更强、更轻、更快：基于材料表征的航空航天工程轻量化

航空航天业正日益向轻量化方向发展，即在不牺牲机械强度、耐久性或性能的前提下，采用密度更低的材料。轻量化具有诸多优势，包括加快生产速度、提高能效以及改善可回收性。该方法的核心在于优化材料的强度重量比，使组件能够在保持或超越所需力学性能的同时，将总质量降至最低。

向轻量化方向的转变，与航空航天业向大规模、高产率生产转型的总体趋势相契合；这种转型要求能够更快速且具备可重复性地制造飞机、卫星及先进空中交通平台。在美国，NASA 致力于实现高效率制造，以提升美国的市场领导地位和成本效益^。1

轻量化得益于复合材料技术的进步，而复合材料现已成为航空航天领域的主导材料。预计未来六年，航空航天热塑性复合材料市场将以 16.8% 的复合年增长率增长，^这为能够满足该不断扩张市场独特需求的制造商提供了绝佳机遇。然而，生产用于航空航天领域的新一代轻质复合材料并非没有独特的挑战。本篇博文将探讨顶尖研究人员如何优化适用于航空航天领域的轻质高效复合材料，同时确保强度与性能不受影响。

夹层结构是一种多层高性能复合材料，由两层薄面板和一个轻质蜂窝状芯材组成。^这些材料具有高强度重量比和高刚度，使其成为航空航天应用的理想选择。有两种热分析技术适用于优化夹层结构，特别是在航空航天领域。热重分析（TGA）用于测定热稳定性和降解特性，帮助工程师选择在高温下不会丧失强度或发生失效的材料。差示扫描量热法（DSC）通过分析熔融、结晶和玻璃化转变行为，有助于确定理想的加工条件，并筛选出具有最佳相变特性的共混物。

研究人员利用 Waters TA Instruments 评估了不同的材料混合配方，开发出了新型 4D 打印生物基形状记忆夹层结构。^他们利用 Waters TGA 评估了新材料的热稳定性，证实了不同混合配方表现出几乎相同的热降解特性。他们利用符合 ASTM D3418 标准的 Waters DSC研究了熔融与结晶行为；结果显示，某些添加剂导致了玻璃化转变温度（Tg）的降低，且其中一种共混物表现出更显著的熔融吸热峰。这项分析对于确定不同混合物之间的差异以及选择最适合特定最终用途的混合物至关重要。

动态力学分析（DMA）为实现材料强度重量比的最大化提供了支持；该技术通过测量材料随时间、温度和频率变化的力学性能来进行分析。DMA（动态热机械分析）通过以下方式支持轻量化：量化储能模量以筛选高刚度、低质量的配方；表征阻尼特性（tan δ）以平衡结构刚度与振动耗散；以及监测热转变过程，确保材料在工作温度范围内保持足够的刚度。

高温推进系统依赖于BMI（双马来酰亚胺）等热固性材料，以利用其玻璃化转变温度（Tg）和热稳定性。NASA研究人员利用Waters DMA，在涵盖从低温到高温的典型火箭燃烧室工况下，对燃烧室用树脂进行了研究。测试结果证实，随着后固化温度的升高，玻璃化转变温度（Tg）^随之提高；但在低于Tg起始温度的所有温度范围内，模量均有轻微下降。

新型制造技术正在推动轻量化创新：感应焊接和超声波焊接能够高效实现大规模、高精度且品质一致的轻量化制造。DMA 通过评估储能模量和损耗模量随温度的变化情况，为焊接设计提供支持。研究人员利用^Waters DMA评估了预热对碳纤维/PEEK复合材料层合板超声波焊接的影响。数据表明，该材料的能量耗散能力随温度变化，这是焊接过程中生热的主要驱动因素。利用DMA（动态热机械分析），他们确定了损耗模量峰值——即材料将超声波振动转化为内部热能效率最高的点——并据此调整了预热工艺，以充分利用这一特性。

增材制造是另一种日益普及的轻量化材料生产方法，具有更高的自动化程度、复杂性、材料利用效率及设计灵活性。在近期的一项研究中，研究人员探讨了两种用于制造航空次承力结构碳纤维增强复合材料（ ^CFRP ）的增材制造方法。他们利用 Waters 动态热机械分析仪（DMA）研究了该材料的粘弹性行为与热转变特性，并使用热机械分析仪（TMA）测量了随时间、温度和力变化而产生的尺寸变化。他们发现，打印参数对尺寸稳定性有显著影响。

