Friction Stir Welding Pin Clearance for Stronger Defect-Suppressed Joints
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Solution Overview
Problem
Existing friction stir welding technologies face challenges in achieving high-strength welding while minimizing welding defects.
Innovation Solution
A rotating member for friction stirring is designed with a clearance between the pin portion and the output shaft, allowing the pin portion to vibrate at a larger amplitude and/or higher frequency than the base vibration, which amplifies the plastic flow of the welding object without hindering it, and is configured to reduce heat generation and shoulder interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If the pin portion is firmly fixed to the output shaft, then the rotation stability is improved, but the plastic flow amplification capability deteriorates
Solution Approach 1:
The pin portion is designed to be loosely fitted to the output shaft, allowing it to dynamically vibrate during friction stir welding. This dynamic capability enables the pin to amplify plastic flow in the welding object, thereby improving welding strength while maintaining sufficient rotational stability through the loose fit configuration.
Solution Approach 2:
The clearance between the pin portion and output shaft allows mechanical vibration to occur during operation. This vibration amplifies the plastic flow of the welding object, enhancing the welding quality and strength without compromising the overall rotational stability of the system.
2Strength
If the pin portion is loosely fitted to the output shaft, then the plastic flow amplification is improved, but the rotation stability deteriorates
Solution Approach 1:
The loose fit configuration allows the pin portion to have dynamic movement capability while maintaining operational stability. The pin can vibrate to amplify plastic flow for improved welding strength, yet the loose fit structure itself provides sufficient rotational stability for effective friction stir welding.
3Stability of the object's composition
If the shoulder width is increased, then the structural stability is improved, but the heat generation and plastic flow hindrance increase
Solution Approach 1:
The shoulder width is optimized to a specific range (0.5mm to 2.0mm) to achieve local quality balance. This dimension provides sufficient structural stability while minimizing excessive heat generation and interference with plastic flow, creating optimal local conditions for friction stir welding.
4Stability of the object's composition
If the shoulder width is increased, then the structural stability is improved, but the plastic flow capability deteriorates
Solution Approach 1:
The shoulder width is precisely controlled within 0.5mm to 2.0mm to achieve optimal local quality. This dimension provides adequate structural stability while minimizing interference with plastic flow, thereby maintaining high productivity and effective material flow during friction stir welding.
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 design enables high-strength welding with reduced defects and lower temperature requirements, enhancing mechanical properties and energy efficiency.
Implementation Method 1
a clearance is formed between the output shaft and a pin portion, which is to be inserted into the welding object member at a time of friction stirring, the clearance allowing the pin portion to vibrate relative to the output shaft, and due to the clearance, at a time of friction stirring, a vibration of the pin portion has a larger amplitude and/or a higher frequency than a vibration of the output shaft
Implementation Method 2
a rotating member for friction stirring, a welding apparatus, and a welding method that are capable of welding with a high strength
Data Source
AI summary
The present teaching, which relates to friction stir welding, aims to provide a rotating member for friction stirring capable of welding with a high strength and with occurrence of a welding defect suppressed. A rotating member for friction stirring installed in a welding apparatus for performing friction stir welding of a welding object member is configured such that when the rotating member for friction stirring is arranged to an output shaft of a driving mechanism included in the welding apparatus so as to be rotated by rotation outputted from the driving mechanism, a clearance is formed between the output shaft and a pin portion, which is to be inserted into the welding object member at a time of friction stirring, the clearance allowing the pin portion to vibrate relative to the output shaft, and due to the clearance, at a time of friction stirring, a vibration of the pin portion has a larger amplitude and/or a higher frequency than a vibration of the output shaft.