Ford Aerospace & Communications Corporation

Jay W Stanwood

William A Clarke

Johannes MacLeane

A method for joining a composite material shaft, such as a graphite epoxy or fiber glass driveshaft, to a metal end member is disclosed, wherein said joint is capable of withstanding large ranges of temperature and humidity, can handle high torque and has high resistance to fatigue. The design of parallel grooves on the end of a metallic sleeve concentrically aligned within the shaft is amenable to mass production. The first layer of fibers of the composite material shaft is preferably wound perpendicular to the orientation of the grooves. On the other end of the metallic sleeve is carved a scalloped pattern which facilitates concentric alignment of the sleeve on the tooling mandrel and helps to reduce shear stress between the sleeve and shaft. A method for mass production of shafts with metallic end joints attached employs an elongated spinning mandrel and pre-preg tape wound at high speed.

Method for mass producing composite shafts

An apparatus for joining a composite material shaft, such as a graphite epoxy or fiber glass driveshaft, to a metal end member is disclosed, wherein said joint is capable of withstanding large ranges of temperature and humidity, can handle high torque and has high resistance to fatigue. The design of parallel grooves on the end of a metallic sleeve concentrically aligned within the shaft is amenable to mass production. The first layer of fibers of the composite material shaft is preferably wound perpendicular to the orientation of the grooves. On the other end of the metallic sleeve is carved a scalloped pattern which facilitates concentric alignment of the sleeve on the tooling mandrel and helps to reduce shear stress between the sleeve and shaft. A method for mass production of shafts with metallic end joints attached employs an elongated spinning mandrel and pre-preg tape wound at high speed.

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Long Beach, CA, United States of America

Jay W Stanwood