最后，热分析对于预测新型轻质材料的最终使用性能及安全性至关重要。例如，在开发用于飞机机身和机翼的复合材料T型接头时，研究人员利用DMA（动态热机械分析）、流变学和DSC（差示扫描量热法）研究了该接头在服役条件下的响应特性，以确保其在飞行过程中保持稳定。8^同样，Waters公司科学家发布的一份应用说明也展示了TGA（热重分析）在预测最终用途性能方面的重要性，因为它能够测定分解温度，并根据温度和时间估算聚合物的使用寿命^。9在这些研究中，热分析技术为那些专为严苛使用环境设计的新型轻质材料提供了最终用途性能预测支持，从而在降低风险的同时加速了创新进程。

上述研究表明，热力学分析对于验证轻质材料在严苛航空航天工况下的强度、使用寿命及稳定性至关重要。随着制造商不断追求更高的生产效率和更大幅度的减重，DSC、TGA、DMA 和流变学等技术提供了必要的数据，助力设计出不仅更轻，而且在整个使用寿命期间更安全、更可靠的材料。从优化加工条件到分析热降解，材料表征是实现轻量化安全与高效的基石。

1. Taminger, K. NASA 高速率航空结构技术计划；美国国家航空航天局，2020年。https://ntrs.nasa.gov/api/citations/20200004300/downloads/20200004300.pdf .
2. 拉贾特·佐佩。2032年航空航天热塑性复合材料市场规模与份额Persistence Market Research。https ://www.persistencemarketresearch.com/market-research/aerospace-thermoplastic-composites-market.asp （访问于 2026年5月18日）。
3. 嗯。Ilham Akbar; Bidayatul Armynah; Tahir, D. 夹层复合结构 (SCS)：以聚合物和金属为填料的木质电磁干扰（EMI）屏蔽材料研究综述Industrial Crops and Products 2024, 215, 118619–118619. https://doi.org/10.1016/j.indcrop.2024.118619 .
4. Ghalayaniesfahani, A.; Oostenbrink, B.; Kasteren, H. van; Gibson, I.; Mehrshad Mehrpouya.生物基形状记忆夹层结构的4D打印Polymer 2024, 307, 127252–127252. https://doi.org/10.1016/j.polymer.2024.127252 .
5. Stelter, C.; Park, C.; Chu, S.-H.; Hudson, T. 经历从低温到高温循环的复合材料缠绕燃烧室用后固化双马来酰亚胺树脂的动态力学分析。Nasa.gov. https://ntrs.nasa.gov/citations/20240012459 （访问于 2026-05-18）。
6. Takeda, S.; Kugi, D.; Hoshi, H.; Mohammad Fikry, MJ; Ogihara, S. 预热对CF/PEEK复合材料层合板超声波焊接的影响。Composite Structures 2025, 373, 119668. https://doi.org/10.1016/j.compstruct.2025.119668 .
7. Maier, R.; Istrate, AM; Despa, A.; Mandoc, AC; Bucaciuc, S.; Stoica, R. 增材制造技术制备的聚合物复合材料热力学响应研究。Materials 2022, 15 (14), 5069. https://doi.org/10.3390/ma15145069 .
8. 张涛, 罗震, 邓京, 裴雨, 程鑫. 基于预浸料-RTM共固化工艺的高弯曲性能复合材料螺栓连接T型接头制备新方法.Polymers 2024, 16 (9), 1259. https://doi.org/10.3390/polym16091259 .
9. Browne, J. 聚醚醚酮（PEEK）的热分析 – Waters TA Instruments。https ://www.tainstruments.com/applications-notes/thermal-analysis-of-polyether-ether-ketone-peek-ta496/ 。

The composites market is evolving fast. Global market projections indicate a 10.8 % growth by 2028, driven by the demand for composites across industries looking for materials with superior performance at reduced weight and cost.¹ This blog explores how advanced material analysis can enhance R&D and manufacturing processes in the composites market, ultimately leading to financial savings and increased efficiency.

While traditionally associated with the aerospace sector, composite materials have been adopted by several industries. Sectors actively utilizing composites include:

• Aerospace: Valued for their high strength-to-weight ratio, composites like carbon fiber reinforced polymer and aramid reinforced polymer enable the production of lighter, more fuel-efficient aircraft and satellites, contributing to reduced operational costs and increased payload capacities.²
• Automotive: A variety of automotive components, such as chassis and suspension systems, rely on composites for improved safety, fuel efficiency, and performance. Stringent emission regulations are driving this shift, including lightweighting automotive materials for enhanced fuel economy.³
• Renewable Energy: Composites are integral to the renewable energy sector, particularly in the construction of wind turbine blades and solar panel components. Companies are leveraging the dimensional stability, durability, and strength of these materials for operation under harsh environmental conditions, enhancing the longevity and efficiency of renewable energy systems.³
• Construction: Advanced composite materials, such as high-performance concrete mixes and fiber-reinforced polymers, can create structures more resistant to environmental degradation while offering excellent design flexibility. This improves construction longevity, reducing maintenance costs over time.⁴

While composites offer numerous advantages, manufacturers and material scientists face several challenges during their development and manufacturing including:

Designing and Selecting the Right Material

One of the main challenges in composites R&D is the selection of appropriate materials for specific applications. Researchers must consider criteria such as mechanical strength, thermal stability, and environmental resistance, which will entail the careful balancing of trade-offs between different performance characteristics.

