Welded Edge Profile for Fiber Metal Laminate Assembly
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Solution Overview
Problem
The existing methods for manufacturing structural components, such as those for aircraft or spacecraft fuselages, using fiber metal laminates are inefficient due to the need for complex assembly and material-intensive riveted or bolted joints, which are time-consuming and require expensive materials like titanium for crack stoppers.
Innovation Solution
A structural component with a laminate structure comprising metal layers and an adhesive layer, where an edge profile made of weldable material is bonded to the laminate, allowing for faster assembly through welding, eliminating the need for riveted joints and expensive materials by using a monolithic aluminum edge profile that can be welded, and incorporating a doubler for improved stress resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If riveted or bolted joints are used to assemble laminates, then the structural component can be manufactured, but the assembly process becomes time-consuming and requires expensive materials like titanium for crack stoppers
Solution Approach 1:
The patent replaces mechanical fastening systems (rivets, bolts, crack stoppers) with a welding system. The edge profiles are designed with welding preparation (beveled edges) and are joined using welding processes, substituting the complex mechanical assembly of multiple metal layers and fasteners with a direct welding operation between edge profiles, thereby significantly reducing assembly time and eliminating the need for titanium crack stoppers
Solution Approach 2:
The patent merges multiple separate components (metal layers, adhesive layers, edge profiles, crack stoppers) into a more integrated structure. The edge profiles are welded directly to each other and to the laminate edges, combining the functions of structural support, edge protection, and joint reinforcement into a unified welded assembly, reducing the total number of discrete parts and assembly steps
2Reliability
If riveted joints with crack stoppers are used, then joint reliability is improved, but material costs increase due to expensive titanium materials
Solution Approach 1:
The welding system replaces the mechanical riveted joint system with titanium crack stoppers. Welding provides inherent crack arrest capability through the continuous metallurgical bond and fusion zone, eliminating the need for separate titanium crack stopper components while maintaining or improving joint reliability through the strength of the weld connection
Solution Approach 2:
The patent changes the material parameter from expensive titanium (for crack stoppers) to more cost-effective materials for the edge profiles and welding consumables. The welding process parameters (heat input, welding speed, electrode selection) are optimized to achieve reliable joints using less expensive material combinations while maintaining structural integrity and crack resistance
3Strength
If complex assembly processes are used for laminates, then structural integrity is maintained, but manufacturing complexity increases
Solution Approach 1:
The welding process replaces the complex multi-step mechanical assembly process (layer stacking, adhesive application, rivet insertion, crack stopper installation, tightening sequences) with a more straightforward welding operation. The edge profiles are positioned and welded directly, reducing the number of assembly steps and tooling requirements while maintaining structural integrity through the strength of the weld joints
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 solution enables quicker assembly and reduced material costs by facilitating faster welded joints and eliminating the need for titanium crack stoppers, while providing a lightweight, durable design with extended inspection intervals.
Implementation Method 1
a laminate (2) having metal layers (3) and an adhesive layer (4) placed between and bonded to the metal layers (3)
Implementation Method 2
applying heat and/or pressure to the laminate and the edge profile
Data Source
Figure 1~2
Figure 3~4
Figure 5
AI summary
The present invention provides a structural component (1), in particular for an aircraft or spacecraft fuselage, comprising: a laminate (2) having metal layers (3) and an adhesive layer (4) placed between and bonded to the metal layers (3); and an edge profile (5) made of a weldable material, which is materially bonded to the laminate (2), wherein the edge profile (5) extends at least in sections along an edge (6) of the laminate (2). Further the present invention provides a method (M) for manufacturing such a structural component (1), and an aircraft (10) or spacecraft comprising such a structural component (1).