Erosion Protection for Composite Components
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Solution Overview
Problem
Organic matrix composite materials suffer from weak resistance to erosion, which limits their use in industries like aerospace and gas turbine engines, and metal-plated polymer components face issues with uniform metal plating and damage in wear-critical regions, necessitating improved methods for selective thickening and erosion protection.
Innovation Solution
A composite component with a first metal coating, such as aluminum, and an outer metal layer like aluminum oxide or titanium dioxide, optionally with a sacrificial layer, is formed using methods like cathodic arc deposition and anodizing, while plated polymer components have selectively thickened regions applied via brush electroplating for enhanced wear and erosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a metallic coating is applied to composite components to improve erosion resistance, then erosion resistance is improved, but galvanic corrosion occurs between the metallic coating and carbon or metallic fibers
Solution Approach 1:
The patent introduces an intermediate layer between the metallic coating and the composite substrate. This intermediate layer acts as a mediator that prevents direct galvanic contact between the metallic coating and carbon/metallic fibers, thereby eliminating galvanic corrosion while preserving the erosion resistance benefits of the metallic coating.
Solution Approach 2:
The patent employs a multi-layer composite structure consisting of the composite substrate, intermediate layer, and metallic coating. This composite material approach allows each layer to perform its specific function: the substrate provides structural integrity, the intermediate layer prevents galvanic corrosion, and the metallic coating provides erosion resistance.
2Reliability
If metal plating layers are thickened to enhance durability in wear-critical regions, then surface durability is improved, but unnecessary weight is added to the part
Solution Approach 1:
The patent applies metal plating selectively only to wear-critical regions and erosion-susceptible areas of the component rather than uniformly across the entire surface. This local quality approach ensures that metal plating is present only where needed for enhanced durability, minimizing unnecessary weight addition while maintaining surface durability in critical 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
The solution enhances erosion resistance and prevents galvanic corrosion, allowing for the use of organic matrix composites in previously restricted areas and providing localized durability without unnecessary weight addition, improving the performance and longevity of components in harsh environments.
Implementation Method 1
depositing the first metal coating on a surface of the body portion may comprise depositing the first metal coating by a method selected from the group consisting of cathodic arc deposition, ion vapor deposition, physical vapor deposition, and chemical vapor deposition
Implementation Method 2
The outer metal layer may be a passive aluminum oxide layer formed by anodizing a surface of the first metal coating
Implementation Method 3
The titanium dioxide coating may be applied to a surface of the first metal coating by electrolytic deposition
Implementation Method 4
a first metal coating may be formed from aluminum or an aluminum alloy. The composite component may further comprise an outer metal layer on the first metal coating
Data Source
AI summary
A composite component and a plated polymer component are disclosed. The composite component may comprise a body portion formed from an organic matrix composite, a first metal coating applied to a surface of the body portion, and an outer metal layer on the first metal coating that is erosion-resistant. The plated polymer component may comprise a polymer substrate, a metal plating layer applied to a surface of the polymer substrate, and at least one selectively thickened region in the metal plating layer. The at least one selectively thickened region may assist in protecting the plated polymer component against wear and/or erosion.