Za a iya gyara kit ɗin mai ɗaukuwa da fiberglass/vinyl ester UV-curable ko carbon fiber/epoxy prepreg da aka adana a zafin ɗaki da kayan aikin batir mai ƙarfi.#cikin masana'antu #kayan more rayuwa
UV-curable prepreg patch gyara Ko da yake carbon fiber / epoxy prepreg gyare-gyaren da Custom Technologies LLC ya ɓullo da don infield composite gada ya zama mai sauƙi da sauri, amfani da fiber gilashin ƙarfafa UV-curable vinyl ester resin Prepreg ya haɓaka tsarin da ya fi dacewa. .Tushen hoto: Custom Technologies LLC
Gadaje masu ɗorewa suna da mahimmancin kadarori don ayyukan dabarun soja da dabaru, da kuma maido da abubuwan sufuri a lokacin bala'o'i.Ana nazarin gine-gine masu haɗaka don rage nauyin irin waɗannan gadoji, ta yadda za a rage nauyi a kan motocin sufuri da hanyoyin sake dawo da su.Idan aka kwatanta da gadoji na ƙarfe, kayan haɗin gwiwar kuma suna da yuwuwar ƙara ƙarfin ɗaukar nauyi da tsawaita rayuwar sabis.
Ƙarfafa Modular Composite Bridge (AMCB) misali ne.Seemann Composites LLC (Gulfport, Mississippi, US) da kuma Materials Sciences LLC (Horsham, PA, US) suna amfani da laminates epoxy mai ƙarfafa fiber carbon (Hoto 1).) Zane da gini).Duk da haka, ikon gyara irin waɗannan gine-gine a cikin filin ya kasance batun da ke hana ɗaukar kayan haɗin gwiwar.
Hoto 1 Composite Bridge, key infield Advanced Modular Composite Bridge (AMCB) Seemann Composites LLC da Materials Sciences LLC ne suka ƙera su kuma suka gina su ta amfani da fiber carbon fiber ƙarfafa abubuwan haɗin gwanon epoxy.Tushen hoto: Seeman Composites LLC (hagu) da Sojojin Amurka (dama).
A cikin 2016, Custom Technologies LLC (Millersville, MD, US) ta sami tallafin Binciken Ƙirƙirar Ƙirƙirar Ƙwararrun Kasuwanci (SBIR) na Sojojin Amurka na 1 don haɓaka hanyar gyarawa wanda sojoji za su iya yin nasara a kan shafin.Dangane da wannan tsarin, an ba da kashi na biyu na tallafin SBIR a cikin 2018 don nuna sabbin kayan aiki da kayan aikin batir, koda kuwa novice ne ya yi facin ba tare da horo na farko ba, 90% ko fiye na tsarin za a iya dawo da shi Raw. ƙarfi.An ƙaddamar da yiwuwar fasaha ta hanyar yin jerin bincike, zaɓin kayan aiki, samfurori na samfurori da ayyukan gwaji na inji, da ƙananan ƙananan gyare-gyare da gyare-gyare.
Babban mai bincike a cikin matakan SBIR guda biyu shine Michael Bergen, wanda ya kafa kuma shugaban Custom Technologies LLC.Bergen ya yi ritaya daga Carderock na Cibiyar Yaƙi na Naval Surface Warfare Center (NSWC) kuma ya yi aiki a Sashen Tsare-tsare da Kayayyaki na tsawon shekaru 27, inda ya gudanar da haɓakawa da aikace-aikacen fasahohin haɗin gwiwa a cikin jiragen ruwa na Amurka.Dokta Roger Crane ya shiga Fasahar Kasuwanci a cikin 2015 bayan ya yi ritaya daga Rundunar Sojan Ruwa ta Amurka a 2011 kuma ya yi aiki na shekaru 32.Ƙwararrun kayan haɗin gwiwarsa sun haɗa da wallafe-wallafen fasaha da haƙƙin mallaka, wanda ke rufe batutuwa kamar sababbin kayan haɗin gwiwa, ƙirar samfuri, hanyoyin haɗin kai, kayan haɗaɗɗun abubuwa masu yawa, kula da lafiya na tsari, da kuma dawo da kayan haɗin gwiwa.
