Plating a composite to enhance bonding of metallic components

Patent metadata

Field	Value
Publication number	US-2016369635-A1
Application number	US-201414903872-A
Country	US
Kind code	A1
Filing date	Jul 9, 2014
Priority date	Jul 9, 2013
Publication date	Dec 22, 2016
Grant date	—

Abstract

A composite component is disclosed. The composite component may comprise a metal plating deposited on a surface of the composite component, and a metallic feature adhesively bonded to the metal plating. The composite component may further comprise an adhesive layer between the metal plating and the metallic feature. The metal plating may provide a metal-to-metal interface between the surface of the composite component and the metallic feature.

First claim

What is claimed is:

1 . A composite component, comprising:
a metal plating deposited on a surface of the composite component; a metallic feature adhesively bonded to the metal plating; and an adhesive layer between the metal plating and the metallic feature.

2 . The component of claim 1 , wherein the metal plating provides a metal-to-metal interface between the surface of the composite component and the metallic feature.

3 . The component of claim 2 , wherein the composite component is formed from a polymeric matrix.

4 . The component of claim 3 , wherein the polymeric matrix is reinforced with fibers selected from the group consisting of metal fibers, carbon fibers, and glass fibers.

5 . The component of claim 3 , wherein the polymeric matrix is a thermoplastic material or a thermoset material.

6 . The component of claim 5 , wherein the metallic feature is formed from a metal or a metal alloy selected from the group consisting of titanium, nickel, and a nickel-cobalt alloy.

7 . The component of claim 5 , wherein the composite component is an airfoil of a gas turbine engine.

8 . The component of claim 7 , wherein the surface of the composite component is a leading edge of the airfoil, and wherein the metallic feature is a sheath configured to protect the leading edge.

9 . A method for fabricating a composite component adhesively bonded to a metallic feature, comprising:
forming the composite component in a desired shape; depositing a metal plating on a surface of the composite component; selecting an adhesive for bonding the metallic feature to the metal plating of the composite component; and adhesively bonding the metallic feature to the metal plating using the selected adhesive.

10 . The method of claim 9 , wherein selecting the adhesive for bonding the metallic feature to the metal plating comprises selecting an adhesive capable of providing a bond at a metal-to-metal interface.

11 . The method of claim 10 , wherein forming the composite component in a desired shape comprises forming the composite component from a thermoplastic material or a thermoset material.

12 . The method of claim 10 , wherein forming the composite component in a desired shape comprises forming the composite component from a thermoplastic material or a thermoset material, the thermoplastic material or the thermoset material having fibers embedded therein.

13 . The method of claim 12 , wherein forming the composite component in a desired shape further comprises forming the composite component by a method selected from the group consisting of injection molding, compression molding, blow molding, additive manufacturing, and composite layup.

14 . The method of claim 13 , wherein depositing the metal plating on the surface of the composite component comprises:
preparing the surface of the composite component to receive a catalyst by etching, abrasion, or reactive-ion etching; depositing a catalyst layer on the surface of the composite component; depositing a first layer on the catalyst layer by electroless deposition; depositing a second layer on the first layer by electrolytic deposition, the second layer being conductive; and depositing the metal plating on the second layer.

15 . The method of claim 14 , wherein depositing the metal plating on the second layer is performed by a method selected from the group consisting of electroplating, electroless plating, and electroforming.

16 . A composite component adhesively bonded to a metallic feature, the composite component being formed by a method comprising:
forming the composite component in a desired shape; depositing a metal plating on a surface of the composite component; selecting an adhesive for bonding the metallic feature to the metal plating of the composite component; and adhesively bonding the metallic feature to the metal plating using the selected adhesive.

17 . The composite component of claim 16 , wherein selecting the adhesive for bonding the metallic feature to the metal plating comprises selecting an adhesive capable of providing a bond at a metal-to-metal interface.

18 . The composite component of claim 17 , wherein forming the composite component in a desired shape comprises forming the composite component from a thermoplastic material or a thermoset material.

19 . The composite component of claim 19 , wherein depositing the metal plating on the surface of the composite component comprises:
preparing the surface of the composite component to receive a catalyst by etching, abrasion, or reactive-ion etching; depositing a catalyst layer on the surface of the composite component; depositing a first layer on the catalyst layer by electroless deposition; depositing a second layer on the first layer by electrolytic deposition, the second layer being conductive; and depositing the metal plating on the second layer.

20 . The composite component of claim 19 , wherein the composite component is an airfoil of a gas turbine engine, and wherein the metallic feature is a sheath configured to protect a leading edge of the airfoil.

Assignees

• United Technologies Corp

Inventors

• Xu Jinquan
• Cook Iii Grant O

Classifications

• B22F1/062

  Fibrous particles · CPC title

• C23C18/1651

  Two or more layers only obtained by electroless plating · CPC title

• C23C18/1653

  Two or more layers with at least one layer obtained by electroless plating and one layer obtained by electroplating · CPC title

• F05D2300/10

  Metals, alloys or intermetallic compounds · CPC title

• F05D2300/30

  Inorganic materials other than provided for in groups F05D2300/10 - F05D2300/2291 · CPC title