Composite Actuator Plating for Wear and Moisture Resistance

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Solution Overview

Problem

Aircraft engine actuators made from traditional metals like aluminum or titanium are costly and heavy, and the use of composite materials is limited due to concerns over wear and high-temperature performance, with chrome plating being phased out due to regulatory issues.

Innovation Solution

The use of a multi-layer plating process on composite material actuators, including electroless copper, electrolytic copper, nickel strike, and a finishing layer, enhances wear resistance and temperature tolerance, reducing weight and cost while meeting aerospace standards.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional metal actuators (aluminum or titanium) are used, then structural strength and wear resistance are achieved, but weight and cost increase significantly

Engineering Contradiction:

Improvestructural strengthVSAvoidactuator weight

Core Design Contradiction:

StrengthVSWeight of moving object

Solution Approach 1:

The patent uses composite materials (such as carbon fiber reinforced polymers) to replace traditional metal actuators. The composite material structure provides sufficient structural strength while significantly reducing the weight of the actuator, directly resolving the contradiction between strength and weight.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies chrome plating or other protective coatings only to specific surfaces of the composite actuator that require wear resistance, rather than making the entire actuator from heavy metal. This localized application maintains strength where needed while preserving the weight advantages of composite materials in other areas.

Inventive Principle:

Principle #3Local quality

2Reliability

If chrome plating is applied to composite material actuators to improve wear resistance, then wear characteristics are enhanced, but environmental compliance deteriorates due to chrome being a regulated material

Engineering Contradiction:

Improvewear resistanceVSAvoidenvironmental compliance

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes chrome from the plating process entirely, extracting the harmful substance while maintaining the functional requirement for wear resistance. Alternative plating materials such as nickel, zinc, or diamond-like carbon coatings are used instead, providing the same protective function without the environmental compliance issues.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent employs alternative plating materials that may require more frequent reapplication or have different service lives compared to chrome, but eliminate the environmental harm. These alternatives can be applied as thin, cost-effective layers that provide adequate wear protection for the intended application lifecycle without regulatory restrictions.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

3Weight of moving object

If composite material actuators are used to reduce weight and cost, then weight and manufacturing cost decrease, but wear resistance and high-temperature performance deteriorate

Engineering Contradiction:

Improveactuator weightVSAvoidwear resistance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent uses advanced composite materials with enhanced properties that inherently provide better wear resistance and high-temperature performance compared to traditional composites. The composite structure is engineered to maintain mechanical properties under elevated temperatures and wear conditions while preserving weight advantages.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The patent applies protective plating layers to specific high-wear or high-temperature exposure areas of the composite actuator. This localized protection enhances reliability where needed most while preserving the overall weight and cost benefits of the composite construction in non-critical areas.

Inventive Principle:

Principle #3Local quality

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

The plating process significantly improves the performance of composite material actuators, reducing weight and cost while ensuring they meet structural and wear requirements for aerospace applications, even in high-temperature environments, without relying on chrome.

Implementation Method 1

an electroless copper layer over the roughened surface

Methodology Applied

Scientific EffectElectroless plating: Chemical Beam Epitaxy

Implementation Method 2

an electrolytic copper layer over the electroless copper layer

Methodology Applied

Scientific EffectElectrolytic plating: Electrodeposition

Implementation Method 3

a nickel strike layer over the electrolytic copper layer

Methodology Applied

Scientific EffectElectrolytic plating: Electrodeposition

Implementation Method 4

a finishing layer over the nickel strike layer

Methodology Applied

Scientific EffectElectrolytic plating: Electrodeposition

Data Source

PatentEP2913426B1Metal plated wear and moisture resistant composite actuator

Publication Date: 2023.12.27 HAMILTON SUNDSTRAND CORP

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AI summary

A component is provided including a body formed at least partially from a composite material. At least a portion of the composite material is covered by a plating. The plating includes a layer of electroless copper, a layer of electrolytic copper, a layer of nickel strike, and a finishing layer. A method of plating (100) is also disclosed.