Friction stir welding device integrating thermal compensation and rapid clamping functions

Abstract

The invention provides a friction stir welding device integrating thermal compensation and rapid clamping functions. The friction stir welding device comprises a base, a base plate, a pressing plate, an ejector block, a cushion block, a handle pressing screw, a heating rod, a water inlet nozzle, a water drainage nozzle and a cooling channel. The base is a device main body structure and is used for supporting the test plate; the backing plate is placed on the back of the test plate; the pressing plate is used for vertically pressing the test plate; the jacking block is used for laterally jacking the test plate; the cushion block is placed between the pressing block and the test plate and transmits vertically downward pressing force to the test plate; the handle compression screw is propped against the top block to reinforce lateral propping of the test plate; a plurality of groups of heating rods are inserted into the base from the side surface to preheat the test plate before welding; and a cooling channel is connected between the water inlet nozzle and the water outlet nozzle, so that the test plate is cooled in the welding process, or the test plate is cooled after welding is completed. According to the device, the problem that time is consumed in traditional tool assembly is solved, the mechanical property of the welding test plate is guaranteed through the thermal compensation function, and reliable tool support is provided for high-quality friction stir welding.

Description

Technical Field

[0001] This invention belongs to the field of friction stir welding tooling technology, and specifically relates to a friction stir welding device that integrates heat compensation and rapid clamping functions. Background Technology

[0002] Friction stir welding technology plays an irreplaceable role in high-end equipment manufacturing fields such as aerospace, rail transportation, and shipbuilding due to its advantages such as high weld joint quality, small deformation, and no need for filler material. Welding fixtures, as core auxiliary equipment for fixing test plates and ensuring welding accuracy during friction stir welding, directly determine welding efficiency and joint quality.

[0003] Currently, existing friction stir welding fixtures have significant shortcomings in the test plate fixing process. To ensure that the test plate does not shift during welding, the fixture needs to simultaneously achieve vertical clamping and lateral tightening: vertical clamping is used to counteract the axial force during welding, while lateral tightening is used to prevent the test plate from shifting laterally under the action of the stirring head. Traditional fixtures typically use a distributed fastener structure, requiring operators to adjust the vertical clamping and lateral tightening components one by one. This is not only cumbersome but also makes it difficult to ensure the uniformity of forces in all directions, resulting in a single assembly taking 25-30 minutes, severely restricting the efficiency of welding tests.

[0004] Furthermore, the temperature field distribution of the test plate has a crucial impact on the mechanical properties of friction stir welded joints. Existing tooling generally lacks targeted thermal management functions: before welding, if the test plate is at room temperature, especially for high-strength aluminum alloys, the low temperature can easily lead to insufficient plasticity in the weld zone, resulting in defects such as incomplete penetration and excessive burrs; after welding, if the test plate cools naturally, uneven cooling rates can generate significant residual stress, leading to decreased joint strength and increased deformation. These problems make existing tooling insufficient to meet the requirements of high-precision, high-performance welding tests. Summary of the Invention

[0005] In order to overcome the shortcomings of the prior art, the inventors have conducted intensive research and provided a friction stir welding device that integrates thermal compensation and rapid clamping functions, thus solving the problems of low assembly efficiency and lack of thermal management in the prior art, thereby completing the present invention.

[0006] The technical solution provided by this invention is as follows: In the first aspect, a friction stir welding device integrating heat compensation and quick clamping functions includes a base, a pad, a pressure plate, a top block, a pad block, a handle clamping screw, a heating rod, a water inlet, a water outlet, and a cooling channel. The base is the main structure of the device, with long strip-shaped protrusions machined on the four sides of the upper surface to form a recess for accommodating the test plate; A backing plate is placed on the back of the test plate to support it. The two ends of the pressure plate are fixed to two opposite long strip-shaped protrusions on the base. Several threaded holes are opened in the middle part of the pressure plate. A pad is placed between the pressure plate and the test plate. The test plate is pressed in the vertical direction by threaded fasteners passing through the threaded holes and the pad. The top block is fixed between the long strip protrusion on the base and the test plate, and is used to laterally tighten the test plate; The pad is placed between the pressure block and the test plate to transmit a vertically downward clamping force to the test plate; One end of the handle tightening screw is for tightening the handle, and the other end is for tightening. It passes through the threaded holes arranged on the two long strip-shaped protrusions of the base. Rotating the tightening handle makes the tightening end press against the side of the top block, which strengthens the lateral tightening of the test plate. Multiple heating rods are evenly inserted into the base from the side, and an external control power supply is connected to preheat the test plate before welding. A cooling channel is connected between the water inlet and the water outlet. The cooling channel is laid inside the base to cool the test plate during welding or after welding.

