Dissimilar Metal Welding with Current-Based Probe Depth Control
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Solution Overview
Problem
Existing dissimilar metal welding methods face challenges in precisely stopping the probe at the correct position over steel plates due to variations in plate thickness sizes, leading to inconsistent weld quality.
Innovation Solution
A dissimilar metal welding method involving a pin member inserted into a cylindrical tool body, where the pin member's rotation and movement are monitored through electric current changes to detect when it penetrates the first metal material, allowing precise control of the welding process regardless of thickness variations, ensuring high-quality welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the probe is stopped at a predetermined downward movement position, then the welding process can be controlled, but the probe cannot be precisely stopped at the predetermined position directly above the steel plate when there are variations in plate thickness sizes
Solution Approach 1:
The patent employs feedback control by monitoring the downward movement distance of the probe and automatically adjusting the stopping position based on actual plate thickness measurements. The system measures the plate thickness first, then calculates and controls the probe's downward movement to ensure it stops at the correct position above the steel plate regardless of thickness variations.
Solution Approach 2:
The patent performs preliminary measurement of the plate thickness before the welding operation. By measuring the actual thickness of the aluminum plate and steel plate in advance, the system can pre-calculate the appropriate probe penetration depth and stopping position, ensuring accurate positioning even when thickness varies.
2Strength
If friction stir spot welding is performed on dissimilar metals, then high strength joints can be achieved, but the process becomes complex due to different material properties
Solution Approach 1:
The patent adjusts welding parameters such as rotation speed, downward movement speed, and welding time based on the specific combination of dissimilar metals being joined. By optimizing these parameters for aluminum-steel combinations, the system achieves high strength joints while managing the complexity through systematic parameter control.
Solution Approach 2:
The welding process is divided into distinct phases: a preparing step where the probe penetrates the aluminum plate to form a through-hole, and a working step where the probe digs into the steel plate. This segmentation allows each phase to be optimized independently for the specific metal combination, simplifying the overall process control.
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 stable and high-quality welding of dissimilar metals by precisely managing the penetration depth and timing, even with variations in plate thickness, without the need for additional surface treatments or heat processes.
Implementation Method 1
friction stir spot welding
Implementation Method 2
the metal plastically flowing due to the formation of the through-hole
Data Source
AI summary
A dissimilar metal welding method includes a preparing step and a working step. In the preparing step, a pin member is moved to a second metal material while being rotated, and a tool body is driven such that the tool body is moved in a direction away from the second metal material while being rotated. In the working step, a through-hole is formed in the second metal material by the pin member, and then a distal end of the pin member is dug into the first metal material to a predetermined depth position in the first metal material.