Carbon Composite Brazing With Metal Carbide Bond Layers
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Carbon composite components in high-temperature applications, such as aerospace, face challenges in forming durable bonds with other components due to the inability of braze materials to adhere effectively, often requiring mechanical fasteners which can be undesirable and lead to delamination and oxidation issues.
Innovation Solution
A method involving the formation of a high-temperature coating with a metal carbide bond layer on carbon composite substrates, allowing for bonding with braze materials at lower temperatures without mechanical fasteners, using techniques like metal infiltration and surface modification to enhance adhesion and resistance to delamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical fasteners are used to join components to carbon composites, then the bonding strength is improved, but the risk of delamination and oxidation increases
Solution Approach 1:
The patent replaces mechanical fastening systems with a chemical bonding system. A braze material is applied to the carbon composite surface and activated through heating or pressure, creating a metallurgical bond without mechanical fasteners. This substitution eliminates stress concentration points and prevents delamination while maintaining bonding strength.
Solution Approach 2:
The patent uses a composite bonding system consisting of a braze material layer applied to the carbon composite surface. This composite structure combines the carbon composite substrate with a metallurgical bonding layer, creating a hybrid material system that provides both strong bonding and resistance to delamination and oxidation.
2Reliability
If high temperature brazing is used to join components, then the bonding durability is improved, but the manufacturing complexity increases
Solution Approach 1:
The patent applies the braze material to the carbon composite surface in advance, before the final assembly and bonding operation. This preliminary application allows the material to be positioned and prepared, then activated through heating or pressure during assembly, simplifying the overall manufacturing process while ensuring durable bonds.
Solution Approach 2:
The patent utilizes changes in temperature and pressure parameters to activate the braze material and create strong bonds. By controlling these parameters during the bonding process, the patent achieves high-temperature brazing durability while managing manufacturing complexity through precise parameter control.
3Weight of moving object
If carbon composites are used for contact surfaces, then the weight is reduced, but the suitability for functional applications decreases
Solution Approach 1:
The patent creates a composite structure where a carbon composite substrate provides lightweight structural support, while a braze material layer applied to the surface provides enhanced functional properties. This composite approach allows the carbon composite to maintain its weight advantage while the surface layer improves suitability for specific functional applications like contact surfaces.
Solution Approach 2:
The patent applies the braze material selectively to specific surface areas of the carbon composite component where functional performance is needed. This local application allows the carbon composite to remain lightweight overall while providing enhanced functional properties only where required, such as at contact surfaces or interface areas.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables robust, durable bonding of components at high temperatures, reducing the need for mechanical fasteners and enhancing resistance to oxidation, thus improving the performance and longevity of carbon composite components in harsh environments.
Implementation Method 1
A surface portion of a carbon composite may be converted by infiltration with a metal to form a bond layer which includes metal carbide
Implementation Method 2
infiltration with a metal to form a bond layer which includes metal carbide
Implementation Method 3
components may be bonded to carbon composites using relatively low temperature brazing techniques
Implementation Method 4
The braze material may form a stronger bond with the bond layer which includes metal carbide layer
Data Source
AI summary
An apparatus includes a first component comprising a carbon composite substrate. A high temperature coating is disposed on the surface of the carbon composite substrate. The high temperature coating includes a bond layer of a metal carbide on the surface of the substrate. The apparatus includes a second component, and braze material joining the surface of the first component to the second component. In some examples, a brake assembly may include a rotor having a surface configured to interface with another component of the brake assembly. The brake assembly includes an insert joined to the surface of the rotor without a mechanical fastener, and the insert defines a tough mechanical contact surface configured to protect the rotor.