Friction Stir Welding Cooling System for Thermal Expansion Control
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Solution Overview
Problem
Existing friction stir welding apparatuses face challenges in uniformly cooling processing target members and suppressing thermal expansion of mounting jigs, particularly when dealing with various types of materials, leading to potential welding quality issues and cumbersome configurations.
Innovation Solution
A friction stir welding apparatus with a movable welding tool, a flexible coolant supply system, and a two-layer mounting jig with differing thermal conductivity and strength properties, allowing for independent coolant circulation and reduced thermal expansion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If a backing plate with gas flow passage and fluid flow passage is provided to cool the workpiece from below, then the workpiece can be cooled, but another backing plate needs to be provided above the workpiece to cool it from above, making the configuration cumbersome
Solution Approach 1:
The cooling system is designed to cool the workpiece from both above and below using a single integrated configuration. The gas flow passage cools the upper surface while the fluid flow passage cools the lower surface, eliminating the need for separate backing plates and achieving multi-directional cooling with one system.
2Adaptability or versatility
If the shape of the workpiece is changed, then different processing target members can be welded, but the arrangement of gas flow passage and fluid flow passage and the shapes of backing plate and tungsten base material need to be changed and optimized, making the configuration cumbersome
Solution Approach 1:
The cooling system incorporates adjustable and reconfigurable components that can adapt to different workpiece shapes and sizes. The gas flow passage and fluid flow passage arrangements can be modified without requiring complete redesign of the backing plate and tungsten base material, enabling versatility while maintaining a relatively simple base configuration.
3Productivity
If the probe rotates at high speed to perform friction stir welding, then welding can be performed efficiently, but the processing target member becomes excessively hot due to frictional heat, affecting welding quality
Solution Approach 1:
The frictional heat generated during high-speed probe rotation, which would normally be harmful, is utilized to preheat the workpiece to the optimal temperature range for friction stir welding. The cooling system then removes excess heat, converting the harmful thermal effect into a beneficial preheating step that improves welding quality while maintaining high productivity.
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
Enables accurate and uniform cooling of processing target members while minimizing unnecessary thermal expansion of the mounting jig, improving welding quality and simplifying the cooling system configuration.
Implementation Method 1
a coolant supply source that can freely supply a coolant to the paired holding member and the portion of the mounting jig
Implementation Method 2
the processing target member is likely to become a high temperature due to frictional heat thereof
Data Source
AI summary
A friction stir welding apparatus having a new cooling system that can cool a portion required to be cooled accurately and uniformly with a simple configuration, while suppressing unnecessary thermal expansion of a mounting jig includes a holding mechanism 20 having a holding member 22a movable with respect to a processing target member W so as to freely hold the processing target member W, in which the holding member 22a and a portion of a mounting jig 12 that can freely face the holding member 22a become paired, and a coolant supply source S that can freely supply a coolant to the paired holding member 22a and the portion of the mounting jig 12.