WO2009094595A1 - Metal/composite joint with attachment projections, and method of joining - Google Patents

Metal/composite joint with attachment projections, and method of joining Download PDF

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Publication number
WO2009094595A1
WO2009094595A1 PCT/US2009/031914 US2009031914W WO2009094595A1 WO 2009094595 A1 WO2009094595 A1 WO 2009094595A1 US 2009031914 W US2009031914 W US 2009031914W WO 2009094595 A1 WO2009094595 A1 WO 2009094595A1
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WO
WIPO (PCT)
Prior art keywords
composite
engagement region
component
metal
area
Prior art date
Application number
PCT/US2009/031914
Other languages
French (fr)
Inventor
Steven P. Wanthal
Original Assignee
The Boeing Company
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by The Boeing Company filed Critical The Boeing Company
Publication of WO2009094595A1 publication Critical patent/WO2009094595A1/en

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
    • B29C66/721—Fibre-reinforced materials
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B29C65/564—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined hidden in the joint, e.g. dowels or Z-pins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
    • B29C66/05—Particular design of joint configurations
    • B29C66/10—Particular design of joint configurations particular design of the joint cross-sections
    • B29C66/11—Joint cross-sections comprising a single joint-segment, i.e. one of the parts to be joined comprising a single joint-segment in the joint cross-section
    • B29C66/112—Single lapped joints
    • B29C66/1122—Single lap to lap joints, i.e. overlap joints
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/41—Joining substantially flat articles ; Making flat seams in tubular or hollow articles
    • B29C66/43—Joining a relatively small portion of the surface of said articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/74—Joining plastics material to non-plastics material
    • B29C66/742—Joining plastics material to non-plastics material to metals or their alloys
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2305/00—Use of metals, their alloys or their compounds, as reinforcement
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T403/00—Joints and connections
    • Y10T403/49—Member deformed in situ
    • Y10T403/4974—Member deformed in situ by piercing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T403/00—Joints and connections
    • Y10T403/55—Member ends joined by inserted section
    • Y10T403/553—Laterally inserted section
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12493—Composite; i.e., plural, adjacent, spatially distinct metal components [e.g., layers, joint, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24479—Structurally defined web or sheet [e.g., overall dimension, etc.] including variation in thickness

