Multi-Material Structures

Solidica proposes a new, more efficient joint design to join composite materials to steel structures. Using Ultrasonic Consolidation (UC), a low cost next generation additive manufacturing process, Solidica can build steel laminates that are later joined to the composite material through both a mechanical interlock and an adhesive bond. Using ultrasonically cold-welded foils shapes can be produced that are difficult or impossible to achieve using standard metal machining techniques. A steel joint with long metal “fingers” would be manufactured by welding layer upon layer of metallic foil. Ultimately, the foils would be built up to specified dimensions and tailored to each individual application, or possibly mass produced in stock sizes. Mechanical interlocks would be machined or physically manipulated into the metal fingers extending into the composite structure. This joint design outlined would significantly increase the usage of composite materials on ships and ground vehicles, by improving the strength of the joint and at the same time removing any worry of galvanic corrosion. The Phase I portion of this program is designed to establish and demonstrate all of the important proof-of-concept milestones required to justify the Phase II investment. Solidica will demonstrate that it is possible to reach strengths at or close to the surrounding monolithic materials and that it is possible to avoid galvanic corrosion issues associated with carbon steel joints.