Braided MMC Tape Preforms Without Molten Metal Infiltration

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Solution Overview

Problem

The fabrication of Metal Matrix Composite (MMC) parts is labor-intensive and time-consuming due to difficulties in infiltrating molten metal into fiber preforms and requiring complex equipment for pressure application at elevated temperatures.

Innovation Solution

The development of pre-impregnated MMC tape that can be easily braided into a stable preform, allowing for consolidation without additional molten metal injection or complex tools, with the option to integrate a mandrel and apply external metal surfaces for enhanced bonding and structural integrity.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If molten metal is driven through fiber preform to infiltrate it, then metal matrix composite parts are formed, but the process is difficult because molten metal may not adequately penetrate the preform or wet the fibers sufficiently to achieve a structural bond

Engineering Contradiction:

Improvestructural bond qualityVSAvoidinfiltration process difficulty

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The fiber preform is pre-impregnated with a reactive metal layer before consolidation, ensuring that the metal is already in contact with and bonded to the fibers. This preliminary action eliminates the infiltration step and guarantees structural bond quality without process difficulty.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent changes the physical state of the metal from molten (requiring infiltration) to a pre-applied reactive layer that bonds directly during consolidation. This parameter change transforms the process from one requiring precise infiltration control to one relying on diffusion bonding, improving both reliability and ease of manufacture.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If external pressure is applied onto stacks of pre-impregnated unidirectional fiber-reinforced metal laminate plies at elevated temperature, then diffusion bond is achieved across the plies, but complex process steps, tooling, and equipment are required

Engineering Contradiction:

Improvediffusion bond qualityVSAvoidprocess equipment complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent merges the diffusion bonding process with the consolidation of braided preforms into a single step. The reactive metal layers on adjacent preform surfaces bond to each other during consolidation, eliminating the need for separate bonding equipment and reducing overall process complexity.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The reactive metal layers on the preform surfaces perform the bonding function automatically during consolidation. The process self-organizes the bonding interfaces through the inherent reactivity of the metal layers, reducing the need for complex external bonding equipment and process control.

Inventive Principle:

Principle #25Self-service

3Manufacturing precision

If large individual precursor plies or laminated preforms are manufactured and handled, then MMC parts can be fabricated, but labor-intensive and time-consuming processes are required

Engineering Contradiction:

Improvepreform fabrication accuracyVSAvoidfabrication speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent segments the final MMC part into multiple braided preforms that are fabricated separately and then consolidated. This segmentation allows parallel fabrication of multiple preform components, significantly increasing productivity while maintaining the precision of individual preform construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses composite braided preforms with reactive metal layers that combine structural integrity with bonding capability. This composite structure allows the preforms to be handled and assembled more efficiently than traditional laminated plies, reducing labor intensity while maintaining manufacturing precision.

Inventive Principle:

Principle #40Composite materials

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 simplifies the MMC fabrication process by enabling easy handling and consolidation of MMC parts with improved structural bonding, reducing labor and equipment requirements while maintaining high strength and stiffness-to-density ratios.

Implementation Method 1

externally applying pressure onto stacks of pre-impregnated unidirectional fiber-reinforced metal laminate plies at a sufficiently elevated temperature to effect a diffusion bond across the plies

Methodology Applied

Scientific EffectDiffusion bonding: Diffusion Welding

Implementation Method 2

During consolidation, sufficient heat and pressure is applied to consolidate the preform, mandrel, and metal overwrap (if used) into a complete and fully bonded MMC part

Methodology Applied

Scientific EffectHeat and pressure consolidation: Hot Isostatic Pressing

Data Source

PatentUS11697895B2Metal matrix composite tape fabrication, braiding, and consolidation to form metal matrix composite parts

Publication Date: 2023.07.11 THE BOEING CO

AI summary

Systems and methods are provided for braiding Metal Matrix Composite (MMC) tape. One method includes drawing multiple lanes of MMC tape, comprising a matrix of metal reinforced by fibers, from bobbins arranged around a mandrel. The method also includes braiding the multiple lanes to form a preform at the mandrel for an MMC part and consolidating the preform via application of heat and pressure.