- 中国科学引文数据库(CSCD)核心期刊
- 中国核心期刊
- 文摘与引文数据库(Scopus)
- 剑桥科学文摘(CSA)
- 英国INSPEC数据库
High-performance thermoplastic resin-based composites have shown broad application prospects in the aviation manufacturing technology due to their excellent mechanical properties, environmental resistance, chemical resistance, recyclability, and rapid molding. In recent years, with the accelerated commercialization of high-performance thermoplastic resins such as polyphenylene sulfide（PPS）, polyetherimide（PEI）, and polyaryletherketone（PAEK）, the related prepregs and molding technologies have been continuously optimized, promoting the industrial application of such materials. This paper systematically reviews the current development status of high-performance thermoplastic resin-based composites, focusing on their material systems and commercialization progress, prepreg preparation, advanced manufacturing technology and application. It proposes key development directions for high-performance thermoplastic resin matrix composites, in order to provide reference for personnel in engineering and technical fields such as aerospace, and promote the innovative development and application of high-performance thermoplastic resin matrix composites.
Thermoplastic composites（TPCs）have exhibited immense potential in aerospace applications, attributed to their exceptional toughness, weldability, recyclability, and efficient processing cycles. However, the manufacturing of complex structures is hindered by the high melting points and viscosities of their constituent resins. Resistance welding, leveraging Joule heating to induce interfacial melting and bonding, emerges as a viable alternative to mechanical fastening and adhesive bonding. This review delves into the fundamental principles underlying resistance welding, strategies for optimizing key process parameters, recent advancements in heating elements, and large-scale welding techniques, such as sequential and continuous resistance welding. The findings indicate that optimizing process parameters and improving heating elements can significantly enhance joint strength. To achieve engineering application of resistance welding technology, further research should be focused on process stability, reliability of welded joints, large-scale welding, and other issues.
: Poly（aryl ether ketone）（PAEK） thermoplastic composites exhibit exceptional impact resistance and possess significant application potential in the aerospace industry. To address mechanical performance limitations of PAEK composites fabricated through automated in-situ placement, this study systematically investigates the impacts of post-processing parameters-including temperature, pressure and time-on pore elimination and mechanical properties. Utilizing the automated fiber placement, PAEK prepregs are processed into laminates. A viscosity-pressure-time coupling model is formulated through differential scanning calorimetry（DSC）, rheological assessments and mechanical characterizations. The results demonstrate the model predicts reasonably pore elimination across varying process parameters and the critical post-processing temperature is identified as 340 ℃. The pore elimination is facilitated rapidly due to low and stable resin viscosity at 340-360 ℃. The post-processing pressure significantly influences pore removal efficiency, with a critical pressure of 0.7 MPa at 360 ℃ and requiring 60 min for complete pore elimination. Higher pressures lead to only marginal performance enhancements. The time dependency of material performance depends on pressure: at 0.7 MPa and 360 ℃, full pore elimination is achieved within 60 min, whereas at 1.6 MPa, the required time is reduced to 20 min. At 0.7 MPa, 360 ℃ and 60 min, the tensile strength, flexural strength and interlaminar shear strength are 2844, 1653 MPa and 103 MPa, respectively.
To address the challenge of inconsistent forming quality observed in carbon fiber-reinforced polyaryl ether ketone（CF/PAEK）composites during in-situ automated fiber placement（AFP）, this study introduces a vacuum-assisted in-situ annealing（VIA）process implemented subsequent to layup. The study systematically examines the impact of VIA parameters—specifically annealing temperature and holding time—on various aspects of CF/PAEK unidirectional laminates, including temperature field uniformity, warpage deformation, porosity, crystallinity, and interlaminar properties. Experimental findings reveal that the VIA process facilitates a uniform temperature field, mitigates crystallinity gradients, and progressively diminishes warpage deformation with an increase in annealing temperature, ultimately achieving complete elimination of warpage. Notably, when the annealing temperature surpasses the resin melting point, internal pores formed during the CF/PAEK prepreg or AFP process undergo substantial reduction, resulting in a porosity level of merely 2%. Furthermore, the interlaminar performance exhibits a remarkable enhancement, with an interlaminar shear strength（ILSS）of 64.66 MPa—representing a 58.6% improvement compared to specimens that have not undergone VIA treatment.
