A high-impact-resistant aluminum alloy material and a preparation method thereof

Abstract

The application provides a high-impact-resistance aluminum alloy material, which comprises an impact-resistant outer layer, a gradient transition layer and an energy-absorbing buffer structure inner layer, the impact-resistant outer layer is composed of an aluminum alloy material and a three-dimensional carbon fiber fabric, the gradient transition layer is composed of an aluminum alloy material and a ceramic reinforced non-woven fabric layer, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer. The application further provides a preparation method of the high-impact-resistance aluminum alloy material, and the impact resistance of the aluminum alloy is improved through the cooperation of the three-layer structure of the impact-resistant outer layer, the gradient transition layer and the energy-absorbing buffer structure inner layer.

Description

Technical Field

[0001] This invention relates to the field of polymer material preparation, specifically to a high-impact ABS conductive resin and its preparation method. Background Technology

[0002] Aluminum alloys are essential materials for transportation vehicles such as automobiles, airplanes, and high-speed trains. However, traditional aluminum alloy structures can no longer meet the demands of modern transportation in terms of structural strength and impact resistance. In the event of a collision, if the energy generated by the impact and the kinetic energy of the vehicle itself are not buffered and released, it will cause severe damage to the equipment structure, potentially leading to significant loss of life and property and posing a potential risk to driving safety. Currently, two commonly used methods to improve the impact resistance of aluminum alloys are fiber-reinforced metal laminates and foam alloy reinforcement.

[0003] Fiber-reinforced metal laminates are hybrid composite laminate structures formed by alternating layers of thin metal sheets and fiber-reinforced composite materials, followed by pressure curing. Due to the combination of the superior properties of metal and fiber-reinforced composite materials, they possess advantages such as high fatigue tolerance, good impact resistance, low density, and good corrosion resistance.

[0004] In automotive manufacturing, aluminum foam is commonly used to create impact-absorbing components, such as filling the interior of bumpers and doors to absorb impact energy during traffic accidents. While ordinary aluminum foam possesses good cushioning and energy absorption capabilities, its low yield strength makes it unsuitable for many high-impact engineering situations, limiting its application prospects. Therefore, materials scientists have employed experimental methods to infiltrate various materials into aluminum, preparing different types and properties of aluminum-based composite foam materials to meet diverse practical needs. However, due to its relatively low strength and stiffness, aluminum foam is generally not suitable for use alone; it is typically combined with high-strength and stiffness thin panels to form sandwich structures. While these methods have yielded some success, they are far from sufficient for applications under more demanding high-impact conditions, requiring further research. Summary of the Invention

[0005] The technical problem to be solved: The purpose of this invention is to provide a method for preparing a high-impact aluminum alloy material, which improves the impact resistance of the aluminum alloy by combining a three-layer structure of an impact-resistant outer layer, a gradient transition layer and an energy-absorbing buffer structure inner layer.

[0006] Technical solution: A high impact-resistant aluminum alloy material, the aluminum alloy material comprising an impact-resistant outer layer, a gradient transition layer and an energy-absorbing buffer structure inner layer, the impact-resistant outer layer being composed of aluminum alloy material and carbon fiber three-dimensional fabric composite, the gradient transition layer being composed of aluminum alloy material and ceramic-reinforced nonwoven fabric composite, and the energy-absorbing buffer structure inner layer being a porous foam alloy layer.

[0007] Preferably, the preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0008] S1. Preparation of the porous foam alloy layer: Aluminum ingots are heated and melted, then metallic calcium powder is added and stirred at low speed until homogeneous. The temperature is lowered to 620-635℃, and foaming agent TiH2 is added. The mixture is stirred at high speed to ensure uniform dispersion, then kept at this temperature for 1-3 minutes and allowed to cool naturally. The resulting porous foam alloy layer has a density of 0.35-0.42 g / cm³. 3 ;

[0009] S2. Preparation of gradient transition layer: A ceramic nonwoven fabric with a thickness of 0.2-0.3 cm is laid on the porous foam alloy layer prepared in step S1, and then aluminum liquid is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.3-0.4 cm.

[0010] S3. Preparation of the impact-resistant outer layer: A three-dimensional carbon fiber fabric with a thickness of 0.2-0.3 cm is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the three-dimensional carbon fiber fabric to obtain an impact-resistant outer layer with a thickness of 0.35-0.5 cm.

