Rapid repairing method for aerospace carbon fiber composite material

Abstract

The invention provides a rapid repairing method for an aerospace carbon fiber composite material, and belongs to the technical field of carbon fiber composite material repairing, in the aspect of cleaning, a special cleaning agent for self-research is free of damage and efficient, a preset cleanliness can be achieved by matching with a tool with a replaceable brush head, a foundation is laid for repairing, the damage is accurately measured by advanced detection equipment, the detection precision is 0.1 mm, and the detection efficiency is high. The repair material is scientific in formula and reasonable in component proportion, it can be guaranteed that the performance of a repaired part is close to that of an original part, the strict repair technology such as vacuum auxiliary pressure injection and autoclave curing guarantees sufficient curing and optimal performance of the material, and it is guaranteed that the quality reaches the standard through surface treatment and detection; all the devices of the equipment cooperate and are provided with intelligent systems, parameters can be regulated and controlled, the technology can be automatically adjusted, the structure meets special aviation requirements, carrying and operation are convenient, various scene requirements are met, and the equipment has great significance in guaranteeing aircraft operation and flight safety.

Description

Technical Field

[0001] The invention belongs to the technical field of carbon fiber composite material repair, and in particular relates to a rapid repair method for aerospace carbon fiber composite materials. Background Art

[0002] In the field of aerospace, carbon fiber composite materials are widely used in the structural components of aircraft due to their excellent properties, such as high strength and low density. However, during the use of aircraft, carbon fiber composite materials may be damaged by various damages, such as impact and fatigue. Traditional repair methods are often time-consuming and it is difficult to ensure that the performance of the repaired parts can fully reach the level of the original parts. With the continuous development of aerospace technology, the safety, reliability and availability of aircraft are required to be higher and higher. It is very important to quickly and effectively repair damaged carbon fiber composite materials so that their performance reaches or approaches the performance indicators of the original parts to ensure the normal operation and flight safety of the aircraft. At present, although there are some repair technologies for carbon fiber composite materials, there are still some problems in practical applications. For example, detergents may have adverse effects on the structure and performance of carbon fiber composite materials, the accuracy and depth of damage detection are not enough, the performance of repair materials cannot meet the strict requirements of aerospace, and the repair process is not perfect, resulting in unstable repair quality.

[0003] Therefore, there is a need for a new rapid repair method for aerospace carbon fiber composite materials and corresponding repair equipment that can solve the problems in the existing technology and achieve efficient and high-quality repair of carbon fiber composite components to meet the ever-changing needs of the aerospace field. Summary of the invention

[0004] The purpose of the present invention is to provide a rapid repair method for aerospace carbon fiber composite materials, aiming to solve the problems in the prior art.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] A rapid repair method for aerospace carbon fiber composite materials, characterized by comprising the following steps:

[0007] Clean the surface of damaged carbon fiber composite parts to remove dirt, dust and other impurities, using specific cleaning agents and cleaning tools to ensure that the surface cleanliness meets the preset standards, where the cleaning agent contains [ethanol], [deionized water], etc., and the ratio of each component is [7:3]; the cleaning tool is a tool with a [soft fiber brush head and replaceable brush head];

[0008] Conduct accurate damage assessment on the damaged area after cleaning, using advanced testing equipment such as [ultrasonic flaw detector] to accurately determine the degree, scope and type of damage, with a detection accuracy of [0.1 mm] level;

[0009] Then, based on the damage assessment results, appropriate repair materials are selected.

[0010] The repair material formula is as follows:

[0011] The main component is [epoxy resin], whose specific model is [EpoxyResinXYZ], accounting for [75%] of the total mass of the repair material;

[0012] [Carbon fiber chopped strands], having a length between [3 mm and 5 mm] and accounting for [25%] of the total mass of the repair material;

[0013] Additive [coupling agent], specifically [silane coupling agent ABC], the function of the additive is to improve the [adhesion] of the repair material, and the amount of the additive added is [3%] of the total mass of the repair material;

[0014] Its performance must meet [tensile strength not less than 80% of the raw material, heat resistance temperature not less than 150 degrees Celsius], and the repair material must be prepared according to a certain formula ratio, the mixing ratio is [epoxy resin: carbon fiber chopped strands = 3:1];

[0015] The prepared repair material is filled into the damaged area using a specific repair process, the repair process includes [vacuum assisted pressure injection] and [autoclave heating and curing], wherein the pressure range of the pressure injection is [0.5 MPa to 1 MPa], the temperature of the heating and curing is [120 degrees Celsius], and the time is [2 hours];

[0016] Finally, the repaired parts are subjected to surface treatment and quality inspection. The surface treatment adopts [fine grinding and polishing] to make the surface flatness of the repaired parts reach [within 0.05 mm]; the quality inspection adopts [X-ray non-destructive testing] to ensure that the performance of the repaired parts reaches or is close to the performance indicators of the original parts.

[0017] As a preferred solution of the present invention, the cleaning agent is a special cleaning agent independently developed for aerospace carbon fiber composite materials, which has the characteristics of being non-destructive to carbon fiber composite materials and being highly efficient in cleaning, and will not have adverse effects on the structure and performance of carbon fiber composite materials during the cleaning process.

[0018] As a preferred solution of the present invention, the detection equipment is capable of detecting microscopic damage inside the carbon fiber composite material, with a detection depth of up to [5 mm], and can generate detailed damage images and data reports, providing an accurate basis for subsequent repair work.

[0019] As a preferred solution of the present invention, a specific additive [coupling agent] needs to be added to the repair material during the preparation process. The function of the additive is to improve the [adhesion] of the repair material. The amount of the additive added is [3%] of the total mass of the repair material.

[0020] As a preferred solution of the present invention, the pressure injection and heating curing in the repair process must be carried out in strict sequence, and during the pressure injection process, it must be ensured that the repair material is evenly filled into the damaged area to avoid defects such as gaps and bubbles. During the heating curing process, the temperature and time must be precisely controlled to ensure that the repair material is fully cured and achieves optimal performance.

