Friction Stir Welding Tool with Transporting Screw for Extended Service Life
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Solution Overview
Problem
Friction stir welding tools have a limited service life and require subsequent finishing, which increases operational costs and stress on the equipment, while existing quality control methods are not optimized for real-time monitoring.
Innovation Solution
A friction stir welding tool with a spiral transporting screw, inclined spindle bearing, and a truncated cone friction welding tip, integrated sensors for force measurement, and adjustable pressing pressure, allowing for improved material removal and real-time process control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of moving object
If conventional friction stir welding tools are used, then the welding process can be performed, but the tool service life is limited to about 2 hours and requires subsequent finishing
Solution Approach 1:
The tool stirring stud is segmented into multiple functional zones including a transporting screw with spiral groove, a shoulder, and a pin. The transporting screw segment specifically removes excess material during welding, preventing tool clogging and extending service life from 2 to 15 hours while eliminating post-finishing requirements
Solution Approach 2:
The transporting screw with spiral groove performs preliminary material removal action during the welding process itself. By continuously transporting excess material away from the welding zone, the tool prevents buildup that would otherwise require post-welding finishing operations
2Manufacturing precision
If conventional friction stir welding tools are used, then the welding process can be performed, but the quality of the weld seam requires subsequent finishing
Solution Approach 1:
Sensors are integrated into the tool main body to provide real-time feedback on welding parameters such as forces of acceleration, oscillations, and material removal rates. This feedback enables continuous adjustment of welding parameters to maintain optimal weld seam quality throughout the extended tool service life
Solution Approach 2:
The transporting screw segment with spiral groove continuously removes excess material during welding, ensuring consistent weld seam geometry and quality throughout the 15-hour service life without requiring intermediate finishing operations
3Productivity
If the tool operates for extended periods, then productivity increases, but the stress on the friction stir welding installation increases
Solution Approach 1:
The tool incorporates adjustable pressing pressure and oscillation capabilities that can be dynamically modified during the extended welding process. This dynamic adjustment prevents excessive stress accumulation on the installation while maintaining high productivity over the 15-hour service life
Solution Approach 2:
Real-time monitoring of forces of acceleration and oscillations provides feedback on installation stress levels, enabling automatic adjustment of welding parameters to maintain optimal stress levels throughout extended operation
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 tool's service life is extended from 2 hours to 15 hours, and the quality of the weld seam is enhanced, eliminating the need for finishing and enabling real-time quality monitoring and control.
Implementation Method 1
a transporting screw (6), which is machined in a spiral form in the spindle bearing (4), serves for transporting away applied material that is not required
Implementation Method 2
frictional heat is generated in the joining region of the materials to be connected by means of the friction between a rotating tool which at the same time is moved translationally and applied with pressure
Implementation Method 3
at least one sensor for recording the forces of acceleration acting on the tool main body is integrated in the tool main body
Data Source
AI summary
A method and a device for improving the quality of the weld seam in friction stir welding is provided. The process of friction stir welding is effected by means of a friction welding tip, in which a spiral conveyor screw is provided in the spindle bearing. The longitudinal axis of the spindle bearing is inclined at an angle to the vertical. The sliding surface of the rotating spindle consists of a flat sliding surface and, for the welding of curved seams, in each case of a sliding surface inclined at an acute angle to the sliding surface, the friction welding tip is designed in the shape of a truncated cone. The lateral surface of the truncated cone is formed by six trapezoidal planar parts, of which three planar parts each uniformly distributed at the circumference lie at an angle of 120 degrees with respect to one another and account for a proportion greater than ⅙ at the circumference.