Airbus Operations Gmbh

Daniel Johns

Jonathan Meyer

Benjamin Farmer

Andrew Henstridge

John Maurice Price

A joint including: a first component and a second component; the first component includes a bond region and an array of projections extending from the bond region, wherein the projections are embedded in the second component.

Preparation of a component for use in a joint

A method of preparing a component () to be joined to another component (). The method comprises growing an array of projections () on a bond region of the component () in a series of layers, each layer being grown by directing energy and/or material from a head to selected parts of the bond region. The joint may be used to join a pair of structural components, for instance in an aerospace application. For instance the joint may be used to join a reinforcing plate, floating rib foot, or stringer to a panel such as a wing or fuselage cover. Alternatively the joint may be used to join adjacent layers in a laminate structure.

A method of joining a first component to a second component, the method comprising preparing the first component by forming an array of elongate projections on a bond surface of the component, each projection having a centerline, a tip, and a base. The centerline at the tip of each projection is oriented at an angle with respect to the normal to the bond surface at its base, and the angular orientation of the tip centerlines varies across the array of projections. Next, the first component and a flexible layer are brought together so as to embed the projections in the flexible layer before hardening the flexible layer to form the second component. Also, a joint so formed.

Orientation of interfacing projections

A method of forming a hybrid component comprising at least two metallic parts, the method comprising preparing a first metallic part by forming at least one macroscopic interfacing feature on an interfacing surface of the part; positioning the first part in a mould tool; introducing a metallic powder into the mould tool and around the interfacing feature(s); and consolidating the metallic powder by a Hot-Isostatic Pressing (HIP) process to form a second metallic part which encapsulates the interfacing feature(s) to provide a mechanical connection between the first and second parts of the component. Also, a hybrid component so formed. The metallic parts may have substantially different material properties.

Hybrid component

A method of joining a first component to a second component, the method comprising forming an array of projections extending from a bond surface of the first component, the projections having a plurality of different profiles; and embedding the array of projections in the second component formed of a plurality of laminate plies, wherein each projection profile is adapted to best transfer load into a respective one of the laminate plies. The resultant joint is able to transfer load more progressively between the two components leading to improved tensile strength.

Height tailoring of interfacing projections

A method of joining a first component to a second component, the method comprising preparing the first component by forming an array of projections extending from a bond surface of the first component, each projection having a base, a tapered tip and a tapered overhang beneath the tip, wherein the overhang has an undercut surface which is inclined and faces towards the local bond surface; bringing the components together so as to embed the projections in the second component; and hardening the second component after the array of projections has been embedded into it. Also, a joint so formed.

Profile of interfacing projections

A method of manufacturing a composite material, the method comprising: growing two or more layers of reinforcement in-situ; and impregnating each layer with a matrix before growing the next layer. The reinforcement layers may be formed by a chemical vapor deposition process. The method can be used as an additive layer manufacturing technique to form a component with a desired shape and physical characteristics.

Method of manufacturing composite material

A method of manufacturing a composite material, the method comprising: providing a first layer () of CNTs reinforcement elements () with liquid matrix material in interstitial gaps between the reinforcement elements; dipping a second layer of reinforcement elements into the liquid matrix material in the interstitial gaps such that the reinforcement elements in the second layer become partially embedded in the first layer of reinforcement elements and partially protrude from the first layer of reinforcement elements, impregnating the protruding parts of the reinforcement elements in the second layer with liquid matrix material; and curing the liquid matrix material.

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Bristol, United Kingdom

Daniel Johns