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CN105857629A - 金属间以及复合金属间隙填充物 - Google Patents

金属间以及复合金属间隙填充物 Download PDF

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Publication number
CN105857629A
CN105857629A CN201610078400.3A CN201610078400A CN105857629A CN 105857629 A CN105857629 A CN 105857629A CN 201610078400 A CN201610078400 A CN 201610078400A CN 105857629 A CN105857629 A CN 105857629A
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Prior art keywords
metal
fibers
structural
alloy
securing member
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CN201610078400.3A
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A·F·格罗斯
D·M·汉森
S·可斯拉法尼
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Boeing Co
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Boeing Co
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Priority to CN202310333455.4A priority Critical patent/CN116331503A/zh
Publication of CN105857629A publication Critical patent/CN105857629A/zh
Pending legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B22—CASTING; POWDER METALLURGY
    • B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
    • B22F7/00—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression
    • B22F7/06—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools
    • B22F7/062—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts
    • B22F7/064—Manufacture of composite layers, workpieces, or articles, comprising metallic powder, by sintering the powder, with or without compacting wherein at least one part is obtained by sintering or compression of composite workpieces or articles from parts, e.g. to form tipped tools involving the connection or repairing of preformed parts using an intermediate powder layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C65/00—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor
    • B29C65/56—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits
    • B29C65/562—Joining or sealing of preformed parts, e.g. welding of plastics materials; Apparatus therefor using mechanical means or mechanical connections, e.g. form-fits using extra joining elements, i.e. which are not integral with the parts to be joined
