Article(id=1321490158789186423, tenantId=1146029695717560320, journalId=1220038251117760515, issueId=1321490128967675980, articleNumber=null, orderNo=null, doi=10.11868/j.issn.1001-4381.2025.000249, pmid=null, cstr=32421.14.j.issn.1001-4381.2025.000249, oa=null, hot=null, price=null, onlineType=0, articleFormat=0, articleType=null, articleTypeStr=research-article, receivedDate=1745856000000, receivedDateStr=2025-04-29, revisedDate=null, revisedDateStr=null, acceptedDate=1747065600000, acceptedDateStr=2025-05-13, onlineDate=1792997405955, onlineDateStr=2026-10-26, pubDate=1768838400000, pubDateStr=2026-01-20, doiRegisterDate=null, doiRegisterDateStr=null, onlineIssueDate=1792997405955, onlineIssueDateStr=2026-10-26, onlineJustAcceptDate=null, onlineJustAcceptDateStr=null, onlineFirstDate=null, onlineFirstDateStr=null, sourceXml=null, magXml=null, createTime=1792997405955, creator=13701087609, updateTime=1792997405955, updator=13701087609, issue=Issue{id=1321490128967675980, tenantId=1146029695717560320, journalId=1220038251117760515, year='2026', volume='54', issue='1', pageStart='1', pageEnd='259', issueExtLink='null', onlineDate='null', pubDate='1768838400000', pubDateStr='2026-01-20', beforeIssueId=null, nextIssueId=null, price=null, status=1, issueComplete=1, articleOrder=1, issueType=-1, specialIssue=null, createTime=1792997398845, creator='13701087609', updateTime=1792997398845, updator='13701087609', preIssue=null, nextIssue=null, articleTotal=null, ext=null, issueFiles=null, downloadFileDto=null}, startPage=114, endPage=126, ext={EN=ArticleExt(id=1321490160928281466, articleId=1321490158789186423, tenantId=1146029695717560320, journalId=1220038251117760515, language=EN, title=Forming strategy and development trend of continuous fiber reinforced metal matrix composites, columnId=1220689389424919062, journalTitle=Journal of Materials Engineering, columnName=REVIEW, runingTitle=null, highlight=null, articleAbstract=

Continuous fiber reinforced metal matrix composites,as representatives of high-performance structure-function integrated materials,the innovation of their preparation technology and the expansion of engineering applications have always been core issues in the field of materials. This paper mainly reviews the forming process of continuous fiber-reinforced metal matrix composites,systematically combing the advantages,disadvantages,and applicability of traditional forming technologies for fiber metal matrix composites. Aiming at the bottlenecks of traditional processes,high-quality integrated forming methods for new composites such as 3D printing technology and fiber metal prepreg preparation technology are discussed. The feasibility and application trends of these methods in forming structural parts of fiber-reinforced metal matrix composites are also discussed,with the aim of providing a reference for the development direction of high-quality preparation processes for metal matrix composites and their engineering applications.

, authors=Kangdi ZHONG1, 2, Kangrong LAI1, 2, Lei SHA1, Lian XUE1, Wen SUN1, Fei LIU1, 2, Cheng YANG3, authorsList=Kangdi ZHONG, Kangrong LAI, Lei SHA, Lian XUE, Wen SUN, Fei LIU, Cheng YANG, authorCompany=null, correspAuthors=Lei SHA, Lian XUE, authorNote=null, correspAuthorsNote=null, copyrightStatement=null, copyrightOwner=null, extLink=null, articleAbsUrl=null, sourceXml=null, magXml=null, pdfUrl=null, pdf=null, pdfFileSize=null, pdfExtLink=null, richHtmlUrl=null, mobilePdfUrl=null, reviewReport=null, pdfFirstPage=null, abstractGraph=null, abstractGraphContent=null, abstractVideo=null, citation=null, cebUrl=null, magXmlContent=null, mapNumber=null, fund=null), CN=ArticleExt(id=1321490166078886793, articleId=1321490158789186423, tenantId=1146029695717560320, journalId=1220038251117760515, language=CN, title=连续纤维增强金属基复合材料成形策略及发展趋势, columnId=1220689389663994406, journalTitle=材料工程, columnName=综述, runingTitle=null, highlight=null, articleAbstract=

连续纤维增强金属基复合材料作为高性能结构-功能一体化材料的代表,其制备技术创新与工程应用拓展始终是材料领域的核心议题。本工作主要围绕连续纤维增强金属基复合材料成形工艺进行综述,系统梳理了成形纤维金属基复合材料的传统成形技术的优劣与适用性。针对传统工艺瓶颈,探讨了3D打印技术、纤维金属预浸料制备技术等新型复合材料的高质量一体化成形方式,讨论其在成形纤维增强金属基复合材料结构件的可行性和应用趋势,以期为高质量金属基复合材料制备工艺的发展方向及工程化应用提供参考。

, authors=钟康迪1, 2, 赖康荣1, 2, 沙磊1, 薛莲1, 孙雯1, 刘飞1, 2, 杨程3, authorsList=钟康迪, 赖康荣, 沙磊, 薛莲, 孙雯, 刘飞, 杨程, authorCompany=null, correspAuthors=沙磊, 薛莲, authorNote=null, correspAuthorsNote=
沙磊(1991—),男,副教授,硕士,研究方向为镍基高温合金,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
薛莲(1989—),女,讲师,硕士,研究方向为金属基复合材料制备,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
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figureFileBig=rw7l3vXqM0w6nE6A3fkKTw==, tableContent=null), ArticleFig(id=1321926877053304879, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图1, caption=物相沉积法(a)SiCf/Al复合材料截面形貌[7-8];(b)SiCf/Al复合材料中基体EBSD图和晶界取向差分布图[7], figureFileSmall=B6EgY7c4tp6wDuYP7VHyYA==, figureFileBig=rw7l3vXqM0w6nE6A3fkKTw==, tableContent=null), ArticleFig(id=1321926877162356784, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Fig.2, caption=Ultrasonic infiltration forming composite wire(d)schematic diagram of composite wire formed by ultrasonic infiltration process[29-30];(b)infiltration cross-section of composite wire[30];, figureFileSmall=duc/hZxjYCYWKX2CnSWV5g==, figureFileBig=Atfouc97oQMgOyu6XWARsg==, tableContent=null), ArticleFig(id=1321926878852661297, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图2, caption=超声浸渗成形复合材料线材分析(a)超声浸渗工艺成形复合材料线材流程图[29-30];(b)复合材料线材浸渗截面[30];(c)镁含量对复合材料力学性能的影响[29]

