Abstract:
The invention provides a method of manufacturing a metallic-composite joint comprising a metallic component having one hole in a surface thereof, and a metallic fastener having a head portion for attaching to the metallic component and a tail portion for attaching to a composite component, comprising the steps of positioning the metallic fastener such that the head portion of the metallic fastener is retained in the hole, and the tail portion of the metallic fastener extends out of the hole, arranging layered fibres of an uncured composite component on the surface of the metallic component such that the tail portion extends through a gap between adjacent fibres in each fibre layer, and curing the composite component. The invention also provides a metallic-composite joint, a structure, an aircraft structure, an aircraft, a method of manufacturing a fastener assembly, a fastener assembly and a metallic fastener.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention concerns a method of manufacturing a metallic-composite joint. More particularly, but not exclusively, this invention concerns a method of manufacturing a metallic-composite joint where the metallic-composite joint comprises a metallic component, the metallic component and a metallic fastener, the metallic fastener having ahead portion for attaching to the metallic component and a tail portion for attaching to a composite component. 
         [0002]    The invention also concerns a metallic-composite joint, a structure, an aircraft structure, an aircraft, a method of manufacturing a fastener assembly, a fastener assembly and a metallic fastener. 
         [0003]    There are various methods of attaching a metallic component to a composite component to form a metallic-composite joint. 
         [0004]    One method involves making the surface of the metallic component liquid by heating it to a very high temperature. A metallic spike is then formed extending away from the surface by forming a “proggle”. In other words, an implement is contacted with the liquid surface and pulled up away from the surface (“proggling”) to form a metallic spike. This spike is made of the same metallic material as the metallic component. The composite component is then attached to the metallic spike (known as a hyper pin) by either laying up fibre layers so that adjacent fibres lie either side of the spike or by shaking the fibre layers onto the spike. The fibre layers are then cured so that the cured composite component is attached to the metallic spike. This process can be time-consuming and expensive. 
         [0005]    Another method uses ALM (Additive Layer Manufacturing) to form the metallic spike (hyper pin) on the surface of the metallic component. The composite component can then be attached to the spike, using the two ways described for the earlier method. ALM is also a time-consuming and expensive process. In addition, ALM machines tend to be of a limited size and so can generally only be used to produce smaller pins and so there is a limit to its applicability, especially with large components, 
         [0006]    For both of these methods, the metallic spike has to be the same material as the metallic component. For example, in aerospace applications, it is often desirable to use an aluminium alloy as the material for the metallic component. However, this then means that, using the methods described earlier, the metallic spike is also made of the aluminium alloy. This can cause problems as aluminium alloy is not readily compatible with composite materials. Hence, so that aluminium alloy and composite materials are prevented from being adjacent to each other, a titanium alloy is used instead for the metallic component. Titanium alloy is more compatible with composite materials so this problem is overcome. However, it is more expensive than aluminium alloy and so is disadvantageous for that reason. 
         [0007]    The present invention seeks to mitigate the above-mentioned problems. Alternatively or additionally, the present invention seeks to provide an improved method of manufacturing a metallic-composite joint. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention provides, according to a first aspect, a method of manufacturing a metallic-composite joint, the metallic-composite joint comprising a metallic component, the metallic component having at least one hole in a surface thereof, and a metallic fastener, the metallic fastener having a head portion for attaching to the metallic component and a tail portion for attaching to a composite component, the method comprising the steps of positioning the metallic fastener such that at least a part of the head portion of the metallic fastener is retained in the hole of the metallic component, and the tail portion of the metallic fastener extends out of the hole and away from the surface of the metallic component, arranging layered fibres of an uncured composite component on the surface of the metallic component such that the tail portion extends through a gap between adjacent fibres in each fibre layer, and curing the composite component, thereby attaching the composite component to the tail portion of the metallic fastener. 
