Fibre Reinforced Metal Matrix Composite Packing Density
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Solution Overview
Problem
Existing methods for manufacturing fibre reinforced metal matrix composite articles, such as rotors, face issues with excess free space due to non-flat fibre spirals, leading to material defects and inefficient consolidation, as the spirals are not ideally packed, causing misalignment and potential fibre breakage during processing.
Innovation Solution
A method involving forming fibre preforms with glue, softening the glue to increase packing density, and then consolidating with heat and pressure to diffusion bond the components, allowing for better alignment and reduced excess space, thereby enhancing the structural integrity and reducing material defects.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If metal coated fibres are wound spirally and stacked in an annular groove, then the fibres can be assembled into the metal ring structure, but the spirals are not ideally packed leaving excess free space between fibres
Solution Approach 1:
The fibres are pre-assembled into spiral forms before being placed in the annular groove. This preliminary formation allows for better control of the spiral geometry and packing arrangement, reducing excess free space while maintaining ease of assembly.
Solution Approach 2:
The invention modifies the spiral winding parameters, such as pitch, diameter, and orientation, to optimize packing density. By adjusting these parameters, the fibres can be more efficiently arranged in the annular groove, reducing void spaces while keeping the manufacturing process simple.
2Reliability
If the annular groove depth is increased to allow metal ring faces to abut, then sealing can be achieved, but the metal ring has to be moved a greater distance to achieve consolidation
Solution Approach 1:
The fibres are pre-packed with higher density before insertion into the annular groove. This preliminary consolidation reduces the required groove depth for achieving proper abutment of metal ring faces, thereby reducing the movement distance needed during consolidation while maintaining sealing capability.
Solution Approach 2:
The invention optimizes the groove depth parameter and the fibre packing density parameter to achieve a balance where sealing is accomplished with minimal groove depth, reducing the consolidation movement distance and improving productivity.
3Ease of manufacture
If excess free space exists between fibres, then assembly is easier, but fibres may move out of position and break during processing creating material defects
Solution Approach 1:
The fibres are pre-assembled into stable spiral configurations with optimized packing before being placed in the annular groove. This preliminary structuring provides inherent stability to the fibre arrangement, preventing movement and breakage during subsequent processing while maintaining ease of assembly.
Solution Approach 2:
The invention optimizes spiral winding parameters such as pitch and tension to create a stable fibre configuration that resists movement during processing. These parameter adjustments maintain fibre position stability while keeping the assembly process straightforward.
4Ease of manufacture
If glue is applied locally to hold fibre spirals together, then assembly is enabled, but the glue must be removed later adding process steps
Solution Approach 1:
The invention uses a water-soluble binder that can be easily removed by washing with water after consolidation. This extraction method eliminates the need for complex removal processes, reducing overall device complexity while maintaining assembly capability during manufacturing.
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 achieves higher fibre packing density, reduces material defects, and allows for the use of less expensive equipment with wider tolerances, resulting in a more reliable and cost-effective manufacturing process for fibre reinforced metal matrix composite articles.
Implementation Method 1
introducing a solvent into the fibre preform to soften the glue
Implementation Method 2
applying heat and pressure such to consolidate the at least one fibre preform and the filler metal and to diffusion bond the filler metal, the first metal component and the second metal component
Data Source
AI summary
A method of manufacturing a fibre reinforced metal matrix composite article, the method comprising placing metal coated (18) fibers (14) between a first metal ring (30) and a second metal ring (36). Each of the metal-coated (18) fibres (14) having a glue (22) to hold the metal-coated (18) fibers (14) in position. A solvent is supplied to the glue (22) on the metal-coated (18) fibers (14) to soften the glue (22) and pressure is applied to allow the metal-coated (18) ceramic fibers (14) to become more closely packed. Thereafter the glue (22) is removed and the metal coated (18) fibers (14) and first and second metal rings (30, 36) are consolidated and diffusion bonded together.