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
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    • B29C66/05—Particular design of joint configurations
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    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/01—General aspects dealing with the joint area or with the area to be joined
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    • B29C66/72—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the structure of the material of the parts to be joined
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    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
    • B29C66/7314—Electrical and dielectric properties
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/74—Joining plastics material to non-plastics material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/88—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced
    • B29C70/882—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts characterised primarily by possessing specific properties, e.g. electrically conductive or locally reinforced partly or totally electrically conductive, e.g. for EMI shielding
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
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    • F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
    • F16B1/00—Devices for securing together, or preventing relative movement between, constructional elements or machine parts
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/40—General aspects of joining substantially flat articles, e.g. plates, sheets or web-like materials; Making flat seams in tubular or hollow articles; Joining single elements to substantially flat surfaces
    • B29C66/47—Joining single elements to sheets, plates or other substantially flat surfaces
    • B29C66/474—Joining single elements to sheets, plates or other substantially flat surfaces said single elements being substantially non-flat
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/50—General aspects of joining tubular articles; General aspects of joining long products, i.e. bars or profiled elements; General aspects of joining single elements to tubular articles, hollow articles or bars; General aspects of joining several hollow-preforms to form hollow or tubular articles
    • B29C66/51—Joining tubular articles, profiled elements or bars; Joining single elements to tubular articles, hollow articles or bars; Joining several hollow-preforms to form hollow or tubular articles
    • B29C66/54—Joining several hollow-preforms, e.g. half-shells, to form hollow articles, e.g. for making balls, containers; Joining several hollow-preforms, e.g. half-cylinders, to form tubular articles
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    • B29C66/00—General aspects of processes or apparatus for joining preformed parts
    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/731—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the intensive physical properties of the material of the parts to be joined
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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    • B29C66/70—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material
    • B29C66/73—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset
    • B29C66/739—General aspects of processes or apparatus for joining preformed parts characterised by the composition, physical properties or the structure of the material of the parts to be joined; Joining with non-plastics material characterised by the intensive physical properties of the material of the parts to be joined, by the optical properties of the material of the parts to be joined, by the extensive physical properties of the parts to be joined, by the state of the material of the parts to be joined or by the material of the parts to be joined being a thermoplastic or a thermoset characterised by the material of the parts to be joined being a thermoplastic or a thermoset
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  • Manufacturing & Machinery (AREA)
  • Materials Engineering (AREA)
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Abstract

本发明的名称是金属间以及复合金属间隙填充物。飞行器的结构组件，其包括由复合材料构造的结构元件，该复合材料包括基质材料和布置以延伸穿过基质材料的多个纤维，其中多个纤维的至少一部分是可从结构元件的表面通过的。紧固件将结构元件固定至结构部件。包括镓的金属结构被布置以与紧固件的表面接触。金属结构从紧固件的表面延伸并且接触多个纤维的所述至少一部分的至少一部分。也包括用于装配结构的方法。