Masanan guda biyu sun haɓaka wani tsari na musamman wanda ke amfani da kayan haɗin gwiwa don gyara ɓarna a cikin babban tsarin aluminum na Ticonderoga CG-47 class guided missile cruiser 5456. "An haɓaka tsarin don rage girman fashe da kuma zama madadin tattalin arziki. don maye gurbin kwamitin dandamali na dala miliyan 2 zuwa 4, ”in ji Bergen.“Don haka mun tabbatar da cewa mun san yadda ake yin gyare-gyare a wajen dakin gwaje-gwaje kuma a cikin yanayin aiki na gaske.Amma kalubalen shine hanyoyin kadarorin soja na yanzu ba su da nasara sosai.Zaɓin yana haɗin gyare-gyaren duplex [musamman a wuraren da suka lalace Manna allo zuwa sama] ko cire kadarar daga sabis don gyaran matakin sito (D-level).Domin ana buƙatar gyara matakin D, an ajiye kadara da yawa a gefe.”
Ya ci gaba da cewa abin da ake bukata shi ne wata hanya da sojoji da ba su da kwarewa a cikin kayan da ake hadawa za su iya yi, ta hanyar amfani da kayan aiki kawai da littattafan kulawa.Manufarmu ita ce yin tsari mai sauƙi: karanta littafin, kimanta lalacewa da yin gyare-gyare.Ba ma son haxa resins na ruwa, saboda wannan yana buƙatar ma'auni daidai don tabbatar da cikakkiyar magani.Har ila yau, muna buƙatar tsarin da ba shi da sharar gida mai haɗari bayan an gama gyarawa.Kuma dole ne a shirya shi azaman kit wanda cibiyar sadarwar da ke akwai za a iya tura shi.”
Magani ɗaya da Fasahar Kwastomomi ta nuna cikin nasara ita ce kit ɗin šaukuwa wanda ke amfani da mannen epoxy mai tauri don keɓance facin haɗaɗɗiyar manne gwargwadon girman lalacewa (har zuwa inci murabba'in 12).An kammala zanga-zangar akan kayan haɗin gwiwa da ke wakiltar bene AMCB mai kauri 3-inch.Kayan da aka haɗa yana da babban itacen balsa mai kauri 3-inch (fam 15 a kowace ƙafar ƙafa mai siffar sukari) da yadudduka biyu na Vectorply (Phoenix, Arizona, US) C -LT 1100 fiber carbon fiber 0°/90° biaxial stitched masana'anta, Layer ɗaya na C-TLX 1900 carbon fiber 0 ° / + 45 ° / -45 ° shafts uku da biyu yadudduka na C-LT 1100, jimlar biyar yadudduka."Mun yanke shawarar cewa kit ɗin za ta yi amfani da facin da aka riga aka tsara a cikin laminate quasi-isotropic mai kama da nau'in axis da yawa domin jagorancin masana'anta ba zai zama matsala ba," in ji Crane.
Batu na gaba shine matrix resin da ake amfani dashi don gyaran laminate.Don guje wa haɗuwa da guduro ruwa, facin zai yi amfani da prepreg."Duk da haka, waɗannan ƙalubalen ajiya ne," in ji Bergen.Don haɓaka maganin faci mai iya adanawa, Custom Technologies ya haɗu tare da Sunrez Corp. (El Cajon, California, Amurka) don haɓaka gilashin fiber / vinyl ester prepreg wanda zai iya amfani da hasken ultraviolet (UV) a cikin mintuna shida Hasken warkarwa.Hakanan ya haɗu da Gougeon Brothers (Bay City, Michigan, Amurka), wanda ya ba da shawarar yin amfani da sabon fim ɗin epoxy mai sassauƙa.
Nazarin farko ya nuna cewa resin epoxy shine mafi dacewa da guduro don prepregs carbon fiber-UV-curable vinyl ester da translucent gilashin fiber yana aiki da kyau, amma ba sa warkewa a ƙarƙashin fiber na toshe haske.Dangane da sabon fim ɗin Gougeon Brothers, farkon epoxy prepreg na ƙarshe yana warkewa na awa 1 a 210°F/99°C kuma yana da tsayin daka a yanayin zafin ɗaki-babu buƙatar ajiya mai ƙarancin zafi.Bergen ya ce idan ana buƙatar mafi girman zafin jiki na canji na gilashi (Tg), za a kuma warke resin a mafi girman zafin jiki, kamar 350 ° F/177 ° C.Dukansu prepregs suna bayar da su a cikin kayan gyara šaukuwa a matsayin tarin faci na prepreg da aka rufe a cikin ambulan fim na filastik.
