Method of casting fail-safe composite metal structure

Metal founding – Process – Shaping liquid metal against a forming surface

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164 98, 164106, 164113, B22D 1902, B22D 1914

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053928407

ABSTRACT:
A method for manufacturing a structural component includes forming a groove in an outer surface of a fiber reinforced body. Molten metal is introduced to an exposed surface of the groove and to a predetermined portion of the outer surface of the body. The metal is cooled in a controlled manner to thermally alter sufficient resin to create a secure interconnection of the metal on the body. The metal adjacent the groove is sized so that it will fail prior to separation of the metal from the body under excessive tensile loads. A portion of the metal remains on the body so that elongation of the component significantly exceeds ultimate elongation of the fiber reinforced body and the cast metal.

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Research Disclosure No. 27638, "Cast-In-Situ Joint for Tubular Beams" Apr. 1987; pp. 209-210.

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