[0021] As a preferred solution of the present invention, it includes a cleaning device, a detection device, a repair material mixing device, a repair process execution device and a quality detection device, and each device cooperates with each other and works in coordination.

[0022] The cleaning device has a specific structure and functional description of [a spray gun with adjustable pressure and a matching cleaning agent storage tank, and the spray gun can replace nozzles of different specifications], and can effectively clean the surface of carbon fiber composite material parts.

[0023] The detection device has a specific structure and functional description of [high-precision probe and supporting data processing and display system, the probe can detect at multiple angles], and can accurately detect and evaluate the damage of components.

[0024] The repair material mixing device has a specific structure and functional description of [a precisely metered mixing tank and a matching feeding system with adjustable mixing speed], and can mix the repair material accurately according to the formula ratio.

[0025] The repair process execution device has the specific structure and functional description of [an injection pump that can accurately control the pressure and a matching sealing mold, and an autoclave with precise temperature control function], and can accurately execute repair processes such as pressure injection and heating curing.

[0026] The quality inspection device has the specific structure and functional description of [high-resolution X-ray imaging system and supporting data analysis software], and can perform comprehensive quality inspection on the repaired parts.

[0027] As a preferred solution of the present invention, the repair equipment is also equipped with an intelligent control system, which can monitor and regulate the operating parameters of each device in real time to ensure the accuracy and stability of the repair process, and can automatically adjust the repair process and parameters according to different damage conditions to achieve intelligent repair;

[0028] The overall structural design of the repair equipment meets the special requirements of the aerospace field, and has the characteristics of small size, light weight, easy to carry and operate, and can be used in aerospace vehicle production workshops and emergency repair scenarios during actual flights.

[0029] Compared with the prior art, the present invention has the following beneficial effects:

[0030] First, in terms of cleaning, the self-developed special cleaning agent is harmless to carbon fiber composite materials and is clean and efficient, and will not affect its structure and performance. The use of tools with soft fiber brush heads and replaceable brush heads can ensure that the surface of the damaged parts meets the preset cleanliness standards, laying a good foundation for subsequent repair work. Secondly, advanced testing equipment can accurately determine the degree, scope and type of damage, with a detection accuracy of 0.1 mm. It can also detect internal microscopic damage with a detection depth of up to 5 mm, and generate detailed damage images and data reports to provide accurate basis for precise repair. Furthermore, the formula of the repair material is scientific and reasonable. Epoxy resin accounts for 75% as the main component, and carbon fiber chopped strands enhance the performance of the material. The length between 3 mm and 5 mm accounts for 25%. The coupling agent added in an amount of 3% of the total mass of the repair material improves the adhesion of the repair material. Its performance requires tensile strength not less than 80% of the raw material and heat resistance temperature not less than 150 degrees Celsius. The mixing ratio is epoxy resin: carbon fiber chopped strands = 3:1 , which can effectively ensure that the performance of the repaired parts is close to that of the original parts. Then, the repair process is rigorous, and vacuum-assisted pressure injection ensures that the repair material is evenly filled into the damaged area to avoid defects such as gaps and bubbles. The pressure range is 0.5 MPa to 1 MPa, and the autoclave heating and curing temperature is 120 degrees Celsius for 2 hours to ensure that the repair material is fully cured and achieves the best performance. Finally, through fine grinding and polishing, the surface flatness is within 0.05 mm, and X-ray non-destructive testing ensures that the performance of the parts meets the standards. In addition, the various devices of the repair equipment cooperate and work together, and are equipped with an intelligent control system that can monitor and regulate the operating parameters of each device in real time to ensure that the repair process is accurate and stable. It can also automatically adjust the repair process and parameters according to different damage conditions to achieve intelligent repair. Its overall structural design meets the special requirements of the aerospace field, with small size, light weight, easy to carry and operate, and can meet the needs of aircraft production workshops and emergency repair scenarios in actual flight, which is of great significance to ensuring the normal operation and flight safety of aircraft. DETAILED DESCRIPTION

[0031] The technical solutions in the embodiments of the present invention will be described clearly and completely below in combination with the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0032] Example 1

[0033] The present invention provides the following technical solutions:

[0034] A rapid repair method for aerospace carbon fiber composite materials comprises the following steps:

[0035] Clean the surface of damaged carbon fiber composite parts to remove dirt, dust and other impurities, using specific cleaning agents and cleaning tools to ensure that the surface cleanliness meets the preset standards, where the cleaning agent contains [ethanol], [deionized water], etc., and the ratio of each component is [7:3]; the cleaning tool is a tool with a [soft fiber brush head and replaceable brush head];

[0036] Conduct accurate damage assessment on the damaged area after cleaning, using advanced testing equipment such as [ultrasonic flaw detector] to accurately determine the degree, scope and type of damage, with a detection accuracy of [0.1 mm] level;

[0037] Then, based on the damage assessment results, appropriate repair materials are selected.

[0038] The repair material formula is as follows:

[0039] The main component is [epoxy resin], whose specific model is [EpoxyResinXYZ], accounting for [75%] of the total mass of the repair material;

[0040] [Carbon fiber chopped strands], having a length between [3 mm and 5 mm] and accounting for [25%] of the total mass of the repair material;

[0041] Additive [coupling agent], specifically [silane coupling agent ABC], the function of the additive is to improve the [adhesion] of the repair material, and the amount of the additive added is [3%] of the total mass of the repair material;

[0042] Its performance must meet [tensile strength not less than 80% of the raw material, heat resistance temperature not less than 150 degrees Celsius], and the repair material must be prepared according to a certain formula ratio, the mixing ratio is [epoxy resin: carbon fiber chopped strands = 3:1];

[0043] The prepared repair material is filled into the damaged area using a specific repair process, the repair process includes [vacuum assisted pressure injection] and [autoclave heating and curing], wherein the pressure range of the pressure injection is [0.5 MPa to 1 MPa], the temperature of the heating and curing is [120 degrees Celsius], and the time is [2 hours];

[0044] Finally, the repaired parts are subjected to surface treatment and quality inspection. The surface treatment adopts [fine grinding and polishing] to make the surface flatness of the repaired parts reach [within 0.05 mm]; the quality inspection adopts [X-ray non-destructive testing] to ensure that the performance of the repaired parts reaches or is close to the performance indicators of the original parts.