[0011] Preferably, in step S1, the content of the foaming agent is 0.5-0.9 wt%, the content of the metallic calcium powder is 2-2.5 wt%, the speed of the low-speed stirring is 500-800 r / min, and the speed of the high-speed stirring is 900-1200 r / min.

[0012] Preferably, in step S2, the ceramic nonwoven fabric is a carbon fiber electrospun film with Al2O3 loaded on its surface, and the preparation method of the carbon fiber electrospun film with Al2O3 loaded on its surface is as follows:

[0013] S11. Add aluminum isopropoxide to pure water at 85-95℃ for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 85-95℃ for 8-12 hours to obtain AlOOH colloid.

[0014] S12. Add a carbon fiber electrospun film with a thickness of 0.15-0.2 cm to a colloidal solution, remove it and dry it, and then calcine it at 500-550℃. Repeat this step 1-2 times to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0015] Preferably, the porosity of the surface-loaded Al2O3 carbon fiber electrospun membrane is 85-92%.

[0016] Preferably, in step S3, the carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is combined in a three-layer composite form. The middle layer is a carbon fiber electrospun layer, and the outer layers on both sides are woven layers. The three-layer structure is woven through the thickness direction by draping yarns.

[0017] Preferably, the thickness of the woven layer is 0.05-0.1cm, and the thickness of the carbon fiber electrospun layer is 0.1-0.2cm.

[0018] Preferably, the porosity of the carbon fiber electrospun layer is 94-96%. The warp cover tightness of the woven layer is 30-40%, and the weft cover tightness is 30-35%.

[0019] Preferably, the aluminum ingot and molten aluminum have the following composition: Fe 0.25-0.35%, Si 0.45-0.6%, Mn 0.1-0.15%, Cu 0.2-0.3%, Ti 0.01-0.05%, Zn 0.01-0.15%, with the balance being Al.

[0020] Beneficial effects: The high impact-resistant aluminum alloy material and its preparation method of the present invention have the following advantages:

[0021] 1. This invention adopts a gradient layered design method to design a high-impact gradient functional composite protective structure model. The structure mainly consists of three parts: an outer layer of ultra-high performance impact-resistant structure, a gradient transition layer (middle layer), and an inner layer of energy-absorbing buffer structure, so as to realize the high strength and high impact resistance of the overall structure.

[0022] 2. The outer layer of the ultra-high impact-resistant structure in this invention is composed of aluminum alloy and carbon fiber three-dimensional fabric. Utilizing the ultra-high strength and high toughness of the carbon fiber three-dimensional fabric, it increases resistance during impact while ensuring the overall structure has a long service life. The inner layer of the energy-absorbing buffer structure is a porous foam alloy layer. Utilizing the porosity of the porous alloy and its ability to absorb energy transmitted through the outer layer under external force, it effectively reduces shock and absorbs energy, ultimately minimizing secondary damage during impact. The intermediate gradient transition layer is composed of aluminum alloy and ceramic-reinforced nonwoven fabric, thus possessing some key characteristics of both the outer and inner layers. This significantly reduces the impedance matching between the first and second structural layers, maximizing the overall protective performance. Detailed Implementation

[0023] The present invention will be further described below with reference to embodiments. These embodiments are illustrative of the present invention, but the present invention is not limited to these embodiments:

[0024] Example 1

[0025] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of an aluminum alloy material and a three-dimensional carbon fiber fabric composite, the gradient transition layer is composed of an aluminum alloy material and a ceramic-reinforced nonwoven fabric layer, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.25%, Si 0.6%, Mn 0.1%, Cu 0.3%, Ti 0.01%, Zn 0.15%, with the balance being Al;

[0026] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0027] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 800 r / min until homogeneous. The temperature was lowered to 635℃, and 0.5 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1200 r / min until homogeneous. The mixture was then kept at this temperature for 3 minutes and allowed to cool naturally to obtain a porous foam alloy layer with a density of 0.36 g / cm³. 3 ;

[0028] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a thickness of 0.2 cm and a porosity of 85% and surface-loaded with Al2O3 is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.3 cm. The method for preparing the carbon fiber electrospun film with surface-loaded Al2O3 is as follows:

[0029] S11. Add aluminum isopropoxide to pure water at 95°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 95°C for 8 hours to obtain AlOOH colloid.

