hydrogen tank skin	Conical shell structure	IM7/977-2+Korex paper honeycomb	Automated placement+ Autoclave process	X-33
4	Wing	Wing skin	Large size curved laminated structure	LTM45EL low temperature curing composite	Oven curing process	X-34
5	Airframe	Lower fuselage, wing, upper fuselage	Complicated integrated structure	IM7/5250-4(Fuselage)+ IM7/PETI-5(Wing)	Integral co-curing process	X-37B
6	Fuselage	Skin panel, lower panel	Large curved laminated structure	−	Vacuum infusion process	HOPE-X
7	Fuselage	Longitudinal beam, bulkhead, ring rib	High dimensional accuracy, small-middle laminated structure	−	Prepreg layup+Autoclave process	HOPE-X
8	Airframe	Blended wing body, upper fuselage	Complicated integrated structure	−	Bonding curing process	HOPE-X
Notes: PI—Polyimide; CF—Carbon fiber; BMI—Bismaleimide resin; HOPE-X—H-Ⅱ orbiting plane experimental.

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表 3 国外空天往返飞行器典型复合材料应用情况

Table 3. Application of typical composite materials in foreign aerospace shuttle vehicles

No.	Application	Segment	Frame name	Structural style	Manufacturing materials	Manufacturing process
1	X-33	Fuselage	Upper TPS composite panel structure	Laminated structure	−	Hot pressing process
		Fuselage	Aft thrust structure	Laminated structure	−	Hot pressing process
		Wing	Skin	Laminated structure	IM7/5250-4 composite	Hot pressing process
		Wing	Inter-tank section	Laminated structure	IM7/5250-4 composite	Hot pressing process
		Liquid hydrogen tank	Tank skin	Honeycomb sandwich structure	IM7/977-2+ Korex paper honeycomb	Hot pressing process
			Horizontal septum, vertical septum	Laminated structure	IM7/977-2 composite	Hot pressing process
			Bulkhead, extended bulkhead	Honeycomb sandwich structure	IM7/977-2 composite	Hot pressing process
			Ring, longeron	Laminated structure	3D woven materials	RTM process
2	X-34	Fuselage	Composite sandwich member	Honeycomb sandwich structure	LTM45EL CFRP	Autoclave process
		Wing	Skin	Laminated structure	LTM45EL CFRP	Vacuum bag pressing process
		Wing	Frame member	Laminated structure	LTM45EL CFRP	−
		Rudder	Composite sandwich member	Honeycomb sandwich structure	LTM45EL CFRP	Co-curing process
		Tank	−	−	LTM45EL CFRP	−
3	X-40	Fuselage		Honeycomb sandwich structure	CF/epoxy composite	−
3	X-40	Wing, flaperon, tail, resistance plate		−	CF/BMI composite	−
4	X-40A	Fuselage		Honeycomb sandwich structure	CF/epoxy composite	−
5	X-37A	Air frame		Laminated and honeycomb sandwich structure	CF/BMI composite	−
6	X-37B	Fuselage	Upper wall panel, lower wall panel	honeycomb sandwich structure	IM7/5250-4 composite+ Flexcore+F50-HRP composite	Hot pressing process+ Bonding curing process
			Cover plate, longitudinal beam	Laminated structure	IM7/5250-4 composite	Hot pressing process
			Resistance plate	Laminated structure	IM7/PETI-5 composite	Hot pressing process
			Body flap	honeycomb sandwich structure	IM7/PETI-5 composite+ Titanium alloy honeycomb	Hot pressing process
		Wing	Upper skin, lower skin, beam, sleeve beam	honeycomb sandwich structure	IM7/PETI-5 composite+ Titanium alloy honeycomb	Hot pressing process
7	HOPE-X	Fuselage	Skin panel, lower panel	Large curved laminated structure	CFRP	Vacuum infusion process
		Fuselage	Longitudinal beam, bulkhead, ring rib	High dimensional accuracy, small-middle laminated structure	CFRP	Prepreg layup+Autoclave process
		Air frame	Blended wing body, upper fuselage	Complicated integrated structure	CFRP	Bonding curing process
8	IXV	Air frame	Beam, cover plate, wall panel	−	CFRP	−

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