Friction Stir Welding With Cryogenic Flash Deburring

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Friction stir welding (FSW) processes often result in material flash and burrs that require separate deburring, increasing manufacturing cycle time and costs due to the need for cooling and additional deburring steps.

Innovation Solution

A system integrating a friction stir welding tool with a deburring tool and cryogenic cooling nozzles that simultaneously welds two parts and removes material flash by directing a cryogenic fluid to the welding area, utilizing a floating double collar configuration and replaceable cutting inserts to engage and remove flash during the welding process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If a separate deburring process is used after FSW, then material flash is removed, but manufacturing cycle time increases

Engineering Contradiction:

Improvematerial flash removalVSAvoidmanufacturing cycle time

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent combines the FSW tool and deburring tool into a single integrated tool assembly, allowing both welding and deburring operations to be performed simultaneously in one pass, thereby eliminating the separate deburring process and reducing manufacturing cycle time

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The deburring tool is positioned and configured to remove material flash during the FSW process itself, performing the deburring action preliminarily before the workpiece fully cools, rather than waiting for a separate post-processing step

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If the workpiece cools to ambient temperature before deburring, then material is easier to machine, but manufacturing cycle time increases

Engineering Contradiction:

Improvematerial machinabilityVSAvoidmanufacturing cycle time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent introduces cryogenic cooling to dramatically lower the workpiece temperature during the FSW process, changing the thermal parameter to enable deburring of materials that would otherwise be too hot to machine, while maintaining simultaneous operation to avoid cycle time extension

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The deburring tool operates continuously during the FSW process without interruption, maintaining useful action throughout the welding operation rather than pausing for cooling periods, thereby eliminating idle time while managing thermal conditions through cryogenic cooling

Inventive Principle:

Principle #20Continuity of useful action

3Strength

If FSW is used on high melting temperature materials, then welding capability is improved, but material flash generation increases

Engineering Contradiction:

Improvewelding capabilityVSAvoidmaterial flash

Core Design Contradiction:

StrengthVSObject-generated harmful factors

Solution Approach 1:

The patent converts the harmful material flash generated during FSW of high-strength materials into a beneficial outcome by using the integrated deburring tool to immediately remove it, and using cryogenic cooling to control the thermal effects that cause flash while enabling the welding of high-melting-point materials

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

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

This integrated system reduces manufacturing cycle time and costs by simultaneously welding and deburring, enhancing efficiency through the use of cryogenic cooling and adaptive deburring mechanisms, ensuring precise removal of material flash without the need for separate cooling and deburring steps.

Implementation Method 1

one or more nozzles disposed in a fixed position relative to the FSW tool, with the nozzles directing a cryogenic fluid to at least one of the FSW tool, the deburring tool, the first work piece, the second work piece, and the weld

Methodology Applied

Scientific EffectHeat transfer: Conduction (thermal)

Implementation Method 2

the interaction between the pin, the shoulder, and the work pieces generates frictional heat, which in turn plasticizes the material on either side of the joint

Methodology Applied

Scientific EffectFrictional heat: Friction

Data Source

PatentUS11660700B2Welding and deburring system with cryogenic cooling

Publication Date: 2023.05.30 LINAMAR STRUCTURES USA ALABAMA INC

AI summary

A welding and deburring system is provided for joining first and second work pieces to one another. The system includes a friction stir welding tool for joining the first and second work pieces to one another at a weld. The system further includes a deburring tool attached to the friction stir welding tool and removing a material flash generated at the weld. The system further includes one or more nozzles disposed in a fixed position relative to the friction stir welding tool, with the nozzles directing a cryogenic fluid to at least one of the friction stir welding tool, the deburring tool, the first work piece, the second work piece, and the weld.