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碳纤维/聚苯硫醚热塑性复合材料电阻焊接工艺

路鹏程 陈栋 王志平

路鹏程, 陈栋, 王志平. 碳纤维/聚苯硫醚热塑性复合材料电阻焊接工艺[J]. 复合材料学报, 2020, 37(5): 1041-1048. doi: 10.13801/j.cnki.fhclxb.20190807.002
引用本文: 路鹏程, 陈栋, 王志平. 碳纤维/聚苯硫醚热塑性复合材料电阻焊接工艺[J]. 复合材料学报, 2020, 37(5): 1041-1048. doi: 10.13801/j.cnki.fhclxb.20190807.002
LU Pengcheng, CHEN Dong, WANG Zhiping. Resistance welding technology of carbon fiber/polyphenylene sulfide thermoplastic composites[J]. Acta Materiae Compositae Sinica, 2020, 37(5): 1041-1048. doi: 10.13801/j.cnki.fhclxb.20190807.002
Citation: LU Pengcheng, CHEN Dong, WANG Zhiping. Resistance welding technology of carbon fiber/polyphenylene sulfide thermoplastic composites[J]. Acta Materiae Compositae Sinica, 2020, 37(5): 1041-1048. doi: 10.13801/j.cnki.fhclxb.20190807.002

碳纤维/聚苯硫醚热塑性复合材料电阻焊接工艺

doi: 10.13801/j.cnki.fhclxb.20190807.002
基金项目: 天津市自然科学基金(19JCQNJC02500);中国民用航空局科技基金(MHRD20160106);中央高校中国民航大学专项(3122018L001)
详细信息
    通讯作者:

    路鹏程,硕士,实验师,研究方向为复合材料 E-mail:pclu@cauc.edu.cn

  • 中图分类号: TB332;TQ327.3

Resistance welding technology of carbon fiber/polyphenylene sulfide thermoplastic composites

  • 摘要: 本文针对航空器结构用碳纤维/聚苯硫醚(CF/PPS)复合材料为研究对象,开展电阻焊接工艺研究;利用CF/PPS复合材料混编织物作为电阻元件,成功制备了CF/PPS复合材料层板电阻焊接接头;重点利用Taguchi方法和方差分析获取CF/PPS复合材料层板电阻焊接最佳工艺参数(电流为12 A,压力为1.5 MPa,时间为30 min)及各参数对焊接接头剪切强度的贡献(电流为83.37%,压力为9.55%,时间为6.02%)。最佳焊接工艺参数焊接的接头单搭接剪切强度约为17.88 MPa;同时,对最佳参数焊接试样(H-LSS)和较低剪切强度试样(L-LSS)的焊接接头截面和剪切失效断口形貌进行了观察和分析。结果表明:H-LSS试样的焊缝区域树脂填充和浸润良好,且主要剪切失效形式为层间剪切失效,即为纤维与树脂基体脱黏及CF/PPS织物复合材料断裂混合失效;L-LSS试样的焊缝区域树脂填充和浸润较差,存在较多空隙,且剪切失效形式为焊缝界面脱黏失效。

     

  • 图  1  碳纤维/聚苯硫醚(CF/PPS)复合材料混编织物

    Figure  1.  Carbon fiber/polyphenylene sulfide (CF/PPS) composite mixed woven fabric

    图  2  热塑性树脂基复合材料焊接设备

    Figure  2.  Welding machine of thermoplastic resin matrix composites

    图  3  CF/PPS复合材料单搭接焊接示意图

    Figure  3.  Schematic diagram of single lap welding of CF/PPS composite laminate

    图  4  试验件尺寸

    Figure  4.  Test piece size

    图  5  CF/PPS复合材料电阻焊接控制过程

    Figure  5.  Resistance welding control process of CF/PPS composites (Tm—PPS hot melt temperature; Ps—Pre-pressure during welding; Pm—Rated pressure during welding; Tf—Cooling rate; RT—Room temperature; t1—Temperature rise time of resistance welding; t2—Pre-pressure time; t 3—Constant temperature and pressure time; t4—Cooling time at Tf rate; t5—Natural cooling time)

    图  6  CF/PPS复合材料的电阻试件

    Figure  6.  Resistance specimen of CF/PPS composites

    图  7  CF/PPS复合材料电阻焊接工艺参数主效应图

    Figure  7.  Main effect diagram of process parameters of CF/PPS composite resistance welding

    图  8  CF/PPS复合材料电阻焊接接头截面形貌

    Figure  8.  Cross-sectional morphology of CF/PPS composite resistance welded joints

    图  9  CF/PPS复合材料电阻焊接单搭接剪切断口形貌

    Figure  9.  Shear fracture morphology of CF/PPS composite resistance welding single lap

    表  1  因素和水平

    Table  1.   Factors and levels

    ParametersLevels
    1234
    Factor A(Current/A)8101214
    Factor B(Pressure/MPa)0.51.01.52.0
    Factor C(Time/min)10203040
    下载: 导出CSV

    表  2  CF/PPS复合材料层板的正交实验参数及结果

    Table  2.   Input parameters of orthogonal arrays and performance characteristics of CF/PPS composite laminates

    Expt.runFactorPerformance
    Current
    A/A
    Pressure
    B/MPa
    Time
    C/min
    LSS/MPaη
    180.510 3.6811.32
    281.020 5.3414.55
    381.530 6.8616.73
    482.040 5.3714.60
    5100.520 9.0219.10
    6101.010 8.6518.74
    7101.54012.4621.91
    8102.03010.3420.29
    9120.53013.0522.31
    10121.04016.7824.50
    11121.51014.2823.09
    12122.02012.1521.69
    13140.540 7.4917.49
    14141.030 9.6519.69
    15141.520 9.8419.86
    16142.010 7.5117.51
    Average η18.96
    Notes: LSS—Lap shear strength; η—Signal to noise ratio.
    下载: 导出CSV

    表  3  CF/PPS复合材料Taguchi方法预测最优因子水平、焊接接头剪切强度和实验验证结果

    Table  3.   Taguchi method for predicting optimal factor level, weld joint shear strength and experimental verification results of CF/PPS composites

    Factor AFactor BFactor C
    Optimal parameter121.530
    Taguchi method predicted optimum shear strength/MPa18.07
    Verification experiment results shear strength/MPa17.88
    下载: 导出CSV

    表  4  CF/PPS复合材料层压板焊接接头信噪比方差分析

    Table  4.   Analysis of variance of signal-to-noise ratio of CF/PPS composite laminate welded joints

    ANOVA-Signal-to-noise ratio values
    Process parametersLevel mean valueSSdfVarianceFSig.P
    Level 1Level 2Level 3Level 4
    Factor A(Current)14.3020.0122.9018.64153.704351.235156.9570 83.37
    Factor B(Pressure)17.5619.3720.4018.52 17.6003 5.867 17.9720.02 9.55
    Factor C(Time)17.6718.8019.7519.62 11.1073 3.702 11.3430.05 6.02
    Errors 1.95960.326 1.06
    Total184.37015100.00
    Notes: SS—Sum of squares of mean deviation; df—Degrees of freedom; F—F statistics; Sig.—Significance; P—Probability.
    下载: 导出CSV
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出版历程
  • 收稿日期:  2019-06-06
  • 录用日期:  2019-07-19
  • 网络出版日期:  2019-08-08
  • 刊出日期:  2020-05-15

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