(c)effect of magnesium content on the mechanical properties of composites[29]

, figureFileSmall=duc/hZxjYCYWKX2CnSWV5g==, figureFileBig=Atfouc97oQMgOyu6XWARsg==, tableContent=null), ArticleFig(id=1321926878995267635, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Fig.3, caption=Schematic diagram of other preparation processes(a)pressure casting method[45];(b)integrate winding,thermal spraying and thixoforming technologies[41];(c)pulsed magnetic field infiltration technology[42];(d)liquid-solid infiltration extrusion technology[47-50], figureFileSmall=GqDlgbNnFY9qKram8FLUaw==, figureFileBig=2tznOo3xb5Y1I3bmDAV1hQ==, tableContent=null), ArticleFig(id=1321926879070765108, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图3, caption=其他制备工艺示意图(a)压力铸造法[45];(b)集成缠绕、热喷涂和触变成形制造连续纤维增强金属基复合材料[41];

(c)脉冲磁场浸渗工艺[42];(d)液固浸渗挤压技术[47-50]

, figureFileSmall=GqDlgbNnFY9qKram8FLUaw==, figureFileBig=2tznOo3xb5Y1I3bmDAV1hQ==, tableContent=null), ArticleFig(id=1321926879146262581, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Fig.4, caption=3D printing fiber reinforced metal matrix composite morphologies

(a),(b)bonding of carbon fiber and Sn48Bi52 matrix in metal melting three-dimensional direct writing technology[51-52];

(c),(d)infiltration morphology of carbon fiber reinforced Sn50Pb50 composite prepared by fiber traction printing[53-54];

(e),(f) continuous fiber reinforced bronze matrix composite shaft side diagram,and the morphology before and after sintering[55]

, figureFileSmall=+/xcHGzwK7RUhM+JDnlRcQ==, figureFileBig=2ZwHPA8y1d5KAjrf3H8Chw==, tableContent=null), ArticleFig(id=1321926879213371446, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图4, caption=3D打印纤维增强金属基复合材料形貌

(a),(b)金属熔融三维直写技术中,碳纤维与Sn48Bi52基体的结合情况[51-52];(c),(d)纤维牵引打印技术制备碳纤维增强

Sn50Pb50复合材料的浸渗形貌[53-54];(e),(f)连续纤维增强青铜基复合材料轴侧图及其烧结前后的形貌[55]

, figureFileSmall=+/xcHGzwK7RUhM+JDnlRcQ==, figureFileBig=2ZwHPA8y1d5KAjrf3H8Chw==, tableContent=null), ArticleFig(id=1321926879297257528, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Fig.5, caption=Forming technology and macro/microstructure of cylindrical parts[59](a)metal prepreg manufacturing process diagram;(b)laser-assisted melt winding technology;(c)surface and microtopography of cylindrical parts, figureFileSmall=9nxjG2YAtCXLwLFMk51PpA==, figureFileBig=bOWcY7/FhA+S0CANTVuO3w==, tableContent=null), ArticleFig(id=1321926879381143608, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图5, caption=美国试金石实验室筒型件成形技术及宏/微结构[59](a)金属预浸料制造工艺示意图;(b)激光辅助熔化缠绕技术;(c)筒型件表面和微观形貌, figureFileSmall=9nxjG2YAtCXLwLFMk51PpA==, figureFileBig=bOWcY7/FhA+S0CANTVuO3w==, tableContent=null), ArticleFig(id=1321926879456641081, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Fig.6, caption=Application structures(a)Hubble Space Telescope high gain antenna waveguide/boom[60];(b)transmission towers in which cables are being installed,illustrated as composite core aluminium stranded wire sections[61];(c)skin structures of space shuttles[64];(d)airfoil cross-section of RB211-E4 stator vane[65];(e)satellite propellant tanks[65];(f)M40/Al composite space infrared remote sensor barrel structure[18,67];(g)aircraft engine blade ring[64];(h)aircraft engine T-shaped structural component[69], figureFileSmall=X4xCpZ86hojMnmQtdXju0A==, figureFileBig=m0L1K1YLjrrrdIucsoZBJA==, tableContent=null), ArticleFig(id=1321926879523749946, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=图6, caption=应用结构件(a)哈勃太空望远镜高增益天线波导/臂架[60];(b)正在安装电缆的输电塔,插图为复合材料芯铝绞线截面[61];

(c)航天飞机蒙皮[64];(d)RB211-E4型静子叶片翼型截面[65];(e)卫星推进剂储罐[65];(f)M40/Al复合材料空间红外遥感器镜筒结构[18,67];(g)航空发动机叶环[64];(h)T型结构件[68]

, figureFileSmall=X4xCpZ86hojMnmQtdXju0A==, figureFileBig=m0L1K1YLjrrrdIucsoZBJA==, tableContent=null), ArticleFig(id=1321926879590858811, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=EN, label=Table 1, caption=

Traditional preparation process of continuous fiber reinforced metal matrix composites

, figureFileSmall=null, figureFileBig=null, tableContent=
Process typeAdvantageDisadvantageRef.

