Permanent Metallic Joint Structure for High-Temperature Tight Spaces
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Solution Overview
Problem
Conventional joints, such as fasteners and adhesives, are unsuitable for high-temperature applications like aircraft engine nacelles, and welded joints face challenges in small spaces with limited bond area.
Innovation Solution
A permanent metallic joint is created using a tab and support plate with different melting temperatures, forming intermetallic and metallurgical bonds without fasteners or adhesives, allowing for secure bonding in multiple directions while enabling movement in specific directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If fasteners or adhesives are used to join parts, then the joint can be easily manufactured, but the joint cannot withstand high temperatures in applications like aircraft engine nacelles
Solution Approach 1:
The invention changes the material parameters by using a metallic material for the second part that has a melting temperature lower than the first part but higher than the operating temperature. This allows the joint to withstand high temperatures while maintaining ease of manufacture through metallurgical bonding processes
Solution Approach 2:
The invention uses composite material structure with two different metallic materials having different melting temperatures. The first part uses a high-temperature resistant metallic material while the second part uses a metallic material with intermediate melting temperature, creating a joint that combines both ease of manufacture and high temperature resistance
2Strength
If welding is used to join parts, then the joint can be strong, but the process is difficult in small spaces and provides a relatively small bond area
Solution Approach 1:
The invention segments the bonding process by creating a tab structure on the first part that extends into the second part. This segmentation allows the metallic material to flow around and bond to multiple surfaces (tab first surface, tab third surface, and support plate), effectively increasing the bond area and making the process more manageable in small spaces while maintaining joint strength
3Area of stationary object
If a tab structure with support plate is used, then the bond area is increased and gapless interface is achieved, but the device complexity increases
Solution Approach 1:
The invention merges the tab and support plate into an integrated structure where the support plate forms a butt joint with the tab. This merging achieves a gapless interface between the first and second parts while the metallic material flows to bond all surfaces simultaneously. The complexity is reduced by integrating functions into fewer components
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 joint provides a strong, gapless interface that withstands high temperatures and is suitable for small spaces, preventing movement in multiple directions without the need for fasteners or adhesives, enhancing the structural integrity of aircraft components.
Implementation Method 1
The second part forms an intermetallic bond with the tab first surface
Implementation Method 2
The second part forms a metallurgical bond with the support plate
Data Source
AI summary
A permanent metallic joint comprises a first part made from a first metallic material having a first melting temperature. The first part comprises a tab comprising a tab first surface and a tab second surface, opposite the tab first surface. The permanent metallic joint also comprises a support plate forming a butt joint with the tab. The support plate is made from a second metallic material having a second melting temperature less than the first melting temperature. The permanent metallic joint further comprises a second part made from a third metallic material having a third melting temperature less than the first melting temperature. The second part forms an intermetallic bond with the tab first surface, and forms a metallurgical bond with the support plate.