三维机织复合材料制造缺陷及无损检测方法研究进展

Research progress on manufacturing defects and non-destructive testing methods for three-dimensional woven composites

  • 摘要: 纤维增强树脂基复合材料在航空航天领域应用广泛,但制造过程因组分材料与成型工艺的复杂物化特性,使其易产生制造缺陷。基于此,本文系统综述了现有三维机织树脂基复合材料的制造缺陷及其无损检测方法。首先,阐明复合材料在基体、纤维增强体及界面处的缺陷形成机制,重点分析树脂基体固化过程中的残余应力、孔洞生成规律及树脂富集缺陷;揭示树脂传递模塑(Resin Transfer Molding,RTM)工艺中因纤维束渗透不均导致的孔洞多尺度分布特性,以及纤维错位、断裂等缺陷的成因;其次,探讨纤维增强体缺陷(纤维皱褶、波纹和缺纱)对材料性能的显著影响以及纤维/树脂界面分层、脱粘等缺陷的损伤演化行为。最后,综述非接触式无损检测技术在多尺度缺陷表征中的应用,强调人工智能驱动的智能检测技术发展趋势,为三维机织复合材料制造工艺优化与可靠性提升提供理论支撑。

     

    Abstract: Fiber-reinforced resin matrix composites are widely used in the aerospace field, but due to the complex physicochemical properties of component materials and molding processes during manufacturing, they are prone to generating manufacturing defects. Based on this, this paper systematically reviews the existing manufacturing defects of three-dimensional woven resin matrix composites and their non-destructive testing methods. First, the formation mechanisms of defects within the matrix, fiber reinforcement, and interfaces are elucidated, with a specific focus on residual stresses, void generation laws, and resin-rich zones arising during the matrix curing process. The study reveals the multi-scale distribution characteristics of voids resulting from uneven fiber tow impregnation in the Resin Transfer Molding (RTM) process, as well as the causes of defects such as fiber misalignment and breakage. Secondly, the significant impact of reinforcement defects—including fiber wrinkling, waviness, and missing yarns—on material performance is discussed, alongside the damage evolution mechanisms of interfacial defects like delamination and debonding. Finally, the application of non-contact non-destructive testing techniques in characterizing multi-scale defects is summarized, emphasizing the emerging trend of intelligent detection driven by machine learning. This review provides theoretical support for the optimization of manufacturing processes and the enhancement of reliability for 3D woven composites.

     

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