Research on quality optimization of RTM molding for aircraft radome

doi:10.19936/j.cnki.2096-8000.20260928.015

Abstract

Abstract: Aiming at the engineering problems such as large dimensional deviation, numerous internal defects and poor quality consistency that may occur in the RTM batch production for aircraft radome, studies were carried out on runner design, mold thermal compensation, process parameter optimization and optimization of non-destructive testing methods. Taking the wedge-shaped thin-walled cylinder component with a large opening (outer diameter Φ_A, height H, wall thickness 1.6 mm) as the research object, the resin flow, thermal stress deformation and defect assessment mechanism were systematically analyzed by means of ESI Group numerical simulation, GOM 3D scanning and rotary through-transmission water ultrasonic testing. The results show that the triggered linear one-inlet-one-outlet runner can significantly improve the filling uniformity and control the injection time within the process window. After mold thermal compensation and profile dimension compensation, the maximum outline deviation is reduced from 4 mm to less than 1.5 mm. The rotary through-transmission water ultrasonic method enables efficient non-destructive testing of thin-walled components embedded with copper mesh, and the products meet the Class C requirements of GJB 2895-97. This research can provide engineering references for the quality consistency control of RTM molded complex curved components of aviation composite materials.

Key words: RTM, radome, quality consistency, runner optimization, thermal deformation compensation, water ultrasonic testing

CLC Number:

TB332

XU Ting, WANG Yang, YAO Qi, WU Haisheng, YU Shuai, HAN Baozhuang. Research on quality optimization of RTM molding for aircraft radome[J]. COMPOSITES SCIENCE AND ENGINEERING, 2026, 0(9): 131-137.

