Manufacturing method and nondestructive testing method for out-of-plane wrinkles of composite material

Abstract

The invention relates to the technical field of composite materials, and particularly discloses a manufacturing method and a nondestructive testing method for out-of-plane wrinkles of a composite material. The manufacturing method of the composite material out-of-plane wrinkles comprises the following steps that a plurality of laying layers are stacked on a wrinkle forming tool with a groove, and a semi-formed piece with a protruding part is formed through vacuum compaction and solidification; and the other side, opposite to the protruding part, of the semi-formed part is placed on a supporting tool, a plurality of laying layers are stacked on the side, provided with the protruding part, of the semi-formed part, and a test piece with out-of-plane simulation wrinkles is formed through vacuum compaction curing. According to the method, an external support for deforming fibers is not introduced, so that the formed out-of-plane simulated wrinkles are closer to real out-of-plane wrinkle defects, the simulation effect is relatively good, the surface flatness is good, effective simulation of the out-of-plane wrinkle defects in the fiber composite material is realized, and during subsequent nondestructive testing, the defect of the out-of-plane wrinkle in the fiber composite material can be effectively overcome. And interference on detection signals caused by redundant supports is avoided.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of composite materials, and in particular to a manufacturing method and a non-destructive testing method for out-of-plane wrinkles of a composite material. BACKGROUND

[0002] A fiber composite material is a material composed of two or more materials with different properties, usually including a continuous matrix phase and one or more dispersed reinforcing phases. The matrix phase serves to bind the reinforcing phases together, while the reinforcing phases provide strength and stiffness to the material. Fiber composite materials have high strength, high modulus, and good corrosion resistance, and are widely used in aerospace, automotive, construction, and other fields.

[0003] During the curing process of a fiber composite material prepreg, if the fibers are subjected to radial loads or the fiber length is designed unreasonably, the fibers will bend and deform, deviating from the set fiber orientation path. At this time, the fibers will bend in the out-of-plane direction, resulting in out-of-plane wrinkle defects. These defects can significantly affect the mechanical properties of the fiber composite material structure and pose a safety risk to the product. Therefore, it is necessary to detect the out-of-plane wrinkles to avoid these potential defects.

[0004] Currently, a non-destructive testing comparison test piece containing a quantitative fiber wrinkle state needs to be prepared before testing. In the prior art, a specific support is embedded between the plies in a specified area of the composite material structure to cause local fiber arching deformation. By controlling the shape of the support, different out-of-plane wrinkle states can be achieved. However, the support in this method is an extraneous excess material relative to the inherent ply design of the composite material, and cannot be removed after the composite material structure is cured, resulting in a large difference between the simulated out-of-plane wrinkle defects and the actual defects. In addition, the presence of the excess material also interferes with the detection signal during non-destructive testing. SUMMARY

[0005] The present application aims to provide a manufacturing method and a non-destructive testing method for out-of-plane wrinkles of a composite material to solve the problem that in the prior art, the support cannot be removed after the composite material structure is cured, resulting in a large difference between the simulated out-of-plane wrinkle defects and the actual defects, and the presence of the excess material also interferes with the detection signal during non-destructive testing.

[0006] To achieve the above-mentioned purpose, the present application adopts the following technical solutions:

[0007] On the one hand, the present application provides a manufacturing method for out-of-plane wrinkles of a composite material, comprising:

[0008] stacking a plurality of plies on a wrinkle forming tool having a groove, and curing by vacuum compaction to form a semi-finished product with a protrusion;

[0009] Placing the other side of the semi-formed piece, which is opposite to the protruding part, on a supporting tool, stacking several of the plies on the side of the semi-formed piece with the protruding part, and curing by vacuum compaction to form a test piece with out-of-plane simulated wrinkles.

[0010] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, before stacking several of the plies on the wrinkle forming tool with the grooves, it further comprises: designing and determining the profile, position and depth of the out-of-plane simulated wrinkles.

[0011] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, when designing and determining the profile, position and depth of the out-of-plane simulated wrinkles, it further comprises: designing and determining the thickness of the test piece and the ply scheme of the test piece.

[0012] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, after designing and determining the profile, position and depth of the out-of-plane simulated wrinkles, before stacking several of the plies on the wrinkle forming tool with the grooves, it further comprises: designing and manufacturing the wrinkle forming tool, and making the profile of the grooves match the profile of the ply with the most severe wrinkles in the out-of-plane simulated wrinkles.

