Compact Counter Support for Long Curved Friction Stir Welds
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Solution Overview
Problem
Friction stir welding processes for joining large and curved components with long, continuous weld seams are economically unfeasible due to the high cost and complexity of counter support designs required to manage process forces, leading to inefficient and expensive machinery setups.
Innovation Solution
A compact counter support device with guide means allowing limited movement between two end positions, enabling the production of long, curved weld seams by seamlessly joining short, straight stitch seams, which reduces the need for large and expensive machinery and supports a robust, cost-effective welding process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a large and complex counter support design is used to join long and curved components, then the weld seam quality is improved, but the device cost and complexity increase significantly
Solution Approach 1:
The patent divides a long continuous weld seam into multiple short stitch seams. The counter support only needs to support the tool during these short stitch welding operations, rather than supporting a long continuous weld. This segmentation allows the use of a compact, simple counter support design while still achieving high-quality welds on long and curved components by performing multiple sequential short welds.
2Reliability
If a large diameter roller is used as counter support for flat or moderately curved metal sheets, then the force flow is closed, but the device size and cost increase
Solution Approach 1:
The patent employs a dynamic counter support system that can move and adjust its position, rather than relying on a large fixed roller. The counter support follows the tool during short stitch welding operations, providing force closure only where and when needed. This dynamic approach eliminates the need for large diameter rollers while maintaining reliable force flow closure.
3Device complexity
If a miniaturized caterpillar track is used as counter support, then the device size is reduced, but material penetration between track shoes causes maintenance issues and poor surface quality
Solution Approach 1:
The patent extracts the problematic track shoe structure from the counter support design and replaces it with a simple, clean support mechanism. The counter support is designed as a compact device that contacts the workpiece in a controlled manner during short stitch welding, eliminating the segmented track shoe structure that allows material penetration. This results in a device that is both compact and reliable with minimal maintenance requirements.
4Device complexity
If the melt pool support length is reduced for compact design, then the device size and cost decrease, but the ability to support long continuous welds is reduced
Solution Approach 1:
The patent applies segmentation to the welding process itself, dividing long weld seams into multiple short stitch seams. The melt pool support is designed to accommodate only these short stitch welds, not long continuous welds. By segmenting the welding process into discrete short stitches, the melt pool support can be compact while still enabling the creation of long weld seams through sequential stitching operations.
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 solution allows for the efficient and cost-effective joining of long and curved components by minimizing the size and complexity of the counter support, enabling a high number of welding processes without frequent maintenance, and reducing the size and cost of the welding device, while maintaining high weld quality.
Implementation Method 1
friction stir welding
Implementation Method 2
friction stir welding processes for joining large and curved components
Data Source
AI summary
A counter support for friction stir welding, which makes it possible to also produce very long weld seams by friction stir welding despite a very compact design, is shown. Curved components and nn-straight weld seams may also be produced.