CN104228059A - Thermosetting polymer matrix composite resistance welding device and method - Google Patents
Thermosetting polymer matrix composite resistance welding device and method Download PDFInfo
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- CN104228059A CN104228059A CN201410474896.7A CN201410474896A CN104228059A CN 104228059 A CN104228059 A CN 104228059A CN 201410474896 A CN201410474896 A CN 201410474896A CN 104228059 A CN104228059 A CN 104228059A
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Abstract
The invention discloses a thermosetting polymer matrix composite resistance welding device and method. A layer of thermoplastic bonding agent is co-cured on the surface of a thermosetting polymer matrix composite structural part to obtain a weld part, resistance welding of a thermosetting polymer matrix composite is realized, the welding device adopts a general thermosetting polymer matrix composite resistance welding method and is improved: firstly, a pressurizing device is used for exerting pressure on the weld part, a heating resistor connected onto copper plate wire clamps is charged with currents, a cooling fan is switched on to perform active cooling on two ends simultaneously, after a temperature controller detects that the welding interface temperature reaches 200 DEG C through K-thermocouples, a direct-current stabilized power supply is switched off, the welding interface temperature is reduced, and a final welded joint is formed through cooling. With the adoption of the welding method, the fringe effect can be effectively reduced, uniform temperature distribution is realized, the welding stress is reduced, and the energy consumption is reduced.
Description
Technical field
The present invention relates to a kind of method for resistance welding of composite, be specifically related to a kind of thermoset polymer matrix composite welder and method.
Background technology
The features such as polymer matrix composite has that specific strength is high, specific stiffness is high, anti-fatigue performance is good, quality is light, designability is good, resistance to chemical attack, dielectric properties are good, easy global formation, are more and more used in the fields such as Aero-Space, communications and transportation, building industry, medicine equipment.Wherein thermoset polymer matrix is with the plurality of advantages such as its excellent combination property, good manufacturability, price be low, field is manufactured by extensive lightweight structure part, particularly aerospace field, for A400M, Boeing 787 aircraft, composite accounts for 36% and 50% of aero-structure weight respectively, wherein, composite structure is epoxy resin base class substantially.Generally, carrying out interconnection technique to polyradical composite material engineering structure has mechanical connection, splicing, melting to connect, easily produce stress collection moderate defect owing to being mechanically connected, and glued joint longer hardening time and surface preparation requirement, need the time and labor of at substantial.Melting interconnection technique can overcome mechanical connection and glued joint the above-mentioned shortcoming had, melting interconnection technique can be divided into sweat soldering by the mechanism of production of heat, and (hot gas welds, hot plate welding, infrared welding, Laser Welding), friction welding (FW) (Spin welding, vibratory weld, supersonic welding, friction stir welding), magnetic discharge welding (induction welding, electric resistance welding, dielectric welds, microwave welds), and wherein the heating means of most attraction only heat matrices of composite material face of weld when heating, make its melted by heat, and do not affect the other parts of matrix, also can not have influence on fiber reinforcement phase simultaneously.Due to the existence of its fiber reinforcement phase and the composite structure of multilayer, by the method for the relative motion frictional heat of matrix, as rotating welding, Vibration Welding etc. can cause the destruction of the non-welding portion microstructure of the distortion of composite fortifying fibre and movement and matrix.In above-mentioned fusion weld technology, supersonic welding, induction welding and electric resistance welding are considered to the optimal welding method of welding polymer matrix composite.
(1) supersonic welding
Ultrasonic bonding is that polymer matrix composite melting connects one of the most frequently used method, widely uses in fields such as many Aeronautics and Astronautics, auto parts and components and medicine equipments.Ultrasonic bonding is a welding process fast, and welding efficiency is high, and what in welding process, composite material interface impedance showed also makes on-line monitoring welding process become possibility with certain relation of molten polymer, easily realizes automation, batch production.In ultrasonic bonding, connected piece makes welding position be close together under certain pressure effect, and then applies the high frequency ultrasound vibration in vertical welding district, heat is produced under the effect of interface and intermolecular friction, when temperature is elevated to certain value, pressurization, cooling, solidifies formation welding point.In ultrasonic bonding; energy can concentrate on around the projection of face of weld usually; can at welding position preformed energy-oriented-ridge (energy directors) of part according to this phenomenon; in vibration processes, concentration of energy is on these energy-oriented-ridges; make it start fusing at first, then apply certain pressure, the molten polymer of flowing soaks linkage interface; cause the diffusion of polymer molecular chain at interface and winding simultaneously, finally form welding point.Affect supersonic welding termination process principal element and have frequency, pressure, amplitude and weld interval, in welding process, need these parameters of choose reasonable to reaching desired welding effect.