[0013] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, the wrinkle forming tool is processed by using a numerical control die forming process combined with subtractive manufacturing technology or additive manufacturing technology.

[0014] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, when stacking several of the plies on the wrinkle forming tool with the grooves, it further comprises: performing a vacuum compaction treatment on the plies on the wrinkle forming tool once for each stacking of at least one ply.

[0015] As an alternative to the above method for manufacturing out-of-plane wrinkles of composite materials, the stacking of several plies on the wrinkle forming tool with grooves and curing by vacuum compaction to form a semi-formed piece with a protruding part comprises:

[0016] Laying a peelable layer on the side of the wrinkle forming tool with the grooves;

[0017] Stacking several of the plies on the peelable layer and curing by vacuum compaction to form the semi-formed piece with the protruding part;

[0018] Taking the semi-formed piece off the wrinkle forming tool and tearing off the peelable layer on the semi-formed piece.

[0019] As an alternative to the above-mentioned manufacturing method of the out-of-plane wrinkle of the composite material, the wrinkle forming tool comprises a flat plate structure, a curved plate structure and an R-angle structure.

[0020] In another aspect, the present application provides a non-destructive testing method of the out-of-plane wrinkle of the composite material, which is used to test a test piece manufactured by using the above-mentioned manufacturing method of the out-of-plane wrinkle of the composite material, and comprises the following steps:

[0021] Full-matrix data acquisition and full-focus imaging processing of the test piece are performed by using an ultrasonic phased array full-focus detection.

[0022] Image filtering processing of the result of the full-focus imaging processing is performed to obtain an out-of-plane simulation wrinkle detection image with clear fiber layer direction.

[0023] As an alternative to the above-mentioned non-destructive testing method of the out-of-plane wrinkle of the composite material, the image filtering processing of the result of the full-focus imaging processing comprises transverse low-pass filtering processing and longitudinal zero-phase filtering processing of the result of the full-focus imaging processing.

[0024] The present application has the following advantages:

[0025] The manufacturing method of the out-of-plane wrinkle of the composite material can manufacture a test piece with an out-of-plane simulation wrinkle. A plurality of layers are stacked on a wrinkle forming tool with a groove, and vacuum compaction curing is performed to form a semi-finished product with a protruding part, i.e., the protruding part on the semi-finished product is part of the out-of-plane simulation wrinkle in the test piece. The other side of the semi-finished product opposite to the protruding part is placed on a support tool, a plurality of layers are stacked on the side of the semi-finished product with the protruding part, and vacuum compaction curing is performed to form a test piece with an out-of-plane simulation wrinkle. This process does not introduce external supports that deform the fibers, so that the out-of-plane simulation wrinkle after forming is closer to the real out-of-plane wrinkle defect, has better simulation effect, and has good surface flatness. Effective simulation of the out-of-plane wrinkle defect in the fiber composite material is achieved, and there is no interference of the excess support to the detection signal during subsequent non-destructive testing.

[0026] The non-destructive testing method of the out-of-plane wrinkle of the composite material is used to test a test piece manufactured by using the above-mentioned manufacturing method of the out-of-plane wrinkle of the composite material. The test piece is tested by using the non-destructive testing method of the out-of-plane wrinkle of the composite material, which can effectively identify and test the out-of-plane simulation wrinkle in the test piece, and avoid the interference of the excess support to the detection signal. BRIEF DESCRIPTION OF DRAWINGS

[0027] Figure 1A flowchart of a manufacturing method of the out-of-plane fold of the composite material provided by the embodiment of the present application;

[0028] Figure 2 A first structure schematic diagram of the semi-formed part formed on the fold forming tool provided by the embodiment of the present application;

[0029] Figure 3 A first structure schematic diagram of the test piece formed on the support tool provided by the embodiment of the present application;

[0030] Figure 4 A second structure schematic diagram of the semi-formed part formed on the fold forming tool provided by the embodiment of the present application;

[0031] Figure 5 A second structure schematic diagram of the test piece formed on the support tool provided by the embodiment of the present application.

[0032] In the drawings:

[0033] 1, ply; 2, fold forming tool; 21, groove; 3, semi-formed part; 4, support tool; 5, peelable layer. DETAILED DESCRIPTION

[0034] The technical solutions of the present application will be described clearly and completely below with reference to the drawings. Obviously, the described embodiments are only part of the embodiments of the present application, rather than all the embodiments. Based on the embodiments in the present application, all other embodiments obtained by those skilled in the art without creative labor fall within the scope of protection of the present application.

