Friction Surfacing Consumable Pin Tool for Solid-State Deposition
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Solution Overview
Problem
Friction stir welding techniques often result in reduced weld ductility due to partial melting at grain boundaries in difficult-to-weld metals like aluminum alloys, leading to a brittle heat-affected zone.
Innovation Solution
A friction surfacing method using a consumable pin tool that traverses the workpiece surface, applying frictional and thermo-mechanical forces below the melting point to deposit material, creating a solid-state deposition process without mechanical mixing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If friction stir welding is used to join difficult-to-weld metals, then the materials can be joined, but weld ductility is reduced due to partial melting at grain boundaries
Solution Approach 1:
The invention changes the fundamental parameter of the welding process from melting-based joining to solid-state friction surfacing. By maintaining temperatures below the melting point of the base metal and using a consumable pin tool that deposits material through frictional heating and plasticization, the process avoids grain boundary melting and the associated ductility loss while still achieving strong material joining
Solution Approach 2:
The invention uses a consumable pin tool that is deliberately designed to be consumed during the process. The pin tool material is plasticized and deposited onto the workpiece surface, while the pin itself is consumed and replaced. This disposable approach allows for controlled material deposition without the harmful effects of repeated use on the same tool
2Ease of manufacture
If frictional heating is used to plasticize material, then material can be deposited, but temperatures must be controlled below melting point
Solution Approach 1:
The consumable pin tool acts as an intermediary between the heat source and the workpiece. It absorbs the frictional heating, plasticizes its own material, and transfers this plasticized material to the workpiece surface. This intermediary approach allows for controlled temperature management, as the pin tool material itself serves as the heat transfer medium, naturally limiting temperatures to below its melting point
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 method achieves solid-state deposition with improved microstructure and mechanical properties, reducing residual stresses and distortion, and allowing for tailored local chemistry and metallurgical structure, resulting in deposits with properties equivalent to or better than the base material.
Implementation Method 1
frictional and thermo-mechanical work produced by the process
Implementation Method 2
frictional heating plasticizes a consumable pin tool, which is forged onto the substrate surface
Implementation Method 3
friction surfacing, frictional heating plasticizes a consumable pin tool, which is forged onto the substrate surface
Data Source
AI summary
A friction surfacing apparatus and method for depositing one or more metals, metal alloys, or other materials is disclosed. The friction surfacing apparatus includes a pin tool holder, a non-consumable shoulder having an inside diameter and an outside diameter, the inside diameter terminating at an end wall and includes an angled side wall that forms a substantially frustoconical opening at one end, and a consumable pin tool coupled to the pin tool holder and at least partially protruding from the end wall of the shoulder. The shoulder is maintained at a predetermined distance from a surface of a workpiece such that the consumable pin tool deposits pin tool material onto the surface of the workpiece during a friction surfacing operation.