Metal-Composite Assembly Structure for Pull-Out and Flexural Strain
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Solution Overview
Problem
Existing assemblies of metal parts and organic matrix composite materials often lack effective mechanical reinforcement and efficient force distribution, leading to flexural strain and pull-out stresses at attachment points.
Innovation Solution
A novel assembly structure featuring a metal part with a connecting portion and an organic matrix composite part with a through-hole, where a metal fastening element is sandwiched between the connecting portions, providing multiple attachment zones and reducing flexural strain by locking the composite part in position, and using additive manufacturing by cold gas spray deposition for enhanced mechanical links.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If traditional welding or bolting is used to assemble metal parts and organic matrix composite parts, then the assembly can be connected, but the assembly structure lacks mechanical reinforcement and experiences flexural strain and pull-out stresses at attachment points
Solution Approach 1:
The fastening element is divided into multiple attachment zones: a first attachment zone that attaches to the metal part, and a second attachment zone that attaches to the composite part. This segmentation allows each zone to be optimized for its specific material, distributing stresses and improving overall assembly strength and reliability.
Solution Approach 2:
The fastening element extends in a direction transverse to the stacking directions of both the metal part and composite part, creating a three-dimensional connection that spans across the interface between dissimilar materials. This dimensional approach provides mechanical reinforcement by bridging the two materials in multiple directions, reducing flexural strain and pull-out stresses.
2Device complexity
If a single attachment point is used to connect the metal part and composite part, then the assembly is simple, but the mechanical forces are not efficiently distributed
Solution Approach 1:
The fastening element incorporates multiple attachment zones (first attachment zone for metal part, second attachment zone for composite part) that are spatially separated. This segmentation distributes mechanical forces across multiple contact points rather than concentrating them at a single location, improving force distribution while maintaining relatively simple assembly structure.
3Device complexity
If the connecting portion of the composite part is exposed without sandwiching, then the assembly is less complex, but the connecting portion is not locked in position and experiences flexural strain
Solution Approach 1:
The fastening element merges multiple functions into a single component: it provides attachment to both metal and composite parts, acts as a clamp to lock the composite connecting portion between the metal part and fastening element, and distributes mechanical loads. This merging achieves position stability and reduced flexural strain while maintaining reasonable assembly complexity.
Solution Approach 2:
The fastening element changes the mechanical parameters of the assembly by providing clamping force that locks the composite connecting portion in position. This clamping action alters the stress distribution, reducing flexural strain and improving position stability without requiring complex assembly procedures.
4Strength
If additive manufacturing by cold gas spray deposition is used to create the fastening element, then the mechanical links are enhanced, but the manufacturing process is more complex than traditional methods
Solution Approach 1:
The fastening element is manufactured using additive manufacturing by cold gas spray deposition, creating a composite structure with enhanced mechanical properties. This manufacturing method produces a material composite that provides superior attachment strength to both metal and composite parts, though the manufacturing process itself is more complex than traditional welding or bolting.
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 assembly structure achieves improved mechanical reinforcement, reduced flexural strain, and enhanced force distribution, increasing the assembly's rigidity and pull-out strength, while avoiding the need for traditional welding or bolting and minimizing mass.
Implementation Method 1
using additive manufacturing by cold gas spray deposition for enhanced mechanical links
Data Source
AI summary
Piece comprising a first metal part and a second part in organic matrix composite material, wherein the first part has a first connecting portion and the second part has a second connecting portion, the second connecting portion having at least one through-hole, the second connecting portion being totally or partially sandwiched between the first connecting portion and a metal fastening element, the fastening element being fastened on the first part both onto the first connecting portion via the through-hole of the second connecting portion and onto a portion other than the first connecting portion, whereby the first part and the second part are fastened to each other.