[0035] In the description of the present application, it should be noted that the orientations or positional relationships indicated by the terms "center", "upper", "lower", "left", "right", "vertical", "horizontal", "inner", "outer", etc. are based on the orientations or positional relationships shown in the drawings, and are only for the convenience of describing the present application and simplifying the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application. In addition, the terms "first", "second", etc. are only for the purpose of description, and cannot be understood as indicating or implying relative importance. Among them, the terms "first position" and "second position" are two different positions, and moreover, the "above", "upper" and "upper surface" of the first feature relative to the second feature include the vertical direction of the first feature above and obliquely above the second feature, or only indicate that the horizontal height of the first feature is higher than that of the second feature. The "below", "below" and "below" of the first feature relative to the second feature include the vertical direction of the first feature below and obliquely below the second feature, or only indicate that the horizontal height of the first feature is less than that of the second feature.

[0036] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0037] The following describes embodiments of the present invention in detail. Examples of the embodiments are shown in the accompanying drawings, wherein the same or similar reference numerals throughout represent the same or similar elements or elements having the same or similar functions. The embodiments described below with reference to the accompanying drawings are exemplary and are intended only to explain the present invention and are not to be construed as limiting the present invention.

[0038] Example 1

[0039] like Figures 1-5 As shown, this embodiment provides a method for manufacturing out-of-plane wrinkles of a composite material, which is used to manufacture a test piece with out-of-plane simulated wrinkles. The method for manufacturing out-of-plane wrinkles of a composite material includes the following steps:

[0040] Several layers 1 are stacked on a pleat forming tool 2 having grooves 21 and solidified by vacuum compaction to form a semi-formed part 3 having a protrusion;

[0041] The other side of the semi-formed part 3 opposite to the raised portion is placed on the supporting tooling 4, and several layers 1 are stacked on the side of the semi-formed part 3 with the raised portion, and are vacuum compacted and cured to form a test piece with out-of-plane simulated wrinkles.

[0042] The method for manufacturing out-of-plane wrinkles of a composite material can manufacture a test piece with out-of-plane simulated wrinkles. Several plies 1 are stacked on a wrinkle forming tool 2 with grooves 21, and vacuum compacted and solidified to form a semi-formed part 3 with a protrusion, that is, the protrusion on the semi-formed part 3 is a part of the out-of-plane simulated wrinkles in the test piece. Then, the other side of the semi-formed part 3 opposite to the protrusion is placed on a supporting tool 4, and several plies 1 are stacked on the side of the semi-formed part 3 with the protrusion, and vacuum compacted and solidified to form a test piece with out-of-plane simulated wrinkles. Since this process does not introduce external supports that cause fiber deformation, the out-of-plane simulated wrinkles after molding are closer to real out-of-plane wrinkle defects, with better simulation effect and good surface flatness, thus achieving effective simulation of out-of-plane wrinkle defects in fiber composite materials. In addition, when non-destructive testing is carried out subsequently, there will be no unnecessary supports that interfere with the detection signal.

[0043] Further, before stacking the plurality of plies 1 on the wrinkle forming tool 2 with the groove 21, the profile, position and depth of the out-of-plane simulation wrinkle are designed and determined, so that when the test piece is manufactured, the test piece contains a quantitative out-of-plane simulation wrinkle, thereby meeting the subsequent needs of the out-of-plane simulation wrinkle in the test piece when non-destructive testing is carried out. At the same time, when designing and determining the profile, position and depth of the out-of-plane simulation wrinkle, the thickness of the test piece and the ply scheme of the test piece are also designed and determined, so as to manufacture a test piece with a specific thickness, wherein stacking the plurality of plies 1 on the wrinkle forming tool 2 with the groove 21 can form a semi-finished product 3 according to the ply scheme of the test piece, and stacking the plurality of remaining plies 1 on one side of the semi-finished product 3 with the protruding part can form a test piece according to the ply scheme of the test piece.

