Analysis of effect of construction process on electrical properties of composite skins
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摘要:
新型商用飞机蒙皮中复合材料的占比越来越高，然而较差的导电性使其需要额外的导电结构实现电流在蒙皮内的流通。为提高蒙皮导电能力，降低复合材料与导电结构的搭接对电流通路的影响，基于各组成结构的电气特性对蒙皮结构进行建模，并利用解析方法分析搭接时可能产生影响的施工工艺。针对蒙皮不同部位各自处理工艺带来的接触面间的电流与整体结构阻抗的变化，分析各结构在装配过程中的施工工艺对飞机蒙皮搭接结构电气特性的影响情况。理论分析与仿真计算结果表明：正确的施工工艺处理方法，尤其是对蒙皮表面树脂与金属连接件氧化膜恰当的处理程度，能够有效减小整体结构阻抗对蒙皮电气性能的影响，并能够为面向现场的施工提供一定的操作建议。
Abstract:Composite materials are increasingly used in modern commercial aircraft skin. However, the poor conductivity makes it necessary to have additional conductive structures to ensure the current flow in the skin. In order to improve the conductivity of the skin and reduce the influence of the bonding between the composite material and the conductive structure on the current path, the skin structure was modeled based on the electrical characteristics of each component structure, and the construction process that may affect the bonding was analyzed by using the analytical method. In view of the changes in the current in the contact surfaces and the overall structural impedance caused by different construction processes applied at different parts of the skin, the influence of the construction process of each structure during assembly on the electrical characteristics of the aircraft skin bonding structure was analyzed. Theoretical analysis and simulation results show that the appropriate construction process, especially the correct treatment of the resin and oxide film of metal connection on the skin surface, can effectively reduce the influence of overall structural impedance on the electrical performance of the skin and provide some operational suggestions in site-oriented construction.
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Key words:
- aircraft skin /
- composite material /
- bonding structure /
- construction process /
- electrical performance
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图 1 蒙皮搭接结构示意图
1. 螺栓；2. 凹型垫圈；3. 树脂；4. 延展金属箔；5. CFRP；6. 金属氧化膜；7. 金属连接件。
Figure 1. Schematic of skin bonding structure
图 3 导电溶液处理后接触面示意图
Figure 3. Schematic of contact surface after using conductive solution
图 6 树脂-延展金属铜箔接触面电流密度分布
Figure 6. Current density distribution on resin-extended meta copper foil contact surface
图 7 延展金属铜箔上表面电流密度变化趋势
Figure 7. Variation trend of current density on upper surface of extended metal copper foil
图 9 碱洗氧化膜对结构阻抗的影响
Figure 9. Influence of oxide film after alkali wash on structural impedance
图 10 阿洛丁处理程度对结构阻抗的影响
Figure 10. Influence of alodine treatment on structural impedance
图 11 氧化膜接触面电流密度分布
Figure 11. Current density distribution on contact surface of metal oxide film
图 12 阿洛丁处理对氧化膜表面电流密度的影响
Figure 12. Influence of alodine treatment on surface current density of oxide film
表 1 螺栓与凹形垫圈的尺寸
Table 1. Dimensions of bolts and concave washers
mm 结构 参数 沉头螺栓总长度 18 沉头螺栓螺杆直径 6.4 沉头螺栓头直径 9 沉头螺栓头厚度 0.5 凹形垫圈高度 2.2 凹形垫圈内径 6.45 凹形垫圈外径 19 凹形垫圈厚度 0.4 
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表 2 各结构件材质及电磁参数
Table 2. Material and electromagnetic parameters of each component
部件名称 材质 电导率/（S·m−1） 延展金属箔 铜 5.998×107 CFRP 碳纤维复合材料 1.5×104 金属氧化膜 氧化铝 0.01 金属连接件 铝 3.03×107 沉头螺栓 钢 4.032×106 凹形垫圈 钛 2.38×106
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