Metal Protrusion Bonding by Hot Isostatic Pressing
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Solution Overview
Problem
Current methods for manufacturing metal-based components with protrusions, such as machining, struggle to achieve complex geometries and often result in poor mechanical properties, especially when using adhesives or friction-based solutions in demanding applications.
Innovation Solution
A method involving a metal-based substrate with cavities and a protrusion element, where the substrate is covered with an inert filler material and subjected to a hot pressing process under high pressure and temperature, forming a metallurgical bond between the substrate and protrusion, allowing for complex geometries and high mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If machining solutions are used to manufacture metal based components with protrusions, then manufacturing precision can be achieved, but the ability to create complex geometries and multi-material components is limited
Solution Approach 1:
The protrusion is divided into two portions: a first portion that fits into a cavity in the substrate and a second portion that protrudes from the substrate surface. This segmentation allows the protrusion to be manufactured separately and then joined to the substrate, enabling complex geometries that would be difficult or impossible to machine directly from a monolithic piece.
Solution Approach 2:
The first portion of the protrusion element is inserted into a cavity within the substrate, creating a nested structure. This nesting approach allows the protrusion to be formed inside the substrate and then bond metallurgically, enabling complex three-dimensional geometries that cannot be achieved by traditional external machining.
2Strength
If adhesives or friction based solutions are used to join substrate and protrusion, then complex geometries can be accommodated, but mechanical properties of the joint deteriorate
Solution Approach 1:
The patent replaces adhesive or friction-based joining mechanisms with a metallurgical bonding process. The substrate and protrusion element are bonded through diffusion bonding or similar metallurgical processes, which occur when the components are heated and pressed together, creating a strong atomic-level bond that superior to mechanical or adhesive joints.
Solution Approach 2:
The joining process utilizes changes in temperature and pressure parameters to achieve metallurgical bonding. By heating the substrate and protrusion element to elevated temperatures and applying pressure, the materials undergo diffusion bonding, transforming the joint strength from weak adhesive bonds to strong metallurgical bonds.
3Reliability
If traditional machining methods are used, then manufacturing process is simple, but the ability to create multi-material components with high strength joints is poor
Solution Approach 1:
The protrusion element is prepared in advance with a specific geometry where the first portion is designed to fit into a cavity in the substrate. This preliminary shaping allows the components to be manufactured separately using optimal processes for each material, and then joined together, ensuring high joint strength while maintaining manufacturing efficiency.
Solution Approach 2:
The patent enables the creation of multi-material components by joining a substrate made of one material with a protrusion element made of a different material. The metallurgical bond created through the bonding process ensures reliable joint strength even when joining dissimilar materials, allowing optimization of each component's material properties for its specific function.
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 enables the creation of metal-based components with complex geometries and high mechanical strength, overcoming the limitations of traditional machining and adhesive-based solutions by forming a strong, metallurgical bond between the substrate and protrusion.
Implementation Method 1
filling at least a portion of the void with an inert filler material such that the surface of the substrate comprising the protrusion is covered by the inert filler material
Implementation Method 2
subjecting said substrate comprising the protrusion to a hot pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that said substrate and protrusion element bond metallurgically to each other
Implementation Method 3
substrate and the protrusion element to form a metallurgical bond. More specifically, the metal based sheets bonds to each other metallurgically in a multiaxial manner due to the isostatic pressing
Implementation Method 4
the metal based sheets bonds to each other metallurgically in a multiaxial manner due to the isostatic pressing
Implementation Method 5
removing gas from the interface between said inert filler material and said substrate comprising the protrusion
Data Source
AI summary
The inventive concept relates to method for manufacturing a metal based component comprising at least one protrusion. The method comprises: providing a metal based substrate comprising a surface having at least one cavity; providing a metal based protrusion element comprising a first portion and a second portion, wherein said first portion has a shape that conforms to a shape of the cavity; arranging the first portion of the protrusion element in said cavity such that at least the second portion of the protrusion element protrudes at least 5 mm from a surface of the metal based substrate, to form a substrate comprising a protrusion; placing said substrate comprising a protrusion in a canister such that a void is formed between the canister and the surface of the substrate comprising the protrusion; filling at least a portion of the void with a diamond powder such that the surface of the substrate comprising the protrusion is covered by the inert filler material; removing gas from the interface between said diamond powder and said substrate comprising the protrusion; subjecting said substrate comprising the protrusion to a hot isostatic pressing process for a predetermined time at a predetermined pressure and a predetermined temperature such that said substrate and protrusion element bond metallurgically to each other to form said metal based component comprising said at least one protrusion; removing at least a part of said diamond powder from said metal based component having a protrusion, wherein a melting point of the diamond powder at said predetermined temperature is higher than said predetermined temperature.