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碳纤维感应元件厚度对碳纤维增强热塑性复合材料感应焊接接头力学性能及断裂形式的影响

王飞云 罗杰帮 张平则 刘星 占小红

王飞云, 罗杰帮, 张平则, 等. 碳纤维感应元件厚度对碳纤维增强热塑性复合材料感应焊接接头力学性能及断裂形式的影响[J]. 复合材料学报, 2023, 40(4): 2405-2414. doi: 10.13801/j.cnki.fhclxb.20220618.001
引用本文: 王飞云, 罗杰帮, 张平则, 等. 碳纤维感应元件厚度对碳纤维增强热塑性复合材料感应焊接接头力学性能及断裂形式的影响[J]. 复合材料学报, 2023, 40(4): 2405-2414. doi: 10.13801/j.cnki.fhclxb.20220618.001
WANG Feiyun, LUO Jiebang, ZHANG Pingze, et al. Effect of thickness of carbon fiber susceptor on mechanical property and fracture mode of carbon fiber reinforced thermoplastic composite induction welded joint[J]. Acta Materiae Compositae Sinica, 2023, 40(4): 2405-2414. doi: 10.13801/j.cnki.fhclxb.20220618.001
Citation: WANG Feiyun, LUO Jiebang, ZHANG Pingze, et al. Effect of thickness of carbon fiber susceptor on mechanical property and fracture mode of carbon fiber reinforced thermoplastic composite induction welded joint[J]. Acta Materiae Compositae Sinica, 2023, 40(4): 2405-2414. doi: 10.13801/j.cnki.fhclxb.20220618.001

碳纤维感应元件厚度对碳纤维增强热塑性复合材料感应焊接接头力学性能及断裂形式的影响

doi: 10.13801/j.cnki.fhclxb.20220618.001
基金项目: 先进复合材料国防科技重点实验室开放基金(6142904180105)
详细信息
    通讯作者:

    占小红,博士,教授,博士生导师,研究方向为激光焊接与增材制造技术、复合材料先进连接技术等 E-mail: xiaohongzhan_nuaa@126.com

  • 中图分类号: TB332

Effect of thickness of carbon fiber susceptor on mechanical property and fracture mode of carbon fiber reinforced thermoplastic composite induction welded joint

Funds: Open Subject of the National Key Laboratory of Advanced Composites (6142904180105)
  • 摘要: 利用碳纤维织物与树脂薄膜制备了0.2 mm、0.3 mm与0.5 mm 3种不同厚度的碳纤维感应元件,并开展碳纤维增强热塑性复合材料(Carbon fiber reinforced thermoplastic composite,CFRTP)感应焊接建模仿真与工艺试验。观察CFRTP感应焊接接头成形形貌,开展接头拉伸剪切强度测试与断口形貌分析,着重探究感应元件厚度对接头力学性能与断裂形式的影响。研究结果表明:碳纤维感应元件能在不引入异质材料的前提下实现CFRTP的高质量感应焊接,但接头界面温度分布具有明显的不均匀性;随着感应元件厚度的增加,过量的树脂会降低接头的成形效果、连接质量与力学性能,同时界面的有效连接面积也随之减小;当感应元件厚度为0.2 mm时,焊接接头的拉伸剪切强度最高可达23.77 MPa;焊接接头的断裂形式包括感应元件内聚破坏、母材表层自破坏、界面破坏和混合破坏,造成接头失效的断裂机制根据感应元件厚度的改变而发生变化。

     

  • 图  1  不同厚度的碳纤维感应元件:(a) 感应元件制备过程示意图;(b) 感应元件实物样品图

    Figure  1.  Carbon susceptors with different thicknesses: (a) Schematic diagram of the manufacturing process for susceptors; (b) Actual picture of susceptors

    PEEK—Polyetheretherketone

    图  2  碳纤维增强聚醚醚酮(CF/PEEK)感应焊接过程示意图:(a) 设备组成及焊接原理;(b) 焊接接头的连接成形过程

    Figure  2.  Schematic diagram of carbon fiber reinforced PEEK (CF/PEEK) induction welding process: (a) Equipment composition and fundamentals of welding; (b) Formation of welded joint

    CFRTP—Carbon fiberreinforced thermoplastic composite; F—Pressure

    图  3  CF/PEEK感应焊接试验设备:(a) 超高频(UHF)感应焊机及专用焊接夹具;(b) 盘式感应线圈

    Figure  3.  Experimental equipment for CF/PEEK induction welding: (a) Ultra-high frequency (UHF) induction power supply and special fixture; (b) Pancake induction coil

