Annular Sheet Components Using Ultrasonic Welding and Rolling

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Solution Overview

Problem

Existing ultrasonic welding processes are unable to form curved or annular components, and conventional joining methods for large-scale annular components often compromise material properties.

Innovation Solution

Combining ultrasonic welding with rolling or bending processes to form and bond sheet metal feedstock into annular shapes, allowing for the creation of multi-layer annular components with improved material properties.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If conventional fusion welding is used to join sub-components, then large-scale annular components can be manufactured, but material properties are lowered undesirably

Engineering Contradiction:

Improvemanufacturability of large-scale annular componentsVSAvoidmaterial properties

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The component is divided into multiple sub-components that are joined together using ultrasonic welding. This segmentation allows the component to be manufactured in sections while maintaining material properties, as ultrasonic welding creates solid-state bonds without the harmful effects of fusion welding on the base material.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent replaces conventional fusion welding (thermal/chemical joining process) with ultrasonic welding (mechanical vibration-based solid-state joining process). This substitution eliminates the heat-affected zone and material property degradation associated with fusion welding, while still achieving strong joints between sub-components.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Strength

If casting or forging is used, then adequate material properties are achieved, but manufacturing cost and complexity increase

Engineering Contradiction:

Improvematerial propertiesVSAvoidmanufacturing economy

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Instead of casting or forging the entire large-scale annular component as a single piece (which would be expensive and complex), the component is segmented into smaller sub-components that can be manufactured more economically and then joined using ultrasonic welding to achieve adequate material properties.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent changes the joining process parameters from high-temperature fusion welding to low-temperature ultrasonic solid-state welding. This parameter change allows sub-components to be joined without the material property enhancement typically requiring casting or forging, thereby reducing manufacturing cost and complexity.

Inventive Principle:

Principle #35Parameter changes

3Strength

If existing ultrasonic welding processes are used, then solid-state bonds are achieved, but curved or annular components cannot be formed

Engineering Contradiction:

Improvebond strengthVSAvoidability to form curved or annular components

Core Design Contradiction:

StrengthVSAdaptability or versatility

Solution Approach 1:

The patent introduces a rolling mechanism that dynamically forms the sheet material into curved or annular shapes during the ultrasonic welding process. This dynamic forming capability allows the ultrasonic welding process to adapt to curved geometries, overcoming the limitation of existing processes that could only weld flat or simple shapes.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent merges the ultrasonic welding process with a rolling/forming process into a single integrated system. This combination allows the sheet material to be simultaneously formed into curved or annular shapes and bonded together, achieving both the desired geometry and strong solid-state bonds.

Inventive Principle:

Principle #5Merging (Combining)

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

This method enables the economical production of large annular structures with material properties comparable to forgings, reduces raw material and tooling costs, and allows for performance enhancements through layered material combinations.

Implementation Method 1

Methodology Applied

Scientific EffectPiezoelectric effect: Piezoelectric Effect

Implementation Method 2

actuated at its resonant frequency to put ultrasonic energy into the workpiece

Methodology Applied

Scientific EffectResonance: Resonance

Implementation Method 3

This process uses an 'ultrasonic horn' which is a thin blade or rib tool powered by a piezoelectric transducer and actuated at its resonant frequency to put ultrasonic energy into the workpiece. This does generate heat

Methodology Applied

Scientific EffectUltrasonic vibration heating: Ultrasonic Vibration

Data Source

PatentUS10919106B2Ultrasonic welding of annular components

Publication Date: 2021.02.16 GENERAL ELECTRIC CO

AI summary

A method of making an annular component includes forming sheet feedstock into an annular shape disposed about a central axis; and bonding one portion of the feedstock to another portion of the feedstock using ultrasonic welding, so as to fix the annular shape.