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2021 Vol. 64, No. 19
Published: 2021-10-01
FEATURE
FORUM
RESEARCH
C0NTENTS
COVER STORY
APPROACHING SCIENCE
 
       COVER STORY
1 COVER
2021 Vol. 64 (19): 1-1 [Abstract] ( 125 ) HTMLNew PDF (1213 KB)  ( 65 )
       C0NTENTS
6 CONTENTS
2021 Vol. 64 (19): 6- [Abstract] ( 88 ) HTMLNew PDF (1241 KB)  ( 61 )
       FEATURE
14 Experimental Investigation on Milling Characteristic of CFRP Composites Under Supercritical Carbon Dioxide Based Cryogenic Environment
ZOU Fan，WANG Xianfeng， ZHANG Hongzhou，AN Qinglon
DOI: 10.16080/j.issn1671-833x.2021.19.014
Carbon fiber reinforced polymer (CFRP) has been widely used in aerospace field because of its excellent material performance. Because of its heterogeneity, anisotropy and high temperature-sensitivity, machining defects is prone to occur. In this work, the milling experiments of T800/X850 carbon fiber composite laminates, which are commonly used in aviation industry, were carried out to investigate the feasibility of supercritical carbon dioxide based cryogenic cooling method in CFRP composites machining. The results show that cryogenic environment can significantly reduce the cutting temperature and improve the surface quality compared with dry environment. Meanwhile, the bending moment of cutting process under cryogenic environment is higher than that under dry environment. The combination of high cutting speed,low feed rate and cryogenic environment is helpful to improve the machining quality and efficiency of CFRP composite.
2021 Vol. 64 (19): 14-19 [Abstract] ( 194 ) HTMLNew PDF (6882 KB)  ( 152 )
       COVER STORY
20 Practice of Electrical System Testing for Aircraft System Integration in Aircraft Assembly Stage
YE Bo, LI Tao, ZHANG Shijiong, LUO Xin, XIONG Hongrui
DOI: 10.16080/j.issn1671-833x.2021.19.020
With the rapid improving of modern aircraft system integration, deeply cross-linking between systems, the function of a single system needs the cooperation of multiple systems, which challenges whether the ground test on aircraft can effectively verify the product’s function in aircraft assembly stage. In the face of highly integrated aircraft systems, how to decouple the cross-linking relationship at different levels of aircraft design in manufacturing stage is the key to establish the effective verification of product function in the ground test on aircraft. By referring to the principles and tools of system engineering (SE), it is established that the internal inheritance relationship between aircraft product design and ground test process design in aircraft assembly stage, which can effectively identify and decouple the internal cross-linking relationship of products. And the cross-linking relationship shows the requirements of hardware-in-the-loop simulation for ground test on aircraft in aircraft assembly stage. Based on these, the general method framework of decoupling “V” model of ground test on aircraft is formed. The initial application of the method showed that the electrical system test simulation requirements are effectively analyzed, and combined with the environment characteristics in aircraft assembly stage, it formed the corresponding test facilities for electrical system.
