阅读说明：本技术 飞行器机翼部件 (Aircraft wing component ) 是由 威廉·塔洛克 于 2020-03-12 设计创作，主要内容包括：本发明涉及一种飞行器机翼部件、包括这种飞行器机翼部件的机翼组件,以及制造这种部件和组件的方法。飞行器机翼的后缘结构件在使用中经受来自飞行器的发动机的高温外排物。这种升高的温度会不利地影响后缘的极限拉伸强度。飞行器机翼部件包括复合材料,该复合材料具有：第一部分(14),第一部分(14)包括包含增强材料(17)的金属基体(16)；以及第二部分(15),第二部分(15)包括包含多个中空金属陶瓷球体(19)的金属基体(18),第二部分与复合材料的表面(20)相邻。设置两个部分、其中一者包括增强材料并且另一者包括中空球体意味着部件在最需要结构强度和隔热性质的位置具有结构强度和隔热性质两者。复合材料的包含中空金属陶瓷球体的一部分用作隔热的嵌入层。(The present invention relates to an aircraft wing component, a wing assembly comprising such an aircraft wing component, and methods of manufacturing such components and assemblies. The trailing edge structure of an aircraft wing is subject to high temperature emissions from the engines of the aircraft in use. Such elevated temperatures can adversely affect the ultimate tensile strength of the trailing edge. An aircraft wing component comprises a composite material having: a first portion (14), the first portion (14) comprising a metal matrix (16) comprising a reinforcement material (17); and a second portion (15), the second portion (15) comprising a metal matrix (18) comprising a plurality of hollow cermet spheres (19), the second portion being adjacent to a surface (20) of the composite material. Providing two sections, one of which comprises a reinforcing material and the other of which comprises hollow spheres means that the component has both structural strength and thermal insulation properties at the locations where they are most needed. A portion of the composite material containing hollow cermet spheres serves as an embedded layer of thermal insulation.)

1. An aircraft wing component comprising a composite material, a first portion of the composite material comprising a first metal matrix comprising a reinforcing material and a second portion of the composite material comprising a second metal matrix comprising a plurality of hollow cermet spheres, the second portion being adjacent a surface of the composite material.

2. The component of claim 1 wherein the spheres have substantially the same diameter.

3. The component of claim 1, wherein the sphere has a plurality of diameters within a predetermined range.

4. A component according to claim 1, 2 or 3, wherein the second portion has a thickness of less than 50% of the composite material.

5. A component according to claim 1, 2 or 3, wherein the second portion has a thickness of less than 25% of the composite material.

6. The component of claim 1, 2 or 3, wherein the reinforcement material comprises at least one of: a plurality of fibers; and microparticles.

7. The component of claim 1, 2 or 3, wherein at least one of the reinforcing material and the spheres comprises alumina.

8. A component according to claim 1, 2 or 3, wherein the first metal matrix is of the same material as the second metal matrix.

9. The component of claim 1, 2 or 3, wherein the metal matrix of at least one of the first and second portions comprises aluminum.

10. A method of manufacturing a component according to claim 1, 2 or 3, the method comprising the steps of: laying the spheres and the reinforcing material in a mould; introducing a liquid metal into the mold; and solidifying the metal.

11. The method of claim 10, wherein the laying step comprises vibrating the mold to distribute the spheres.

12. A component according to any one of claims 1, 2 or 3, comprising at least a portion of the trailing edge of an aerofoil.

13. The component of any of claims 1, 2, or 3, comprising an aircraft control surface.

14. A wing assembly, comprising: a wing body; an engine; and a component according to any one of claims 1 to 3, the component being disposed downstream of the engine.

15. An aircraft incorporating a wing assembly according to claim 14.

Technical Field

The invention relates to a component part of an aircraft wing. The invention also relates to a wing assembly comprising such a component part, and to a method of manufacturing such a component and assembly.

Background

Developments in aircraft engine technology have made jet engines more efficient and powerful and have high bypass ratios. Such engines tend to be larger in size than conventional jet engines and more closely integrated with the structural members of adjacent wing assemblies.

A problem that may be encountered with the development of such aircraft engines is that the proximity of the engine to the aircraft wing means that, in use, the trailing edge of the wing is more exposed to the hot, high pressure gases emitted by the engine. The emissions from such engines can reach temperatures of about 1600 c. Wing structures are typically made of aluminum and aluminum alloys; high temperatures have a detrimental effect on the Ultimate Tensile Strength (UTS) of such materials.

