Repair methods for honeycomb structures in engine intake ducts

Abstract

This disclosure relates to the field of aircraft component repair technology, and in particular to a method for repairing the honeycomb structure of an engine intake duct. The method includes: inspecting the honeycomb structure of the engine intake duct inner cylinder to confirm the degree of corrosion; determining the repair area based on the degree of corrosion; removing the corroded reinforcing plate and honeycomb core structure in the repair area; preparing a new reinforcing plate, honeycomb core structure, and positioning piece based on the dimensions of the removed reinforcing plate and honeycomb core structure; the positioning piece and reinforcing plate having the same thickness; bonding the new honeycomb core structure to the repair area and pre-positioning the new honeycomb core structure using the positioning piece; performing a bonding pretreatment on the new reinforcing plate; and removing the positioning piece and bonding the pre-treated reinforcing plate to the new honeycomb core structure. This method only requires removing the corroded structural components, simplifying the process and reducing complexity. It eliminates the need for the high-temperature, high-pressure environment of an autoclave, fundamentally avoiding structural thermal deformation and the risk of scrapping.

Description

Technical Field

[0001] This disclosure relates to the technical field of aircraft component repair, and in particular to a method for repairing a honeycomb structure in an engine air intake. Background Technology

[0002] The aircraft engine air intake is a crucial component. It not only guides air smoothly into the engine, but its outer surface must also maintain smooth airflow with the fan cowling to reduce drag. To ensure strength while minimizing weight, the inner cylinder of the air intake is typically constructed with a honeycomb structure, ensuring high structural strength and light weight. Near the engine mounting ring at the rear of the inner cylinder, the outer wall of the honeycomb core structure is usually bonded with a reinforcing plate. This reinforcing plate is made of thick aluminum alloy to improve local structural strength and withstand greater stress. However, during long-term flight use, the reinforcing plate area is susceptible to corrosion damage from moisture, oil, and temperature differences. Corrosion directly undermines the structural strength of the air intake, threatening flight safety. Therefore, corrosion repair in this area is a critical aspect of aircraft maintenance. Currently, repairing corroded reinforcing plates usually requires the complete removal of all structures associated with the corroded area, scrapping the entire reinforcing plate structure and the entire honeycomb core structure. After fabricating a new component, it needs to be hot-pressed in an autoclave, using a high-temperature, high-pressure environment to bond and assemble the new component. However, the repair process is complex, the repair cost is high, and the repair technology requirements are high. For example, improper pressure and temperature control of the autoclave, or mismatch between the thermal expansion coefficients of the new parts and the engine inner cylinder body, can easily lead to irreversible thermal deformation of the entire part, or even scrap the intake manifold inner cylinder, causing huge economic losses.

[0003] Therefore, it is necessary to propose a method for repairing the honeycomb structure of the engine intake manifold in order to at least partially solve the problems existing in the prior art. Summary of the Invention

[0004] This disclosure aims to address at least one of the technical problems existing in the prior art or related technologies.

[0005] Therefore, this disclosure proposes a method for repairing the honeycomb structure of an engine intake manifold.

[0006] In view of this, a method for repairing the honeycomb structure of an engine intake duct is proposed according to an embodiment of this disclosure, comprising: The honeycomb structure of the engine intake manifold inner cylinder was inspected to confirm the degree of corrosion of the honeycomb structure; wherein the honeycomb structure is a reinforcing plate and a honeycomb core structure, and the honeycomb core structure is bonded to the reinforcing plate; the degree of corrosion includes the corrosion size and corrosion depth of the honeycomb structure. Based on the degree of corrosion of the aforementioned honeycomb structure, the repair area is determined, and the aforementioned reinforcing plate and honeycomb core structure that have failed due to corrosion in the repair area are removed. Based on the dimensions of the removed reinforcing plate and the honeycomb core structure, a new reinforcing plate, a new honeycomb core structure, and a positioning piece are prepared; wherein the thickness of the positioning piece and the reinforcing plate is the same. The new honeycomb core structure is bonded to the repair area, and the new honeycomb core structure is pre-positioned using the positioning piece. The aforementioned new reinforcing plates undergo bonding pretreatment. Remove the positioning piece and bond the reinforcing plate, after completing the above bonding pretreatment, to the new honeycomb core structure.