[0030] S12. Add a carbon fiber electrospun film with a thickness of 0.15 cm to a colloidal solution, take it out and dry it, and then calcine it at 500 °C. Repeat this step once to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0031] S3. Preparation of the impact-resistant outer layer: A 0.3cm thick carbon fiber three-dimensional fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber three-dimensional fabric to obtain an impact-resistant outer layer with a thickness of 0.5cm. The carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.2cm and a porosity of 94%. The outer layers on both sides are woven layers with a thickness of 0.05cm. The warp cover tightness is 30% and the weft cover tightness is 35%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0032] Example 2

[0033] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of an aluminum alloy material and a three-dimensional carbon fiber fabric composite, the gradient transition layer is composed of an aluminum alloy material and a ceramic-reinforced nonwoven fabric layer, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.35%, Si 0.45%, Mn 0.15%, Cu 0.2%, Ti 0.05%, Zn 0.01%, with the balance being Al;

[0034] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0035] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.5 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 500 r / min until homogeneous. The temperature was lowered to 620℃, and 0.9 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 900 r / min until homogeneous. The mixture was then kept at this temperature for 1 min and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.42 g / cm³. 3 ;

[0036] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a thickness of 0.3 cm and a porosity of 92% and surface-loaded with Al2O3 is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.4 cm. The method for preparing the carbon fiber electrospun film with surface-loaded Al2O3 is as follows:

[0037] S11. Add aluminum isopropoxide to pure water at 85°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 85°C for 12 hours to obtain AlOOH colloid.

[0038] S12. Add a carbon fiber electrospun film with a thickness of 0.2 cm to a colloidal solution, take it out and dry it, and then calcine it at 550℃. Repeat this step twice to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0039] S3. Preparation of the impact-resistant outer layer: A 0.2cm thick three-dimensional carbon fiber fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the three-dimensional carbon fiber fabric to obtain an impact-resistant outer layer with a thickness of 0.35cm. The three-dimensional carbon fiber fabric is made of carbon fiber as raw material and is composed of three layers in a composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.1cm and a porosity of 96%. The outer layers on both sides are woven layers with a thickness of 0.05cm. The warp cover tightness is 40% and the weft cover tightness is 30%. The three-layer structure is pierced through the thickness direction by the drape yarn.

[0040] Example 3

[0041] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of an aluminum alloy material and a three-dimensional carbon fiber fabric composite, the gradient transition layer is composed of an aluminum alloy material and a ceramic-reinforced nonwoven fabric layer, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.28%, Si 0.55%, Mn 0.1%, Cu 0.26%, Ti 0.02%, Zn 0.1%, with the balance being Al;

[0042] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0043] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.2 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 600 r / min until homogeneous. The temperature was lowered to 625℃, and 0.6 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1000 r / min until homogeneous. The mixture was then kept at this temperature for 3 minutes and allowed to cool naturally to obtain a porous foam alloy layer with a density of 0.40 g / cm³. 3 ;

[0044] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a thickness of 0.3 cm and a porosity of 92% and surface-loaded with Al2O3 is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.4 cm. The method for preparing the carbon fiber electrospun film with surface-loaded Al2O3 is as follows:

[0045] S11. Add aluminum isopropoxide to pure water at 95°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 95°C for 11 hours to obtain AlOOH colloid.

[0046] S12. Add a carbon fiber electrospun film with a thickness of 0.2 cm to a colloidal solution, take it out and dry it, and then calcine it at 550℃. Repeat this step twice to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0047] S3. Preparation of the impact-resistant outer layer: A 0.2cm thick carbon fiber three-dimensional fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber three-dimensional fabric to obtain an impact-resistant outer layer with a thickness of 0.35cm. The carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.1cm and a porosity of 96%. The outer layers on both sides are woven layers with a thickness of 0.05cm, a warp cover tightness of 33%, and a weft cover tightness of 34%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0048] Example 4

[0049] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of an aluminum alloy material and a three-dimensional carbon fiber fabric composite, the gradient transition layer is composed of an aluminum alloy material and a ceramic-reinforced nonwoven fabric layer, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.32%, Si 0.5%, Mn 0.15%, Cu 0.23%, Ti 0.04%, Zn 0.05%, with the balance being Al;

