Autogenous Torque Converter Welding Without Filler Material
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Solution Overview
Problem
The existing welding methods for torque converters, such as MIG welding, require filler materials, increasing complexity, cost, and contamination due to spatter and 'lack of fusion', which complicates the formation of a liquid-tight seal.
Innovation Solution
The method involves overlapping and tapering edge portions of components in a torque converter, applying energy at a specific angle without filler material to form an autogenous weld, creating a liquid-tight seal or chamfer, thereby eliminating the need for filler materials and simplifying the welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If MIG welding with filler material is used, then the welding process can be completed, but complexity and cost increase along with contamination from spatter and lack of fusion
Solution Approach 1:
The patent removes the filler material from the welding process entirely, using only the base metal itself to form the weld. This extraction of the filler material eliminates the complexity associated with selecting, positioning, and managing filler materials while still achieving reliable welds through the autogenous process where the work pieces themselves provide the welding material.
Solution Approach 2:
The work pieces serve themselves by providing the material needed for the weld without requiring external filler material. The edges of the components being joined melt and fuse together using only their own material, making the welding process self-sufficient and eliminating the need for additional materials that would increase complexity and cost.
2Reliability
If MIG welding with filler material is used, then the welding process can be completed, but cost increases due to filler material requirements
Solution Approach 1:
The patent extracts and eliminates the filler material from the welding process, thereby removing the associated costs of purchasing, storing, and managing filler materials. The welding process relies solely on the base metal, which is already present in the components being joined, thus reducing overall manufacturing costs while maintaining weld quality.
Solution Approach 2:
The components being welded provide their own material for the weld, eliminating the need to purchase and apply separate filler materials. This self-service approach reduces material costs and simplifies the manufacturing process, making it more cost-effective while still achieving reliable welds.
3Reliability
If MIG welding with filler material is used, then the welding process can be completed, but contamination increases due to spatter and lack of fusion
Solution Approach 1:
The patent removes the filler material that is the source of spatter contamination. By using only the base metal for the weld, the process eliminates the spatter that occurs when filler material is melted and deposited, thereby reducing contamination and the need for post-weld cleaning operations.
Solution Approach 2:
The work pieces themselves provide the welding material without requiring external filler material that would generate spatter. This self-service welding process significantly reduces contamination because the only material being melted is the base metal of the components being joined, which does not produce the same level of spatter as filler materials.
4Reliability
If filler material is used in welding, then the welding process can be completed, but the formation of a liquid-tight seal becomes more difficult
Solution Approach 1:
The patent extracts and eliminates filler material from the welding process, simplifying the formation of liquid-tight seals. Without filler material to manage, the welding process focuses solely on melting and fusing the base metal edges together, making it easier to achieve continuous, defect-free welds that provide reliable liquid-tight sealing.
Solution Approach 2:
The components being joined provide their own material for creating the liquid-tight seal, eliminating the complexity of managing filler material. This self-service approach allows for simpler welding parameters and processes that focus on achieving complete fusion of the base metal edges, resulting in more reliable liquid-tight seals with fewer defects.
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 approach reduces the complexity, cost, and contamination associated with welding torque converter components, ensuring a reliable and efficient liquid-tight seal without the use of filler materials, enhancing the overall efficiency and reliability of the torque converter.
Implementation Method 1
applying energy to the first edge portion; and melting, in the absence of a filler material, at least a portion of the first edge portion to form a weld
Implementation Method 2
forming an autogenous weld connecting the first and second components
Data Source
AI summary
A method for welding components in a torque converter, including: overlapping first and second edge portions of first and second components in the torque converter, respectively; applying energy to the first portion; and melting, in the absence of filler material, at least a portion of the first portion to weld the first and second components. In some aspects, the converter includes a cover and pump and the first component is one of the cover and pump and the second component is the other of the cover and pump. The present invention also broadly comprises a torque converter, including first and second components with overlapping respective edge portions and an autogenous weld, formed from the first component edge portion and in the absence of a filler material, connecting the first and second components.