[0007] In one feasible implementation, the steps of determining the repair area based on the degree of corrosion of the honeycomb structure, and removing the corroded reinforcing plate and the honeycomb core structure within the repair area include: The extent of the repair area is determined based on the degree of corrosion of the aforementioned honeycomb structure. Remove all the corroded and failed reinforcing plates in the repair area, and cut off the honeycomb core structure with corrosion damage that is bonded to the corroded and failed reinforcing plates, while retaining the uncorroded base honeycomb core structure on the periphery and bottom of the repair area and the main body of the air intake inner cylinder. The above-mentioned honeycomb core structure and the inner cylinder of the air intake are subjected to surface treatment to remove the paint layer and adhesive layer.

[0008] In one feasible implementation, the step of preparing the new reinforcing plate, the new honeycomb core structure, and the positioning piece based on the dimensions of the removed reinforcing plate and the honeycomb core structure includes: Based on the dimensional parameters of the removed reinforcing plate, the new reinforcing plate was prepared using 2-series aluminum alloy; Based on the dimensional parameters and arrangement direction of the dismantled honeycomb core structure, the new honeycomb core structure is prepared. Based on the thickness of the removed reinforcing plate, the positioning piece was made using 2-series aluminum alloy. The surface of the new reinforcing plate is then treated.

[0009] In one feasible implementation, there is an adhesive gap between the new honeycomb core structure and the substrate honeycomb core structure.

[0010] In one feasible implementation, the steps of bonding the new honeycomb core structure to the repair area and pre-positioning the new honeycomb core structure using the positioning piece include: Foaming adhesive is applied to the sidewalls of the new honeycomb core structure, and a supporting adhesive film is applied to the first bonding surface of the new honeycomb core structure. The new honeycomb core structure is placed in the repair area according to the assembly direction, and the first adhesive surface is bonded to the body of the inner cylinder of the air intake, and the foaming adhesive is filled in the adhesive gap. Evenly apply the above positioning pieces to the second bonding surface; The second adhesive surface and the first adhesive surface are arranged opposite to each other, and the second adhesive surface is used to bond the new reinforcing plate. The supporting adhesive film is an epoxy material, and a supporting mesh structure is sandwiched in the middle of the supporting adhesive film.

[0011] In one feasible implementation, the above-mentioned pre-treatment step of bonding the new reinforcing plate includes: The aforementioned support adhesive film is used to wrap all the bonding surfaces of the new reinforcing plate; wherein, all the bonding surfaces of the new reinforcing plate include a third bonding surface, a fourth bonding surface, and a fifth bonding surface, wherein the third bonding surface is used to bond to the second bonding surface; the fourth bonding surface is used to bond to the bottom of the substrate honeycomb core structure; and the fifth bonding surface is used to bond to the side of the substrate honeycomb core structure. A visual inspection was conducted on the new reinforcing plate that completely covered the aforementioned support adhesive film to confirm that there were no exposed adhesive areas on any of the bonding surfaces of the new reinforcing plate.

[0012] In one feasible implementation, the steps of removing the positioning piece and bonding the reinforcing plate after the bonding pretreatment to the new honeycomb core structure include: Remove the aforementioned positioning piece and heat the new honeycomb core structure in the aforementioned repair area at a preset temperature; While maintaining the temperature at the preset temperature for the preset time, the new reinforcing plate that completely covers the supporting adhesive film is installed, so that the third adhesive surface is bonded to the second adhesive surface, the fourth adhesive surface is bonded to the base honeycomb core structure at the bottom of the repair area, and the fifth adhesive surface is bonded to the base honeycomb core structure on the side of the repair area.

[0013] In one feasible implementation, the preset temperature is 140℉ to 149℉, ​​and the first heating rate during the process of heating from the initial temperature to the preset temperature is 1℉ / min to 8℉ / min; The preset time is 8 to 12 minutes.

[0014] In one feasible implementation, the method for repairing the honeycomb structure of the engine intake duct further includes: After the installation of the new reinforcing plate that completely covers the above-mentioned support film is completed, the repaired honeycomb structure is subjected to curing heat treatment at a curing temperature of 350±10℉ and maintained at the curing temperature for 60 to 90 minutes. The second heating rate of the curing heat treatment is 1℉ / min to 8℉ / min.