[0050] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0051] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.4 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 700 r / min until homogeneous. The temperature was lowered to 630℃, and 0.8 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1100 r / min until homogeneous. The mixture was then kept at this temperature for 1 min and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.38 g / cm³. 3 ;

[0052] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a thickness of 0.2 cm and a porosity of 88% and surface-loaded with Al2O3 is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.3 cm. The method for preparing the carbon fiber electrospun film with surface-loaded Al2O3 is as follows:

[0053] S11. Add aluminum isopropoxide to pure water at 85°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 85°C for 9 hours to obtain AlOOH colloid.

[0054] S12. Add a carbon fiber electrospun film with a thickness of 0.15 cm to a colloidal solution, take it out and dry it, and then calcine it at 500 °C. Repeat this step once to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0055] S3. Preparation of the impact-resistant outer layer: A 0.3cm thick carbon fiber three-dimensional fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber three-dimensional fabric to obtain an impact-resistant outer layer with a thickness of 0.45cm. The carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.2cm and a porosity of 94%. The outer layers on both sides are woven layers with a thickness of 0.05cm, a warp cover tightness of 38%, and a weft cover tightness of 32%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0056] Example 5

[0057] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of aluminum alloy material and carbon fiber three-dimensional fabric composite, the gradient transition layer is composed of aluminum alloy material and ceramic-reinforced nonwoven fabric layer composite, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.3%, Si 0.5%, Mn 0.12%, Cu 0.25%, Ti 0.03%, Zn 0.08%, with the balance being Al;

[0058] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0059] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.2 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 650 r / min until homogeneous. The temperature was lowered to 625℃, and 0.8 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1100 r / min until homogeneous. The mixture was then kept at this temperature for 2 minutes and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.39 g / cm³. 3 ;

[0060] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a surface load of Al2O3 and a porosity of 90% with a thickness of 0.25 cm is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.35 cm. The method for preparing the carbon fiber electrospun film with a surface load of Al2O3 is as follows:

[0061] S11. Add aluminum isopropoxide to pure water at 90°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 90°C for 10 hours to obtain AlOOH colloid.

[0062] S12. Add a carbon fiber electrospun film with a thickness of 0.2 cm to a colloidal solution, take it out and dry it, and then calcine it at 500℃. Repeat this step once to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0063] S3. Preparation of the impact-resistant outer layer: A 0.25cm thick carbon fiber three-dimensional fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber three-dimensional fabric to obtain an impact-resistant outer layer with a thickness of 0.40cm. The carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.15cm and a porosity of 95%. The outer layers on both sides are woven layers with a thickness of 0.05cm, a warp cover tightness of 36%, and a weft cover tightness of 34%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0064] Comparative Example 1

[0065] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of aluminum alloy material and carbon fiber three-dimensional fabric composite, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.32%, Si 0.5%, Mn 0.15%, Cu 0.23%, Ti 0.04%, Zn 0.05%, with the balance being Al;

[0066] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0067] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.4 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 700 r / min until homogeneous. The temperature was lowered to 630℃, and 0.8 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1100 r / min until homogeneous. The mixture was then kept at this temperature for 1-3 minutes and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.38 g / cm³. 3 ;

[0068] S2. Preparation of the impact-resistant outer layer: A 0.3cm thick three-dimensional carbon fiber fabric is laid on the porous foam alloy layer prepared in S1, and then aluminum liquid is poured onto the three-dimensional carbon fiber fabric to obtain an impact-resistant outer layer with a thickness of 0.45cm. The three-dimensional carbon fiber fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.2cm and a porosity of 94%. The outer layers on both sides are woven layers with a thickness of 0.05cm, a warp cover tightness of 38%, and a weft cover tightness of 32%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0069] Comparative Example 2

[0070] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of aluminum alloy material and carbon fiber three-dimensional fabric composite, the gradient transition layer is composed of aluminum alloy material and ceramic-reinforced nonwoven fabric layer composite, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.3%, Si 0.5%, Mn 0.12%, Cu 0.25%, Ti 0.03%, Zn 0.08%, with the balance being Al;

[0071] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0072] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.2 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 650 r / min until homogeneous. The temperature was lowered to 625℃, and 0.8 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1100 r / min until homogeneous. The mixture was then kept at this temperature for 2 minutes and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.39 g / cm³. 3 ;

[0073] S2. Preparation of gradient transition layer: A carbon fiber electrospun membrane with a thickness of 0.25 cm and a porosity of 92% is laid on the porous foam alloy layer prepared in step S1, and then aluminum liquid is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.35 cm.