References

[1] 闫学良, 赵铭, 穆亚南, 等. 美军下一代电子干扰吊舱技战术剖析[C]//第十三届中国指挥控制大会论文集. 北京: 中国指挥与控制学会, 2023: 509-512.
Yan Xueliang, Zhao Ming, Mu Yanan, et al. Technical and tactical analysis of the US military's next-generation electronic jamming pod[C]//Proceedings of the 13th China Command and Control Conference. Beijing: Chinese Institute of Command and Control, 2023: 509-512.
[2] 朱庆流, 叶元鹏, 黄飞, 等. 机载电子吊舱舱体设计[J]. 电子机械工程, 2023, 39(4): 8-12, 64.
Zhu Qingliu, Ye Yuanpeng, Huang Fei, et al. Cabin structure design of airborne electronic pod[J]. Electro-Mechanical Engineering, 2023, 39(4): 8-12, 64.
[3] 叶明, 朱恒义. 某机载电子吊舱天线罩结构设计[J]. 舰船电子对抗, 2022, 45(1): 98-101.
Ye Ming, Zhu Hengyi. Structure design of radome for an airborne electronic pod[J]. Shipboard Electronic Countermeasure, 2022, 45(1): 98-101.
[4] 陈祥宝. 先进复合材料低成本技术[M]. 北京: 化学工业出版社, 2004.
Chen Xiangbao. Low-cost technology of advanced composite materials[M]. Beijing: Chemical Industry Press, 2004.
[5] 沈尔明, 李晓欣, 王刚, 等. 先进复合材料在国外航空发动机应用与发展[J]. 航空材料学报, 2026, 46(2): 1-12.
Shen Erming, Li Xiaoxin, Wang Gang, et al. Application and development of advanced composite materials in foreign aero engines[J]. Journal of Aeronautical Materials, 2026, 46(2): 1-12.
[6] 候春莉, 焦卫卫, 王荣国, 等. 树脂基复合材料的可持续性发展现状及技术管理建议[J/OL].复合材料科学与工程, 2026-03-12. https://link.cnki.net/urlid/10.1683.TU.20260312.1025.003.
Hou Chunli, Jiao Weiwei, Wang Rongguo, et al. Sustainable development status and technical management suggestions of resin basedcomposites[J/OL]. Composites Science and Engineering, 2026-03-12. https://link.cnki.net/urlid/10.1683.TU.20260312.1025.003.
[7] 高丽红, 杨健, 刘刚, 等. 碳纤维增强高温固化环氧RTM复合材料应用性能研究[J]. 高科技纤维与应用, 2025, 50(5): 48-57.
Gao Lihong, Yang Jian, Liu Gang, et al.Research on the performance and application of carbon fiber reinforced high-temperature curing epoxy RTM composites[J]. Hi-Tech Fiber and Application, 2025, 50(5): 48-57.
[8] 刘文浩, 李炜, 曾亮, 等. HP-RTM用树脂体系研究进展[J]. 材料导报, 2025, 39(增刊2): 718-722.
Liu Wenhao, Li Wei, Zeng Liang, et al. Research progress of resin system for HP-RTM[J]. Materials Reports, 2025, 39(S2): 718-722.
[9] 章宇界, 叶鹏华, 李翔宇, 等. 软模辅助RTM工艺在三维编织复合材料制备中的应用[J]. 工程塑料应用, 2025, 53(10): 81-87, 115.
Zhang Yujie, Ye Penghua, Li Xiangyu, et al.Application of soft mould assisted RTM process in preparation of three-dimensional braided composites[J]. Engineering Plastics Application, 2025, 53(10): 81-87, 115.
[10] 刘西振, 苏佳智, 陈旭, 等. 复合材料自动成型工艺进展及其在航空中的应用[J]. 合成纤维, 2025, 54(11): 68-70.
Liu Xizhen, Su Jiazhi, CHEN Xu, et al.Progress in automated forming processes of composite materials and their applications in aviation[J]. Synthetic Fiber in China, 2025, 54(11): 68-70.
[11] 李红强. 铺缝液体成型复合材料主要缺陷检测及识别研究[D]. 北京: 北京化工大学, 2020.
Li Hongqiang.Inspection and recognition on the defects of laminates manufactured by liquid composites molding with tailored fiber placement[D]. Beijing: Beijing University of Chemical Technology, 2020.
[12] 刘伟, 李红强, 舒巍, 等. 铺缝液体成型复合材料孔隙率与超声衰减系数关系研究[J]. 高科技纤维与应用, 2021, 46(6): 39-43.
Liu Wei, Li Hongqiang, Shu Wei, et al.Study on the relationship between pore morphology and ultrasonic attenuation coefficient of TFP liquid molding composites[J]. Hi-Tech Fiber and Application, 2021, 46(6): 39-43.
[13] 胡昊, 薛小锋, 宋祉岑, 等. 面向液体成型结构的双尺度孔隙率分区刚度折减方法[J/OL]. 复合材料学报, 2025-10-09. https://doi.org/10.13801/j.cnki.fhclxb.20251009.009.
Hu Hao, Xue Xiaofeng, Song Zhicen, et al. Dual-scale porosity partition stiffness reduction method for liquid forming structure[J/OL].Acta Materiae Compositae Sinica, 2025-10-09. https://doi.org/10.13801/j.cnki.fhclxb.20251009.009.
[14] 李玉军, 闫超. 复合材料液体成型技术中的孔隙形成、演化及调控研究进展[J]. 复合材料学报, 2026, 43(3): 1309-1327.
Li Yujin, Yan Chao.Research progress on void formation, evolution, and control inliquid composite molding technology[J]. Acta Materiae Compositae Sinica, 2026, 43 (3): 1309-1327.
[15] 何梓科. 复杂型面航空复合材料力学性能与缺陷形貌超声原位无损检测方法[D]. 深圳: 中国科学院深圳先进技术研究院, 2024.
He Zike. Ultrasonic in-situ nondestructive testing method for mechanical properties and defect morphology of aeronautical composites with complex shape[D]. Shenzhen: Shenzhen Institutes of Advanced Technology, Chinese Academy of Sciences, 2024.
[16] 姜劲驰, 李文晓, 方可言. 人工智能方法在RTM工艺仿真中的应用[J]. 材料导报, 2026, 40(1): 263-270.
Jiang Jinchi, Li Wenxiao, Fang Keyan. The application of artificial intelligence methods in RTM simulation[J]. Materials Reports, 2026, 40(1): 263-270.
[17] 张淏龙, 郭平安, 金飞翔, 等. 复合材料层合板RTM工艺的模流分析与优化[J]. 塑性工程学报, 2025, 32(12): 154-163.
Zhang Haolong, Guo Ping'an, Jin Feixiang, et al. Mold flow analysis and optimization of RTM process for composite laminates[J]. Journal of Plasticity Engineering, 2025, 32(12): 154-163.
[18] XU Ting, Wu Haisheng, Sheng Chao, et al. Research on the manufactured technology of high-precision load connecting frame structure with special-shaped variable shaped cross-section[J]. Journal of Physics: Conference Series, 2023, 2639(1): 012030.
[19] Sangle K J, Sawate R A, Shirale O D, et al. Effect of guar gum on viscosity of ice cream[J]. Asian Journal of Dairy and Food Research, 2015, 33(4): 259-262.
[20] 宋豪, 杜薇, 周芷言, 等. 不同工艺参数下干纤维预制体面内渗透特性分析及仿真模拟验证[J]. 产业用纺织品, 2026, 44(3): 1-10, 31.
Song Hao, Du Wei, Zhou Zhiyan, et al.Analysis and simulation verification of in-plane permeability characteristics of dry fiber preforms under different process parameters[J]. Technical Textiles, 2026, 44 (3): 1-10, 31.
[21] 李先阳, 刘彬, 于雅琳, 等. 碳纤维复杂构件LCM成型工艺技术发展综述[J]. 复合材料科学与工程, 2023(11): 116-121.
Li Xianyang, Liu Bin, Yu Yalin, et al.A review of the development of LCM forming technology for carbon fiber complex components[J]. Composites Science and Engineering, 2023(11): 116-121.
[22] 彭勃. 考虑温度影响的纺织复合材料RTM接头设计与模拟仿真研究[J]. 纺织报告, 2025, 44(7): 4-6.
Peng Bo.Design and simulation study of RTM joint for textile composite materials considering temperature influence[J]. Textile Reports, 2025, 44(7): 4-6.
[23] 周钰博, 李敏, 王绍凯, 等. 面向AI时代的纤维增强树脂基复合材料工艺仿真[J]. 航空材料学报, 2024, 44(5): 17-36.
Zhou Yubo, Li Min, Wang Shaokai, et al.Process simulations of fiber reinforced polymer composites towards AI ages[J]. Journal of Aeronautical Materials, 2024, 44(5): 17-36.
[24] 汪晓允, 赵宏飞, 李明明, 等. 多墙结构副翼RTM整体成型工艺研究[J]. 合成纤维, 2023, 52(5): 80-84.
Wang Xiaoyun, Zhao Hongfei, Li Mingming, et al. Research on RTM integral formingprocess of multi-wall structure ailerons[J]. Synthetic Fiber in China, 2023, 52(5): 80-84.
[25] 刘广华, 姚丁杨, 沈蒙莎, 等. 基于正交试验优化HP-RTM成型工艺参数[J]. 上海塑料, 2025, 53(6): 20-24.
Liu Guanghua, Yao Dingyang, Shen Mengsha, et al. Optimizing HP-RTM molding process parameters based on orthogonal tests[J]. Shanghai Plastics, 2025, 53(6): 20-24.