[0015] In one feasible implementation, the method for repairing the honeycomb structure of the engine intake duct further includes: The repair status of the honeycomb structure after the above curing and heat treatment was inspected.

[0016] Compared with the prior art, this disclosure has at least the following beneficial effects: The method for repairing the honeycomb structure of the engine intake manifold provided in the embodiments of this disclosure confirms the degree of corrosion of the honeycomb structure by inspecting the honeycomb structure of the inner cylinder of the engine intake manifold; wherein the honeycomb structure is a reinforcing plate and a honeycomb core structure, and the honeycomb core structure is bonded to the reinforcing plate; the degree of corrosion includes the corrosion size and corrosion depth of the honeycomb structure; by determining the repair area according to the degree of corrosion of the honeycomb structure, and removing the corroded reinforcing plate and the honeycomb core structure in the repair area; by preparing the new reinforcing plate, the honeycomb core structure, and the positioning piece according to the size of the removed reinforcing plate and the honeycomb core structure; wherein the thickness of the positioning piece and the reinforcing plate is the same; by bonding the new honeycomb core structure to the repair area, and pre-positioning the new honeycomb core structure using the positioning piece; by performing a bonding pretreatment on the new reinforcing plate; by removing the positioning piece, and bonding the reinforcing plate after the bonding pretreatment to the new honeycomb core structure. This method allows for the repair work to be completed simply by removing the relevant structural components in the corroded area, simplifying the process and reducing its complexity. It eliminates the need for the high-temperature and high-pressure environment of an autoclave, thereby preventing structural thermal deformation at the source, avoiding the risk of scrapping, and reducing costs. Attached Figure Description

[0017] Various other advantages and benefits will become apparent to those skilled in the art upon reading the following detailed description of exemplary embodiments. The accompanying drawings are for illustrative purposes only and are not intended to limit the scope of this disclosure. Furthermore, the same reference numerals denote the same parts throughout the drawings. In the drawings: Figure 1 A schematic flowchart illustrating a method for repairing a honeycomb structure in an engine intake manifold according to an embodiment of this disclosure; Figure 2 This is a schematic structural diagram of the engine mounting ring at the rear end of the engine intake manifold inner cylinder according to an embodiment of the present disclosure. Figure 3 for Figure 2A schematic cross-sectional view of a honeycomb structure corroded in the middle; Figure 4 To Figure 3 A schematic diagram of the repair process for a corroded honeycomb structure.

[0018] in, Figures 2 to 4 The correspondence between the reference numerals and component names in the attached drawings is as follows: 200. Engine mounting ring at the rear end of the engine intake manifold inner cylinder; 210. New reinforcing plate; 220. New honeycomb core structure; 230. Supporting film; 240. Foam; a. Repair area. Detailed Implementation

[0019] The present invention will be further described below with reference to the accompanying drawings and specific embodiments. It should be noted that the description of these embodiments is intended to aid in understanding the invention, but does not constitute a limitation thereof. The specific structural and functional details disclosed herein are merely for describing exemplary embodiments of the invention. However, the invention can be embodied in many alternative forms and should not be construed as being limited to the embodiments described herein.

[0020] like Figures 1 to 4 As shown, according to an embodiment of this disclosure, a method for repairing the honeycomb structure of an engine intake duct is proposed, including steps S110 to S160.

[0021] In step S110: the honeycomb structure of the engine intake manifold inner cylinder is inspected to confirm the degree of corrosion of the honeycomb structure; wherein the honeycomb structure is a reinforcing plate and a honeycomb core structure, and the honeycomb core structure is bonded to the reinforcing plate; the degree of corrosion includes the corrosion size and corrosion depth of the honeycomb structure. Understandably, a reinforcing plate, typically made of thick aluminum alloy, is installed in the honeycomb structure at the rear end of the engine intake manifold, near the engine mounting ring 200, to improve local structural strength and withstand greater stress. During long-term flight operation, the reinforcing plate area is susceptible to corrosion damage from moisture, oil, and temperature variations. Therefore, a comprehensive inspection of the entire reinforcing plate area is necessary to determine the extent of corrosion on the reinforcing plate and the honeycomb core structure bonded to it, facilitating subsequent repair of any corroded reinforcement plates and honeycomb core structures.

