Sinter Joining Complex Engine Parts Using Jacket Element
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Solution Overview
Problem
Current joining methods for complex engine parts, particularly in the aerospace sector, face challenges due to material limitations and the difficulty in applying uniform forces during sinter joining processes, leading to suboptimal joint quality and potential deformation.
Innovation Solution
A method involving a jacket element with a lower thermal expansion coefficient than the components to be joined, which surrounds and applies opposing forces through thermal expansion, ensuring precise contact and uniform pressure during the sinter joining process, thereby enhancing joint quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional joining methods (welding, brazing, adhesive bonding) are used, then joining capability is achieved, but material limitations and additional weight or temperature stability issues occur
Solution Approach 1:
The patent changes the thermal parameters by heating components to sintering temperatures where material diffusion occurs, enabling joining without additional weight. The temperature parameter transformation enables direct material bonding instead of mechanical or chemical joining methods that add weight.
Solution Approach 2:
The patent replaces mechanical joining systems (screws, adhesives) with a thermal-field-based sintering process. The mechanical force application device is substituted by thermal expansion of the jacket element, which generates the necessary compressive forces through temperature changes rather than mechanical actuators.
2Manufacturing precision
If mechanical force is applied during sinter joining, then joint quality improves, but uniform force distribution is difficult to achieve
Solution Approach 1:
The jacket element serves dual functions: it provides the compressive force through its own thermal expansion when heated, and it maintains contact with the components throughout the sintering process. The system uses itself to generate the necessary force rather than requiring external actuation mechanisms.
Solution Approach 2:
The patent utilizes thermal expansion of the jacket element as the primary mechanism to generate and distribute compressive force uniformly across the joining surfaces. When heated, the jacket element expands and applies consistent pressure to all contact points, ensuring uniform force distribution without complex mechanical systems.
3Stability of the object's composition
If thermal expansion coefficients are matched, then dimensional stability is achieved, but force application during joining becomes insufficient
Solution Approach 1:
The patent applies different thermal expansion characteristics to different parts of the system: the jacket element has a higher thermal expansion coefficient than the components to be joined. This local differentiation allows the jacket to expand more during heating, generating the necessary compressive force, while the components maintain their dimensional stability.
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 approach allows for the production of complex engine parts with improved joint quality and structural integrity by controlling the force direction and magnitude, reducing the risk of deformation and achieving a strong, uniform connection.
Implementation Method 1
the thermal expansion coefficient of the jacket element is lower than the thermal expansion coefficient of the first component and/or the thermal expansion coefficient of the second component, wherein the thermal expansion coefficient of the jacket element and the thermal expansion coefficient of the first component and/or the thermal expansion coefficient of the second component are designed in such a way as to bring the jacket-element bearing surface into contact with the first bearing surface and the second bearing surface and to bring the first joining surface and the second joining surface into contact in the heated state while the joining process is being carried out, with the result that the first joining surface and the second joining surface are subjected to an opposing force action
Data Source
AI summary
The production of engine parts with a complex geometrical structure. More particularly, a method for producing a complex part, comprising making available a first component, having a thermal expansion coefficient of the first component; a first joining surface; and a first bearing surface; making available a second component, having a thermal expansion coefficient of the second component; a second joining surface; a second bearing surface; and making available a jacket element, having a thermal expansion coefficient of the jacket element; and a jacket-element bearing surface; and heating the first component, the second component and the jacket element from a first temperature to a second temperature in order to carry out a joining process on the first component and the second component. Furthermore, a part, in particular for a gas turbine engine for an aircraft, and to a gas turbine engine of this kind.