Study on the interlayer bonding property of dry fiber tows used in automated fiber placement for aerospace composites
-
摘要: 为了保证干纤维预成型体的层间良好贴覆,分别对一种成熟应用于航空级主承力构件的干纤维自动铺放材料和一种研发级材料进行层间粘结性研究。采用热压工艺模拟自动铺丝过程,通过T型剥离和多种表征方法测试干纤维层间粘结力、表面性能和定型剂扩展,比较两种干纤维的层间粘结力,并研究其层间粘结机制。研究发现:成熟干纤维的层间粘结力在一定范围内远大于研发干纤维,二者均显著受到层压温度、层压时间及协同作用的影响,但最显著的影响因素不同;干纤维层间粘结机制与干纤维表面性能、定型剂性能及受热扩展过程有关,推测成熟干纤维的较高层间粘结力与定型剂的交联有关;此外,通过自动铺放工艺的验证,在一定层压时间范围内,采用热压工艺代替自动铺丝进行干纤维层间粘结性的评价具有良好可靠性;最后,干纤维表面涂覆热塑性增韧材料后,层间粘结力大幅下降。通过对材料和工艺的研究,本文为干纤维自动铺丝工艺的优化提供了数据及理论支持。Abstract: In order to guarantee the good adhesion between layers of dry fiber preform, the interlayer bonding properties of two kinds of automatic fiber placement dry fiber tows were investigated, one has been maturely used in aerospace primary force-taking structure and the other one is under development. Dry fiber laminate samples were prepared by hot pressing to simulate the automatic fiber placement. The interlayer bonding property, surface properties and binder extension of dry fibers were measured by the T-type peeling test and various characterization methods. The interlayer bonding strength of the two kinds of dry fibers was compared and the interlayer bonding mechanism was studied. The results show that the interlayer bonding strength of mature dry fibers is much greater than that of developing dry fibers in a certain temperature range. Both of them are significantly affected by lamination temperature, lamination time and the synergistic effect, but the most significant factors of the two materials are different. The interlayer bonding mechanism of dry fibers is related to surface properties of dry fibers, properties of binder and the binder extension at elevated temperature. It is speculated that the interlayer bonding force of mature dry fibers is related to the crosslinking of the binder. In addition, through the verification of the automatic laying process, the hot pressing process has good reliability in the evaluation of interlayer bonding between the dry fiber layers within a certain lamination time comparing to the automatic fiber placement. Finally, when the dry fiber surface is coated with the thermoplastic toughening material, the adhesion between layers decreases significantly. Through the study of materials and technology, this paper provides data and theoretical support for the optimization of automatic fiber placement process.
-
Key words:
- automated fiber placement /
- dry fiber tow /
- preform /
- interlayer bonding /
- binder
-
图 6 压力作用时间10 s时成熟干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 层间粘结力与标准偏差
Figure 6. Relationship curves between T-peel force and displacement for mature dry fiber tow samples with compression time of 10 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 7 压力作用时间30 s时成熟干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 7. Relationship curves between T-peel force and displacement for mature dry fiber tow samples wtth compression time of 30 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 8 压力作用时间60 s时成熟干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 8. Relationship curves between T-peel force and displacement for mature dry fiber tow samples with compression time of 60 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 9 压力作用时间10 s时研发干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 9. Relationship curves between T-peel force and