Friction Stir Bonding for Seamless Pipe Manufacturing
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Solution Overview
Problem
Direct extrusion methods for manufacturing metal pipes result in seam lines that are mechanically weak and prone to damage under pressure, while indirect extrusion methods are limited by batch processing and spatial constraints, leading to inefficiencies and increased costs.
Innovation Solution
A friction stir bonding apparatus that eliminates seam lines by bonding metal pieces after they have passed through extrusion holes, using rotation members and a driving unit to transmit rotational force for continuous seamless pipe production, reducing the size and energy requirements of the manufacturing apparatus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If direct extrusion method is used to manufacture metal pipe, then productivity is improved and continuous production is achieved, but seam lines are generated which reduce mechanical strength and reliability
Solution Approach 1:
The invention extracts and removes the harmful seam lines generated during direct extrusion through a dedicated seam line removal unit. This unit mechanically removes the seam lines from the extruded metal pipe surface, eliminating the weak bonding portions while preserving the continuous production capability of the direct extrusion method.
Solution Approach 2:
The invention converts the harmful effect of seam lines into a beneficial process by using the presence of seam lines as an indicator for where removal treatment is needed. The seam line removal unit specifically targets these generated seam lines, transforming the defect into a controlled removal process that enhances overall pipe reliability.
2Reliability
If indirect extrusion method is used to avoid seam lines, then reliability is improved by eliminating bonding traces, but productivity deteriorates due to batch processing limitations
Solution Approach 1:
The invention maintains continuous production by keeping the extrusion process running continuously while adding a seam line removal unit that operates concurrently. This eliminates the need to stop for batch processing and bonding operations, allowing uninterrupted metal pipe production while still removing seam lines to ensure reliability.
Solution Approach 2:
The invention segments the seam line removal function from the main extrusion process by using a separate removal unit with rotating bodies that independently remove seam lines. This segmentation allows the extrusion and seam line removal to occur simultaneously without interfering with each other, maintaining continuous production.
3Ease of operation
If multiple driving sources are installed in narrow space for extrusion molding, then ease of operation is improved, but device complexity increases and energy waste occurs
Solution Approach 1:
The invention merges multiple driving sources into a single integrated driving unit that controls both the extrusion process and the seam line removal operation. This single driving source powers the rotating bodies for seam line removal while coordinating with the extrusion molding, reducing the total number of driving sources and simplifying the overall system.
Solution Approach 2:
The invention creates a multi-functional driving unit that performs both extrusion control and seam line removal functions. This universal driving source replaces multiple specialized motors, reducing device complexity while maintaining full operational capability for both extrusion and seam line removal tasks.
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 enables the continuous production of seamless pipes with enhanced mechanical strength, reduced installation space, and lower energy waste, thereby improving manufacturing efficiency and cost-effectiveness.
Implementation Method 1
bonding the metal pieces by rotating the rotation members, which directly contact a region where the plurality of metal pieces contact each other
Implementation Method 2
a driving unit that transmits a rotation driving force to the rotation members
Data Source
Figure 1~2(b)
Figure 3~4
Figure 5~6
AI summary
Provided is an apparatus of manufacturing a seamless pipe. The apparatus includes a container receiving a work therein, a stem pressing one end of the work within the container, a die installed in a direction opposite to the stem, and having an extrusion hole comprised of a plurality of ports, a rotation member installed on a front end of the die, having a stirring tip inserted into a joint surface formed by abutting a plurality of metal pieces to each other on one surface, and rotating to perform a friction stir bonding in a state in which the one surface contacts the joint surface, and a correction mold including a metal pipe discharging path receiving a metal pipe manufactured by the friction stir bonding and discharging the metal pipe to an outside.