Friction Stir Welding Device for Variable Thickness and Fillet Joints
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current friction stir welding methods lack suitable measures for processing materials of different thicknesses and fillet welds, particularly in non-linear connections or angled arrangements.
Innovation Solution
A device and method for friction stir welding that includes a mounting plate guided by a robot arm, a drive head with a retaining cone for a welding shoe and pin bearing, allowing for adjustable contact pressure and precise movement of the welding pin, enabling effective processing of materials with varying thicknesses and fillet welds.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional friction stir welding methods are used, then welding of standard configurations is achieved, but welding of materials with different thicknesses and fillet welds is not possible
Solution Approach 1:
The welding pin is designed with independent axial displacement capability relative to the shoulder surface, allowing dynamic adjustment of pin penetration depth. This enables the same device to handle varying material thicknesses and fillet weld configurations without structural modification, resolving the contradiction between versatility and complexity
Solution Approach 2:
The welding tool is divided into functionally independent components: the shoulder surface for friction heat generation and the welding pin for material stirring and transport. The pin can move independently in the z-direction, allowing it to adapt to different welding geometries (different thicknesses and fillet welds) while the shoulder maintains stable contact, thus achieving versatility without proportionally increasing overall device complexity
2Manufacturing precision
If friction stir welding is applied to materials of different thicknesses and fillet welds, then welding quality improves, but tool service life decreases
Solution Approach 1:
The independently displaceable welding pin allows optimization of the pin-shoulder interaction during welding of complex configurations. By dynamically adjusting pin penetration, the tool distributes mechanical stresses more evenly, reducing premature wear and extending service life while maintaining high welding quality
Solution Approach 2:
The device enables independent control of pin penetration depth and welding parameters. This parameter flexibility allows optimization of the welding process for different configurations (different thicknesses and fillet welds), achieving high manufacturing precision while reducing excessive mechanical loads that would otherwise shorten tool life
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 high-quality welding of materials with different thicknesses and fillet welds, reducing the need for post-processing and increasing the service life of the friction stir tool, while allowing for real-time monitoring and adjustment of welding parameters.
Implementation Method 1
frictional heat is generated in the joining area of the materials to be joined by means of the friction between a rotating tool that is simultaneously moved in translation and applied with pressure
Implementation Method 2
The applied pressure compresses the plasticized material
Data Source
Figure 1
Figure 2a~2d
Figure 3a~3d
AI summary
The invention relates to a device and a method for friction stir welding materials of different thicknesses and that have fillet welds, comprising the following features: a) a receiver panel (1) that has a drive head (2) and a welding shoe (4) that has a pin bearing, said welding shoe (4) being selected and inserted according to whether it is being used with materials of different thicknesses or with materials that have fillet welds, b) the longitudinal axis of the spindle bearing being at an incline of an angle between 0 and 5 degrees relative to the vertical line; the transverse incline being 0 degrees for the fillet weld shoe (4), and c) when the welding pin (6) is exchanged, the length of the welding pin (6) being adjusted using an adjustment element (12) and the position of the counter-bearing of the welding pin (6) being adjusted using an adjustable pin stop (19) and, in the case of the pin stop (19), additionally secured by an adjustment screw (20).