Friction Stir Weld Joint Configuration for Single-Sided Plate Repair
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Solution Overview
Problem
Existing welding methods, such as Metal Inert Gas Welding, are ineffective for repairing metal plates with limited access due to the need for filler materials that compromise mechanical properties and require access from both sides, whereas Friction Stir Welding maintains structural integrity and allows single-direction welding.
Innovation Solution
A joint configuration using recess portions and insert elements with Friction Stir Welds, allowing welding from a single direction, and optionally incorporating stitching, angled or non-linear abutted surfaces, co-locating lugs and voids, and adhesive layers to enhance strength and stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If Metal Inert Gas Welding is used to join metal plates, then the welding process can be performed with filler material, but the mechanical properties of the weld are significantly reduced to approximately 60% of the original material strength
Solution Approach 1:
The patent replaces traditional Metal Inert Gas Welding (thermal process with filler material) with Friction Stir Welding (mechanical process without filler material). The friction stir weld tool mechanically mixes the base metal and insert material through friction and stirring action, creating a Forge Joint that maintains approximately 90% of the original material's mechanical properties, significantly improving weld strength and structural integrity compared to MIG welding.
2Ease of operation
If traditional welding methods are used on plates with limited access, then welding from both sides is required, but this requires removing large amounts of equipment and provides no solution for single-sided access repairs
Solution Approach 1:
The patent creates a recess portion in the metal plate that provides vertical dimension access for the friction stir weld tool. This recess allows the tool to approach the weld area from the accessible side (first surface) and perform welding through the thickness of the plate without requiring access from the opposite side (second surface), effectively solving the limited access problem by utilizing the vertical dimension created by the recess.
Solution Approach 2:
The patent divides the repair process into distinct components: the base metal plate, the insert element that fills the defect, and the recess portion that accommodates the welding tool. This segmentation allows the insert element to be positioned within the recess and welded to the base metal from a single accessible direction, eliminating the need for bilateral access required by traditional welding methods.
3Adaptability or versatility
If filler material is used in welding processes, then the welding can be performed on various metal plates, but the filler material significantly impacts and reduces the physical properties of the weld
Solution Approach 1:
The patent extracts and eliminates the filler material from the welding process entirely. Instead of adding external filler material as in MIG welding, the Friction Stir Welding process uses only the base metal and insert material itself, mechanically mixing them through the friction stir weld tool. This extraction of filler material prevents the degradation of mechanical properties while maintaining welding versatility through the use of insert elements made from the same or compatible materials.
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 configuration enables robust, defect-low welds that maintain approximately 90% of the original material's mechanical properties, suitable for applications requiring structural integrity, like armor plating and high-pressure vessels, while minimizing equipment removal and distortion.
Implementation Method 1
Friction Stir Welding is a method of welding that substantially maintains the physical and mechanical properties of the elements it is applied to
Implementation Method 2
Friction Stir Welding can also be used for joining other metals and metal alloys as well as aluminium based composite materials
Data Source
AI summary
The invention relates to a joint and welding configuration used during repair of metal and metal alloy plates specifically for providing a means of joining metal plates and filling voids in metal plates where access from one side is restricted. A joint arrangement suitable for repairing a void in at least one element, wherein said at least one element has a first surface and a second surface, wherein the thickness of the at least one element is at least 10 mm, further comprising two or more insert elements, each of said two or more insert elements each being friction stir welded at their abutted surfaces to said at least one element, characterized wherein said at least one element comprises at least one recess portion, wherein a Friction Stir Weld is caused from the direction of said first surface.