         [0009]    Having a metallic component and a non-integral metallic fastener allows the materials of the two metallic elements to be different. This allows the fastener to be made  08252  of titanium alloy (so that it can be compatible with extending through the composite component) and the metallic component to be made from aluminium alloy (less ex pensive). 
         [0010]    The metallic component may be or may comprise a plate, bracket, flange or tubular end fitting, for example. The metallic component may be generally planar, curved or non-planar, for example. 
         [0011]    The composite component is not necessarily placed directly on the metallic component surface. For example, it is noted that, in order to prevent the, for example, carbon fibres of the composite component being adjacent the aluminium alloy (or other material) metallic component, a glass layer can be used in between the composite component and the metallic component. The glass layer may be integral with the (cured) composite component. 
         [0012]    The method could include the step of providing the hole in the metallic component. Alternatively, the metallic component may already have the hole present prior to the carrying out of the method. 
         [0013]    Preferably, the arranging of the layered fibres comprises the steps of laying up the fibres in layers, then positioning the layers adjacent an end of the tail portion distal from the surface of the metallic component, and then shaking the layers so that the tail portion to passes through the gap in each layer. 
         [0014]    Alternatively, the arranging of the layered fibres comprises the step of for each layer, laying up the fibres on the metallic component such that two adjacent fibres pass on substantially opposite sides of the tail portion of the metallic fastener so that the tail portion extends through the layer. 
         [0015]    Preferably, either the method further comprises the step of shaping the tail portion or the tail portion of the metallic fastener has already been shaped. 
         [0016]    Here, shaped means that the tail portion has been deformed in some way to achieve the desired special shaping. This could be from punching, casting or another type of forming. The shaping may, for example, by provided by reciprocal, cylindrical or compressive forming techniques. 
         [0017]    Preferably, the tail portion is or has been shaped to have an outer region, towards the end of the tail portion furthest away from the head portion, and an inner region, towards the end of the tail portion nearest the head portion, wherein the cross-section at the outer region is larger than at the inner region. 
         [0018]    The larger outer ref-lion prevents the composite component from being removed over the end of the tail portion. The inner region may make up the majority of the length of the tail portion. 
         [0019]    More preferably, the tail portion is or has been shaped to have an intermediate region, in between the inner and outer regions, with a cross-section smaller than the inner region. This means that the intermediate region provides a wasted neck to further prevent the composite component from being removed over the end of the tail portion. 
         [0020]    Preferably, the tail portion is or has been shaped so that the end of the tail portion furthest away from the head portion is tapered. This provides a sharp point to aid the tail portion in extending through a gap between adjacent fibres in each fibre layer. 
         [0021]    Preferably, either the method further comprises the step of shaping the head portion or the head portion of the metallic fastener has already been shaped. 
         [0022]    Here, shaped means that the head portion has been deformed in some way to achieve the desired special shaping. This could be from punching, casting or another type of forming. The shaping may, for example, by provided by reciprocal, cylindrical or compressive forming techniques. 
         [0023]    The head portion may be shaped at the same time as the tail portion is shaped. Alternatively, the head portion and the tail portion may be shaped one after the other. 
         [0024]    The head portion may be shaped prior to at least a part of the head portion of the metallic fastener being positioned in the hole of the metallic component. 
         [0025]    More preferably, the head portion is or has been shaped to have an outer region, towards the end of the head portion furthest away from the tail portion, an inner region, towards the end of the head portion nearest the tail portion, wherein the cross-section at the outer region is larger than at the inner region. The outer region prevents the metallic fastener being positioned too far into the hole of the metallic component. The outer region of the head portion may be removed after the metallic fastener has been positioned. 
         [0026]    More preferably, the outer region of the head portion is or has been chamfered to correspond to a chamfered region of the hole in the metallic component. This prevents separation of the metallic component and metallic fastener in a first direction. The outer region of the head portion may be countersunk in the chamfered region of the hole so that the head portion is flush with the metallic component. 