Solid phase

method

Diffusion bonding method

Lower forming temperature and weaker

interfacial reaction

Complex production process[4,37-38]

Physical vapor deposition

method

Suitable for any metal matrix

Higher cost and complex production

process

[7-8,10,39]

Liquid phase

method

Die castingForming complex structures

Preform prone to damage and

complex preparation process

[40]
Squeeze casting

High densification degree and excellent

mechanical properties

Prone to cause deformation and

damage of the preform

[14-15]
Semi-solid rolling methodNon-closed infiltration

Poor infiltration quality and complex

operation

[19-20]

Thermal spray coating

method

On-demand manufacturing and reduced interface

reactions

Low fiber volume fraction[41]

Pulsed magnetic field

infiltration method

Non-closed infiltrationPoor infiltration quality[42]

Ultrasonic infiltration

method

Low equipment requirements,capable of

continuous forming of composite wires

Difficulty in forming three-

dimensional structures

[29-30]

Gas pressure infiltration

method

Few casting defects and reduced high-

temperature oxidation

Higher production cost[23-24,43]
), ArticleFig(id=1321926879653773372, tenantId=1146029695717560320, journalId=1220038251117760515, articleId=1321490158789186423, language=CN, label=表1, caption=

连续纤维增强金属基复合材料传统成形工艺

, figureFileSmall=null, figureFileBig=null, tableContent=
Process typeAdvantageDisadvantageRef.

Solid phase

method

Diffusion bonding method

Lower forming temperature and weaker

interfacial reaction

Complex production process[4,37-38]

Physical vapor deposition

method

Suitable for any metal matrix

Higher cost and complex production

process

[7-8,10,39]

Liquid phase

method

Die castingForming complex structures

Preform prone to damage and

complex preparation process

[40]
Squeeze casting

High densification degree and excellent

mechanical properties

Prone to cause deformation and

damage of the preform

[14-15]
Semi-solid rolling methodNon-closed infiltration

Poor infiltration quality and complex

operation

[19-20]

Thermal spray coating

method

On-demand manufacturing and reduced interface

reactions

Low fiber volume fraction[41]

Pulsed magnetic field

infiltration method

Non-closed infiltrationPoor infiltration quality[42]

Ultrasonic infiltration

method

Low equipment requirements,capable of

continuous forming of composite wires

Difficulty in forming three-

dimensional structures

[29-30]

Gas pressure infiltration

method

Few casting defects and reduced high-

temperature oxidation

Higher production cost[23-24,43]
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钟康迪 1, 2 , 赖康荣 1, 2 , 沙磊 1 , 薛莲 1 , 孙雯 1 , 刘飞 1, 2 , 杨程 3
材料工程 | 综述 2026,54(1): 114-126
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材料工程 |综述 2026 , 54 (1) : 114 -126
连续纤维增强金属基复合材料成形策略及发展趋势
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钟康迪1, 2, 赖康荣1, 2, 沙磊1 , 薛莲1 , 孙雯1, 刘飞1, 2, 杨程3
作者信息
  • 1.昌吉学院 航空学院,新疆 昌吉 831100
  • 2.昌吉学院 飞行器设计制造与维修重点实验室,新疆 昌吉 831100
  • 3.天水师范大学 机电与汽车工程学院,甘肃 天水 741001
通讯作者:
沙磊(1991—),男,副教授,硕士,研究方向为镍基高温合金,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
薛莲(1989—),女,讲师,硕士,研究方向为金属基复合材料制备,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
Forming strategy and development trend of continuous fiber reinforced metal matrix composites
Kangdi ZHONG1, 2, Kangrong LAI1, 2, Lei SHA1 , Lian XUE1 , Wen SUN1, Fei LIU1, 2, Cheng YANG3
Affiliations
  • 1.School of Aeronautics,Changji University,Changji 831100,Xinjiang,China
  • 2.Key Laboratory of Aircraft Design,Manufacture and Maintenance,Changji University,Changji 831100,Xinjiang,China
  • 3.School of Electromechanical and Automobile Engineering,Tianshui Normal University,Tianshui 741001,Gansu,China
出版时间: 2026-01-20 doi: 10.11868/j.issn.1001-4381.2025.000249
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连续纤维增强金属基复合材料作为高性能结构-功能一体化材料的代表,其制备技术创新与工程应用拓展始终是材料领域的核心议题。本工作主要围绕连续纤维增强金属基复合材料成形工艺进行综述,系统梳理了成形纤维金属基复合材料的传统成形技术的优劣与适用性。针对传统工艺瓶颈,探讨了3D打印技术、纤维金属预浸料制备技术等新型复合材料的高质量一体化成形方式,讨论其在成形纤维增强金属基复合材料结构件的可行性和应用趋势,以期为高质量金属基复合材料制备工艺的发展方向及工程化应用提供参考。

连续纤维增强金属基复合材料  /  3D打印  /  成形策略  /  发展趋势

Continuous fiber reinforced metal matrix composites,as representatives of high-performance structure-function integrated materials,the innovation of their preparation technology and the expansion of engineering applications have always been core issues in the field of materials. This paper mainly reviews the forming process of continuous fiber-reinforced metal matrix composites,systematically combing the advantages,disadvantages,and applicability of traditional forming technologies for fiber metal matrix composites. Aiming at the bottlenecks of traditional processes,high-quality integrated forming methods for new composites such as 3D printing technology and fiber metal prepreg preparation technology are discussed. The feasibility and application trends of these methods in forming structural parts of fiber-reinforced metal matrix composites are also discussed,with the aim of providing a reference for the development direction of high-quality preparation processes for metal matrix composites and their engineering applications.

