Friction Welding Curl Formation and Fusion
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Solution Overview
Problem
Current friction welding methods often result in material wastage and increased cycle times due to the need for separate processes to form and remove external and internal curls, which can lead to voids and reduced strength in the weld.
Innovation Solution
A system and method for friction welding that utilizes curl forming dies to generate external and internal curls during the welding process, allowing these curls to engage and fuse with the parts, thereby forming a solid mass without separate removal, and optionally forming features like threads or protrusions directly during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If separate processes are used to form and remove external and internal curls after friction welding, then the welding process is completed, but material wastage increases and cycle time increases
Solution Approach 1:
The patent combines the curl formation process with the friction welding process by positioning curl forming dies against the workpiece during welding. The external curl forming die engages the external surface while the internal curl forming die engages the internal surface, allowing curls to be formed simultaneously with welding rather than as separate post-processing steps. This merging eliminates the need for separate curl formation and removal operations, directly reducing cycle time and material wastage.
2Ease of manufacture
If separate processes are used to form and remove external and internal curls, then the welding is completed, but material wastage increases
Solution Approach 1:
The patent performs curl formation as a preliminary action during the friction welding process itself. By positioning the curl forming dies against the workpiece before and during welding, the curls are formed in advance rather than requiring subsequent removal operations. This preliminary formation of curls that would otherwise need to be removed prevents material wastage while ensuring the welding is properly completed.
3Strength
If curls are not formed during welding, then the process is simpler, but voids and reduced strength occur in the weld
Solution Approach 1:
The patent segments the curl formation function into two separate dies: an external curl forming die for the external surface and an internal curl forming die for the internal surface. This segmentation allows each die to be optimally designed for its specific function while working together during the welding process. The segmented approach ensures proper curl formation to prevent voids and maintain weld strength without requiring a single overly complex die system.
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 reduces material scrap, cycle time, and costs by integrating curl formation into the welding process, enhancing the strength and durability of the weld while minimizing post-processing needs.
Implementation Method 1
The first part may be friction welded to the second part, such that a first external curl and a first internal curl are generated from the first part
Data Source
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AI summary
A system and method of friction welding a workpiece. A curl forming die may be disposed proximate a first part and a second part. The curl forming die may form a curl that is generated when the first part is friction welded to the second part.