CN113165289A - 有机基质复合材料零件的修复 - Google Patents
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Abstract
一种用于修复零件(11)的方法,所述零件由覆盖有至少一层油漆(102)的有机基质复合材料(100)制成,所述方法包括以下步骤:a)去除零件(11)的损坏区域的油漆,b)去除损坏区域的复合材料(100)以形成凹陷部分,c)在凹陷部分中沉积修复树脂,d)使得所述修复树脂交联,e)将至少一层油漆(102)施加于修复区域。修复树脂填充有可磁检测颗粒(41)的方法。
Description
技术领域
本发明涉及由有机基质复合物(OMC)材料(即包括由有机性质的基质致密化的纤维增强材料)制成的零件的修复。
现有技术
获得复合材料零件的常见工艺是液体工艺。液体方法包括制造纤维预制件,该纤维预制件基本上具有要制造的零件的形状并且旨在构成复合材料的增强件,并且用包含基质材料前体的液体组合物浸渍该预制件。前体通常呈聚合物形式,例如热塑性或热固性树脂,可能在溶剂中稀释。在去除可能的溶剂和聚合物交联之后,通过热处理进行前体到基质的转化。用于燃气涡轮飞机发动机的有机基质复合材料叶片的制造特别描述于文件US2016/243777中。
OMC零件可能会因震动或撞击而损坏。例如,飞机发动机风扇叶片或外壳受到鸟类或碎片等异物撞击就是这种情况。在零件重新投入使用之前,必须修复损坏区域,以恢复结构完整性并避免缺陷从损坏区域发生任何传播。
大多数OMC零件的表面上都有一层油漆,其覆盖有机基质材料。因此,涂漆的OMC零件的修复除了更换OMC的损坏区域外,还包括重新涂漆整个区域。因此,一旦修复完成,修复区域将不再可见。然而,例如出于机械完整性的原因,希望能够在OMC零件中定位修复处,因为在两次修复之间保持最小安全距离很重要。
发明内容
本发明的目的是提出一种用于修复有机基质复合材料零件的解决方案,使得即使在视觉上不可检测的情况下也能够对修复的部分或区域定位。
该目的是通过一种用于修复零件的方法来实现的,该零件由涂有至少一层油漆的有机基质复合材料制成,该方法包括:
a)去除零件损坏区域的油漆,
b)去除损坏区域的复合材料以形成凹陷部分,
c)在凹陷部分中沉积修复树脂,
d)使得修复树脂固化,
e)将至少一层油漆施加到修复区域,其中修复树脂携载有可磁检测颗粒。
通过使修复树脂携载有可磁检测颗粒,可以通过简单的磁检测来对复合材料零件上的一个或多个先前修复的区域进行识别和定位。复合材料表面上油漆层的存在不再是检测修复区域的障碍。
根据本发明修复方法的第一特征,在步骤a)至e)之前,还包括在距损坏区域一个确定距离处检查是否存在修复树脂的步骤。因此,如果已经在离损坏区域太近的距离处已经用携载有可磁检测颗粒的修复树脂进行了一次或多次修复,则其可以被检测到。在这种情况下,不会进行新的维修,因为这是不可以的,并且该零件将被丢弃。
根据本发明修复方法的第二特征,可磁检测颗粒是铁磁材料颗粒。零件中一个或多个修复区域的存在可以通过检测修复树脂中存在的铁磁颗粒发出的磁场来检测。在这种情况下,修复树脂优选地包含按重量计在10%至50%之间的铁磁材料颗粒。
根据本发明修复方法的第三特征,可磁检测颗粒是顺磁性或超顺磁性材料颗粒。零件中一个或多个修复区域的存在可以通过修复树脂中存在的顺磁性或超顺磁性颗粒的磁响应来检测。在这种情况下,修复树脂优选地包含按重量计在1%至10%之间的顺磁性或超顺磁性材料颗粒。
本发明还涉及由涂有至少一层油漆的有机基质复合材料制成的零件,该零件具有至少一个存在于有机基质复合材料中的修复部分,所述部分包含交联的修复树脂,其中所述修复树脂携载有可磁检测颗粒。
根据本发明零件的第一特征,能够被磁检测的颗粒是铁磁材料颗粒。零件中一个或多个修复区域的存在可以通过检测修复树脂中存在的铁磁颗粒发出的磁场来检测。在这种情况下,修复树脂优选地包含按重量计在10%至50%之间的铁磁材料颗粒。
根据本发明零件的第二特征,可磁检测颗粒是顺磁性或超顺磁性材料颗粒。零件中一个或多个修复区域的存在可以通过修复树脂中存在的顺磁性或超顺磁性颗粒的磁响应来检测。在这种情况下,修复树脂优选地包含按重量计在1%至10%之间的顺磁性或超顺磁性材料颗粒。
附图简要说明
本发明的其它特征和优势通过下文关于本发明具体实施方式的描述并参照附图而显而易见,所述具体实施方式以非限制示例的形式给出,附图中:
[图1]图1是包括风扇的飞机发动机的透视图,
[图2]图2是具有损坏区域的图1发动机的风扇叶片的示意性透视图,
