双辊铸轧工艺制备连续碳纤维增强铝基复合材料的研究

doi:10.19936/j.cnki.2096-8000.20240728.014

摘要/Abstract

摘要： 连续碳纤维增强铝基(CCF/Al)复合材料具有高比强度、低密度、良好的传热性以及低热膨胀系数等诸多优良的特性,在航空材料、汽车制造、电子设备和工业生产等领域均具有广阔的应用前景。对连续碳纤维表面涂层的制备方法进行了讨论,并总结了近年来CCF/Al复合材料的主要制备工艺、重要研究成果以及存在的问题;重点阐述了采用双辊铸轧工艺制备CCF/Al复合材料的研究结果,具体包括搭建的实验设备、改性后碳纤维的性能、所制备复合材料的组织结构及强化机理;讨论了该工艺目前存在的主要问题,并对其发展前景进行了展望。

关键词: 连续碳纤维, 铝基复合材料, 涂层, 制备工艺, 双辊铸轧

Abstract: Continuous carbon fiber reinforced aluminum matrix composites have many excellent characteristics such as high specific strength, low density, good heat transfer, and low coefficient of thermal expansion, making them have broad application prospects in fields such as aviation materials, automotive manufacturing, electronic equipment, and industrial production. The preparation method of continuous carbon fiber surface coating was discussed. Summarized the main preparation processes, important research achievements and existing problems of CCF/Al composites in recent years. Finally, the article focuses on the research results of our team's use of twin-roll casting technology to prepare CCF/Al composites, including the experimental equipment built, properties of modified carbon fibers, microstructure and strengthening mechanism of the prepared composites. The main problems currently existing were elaborated and the development prospects were discussed.

Key words: continuous carbon fibers, aluminum matrix composites, coating, preparation process, twin-roll casting

中图分类号:

TB332

牟维鹏, 朱保顺, 魏娜娜, 丰铭, 林金保. 双辊铸轧工艺制备连续碳纤维增强铝基复合材料的研究[J]. 复合材料科学与工程, 2024, 0(7): 105-115.

MU Weipeng, ZHU Baoshun, WEI Nana, FENG Ming, LIN Jinbao. Study on preparation of continuous carbon fiber reinforced aluminum matrix composites by twin-roll casting technology[J]. COMPOSITES SCIENCE AND ENGINEERING, 2024, 0(7): 105-115.