[0044] Further, before stacking the plurality of plies 1 on the wrinkle forming tool 2 with the groove 21, the profile, position and depth of the out-of-plane simulation wrinkle are designed and determined, so that when the test piece is manufactured, the test piece contains a quantitative out-of-plane simulation wrinkle, thereby meeting the subsequent needs of the out-of-plane simulation wrinkle in the test piece when non-destructive testing is carried out. At the same time, when designing and determining the profile, position and depth of the out-of-plane simulation wrinkle, the thickness of the test piece and the ply scheme of the test piece are also designed and determined, so as to manufacture a test piece with a specific thickness, wherein stacking the plurality of plies 1 on the wrinkle forming tool 2 with the groove 21 can form a semi-finished product 3 according to the ply scheme of the test piece, and stacking the plurality of remaining plies 1 on one side of the semi-finished product 3 with the protruding part can form a test piece according to the ply scheme of the test piece.

[0045] Wherein, the wrinkle forming tool 2 is processed by using a numerical control die forming process combined with subtractive manufacturing technology or additive manufacturing technology, so as to freely design and accurately control the profile structure of the wrinkle forming tool 2, that is, when using subtractive manufacturing technology, the numerical control machine tool technology is used to machine the wrinkle forming tool 2, so as to realize rapid and low-cost manufacturing, and to improve the manufacturing speed of the wrinkle forming tool 2 while reducing the cost; when using additive manufacturing technology, the 3D printing technology is used to print the wrinkle forming tool 2. Alternatively, by using a numerical control die forming process combined with a prepreg preforming process, the degree of fiber slip deformation can be effectively controlled, thereby realizing accurate simulation of various complex out-of-plane simulation wrinkles.

[0046] Further, the wrinkle forming tool 2 includes a flat plate structure, a curved plate structure and an R angle structure, so that the test piece with different shapes can be manufactured by using the flat plate structure, the curved plate structure and the R angle structure, thereby meeting the subsequent detection of test pieces with different structures. At the same time, the support tool 4 is a flat plate structure or a curved plate structure or an R angle structure corresponding to the wrinkle forming tool 2. Of course, the wrinkle forming tool 2 can also be other structures, which are not limited in the embodiment.

[0047] Further, when the several plies 1 are stacked on the corrugated forming tool 2 with the grooves 21, the method further comprises that, when each ply 1 is stacked, the ply 1 on the corrugated forming tool 2 is subjected to a vacuum compaction treatment, i.e. the ply 1 or the several plies 1 are subjected to the vacuum compaction treatment, which can enhance the bonding strength between the plies 1 and improve the forming quality of the semi-finished product 3.

[0048] Further, the method of manufacturing the composite out-of-plane corrugation, in which the several plies 1 are stacked on the corrugated forming tool 2 with the grooves 21 and cured by vacuum compaction to form the semi-finished product 3 with the protrusions, comprises:

[0049] The peelable layer 5 is laid on the side of the corrugated forming tool 2 with the grooves 21;

[0050] The several plies 1 are stacked on the peelable layer 5 and cured by vacuum compaction to form the semi-finished product 3 with the protrusions;

[0051] The semi-finished product 3 is taken off from the corrugated forming tool 2 and the peelable layer 5 on the semi-finished product 3 is torn off.

[0052] In the method of manufacturing the composite out-of-plane corrugation, the peelable layer 5 is laid on the side of the corrugated forming tool 2 with the grooves 21, which can reduce the glue accumulation of the plies 1 during the curing process, thereby improving the forming quality of the semi-finished product 3. After the semi-finished product 3 is formed, the peelable layer 5 is peeled off to avoid the influence of the peelable layer 5 on the forming of the subsequent test piece.

[0053] Embodiment Two

[0054] The embodiment also provides a non-destructive testing method of the composite out-of-plane corrugation, which is used to test the test piece manufactured by the method of manufacturing the composite out-of-plane corrugation as in Embodiment One. The non-destructive testing method of the composite out-of-plane corrugation comprises the following steps:

[0055] The test piece is subjected to full-matrix data acquisition and full-focus imaging processing by the ultrasonic phased array full-focus detection;

[0056] The result of the full-focus imaging processing is subjected to image filtering processing to obtain the out-of-plane simulated corrugation detection image with clear fiber ply 1 orientation.