2021 Vol. 64 (19): 20-26 [Abstract] ( 172 ) HTMLNew PDF (1042 KB)  ( 393 )
       FORUM
30 Experimental and Numerical Analysis of Coverage of TC4 Titanium Alloy by Ultrasonic Shot Peening
CAI Jin, XIE Guang’an, YAN Xue, LI Wei
DOI: 10.16080/j.issn1671-833x.2021.19.030
To explore the influence of ultrasonic shot peening process parameters (spheres number, spheres diameter) on the surface coverage of components, based on ABAQUS/Explicit, combined with ultrasonic shot peening experiment, a three-dimensional finite element model of ultrasonic shot peening (chamber geometry model, batch spheres model, vibration system, Johnson–Cook material constitutive model) is established. Six groups of models are established around two process parameters and ultrasonic shot peening time. The image J coverage image analysis of the equivalent strain field on the surface of component is combined to realize the establishment of the ultrasonic shot peening surface coverage prediction system. The coverage of the 100, 150 and 200 spheres models in 10s are 16.6%, 36.2% and 48.1% respectively. The coverage of the 0.5mm, 1mm and 2.5mm diameter spheres models at 10s are 0, 8.1% and 16.6% respectively. The errors between the experimental value and the simulated value of the spheres number and diameter variables are 7.5% and 9.2%, which are both less than 10%. The results show that the increase in the number and diameter of spheres can increase the surface coverage. Within the range of common parameters, the impact of spheres diameter on the coverage of the initial impact plasticity critical value is more significant. After the spheres diameter reaches the impact plasticity critical value, the increase in coverage caused by the number of spheres is more significant. Compared with increasingn the number of spheres, the increase in the diameter of the spheres will increase the coverage more significantly. Through the numerical analysis of the coverage of process simulation, effective prediction of the surface coverage of ultrasonic shot peening can be realized.
2021 Vol. 64 (19): 30-36 [Abstract] ( 185 ) HTMLNew PDF (4389 KB)  ( 223 )
37 Processing Factors of Ultrasonic Impact Surface Modification
ZHANG Han，ZHU Jiangpei，CAO Xiaofeng，EDDIE Barmor， CAO Xiaojian
DOI: 10.16080/j.issn1671-833x.2021.19.037
The technology of ultrasonic impact surface modification adopts the mechanical method. It applies a sine vibration wave with a frequency of tens of thousands of Hertz on the surface of metals. The ultrasonic strike carries out through the combination of static load, stepping speed, rotating speed, the size of ball-tip, the amplitude and so on. It helps to induce the grain refinement of the surface, and the nanocrystalline surface layers can be achieved ultimately. The mechanical properties can be improved with the increase of the static load and the strike number per unit. However, the excessive static load is harmful to the surface smoothness. The microcracks can be observed due to the surface plastic deformation. They are easy to be the source of surface cracks, and they accelerate the propagation of surface cracks. After the treatment with an 8mm diameter impact ball tip, the surface nanocrystals and the field of residual stress change the mechanism of fatigue crack initiation, mass of inner cracks appear in the rotating-bending fatigue instead of surface crack initiation. The amplitude, lubrication and temperature also affect the surface treatment. The influences of these main factors on the properties are not consistent. To achieve the best treatment effect, it is necessary to optimize the combination of them for different materials and different working conditions.
2021 Vol. 64 (19): 37-41 [Abstract] ( 168 ) HTMLNew PDF (3434 KB)  ( 248 )
42 Research on Oxide Layer on Titanium Alloy Surface Treated by Electropulsing-Assisted Ultrasonic Rolling
WANG Baokun，WANG Haoyu，JI Renjie，ZHENG Qian，DONG Tiancong，LIU Yonghong
DOI: 10.16080/j.issn1671-833x.2021.19.042
In order to study the effect of electropulsing-assisted ultrasonic rolling on metal oxide layer, double annealed TC4 titanium alloy was treated in this way. The cross section metallograph, wear resistance and wear surface morphology of the treated surface were detected and analyzed by optical microscope, friction wear testing machine and electron microprobe. The results show that the surface oxide layer with the thickness of 120μm is transformed into a compact α–phase oxide layer with the thickness about 11μm after electropulsing-assisted ultrasonic rolling with the current of 400A. The friction and wear properties of the treated sample were tested and the low friction coefficient can maintain for a long time during the testing. The testing results show that the abrasion loss of treated sample is half of that of the turning sample and the wear surface is smooth. Meanwhile, the particles that adhere to the wear surface and the ploughs on the wear surface are less, which indicates that the wear resistance after treatment is greatly enhanced.
