Electromagnetic Pulse Joining Aircraft Shell Components
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Solution Overview
Problem
Conventional methods for manufacturing structural components for aircraft and spacecraft, such as riveting and welding, are time-consuming and costly, requiring numerous holes to be drilled and a large number of rivets, leading to high noise emissions and long manufacturing times.
Innovation Solution
The use of an electromagnetic pulse to join shell components with adjacent components, eliminating the need for drilling, clamping, and bonding processes, and enabling a virtually instantaneous connection through Magnetic Pulse Welding, which reduces manufacturing time and cost while allowing for automation and weight reduction.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional riveting or welding methods are used to join shell components, then structural strength is achieved, but manufacturing time increases and noise emissions increase
Solution Approach 1:
The patent replaces conventional mechanical joining methods (drilling, riveting, welding) with electromagnetic pulse forming technology. The electromagnetic pulse generates a high-speed deformation wave that plastically deforms the workpiece material to achieve joining, eliminating the need for mechanical fasteners and reducing manufacturing time significantly.
Solution Approach 2:
The invention changes the physical state and parameters of the material through electromagnetic pulse application. The intense electromagnetic field induces rapid plastic deformation at controlled locations, transforming the material locally to achieve joining while maintaining overall structural integrity and reducing process time.
2Strength
If numerous rivets are used to join components, then connection strength is achieved, but manufacturing cost increases due to rivet material cost
Solution Approach 1:
The patent extracts and eliminates the need for separate fastening elements (rivets, bolts, clips) by integrating the joining function directly into the shell component through electromagnetic pulse forming. The shell itself is deformed to create self-containing structures that eliminate the need for additional fastening materials.
Solution Approach 2:
The invention merges the shell component with the fastening function by creating integrated self-containing structures through electromagnetic deformation. The shell and its fastening features become a unified structure, eliminating the need for separate rivets and reducing material quantity.
3Ease of manufacture
If drilling and riveting processes are used, then component joining is achieved, but noise emissions increase during deployment of rivets
Solution Approach 1:
The patent replaces noisy mechanical rivet deployment with electromagnetic pulse forming. The electromagnetic process generates joining through controlled material deformation without the impact and friction noises characteristic of mechanical fastening, significantly reducing noise emissions.
4Ease of manufacture
If bonding processes are used to join components, then connection is achieved, but manufacturing time increases due to surface preparation and long curing times
Solution Approach 1:
The patent replaces chemical bonding processes with electromagnetic pulse forming. This mechanical-deformation-based approach eliminates the need for surface preparation and long curing times, achieving immediate joining through controlled plastic deformation of the material.
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 approach significantly reduces manufacturing time and cost, minimizes noise, and facilitates automation by eliminating the need for rivets and multiple manufacturing steps, while enabling precise positioning and efficient assembly of complex structural components.
Implementation Method 1
an electromagnetic pulse is used to join a shell component of the aircraft or spacecraft to a further component... by Magnetic Pulse Welding (MPW), a welding process that uses magnetic forces to drive, and weld two workpieces together
Implementation Method 2
a welding process that uses magnetic forces to drive, and weld two workpieces together
Implementation Method 3
magnetic deformation of the further component to achieve a positive-fit connection between the shell component and the further component
Data Source
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AI summary
The present invention provides a method of manufacturing a structural component (100) for an aircraft or spacecraft, which comprises a step of positioning a shell component (150,151) of the aircraft or spacecraft, and a further component (122, 123, 153, 154, 155, 156) adjacent to each other, and a step of generating an electromagnetic pulse to join the shell component and the further component. Under a further aspect, the invention provides an apparatus (130) for manufacturing a structural component for an aircraft or spacecraft, the apparatus comprising a positioner for positioning a shell component, of the aircraft or spacecraft, and a further component adjacent to each other, and an electromagnetic pulse generator (134) for generating an electromagnetic pulse to join the shell component and the further component.