[0022] Step S120: Based on the degree of corrosion of the honeycomb structure, determine the repair area a, and remove the corroded reinforcing plate and the honeycomb core structure in the repair area a. Step S120 includes steps S121 to S123.

[0023] Among them, step S121: determine the range of the repair area a based on the degree of corrosion of the honeycomb structure; Understandably, the repair area 'a' can be determined based on the corrosion size and depth of the reinforcing plate and honeycomb core structure of the honeycomb structure. Repair area 'a' can be marked by methods such as scribing to facilitate the subsequent removal of the corroded and failed reinforcing plate and honeycomb core structure at that location.

[0024] It should be noted that, Figure 2 This is a schematic structural diagram of the engine mounting ring at the rear end of the engine intake manifold inner cylinder. Figure 2 The area to be repaired is indicated by the dashed box in the middle. Figure 3 for Figure 2 A schematic cross-sectional view taken along the DD direction, so as to... Figure 3 The diagram illustrates a rusted honeycomb structure.

[0025] Step S122: Remove all the corroded and failed reinforcing plates in the above-mentioned repair area a, and cut off the honeycomb core structure with corrosion damage that is bonded to the corroded and failed reinforcing plates, while retaining the uncorroded base honeycomb core structure on the periphery and bottom of the above-mentioned repair area a and the main body of the above-mentioned air intake inner cylinder. It is understandable that, such as Figure 4 The placement direction allows for the removal of only the corroded and failed reinforcing plate in repair area a, as well as the honeycomb core structure with corrosion damage adhered to it. The uncorroded base honeycomb core structure at the bottom of the corroded and failed reinforcing plate in repair area a, the uncorroded base honeycomb core structures on both sides of the corroded and failed honeycomb core structure in repair area a, and the uncorroded intake duct inner cylinder at the top of the corroded and failed honeycomb core structure in repair area a are preserved. This ensures that while removing the corroded and failed structure, the uncorroded structure is preserved to the maximum extent, eliminating the need to replace the entire honeycomb core structure, thus reducing costs and repair time.

[0026] Step S123: Perform surface treatment on the above-mentioned base honeycomb core structure and the above-mentioned intake duct inner cylinder to remove the paint layer and adhesive layer.

[0027] Understandably, after removing the corroded and damaged structure, the substrate bonding surfaces of the aforementioned retained honeycomb core structure and the inner cylinder of the air intake are repaired to remove residual paint, adhesive, primer, and other impurities, ensuring that the substrate bonding surfaces are flat and clean.

[0028] Step S130: Based on the dimensions of the removed reinforcing plate and the honeycomb core structure, prepare the new reinforcing plate 210, the new honeycomb core structure 220, and the positioning piece; wherein the positioning piece and the reinforcing plate have the same thickness. Step S130 includes steps S131 to S134.

[0029] Among them, step S131: according to the size parameters of the removed reinforcing plate, the new reinforcing plate 210 is prepared using 2-series aluminum alloy; Understandably, a new reinforcing plate 210 can be prepared using 2-series aluminum alloy sheet according to the design thickness and dimensional parameters of the reinforcing plate, as well as the area of ​​the reinforcing plate that has been removed due to corrosion failure, to fill the repair area a.

[0030] Step S132: Based on the dimensional parameters and arrangement direction of the dismantled honeycomb core structure, prepare the new honeycomb core structure 220. Understandably, a new aluminum honeycomb core structure can be cut according to the size of the removed corroded and failed honeycomb core structure, and the arrangement direction of the new honeycomb core structure 220 should be consistent with the arrangement direction of the base honeycomb core structure. This ensures that after the new honeycomb core structure 220 fills and repairs the area a, the stress direction and structural strength are consistent with the base honeycomb core structure, thereby improving reliability.

[0031] In some examples, there is an adhesive gap between the new honeycomb core structure 220 and the substrate honeycomb core structure.

[0032] Understandably, the new honeycomb core structure 220 is slightly smaller than the removed, corroded, and failed honeycomb core structure to create an adhesive gap between the new honeycomb core structure 220 and the base honeycomb core structure. This gap allows an adhesive, such as expanding foam 240, to fill the adhesive gap, ensuring a good bond, and the adhesive gap is less than or equal to 0.1 inches.

