Annular Workpiece Support for Low-Distortion Friction Welding
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Inertia welding of large engine components with varying cross-sections often results in high stresses and distortion at weld locations, leading to potential deformation or rupture, as the load distribution is uneven, causing bending moments at prior welds.
Innovation Solution
The use of annular support members, which are secured around workpieces at locations with reduced cross-sections to balance load distribution and reduce stress and distortion during the welding process, by temporarily increasing the cross-sectional dimension or area of the welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If multiple inertia welds are performed on large engine components with varying cross-sections, then the components can be manufactured by joining multiple sections, but high stresses and bending moments occur at existing weld locations causing deformation or rupture
Solution Approach 1:
An annular support member is introduced as an intermediary element between the welding system and the workpiece. This support member temporarily reinforces the workpiece at the weld location, distributing the welding loads and preventing excessive bending moments that would cause deformation or rupture of the existing weld.
Solution Approach 2:
The annular support member is installed on the workpiece before the welding process begins. This preliminary action prepares the workpiece to withstand the upcoming welding loads by providing additional structural support at the vulnerable weld location, preventing deformation before it occurs.
2Shape
If workpieces with reduced cross-sectional areas are welded, then the component geometry is achieved, but the load distribution becomes uneven creating bending moments at prior weld locations
Solution Approach 1:
The annular support member provides localized reinforcement specifically at the reduced cross-section area where the geometry change occurs. This local quality enhancement allows the workpiece to maintain its varying cross-section shape while compensating for the uneven load distribution at the specific location of geometric transition.
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
The annular support members effectively reduce stress and distortion by supporting areas with reduced cross-sections during welding, preventing deformation and rupture, and ensuring successful joining of components with varying cross-sectional geometries.
Implementation Method 1
The second workpiece therefore frictionally engages and brakes the rotating first workpiece creating friction heating at the contact area therebetween which raises the temperature thereof to effect an inertia weld without melting
Data Source
AI summary
A method for reducing stress and distortion in a component during a friction welding process includes securing first and second workpieces of the component within an inertia welding machine such that the first and second workpieces are affixed in opposition to each other. The method also includes securing at least one annular support member at least partially around the first workpiece and/or the second workpiece at a location having a reduced cross-section as compared to remaining portions of the first workpiece and/or the second workpiece. Further, the method includes rotating the first workpiece to a predetermined rotational speed. In addition, the method includes engaging the second workpiece with the rotating first workpiece so as to generate frictional heat therebetween, thereby welding the first and second workpieces together. As such, the annular support member(s) supports the location having the reduced cross-section during welding.