Friction Stir Welding Hollow Profile Node Part
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Solution Overview
Problem
The existing methods for connecting hollow metallic profiles, such as those used in motor vehicle construction, face challenges with heat distortion and welding spatter during conventional welding, and friction stir welding has limitations when applied to hollow profiles.
Innovation Solution
A node part with profiled end pieces featuring webs and ribs is used to connect hollow profiles via friction stir welding, allowing for punctiform, continuous, or linear connections that absorb pressure and can include external gusset plates connected through friction stir welds along the ribs and webs, ensuring stable and accurate assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If conventional welding is used to connect hollow profiles with gusset plates, then the connection strength is improved, but heat distortion occurs and dimensional accuracy deteriorates
Solution Approach 1:
The patent replaces thermal welding processes with mechanical friction stir welding. The friction stir welding tool applies mechanical friction and pressure to create a solid-state metallurgical bond between the aluminum profile and gusset plate, eliminating the high heat input that causes distortion while maintaining strong connections.
Solution Approach 2:
The invention changes the fundamental welding parameters from high-temperature thermal processes to low-temperature mechanical processes. By controlling friction pressure, rotational speed, and linear feed rate, the process achieves reliable welding without the heat-affected zone and distortion associated with conventional welding.
2Strength
If conventional welding is used to connect hollow profiles, then the connection strength is improved, but welding spatter is generated and surface quality deteriorates
Solution Approach 1:
The patent replaces thermal welding processes with mechanical friction stir welding. The friction stir welding tool applies mechanical friction and pressure to create a solid-state metallurgical bond between the aluminum profile and gusset plate, eliminating the high heat input that causes distortion while maintaining strong connections.
3Manufacturing precision
If friction stir welding is used to join aluminum sheets, then heat input is reduced and distortion is minimized, but application to hollow profiles is not possible
Solution Approach 1:
The invention segments the hollow profile into components that can be separately welded. The gusset plate is welded to the external surface of the hollow profile, while the internal geometry of the hollow profile is preserved and accommodated during the friction stir welding process.
Solution Approach 2:
The patent introduces a friction stir welding tool as an intermediary that can access and weld the hollow profile structure. The tool design allows it to apply friction and pressure to create solid-state bonds within the hollow profile configuration, bridging the gap between sheet metal welding capabilities and hollow profile application requirements.
4Manufacturing precision
If holes are made in sheets for plug welding to create flat connections, then dimensional accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces thermal welding processes with mechanical friction stir welding. The friction stir welding tool applies mechanical friction and pressure to create a solid-state metallurgical bond between the aluminum profile and gusset plate, eliminating the high heat input that causes distortion while maintaining strong connections.
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 minimizes heat input and distortion, allows for precise connections, and eliminates welding spatter by using friction stir welding within the hollow profiles and external gusset plates, enhancing the dimensional accuracy and stability of the connections.
Implementation Method 1
the friction stir welding tool is placed on the upper side of one sheet with pressure and moved along a connecting line provided
Implementation Method 2
By means of friction stir welding, the indirect friction stir welding, aluminum sheets can be joined together with low heat input
Data Source
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AI summary
A hollow profile connection for connecting at least two hollow profiles is described, consisting of a node part (KT) whose end pieces can be inserted into the hollow profiles (H1, H2, H3), wherein at least the end pieces of the node part (KT) assigned to the ends of the hollow profiles (H1, H2, H3) have a profile formed by webs, ribs (R), wherein the node part (KT) and the hollow profile (H1, H2, H3) are connected to each other by friction stir welding, and wherein the connections (V) produced by friction stir welding between the hollow profile (H1, H2, H3) and the node part (KT) run along the ribs, webs (R) of the node part (KT).