continuous fiber reinforced metal matrix composites  /  3D printing  /  forming strategy  /  development trend
钟康迪, 赖康荣, 沙磊, 薛莲, 孙雯, 刘飞, 杨程. 连续纤维增强金属基复合材料成形策略及发展趋势. 材料工程, 2026 , 54 (1) : 114 -126 . DOI: 10.11868/j.issn.1001-4381.2025.000249
Kangdi ZHONG, Kangrong LAI, Lei SHA, Lian XUE, Wen SUN, Fei LIU, Cheng YANG. Forming strategy and development trend of continuous fiber reinforced metal matrix composites[J]. Journal of Materials Engineering, 2026 , 54 (1) : 114 -126 . DOI: 10.11868/j.issn.1001-4381.2025.000249
连续纤维增强金属基复合材料具有较高的比强度和比刚度、抗蠕变、高温结构稳定性和使役性能可设计性等特点,是航空航天、交通运输、电力传输等高端技术领域亟须的中高温关键材料,具有极大的结构性能设计及应用空间[1-2]。这类材料通过将高强度连续纤维(如碳化硅纤维、硼纤维、碳纤维、氧化铝纤维等)按需设计嵌入金属基体(铝、镁、钛及其合金等)中,实现纤维与基体间性能协同强化。纤维作为主承载相赋予材料优异的轴向力学性能,而基体则通过传递载荷、保护纤维及提供功能性(导热/导电)进一步优化整体性能。然而,随着现代装备向大型化、集成化、功能化方向发展,复合材料构件呈现出大型化、集成化、整体化的应用趋势。面向高温、高稳定性、大负载等极端服役环境的复合材料结构件研发和制造仍停留在材料性能优化、近净成形以及工艺的创新等方面,传统制备技术难以满足构件“微结构-宏观性能”跨尺度精准调控的需求,成为制约其工程化应用的关键瓶颈。
本工作系统梳理了国内外纤维增强金属基复合材料成形技术的发展现状,对比分析了连续纤维增强金属基复合材料传统成形技术和新型成形技术的优劣性和发展趋势,进一步汇总了复合材料及其结构件的应用进展,以期为新一代连续纤维增强金属基复合材料的发展决策制定提供参考。
连续纤维增强金属基复合材料的传统成形工艺体系主要可分为固相复合法与液相复合法两类技术路径,其核心差异在于基体金属相变状态和纤维/基体间的交互作用机制。
固相复合成形工艺利用固相扩散理论,并采用外力或热激活等手段,克服原子间的势垒,实现金属基体与纤维间的物理冶金结合。
扩散粘接法作为一种典型的固相制备连续纤维增强金属基复合材料的方法,主要利用金属的塑性变形及自身扩散的作用,可制得层间结合优异的复合材料构件,但也存在工艺过程复杂、生产成本高等不足[3-4]。此外,在固相复合成形工艺中,基体金属受限于固态塑性变形抗力,需通过大尺度流变实现纤维间隙填充,此过程产生的剪切应力场也会诱发纤维局部偏移甚至重排。Zhang等[5]提出了采用扩散粘接工艺制备了复合涂层改性的37%(体积分数,下同)连续碳化硅纤维增强镍基复合材料,有效防止碳化硅纤维与镍基之间的反应。Vecchio等[6]采用反应箔烧结技术合成了微观结构可控的纤维增强金属间层压板复合材料,其中,Ti层和Al2O3纤维层间的Al箔在反应烧结过程中被消耗,形成了交替的金属间化合物Al3Ti层,使得界面实现冶金结合。
物相沉积法是将基体材料沉积或涂覆到纤维增强相表面,获取先驱丝,再将先驱丝按需设计进行排布、编制、缠绕等,然后采用真空热压或热等静压的工艺固结成形。先驱丝制备通过采用物理气相沉积法,该方法可以在纤维表面涂覆任何金属基体,较液相法应用范围更广泛[7-12]。Chu等[7-8]采用磁控溅射法和热等静压等工艺成功制备45%SiCf/Al复合材料,SiC纤维在铝基体中分布均匀,界面处没有发现孔洞和裂纹等缺陷(图1(a))。掺入纤维对于基体形貌也有较大影响,图1(b)中,基于EBSD表征发现了纤维间基体呈细等轴晶和粗柱状晶组成的双峰结构,且低角度晶界相比原基体显著提升,晶粒尺寸得到细化[7]。Jiang等[10]采用磁控溅射法和热等静压法制备SiCf/Ti2AlNb复合材料,揭示了热等静压诱导的界面反应机理和基体微观结构演变规律。但物相沉积法在实现大规模工业化生产中面临以下缺点:设备投资高昂,且需在高真空环境下运行;纤维表面的涂层厚度易受沉积角度、纤维排布密度等影响,极易导致局部厚度不均或针孔缺陷;沉积过程中的高能粒子轰击,导致纤维强度下降。
液态法是指将处于熔融状态下的基体金属与纤维增强相在外界压力下复合,金属液浸渗入纤维预制体内部的微小间隙凝固形成复合材料。液相法主要包括挤压铸造法、半固态轧制浸渗法、气压浸渗法、超声浸渗法等。但液相法制备过程中,组分间易发生界面反应,纤维表面通常需要进行涂层处理。