Tun da ana iya adana kayan gyaran gyare-gyare na dogon lokaci, Ana buƙatar Fasahar Fasaha don gudanar da nazarin rayuwa."Mun sayi shingen filastik masu ƙarfi guda huɗu - nau'in soja na yau da kullun da ake amfani da su a cikin kayan sufuri - kuma mun sanya samfuran mannen epoxy da vinyl ester prepreg a cikin kowane shinge," in ji Bergen.Sannan an sanya akwatunan a wurare daban-daban guda hudu don gwaji: rufin masana'antar Gougeon Brothers da ke Michigan, rufin filin jirgin sama na Maryland, wurin da ke waje a kwarin Yucca (hamadar California), da dakin gwaje-gwajen lalata na waje a kudancin Florida.Dukkan shari'o'in suna da masu tattara bayanai, in ji Bergen, "Muna ɗaukar bayanai da samfuran kayan aiki don kimantawa kowane watanni uku.Matsakaicin zafin jiki da aka rubuta a cikin kwalaye a Florida da California shine 140 ° F, wanda ke da kyau ga mafi yawan resins maidowa.Babban kalubale ne.”Bugu da kari, Gougeon Brothers a ciki ya gwada sabon ingantaccen resin epoxy."Samfotin da aka sanya a cikin tanda a 120 ° F na watanni da yawa sun fara polymerize," in ji Bergen."Duk da haka, don samfurori masu dacewa da aka ajiye a 110 ° F, resin chemistry kawai ya inganta da ƙaramin adadi."
An tabbatar da gyaran gyare-gyare a kan allon gwaji da kuma wannan sikelin samfurin AMCB, wanda yayi amfani da laminate iri ɗaya da kayan mahimmanci kamar gada na asali da Seemann Composites ya gina.Tushen hoto: Custom Technologies LLC
Don nuna fasahar gyaran gyare-gyare, dole ne a kera laminate wakili, lalacewa da gyarawa."A cikin kashi na farko na aikin, da farko mun yi amfani da ƙananan katako na 4 x 48-inch da gwaje-gwajen lankwasa maki hudu don kimanta yiwuwar tsarin gyaran mu," in ji Klein.“Sannan, mun canza zuwa bangarori 12 x 48 a cikin kashi na biyu na aikin, mun yi amfani da kaya don haifar da yanayin damuwa na biaxial don haifar da gazawa, sannan muka kimanta aikin gyaran.A kashi na biyu, mun kuma kammala tsarin AMCB da muka gina Maintenance.”
Bergen ya ce kwamitin gwajin da aka yi amfani da shi don tabbatar da aikin gyaran an kera shi ne ta hanyar amfani da layin layi na laminates da kayan masarufi kamar yadda AMCB ke kera ta Seemann Composites, “amma mun rage kauri daga inci 0.375 zuwa inci 0.175, bisa la’akari da ka’idar axis a layi daya. .Haka lamarin yake.Hanyar, tare da ƙarin abubuwa na ka'idar katako da ka'idar laminate na gargajiya [CLT], an yi amfani da ita don haɗa lokacin rashin aiki da ingantaccen taurin AMCB mai cikakken girma tare da ƙaramin ƙaramin samfurin demo wanda ya fi sauƙin sarrafawa da ƙari. m.Sa'an nan, mu The thefinition element analysis [FEA] model ɓullo da XCraft Inc. (Boston, Massachusetts, USA) da aka yi amfani da su inganta zane na tsarin gyara."An siyi masana'anta na fiber carbon da aka yi amfani da su don gwaje-gwajen gwaje-gwaje da samfurin AMCB daga Vectorply, kuma an samar da balsa core ta Core Composites (Bristol, RI, US).
Mataki na 1. Wannan rukunin gwajin yana nuna diamita na rami inch 3 don yin kwatankwacin lalacewa da aka yiwa alama a tsakiya da gyara kewaye.Tushen hoto don duk matakai: Custom Technologies LLC.
Mataki 2. Yi amfani da injin niƙa mai ƙarfin baturi don cire abubuwan da suka lalace kuma a haɗa facin gyare-gyare tare da taper 12:1.
