Curved Crown Weld Structure for Stronger Material Joining
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Solution Overview
Problem
Current weld structures for joining materials lack optimal geometrical configurations that ensure strong and consistent fusion across various materials and applications, particularly in vehicle battery support trays and vehicle bodies, where the strength and reliability of welds are critical.
Innovation Solution
A weld structure comprising a first curved end, a second curved end, a connecting portion, a first curved crown, and a second curved crown, with specific geometric dimensions and spacings, formed using a welding element such as laser, electron beam, or arc welding, to create a robust and consistent weld configuration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional weld structures are used, then the welding process is simple, but the weld strength and reliability are insufficient
Solution Approach 1:
The weld structure employs curved geometry with a crown portion that has a radius of curvature R, where 0.5mm ≤ R ≤ 2mm. This curvature is formed during the welding process to create a convex profile on the weld surface. The curved shape distributes stress more effectively compared to flat welds, improving weld strength and reliability while maintaining a relatively simple formation process through controlled welding parameters.
2Manufacturing precision
If simple weld structures are used, then the manufacturing process is easy, but the fusion quality is inconsistent
Solution Approach 1:
The method controls weld formation by adjusting specific welding parameters including heat input (0.5-2.0 kJ/mm), welding speed (5-50 mm/s), and electrode offset (0.1-0.5mm). These parameter changes ensure consistent crown radius (0.5mm ≤ R ≤ 2mm) and crown height (0.1-0.5mm) are achieved reliably across different welding conditions, improving fusion quality consistency without requiring complex post-processing.
3Reliability
If optimized curved weld structures are formed, then the structural integrity is improved, but the welding process complexity increases
Solution Approach 1:
The welding process automatically forms the desired curved crown structure through self-adjusting mechanisms. The electrode offset creates a natural crown formation as the weld progresses, and the heat distribution self-regulates to achieve the target crown radius (0.5mm ≤ R ≤ 2mm). This self-service approach reduces the need for complex real-time control systems while maintaining reliable weld quality.
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 described weld structure enhances the strength and reliability of material joins by ensuring precise geometric configurations, which improve the fusion quality and structural integrity in applications like vehicle battery support trays and vehicle bodies, accommodating different materials like zinc-coated steel, aluminum, and polymers.
Implementation Method 1
Welding uses high heat to melt the materials together. As the materials cool, they become fused together.
Implementation Method 2
Welding uses high heat to melt the materials together.
Data Source
AI summary
A system for joining a first part and a second part together with a weld structure. The system includes: a welding element configured to form the weld structure between the first part and the second part; and a control module configured to operate the welding element to form the weld structure. The weld structure includes: a first curved end; a second curved end; a connecting portion connecting the first curved end and the second curved end; a first curved crown spaced apart from the first curved end and concentric with the first curved end; and a second curved crown spaced apart from the second curved end and concentric with the second curved end. The first curved end, the second curved end, and the connecting portion are between the first curved crown and the second curved crown.