阅读说明：本技术 一种结构可控的3d增强铝基复合材料及其制备方法 (3D reinforced aluminum matrix composite material with controllable structure and preparation method thereof ) 是由 王振军 徐志锋 蔡长春 余欢 熊博文 杨伟 张守银 汪志太 于 2020-06-15 设计创作，主要内容包括：本发明提供了一种结构可控的3D增强铝基复合材料及其制备方法,属于高性能铝基复合材料精密成形技术领域。本发明首先采用第一液态铝合金对单向纤维板沿纤维方向进行浸渗,然后将所得单向纤维增强铝基复合材料板材切割成单向铝基复合材料丝材,再以该丝材构建3D增强体,使其与第二液态铝合金进行复合获得3D增强铝基复合材料,可显著降低液态浸渗阻力,减少纤维偏聚,能够克服传统液态压力浸渗法中铝合金对3D纤维增强体中横向纤维束填充困难和制备缺陷多的问题。而且能够按需求精确制造3D增强体,具有制备成本低、纤维体积分数可精确调节、增强体结构精确可控等优势,可实现大尺寸规格3D增强铝基复合材料的精确成形和批量化工业生产。(The invention provides a 3D reinforced aluminum matrix composite material with a controllable structure and a preparation method thereof, and belongs to the technical field of high-performance aluminum matrix composite material precision forming. According to the invention, the unidirectional fiber board is impregnated along the fiber direction by adopting the first liquid aluminum alloy, then the obtained unidirectional fiber reinforced aluminum-based composite material plate is cut into unidirectional aluminum-based composite material wires, and then the wires are used for constructing the 3D reinforcement body, so that the 3D reinforced aluminum-based composite material is obtained by compounding the 3D reinforcement body with the second liquid aluminum alloy, the liquid impregnation resistance can be obviously reduced, the fiber segregation is reduced, and the problems of difficult filling of the aluminum alloy to the transverse fiber bundles in the 3D fiber reinforcement body and many preparation defects in the traditional liquid pressure impregnation method can be overcome. And the 3D reinforcement can be accurately manufactured according to the requirement, the preparation method has the advantages of low preparation cost, accurately adjustable fiber volume fraction, accurate and controllable reinforcement structure and the like, and can realize accurate forming and batch industrial production of large-size 3D reinforced aluminum matrix composite materials.)

1. The preparation method of the 3D reinforced aluminum matrix composite material with the controllable structure is characterized by comprising the following steps:

laying unidirectional fiber cloth along the fiber direction, and fixing to obtain a unidirectional fiber board;

carrying out liquid infiltration compounding on the unidirectional fiber board and a first liquid aluminum alloy along a fiber direction to obtain a unidirectional fiber reinforced aluminum matrix composite board;

cutting the unidirectional fiber reinforced aluminum matrix composite material plate along the direction parallel to the fiber direction to obtain a unidirectional aluminum matrix composite material wire;

overlapping the unidirectional aluminum-based composite material wire according to a 3D structure, and then performing consolidation binding to obtain a 3D reinforcement;

and compounding the 3D reinforcement with a second liquid aluminum alloy to obtain the 3D reinforced aluminum-based composite material with a controllable structure.

2. The method of claim 1, wherein the unidirectional fiber cloth comprises a graphite fiber cloth, a silicon carbide fiber cloth, or an alumina fiber cloth.

3. The method of claim 1, wherein the unidirectional fiber sheet has a fiber content of 50 to 70% by volume.

4. The method according to claim 1, wherein before the liquid infiltration compounding, the method further comprises: preheating the unidirectional fiberboard, wherein the preheating temperature is 500-600 ℃.

5. A method as set forth in claim 1, wherein the first liquid aluminum alloy is produced by a process comprising: smelting an aluminum alloy to obtain a first liquid aluminum alloy; the smelting temperature is 700-750 ℃.

6. The method for preparing the composite material according to the claim 1, wherein the conditions of the liquid infiltration compounding comprise: the vacuum degree is 10-25 Pa, and the infiltration pressure is 0.4-0.5 MPa.

7. The preparation method of the unidirectional fiber reinforced aluminum matrix composite plate according to claim 1, wherein the volume fraction of the aluminum alloy is 30-50%, and the volume fraction of the fiber is 50-70%.

