Curved Structural Component Assembly With Low-Stress Reinforcement
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Solution Overview
Problem
Conventional methods for manufacturing complex structural components with L-shaped or U-shaped cross-sectional profiles, such as those with gussets, fins, and tabs, result in high residual stresses, material inefficiency, and increased manufacturing time and cost due to the need for extensive machining to remove unnecessary material.
Innovation Solution
A method involving hot stretch forming a base member with a predetermined curvilinear configuration and affixing reinforcing members using linear friction welding, reducing residual stresses and minimizing material usage by integrating features like gussets, fins, and tabs directly into the component.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional methods (forging, laser welding, fusion welding) are used to form L-shaped or U-shaped components with gussets, fins, and tabs, then the component can be manufactured with complex features, but the component develops unacceptable levels of residual stress and has weaker bonds between base piece and combined elements
Solution Approach 1:
The patent applies hot stretch forming instead of conventional cold forming, changing the temperature parameter to reduce residual stresses. The base member is heated to austenitic temperature range and then rapidly cooled, which allows complex features to be formed without developing unacceptable residual stress levels that would occur with conventional forging or forming methods
Solution Approach 2:
The patent divides the component into separate base member and reinforcing members that are joined through linear friction welding. This segmentation allows each part to be optimized independently and joined with a process that creates strong bonds without the residual stress problems associated with conventional welding methods
2Shape
If conventional methods are used to form L-shaped or U-shaped components with features like gussets, fins, and tabs, then the component can achieve desired shape, but extensive machining is required to remove unnecessary material, significantly increasing manufacturing time and cost
Solution Approach 1:
The patent performs hot stretch forming to create the base member with the precise curvilinear cross-sectional profile and desired features (gussets, fins, tabs) built-in during the forming process itself. This preliminary action eliminates the need for extensive subsequent machining operations to remove unnecessary material, significantly reducing manufacturing time and cost
3Ease of manufacture
If conventional welding methods (laser welding, fusion welding) are used to attach reinforcing members to the base member, then the component can be assembled, but the bonds between base piece and combined elements are weaker than preferred
Solution Approach 1:
The patent replaces conventional thermal welding methods (laser welding, fusion welding) with linear friction welding, which uses mechanical oscillation and friction to generate heat and create strong metallurgical bonds. This substitution of the welding mechanism produces bonds between the base member and reinforcing members that are stronger than those achieved with conventional welding methods
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 method reduces raw material requirements and machining operations, resulting in components with minimal residual stresses and improved bond strength, suitable for aerospace applications.
Implementation Method 1
The profile is resistance heated to a working temperature by passing electrical current through the profile
Implementation Method 2
A reinforcing member is affixed to the at least two sidewalls using linear friction welding
Data Source
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AI summary
A structural component is provided comprising a base member comprising at least two sidewalls and a space therebetween, the base member having a predetermined curvilinear configuration formed using hot stretch forming. The structural component comprises at least one reinforcing member linear friction welded to the at least two sidewalls so that the reinforcing member is positioned at least partially within the space between the at least two sidewalls.