Cooled Friction Stir Welding Shoulder to Prevent Adhesion
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Solution Overview
Problem
Friction stir welding devices face the issue of adhesion between the welding device and the workpieces due to heat generation during the welding process, which can compromise the energy efficiency and integrity of the welded structure.
Innovation Solution
The implementation of a friction stir welding device featuring a probe that rotates to press the welding target, a shoulder with a cooling medium flow path to prevent overheating, and a support table that acts as an electrode to manage heat, thereby inhibiting adhesion by using a cooling medium to flow through the flow path formed between the shoulder and its attachment member.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir welding is performed to join workpieces, then welding strength and structural integrity are improved, but heat is generated causing adhesion between the device and workpieces
Solution Approach 1:
A cooling medium flow path is introduced as an intermediary system between the shoulder and the external environment. This flow path allows cooling medium to circulate through the shoulder, acting as a thermal mediator that transfers heat away from the welding interface, thereby preventing adhesion while maintaining welding strength.
Solution Approach 2:
The temperature parameter at the shoulder-workpiece interface is actively controlled by introducing a cooling medium through the flow path. By changing the thermal state of the shoulder through internal cooling, the system maintains optimal temperature conditions that prevent adhesion while preserving the necessary heat for welding.
2Object-affected harmful factors
If cooling medium flow path is added to the shoulder, then adhesion is prevented, but device complexity increases
Solution Approach 1:
The cooling medium flow path is merged into the shoulder structure itself, rather than being a separate external system. The shoulder integrates both welding and cooling functions, with the flow path formed as part of the shoulder's internal structure, thereby reducing overall device complexity while maintaining adhesion prevention capability.
Solution Approach 2:
The shoulder is designed to perform multiple functions simultaneously: it provides the welding interface for joining workpieces and houses the cooling medium flow path for thermal management. This multi-functionality eliminates the need for separate cooling components, reducing device complexity while preventing adhesion.
3Object-affected harmful factors
If cooling medium flows through the flow path, then adhesion is inhibited, but energy consumption increases
Solution Approach 1:
The cooling medium flow path utilizes the natural flow characteristics of the cooling medium to achieve effective cooling. The system is designed so that the cooling medium can circulate through the shoulder with minimal external energy input, allowing the system to self-regulate temperature and prevent adhesion with reduced energy consumption.
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 solution effectively prevents adhesion during the welding process, enhancing the energy efficiency and structural integrity of the welded components by maintaining the device and workpieces separate, ensuring a reliable and efficient welding operation.
Implementation Method 1
heat is generated in the surroundings of the melt/join pin and the melt/join/smoothing shoe
Implementation Method 2
a flow path formed at a contact part between the shoulder and the shoulder attachment member and adapted to allow a cooling medium to flow therethrough
Implementation Method 3
a probe capable of pressing a welding target part of a workpiece while rotating
Implementation Method 4
in a state in which the workpiece is sandwiched between the shoulder and the support table, the shoulder and the support table may serve as electrodes, and an electric current may be caused to flow between the shoulder and the support table
Data Source
AI summary
A friction stir welding device includes: a probe capable of pressing a welding target part of a workpiece while rotating; a shoulder externally surrounding an outside of the probe, on a plane intersecting a rotation axis of the probe; a shoulder attachment member provided with the shoulder; and a flow path formed at a contact part between the shoulder and the shoulder attachment member and adapted to allow a cooling medium to flow therethrough.