参考文献

[1] SHIRVANIMOGHADDAM K, HAMIM S U, AKBARI M K, et al. Carbon fiber reinforced metal matrix composites: Fabrication processes and properties[J]. Composites Part A: Applied Science and Manufacturing, 2017, 92: 70-96.
[2] 赵娜娜, 陈浩, 章晨曦, 等. 金属基复合材料构型化与界面特性的研究现[J]. 热加工工艺, 2023, 52(23): 17-23.
[3] HUANG Y, OUYANG Q B, ZHANG D, et al. Carbon materials reinforced aluminum composites: A review[J]. Acta Metallurgica Sinica-English Letters, 2014, 27(5): 775-786.
[4] GALYSHEV S, GOMZIN A, GALLYAMOVA R, et al. On the liquid-phase technology of carbon fiber/aluminum matrix composites[J]. International Journal of Minerals, Metallurgy and Materials, 2019, 26: 1578-1585.
[5] GUO Y, LI W Q, LIU X G, et al. Effect of short-carbon fiber and nano-carbon fiber as reinforcement on microstructure and properties of hot-rolled aluminum matrix composites[J]. Journal Materials Science, 2022, 57: 20197-20209.
[6] 李杨, 陈存广, 刘新华, 等. 碳纤维/铝基复合材料的制备与性能[J]. 海军工程大学学报, 2023, 35(4): 41-47.
[7] 成小乐, 彭耀, 杨磊鹏, 等. 连续碳纤维增强金属基复合材料研究进展及展望[J]. 复合材料科学与工程, 2022(10): 119-128.
[8] 征立志, 周玉兰, 张云虎, 等. 碳纤维增强金属基复合材料的研究进展[J]. 上海金属, 2023, 45(4): 1-9.
[9] 冉旭, 邹豪豪, 李乾, 等. 镀层碳纤维增强铜基复合材料的制备及其性能研究[J]. 长春工业大学学报, 2022, 43(Z1): 332-340.
[10] WU M J, JIA L X, LU S L, et al. Interfacial performance of high-performance fiber-reinforced composites improved by cold plasma treatment: A review[J]. Surfaces and Interfaces, 2021, 24: 101077.
[11] HUANG D, LIU Q L, ZHANG P, et al. Thermal response of the two-directional high-thermal-conductive carbon fiber reinforced aluminum composites with low interface damage by a vacuum hot pressure diffusion method[J]. Journal of Alloys and Compounds, 2022, 905: 164195.
[12] FAN G L, JIANG Y, TAN Z Q, et al. Enhanced interfacial bonding and mechanical properties in CNT/Al composites fabricated by flake powder metallurgy[J]. Carbon, 2018, 130: 333-339.
[13] JANG D, LEE M E, CHOI J, et al. Strategies for the production of PAN-based carbon fibers with high tensile strength[J]. Carbon, 2022, 186: 644-677.
[14] 刘甲秋, 伊翠云, 刘芳芳, 等. 碳纤维复合材料电磁屏蔽性能研究[J]. 纤维复合材料, 2020, 37(2): 26-28.
[15] 董志刚, 王中旺, 冉乙川, 等. 碳纤维增强陶瓷基复合材料超声振动辅助铣削加工技术的研究进展[J]. 机械工程学报, 2023, 59: 1-31.
[16] WEI H W, LI Z Q, XIONG D B, et al. Towards strong and stiff carbon nanotube-reinforced high-strength aluminum alloy composites through a microlaminated architecture design[J]. Scripta Materialia, 2014, 75: 30-33.
[17] KORDKHEILI H Y, HIZIROGLU S, FARSI M. Some of the physical and mechanical properties of cement composites manufactured from carbon nanotubes and bagasse fiber[J]. Materials and Design, 2012, 33: 395-398.
[18] 李晋. 金属基复合材料的现状与未来发展[J].现代盐化工, 2022, 49(2): 22-23.
[19] 王洪恩, 李云, 夏令, 等. 碳纤维增强树脂基复合材料表面的紫外激光清洗微观形貌[J]. 复合材料科学与工程, 2023(5): 102-107.
[20] 刘丰华, 赵文豪, 蔡长春, 等. 三向正交纤维增强铝基复合材料经向拉伸渐进损伤及其断裂力学行为[J]. 材料研究学报, 2022, 36(7): 500-510.
