Friction Stir Welding Tool with Retractable Guide Member
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Solution Overview
Problem
Friction stir welding of aircraft fuselage panels is hindered by obstacles such as mounting flanges or stiffeners, which prevent complete welding of the interface line, leading to inhomogeneous welds and mechanical property degradation when using multiple tools or securing means.
Innovation Solution
A friction stir welding tool with a guide member that can be moved from a guide position to a retracted position to avoid obstacles, allowing the same tool to weld the entire interface line, featuring adjustable pressure forces and automatic detection for obstacle avoidance, ensuring a homogeneous weld bead.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a fixed guide member is used to stabilize the welding tool, then welding precision is improved, but the ability to weld around obstacles is reduced
Solution Approach 1:
The guide member is made movable relative to the welding tool, transitioning between a guide position (extending into the scout zone) for precision welding and a retracted position (withdrawn from the scout zone) for navigating obstacles. This dynamic configuration allows the system to adapt its guidance function based on real-time welding conditions.
Solution Approach 2:
The guide member is divided into separable components that can be independently positioned. The movable guide member works in conjunction with a fixed guide member, allowing the movable portion to be retracted while the fixed portion maintains guidance, enabling welding around obstacles while preserving precision where possible.
2Manufacturing precision
If multiple welding tools or securing means are used to overcome obstacles, then complete welding coverage is achieved, but weld homogeneity and mechanical properties are degraded
Solution Approach 1:
The welding tool is designed with a movable guide member that can perform both guidance and obstacle negotiation functions. This single multi-functional tool eliminates the need for switching between different welding tools or using securing means, maintaining weld homogeneity throughout the entire interface line.
3Manufacturing precision
If the guide member extends into the scout zone, then welding guidance is optimized, but obstacle avoidance capability is reduced
Solution Approach 1:
The guide member's position is dynamically adjusted based on obstacle detection. When no obstacle is present, the guide member extends into the scout zone for optimal guidance. When an obstacle is detected, the guide member is retracted to avoid interference, allowing the welding tool to navigate around the obstacle while maintaining guidance capability where possible.
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 complete welding of the interface line with improved mechanical properties and reduced deformation, eliminating the need for additional securing means and maintaining weld quality across the entire length.
Implementation Method 1
The pressure force applied continuously by the pin and the rotation of said pin generate friction and kneading which heat the material of the panels at the interface of the two panels
Implementation Method 2
Due to this heating, the material of the panels at their interface deforms plastically and enters a pasty phase
Implementation Method 3
By cooling and crystallization of the pasty material, a weld bead is formed at the interface of the two panels to connect them together
Data Source
Figure 1~2
Figure 3~4
AI summary
A friction stir welding tool (4) comprising a base (40), a friction stir pin (41) rotatably mounted in said base (40) and at least one guide member (7A, 7B) connected to said base (40), the welding tool (4) being adapted to move upstream to downstream, welding tool (4) comprising at least one displacement member (6A, 6B) of the guide member (7A, 7B) relative to said base (40) enters at least one guide position in which the guide member (7A, 7B) extends into a scout zone (Z) located downstream and opposite the friction stir pin (41) and at least one retracted position in which the guide member (7A, 7B) is offset relative to said scout zone (Z).