挤压铸造法是目前制备金属基复合材料最成熟的制备工艺之一,其特点在于高压(10~100 MPa)强制补缩破坏了枝晶的生长,减少了复合材料中缩松和缩孔等缺陷,浸渗过程易出现预制体变形开裂、损坏等现象。此外,由于制备环境温度较高,碳纤维与铝间易发生界面反应,生成的碳化物脆性相损伤材料的力学性能。Zhang等[13]采用挤压铸造法成功制备了质量分数为1%钇(Y)涂层掺杂的60%碳纤维增强镁基复合材料,纤维分布均匀,形成片状金属间化合物Mg2Y偏析在碳纤维表面,显著提高了复合材料的抗弯强度和层间抗剪强度。Pei等[14]采用挤压浸渗法制备了高强高模单向沥青基碳纤维增强铝基复合材料,发现沥青基纤维基本不与铝元素发生界面反应,沿纤维方向复合材料导热系数为(391±1) W/(mK),达到混合模型的95%,热膨胀系数在-1×10-6 K-1和1×10-6 K-1之间,弯曲弹性模量高于400 GPa,这种高导热、低热膨胀系数和优异力学性能的复合材料在微电子芯片中具有广阔的应用前景。Xu等[15]在挤压铸造工艺成形的CF/Al-Fe-Mg-Si复合材料中发现了一种新型富铁相,揭示了其在应力松弛、裂纹挠曲和高温强化等方面的作用机制,使得复合材料在400 ℃时弯曲强度达到880 MPa。研究者采用挤压铸造法制备了单向纤维增强金属基复合材料,浸渗组织均匀且未发现微观缺陷,复合材料抗拉强度得到大幅度提升[15-18]。
半固态轧制法是一种通过辊筒引入渐进的机械压力,促使半固态铝合金基体浸渗入纤维束内部的方法[19-21],打破了传统生产过程对密闭空间的依赖,但存在纤维分数低、浸渗质量欠佳以及操作复杂等不足。Zhang等[20-21]采用半固态轧制法制备了镍涂层编织碳纤维增强铝基(Ni-CF/Al)复合材料,通过调控半固态基体的温度、轧制压力以及轧制速度可使熔体充分渗入纤维织物中,并在传热和材料变形间达到平衡状态,有效地避免了纤维损伤。由于轧制过程中压力渗透、快速凝固和热变形等强化因素,复合材料的弯曲强度提高43%以上。在半固态轧制过程中,渗透行为的驱动力也被证实主要来自轧制压力,而非Ni涂层润湿能力[19]。Liu等[22]采用原位同步辐射成像技术,观察了轧制过程中铝熔液在单向碳纤维束中的浸润过程,其浸润过程为物理填充过程,且浸渗距离随时间呈近似线性增长,证实了涂层处理和基体合金化均能改变浸渗机制,由原来的物理填充方式转变为自发浸渗,渗透速率从0.25 μm/s提高至0.72 μm/s和0.91 μm/s。然而,半固态轧制过程中,熔融基体受黏度-剪切速率耦合效应影响,在单向压力场作用下熔体优先沿预制体低流阻通道流动,导致纤维束间/束内浸渗深度不均。
气压浸渗法是通过外场气压驱动熔融金属渗透至预制体孔隙的液相成形技术。其物理本质在于建立气-液界面压力梯度以克服熔体表面张力、黏滞阻力及孔隙内气体反压等多重能垒,实现熔体在纤维增强相间隙的定向迁移与凝固致密化。美国东北大学Blucher等[23]报道了一种采用气压浸渗工艺连续生产40%碳化硅纤维增强铝基复合材料线材,通过控制生产速度、纤维体积分数和复合材料线材直径等生产参数,生产的复合材料线材长度可达200 m、丝径为0.85 mm、抗拉强度不低于1000 MPa,且此种线材满足电力电缆对更高传输容量的需求。上海交通大学OUYANG团队[24]采用气压浸渗技术成功制备出Al2O3涂层改性的CF/Al复合材料,并证实了Al2O3涂层可以有效地改善浸渗质量和力学性能,复合材料的力学性能提升149%。南昌航空大学余欢团队[25-26]基于自主研发的真空压力铸造设备,成功近净成形出三维编织纤维增强铝基复合材料航空发动机T型叶片模拟件,碳纤维在复合材料中的分布均匀,在基体合金中未发现明显的缩孔缩松现象,其室温拉伸强度超过800 MPa,350 ℃下的拉伸强度为774.7 MPa,拉伸模量达到204.3 GPa。Daoud[27]采用气压浸渗法制备了30%的单向镀镍碳纤维增强铝基复合材料,纤维预制体内部得到充分浸渗,纤维分布均匀,且没有发现纤维簇或残余孔隙的迹象,复合材料的模量和拉伸强度显著提高。然而,该技术仍存在以下核心局限性:(1)多工艺参数耦合效应显著,熔体温度、气压加载速率与纤维预制体孔隙拓扑结构间的动态匹配机制尚未明晰,易引发局部浸渗不足、纤维偏转和纤维损伤等缺陷;(2)对高气密性反应腔体与精密温控系统的设备要求较高,限制复杂构件的工程化生产。
超声浸渗技术是一种基于空化效应、声流效应与机械振动多场耦合作用的液相成型工艺。其核心机理在于利用高频超声能量打破熔体表面张力壁垒,通过空化泡溃灭产生的微射流冲击预制体,致使孔隙内气体排出,同时声流效应驱动熔体定向迁移,实现纤维束间隙的强制浸润[28-31]。此外,理论计算表明[32]超声空化效应能够增大过冷度以提高形核率,从而导致晶粒细化。在超声液体处理中,声压梯度诱导的声流是关键因素,其可促进传热传质及溶质均匀分布。Riedel等[33]采用计算流体动力学模拟A356合金空化和声流起始及扩展的能力,证实了流场呈中心轴向下射流(1 m/s)且在底部扩散形成整体环流。Matsunaga等[29-30]使用超声浸渗法制备了连续碳纤维增强金属基复合材料线材,图2(a)显示了超声浸渗工艺制备线材示意图。具体步骤如下:将预热后的碳纤维束通入合金液熔炉,铝液在超声波的空化-声流协同作用下浸渗至纤维束间隙中,定向凝固后形成直径为0.5~0.6 mm的复合材料丝材,纤维体积分数达到40%~45%。图2(b)显示了复合材料线材截面的微观形貌,证实了熔体浸渗难易程度与声空化工艺参数密切相关,超声能量不足时难以将合金熔液浸渗至纤维束内部。此外,通过在铝熔体中添加镁元素表面活性剂可以实现表面张力降低,提高声空化效率,复合材料线材的抗拉强度达到1400 MPa,如图2(c)所示。基于上述优势,将超声浸渗丝材作为连续纤维增强金属基复合材料预浸料,再采用激光选区熔化或定向能量沉积等增材工艺可以实现结构件的可设计近净成形,对推动金属基复合材料进入“设计-制造-性能”一体化闭环调控的新模式具有重要应用价值。
