Method for improving dimensional stability and vibration reduction and isolation performance of composite material, composite material and application

Abstract

The invention belongs to the technical field of laser additive manufacturing, and particularly relates to a method for improving the dimensional stability and vibration reduction and isolation performance of a composite material, the composite material and application. Carbon fibers and aluminum alloy are alternately arranged layer by layer in a fiber form, the fibers formed by the aluminum alloy are fused and solidified and then connected with the carbon fibers into a whole to obtain the composite material, and the size stability and vibration reduction and isolation performance of the composite material are improved through gaps formed by alternately arranging the fibers. The bonding interface of the aluminum alloy and the carbon fibers can improve the overall vibration reduction characteristic of the material, and the low heat sensitivity of the carbon fibers can achieve the overall zero-expansion function of the material. Vibration reduction and isolation and zero expansion can be achieved at the same time based on the multi-wire additive manufacturing process, and the additive manufacturing process and a material selection method are provided for key components in the fields of aviation, aerospace and the like.

Description

Technical Field

[0001] This invention belongs to the field of laser additive manufacturing technology, specifically relating to a method for improving the dimensional stability and vibration reduction performance of composite materials, as well as the composite materials and their applications. Background Technology

[0002] Space field measurement satellites face varying temperatures and external forces in the space environment, resulting in thermal deformation and buckling, which reduces structural stability and directly affects the accuracy and clarity of measurement results. The structural deformation of the space field measurement satellite's load-bearing structure under the influence of temperature and external forces in space must be controlled below 1 µm to keep the impact on the satellite's functionality within a manageable range. Therefore, optimizing the design and manufacturing of key components for "zero expansion and vibration reduction" has significant military and civilian implications.

[0003] Zero-expansion vibration-damping structures have complex geometric configurations. They achieve zero expansion and vibration-damping functionality through rational microstructure design and periodic / aperiodic arrangement of lattice structures. These structures not only require high mechanical performance but also lightweight design while achieving zero expansion and vibration-damping functionality. Traditional foaming methods result in lower strength and difficulty in controlling micropores; welding methods struggle to integrally form complex lattice structures; machining offers high precision but faces the challenge of "difficulty in realizing optimized designs" for complex lattice structures. Additive manufacturing (AM) is a material layer-by-layer deposition method driven by three-dimensional part data. It slices and layers the part, transforming the complex three-dimensional structure into a two-dimensional cross-section for machining. This enables lightweight, personalized, and integral manufacturing of complex parts, achieving zero-expansion vibration-damping structures that balance complex shapes and integral manufacturing.

[0004] Currently, research on additive manufacturing of zero-expansion vibration-damping structures is still in its early stages both domestically and internationally. Current research focuses primarily on structural optimization and additive manufacturing of single thermal or mechanical properties, without delving into the coupling relationship between these properties under multi-physics conditions. Furthermore, due to the complex geometry and multi-performance requirements of zero-expansion vibration-damping structures, current additive manufacturing materials and processes are insufficient, necessitating the development of new additive manufacturing processes. Summary of the Invention

[0005] The purpose of this invention is to provide a method, composite material and application for improving the dimensional stability and vibration isolation performance of composite materials, by means of the distribution design of carbon fiber and aluminum alloy wires to improve the dimensional stability and vibration isolation performance of composite materials.

[0006] To achieve the above objectives, the present invention provides a method for improving the dimensional stability and vibration isolation performance of composite materials, comprising: arranging carbon fibers and aluminum alloys alternately in fiber form layer by layer; using the aluminum alloy to form fibers that melt and solidify to bond with the carbon fibers to obtain a composite material; and using the gaps formed by the alternating arrangement of fibers to improve the dimensional stability and vibration isolation performance of the composite material.

[0007] Furthermore, the composite material includes n fiber layers, where n is a positive integer greater than or equal to 1; when n=1, the fiber layer contains both carbon fiber and aluminum alloy fiber, and each carbon fiber is adjacent to at least one aluminum alloy fiber. When n is greater than 1, each carbon fiber is adjacent to at least one aluminum alloy fiber in its fiber layer or in its adjacent fiber layer.