(2) induction welding
The induction welding method of polymer matrix composite is the welding method that a kind of weldment does not directly contact with induction coil, by reasonably designing induction coil, heat can be made only to produce in the region of hope welding, can be used for welding the labyrinth with irregular surface.Its principle is very simple, be similar to the heating mechanism of electromagnetic oven, alternating voltage is passed in a conductive coil, the electric current of alternation will be produced by coil, an alternating magnetic field identical with power frequency will be produced around coil, the polymer matrix composite one being implanted ferromagnetic material is placed in this alternating magnetic field, will produce vortex flow, is produced by the known heat that just has of Joule's law.Melt after temperature exceedes the fusing point of polymer matrix composite, apply certain pressure, cooling, defines welding point.A successful fusion weld process need forms a uniform Temperature Distribution at welding region, and for induction welding, the main factor affecting welding region Temperature Distribution depends on the design of conductive coil and the ferromagnetic material of implantation.These ferromagnetic materials can be iron particle, iron oxide particles, stainless steel, graphite etc., different ferromagnetic materials there is different heat-dissipating efficiency.In induction welding, the design of conductive coil is a very important parameter, can produce a uniform alternating magnetic field as far as possible, thus it is more even that heat can be made to distribute by reasonably designing coil, finally forms a high-quality induction welding joint.
(3) electric resistance welding
Electric resistance welding is the one of magnetic discharge welding connection technology, weld interval of polyradical composite material resistance welding and to the demand of equipment and simple to operate, cost is low.The electric resistance welding of polymer matrix composite makes again resistance implant weldering, electrofusion weldering, has developed into the comparatively effective method of welding polymer matrix composite.Welding method is placed between two composite plate weld surfaces by heating resistor (carbon fiber heating element or wire netting heating element heater), then in heating resistor, passes into electric current.After heating-up temperature reaches the glass transition temperature of noncrystal body polymer and the fusion temperature of semi-crystalline polymer, matrices of composite material just starts fusing, powered-down after fusing acquires a certain degree, and applies a suitable pressure, cooling, forms final joint.In resistance welding procedures, apply a suitable pressure very important, it can merge by the molecule between the close contact of promoting layer pressing plate face of weld and interface.In order to improve welding quality as far as possible, should the various parameters of the final welding quality of control effect, as the resistance, input power, clamping pressure etc. of heating element heater.After having welded, heating element heater has still remained within a fitting, can produce a very large impact by welding quality, at this moment just requires there is good compatibility between heating element heater and welded part.One layer of polymeric film can be placed between heating element heater and welded part, not only can make to insulate between heating element heater and the current-carrying part of welded part, and a resin concentration district can be produced to promote diffusion process, thus improve welding quality.
The welding method of above-mentioned polymer matrix composite effectively can be used for sweating heat thermoplastic polymer based composites, thermosetting resin is that a class has cancellated crosslinked polymer material, there is good mechanical property, electrical property and adhesive property, but, can not second melting after the cross-linked structure of thermosetting resin makes it solidify, therefore the method for welding can not be used directly to connect thermoset polymer matrix composite.
Summary of the invention
The object of the present invention is to provide a kind of method for resistance welding of thermoset polymer matrix composite, to solve the problem that melting interconnection technique can not be applied to thermoset polymer matrix composite, effectively can also solve current leakage, edge effect problem during welding simultaneously, improve welding quality.
In order to achieve the above object, the thermoset polymer matrix composite welder that the present invention adopts comprises housing, the heating resistor be located in housing, for placing the insulated heat fixture of heating resistor and the pressue device for applying 0.4 ~ 1.0MPa pressure to thermoset polymer matrix composite weldment, the two sides of heating resistor is respectively covered with one deck thermoplastic plastic membrane; Heating resistor is connected with temperature controller by D.C. regulated power supply, and temperature controller is connected with a K type thermocouple that can detect solder side temperature; The two ends of heating resistor are also respectively equipped with cooling fan.
Described heating resistor adopts carbon cloth that is unidirectional and/or braiding, and the thickness of thermoplastic plastic membrane is 50 ~ 100 μm.
