Composite Component Sintering for Fiber-Metal Connection
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Solution Overview
Problem
Existing methods for producing composite components with metal and fiber structures face challenges such as insufficient strength, damage to the fiber structure, and high production costs due to high melting temperatures and wetting issues during casting, as well as mechanical damage from rivets or screws.
Innovation Solution
A method involving sintering of metallic powder to connect a fiber structure with metal elements on opposite surfaces, using reinforcement elements with functional layers to achieve a material-to-material and form-fitting connection, which reduces thermal stress and wetting problems, and allows for a stronger, more durable composite component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If casting process is used to enclose fiber composite with metal melt, then integral connection is achieved, but fibers are damaged due to high melting temperatures
Solution Approach 1:
The invention changes the temperature parameter from high (casting) to low (sintering). Instead of using metal melt at high temperatures, metallic powder is sintered at lower temperatures to achieve the same connection effect without damaging the fibers.
Solution Approach 2:
The invention uses phase transition of metallic powder during sintering process. The powder transitions from loose granular state to consolidated metal structure through controlled heating and pressure, enabling connection without requiring complete melting.
2Strength
If casting process is used to enclose fiber composite with metal melt, then integral connection is achieved, but cavities occur due to wetting behavior
Solution Approach 1:
The invention changes the physical state parameter from liquid melt to solid powder, which fundamentally alters the interaction with fiber surfaces. Powder particles can conform to surface irregularities better than liquid, reducing cavity formation during consolidation.
3Productivity
If die casting is used to produce composite component, then production efficiency is improved, but fiber structure is damaged by high forces and accelerations
Solution Approach 1:
The invention replaces the high-force mechanical die casting process with a sintering process that uses thermal and pressure fields instead of high-speed injection forces. This substitution maintains productivity while preserving fiber structure integrity.
4Strength
If mechanical connections using rivets or screws are used, then connection strength is improved, but fiber structure is damaged
Solution Approach 1:
The invention extracts the connection function from discrete mechanical fasteners (rivets/screws) and distributes it throughout the interface area via sintered metallic powder. This eliminates localized mechanical damage while achieving comparable or superior connection strength.
5Strength
If high melting temperature metals are used for casting, then connection strength is improved, but production costs increase due to limited fiber choices
Solution Approach 1:
The invention changes the temperature parameter from high (metal melting point) to low (sintering temperature below fiber damage threshold). This enables use of temperature-sensitive fibers like polymers while maintaining strong metal-to-fiber connections.
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 method enables the production of composite components with enhanced strength and reduced production costs, as it uses lower temperatures and avoids damage to the fiber structure, resulting in a more reliable and long-lasting composite component.
Implementation Method 1
An integral and/or form-fitting connection of the structure to the elements has been achieved by sintering at least one metallic powder
Implementation Method 2
producing a composite component from a fiber composite material and metal by a casting process in which part of the fiber composite is to be enclosed by the metal melt during casting
Data Source
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AI summary
The invention relates to a composite component, a flat fiber structure comprising voids and/or cavities being bordered at least in certain areas on two opposite faces with one metal element each. The flat structure is connected to the elements in a material and/or form fit. Said material and/or form fit is achieved by reinforcing elements that extend through cavities or voids in the structure and that are oriented perpendicular to the plane of the flat structure at least in the region of the structure. Alternatively or in addition thereto, a material and/or form fit connection of the structure and the elements is achieved by sintering of at least one metal powder, at least one metal element being producible from said powder, and voids or cavities of the structure being filled with metal.