[0007] Secondly, a friction stir welding apparatus integrating heat compensation and rapid clamping functions includes the following steps: It connects to the welding platform through the mounting holes at the bottom of the base; A pre-placed backing plate is used to provide back support for the welding test plate. Place two welding test plates in the recess of the base, and then tighten the two test plates together as a whole, with the two adjacent sides in close contact with the two adjacent elongated protrusions. Install and adjust the pressure plate to pre-tighten the top of the welding test plate. The pressure plate should avoid the center of the weld. Use a shim between the pressure plate and the test plate to transfer the downward clamping force. Install and adjust the top block to pre-tighten the welding test plate laterally, ensuring no gaps or warping. If the top block cannot tighten the test plate laterally at its maximum movement distance, place a shim between the top block and the test plate. Adjust the fasteners of the pressure plate and the top block, and tighten the handle clamping screws. By tightening the top block, the welding test plate is pressed laterally to ensure that the test plate is relatively stationary with respect to the friction stir welding head during the welding process. If the welding test plate needs to be preheated, it is heated by an external power source through a heating rod inserted into the base; if cooling is required during the welding process, cooling water is introduced into the cooling channel through the water inlet and outlet; after welding, the test plate is cooled in a gradient using a cooling assembly, and the cooling rate is controlled by an external cooling water source.

[0008] The friction stir welding apparatus integrating heat compensation and rapid clamping functions provided by the present invention has the following beneficial effects: This invention provides a friction stir welding device integrating thermal compensation and rapid clamping functions, comprising a base, a rapid clamping mechanism (top block, pressure plate, and fasteners), a preheating component (heating rod), and a cooling component (water inlet, water outlet, and cooling channel). The rapid clamping mechanism adopts a linkage design, achieving rapid vertical and lateral clamping through the top block, pressure plate, and fasteners. The forces acting in all directions are kept uniform through a mechanical balance design, effectively improving assembly efficiency and reliability. A single assembly takes approximately 5-10 minutes. The preheating component uses a zoned, controllable resistance heating method, which can precisely adjust the preheating temperature according to the characteristics of the test plate material (e.g., aluminum alloy requires preheating to 150-250℃), ensuring the welding zone reaches its optimal plasticity before welding. The cooling component, through built-in cooling channels, cools the test plate during welding to prevent softening of the stirring head, or performs gradient cooling of the test plate after welding, controlling the cooling rate within the range of 5-10℃ / s, significantly reducing residual stress. Through the above technical solutions, this device not only solves the problem of time-consuming assembly of traditional tooling, but also ensures the mechanical properties of the welded test plate through the thermal compensation function, providing reliable tooling support for high-quality friction stir welding tests. Attached Figure Description

[0009] Figure 1 This is a perspective view of the friction stir welding device integrating heat compensation and rapid clamping functions of the present invention. Figure 2 This is a bottom view of the friction stir welding device integrating heat compensation and rapid clamping functions of the present invention. Figure 3 This is a top view of the friction stir welding device integrating heat compensation and rapid clamping functions of the present invention. Detailed Implementation

[0010] The features and advantages of the present invention will become clearer and more apparent from the following detailed description.

[0011] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments.

[0012] See Figures 1 to 3 The present invention provides a friction stir welding device integrating heat compensation and quick clamping functions, comprising: a base 1, an assembly hole 2, a lifting ring 3, a pad 4, a pressure plate 5, a top block 6, a pad block 7, a handle clamping screw 8, a heating rod 9, a water inlet 10, a drain outlet 11, and a cooling channel.