[0033] Step S133: Based on the thickness of the removed reinforcing plate, prepare the positioning piece using 2-series aluminum alloy; Understandably, multiple positioning pieces can be made using 2-series aluminum alloy of the same material as the reinforcing plate, according to the design thickness of the reinforcing plate. These positioning pieces can be bonded to the surface of the new honeycomb core structure 220 to provide bonding, positioning, and limiting support for the new honeycomb core structure 220.

[0034] Step S134: Perform surface treatment on the new reinforcing plate 210.

[0035] Understandably, after the new reinforcing plate 210, the new honeycomb core structure 220 and the positioning piece are processed and the dimensions are inspected to ensure that the surfaces of the new reinforcing plate 210 and the new honeycomb core structure 220 are free of cracks and damage, and the surface of the new reinforcing plate 210 is treated according to the design requirements of the reinforcing plate to meet the subsequent bonding and repair standards.

[0036] It should be noted that the sol-gel method can be used for surface treatment. First, sand away the oxide layer on the bonding surface of the new reinforcing plate 210. Apply 3-glycidyl ether oxypropyltrimethoxysilane surface pretreatment agent to the bonding surface after removing the oxide layer. Keep the bonding surface completely wetted with the solution for at least 2 minutes. After 2 minutes, observe the surface condition of the bonding surface. Once it meets the requirements, dry the bonding surface at room temperature for 60 minutes. Apply an adhesive primer to the bonding surface. This can improve the bonding performance of the reinforcing plate and ensure the subsequent bonding strength.

[0037] Step S140: The new honeycomb core structure 220 is bonded to the repair area a, and the new honeycomb core structure 220 is pre-positioned using the positioning piece.

[0038] Step S140 includes steps S141 to S143.

[0039] Among them, step S141: Foam 240 is applied to the sidewall of the new honeycomb core structure 220, and support film 230 is applied to the first bonding surface of the new honeycomb core structure 220. Understandably, the new honeycomb core structure 220 can undergo adhesive pretreatment. Specifically, expanding foam 240 is applied to the sidewalls of the new honeycomb core structure 220, and a support film 230 is applied to the first bonding surface of the new honeycomb core structure 220. The support film 230 includes an epoxy-based material and a support mesh structure. The epoxy-based material, as the adhesive matrix, can be a thermosetting epoxy resin, which can be uniformly coated on the surface of the first bonding surface in thin film form to provide adhesive strength. The support mesh structure can be made of inert reinforcing fabrics such as fiberglass cloth, polyester fiber, or non-woven fabric. The support mesh structure ensures the uniform thickness of the support film 230, avoiding localized adhesive gaps and guaranteeing bonding quality and repair reliability.

[0040] Step S142: Place the new honeycomb core structure 220 into the repair area a according to the assembly direction, and bond the first adhesive surface to the body of the air intake inner cylinder, and fill the adhesive gap with the foam 240.

[0041] Understandably, the new honeycomb core structure 220 can be placed in the repair area a according to the designed assembly direction so that the first bonding surface can be bonded to the body of the air intake inner cylinder through the support film 230. At the same time, the foam 240 can be filled in the bonding gap so that the new honeycomb core structure 220 can be bonded to the base honeycomb core structure through the foam 240.

[0042] Step S143: Evenly apply the above positioning pieces to the second bonding surface; Understandably, the second bonding surface is the side opposite to the first bonding surface and is used to bond to the new reinforcing plate 210. After the new honeycomb core structure 220 is bonded in place, it needs to conform to the curved surface of the engine intake duct. However, during the bonding process, the rebound stress caused by the rigidity of the new honeycomb core structure 220 will overcome the adhesive force, leading to displacement, warping, and rebound problems. Therefore, by evenly laying multiple positioning pieces on the second bonding surface, the rebound stress of the new honeycomb core structure 220 is offset by the limiting support of the positioning pieces and the adhesive force of the supporting adhesive film 230, ensuring that the new honeycomb core structure 220 is accurately fixed in position and improving reliability.

