Nanowire-Bonded Metal Component Assembly for Complex Geometries
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Solution Overview
Problem
Manufacturing metallic components with complex geometries typically requires extensive milling or high-temperature processes like welding, resulting in significant material waste and potential loss of mechanical properties.
Innovation Solution
A component comprising two sub-components with metallized surfaces or nanowires grown on their connection interfaces, allowing for a permanent, low-temperature connection that conserves material and mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If milling processes are used to manufacture metallic components with complex geometries, then the final shape can be obtained, but significant material waste is generated and costs increase
Solution Approach 1:
The component is divided into multiple sub-components that are manufactured separately and then joined together. This allows each sub-component to be optimized for its specific function and reduces the need for extensive material removal, thereby minimizing material waste while achieving complex geometries.
Solution Approach 2:
The invention uses hybrid connections combining mechanical elements (nanowires) with metallized surfaces. This composite approach enables joining of complex geometries without requiring traditional high-temperature welding or extensive material removal, thus reducing material waste while maintaining structural integrity.
2Strength
If high temperature processes such as welding are used to join metallic components, then permanent connection is achieved, but mechanical properties of the material are not sustained
Solution Approach 1:
The invention changes the temperature parameter from high-temperature welding to low-temperature joining processes. The nanowire-based connection operates at temperatures that do not compromise the mechanical properties of the base materials, thereby maintaining reliability while achieving permanent connection.
Solution Approach 2:
Nanowires serve as an intermediary element between the metallized surfaces of sub-components. These nanowires facilitate bonding at lower temperatures, acting as a mediator that enables permanent connection without subjecting the base materials to damaging high temperatures, thus preserving their mechanical properties.
3Ease of manufacture
If traditional milling or welding processes are used, then metallic components can be manufactured, but the processes are time-consuming and costly
Solution Approach 1:
The sub-components are prepared in advance with metallized surfaces and nanowire structures before assembly. This preliminary preparation allows for faster final assembly compared to traditional processes where shaping and joining occur sequentially, thereby reducing total manufacturing time while maintaining ease of production.
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 method enables the production of metallic components with reduced material usage and preserved mechanical properties, avoiding the inefficiencies and property losses associated with traditional milling and welding processes.
Implementation Method 1
During this, the nanowires interlock, diffusion of metal atoms takes place and the subcomponents are joint
Data Source
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AI summary
The present invention provides a component (100) comprising at least a first sub-component (101) and a second sub-component (102a, b, c, d), each consisting fully or partially of metal or metal alloy material or having an at least partially metallized surface (120) or surface region, the first sub-component (101) and the second sub-component (102a, b, c, d) providing a pair of connection interfaces (111; 112) configured to establish a permanent connection of the first sub-component (101) and the second sub-component (102a, b, c, d), wherein at least one of the pair of connection interfaces (111; 112) comprises nanowires. The present invention further provides a method for manufacturing such a component.