Interlocked Ceramic Metallic Sensor Components

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Solution Overview

Problem

Existing sensors employing metallic and ceramic components held by braze joints face challenges in harsh environments, where high temperatures and pressures can cause the components to liberate into the engine, potentially damaging it, and there is a need for an economically viable solution to prevent this.

Innovation Solution

A composite element with interlocked ceramic and metallic components is created using a method where a ceramic component with a cavity is filled with a degradable material, followed by molten metal, which solidifies to form the metallic component, eliminating the need for braze joints and ensuring the metallic component cannot liberate during operation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If braze joints are used to hold metallic and ceramic components together, then the components can be assembled, but the joint may fail under high temperature and pressure causing component liberation

Engineering Contradiction:

Improvejoint reliabilityVSAvoidcomponent liberation risk

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the braze joint from the assembly by using a interference fit design where the metallic component is pressed directly into the ceramic component with an interference fit, eliminating the need for braze joints that can fail under high temperature and pressure conditions

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent creates a composite structure where metallic and ceramic components are directly interlocked through interference fit, forming a unified assembly that withstands harsh environments without relying on intermediate joining materials like braze joints

Inventive Principle:

Principle #40Composite materials

2Reliability

If interference fit is used to interlock ceramic and metallic components, then component liberation is prevented, but manufacturing complexity increases

Engineering Contradiction:

Improvecomponent retentionVSAvoidmanufacturing complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent controls the interference fit by precisely controlling the dimensional parameters of the metallic component and the cavity in the ceramic component, using parameter optimization to achieve reliable retention while maintaining manufacturing feasibility

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent incorporates the interference fit design into the molding process itself, where the metallic component is formed with the appropriate interference dimensions during casting, eliminating the need for subsequent complex assembly operations

Inventive Principle:

Principle #10Preliminary action

3Reliability

If metallic component cross-sectional area is increased to prevent liberation, then retention is improved, but material usage and cost increase

Engineering Contradiction:

Improvecomponent retentionVSAvoidmetal material usage

Core Design Contradiction:

ReliabilityVSQuantity of substance

Solution Approach 1:

The patent applies interference fit only at the specific location where the metallic component interfaces with the ceramic component, concentrating the retention mechanism where it is most needed rather than increasing the overall size of the metallic component throughout

Inventive Principle:

Principle #3Local quality

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 interlocked composite elements effectively prevent the metallic components from being liberated into the engine, ensuring safe operation and providing an economically viable method for manufacturing sensors, such as clearance sensors for turbines, while maintaining accuracy in measuring clearance between objects.

Implementation Method 1

disposing molten metal in the cavity, and solidifying the molten metal to form the metallic component

Methodology Applied

Scientific EffectSolidification: Freezing

Data Source

PatentUS8257833B2Ceramic metallic interlocked components and methods of making and using the same

Publication Date: 2012.09.04 GENERAL ELECTRIC CO

AI summary

A composite element is provided. The composite element includes a ceramic component defining a cavity having a first end and a second end, and a metallic component comprising a head and a body. At least a portion of the body of the metallic component is disposed in the cavity, and the head of the component is disposed on the first end of the cavity. A cross-sectional area of a portion of the body is greater than an area of the first end. In addition, the ceramic and metallic components are interlocked. Methods of making a composite element and of making a clearance sensor part are also provided.