Bimetallic Screw Laser Welding Without Rotation or Bulges
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Solution Overview
Problem
Existing methods for manufacturing bimetallic screws, such as those described in European patent applications EP 3 536 812 A1 and EP 3 674 028 A1, are complex and inefficient, particularly due to the need for pressing and rotating shaft parts during welding, which can lead to bulges and require additional post-weld processing.
Innovation Solution
A method involving laser beam welding of two shaft parts with continuous movement through the welding beam, without rotation, to form a base body, followed by thread rolling, ensuring efficient and cost-effective production of bimetallic screws with a hardenable front shank section for cutting and a corrosion-resistant rear section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If shaft parts are pressed and rotated during welding, then welding can be performed, but bulges are formed requiring additional post-weld processing
Solution Approach 1:
The patent replaces the mechanical pressing and rotating system with a laser beam welding system. The laser beam provides localized heating to melt and fuse the shaft parts without requiring mechanical pressure or rotation, thereby eliminating the formation of bulges and the need for post-weld processing.
Solution Approach 2:
The patent changes the welding parameters from mechanical (pressure, rotation) to thermal (laser beam energy, temperature distribution). By controlling the laser beam parameters such as power, focus, and scanning speed, the welding process achieves precise fusion without mechanical deformation, maintaining surface quality.
2Reliability
If complex welding processes are used, then welding can be performed, but production time increases
Solution Approach 1:
The patent replaces complex mechanical welding processes with laser beam welding, which offers faster heating and cooling rates. This reduces the overall welding cycle time while maintaining weld integrity through precise thermal control and localized energy input.
Solution Approach 2:
The laser beam welding process allows for continuous welding operation without the need for intermittent mechanical adjustments or repositioning. The beam can continuously move along the joint line, maintaining constant energy input and achieving rapid, uninterrupted welding that increases production throughput.
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 reduces production time and costs while maintaining quality by avoiding bulges and enabling high throughput, with the ability to produce multiple base bodies in a shorter time without compromising weld integrity.
Implementation Method 1
the two shaft parts are welded together at a weld point by means of a welding beam, in particular a laser beam
Data Source
Figure 1~3d
Figure 4a~4c
AI summary
The invention relates to a process for manufacturing a bimetallic screw (1) comprising a first shank portion (8) and a second shank portion (9) which are arranged behind one another in the direction of a longitudinal axis (L) and are welded together at a weld point (10) using beam welding. The method is characterized in that the two shank portions (8, 9) are continuously moved relative to and through the welding beam (13) during the welding operation.