碳纤维复合材料导线芯的制备及其特性研究
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摘要
本文以碳纤维作为增强材料,采用拉挤成型工艺,制备出复合材料导线芯,并在外部绞合铝合金导线制备出架空导线。该新型碳纤维复合芯导线可以实现对现有输电线路的改造,增加输电能力,对于碳纤维复合芯及复合芯导线的研究具有重大的经济和社会意义。本文对自制的复合芯及导线的制备与性能做了系统的研究。
调整了拉挤工艺中的排纱、树脂浸渍、入模及固化、牵引四部分的关键设置,获取了制备碳纤维复合芯的最佳工艺参数为后固化温度在200-220℃之间,固化剂的含量为40%。
对比分析了实验室自制复合芯与CTC公司产品ACCC的性能,结果表明：实验室自制碳纤维复合芯的热膨胀系数比ACCC的小,更能有效地降低架空导线的弧垂；通过动态机械热分析(DMA)考察了复合芯的动态力学性能,发现自制复合芯具有更高的储能模量,抵抗变形的能力更强。自制复合芯的玻璃化转变温度(Tg)比ACCC低10℃,需通过对环氧基体进行改性提高复合芯的耐热性；考察复合芯的静态力学性能发现自制复合芯的抗拉强度比ACCC大；采用扫描电镜(SEM)观察了复合芯的横截面与剖面,纤维与基体界面粘结良好,无纤维的拨出、脱粘现象。
初步探索了复合芯的湿热老化行为。复合芯的吸湿特性复合芯在低温下的湿热老化符合Fick扩散定律。在100℃的蒸馏水中,浸泡前期复合芯符合Fick扩散定律,后期吸湿率出现下降。同时,温度越高,复合芯的饱和吸湿率越大,达到饱和吸湿率的时间越短；湿热老化导致了复合芯的弯曲强度下降,温度越高,弯曲强度下降的越快,幅度越大;复合芯的动态力学性能测试结果表明,复合芯的储能模量随老化时间的延长而下降,损耗因子随老化时间的延长而增大；通过分析浸泡前后的复合芯的红外谱(IR)发现,复合芯在浸泡过程中结构未发生化学变化,只存在未固化的环氧基体的溶解或析出；采用扫描电镜观察了浸泡前后复合芯的劈裂面形貌,浸泡后的复合芯的纤维与基体的界面都出现了不同程度的破坏,尤其以在100℃蒸馏水中浸泡时破坏最严重。
测试分析了自制新型碳纤维复合芯铝导线的各项性能,新型导线的各种表观质量均达到标准要求,与传统钢芯导线相比,新型导线的重量轻,抗拉强度大；在拉伸过程中复合芯只表现出弹性变化,而铝绞线要发生弹塑性变形,使导线的应力应变曲线上存在斜率的突然变化；碳纤维复合芯的热膨胀系数比铝绞线要小的多,在温度升高到一定值时导线的弧垂基本不再增加,大大降低了导线的弧垂,从而允许导线在更高的温度下使用；载流量测试结果表明新型导线的载流量大大超过传统钢芯铝导线,可以实现对输电线路扩容的改造；新型导线顺利通过了微风振动,电晕及无线电干扰测试；总之,自制碳纤维复合芯铝导线的各项性能均能够达到施工设计要求,并且在现场应用情况良好。
In this paper, a carbon fiber reinforced composites core was made by pultrusion, and the conductor was made by twisting aluminum wire outside. The aluminum conductor of carbon fiber reinforced composites core could achieve the transformation of exiting transmission lines and increase transmission capacity. So it was of great economic and social significance to study carbon fiber reinforced composites core and the conductor. Some research was done for the preparation and properties of the composites core and conductor in the paper.
Pultrusion process, which consisted of setting of yarm, impregnation of resin, curing and traction, was adjusted. Carbon fiber reinforced composites core was made by pultrusion, whose final curing temperature was 200-220℃and content of curing agent was 40%.
