Metal-to-Composite Structural Joining for Drivetrain Applications

Abstract

Dissimilar material components in structural applications require advanced joining geometries and processes that permit the interface of these components to have mechanical behavior equivalent to the lesser of the base metal material behavior and the base composite material behavior. In volume-constrained applications, such as drivetrain parts, the interface must have the strength of the base materials, and the envelope of space of the current drivetrain componentry. The interface surfaces of the composite and metal are demonstrated here to achieve base material capability for the thickness, width, and length directions, resulting in conservation of mechanical properties throughout the interfaces, for all loading and deformation at material transitions. The method of material forming, modification, combining, and product operation is explained here, for optimization of materials usage and for processing equipment.

In designs to date, the metal to composite interface has been the weak link of the assembly, and product performance has been limited to this characteristic. This new method of interface build, and theory of base-to-joint equivalent strength, results in a new capability for drivetrain component design, and will start a new era of dissimilar materials combinations to offer the consumer improved product functionality with enhanced interface design, manufacture, envelope, and operational improvements.