Definitions

  • the disclosure relates to metal /composite joints. More particularly, the disclosure relates to a metal/composite joint having selective interlaminar reinforcement to maintain structural integrity of a composite adherend.
  • Bonded metal-to-composite joints may require reinforcement either within the adhesive or within the first few plies of composite material due to high interlaminar stresses. These stresses may peak at the ends of the bondline or engagement region between the composite and the metal; therefore, ply distortions of the composite may be initiated at the end of the engagement region. Local reinforcement of the engagement region may enhance the structural strength of the joint.
  • One current technique of reinforcing a metal-to-composite joint may include use of a complex bond design such as a step lap joint which may effectively reduce the peak stresses between the metal and composite.
  • Another reinforcement technique may include the use of mechanical reinforcements such as fasteners. However, these reinforcement techniques may be complex and expensive to manufacture.
  • the disclosure is generally directed to a metal/composite joint.
  • An illustrative embodiment of the metal/composite joint includes a metallic component, a composite component provided in engagement with the metallic component, an engagement region defining contact between the metallic component and the composite component and a plurality of attachment projections joining the metallic component and the composite component.
  • the attachment projections may be non-uniformly distributed along the engagement region. In some embodiments, distribution of the attachment projections may be limited to the area or areas of high interlaminar stress along the engagement region. In some embodiments, the attachment projections may be non-uniformly distributed along the engagement region.
  • the metal/composite joint may delay the onset of failure in a metal-to-composite joint by providing local Z-direction reinforcement in the area or areas where the joint is subjected to high Z-direction stresses.
  • the design of the metal/composite joint may allow for simpler metal adherands than a step-lap joint design and may eliminate the need for added fasteners for a mechanically-reinforced option.
  • the disclosure is generally further directed to a method of joining a metallic component and a composite component.
  • An illustrative embodiment of the method includes providing a metallic component and a composite component in engagement with the metallic component; defining an engagement region between the metallic component and the composite component; forming attachment projections along the engagement region in a nonuniform distribution along the engagement region; and engaging the metallic component and the composite component along the engagement region.
  • the attachment projections may penetrate into the composite component.
  • FIG. 1 is a cross-sectional view of an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, with attachment projections extending from a metal component of the metal/composite joint into a composite component of the joint.
  • FIG. IA is a cross-sectional view of an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, with attachment projections extending into a metal component of the metal /composite joint.
  • FIG. IB is a cross-sectional view of an illustrative embodiment of the metal /composite joint with selective interlaminar reinforcement, with attachment projections distributed non-uniformly along an engagement region of a metal component with a composite component.
  • FIG. 2 is a flow diagram which illustrates an illustrative method of joining a metallic component and a composite component .
  • FIG. 3 is a flow diagram of an aircraft production and service methodology.
  • FIG. 4 is a block diagram of an aircraft.
  • the disclosure is generally directed to a metal/composite joint which may include a metal component which is attached to a composite component along an engagement region or region of contact between the components.
  • Multiple attachment projections may extend from the metal component into the composite component at the engagement region.
  • the distribution of attachment projections along the engagement region may be non-uniform and may be more concentrated in areas of relatively high interlaminar stress than in areas of relatively low interlaminar stress of the engagement region. This may provide Z-axis reinforcement of the attachment in the area or areas in which reinforcement is most needed while minimizing ply distortions and maximizing the structural integrity of the composite component in the remaining area or areas of the engagement region.
  • the metal/composite joint may be suitable for aerospace applications or any other application in which fastening of a composite component to a metallic component is deemed necessary and in which the composite component may be subjected to relatively high interlaminar stresses in the engagement region between the components, particularly in the area or areas in which attachment projections extend from the metal component into the composite component.
  • an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, hereinafter joint is generally indicated by reference numeral 1.
  • the joint 1 joins a metal component 2 to a composite component 3.
  • the metal component 2 may be titanium, for example and without limitation.
  • the composite component 3 may include multiple laminated composite plies 4.
  • the metal component 2 may engage the composite component 3 along an engagement region 8.
  • the engagement region 8 may be coextensive with the area of contact between the metal component 2 and the composite component 3.
  • the areas of interlaminar stress along the engagement region 8 may vary in magnitude depending on the structural forces which are exerted on the joint 1.
  • areas of relatively high interlaminar stress 12 may be concentrated at or near the respective end portions of the engagement region 8.