displacement for developing dry fiber tow samples with compression time of 10 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 10 压力作用时间30 s时研发干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 10. Relationship curves between T-peel force and displacement for developing dry fiber tow samples with compression time of 30 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 11 压力作用时间60 s时研发干纤维层合样条的T型剥离力-位移曲线:(a) 层压温度110℃;(b) 层压温度140℃;(c) 层压温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 11. Relationship curves between T-peel force and displacement for developing dry fiber tow samples with compression time of 60 s: (a) Compression temperature 110℃; (b) Compression temperature 140℃; (c) Compression temperature 170℃; (d) Average T-peel force and standard deviation
图 18 环氧树脂与成熟干纤维带在不同温度下的接触角:(a) 成熟干纤维定型剂面在80℃时与环氧树脂的接触角;(b) 成熟干纤维网纱面在80℃时与环氧树脂的接触角;(c) 成熟干纤维定型剂在110℃时与环氧树脂的接触角;(d) 成熟干纤维网纱面在110℃时与环氧树脂的接触角
Figure 18. Contact angle between epoxy resin and mature dry fiber tow at varied temperature: (a) Contact angle between epoxy resin and binder surface of mature dry fiber tow at 80℃; (b) Contact angle between epoxy resin and fiber veil surface of mature dry fiber tow at 80℃; (c) Contact angle between epoxy resin and binder surface of mature dry fiber tow at 110℃; (d) Contact angle between epoxy resin and fiber veil surface of mature dry fiber tow at 110℃
图 23 环氧树脂与研发干纤维带在不同温度下的接触角:(a)定型剂面在80℃时与环氧树脂的接触角;(b)网纱面在80℃时与环氧树脂的接触角;(c)定型剂在110℃时与环氧树脂的接触角;(d)网纱面在110℃时与环氧树脂的接触角
Figure 23. Contact angle between epoxy resin and developing dry fiber tow at varied temperature: (a) Contact angle between epoxy resin and binder surface at 80℃; (b) Contact angle between epoxy resin and veil surface at 80℃; (c) Contact angle between epoxy resin and binder surface at 110℃; (d) Contact angle between epoxy resin and veil surface at 110℃
图 26 不同铺丝温度时,成熟干纤维层合样条的T型剥离力-位移曲线:(a) 铺丝温度110℃;(b) 铺丝温度140℃;(c) 铺丝温度170℃;(d) 本测试中平均T型剥离力与标准偏差
Figure 26. Relationship curve between T-peel force and displacement for mature dry fiber tow samples when placed by automatic placement machine:(a) Placing temperature 110℃; (b) Placing temperature 140℃; (c) Placing temperature 170℃; (d) Average T-peel force and standard deviation
表 1 实验设计因子及水平信息
Table 1. Experiment design factor and levels information
Factor Level Value Compression temperature/oC 3 110, 140, 170 Compression time/s 3 10, 30, 60 表 2 层合样条名称、材料和制备参数
Table 2. Name, materials and experiments parameters of test samples
Sample
lablesCompression temperature/℃ Compression time/s Sample
materialMA11010 110 10 Mature MA14010 140 10 Mature MA17010 170 10 Mature MA11030 110 30 Mature MA14030 140 30 Mature MA17030 170 30 Mature MA11060 110 60 Mature MA14060 140 60 Mature MA17060 170 60 Mature DE11010 110 10 Developing DE14010 140 10 Developing DE17010 170 10 Developing DE11030 110 30 Developing DE14030 140 30 Developing DE17030 170 30 Developing DE11060 110 60 Developing DE14060 140 60 Developing DE17060 170 60 Developing 表 3 成熟干纤维测试结果方差分析
Table 3. Analysis of variance of test results of developing dry fiber
Sources Degree of freedom Adjusted sum of squares of deviation from mean Adjusted mean value F-value of
hypothesis-testingP-value of
hypothesis-testingTemperature 2 0.022 0.011 40.78 0.000 Time 2 0.030 0.015 56.32 0.000 Temperature×time 4 0.018 0.004 16.33 0.000 表 4 国产干纤维测试结果方差分析