[21] ROLLIN M, JOUANNIGOT S, LAMON J, et al. Characterization of fibre/matrix interfaces in carbon/carbon composites[J]. Composites Science and Technology, 2009, 69: 1442-1446.
[22] 刘建秀, 贾旭刚, 樊江磊, 等. 碳纤维增强铜基复合材料中碳纤维表面改性与结合界面性能的研究现状[J]. 材料科学与工程学报, 2021, 39(5): 847-854.
[23] MA Y, YANG Y Q, SUGAHARA T, et al. A study on the failure behavior and mechanical properties of unidirectional fiber reinforced thermosetting and thermoplastic composites[J]. Composites Part B: Engineering, 2016, 99: 162-172.
[24] 周璇, 高义民, 路向前, 等. 双相多尺度镀镍碳纤维和碳化锆颗粒增强铝基复合材料制备及力学性能研究[J]. 铸造技术, 2022, 43(6): 417-422.
[25] LEE M, CHOI Y, SUGIO K, et al. Effect of aluminum carbide on thermal conductivity of the unidirectional CF/Al composites fabricated by low pressure infiltration process[J]. Composites Science and Technology, 2014, 97: 1-5.
[26] 崔鹏杰, 钟黎声, 白海强, 等. 铸造在层状双金属复合材料中的应用[J]. 热加工工艺, 2020, 49(19): 1-6.
[27] 王彬, 秋海滨, 王祝堂. 双辊铸轧轻合金及其复合材料在轻量化领域的应用[J]. 世界有色金属, 2015(4): 40-45.
[28] MIRANDA A T, BOLZONI L, BAREKAR L, et al. Processing, structure and thermal conductivity correlation in carbon fibre reinforced aluminium metal matrix composites[J]. Materials and Design, 2018, 156: 329-339.
[29] ALTEN A, ERZI E, GURSOY G, et al. Production and mechanical characterization of Ni-coated carbon fibers reinforced Al-6063 alloy matrix composites[J]. Journal of Alloys and Compounds, 2019, 787: 543-550.
[30] WANG Q S, NING H B, VAIDYA U, et al. Development of a carbonization-in-nitrogen method for measuring the fiber content of carbon fiber reinforced thermoset composites[J]. Composites Part A: Applied Science and Manufacturing, 2015, 73: 80-84.
[31] 陈思魁, 郭荣辉. 碳纤维表面改性的研究进展[J]. 纺织科学与工程学报, 2023, 40(3): 94-100.
[32] 于长清, 陈利, 裴雨辰. 碳纤维表面涂层对碳纤维增强锂铝硅玻璃陶瓷复合材料热导率的影响[J]. 材料工程, 2018, 46(6): 101-105.
[33] 侯党社, 李克智. C/C复合材料SiC-Mo(Si,Al)₂涂层结构和抗氧化性能研究[J]. 复合材料科学与工程, 2021(8): 91-94.
[34] 任富忠, 吴思展, 石维. 镍涂层短碳纤维增强AZ91D镁基复合材料的界面特征和阻尼性能[J]. 材料研究学报, 2017, 31(1): 74-80.
[35] DEO Y, GUHA S, SARKAR K, et al. Electrodeposited Ni-Cu alloy coatings on mild steel for enhanced corrosion properties[J]. Applied Surface Science, 2020, 515: 146078.
[36] LIU J M, ZHANG Y B, GUO Z K, et al. In situ infiltration behavior and interfacial microstructure evolution between Al and carbon fibers[J]. Journal of Alloys and Compounds, 2021, 853: 157120.
[37] 乔英铭, 甘春雷, 曲迎东, 等. 工艺参数对连续碳纤维表面电磁搅拌化学镀镍的影响[J]. 表面技术, 2020, 49(5): 325-334.
[38] CUI H Z, WEI N, ZENG L L, et al. Microstructure and formation mechanism of Ni-Al intermetallic compounds fabricated by reaction synthesis[J]. Transactions of Nonferrous Metals Society of China, 2013, 23: 1639-1645.
[39] 高雷, 王文芳, 吴玉程, 等. 碳纤维表面连续镀铜工艺及性能研究[J]. 电镀与涂饰, 2012, 31(4): 4-7.
[40] 杜颖. 碳复合材料表面处理和镀铜的工艺研究[D]. 湖南: 湖南大学, 2021.
[41] 杨波, 于杰. 碳纤维增强铝基复合材料的研究进展[J]. 热加工工艺, 2016, 45(8): 16-18.
[42] 刘建秀, 宋阳, 樊江磊, 等. 碳纤维增强铜基复合材料研究进展[J]. 材料科学与工程学报, 2018, 36(2): 342-346.
[43] 张萍, 邓为难. 碳纤维表面涂层制备研究进展[J]. 贵州工程应用技术学院学报, 2015, 33(6): 152-156.
