Butt Welding Joint Geometry for Variable-Thickness Components
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Solution Overview
Problem
Existing butt welding methods struggle to effectively join components with varying thicknesses at different joint positions, as changing welding conditions based on thickness and shape can be difficult and often impractical.
Innovation Solution
A joint method involving groove formation to create inclined surfaces on projections, followed by butt welding and buildup welding using high-density energy and metal deposition techniques, respectively, to accommodate varying thicknesses and shapes without complex adjustments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If welding conditions are changed to accommodate varying thicknesses at joint positions, then welding quality improves, but operational complexity and difficulty increase
Solution Approach 1:
The groove is formed in advance on the component surfaces before welding, creating a predetermined geometric structure that accommodates thickness variations. This preliminary action eliminates the need for real-time welding condition adjustments, as the groove geometry itself adapts to different thicknesses while maintaining consistent welding parameters.
Solution Approach 2:
The groove formation creates localized geometric variations at the joint position, with the groove depth and shape adapting to the specific thickness conditions at each location. This local geometric adaptation allows uniform welding conditions to produce high-quality welds across components of varying thicknesses.
2Ease of operation
If welding conditions are kept constant for simplicity, then ease of operation improves, but welding quality deteriorates when joining components with varying thicknesses
Solution Approach 1:
The groove is formed in advance on the component surfaces before welding, creating a predetermined geometric structure that accommodates thickness variations. This preliminary action eliminates the need for real-time welding condition adjustments, as the groove geometry itself adapts to different thicknesses while maintaining consistent welding parameters.
3Adaptability or versatility
If projections are fully removed to join components of varying thicknesses, then adaptability improves, but material loss increases
Solution Approach 1:
The groove formation removes material only from specific localized regions where thickness variations exist, rather than removing entire projections. This selective local removal maintains adaptability for joining components with varying thicknesses while minimizing overall material loss by preserving projection material in areas where it is not needed.
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 expands the application range for joining components with varying thicknesses by allowing for efficient welding without the need for frequent changes in welding conditions, improving the possibility of joining complex shapes and reducing interference with welding devices.
Implementation Method 1
a groove formation step of removing part of the first projection opposed to the second projection and part of the second projection opposed to the first projection to form a groove region between the first projection and the second projection
Implementation Method 2
a first welding step of joining the first member and the second member to each other by butt welding after the groove formation step
Implementation Method 3
a second welding step of filling the groove region by buildup welding after the first welding step, wherein the buildup welding is executed by use of a metal deposition-type second welding device using a laser beam as a heat source
Data Source
AI summary
A joint method includes a groove formation step of removing part of a first projection and part of the second projection to form a groove region between the first projection and the second projection, a first welding step of joining a first member and a second member to each other by butt welding, and a second welding step of filling the groove region by buildup welding. The groove formation step forms a first inclined surface in the first projection facing the groove region to be gradually distant from a joint position joined with the second projection so as to be closer to an outer surface of the first projection, and forms a second inclined surface in the second projection facing the groove region to be gradually distant from the joint position joined with the first projection so as to be closer to an outer surface of the second projection.