[0045] In a specific embodiment of the present invention, the first step of the rapid repair method for aerospace carbon fiber composite materials is surface cleaning. The use of a special cleaning agent containing ethanol and deionized water in a ratio of 7:3 has many important benefits. First, ethanol has good solubility and can effectively dissolve impurities such as oil on the surface of the component, and deionized water can prevent impurities in the water from causing secondary pollution to the carbon fiber composite material during the cleaning process. This specific ratio of mixed cleaning agents can minimize the damage to the material while ensuring the cleaning effect. Using a cleaning tool with a soft fiber brush head and a replaceable brush head, on the one hand, the soft fiber brush head can gently remove dirt without scratching the surface of the carbon fiber composite material and protecting its structural integrity. The design of the replaceable brush head increases the flexibility and service life of the cleaning tool. When the brush head is worn or contaminated, it can be replaced in time to ensure the continuous and stable cleaning effect. By ensuring that the surface cleanliness reaches the preset standard, a clean and suitable basic condition is provided for subsequent repair work, so that the repair material can be better combined with the damaged parts, and the quality and durability of the repair are improved. For example, in actual aerospace applications, if the surface of a component is not cleaned thoroughly, impurities may affect the adhesion of the repair material during the subsequent repair process, resulting in a decrease in the performance of the repaired component, or even further damage during the operation of the aircraft, endangering flight safety. Through strict surface cleaning steps, these problems can be effectively avoided, laying a solid foundation for high-quality repair work.

[0046] The step of conducting precise damage assessment of the damaged area after cleaning also has significant benefits. Using advanced detection equipment such as ultrasonic flaw detectors, the degree, scope and type of damage can be accurately determined with a detection accuracy of 0.1 mm. This high-precision detection capability is crucial, as it can detect micro-damage inside the component in detail. In the aerospace field, even small damage may gradually expand during the operation of the aircraft, ultimately affecting the structural integrity and safety of the aircraft. For example, when a carbon fiber composite component is hit, some internal cracks that are difficult to detect with the naked eye may appear. Through the high-precision detection of ultrasonic flaw detectors, the location, length and depth of these cracks can be accurately located. At the same time, the detection equipment can detect internal microscopic damage with a detection depth of up to 5 mm. This means that a more comprehensive understanding of the damage of the component can be obtained, not only detecting surface damage, but also deeply detecting potential problems within a certain depth. For example, some fatigue damage may gradually accumulate inside the material. Through this deep detection capability, it can be discovered and corresponding repair measures can be taken in a timely manner. In addition, the detection equipment can generate detailed damage images and data reports, which provides an accurate basis for subsequent repair work. Repair personnel can develop more scientific and reasonable repair plans based on these images and reports. For example, for different types and degrees of damage, they can choose appropriate repair materials and processes, accurately determine the filling amount of repair materials and repair process parameters, etc., so as to improve the efficiency and quality of repair, ensure that the repaired parts can meet the strict requirements of the aerospace field, and ensure the safe operation of the aircraft.

[0047] The regulations on the formula of repair materials have many beneficial effects. First, epoxy resin as the main component accounts for 75% of the total mass of the repair material. Epoxy resin has excellent bonding properties, chemical stability and mechanical strength. During the repair process, it can effectively fill the damaged area and form a good bond with the carbon fiber composite material parts. Its high proportion ensures the overall bonding strength and stability of the repair material, so that the repaired parts can withstand various mechanical loads during the operation of the aircraft. For example, during the flight of the aircraft, the parts will be subjected to various forces such as aerodynamics and vibration. The good performance of epoxy resin can ensure that the repaired parts will not crack or separate again due to these forces. Secondly, the length of carbon fiber chopped strands is between 3 mm and 5 mm, accounting for 25% of the total mass of the repair material. The addition of carbon fiber chopped strands can enhance the mechanical properties of the repair material, and its suitable length range can form a good reinforcement structure in the epoxy resin matrix. The chopped strands play a reinforcing role in the repair material similar to that of steel bars in concrete, improving the strength and stiffness of the repair material. For example, when the repaired component is impacted by external force again, the carbon fiber chopped strands can effectively disperse stress and reduce local stress concentration, thereby improving the impact resistance of the component. Furthermore, the addition of silane coupling agent ABC at a rate of 3% of the total mass of the repair material can improve the adhesion of the repair material. The coupling agent acts as a bridge between epoxy resin and carbon fiber chopped strands. It can improve the interfacial bonding between the two different materials and enable them to work together better. For example, without the addition of a coupling agent, epoxy resin and carbon fiber chopped strands may have poor interfacial bonding, resulting in a decrease in the overall performance of the repair material. After the coupling agent is added, the adhesion of the repair material is significantly improved, so that the repaired component will not experience performance degradation during use due to the interface separation of the two materials. At the same time, the performance requirements of the repair material are that the tensile strength is not less than 80% of the raw material, the heat resistance temperature is not less than 150 degrees Celsius, and the mixing ratio is epoxy resin: carbon fiber chopped strands = 3:1. Such performance requirements and mixing ratios ensure that the mechanical properties and heat resistance of the repaired component can be close to the level of the original component. In the aerospace field, aircraft will face different temperature environments during operation, especially when flying at high speeds, the surface temperature of components may rise. The requirement of heat resistance temperature not less than 150 degrees Celsius can ensure that the repaired parts can still maintain good performance in such high temperature environment, and will not soften or deform due to temperature increase. The requirement of tensile strength not less than 80% of the raw material ensures that the repaired parts have sufficient strength when subjected to mechanical effects such as tensile force, ensuring the structural integrity and safety of the aircraft. Through precise mixing ratios, epoxy resin and carbon fiber chopped strands can give full play to their respective advantages, forming excellent performance repair materials and improving the quality and effect of repair.

