Welding Stud with Deformable Tip for Dissimilar Metal Joining
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Solution Overview
Problem
Existing methods for connecting components made of non-weldable materials with weldable materials are time-consuming, complex, and result in poor mechanical load capacity and lifetime due to small contact surfaces and waste material contamination during the welding process.
Innovation Solution
A welding auxiliary joining part in the form of a stud made of plastically deformable weldable material, which is set into a non-weldable component using high-speed joining methods without pre-punching, forming a large welding head for enhanced contact and minimizing waste, allowing for flexible and efficient connections between non-weldable and weldable materials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a stud with a small tip contact surface is used for welding auxiliary joining, then the setting process is simple, but the welding contact area is small which prolongs welding time and degrades connection quality
Solution Approach 1:
The stud is pre-formed with a enlarged head portion before insertion. This preliminary shaping creates a large welding contact surface in advance, eliminating the need for complex post-setting operations and enabling fast welding without prolonging the welding process.
Solution Approach 2:
The stud geometry is changed from a uniform cylindrical shape to one with an enlarged head portion. This parameter change in the stud's dimensional configuration provides a large contact surface area for welding while keeping the insertion portion slender for easy setting.
2Ease of manufacture
If a semi-hollow punch rivet is used as welding auxiliary joining part, then the setting process is straightforward, but a waste slug is created that contaminates the welding area and affects connection quality
Solution Approach 1:
The harmful waste slug is extracted from the process by using a solid stud design that does not require material removal during setting. The stud is simply inserted and deformed plastically to create the enlarged head, eliminating waste material generation entirely.
Solution Approach 2:
The plastic deformation capability of the stud material is converted from a potential disadvantage into an advantage. The material's ability to deform allows the stud to create its own enlarged head during setting without requiring punching or creating waste, transforming the material property into a beneficial feature.
3Reliability
If multiple method steps are used to laterally deform the shank for positive connection, then reliable fixation is achieved, but the connection method becomes technically complex and time consuming
Solution Approach 1:
The setting and fixation functions are merged into a single operation. The stud is inserted and deformed in one continuous process, combining the insertion action with the deformation action that creates the enlarged head for positive connection, eliminating separate deformation steps.
Solution Approach 2:
The stud performs its own fixation function through self-deformation during insertion. As the stud is set into the component, it plastically deforms to create the enlarged head portion that provides positive connection, eliminating the need for external deformation devices or additional fixation steps.
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 provides a reliable, efficient, and flexible connection method with improved mechanical load capacity and lifetime by creating a large welding head without waste material interference, simplifying the process and reducing installation effort.
Implementation Method 1
a tip portion (11) extending in longitudinal direction of the welding auxiliary joining part and having a maximum thickness (D) transversely to the longitudinal direction
Data Source
AI summary
A welding auxiliary joining part in the shape of a stud having a head, a shank and a tip is disclosed. The welding auxiliary joining part is driven into a component made of a non- or poorly weldable material by means of a setting method. A welding head is created during driving-in due to mechanical deformation such that subsequently the component can be connected by welding via the welding auxiliary joining part to a further component made of a weldable material.