Fig. 1a and 1b are graphs showing the effect of high temperature air flow applied to the surface of a material made of a homogeneous aluminum alloy having a thickness'd'. The surface of the material is at d-0. Fig. 1a shows the temperature distribution in a cross section of a material. Due to the homogeneity of the material, the temperature of the material is highest at its surface and decreases substantially uniformly through the thickness of the material. Fig. 1b shows the change in UTS of the material. The broken line in fig. 1b indicates the ultimate tensile strength of the material at room temperature. Throughout the thickness of the material, the UTS of the material is less than the UTS at which the material will be at room temperature. This is most pronounced at the high temperature exposed surface of the material where a significant reduction in UTS can be seen. It will be appreciated that such effects may adversely affect the structural integrity of the trailing edge of the wing assembly and may limit the useful life of the assembly.

Various proposals have been made to protect the trailing edge wing structural members from the adverse effects of high temperature foreign matter. In one proposal, the trailing edge structure includes an epoxy composite material capable of withstanding elevated temperatures. Nevertheless, this proposal is only able to protect the wing at temperatures up to and far below the temperatures to which the trailing edge is subjected in use.

In another proposal, the insulation paste is applied to the trailing edge of the wing. However, such slurry layers are unsightly and require regular monitoring and maintenance. If applied incorrectly, the slurry may alter the aeromechanical properties of the wing.

Another proposal is to manufacture the trailing edge of the wing using a metal or alloy that can work better at high temperatures, such as titanium or so-called superalloys. However, such materials are generally expensive to produce and process.

Disclosure of Invention

The invention provides an aircraft wing component comprising a composite material, a first portion of the composite material comprising a first metal matrix comprising a reinforcing material and a second portion of the composite material comprising a second metal matrix comprising a plurality of hollow cermet spheres, the second portion being adjacent to a surface of the composite material. Providing two sections, one of which comprises a reinforcing material and the other of which comprises hollow spheres means that the component has both structural strength and thermal insulation properties at the locations where they are most needed. The portion of the composite material containing the hollow cermet spheres acts as an embedded layer of thermal insulation at the surface of the composite material.

Preferably, the spheres have substantially the same diameter. This evens out the temperature response of the second portion of the composite material at or near the surface of the material. Alternatively, to provide better filling of the spheres within the metal matrix, the spheres may have a plurality of diameters within a predetermined range.

Preferably, the second portion containing the spheres has a thickness of less than 50% of the material, or even less than 25% of the material. By providing the reinforcement material over a substantial portion of the thickness of the composite material, a material having a relatively high tensile strength is formed.

The spheres may be inexpensive and lightweight alumina.

Advantageously, the reinforcing material comprises a plurality of fibres that increase the tensile strength of the composite material. Alternatively, or additionally, the reinforcing material comprises particles.

The reinforcement material may also comprise alumina, or be entirely alumina.

Preferably, the metal matrix of the first part is of the same material as the metal matrix of the second part. The or each metal substrate may be aluminium.

The invention also provides a method of manufacturing an aircraft wing component of the invention, the method comprising the steps of: laying the spheres and the reinforcing material in a mould; introducing a liquid metal into the mold; and cooling the mold.

Preferably, the step of laying comprises vibrating the mould to distribute the cermet spheres.

The present invention also provides such a component: the component is formed as at least a portion of a trailing edge of an aircraft wing assembly. The component may form part of a control surface for an aircraft.

A wing assembly for an aircraft may comprise a wing body having an engine, wherein a portion of a downstream region of the engine, such as a trailing edge, comprises a component of the invention.

Drawings

The invention will now be described, by way of example, with reference to the accompanying drawings, in which:

FIG. 1a is a graph showing a temperature profile through a cross section of a typical conventional aluminum alloy material when exposed to high temperature air;

FIG. 1b is a graph showing UTS of the alloy of FIG. 1a when exposed to high temperature air;

FIG. 2a is a plan view of an aircraft incorporating a composite material constructed in accordance with the present invention;

FIG. 2b is a perspective view from below of a portion of a wing of the aircraft of FIG. 2 a;

FIG. 3 is a cross-sectional view of a portion of the material forming a portion of the airfoil of FIGS. 2a and 2 b;

FIG. 4a is a graph showing a temperature profile through a cross-section of the material of FIG. 3 when exposed to high temperature air;

FIG. 4b is a graph showing UTS of the material of FIG. 3 when exposed to high temperature air;

FIG. 5 is a flow diagram of an exemplary process for manufacturing the material of FIG. 3;

FIG. 6a is a cross-sectional view of a material constructed in accordance with an alternative embodiment of the invention; and

fig. 6b is a cross-sectional view of a material constructed in accordance with another alternative embodiment of the invention.