[0048] The prescribed repair process is rigorous and has important beneficial effects. First, the repair process of vacuum-assisted pressure injection is adopted to uniformly fill the prepared repair material into the damaged area within the pressure range of 0.5 MPa to 1 MPa. This process can effectively avoid defects such as voids and bubbles in the repair material during the filling process. Under the action of pressure, the repair material can fully flow into every corner of the damaged part to ensure the integrity and density of the filling. For example, in aerospace parts, if there are voids or bubbles in the repair material, these parts may become stress concentration points during the operation of the aircraft, making the parts more susceptible to damage again. Through vacuum-assisted pressure injection, the air can be discharged, so that the repair material fits tightly to the damaged area, improving the quality and reliability of the repair. Secondly, the autoclave heating curing process is cured at a temperature of 120 degrees Celsius for 2 hours, which can ensure that the repair material is fully cured and achieves optimal performance. The appropriate curing temperature and time are crucial to the performance of the repair material. At a temperature of 120 degrees Celsius, repair materials such as epoxy resin can fully react chemically to form a stable cross-linked structure, improving the strength and hardness of the material and other properties. The 2-hour curing time ensures that the reaction is fully carried out, so that the performance of the repair material reaches the best. For example, if the curing temperature is too low or the time is too short, the repair material may not be completely cured, resulting in its mechanical properties and heat resistance properties not meeting the requirements of the aerospace field. By strictly controlling the process parameters of the autoclave heating curing, the repaired parts can have good performance, ensuring the normal operation and flight safety of the aircraft in various complex environments.

[0049] The steps of surface treatment and quality inspection of repaired parts are of great significance and have significant beneficial effects. First, the surface treatment adopts fine grinding and polishing to make the surface flatness of the repaired parts reach within 0.05 mm. In the field of aerospace, the surface flatness of the parts has an important impact on the aerodynamic performance and overall appearance of the aircraft. Through fine grinding and polishing, the surface unevenness that may be generated by the repair material during the filling and curing process can be removed, making the surface of the parts smoother. For example, when the aircraft is flying at high speed, parts with poor surface flatness may increase air resistance and affect the flight efficiency and fuel consumption of the aircraft. Controlling the surface flatness within 0.05 mm can effectively reduce air resistance and improve the performance of the aircraft. At the same time, the smooth surface also helps to reduce the adhesion of impurities such as dust and reduce the erosion and wear of the parts during flight. Secondly, the quality inspection adopts X-ray non-destructive testing to ensure that the performance of the repaired parts reaches or approaches the performance indicators of the original parts. X-ray non-destructive testing has the advantages of strong penetration and high detection accuracy. It can detect defects inside the component and the distribution of repair materials without causing damage to the component. For example, X-ray testing can detect whether there are areas inside the repair material that are not fully filled or whether there are potential problems such as cracks. This detection method can comprehensively and accurately evaluate the quality of the repaired component to ensure that its performance meets the strict requirements of the aerospace field. If the quality of the repaired component does not meet the standards, it may fail during the operation of the aircraft, endangering flight safety. Through X-ray non-destructive testing, problems can be discovered in a timely manner and corresponding improvement measures can be taken to improve the success rate of repairs and the reliability of components, thereby ensuring the normal operation of the aircraft and flight safety.

[0050] Specifically, the cleaning agent is a special cleaning agent independently developed for aerospace carbon fiber composites. It has the characteristics of being harmless to carbon fiber composites and being highly efficient in cleaning. It will not have adverse effects on the structure and performance of carbon fiber composites during the cleaning process.

[0051] In this embodiment: In terms of non-damage, the structural integrity and performance stability of aerospace carbon fiber composite components are crucial. Traditional detergents may react chemically with carbon fiber composites, or damage the surface structure of the material due to excessive cleaning power during the cleaning process, resulting in the mechanical properties, chemical properties, etc. of the material being affected. This self-developed special detergent can avoid these problems. It will not damage the microstructure of the carbon fiber composite material during the cleaning process, and will not change the fiber arrangement and pore structure of the material, thereby ensuring that the original strength, stiffness and other mechanical properties of the material are not affected. For example, in the key structural components of an aircraft, the strength of the carbon fiber composite material is an important factor in ensuring the safe flight of the aircraft. If the detergent damages the material, it may cause the component to break when subjected to various loads during the flight. This non-damaging detergent can ensure the structural integrity of the component and improve the safety of the aircraft.

[0052] In terms of cleaning efficiency, its efficient cleaning ability can quickly remove dirt, dust and other impurities on the surface of components. In the field of aerospace, the operating environment of aircraft is complex, and various pollutants are easily accumulated on the surface of components. If the cleaning efficiency is low, it will not only increase the maintenance time and cost, but also may affect the quality of subsequent repair work. This special cleaning agent can quickly dissolve and remove impurities such as oil, dust, etc., so that the surface of the component can reach the preset cleanliness standard in a shorter time. For example, in the regular maintenance of aircraft, the use of this high-efficiency cleaning agent can shorten the cleaning time, improve the maintenance efficiency, and enable the aircraft to be put into use faster. At the same time, cleaning efficiency also means that the amount of cleaning agent used can be reduced and the cost can be reduced. Due to its good cleaning effect, a large amount of cleaning agent is not required to achieve the cleaning purpose, which has positive significance for cost control in the field of aerospace. Moreover, cleaning efficiency also helps to reduce the impact of cleaning agents on the environment. Traditional cleaning agents may produce a large amount of pollutants such as wastewater and exhaust gas, while this special cleaning agent produces relatively few pollutants during use, which is more in line with the environmental protection requirements of the aerospace field. In short, the non-destructive and efficient cleaning characteristics of this special cleaning agent provide reliable guarantees for the repair and maintenance of aerospace carbon fiber composite parts, and play an important role in improving the reliability and service life of aircraft.

