Friction Welded Chain Links for Complex Cross-Sections
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Solution Overview
Problem
Existing methods for producing welded round and profile chains are limited by the need for pre-bending, which restricts the production of chain links with complex cross-sections and limits the use of materials with higher carbon content or certain alloys, as well as the feasibility of friction welding due to fatigue fracture concerns.
Innovation Solution
The method involves producing chain links from two connected parts using friction welding, allowing for the use of a wider range of materials and complex cross-sectional shapes by eliminating the need for pre-bending and enabling axially-deviating relative movement of butt surfaces, which reduces the risk of fatigue fracture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If pre-bent chain links are used with resistance or flash butt welding, then welding can be performed on simple cross-sections, but complex cross-sections and varying cross-sections cannot be produced
Solution Approach 1:
The chain link is divided into two separate parts that are welded together, rather than attempting to bend and weld a single piece. This segmentation allows each part to be manufactured with simpler geometry while the final assembly achieves the desired complex cross-sectional shape through the combination of parts.
Solution Approach 2:
The invention employs friction welding to join two different chain link parts, enabling the creation of composite structures with varying cross-sections. This approach allows combining materials and geometries that would be difficult or impossible to achieve through traditional bending of a single piece.
2Ease of manufacture
If resistance or flash butt welding is used on pre-bent chain links, then welding is feasible for low carbon steels, but steels with carbon content greater than 0.25% cannot be welded due to cracking danger
Solution Approach 1:
The invention replaces resistance or flash butt welding with friction welding. This substitution of welding method enables the processing of high carbon steels and alloys that are otherwise unsuitable for traditional welding methods, eliminating the cracking problem while maintaining manufacturing feasibility.
3Productivity
If pre-bending is required for chain link production, then simple cross-sections can be manufactured, but complex and varying cross-sections are not producible
Solution Approach 1:
The chain link is segmented into two manufacturable parts that are subsequently joined by friction welding. This approach allows each part to be produced with simpler geometry through conventional processes, while the final assembled link achieves complex and varying cross-sections that would be impossible through single-piece bending.
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 approach enables the production of chains with superior wear resistance and strength, allowing for the use of materials like high-carbon steels and non-ferrous metals, and expands design possibilities for chain links, including the use of thermoplastics and composite materials, while avoiding the limitations of traditional welding methods.
Implementation Method 1
The terminal surfaces of the chain link parts facing toward one another each press against one another or against a friction disc lying between them over their entire area and may each rub on one another over their entire area upon movement relative to one another, the terminal surfaces of each chain link part being heated over their entire surface area by the occurring friction to the desired temperature for friction welding
Data Source
AI summary
A method for producing welded round and profile chains of chain links that are connected to each other. The chain links for round and profile chains produced by this method include two chain link partial pieces that are connected to each other by friction welding.