Fire-and electromagnetic interference (EMI)-resistant aircraft components and methods for manufacturing the same
View Patent ↗Fire- and electromagnetic interference (EMI)-resistant aircraft components and methods for manufacturing the same are provided. A thermally and electrically conductive coating material layer is formed on at least a portion of an intermediate article comprised of a non-metallic material. The thermally and electrically conductive coating material layer is comprised of a metal. A fire-retardant material layer is cold sprayed on the thermally and electrically conductive coating material layer. At least one continuous electrically conductive element may be integrated with the non-metallic material of the intermediate article.
1. A method for manufacturing a fire- and electromagnetic interference (EMI)-resistant aircraft component, the method comprising the steps of:
forming an intermediate article comprised of a non-metallic material;
integrating a continuous electrically conductive element within a substrate of the non-metallic material during the forming of the intermediate article;
forming a thermally and electrically conductive coating material layer on at least a portion of the intermediate article, the thermally and electrically conductive coating material layer comprising a metal; and
cold spraying a fire-retardant material layer on the thermally and electrically conductive coating material layer,
wherein the integrating the continuous electrically conductive element within the substrate of the non-metallic material during the forming of the intermediate article comprises:
substantially simultaneously feeding a filament of the non-metallic material and the continuous electrically conductive element through a dual extrusion head of a fused deposition modeling system.
2. The method of claim 1 , wherein the intermediate article comprises the non-metallic material selected from the group consisting of a polymeric material and a composite material.
3. The method of claim 1 , wherein the continuous electrically conductive element comprises a metal selected from the group consisting of copper, aluminum, alloys thereof, brass, and combinations thereof.
4. The method of claim 1 , wherein the step of forming a thermally and electrically conductive coating material layer comprises applying the thermally and electrically conductive coating material layer comprised of a metal selected from the group consisting of copper, aluminum, alloys thereof, brass, and combinations thereof.
5. The method of claim 1 , wherein the step of cold spraying a fire retardant material layer comprises cold spraying a fire-retardant material selected from the group consisting of a nickel-based alloy or superalloy, a ferrous-based alloy, a cobalt-based alloy, and combinations thereof.
6. The method of claim 5 , wherein the step of cold spraying a fire retardant material layer comprises cold spraying to a material thickness of about 100 μm to about 700 μm.
7. A method for manufacturing a fire- and EMI-resistant aircraft component comprising the steps of:
forming an additive-manufactured intermediate article comprising a polymeric material;
integrating a continuous electrically conductive filament within a substrate of the polymeric material during the forming of the additive-manufactured intermediate article such that the continuous electrically conductive filament extends from one end of the additive-manufactured intermediate article to another end of the additive-manufactured intermediate article;
applying a thermally and electrically conductive coating material layer on the additive-manufactured article forming a coated article, the thermally and electrically conductive coating material layer comprising a metal; and
cold spraying a fire retardant material layer on the coated article,
wherein the integrating the continuous electrically conductive filament within the substrate of the polymeric material during the forming of the additive-manufactured intermediate article comprises:
substantially simultaneously feeding a filament of the polymeric material and the continuous electrically conductive filament through a dual extrusion head of a fused deposition modeling system.
8. The method of claim 7 , wherein the continuous electrically conductive filament comprises a metal selected from the group consisting of copper, aluminum, alloys thereof, brass, and combinations thereof.
9. The method of claim 7 , wherein the step of applying a thermally and electrically conductive coating material layer comprises applying the metal selected from the group consisting of copper, aluminum, alloys thereof, brass, and combinations thereof.
10. The method of claim 7 , wherein the step of cold spraying a fire retardant material layer comprises cold spraying a fire-retardant material selected from the group consisting of an nickel-based alloy or superalloy, a ferrous-based alloy, a cobalt-based alloy, and combinations thereof.
11. The method of claim 10 , wherein the step of cold spraying a fire retardant material layer comprises cold spraying to a material thickness of about 100 μm to about 700 μm.