航空电连接器海洋环境加速试验与腐蚀仿真研究

目的 通过加速试验和有限元仿真,研究航空电连接器在南海岛礁服役条件下的失效行为和腐蚀机理.方法 根据典型航空装备南海服役环境数据,设计海洋环境加速腐蚀试验环境谱,基于此环境谱开展航空电连接器在实验室加速试验条件下的外观腐蚀、接触电阻、绝缘电阻和耐压强度的变化行为和机理研究.重点分析接触电阻变化原因,并基于水平集方法,建立插针插孔结合处的COMSOL有限元腐蚀仿真模型,模拟和验证接触件的腐蚀行为和机理.结果 3种规格的电连接器均发生壳体腐蚀,但程度不同,其中不锈钢壳体电连接器壳体腐蚀最轻,但壳体内部金属卡圈腐蚀最严重,其接触电阻波动最大.所有电连接器的耐压强度和绝缘电阻均有明显减小.结论 导致接触电阻增加的直接原因是插针和插孔结合处的毛细区内发生了严重腐蚀.有限元模型复现了腐蚀界面发展和腐蚀产物沉积过程.

Acceleration Test and Corrosion Simulation of Aviation Electrical Connectors in Marine Environment

This paper studied the failure behavior and corrosion mechanism of aviation electrical connectors in the islands and reefs in South China Sea under conditions of service by accelerated test and finite element simulation. An environmental spectrum of accelerated corrosion test in marine environment was developed according to environmental data of typical aviation equipment in service in South China Sea, based on this environmental spectrum, the change behavior and mechanism of appearance corrosion, contact resistance, insulation resistance and voltage strength of aviation electrical connectors were researched under laboratory accelerated test conditions. The reasons of the change of contact resistance were analyzed, and a COMSOL finite element corrosion simulation model of the joint of the pin and socket was built to simulate and verify the corrosion behavior and mechanism of contacts. The results showed that the corrosion degree of the three types of electrical connectors was different. The appearance corrosion degree of the connectors with stainless steel shell was the lightest, but the corrosion degree of the inner metal clamps was the most serious, and the contact resistance fluctuated the most. The voltage strength and insulation resistance of all electrical connectors were obviously reduced. The direct cause of the increase of contact resistance was the serious corrosion in the capillary area at the junction of the pin and jack. The finite element model reproduced the process of corrosion interface development and corrosion product deposition.