US-20260124829-A1 - SYSTEMS AND METHODS FOR JOINING COMPOSITE STRUCTURES TO METAL STRUCTURES

US20260124829A1US 20260124829 A1US20260124829 A1US 20260124829A1US-20260124829-A1

Abstract

Systems, methods, and devices for providing a joining technique for a metal part and a composite part. The joining technique in which either the metal or the composite part has at least one portion receive a laser etching treatment according at least in part to a laser configuration. Further, the joining technique in which the metal and composite parts are positioned to contact at least one etched surface. Even further, the joining technique in which a joining process is used to join the metal part and composite part to produce a unitary structure.

Inventors

Gabriel Silva

Assignees

FMC TECHNOLOGIES, INC.

Dates

Publication Date: 20260507
Application Date: 20251229

Claims (20)

1 . A pressure containment structure comprising: a metal part comprising at least one surface having an etching pattern formed by a laser etching treatment; and a composite part joined to the at least one surface of the metal part, the composite part comprising a corrosion resistant composite material, wherein the composite part encompasses at least a portion of the metal part such that the composite part shields the at least a portion of the metal part from one or more hazardous materials.
2 . The pressure containment structure of claim 1 , wherein the metal part further comprises a tube joint, the tube joint operable to connect to a composite tube.
3 . The pressure containment structure of claim 2 , wherein the etching pattern is a first etching pattern, wherein the tube joint comprises a surface having a second etching pattern, wherein the composite tube is joined to the surface of the tube joint.
4 . The pressure containment structure of claim 1 , wherein the etching pattern is a first etching pattern and the laser etching treatment is a first laser etching treatment, wherein the composite part comprises at least one surface having a second etching pattern formed by a second laser etching treatment.
5 . The pressure containment structure of claim 4 , wherein the at least one surface of the composite part having the second etching pattern is joined to the at least one surface of the metal part having the first etching pattern.
6 . The pressure containment structure of claim 1 , wherein the etching pattern comprises a first portion having a first depth and a second portion having a second depth, wherein the second depth is greater than the first depth.
7 . The pressure containment structure of claim 1 , wherein the etching pattern comprises a first portion having a first width of etching and a second portion having a second width of etching, wherein the second width of etching is greater than the first width of etching.
8 . A pressure containment structure comprising: a tubing assembly comprising: a metal tube comprising at least one surface having an etching pattern formed by a laser etching treatment; and a composite tube joined to the at least one surface of the metal tube and fluidly coupled to the metal tube.
9 . The pressure containment structure of claim 8 , wherein the etching pattern comprises a first portion having a first depth and a second portion having a second depth, wherein the second depth is greater than the first depth.
10 . The pressure containment structure of claim 8 , wherein the composite tube is a second composite tube, wherein the metal tube is disjoined from a first composite tube prior to joining the second composite tube to the metal tube.
11 . The pressure containment structure of claim 8 , wherein the metal tube is a first metal tube, the etching pattern is a first etching pattern, the laser etching treatment is a first laser etching treatment, and the composite tube is a first composite tube, wherein the tubing assembly further comprises: a second metal tube comprising at least one surface having a second etching pattern formed by a second laser etching treatment; and a second composite tube joined to the at least one surface of the second metal tube and fluidly coupled to the second metal tube.
12 . The pressure containment structure of claim 11 , wherein the first etching pattern has a first etching depth and a first etching width, wherein the second etching pattern has a second etching depth and a second etching width, wherein the first etching depth is distinct from the second etching depth, wherein the first etching width is distinct from the second etching width.
13 . The pressure containment structure of claim 12 , wherein the composite tube comprising a corrosion resistant composite material, wherein the composite tube encompasses at least a portion of the metal tube such that the composite tube shields the at least a portion of the metal tube from one or more hazardous materials.
14 . The pressure containment structure of claim 8 , wherein the metal tube comprises a metal flange.
15 . A pressure containment structure comprising: a metal part comprising: a metal material; and at least one surface comprising an etching pattern formed by a laser etching treatment; and a composite part joined to the at least one surface of the metal part, the composite part comprising a composite material, wherein the composite part is joined to the at least one surface of the metal part by providing heat to the at least one surface of the metal part and, simultaneously while providing heat, compressing the at least one surface of the metal part and the composite part together.
16 . The pressure containment structure of claim 15 , wherein the pressure containment structure comprises a pressure containing tank.
