Friction Stir Welding Tool With Faster Pin Rotation for High-Speed Welds
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional friction stir welding methods are limited by low welding speeds due to the occurrence of welding defects at higher advancement speeds, which restricts the reduction of cycle times.
Innovation Solution
A method using a friction stir welding tool with a pin rotating at a higher speed than the shoulder, where the rotational speed of the pin is at least 1.15 times the rotational speed of the shoulder, and the advancement speed is increased to 1.0 m/min or higher, thereby maintaining process temperatures and preventing overheating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the advancement speed is increased to reduce cycle times, then welding efficiency is improved, but welding defects occur due to insufficient heat generation
Solution Approach 1:
The system transitions from a fixed rotational speed for the entire tool to a dynamic configuration where the pin and shoulder can rotate at different speeds. This dynamic adjustment allows the pin to generate sufficient heat even at high advancement speeds, maintaining weld quality while improving productivity.
Solution Approach 2:
The rotational speed parameter is differentiated between the pin and shoulder. By increasing the pin's rotational speed relative to the shoulder, the heat generation rate is increased locally at the pin, enabling high advancement speeds without compromising weld quality.
2Temperature
If the forging pressure is reduced to avoid tool dipping, then the shoulder overheating is prevented, but the welding quality may be compromised
Solution Approach 1:
By segmenting the tool into independently rotatable pin and shoulder, the system can maintain adequate forging pressure without causing tool dipping. The slower shoulder rotation prevents excessive heat generation and tool penetration, while the faster pin rotation ensures adequate heat for material plasticization and weld quality.
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 approach allows for high-quality welds at higher advancement speeds without defects, enabling reduced cycle times and increased welding efficiency.
Implementation Method 1
a friction stir welding tool having a pin (2) and a shoulder (3)... rotates about an axis of rotation... to connect the components... lower heat generation in the region of the pin due to a smaller circumference of the pin and a smaller frontal area compared to the shoulder area is compensated by a higher circumferential speed of the pin
Data Source
AI summary
A method for connecting components using friction stir welding and a device for carrying out the stir friction welding method. A friction stir welding tool having a pin and a shoulder rotates about an axis of rotation and is moved along an advancement direction to connect the components. To obtain a high-quality weld with a simultaneously high welding speed, a friction stir welding tool having a shoulder movable relative to the pin is used and a rotational speed of the pin about the axis of rotation corresponds to at least 1.15 times, preferably at least 1.5 times, in particular 2 to 12 times, the rotational speed of the shoulder about the axis of rotation. The advancement speed is at least 1.0 m/min, preferably 2.0 m/min to 15 m/min.