Micromechanical FE analysis on thermal residual stress and shrinkage behavior of 2.5D woven Cf/Al composites
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摘要: 采用细观力学数值模拟与热性能实验结合的方法，研究2.5D机织Cf/Al复合材料降温热变形行为和热残余应力分布。根据解析法计算的纱线轴/横向热膨胀性能和纱线空间分布结构，建立复合材料细观力学有限元模型，计算得到的宏观热应变-温度曲线与热变形实验曲线吻合较好。复合材料制备后经纱和纬纱主要处于残余压应力状态，且纬纱表现出较高的残余应力水平；基体合金则主要处于残余拉应力状态，最大拉应力出现在经纱界面处并导致经纱与纬纱之间的区域出现局部界面脱粘，降低热残余应力是改善复合材料力学性能的重要技术手段。Abstract: 2.5D woven Cf/Al composites were fabricated by vacuum-assisted pressure infiltration method. Thermal shrinkage behavior and residual stress of the composites were investigated using micromechanical analysis and experimental method. The thermal expansion properties of yarn along longitudinal and transverse direction were evaluated by analytical method. Based on the yarn’s structural characteristic, the micromechanical finite element models of composites were established. The calculated macroscopic thermal strain-temperature curve from micromechanical simulation agrees well with the thermal shrinkage curve from the experiments. The simulation results indicate that the warp and weft yarns are in compressive stress state, and the residual stress on weft yarns are higher than that on the warp yarns. However, the matrix alloy is mainly in tensile stress state, and the maximum tensile stress occurs in the matrix alloy near warp yarn’s surface. The over high residual stress between the warp and weft yarns lead to local interface debonding. It is an important technical approach to reduce the residual stress in order to improve the mechanical properties of composites.
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Key words:
- 2.5D woven /
- Cf/Al composites /
- residual stress /
- micromechanics /
- finite element analysis
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图 1 2.5D机织物和2.5D机织Cf/Al复合材料板材 （a）2.5D织物形貌；（b）2.5D机织结构；（c）2.5D机织复合材料板材
Figure 1. 2.5D fabric structure and 2.5D woven Cf/Al composite plate (a)2.5D fabric morphology； (b)2.5D woven structure； (c)2.5D woven composite plate
图 2 2.5D机织Cf/Al复合材料纱线显微结构 （a）纬纱和衬纬纱截面形态；（b）经纱截面形态；（c）纱线内部微观组织
Figure 2. Microstructures of yarns in the 2.5D Cf/Al composites (a)section shape of weft and liner yarn； (b)section shape of warp yarn； (c)microstructure of fiber bundle(SEM)
图 5 2.5D机织Cf/Al复合材料经向热应变实验曲线
Figure 5. Thermal strain experimental curve of warp direction in CF/Al composites
图 6 2.5D机织Cf/Al复合材料制备降温热应变-温度实验曲线与计算曲线
Figure 6. Experimental and calculated curves of thermal strain- temperature during the cooling process of 2.5D woven Cf/Al composites
图 7 热收缩应变量实验与计算值的相关性
Figure 7. Correlation coefficient between experimental and calculated values of thermal shrinkage strain variables
图 8 2.5D机织Cf/Al复合材料的残余应力测试结果（X射线衍射法）
Figure 8. Residual stress on 2.5D woven Cf/Al composites measured by X-ray diffraction method
图 9 2.5D机织Cf/Al复合材料热残余应力分布数值模拟结果 （a）复合材料；（b）基体合金；（c）纱线； （1）等效拉应力； （2）等效压应力
Figure 9. Numerical simulation results distribution of residual stress in composites (a)composites； (b)matrix alloy； (c) yarn； (1)equivalent residual tensile stress； (2)equivalent residual compressive stress
图 10 2.5D机织Cf/Al复合材料组元结构损伤状态模拟结果 （a）纱线状态； （b）基体状态； （c）界面状态； （d）界面脱粘；（e）界面微裂纹(TEM)
Figure 10. Simulation results of failure state of structure in 2.5 D woven Cf/Al composites (a)status of yarn； (b)status of matrix ；(c)status of interface ；(d)interface debonding ；(e)interfacial microcrack (TEM)
表 1 2.5D机织结构参数
Table 1. Structural parameters of the 2.5D woven fabric
Warp/Weft yarn
specificationLiner weft
specificationWarp density/
(bundle•10 mm–1)Weft density/
(bundle•10 mm–1)Fiber volume
fraction/%225 tex×2 225 tex×1 8.0 4.0 42 
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表 2 碳纤维M40J基本性能参数
Table 2. Primary properties of carbon fiber M40J
E1/GPa E2/GPa ν12 ν22 G12/GPa G22/GPa α1/10–6K－1 α2/10–6K－1 377 19 0.26 0.3 8.9 7.3 2 8
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表 3 铝合金ZL301的化学成分(质量分数/%)
Table 3. Chemical composition of the aluminum alloy ZL301 (mass fraction/%)
Mg Si Cu Mn Ti Al Others 9.5-11.0 0.3 0.1 0.15 0.15 Bal —
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表 4 细观力学模型中纱线的弹性性能参数
Table 4. Elastic constants of yarns in micromechanical model
E11/MPa E22=E33/MPa G12=G13/MPa G23/MPa ν12=ν13 ν23 302700 23500 14700 10000 0.28 0.41
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表 5 纱线的轴向和横向线性热膨胀系数计算结果
Table 5. Calculated results of linear transverse direction thermal expansion coefficient in yarn’s longitudinal
Temperature/℃ αL/10–6K–1 αT/10–6K–1 25 3.11 9.94 100 3.03 10.28 200 2.94 10.39 300 2.82 10.53 400 2.68 10.78
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