Description

金属间以及复合金属间隙填充物
技术领域
本发明涉及布置在结构的结构部件之间的间隙填充物，并且更特别地，涉及在飞行器的结构部件之间提供电传导性的间隙填充物。
背景技术
结构以及特别地飞行器被设计为抗雷击并且保持其结构完整性。飞行器的传统构造，例如，包括用金属紧固件固定在一起的金属结构元件。紧固件被电接地至金属结构元件，金属紧固件与金属结构元件接触。这种布置提供在紧固件和结构元件之间的电传导性，从而不会使紧固件与结构元件电绝缘。否则，当飞行器发生被雷击时，使紧固件绝缘在紧固件和结构元件之间提供不期望的静电力。
最近，飞行器通过由复合材料制成的结构部件构造。复合材料包括基质材料，通常为树脂，和纤维材料，例如碳纤维。与纤维材料相比，树脂通常是不导电的。此复合材料通常是碳纤维增强的塑料(“CFRP”)。用紧固件例如金属螺栓将CFRP结构元件固定在一起。用于紧固由CFRP构造的结构元件的螺栓可以不必要地电接地至CFRP结构元件。螺栓的粗糙表面和结构元件的粗糙表面可以在金属螺栓的表面和电传导性纤维的表面之间形成间隙。这种条件可以导致在紧固件和由CFRP构造的结构元件之间积聚静电力。
目前，试图为了防止在紧固件和结构元件之间积聚静电力，在它们被固定至由CFRP材料构造的结构元件之前用电绝缘的密封剂材料涂布紧固件或螺栓。因而，当飞行器被雷击时，紧固件与结构元件绝缘防止了在紧固件和结构元件之间不期望的静电积聚。
然而，与用金属紧固件传统地固定金属结构元件相比，用密封剂涂布紧固件并且然后将它们固定至结构元件要特别细心、花费大量时间和费用。密封剂必须完全覆盖紧固件的表面，否则，当飞行器被雷击时，电流可以穿过密封剂的开口或缺口从结构元件的纤维行进至紧固件。穿过这种开口的电流将给紧固件充电并且在紧固件和CFRP的纤维之间产生电荷不平衡。这种条件可以在螺栓和CFRP的纤维之间产生不期望的静电力。另外，在固定紧固件时需要小心以便在此过程中不去除密封剂。而且，一旦紧固件被安装，需要进行仔细检查以便在紧固件的固定过程期间不形成穿过密封剂的开口。因而，在紧固过程中在涂布紧固件、固定紧固件和检查紧固件时必须进行仔细的步骤。这些步骤增加了飞行器装配的成本。
已经尝试了防止在结构元件的CFRP材料和金属紧固件或螺栓之间积聚不期望的静电力的其他努力。这些尝试是不可行的。例如，使用金属焊剂是不可采用的。即使焊剂可以在螺栓和CFRP材料之间提供电传导性和结构完整性，在超过二百五十四华氏度(254°F)的温度下将在结构上损害CFRP材料的完整性，其低于许多焊剂的熔化温度。可选地，可以在螺栓和CFRP材料之间采用导电性黏合剂。然而，黏合剂的传导性比金属结合具有更大的电阻率。此电阻率可以导致在螺栓和CFRP材料的两个表面之间积聚电荷并且导致不期望的静电放电。
也可以采用柔软的金属插入物并且将其布置在螺栓和CFRP材料的两个表面之间。然而，这可以改进两个表面之间的电传导性但是在两个表面之间产生结构弱点并且其贴合两个表面的能力受到限制。可选地，将螺栓焊接至CFRP结构部件是不可行的，其中一个表面——CFRP结构部件的一个表面——是非金属的。
存在对于廉价并且可靠的间隙填充物的需要，其将贴合紧固件或螺栓和由CFRP构造的结构元件的粗糙表面。该间隙填充物将需要在紧固件或螺栓和CFRP材料的纤维之间提供导电性以将紧固件接地至由CFRP材料构造的结构元件。
发明内容
飞行器结构组件的实例包括由复合材料构造的结构元件，其包括基质材料以及布置以延伸穿过基质材料的多个纤维，其中多个纤维的至少一部分是可从结构元件的表面通过的。紧固件固定结构元件至结构部件。布置包括镓的金属结构与紧固件的表面接触。金属结构从紧固件的表面延伸并且接触多个纤维的所述至少一部分的至少一部分。
用于装配结构的方法的实例包括提供由复合材料构造的结构元件的步骤，该复合材料包括基质材料和多个布置以延伸穿过基质材料的纤维，其中多个纤维的至少一部分是可从结构元件的表面通过的。另一个步骤包括将包含镓的液体金属合金与固体金属或固体金属合金的至少一种混合，形成浆料。方法进一步包括将浆料施加在紧固件的表面上和施加在多个纤维的所述至少一部分的至少一部分上的步骤。方法的另一个步骤包括用紧固件将结构元件固定至结构部件的步骤，其中布置浆料与紧固件的表面接触并且使紧固件的表面与多个纤维的所述至少一部分的至少一部分相互连接。
已经讨论的特征、功能和优势可以在各实施方式中单独实现或者可以在又其他实施方式结合，其进一步细节可参考以下的描述和附图看出。
附图说明
图1是飞行器的侧视图；
图2是图1的飞行器的选定部分的示例性局部示意图，其中横截面显示连接由复合材料构造的结构元件至结构部件的紧固件，其中金属间隙填充物被布置与紧固件的表面接触并且使紧固件的表面与结构元件的复合材料的纤维相互连接；
图3是显示间隙填充物的样品组成的表1，其包括与纯固体金属或与固体金属合金组合的基于镓的液体金属合金；
图4是显示从图3的表1选择的金属间隙填充物样品的自由腐蚀速率的图表；
图5是显示从图3的表1选择的金属间隙填充物样品的电腐蚀速率的图表；
