Embossed Workpiece Joint for Thermal Joining of Unequal Thickness Parts
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Solution Overview
Problem
Existing methods for producing composite workpieces with large differences in thickness are limited by thermal joining issues and require complex construction measures, making it difficult to achieve reliable joints, especially with unfavorable material pairings.
Innovation Solution
A method involving a thermal joining process where one workpiece is reduced in thickness at the joining section through embossing, allowing for a material bond between workpieces with significant thickness differences, and optionally using a surface coating to enhance joining and corrosion resistance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal joining methods are used to connect workpieces with large thickness differences, then material bond is achieved, but joining reliability deteriorates due to thermal issues and unfavorable material pairings
Solution Approach 1:
The patent applies local quality by creating a localized thickness reduction (indentation) at the joining section of the first workpiece. This indentation is formed only in the specific joining area, allowing the thickness to be reduced locally while maintaining the original thickness elsewhere. This enables reliable thermal joining at the localized area without requiring complex global modifications to the workpiece geometry.
Solution Approach 2:
The patent implements preliminary action by forming the indentation in the first workpiece before the actual thermal joining process. This pre-preparation of the joining geometry allows the thermal joining to proceed more reliably, as the indentation is already in place to facilitate proper contact and heat distribution between the workpieces with different thicknesses.
2Ease of manufacture
If workpieces with large thickness differences are joined directly without thickness reduction, then manufacturing process is simple, but joining reliability deteriorates
Solution Approach 1:
Instead of reducing the thickness of the entire first workpiece, the patent applies local quality by creating an indentation only in the joining section. This localized modification maintains manufacturing simplicity while achieving the necessary thickness reduction only where required for reliable joining, avoiding the need to process the entire workpiece.
Solution Approach 2:
The indentation is formed as a preliminary action before joining, preparing the joining geometry in advance. This approach maintains ease of manufacture by using a simple forming process rather than complex machining, while ensuring reliable joining conditions are established before the thermal joining process begins.
3Reliability
If the first workpiece is reduced in thickness at the joining section through embossing, then joining reliability of workpieces with thickness differences is improved, but manufacturing complexity increases
Solution Approach 1:
The patent applies local quality by forming an indentation only in the joining section of the first workpiece, rather than modifying the entire workpiece. This localized approach improves joining reliability where needed while minimizing the overall complexity of the manufacturing process, as only a specific area requires the embossing operation.
Solution Approach 2:
The indentation is created as a preliminary action using embossing or similar forming processes, which are relatively simple operations compared to alternative methods like machining or removal. This preliminary preparation simplifies the overall process by establishing the correct joining geometry before the thermal joining takes place.
4Strength
If conventional joining methods are used for unfavorable material pairings, then joining is attempted, but corrosion resistance deteriorates due to uncontrolled material transition
Solution Approach 1:
The patent applies local quality by creating a controlled material transition zone through the indentation at the joining section. This localized geometric modification influences the material flow and mixing during thermal joining, creating a more controlled transition between different materials (e.g., aluminum and steel). The controlled transition reduces the formation of corrosive galvanic cells by limiting the extent and distribution of the mixed material zone.
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 reliable joining of workpieces with large thickness variations, improves joining of difficult material pairings like aluminum and steel, and reduces corrosion tendencies by controlling the material transition at the joint, while simplifying the process and reducing additional manufacturing steps.
Implementation Method 1
the material of the joining partners to be joined is heated to above the liquidus temperature
Implementation Method 2
The molten phases of both workpieces mix and solidify after cooling to form a material bond
Implementation Method 3
the first workpiece is provided with an indentation adjoining the end face, at least in the joining section, whereby the thickness of the first workpiece is reduced in the area of the end face
Implementation Method 4
optionally using a surface coating to enhance joining and corrosion resistance
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
The invention relates to a workpiece composite (1) and a method for producing a workpiece composite (1) comprising at least two workpieces (2, 3). A first workpiece (2) and a second workpiece (3) are positioned relative to each other, and a bonded connection (5) between the end face (6) of the first workpiece (2) and the second workpiece (3) is formed in a joint section (4) by means of a thermal joining method. Prior to forming the bonded connection (5), the first workpiece (2) is provided with an embossing (7), which adjoins the end face (6), at least in the joint section (4), whereby the thickness of the first workpiece (2) is reduced in the region of the end face (6).