2021 Vol. 64 (19): 42-47 [Abstract] ( 169 ) HTMLNew PDF (4503 KB)  ( 296 )
48 Microstructure Evolution and Performance Enhancement of Laser Shock Peening
HE Zhaoru,SHEN Yizhou,ZHOU Jin, LIU Weilan,SUN Rujie
DOI: 10.16080/j.issn1671-833x.2021.19.048
Laser shock peening (LSP) is a new surface modification technology that uses laser-induced plasma shock waves to improve the fatigue life of materials. Through the mechanical action of shock waves, the plastic deformation of materials surface occurs at a high strain rate, which can significantly improve the surface microstructure of materials, realize grain refinement, increase dislocation density, and form dislocation tangles, dislocation walls as well as other structures. Based on LSP, warm laser shock peening (WLSP) and cryogenic laser shock peening (CLSP) can further improve the residual stress stability of materials by dynamic strain aging (DSA) effect, dynamic precipitation (DP) effect, high-density deformation twinning, and stacking faults. Based on the evolution of the microstructure of metal surface, LSP technology can significantly increase the hardness and yield strength of material, thereby effectively improve the working stability of component. In addition, LSP technology can also enhance the corrosion resistance and fatigue life of materials to broaden the application field of LSP processing materials.
2021 Vol. 64 (19): 48-58 [Abstract] ( 296 ) HTMLNew PDF (5354 KB)  ( 796 )
59 Research Progress on Corrosion Behavior and Protection Technology of Magnesium Alloys
LI Xin，ZHANG Chi，WANG Junsheng，TIAN Guangyuan
DOI: 10.16080/j.issn1671-833x.2021.19.059
Due to the extremely negative electrode potential, the poor corrosion resistance of magnesium has become a critical barrier preventing its wide applications. Therefore, it is critical to find out the corrosion mechanism of magnesium, and explore the relationship between corrosion rate and surface modification and coating. It can provide important theoretical support for developing corrosion-resistant magnesium alloys and its surface protection technique. The characteristics of magnesium alloy corrosion and its protection methods, the research progress on corrosion-resistant of magnesium alloys, and perspectives for surface protection technologies of magnesium alloys in the future are summarized in this article. In addition, this work also highlights the potential of computational simulation methods for discovering corrosion mechanisms.
2021 Vol. 64 (19): 59-70 [Abstract] ( 233 ) HTMLNew PDF (4910 KB)  ( 882 )
71 Effects of TiN Content on Microstructures and Properties of Ti0.8 CoCrFeNiAl0.5 High-Entropy Alloy Composite Coating
HU Ji, SUI Xinmeng, ZHANG Lin, ZHAO Wei, ZHANG Weiping
DOI: 10.16080/j.issn1671-833x.2021.19.071
The work aims to further enhance the microhardness and wear resistance of high-entropy alloy (HEA) Ti0.8 CoCrFeNiAl0.5. The Ti0.8 CoCrFeNiAl0.5/TiN composite coatings with different TiN contents were prepared on the  surface of TC21 by laser cladding. The microstructures and phases of cladding layer were analyzed with scanning electron microscopy (SEM), X–ray diffractometry (XRD) and electron probe microanalysis (EPMA). The hardness distribution and wear resistance of the cladding layer are characterized by the microhardness tester and the material surface comprehensive performance tester. The results showed that the cladding layer is formed well and has good metallurgical bonding. Without TiN, the cladding layer is mainly composed of BCC1, FCC, Laves phases and β–Ti. After adding TiN, TiN particles precipitate in-situ in the cladding layer. The cladding layer is mainly composed of dendritic structure of BCC1 phase rich in Al–Co–Ni–Ti, interdendritic structure of BCC2 phase rich in Fe–Cr–Ti and Laves phase, β–Ti and TiN particles embedded between dendritic structure and interdendritic structure. The microhardness of the cladding layer increases to more than 2 times of the substrate, and the hardness of the cladding layer with 8% TiN is 1.23 times of the sample without TiN. When the content of TiN is 6%, the wear resistance is high, which is about 2.92 times that of the sample without TiN. It reveals that the addition of TiN is beneficial to the precipitation of TiN particles and the formation of BCC phase in the cladding layer, which can effectively improve the hardness and wear resistance of the cladding layer.
