Friction Stir Welding Fixture With Contour-Matched Thermal Load Control
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Solution Overview
Problem
Existing holding fixtures for friction stir welding are costly, complex, and inefficient, often requiring individual manufacturing for each component type, leading to high material and manufacturing costs, and can result in undesirable rework and component damage due to insufficient consideration of thermal and mechanical loads.
Innovation Solution
Manufacturing holding devices using 3D printing and/or casting, adapting them to the outer contours of workpiece parts, and incorporating thermal management systems to absorb and manage loads during friction stir welding, ensuring reliable and precise clamping.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If holding fixtures are manufactured individually for each component type using traditional methods, then the dimensional accuracy and reliability of workpiece clamping is improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The patent applies universality by designing a holding fixture that can accommodate multiple different workpiece types through a standardized interface system. The fixture includes a base body with multiple receptacles that can hold different workpiece types, and a common clamping mechanism that can clamp various workpieces without requiring individual fixtures for each component type. This reduces device complexity while maintaining manufacturing precision through the standardized receptacle and clamping element design.
2Reliability
If holding fixtures are designed to be robust to withstand friction stir welding loads, then the reliability of the joining process is improved, but the material cost and manufacturing effort increase
Solution Approach 1:
The patent applies segmentation by dividing the holding fixture into modular components: a base body, multiple receptacles, and separate clamping elements. The base body provides the robust structure needed to withstand friction stir welding loads, while the receptacles and clamping elements can be independently manufactured and assembled. This modular approach maintains reliability by ensuring each component can be optimized for its specific function, while reducing overall manufacturing effort through standardized production of individual modules.
Solution Approach 2:
The patent applies composite materials by combining different materials in the holding fixture construction. The base body is made of a material suitable for withstanding mechanical loads during friction stir welding, while other components may use different materials optimized for their specific functions. This allows each part to be manufactured with appropriate material properties, improving reliability without requiring the entire fixture to be over-engineered with excessive material.
3Stability of the object's composition
If holding fixtures are made solid and robust, then the stability during friction stir welding is improved, but the space required and manufacturing cost increase
Solution Approach 1:
The patent applies segmentation by creating a modular holding fixture where the base body provides structural stability, and separate receptacles and clamping elements provide workpiece-specific stabilization. This segmented approach allows the fixture to achieve necessary stability without requiring a monolithic solid structure, thereby reducing the overall volume and space required while maintaining clamping stability during friction stir welding.
4Adaptability or versatility
If holding fixtures are customized for each workpiece type, then the adaptability to different component geometries is improved, but the manufacturing cost and production time increase
Solution Approach 1:
The patent applies universality by designing a holding fixture with a standardized base body, receptacles, and clamping elements that can accommodate multiple different workpiece types. The receptacles are designed to hold various workpiece geometries, and the clamping elements can be adjusted or exchanged to adapt to different component shapes. This universal design maintains adaptability to different workpiece geometries while significantly improving production efficiency by eliminating the need to manufacture individual fixtures for each workpiece type.
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
Enables cost-effective, reliable, and precise joining of workpiece parts with improved dimensional accuracy and reduced material usage, minimizing rework and component damage.
Implementation Method 1
The rotation of the tool against the workpiece parts leads to a temperature increase and plastic deformation of the material
Implementation Method 2
The rotation of the tool against the workpiece parts leads to a temperature increase and plastic deformation of the material
Implementation Method 3
Due to the friction and heat-based operating principle of friction stir welding, as well as the loads involved, such holding devices for friction stir welding are subject to high demands
Implementation Method 4
manufacturing the at least one holding device by means of 3D printing
Implementation Method 5
manufacturing the at least one holding device by means of casting or a casting process
Data Source
Figure 1
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Figure 2b
AI summary
The invention relates to a method for producing at least one workpiece (6) consisting of at least two workpiece parts (2, 4), comprising the following steps: providing (108) the at least two workpiece parts (2, 4); providing (110) at least one holding device (24) for clamping the at least two workpiece parts (2, 4); clamping (112) the at least two workpiece parts (2, 4) in the at least one holding device (24); and friction stir welding (114) of the at least two workpiece parts (2, 4) to form the at least one workpiece (6). Holding device for clamping at least two workpiece parts (2, 4) for friction stir welding of the at least two workpiece parts (2, 4) to form at least one workpiece (6). System for friction stir welding of at least two workpiece parts to form at least one workpiece, comprising: at least one holding device (24) according to any one of claims 8 to 13 and at least one device for friction stir welding (10).