Extrusion Piece With Dissimilar Material Insert For Welding
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Solution Overview
Problem
Welding dissimilar materials like aluminum and steel is not always feasible, leading to the use of rivets with protruding heads, which can interfere with subsequent components or surfaces.
Innovation Solution
An extruded aluminum piece with a mouth portion and an embedded steel insert, where the jaws are clinched to securely attach the insert, allowing for welding to a steel component without protrusions, using adhesive in the channel for enhanced attachment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If riveting is used to join aluminum and steel pieces, then the joining of dissimilar materials is achieved, but the rivet head protrudes above the flange surface interfering with subsequent components
Solution Approach 1:
The steel insert is nested within the aluminum extrusion piece, with the insert being received by a mouth portion of the extrusion. The jaws of the mouth portion close to grip the insert, creating a nested configuration where the dissimilar materials are joined without protruding elements on the external surface.
Solution Approach 2:
The aluminum extrusion piece acts as an intermediary component between the steel insert and the steel component to be joined. The extrusion contains the steel insert within its structure, and this composite assembly then welds to the steel component, mediating the connection between dissimilar materials while maintaining a flush surface.
2Shape
If welding is used to join aluminum and steel pieces, then a flush surface is achieved, but welding dissimilar materials is not always feasible
Solution Approach 1:
The invention applies local quality by using different joining methods for different material interfaces. The steel insert is mechanically secured within the aluminum extrusion via the gripping jaws, while the aluminum extrusion itself is welded to the steel component. This allows each material interface to be joined by the most appropriate method for that specific combination.
Solution Approach 2:
The invention creates a composite structure consisting of an aluminum extrusion piece containing a steel insert. This composite component combines the advantages of both materials and joining methods, allowing mechanical attachment of the insert within the extrusion while enabling welding of the extrusion to external steel components.
3Reliability
If self-piercing rivets are used to join aluminum and steel, then the joining of dissimilar materials is achieved, but the rivet head must be positioned on top of or above the fastened area
Solution Approach 1:
The steel insert is nested within the aluminum extrusion piece, with the insert being received by a mouth portion of the extrusion. The jaws of the mouth portion close to grip the insert, creating a nested configuration where the dissimilar materials are joined without protruding elements on the external surface.
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 a fast and reliable attachment of dissimilar materials without protruding rivets, facilitating welding between aluminum and steel components, ensuring a flush surface for further assembly.
Implementation Method 1
The jaws are roller clinched from the open position into the closed position
Implementation Method 2
adhesive is placed in the channel before the insert is attached
Implementation Method 3
welding the insert to a component of a second material, wherein the extruded piece is attached to the component
Data Source
AI summary
A profile piece includes: an extruded piece of a first material having a mouth portion along at least part of its length; and an insert of a second material different than the first material, the insert attached to the extruded piece by the mouth portion, wherein the insert is configured for welding the profile piece to a component of a third material different than the first material.