Increased Complexity of Material Design

In achieving the desired balance of characteristics, scientists need to precisely control parameters such as filler orientation and distribution. Research has shown that the incorporation of nanofillers into a polymer matrix can bolster its mechanical properties and reduce water absorption in fiber-reinforced composites. As a result, strong interfacial adhesion is established between the matrix and nanofillers, allowing for efficient stress transfer during loading.

However, if not properly managed, the orientation and distribution of fillers within a composite can lead to variations in strength and other properties. The subsequent effect on the interfacial interactions can induce premature failure in the material.⁵

Sustainability

Reinforced polymer composites present several benefits, including the conservation of depleting resources such as metals and alloys. However, their disposal poses significant environmental challenges due to the non-biodegradable nature of petroleum-based polymers and synthetic fibers.

Consequently, research has increasingly focused on developing fully biodegradable and eco-friendly materials known as green composites. The use of green composites has significantly expanded across various engineering disciplines, yet the limited solubility of lignin-based materials for analytical purposes restricts the complete understanding and development of lignin-based green composites.⁶

New Manufacturing Techniques

Techniques like lightweighting and additive manufacturing deliver benefits but also introduce new challenges. Lightweighting replaces heavy materials with lighter-weight composites without compromising strength-to-weight ratios or structures’ fundamental design, while additive manufacturing increases throughput and design complexity. However, researchers must tackle the expensive nature of lightweighting processes, which can also risk impairing the ductility and formability of the materials, as well as concerns regarding the fabrication of composites with long fibers and complex cavities that surround additive manufacturing.^7,8

High Manufacturing Costs

Producing complex composite parts can require costly raw materials, specialized equipment, and skilled labor, leading to high costs. Effective quality control measures are essential to ensure that the final products meet the required standards without excessive waste or rework.⁹

To overcome these challenges, precise material analysis is essential. Key material properties to measure include:

• Glass Transition and Crystallinity: Differential Scanning Calorimetry (DSC) is a powerful technique for measuring the glass transition temperature and crystallinity of composites. These parameters are critical for understanding the thermal and mechanical properties of the material. For example, NASA uses a TA Instruments DSC to determine the quality of thermoplastic composite panels, which is vital for ensuring their performance in space applications.¹⁰ Further examples of real-world composites research using DSC can be found in our blog.
• Cure Kinetics, Cross-Linking, Gelation, and Cure Conversion: DSC paired with LED-PCA accessory can measure cure kinetics and the extent of cross-linking, gelation, and cure conversion in composite materials. These measurements help optimize processing conditions to achieve the desired mechanical properties and durability.^11,12
• Structural Relaxation, Time-Temperature Superposition, and Aging: Dynamic Mechanical Analysis (DMA) provides insights into the viscoelastic behavior of composites, including structural relaxation, time-temperature superposition, and aging effects. This information is key for predicting the long-term performance and stability of composite materials under various, sometime harsh, environmental conditions.¹³ Learn more about DMA testing of composites in this blog.
• Coefficient of Thermal Expansion: Thermomechanical Analysis (TMA) measures the coefficient of thermal expansion, which is important for understanding how composite materials will behave under thermal cycling. This is particularly relevant for applications where materials are exposed to varying temperatures, such as in aerospace and automotive industries.¹⁴

In response to the rising demand for materials that combine superior performance with low weight and cost, the composites market is rapidly expanding. This growth trajectory underscores the importance of addressing inherent challenges in the development and manufacturing of composites, such as selecting and designing appropriate materials, ensuring sustainability, implementing new manufacturing techniques, and managing high production costs.

Advanced material analysis techniques, including DSC, DMA, and TMA, are crucial in overcoming these challenges. These techniques provide critical insights into the thermal and mechanical properties of composites, enabling researchers and manufacturers to optimize processes and achieve the desired performance and durability.

TA Instruments supports composite R&D with cutting-edge material analysis instruments, helping you to overcome the complexities of composite design and manufacturing. By investing in advanced material analysis, companies can lower costs, increase efficiency, and stay competitive in the rapidly evolving composites market.