The self-made composites core was compared to ACCC made by CTC company. It was shown that the coefficient of thermal expansion of the core was smaller than ACCC, which meant that it was more effective to reduce the sag of conductor. Dynamic mechanical properties of the core were studied by dynamic mechanical analysis. The results show that the capability of resisting deformation of self-made core was greater for its higher storage modulus. The glass transition temperature of self-made core was lower than ACCC by 10℃, which should be improved through the modification of epoxy matrix. The tensile strength of self-made core was great than ACCC. The results of scanning electron microscope show that the matrix bond tightly with fiber without debonding phenomenon.
Aging behavior of composites core was explored. It was found that the absorption characteristics of composites core obey the Fick's law at low temperature. When inmmersing in distilled water at 100℃, the absorption behavior agreed with Fick's law at the early stage, while the moisture rate decreased at the later stage. Moreover, the increase of environmental temperature led to a higher equilibrium moisture content and a shorter time to the equilibrium. Heat aging resulted in the decrease in the flexural strength of the composites core, and the higher the environmental temperature, the faster decline in flexural strength decreased, the greater the content. The results of DMA show that the storage modulus decreased with aging time, and loss factor increased with aging time. Infrared spectrometer was employed to study the composites core, it was found that there was no chemical reaction through the aging, only dissolution or precipitation of the uncured epoxy. The results of the SEM show that the interface between the fiber and matrix suffered different degrees of damage, especially in the distilled water at 100℃.
Properties of self-made conductor was tested. The apparent quality of the conductor reached the standards, and compared with traditional conductor steel reinforced, the new conductor was ligher with higher tensile strength. There was a sudden change of slope in the stress-strain curve, because the core response in loading and unloading was entirely elastic, while the aluminum undergowent elastic-plastic deformation. The composite core had a much lower coefficient of thermal expansion than aluminum, which caused that the sag of the conductor hardly changed when temperature increased to certain constant. Thus, the new conductor could be used at higher temperature. Capacity of the test results show that the capacity of the new conductor was much more than traditional one, which enabled the expansion of transmission line. Moreover, the new conductor passed the vibration, corona and radio interference test successfully. All results shown that self-made aluminum conductor carbon fiber reinforced composites core was able to achieve the construction design requirements, and was in good condition in field application.
调整了拉挤工艺中的排纱、树脂浸渍、入模及固化、牵引四部分的关键设置,获取了制备碳纤维复合芯的最佳工艺参数为后固化温度在200-220℃之间,固化剂的含量为40%。
对比分析了实验室自制复合芯与CTC公司产品ACCC的性能,结果表明：实验室自制碳纤维复合芯的热膨胀系数比ACCC的小,更能有效地降低架空导线的弧垂；通过动态机械热分析(DMA)考察了复合芯的动态力学性能,发现自制复合芯具有更高的储能模量,抵抗变形的能力更强。自制复合芯的玻璃化转变温度(Tg)比ACCC低10℃,需通过对环氧基体进行改性提高复合芯的耐热性；考察复合芯的静态力学性能发现自制复合芯的抗拉强度比ACCC大；采用扫描电镜(SEM)观察了复合芯的横截面与剖面,纤维与基体界面粘结良好,无纤维的拨出、脱粘现象。
初步探索了复合芯的湿热老化行为。复合芯的吸湿特性复合芯在低温下的湿热老化符合Fick扩散定律。在100℃的蒸馏水中,浸泡前期复合芯符合Fick扩散定律,后期吸湿率出现下降。同时,温度越高,复合芯的饱和吸湿率越大,达到饱和吸湿率的时间越短；湿热老化导致了复合芯的弯曲强度下降,温度越高,弯曲强度下降的越快,幅度越大;复合芯的动态力学性能测试结果表明,复合芯的储能模量随老化时间的延长而下降,损耗因子随老化时间的延长而增大；通过分析浸泡前后的复合芯的红外谱(IR)发现,复合芯在浸泡过程中结构未发生化学变化,只存在未固化的环氧基体的溶解或析出；采用扫描电镜观察了浸泡前后复合芯的劈裂面形貌,浸泡后的复合芯的纤维与基体的界面都出现了不同程度的破坏,尤其以在100℃蒸馏水中浸泡时破坏最严重。
测试分析了自制新型碳纤维复合芯铝导线的各项性能,新型导线的各种表观质量均达到标准要求,与传统钢芯导线相比,新型导线的重量轻,抗拉强度大；在拉伸过程中复合芯只表现出弹性变化,而铝绞线要发生弹塑性变形,使导线的应力应变曲线上存在斜率的突然变化；碳纤维复合芯的热膨胀系数比铝绞线要小的多,在温度升高到一定值时导线的弧垂基本不再增加,大大降低了导线的弧垂,从而允许导线在更高的温度下使用；载流量测试结果表明新型导线的载流量大大超过传统钢芯铝导线,可以实现对输电线路扩容的改造；新型导线顺利通过了微风振动,电晕及无线电干扰测试；总之,自制碳纤维复合芯铝导线的各项性能均能够达到施工设计要求,并且在现场应用情况良好。
