Gradient Titanium-Steel Composite for Wear Resistance

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Solution Overview

Problem

Aircraft and racing vehicle components face challenges in reducing weight while maintaining contact wear resistance, particularly due to the limitations of titanium's low contact resistance and high vulnerability to wear, as well as the stress concentrations and brittle intermetallics formed when combining titanium with steel through conventional methods like soldering or brazing.

Innovation Solution

The method involves creating a composite material by diffusion bonding gradient layers of titanium and steel, with barrier particles to prevent direct contact and stress concentrations, and using Hot Isostatic Pressing (HIP) to consolidate loosely thermally sprayed powdered steel or steel alloy onto a titanium core, enhancing wear resistance and reducing weight.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Weight of moving object

If titanium is used as the component body to reduce weight, then weight is reduced, but contact wear resistance deteriorates

Engineering Contradiction:

Improvecomponent weightVSAvoidcontact wear resistance

Core Design Contradiction:

Weight of moving objectVSReliability

Solution Approach 1:

The patent applies composite materials by combining titanium (for weight reduction) with steel alloy cladding (for wear resistance). The diffusion bonding process creates a metallurgical bond between the titanium core and steel overlay, forming a composite structure that simultaneously achieves low weight and high contact wear resistance in power transmission components.

Inventive Principle:

Principle #40Composite materials

2Reliability

If steel and titanium are combined through conventional methods like soldering or brazing, then wear resistance is improved, but stress concentrations and brittle intermetallics are generated

Engineering Contradiction:

Improvewear resistanceVSAvoidstress concentration resistance

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The patent changes the bonding parameters by using diffusion bonding at controlled temperatures (900-1100°C) with applied pressure, rather than conventional soldering or brazing. This parameter change prevents the formation of brittle intermetallics by controlling the diffusion process, while still achieving strong metallurgical bonding between steel and titanium that resists stress concentrations.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent introduces a transitional layer as an intermediary between the steel alloy overlay and titanium core. This transitional layer, formed through controlled diffusion bonding, gradually transitions the material composition and properties, reducing stress concentrations and preventing direct formation of brittle intermetallic compounds at the steel-titanium interface.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Reliability

If cladding is used to apply wear-resistant material to titanium core, then wear resistance is improved, but manufacturing complexity increases due to component shape and access limitations

Engineering Contradiction:

Improvecontact wear resistanceVSAvoidmanufacturing accessibility

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent replaces conventional mechanical cladding processes (which require line-of-sight access and are limited by component geometry) with a thermal spray deposition system followed by diffusion bonding. This substitution allows the steel alloy powder to be deposited as a loose coating on complex-shaped titanium components, and then consolidated through thermal diffusion bonding, thereby overcoming accessibility limitations while achieving wear-resistant cladding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 effectively reduces the weight of components while maintaining or improving wear resistance, allowing aircraft and racing vehicles to meet strict weight requirements without compromising performance.

Implementation Method 1

diffusion bonding the plurality of layers and the outer layer by consolidation of the layers

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Implementation Method 2

using Hot Isostatic Pressing (HIP) to consolidate loosely thermally sprayed powdered steel or steel alloy onto a titanium core

Methodology Applied

Scientific EffectHot Isostatic Pressing: Hot Isostatic Pressing

Implementation Method 3

loosely thermally sprayed powdered steel or steel alloy onto a titanium core

Methodology Applied

Scientific EffectThermal spraying: Plasma Spray

Data Source

PatentUS10434597B1Methods of fabricating reduced weight components

Publication Date: 2019.10.08 BURGESS STEVEN P

AI summary

Methods of fabricating reduced weight components for apparatuses include obtaining a component including a relatively lightweight material; placing at least one stabilizing structure on the component; sequentially applying a plurality of applied layers on the component and the stabilizing structure by applying the relatively lightweight material over the component and applying over the relatively lightweight material a plurality of layers having gradually progressively higher proportions of the relatively heavyweight material than preceding ones of the plurality of layers closer to the component, with an outer layer of the plurality of applied layers including the relatively heavyweight material; diffusion bonding the plurality of applied layers by consolidation of the plurality of applied layers; and cutting component features in the plurality of applied layers.