8. The preparation method of claim 1, wherein the preparation process of the second liquid aluminum alloy comprises the steps of smelting the aluminum alloy at 660-700 ℃, and preserving heat for 20-30 min to obtain the second liquid aluminum alloy, wherein the compounding time is 120-180 s.

9. The 3D reinforced aluminum-based composite material with the controllable structure prepared by the preparation method of any one of claims 1 to 8, wherein the volume fraction of the aluminum alloy in the 3D reinforced aluminum-based composite material with the controllable structure is 50-70%, and the volume fraction of the fiber is 30-50%.

Technical Field

The invention relates to the technical field of high-performance aluminum-based composite material precision forming, in particular to a 3D reinforced aluminum-based composite material with a controllable structure and a preparation method thereof.

Background

The continuous fiber reinforced aluminum-based composite material has excellent comprehensive properties such as high specific strength and specific modulus, low thermal expansion coefficient, good heat resistance, aging resistance and the like, and is taken as a powerful competitor and a substitute of traditional structural materials such as titanium alloy, resin-based composite materials and the like, so that the continuous fiber reinforced aluminum-based composite material is paid attention by researchers at home and abroad. A large number of researches show that the unidirectional reinforced aluminum-based composite material has extremely high strength and modulus along the axial direction of the fiber, and has poor mechanical property along the transverse direction of the fiber; the 2D laminated reinforced aluminum-based composite material can adjust the in-plane performance through the design of the layering angle, but still has the defects of low interlayer bonding strength, poor impact toughness and the like, thereby limiting the engineering application range of the composite material. The 3D reinforced aluminum-based composite material appearing in recent years not only inherits the advantages of light weight, high strength, high modulus and low thermal expansion rate of the continuous fiber reinforced aluminum-based composite material, but also has good structural integrity and performance designability due to the completely integral and three-dimensional interwoven 3D reinforcement network, and is a new-generation aluminum-based composite material which meets the development of aerospace structures towards integration, light weight and structure/performance integration.

At present, the main preparation method of the 3D reinforced aluminum matrix composite material is a liquid pressure infiltration method, and the basic technical thought is as follows: preparing the continuous fiber bundles into a 3D fiber preform by a weaving method or a mechanical weaving method, then forcedly permeating liquid aluminum alloy into the 3D fiber preform and the fiber bundles in the 3D fiber preform under the action of pressure by adopting a process such as an extrusion casting method, a vacuum infiltration method or a vacuum pressure infiltration method, cooling and demolding to obtain the 3D reinforced aluminum-based composite material. However, the current preparation method has the following technical difficulties: (1) the fiber bundles in the 3D fiber preform are distributed along different directions and are mutually overlapped, when liquid metal infiltrates and flows along the fiber bundles, gaps in the fiber bundles are filled sufficiently, infiltration and flow of the liquid metal along the direction perpendicular to the fiber bundles are difficult, the gaps in the fiber bundles cannot be filled completely, and particularly the liquid metal cannot penetrate and fill completely at the overlapping positions of the fiber bundles, so that the prepared composite material has many defects and low tissue compactness, and the tissue and mechanical properties of the composite material are influenced; (2) the volume fraction of fibers in a 3D fiber preform prepared by a weaving method or a mechanical weaving method is difficult to accurately control, and meanwhile, the pressure in the preparation of a liquid pressure infiltration method easily causes macroscopic deformation of the 3D fiber preform, fiber bundle deviation in each direction in the fiber preform and fiber segregation in the fiber bundle, so that the structural shape and the volume fraction of the fibers in the 3D reinforced aluminum matrix composite material cannot be accurately controlled.

Disclosure of Invention

The invention aims to provide a 3D reinforced aluminum-based composite material with a controllable structure and a preparation method thereof, the prepared 3D reinforced aluminum-based composite material not only has the characteristics of high tissue compactness and few microscopic defects, but also has the advantages of fiber volume fraction, precise design and control of a reinforced structure and the like, can realize the mass production of large-size components, and has good application prospect. .