"Muna so mu kwaikwayi girman lalacewa a kan allon gwajin fiye da yadda ake iya gani a kan gada a filin," in ji Bergen.“Don haka hanyarmu ita ce mu yi amfani da tsintsiya madaurinki guda don yin rami mai tsawon inci 3.Sa'an nan kuma, za mu ciro filogi na kayan da suka lalace kuma mu yi amfani da injin niƙa mai ɗaukar hoto don sarrafa gyale na 12:1."
Crane ya bayyana cewa don gyaran carbon fiber / epoxy, da zarar an cire kayan panel "lalacewa" kuma an yi amfani da gyale mai dacewa, za a yanke prepreg zuwa fadi da tsayi don dacewa da taper na yankin da ya lalace."Ga kwamitin gwajin mu, wannan yana buƙatar nau'ikan prepreg guda huɗu don kiyaye kayan gyara daidai da saman babban rukunin carbon ɗin da bai lalace ba.Bayan haka, nau'ikan rufewa guda uku na carbon/epoxy prepreg suna mai da hankali akan wannan akan sashin da aka gyara.Kowane Layer na gaba yana ƙara inch 1 a kowane gefen ƙananan Layer, wanda ke ba da jigilar kaya a hankali daga kayan "mai kyau" kewaye zuwa wurin da aka gyara.Jimlar lokacin yin wannan gyaran-ciki har da shirye-shiryen yankin gyarawa, Yankewa da ajiye kayan maidowa da amfani da hanyar warkewa-kimanin awanni 2.5.
Don carbon fiber/epoxy prepreg, wurin gyarawa yana cike da bushewa kuma an warke shi a 210°F/99°C na awa ɗaya ta amfani da maɗaurin zafi mai ƙarfin baturi.
Kodayake gyaran carbon / epoxy yana da sauƙi kuma mai sauri, ƙungiyar ta gane buƙatar mafi dacewa bayani don mayar da aikin.Wannan ya haifar da binciken ultraviolet (UV) curing prepregs."Sha'awar Sunrez vinyl ester resins ya dogara ne akan kwarewar sojan ruwa da ta gabata tare da wanda ya kafa kamfanin Mark Livesay," Bergen ya bayyana."Mun fara samar wa Sunrez wani masana'anta na gilashin isotropic, ta amfani da vinyl ester prepreg, kuma mun kimanta yanayin warkewa a ƙarƙashin yanayi daban-daban.Bugu da ƙari, saboda mun san cewa resin vinyl ester ba kamar resin epoxy ba ne wanda ke ba da aikin mannewa na biyu da ya dace, don haka ana buƙatar ƙarin ƙoƙarce-ƙoƙarce don kimanta nau'ikan haɗin haɗin gwiwar manne da kuma tantance wanda ya dace da aikace-aikacen.
Wata matsala kuma ita ce filayen gilashin ba za su iya samar da kayan aikin injiniya iri ɗaya kamar filayen carbon ba."Idan aka kwatanta da carbon / epoxy patch, ana magance wannan matsala ta hanyar amfani da karin gilashin gilashi / vinyl ester," in ji Crane."Dalilin da yasa ake buƙatar ƙarin Layer ɗaya kawai shine kayan gilashin ya zama masana'anta mafi nauyi."Wannan yana samar da facin da ya dace wanda za'a iya shafa shi kuma a haɗa shi cikin mintuna shida har ma a cikin yanayin sanyi/daskarewa sosai.Warkewa ba tare da samar da zafi ba.Crane ya nuna cewa ana iya kammala wannan aikin gyaran cikin sa'a guda.
Dukkanin tsarin facin an nuna su kuma an gwada su.Ga kowane gyare-gyare, wurin da za a lalace yana da alama (mataki na 1), an ƙirƙira shi da rami, sannan a cire shi ta amfani da injin niƙa mai ƙarfin baturi (mataki na 2).Sa'an nan kuma yanke wurin da aka gyara zuwa 12: 1 taper.Tsaftace saman gyale tare da kushin barasa (mataki na 3).Na gaba, yanke gyare-gyaren gyaran gyare-gyare zuwa wani girman girman, sanya shi a kan tsabtaccen tsabta (mataki na 4) kuma haɗa shi da abin nadi don cire kumfa na iska.Don gilashin fiber / UV-curing vinyl ester prepreg, sa'an nan kuma sanya Layer saki a kan yankin da aka gyara kuma a yi maganin facin tare da fitilar UV maras igiya na minti shida (mataki 5).Don prepreg carbon fiber/epoxy prepreg, yi amfani da riga-kafi, maɓalli ɗaya, maɓalli ɗaya, mai ƙarfin baturi zuwa fakitin injin da kuma warkar da wurin da aka gyara a 210°F/99°C na awa ɗaya.
