Friction Welding Element Sealing via Melted Head Material
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Solution Overview
Problem
Friction welding connections are prone to corrosion due to unreliable sealing of transition areas between components and friction welding elements.
Innovation Solution
A friction welding element with a heat-generating head that uses a melting and solidifying material, such as thermoplastic, to create a sealed connection site during the friction welding process, preventing humidity intrusion and corrosion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If friction welding is performed without additional sealing measures, then the welding process is simple and fast, but the transition area is not reliably sealed and corrosion occurs
Solution Approach 1:
The sealing function is merged with the friction welding element itself. The material (36) is integrated onto the head (12) of the friction welding element (10), combining the welding and sealing functions into a single component system, eliminating the need for separate sealing structures.
Solution Approach 2:
The material undergoes parameter changes through phase transition. During the friction welding process, the material melts due to generated heat, then solidifies upon cooling to form a reliable seal in the transition area between the friction welding element and the component.
2Reliability
If subsequent sealing processes are applied after friction welding, then sealing reliability is improved, but production time increases
Solution Approach 1:
The sealing action is performed preliminarily during the friction welding process itself. The material is positioned on the head before welding, and the friction heat automatically melts and solidifies it to create the seal, eliminating the need for subsequent sealing operations.
Solution Approach 2:
The sealing operation is merged with the friction welding process. Both functions are achieved in a single operational sequence, where the friction heat serves dual purposes of creating the weld connection and activating the sealing material simultaneously.
3Ease of manufacture
If the transition area is left unsealed, then the manufacturing process is simple, but corrosion and humidity intrusion occur
Solution Approach 1:
The friction welding element performs self-sealing through its own friction heat. The material (36) on the head (12) is automatically melted and solidified by the heat generated during the welding process itself, creating a corrosion-resistant seal without requiring external sealing systems or additional processing steps.
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 solution provides a reliable, time-saving sealing of the connection site, avoiding subsequent sealing processes and protecting against corrosion by utilizing the friction heat to melt and harden a material that seals the transition area permanently.
Implementation Method 1
heat is generated by means of the rotation of the friction welding element under the influence of an axial force
Implementation Method 2
a material is provided on the head which material is melting by means of the heat generated during the friction welding process
Implementation Method 3
which material is melting by means of the heat generated during the friction welding process upon contact with an surface of a component arranged closest to the head, and (which material) solidifies upon cooling
Data Source
AI summary
The invention relates to a friction welding element (10, 30, 40) comprising a friction welding geometry (14, 15) and a head (12, 24, 32, 42) with a driving geometry (16, 34) for connection to a component (18, 20, 50) wherein heat originates during the friction welding process, characterized in that, at the head (12, 24, 32, 42), a material (22 26, 36, 44) is applied which is at least partially melting by means of the heat generated by the friction welding process upon contact with the surface of a component (18, 50) arranged closest to the head, and which material solidifies during cooling whereby the transition from the friction welding element (10, 30, 40) to the component (18, 50) arranged closest to the head, is sealed.