In order to achieve the above object, the present invention provides the following technical solutions:

the invention provides a preparation method of a structure-controllable 3D reinforced aluminum-based composite material, which comprises the following steps:

laying unidirectional fiber cloth along the fiber direction, and fixing to obtain a unidirectional fiber board;

carrying out liquid infiltration compounding on the unidirectional fiber board and a first liquid aluminum alloy along a fiber direction to obtain a unidirectional fiber reinforced aluminum matrix composite board;

cutting the unidirectional fiber reinforced aluminum matrix composite material plate along the direction parallel to the fiber direction to obtain a unidirectional aluminum matrix composite material wire;

overlapping the unidirectional aluminum-based composite material wire according to a 3D structure, and then performing consolidation binding to obtain a 3D reinforcement;

and compounding the 3D reinforcement with a second liquid aluminum alloy to obtain the 3D reinforced aluminum-based composite material with a controllable structure.

Preferably, the unidirectional fiber cloth comprises graphite fiber cloth, silicon carbide fiber cloth or alumina fiber cloth.

Preferably, the fiber content of the unidirectional fiber board is 50-70% by volume percentage.

Preferably, before the liquid infiltration compounding, the method further comprises: preheating the unidirectional fiberboard, wherein the preheating temperature is 500-600 ℃.

Preferably, the preparation process of the first liquid aluminum alloy comprises the following steps: smelting an aluminum alloy to obtain a first liquid aluminum alloy; the smelting temperature is 700-750 ℃.

Preferably, the liquid infiltration compounding conditions include: the vacuum degree is 10-25 Pa, and the infiltration pressure is 0.4-0.5 MPa.

Preferably, in the unidirectional fiber reinforced aluminum matrix composite plate, the volume fraction of the aluminum alloy is 30-50%, and the volume fraction of the fiber is 50-70%.

Preferably, the preparation process of the second liquid aluminum alloy comprises the steps of smelting the aluminum alloy at 660-700 ℃, and preserving heat for 20-30 min to obtain the second liquid aluminum alloy, wherein the compounding time is 120-180 s.

The invention provides the 3D reinforced aluminum-based composite material with the controllable structure, which is prepared by the preparation method in the technical scheme, wherein the volume fraction of aluminum alloy is 50-70% and the volume fraction of fiber is 30-50% in the 3D reinforced aluminum-based composite material with the controllable structure.

The invention provides a preparation method of a structure-controllable 3D reinforced aluminum-based composite material, which comprises the following steps: laying unidirectional fiber cloth along the fiber direction, and fixing to obtain a unidirectional fiber board; carrying out liquid infiltration compounding on the unidirectional fiber board and a first liquid aluminum alloy along a fiber direction to obtain a unidirectional fiber reinforced aluminum matrix composite board; cutting the unidirectional fiber reinforced aluminum matrix composite material plate along the direction parallel to the fiber direction to obtain a unidirectional aluminum matrix composite material wire; overlapping the unidirectional aluminum-based composite material wire according to a 3D structure, and then performing consolidation binding to obtain a 3D reinforcement; and compounding the 3D reinforcement with a second liquid aluminum alloy to obtain the 3D reinforced aluminum-based composite material with a controllable structure.

According to the invention, the unidirectional fiber board is impregnated along the fiber direction by adopting the first liquid aluminum alloy, the impregnation defect of the unidirectional fiber board is few, the liquid aluminum alloy is impregnated along the fiber direction, the impregnation resistance is small, the transverse impregnation does not exist, the liquid aluminum alloy is impregnated into the unidirectional fiber board before the 3D reinforcement body is constructed, the liquid impregnation resistance can be obviously reduced, the fiber segregation is reduced, the advantages of small impregnation pressure, few preparation defects, low cost and the like are achieved, and the problems of difficult filling of the aluminum alloy to the transverse fiber bundles in the 3D fiber reinforcement body and many preparation defects in the traditional liquid pressure impregnation method can be solved.

