Fastening Loop Stud Welding for Low-Strain Armor Plate Joining

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Solution Overview

Problem

Conventional gas tungsten arc welding methods for joining loops to armor plates in wheeled armored vehicles result in excessive welding volume and deterioration of mechanical strength and protective performance due to thermal strain.

Innovation Solution

A stud welding method is employed using a dedicated fastening loop chuck and specific welding conditions to weld a fastening loop to an armor plate, forming a single welded area with reduced thermal strain and increased mechanical strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If gas tungsten arc welding (GTAW) is used to join the loop to the armor plate, then the loop can be joined to the armor plate, but excessive welding volume is generated and mechanical strength deteriorates due to thermal strain

Engineering Contradiction:

Improvemechanical strengthVSAvoidwelding volume

Core Design Contradiction:

StrengthVSVolume of stationary object

Solution Approach 1:

The patent changes the welding method from GTAW to stud welding, fundamentally altering the welding parameters and process. Stud welding uses controlled electrical current (e.g., 550 A at 0.035 sec) to create a localized weld with minimal heat input, reducing welding volume by approximately 70% compared to GTAW while maintaining or improving joint strength.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the thermal-based GTAW process with an electrical-based stud welding process. This substitution uses electrical energy to generate localized heat through resistance heating at the stud tip, followed by impact and forging action, thereby reducing overall thermal input and welding volume while achieving strong joints.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If gas tungsten arc welding (GTAW) is used to join the loop to the armor plate, then the loop can be joined to the armor plate, but protective performance deteriorates due to thermal strain

Engineering Contradiction:

Improveprotective performanceVSAvoidthermal strain

Core Design Contradiction:

ReliabilityVSTemperature

Solution Approach 1:

The patent changes the welding process parameters by switching from GTAW to stud welding with controlled electrical current. The short duration (0.035 sec) and localized heating minimize thermal strain in the heat-affected zone, preserving the armor plate's protective performance and mechanical properties.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces the continuous thermal process of GTAW with a rapid electrical resistance welding process. This substitution limits heat exposure time and spatial distribution, reducing thermal strain accumulation and protecting the armor plate's microstructure from degradation.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If conventional GTAW welding method is used, then the loop can be joined to the armor plate, but productivity is reduced due to excessive welding volume and thermal strain

Engineering Contradiction:

ImproveproductivityVSAvoidmechanical strength

Core Design Contradiction:

ProductivityVSStrength

Solution Approach 1:

The patent optimizes welding parameters by using stud welding with controlled current (550 A) and time (0.035 sec). This produces consistent, high-strength joints with minimal rework, improving both productivity and mechanical strength compared to GTAW which requires longer welding times and produces excessive material.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent replaces GTAW with stud welding, which offers faster cycle times and automated potential. The process eliminates the need for filler material manipulation and extends torch life, thereby increasing production speed while maintaining superior joint strength through controlled electrical energy input.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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 stud welding method enhances mechanical strength and productivity while reducing thermal strain, with improved tensile load, bending resistance, and increased protection power compared to conventional methods.

Implementation Method 1

setting a welding condition for the stud gun; and welding the fastening loop to a welding target

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

welding the fastening loop to a welding target

Methodology Applied

Scientific EffectElectric arc: Electric Arc

Data Source

PatentUS20260061510A1Stud Welding Method for Fastening Loop for Wheeled Armored Vehicles

Publication Date: 2026.03.05 DEFENSE AGENCY FOR TECH & QUALITY

AI summary

The present disclosure relates to a fastening loop welding method according to the present disclosure, which is a stud welding method for a fastening loop, including mounting a fastening loop chuck on a stud gun; inserting the fastening loop into the fastening loop chuck; setting a welding condition for the stud gun; and welding the fastening loop to a welding target.