Repair performance of damaged aircraft metal structure with one-sided composite patch
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摘要:
航空金属结构在服役过程中容易产生开孔、裂纹和腐蚀等损伤，传统的机械修理方式(铆接、螺接)因效率低、增重大、需对母板进行制孔等无法满足修理要求。随着先进复合材料和胶接技术的不断成熟，金属构件损伤复合材料贴补修复技术因增重小、可设计性强、无二次损伤、便于原位操作等优点在航空维修等领域中具有广泛的应用前景。本文使用试验研究、数值模拟和理论分析等手段，研究了三种贴补修复工艺(湿铺法、预浸料法、预固化法)、复合材料补片厚度、补片长度与修复界面形貌、胶接特性、失效形式和极限载荷之间的对应关系。研究发现：湿铺法的修复性能最好，是预固化法的3.3倍、预浸料法的1.3倍；随着复合材料补片厚度的增加，修补结构的极限失效载荷先增大后减小，最后趋向稳定，失效形式经历了从补片分层崩裂、纤维拉伸断裂和胶层损伤的混合失效到胶层剪切破坏的演化过程，当补片厚度为7层约1.05mm厚度时修复效果最好；随着复合材料补片长度的增大，修补结构的极限失效载荷先增大后线性减小，原因是胶接面积增大带来增益性能的同时，固化内应力诱发单面弯矩对结构的减损影响也逐渐增加且超过面积增大带来的增益影响，当补片长度为80mm时修复效果最好；本文中建立的连续损伤模型全面模拟了胶层、复合材料层内和层间的损伤起始与演化情况，并得到了试验的充分验证。 左：不同CFRP补片长度的极限载荷和失效形式；右：CFRP补片的应变场分布 A型失效模式：CFRP补片的分层和崩裂 Abstract: For the repair structures of aircraft metal components with one-sided CFRP patches, the tensile tests on repair specimens with different repair processes (wet lay-up, prepreg and pre-curing methods) and CFRP patch parameters were carried out. The ultimate load, failure mode and interface of the specimens were observed. The three-dimensional (3D) finite element (FE) model has been established. Based on 3D Hashin failure criteria, the damage initiation and evolution in CFRP were simulated. The damages of the adhesive layer and delamination of CFRP were simulated with cohesive zone model. The FE model was validated by experimental and theoretical analysis. The results show that the three repair processes have different interface morphology and failure modes. The wet lay-up method has the best repair effect, 3.3 times of the pre-curing method and 1.3 times of the prepreg method. With the increase of patch thickness, the ultimate load first increases, then decreases, and finally tends to be stable. The failure mode gradually evolves from patch delamination, mixed failure of fiber breakage and adhesive layer damage to adhesive layer shear failure. The best patch thickness is 7 layers, about 1.05mm in thickness. With the increase of patch length, the ultimate load first increases and then decreases linearly. The damage of the adhesive layer starts from the center and both ends of the joint and evolves to the middle region. The best patch length is 80 mm. The results reported herein could provide useful guidance for the application of aviation maintenance engineering.-
Key words:
- composite patch /
- aviation metal /
- adhesive bonded structure /
- finite element analysis /
- repair effect
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图 1 金属损伤复合材料单面贴补修复结构示意图
Figure 1. Schematic illustration of one-side repair of damaged metal structure using carbon fiber-reinforced polymer
图 7 三种修复试件的极限载荷与变异系数
Figure 7. Ultimate load and coefficient of variation of three methods of repair specimens
图 9 CFRP补片的表面形貌：(a)观察设备；(b)预固化法补片；(c)预浸料法补片；(d)湿铺法补片
Figure 9. Surface morphology of CFRP patch: (a) Observation equipment; (b) Pre-curing patch;(c) Prepreg lay-up patch; (d) Wet lay-up patch
图 10 CFRP补片的三维形貌：(a)观测区域；(b)预固化法补片；(c)预浸料法补片；(d)湿铺法补片
Figure 10. Three-dimensional morphology of CFRP patch: (a)Observation zone; (b) Pre-curing patch; (c) Prepreg lay-up patch; (d) Wet lay-up patch
图 11 CFPR补片厚度为4层时修补结构的载荷-位移曲线
Figure 11. Load-displacement curve of the repair structure with the thickness of CFPR patch is 4 layers
图 12 不同厚度CFRP补片单面修补结构的极限失效载荷变化曲线
Figure 12. Ultimate failure load curves of one-side repair structure with CFRP patches of different thickness
图 13 A型失效模式：CFRP补片的分层和崩裂
Figure 13. A failure mode: CFRP patch delamination and splitting
图 14 B型失效模式：CFRP补片分层和胶层剪切的混合失效(补片分层占比较大)
Figure 14. B failure mode: Mixed failure of CFRP patch delamination and shear failure of adhesive layer (Patch delamination accounts for a large proportion)
图 15 C型失效模式：CFRP补片分层和胶层剪切的混合失效(胶层损伤占比较大)
Figure 15. C failure mode: Mixed failure of CFRP patch delamination and shear failure of adhesive layer (Shear failure of adhesive layer accounts for a large proportion)
图 17 不同长度CFRP补片修补结构的极限失效载荷和剪切强度变化曲线
Figure 17. Ultimate failure load and shear strength curves of repair structure with CFRP patches of different lengths
图 18 单面修补结构的受力分析示意图
Figure 18. Schematic diagram of stress analysis of one-side repair structure
图 19 补片长度为80 mm的单面修补结构胶层法向应力S33
Figure 19. Normal stress S33 of adhesive layer for one-side repair structure with 80 mm patch length
表 1 TC4钛合金板的材料参数
Table 1. Mechanical properties of TC4 titanium alloy plate
Property Value E/GPa 110 ρ/(10−9 t·mm−3) 4.51 v12 0.34 Notes: E, ρ and v12 – Elastic modulus, density and Poisson’s ratio, respectively. 
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表 2 SY-24 C胶膜的材料参数
Table 2. Mechanical properties of SY-24 C adhesive film
Property Value E/MPa 5750 G/MPa 1920 σ/MPa 451.6 τ/MPa 225.8 GC n/(N·mm−1) 0.48 GC s, GC t/(N·mm−1) 0.64 Notes: E, G – Elastic modulus in tension and shear; σ, τ – Failure strengths in tension and shear; GC n– Toughness in tension; GC s, GC t– Toughness in shear.
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表 3 T300/7901碳纤维增强树脂(CFRP)复合材料层合板的材料参数
Table 3. Mechanical properties of T300/7901 carbon fiber Reinforced polymer (CFRP) composite laminate
Property Value Property Value E11/GPa 125 Yc/MPa 280 E22, E33/GPa 11.3 S/MPa 120 G12, G13/GPa 5.43 Kn/(N·mm−3) 100000 G23/GPa 3.98 Ks/(N·mm−3) 100000 v12, v13 0.3 σ/MPa 28.5 v23 0.42 τ/MPa 35.5 Xt/MPa 2000 GC n/(N·mm−1) 0.34 Xc/MPa 1100 GC s/(N·mm−1) 0.38 Yt/MPa 80 GC t/(N·mm−1) 0.38 Notes: Eii (i =1, 2, 3) – Young’s modulus in the i direction; Gij (i =1, 2, 3) – Shear modulus in the i-j plane; vij (i =1, 2, 3) – Poisson’s ratio in the i-j plane; Xt, Xc, and Yt, Yc – Tensile and compressive strengths in the 1 and 2 directions; S – Shear strength; Kn, Ks – Stiffness components in tension and shear; σ, τ – Failure strengths in tension and shear.
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