[0008] Furthermore, the volume fraction of aluminum alloy fibers in the composite material is greater than the volume fraction of carbon fibers.

[0009] Furthermore, the carbon fiber is a single carbon fiber filament with a diameter of 1-10 micrometers or a carbon fiber bundle with a diameter of 0.1-2 mm formed by multiple carbon fiber filaments, and the aluminum alloy fiber has a diameter of 0.01-5 mm.

[0010] Furthermore, both the carbon fiber and aluminum alloy fiber have circular cross-sections, with adjacent fibers in the same layer being tangent to each other, and the centers of each fiber lying on a straight line; the fiber arrangement in adjacent fiber layers includes one or more of the following: Method 1 is as follows: the fiber in the (N+1)th layer is tangent to only one fiber in the Nth layer. ; Method 2 is: the fiber in the (N+1)th layer is simultaneously tangent to two fibers in the Nth layer; Method 3 is: the fiber in the (N+1)th layer is simultaneously tangent to the three fibers in the Nth layer.

[0011] Furthermore, the dimensional stability and vibration damping performance of the composite material can be controlled by adjusting the diameter, content, arrangement, and melting state of the aluminum alloy fibers and carbon fibers.

[0012] Furthermore, based on the target requirements for dimensional stability and vibration reduction performance, the fiber arrangement structure of the composite material is designed. Then, according to the designed arrangement structure, using carbon fiber and aluminum alloy as raw materials, the aluminum alloy is melted by 3D printing and printed out in fiber form, which is then alternately arranged with the carbon fiber. After curing, the composite material is obtained.

[0013] Furthermore, the aluminum alloy is laser-printed, and the melting state of the aluminum alloy is controlled by adjusting the laser power, thereby controlling the interface morphology between the aluminum alloy fibers and carbon fibers, and thus controlling the dimensional stability and vibration reduction performance.

[0014] The present invention provides a second aspect of a composite material, which is prepared by the method described in any one of the preceding claims for improving the dimensional stability and vibration isolation performance of the composite material.

[0015] A third aspect of the present invention provides an application of composite materials in the fields of aerospace, precision instruments and optical setups, and semiconductor manufacturing equipment.

[0016] In summary, compared with the prior art, the above-described technical solutions conceived by this invention mainly possess the following technical advantages: 1. The method for improving the dimensional stability and vibration damping performance of composite materials provided by this invention, targeting the multi-field coupling function design of zero-expansion vibration damping structures, utilizes continuous carbon fiber / aluminum alloy filaments. Aluminum alloy fibers are laser-deposited onto the surface of carbon fibers laid at specific points to prepare the carbon fiber / aluminum alloy composite material. Through the distribution design of the carbon fiber and aluminum alloy, the thermal expansion coefficient and strength of the composite component are adjustable. Specifically, the interface between the aluminum alloy and carbon fiber improves the overall vibration damping characteristics of the material, while the low thermal sensitivity of the carbon fiber enables the material to achieve zero overall expansion.

[0017] 2. This manufacturing process allows for customization of the aluminum alloy and carbon fiber content in each layer as needed, resulting in a multi-material spatial arrangement in multiple directions, both parallel and perpendicular to the printing direction. The mechanical and thermal properties can be customized through the volume fraction, structural configuration, and spatial layout of aluminum alloy and carbon fiber. Furthermore, the performance control range of the multi-materials can be expanded through process parameters such as laser power and printing speed in laser additive manufacturing.

