Interlocking Multi-Material Joint for Thermal Expansion Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Multi-material components face challenges with thermal expansion and impaired bonding between dissimilar materials, such as Inconel and Aluminium, leading to high part counts and assembly costs in aircraft components that handle significant thermal loads.
Innovation Solution
A multi-material component design featuring complementary interlocking protrusions and a lattice member capable of elastic deformation, which isolates the interface from deformation and thermal loads, allowing for additive manufacturing and reducing the need for fasteners and complex assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If multi-material additive manufacturing is used to create monolithic components, then part count and assembly costs are reduced, but thermal expansion differences and bonding challenges between dissimilar materials worsen
Solution Approach 1:
A transition layer comprising a gradient of material compositions is introduced between the first material and second material. This transition layer gradually changes from the first material composition adjacent to the first material to the second material composition adjacent to the second material, thereby reducing thermal expansion mismatch and improving bonding strength at the interface.
2Temperature
If Inconel is used to manage thermal load, then thermal stability is improved, but weight and cost increase
Solution Approach 1:
The component is designed with spatially varying material properties. The first material with high thermal stability (e.g., Inconel) is localized to regions experiencing high thermal loads, while the second material with lower density is used in regions with lower thermal demands. This gradient structure optimizes the balance between thermal stability and weight by placing each material only where its specific properties are most beneficial.
3Ease of manufacture
If dissimilar materials are joined directly, then manufacturing simplicity is improved, but interface strength deteriorates due to brittle inter-metallic compounds
Solution Approach 1:
A composite transition layer is created between the dissimilar materials, consisting of a gradient structure that combines elements of both materials in varying proportions. This composite structure prevents the formation of brittle inter-metallic compounds by avoiding direct contact between the dissimilar base materials, while maintaining manufacturing simplicity through additive manufacturing processes.
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 design minimizes the use of dense materials, reduces assembly complexity, and enhances the strength and thermal insulation of components, while allowing non-destructive inspection and maintaining structural integrity under high thermal loads.
Implementation Method 1
a lattice member situated and joined between the first member and the third member, the lattice being capable of elastic deformation so as to substantially isolate the multi-material join from any deformation of the third member
Implementation Method 2
complementary interlocking protrusions that form a multi-material join and define an interface between the first and second members such that a substantial proportion of any tension between the first and second members across the multi-material join is experienced as a shear force at the convoluted interface
Data Source
AI summary
A multi-material component is provided including two members formed of different materials joined together at a multi-material join. The two members have complementary protrusions that form a multi-material join with a zig-zag interface, such that a tension between them is experienced in at least part as a shear force at the interface between the protrusions. The component further includes a third member connected to the first member by a lattice, which is capable of elastic deformation so as to substantially isolate the interface between the complementary protrusions from deformation of the third member such as that caused by thermal expansion. Methods of designing and constructing such a component in a single piece via additive manufacturing are provided. The component is particularly suitable for use in pylons connecting jet engines to aircraft wings.