Composite Joining by Electric Resistance Welding with Basalt Fiber Isolation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Welding composite materials, especially those with carbon fibers, often leads to current leakage due to their electrical conductivity, affecting the quality of the weld joint.
Innovation Solution
Incorporating an electrically insulating component made of basalt fibers between the parts to be welded, which prevents current leakage during electric resistance welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If electric resistance welding is used to join composite parts, then welding capability is achieved, but current leakage occurs due to electrical conductivity of carbon fibers
Solution Approach 1:
An electrically insulating layer is introduced as an intermediary component between the conductive heating element and the carbon fiber composite parts. This insulating layer prevents direct electrical contact and current leakage through the carbon fibers, while still allowing the welding process to function effectively.
Solution Approach 2:
The harmful electrical conductivity property of the carbon fibers is addressed by extracting or isolating the carbon fiber parts from direct electrical contact with the heating element, using the insulating layer to separate the conductive and insulating functions.
2Ease of manufacture
If traditional welding methods are used for composite materials, then joining is achieved, but additional fastening elements are required
Solution Approach 1:
The electric resistance welding process itself provides the joining function without requiring additional fastening elements. The heating element directly welds the composite parts together through controlled heating and pressure, making the welding process self-sufficient and eliminating the need for separate fastening components.
3Strength
If multiple materials and fastening elements are used, then structural integrity is improved, but material variety and weight increase
Solution Approach 1:
The electrically insulating layer serves multiple functions simultaneously: it prevents current leakage, provides electrical isolation, and maintains structural integrity during the welding process. This multi-functionality eliminates the need for separate components for each function, reducing overall material variety and weight.
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
Enhances the quality of the weld joint by preventing shunts and short circuits, allowing for improved welding of composite materials without additional fastening elements and reducing material variety and weight.
Implementation Method 1
Causing an electric current to flow through the heating component for electric resistance heating by welding of the layer structure along a weld joint surface
Implementation Method 2
an electrically insulating component arranged between the heating component and the at least one electrically conductive part, the insulating component comprising one or more basalt fibers
Data Source
Figure 1~2
Figure 3(a)~3(c)
AI summary
A method for joining two parts (12, 12a, 12b) by means of electric resistance welding, the method comprising: a) Providing a layer structure (14) for electric resistance welding, the layer structure (14) including: - two parts (12, 12a, 12b) to be joined, wherein at least one of the parts (12, 12a, 12b) is electrically conductive, - an electrically conductive heating component (16) arranged between the two parts (12, 12a, 12b), and - an electrically insulating component (28) arranged between the heating component (16) and the at least one electrically conductive part (12, 12a, 12b), the insulating component (28) comprising one or more basalt fibers (30); and b) Causing an electric current to flow through the heating component (16) for electric resistance welding of the layer structure (14) along a weld joint surface (26) of the layer structure (14) and thus joining the two parts (12, 12a, 12b).