Be provided with brace table in described housing, brace table be fixed with U-shaped bracing frame, insulated heat fixture is placed on U-shaped bracing frame, and the two ends of U-shaped bracing frame are respectively equipped with the copper coin wire clamp for connecting heating resistor, and copper coin wire clamp is connected with D.C. regulated power supply.
Be provided with temperature data recorder in described housing, temperature data recorder with for monitor solder side Temperature Distribution second and third, four, five K type thermocouples are connected.
Described pressue device adopts the piston rod head connecting hydraulic hand-pump.
A kind of method for resistance welding based on thermoset polymer matrix composite welder, there is at junction co-curing one deck to be welded of thermosetting epoxy resin laminate and thermoplastic plastic membrane the adhesive film of compatibility, form thermoset polymer matrix composite weldment, then thermoset polymer matrix composite weldment is placed in insulated heat fixture, again heating resistor is placed on the junction to be welded of thermoset polymer matrix composite weldment, utilize pressue device to treat solder side and apply pressure, the two ends of heating resistor to be connected on D.C. regulated power supply and to connect D.C. regulated power supply, open cooling fan simultaneously, after by a K type thermocouple, temperature controller detects that the temperature of solder side centre reaches 200 DEG C, close D.C. regulated power supply, solder side pressurize is cooled to final welding point.
Described adhesive film thickness is 50 ~ 120 μm, and the power supply that D.C. regulated power supply provides is 10 ~ 40V.
Described pressue device adopts the piston rod head connecting hydraulic hand-pump; When utilizing pressue device to apply pressure to solder side, pressure hydraulic hand-pump, applies the pressure of 0.4 ~ 1.0MPa to solder side by piston rod head.
Be provided with brace table in described housing, brace table be fixed with U-shaped bracing frame, insulated heat fixture is placed on U-shaped bracing frame, and the two ends of U-shaped bracing frame are respectively equipped with the copper coin wire clamp for connecting heating resistor, and copper coin wire clamp is connected with D.C. regulated power supply; By on two termination copper coin wire clamps of heating resistor, and the clamping pressure of copper coin wire clamp is 4 ~ 20MPa.
Compared with prior art, beneficial effect of the present invention is:
The present invention is by having the adhesive film of compatibility at surperficial co-curing one deck of thermosetting epoxy resin laminate and thermoplastic plastic membrane, so just effectively can be used for carrying out the electric resistance welding of thermoset polymer matrix composite, so just can solve the electric resistance welding problem of thermoset polymer matrix composite.Meanwhile, the present invention arranges cooling fan at heating resistor two ends, and cooling fan can be lowered the temperature when weldment welds, to reduce edge effect.And insulated heat fixture can to provide good insulation and insulation, to prevent scattering and disappearing of heat and electric current, therefore, when the present invention can improve welding, the problem of edge effect and current leakage, makes the Temperature Distribution of weld interface more even.
Further, the present invention is also provided with temperature data recorder in housing, temperature data recorder with for monitor solder side Temperature Distribution second and third, four, five K type thermocouples are connected, when second and third, four, after five K type thermocouples detect that temperature has reached 200 DEG C all, one K type thermocouple detects signal feedback to temperature controller, temperature controller deenergization, so just can ensure the uniformity of temperature profile of solder side.
Accompanying drawing explanation
Fig. 1 is the invention process schematic diagram.
Fig. 2 is the schematic diagram of weldment
Fig. 3 is the functional block diagram that this welding method controls welding temperature;
Wherein, 1, hydraulic hand-pump, 2, housing, 3, piston rod head, 4, Pressure gauge, 5, insulated heat fixture, 6, copper cash clamping plate, the 7, the one K type thermocouple, 8, temperature controller, 9, cooling fan, 10, D.C. regulated power supply, 11, U-shaped bracing frame, 12, temperature data recorder, 13, thermoset polymer matrix composite weldment, 14, heating resistor, 15, adhesive film, 16, thermosetting epoxy resin laminate.
Detailed description of the invention
Below in conjunction with accompanying drawing, the present invention is described in further details.
