Composite reinforcement of metallic structural elements

Abstract

A selectively reinforced hybrid metal-composite structural element can include a metal element and a composite material. The composite material can be bonded to the metal element by an adhesive layer including a polymer matrix using a radiation curing process, resulting in insubstantial or negligible residual stresses at the bond line between the metal element and the composite element. The structural element also can include a metal closeout cap to provide a barrier from a corrosive atmosphere, and the adhesive layer can encapsulate the composite element to provide a corrosion-resistant barrier between the composite element and the surrounding metal.

Description

FIELD OF THE INVENTION [0001] The present disclosure relates generally to structural reinforcement. More particularly, the present invention relates to selective reinforcement of metallic structural elements using composite materials. BACKGROUND OF THE INVENTION [0002] Structural elements are used to maintain the structural integrity of a wide variety of structures, including, for example, bridges, buildings, airplanes, trains, sea vessels and propellers. A structural element for a particular application generally can be either selected from existing types of commonly available structural elements or specially designed to suit the needs of an application. [0003] In either case, the cross-sectional shape of the structural element often is selected or designed to include more material at locations in the cross-section that will experience greater stress under the design loading. Thus, structural elements can be designed to carry specific types of loads. For example, common structural ...

AI Technical Summary

Benefits of technology

[0008] In accordance with one aspect of the present invention, a reinforced hybrid structural element can include a metal element and a composite ply. In addition, the composite play can be bonded to the metal element using radiation. The structural element can optionally include an adhesive layer that is at least partially cured using radiation in order to bond the composite ply to the metal element.

[0009] In accordance with another aspect of the present invention, a method of manufacturing a selectively reinforced hybrid structural element can include the steps of providing a metal element and laying up a composite ply over at least a partial surface of the metal element. In addition, the met

Problems solved by technology

However, when composite materials have been bonded to metal elements using conventional thermal composite matrix curing techniques, in at least some instances the differential thermal contraction between the metal element and the composite material following the relatively high-temperature curing has resulted in significant residual stresses at the bond interface between the metal element and the composite material, weakening the structure and essentially defeating the purpose of bonding the two materials.

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