Composite Attachment Insert for Machining-Free Metal Coupling

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Solution Overview

Problem

Conventional attachment systems for gas turbine engines require machining of composite components, leading to increased manufacturing time and cost.

Innovation Solution

An attachment assembly that eliminates the need for machining composite components by using an insert with an annular wall and flange, a bushing with an annular wall and flange, and a spring washer, which are co-cured with the composite component, allowing for secure coupling without machining.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional attachment systems are used to couple composite components, then secure coupling is achieved, but machining of composite components is required which increases manufacturing time and cost

Engineering Contradiction:

Improvemanufacturing time and costVSAvoidattachment system complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The attachment system is divided into separate functional components: a composite component with integrated attachment features, a metallic component, and a fastening system. The composite component includes an insert with an insert aperture and a recess, while the metallic component has a bushing with a bushing aperture. This segmentation allows each component to be manufactured independently using appropriate processes, eliminating the need for machining the composite component while maintaining secure coupling capability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The insert and bushing act as intermediary elements between the composite component and the metallic component. The insert is embedded in the composite component during manufacturing, and the bushing is received by the insert. These intermediaries provide the necessary mechanical interfaces for fastening without requiring post-manufacturing machining of the composite component, thus reducing manufacturing time and cost while ensuring secure attachment.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If machining is performed on composite components to enable attachment, then attachment capability is achieved, but manufacturing time and cost increase

Engineering Contradiction:

Improveattachment capabilityVSAvoidmanufacturing time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The attachment features (insert with aperture and recess) are incorporated into the composite component during the initial manufacturing process rather than being added through subsequent machining operations. The insert is placed in the mold and co-cured with the composite material, creating a pre-integrated attachment system that is ready for assembly without requiring additional machining time.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The solution utilizes composite material manufacturing techniques to integrate metallic inserts into the composite structure during the curing process. This approach leverages the capabilities of composite manufacturing to embed functional elements, eliminating the need for traditional machining operations on composite materials and significantly reducing manufacturing time while maintaining attachment reliability.

Inventive Principle:

Principle #40Composite materials

3Reliability

If machining is performed on composite components, then attachment capability is achieved, but manufacturing cost increases

Engineering Contradiction:

Improveattachment capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The manufacturing process merges the creation of the composite component and the integration of the metallic insert into a single operation. The insert is placed in the mold cavity and co-cured with the composite material in one process step, eliminating the need for separate machining operations. This merging of processes reduces manufacturing complexity and cost while ensuring reliable attachment capability.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The solution replaces traditional mechanical machining operations with a chemical/curing-based integration process. Instead of using cutting tools to create attachment features after composite manufacturing, the insert is chemically bonded to the composite matrix during the curing process. This substitution eliminates expensive and time-consuming machining operations while maintaining secure mechanical attachment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS11859509B2Metallic attachment system integrated into a composite structure

Publication Date: 2024.01.02 GENERAL ELECTRIC CO

AI summary

The present disclosure is directed to a composite component defining a component aperture extending between a first surface and a second surface. The composite component includes an insert having an insert annular wall positioned in the component aperture. The insert annular wall defines an insert aperture therethrough. An insert flange extends radially outwardly from the insert annular wall and contacts the first surface of the composite component. The insert flange includes a diameter about 1.5 times to about 5 times greater than a smallest diameter of the component aperture defined by the composite component.