图6是表2，显示从表1选择的金属间隙填充物样品连同铜箔和铝6061合金的自由腐蚀速率和电腐蚀速率、以及电腐蚀速率与自由腐蚀速率比。
虽然以上已经描述了多种实施方式，但本公开不意欲局限于此。可以对公开的实施方式做出各种变化，其仍然在所附的权利要求的范围内。
具体实施方式
如前面所讨论的，装配当被雷击时抵御损害的结构是重要的。这种装配的结构的实例包括飞行器。期望的是，当雷击时不会在装配的飞行器的金属紧固件和结构元件之间形成静电力积聚。随着现在选择性地将飞行器与复合材料装配，需要将金属紧固件与结构元件的复合材料的传导性纤维接地。
参考图1，显示装配的结构的实施例，飞行器10。飞行器10包括其装配的各种部分。这些部分，在此实施例中，包括机身12和从机身12的相对侧面延伸的机翼14。机身12也包括机头部16和相对的机尾部18。飞行器10的这些部分的每一个可以选择性地用由复合材料构造的结构元件构造。
参考图2，对于飞行器10的选择部分的装配显示了结构元件20的示例性固定。结构元件20由复合材料构造，其包括基质材料22和布置以延伸穿过基质材料22的多个纤维24。
在图2中显示的此实施例中，结构元件20叠置在也由复合材料构造的另一个结构元件26上，其包括基质材料28和也被布置以延伸穿过基质材料28的多个纤维30。结构元件20和其他的结构元件26二者被固定至结构部件32。结构部件32是飞行器10一部分的组件的另一个结构构件。结构部件32可以由复合材料、金属或类似物构造。在此实施例中，结构部件32是布置在飞行器10选择性部分内的金属框架的一部分。
在此实施例中的多个纤维24和30由电传导性材料例如碳构造。在此实施例中的基质材料22和28由热塑性树脂或热固性树脂的一种构造，热塑性树脂例如聚丙烯、聚乙烯和尼龙，热固性树脂例如环氧树脂。
结构元件20和另一个结构元件26被用紧固件34固定至结构部件32。紧固件34是固定构件，其可以将两个或多个构件固定在一起，例如螺栓、螺钉、销钉或类似物。在此实施例中，紧固件34是螺栓，其包括头36、螺纹轴38(螺纹未显示)和螺母40(螺纹未显示)。紧固件或螺栓34由金属例如碳钢、钛合金或类似物构造。
在此实施例中，将通孔42布置穿过结构部件32。在此实施例中，通孔是在结构部件32中预先形成的。通过钻孔穿过结构部件32也可以将通孔42布置穿过结构部件32。在此实施例中，随着钻孔穿过结构元件20和其他结构元件26，结构元件20的通孔44和凹部54以及其他结构元件26的通孔46已经形成。在钻孔穿过结构元件20和另外结构元件26的复合材料时，形成了结构元件20的粗糙表面48和其他结构元件26的粗糙表面50。此外，粗糙表面52在结构元件20的凹部54中形成。
图2中示意性地表示了延伸穿过结构元件20的基质材料22的多个纤维24。在此实施例中，多个纤维24延伸穿过基质材料22并且被布置在整个结构元件20上，在结构元件20的长度方向、宽度方向延伸并且在结构元件20的厚度方向分层。图2中的多个纤维24示意性地显示了在结构元件20的长度方向的延伸以及在结构元件20的厚度方向的分层而没有显示多个纤维24在基质22内的宽度方向的延伸。
随着穿过结构元件20的不连续的通孔44和凹部54的形成，通孔44和凹部54啮合全部多个纤维24的至少一部分25，其被布置遍及结构元件20。在图2中，结构元件20的多个纤维24的至少一部分25示意性地显示放置在并且沿着通孔44的粗糙表面48和放置在并且沿着凹部54的粗糙表面52。多个纤维24的部分25也围绕通孔44和凹部54放置，但是没有显示。在图2中，多个纤维24的至少一部分25示意性地显示延伸至通孔44处的粗糙表面48并且至凹部54处的粗糙表面52。然而，在此实施例中，随着通孔44和凹部54的形成，通过钻孔穿过结构元件20，布置在通孔44和凹部54的多个纤维24的至少一部分25的末端可以从粗糙表面48和粗糙表面52延伸，与粗糙表面48和粗糙表面52齐平或者从粗糙表面48和粗糙表面52凹进。不管多个纤维24的至少一部分25的纤维末端相对于粗糙表面48和52的位置如何，末端将可从通孔44中的粗糙表面48以及从凹部54的粗糙表面52通过。
如以上对于带有多个纤维24的结构元件20的描述，类似地配置并且示意性地呈现带有多个纤维30的其他结构元件26。如多个纤维24在结构元件20内配置并且示意性地显示一样，多个纤维30示意性地显示延伸穿过基质材料28并且布置遍及另外结构元件26，在另外结构元件26的长度方向、宽度方向延伸并且在厚度方向分层。在此实施例中，多个纤维30显示在另外结构元件26的长度方向延伸并且在厚度方向分层而没有显示多个纤维24在基质28内的宽度方向延伸。
随着穿过结构元件26形成不连续的通孔46，通孔46啮合全部多个纤维30的至少一部分47，其被布置遍及另外结构元件26。结构元件26的多个纤维30的至少一部分47示意性地显示放置在并且沿着通孔46的粗糙表面50。多个纤维30的至少一部分47也围绕通孔46布置但是没有显示。多个纤维30的至少一部分47示意性地显示延伸至通孔46的粗糙表面50。然而，在此实施例中，随着通孔46的形成，通过钻孔穿过结构元件26，布置在通孔46的多个纤维30的至少一部分47的末端可以从粗糙表面50延伸，与粗糙表面50平齐或者从粗糙表面50凹进。不管多个纤维30的至少一部分47的纤维末端相对于粗糙表面50的位置如何，末端将可从通孔46中的粗糙表面50通过。