         [0027]    Preferably, after the metallic fastener is positioned in the hole of the metallic component, the metallic fastener is shaped to have a securing lip at a junction of the head portion and tail portion, for securing the head portion in the hole. This prevents separation of the metallic component and metallic fastener in a second direction (opposite to the first direction), especially prior to curing of the composite component. 
         [0028]    More preferably, the metallic component has a correspondingly shaped recess to accommodate the securing lip. 
         [0029]    Preferably, the head portion of the metallic fastener is retained in the hole of the metallic component at least partially by an interference fit. Here, no outer region of the head portion is required. This is especially practical for a joint that is subjected to low tension forces, for example a tubular end fitting where the joint would experience almost solely a shear force. 
         [0030]    Preferably, the hole in the metallic component is a through-hole extending through a thickness of the metallic component. 
         [0031]    Preferably, the method further includes the step of cutting a wire feed stock to form the metallic fastener, 
         [0032]    The present invention provides, according to a second aspect, a metallic-composite joint comprising a metallic component having at least one hole in a surface thereof, a composite component having a plurality of fibre layers, a metallic fastener having a head portion attached to the metallic component and a tail portion attached to the composite component, wherein at least part of the head portion is retained in the hole of the metallic component, and wherein the tail portion extends through a gap between adjacent fibres in each fibre layer of the composite component. 
         [0033]    The present invention provides, according to a third aspect, a structure comprising the metallic-composite joint as described above. The structure may be any structure where there is a metallic component joined to a composite component. The structure may be for use in sports equipment, such as a bike, boat hulls or wind turbine blades, for example. 
         [0034]    The present invention provides, according to a fourth aspect, an aircraft structure comprising he metallic-composite joint as described above. 
         [0035]    The present invention provides, according to a fifth aspect,an aircraft comprising the metallic-composite joint as described above. 
         [0036]    The present invention provides, according to a sixth aspect, a method of manufacturing a fastener assembly, the fastener assembly comprising a metallic component, the metallic component having at least one hole in a surface thereof, and a metallic fastener, the metallic fastener having a head portion for attaching to the metallic component and a tail portion for attaching to a composite component, the method comprising the steps of positioning the metallic fastener such that at least a part of the head portion of the metallic fastener is retained in the hole of the metallic component, and the tail portion of the metallic fastener extends out of the hole and away from the surface of the metallic component, wherein either the method further comprises the step of shaping the tail portion or the tail portion of the metallic fastener has already been shaped. 
         [0037]    Preferably, the tail portion is or has been shaped to have an outer region, towards the end of the tail portion furthest away from the head portion, and an inner towards the end of the tail portion nearest the head portion, wherein the cross-section at the outer region is larger than at the inner region. 
         [0038]    More preferably,the tail portion is or has been shaped to have an intermediate region, in between the inner and outer regions, with a cross-section smaller than the inner region. 
         [0039]    Preferably, the tail portion is or has been shaped so that the end of the tail portion furthest away from the head portion is tapered. 
         [0040]    The present invention provides, according to a seventh aspect, a fastener assembly comprising a metallic component having at least one hole in a surface thereof, a metallic fastener having ahead portion attached to the metallic component and a tail portion for attaching to a composite component, wherein at least part of the head portion is retained in the hole of the metallic component, and wherein the tail portion has been shaped such that either the tail portion has an outer region, towards the end of the tail portion furthest away from the head portion, and an inner region, towards the end of the tail portion nearest the head portion, and wherein the cross-section at the outer region is larger than at the inner region, or the end of the tail portion furthest away from the head portion is tapered. 
         [0041]    The present invention provides, according to an eighth aspect, a metallic fastener comprising ahead portion for attaching to metallic component, and a tail portion for attaching to a composite component, wherein the tail portion has been shaped such that either the tail portion has an outer region, towards the end of the tail portion furthest away from the head portion, and an inner region, towards the end of the tail portion nearest the head portion, and wherein the cross-section at the outer region is larger than at the inner region, or the end of the tail portion furthest away from the head portion is tapered. 