  • An area of relatively low interlaminar stress 14 may extend along the engagement region 8 between the areas of high interlaminar stress 12.
  • the number and locations of the area or areas of relatively high interlaminar stress 12 and the area or areas of relatively low interlaminar stress 14 along the engagement region 8 may vary depending on the particular application of the joint 1. As shown in FIG.
  • multiple attachment projections 18 may extend from the metal component 2 and into the composite component 3. As shown in FIG. IA, in some embodiments of the joint Ia, the attachment projections 18 may extend into the metal component 2, as indicated in phantom.
  • the attachment projections 18 may be the same metal as or a different metal than the metal component 2.
  • the distribution of the attachment projections 18 may be non-uniform across the engagement region 8. As shown in FIG. 1, the concentration of the attachment projections 18 may be greater at each of rhe areas of relatively high interlaminar stress 12 relative to the areas of relatively low interlaminar stress 14 of the engagement region 8. As shown in FIG.
  • the areas of relatively high interlaminar stress 12 are generally located at or near the respective ends of the engagement region 8; therefore, the attachment projections 18 are concentrated at or near the respective ends of the engagement region 8 and are absent or less numerous or concentrated in the area of relatively low interlaminar stress 14 which extends between the areas of relatively high interlaminar stress 12.
  • the location or locations of the area or areas of relatively high interlaminar stress 12 and the area or areas of relatively low interlaminar stress 14 and therefore, the concentration or distribution of the attachment projections 18 along the engagement region 8 may vary depending on the particular application of the metal/composite joint 1.
  • the distribution of the attachment projections 18 along the engagement region 8 may be based on an optimization. As shown in FIG. IB, in some embodiments of the joint Ib, the attachment projections 18 may be distributed non-uniformly along the engagement region 8.
  • interlaminar stresses may be applied to the composite component 1.
  • the magnitude of the interlaminar stresses may be greater at the area or areas of relatively high interlaminar stress 12 than at the area or areas of relatively low interlaminar stress 14 along the engagement region 8. Therefore, the relatively higher concentration of the attachment projections 18 at the area or areas of relatively high interlaminar stress 12 may provide Z- axis reinforcement or enhance the strength of attachment of the composite component 3 to the metal component 2, preventing or at least minimizing initial peeling of the composite plies 4 of the composite component 3 in the area or areas of relatively high interlaminar stress 12. This may prevent or at least minimize peeling of the composite plies 4 along the engagement region 8.
  • the absence or relatively lower concentration of the attachment projections 18 at the area or areas of relatively low interlaminar stress 14 may minimize ply distortions and maintain the structural integrity of the composite component 3 at the area or areas of relatively low interlaminar stress 14.
  • FIG. 2 a flow diagram 200 which illustrates an illustrative method of joining a metallic component and a composite component is shown.
  • an engagement region between a metallic component and a composite component which are to be joined may be defined.
  • areas of relatively higher interlaminar stress concentration and areas of relatively lower interlaminar stress concentration along the engagement region may be identified.
  • attachment projections may be extended from the metallic component along the area or areas of relatively higher interlaminar stress concentration in the engagement region.
  • the attachment projections may be omitted from the metallic component along the area or areas of relatively lower stress concentration in the engagement region. The distribution of the attachment projections along the engagement region may be based on an optimization.
  • exemplary method 78 may include specification and design 80 of the aircraft 94 and material procurement 82.
  • component and subassembly manufacturing 84 and system integration 86 of the aircraft 94 takes place.
  • the aircraft 94 may go through certification and delivery 88 in order to be placed in service 90.
  • the aircraft 94 may be scheduled for routine maintenance and service 92 (which may also include modification, reconfiguration, refurbishment, and so on) .
  • Each of the processes of method 78 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer) .
  • a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors;
  • a third party may include without limitation any number of vendors, subcontractors, and suppliers;
  • an operator may be an airline, leasing company, military entity, service organization, and so on.
  • the aircraft 94 produced by exemplary method 78 may include an airframe 98 with a plurality of systems 96 and an interior 100.
  • high-level systems 96 include one or more of a propulsion system 102, an electrical system 104, a hydraulic system 106, and an environmental system 108. Any number of other systems may be included.
  • an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.
  • the apparatus embodied herein may be employed during any one or more of the stages of the production and service method 78.
  • components or subassemblies corresponding to production process 84 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 94 is in service.
  • one or more apparatus embodiments may be utilized during the production stages 84 and 86, for example, by substantially expediting assembly of or reducing the cost of an aircraft 94.
  • one or more apparatus embodiments may be utilized while the aircraft 94 is in service, for example and without limitation, to maintenance and service 92.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Connection Of Plates (AREA)
  • Pressure Welding/Diffusion-Bonding (AREA)