在形成结构元件20的凹部54和通孔44和形成其他结构元件26的通孔46中，这些开口的尺寸形成为比紧固件34稍大以使紧固件34能够延伸穿过结构元件20和另外结构元件26。出于相同的原因，结构部件32的通孔42类似地比紧固件34的尺寸稍大。间隙55一方面，在头36和螺纹轴38之间形成，和另一方面，在结构元件20的粗糙表面48、50和52，结构元件20以及另一个结构元件26的凹部54之间形成。如图2中可见，间隙55也在结构部件32和紧固件或螺栓34之间形成。
金属结构56被布置在间隙55内并且贴合间隙55的形状。金属是固体材料，其通常是韧性的、可熔的和可延展的，有良好的电传导性和热传导性。金属结构56与紧固件34的表面57接触，该表面57包括头36的表面58和螺纹轴38的表面60。金属结构56从表面58和60延伸穿过间隙55并且接触与结构元件20相关联的多个纤维24的至少一部分25的至少一部分和结构元件20的凹部54。金属结构56的这种构造使纤维和紧固件34建立了电连接，从而使紧固件34接地。类似地，金属结构56接触紧固件34的表面57，其包括表面60并且延伸穿过间隙55并且接触与另外结构元件26相关联的多个纤维30的至少一部分47的至少一部分。同样地，金属结构56的这种构造使纤维和紧固件34建立了电连接，从而使紧固件34接地。并且，在此实施例中，金属结构56接触紧固件34的表面57，其包括表面60并且延伸穿过间隙55并且接触在通孔42处的结构部件32的表面62。金属结构56的这种构造在紧固件34和结构部件32之间也建立电连接。
如以上所描述的，金属结构56，从紧固件34的以上所描述的表面延伸穿过间隙55分别至以上所描述的多个纤维24和30的至少一部分25和47的至少一部分，并且至结构部件32。在完成这些电连接中，金属结构56在二十五微米(25μm)和一毫米(1mm)之间的范围内延伸。在延伸穿过间隙55中，金属结构56与粗糙表面48、50和52接触并且贴合粗糙表面48、50和52。如以下将描述的，以浆或糊状稠度将金属结构56施加至以上所描述的紧固件34的表面并且至粗糙表面48、50和52和表面62。在施加金属结构至粗糙表面48、50和52中，多个纤维24和30的至少一部分25和47的至少一部分分别与金属结构56接触。在用紧固件34将结构元件20和其他结构元件26固定至结构部件32中，糊状稠度的金属结构56被布置在间隙55内并且占据间隙55并且在紧固件34和以上所述的复合材料的纤维之间提供连续的电连接。金属结构也在紧固件34和结构部件32之间提供电连接。
用于装配结构——例如在此实施例中为飞行器10——的方法包括提供结构元件20。在此实施例中，另外地提供其他的结构元件26。结构元件20如同其他的结构元件26由复合材料构造，如早前所述，该复合材料包括用于结构元件20的基质材料22和用于其他结构元件26的基质材料28。多个纤维24延伸穿过结构元件20的基质材料22并且多个纤维30延伸穿过基质材料28。如以上所描述的，多个纤维24的至少一部分25可从与结构元件20相关联的粗糙表面48和52通过，以及多个纤维30的至少一部分47如以上所描述的可从与结构元件26相关联的粗糙表面50通过。随着结构元件20、其他结构元件26、结构部件32和紧固件34可装配，可以进行混合含有镓的液体金属合金与固体金属和固体金属合金的至少一种。在此实施例中，采用Wig-L-Bug牙科汞合金搅拌机。此混合物形成浆料。
将浆或糊状混合物施加至包括紧固件34的表面58和60的表面57，并且通过施加糊状材料至粗糙表面48、50和52分别施加在多个纤维24和30的至少一部分25和47的至少一部分上。也将糊状材料施加至结构部件32的表面62。如以上所描述的，随着金属结构56的糊状材料合适地施加，用紧固件34可以将结构元件20——在此实施方式中随同其他的结构元件26——固定至结构部件32。随着固定紧固件或螺栓34，间隙55被占据并且用糊状稠度的金属结构56填充并且贴合间隙55的形状。如以下将要描述的，糊状材料经过一段时间沉降并且固化。金属结构56提供紧固件34和纤维以及结构部件32之间所需的电连接并且使紧固件34接地。
金属结构56，其含有镓合金，在大约室温下最初是液体状态并且然后与金属粉末或薄膜混合以形成浆料，其中包晶键(peritectic bond)形成，其中在液体金属合金内的镓扩散到固体金属例如纯金属或金属合金内。初始混合物形成浆或糊状混合物，其转变成具有较高熔化温度的合金。随着时间，浆或糊状稠度固化成固体。
参考图3，显示表1，其包括用于金属结构56的组合物的样品。如在表1中可见，随着将镓与锡和铟的一种或二者组合形成镓合金。在大约低于三十摄氏度(30℃)的室温下这些金属合金最初是液体状态。然后将含有镓的液体金属合金与固体金属或固体金属合金混合。将要与液体金属合金混合的固体金属或固体金属合金或者是粉末状态或者是薄膜状态。颗粒大小或薄膜厚度的尺寸在五十纳米(50nm)和一百微米(100μm)之间。如图3的表1中可见，与镓合金混合的固体金属或者是纯镍、纯铜或者是纯银。青铜的固体金属合金可以选择性地用于与液体镓金属合金混合。表1显示将被混合以产生金属结构56的每个样品的化学组分的材料元素重量比。