Detailed Description

With reference to fig. 2a and 2b, a passenger aircraft is shown and is generally designated by reference numeral 1. The aircraft 1 comprises a fuselage 2 for holding passengers and cargo, a right (starboard) wing 3 and a left (port) wing 4. A plurality of engines housed in nacelles 5, 6, 7, 8 are provided on the wings 3, 4. The engine is arranged to, in use, take in a quantity of air which is heated and compressed, mixed with jet fuel and combusted. The air subsequently discharged from the exhaust nozzle of the engine generates thrust that induces movement of the aircraft. The exhausted air, or effluent, is very hot and can reach 1600 ℃ at its center. The part of the aircraft wing immediately downstream of the exhaust nozzle, in particular the part located on the underside of the wing, must be able to withstand such elevated temperatures.

Fig. 2b shows a portion of the underside of the wing 3. In this figure, the exhaust pipe 9 of the engine is shown housed in a nacelle 8. The large arrow 10 indicates the direction of the hot exhaust exiting the exhaust nozzle. The area bounded by the dashed line 11 is subject to the greatest exposure to high temperature air flow. According to the invention, at least a part of the trailing edges 12, 13 of the wings 3, 4 is made of a composite material, which is shown in cross-section in fig. 3.

In order to function effectively as the trailing edge of the wing, the material must provide structural strength and be able to handle high temperature emissions from the nozzle of the engine. To this end, two portions or regions 14, 15 of a Metal Matrix Composite (MMC) material are provided. The first region 14 includes a major portion of the material thickness and includes a metal matrix 16, the metal matrix 16 having a reinforcing material embedded within the metal matrix 16. In this embodiment, the reinforcement material comprises a plurality of layers of alumina filaments 17. This region 14 of MMC material provides the necessary structural strength required at the trailing edge of the aircraft wing to maintain the aeromechanical profile of the wing while being able to withstand the forces to which the wing is subjected during flight.

According to the invention, the second region 15 comprises a metal matrix 18, the metal matrix 18 comprising a plurality of hollow cermet spheres 19 embedded within the metal matrix 18. In this embodiment, the hollow spheres 19 have a substantially constant diameter and are made of alumina. The region 15 of the composite material containing the cermet spheres is disposed at the surface 20 of the material such that the region 15 is more directly exposed to the hot engine exhaust. In both the first and second regions 14, 15, the metal matrix is aluminum which is both lightweight and relatively inexpensive to produce. The region 15 acts as a heat shield to insulate the structural members of the trailing edge from the adverse effects of high temperature exhaust.

Fig. 4a and 4b are graphs showing the effect of high temperature air flow applied to the surface 20 of the composite material according to the present invention. The surface 20 of the material is at about d-0. Fig. 4a shows the temperature distribution in a cross section of the material. Since region 15 acts as an embedded layer of insulation that separates region 14 from the hot air, the temperature of the material is highest at its surface and drops in a hyperbolic fashion through the thickness of the material. Fig. 4b shows the change in UTS of the material. The UTS of the material is lower in region 15, but much higher in region 14 than has hitherto been achievable. The embedded insulating region 15 helps to protect the main portion 14 of the composite material from the adverse effects of heating so that the trailing edge of the wing assembly retains its structural integrity, thereby improving the useful life of the trailing edge of the wing assembly.

The material of fig. 3 may be manufactured by, for example, a casting method, the steps of which are schematically represented in fig. 5.

In one embodiment of the casting method according to the invention, the first step comprises "laying down" the hollow cermet spheres and the reinforcement material. First, a ball is placed in a mold (step 21). Hollow spheres may be placed inside the mold, such as by fluttering, to enable filling of the spheres with the best possible close packing density. Once the spheres are filled in the mold, a reinforcing material is added to the mold (step 22). This can be done simply by laying the fibres within the mould, or by winding the fibres around one of more support structures that can be formed in the casting mould itself.

The next step 23 in the manufacturing process is to introduce the metal matrix material. One method of introducing the metal matrix material may be accomplished by pouring a liquid metal into a mold. In this embodiment, the mold for combining the spheres and the reinforcing material is first preheated. Preferably, the pre-heating temperature is approximately equal to the casting temperature of the liquid metal forming the substrate, in order to prevent premature solidification of the substrate before the mold is completely filled.