[图3]图3是图2的叶片沿剖面III的局部剖视图,
[图4]图4显示了图3的叶片在进行预备工作后的损坏区域的截面,
[图5]图5显示了图4的叶片部分在沉积修复树脂后的视图,
[图6]图6显示了图5的叶片在修复树脂固化并且底漆层和油漆层已经重新涂漆之后的截面图。
具体实施方式
本发明一般适用于由有机基质复合材料制成的任何零件,即,所述有机基质复合材料包括由例如碳、玻璃或陶瓷纤维制成并由通常对应于聚合物树脂的基质致密化的纤维增强材料,所述聚合物树脂包括例如热塑性或热固性树脂,可能在溶剂中稀释,该零件还涂有至少一层油漆。
下面将在本发明用于修复燃气涡轮飞机发动机风扇叶片的上下文中描述本发明。
如图1中非常示意性地示出的这样的发动机包括,沿气流方向从上游到下游,布置在发动机入口处的风扇1、压缩机2、燃烧室3、高压涡轮4和低压涡轮5。
风扇1包括由多个叶片11组成的旋转器10,每个叶片11安装在涡轮转子12上并且被具有旋转形式的风扇外壳13围绕。
图2示出了风扇叶片11,其在此由有机基质复合材料制成,即由例如碳、玻璃、芳族聚酰胺或陶瓷纤维制成并被聚合物基质如环氧化物、双马来酰亚胺或聚酰亚胺致密化的纤维增强材料制成。纤维增强材料由通过单件三维编织获得的纤维织构制成,该织构在工具中成形。如此形成的纤维增强材料然后通过基质致密化,例如根据众所周知的“RTM”注塑工艺进行。在文件US 2016/243777中具体描述了这种叶片的制造。
通常,本发明复合材料零件的纤维增强材料可以由各种性质的纤维,特别是碳、玻璃或陶瓷(例如碳化硅)或碳纤维的纤维织构制成。所使用的纤维织构可以具有各种性质和形式,具体地,例如包括:
-二维(2D)织物,
-通过3D或多层编织获得的三维(3D)织物,特别是在文件WO2010/061140中描述的,其内容通过引用并入本文,
-辫状物(braid),
-针织织物,
-毛毡(felt),
-纱线或缆线的单向(UD)网或多向(nD)网,所述多向网通过在不同方向叠加多个UD网并将UD网粘合在一起获得,例如通过缝纫、化学粘合剂或针刺进行。
叶片的复合材料涂有一层油漆102,在视觉上掩盖了复合材料。
风扇叶片11包括纵向延伸的叶片主体110和由较厚部分形成的根部111,该根部例如具有球根状截面,其通过毂112连接到叶片主体110。通过将根部111接合到布置在涡轮转子12***的相应形状的外壳中而将叶片11安装在涡轮转子12上。
在图2和图3中,叶片11具有损坏区域20,例如由于被发动机风扇吸入的物体(例如鸟、碎片、冰等)撞击所造成的。
在图3和此处描述的示例中,叶片11包括限定叶片的总体形状并且特别是限定其体积的有机基质复合材料100。复合材料涂有一层油漆102。仍然在这里描述的例子中,首先将底漆层101,例如硅烷/乙醇类型的粘合底漆层沉积在复合材料100的表面上,以促进油漆层102的粘附性。但是,当零件的复合材料具有与油漆粘附性相适应的表面光洁度时,不需要预先沉积底漆,可以直接将油漆沉积在复合材料的暴露表面上。
仍然在图3中,可以看到损坏区域20延伸到油漆层102和底漆层101中,并延伸到复合材料100中。
在开始对损坏区域进行实际修复之前,所述方法可以包括检查在与损坏区域相距一定距离处是否没有修复树脂。如果零件中与损坏区域距离太近(例如距离小于2mm)处已经存在修复,则不可以进行新的修复。因此,如果在离损坏区域太近的距离处已经用携载有可磁检测颗粒的修复树脂进行了一次或多次修复,则其可以被检测到。在这种情况下,不会进行新的维修,因为这是不可以的,并且该零件将被丢弃。
叶片11的修复开始于在损坏区域20处对外壳进行机加工以去除受影响的复合材料。更准确地说,首先去除损坏区域20处的油漆102和底漆101,例如通过打磨去除,以暴露该区域中的有机基质复合材料100。然后对复合材料100进行机加工,例如通过磨损进行,以去除复合材料100的已损坏部分。复合材料的去除在叶片的指定区域和深度上进行,至少是在识别为损坏的区域进行。
如图4所示,获得了在叶片11的外表面上开口的凹陷部分30。
在可能用例如异丙醇对暴露区域进行脱脂之后,在凹陷部分中沉积修复树脂40。修复树脂可包括例如环氧树脂、聚氨酯树脂、BMI树脂、邻苯二甲腈树脂和酚醛树脂。
根据本发明,如图5所示,修复树脂40携载有可磁检测颗粒41。
根据本发明的第一方面,适用于磁检测的颗粒是铁磁材料颗粒。用于制造颗粒的铁磁材料具体来说可以是铁氧体、钴钐、钕-铁-硼或镍。铁磁材料具有变成磁性的特性,即,当置于磁场中时会被磁化,而当磁场移开时会保留一些这种磁性。铁磁颗粒发出的磁场可以用磁力计检测。为了易于检测,优选在修复树脂中具有大量的铁磁颗粒。修复树脂含有按重量计在10%至50%之间的铁磁材料颗粒,优选30%的铁磁材料颗粒。铁磁颗粒的尺寸范围从纳米到毫米(数纳米到数毫米)。