The obtained unidirectional aluminum-based composite material wire with compact tissue is used as a reinforcing material, a 3D reinforcing body can be accurately manufactured according to the requirement, the prepared 3D reinforcing body has large gaps, when the wire is compounded with a second liquid aluminum alloy, the filling of the gaps by the liquid aluminum alloy is easy to carry out, the problem of fiber aggregation or segregation in the traditional liquid pressure infiltration preparation process is solved, the deformation of the reinforcing body structure in the compounding process can be avoided, the unidirectional aluminum-based composite material wire has the advantages of low preparation cost, accurately adjustable fiber volume fraction (difficult deformation, high strength and rigidity), accurate and controllable reinforcing body structure and the like, can realize the accurate forming and batch industrial production of large-size 3D reinforced aluminum-based composite materials, and has great application prospects in the fields of aerospace and advanced weapons.

Drawings

FIG. 1 is a graph of the optical microscopy and SEM microstructure of a graphite fiber 3D reinforced ZL301 aluminum matrix composite prepared in example 1;

FIG. 2 is a light microscopic and SEM microstructural view of a silicon carbide fiber 3D reinforced ZL114A aluminum matrix composite prepared in example 2;

fig. 3 is an optical microscopic and SEM microstructural view of the alumina fiber 3D reinforced ZL205 aluminum matrix composite prepared in example 3.

Detailed Description

The invention provides a preparation method of a structure-controllable 3D reinforced aluminum-based composite material, which comprises the following steps:

laying unidirectional fiber cloth along the fiber direction, and fixing to obtain a unidirectional fiber board;

carrying out liquid infiltration compounding on the unidirectional fiber board and a first liquid aluminum alloy along a fiber direction to obtain a unidirectional fiber reinforced aluminum matrix composite board;

cutting the unidirectional fiber reinforced aluminum matrix composite material plate along the direction parallel to the fiber direction to obtain a unidirectional aluminum matrix composite material wire;

overlapping the unidirectional aluminum-based composite material wire according to a 3D structure, and then performing consolidation binding to obtain a 3D reinforcement;

and compounding the 3D reinforcement with a second liquid aluminum alloy to obtain the 3D reinforced aluminum-based composite material with a controllable structure.

In the present invention, unless otherwise specified, all the starting materials required for the preparation are commercially available products well known to those skilled in the art.

The unidirectional fiber cloth is laid along the fiber direction and fixed to obtain the unidirectional fiber board. In the present invention, the unidirectional fiber cloth preferably includes graphite fiber cloth, silicon carbide fiber cloth, or alumina fiber cloth; the graphite fiber cloth is preferably M40J-6K graphite fiber cloth; the silicon carbide fiber cloth is preferably Hi-Nicalon-1K (Japan carbon company) silicon carbide fiber cloth; the alumina fiber cloth is preferably Nextel610-1K alumina fiber cloth. The specification of the unidirectional fiber cloth is not particularly limited, and commercially available products well known in the art may be selected.

The fixing mode is not particularly limited, and a mode well known in the art can be selected, and particularly, the fixing mode can be graphite mold clamping fixing.

In the invention, the fiber content of the unidirectional fiber board is preferably 50-70% by volume, more preferably 55-65% by volume, and even more preferably 55-60% by volume. The thickness of the unidirectional fiberboard is not specially limited, and the unidirectional fiberboard can be adjusted according to actual requirements and can reach the fiber content of the unidirectional fiberboard. In an embodiment of the invention, the unidirectional fibre sheet has a thickness of 10 mm.

After the unidirectional fiber board is obtained, the unidirectional fiber board and the first liquid aluminum alloy are subjected to liquid infiltration compounding along the fiber direction, and the unidirectional fiber reinforced aluminum matrix composite board is obtained. In the present invention, before the liquid infiltration compounding, it is preferable to further include: preheating the unidirectional fiberboard, wherein the preheating temperature is preferably 500-600 ℃, more preferably 520-580 ℃, and further preferably 550-560 ℃. According to the invention, the unidirectional fiberboard is preheated, so that the solidification process of the first liquid aluminum alloy in the infiltration flowing process of the inner pores of the unidirectional fiberboard can be delayed, the resistance of the first liquid aluminum alloy in the infiltration flowing process of the inner pores of the unidirectional fiberboard is reduced, and the infiltration filling integrity and the compactness of the unidirectional aluminum-based composite material are improved.