[0013] The base 1 is the main structure of the device. Long, rectangular protrusions are machined along the four sides of its upper surface, forming a recess to accommodate the test plates. Two test plates are placed side-by-side within the recess, forming a single unit. Two adjacent sides of the test plates are tightly fitted against two adjacent long, rectangular protrusions, while the remaining two sides are secured by the sides of the top block 6. Assembly holes 2 are machined at the bottom of the base 1 to connect with the welding platform, and lifting rings 3 are installed at the four corners of the upper part to facilitate the overall lifting and transfer of the device.

[0014] The backing plate 4 is placed on the back of the test plate to support the test plate. It has the functions of ensuring good back formation of the weld, balancing the welding upsetting force, and preventing damage to the tooling table. The backing plate 4 in this device can be replaced after it is worn out.

[0015] The two ends of the pressure plate 5 are fixed on two opposite elongated protrusions on the base 1. Several threaded holes are opened in the middle part of the pressure plate 5. A pad 7 is placed between the pressure plate 5 and the test plate. The test plate is pressed in the vertical direction by the threaded fasteners passing through the threaded holes and the pad 7 to prevent the test plate from warping during the welding process.

[0016] At least two pressure plates (5) are required, each placed above one of the two test plates to be welded. The number of pressure plates is determined based on the dimensions of the test plates to ensure that the test plates do not warp during welding.

[0017] The top block 6 is located between the elongated protrusion of the base 1 and the test plate. The top block 6 has a longitudinal elongated hole and is fixed to the base by a threaded fastener passing through the elongated hole. It is used to laterally tighten the test plate and prevent the test plate from shifting during welding. If the top block 6 is still unable to laterally tighten the test plate due to the size limitation of the elongated hole, a pad block 7 is placed between the top block 6 and the test plate at the maximum movement distance.

[0018] The pad 7 is placed between the pressure block 5 and the test plate, and if necessary, between the top block 6 and the test plate. The thickness can be adjusted according to the thickness of the test plate to ensure assembly.

[0019] One end of the handle tightening screw 8 is for tightening the handle, and the other end is for tightening. It passes through the threaded holes arranged on the two long strip-shaped protrusions of the base 1. Rotating the tightening handle makes the tightening end press against the side of the top block 6, thus strengthening the lateral tightening effect of the top block 6.

[0020] Multiple heating rods 9 are evenly inserted into the base 1 from the side, and an external control power supply is connected to ensure a preheating temperature of 150~250℃ before welding according to the requirements of different test plates.

[0021] A cooling channel is connected between the water inlet 10 and the water outlet 11. The cooling channel is laid inside the base 1 to cool the test plate during the welding process and prevent the stirring head from softening; or to perform gradient cooling of the test plate after welding. The cooling rate is controlled within the range of 5~10℃ / s by external cooling water and controller.

[0022] When using this friction stir welding device: (1) The base 1 is connected to the welding platform through the mounting hole 2 at the bottom to ensure the stability of the process equipment; (2) Pre-placed pad 4. The function of pad 4 is to provide back support for the welding test plate and to prevent the stirring head from damaging the base 1 during the welding process. (3) Place the welding test plate in an appropriate position to ensure that there is no interference during the welding process; (4) Install and adjust the pressure plate 5 to pre-tighten the top of the welding test plate. The pressure plate 5 should avoid the center of the weld. Use pads 7 of different thicknesses to place between the pressure plate 5 and the test plate to meet the clamping requirements of test plates of different thicknesses. (5) Install and adjust the top block 6 to pre-tighten the welding test plate laterally to ensure no gaps or warping. If necessary, use shims 7 of different widths to place between the top block 6 and the test plate to meet the lateral tightening requirements of test plates of different lengths and widths. (6) Adjust each fastener and tighten the handle clamping screw 8. Press the welding test plate laterally by tightening the top block 6 to ensure that the test plate is relatively stationary with the friction stir welding head during the welding process.

[0023] The test panel assembly is now complete.