根据本发明的第二方面,适用于磁检测的颗粒是顺磁性或超顺磁性材料颗粒。与铁磁材料不同,顺磁性或超顺磁性材料不会自然地发出磁场。这些材料在与它们浸入的磁场相同的方向上获得磁化,但是当它们离开磁场时会失去这种磁化。换句话说,由顺磁性或超顺磁性材料制成的颗粒只有在被另一个磁场激发时才具有磁响应。用于制造颗粒的顺磁性或超顺磁性材料可以是纳米铁氧体或单晶镍。在单晶镍的情况下,其是超淬火镍,超淬火是一种不允许形成马氏体的快速冷却。超淬火后,获得屈服强度相当低的奥氏体钢(可转化为马氏体的奥氏体(matestible austenite)),其屈服强度约为200MPa。
顺磁性或超顺磁性颗粒的存在可以用探针检测,该探针由电感(线圈)组成,该电感(线圈)由具有频率fu的交流电压激发,并且在该电感中流动的电流的频率fi被测量。fu和fi之间的任何值差异都表明存在由于颗粒材料磁响应的存在而引起的扰动。
顺磁性或超顺磁性颗粒的优点是可在相对低的浓度水平下检测到。在顺磁性或超顺磁性材料颗粒的情况下,修复树脂含有1重量%至10重量%的铁磁材料颗粒,优选含有3重量%的铁磁材料颗粒。顺磁性或超顺磁性颗粒的尺寸从纳米到毫米不等。因此,与铁磁颗粒相比,顺磁性或超顺磁性颗粒的使用减少了修复树脂中存在的颗粒量,并保持树脂的机械性能几乎不变。
一旦沉积在凹部30中,携载有可磁检测颗粒41的修复树脂40就经受交联处理,例如热处理,以获得如图6所示的仍包含可磁检测颗粒41的修复部分50。底漆层和油漆层沉积在暴露区域上以重构存在于叶片11的复合涂层100上的底漆层101和油漆层102。
因此,本发明可以检测复合零件中修复的任何部分,并且以对存在于经修复的复合材料的表面上的涂层非破坏性的方式进行检测。非限制性地,本发明有利地适用于外壳、隔音板、出口导向叶片(OGV)和燃气涡轮发动机机舱。
Claims (11)
1.一种用于修复零件(11)的方法,所述零件由涂有至少一层油漆(102)的有机基质复合材料(100)制成,所述方法包括以下步骤:
a)去除零件(11)的损坏区域(20)的油漆,
b)去除损坏区域(20)的复合材料(100)以形成凹陷部分(30),
c)在凹陷部分(30)中沉积修复树脂(40),
d)使得所述修复树脂(40)固化,
e)将至少一层油漆施加于修复区域,
其中,所述修复树脂(40)携载有可磁检测颗粒(41)。
2.如权利要求1所述的方法,所述方法在步骤a)至e)之前,还包括在距损坏区域一个确定距离处检查是否存在修复树脂的步骤。
3.如权利要求1或2所述的方法,其中,所述可磁检测颗粒(41)是铁磁材料颗粒。
4.如权利要求3所述的方法,其中,修复树脂(40)含有在10重量%至50重量%之间的铁磁材料颗粒。
5.如权利要求1或2所述的方法,其中,所述可磁检测颗粒(41)是顺磁性或超顺磁性材料颗粒。
6.如权利要求5所述的方法,其中,修复树脂(40)含有在1重量%至10重量%之间的顺磁性或超顺磁性材料颗粒。
7.一种零件(11),其由涂有至少一层油漆(102)的有机基质复合材料(100)制成,所述零件具有至少一个存在于有机基质复合材料中的修复部分(50),所述部分包含交联的修复树脂,其中修复树脂(40)携载有可磁检测颗粒(41)。
8.如权利要求7所述的零件,其中,所述可磁检测颗粒(41)是铁磁材料颗粒。
9.如权利要求8所述的零件,其中,修复树脂(40)含有在10重量%至50重量%之间的铁磁材料颗粒。
10.如权利要求7所述的零件,其中,所述可磁检测颗粒(41)是顺磁性或超顺磁性材料颗粒。
11.如权利要求10所述的零件,其中,修复树脂(40)含有在1重量%至10重量%之间的顺磁性或超顺磁性材料颗粒。
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PCT/FR2019/053014 WO2020120902A1 (fr) | 2018-12-13 | 2019-12-11 | Reparation de pieces en materiau composite a matrice organique |
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FR3089857A1 (fr) | 2020-06-19 |
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