[0043] Step S150: Perform bonding pretreatment on the new reinforcing plate 210.

[0044] Step S150 includes steps S151 and S152.

[0045] In step S151: the support adhesive film 230 is used to wrap all the bonding surfaces of the new reinforcing plate 210; wherein, all the bonding surfaces of the new reinforcing plate 210 include a third bonding surface, a fourth bonding surface and a fifth bonding surface, wherein the third bonding surface is used to bond to the second bonding surface; the fourth bonding surface is used to bond to the bottom of the base honeycomb core structure; and the fifth bonding surface is used to bond to the side of the base honeycomb core structure. Understandably, the entire bonding surface of the reinforcing plate can be wrapped with the support adhesive film 230. By utilizing the structural characteristics of the support adhesive film 230, the overall thickness of the support adhesive film 230 on all bonding surfaces of the reinforcing plate can be ensured, avoiding localized glue shortages and film detachment, thus ensuring bonding quality and repair reliability.

[0046] Step S152: Perform a visual inspection on the new reinforcing plate 210 that completely covers the support adhesive film 230 to confirm that there are no exposed adhesive areas on all bonding surfaces of the new reinforcing plate 210.

[0047] Step S160: Take out the positioning piece and bond the reinforcing plate after the above bonding pretreatment to the new honeycomb core structure 220.

[0048] Step S160 includes steps S161 and S162.

[0049] In step S161: Take out the above positioning piece and heat the new honeycomb core structure 220 in the above repair area a at a preset temperature. Understandably, before installing the new reinforcing plate 210, the positioning piece can be removed, and the new honeycomb core structure 220 in the repair area a can be heated at a preset temperature to soften the supporting adhesive film 230 and improve the fluidity of the supporting adhesive film 230, so that the new reinforcing plate 210 can slide smoothly into the assembly position, which facilitates subsequent bonding operations and ensures proper assembly.

[0050] Step S162: While maintaining the temperature at the preset temperature for the preset time, install the new reinforcing plate 210 that completely covers the support film 230, so that the third adhesive surface is bonded to the second adhesive surface, the fourth adhesive surface is bonded to the base honeycomb core structure at the bottom of the repair area a, and the fifth adhesive surface is bonded to the base honeycomb core structure on the side of the repair area a.

[0051] Understandably, after the support film 230 is in a flowing state, the new reinforcing plate 210 can be pushed into the position of the positioning piece so that the third adhesive surface is bonded to the second adhesive surface, the fourth adhesive surface is bonded to the base honeycomb core structure located at the bottom of the repair area a, and the fifth adhesive surface is bonded to the base honeycomb core structure on the side of the repair area a, so as to ensure the bonding and fixing effect of the reinforcing plate.

[0052] In some examples, the preset temperature is 140℉ to 149℉, ​​the first heating rate during the process of heating from the initial temperature to the preset temperature is 1℉ / min to 8℉ / min, and the preset time is 8 minutes to 12 minutes.

[0053] Understandably, setting the heating conditions for the support film 230 in this way ensures that the support film 230 is initially softened and has slight fluidity, which facilitates the assembly of the new reinforcing plate 210, while preventing the foaming adhesive 240 from foaming and occupying the assembly space in advance, further ensuring that the new reinforcing plate 210 is installed in place and improving reliability.

[0054] In some examples, the method for repairing the honeycomb structure of the engine intake duct further includes: after completing the installation of the new reinforcing plate 210 that completely covers the support film 230, the repaired honeycomb structure is subjected to curing heat treatment at a curing temperature of 350±10℉ and maintained at the curing temperature for 60 to 90 minutes, and the second heating rate of the curing heat treatment is 1℉ / min to 8℉ / min.

[0055] Understandably, after the new reinforcing plate 210 is assembled, the repair area a can be heated and cured to ensure that the supporting adhesive film 230 and the foam adhesive 240 are fully cured and the bonding strength meets the design standard.

[0056] In some examples, the repair method for the honeycomb structure of the engine intake duct further includes: inspecting the repair status of the honeycomb structure after the curing and heating treatment is completed.

[0057] Understandably, after the curing and heating treatment is completed, the adhesion density and fit of the repaired area a can be checked to confirm that there are no defects such as delamination or hollowness. At the same time, the overall structural dimensions of the air intake inner cylinder should be checked to ensure that the structural performance and external dimensions after repair meet the design requirements.

