Friction Stir Void Filling With Insert and Anvil Support
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Solution Overview
Problem
Self-reacting friction stir welding processes result in termination voids or holes in metal workpieces, which are conventionally sealed using methods like friction plug welding or bolt and nut systems, but these methods can leak, require significant capital investment, and are not effective for all aluminum alloys or workpieces greater than ½″ thick.
Innovation Solution
A welding system comprising a metal insert, a welder configured for friction stir welding, and an anvil with an expandable member, which positions the anvil for a press fit with the workpiece, allowing the welder to rotate and extend a pin to weld the insert to the workpiece, sealing the void.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional filling methods (friction plug welding, manual fusion welding, bolt and nut) are used to seal the void, then the void can be sealed, but the methods may leak, require large capital investment, and are not effective on certain aluminum alloys or workpieces greater than 1/2" thick
Solution Approach 1:
The patent replaces conventional mechanical filling methods (friction plug welding, manual fusion welding, bolt and nut systems) with friction stir welding technology. This substitution provides a more reliable sealing mechanism that simultaneously improves adaptability to different aluminum alloys and thicknesses, eliminating the trade-off between sealing effectiveness and material compatibility.
Solution Approach 2:
The patent changes the welding parameters and process characteristics by using friction stir welding instead of conventional methods. This parameter change enables effective sealing across a broader range of aluminum alloys and thicknesses, particularly workpieces greater than 1/2" thick, while maintaining sealing reliability through the controlled plastic deformation and mixing characteristics of the friction stir process.
2Reliability
If friction plug welding or manual fusion welding is used to fill the void, then the void can be sealed, but large capital investment in additional welding systems is required
Solution Approach 1:
The patent makes the existing friction stir welding system multi-functional by enabling it to perform both the primary welding operation and the void filling operation. The same FSW tool and process parameters can be used for both sealing the void and welding the workpiece, eliminating the need for separate welding systems and reducing capital investment while maintaining reliable sealing.
Solution Approach 2:
The patent merges the void filling operation with the primary welding process by using the friction stir welding tool to perform both functions. Instead of using separate friction plug welding or manual fusion welding systems, the FSW process itself is used to fill and seal the void, combining multiple operations into a single integrated process that reduces equipment requirements and capital investment.
3Reliability
If conventional filling methods are used, then the void can be sealed, but the methods are not effective on workpieces greater than 1/2" thick
Solution Approach 1:
The patent changes the welding process parameters by using friction stir welding, which generates sufficient heat and plastic deformation to effectively seal voids in thicker workpieces. The controlled parameters of the FSW process, including rotation speed, travel speed, and tool geometry, enable reliable sealing of voids in workpieces greater than 1/2" thick, overcoming the thickness limitation of conventional methods.
Solution Approach 2:
The patent employs a spherical or rounded tool profile in the friction stir welding process, which allows the tool to effectively engage and seal voids in thicker material. The curved geometry of the FSW tool enables it to maintain contact and apply sufficient pressure and heat to seal voids in workpieces greater than 1/2" thick, where linear or angular tools would be ineffective.
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 system effectively seals the void in metal workpieces by welding a metal insert in place, preventing leaks and enhancing the structural integrity of the workpiece, while being compatible with various aluminum alloys and thicker workpieces.
Implementation Method 1
a welder configured to perform a friction stir welding process on the metal workpiece and the metal insert
Implementation Method 2
an anvil capable of being positioned adjacent the second surface and opposite the welder, the anvil configured to couple to the workpiece by at least one of a clamp and a fastener
Data Source
AI summary
A welding system and method for filing a void on a metal workpiece is provided. The workpiece includes a first surface and an opposite second surface. The system and method may include a metal insert configured to fill the void and a welder configured to perform a friction stir welding process on the metal workpiece. The metal insert may be capable of being positioned adjacent the first surface. The system and method may also include an anvil capable of being positioned in an interior space of the workpiece, adjacent to the second surface, and opposite the welder.