Angular Oscillation Friction Welding Non-Uniform Surfaces
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Solution Overview
Problem
Spin friction welding is limited to parallel faying surfaces, while linear and orbital friction welding require complex and expensive machinery and cannot handle non-uniform shapes effectively due to geometric constraints on the welding surface.
Innovation Solution
Angular oscillation friction welding method that aligns a complementary surface of a component part with an axially symmetric weld surface of a workpiece, using predetermined forces and oscillation patterns to create and consolidate a plasticized material joint, allowing for the welding of components with non-uniform shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If spin friction welding is used, then the welding process is simple and machinery is inexpensive, but it can only join parts with parallel faying surfaces
Solution Approach 1:
The invention transitions from static parallel surface contact (spin welding) to dynamic angular oscillation contact. The workpiece oscillates angularly about an axis during welding, enabling the process to accommodate non-parallel and non-uniform surfaces while maintaining relatively simple machinery architecture.
Solution Approach 2:
The welding process employs periodic angular oscillation of the workpiece about an axis. This periodic motion creates alternating contact and separation between the faying surfaces, generating friction heat and enabling material plasticization across varied geometries, resolving the limitation of spin welding to parallel surfaces.
2Adaptability or versatility
If linear or orbital friction welding is used to handle non-uniform shapes, then surface geometry adaptability is improved, but device complexity and cost increase
Solution Approach 1:
Instead of complex linear or orbital motion systems, the invention uses simpler angular oscillation about a fixed axis. This dynamic approach allows accommodation of non-uniform shapes through controlled oscillatory motion rather than complex multi-axis movement, reducing machinery complexity while maintaining geometry adaptability.
Solution Approach 2:
The invention changes the motion parameter from continuous linear/orbital movement to periodic angular oscillation. By controlling oscillation amplitude, frequency, and axis orientation, the process adapts to various non-uniform geometries without requiring complex machinery, achieving versatility through parameter adjustment rather than mechanical complexity.
3Adaptability or versatility
If linear or orbital friction welding is used, then non-uniform shapes can be welded, but the welding surface must have no geometric variation along the oscillation axis
Solution Approach 1:
The angular oscillation creates dynamic contact conditions that accommodate surface geometric variations. As the workpiece oscillates, different portions of the non-uniform surface sequentially engage with the tool, allowing welding of components with geometric variations along the oscillation axis that would be impossible with static linear or orbital methods.
Solution Approach 2:
The periodic angular oscillation enables sequential engagement of varied surface geometries with the welding tool. This periodic contact pattern allows material from different geometric regions to be plasticized and joined, removing the constraint that welding surfaces must be uniform along the oscillation axis.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables efficient joining of components with non-uniform shapes without the need for complex machinery, overcoming the limitations of spin friction welding and facilitating the assembly of components with geometric variations.
Implementation Method 1
angular oscillation friction welding a complementary surface of a component part to an axially symmetric weld surface of a workpiece
Implementation Method 2
create a region of a plasticized material between the workpiece and the at least one component part
Data Source
AI summary
A method of friction welding a workpiece and a component part is disclosed. The workpiece has a weld surface that is coextensive with at least a portion of a virtual surface, which is symmetric about an axis, and the component part includes a complementary surface that conforms to the weld surface. The method includes angularly oscillating the workpiece about the axis; urging the weld surface and the complementary surface together with a first predetermined force to create a plasticized region between the workpiece and the component part; urging the weld surface and the complementary surface together with a second predetermined force; discontinuing angularly oscillating the workpiece; urging the weld surface and the complementary surface together with a third predetermined force; and discontinuing to urge the weld surface and the complementary surface together when the workpiece and the component part coalesce.