Deformable Flange Plug for Filling Friction Stir Weld Exit Openings
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Solution Overview
Problem
Friction stir welding often results in undesirable weld-exit openings, which can lead to voids and reduced joint strength when subsequent welds traverse these openings, and existing methods for filling these openings are either time-consuming or ineffective.
Innovation Solution
A plug with a body, first flange, and second flange, where the second flange is made of a softer material than the first flange, allowing it to deform during installation and secure the plug in the opening, thereby consolidating it and preventing voids.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If polygonal wedges are staked into openings using punches and hammers, then the openings are filled, but the process is time-consuming and produces voids due to the polygonal cross-sectional shape
Solution Approach 1:
The invention changes the cross-sectional shape parameter from polygonal to circular, and changes the installation method from mechanicalstaking to friction stir welding. The circular cross-section eliminates voids between the filler material and opening walls, while the friction stir welding process provides rapid installation without the time-consuming staking operations.
Solution Approach 2:
The invention replaces the mechanical staking system (punches and hammers) with a friction stir welding system. The friction stir welding tool applies rotational friction and plunging forces to install the circular filler material, achieving both rapid installation and void-free filling simultaneously.
2Manufacturing precision
If reaming out the openings and press-fitting cylindrical members therein, then the openings are filled effectively, but the manufacturing cycle time increases
Solution Approach 1:
The invention merges the filling operation with the friction stir welding process itself. The circular filler material is installed and welded in a single continuous operation using the friction stir welding tool, eliminating the separate reaming and press-fitting steps required by conventional methods.
Solution Approach 2:
The friction stir welding process provides continuous installation of the circular filler material throughout the welding operation. The tool rotates and plunges continuously, installing multiple filler pieces in sequence without interrupting the welding process, thereby maintaining high productivity while achieving effective filling.
3Ease of manufacture
If weld-exit openings are left unfilled, then the manufacturing process is simple, but subsequent welds create voids and reduce joint strength
Solution Approach 1:
The invention performs preliminary filling of the weld-exit opening with circular filler material before the subsequent weld is made. This preliminary action ensures that when the welding tool passes through the opening, there is no volumetric material deficiency, preventing void formation and maintaining joint strength.
Solution Approach 2:
The circular filler material acts as an intermediary substance that occupies the weld-exit opening space. This intermediary material prevents the formation of voids during subsequent welding operations while maintaining the simplicity of the overall manufacturing process by using the same friction stir welding tool for both installation and welding.
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 plug effectively fills the weld-exit openings without creating voids, enhancing joint strength and surface quality by ensuring complete integration into the subsequent welds.
Implementation Method 1
the second flange is made of a different material than the first flange, and the different material that the second flange is made of is softer than the material of the first flange, thereby allowing the second flange to deform during installation of the plug into the opening
Implementation Method 2
installing the plug into the opening to consolidate the plug in the opening and to rotationally and translationally secure the plug in the opening
Data Source
Figure 1
Figure 2A
Figure 2B
AI summary
A method of installing a plug into an opening in an object includes providing a plug having a body, a first flange, and a second flange. The first flange is in contact with the body and extends away from the body. The second flange is in contact with the first flange and extends away from the first flange and the body. The method also includes installing the plug into the opening to consolidate the plug in the opening and to rotationally and translationally secure the plug in the opening.