Barrel Tank Seam Welding with Induction Heating and Forging
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for welding sheet metal into cylindrical shapes face challenges such as rebounding, vibratory issues, and accuracy problems during the translation and support of longitudinal edges, leading to reduced weld quality and increased seam thickness, particularly with advanced high-strength steel materials.
Innovation Solution
A system comprising a positioning assembly, guide member, and welding and forging assembly that includes heating and forging wheels to create a solid-phase bond by partially bonding sheet ends with weld wheels, heating them, and then forging the seam to enhance bond quality and reduce weld thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If existing welding methods are used on advanced high-strength steel, then welding can be performed with current technology, but weld quality is reduced and weld toughness decreases
Solution Approach 1:
The patent applies induction heating to raise the temperature of the sheet metal to a specific range (1500°F to 2400°F) before welding, and controls the welding parameters including electrode pressure and current to optimize the solid-phase bond. These parameter changes enable high-quality welding of advanced high-strength steel that would otherwise be difficult to weld with conventional methods.
2Manufacturing precision
If conventional welding is performed without heating, then the process is simpler, but seam thickness increases and weld quality decreases
Solution Approach 1:
The patent employs induction heating as a preliminary action before welding to heat the sheet metal to the optimal temperature range. This pre-heating step prepares the material for welding, ensuring proper metallurgical bonding and reducing seam thickness, though it does increase process complexity.
3Measurement precision
If the sheet metal is translated through a Z-shaped frame during welding, then the longitudinal edges can be supported, but rebounding and vibratory issues occur causing accuracy problems
Solution Approach 1:
The patent replaces the mechanical support system (Z-shaped frame with rollers) with a magnetic field-based positioning system. Magnets are used to hold the sheet metal in place during welding, eliminating the mechanical contact that causes rebounding and vibration while maintaining precise alignment of the longitudinal edges.
4Length of moving object
If narrow overlap of sheet ends is used, then weld thickness is reduced, but bonding difficulty increases with advanced high-strength steel
Solution Approach 1:
The patent changes the temperature parameter by heating the sheet metal to 1500°F-2400°F before welding the narrow overlap. This temperature increase makes the advanced high-strength steel more ductile and easier to bond, enabling successful welding of narrow overlaps (e.g., 1/8 inch) that would be difficult or impossible to weld at room temperature.
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 system achieves improved weld quality and reduced weld thickness ratio, enhancing the solid-phase bond interface and addressing issues of accuracy and rebounding, suitable for applications like pressure vessels and strip welding processes.
Implementation Method 1
heating (e.g., via induction heating) the partially bonded sheet ends to a significant temperature
Implementation Method 2
partially bonding narrowly overlapped sheet ends with a leading set of weld wheels (e.g., via resistance welding)
Data Source
AI summary
An apparatus (10) for joining a predetermined geometrical profile shape from a sheet material (SM) includes a positioning assembly (12) including a base member (14) and a frame (16) that is operable to receive the sheet material (SM), to configure the sheet material in a predetermined orientation and to linearly translate the sheet material along a process direction (20). A Z-bar (22) is configured to guide a first longitudinal edge (FE) and second longitudinal edge (SE) of the sheet material (SM) into adjacent alignment along the process direction (20). A welding and forging assembly (60) welds and then forges a seam between the first longitudinal edge (FE) and the second longitudinal edge (SE) of the associated sheet material (SM).