Metal-Composite Assembly via Embedded Insert Welding
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Solution Overview
Problem
Current methods for assembling metal and organic-matrix composite materials, such as welding, mechanical assembly, and adhesion, face challenges like weight increase, stress concentration, and unpredictable long-term behavior, making them unsuitable for achieving satisfactory stiffness and compatibility.
Innovation Solution
A high-speed welding technique is employed by embedding a metal insert into the composite part, which is then projected against a complementary metal part surface to form a strong weld, eliminating the need for additional link elements and surface preparation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanical assembly (screwing or riveting) is used to join metal and composite parts, then the parts can be connected, but the structure weight increases due to added link elements
Solution Approach 1:
The invention extracts the metal link elements (screws, rivets) from the assembly process by embedding a metal insert directly into the composite part. This eliminates the need for separate mechanical fasteners, thereby reducing structure weight while maintaining connection strength through direct welding between the metal insert and metal part.
Solution Approach 2:
The invention merges the functions of the metal insert and the composite part into a single integrated component. The metal insert is embedded within the composite part, combining structural support and connection functions, which eliminates the need for additional link elements and reduces overall weight.
2Strength
If mechanical assembly (screwing or riveting) is used to join metal and composite parts, then the parts can be connected, but zones of weakness and stress concentration are generated due to drilling
Solution Approach 1:
The invention removes the drilling operation entirely by embedding the metal insert into the composite part during or before final assembly. This eliminates the creation of holes that would generate stress concentration zones and potential fracture ignition points, thereby improving structural integrity while maintaining connection strength.
3Strength
If bonding assembly is used to join metal and composite parts, then the parts can be connected, but surface preparation is required and long term behavior prediction is unreliable
Solution Approach 1:
The invention replaces the chemical bonding system with a mechanical welding system. Instead of using adhesives that require surface preparation and have unpredictable long-term behavior, the metal insert is welded directly to the metal part, providing a reliable, predictable connection without the need for surface treatment of the composite material.
4Strength
If welding is used to join metal and composite parts directly, then a strong connection can be achieved, but the materials are incompatible for heterogeneous welding
Solution Approach 1:
The invention segments the composite part by embedding a metal insert within it. This creates a heterogeneous structure where the metal insert serves as an interface between the composite material and the metal part, enabling welding while maintaining the integrity of the composite material.
Solution Approach 2:
The metal insert acts as an intermediary element between the composite part and the metal part. It provides a compatible welding surface for joining to the metal part while being embedded in and supported by the composite material, thus resolving the material incompatibility issue for direct welding.
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 method provides a strong, lightweight assembly with predictable long-term behavior, ensuring compatibility and mechanical integrity between metal and composite materials without adding weight or generating stress concentrations.
Implementation Method 1
a step of projecting (or thrusting or accelerating) at high speed the surface to be welded of the metal part and/or of the exposed portion of the metal insert, against one another, to obtain high-speed pressing of said surfaces to be welded against each other and to obtain a weld
Data Source
AI summary
An assembly method between a part made of metal material and a part made of organic matrix composite material, said method having a step of providing two parts, each including a surface to be welded, and the surface to be welded of said composite part is made up, at least partially, of an exposed portion of at least one metal insert which is partially embedded in said composite part; positioning said surfaces to be welded opposite and separated from each other; and projecting, at high speed, the surface to be welded of the metal part or the exposed portion of the metal insert, onto one another, to obtain high-speed clamping to one another and to obtain a weld between the exposed portion of the metal insert of the composite part and the complementary portion of the surface to be welded.