Friction-Welded Stud Patch for Leak-Safe Curved Pipe Repair
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Solution Overview
Problem
Existing methods for repairing valves and pipes in hazardous environments are inefficient and pose risks due to the use of combustible welding processes and potential chemical leaks.
Innovation Solution
A system utilizing a portable friction forge bonder with a collet and drill guide, which allows for the attachment of a boss to a valve or pipe using friction welding, and an injection system that maintains positive pressure to contain hazardous materials during repair.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If arc, MIG, TIG welding or oxy-acetylene torch brazing is used to attach fasteners to pipes or valves, then the attachment strength is improved, but the risk of ignition in hazardous environments increases
Solution Approach 1:
The patent replaces thermal welding processes (arc welding, MIG, TIG, oxy-acetylene) with friction welding, which uses mechanical friction and pressure instead of heat and open flames. This substitution eliminates ignition sources while maintaining attachment strength, directly resolving the contradiction between strong fastening and safety in hazardous environments.
Solution Approach 2:
The patent changes the fundamental parameters of the joining process from thermal (high temperature, open flame) to mechanical (friction, pressure, rotation). By altering the energy form and process parameters, the invention achieves strong attachments without the harmful thermal effects that create ignition risks in volatile chemical environments.
2Ease of manufacture
If threading is used to attach fittings to valve housings, then the attachment process is simplified, but the connection reliability deteriorates due to corrosion and vibration
Solution Approach 1:
The patent replaces the threaded mechanical connection system with a friction-welded solid joint. This eliminates threads that are susceptible to corrosion and vibration loosening, while the welding process itself creates a strong, corrosion-resistant metallurgical bond that maintains reliability in harsh refinery environments.
3Ease of repair
If drilling is performed to inject sealant into valves, then the repair capability is improved, but hazardous chemical leakage increases
Solution Approach 1:
The patent applies preliminary action by performing the friction welding of the boss to the valve housing before drilling and sealant injection. This creates a secure, leak-proof attachment point first, ensuring that subsequent drilling and chemical handling operations have a reliable foundation that prevents hazardous material escape.
Solution Approach 2:
The friction-welded boss serves as an intermediary component that provides a secure mounting point for drill guides and sealant injection equipment. This intermediary structure enables safe repair operations by creating a controlled interface between the repair tools and the valve, preventing uncontrolled chemical leakage.
4Strength
If traditional welding processes are used in hazardous environments, then the attachment strength is improved, but the safety of technicians and environment deteriorates
Solution Approach 1:
The patent replaces all thermal welding processes (arc, MIG, TIG, oxy-acetylene) with friction welding, which uses mechanical friction and pressure instead of heat and open flames. This substitution eliminates ignition sources that threaten technician safety and environmental protection, while maintaining attachment strength through mechanical bonding.
Solution Approach 2:
Friction welding creates a localized environment that does not require external ignition sources or reactive atmospheres. The process generates heat through controlled friction between surfaces, creating an inherently safer working environment in the presence of volatile chemicals, thereby protecting both technicians and the environment.
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 system enables safe and efficient repair of valves and pipes in hazardous environments by preventing chemical leaks and eliminating the need for combustible welding processes, thereby protecting technicians and the environment.
Implementation Method 1
attachment of a boss to a valve or pipe using friction welding
Implementation Method 2
friction forge bonder with a collet and drill guide, which allows for the attachment of a boss to a valve or pipe using friction welding
Implementation Method 3
an injection system that maintains positive pressure to contain hazardous materials during repair
Data Source
AI summary
In some implementations, an apparatus including a curved structure having an exterior surface, having an interior surface and having a defect, a device positioned over the exterior surface of the curved structure, a block patch in between the device and the exterior surface of the curved structure, and a plurality of studs and nuts positioned near an outer perimeter of the device, the plurality of the studs being friction welded to the exterior surface of the curved structure.