This study investigates the performance evolution of T800/polyaryletherketone（PAEK） thermoplastic composites subjected to hygrothermal aging conditions. By meticulously controlling the cooling rate, two distinct types of carbon fiber-reinforced PAEK composites with varying crystallinities are prepared: CF/PAEK-CL（low crystallinity） and CF/PAEK-CH（high crystallinity）. These composites are then systematically examined for their moisture absorption behavior, thermal properties, and mechanical performance in hygrothermal environments. Experimental results reveal that the water absorption of CF/PAEK composites increases progressively over time, with CF/PAEK-CL exhibiting a notably higher moisture uptake rate due to its lower crystallinity. Following hygrothermal aging, the glass transition temperature（Tg） of all samples decreases, with CF/PAEK-CL experiencing a specific reduction of approximately 5%. Thermal analysis further indicates that hygrothermal aging has a negligible impact on the crystallinity of the materials, and notably, the high-crystallinity composite demonstrates superior thermal stability in such environments. Flexural testing results demonstrate that hygrothermal aging has a limited influence on the flexural strength and modulus of CF/PAEK composites, underscoring their robust resistance to the detrimental effects of hygrothermal conditions on flexural mechanical properties. This resilience ensures their long-term stability and reliability in harsh environments. The findings of this study offer pivotal data and theoretical insights, paving the way for the application of CF/PAEK composites in demanding service conditions.
Carbon fiber reinforced thermoplastic composite（CFRTP） is increasingly utilized in aerospace and automotive manufacturing sectors owing to its exceptional specific strength, strong toughness, and weldability. Induction welding stands as a pivotal method for fabricating typical CFRTP components. However, the intricate interplay of magnetic, thermal, and stress coupling during the induction welding process, along with its evolution and distribution characteristics, remains unclear, significantly impeding the cost-effective, efficient, and high-quality production of CFRTP components. In this study, a magnetic-thermal-mechanical coupling simulation model is developed for the induction welding of CFRTP stringer skin structures. This model is employed to investigate the distribution and evolution patterns of the magnetic field, temperature field, and residual stress field. The results show that under the influence of an alternating electromagnetic field, the magnetic field strength peaked at 1.45 mT in the component’s edge region. Notably, the simulated magnetic, temperature, and stress field all exhibit significant edge effects, which are intimately tied to the skin effect induced by high-frequency eddy currents. During welding, asymmetric and nearly elliptical high-temperature zones emerge on both sides of the skin’s bottom, with temperatures in proximity to the stringer area notably higher than those farther away. When the current frequency increases from 150 kHz to 250 kHz, the maximum stress of the induction joint increases from 637 MPa to 778 MPa, and the asymmetric stress concentration area at the welding interface expands accordingly. The measured temperature field and stress results are in high agreement with the simulation outcomes, effectively validating the model’s accuracy and applicability. This study offers theoretical backing for process optimization and quality control in the induction welding of intricate CFRTP components.
The resistance welding process of 7075 aluminum alloy（7075AA） and carbon fiber reinforced polyether ether ketone（CF/PEEK） is optimized through the activation of the aluminum alloy surface and its subsequent integration with a thermoplastic layer. A microgroove network is fabricated on the aluminum alloy surface using laser treatment, which notably augmented the mechanical coupling with the polyetherimide（PEI） thermoplastic layer. In contrast, the bonding effectiveness of sandblasted and untreated samples are inferior. Surface analysis conducted via Fourier transform infrared spectroscopy（FT-IR） and X-ray photoelectron spectroscopy（XPS） reveal the formation of Al—O—Si bonds and a silane coupling film transition layer, both of which fortified the interface. In the resistance welded joints, incomplete bonding between the sandblasted/laser-etched aluminum alloy and the PEI layer lead to debonding of the thermoplastic layer, which emerge as the predominant failure mode. The single lap shear strength（LSS） of the sandblasted joint is 10.47 MPa, whereas the LSS of the laser-etched joint attains 15.35 MPa. Following silane treatment, the bonding of the PEI thermoplastic layer is markedly enhanced, resulting in an LSS of 19.03 MPa for the laser-etched and silane-treated joint—a 23.97% increase compared to simple laser etching. At this juncture, the cross-section of the joint exhibites characteristics indicative of heating element fracture, with the failure mode transitioning to interlayer fracture.
