Cold spray and mechanical bonding technology for the production of aerospace hybrid composites

用于生产航空航天混合复合材料的冷喷涂和机械粘合技术

• 批准号: 500394-2016
• 负责人: Robitaille, François
• 金额: $ 1.82万
• 依托单位: University of Ottawa
• 依托单位国家: 加拿大
• 项目类别: Engage Grants Program
• 财政年份: 2016
• 资助国家: 加拿大
• 起止时间: 2016-01-01 至 2017-12-31
• 项目状态: 已结题
• 来源: https://www.nserc-crsng.gc.ca/ase-oro/Details-Detailles_eng.asp?id=608075
• 关键词: Cold; spray; mechanical; bonding; technology

Aircraft primary structures are constantly being redesigned for reducing weight without encumbering structural integrity and safety. Following this trend, industry leaders incorporate a greater proportion of carbon fibre reinforced composites (CFRCs) that improve the aircraft skin's strength-to-weight ratio and resistance to mechanical stress. However, issues regarding wear/erosion at specific locations arise, leading to swift degradation. This is currently solved through costly and labour intensive methods of shaping and gluing titanium sheets on CFRC skins in critical areas. It is envisioned that additive manufacturing processes can offer better alternatives to the current solution. Cold spray is a low temperature additive manufacturing process suitable for heat sensitive substrate materials, that enables depositing thin layers of material in variable thickness. This project proposes to use Nucap's GRIP Metal patented hook technology to create a bond coat on CFRCs prior to spraying. The combination of both technologies aims at enabling reliable and reproducible cold spray coatings on CFRCs through mechanical bonding, in a cost effective way. The project uses GRIP Metal steel and aluminium sheets instead of titanium to minimize costs while allowing validation of the proof of concept. CFRC plates integrating GRIP Metal sheets with different hook densities and sizes will be manufactured by laminating on uncured carbon fibre prepreg stacks. The quality of the resulting laminates will be probed. Steel coatings and aluminium coatings, depending on initial results obtained with steel, will be sprayed on the assemblies to assess the productibility of variable thickness coatings. The successful development and implementation of the proposed technology has the potential to result in major cost savings and reduced manufacturing time.

飞机的主要结构不断地被重新设计，以减轻重量，而不破坏结构的完整性和安全性。随着这一趋势的发展，行业领导者采用了更大比例的碳纤维增强复合材料（CFRC），以提高飞机蒙皮的强度重量比和抗机械应力能力。然而，在特定位置出现关于磨损/侵蚀的问题，导致迅速退化。目前，这一问题是通过昂贵且劳动密集型的方法来解决的，即在关键区域的CFRC蒙皮上成型和粘合钛板。据设想，增材制造工艺可以为当前解决方案提供更好的替代方案。冷喷涂是一种适用于热敏基底材料的低温增材制造工艺，其能够以可变厚度沉积薄层材料。该项目建议使用Nucap的GRIP Metal专利挂钩技术，在喷涂前在CFRC上形成粘合涂层。这两种技术的结合旨在通过机械结合以具有成本效益的方式在CFRC上实现可靠和可重复的冷喷涂涂层。该项目使用GRIP Metal钢和铝板代替钛，以最大限度地降低成本，同时允许验证概念。CFRC板集成GRIP金属板与不同的钩密度和大小将制造层压在未固化的碳纤维预浸料堆。将探讨所得层压板的质量。根据钢的初步结果，将在组件上喷涂钢涂层和铝涂层，以评估可变厚度涂层的生产能力。所提出的技术的成功开发和实施有可能节省大量成本并缩短制造时间。