关于超声浸渗工艺,在20世纪末期国防科技大学也曾进行探究[34],但未得到进一步应用。近几年,陈兴旺[35]采用超声振动法成功制备出碳纤维分散均匀且与基体结合良好的层状连续CF/Al复合材料,其抗拉强度达到243.6 MPa。李广龙[36]采用超声振动并结合顺序凝固的方式成功实现镀镍CF/Al复合材料的制备。结果表明:在超声固有频率为20 kHz、振幅为37~39 μm、碳纤维预紧力为4 N、超声振头与碳纤维之间的距离为15 mm的条件下,制备出无明显缩孔缺陷的复合材料,其抗拉强度达到203 MPa。层状复合材料力学性能较线材大幅下降,归因于超声波振动棒作用面积小,且声波呈辐射状,难以将合金熔液均匀浸渗至纤维布内。
综上所述,该技术仍存在以下关键瓶颈:一方面是工艺参数敏感性强,超声频率、功率与熔体温度需维持严格匹配关系,仅微小偏差即可引发纤维机械损伤或熔体氧化物夹杂等缺陷;另一方面是复杂构件成型时声场衰减显著,难以实现三维结构内部均匀能量传递,仅能实现复合材料线材的高质量成形。
表1[4,7-8,10,14-15,19-20,23-24,37-43]展示了传统成形工艺的综合对比。除了上述制造技术之外,传统的纤维增强金属基复合材料成形技术还包括压力铸造、脉冲磁场浸渗、等离子喷涂、离心铸造[44]等工艺,如图3(a)所示,Kachold等[45]采用压力铸造工艺制备了27%碳纤维增强铝基复合材料,鉴于碳纤维的高温氧化损伤及高界面残余应力等因素,该复合材料抗拉强度低于基体合金。Ballmes等[46]实验证明了利用冷室压铸机在连续碳纤维预制体内浸渗铝合金液的可行性,该工艺能够实现纤维预制体高质量的宏观和微观浸渗,同时避免预制体损伤变形。Silber等[41]提出热喷涂结合半固态锻造工艺成形纤维增强金属基复合材料,不仅减少了纤维的化学侵蚀,而且较低的温度范围也显著缩短了工艺时间(图3(b))。在图3(c)中,Zhang等[42]证实了脉冲磁场中熔融基体对纤维具有周期性挤压和冲击作用,揭示了电磁力作用下的合金熔液浸渗机理。面对航空航天对轻质高强结构件的重大需求,西北工业大学Zhou团队[47-50]采用液固浸渗挤压技术成功实现了碳纤维增强铝基复合材料环形件、模拟叶片件的高质量成形,复合材料的抗拉强度和抗剪切能力分别提高了98%和73%,图3(d)为成形工艺示意图。
随着航空航天、深空探索技术的迅速发展,传统复合成形技术很难保证材料微结构-宏观性能设计相匹配,难以精确地实现结构性能按需设计。如何根据复合材料构件服役需求,调控复合材料微观结构信息,实现后续结构件的按需成形,无疑对缩短连续纤维增强金属基复合材料构件设计开发周期、促进高性能复合材料应用等是重大突破。
近年来,以选区激光熔化成型、电子束选区熔化成型为主的增材制造技术受到广泛关注。西安交通大学、河北科技大学等高校提出连续碳纤维增强金属基复合材料的3D打印技术,实现了纤维金属复合材料的逐层熔融沉积成型。杨立宁等[51-52]提出一种适用于连续增强金属基复合材料的增材制造技术-金属熔融三维直写技术,并探究了碳纤维表面改性、路径搭接率、打印喷头温度、基板温度、打印速度等过程处理方法对复合材料力学性能的影响。然而,图4(a),(b)展示的连续纤维增强金属基复合材料薄壁结构件微观形貌,观测显示纤维束内并没有得到合金液的充分浸渗,纤维仅“嵌入”基体合金中。西安交通大学Tian团队[53-54]提出基于毛细作用的连续纤维增强金属基复合材料及结构件的低成本快速3D打印工艺—纤维牵引打印技术,证实纤维表面改性处理能有效改善基体与纤维润湿性能,使熔体在毛细力下自发渗入纤维单丝间隙、仅少部分区域聚集(图4(c),(d)),实现良好浸润复合,复合材料性能接近传统加压铸造工艺水平(240 MPa)。Mousapour等[55]提出采用低成本材料挤压技术3D打印连续碳纤维增强铜基复合材料,其断裂挠度提高了210%,但基体经烧结后仍无法填充至纤维束内部,纤维与基体间出现接缝(图4(e),(f)),导致弯曲强度轻微降低。西安交通大学Lu团队[56]基于定向能量沉积增材制造技术,研发出一种新型连续金属纤维增强复合材料的增材制造技术,首次实现钛纤维增强铝基复合材料构件的制造。Raja等[57]提出了一种增减材复合制造方法,以线弧定向能沉积基体、减材制造凹槽放置连续纤维,实现了1.2 mm钨纤维增强低碳钢复合材料大规模制备,其抗拉、压缩、弯曲强度及断裂韧性分别提高152%、264%、152%和153%。综上所述,当前纤维增强金属基复合材料3D打印技术仍存在挑战:一是熔池动态失稳引发纤维排布杂乱和不充分浸渗,致使复合材料强韧化协同效应弱于传统工艺;二是逐层沉积策略形成“嵌入式”物理包埋结构,而非化学互锁界面,跨尺度载荷传递机制失效导致材料性能远低于理论值,严重限制其工程化应用。