In the present invention, the preparation process of the first liquid aluminum alloy preferably includes: smelting an aluminum alloy to obtain a first liquid aluminum alloy; the smelting temperature is preferably 700-750 ℃, and more preferably 720-740 ℃. The type of the aluminum alloy in the first liquid aluminum alloy is not particularly limited in the present invention, and any commercially available aluminum alloy known in the art may be used, and in the embodiment of the present invention, the aluminum alloy is specifically ZL301, ZL114A or ZL 205.

In the present invention, the method of liquid infiltration compounding is preferably a vacuum air pressure infiltration method, and the conditions of the liquid infiltration compounding preferably include: the vacuum degree is 10-25 Pa, and the infiltration pressure is 0.4-0.5 MPa; the vacuum degree is more preferably 10-20 Pa, and further preferably 10-15 Pa; the infiltration pressure is more preferably 0.42 to 0.48MPa, and still more preferably 0.45 to 0.46 MPa.

In the liquid infiltration compounding process, the first liquid aluminum alloy is infiltrated inside the unidirectional fiber board along the fiber direction until the first liquid aluminum alloy completely penetrates into gaps among all the fiber yarns, so that the fiber yarns are completely wrapped by the first liquid aluminum alloy, the liquid infiltration resistance is reduced when the second liquid aluminum alloy is compounded on the reinforcement body subsequently, the fiber segregation is reduced, and the problem of difficulty in filling the transverse fiber bundles when the liquid infiltration is carried out after the 3D reinforcement body is constructed subsequently can be solved.

In the unidirectional fiber reinforced aluminum matrix composite plate, the volume fraction of the aluminum alloy is preferably 30-50%, more preferably 35-45%, and the volume fraction of the fiber is preferably 50-70%, more preferably 55-65%. The dosage of the unidirectional fiberboard and the first liquid aluminum alloy can meet the volume fraction. In the unidirectional fiber reinforced aluminum matrix composite plate, the first liquid aluminum alloy and the fiber yarns are combined in two modes of mechanical combination and chemical combination, wherein the mechanical combination refers to that the first liquid aluminum alloy and the fiber yarns are in full and close contact, and the chemical combination refers to that the first liquid aluminum alloy and the fiber yarns are subjected to chemical reactions of different degrees to generate Al₄C₃A compound is provided.

After the unidirectional fiber reinforced aluminum matrix composite plate is obtained, the unidirectional fiber reinforced aluminum matrix composite plate is cut along the direction parallel to the fiber direction, and the unidirectional aluminum matrix composite wire is obtained. In the invention, the cutting process preferably includes cutting the unidirectional fiber reinforced aluminum matrix composite material plate into a plate with a set thickness along the thickness direction by using a wire electrical discharge machine, then realigning the cut plates, laminating the aligned plates, and cutting the aligned plates into wires with a set width (preferably 1-2 mm) along the fiber direction by using the wire electrical discharge machine. The thickness of the plate with the set thickness is not specially limited, and the plate can be adjusted according to actual requirements; in the embodiment of the invention, the thickness can be 1-2 mm. The width of the wire with the set width is not specially limited, and the wire can be adjusted according to actual requirements, and in the embodiment of the invention, the width can be 1-2 mm. In the embodiment of the invention, the cross-sectional dimension of the unidirectional aluminum-based composite material wire is 1mm multiplied by 1mm, 1.5mm multiplied by 1.5mm or 2mm multiplied by 2 mm.

After the unidirectional aluminum-based composite material wire is obtained, the unidirectional aluminum-based composite material wire is lapped according to a 3D structure and then is consolidated and bound, so that the 3D reinforcement is obtained. In the invention, the lapping process according to the 3D structure is preferably to arrange the unidirectional aluminum matrix composite wire material on the aluminum substrate in parallel along the X direction to obtain a first layer; arranging the unidirectional aluminum-based composite material wire material on the first layer in parallel along the Y direction to obtain a second layer; according to the method, the layers are sequentially overlapped layer by layer according to the sequence of X/Y/X …, and two adjacent layers of wires are lapped and fixed by acrylate adhesive; then, carrying out interlayer penetration on the unidirectional aluminum matrix composite wire material in the Z direction, wherein the wire material in the Z direction is fixed on the aluminum substrate by using an acrylate adhesive; the interlayer penetration refers to the penetration of Z-direction wires through the gaps between layers formed by the X and Y orthogonal arrangement.