In this paper, a carbon fiber reinforced composites core was made by pultrusion, and the conductor was made by twisting aluminum wire outside. The aluminum conductor of carbon fiber reinforced composites core could achieve the transformation of exiting transmission lines and increase transmission capacity. So it was of great economic and social significance to study carbon fiber reinforced composites core and the conductor. Some research was done for the preparation and properties of the composites core and conductor in the paper.
Pultrusion process, which consisted of setting of yarm, impregnation of resin, curing and traction, was adjusted. Carbon fiber reinforced composites core was made by pultrusion, whose final curing temperature was 200-220℃and content of curing agent was 40%.
The self-made composites core was compared to ACCC made by CTC company. It was shown that the coefficient of thermal expansion of the core was smaller than ACCC, which meant that it was more effective to reduce the sag of conductor. Dynamic mechanical properties of the core were studied by dynamic mechanical analysis. The results show that the capability of resisting deformation of self-made core was greater for its higher storage modulus. The glass transition temperature of self-made core was lower than ACCC by 10℃, which should be improved through the modification of epoxy matrix. The tensile strength of self-made core was great than ACCC. The results of scanning electron microscope show that the matrix bond tightly with fiber without debonding phenomenon.
Aging behavior of composites core was explored. It was found that the absorption characteristics of composites core obey the Fick's law at low temperature. When inmmersing in distilled water at 100℃, the absorption behavior agreed with Fick's law at the early stage, while the moisture rate decreased at the later stage. Moreover, the increase of environmental temperature led to a higher equilibrium moisture content and a shorter time to the equilibrium. Heat aging resulted in the decrease in the flexural strength of the composites core, and the higher the environmental temperature, the faster decline in flexural strength decreased, the greater the content. The results of DMA show that the storage modulus decreased with aging time, and loss factor increased with aging time. Infrared spectrometer was employed to study the composites core, it was found that there was no chemical reaction through the aging, only dissolution or precipitation of the uncured epoxy. The results of the SEM show that the interface between the fiber and matrix suffered different degrees of damage, especially in the distilled water at 100℃.
Properties of self-made conductor was tested. The apparent quality of the conductor reached the standards, and compared with traditional conductor steel reinforced, the new conductor was ligher with higher tensile strength. There was a sudden change of slope in the stress-strain curve, because the core response in loading and unloading was entirely elastic, while the aluminum undergowent elastic-plastic deformation. The composite core had a much lower coefficient of thermal expansion than aluminum, which caused that the sag of the conductor hardly changed when temperature increased to certain constant. Thus, the new conductor could be used at higher temperature. Capacity of the test results show that the capacity of the new conductor was much more than traditional one, which enabled the expansion of transmission line. Moreover, the new conductor passed the vibration, corona and radio interference test successfully. All results shown that self-made aluminum conductor carbon fiber reinforced composites core was able to achieve the construction design requirements, and was in good condition in field application.
引文
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