Mataki 5. Bayan sanya bawon bawon a kan yankin da aka gyara, yi amfani da fitilar UV mara igiya don warkar da facin na tsawon mintuna 6.
"Sa'an nan kuma mun gudanar da gwaje-gwaje don kimanta mannewa na faci da kuma ikonsa na mayar da nauyin nauyin tsarin," in ji Bergen."A matakin farko, muna buƙatar tabbatar da sauƙin aikace-aikacen da kuma ikon dawo da aƙalla 75% na ƙarfin.Ana yin wannan ta hanyar lanƙwasa maki huɗu akan 4 x 48 inch carbon fiber / epoxy resin da balsa core beam bayan gyara lalacewar da aka kwaikwayi.Ee.Kashi na biyu na aikin ya yi amfani da panel 12 x 48 inch, kuma dole ne ya nuna fiye da 90% buƙatun ƙarfin ƙarfi a ƙarƙashin ƙayyadaddun nauyin nauyi.Mun cika duk waɗannan buƙatun, sa'an nan kuma mun ɗauki hotunan hanyoyin gyara akan tsarin AMCB.Yadda ake amfani da fasahar infield da kayan aiki don samar da tunani na gani."
Wani muhimmin al'amari na aikin shine tabbatar da cewa novices na iya kammala gyara cikin sauƙi.Saboda wannan dalili, Bergen yana da ra'ayi: "Na yi alkawari zan nuna wa abokan hulɗarmu na fasaha guda biyu a cikin Sojoji: Dr. Bernard Sia da Ashley Genna.A cikin bita na ƙarshe na kashi na farko na aikin, na nemi ba a gyara ba.Shahararren Ashley ya yi gyaran.Ta yi amfani da kit da littafin da muka tanadar, ta shafa facin ta kammala gyaran ba tare da wata matsala ba.”
Hoto 2 Na'ura mai sarrafa baturi da aka riga aka tsara, na'ura mai haɗawa da batir na iya warkar da facin carbon fiber/epoxy gyara maɓalli, ba tare da buƙatar ilimin gyarawa ko shirye-shiryen sake zagayowar ba.Tushen hoto: Custom Technologies, LLC
Wani ci gaba mai mahimmanci shine tsarin warkarwa mai ƙarfin baturi (Hoto 2)."Ta hanyar kula da infield, kuna da ƙarfin baturi kawai," in ji Bergen."Duk kayan aikin da ke cikin kayan gyaran da muka ɓullo da su mara waya ne."Wannan ya haɗa da haɗin wutar lantarki mai ƙarfin baturi wanda aka haɓaka tare ta Custom Technologies da na'ura mai ba da kayan haɗin kai na WichiTech Industries Inc. (Randallstown, Maryland, Amurka).Crane ya ce "An riga an shirya wannan haɗin wutar lantarki mai ƙarfin baturi don kammala warkewa, don haka novice ba sa buƙatar shirin sake zagayowar waraka," in ji Crane."Suna buƙatar kawai danna maɓalli don kammala matakan da ya dace kuma su jiƙa."Batirin da ake amfani da su a halin yanzu na iya ɗaukar tsawon shekara guda kafin a yi musu caji.
Tare da kammala kashi na biyu na aikin, Custom Technologies yana shirya shawarwarin ingantawa da kuma tattara wasiƙun sha'awa da tallafi."Manufarmu ita ce girma wannan fasaha zuwa TRL 8 kuma mu kawo shi a filin," in ji Bergen."Muna kuma ganin yuwuwar aikace-aikacen da ba na soja ba."
Ya bayyana tsohuwar fasaha a bayan masana'antar ƙarfafa fiber na farko, kuma yana da zurfin fahimtar sabon kimiyyar fiber da ci gaban gaba.
Ana zuwa nan ba da jimawa ba kuma ya tashi a karon farko, 787 ya dogara da sabbin abubuwa a cikin abubuwan da aka haɗa da matakai don cimma burin sa.
Lokacin aikawa: Satumba-02-2021