The machine learning technology has broad prospects in the field of aerospace materials and plays an important role in material selection, design, and optimization. Firstly, a brief discussion was made on the advantages and potential of machine learning technology in the aerospace field, outlining the technological developments, algorithm categories, features, and limitations. The conventional or potential applications of machine learning in scientific exploration, especially in complex material data formats, are introduced. Secondly, the research status of machine learning in aviation materials is mainly focused on, discussing the recent progress in utilizing machine learning to assist in the research of high-temperature alloy materials, high-strength structural materials, thermal protection coating materials, as well as functional and smart materials. The strategies and methods of machine learning-driven aviation material research are elucidated. Finally, the challenges encountered in machine learning-assisted aerospace material research and development are examined. Facilitating the transformation of aerospace material research towards the fourth paradigm of data-driven materials science necessitates efforts in promoting the open sharing of data resources, integrating domain knowledge and physical laws more deeply into machine learning models, and ensuring feature consistency across different data types.
With advancements in material technology, a surge in research and development has been witnessed for various high-performance materials, including metamaterials, each possessing unique functionalities. However, meeting the demands of high performance has rendered the application of a single material insufficient for achieving the required interface mechanical and functional integration properties. Functionally gradient composite materials have emerged as a pivotal breakthrough to address this issue. This paper introduces the application background, as well as the research and application status of functionally gradient composite materials in foreign countries. Furthermore, based on the prevalent issues in the domestic engineering field concerning functionally gradient composite materials, the challenges faced in their utilization are highlighted. When compared to international advanced levels, the development of functionally gradient composite materials in China encounters three major hurdles. Firstly, the preparation process remains relatively underdeveloped, impeding large-scale engineering applications. Secondly, due to the scarcity of performance evaluation methods, there is an urgent necessity to establish a coupled functional evaluation system. Thirdly, there is a scarcity of proprietary intellectual property rights pertaining to material design and simulation methods, coupled with the absence of a comprehensive database. Consequently, material design still largely relies on the experience of designers. Lastly, suggestions for the future application and development of functionally gradient composite materials are proposed.
This article provides an overview of the latest research status and application prospects of titanium/titanium alloy composite materials, highlighting their advantages in high specific strength, lightweight properties, thermal stability, and wear resistance, which position them as crucial materials in high-tech sectors such as aerospace, military equipment, and medicine. It summarizes research outcomes demonstrating the steady enhancement of mechanical properties, wear resistance, and thermal stability of titanium matrix composites through the addition of reinforcing phases. The review also reveals advancements in various processing technologies that have improved the grain structure and performance of these composites, while pointing out that challenges persist regarding the stability of these materials under high temperature and pressure conditions, as well as the bonding strength at interfaces. These issues necessitate the optimization of reinforcement distribution, bonding methods, and the exploration of novel composite systems. Furthermore, the combination of surface nanotechnology with digital simulation offers new avenues for optimizing the properties of titanium-based composites. Interface reinforcement and thermal stability research are identified as pivotal for future developments. Ultimately, the essay underscores that the enhancement of titanium-based composite properties and innovations in processing technologies are central to realizing their extensive application in extreme environments. This dual focus also constitutes the direction for pushing the boundaries of composite material performance even further.
