Welded Dual-Material Flow Drill Screw for Ultra-High-Strength Steel
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Solution Overview
Problem
Existing flow drill screws face challenges in penetrating and forming threads in high-strength metal materials like ultra-high strength steel plates, which are difficult to process and costly, and lack customization for various usage scenarios.
Innovation Solution
A flow drill screw with a threaded section and tip portion made of different metal materials, such as tungsten steel for the tip and stainless steel for the threaded section, connected by welding, to withstand high temperatures and pressures, and featuring concave points for increased friction and a through hole for aligned force transmission.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If metal materials with stronger wear resistance are used to penetrate high-strength plates, then penetration capability is improved, but manufacturing cost increases and thread formation becomes difficult
Solution Approach 1:
The screw rod is divided into two segments with different materials: the tip portion made of wear-resistant metal material for penetration, and the threaded section made of easily processable material for thread formation. This segmentation allows each part to have optimized properties for its specific function.
Solution Approach 2:
Different parts of the screw rod have different material properties tailored to their specific functions. The tip portion has high wear resistance for penetrating high-strength plates, while the threaded section has good formability for easy thread creation. This local quality optimization resolves the contradiction between penetration capability and manufacturability.
2Strength
If metal materials with stronger wear resistance are used to penetrate high-strength plates, then penetration capability is improved, but manufacturing cost increases
Solution Approach 1:
The screw rod is segmented into tip portion and threaded section with different materials. Only the tip portion requires expensive wear-resistant material, while the threaded section uses cost-effective material, thereby reducing overall manufacturing cost while maintaining penetration capability.
Solution Approach 2:
High-performance wear-resistant material is applied locally only where needed (tip portion), rather than throughout the entire screw rod. This local quality approach minimizes material costs while ensuring penetration capability is achieved where required.
3Ease of manufacture
If existing standardized screws are used, then manufacturing simplicity is maintained, but adaptability to different usage scenarios is limited
Solution Approach 1:
The screw rod is segmented into functional sections (tip portion and threaded section) that can be independently optimized. This segmentation enables customization of material composition, dimensions, and properties for each section to meet specific application requirements while maintaining a relatively simple overall structure.
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
Enables efficient penetration and thread formation in ultra-high strength steel plates under high temperatures, improving applicability and reliability while reducing costs through material segmentation and structural design.
Implementation Method 1
the flow drill screw is transmitted to the connected plate through high-speed rotation, it is caused to generate frictional heat and plastic deformation, and then self-tapping and screwing
Implementation Method 2
ends of the threaded section of the rod and the tip portion are connected and fixed by welding
Data Source
AI summary
A flow drill screw is provided, which includes a head, a threaded section of a rod, and a tip portion; the head is configured to connect with an external tool; the threaded section of the rod is configured for self-tapping a plate; the tip portion is configured to penetrate the plate; the threaded section of the rod and the tip portion are made of different metal materials, and ends of the threaded section of the rod and the tip portion are connected and fixed by welding. By using two different materials to make the threaded section of the rod and the tip portion, it can cope with different plates and meet different usage scenarios, and save costs. This design enables the screw to perform well under various complex conditions, thereby improving its applicability and reliability, and has significant economic and social benefits.