    图  4  CF/PEEK感应焊接试样尺寸:(a) 俯视图;(b)正视图

    Figure  4.  Size of CF/PEEK induction welded sample: (a) Top view; (b) Front view

    h—Thickness of susceptor

    图  5  CF/PEEK感应焊接过程有限元模型:((a)、(b)) 几何模型;((c)~(e)) 网格划分

    Figure  5.  Finite element model of CF/PEEK induction welding process: ((a), (b)) Geometric models; ((c)-(e)) Mesh division

    图  6  CF/PEEK感应焊接过程温度场仿真结果验证:(a) 截面温度分布;(b) 截面最高温度

    Figure  6.  Verification of temperature simulation results of CF/PEEK induction welding: (a) Temperature distribution in cross-section; (b) Maximum temperature in cross-section

    Tmax—Maximum temperature

    图  7  CF/PEEK感应焊接接头变形测量

    Figure  7.  Deformation measurement of CF/PEEK induction welded joint

    图  8  不同感应元件厚度下CF/PEEK焊接接头宏观形貌:(a) 0.2 mm;(b) 0.3 mm;(c) 0.5 mm

    Figure  8.  Macro morphologies of CF/PEEK induction welded joints using susceptors with different thicknesses: (a) 0.2 mm; (b) 0.3 mm; (c) 0.5 mm

    图  9  不同感应元件厚度下CF/PEEK焊接接头断口形貌:(a) 0.2 mm;(b) 0.3 mm;(c) 0.5 mm

    Figure  9.  Fracture morphologies of CF/PEEK induction welded joints using susceptors with different thicknesses: (a) 0.2 mm; (b) 0.3 mm; (c) 0.5 mm

    BM—Base material

    图  10  CF/PEEK焊接接头温度分布仿真结果:(a) 切面位置;(b) XY切面;(c) XZ切面;(d) YZ切面

    Figure  10.  Temperature distribution simulation of CF/PEEK induction welded joint: (a) Tangent plane position; (b) XY plane; (c) XZ plane; (d) YZ plane

    Tmin—Minimum temperature

    图  11  CF/PEEK感应焊接接头的断裂形式:(a) 感应元件的内聚破坏;(b) 母材表层的自破坏;(c) 混合破坏;(d) 母材与感应元件的界面破坏

    Figure  11.  Fracture modes of CF/PEEK induction welded joints: (a) Cohesive failure of susceptor; (b) Self failure of base material; (c) Mixed failure; (d) Interface failure between base material and susceptor

    图  12  4种CF/PEEK感应焊接接头断裂形式的典型微观形貌特征:(a) 感应元件的内聚破坏;(b) 母材表层的自破坏;(c) 混合破坏;(d) 母材与感应元件的界面破坏

    Figure  12.  Typical micro morphologies corresponding to four fracture modes of CF/PEEK induction welded joints: (a) Cohesive failure of susceptor; (b) Self failure of base material; (c) Mixed failure; (d) Interface failure between base material and susceptor

    表  1  材料电磁性能参数与热物性参数

    Table  1.   Material parameters of electromagnetic performance and thermal property

    MaterialDensity/
    (g·cm−3)
    Thermal conductivity/
    (W·m−1·K−1)
    Specific heat capacity/
    (J·kg−1·K−1)
    Conductivity/
    (S·m−1)
    Relative dielectric constant
    Carbon susceptor1.53kX=5.4
    kY=5.4
    kZ=0.5
    1088σX=4000
    σY=4000
    σZ=0.33
    3.70
    Base material1.300.2513871×10−144
    Copper8.704003856×1071
    Notes: kX, kY, kZ—Thermal conductivity in the X, Y and Z directions; σX, σY, σZ—Conductivity in the X, Y and Z directions.
    下载: 导出CSV

    表  2  CF/PEEK感应焊接接头变形测量结果

    Table  2.   Deformation measurement results of CF/PEEK induction welded joints

    Thickness of susceptor/mmAverage
    thickness/mm
    Original
    thickness/mm
    Deformation/
    mm
    0.24.3254.488−0.163
    0.34.3384.596−0.268
    0.54.4104.801−0.361
    下载: 导出CSV

    表  3  CF/PEEK感应焊接接头拉伸剪切强度

    Table  3.   Tensile-shear strength of CF/PEEK induction welded joint

    Thickness of susceptor/mmAverage tensile-shear
    strength/MPa
    Standard deviation
    0.223.771.39
    0.316.341.20
    0.510.311.19
    下载: 导出CSV
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  • 收稿日期:  2022-04-20
  • 修回日期:  2022-05-24
  • 录用日期:  2022-06-03
  • 网络出版日期:  2022-06-20
  • 刊出日期:  2023-04-15

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