See Fig. 1, thermoset polymer matrix composite welder of the present invention comprises housing 2 and is located at heating resistor 14 in housing 2, for placing the insulated heat fixture 5 of heating resistor 14 and the pressue device for applying 0.4 ~ 1.0MPa pressure to thermoset polymer matrix composite weldment 13, pressue device adopts the piston rod head 3 connecting hydraulic hand-pump 1, the top of piston rod head 3 is provided with Pressure gauge, and the two sides of heating resistor 14 is respectively covered with the thermoplastic plastic membrane that a layer thickness is 50 ~ 100 μm; Heating resistor 14 adopts carbon cloth that is unidirectional and/or braiding, and the two sides of heating resistor 14 is respectively covered with one deck thermoplastic plastic membrane; Also brace table is provided with in housing 2, brace table is fixed with U-shaped bracing frame 11, insulated heat fixture 5 is placed on U-shaped bracing frame 11, the two ends of U-shaped bracing frame 11 are respectively equipped with the copper coin wire clamp 6 for connecting heating resistor 14, copper coin wire clamp 6 is connected with D.C. regulated power supply 10, and D.C. regulated power supply 10 is connected with temperature controller 8.Temperature controller 8 is connected with a K type thermocouple 7 that can detect solder side temperature; Be provided with temperature data recorder 12 in housing 12, temperature data recorder 12 with for monitor solder side Temperature Distribution second and third, four, five K type thermocouples are connected.
See Fig. 1-3, a kind of method for resistance welding based on above-mentioned thermoset polymer matrix composite welder is: the junction high temperature co-curing one deck to be welded of the thermosetting epoxy resin laminate 16 formed at 12 layers of carbon fiber prepreg and thermoplastic plastic membrane have the adhesive film 15 of compatibility, form thermoset polymer matrix composite weldment 13, the thickness of adhesive film 15 is 50 ~ 120 μm, then thermoset polymer matrix composite weldment 13 is placed in insulated heat fixture 5, again heating resistor 14 is placed on the junction to be welded of thermoset polymer matrix composite weldment 13, piston rod head 3 is utilized to treat the pressure of solder side applying 0.4 ~ 1.0MPa, the two ends of heating resistor 14 are connected to copper coin wire clamp 6, and make the clamping pressure of copper coin wire clamp 6 be 4 ~ 20MPa, then D.C. regulated power supply 10 is connected, the power supply that D.C. regulated power supply 10 provides is 10 ~ 40V, open cooling fan 9 simultaneously, first, two, three, four, five K type thermocouples detect the temperature in the middle of solder side reach 200 DEG C after (temperature data recorder 12 records the temperature of solder side in the process detecting solder side temperature), close D.C. regulated power supply 10, solder side pressurize is cooled to final welding point.Adhesive film material described in this welding method in table 1,
Table 1
Do not occur interfacial failure between welding point test result display bonding agent and thermoset polymer matrix, strength of joint can reach more than 80% of mother metal.
The present invention is by having the adhesive film of compatibility at surperficial co-curing one deck of thermosetting epoxy resin laminate and thermoplastic plastic membrane, so just effectively can be used for carrying out the electric resistance welding of thermoset polymer matrix composite, so just can solve the electric resistance welding problem of thermoset polymer matrix composite.Meanwhile, the present invention arranges cooling fan at heating resistor two ends, and cooling fan can be lowered the temperature when weldment welds, to reduce edge effect.And insulated heat fixture can to provide good insulation and insulation, to prevent scattering and disappearing of heat and electric current, therefore, when the present invention can improve welding, the problem of edge effect and current leakage, makes the Temperature Distribution of weld interface more even.
Further, the present invention is also provided with temperature data recorder in housing, temperature data recorder with for monitor solder side Temperature Distribution second and third, four, five K type thermocouples are connected, when second and third, four, after five K type thermocouples detect that temperature has reached 200 DEG C all, one K type thermocouple detects signal feedback to temperature controller, temperature controller deenergization, so just can ensure the uniformity of temperature profile of solder side.
Claims (9)
1. a thermoset polymer matrix composite welder, it is characterized in that: comprise housing (2), the heating resistor (14) be located in housing (2), for placing the insulated heat fixture (5) of heating resistor (14) and the pressue device for applying 0.4 ~ 1.0MPa pressure to thermoset polymer matrix composite weldment (13), the two sides of heating resistor (14) is respectively covered with one deck thermoplastic plastic membrane; Heating resistor (14) is connected with temperature controller (8) by D.C. regulated power supply (10), and temperature controller (8) is connected with a K type thermocouple (7) that can detect solder side temperature; The two ends of heating resistor (14) are also respectively equipped with cooling fan (9).
2. thermoset polymer matrix composite welder according to claim 1, is characterized in that: described heating resistor (14) adopts carbon cloth that is unidirectional and/or braiding, and the thickness of thermoplastic plastic membrane is 50 ~ 100 μm.