[44] ZHANG P Y, MENG G Z, WANG Y Q, et al. Significantly enhanced corrosion resistance of Ni-Cu coating modified by minor cerium[J]. Corrosion Communications, 2021, 2: 72-81.
[45] TANG Y P, DENG Y D, ZHANG K, et al. Improvement of interface between Al and short carbon fibers by α-Al₂O₃ coatings deposited by sol-gel technology[J]. Ceramics International, 2008, 34(7): 1787-1790.
[46] LI S, ZHANG Y M, ZHOU Y F. Preparation and characterization of sol-gel derived zirconia coated carbon fiber[J]. Surface & Coatings Technology, 2012, 206: 4720-4724.
[47] HU X L, HUANG M, KONG N Z, et al. Enhancing the electrical insulation of highly thermally conductive carbon fiber powders by SiC ceramic coating for efficient thermal interface materials[J]. Composites Part B: Engineering, 2021, 227: 109398.
[48] 韩敏娜, 郭领军, 李克智, 等. 碳纤维增强碳复合材料高温抗氧化硅基陶瓷涂层的研究进展[J]. 硅酸盐学报, 2010, 38(5): 991-996.
[49] ZHU C N, SU Y S, ZHANG D, et al. Effect of Al₂O₃ coating thickness on microstructural characterization and mechanical properties of continuous carbon fiber reinforced aluminum matrix composites[J]. Materials Science & Engineering: A, 2020, 793: 139839.
[50] OLSZÓWKA-MYALSKA A, BOTOR-PROBIERZ A. Effect of TiN nano-coating on the interface microstructure of carbon fibres-AZ91 alloy composite[J]. Materials Science and Engineering, 2012, 32: 012019.
[51] GADIOU R, SERVERIN S, GIBOT P, et al. The synthesis of SiC and TiC protective coatings for carbon fibers by the reactive replica process[J]. Journal of the European Ceramic Society, 2008, 28: 2265-2274.
[52] 钱鑫, 韩卫东, 马洪波, 等. 电化学镀镍对PAN基高模量碳纤维结构及性能的影响[J]. 中国有色金属学报, 2022, 32(6): 1708-1718.
[53] 李是捷, 周海涛, 应韬, 等. 表面涂覆对碳纤维镁基复合材料组织与性能的影响[J]. 铸造技术, 2021, 42(2): 69-74.
[54] DONG Z J, LI K K, YUAN G M, et al. Tensile strength, oxidation resistance and wettability of carbon fibers coated with a TiC layer using a molten salt method[J]. Materials and Design, 2013, 50: 156-164.
[55] ZHANG M, DING L, ZHENG J, et al. Surface modification of carbon fibers with hydrophilic Fe₃O₄ nanoparticles for nickel-based multifunctional composites[J]. Applied Surface Science, 2020, 509: 145348.
[56] 杨立宁, 杨光, 张永弟, 等. 碳纤维表面电镀铜改性工艺方法研究[J]. 机械设计与制造, 2023(2): 251-254.
[57] 赵雪妮, 杨建军, 何富珍, 等. 碳纤维表面处理及熔盐电镀Al涂层的研究[J]. 材料导报, 2019, 33(4): 674-678.
[58] ZHAO L, ZHANG L X, TIAN X Y, et al. Interfacial microstructure and mechanical properties of joining electroless nickel plated quartz fibers reinforced silica composite to Invar[J]. Materials and Design, 2011, 32: 382-387.
[59] 吕钊钊, 沙建军, 祖宇飞, 等. 碳纤维表面超声振荡辅助电镀镍涂层工艺及其参数的影响规律[J]. 中国有色金属学报, 2020, 30(3): 571-579.
[60] 万里鹰, 尧章福. 碳纤维表面连续电镀镍的研究[J]. 南昌航空大学学报: 自然科学版, 2015, 29(2): 57-61.
[61] 赵晓莉, 齐暑华, 刘建军, 等. 正交设计法优化碳纤维表面连续镀镍工艺及性能[J]. 工程塑料应用, 2019, 47(3): 55-64.
[62] 杨斌, 刘敬萱, 齐亮, 等. 碳纤维表面镀镍工艺研究[J]. 有色金属材料与工程, 2016, 7(5): 49-54.
[63] 赵宇, 刘润红, 冉旭, 等. 碳纤维增强铜基复合材料的制备与表征[J]. 热加工工艺, 2015, 44(10): 145-148.