Abstract

A metal /composite joint (1). An illustrative embodiment of the metal/composite joint (1) includes a metallic component (2), a composite component (3) provided in engagement with the metallic component, an engagement region (8) defining contact between the metallic component (2) and the composite component (3) and a plurality of attachment projections (18) joining the metallic component (2) and the composite component (3). The attachment projections (18) are non-uniformly distributed along the engagement region (8). A method of joining a metallic component (2) and a composite component (3) is also disclosed.

Description

METAL/COMPOSITE JOINT WITH SELECTIVE INTERLAMINAR REINFORCEMENT
BACKGROUND
The disclosure relates to metal /composite joints. More particularly, the disclosure relates to a metal/composite joint having selective interlaminar reinforcement to maintain structural integrity of a composite adherend.
Bonded metal-to-composite joints may require reinforcement either within the adhesive or within the first few plies of composite material due to high interlaminar stresses. These stresses may peak at the ends of the bondline or engagement region between the composite and the metal; therefore, ply distortions of the composite may be initiated at the end of the engagement region. Local reinforcement of the engagement region may enhance the structural strength of the joint. One current technique of reinforcing a metal-to-composite joint may include use of a complex bond design such as a step lap joint which may effectively reduce the peak stresses between the metal and composite. Another reinforcement technique may include the use of mechanical reinforcements such as fasteners. However, these reinforcement techniques may be complex and expensive to manufacture.
SUMMARY
The disclosure is generally directed to a metal/composite joint. An illustrative embodiment of the metal/composite joint includes a metallic component, a composite component provided in engagement with the metallic component, an engagement region defining contact between the metallic component and the composite component and a plurality of attachment projections joining the metallic component and the composite component. The attachment projections may be non-uniformly distributed along the engagement region. In some embodiments, distribution of the attachment projections may be limited to the area or areas of high interlaminar stress along the engagement region. In some embodiments, the attachment projections may be non-uniformly distributed along the engagement region.
The metal/composite joint may delay the onset of failure in a metal-to-composite joint by providing local Z-direction reinforcement in the area or areas where the joint is subjected to high Z-direction stresses. The design of the metal/composite joint may allow for simpler metal adherands than a step-lap joint design and may eliminate the need for added fasteners for a mechanically-reinforced option.
The disclosure is generally further directed to a method of joining a metallic component and a composite component. An illustrative embodiment of the method includes providing a metallic component and a composite component in engagement with the metallic component; defining an engagement region between the metallic component and the composite component; forming attachment projections along the engagement region in a nonuniform distribution along the engagement region; and engaging the metallic component and the composite component along the engagement region. The attachment projections may penetrate into the composite component.
BRIEF DESCRIPTION OF THE ILLUSTRATIONS
FIG. 1 is a cross-sectional view of an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, with attachment projections extending from a metal component of the metal/composite joint into a composite component of the joint.
FIG. IA is a cross-sectional view of an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, with attachment projections extending into a metal component of the metal /composite joint.
FIG. IB is a cross-sectional view of an illustrative embodiment of the metal /composite joint with selective interlaminar reinforcement, with attachment projections distributed non-uniformly along an engagement region of a metal component with a composite component.
FIG. 2 is a flow diagram which illustrates an illustrative method of joining a metallic component and a composite component .
FIG. 3 is a flow diagram of an aircraft production and service methodology.
FIG. 4 is a block diagram of an aircraft.
DETAILED DESCRIPTION
The disclosure is generally directed to a metal/composite joint which may include a metal component which is attached to a composite component along an engagement region or region of contact between the components. Multiple attachment projections may extend from the metal component into the composite component at the engagement region. The distribution of attachment projections along the engagement region may be non-uniform and may be more concentrated in areas of relatively high interlaminar stress than in areas of relatively low interlaminar stress of the engagement region. This may provide Z-axis reinforcement of the attachment in the area or areas in which reinforcement is most needed while minimizing ply distortions and maximizing the structural integrity of the composite component in the remaining area or areas of the engagement region. The metal/composite joint may be suitable for aerospace applications or any other application in which fastening of a composite component to a metallic component is deemed necessary and in which the composite component may be subjected to relatively high interlaminar stresses in the engagement region between the components, particularly in the area or areas in which attachment projections extend from the metal component into the composite component. Referring initially to FIGS. 1-3, an illustrative embodiment of the metal/composite joint with selective interlaminar reinforcement, hereinafter joint, is generally indicated by reference numeral 1. The joint 1 joins a metal component 2 to a composite component 3. The metal component 2 may be titanium, for example and without limitation. The composite component 3 may include multiple laminated composite plies 4.