[0018] 3. By controlling the degree of aluminum alloy melting, the interface structure can be adjusted, thereby enabling targeted design and optimization of dimensional stability and vibration reduction performance. Attached Figure Description

[0019] Figure 1 This is a schematic diagram showing the alternating arrangement of aluminum alloy and carbon fiber within and between layers according to an embodiment of this disclosure; Figure 2 This is a schematic diagram of different alternating configurations of aluminum alloy and carbon fiber according to embodiments of this disclosure; Figure 3 This disclosure presents embodiments of aluminum alloys and carbon fiber multi-material arrangements with different carbon fiber volume fractions. Figure 4 This is a schematic diagram of aluminum alloys in different melting states under different printing parameters such as different laser power in an embodiment of this disclosure; Figure 5 This is a schematic diagram showing different diameters of aluminum alloys and carbon fibers according to embodiments of this disclosure; Figure 6 This is a schematic diagram showing that the fiber in the (N+1)th layer of this disclosure is tangent to three fibers in the Nth layer at the same time. Detailed Implementation

[0020] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be further described in detail below with reference to embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0021] Please see Figure 1-6 The present invention provides a method for improving the dimensional stability and vibration isolation performance of composite materials, comprising: arranging carbon fibers and aluminum alloys alternately in the form of fibers layer by layer; using the aluminum alloy to form fibers that melt and solidify to bond with the carbon fibers to obtain a composite material; and using the gaps formed by the alternating arrangement of fibers to improve the dimensional stability and vibration isolation performance of the composite material.

[0022] This invention uses both aluminum alloy and carbon fiber as filaments, which can be alternately laid and printed. Utilizing the low melting point of aluminum alloy, it is melted by laser treatment and then connected to different layers of refractory carbon fiber, forming an aluminum alloy-carbon fiber multi-material molding process. The advantages of this process strategy are: firstly, the raw material preparation of the filaments is relatively convenient and streamlined, avoiding the introduction of minor defects during laser forming; secondly, aluminum alloy is chosen as one of the mediums for the multi-filaments due to its low melting point and light weight, which facilitates the composite of carbon fiber materials and the manufacture of lightweight, high-strength structures; and thirdly, the spatial arrangement design of the multi-filaments can be customized to achieve different mechanical and thermal properties, fully meeting the target requirements for vibration reduction and heat insulation.

[0023] This process allows for customization of the aluminum alloy and carbon fiber content in each layer, creating a multi-material spatial arrangement parallel and perpendicular to the printing direction. The interface between the aluminum alloy and carbon fiber improves the overall vibration damping characteristics of the material, while the low thermal sensitivity of carbon fiber enables zero overall material expansion.

[0024] The aluminum alloy is manufactured using additive manufacturing processes, preferably laser thermal printing. The mechanical and thermal properties are customized by adjusting the volume fraction, structural configuration, and spatial layout of the aluminum alloy and carbon fiber. The performance control range of multiple materials is further expanded by using process parameters such as laser power and printing speed in laser additive manufacturing.

[0025] Laser additive manufacturing process parameter control measures include: laser power, printing speed, and printing spacing; the printing layer thickness is determined by the diameter of the aluminum alloy and carbon fiber.

[0026] Specifically, the aluminum alloy is laser-printed, and the melting state of the aluminum alloy is controlled by adjusting the laser power, thereby controlling the interface morphology between the aluminum alloy fibers and carbon fibers, and thus controlling the dimensional stability and vibration reduction performance.

[0027] The composite material comprises n fiber layers, where n is a positive integer greater than or equal to 1; when n=1, the fiber layer contains both carbon fiber and aluminum alloy fiber, and each carbon fiber is adjacent to at least one aluminum alloy fiber. When n is greater than 1, each carbon fiber is adjacent to at least one aluminum alloy fiber in its fiber layer or in its adjacent fiber layer.

[0028] The content of aluminum alloy and carbon fiber in the interlayer and intralayer layers can be determined according to the required mechanical and thermal properties. The changes in the intralayer and interlayer content of aluminum alloy and carbon fiber respectively control the mechanical and thermal properties. The higher the aluminum alloy content, the better the mechanical properties are improved; the higher the carbon fiber content, the better the thermal stability is enhanced.

[0029] The volume fraction of aluminum alloy fibers in the composite material is greater than that of carbon fibers. This is to prevent excessive carbon fiber content from increasing the expansion effect of the material.

[0030] The carbon fiber is a single carbon fiber filament with a diameter of 1-10 micrometers or a carbon fiber bundle with a diameter of 0.1-2 mm formed by multiple carbon fiber filaments. The aluminum alloy fiber has a diameter of 0.01-5 mm, preferably 0.1-5 mm. By adjusting the diameter, the interface contact space can be controlled, thereby controlling the dimensional stability (mainly the dimensional stability caused by thermal expansion) and mechanical strength.