For more information on how TA Instruments can support the R&D of your composites, visit our composites page or contact us to speak with an expert.

技术的发展日新月异。无论您是升级旧设备还是为您的工作台添加新技术，使用尖端仪器都一定会提高您实验室的效率和成果。新型仪器可提供更可靠的数据和更先进的功能，这对于始终立足于材料创新前沿而言至关重要。

但是，如何在升级仪器以获得最佳投资回报的同时最大限度地减少停机时间呢？以下是可让您无缝且轻松地升级实验室的 4 种方法。

用最新型号的仪器更换服务多年的老旧仪器是改善实验室结果的最简单的方法之一。更好的消息是，您可以用旧仪器换取升级折扣。

2000 年推出的 TA Instruments Q 系列热分析仪彻底革新了测量方法，Discovery 系列以其改进的测量和易用性延续了品牌传统。用户可对其 Q 系列 DSC、TGA、DMA、SDT、TMA 仪器或竞争型号仪器进行以旧换新，以节省购买新的 Discovery 系列热分析仪的费用。Discovery 系列提供无与伦比的灵敏度和准确性，可检测样品中的最小变化，并通过强大的 TRIOS 软件提供革命性的用户体验。点击此处以解更多信息并联系我们以对您的热分析仪进行以旧换新。

同样，您可以对 TA Instruments AR 流变仪或竞争型号仪器进行以旧换新，以节省购买新的 Discovery 混合流变仪的费用。升级到 DHR 实现了卓越的功能改进 – 由于 DHR 优异的扭矩灵敏度，用户可使用更少的样品测量更低的黏度和更小的应力。该仪器的混合功能是游戏规则的改变者：可在一台含集成线性 DMA 的流变仪上进行剪切流变学、黏性/剥离、拉伸黏度测量，以及张力、弯曲和压缩测量。DHR 广泛的功能和配件（包括与许多 AR 配件的兼容性）可为您实验室未来可能需要的任何测量提供保障。联系我们以了解有关流变仪以旧换新的更多信息。

除节省成本外，对您的热分析仪或流变仪进行以旧换新也非常易于操作且回报丰厚：

• 通过承接已有的历史数据和操作程序实现平稳过渡
• 使用新的“无人值守”自动进样器减少瓶颈（可在特定的热分析仪型号上使用）
• 借助专为每个用户级别的易用性而构建的 TRIOS 软件，最大限度地减少操作适应时间
• 通过可靠的结果和更高的准确性提高数据可信度
• 通过新功能和测量选项扩展实验室能力

3D 打印也称为增材制造，许多行业都将其视为一种多功能制造技术。3D 打印可以实现快速成型和按需打印服务，以避免批量运行带来的潜在浪费。

3D 打印拥有创造复杂形状的独特能力，被广泛应用于制造业。许多标准制造方法无法在结构中产生空腔和底切。添加模式可以轻松创造各类独特形状。

3D 打印目前已扩展到一系列材料，包括生物相容性聚合物和各类金属。3D 打印甚至被用于医疗保健等领域，用于定制打印医疗设备。¹

为了优化 3D 打印材料，制造商需要仔细考虑最终材料的机械和热性能。虽然 3D 打印部件往往很轻，而且聚合物部件的正确组合可以拥有与金属相似的抗拉强度，但克服增材制造部件较低的机械和热性能是最大的挑战之一。²

了解挤压过程如何影响打印材料的最终性能是一个非常热门的研究领域。汽车应用对材料的拉伸和热性能要求最高。

幸好，目前有许多含有碳纤维、玻璃纤维和凯夫拉纤维的热塑性聚合物基质可用于 3D 打印部件，并能够在汽车应用中充分实现高性能。²

在 3D 打印过程中，要打印的基材被熔化，然后分层沉积以创建最终对象。在此过程中有多个参数可以优化，例如聚合物床层和喷嘴温度以及层间固化时间。

3D 打印有多种方法，包括选择性激光烧结、生物打印和熔融沉积建模。熔融沉积建模是最常用的方法。

玻璃态转化温度是选择正确温度挤压非晶态聚合物的必要信息。对于半结晶聚合物，其熔化温度是应重点关注的数值。结晶度强烈影响聚合物的机械性能。

许多聚合物用紫外线固化，紫外线在聚合物材料中产生自由基，作为最终聚合物生产中交联过程的引发剂。交联程度越高，材料的硬度和强度就越高。通过改变样品暴露在紫外线下的时间长度可以影响交联的材料强度。

温度和固化时间都会影响聚合物在材料中的分子结构及其性能。因此，为了优化这些参数并探索其对最终材料的影响，材料设计师使用对聚合物性能细节敏感的测试技术。