[0058] It should be understood that the terms "first," "second," etc., are used only for distinguishing descriptions and should not be construed as indicating or implying relative importance. Although the terms "first," "second," etc., may be used herein to describe various units, these units should not be limited by these terms. These terms are only used to distinguish one unit from another. For example, a first unit may be referred to as a second unit, and similarly, a second unit may be referred to as a first unit, without departing from the scope of the exemplary embodiments of the invention.

[0059] It should be understood that the term "and / or" in this article is merely a description of the relationship between related objects, indicating that three relationships can exist. For example, A and / or B can mean: A exists alone, B exists alone, and A and B exist simultaneously. The term " / and" in this article describes another relationship between related objects, indicating that two relationships can exist. For example, A / and B can mean: A exists alone, and A and B exist alone. In addition, the character " / " in this article generally indicates that the related objects before and after it are in an "or" relationship.

[0060] It should be understood that in the description of this invention, the terms "upper," "vertical," "inner," "outer," etc., indicate the orientation or positional relationship as commonly placed when the disclosed product is used, or the orientation or positional relationship commonly understood by those skilled in the art. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0061] In the description of this invention, it should also be noted that, unless otherwise explicitly specified and limited, the terms "set," "install," and "connect" should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral connection; they can refer to a direct connection or an indirect connection through an intermediate medium; and they can refer to the internal connection of two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the specific circumstances.

[0062] The terminology used herein is for the purpose of describing particular embodiments only and is not intended to limit the exemplary embodiments of the invention. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms unless the context clearly indicates otherwise. It should also be understood that the terms “comprising,” “including,” “containing,” and / or “including” as used herein specify the presence of the stated features, integers, steps, operations, units, and / or components, and do not exclude the presence or addition of one or more other features, quantities, steps, operations, units, components, and / or combinations thereof.

[0063] Specific details are provided in the following description to provide a complete understanding of the exemplary embodiments. However, those skilled in the art will understand that the exemplary embodiments can be implemented without these specific details. In other embodiments, well-known processes, structures, and techniques may be omitted in the depiction of non-essential details to avoid obscuring the exemplary embodiments.

[0064] The above are merely specific embodiments of this application, enabling those skilled in the art to understand or implement this application. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of this application. Therefore, this application is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features claimed herein.

[0065] It should be noted that the information disclosed in the background section above is only used to enhance the understanding of the background of this disclosure, and therefore may include information that does not constitute prior art known to those skilled in the art.

Claims

1. A method for repairing the honeycomb structure of an engine intake duct, characterized in that, include: The honeycomb structure of the engine intake manifold inner cylinder is inspected to confirm the degree of corrosion of the honeycomb structure; wherein, the honeycomb structure is a reinforcing plate and a honeycomb core structure, and the honeycomb core structure is bonded to the reinforcing plate; the degree of corrosion includes the corrosion size and corrosion depth of the honeycomb structure; Based on the degree of corrosion of the honeycomb structure, the repair area is determined, and the corroded and failed reinforcing plate and honeycomb core structure in the repair area are removed; Based on the dimensions of the removed reinforcing plate and the honeycomb core structure, a new reinforcing plate, a new honeycomb core structure, and a positioning piece are prepared; wherein the positioning piece and the reinforcing plate have the same thickness. The new honeycomb core structure is bonded to the repair area, and the new honeycomb core structure is pre-positioned using the positioning piece; The new reinforcing plate undergoes bonding pretreatment; Remove the positioning piece and bond the new reinforcing plate, after completing the bonding pretreatment, to the new honeycomb core structure.

2. The method for repairing the honeycomb structure of the engine intake duct according to claim 1, characterized in that, The step of determining the repair area based on the degree of corrosion of the honeycomb structure, and removing the corroded and failed reinforcing plate and honeycomb core structure in the repair area includes: The extent of the repair area is determined based on the degree of corrosion of the honeycomb structure; Remove all the corroded and failed reinforcing plates in the repair area, and cut off the honeycomb core structure with corrosion damage that is bonded to the corroded and failed reinforcing plates, while retaining the uncorroded base honeycomb core structure on the periphery and bottom of the repair area and the body of the air intake inner cylinder. The base honeycomb core structure and the inner cylinder of the air intake are surface treated to remove the paint layer and adhesive layer.

