Metal-Composite Joint Assembly Using Cold Spray Sealed Fastening
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for assembling metal parts with organic matrix composite materials face issues of material abrasion and defects at the interface due to escaped sprayed material during cold gas spray deposition, leading to weakened mechanical strength.
Innovation Solution
A method involving the formation of a protective layer and seal on the organic matrix composite material, followed by additive manufacturing using cold gas spray deposition to create a fastening element, ensuring the sprayed material does not escape and forming a defect-free joint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If cold gas spray deposition is used to form the fastening element, then the fastening element can be formed at low temperature suitable for organic matrix composite material, but sprayed material escapes between the connecting portions causing interface defects and material abrasion
Solution Approach 1:
A protective layer is introduced as an intermediary between the sprayed material and the organic matrix composite material. This protective layer captures escaped sprayed material, preventing it from causing abrasion and defects on the composite material surface, thus maintaining interface quality while allowing cold gas spray deposition to proceed
Solution Approach 2:
The protective layer is formed in advance before the cold gas spray deposition process. This preliminary action prepares the surface to receive sprayed material without damage, preventing the harmful effects of material escape before they can occur during the deposition process
2Temperature
If cold gas spray deposition is used to form the fastening element, then the organic matrix composite material is not damaged by high temperature, but the sprayed material escapes causing material abrasion on the composite material
Solution Approach 1:
The protective layer serves as a mediator that intercepts escaped sprayed material, preventing direct contact with and abrasion of the organic matrix composite material. This allows the cold gas spray deposition to proceed at low temperatures without the harmful abrasion effect
3Adaptability or versatility
If cold gas spray deposition is used to form the fastening element, then the process is suitable for organic matrix composite material, but defects occur at the interface between the fastening element and the first connecting portion
Solution Approach 1:
The protective layer acts as an intermediary that prevents escaped sprayed material from creating defects at the interface between the fastening element and the first connecting portion. This maintains manufacturing precision while preserving the compatibility of cold gas spray deposition with organic matrix composite material
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 method enhances the mechanical strength of the assembly by preventing material escape and interface defects, resulting in a robust and reliable connection.
Implementation Method 1
forming, by additive manufacturing using cold gas spray deposition of metal powder, also known by the acronym CGS for 'Cold Gas Spraying', a fastening element
Implementation Method 2
a part of the sprayed material could escape between the first connecting portion and the second connecting portion. This leads both to abrasion of the second connecting portion
Data Source
AI summary
The invention relates to a method for assembling a first metal part with a second part made of an organic matrix composite material, the first part having a first connecting portion and the second part having a second connecting portion, the method comprising the steps of:causing the first connecting portion and the second connecting portion to overlap, a through-hole of the second connecting portion opening onto the first connecting portion,forming a protective layer on the side wall of the through-hole,forming a seal between the protective layer and the first connecting portion, andforming, by additive manufacturing using cold gas spray deposition of metal powder, a fastening element which extends into the through-hole, is fastened to the first connecting portion and encloses the second connecting portion.