[64] MU W P, LIN J B, GONG Y, et al. Microstructure and mechanical properties of Ni-coated continuous carbon fibers-reinforced pure aluminum matrix composites prepared by twin-roll casting method[J]. Advanced Engineering Materials, 2021, 23: 1-14.
[65] 陈明. 一种碳纤维表面化学镀铜方法[J]. 材料保护, 2020, 53(S1): 37-41.
[66] 张健. 连续Al₂O₃纤维表面金属化改性及性能研究[D]. 郑州: 河南工业大学, 2023.
[67] SINGH B B, BALASUBRAMANIAN M. Processing and properties of copper-coated carbon fiber reinforced aluminum alloy composites[J]. Journal of Materials Processing Technology, 2009, 209: 2104-2110.
[68] ZHANG J J, LIU S C, LIU J M, et al. Electroless nickel plating and spontaneous infiltration behavior of woven carbon fibers[J]. Materials and Design, 2020, 186: 108301.
[69] LIU J M, ZHANG Y B, GUO Z K, et al. Enhancement of fiber-matrix adhesion in carbon fiber reinforced Al-matrix composites with an optimized electroless plating process[J]. Composites Part A: Applied Science and Manufacturing, 2021, 142: 106258.
[70] 杨光远. 碳纤维抗氧化涂层的制备及其增强复合材料性能的研究[D]. 武汉: 武汉理工大学, 2019.
[71] WANG J W, HONG T, LI G Y, et al. A combined process of coating and hybridizing for the fabrication of carbon fiber reinforced aluminum matrix composites[J]. Composites Part A: Applied Science and Manufacturing, 1997, 28: 943-948.
[72] 楚电明, 董乾鹏, 白文娟, 等. 碳纤维/碳纳米管界面增强技术研究进展[J]. 化工新型材料, 2023, 51(1): 1-7.
[73] 杨来侠, 周文明, 赵贞慧, 等. PS/化学气相沉积CF选区激光烧结多指标正交试验参数的优化[J]. 工程塑料应用, 2017, 45(10): 46-51.
[74] ABIDIN A Z, KOZERA R, HOHN M, et al. Preparation and characterization of CVD-TiN-coated carbon fibers for applications in metal matrix composites[J]. Thin Solid Films, 2015, 589: 479-486.
[75] POPOVSKA N, GERHARD H, WURM D, et al. Chemical vapor deposition of titanium nitride on carbon fibres as a protective layer in metal matrix composites[J]. Materials & Design, 1997, 18: 239-242.
[76] 吕品, 肖志超, 张永辉, 等. 炭/炭复合材料表面熔盐反应制备TiC涂层及其性能研究[J]. 炭素技术, 2014, 33(3): 26-29.
[77] 梁赤勇, 堵永国, 张为军, 等. Cf/SiC复合材料表面熔盐反应法锆金属化研究[J]. 航空材料学报, 2009, 29(2): 92-96.
[78] 董志军, 李轩科, 袁观明, 等. 熔盐反应法在碳纤维表面制备TaC涂层[J]. 材料导报, 2009, 23(8): 77-80.
[79] 李旭勤, 谭志勇, 成来飞, 等. 先驱体浸渍裂解C/SiCN复合材料的拉伸行为与基体开裂机制[J]. 无机材料学报, 2020, 35(11): 1227-1233.
[80] 文章苹, 张骋, 张永刚. 碳纤维增强碳化硅陶瓷基复合材料的研究进展及应用[J]. 人造纤维, 2018, 48(1): 18-24.
[81] 陈刚军, 肖汉宁, 高朋召. SiC涂层工艺对三维碳纤维编织物抗氧化性的影响[J]. 稀有金属材料与工程, 2008, 37(S1): 78-81.
[82] 徐永龙, 郝安林, 孙威. 热蒸镀-原位反应法制备的Mo-Si-X-C(X=Al,Ti)复相陶瓷涂层的微观结构和力学性能[J]. 中国有色金属学报, 2016, 26(11): 2326-2339.
[83] 张海莲, 段淼, 李四中, 等. 催化炭化-原位反应/反应熔体浸渗法制备C/C-SiC复合材料[J]. 材料工程, 2021, 49(7): 85-91.
[84] 康鹏超, 张斌, 武高辉, 等. SiC涂层对碳纤维抗氧化性能的影响[J]. 材料热处理学报, 2009, 30(2): 142-145.
[85] PENG X Y, HUANG Y, HAN X P, et al. High volume fraction of copper coated graphite flake\Nitrogen doped carbon fiber reinforced aluminum matrix composites[J]. Journal of Alloys and Compounds, 2020, 822: 153584.