[0074] S3. Preparation of the impact-resistant outer layer: A 0.25cm thick carbon fiber three-dimensional fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber three-dimensional fabric to obtain an impact-resistant outer layer with a thickness of 0.40cm. The carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is composed of three layers in a layered composite form. The middle layer is a carbon fiber electrospun layer with a thickness of 0.15cm and a porosity of 95%. The outer layers on both sides are woven layers with a thickness of 0.05cm, a warp cover tightness of 36%, and a weft cover tightness of 34%. The three-layer structure is pierced through the thickness direction by drape yarns.

[0075] Comparative Example 3

[0076] A high-impact-resistant aluminum alloy material, comprising an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer, wherein the impact-resistant outer layer is composed of aluminum alloy material and carbon fiber three-dimensional fabric composite, the gradient transition layer is composed of aluminum alloy material and ceramic-reinforced nonwoven fabric layer composite, and the energy-absorbing buffer structure inner layer is a porous foam alloy layer; the composition of the aluminum alloy material is: Fe 0.3%, Si 0.5%, Mn 0.12%, Cu 0.25%, Ti 0.03%, Zn 0.08%, with the balance being Al;

[0077] The preparation method of the high impact-resistant aluminum alloy material includes the following steps:

[0078] S1. Preparation of the porous foam alloy layer: Aluminum ingots were heated and melted, then 2.2 wt% metallic calcium powder was added. The mixture was stirred at a low speed of 650 r / min until homogeneous. The temperature was lowered to 625℃, and 0.8 wt% foaming agent TiH2 was added. The mixture was stirred at a high speed of 1100 r / min until homogeneous. The mixture was then kept at this temperature for 2 minutes and allowed to cool naturally. The resulting porous foam alloy layer had a density of 0.39 g / cm³. 3 ;

[0079] S2. Preparation of the gradient transition layer: A carbon fiber electrospun film with a surface load of Al2O3 and a porosity of 90% with a thickness of 0.25 cm is laid on the porous foam alloy layer prepared in step S1. Then, molten aluminum is poured onto the ceramic nonwoven fabric to obtain a gradient transition layer with a thickness of 0.35 cm. The method for preparing the carbon fiber electrospun film with a surface load of Al2O3 is as follows:

[0080] S11. Add aluminum isopropoxide to pure water at 90°C for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 90°C for 10 hours to obtain AlOOH colloid.

[0081] S12. Add a carbon fiber electrospun film with a thickness of 0.2 cm to a colloidal solution, take it out and dry it, and then calcine it at 500℃. Repeat this step once to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface.

[0082] S3. Preparation of the impact-resistant outer layer: A 0.25cm thick three-dimensional carbon fiber fabric is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the carbon fiber fabric to obtain an impact-resistant outer layer with a thickness of 0.40cm. The carbon fiber fabric is made of carbon fiber as raw material and is combined in a three-layer composite form. All three layers are woven layers, and adjacent layers are rotated 90° during the laying process. The thickness of the woven layer is 0.1cm, the warp cover tightness is 36%, and the weft cover tightness is 34%. The three-layer structure is penetrated in the thickness direction by the drape yarn.

[0083] The aluminum alloy materials used in the above embodiments and comparative examples were used to fabricate automotive anti-collision beams, and performance tests were conducted. The test results are shown in the table below:

[0084] Yield strength MPa Tensile strength (MPa) V-shaped impact energy (J) (-20℃) Example 1 408 501 93 Example 2 405 509 96 Example 3 412 511 99 Example 4 416 513 101 Example 5 415 515 98 Comparative Example 1 298 422 56 Comparative Example 2 346 462 80 Comparative Example 3 368 485 85

[0085] Impact tests were conducted on an impact testing machine in accordance with GB / T 229—2020; tensile tests were conducted on a tensile testing machine in accordance with GB / T228—2010.

