Axially Swaged Fitting with Soft Metal Layer for Conductive Path
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Solution Overview
Problem
Prior axially swaged fittings do not provide a complete conductive path between metal components, leading to potential sparking or heat buildup due to lubricant resistance in the electrical current path, which is undesirable, especially in applications like aircraft hydraulic systems.
Innovation Solution
An axially swaged fitting design featuring a sleeve with a hard or soft metal layer and a swaging ring with opposing metal layers, where the soft metal is deformed during the swaging process to create a permanent metal-to-metal electrical bond, ensuring a continuous conductive path.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lubricant is placed between the sleeve and swaging ring to reduce friction, then the swaging process is facilitated and surface damage is reduced, but electrical resistance increases causing heat buildup and potential sparking
Solution Approach 1:
The harmful lubricant is completely removed from the interface between the swaging ring and sleeve. The patent achieves this by using a soft metal layer on the sleeve that directly contacts the hard metal layer on the ring, eliminating the need for lubricant while maintaining smooth swaging through material compatibility.
Solution Approach 2:
A soft metal layer is introduced as an intermediary between the hard metal swaging ring and the sleeve. This soft layer facilitates the swaging process through controlled deformation and metal-to-metal contact, providing electrical conductivity while enabling the necessary friction for deformation.
2Strength
If swaging ring is positioned onto the sleeve to deform and join the tube, then a permanent mechanical joint is created, but the electrical current path is interrupted causing resistance and heat
Solution Approach 1:
The sleeve is constructed with a composite structure featuring a soft metal layer on its outer surface. This composite design combines the mechanical strength needed for swaging with the electrical conductivity required for continuous current flow, as the soft metal layer maintains metal-to-metal contact with the swaging ring.
Solution Approach 2:
The patent changes the material parameters of the sleeve by applying a soft metal layer with different properties than the base sleeve material. This soft layer has both the ductility needed for deformation during swaging and the electrical conductivity needed to maintain continuous current flow through the fitting.
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 design eliminates the risk of sparking and heat buildup by providing a complete conductive path through metal components, enhancing the safety and reliability of hydraulic connections in various applications.
Implementation Method 1
The inner surface of the ring includes a soft metal layer, while the outer surface of the sleeve includes a soft metal layer. These soft metal layers are deformed during the swaging process to create a permanent metal-to-metal bonded joint.
Implementation Method 2
In order to effectuate the swaging process, a lubricant may be placed between the sleeve and swaging ring, thereby allowing the swaging process by reducing friction between the ring and sleeve.
Implementation Method 3
Because of the low electrical conductivity of the lubricant, as current flows through the material it acts as a resistor and heats up.
Data Source
AI summary
An axially swaged fitting for use in permanently coupling tubes together. The swaged fitting may be useful in coupling metal hydraulic lines to one another in an airplane. According to one embodiment, the swaged fitting includes a sleeve with a hard metal surface and a swaging ring with a soft metal surface, such that during the swaging process the soft metal surface of the swaging ring is deformed.