Extruded Weld Backing Insert for Full-Penetration Butt Joints
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Solution Overview
Problem
Gas metal arc welding of open root butt joints in automotive battery case assemblies often results in insufficient penetration and burn-through, leading to leakage and excessive rework due to design constraints and the use of extruded profiles.
Innovation Solution
An extruded weld joint backing insert provides internal backing for all sides of the structural aluminum extrusions in the butt joint configuration, manufactured from the same alloy, with deflectable retention legs and an optional gap-control joint spacer to ensure full penetration welds without burn-through.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If gas metal arc welding is performed on open root butt joints of extruded profiles, then the welding process can be completed, but insufficient penetration and burn-through occur resulting in poor weld robustness
Solution Approach 1:
A backing insert is introduced as an intermediary component between the welding torch and the extruded profile. This insert provides internal support during welding, preventing burn-through while maintaining adequate penetration. The insert acts as a mediator that modifies the welding environment to achieve both penetration quality and joint robustness simultaneously.
Solution Approach 2:
The backing insert is installed in the hollow profile before the welding operation begins. This preliminary action prepares the joint by providing internal support structure that will prevent burn-through during the subsequent welding process, ensuring both penetration quality and weld robustness are achieved from the outset.
2Reliability
If backing is provided for butt joint welding of hollow profile extrusions, then penetration and burn-through problems are solved, but the device complexity increases
Solution Approach 1:
The backing insert is manufactured from the same alloy material as the extruded profile components. This homogeneity in material composition simplifies the overall assembly by eliminating material incompatibility issues and allowing the insert to be treated as an integral part of the profile system, thereby reducing perceived complexity despite the added component.
Solution Approach 2:
The retention legs of the backing insert are designed to be deflectable, allowing the insert to be inserted easily and then spring into its final retained position. This dynamic characteristic simplifies the installation process and reduces the complexity of retention mechanisms, as the elastic deformation of the legs provides automatic retention without additional fastening components.
3Reliability
If retention members are added to secure the backing insert, then the insert is retained firmly, but the device complexity increases
Solution Approach 1:
The retention legs are designed to secure the backing insert through their own elastic deformation. When inserted, the legs deflect and then spring back to exert retaining force on the profile walls. This self-service mechanism eliminates the need for separate retention devices, fasteners, or additional retention mechanisms, thereby achieving firm retention while minimizing device complexity.
Solution Approach 2:
The retention legs utilize flexible, thin-walled construction that allows them to deflect during insertion and then spring into position to provide retention. This flexibility enables the retention function to be achieved through the inherent elastic properties of the legs themselves, rather than requiring rigid, complex retention mechanisms with multiple components.
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
The solution effectively prevents burn-through and ensures complete penetration welds, enhancing the robustness of the weld joint and reducing rework by providing internal backing and secure retention within the hollow profile extrusions.
Implementation Method 1
The retention member includes at least one leg that is deflectable to enable insertion into a hollow profile structural extrusion. Once the insert is inside the hollow profile structural extrusion, at least one leg attempts to return to its original position exerting a force onto the inside of the hollow profile structural extrusion to retain the backing insert onto the extrusion profile.
Data Source
AI summary
A welding backing insert (20) includes a body (22), a retention member (24) and an insertion member (26). The retention member (24) includes at least one leg (28) being deflectable to enable insertion into a hollow profile structural extrusions (14). At least one leg (28) tries to return to its original position exerting a force on the hollow profile structural extrusion (14) to retain the backing insert (20) in the hollow profile structural extrusion (14). The insertion member (26) projects from the body for inserting into a second hollow profile structural extrusion (14). A gap-control joint spacer (50) projects from the body to provide a gap between adjacent hollow profile structural extrusions.