Non-Electric Welding Apparatus TRIZ Cases

A two-layer metal bump uses larger grains near the electrode to absorb mounting stress, reducing peeling and improving bond strength.

Automated analysis of loop overlap, height, bend, and position data sets a clearer wire bonding sequence and reduces manual setup time.

Laser interferometer feedback corrects horizontal wafer position shifts during vertical chuck movement, improving bonding alignment accuracy.

Actuatable clamps and an external connector automate friction stir welding head mounting and removal, cutting manual changeover time and effort.

A flat-area groove at the wedge tip stabilizes stacked wire bonds, raising current capacity without larger wires or bond pads.

A step-shaped pin tip cuts fibers and improves material flow in friction stir spot welding while lowering joining pressure and equipment size.

Convex parts in the wedge tool leave contact marks on bonded wire, enabling more accurate press force inspection and less bonding damage.

A rotating sonotrode with frictionless nodal bearings cuts size and power demand while maintaining axial alignment for off-grid metal welding.

A shaped deposition head deposits filler into through holes during friction stir joining, creating smoother welds and integrated rivets in one pass.

An elastic, spring-biased tool assembly enables load-controlled friction stir welding on low-cost machining centers while reducing flash and protecting the spring.

Phase-based current limits during initial friction heating reduce torque-induced failures and improve joint quality determination.

Opposed spiral sections and a heat receiving portion limit weld width, transfer frictional heat, and reduce burrs and expansion.

Ultrasonic vibration and guided groove geometry bend container edges cleanly beyond 90° while avoiding damage and undefined buckling.

A non-uniform sonotrode with tuned mass, slots, and offset energy input welds complex geometries while limiting parasitic modes and transducer failure.

A preformed recess is sealed by a rotating tool that friction-softens the opening surface, enabling hollow metal members with complex internal shapes.

An elastic stir member enables load-controlled friction stir welding on position-controlled machining centers while limiting pin overload and breakage.

Counter-spiral probe sections and a heat receiving portion control material flow and frictional heat to raise weld strength without wider joints or burrs.

Automated pin and shoulder contact detection sets accurate zero points in friction stir welding, improving alignment safety and efficiency.

A loose-fit friction stir welding pin boosts vibration-driven plastic flow to raise joint strength, suppress defects, and reduce heat.

An aligned sonotrode tip guides conductive pins into the aperture to prevent misalignment, reduce whiskers, and improve weld reliability.

Cross-seam force feedback replaces unstable axial-force depth control in friction stir welding, improving tool engagement and weld consistency.

A shrink-fit shoulder adapter lets only the worn welding shoulder body be replaced, cutting material and maintenance costs.

By linking rotating tool load to separation distance, this case maintains heat input and plastic flow for stable steel friction stir welds.

Elastic biasing between the stirring pin and shoulder enables load control on machining centers while improving insertion depth and weld surface finish.

Elastic members in the stirring pin and shoulder enable machining-center friction stir welding with stable pin depth, lower burrs, and consistent joining quality.

By splitting the vibrating rod around an acoustic rod, this welding head expands layout options while preserving ultrasonic welding quality.

A low h/w horn tip structure improves screw attachment and avoids resonance, helping ultrasonic bonding stay accurate and stable.

A deformable frame clamps the sonotrode under load, replacing screws to cut weight, save space, and reduce vibration and heat losses.

A voice coil actuator and lever transmission keep sonotrode-anvil spacing constant despite material thickness variation and vibration.

Height measurement near the joint sets rotating tool depth before friction stir joining, reducing defects from warping, twisting, and clamping issues.

Pre-oriented pin feeding with a supply tube, singulator, and transfer structure speeds ultrasonic welding while improving pin placement consistency.

Linear friction joining connects dissimilar-strength metal sheets while limiting joint hardening and softening to preserve tailored blank formability.

A coaxial stir pin and sleeve drive removes side-shaft bending and hysteresis, improving refill friction stir spot weld accuracy.

Localized heating and rotation join metal workpieces in tight spaces, producing fine-grained assemblies without heat-affected zones.

Automatic pin and shoulder origin alignment uses contact-based movement and displacement checks to improve welding setup safety and accuracy.

Constant-speed shoulder press-in to at least 46% of workpiece thickness helps friction stir spot welding avoid longer weld times on thick workpieces.

Elastic biasing lets a rotary friction stir tool hold insertion depth and shoulder pressure on machining centers while reducing burrs.

Linear and annular sonotrode depressions capture unwelded pin material, containing whiskers that could otherwise short-circuit the workpiece.

A replaceable joining and backfilling probe forms an overlay that seals the joint area, suppressing electric corrosion without extra sealing steps.

Segmented conductive and insulated anvil surfaces control current paths and limit plate deformation for stable multi-plate bonding.

A fine crystal grain layer enables flat-surface welding of overlapped metal members, reducing indentation, moisture traps, and weld reliability loss.

A segmented pin supply, singulation, and transfer path uses vacuum or pneumatic motion to align conductive pins and speed ultrasonic welding cycles.

Two-stage shoulder force control keeps press-in speed constant to 46%+ of workpiece thickness, avoiding longer weld time on thick sections.

A compact friction stir welding setup joins confined interior or exterior structures while reducing heat distortion and rework from fusion welding.

A hollow consumable stirring bar with forced coolant circulation prevents tool wear and fracture while enabling full-penetration friction stir welding.

Localized low plasticity burnishing forms recessed and protruding stiffening cells that improve engine component stiffness with less aerodynamic disturbance.

A built-in cutting device drills the workpiece during rotation, enabling one-step friction welding that cuts attachment time and cost.

Oil held and discharged between the pin and hollow shoulder prevents powder adhesion, keeping friction-stir spot welding operable over many welds.

Opposed probe-free rotating tools use curved end faces to improve plastic flow, raise welding speed, and reduce defects in structural steel.

Indentation-depth feedback stops ultrasonic spot welding at a target sonotrode displacement to keep joint strength consistent across geometries.

A segmented wire guide with an elongated channel and rollers keeps bonding wire torsion-free under the tool, reducing misalignment and wear.

A gear-driven work tool added to the friction stir welding head removes weld-line burrs and asperities in the same pass, cutting extra finishing steps.

Ultrasonic vibration and a curved crimping groove bend container edges beyond 90° while reducing crushing loads, buckling, and damage.

A conformable manifold injects and cures bonding material in cracks on irregular surfaces without drilling holes or relying on vacuum integrity.

Filler deposition into through holes during friction stir joining forms in-situ rivets, improving weld consistency and avoiding part deformities.