[0053] Specifically, the detection equipment can detect microscopic damage inside carbon fiber composite materials with a detection depth of up to [5 mm], and can generate detailed damage images and data reports, providing an accurate basis for subsequent repair work.

[0054] In this embodiment: From the perspective of microscopic damage detection capability, in the field of aerospace, carbon fiber composite material components are often subjected to complex mechanical and environmental loads, and some microscopic damage may occur inside, such as microcracks, debonding of the interface between the fiber and the matrix, etc. These microscopic damages may not be easily detected in the early stage, but with the passage of time and the use of the aircraft, they may gradually expand, and ultimately affect the overall performance and safety of the components. The detection equipment can detect microscopic damage up to 5 mm in depth, which means that problems can be found in the early stages of damage, providing the possibility for timely repair measures. For example, when a carbon fiber composite wing is subjected to airflow impact and vibration during flight, tiny cracks may occur inside. If there is no such device capable of detecting microscopic damage, these cracks may continue to expand until the component shows obvious signs of damage, at which time the difficulty and cost of repair will be greatly increased. With this detection equipment, cracks can be accurately detected when they are still in the microscopic stage, so that effective repair measures can be taken to avoid further deterioration of the damage.

[0055] The function of generating detailed damage images and data reports is also of great significance. The damage image can intuitively display the location, shape, size and other information of the internal damage of the component, helping the repair personnel to understand the damage more clearly. For example, through the damage image, the repair personnel can accurately determine whether the crack is penetrating or surface, as well as the direction of the crack, so as to formulate a more targeted repair plan. The data report provides more accurate damage information, including quantitative data such as the degree and type of damage. These data are crucial for selecting appropriate repair materials and process parameters. For example, based on the data of the degree of damage, the repair personnel can determine the filling amount of the repair material; based on the information of the damage type, the appropriate repair process can be selected, such as the use of special adhesives for interface debonding damage. In addition, detailed damage images and data reports can also provide important references for subsequent aircraft maintenance and performance evaluation. By comparing and analyzing the damage images and data of different periods, we can understand the development trend of component damage, predict the remaining service life of components, formulate preventive maintenance plans in a timely manner, improve the overall reliability and safety of the aircraft, and reduce the risk of flight accidents caused by sudden damage to components.

[0056] Specifically, a specific additive [coupling agent] needs to be added to the repair material during the preparation process. The function of the additive is to improve the [adhesion] of the repair material. The amount of the additive added is [3%] of the total mass of the repair material.

[0057] In this embodiment: the coupling agent can significantly improve the adhesion of the repair material. In the repair of carbon fiber composite materials, the bonding strength between the repair material and the original material is one of the key factors affecting the repair effect. Although epoxy resin, as the main repair material, has certain bonding properties, it may not be able to bond with carbon fiber composite materials. The addition of a coupling agent is like building a bridge between the two. It can improve the interfacial bonding between epoxy resin and carbon fiber composite materials, allowing the repair material to better adhere to the damaged parts. For example, without the addition of a coupling agent, the repaired parts may be prone to separation at the interface between the repair material and the original material when subjected to a certain external force, resulting in poor repair effect. After adding a coupling agent, the repair material can be more firmly bonded to the surface of the carbon fiber composite material, improving the reliability and durability of the repair.

[0058] Secondly, the addition amount of 3% of the total mass of the repair material is a reasonable proportion verified by scientific research and practice. If the addition amount is too small, the role of the coupling agent in improving the adhesion may not be fully utilized, resulting in the bonding force between the repair material and the original material is still weak. For example, when the amount of coupling agent added is insufficient, in the repair of some key aerospace components, the repaired components may be damaged again during flight due to poor bonding. On the contrary, if the addition amount is too much, the coupling agent may be unevenly distributed in the repair material, and may even have an adverse effect on other properties of the repair material. For example, too much coupling agent may affect the curing process of epoxy resin and reduce the strength and other properties of the repair material. The addition amount of 3% can not only effectively improve the adhesion of the repair material, but also ensure the overall stability of the repair material. This is crucial for the repair of carbon fiber composite materials in the aerospace field, because the aircraft will face various complex mechanical and environmental conditions during operation, and the repaired parts need to have sufficient strength and stability to ensure flight safety.

[0059] Specifically, the pressure injection and heating curing in the repair process must be carried out in a strict sequence, and during the pressure injection process, it is necessary to ensure that the repair material is evenly filled into the damaged area to avoid defects such as gaps and bubbles. During the heating curing process, the temperature and time must be precisely controlled to ensure that the repair material is fully cured and achieves optimal performance.

[0060] In this embodiment: pressure injection and heat curing are carried out in strict sequence based on the characteristics of the repair material and the scientific nature of the repair process. Pressure injection first allows the repair material to be fully filled into the damaged area under the action of pressure, expelling the air therein, and avoiding defects such as voids and bubbles. If heat curing is performed first, the repair material may begin to solidify without being fully filled, resulting in quality risks inside the repaired component. For example, in aerospace components, voids and bubbles may expand or compress when pressure changes during the flight of the aircraft, thereby affecting the mechanical properties and structural stability of the component. Pressure injection first ensures uniform filling of the repair material and provides a good foundation for subsequent heat curing.

