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Joining of light alloys to fiber reinforced composites for hybrid lightweight applications in aircrafts by high power ultrasonics

通过高功率超声波将轻合金连接到纤维增强复合材料，用于飞机混合轻量化应用

基本信息

批准号：
263047333
负责人：
Professor Dr.-Ing. Frank Balle
金额：
--
依托单位：
CTC GmbH Stade
依托单位国家：
德国
项目类别：
Research Grants (Transfer Project)
财政年份：
2015
资助国家：
德国
起止时间：
2014-12-31 至 2019-12-31
项目状态：
已结题

来源：
https://gepris.dfg.de/gepris/projekt/263047333?language=en
关键词：
Joining light alloys fiber reinforced

项目摘要

The improvement of the structural weight of aircrafts by efficient lightweight materials, especially CFRP, has reached a maximum with the Airbus A350 project. The substitution of full-metal fuselage by a suitable CFRP structures has driven the amount of fiber-reinforced composites to over 50%, regarding the entire aircraft. Structural lightweight design by material substitution seems to be achieved and manufacturing processes for CFRP components with high variable geometries are still manual work and expensive. So following aircraft programs with higher volumes and smaller ranges will therefore not be profitable with today's process technology. Current and future approaches are increasingly based on hybrid structures following the right material at the right place-concept and joining of multi-material components is consequently one of the key aspects. A hybrid structure must satisfy all required functions without oversizing the single components. As a result the interface of the materials to be joined determines the achievable weight of the entire hybrid structure. Objectives of the research project are the evidence of a stable joining process for selected aerospace materials. As a highly promising technique ultrasonic metal welding was selected and here especially the variant of ultrasonic torsion welding. The hybrid joints are realized by statistical test methods and online measurement of the central process parameters. Regarding specific aviation requirements, the mechanical properties of light alloy/CFRP-joints are characterized and modified by specific process steps in terms of mechanical performance. To ensure non-ageing hybrid composites so called 3-layer hybrids (Al/Ti-foil/CFRP, Al/GF-fabric/CFRP) will be developed and investigated in detail regarding their microstructural, mechanical and aging properties. Furthermore a future aerospace application of ultrasonic welding at component level will be examined by the design and manufacturing of a hybrid demonstrator corresponding to the achievement of a defined Technology Readiness Level (TRL). In addition, a concept for the industrial implementation of ultrasonic welding will be developed using the example of a specific aircraft structure based on the demonstrator.

随着空中客车A350项目的实施，高效轻质材料，特别是碳纤维材料对飞机结构重量的改善达到了最大。采用合适的碳纤维复合材料结构替代全金属机身，使纤维增强复合材料在整机中的比例达到50%以上。通过材料替代进行结构轻量化设计似乎已经实现，高可变几何形状的CFRP组件的制造过程仍然是手工操作和昂贵的。因此，在今天的工艺技术下，跟随更大数量和更小航程的飞机项目将不会有利可图。目前和未来的方法越来越多地基于混合结构，遵循正确的材料在正确的地方-概念和多材料组件的连接因此是关键方面之一。混合结构必须满足所有必需的功能，而不会使单个组件尺寸过大。因此，待连接材料的界面决定了整个混合结构的可实现重量。该研究项目的目标是证明选定的航空航天材料有一个稳定的连接过程。作为一种极具发展前景的焊接技术，本文选择了超声波金属焊接，特别是超声扭转焊接的变种。通过统计试验方法和中心工艺参数在线测量，实现了混杂接头。针对特殊的航空要求，对轻合金/碳纤维复合材料接头的力学性能进行了表征，并通过具体的工艺步骤对其力学性能进行了改进。为了确保不老化的混杂复合材料，将开发所谓的三层混杂(Al/Ti箔/CFRP，Al/GF-Fabric/CFRP)，并对其微观结构、力学和老化性能进行详细的研究。此外，将通过设计和制造符合规定的技术准备水平(TRL)的混合演示器来检验未来超声波焊接在部件级的航空应用。在此基础上，以某型飞机结构为例，提出了超声波焊接工业化应用的构想。