         [0042]    It will of course be appreciated that features described in relation to one aspect of the present invention may be incorporated into other aspects of the present invention. For example, the method of the invention may incorporate any of the features described with reference to the apparatus of the invention and vice versa. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0043]    Embodiments of the present invention will now be described by way of example only with reference to the accompanying schematic drawings of which: 
           [0044]      FIG. 1 a    shows a perspective view of a metallic plate for forming a metallic-composite joint according to a first embodiment of the invention; 
           [0045]      FIG. 1 b    shows a metallic wire used to form a fastener for the joint; 
           [0046]      FIG. 1 c    shows the fastener with a shaped head; 
           [0047]      FIG. 1 d    shows a cut-away view of the fastener placed in a hole of the metallic plate; 
           [0048]      FIG. 1 e    shows a cut-away view of the fastener in the plate with a shaped tail; 
           [0049]      FIG. 2 a    shows a second fastener with a shaped head and a shaped tail; 
           [0050]      FIG. 2 b    shows a cut-away view of the fastener placed in a hole of the metallic plate; 
           [0051]      FIG. 3 a    shows a cut-away view of a hole in the plate provided with a chamfer on the top surface; 
           [0052]      FIG. 3 b    shows a cut-away view of a fastener with a shaped head in the hole; 
           [0053]      FIG. 3 c    shows a cut-away view of the fastener with a shaped tail with a lip; 
           [0054]      FIG. 4 a    shows a cut-away view of a hole in the plate provided with a chamfer on the bottom surface; 
           [0055]      FIG. 4 b    shows a fastener with a chamfered head; 
           [0056]      FIG. 4 c    shows a cut-away view of the fastener with a chamfered head in the hole; 
           [0057]      FIG. 4 d    shows a cut-away view of the fastener with a shaped tail; 
           [0058]      FIG. 5 a    shows a fastener with a shaped and chamfered head; 
           [0059]      FIG. 5 b    shows a cut-away view of the fastener in a chamfered hole of the plate; 
           [0060]      FIG. 5 c    shows a cut-away view of the fastener with a shaped tail; 
           [0061]      FIG. 6 a    shows a cut-away view of a non-through hole in a metallic component for forming a metallic-composite joint according to another embodiment of the invention; 
           [0062]      FIG. 6 b    shows a cut-away view of a fastener interference fitted in the hole; 
           [0063]      FIG. 6 c    shows a cut-away view of the fastener with a shaped tail; 
           [0064]      FIG. 7  shows the equipment used to form the various joints; 
           [0065]      FIG. 8 a    shows a wire being stopped by the equipment; 
           [0066]      FIG. 8 b    shows the wire being gripped by the equipment; 
           [0067]      FIG. 8 c    shows the wire being punched by the equipment; 
           [0068]      FIG. 8 d    shows the finished fastener in a plate; and 
           [0069]      FIG. 9  shows an aircraft including at least one metallic-composite joint. 
       
    
    
     DETAILED DESCRIPTION 
       [0070]      FIGS. 1 a  to 1 e    show various steps in the process of manufacturing a metallic-composite joint, according to a first embodiment of the invention. The joint comprises a metallic (aluminium alloy) component (a plate  10 ) and a composite component (not shown), joined together by a metallic (titanium alloy) fastener  20 . 
         [0071]    Firstly, as shown in  FIG. 1   a,  the plate  10  is drilled with a number of through-holes  11 . 
         [0072]    Secondly, as shown in  FIG. 1   b,  a titanium alloy wire  21  used to form the fastener  20  is provided. 
         [0073]    Thirdly, as shown in  FIG. 1   c,  the fastener is provided with a shaped head  30 , comprising a disc shape  31 , at one end of the wire  21 . 
         [0074]    Fourthly, as shown in  FIG. 1   d,  the fastener  20  is placed in a hole  11  of the plate  10 . 