The source of the aluminum substrate is not specially limited, and the aluminum substrate can be obtained by selecting well-known commercial products, and can be a pure aluminum plate specifically; the size of the aluminum substrate is not specially limited, and the aluminum substrate can be adjusted according to actual requirements.

The arrangement distance of the parallel arrangement along the X direction is not specially limited, and the arrangement distance can be adjusted according to actual requirements, and is 1mm in the embodiment of the invention. The arrangement distance of the parallel arrangement along the Y direction is not specially limited, and the arrangement distance can be adjusted according to actual requirements, and is specifically 2mm in the embodiment of the invention. The number of layers sequentially stacked layer by layer according to the sequence of X/Y/X … is not particularly limited, and may be adjusted according to actual requirements, specifically 10 layers in the embodiment of the present invention.

After the lapping is finished, the lapping part of the unidirectional aluminum-based composite material wire is preferably consolidated and bound by using a metal wire, and the obtained framework is put into a temperature box to volatilize and remove the acrylate adhesive, so that the 3D reinforcement with the three-dimensional orthogonal structure is obtained. The acrylate adhesive of the present invention is not particularly limited, and commercially available products well known in the art may be used. In the invention, the material used for consolidation binding is preferably a metal wire, and the metal wire is preferably a pure aluminum wire; the pure aluminum wire is not particularly limited in the present invention, and commercially available products well known in the art may be used. In the present invention, the temperature of the temperature chamber is preferably 300 ℃.

After the 3D reinforcement is obtained, the 3D reinforcement is compounded with the second liquid aluminum alloy to obtain the 3D reinforced aluminum-based composite material with a controllable structure. In the invention, the preparation process of the second liquid aluminum alloy preferably comprises the steps of smelting the aluminum alloy at 660-700 ℃, and preserving heat for 20-30 min to obtain the second liquid aluminum alloy. The type of aluminum alloy in the second liquid aluminum alloy is not particularly limited in the present invention, and any commercially available aluminum alloy known in the art may be used, and in the examples of the present invention, the aluminum alloy is specifically ZL301, ZL114A or ZL 205.

After obtaining the 3D reinforcement, the invention preferably processes a casting mold according to the size of the 3D reinforcement, and then transfers the 3D reinforcement into the obtained casting mold and closes the mold; and injecting the second liquid aluminum alloy into the casting mold by adopting a gravity casting method, compounding, solidifying and cooling, and then opening the mold to obtain the 3D reinforced aluminum-based composite material with a controllable structure. In the present invention, the casting mold is preferably a graphite mold. The processes of processing the casting mold, closing the mold and injecting by gravity casting are not particularly limited in the present invention, and may be performed according to the processes well known in the art. In the invention, the compounding time is preferably 120-180 s, more preferably 130-160 s, and further preferably 140-150 s.

In the compounding process, the second liquid aluminum alloy is fully soaked into the 3D reinforcement body, and is metallurgically bonded with a first aluminum alloy matrix formed by the first liquid aluminum alloy attached to the surface of the 3D reinforcement body to form the 3D reinforced aluminum-based composite material.

The invention provides the 3D reinforced aluminum-based composite material with the controllable structure, which is prepared by the preparation method in the technical scheme, in the 3D reinforced aluminum-based composite material with the controllable structure, the volume fraction of aluminum alloy is preferably 50-70%, more preferably 55-65%, and the volume fraction of fiber is preferably 30-50%, more preferably 35-45%. According to the invention, the unidirectional fiber board is impregnated by adopting the first liquid aluminum alloy along the fiber direction, then the obtained unidirectional fiber reinforced aluminum-based composite material plate is cut into unidirectional aluminum-based composite material wires, and then the 3D reinforcement is constructed by using the wires.

The technical solution of the present invention will be clearly and completely described below with reference to the embodiments of the present invention. It is to be understood that the described embodiments are merely exemplary of the invention, and not restrictive of the full scope of the invention. All other embodiments, which can be derived by a person skilled in the art from the embodiments given herein without making any creative effort, shall fall within the protection scope of the present invention.