At the joint 1, the metal component 2 may engage the composite component 3 along an engagement region 8. The engagement region 8 may be coextensive with the area of contact between the metal component 2 and the composite component 3. The areas of interlaminar stress along the engagement region 8 may vary in magnitude depending on the structural forces which are exerted on the joint 1. In some applications, areas of relatively high interlaminar stress 12 may be concentrated at or near the respective end portions of the engagement region 8. An area of relatively low interlaminar stress 14 may extend along the engagement region 8 between the areas of high interlaminar stress 12. However, the number and locations of the area or areas of relatively high interlaminar stress 12 and the area or areas of relatively low interlaminar stress 14 along the engagement region 8 may vary depending on the particular application of the joint 1. As shown in FIG. 1, multiple attachment projections 18 may extend from the metal component 2 and into the composite component 3. As shown in FIG. IA, in some embodiments of the joint Ia, the attachment projections 18 may extend into the metal component 2, as indicated in phantom. The attachment projections 18 may be the same metal as or a different metal than the metal component 2. The distribution of the attachment projections 18 may be non-uniform across the engagement region 8. As shown in FIG. 1, the concentration of the attachment projections 18 may be greater at each of rhe areas of relatively high interlaminar stress 12 relative to the areas of relatively low interlaminar stress 14 of the engagement region 8. As shown in FIG. 1, in some applications the areas of relatively high interlaminar stress 12 are generally located at or near the respective ends of the engagement region 8; therefore, the attachment projections 18 are concentrated at or near the respective ends of the engagement region 8 and are absent or less numerous or concentrated in the area of relatively low interlaminar stress 14 which extends between the areas of relatively high interlaminar stress 12. However, the location or locations of the area or areas of relatively high interlaminar stress 12 and the area or areas of relatively low interlaminar stress 14 and therefore, the concentration or distribution of the attachment projections 18 along the engagement region 8, may vary depending on the particular application of the metal/composite joint 1. The distribution of the attachment projections 18 along the engagement region 8 may be based on an optimization. As shown in FIG. IB, in some embodiments of the joint Ib, the attachment projections 18 may be distributed non-uniformly along the engagement region 8.
In typical application of the metal/composite joint 1, interlaminar stresses may be applied to the composite component 1. The magnitude of the interlaminar stresses may be greater at the area or areas of relatively high interlaminar stress 12 than at the area or areas of relatively low interlaminar stress 14 along the engagement region 8. Therefore, the relatively higher concentration of the attachment projections 18 at the area or areas of relatively high interlaminar stress 12 may provide Z- axis reinforcement or enhance the strength of attachment of the composite component 3 to the metal component 2, preventing or at least minimizing initial peeling of the composite plies 4 of the composite component 3 in the area or areas of relatively high interlaminar stress 12. This may prevent or at least minimize peeling of the composite plies 4 along the engagement region 8. The absence or relatively lower concentration of the attachment projections 18 at the area or areas of relatively low interlaminar stress 14 may minimize ply distortions and maintain the structural integrity of the composite component 3 at the area or areas of relatively low interlaminar stress 14.
Referring next to FIG. 2, a flow diagram 200 which illustrates an illustrative method of joining a metallic component and a composite component is shown. In block 202, an engagement region between a metallic component and a composite component which are to be joined may be defined. In block 204, areas of relatively higher interlaminar stress concentration and areas of relatively lower interlaminar stress concentration along the engagement region may be identified. In block 206, attachment projections may be extended from the metallic component along the area or areas of relatively higher interlaminar stress concentration in the engagement region. In block 208, the attachment projections may be omitted from the metallic component along the area or areas of relatively lower stress concentration in the engagement region. The distribution of the attachment projections along the engagement region may be based on an optimization. In block 210, the composite and metallic components may be engaged along the engagement region. In block 212, the attachment projections may be extended into the composite component. Referring next to FIGS. 3 and 4, embodiments of the disclosure may be used in the context of an aircraft manufacturing and service method 78 as shown in FIG. 3 and an aircraft 94 as shown in FIG. 4. During pre-production, exemplary method 78 may include specification and design 80 of the aircraft 94 and material procurement 82. During production, component and subassembly manufacturing 84 and system integration 86 of the aircraft 94 takes place. Thereafter, the aircraft 94 may go through certification and delivery 88 in order to be placed in service 90. While in service by a customer, the aircraft 94 may be scheduled for routine maintenance and service 92 (which may also include modification, reconfiguration, refurbishment, and so on) .
Each of the processes of method 78 may be performed or carried out by a system integrator, a third party, and/or an operator (e.g., a customer) . For the purposes of this description, a system integrator may include without limitation any number of aircraft manufacturers and major-system subcontractors; a third party may include without limitation any number of vendors, subcontractors, and suppliers; and an operator may be an airline, leasing company, military entity, service organization, and so on.
As shown in FIG. 4, the aircraft 94 produced by exemplary method 78 may include an airframe 98 with a plurality of systems 96 and an interior 100. Examples of high-level systems 96 include one or more of a propulsion system 102, an electrical system 104, a hydraulic system 106, and an environmental system 108. Any number of other systems may be included. Although an aerospace example is shown, the principles of the invention may be applied to other industries, such as the automotive industry.
The apparatus embodied herein may be employed during any one or more of the stages of the production and service method 78. For example, components or subassemblies corresponding to production process 84 may be fabricated or manufactured in a manner similar to components or subassemblies produced while the aircraft 94 is in service. Also, one or more apparatus embodiments may be utilized during the production stages 84 and 86, for example, by substantially expediting assembly of or reducing the cost of an aircraft 94. Similarly, one or more apparatus embodiments may be utilized while the aircraft 94 is in service, for example and without limitation, to maintenance and service 92.
Although the embodiments of this disclosure have been described with respect to certain exemplary embodiments, it is to be understood that the specific embodiments are for purposes of illustration and not limitation, as other variations will occur to those of skill in the art.