[0024] In addition, the device has a preheating component and a cooling component. If the welding test plate needs to be preheated, it is heated by an external power source through a heating rod 9 inserted into the base 1; if cooling is required during the welding process, cooling water is introduced into the cooling channel through the water inlet 10 and the water outlet 11. After welding, the cooling component is used to gradually cool the test plate, and the cooling rate is controlled within the range of 5~10℃ / s by an external cooling water source and a controller.

[0025] Example Example 1 In this embodiment, the welding test plate is made of 6061 aluminum alloy with dimensions of 10mm (thickness) × 100mm (width) × 300mm (length). Two test plates are welded using friction stir welding.

[0026] First, install the device base 1 on the welding platform and place the pad 4 stably. Then, place the welding test plate, ensuring that the edge of the test plate is tightly fitted with the two elongated protrusions of the device base 1. Place the pressure plate 5 and the appropriately thick pad 7 on top of the test plate, and lightly tighten the fastening screws at both ends and the middle clamping screw of the pressure plate 5. Then, install and adjust the top block 6 to properly assemble the welding test plate, i.e., the misalignment height between the two test plates is less than 0.2 mm and the gap is less than 0.1 mm. Adjust the fasteners of the pressure plate 5 and the top block 6, and further enhance the lateral clamping force by tightening the handle screw 8 to ensure that the welding test plate is firmly assembled.

[0027] Because 6061 aluminum alloy has high thermal sensitivity, excessive temperature gradients during welding can lead to compositional segregation and internal stress. Therefore, preheating is necessary before welding. During preheating, connect heating rod 9 to an external control power supply, set the temperature to 150℃, and hold for 10 minutes after heating to the specified temperature to ensure the test plate is heated evenly and fully. Stop heating when welding officially begins.

[0028] Thus, the pre-welding assembly and preheating operations of the 6061 aluminum alloy friction stir welding test plate were completed.

[0029] After welding, cooling water is introduced into the cooling channel through the water inlet 10 and the water outlet 11 to perform gradient cooling of the test plate, and the cooling rate is controlled within the range of 5~10℃ / s, which significantly reduces residual stress.

[0030] Example 2 In this embodiment, the welding test plate is made of 5A06 aluminum alloy with dimensions of 5mm (thickness) × 80mm (width) × 200mm (length). Two test plates are welded using friction stir welding.

[0031] First, install the device base 1 on the welding platform and place the pad 4 stably. Then, place the welding test plate, ensuring that the edge of the test plate is tightly fitted with the protrusion of the device base 1. Place the pressure plate 5 and the appropriately thick pad 7 on top of the test plate, and lightly tighten the fastening screws at both ends and the middle clamping screw of the pressure plate 5. Then, install and adjust the top block 6, and place the appropriately wide pad 7 between the test plate and the top block 6 to assemble the welding test plate properly, i.e., the misalignment height between the two test plates is less than 0.2 mm and the gap is less than 0.1 mm. Adjust the fasteners of the pressure plate 5 and the top block 6, and further enhance the lateral clamping force by tightening the handle screw 8 to ensure that the welding test plate is firmly assembled.

[0032] Because 5A06 aluminum alloy has high strength, it generates a lot of heat during friction stir welding, which can cause the joint to soften. Therefore, cooling is necessary during the welding process. For cooling, connect the water inlet 10 to the cooling water and controller. Turn on the cooling water 2 minutes before welding and stop cooling 2 minutes after welding is complete.

[0033] Thus, the pre-welding assembly and welding cooling operations of the 5A06 aluminum alloy friction stir welding test plate were completed.

[0034] The present invention has been described in detail above with reference to specific embodiments and exemplary examples; however, these descriptions should not be construed as limiting the present invention. Those skilled in the art will understand that various equivalent substitutions, modifications, or improvements can be made to the technical solutions and embodiments of the present invention without departing from the spirit and scope of the invention, and all such modifications and improvements fall within the scope of the present invention. The scope of protection of the present invention is defined by the appended claims.

[0035] The contents not described in detail in this specification are common knowledge to those skilled in the art.