[0057] The test piece is detected through the nondestructive testing method of the out-of-plane wrinkle of the composite material, effective identification and detection of the out-of-plane simulation wrinkle in the test piece can be realized, and interference of the detection signal caused by the redundant support is avoided. Optionally, when the test piece is detected through the full matrix data acquisition and full focus imaging processing of the ultrasonic phased array full focus detection, appropriate detection parameters can be combined. Specifically, the detection parameters are as follows: the number of probe array elements is 64, the array element spacing is 1mm, the array element length is 7mm, the probe frequency is 5MHz, the full focus transverse resolution is 0.02mm, and the longitudinal resolution is 0.02mm.

[0058] Further, the image filtering processing is performed on the result of the full focus imaging processing, including transverse low-pass filtering processing and longitudinal zero-phase filtering processing on the result of the full focus imaging processing, the transverse burr noise in the image can be eliminated through the transverse low-pass filtering processing on the result of the full focus imaging processing, and the longitudinal data in the full focus image can be normalized through the longitudinal zero-phase filtering processing on the result of the full focus imaging processing.

[0059] Obviously, the above embodiments of the present application are only examples for clarity, and are not intended to limit the embodiments of the present application. Based on the above description, other different forms of changes or variations can be made by those skilled in the art. Here, all the embodiments are not required to be exhausted. Any modification, equivalent replacement and improvement within the spirit and principle of the present application shall be included in the protection scope of the claims of the present application.

Claims

1. A method for producing out-of-plane wrinkles in a composite material, characterized in that: include: Stacking several plies on a pleat forming tool with grooves and curing them by vacuum compaction to form a semi-formed part with protrusions; The other side of the semi-formed part opposite to the protrusion is placed on a supporting tool, and a plurality of the plies are stacked on the side of the semi-formed part having the protrusion, and are vacuum compacted and cured to form a test piece with out-of-plane simulated wrinkles.

2. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 1, characterized in that: Before stacking a plurality of the plies on the wrinkle forming tool having the grooves, the method further includes: designing and determining the shape, position and depth of the out-of-plane simulated wrinkles.

3. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 2, characterized in that: When designing and determining the morphology, position and depth of the out-of-plane simulated wrinkles, it also includes: designing and determining the thickness of the test piece and the ply plan of the test piece.

4. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 2, characterized in that: After designing and determining the morphology, position and depth of the out-of-plane simulated wrinkles, and before stacking several of the plies on the wrinkle forming tooling having the grooves, it also includes: designing and manufacturing the wrinkle forming tooling, and making the contour of the grooves match the contour of the ply with the most severe wrinkles among the out-of-plane simulated wrinkles.

5. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 4, characterized in that: The pleat forming tool is formed by using a CNC mold forming process combined with a subtractive manufacturing technology or an additive manufacturing technology.

6. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 1, characterized in that: When stacking a plurality of the plies on the pleat forming tool having the groove, the method further includes: performing a vacuum compaction process on the plies on the pleat forming tool every time at least one ply is stacked.

7. The method for manufacturing out-of-plane wrinkles of a composite material according to claim 1, characterized in that: The method comprises stacking a plurality of plies on a pleat forming tool having a groove and solidifying the plies by vacuum compaction to form a semi-formed part having a protrusion, comprising: Laying a peelable layer on the side of the pleat forming tool having the groove; stacking a plurality of the plies on the peelable layer and curing the plies by vacuum compaction to form the semi-formed part having the protrusion; The semi-formed part is removed from the pleat forming tool, and the peelable layer on the semi-formed part is torn off.

8. The method for producing out-of-plane wrinkles of a composite material according to any one of claims 1 to 7, characterized in that: The pleat forming tooling includes a flat plate structure, a curved plate structure and an R-angle structure.

9. A method for nondestructive detection of out-of-plane wrinkles in composite materials, characterized in that: A test piece manufactured using the method for manufacturing out-of-plane wrinkles of a composite material according to any one of claims 1 to 8 is tested, wherein the non-destructive testing method for out-of-plane wrinkles of a composite material comprises the following steps: Performing full-matrix data acquisition and full-focus imaging processing on the test piece through ultrasonic phased array full-focus detection; The result of the full-focus imaging processing is subjected to image filtering processing to obtain an out-of-plane simulated wrinkle detection image with a clear direction of the fiber ply.

10. The non-destructive detection method for out-of-plane wrinkles of composite materials according to claim 9, characterized in that: The performing image filtering processing on the result of the all-focus imaging processing includes: performing transverse low-pass filtering processing and longitudinal zero-phase filtering processing on the result of the all-focus imaging processing.

Images