Friction Welding Dissimilar Metals Recessed Joint
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Solution Overview
Problem
The existing methods for joining metal members of different metals, such as in piston shoes, often result in unstable fixation due to engagement-only mechanisms, and require costly machining or deformation, which can lead to temperature inconsistencies and poor joining.
Innovation Solution
A method involving enclosed friction welding, where a first metal member with a recessed surface and a second metal member of lower deformation resistance are rotated and pressed together, with the second member deforming to fill the recess, ensuring even heat distribution and stable joining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If members are joined by engagement-only mechanism, then manufacturing complexity is reduced, but joining reliability deteriorates
Solution Approach 1:
The recess formed in the first member creates a nested structure where the second member is inserted and retained. The recess acts as a receptacle that receives and secures the second member, providing mechanical interlocking without requiring additional fastening components. This nesting approach enhances joining reliability while maintaining structural simplicity.
2Temperature
If second member flows into recess, then temperature distribution is equalized, but deformation resistance requirements increase
Solution Approach 1:
The invention utilizes temperature as a controllable parameter to dynamically change the deformation resistance of the second member. By heating the second member during the joining process, its deformation resistance is reduced, enabling it to flow into the recess and equalize temperature distribution. The parameter change from cold to hot state allows the material to exhibit different mechanical properties at different stages of the process.
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 stable and efficient joining of metal members by ensuring consistent temperature across the joint surface, reducing production costs and enhancing the durability of the metal member.
Implementation Method 1
the first member and the second member are heated by relatively rotating the first member and the second member with respect to each other about an axis of rotation, while pressing the first member and the second member against each other
Implementation Method 2
the heated and softened second member flows into the recess. With the heated second member entering the recess, the heat is supplied to the central portion (region including the rotational axis). This decreases the difference in temperature between the outer peripheral portion and the central portion.
Implementation Method 3
joining the first member and the second member includes a step of heating the first member and the second member by relatively rotating the first member and the second member with respect to each other about an axis of rotation, while pressing the first member and the second member against each other, and a step of cooling the first member and the second member heated, with the members being pressed against each other
Data Source
AI summary
The method includes a step of preparing a first member made of a first metal and a second member made of a second metal having a smaller deformation resistance than the first metal, and a step of joining the first member and the second member. The step of joining includes a step of heating the first member and the second member by relatively rotating the first member and the second member, while pressing the first member and the second member against each other, without changing a relative positional relationship therebetween, and a step of cooling the first member and the second member heated, while being pressed against each other. In a first contact surface which is a surface of the first member coming into contact with the second member, a recess is formed so as to include a region intersecting the axis of rotation.