3. thermoset polymer matrix composite welder according to claim 1, it is characterized in that: in described housing (2), be provided with brace table, brace table is fixed with U-shaped bracing frame (11), insulated heat fixture (5) is placed on U-shaped bracing frame (11), the two ends of U-shaped bracing frame (11) are respectively equipped with the copper coin wire clamp (6) for connecting heating resistor (14), and copper coin wire clamp (6) is connected with D.C. regulated power supply (10).
4. thermoset polymer matrix composite welder according to claim 1, it is characterized in that: in described housing (2), be provided with temperature data recorder (12), temperature data recorder (12) with for monitor solder side Temperature Distribution second and third, four, five K type thermocouples are connected.
5. thermoset polymer matrix composite welder according to claim 1, is characterized in that: described pressue device adopts the piston rod head (3) connecting hydraulic hand-pump (1).
6. the method for resistance welding based on thermoset polymer matrix composite welder according to claim 1, it is characterized in that: the adhesive film (15) at junction co-curing one deck to be welded of thermosetting epoxy resin laminate (16) and thermoplastic plastic membrane with compatibility, form thermoset polymer matrix composite weldment (13), then thermoset polymer matrix composite weldment (13) is placed in insulated heat fixture (5), again heating resistor (14) is placed on the junction to be welded of thermoset polymer matrix composite weldment (13), utilize pressue device to treat solder side and apply pressure, the two ends of heating resistor (14) are connected to D.C. regulated power supply (10) go up and connect D.C. regulated power supply (10), open cooling fan (9) simultaneously, after by a K type thermocouple (7), temperature controller (8) detects that the temperature of solder side centre reaches 200 DEG C, close D.C. regulated power supply (10), solder side pressurize is cooled to final welding point.
7. method for resistance welding according to claim 6, is characterized in that: described adhesive film (16) thickness is 50 ~ 120 μm, and the power supply that D.C. regulated power supply (10) provides is 10 ~ 40V.
8. method for resistance welding according to claim 6, is characterized in that: described pressue device adopts the piston rod head (3) connecting hydraulic hand-pump (1); When utilizing pressue device to apply pressure to solder side, pressure hydraulic hand-pump (1), applies the pressure of 0.4 ~ 1.0MPa to solder side by piston rod head (3).
9. the method for resistance welding according to claim 6 or 8, it is characterized in that: in described housing (2), be provided with brace table, brace table is fixed with U-shaped bracing frame, insulated heat fixture (5) is placed on U-shaped bracing frame, the two ends of U-shaped bracing frame are respectively equipped with the copper coin wire clamp (6) for connecting heating resistor (14), and copper coin wire clamp (6) is connected with D.C. regulated power supply (10); By on two termination copper coin wire clamps (6) of heating resistor (14), and the clamping pressure of copper coin wire clamp (6) is 4 ~ 20MPa.
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| CN110293298A (en) * | 2019-06-06 | 2019-10-01 | 沈阳航空航天大学 | The light alloy electric resistance welding resin welded joint and preparation method thereof of CNT enhancing |
| CN110356012A (en) * | 2019-06-21 | 2019-10-22 | 沈阳航空航天大学 | CNT array modifies heater element and its composite material resistance plumb joint and preparation method |
| CN110774591A (en) * | 2019-11-13 | 2020-02-11 | 南京航空航天大学 | Automatic temperature control equipment for induction welding of thermoplastic composite material |
| CN111907069A (en) * | 2020-07-21 | 2020-11-10 | 大连理工大学 | Robot-assisted continuous resistance welding equipment and welding method for thermoplastic materials |
| CN112172179A (en) * | 2020-09-18 | 2021-01-05 | 沈阳航空航天大学 | Ultrasonic-resistance hybrid welding method for resin-based composite material |
| CN114919197A (en) * | 2022-05-13 | 2022-08-19 | 北京航空航天大学 | Resistance welding system and welding method for carbon fiber/polyaryletherketone composite material laminate |
| CN114919186A (en) * | 2022-06-07 | 2022-08-19 | 大连理工大学 | Resistance welding method for thermosetting composite material |
| CN115056496A (en) * | 2022-05-26 | 2022-09-16 | 北京航空航天大学 | Induction welding system and welding method for carbon fiber/polyaryletherketone composite material laminate |
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| CN114919186A (en) * | 2022-06-07 | 2022-08-19 | 大连理工大学 | Resistance welding method for thermosetting composite material |
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