The liquid metal forming the matrix is cast into the mold in a manner that fills the voids around the hollow spheres and the reinforcing material while avoiding interference with the spheres and reinforcing material within the mold. In some embodiments, it may be useful to use screens, pins, or other similar devices for holding the arrangement of spheres and reinforcing material within the mold. In addition to gravity casting, the mold may be subjected to pressure differentials during the casting process. For example, the mold may be pressurized or held under vacuum.

Once the liquid metal forming the matrix has been satisfactorily cast into the mold, the liquid metal is solidified (step 24) to form a solid metal matrix around the hollow spheres and the reinforcing material. This solidification is usually carried out by cooling the mould, which solidification can be carried out by atmospheric cooling or by more controlled cooling methods.

Fig. 6a and 6b illustrate an alternative composite material constructed in accordance with the present invention. In fig. 6a, the first region 25 comprises a metal matrix 26, the metal matrix 26 containing reinforcing elements in the form of a plurality of layers of fibres 27, the fibres 27 being shorter in length than in the embodiment of fig. 3. Shorter fibers are generally less brittle than longer fibers. The second region 28 comprises a metal matrix 29 with embedded hollow cermet spheres 30, the embedded hollow cermet spheres 30 having various diameters within a range of predetermined values in this embodiment. The selection of such spheres allows for a more compact arrangement to be packed than an arrangement in which the spheres are all one diameter.

In the embodiment of fig. 6b, the first region 31 comprises a metal matrix 32, the metal matrix 32 containing reinforcing elements in the form of particulate material 33, the particulate material 33 being considered as the limit of the length of the short fibres. An advantage of using particle reinforcement is that the first region 31 of the resulting composite will be isotropic, having the same mechanical properties in all directions. In this embodiment, the second region 34 comprises a metal matrix 35, the metal matrix 35 comprising two spheres of different diameters 36, 37; the spheres of larger diameter 36 are disposed in the layer closest to the surface of the material and the spheres of smaller diameter are disposed between the first layer of spheres 36 and the region of enhanced particles 31. This arrangement provides a transition between the thermally insulating portion of the composite material and the reinforcing portion of the composite material.

Of course, any combination of reinforcing material and spheres may be embedded in a metal matrix to form a wing component constructed in accordance with the invention. The composite material may be tailored to have different regions depending on the desired physical properties of the material. For example, areas that require structural strength but are not exposed to extreme temperatures will include more reinforcement material in the matrix, while areas exposed to the highest temperatures will contain more cermet spheres. The portion of the composite material comprising the spheres has been shown in the drawings as forming a relatively small portion of the overall thickness of the composite material, but this may of course be varied and tailored according to the required properties of the resulting composite material. The spheres may comprise up to 50% of the respective portion by weight of the composite material. Similarly, the reinforcing material may comprise up to 50% of the respective portion by weight of the composite material.

Other variations may be made without departing from the scope of the invention. For example, the reinforcing element may be selected from any one or combination of cables, fibers, tapes, filaments and particles. The reinforcing elements may include, for example, aluminum oxide (alumina), silicon dioxide, boron, plated carbon, or any other high strength fiber or particle.

The spheres may have any diameter in the range of micrometers to millimeters. The spheres may all have substantially the same diameter or a selection of diameters. The spheres may be composed of one material, such as alumina or carbon dioxide, or of a plurality of different materials of the same composition. The spheres may be coated to make the spheres more easily integrated with the metal matrix.

The base material is a metallic material such as aluminum, titanium, or any other suitable material. Preferably, the matrix material is relatively lightweight, low cost, and easy to process. The metal matrix may be the same throughout the material or different materials may be used in different regions depending on the desired properties of the final product.

The composite material may be formed by other suitable processes known to those skilled in the art, such as powder metallurgy, extrusion casting, or diffusion bonding.

The wing component of the invention may comprise, in whole or in part, the trailing edge of the wing itself and/or may comprise the underside of the wing downstream of the engine. The wing component may comprise a flap, aileron or other control surface of the aircraft that will be exposed to high temperature airflow in use.

The invention may be used in other wing structures requiring structural integrity at high temperatures, for example due to proximity to heat generating components, or due to aeromechanical friction. The invention may be used to provide a guard for extreme conditions of low temperature. Other variations and applications will be apparent to those skilled in the art.