Claims

CLAIMSWhat is claimed is:
1. A metal/composite joint, comprising: a metallic component; a composite component provided in engagement with said metallic component; an engagement region defining contact between said metallic component and said composite component; a plurality of attachment projections joining said metallic component and said composite component; and wherein said attachment projections are non-uniformly distributed along said engagement region.
2. The metal/composite joint of claim 1 wherein distribution of said attachment projections along said engagement region is based on an optimization.
3. The metal/composite joint of claim 1 wherein said metallic component comprises titanium.
4. The metal/composite joint of claim 1 further comprising at least one area of relatively high interlaminar stress and at least one area of relatively low inerlaminar stress along said engagement region, and wherein said attachment projections are concentrated at said at least one area of relatively high interlaminar stress.
5. The metal/composite joint of claim 4 wherein said attachment projections are absent from said at least one area of relatively low interlaminar stress.
6. The metal/composite joint of claim 4 wherein said at least one area of relatively high interiaminar stress comprises a pair of areas of relatively high interlaminar stress at respective ends of said engagement region.
7. The metal /composite joint of claim 6 wherein said at least one area of relatively low interlaminar stress extends between said pair of areas of relatively high interlaminar stress.
8. A metal/composite joint, comprising: a metallic component; a composite component provided in engagement with said metallic component; an engagement region defining contact between said metallic component and said composite component; a plurality of attachment projections extending from said metallic component into said composite component and joining said metallic component and said composite component; and wherein said attachment projections are non-uniformly distributed along said engagement region.
9. The metal/composite joint of claim 8 wherein distribution of said attachment projections along said engagement region is based on an optimization.
10. The metal/composite joint of claim 8 wherein said metallic component comprises titanium.
11. The metal/composite joint of claim 8 further comprising at least one area of relatively high interlaminar stress and at least one area of relatively low inerlaminar stress along said engagement region, and wherein said attachment projections are concentrated at said at least one area of relatively high interlaminar stress .
12. The metal/composite joint of claim 11 wherein said attachment projections are absent from said at least one area of relatively low interlaminar stress.
13. The metal/composite joint of claim 11 wherein said at least one area of relatively high interlaminar stress comprises a pair of areas of relatively high interlaminar stress at respective ends of said engagement region.
14. The metal /composite joint of claim 13 wherein said at least one area of relatively low interlaminar stress extends between said pair of areas of relatively high interlaminar stress.
15. A method of joining a metallic component and a composite component, comprising: providing a metallic component and a composite component in engagement with said metallic component; defining an engagement region between said metallic component and said composite component ; forming attachment projections along said engagement region in a non-uniform distribution along said engagement region; engaging said metallic component and said composite component along said engagement region; and wherein said attachment projections penetrate into said composite component.
16. The method of claim 15 further comprising optimizing distribution of said attachment projections along said engagement region.
17. The method of claim 15 further comprising identifying at least one area of relatively high interlaminar stress concentration and at least one area of relatively low interlaminar stress concentration along said engagement region and wherein said forming attachment projections along said engagement region in a non-uniform distribution along said engagement region comprises concentrating said attachment projections in said at least one area of relatively high interlaminar stress concentration.
18. The method of claim 17 wherein said identifying at least one area of relatively high interlaminar stress concentration along said engagement region comprises identifying areas of relatively high interlaminar stress concentration at respective ends of said engagement region.
19. The method of claim 18 wherein said identifying at least one area of relatively low interlaminar stress concentration along said engagement region comprises identifying at least one area of relatively low interlaminar stress concentration extending between said areas of relatively high interlaminar stress concentration .
20. The method of claim 15 wherein said providing a metallic component comprises providing a titanium component.
PCT/US2009/031914 2008-01-25 2009-01-23 Metal/composite joint with attachment projections, and method of joining WO2009094595A1 (en)

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