[86] WANG J, YANG G Z, ZHANG F Q, et al. The preparation and mechanical properties of carbon/carbon (C/C) composite and carbon fiber reinforced silicon carbide (C_f/SiC) composite joint by partial transient liquid phase (PTLP) diffusion bonding process[J]. Vacuum, 2018, 158: 113-116.
[87] 刘兴峰. 连续C_f/Al复合材料热压扩散结合工艺及微观组织研究[D]. 南昌: 南昌航空大学, 2014.
[88] 陈利文, 赵宇宏, 孙晓平, 等. ZM5镁合金隔板件挤压铸造工艺研究[J]. 特种制造及有色合金, 2023, 43(7): 865-870.
[89] KACZMAR J W, NAPLOCHA K, MORGIEL J. Microstructure and strength of Al₂O₃ and carbon fiber reinforced 2024 aluminum alloy composites[J]. Journal of Materials Engineering and Performance, 2014, 23: 2801-2808.
[90] ALHASHMY H A, NGANBE M. Laminate squeeze casting of carbon fiber reinforced aluminum matrix composites[J]. Materials and Design, 2015, 67: 154-158.
[91] 俞雨, 程继贵, 万磊, 等. 无压渗透法制备Al/AlN复合材料及其性能[J]. 复合材料学报, 2011, 28(6): 166-171.
[92] WANG W G, XIAO B L, MA Z Y. Evolution of interfacial nanostructures and stress states in Mg matrix composites reinforced with coated continuous carbon fibers[J]. Composites Science and Technology, 2012, 72: 152-158.
[93] MU W P, LIN J B, LIU E Q, et al. Fabrication of continuous carbon-fibers reinforced aluminum matrix composites and coating evolution during heat treatment[J]. Journal of Materials Research and Technology, 2022, 17: 1852-1867.
[94] ADABI M, AMADEH A A. Formation mechanisms of Ni-Al intermetallics during heat treatment of Ni coating on 6061 Al substrate[J]. Transactions of Nonferrous Metals Society of China, 2015, 25: 3959-3966.
[95] XU Q, HU S W, WANG W J, et al. Temperature-induced structural evolution of Sm nanoparticles on Al₂O₃ thin film: An in-situ investigation using SRPES, XPS and STM[J]. Applied Surface Science, 2018, 432: 115-120.
[96] MU W P, LIN J B, LIU E Q, et al. Fabrication and interface optimization of continuous CF/Al composites with different reinforcement volume fraction[J]. Journal of Alloys and Compounds, 2023, 938:168297.
[97] HANSEN N. Hall-Petch relation and boundary strengthening[J]. Scripta Materialia, 2004, 51: 801-806.
[98] ZHANG J J, LIU J M, LU Y P, et al. Infiltration behavior and mechanism in semi-solid rolling of carbon fibers reinforced Al-matrix composite[J]. Materials and Design, 2019, 182: 108102.
[99] HUANG Y, SU Y S, GUO X W, et al. Fabrication and thermal conductivity of copper coated graphite film/aluminum composites for effective thermal management[J]. Journal of Alloys and Compounds, 2017, 711: 22-30.
[100] 李先阳, 刘彬, 于雅琳, 等. 碳纤维复杂构件LCM成型工艺技术发展综述[J]. 复合材料科学与工程, 2023(11): 116-121.
[101] RONG X D, ZHAO D D, HE C N, et al. Revealing the strengthening and toughening mechanisms of Al-CuO composite fabricated via in-situ solid-state reaction[J]. Acta Materialia, 2021, 204:116524.
[102] NOVITSKAYA K, KARANDIKAR K, CUMMINGS K, et al. Hall-Petch effect in binary and ternary alumina/zirconia/spinel composites[J]. Journal of Materials Research and Technology, 2021, 11: 823-832.