[0061] It is of great significance to ensure that the repair material is evenly filled into the damaged area during the pressure injection process. Even filling can make the mechanical properties of the repaired parts more uniform and consistent, and avoid local stress concentration. When the aircraft is in flight, the parts will be subjected to forces in various directions. If the repair material is not evenly filled, some parts may be subjected to greater stress, which may easily lead to further damage. For example, in the repair of a wing, if the repair material is filled too much on one side and not enough on the other side, the wing may deform or even break due to uneven force during flight. By ensuring even filling, the performance of each part of the repaired component can be coordinated and consistent, improving its overall reliability and service life.

[0062] Precise control of temperature and time during the heating and curing process is crucial to the performance of the repair material. Appropriate temperature and time can ensure that repair materials such as epoxy resins fully react chemically to form a stable cross-linked structure, thereby achieving optimal performance. If the temperature is too high or the time is too long, the repair material may age and its performance may deteriorate; if the temperature is too low or the time is too short, the repair material cannot be completely cured, and its mechanical properties and heat resistance cannot meet the strict requirements of the aerospace field. For example, in the repair of spacecraft components, precise control of the temperature and time of heating and curing can enable the repaired components to maintain good performance under the extreme temperature changes in the space environment, and will not crack, deform, or other problems due to temperature changes, thereby ensuring the safe operation of the spacecraft.

[0063] Specifically, it includes a cleaning device, a detection device, a repair material mixing device, a repair process execution device and a quality detection device, and each device cooperates with each other and works in coordination.

[0064] The cleaning device has a specific structure and functional description of [a spray gun with adjustable pressure and a matching cleaning agent storage tank, and the spray gun can replace nozzles of different specifications], and can effectively clean the surface of carbon fiber composite material parts.

[0065] The detection device has a specific structure and functional description of [high-precision probe and supporting data processing and display system, the probe can detect at multiple angles], and can accurately detect and evaluate the damage of components.

[0066] The repair material mixing device has a specific structure and functional description of [a precisely metered mixing tank and a matching feeding system with adjustable mixing speed], and can mix the repair material accurately according to the formula ratio.

[0067] The repair process execution device has the specific structure and functional description of [an injection pump that can accurately control the pressure and a matching sealing mold, and an autoclave with precise temperature control function], and can accurately execute repair processes such as pressure injection and heating curing.

[0068] The quality inspection device has the specific structure and functional description of [high-resolution X-ray imaging system and supporting data analysis software], and can perform comprehensive quality inspection on the repaired parts.

[0069] In this embodiment: In terms of the cleaning device, the pressure-adjustable spray gun and the matching detergent storage tank allow the spray pressure of the detergent to be adjusted according to actual needs. When facing carbon fiber composite parts with different degrees of dirt and impurities attached, the appropriate pressure can ensure that the detergent acts effectively on the surface of the parts. For example, for more stubborn dirt, the pressure can be appropriately increased to enhance the impact of the detergent so that it can better remove the dirt. The design of the spray gun with replaceable nozzles of different specifications further increases the flexibility of cleaning. When facing parts with complex shapes, a suitable nozzle can be selected to ensure that the detergent can evenly cover all surface areas, including some corners and gaps that are difficult to clean. The tool with a soft fiber brush head and a replaceable brush head can further wipe the surface of the part after the detergent acts to remove residual impurities. At the same time, the design of the replaceable brush head can ensure that the cleanliness and good cleaning effect of the brush head are always maintained when cleaning different parts or multiple cleanings, providing a clean surface that meets the standards for subsequent repair work.

[0070] The high-precision probe of the detection device and the supporting data processing and display system have greatly improved the accuracy and comprehensiveness of damage detection. The high-precision probe can deeply detect the interior of carbon fiber composite materials, and can accurately capture some microscopic damage that cannot be directly observed by the naked eye. Its detection depth can reach 5 mm, which means that even deeper damage inside the component can be discovered in time. In practical applications, for example, after the aircraft has experienced a long flight or has been subjected to some slight but continuous stress, some tiny cracks or delamination may appear inside the component. The detection device can accurately identify these problems. The supporting data processing and display system can quickly process and analyze the information detected by the probe to generate detailed damage images and data reports. In this way, the repair personnel can intuitively understand the specific location, degree and type of the damage, which provides an accurate basis for the subsequent formulation of accurate repair plans, and avoids problems such as improper repair due to incomplete understanding of the damage.

[0071] The precise metering mixing tank and the supporting feeding system of the repair material mixing device ensure the accuracy and stability of the repair material mixing. The precise metering function can be mixed strictly according to the formula ratio of the repair material. The mixing tank can accurately achieve the precise ratio requirements such as epoxy resin accounting for 75% of the total mass of the repair material, carbon fiber chopped strands accounting for 25%, and coupling agent added in an amount of 3% of the total mass of the repair material. In actual operation, this helps to ensure that the performance of the repair material meets the design requirements. For example, if the proportion of epoxy resin is too high or too low, it may affect the adhesion and strength of the repair material. The supporting feeding system can accurately add various materials, avoiding the errors that may occur in manual feeding. At the same time, the adjustable stirring speed function is also very important. Different stirring speeds will affect the mixing uniformity of the materials. For some repair materials that require high mixing uniformity, by reasonably adjusting the stirring speed, various components can be fully mixed, the quality of the repair material can be improved, and a reliable material foundation for subsequent repair work can be provided.