Titanium alloys are widely used in the fields of aviation, aerospace and marine due to their excellent strength, weldability and plasticity. This study focuses on a near-α titanium alloy Ti-6.5Al-2Zr-Mo-V（TA15）, fabricated by selective laser melting（SLM） technology. The impact of laser scanning speed on the macroscopic morphology and microstructure of the TA15 alloy is investigated using a range of analytical methods such as confocal laser scanning microscopy（CLSM）, optical microscopy（OM）, scanning electron microscopy（SEM）, X-ray diffraction（XRD） and energy dispersive spectroscopy（EDS）. The results show that variations in laser scanning speed significantly influence the forming quality of the alloy. Specifically, higher scanning speeds induce discontinuous fluctuations in the melt pool and irregular surface undulations, whereas lower speeds promote porosity formation at the cross-section. Initially, an increase in laser scanning speed enlarges the size of the martensite structure, followed by a decrease, accompanied by a gradual reduction in martensite hierarchy. Low or high laser scanning speeds cause local cracks on the alloy surface, where elemental depletion and enrichment are observed. These findings demonstrate a direct correlation between laser scanning speed and alloy forming quality. These results provide valuable insights for optimizing the process parameters and strategies of SLM for TA15 alloy, thereby facilitating its further promotion and application.
The mechanical properties and thermodynamic stability of nickel-based single-crystal superalloys are largely dependent on the charateristics of the precipitated phase interface. In this work, density functional theory（DFT）is utilized to investigate the influence of alloying elements, specially Co, Cr, Mo, W, Re and Ta, on the mechanical properties of γ-Ni/γ′-Ni3Al interface. Following a convergence analysis to the optimal computational model, our findings reveal that Re and W exhibit the most significant strengthening effects within both the γ and γ′ phases. Notably, Re stands out for its substantial enhancement of Young’s modulus（27 GPa and 11 GPa）and shear modulus（16 GPa and 6 GPa） in the γ and γ′ phases, respectively, while Ta demonstrates a unique proficiency in augmenting the bulk modulus of 21 GPa and 14 GPa in the γ and γ′ phases, respectively. Analysis of interfacial tensile properties indicates that the Re-doped system exhibit the highest ideal tensile strength（approximately 25 GPa）and deformation energy（approximately 1.84 J·m−2）. Furthermore, the strengthening impact of alloying elements on interface tensile properties diminishes in the order: Re＞W＞Cr＞Mo＞Ta＞Co＞undoped. Analyses of differential charge density and density of states reveal that the strengthening mechanisms of theses alloying elements are attributable to the augmentation in the chemical bonding strength between doped atoms and their nearest-neighbouring host atoms. Electron orbital characteristics indicate that these alloying elements contribute to retarding interfacial fracture by maintaining local structural stability. A series of results provide ideas for the development of novel nickel-based single-crystal superalloys.
The tribological properties and wear mechanisms of PTFE filled with graphene at mass fractions of 0.5%, 1%, 3%, 5%, and 7% are investigated, and these are compared with those of PTFE filled with the traditional modifier MoS2 at mass fractions ranging from 5% to 25%（in increments of 5%）. Additionally, a synergistic modification of PTFE with a combination of "graphene+MoS2" is conducted, focusing specifically on the tribological properties and wear mechanisms of composites containing MoS2 at a mass fraction of 15% combined with graphene at mass fractions of 1%, 3%, and 5%. The findings reveal that the incorporation of graphene significantly enhances the tribological performance of PTFE and its composites. Notably, the optimal tribological properties are observed when graphene is present at a mass fraction of 5%, exhibiting an average friction coefficient of 0.0763 and a volumetric wear rate of 230.34×10−9 mm3·N−1·m−1. The predominant wear mode shifts from adhesive wear to fatigue wear under these conditions. When graphene is used in conjunction with MoS2 for synergistic modification, it effectively addresses the issue of poor compatibility between MoS2 and PTFE, mitigating the tendency of MoS2 to be worn away and causing abrasive wear during friction.
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