重载阻尼构件注射成型中微相取向结构的在线表征与精确调控

Thermoplastic elastomers have been widely used in producing damping parts. As national development strategy requires, it needs to extend the service performance of heavy-load damping parts that are used in high-end equipment. Micro-phase orientation of thermoplastic elastomers is the dominating factor that influences their service performance. However, evolution of the micro structure during the molding process is too complicated to control, and consequently the service performance of these parts becomes unpredictable and even deteriorated. To address this issue, an online methodology is proposed for characterizing and controlling the micro-phase orientation of the injection molded heavy-load damping parts. A novel method of online characterization using ultrasonic longitudinal waves is presented, which can be used to monitor the evolution of the micro-structure during molding process. The influence of micro-phase orientation on the parts’ service performance can be revealed. A new technique that can effectively control the micro-phase orientation basing on the field of vibration and shear-temperature is developed. On the basis of above technologies, an integrated optimization and precise control method for molding process - micro-phase orientation - service performance can be developed, and the method is applied in manufacturing the buffers of 20,000-tons-loaded train. This project could have significant contribution in breaking the technical bottleneck in molding heavy-load damping parts, proposing novel methods for achieving online characterization and precise control during the molding process, and developing advanced theory and technology in the discipline of high performance precise molding.

热塑性弹性体聚合物广泛用于制造阻尼构件，发展高端装备的国家战略需求对重载阻尼构件提出了更严格的服役性能要求。热塑性弹性体微相取向结构是影响其服役性能的最主要因素，但注射成型中微相取向演化复杂且难以控制，导致构件服役性能劣化。为此，本项目提出注射成型重载阻尼构件微相取向结构在线表征与精确调控新思路：提出微相取向结构超声纵波在线表征新方法以明晰其成型过程中的演变行为，揭示考虑微相结构演化的构件服役性能形成规律，发展行之有效的振荡剪切-温度外场精确调控新手段，最终形成重载阻尼构件成型工艺-微相取向-服役性能的集成优化与成形成性新技术，并在20000吨重载列车缓冲装置等典型高端装备中应用验证。项目的实施对突破重载阻尼构件成型的技术瓶颈，探索材料成型过程在线表征与精确调控的新方法，发展高性能精确成形制造学科前沿理论与技术具有重要意义。

本项目对聚合物注射成形过程在线测量、介观结构演化机理、工艺参数智能优化和产品质量高效检测等关键基础问题进行了深入研究，成功注射成形出重载列车缓冲构件，取得工作进展如下：1）开发出成形过程信息的超声纵波在线测量方法，构建聚合物温度、密度与超声参量关联模型，实现了成形过程中熔体温度和密度的超声在线无损测量，为缓冲构件的制造提供重要成形信息；2）研究了介观结构的成形演化机理，建立聚合物物性参数的高精度计算方法，研制出注射成形中介观取向结构演化研究平台，为缓冲构件的制造提供关键理论支撑；3）研发出产品形性一体化智能调控方法，开发出工艺参数无模型自学习优化方法，解决了产品试制过程中工艺参数只能凭经验或简单规律进行反复“试凑”的难题，为缓冲构件的制造提供最优工艺参数；4）提出了原材料一致性及产品内部缺陷的磁悬浮高效检测方法，建立起原材料密度与磁悬浮高度的关联模型，实现了聚合物原材料一致性的磁悬浮高效评价，推导出密度分布-悬浮姿态关联模型，搭建大型阵列化磁铁磁悬浮检测装置，实现了聚合物内部缺陷的无损检测，为缓冲构件的制造提供高效检测手段；5）利用上述技术成果开展了产品试制研究，注射成形出重载列车缓冲构件。经测试实验验证，缓冲构件具有缓冲吸能作用，动态容量＞70kJ，能量吸收率＞80%，最大静态阻抗力≥1200kN。.在本项目执行期间，研究成果获2019年国家科学技术进步奖二等奖、2021年浙江省科学技术进步一等奖、2021年中国产学研合作创新成果一等奖。项目负责人入选教育部青年长江学者。本项目已发表SCI论文35篇（其中3篇封面论文）；参加国内外学术会议9次，其中作大会报告1次、主旨报告2次；申请并授权发明专利7件（包括美国专利1件），专利转化37.2万元；培养博士后2人、博士生11人、硕士生13人。