[0072] The precise pressure-controllable injection pump and the matching sealing mold of the repair process execution device, and the precise temperature control function of the autoclave are crucial for the implementation of the repair process. The precise pressure-controllable injection pump can strictly control the injection pressure of the repair material during the vacuum-assisted pressure injection process. When the pressure range is between 0.5 MPa and 1 MPa, the appropriate pressure value can be selected according to different damage conditions and the characteristics of the repair material. For example, for some smaller damaged areas, lower pressure may be required to avoid excessive filling of the repair material and other problems; while for larger damaged areas or where better filling effects are required, the pressure can be appropriately increased. The matching sealing mold can ensure that the repair material can be accurately filled into the damaged area during the pressure injection process, prevent the repair material from leaking to other parts that do not need to be repaired, and ensure the accuracy and efficiency of the repair. The precise temperature control function of the autoclave can accurately control the temperature at 120 degrees Celsius for 2 hours during the heating and curing process, which can ensure that the repair material is fully cured and achieves optimal performance. Precise control of temperature and time is crucial to the curing reaction of restorative materials. If the temperature is too high or the time is too long, the performance of the restorative material may deteriorate. Conversely, if the temperature is too low or the time is insufficient, the restorative material may not be fully cured, affecting the quality of the repair.

[0073] The high-resolution X-ray imaging system and supporting data analysis software of the quality inspection device provide a strong guarantee for the quality inspection of repaired parts. The high-resolution X-ray imaging system can penetrate the repaired parts and detect possible defects inside, such as incompletely filled gaps, bubbles or uneven material distribution. Its high resolution allows even tiny defects to be clearly identified. In actual inspection, this helps to promptly discover possible quality problems in the repair process and prevent defective parts from being installed on the aircraft, thereby ensuring the safe operation of the aircraft. The supporting data analysis software can conduct in-depth analysis of the image data obtained by the X-ray imaging system, and accurately evaluate whether the performance of the repaired parts reaches or approaches the performance indicators of the original parts through calculations and comparisons. For example, the density distribution of the parts and the integrity of the internal structure can be analyzed to provide a scientific basis for judging the quality of the repair and ensure that the repaired parts meet the strict quality requirements in the aerospace field.

[0074] Specifically, the repair equipment is also equipped with an intelligent control system, which can monitor and regulate the operating parameters of each device in real time to ensure the accuracy and stability of the repair process, and can automatically adjust the repair process and parameters according to different damage conditions to achieve intelligent repair;

[0075] The overall structural design of the repair equipment meets the special requirements of the aerospace field. It has the characteristics of small size, light weight, easy to carry and operate. It can be used in aerospace vehicle production workshops and in emergency repair scenarios during actual flight.

[0076] In this embodiment: The introduction of the intelligent control system has many significant beneficial effects. It can monitor and regulate the operating parameters of each device in real time, which is like installing a pair of sharp eyes and a pair of dexterous hands for the repair equipment. Through the precise control of the operating parameters, it is ensured that every link in the repair process can be carried out accurately. For example, when the repair material is prepared, the stirring speed, the amount of material added and other parameters can be accurately controlled, so that the materials are accurately prepared according to the established scientific formula, providing a basic guarantee for the quality of the repair. At the same time, it can automatically adjust the repair process and parameters according to different damage conditions, greatly improving the intelligent level of repair. When faced with different degrees and types of damage, the system can automatically optimize the pressure range of pressure injection, the temperature and time of autoclave heating and curing, and other parameters to achieve personalized repair and ensure that the performance of the repaired parts is as close to the original parts as possible.

[0077] The overall structural design of the repair equipment meets the special requirements of the aerospace field. Its small size and light weight make it extremely flexible in terms of usage scenarios. In the production workshop of aerospace vehicles, it will not take up too much space, making it easy to operate in a limited space and improving the space utilization of the production workshop. In the emergency repair scenario during actual flight, its light and easy-to-carry characteristics are even more important. Maintenance personnel can quickly carry it to the fault site and repair the damaged carbon fiber composite parts in time to ensure the normal operation and flight safety of the aircraft. This design is also easy to operate, reduces the difficulty and burden of the operator's work, improves the repair efficiency, and enables the repair work to be completed quickly and effectively even in complex flight environments, providing strong technical support for the development of the aerospace field.

[0078] The working principle and use process of the present invention:

[0079] The first is the surface cleaning stage. We use a self-developed special cleaning agent containing ethanol and deionized water in a ratio of 7:3. We use a tool with a soft fiber brush head and a replaceable brush head to clean the damaged carbon fiber composite parts to remove dirt, dust and other impurities, ensuring that the surface cleanliness meets the preset standards. This lays a good foundation for subsequent repair work. Then we conduct damage assessment, using advanced ultrasonic flaw detectors and other testing equipment to accurately determine the degree, scope and type of damage. The detection accuracy must reach 0.1 mm. We can also detect internal microscopic damage with a detection depth of up to 5 mm. And generate detailed damage images and data reports, followed by the preparation of repair materials, according to the formula ratio of epoxy resin accounting for 75% of the total mass of the repair material, carbon fiber chopped strands with a length of 3 mm to 5 mm accounting for 25%, and the addition amount of silane coupling agent ABC accounting for 3% of the total mass of the repair material. The preparation ratio is epoxy resin: carbon fiber chopped strands = 3:1 to improve the adhesion and performance of the repair material. After that, the repair process is adopted, first through vacuum-assisted pressure injection, the prepared repair material is evenly filled into the damaged area within the pressure range of 0.5 MPa to 1 MPa to avoid voids and air The repair material is cured by heating in an autoclave at 120 degrees Celsius for 2 hours to ensure that the repair material is fully cured and reaches the best performance. Finally, surface treatment and quality inspection are carried out. The surface flatness of the repaired parts is within 0.05 mm through fine grinding and polishing. X-ray non-destructive inspection is used to ensure that the performance of the repaired parts reaches or approaches the performance indicators of the original parts. During the entire repair process, the various devices of the repair equipment cooperate and work together. The cleaning device uses a spray gun with adjustable pressure and a supporting detergent storage tank to effectively clean the surface of the parts; the detection device accurately evaluates the damage with high-precision probes and supporting data processing and display systems; the repair material mixing device accurately mixes materials through a precisely measured mixing tank and a supporting feeding system; the repair process execution device relies on an injection pump with precisely controlled pressure and a supporting sealing mold and an autoclave with precise temperature control to execute the repair process; the quality inspection device uses a high-resolution X-ray imaging system and supporting data analysis software to comprehensively detect the quality. At the same time, the intelligent control system monitors and regulates the operating parameters of each device in real time, and can also automatically adjust the repair process and parameters according to different damage conditions to achieve intelligent repair and ensure the normal operation and flight safety of the aircraft.