17 . The pressure containment structure of claim 15 , wherein the pressure containment structure comprises a valve body.
18 . The pressure containment structure of claim 15 , wherein the pressure containment structure comprises a tube joint.
19 . The pressure containment structure of claim 15 , wherein the metal material comprises a metal alloy and the composite material comprises carbon fiber polyether ether ketone.
20 . The pressure containment structure of claim 19 , wherein the pressure containment structure is configured to be disposed underwater in a subsea assembly.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS This patent application is a divisional application claiming priority benefit, with regard to all common subject matter, of U.S. Patent Application No. 18/360,203, filed July 27, 2023, and entitled “SYSTEMS AND METHODS FOR JOINING COMPOSITE STRUCTURES TO METAL STRUCTURES.” The above-referenced application is hereby incorporated by reference in its entirety into the present application. BACKGROUND 1. FIELD Embodiments of the present disclosure relate to joining techniques. More specifically, embodiments of the present disclosure relate to techniques for joining composite structures to metal structures. 2. RELATED ART Joining techniques such as fasteners, adhesives, and induction welding have been used to join composite structures to metal structures. However, the typical joining techniques are prone to complications. For example, joining techniques using fasteners require drilling holes, which may be a critical area for structural failure for composite materials. Further, for example, joining techniques using adhesives have limitations for certain environmental applications and shear stress loading. Even further, joining techniques using adhesives may result in the adhesive melting away due to high-temperature use or heat from subsequent manufacturing processes causing the joined structures to become disjoined. SUMMARY Embodiments of the present disclosure solve the above-mentioned problems by providing a joining technique that avoids material damage associated with joining techniques using fasteners and has an increased shear stress capability of the joint compared to joining techniques using adhesives. Embodiments of the present disclosure contemplate a joining technique that involves applying a laser etching to at least one surface of a first structure based on a selected laser configuration. The laser etched surface of the first structure provides increased adhesion to at least one surface of a second structure as compared to traditional joining techniques such as fasteners and adhesives. Further, the joining technique provided may have a higher failure temperature for the joint compared to joints using adhesives. In some aspects, the techniques described herein relate to a method of joining a metal part and a composite part to form a unitary structure, the method including: selecting a laser configuration for a laser etching treatment to be applied to at least one surface of the metal part, wherein the metal part includes a metal material and the composite part includes a composite material, wherein the laser configuration is selected based at least in part on a material property of the metal material; etching the at least one surface of the metal part using the laser etching treatment according to the laser configuration; positioning the metal part such that the at least one surface of the metal part contacts the composite part; providing heat, using at least one heating element, to the at least one surface of the metal part; and simultaneously while providing heat, compressing the at least one surface of the metal part and the composite part together to form the unitary structure. In some aspects, the techniques described herein relate to a method, wherein the laser configuration includes a parallel line pattern. In some aspects, the techniques described herein relate to a method, wherein the metal material includes steel. In some aspects, the techniques described herein relate to a method, wherein the metal material includes aluminum. In some aspects, the techniques described herein relate to a method, wherein the metal material includes Inconel. In some aspects, the techniques described herein relate to a method, wherein the composite material includes carbon fiber. In some aspects, the techniques described herein relate to a method, wherein the compressing is performed by a press configured to receive the metal part and the composite part. In some aspects, the techniques described herein relate to a method, wherein the heat is provided by generating eddy currents using the at least one heating element, and wherein the at least one heating element is coupled to the press. In some aspects, the techniques described herein relate to a method, wherein an adhesive is not applied to the at least one surface of the metal part prior to compressing the at least one surface of the metal part and the composite part together. In some aspects, the techniques described herein relate to a method of joining a metal part and a composite part to form a unitary structure, the method including: selecting a laser configuration for a laser etching treatment to be applied to at least one surface of the metal part, wherein the metal part includes a steel material and the composite part includes a carbon fiber material, wherein the laser configuration is selected based at least in part on a material property of the steel material; etching the at least one surface of the metal part usi