近年来,多尺度界面工程为突破上述瓶颈提供新思路:通过在纤维表面构建“纳米晶涂层-微米级粗糙结构”梯度界面层,可显著改善金属熔体浸润性,并且引入的界面纳米相作为跨尺度载荷传递关键组分,能缓解和转移纤维/基体界面应力集中[58];多尺度增强体与金属基的构型化复合设计,也有助于改善强度、模量与塑韧性间的倒置关系。这种“纤维表面纳米结构化-基体微结构调控”的构型化复合设计,为3D打印连续纤维增强金属基复合材料的界面性能提升与工程化应用开辟了新路径。
美国试金石实验室开发了一种60%连续纤维增强金属预浸带(MetPregTM)的制造工艺(图5(a))[59],带材厚度为0.15~0.50 mm,宽度为10~40 mm,具备精确控制纤维体积分数与带材尺寸的特点。该团队进一步采用激光辅助MetPregTM丝束缠绕技术规模化生产金属基复合材料结构件(图5(b)),工艺过程中通过激光热源精确调控基体金属的熔融状态与纤维浸润效果(图5(c))。MetPregTM筒型件金相截面显示,纤维丝分布均匀,界面结合良好。将低成本丝束缠绕工艺与高性能金属基复合材料预浸料制造工艺结合,可显著提升经济型金属基复合材料构件的生产效能,可灵活制造圆柱体、球体及其他复杂形状的部件。采用该复合工艺制备的金属浸渗纤维缠绕容器,展现出卓越的综合性能:爆破压力、纵向和扭转刚度以及抗压强度均达到工业级高标准,其中压缩强度高达4.0 GPa,且高温性能稳定。这类构建适合于承受高压缩载荷的军械领域,如火箭发动机壳体、压力容器、航天贮箱、兵器物品、氢燃料贮箱等管状结构。
航空航天、远距离电力传输等领域对材料高性能、轻量化和功能性的严苛需求,确立了纤维增强金属基复合材料作为先进结构材料的核心地位。其凭借优异的综合性能,逐步成为满足复杂服役环境下多维度性能需求的关键材料体系,已广泛应用于卫星载荷结构、航空发动机承力部件及运载火箭动力系统关键组件等核心部位。
连续纤维增强金属基复合材料最成功的应用是美国哈勃太空望远镜的高增益天线悬架[60],这种悬架长3.6 m(见图6(a)),该悬架具有较高的轴向刚度和超低的轴向线膨胀系数,其作为支撑结构能在太空运行过程中稳定天线位置。硼纤维增强铝基复合材料管状支柱被应用于飞机机身中部的框架和肋桁构件[60],以及航天飞机轨道器的起落架拉杆,是连续纤维增强金属基复合材料的首次成功应用。3 M公司开发了一种50%连续氧化铝纤维增强铝铜基复合材料导体材料[61](图6(b)),取代了现有铝绞线钢芯绞线,比强度提高2~3倍,电导率提高4倍,温度达240 ℃。DWA公司采用石墨纤维增强铝基复合材料制造卫星波导管,其不但具有高轴向刚度、低膨胀系数、优异导电性,而且相比原用石墨/环氧-铝层复合波导管减重30%[62]。罗-罗公司和美国空军研究实验室将碳化硅纤维增强钛基复合材料应用于超音速飞机的热结构蒙皮、热防护系统和涡轮部件等。荷兰Fokker公司研制了玻璃纤维增强铝层合板,具有极高的疲劳强度和损伤容限,已成功应用于波音777飞机的货舱地板和空客A380机身壁板[63]。美国德事隆集团采用热压扩散结合法制备SiC/Ti板材,并应用于NASP飞机蒙皮[64],如图6(c)所示。图6(d)展示了由钛基复合材料技术评估联盟(TMCTECC)合力制造的SCS-6碳化硅纤维作为外蒙皮的超空心静子翼型部件[65]。萨里卫星技术有限公司成功研发一种SiC纤维增强钛基复合材料卫星推进剂储罐[65],经测试其爆裂压力超过48 MPa(图6(e))。在汽车领域,英国Alvant公司开发出低成本SiC纤维和Al2O3纤维增强铝基复合材料结构件(动力总成发动机组件、发动机活塞、气缸、连杆等),替代汽车结构部件,实现了减重增效[66]。尽管国外在材料研发及构件制备领域已取得显著进展,但其供应链关键工艺仍存在技术瓶颈,且材料制备成本高昂,成为限制其工程化应用及商业化进程的主要因素。
国内不少高校和科研机构已在连续纤维增强金属基复合材料方面开展大量研究工作,并应用于航空航天结构件[18,64,67-69]。哈尔滨工业大学[18,67]突破了连续石墨纤维与铝基体间的界面反应控制、纤维铺层和缠绕设计等关键技术,成功制备出石墨纤维增强铝基复合材料空间遥感器镜筒(图6(f)),该镜筒较钛镜筒减重31.8%,弹性模量为129 GPa,热膨胀系数为5×10-6 K-1,镜筒组件的一阶谐振频率为284 Hz,高于100 Hz的设计要求。西北工业大学Qi团队[68]采用具有自主知识产权的液固高压成形技术成功近净成形出轻质高强碳纤维复合材料及其结构件,用于替代航空、航天、民用等领域现使用的结构件,密度为1.8~2.35 g/cm3,减重效果达30%。北京航空材料研究院和中国科学院金属研究所[64]成功打通复合材料叶环全流程制备工艺,突破叶环内部缺陷控制、复合材料芯尺寸精度控制等核心技术,实现全尺寸钛基复合材料叶环的制备(图6(g)),并通过超转破裂等地面考核。南昌航空大学余欢团队[69]采用真空压力浸渗法制备了CF/Al复合材料航空发动机中典型T型结构件(图6(h)),其平均弯曲强度为384.2 MPa,且该复合材料T型件弯曲失效后未发生碎裂和断裂,仍保持结构完整性。未来,随着制备工艺成熟、成本下降及应用场景拓展,纤维增强金属基复合材料有望在高端制造、绿色能源等领域发挥更大作用。