随着将镓合金与固体金属或固体金属合金混合，所得的浆或糊状稠度提供使用者合适地施加材料以贴合紧固件和复合材料的粗糙表面的能力。一旦使用紧固件34完成固定，材料或金属结构56固化成固体状态。装配的结构，或者在此实施例中为飞行器10，然后可以用于飞行。
可以将另外的机械增强相添加至液体镓金属合金与固体金属或固体金属合金的混合物的浆料。此机械相将提供增强的抗剪切性至固化的合金。此机械相材料可以选择性地包括纯钴、纯钨、纯钼或纯钛或者钛例如AMS 4911或者不锈钢例如302或316的合金的一种。
现在参考图4，图表显示了金属结构56的五个选择样品的自由腐蚀测试结果，其显示在图3的表1中。耐腐蚀性对于金属结构56是重要的，其将在暴露于变化的环境条件的外部环境中进行。测试标准评价使用商业的3-电极腐蚀测试电池。除了测试的样品之外——测试的样品包括工作电极，电池含有铂网反电极和银线参照电极。电解液(腐蚀环境)是暴露于实验室空气的按重量计百分之三(3.0wt％)的氯化钠(NaCl)溶液，即，含有溶解氧。使用电池中的夹具，每个样品的1平方厘米的(1cm x 1cm)表面积暴露于电解液。使用-10mV至+10mV电势扫描，在(开路)腐蚀电势附近进行标准线性极化测量。数据被拟合到直线以获得极化电阻(Rp，Ohms)。使用极化电阻的倒数表示相对腐蚀速率。如在图表中可见，在至少一种情况中的测试延长至八十小时。
在图4中的此图表中显示了通过极化电阻的倒数给出的自由腐蚀速率。在此图表上的较低的倒数极化电阻值指示较大的耐腐蚀性。不管当使用相同的液体金属合金(Ga/In或Ga/In/Sn)时金属的组合物如何，所有含有铜的金属合金具有相同的腐蚀速率。镓液体金属合金具有一些效果。镓/锡液体金属合金比镓/铟液体金属更耐腐蚀。差异归因于锡比铟在氧化上稳定。可以注意到的是，含有银的固化金属比任何含有铟的材料更稳定。
参考图5，此图表显示了来自图3的表1的金属结构56的三个选择的样品的电腐蚀测试结果。因为金属结构56与复合材料的传导性碳纤维恒定地电接触，电测试在金属结构56的样品上进行。
测试标准包括放置每个样品与碳纤维增强的塑料(“CFRP”)接触和使用在组合的测试样品/CFRP电极上进行的线性极化测量。此方法将电偶处理为单个电极并且使自由腐蚀速率和电偶腐蚀速率能够进行相对比较。通过从CFRP板切割一平方厘米(1cm2)的片制备CFRP。一个面被打磨以暴露碳纤维。边缘和后面用5分钟环氧树脂密封，在五十摄氏度(50℃)固化一夜。将整个CRFP片邻近测试样品浸没在电解液中。使用从测试样品至连接至CFRP的环氧树脂密封的螺纹杆的跳线建立测试样品和CFRP之间的电连接。测试样品的面积是0.785平方厘米(0.785cm2)并且CFRP的面积是两厘米乘以两厘米(2cm x2cm)，其等于四平方厘米(4cm2)。因而，CFRP/金属合金的面积比率是5∶1。
参考图5中的图表，图表上描绘的初始18至20小时是这三个样品的自由腐蚀测试结果。然后开始以上的电测试，其指示了在此图表中每个样品的腐蚀速率的急剧上升。随着时间的推移，三个样品的每个的腐蚀速率基本上水平并且达到稳定状态。再一次地，在此图表上的较高位置指示较大的腐蚀速率。由此可见，镓/锡与铜合金以及镓/铟与铜合金具有类似的腐蚀速率。镓/铟和银合金具有最低的腐蚀速率。
参考图6，提供了五个样品的腐蚀速率的表2。前三个样品是来自图3的表1的样品组合物并且在图4和5中阐明的图表中的腐蚀测试中存在。表2中的下一个样品是铜箔并且最后一个样品是铝合金6061。此表第一栏中显示三个腐蚀速率。在第二栏中显示了电腐蚀速率。在第三栏中，显示了电偶腐蚀对自由腐蚀速率的比率。与铜固体金属样品混合的镓液体合金具有比铜箔和与银固体金属混合的镓液体合金稍微更大的电偶腐蚀速率，但是比铝合金6061显著更小的腐蚀速率。
进一步地，本公开包括根据以下条款的实施方式：
条款1：飞行器的结构组件，其包括：由复合材料构造的结构元件，该复合材料包括基质材料和被布置以延伸穿过基质材料的多个纤维，其中多个纤维的至少一部分是可从结构元件的表面通过的；固定结构元件至结构部件的紧固件；以及布置以与紧固件的表面接触的金属结构，其中金属结构从紧固件的表面延伸并且接触多个纤维的所述至少一部分的至少一部分。
条款2：条款1的结构组件，其中：多个纤维包括碳；基质材料包括热塑性树脂和热固性树脂的一种；并且紧固件由金属构造。
条款3：条款1的结构组件，其中金属结构包括包含铟和锡中至少一种的镓合金。
条款4：条款1的结构组件，其中金属结构进一步包括固体金属和固体金属合金的一种。
条款5：条款4的结构组件，其中：固体金属和固体金属合金的一种包括粉末和薄膜的一种；并且粉末的颗粒大小或薄膜的厚度具有在50nm和100μm之间范围内的尺寸。
条款6：条款5的结构组件，其中固体金属包括纯铜、纯银和纯镍的一种。
