Dissimilar-Metal Bonding Structure With Interlayer for Stable FSW
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Solution Overview
Problem
Conventional friction stir welding methods face challenges in consistently bonding different kinds of metals, particularly hard materials, due to difficulties in controlling the penetration depth and generating uniform bonding strength, leading to variations in bonding quality and probe pin wear.
Innovation Solution
A heterogeneous bonding structure is achieved by inserting a first metal layer of lower melting point and hardness between two dissimilar metals, allowing for stable bonding through friction stir welding, where the first metal layer contacts the stirring portion, reducing variations in bonding strength and probe pin wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional friction stir welding is used to bond different kinds of metals, then bonding of dissimilar metals is achieved, but bonding strength varies and probe pin wear increases
Solution Approach 1:
A metal layer with intermediate properties (lower melting point and hardness than the harder metal) is introduced between the dissimilar metals. This intermediate layer acts as a mediator that reduces probe pin wear during friction stir welding while maintaining stable bonding strength, resolving the contradiction between bonding reliability and probe pin durability
Solution Approach 2:
The invention changes the physical parameters (melting point and hardness) of the bonding interface by introducing a metal layer with different properties than either of the base metals. This parameter change allows for more consistent bonding strength and reduced probe pin wear by creating a more favorable bonding environment
2Strength
If friction stir welding is applied to hard materials, then bonding of hard metals is achieved, but controlling penetration depth becomes difficult
Solution Approach 1:
The intermediate metal layer with lower hardness serves as a mediator that facilitates more precise control of probe pin penetration depth. The softer layer allows the probe pin to penetrate to the desired depth more accurately without the difficulties associated with bonding hard materials directly, thereby improving manufacturing precision while maintaining bonding strength
3Reliability
If conventional methods are used for bonding dissimilar metals, then bonding is achieved, but bonding structure stability is insufficient
Solution Approach 1:
The intermediate metal layer creates a more stable bonding structure by mediating between the dissimilar metals. This layer promotes uniform distribution of the bonding zone and reduces structural instability, leading to more reliable and consistent bonding results across different bonding positions
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
This method enables reproducible, stable bonding of different metals with reduced variations in bonding strength and minimized probe pin wear, improving the reliability and consistency of the bonding process.
Implementation Method 1
The friction stir welding (FSW) has been tried to use as a method for bonding different kinds of metals
Implementation Method 2
The friction stir welding (FSW) has been tried to use as a method for bonding different kinds of metals
Implementation Method 3
The first metal layer includes the second metal. The first metal layer contacts the stirring portion
Data Source
Figure 1A~1F
Figure 2A~2B
Figure 3A~3B
AI summary
In an embodiment, a heterogeneous bonding structure of metals includes a first member (10), a second member (20), and a first metal layer (11). The first member (10) includes first metal. The second member (20) includes second metal different from the first metal. The second member (20) includes a stirring portion (21). The first metal layer (11) is positioned between the first member (10) and the second member (20). The first metal layer (11) includes the second metal. The first metal layer (11) contacts the stirring portion (21).