Combustion synthesis to bond metal inserts to C-C composite surfaces
First Claim
1. A method comprising:
- depositing a layer comprising titanium powder and carbon powder on at least one of a first complementary mating surface and a second complementary mating surface that is complementary to the first complementary mating surface, wherein a carbon-carbon composite piece defines the first complementary mating surface and a metal insert defines the second complementary mating surface, wherein the carbon-carbon composite piece has an annular disk shape comprising an outer axial surface defining at least one radially extending opening, the at least one radially extending opening defining at least a portion of the first complementary mating surface;
arranging the first and second complementary mating surfaces such that the powder layer is between the second complementary mating surface of the metal insert and the first complementary mating surface of the carbon-carbon composite at the at least one radially extending opening to form a construct of the carbon-carbon composite piece, the powder layer, and the metal insert;
applying pressure to the construct to press together the carbon-carbon composite piece and the metal insert joined at their complementary mating surfaces; and
applying an electrical current to the powder layer in the construct to initiate an oxidation reduction reaction to bond the carbon-carbon composite piece and the metal insert together.
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Accused Products
Abstract
Method of joining a carbon-carbon composite piece 30 together with a metal insert 20, e.g. in the manufacture of aircraft brake discs 10. The method includes the steps of: providing a carbon-carbon composite piece 30 and a metal insert 20, wherein the metal insert 20 has a surface that is complementary to a surface of said carbon-carbon composite piece 30; providing a layer of a mixture of titanium powder and carbon powder on the first complementary mating surface; arranging the powder layer such that a second complementary mating surface is matched to the complementary mating surface, thereby forming a construct of the carbon-carbon composite piece 30, the powder layer, and the metal insert 20; placing the construct into a press and applying pressure to the construct to press together the carbon-carbon composite piece and the metal insert joined at their complementary surfaces; and applying an electrical current to the powder in the construct to initiate a metal-carbon reaction, thereby bonding the carbon-carbon composite piece 30 together the metal insert 20. The titanium powder particles may be from 25 to 100 microns in diameter, and the carbon powder (e.g., graphite particles) may be 0.1 to 1 microns in diameter.
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Citations
19 Claims
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1. A method comprising:
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depositing a layer comprising titanium powder and carbon powder on at least one of a first complementary mating surface and a second complementary mating surface that is complementary to the first complementary mating surface, wherein a carbon-carbon composite piece defines the first complementary mating surface and a metal insert defines the second complementary mating surface, wherein the carbon-carbon composite piece has an annular disk shape comprising an outer axial surface defining at least one radially extending opening, the at least one radially extending opening defining at least a portion of the first complementary mating surface; arranging the first and second complementary mating surfaces such that the powder layer is between the second complementary mating surface of the metal insert and the first complementary mating surface of the carbon-carbon composite at the at least one radially extending opening to form a construct of the carbon-carbon composite piece, the powder layer, and the metal insert; applying pressure to the construct to press together the carbon-carbon composite piece and the metal insert joined at their complementary mating surfaces; and applying an electrical current to the powder layer in the construct to initiate an oxidation reduction reaction to bond the carbon-carbon composite piece and the metal insert together. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18)
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19. A method comprising:
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applying pressure to a composite construct, the composite construct comprising; a carbon-carbon composite piece including a first complementary mating surface, wherein the carbon-carbon composite piece has an annular disk shape with an outer axial surface including at least one radially extending opening, the at least one radially extending opening defining at least a portion of the first complementary mating surface, a metal insert including a second complementary mating surface, and a powder layer separating the first and second complementary mating surfaces at the at least one radially extending opening of the carbon-carbon composite, wherein the powder layer comprises titanium powder and carbon powder; and applying an electrical current to the powder layer in the construct to initiate an oxidation reduction reaction to bond the carbon-carbon composite piece and the metal insert together.
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Specification