2021 Vol. 64 (19): 71-79 [Abstract] ( 161 ) HTMLNew PDF (5043 KB)  ( 265 )
       APPROACHING SCIENCE
80 Research and Develop Advanced Manufacturing Technology to Serve Tianjin’s Industrial Development
2021 Vol. 64 (19): 80-81 [Abstract] ( 104 ) HTMLNew PDF (407 KB)  ( 99 )
       RESEARCH
82 Ultrasonic Phased Array Inspection of Composite Fuselage Panel
LI Zhiying, LIU Feifei, YANG Yusen, LIU Songping
DOI: 10.16080/j.issn1671-833x.2021.19.082
Composite fuselage panel is the large size key part of wide-body airliner. It has a higher requirement for defect detection and nondestructive testing (NDT) efficiency. Ultrasonic phased array testing method can improve NDT efficiency and defect detection effect, in the early stage, it is necessary to validate the reliability of ultrasonic phased array to detect the defects according to the structural characteristics of the fuselage panel. According to the material and structure characteristics and defect detection requirements of wide-body fuselage panel, different specimens, reflecting characteristics of the panel were designed and prepared. Different artificial defects were embedded in the specimens. With ultrasonic phased array method, a series of testing parameter optimization experiments and defect detectability were carried out. The quantitative analysis was conducted to the detected defects, and the results were compared with those obtained by traditional ultrasonic automatic scanning technique, so as to validate the detectability of the developed ultrasonic phased array method. These studies provide a technical support for the application of ultrasonic phased array technique in NDT of large-scale composite fuselage panel.
2021 Vol. 64 (19): 82-89 [Abstract] ( 186 ) HTMLNew PDF (1675 KB)  ( 227 )
90 Investigation of Tool Wear in High Feed Milling Novel Ultra-Strength Titanium Alloy
JIANG Yifan， TIAN Hui，MA Liangdong，LI Liang
DOI: 10.16080/j.issn1671-833x.2021.19.090
Carbide inserts of ISO grade M35 and P45 were utilized in the experiment of highfeed milling M28, a kind of ultra-strength titanium alloy to make a further understanding of the tool wear. The flank wear development and its effect on cutting forces were compared between these two kinds of carbides. The flank wear region was observed by the scanning electron microscope (SEM), and the components of adhesion material were detected by the energy dispersive spectrometer (EDS) to analyze the wear mechanism in M28 high feed cutting. The carbide tools were rapidly worn out. Notch wear was caused in a specific region of the edge by burrs and hardening layer. With the relative motion between the adhesion and the tool, WC grains were pulled out by the adhesion material, and cracks grew as the result of shear in the carbide matrix. Finally, the slice-like peeling was formed on the flank face. The peeling dimension is associated with WC grain size. The P45 carbide tool with coarser grains shows relatively less wear damage than that of the M35 carbide tool since the coarse grain can offer better wear resistance.
2021 Vol. 64 (19): 90-96 [Abstract] ( 166 ) HTMLNew PDF (3093 KB)  ( 285 )
97 Research and Application of Delivery Status Cleaning Method for Aircraft Based on Large Component Matching Production
YANG Biyi，LIU Zhenyu，XI Xianpin，LUO Xin，ZHANG Yanming
DOI: 10.16080/j.issn1671-833x.2021.19.097
In the process of production, manufacture and delivery of aviation products, it is necessary to carry out materials and components matching, and to control the status of their products during delivery. The traditional mode of cleaning up paper documents and electronic accounts is difficult and time-consuming. Based on the existing information platform resources of the company, this paper proposes a delivery status control model with single process index resource package as traction, aircraft component supporting structure as context and AO/FO as terminal information carrier in order to achieve the purpose of accurate and efficient delivery status cleaning.
2021 Vol. 64 (19): 97-101 [Abstract] ( 161 ) HTMLNew PDF (1393 KB)  ( 240 )
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