Patent ID: 8512808
Filing Date: 2013-08-20
Classification: B22F,B33Y,C23C,F02K,F05D,Y02P,Y10T

Abstract:
1. A method for producing an aerospace structure with an integrated composite interface with a graded coefficient of thermal expansion (CTE) joining structural members with highly different CTE comprising the steps of: identifying an extreme environment application for attachment of a first separate member and second separate member; determining a connecting component design for a CTE-graded composite including determining the attachment methodology from the CTE-graded composite to the first member and to the second member conducting a thermomechncial analysis including evaluating the temperature dependent CTE properties of each member to determine the level of CTE mismatch accommodation required by the structure; evaluating the level of heating/cooling temperature gradients encountered during service and, analyzing the thermomechanical loading conditions in the assembly; conducting material selection for the graded CTE composite; choosing a build-up fabrication technique; providing a local interface design of interlayers between first and second adjacent layers with a first interlayer having a material composition of about 75% of the material of the first adjacent layer and about 25% of the material of the second adjacent layer, a second interlayer having a material composition of about 50% of the material of the first adjacent layer and about 50% of the material of the second adjacent layer and a third interlayer having a material composition of about 25% of the material of the first adjacent layer and about 75% of the material of the second adjacent layer; building up a CTE-graded component laser assisted metal deposition to produce a near net shape CTE-graded composite using layers of differing CTE materials employing the selected materials, fabrication technique and local interface design; performing secondary processing; and, assembling the first separate member and second separate member to the CTE graded component.