条款7：条款5的结构组件，其中固体金属合金包括青铜。
条款8：条款1的结构组件，其中金属结构进一步包括机械增强相，该机械增强相包括纯钴、纯钨、纯钼和纯钛或包括钛合金和不锈钢之一的合金的一种。
条款9：条款1的结构组件，其中：金属结构在紧固件的表面与多个纤维的所述一部分的至少一部分之间延伸25μm和1mm之间的范围；并且金属结构与结构元件的表面接触。
条款10：用于装配结构的方法，其包括以下步骤：提供由复合材料构造的结构元件，该复合材料包括基质材料和被布置以延伸穿过基质材料的多个纤维，其中多个纤维的至少一部分是可从结构元件的表面通过的；将包括镓的液体金属合金与固体金属和固体金属合金的至少一种混合形成浆料；将浆料施加在紧固件的表面上并且施加在多个纤维的所述至少一部分的至少一部分上；并且用紧固件将结构元件固定至结构部件，其中浆料被布置与紧固件的表面接触并且使紧固件的表面与多个纤维的所述至少一部分的至少一部分相互接触。
条款11：条款10的用于装配结构的方法，其中：多个纤维包括碳；基质材料包括热塑性树脂和热固性树脂的一种；紧固件由金属构造；并且固定步骤包括放置浆料以与结构元件的表面接触。
条款12：条款10的用于装配结构的方法，其中：液体金属是包括铟和锡中至少一种的合金；并且混合步骤包括将液体金属合金与固体金属和固体金属合金的至少一种混合。
条款13：条款12的用于装配结构的方法，其中固体金属和固体金属合金的一种包括粉末和薄膜的一种。
条款14：条款13的用于装配结构的方法，其中粉末的颗粒大小或薄膜的厚度具有在50nm和100μm之间范围内的尺寸。
条款15：条款12的用于装配结构的方法，其中固体金属包括纯铜、纯银和纯镍的至少一种。
条款16：条款12的用于装配结构的方法，其中固体金属合金包括青铜的合金。
条款17：条款10的用于装配结构的方法，其中混合步骤进一步包括混合机械增强相，该机械增强相包括纯钴、纯钨、纯钼和纯钛或包括钛合金和不锈钢的一种的合金的一种。
条款18：条款10的用于装配结构的方法，其中液体金属具有低于三十摄氏度(30℃)的熔化温度。
条款19：条款10的用于装配飞行器的方法，其进一步包括在飞行器进行飞行之前允许浆料固化的步骤。
条款20：条款10的用于装配结构的方法，其中结构元件和结构部件是飞行器的部件。
虽然以上已经描述了许多实施方式，本公开不意欲限制于此。可以对公开的实施方式做出许多变化，其仍然在所附的权利要求的范围内。

Claims (10)

1.飞行器(10)的结构组件(14)，其包括：
由复合材料构造的结构元件(20，26)，该复合材料包括基质材料(22，28)和被布置以延伸穿过所述基质材料的多个纤维(24，30)，其中所述多个纤维的至少一部分是可从所述结构元件的表面(48，50，52)通过的；
固定所述结构元件至结构部件(32)的紧固件(34)；和
被布置以与所述紧固件的表面(38)接触的金属结构(56)，其中所述金属结构从所述紧固件的所述表面延伸并且接触所述多个纤维的所述至少一部分的至少一部分(25)。
2.权利要求1所述的结构组件，
其中：所述多个纤维包括碳；
所述基质材料包括热塑性树脂和热固性树脂的一种；和
所述紧固件由金属构造。
3.权利要求1所述的结构组件，其中所述金属结构包括包含铟和锡的至少一种的镓合金。
4.权利要求1所述的结构组件，其中所述金属结构进一步包括固体金属和固体金属合金的一种。
5.权利要求1所述的结构组件，其中：
所述金属结构在所述紧固件的所述表面至所述多个纤维的所述部分的至少一部分之间延伸25μm和1mm之间的范围；和
所述金属结构与所述结构元件的所述表面接触。
6.用于装配结构(10)的方法，包括以下步骤：
提供由复合材料构造的结构元件(20，26)，该复合材料包括基质材料(22，28)和布置以延伸穿过所述基质材料的多个纤维(24，30)，其中所述多个纤维的至少一部分是可从所述结构元件的表面(48，50，52)通过的；
将包括镓的液体金属合金与固体金属和固体金属合金的至少一种混合形成浆料(56)；
将所述浆料施加在紧固件(34)的表面(38)上并且施加在所述多个纤维的所述至少一部分的至少一部分(25)上；并且
用所述紧固件将所述结构元件固定至结构部件(32)，其中所述浆料被布置以与所述紧固件的所述表面接触并且使所述紧固件的所述表面与所述多个纤维的所述至少一部分的所述至少一部分相互接触。
7.权利要求6所述的用于装配结构的方法，其中：
所述多个纤维包括碳；
所述基质材料包括热塑性树脂和热固性树脂的一种；
所述紧固件由金属构造；和
所述固定的步骤包括放置所述浆料以与所述结构元件的所述表面接触。
8.权利要求6所述的用于装配结构的方法，其中：
所述液体金属是包括铟和锡中至少一种的合金；和
所述混合的步骤包括将所述液体金属合金与固体金属和固体金属合金的至少一种混合。
9.权利要求6所述的用于装配飞行器的方法，进一步包括在所述飞行器进行飞行之前允许所述浆料固化的步骤。
10.权利要求6所述的用于装配结构的方法，其中所述结构元件和所述结构部件是飞行器的部件。
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