[0080] Finally, it should be noted that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Although the present invention has been described in detail with reference to the aforementioned embodiments, those skilled in the art can still modify the technical solutions described in the aforementioned embodiments or replace some of the technical features therein by equivalents. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present invention shall be included in the protection scope of the present invention.

Claims

1. A rapid repair method for aerospace carbon fiber composite materials, characterized in that: The following steps are involved: Clean the surface of damaged carbon fiber composite parts to remove dirt, dust and other impurities, using specific cleaning agents and cleaning tools to ensure that the surface cleanliness meets the preset standards, where the cleaning agent contains [ethanol], [deionized water], etc., and the ratio of each component is [7:3]; the cleaning tool is a tool with a [soft fiber brush head and replaceable brush head]; Conduct accurate damage assessment on the damaged area after cleaning, using advanced testing equipment such as [ultrasonic flaw detector] to accurately determine the degree, scope and type of damage, with a detection accuracy of [0.1 mm] level; Then, based on the damage assessment results, appropriate repair materials are selected. The repair material formula is as follows: The main component is [epoxy resin], whose specific model is [EpoxyResinXYZ], accounting for [75%] of the total mass of the repair material; [Carbon fiber chopped strands], having a length between [3 mm and 5 mm] and accounting for [25%] of the total mass of the repair material; Additive [coupling agent], specifically [silane coupling agent ABC], the function of the additive is to improve the [adhesion] of the repair material, and the amount of the additive added is [3%] of the total mass of the repair material; Its performance must meet [tensile strength not less than 80% of the raw material, heat resistance temperature not less than 150 degrees Celsius], and the repair material must be prepared according to a certain formula ratio, the mixing ratio is [epoxy resin: carbon fiber chopped strands = 3:1]; The prepared repair material is filled into the damaged area using a specific repair process, the repair process includes [vacuum assisted pressure injection] and [autoclave heating and curing], wherein the pressure range of the pressure injection is [0.5 MPa to 1 MPa], the temperature of the heating and curing is [120 degrees Celsius], and the time is [2 hours]; Finally, the repaired parts are subjected to surface treatment and quality inspection. The surface treatment adopts [fine grinding and polishing] to make the surface flatness of the repaired parts reach [within 0.05 mm]; Quality inspection uses [X-ray non-destructive testing] to ensure that the performance of the repaired parts reaches or is close to the performance indicators of the original parts.

2. The rapid repair method for aerospace carbon fiber composite materials according to claim 1, characterized in that: The cleaning agent is a special cleaning agent independently developed for aerospace carbon fiber composite materials. It has the characteristics of being non-destructive to carbon fiber composite materials and being highly efficient in cleaning, and will not have adverse effects on the structure and performance of carbon fiber composite materials during the cleaning process.

3. The rapid repair method for aerospace carbon fiber composite materials according to claim 2, characterized in that: The detection equipment is capable of detecting microscopic damage inside carbon fiber composite materials with a detection depth of up to [5 mm], and can generate detailed damage images and data reports, providing an accurate basis for subsequent repair work.

4. The rapid repair method for aerospace carbon fiber composite materials according to claim 3, characterized in that: The repair material needs to be added with a specific additive [coupling agent] during the preparation process. The function of the additive is to improve the [adhesion] of the repair material. The amount of the additive added is [3%] of the total mass of the repair material.

5. The rapid repair method for aerospace carbon fiber composite materials according to claim 4, characterized in that: The pressure injection and heating curing in the repair process must be carried out in a strict sequence, and during the pressure injection process, it is necessary to ensure that the repair material is evenly filled into the damaged area to avoid defects such as gaps and bubbles. During the heating curing process, the temperature and time must be precisely controlled to ensure that the repair material is fully cured and achieves optimal performance.

6. The repair device of the aerospace carbon fiber composite material rapid repair method according to claim 5, characterized in that: It includes a cleaning device, a testing device, a repair material mixing device, a repair process execution device and a quality testing device, and each device cooperates with each other and works in coordination. The cleaning device has a specific structure and functional description of [a spray gun with adjustable pressure and a matching cleaning agent storage tank, and the spray gun can replace nozzles of different specifications], and can effectively clean the surface of carbon fiber composite material parts. The detection device has a specific structure and functional description of [high-precision probe and supporting data processing and display system, the probe can detect at multiple angles], and can accurately detect and evaluate the damage of components. The repair material mixing device has a specific structure and functional description of [a precisely metered mixing tank and a matching feeding system with adjustable mixing speed], and can mix the repair material accurately according to the formula ratio. The repair process execution device has the specific structure and functional description of [an injection pump that can accurately control the pressure and a matching sealing mold, and an autoclave with precise temperature control function], and can accurately execute repair processes such as pressure injection and heating curing. The quality inspection device has the specific structure and functional description of [high-resolution X-ray imaging system and supporting data analysis software], and can perform comprehensive quality inspection on the repaired parts.

7. The rapid repair device for aerospace carbon fiber composite materials according to claim 6, characterized in that: The repair equipment is also equipped with an intelligent control system, which can monitor and regulate the operating parameters of each device in real time to ensure the accuracy and stability of the repair process, and can automatically adjust the repair process and parameters according to different damage conditions to achieve intelligent repair; The overall structural design of the repair equipment meets the special requirements of the aerospace field. It has the characteristics of small size, light weight, easy to carry and operate, and can be used in aerospace vehicle production workshops and emergency repair scenarios during actual flights.