Table 4. Analysis of variance of test results of developing dry fiber
Sources Degree of freedom Adj SS Adj MS F-value P-value Temperature 2 0.0107 0.005 43.55 0.000 Time 2 0.010 0.005 38.73 0.000 Temperature×time 4 0.006 0.001 12.16 0.000 表 5 自动铺丝(AFP)实验制备的层合样条名称及制备参数
Table 5. Name and experiments parameters of test samples made by automated fiber placement (AFP)
Sample lables Target temperature/℃ Setting power/W Actual temperature/℃ AFP110 110 260 107±15 AFP140 140 340 143±15 AFP170 170 420 176±15 -
[1] SUN S, HAN Z, FU H, et al. Defect characteristics and online detection techniques during manufacturing of FRPs using automated fiber placement: A review[J]. Polymers,2020,12(6):1337-1359. doi: 10.3390/polym12061337 [2] BUDELMANN D, SCHMIDT C, MEINERS D, et al. Prepreg tack: A review of mechanisms, measurement, and manufacturing implication[J]. Polymer Composites,2020,41(9):3440-3458. doi: 10.1002/pc.25642 [3] 陈吉平, 李岩, 刘卫平, 等. 连续纤维增强热塑性树脂基复合材料自动铺放原位成型技术的航空发展现状[J]. 复合材料学报, 2019, 36(4):784-794. doi: 10.13801/j.cnki.fhclxb.20190102.001CHEN Jiping, LI Yan, LIU Weiping, et al. Development of AFP in-situ consolidation technology on continuous fiber reinforced thermoplastic matrix composites in aviation[J]. Acta Materiae Composite Sinica,2019,36(4):784-794(in Chinese). doi: 10.13801/j.cnki.fhclxb.20190102.001 [4] 张洋, 钟翔屿, 包建文. 先进树脂基复合材料自动丝束铺放技术研究现状及发展方向[J]. 航空制造技术, 2013, 23: 131-136, 140(in Chinese).ZHANG Yang, ZHONG Xiangyu, BAO Jianwen. Research status and future trend of automated fiber placement technology for advanced polymer matrix composites[J]. Aeronautical Manufacturing Technology, 2013, 23: 131-136, 140(in Chinese). [5] KADIYALA A K, PORTELA A, DEVLIN K, et al. Mechanical evaluation and failure analysis of composite laminates manufactured using automated dry fibre tape placement followed by liquid resin infusion[J]. Composites Science and Technology,2021,201:108512. doi: 10.1016/j.compscitech.2020.108512 [6] GINGER G. Resin infused MS-21 wings and wing box[J]. High Performance Composites,2014,1:29. [7] JUAN S. OAK aero composites choose innovative solutions to build the MS-21 composire wings[R]. Paris: JEC composite, 2012. [8] WEI K, LIANG D, MEI M, et al. Preforming behaviors of carbon fiber fabrics with different contents of binder and under various process parameters[J]. Composites Part B: Engineering,2019,166:221-232. doi: 10.1016/j.compositesb.2018.11.143 [9] LIU Y N, YUAN C, LIU C, et al. Study on the resin infusion process based on automated fiber placement fabricated dry fiber preform[J]. Scientific Reports,2019,9(1):7440. doi: 10.1038/s41598-019-43982-1 [10] VELDENZ L, DI M, ASTWOOD S, et al. Characteristics and processability of bindered dry fiber material for automated fiber placement[J]. ECCM17-17 th European Conference on Composite Materials, Munich, Germany,2016. [11] CROSSLEY R J, SCHUBEL P J, WARRIOR N A. The experimental determination of prepreg tack and dynamic stiffness[J]. Composites Part A: Applied Science and Manufacturing,2012,43(3):423-434. doi: 10.1016/j.compositesa.2011.10.014 [12] DI FRANCESCO M, VELDENZ L, DELLANNO G, et al. Heater power control for multi-material, variable speed automated fibre placement[J]. Composites Part A: Applied Science and Manufacturing,2017,101:408-421. doi: 10.1016/j.compositesa.2017.06.015 [13] CROFT K, LESSARD L, PASINI D, et al. Experimental study of the effect of automated fiber