Nanowire Metal Component Joining for Complex Geometry Assembly
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Solution Overview
Problem
Manufacturing metallic components with complex geometries often requires extensive milling or high-temperature processes like welding, leading to material waste and potential degradation of mechanical properties.
Innovation Solution
A component and method utilizing nanowires to establish a permanent connection between metal sub-components at room temperature, reducing material usage and preserving 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 material waste increases and manufacturing costs rise
Solution Approach 1:
The component is divided into multiple thin metal sheets or strips that are stacked and joined together through nanowire interlocking, replacing the traditional single-piece milling approach. This segmentation allows near-net-shape manufacturing with minimal material waste.
Solution Approach 2:
Multiple metal sheets are combined into a composite structure joined by nanowires, creating a new composite material system that achieves complex geometries without extensive material removal.
2Strength
If high temperature processes such as welding are used to join metal components, then permanent connection is achieved, but mechanical properties of the material and workpieces are degraded
Solution Approach 1:
The thermal welding process is replaced with a mechanical nanowire interlocking system where nanoscale wires physically interlock between metal sheets, providing strong joints without thermal degradation of material properties.
Solution Approach 2:
The joining process parameters are changed from high temperature (welding) to room temperature or low temperature (nanowire interlocking), preserving the mechanical properties of the base metals while achieving permanent connection.
3Shape
If extensive milling is performed to achieve complex geometries, then the final component shape is obtained, but manufacturing time and productivity are reduced
Solution Approach 1:
The metal sheets are pre-formed into near-final shapes before stacking, and nanowires are pre-grown on the surfaces. This preliminary preparation eliminates the need for extensive post-assembly milling, significantly improving manufacturing efficiency.
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 allows for efficient joining of metallic components with complex geometries using nanowires, achieving strong mechanical bonds while minimizing material waste and maintaining material properties.
Implementation Method 1
nanowires interlock, diffusion of metal atoms takes place and the subcomponents are joint
Implementation Method 2
nanowires interlock
Data Source
AI summary
A component includes at least a first sub-component and a second sub-component each fully or partially including metal or metal alloy material or having an at least partially metallized surface or surface region, the first sub-component and the second sub-component providing a pair of connection interfaces configured to establish a permanent connection of the first sub-component and the second sub-component, wherein at least one of the pair of connection interfaces comprises nanowires. The disclosure further provides a method for manufacturing such a component.