         [0075]    Fifthly, as shown in  FIG. 1   e,  the fastener  20  is provided with a shaped tail.  40  at the opposite end of the wire  21  to the head  30 . Hence, the fastener comprises a shaft  50 , a shaped head  30  and a shaped tail  40 . The shaped tail  40  comprises a narrow neck portion  41  in between two sloping sections  42 ,  43 . It also has a pointed end  44 . 
         [0076]    Sixthly (not shown), a composite component is placed around the fastener above the plate  10 . This can be done either by laying up fibre layers so that adjacent fibres lie either side of the fastener or by shaking the fibre layers onto the fastener (aided by the pointed end  44 ). 
         [0077]    Seventhly (not shown), the fibre layers are then cured so that the cured composite component is attached to the fastener. The neck portion  41  and sloping sections  42 ,  43  also aid in retaining the composite component on the fastener. 
         [0078]    Referring to the parts of the fastener  20  that attach to the different parts of the joint, it can be seen that a head portion  22  (defined by the shaped head  30  and a head end of the shaft  50 ) attaches to the metallic component (plate  10 ) and a tail portion.  23  (defined by the shaped tail  40  and a tail end of the shaft  50 ) attaches to the composite component. 
         [0079]    In the following Figures sets ( 2  to  6 ) various different methods of forming the joints will be described. Only the differences from the method steps described in relation to  FIGS. 1 a  to 1 e   ) will be described. 
         [0080]    In Figure set  2 , the tail is shaped prior to the fastener being placed in the hole (i.e.  FIGS. 2 a  and 2 b    replace  FIGS. 1 d    and  1   e,  respectively—steps  4  and  5 ), 
         [0081]    In Figure set  3 , the hole  11  is provided with a chamfer  12  on the top surface of the plate  10  (see  FIG. 3 a   ). When the tail  40  is shaped (with the fastener in the hole  11 ), the tail includes a lip  45  corresponding to the chamfer  12 . This lip  45  retains the plate  10  on the fastener  20 . ( FIGS. 3 a  to 3 c    effectively replace  FIGS. 1   a,    1   d  and  1   e,  respectively—steps  1 ,  4  and  5 .) 
         [0082]    In Figure set  4 , the hole  11  is provided with a chamfer  13  on the bottom surface of the plate  10  (see  FIG. 4 a   ). The head  30  is shaped (see  FIG. 4 b   ) so as to have a matching chamfered portion  32  (instead of the disc  31 ). The chamfered portion  32  of the head  30  sits in the chamfer  13  on the hole  11  and allows the head to be counter sunk to give a flush bottom surface of the plate  10 . ( FIGS. 4 a  to 4 d    effectively replace  FIGS. 1   a,    1   c,    1   d  and  1   e,  respectively—steps  1 ,  3 ,  4  and  5 .) 
         [0083]    In Figure set  5 , the head  30  is shaped so as to have a similar (to  FIG. 4 b   ) matching chamfered portion  32  on top of the disc  31 . The chamfered portion  32  of the head  30  sits in the chamfer  13  on the hole  11  and allows the chamfered portion  32  of the head to be counter sunk. The disc  31  may be removed afterwards to give a flush bottom surface of the plate  10 . ( FIGS. 4 a  and 5 a  to 5 c    effectively replace  FIGS. 1   a,    1   c,    1   d  and  1   e,  respectively —steps  1 ,  3 ,  4  and  5 .) 
         [0084]    In Figure set  6 , the metallic (aluminium alloy) component  110  is not a plate. In addition, the hole  111  is not a through-hole. Here, the fastener  20  made out of wire  21  is a larger diameter than the hole  11  and is put into the hole with an interference fit. There is no shaped head  30 . After the head portion  22  is attached in the hole  111 , the shaped tail  40  is formed, as before. ( FIGS. 6 a  to 6 c    effectively replace  FIGS. 1 a    to  1   e,  respectively—steps  1 ,  4  and  5  (no step  3 ).) 