[0086] Obviously, the above embodiments are merely illustrative examples for clear explanation and are not intended to limit the implementation. Those skilled in the art will recognize that other variations or modifications can be made based on the above description. It is neither necessary nor possible to exhaustively list all possible implementations here. However, obvious variations or modifications derived therefrom are still within the scope of protection of this invention.

Claims

1. A high impact resistant aluminum alloy material, characterized by, The aluminum alloy material includes an impact-resistant outer layer, a gradient transition layer, and an energy-absorbing buffer structure inner layer. The impact-resistant outer layer is composed of aluminum alloy material and carbon fiber three-dimensional fabric. The gradient transition layer is composed of aluminum alloy material and ceramic-reinforced nonwoven fabric layer. The energy-absorbing buffer structure inner layer is a porous foam alloy layer. The above-mentioned method for preparing high-impact aluminum alloy materials includes the following steps: S1. Preparation of the porous foam alloy layer: Aluminum ingots are heated and melted, then metallic calcium powder is added and stirred at low speed until homogeneous. The temperature is lowered to 620-635℃, and foaming agent TiH2 is added. The mixture is stirred at high speed to ensure uniform dispersion, then kept at this temperature for 1-3 minutes and allowed to cool naturally. The resulting porous foam alloy layer has a density of 0.35-0.42 g / cm³. 3 ; S2. Preparation of gradient transition layer: A ceramic-reinforced nonwoven fabric with a thickness of 0.2-0.3 cm is laid on the porous foam alloy layer prepared in step S1, and then aluminum liquid is poured onto the ceramic-reinforced nonwoven fabric to obtain a gradient transition layer with a thickness of 0.3-0.4 cm. S3. Preparation of the impact-resistant outer layer: A three-dimensional carbon fiber fabric with a thickness of 0.2-0.3 cm is laid on the gradient transition layer prepared in S2, and then aluminum liquid is poured onto the three-dimensional carbon fiber fabric to obtain an impact-resistant outer layer with a thickness of 0.35-0.5 cm. In step S2, the ceramic-reinforced nonwoven fabric is a carbon fiber electrospun film with Al2O3 loaded on its surface. The preparation method of the carbon fiber electrospun film with Al2O3 loaded on its surface is as follows: S11. Add aluminum isopropoxide to pure water at 85-95℃ for hydrolysis. After hydrolysis, add concentrated nitric acid and age at 85-95℃ for 8-12 hours to obtain AlOOH colloid. S12. Add a carbon fiber electrospun film with a thickness of 0.15-0.2cm to the colloid, take it out and dry it, and then calcine it at 500-550℃. Repeat this step 1-2 times to obtain a carbon fiber electrospun film with Al2O3 loaded on the surface. In step S3, the carbon fiber three-dimensional fabric is made of carbon fiber as raw material and is combined in a three-layer composite form. The middle layer is a carbon fiber electrospun layer, and the outer layers on both sides are woven layers. The three-layer structure is woven through the thickness direction by draping yarns.

2. The high-impact-resistance aluminum alloy material according to claim 1, characterized by: In step S1, the foaming agent content is 0.5-0.9 wt%, the calcium metal powder content is 2-2.5 wt%, the low-speed stirring speed is 500-800 r / min, and the high-speed stirring speed is 900-1200 r / min.

3. The high-impact-resistance aluminum alloy material according to claim 1, characterized by: The porosity of the surface-loaded Al2O3-coated carbon fiber electrospun membrane is 85-92%.

4. The high-impact-resistance aluminum alloy material according to claim 1, characterized by: The thickness of the woven layer is 0.05-0.1cm, and the thickness of the carbon fiber electrospun layer is 0.1-0.2cm.

5. The high-impact-resistance aluminum alloy material according to claim 4, characterized by: The porosity of the carbon fiber electrospun layer is 94-96%, and the warp cover tightness of the woven layer is 30-40%, while the weft cover tightness is 30-35%.

6. The high-impact-resistance aluminum alloy material according to claim 1, wherein: The composition of the aluminum ingot and molten aluminum is as follows: Fe 0.25-0.35%, Si 0.45-0.6%, Mn 0.1-0.15%, Cu 0.2-0.3%, Ti 0.01-0.05%, Zn 0.01-0.15%, with the balance being Al.