Claims

1. A friction stir welding device integrating thermal compensation and rapid clamping functions, characterized in that, Includes base (1), pad (4), pressure plate (5), top block (6), pad (7), handle clamping screw (8), heating rod (9), water inlet (10), drain outlet (11) and cooling channel; The base (1) is the main structure of the device. The upper surface is machined with long strip-shaped protrusions on all four sides to form a recess for accommodating the test plate. The pad (4) is placed on the back of the test plate to support the test plate; The two ends of the pressure plate (5) are fixed on two opposite long strip protrusions on the base (1). Several threaded holes are opened in the middle part of the pressure plate (5). A pad (7) is placed between the pressure plate (5) and the test plate. The test plate is pressed in the vertical direction by the threaded fasteners passing through the threaded holes and the pad (7). The top block (6) is fixed between the long strip protrusion of the base (1) and the test plate for lateral clamping of the test plate; The pad (7) is placed between the pressure block (5) and the test plate to transmit a vertically downward clamping force to the test plate; One end of the handle clamping screw (8) is the tightening handle, and the other end is the top tightening end. It passes through the threaded holes arranged on the two long strip protrusions of the base (1). Rotate the tightening handle so that the top tightening end is pressed against the side of the top block (6) to strengthen the lateral tightening of the test plate. Multiple heating rods (9) are evenly inserted into the base (1) from the side, and an external control power supply is connected to preheat the test plate before welding. A cooling channel is connected between the water inlet (10) and the drain outlet (11). The cooling channel is laid in the base (1) to cool the test plate during the welding process or after the welding is completed.

2. The friction stir welding device integrating thermal compensation and rapid clamping functions according to claim 1, characterized in that, Two test plates are placed tightly in the recess of the base (1). The two test plates are as a whole, with two adjacent sides tightly attached to two adjacent long strip protrusions, and the remaining two sides are pressed and limited by the side of the top block (6).

3. The friction stir welding device integrating thermal compensation and rapid clamping functions according to claim 1, characterized in that, The bottom of the base (1) is machined with assembly holes (2) to connect with the welding platform; the upper four corners of the base (1) are equipped with lifting rings (3) to carry out the overall lifting and transfer of the device.

4. The friction stir welding device integrating thermal compensation and rapid clamping functions according to claim 1, characterized in that, The number of pressure plates (5) is at least two, which are placed above the two test plates to be welded.

5. The friction stir welding device integrating thermal compensation and rapid clamping functions according to claim 1, characterized in that, The top block (6) has a longitudinal elongated hole, which is fixed to the base by a threaded fastener passing through the elongated hole. The longitudinal elongated hole allows the top block (6) to move back and forth for adjustment.

6. The friction stir welding apparatus with integrated thermal compensation and rapid clamping functions according to claim 1, characterized in that, When the top block (6) cannot press the test plate laterally at the maximum moving distance, a pad block (7) is placed between the top block (6) and the test plate.

7. A method of using a friction stir welding apparatus with integrated thermal compensation and rapid clamping functions as described in any one of claims 1 to 6, characterized in that, Includes the following steps: It connects to the welding platform through the mounting holes at the bottom of the base; A pre-placed backing plate is used to provide back support for the welding test plate. Place two welding test plates in the recess of the base, and then tighten the two test plates together as a whole, with the two adjacent sides in close contact with the two adjacent elongated protrusions. Install and adjust the pressure plate to pre-tighten the top of the welding test plate. The pressure plate should avoid the center of the weld. Use a shim between the pressure plate and the test plate to transfer the downward clamping force. Install and adjust the top block to pre-tighten the welding test plate laterally, ensuring no gaps or warping. If the top block cannot tighten the test plate laterally at its maximum movement distance, place a shim between the top block and the test plate. Adjust the fasteners of the pressure plate and the top block, and tighten the handle clamping screws. By tightening the top block, the welding test plate is pressed laterally to ensure that the test plate remains relatively stationary with respect to the friction stir welding head during the welding process.

8. The method of using the friction stir welding device with integrated heat compensation and rapid clamping functions according to claim 7, characterized in that, Also includes: If the welding test plate needs to be preheated, it is heated by an external power source through a heating rod inserted into the base; if cooling is required during the welding process, cooling water is introduced into the cooling channel through the water inlet and outlet; after welding, the test plate is cooled in a gradient using a cooling assembly, and the cooling rate is controlled by an external cooling water source.

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