         [0085]      FIG. 7  shows the equipment used to form the various joints of the Figure sets. The equipment  200  includes a drill  201  (for drilling and chamfering holes  11 ,  111  in the plate  10  or component  110 ) and a wire feed  202  for supplying the wire  21  to make the fasteners  20 . The fasteners are formed in the forming apparatus  203 . 
         [0086]      FIGS. 8 a  to 8 d    show the processes which might happen in the forming apparatus  203 . Firstly, the wire  21  of the wire feed  202  is fed through a hole in a plate  10  and stopped by a stopper (rivet head)  204  ( FIG. 8 a   ). After it is stopped, the wire  21  is squeezed by a two part gripping die  205   a,    205   b  ( FIG. 8 b   ) to form the shaped tail  40  of the fastener  20 . The dies  205   a,    205   b  also cuts the wire  21  above the tail. 
         [0087]    The gripping die  205   a,    205   b  is then pushed down to the plate  10  and the stopper  204  is pushed up to the plate  10  to form the head  30  of the fastener  20  ( FIG. 8 c   ). Finally, the stopper  204  and gripping die  205   a,    205   b  are removed (along with the cut wire  21 ) to another hole in the plate, leaving the fastener  20  in the hole in the plate  10  ( FIG. 8 d   ), 
         [0088]      FIG. 9  shows an aircraft  300  including at least one metallic-composite joint  301 , which has been manufactured by one of the methods described above. 
         [0089]    Whilst the present invention has been described and illustrated with reference to particular embodiments, it will be appreciated by those of ordinary skill in the art that the invention lends itself to many different variations not specifically illustrated herein. By way, of example only, certain possible variations will now be described. 
         [0090]    The metallic component  10 ,  110  could be any shape or configuration. For example, it could be a plate, butt strap, stiffener, cleat, bracket, flange or tubular end fitting, for example. The metallic component may be generally planar, curved or non-planar, for example. 
         [0091]    The joint may or may not be part of an aircraft. For example, the joint may be for use in sports equipment, such as a bike, a boat hull or a wind turbine blade. 
         [0092]    The shaped head  30  and/or shaped tail  40  may take any suitable shape, including the lip  45  of the tail  40  and the chamfered portion  32  of the head  30 . 
         [0093]    The shaped head  30  and/or shaped tail  40  may be shaped using compressive forming techniques, reciprocal or rotating cylindrical methods. 
         [0094]    The head  30  may not be shaped. This could be the case where an interference fit (in a through hole or a non-through hole) is used. 
         [0095]    The tail may not be shaped. This could he the case where the arranging of the layered fibres comprises the step of for each layer, laying up the fibres on the metallic component such that two adjacent fibres pass on substantially opposite sides of the tail portion of the metallic fastener so that the tail portion extends through the layer. 
         [0096]    The composite component is not necessarily placed directly on the metallic component  10 ,  110  surface. For example, it is noted that, in order to prevent the, for example, carbon fibres of the composite component being adjacent the aluminium alloy or other material) metallic component, a glass layer can be used in between the composite component and the metallic component. The glass layer may be integral with the (cured) composite component. 
         [0097]    The hole  11 ,  111  in the metallic component  10 ,  110  may be provided before, during or after the cutting of the wire  21  or the shaping of the head  30  and/or tail  40  of the fastener  20 , as appropriate. 
         [0098]    Other materials may be used for the metallic component  10 ,  110  and/or fastener  20 . 
         [0099]    Where in the foregoing description, integers or elements are mentioned which have known, obvious or foreseeable equivalents, then such equivalents are herein incorporated as if individually set forth. Reference should be made to the claims for determining the true scope of the present invention, which should be construed so as to encompass any such equivalents. It will also be appreciated by the reader that integers or features of the invention that are described as preferable, advantageous, convenient or the like are optional and do not limit the scope of the independent claims. Moreover, it is to be understood that such optional integers or features, whilst of possible benefit in some embodiments of the invention, may not be desirable, and may therefore be absent, in other embodiments.