placement induced defects on performance of composite laminates[J]. Composites Part A: Applied Science and Manufacturing,2011,42(5):484-491. doi: 10.1016/j.compositesa.2011.01.007 [14] VELDENZ L, DI FRANCESCO M, GIDDINGS P, et al. Material selection for automated dry fiber placement using the analytical hierarchy process[J]. Advanced Manufacturing: Polymer & Composites Science,2018,4(4):83-96. [15] BELHAJ M, DELEGLISE M, COMAS-CARDONA S, et al. Dry fiber automated placement of carbon fibrous preforms[J]. Composites Part B: Engineering,2013,50:107-111. doi: 10.1016/j.compositesb.2013.01.014 [16] ROHATGI V, LEE L J. Moldability of tackified fiber preforms in liquid composite molding[J]. Journal of Composite Materials,1997,31(7):720-744. doi: 10.1177/002199839703100705 [17] RAO S, UMER R, THOMAS J. Investigation of peel resistance during the fibre placement process[J]. Journal of Reinforced Plastics and Composites,2015,35(4):275-286. [18] 钟翔屿, 张代军, 包建文, 等. 增韧剂含量对国产高强中模炭纤维环氧复合材料耐冲击性的影响[J]. 固体火箭技术, 2017, 40(3):372-379.ZHONG Xiangyu, ZHANG Daijun, BAO Jianwen, et al. Effect of toughening thermoplastic particles content on impact resistance of epoxy matrix composite reinforced by domestic intermediate modulus carbon fiber[J]. Journal of Solid Rocket Technology,2017,40(3):372-379(in Chinese). [19] NASH N H, YOUNG T M, MCGRAIL P T, et al. Inclusion of a thermoplastic phase to improve impact and post-impact performances of carbon fibre reinforced thermosetting composites — A review[J]. Materials & Design,2015,85:582-597. [20] WONG D W Y, LIN L, MCGRAIL P T, et al. Improved fracture toughness of carbon fibre/epoxy composite laminates using dissolvable thermoplastic fibres[J]. Composites Part A: Applied Science and Manufacturing,2010,6:759-767. [21] SAZ-OROZCO B D, RAY D, KERVENNIC A, et al. Toughening of carbon fibre/polybenzoxazine composites by incorporating polyethersulfone into the interlaminar region[J]. Materials & Design,2016,93:297-303. [22] 闫丽, 安学峰, 董慧民. RTM用ES-Fabric 增强织物的制备及其复合材料性能研究[J]. 化工新型材料, 2016, 44(4):94-96.YAN Li, AN Xuefeng, DONG Huimin, et al. Preparation of ES-fabric reinforced fabric for RTM process and study on the property of the composite[J]. New Chemical Materials,2016,44(4):94-96(in Chinese). [23] ZHAO X, CHEN W, HAN X, et al. Enhancement of interlaminar fracture toughness in textile-reinforced epoxy composites with polyamide 6/graphene oxide interlaminar toughening tackifier[J]. Composites Science and Technology,2020,191:108094. doi: 10.1016/j.compscitech.2020.108094 [24] QUAN D, BOLOGNA F, SCARSELLI G, et al. Mode-II fracture behaviour of aerospace-grade carbon fibre/epoxy composites interleaved with thermoplastic veils[J]. Composites Science and Technology,2020,191:108065. doi: 10.1016/j.compscitech.2020.108065 [25] 国家技术监督局. 胶粘剂T剥离强度试验方法-挠性材料对挠性材料: GB/T 2791—1995[S]. 北京: 中国标准出版社, 1995.The State Bureau of Quality and Technical Supervision. Adhesives, T peel strength test method for a flexible-to-flexible test specimen assembly: GB/T 2791—1995[S]. Beijing: China Standard Press, 1995(in Chinses). [26] NGUYEN N Q, MEHDIKHANI M, STRAUMIT I, et al. Micro-CT measurement of fibre misalignment: Application to carbon/epoxy laminates manufactured in autoclave and by vacuum assisted resin transfer moulding[J]. Composites Part A: Applied Science and Manufacturing,2018,104:14-23. doi: 10.1016/j.compositesa.2017.10.018