[0031] The distribution of aluminum alloys and carbon fibers can be linear, or it can be distributed in various structural configurations such as bending and honeycomb.

[0032] Both the carbon fiber and aluminum alloy fiber have circular cross-sections, with adjacent fibers in the same layer being tangent to each other, and the centers of each fiber lying on a straight line; the fiber arrangement in adjacent fiber layers includes one or more of the following: Method 1 is as follows: the fiber in the (N+1)th layer is tangent to only one fiber in the Nth layer. ,like Figure 2 middle; Method two involves the fibers in the (N+1)th layer simultaneously being tangent to two fibers in the Nth layer, such as... Figure 1 ; Method three involves the fibers in the (N+1)th layer simultaneously being tangent to three fibers in the Nth layer, such as... Figure 6 .

[0033] In particular, the cross-sections of carbon fiber and aluminum alloy fiber can also be selected with irregular cross-sections, such as elliptical, rectangular, rhomboid, cross-shaped, figure-eight shaped, etc. The design of irregular cross-sections makes the interface control of the two more flexible.

[0034] Furthermore, the dimensional stability and vibration damping performance of the composite material can be controlled by adjusting the diameter, content, arrangement, and melting state of the aluminum alloy fibers and carbon fibers.

[0035] First, based on the target requirements for dimensional stability and vibration reduction performance, the fiber arrangement structure of the composite material is designed. Then, according to the designed arrangement structure, using carbon fiber and aluminum alloy as raw materials, the aluminum alloy is melted by 3D printing and printed out in fiber form, which is then alternately arranged with the carbon fiber. After curing, the composite material is obtained.

[0036] Example 1 In this embodiment, the alternating printing arrangement of aluminum alloy and carbon fiber allows for the control of the overall mechanical and thermal properties of the multi-material component through spatial arrangement, structural configuration, and volume fraction. Specifically, the spatial arrangement can achieve both intra-layer and inter-layer spatial distribution. After the carbon fiber material is formed, aluminum alloy filaments are then formed. Laser treatment easily melts the aluminum alloy, thus promoting the interconnection of the carbon fibers with higher melting points. The alternating arrangement within layers facilitates tight bonding of carbon fibers in the transverse direction; the alternating arrangement between layers (layers N-1, N, and N+1) facilitates tight bonding of carbon fibers in the longitudinal direction. Furthermore, the distribution of aluminum alloy and carbon fiber can be adjusted by designing different arrangement configurations within and between layers, such as… Figure 2 As shown. Different structural configurations are achieved by controlling the position of each layer of carbon fiber / aluminum alloy, such as alternating zigzag lines and alternating vertical lines. The volume fraction of the carbon fiber / aluminum alloy also significantly affects its mechanical and thermal properties (e.g., ...). Figure 3 (as shown) Figure 3 This illustrates the gradual increase in the volume fraction of carbon fiber.

[0037] Laser additive manufacturing processes, such as laser power and scanning speed, can achieve different melting states of aluminum alloys. Typically, aluminum alloy wires are first arranged, and then laser scanning is used to achieve fusion bonding. Figure 4This diagram illustrates aluminum alloys in different melting states under varying laser power and other printing parameters. The laser power is represented by P, increasing gradually from P1 to P5, and the melting states range from partial to complete melting. Differences in melting state can alter the interface morphology between carbon fiber and aluminum alloy, thus affecting the mechanical and thermal insulation properties of this composite material. The layer thickness in laser additive manufacturing can be controlled by using filaments of different diameters, such as... Figure 5 As shown, D1 to D5 are aluminum alloy wires with different diameters.

[0038] Finally, using a typical aerospace component model, the model was discretized into layers using Materialise Magics software, and the discretized files were imported into the 3D printing equipment. The 3D printing equipment performed layer-by-layer printing. After each layer was completed, the substrate was lowered, and the printing of the next layer was carried out. This process was repeated, layer by layer, until all discrete layers of the part were printed. The part was then removed from the substrate. If necessary, post-treatments such as shot peening and polishing were used to improve the surface quality of the component and the internal structure of the printing material.

