MAX-Phase Composite Molding Core for Hollow Aeronautical Parts
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Solution Overview
Problem
Current methods for manufacturing hollow aeronautical parts using organic matrix composites (OMC) face challenges such as the need for complex and expensive tooling, environmental hazards from dissolving cores, and inadequate consideration of thermal expansion coefficients, leading to potential material degradation and limited machinability.
Innovation Solution
A composite material comprising a 'MAX phase' (Mn+1AlCn) with a second phase of Al4C3 is used for the molding core, allowing easy detachment and recycling without harmful chemicals, and providing thermal and mechanical stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If soluble cores are used to manufacture hollow CMO parts, then complex internal cavity geometries can be achieved, but the dissolved cores cannot be recycled and the dissolution material cannot be discharged into wastewater due to environmental concerns
Solution Approach 1:
The core material undergoes a parameter change from solid to powder through controlled oxidation at elevated temperatures (200-400°C) in an oxygenated atmosphere. This thermal treatment transforms the soluble core into an oxidized powder that can be easily removed and recycled, eliminating the environmental pollution problem associated with traditional dissolution methods while maintaining the ability to create complex internal cavity geometries
Solution Approach 2:
Instead of discarding the dissolved core material as waste, the invention recovers it by oxidizing the core at elevated temperatures to produce an oxidized powder. This powder can then be removed from the CMO part and potentially reused or disposed of in an environmentally friendly manner, thus recovering value from what would otherwise be harmful waste
2Weight of moving object
If molding cores are used to create hollow structures with complex shapes, then mass savings are achieved, but the cores may deteriorate due to thermal expansion stresses during cooking and cooling stages
Solution Approach 1:
The core material's physical and chemical parameters are changed through oxidation treatment at elevated temperatures. This creates a more stable core structure with improved thermal stability and reduced thermal expansion, allowing the core to withstand the thermal stresses of the cooking and cooling stages without deteriorating, while still enabling mass savings through hollow structure fabrication
3Shape
If current core solutions are used, then hollow structures can be manufactured, but the cores are intrinsically fragile and not necessarily machinable, limiting production to demouldable shapes
Solution Approach 1:
The core material undergoes parameter changes through controlled oxidation at elevated temperatures, transforming it from a fragile, difficult-to-machine state to a more stable, oxidized powder state. This enables both the creation of complex hollow shapes and improved machinability, as the oxidized core can be easily removed and the process is not limited to simple demouldable shapes
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
Enables the production of hollow structures with complex shapes, ensuring mechanical rigidity and thermal stability, while facilitating easy core removal and recycling, thus addressing environmental and cost issues.
Implementation Method 1
the core material is oxidized at least partially at an elevated temperature in an oxygenated atmosphere so as to produce an oxidized powder
Data Source
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AI summary
Disclosed is a molding core (30) for producing a hollow aeronautical part, in particular a fan module part, made of an organic matrix composite (OMC) comprising a composite material containing, on the one hand, a first phase having formula Mn+1AlCn, where n = 1 to 3 and M is a transition metal selected from the group consisting of titanium, niobium, chromium or zirconium, and, on the other hand, a second phase having formula Al4C3.