Cu-Zr Composite Welding Arm Shank for Conductivity and Hardness
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Solution Overview
Problem
Welding electrodes used in welding robot arms require higher conductivity and hardness to improve welding efficiency and durability, but existing solutions do not adequately meet these demands.
Innovation Solution
A conductive supporting member is created using a composite structure with copper metal as the inner portion and a Cu-Zr alloy as the outer portion, achieving high conductivity and hardness through spark plasma sintering of Cu and Cu-Zr master alloy or ZrH2 powders.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a highly conductive copper material is used for the conductive supporting member, then conductivity is improved, but hardness and strength are insufficient
Solution Approach 1:
The patent applies composite materials by creating a layered structure consisting of a copper-based alloy material (providing high conductivity) and a copper-zirconium alloy material (providing high hardness and strength). This composite structure allows the conductive supporting member to simultaneously achieve high conductivity from the copper-based layer and high mechanical properties from the Cu-Zr layer, resolving the contradiction between electrical conductivity and mechanical strength.
Solution Approach 2:
The patent implements local quality by assigning different material properties to different regions of the conductive supporting member. The copper-based alloy material is positioned in the central region to provide high conductivity where electrical current flows, while the copper-zirconium alloy material is positioned in the outer region to provide high hardness and strength where mechanical loads are applied. This spatial differentiation of material properties allows each region to optimize its function.
2Reliability
If copper content is increased to improve conductivity, then electrical performance is enhanced, but mechanical strength and hardness decrease
Solution Approach 1:
The patent uses composite materials to combine a copper-based alloy material (with high conductivity but lower strength) and a copper-zirconium alloy material (with high strength and hardness). The copper-based material ensures high electrical conductivity for efficient current transmission, while the Cu-Zr material provides the mechanical strength needed for durability. Together, they achieve both high conductivity and high welding efficiency without sacrificing either property.
3Ease of manufacture
If a single-material structure is used, then manufacturing is simplified, but it cannot simultaneously achieve high conductivity and high hardness
Solution Approach 1:
The patent applies composite materials by sintering copper-based alloy powder and copper-zirconium alloy powder together to form a layered composite structure. This approach, while creating a multi-material structure, uses a single sintering process that can simultaneously consolidate both materials. The composite structure achieves the dual properties of high conductivity and high hardness that would be impossible with a single material, while the sintering process keeps manufacturing relatively simple.
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 conductive supporting member achieves high conductivity and mechanical strength, with the Cu-Zr compound providing enhanced hardness and stability, suitable for high-temperature applications and increased welding efficiency.
Implementation Method 1
Through a relatively simple treatment in which such raw material powders are subjected to spark plasma sintering, an outer portion containing a Cu-Zr compound can be produced.
Data Source
Figure 1
Figure 2A~2D
Figure 3(a)~3(c)
AI summary
A welding arm 10 includes a tip electrode 11, a holder 12, and a shank 20. The shank 20 serving as a conductive supporting member includes an outer portion 22 that includes a Cu matrix phase and a second phase dispersed in the Cu matrix phase and containing a Cu-Zr compound and that has an alloy composition represented by Cu-xZr (x is atomic% of Zr and 0.5 ≤ x ≤ 16.7 is satisfied) and an inner portion 21 that is present on an inner side of the outer portion 22, is formed of a metal containing Cu, and has higher conductivity than the outer portion 22.