[0039] In summary, this invention proposes a method for improving the dimensional stability and vibration isolation performance of composite materials, along with the composite materials and their applications. Addressing the scientific challenges related to the multi-field coupling functional design of zero-expansion vibration isolation structures and the optimization of multi-material additive manufacturing processes, this invention utilizes continuous carbon fiber / aluminum alloy filaments. Aluminum alloy is deposited onto the surface of the carbon fibers at specific locations using laser deposition, thus fabricating the carbon fiber / aluminum alloy composite material. Through the distribution design of the carbon fiber and aluminum alloy, the thermal expansion coefficient and strength of the composite component can be adjusted. These research findings can provide theoretical guidance for the engineering application of key zero-expansion vibration isolation components in space field measurement satellites.

[0040] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for improving the dimensional stability and vibration isolation performance of composite materials, characterized in that, include: Carbon fibers and aluminum alloys are arranged alternately in layers in the form of fibers. The fibers formed by the aluminum alloy are melted and solidified to bond with the carbon fibers to form a composite material. The gaps formed by the alternating arrangement of fibers improve the dimensional stability and vibration reduction performance of the composite material.

2. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 1, characterized in that, The composite material comprises n fiber layers, where n is a positive integer greater than or equal to 1; when n=1, the fiber layer contains both carbon fiber and aluminum alloy fiber, and each carbon fiber is adjacent to at least one aluminum alloy fiber. When n is greater than 1, each carbon fiber is adjacent to at least one aluminum alloy fiber in its fiber layer or in its adjacent fiber layer.

3. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 2, characterized in that, The volume fraction of aluminum alloy fibers in the composite material is greater than that of carbon fibers.

4. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 2, characterized in that, The carbon fiber is a single carbon fiber filament with a diameter of 1-10 micrometers or a carbon fiber bundle with a diameter of 0.1-2 mm formed by multiple carbon fiber filaments, and the aluminum alloy fiber has a diameter of 0.01-5 mm.

5. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 2, characterized in that, Both the carbon fiber and aluminum alloy fiber have circular cross-sections, with adjacent fibers in the same layer being tangent to each other, and the centers of each fiber lying on a straight line; the fiber arrangement in adjacent fiber layers includes one or more of the following: Method 1 is as follows: the fiber in the (N+1)th layer is tangent to only one fiber in the Nth layer. ; Method 2 is: the fiber in the (N+1)th layer is simultaneously tangent to two fibers in the Nth layer; Method 3 is: the fiber in the (N+1)th layer is simultaneously tangent to the three fibers in the Nth layer.

6. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 2, characterized in that, The dimensional stability and vibration damping performance of the composite material are controlled by adjusting the diameter, content, arrangement, and melting state of the aluminum alloy fibers and carbon fibers.

7. The method for improving the dimensional stability and vibration isolation performance of composite materials according to any one of claims 1-6, characterized in that, First, based on the target requirements for dimensional stability and vibration reduction performance, the fiber arrangement structure of the composite material is designed. Then, according to the designed arrangement structure, using carbon fiber and aluminum alloy as raw materials, the aluminum alloy is melted by 3D printing and printed out in fiber form, which is then alternately arranged with the carbon fiber. After curing, the composite material is obtained.

8. The method for improving the dimensional stability and vibration isolation performance of composite materials according to claim 7, characterized in that, The aluminum alloy is printed using laser technology. By adjusting the laser power, the molten state of the aluminum alloy is controlled, thereby controlling the interface morphology between the aluminum alloy fibers and carbon fibers, and thus controlling the dimensional stability and vibration reduction performance.

9. A composite material, characterized in that, It is prepared by the method for improving the dimensional stability and vibration isolation performance of composite materials as described in any one of claims 1-8.

10. An application of the composite material according to claim 9, characterized in that, Used in aerospace, precision instruments and optical setups, and semiconductor manufacturing equipment.

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