3. The method for repairing the honeycomb structure of the engine intake duct according to claim 2, characterized in that, The step of preparing the new reinforcing plate, the new honeycomb core structure, and the positioning piece based on the dimensions of the removed reinforcing plate and the honeycomb core structure includes: Based on the dimensional parameters of the removed reinforcing plate, a new reinforcing plate is fabricated using 2-series aluminum alloy; Based on the dimensional parameters and arrangement direction of the dismantled honeycomb core structure, the new honeycomb core structure is prepared. The positioning piece is made of 2-series aluminum alloy according to the thickness of the removed reinforcing plate; The new reinforcing plate undergoes surface treatment.

4. The method for repairing the honeycomb structure of the engine intake duct according to claim 3, characterized in that, There is an adhesive gap between the new honeycomb core structure and the base honeycomb core structure.

5. The method for repairing the honeycomb structure of the engine intake duct according to claim 4, characterized in that, The step of bonding the new honeycomb core structure to the repair area and pre-positioning the new honeycomb core structure using the positioning piece includes: Foaming adhesive is applied to the sidewalls of the new honeycomb core structure, and a supporting adhesive film is applied to the first bonding surface of the new honeycomb core structure. The new honeycomb core structure is placed in the repair area according to the assembly direction, and the first adhesive surface is bonded to the body of the air intake inner cylinder, and the foaming adhesive is filled in the adhesive gap. The positioning pieces are evenly laid on the second bonding surface; The second adhesive surface and the first adhesive surface are arranged opposite to each other, and the second adhesive surface is used to bond the new reinforcing plate. The supporting adhesive film is an epoxy material, and a supporting mesh structure is sandwiched in the middle of the supporting adhesive film.

6. The method for repairing the honeycomb structure of the engine intake duct according to claim 5, characterized in that, The pre-treatment step for bonding the new reinforcing plate includes: The supporting adhesive film is used to wrap all the bonding surfaces of the new reinforcing plate; wherein, all the bonding surfaces of the new reinforcing plate include a third bonding surface, a fourth bonding surface, and a fifth bonding surface, the third bonding surface is used to bond to the second bonding surface; the fourth bonding surface is used to bond to the bottom of the base honeycomb core structure; and the fifth bonding surface is used to bond to the side of the base honeycomb core structure; A visual inspection was performed on the new reinforcing plate that completely covered the supporting adhesive film to confirm that there were no exposed adhesive areas on all the bonding surfaces of the new reinforcing plate.

7. The method for repairing the honeycomb structure of the engine intake duct according to claim 6, wherein the step of removing the positioning piece and bonding the reinforcing plate after the bonding pretreatment to the new honeycomb core structure includes: Remove the positioning piece and heat the new honeycomb core structure in the repair area at a preset temperature; While maintaining the temperature at the preset temperature for a preset time, the new reinforcing plate that completely covers the supporting adhesive film is installed so that the third adhesive surface is bonded to the second adhesive surface and the fourth adhesive surface is bonded to the base honeycomb core structure at the bottom of the repair area. The fifth adhesive surface is bonded to the matrix honeycomb core structure on the side of the repair area.

8. The method for repairing the honeycomb structure of the engine intake duct according to claim 7, characterized in that, The preset temperature is 140℉ to 149℉, ​​and the first heating rate during the process of heating from the initial temperature to the preset temperature is 1℉ / min to 8℉ / min; The preset time is 8 to 12 minutes.

9. The method for repairing the honeycomb structure of the engine intake duct according to claim 7, characterized in that, Also includes: After the new reinforcing plate, which completely covers the supporting adhesive film, is installed, the repaired honeycomb structure is subjected to a curing heat treatment at a curing temperature of 350±10℉ and maintained at the curing temperature for 60 to 90 minutes. The second heating rate of the curing heat treatment is 1℉ / min to 8℉ / min.

10. The method for repairing the honeycomb structure of the engine intake duct according to claim 9, characterized in that, Also includes: The repair status of the honeycomb structure after the curing and heat treatment is inspected.

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