本工作主要介绍了国内外传统连续纤维增强金属基复合材料的制备工艺研究现状、发展趋势和应用展望,探讨了3D打印技术、纤维金属预浸料成形技术等新型高质量一体化成形方法,剖析其在结构件成形中的技术可行性与工程应用潜力,并归纳现存问题如下:
(1)多工艺参数耦合效应显著,熔体温度、浸渗加载速率与纤维预制体孔隙拓扑结构间的动态匹配机制尚未明晰,易引发局部浸渗不足、纤维偏转和纤维损伤等缺陷。
(2)对高气密性反应腔体与精密温控系统的设备要求较高,限制复杂构件的工程化生产;工艺参数敏感性强,仅微小偏差即可引发宏观性能离散性大、服役可靠性低等问题。
(3)3D打印技术因熔池失稳导致纤维排布杂乱,逐层沉积策略形成“嵌入式”物理包埋结构,而非化学互锁界面,跨尺度载荷传递机制失效导致材料性能远低于理论值。
(4)多维度几何特征与跨尺度结构的耦合效应加剧了工艺参数调控难度,生产过程中良品率低、一致性差等问题突出,严重制约复杂承力构件的工程化应用。
为提高连续纤维增强金属基复合材料的综合性能,扩展应用潜能,仍有大量技术需要完善与突破,主要包括以下方面:
(1)多尺度结构设计与性能调控的深度融合。未来研究需突破传统“纤维-基体”二元体系,构建跨尺度协同设计框架。通过原子尺度界面键合优化、介观尺度纤维拓扑排列算法以及宏观结构-功能一体化设计,实现材料性能的定向强化。
(2)智能化制造工艺与在线监测技术革新。开发多物理场耦合原位监测/观测系统,可实时捕捉界面脱粘、纤维断裂、界面冶金反应等损伤演化行为,建立工艺参数-缺陷类型-力学性能的定量映射模型。
(3)预浸料基增材制造的微/宏结构协同设计。以连续纤维增强金属基复合材料预浸料为前驱体,基于激光选区熔化定向能量沉积等增材工艺,构建“微观界面-介观组构-宏观结构”跨尺度协同设计框架,揭示增材过程中多界面的动态冶金结合机制,实现结构件微/宏协同近净成形制造。
(4)功能-结构一体化与新兴应用场景拓展。需要开发兼具力-热-电-磁多功能响应的智能复合材料体系,如嵌入压电陶瓷纳米线构建自感知功能材料、功能化多尺度纤维制备高导热高导电材料等。应用场景除传统航空航天领域外,可拓展至核聚变堆第一壁(抗中子辐照-耐高温)、氢能源储运装备(氢阻隔-高强韧)等。
  • 新疆维吾尔自治区自然科学基金资助项目(2024D01C210)
  • 新疆维吾尔自治区自然科学基金资助项目(2024D01C02)
  • 国家自然科学基金项目(52465049)
  • 昌吉学院校级科研项目(KY2024024)
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2026年第54卷第1期
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doi: 10.11868/j.issn.1001-4381.2025.000249
  • 接收时间:2025-04-29
  • 首发时间:2026-10-26
  • 出版时间:2026-01-20
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  • 收稿日期:2025-04-29
  • 录用日期:2025-05-13
基金
新疆维吾尔自治区自然科学基金资助项目(2024D01C210)
新疆维吾尔自治区自然科学基金资助项目(2024D01C02)
国家自然科学基金项目(52465049)
昌吉学院校级科研项目(KY2024024)
作者信息
    1.昌吉学院 航空学院,新疆 昌吉 831100
    2.昌吉学院 飞行器设计制造与维修重点实验室,新疆 昌吉 831100
    3.天水师范大学 机电与汽车工程学院,甘肃 天水 741001

通讯作者:

沙磊(1991—),男,副教授,硕士,研究方向为镍基高温合金,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
薛莲(1989—),女,讲师,硕士,研究方向为金属基复合材料制备,联系地址:新疆昌吉市世纪大道南段9号(831100),E-mail:
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2种不同金属材料的力学参数
科
Family
属数
Number of
genus
种数
Number of
species
占总种数比例
Percentage of
total species (%)
属
Genus
种数
Number of
species
占总种数比例
Percentage of total
species (%)
鹅膏菌科Amanitaceae 2 11 5.26 鹅膏菌属 Amanita 10 4.78
小菇科 Mycenaceae 2 12 5.74 丝盖伞属 Inocybe 5 2.39
多孔菌科 Polyporaceae 8 14 6.70 蜡蘑属 Laccaria 5 2.39
红菇科 Russulaceae 3 23 11.00 小皮伞属 Marasmius 6 2.87
小菇属 Mycena 11 5.26
光柄菇属 Pluteus 5 2.39
红菇属 Russula 17 8.13
栓菌属 Trametes 5 2.39
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