Friction Stir Welding Rotary Tool with Internal Temperature Channels
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Solution Overview
Problem
Friction stir welding of thick plates and dissimilar materials requires extensive trial and error to adjust welding conditions, leading to inefficiencies and suboptimal heat input, which complicates achieving uniform plastic flow and mechanical properties.
Innovation Solution
A friction stir welding device with a rotary tool equipped with temperature measurement channels and thermocouples at strategic positions, allowing real-time temperature monitoring and transmission, enabling precise evaluation of heat input and optimization of welding conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of time
If friction stir welding is performed on thick plates or dissimilar materials without temperature monitoring, then welding can be completed, but extensive trial and error is required to adjust welding conditions, consuming enormous time and leading to suboptimal heat input
Solution Approach 1:
The patent incorporates temperature measurement elements (thermocouples) positioned at the lower end and outer edge of the rotary tool to provide real-time temperature feedback during friction stir welding. This feedback enables dynamic adjustment of welding parameters, eliminating extensive trial-and-error processes and significantly reducing the time required to optimize welding conditions for thick plates and dissimilar materials.
Solution Approach 2:
The patent replaces the conventional mechanical trial-and-error adjustment method with a thermal measurement and control system. By substituting empirical parameter adjustment with scientific temperature monitoring and control, the welding process becomes more efficient and predictable, directly addressing the time loss issue.
2Manufacturing precision
If heat input is increased to achieve uniform plastic flow in thick plates, then welding of large plate thickness can be achieved, but excessive heat input softens members, generates burrs, or reduces mechanical properties
Solution Approach 1:
Temperature measurement elements provide real-time thermal feedback during welding, enabling precise control of heat input. This feedback mechanism allows the welding process to maintain optimal temperature ranges for uniform plastic flow while preventing excessive heat input that would soften members or reduce mechanical properties.
Solution Approach 2:
The patent employs dynamic adjustment of welding parameters (rotational speed, feed rate, axial load) based on real-time temperature measurements. By changing these parameters in response to temperature feedback, the system maintains optimal heat input levels that ensure uniform plastic flow without compromising the mechanical properties of the welded joint.
3Adaptability or versatility
If heat input is increased to reduce deformation resistance of dissimilar materials, then welding of different materials can be achieved, but excessive heat input causes non-uniform mixing or generates excessive burrs
Solution Approach 1:
Temperature measurement elements provide real-time thermal feedback specific to dissimilar material welding, enabling precise control of heat input. This feedback allows the system to maintain optimal temperature ranges that ensure uniform mixing of dissimilar materials while preventing excessive heat input that would cause non-uniform mixing or generate excessive burrs.
Solution Approach 2:
The patent employs dynamic adjustment of welding parameters based on real-time temperature measurements specific to dissimilar material combinations. By changing rotational speed, feed rate, and axial load in response to temperature feedback, the system achieves uniform mixing of dissimilar materials without generating harmful effects.
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 real-time temperature monitoring of the welding process, facilitating the derivation of optimal welding conditions for uniform heat input, improved plastic flow, and enhanced mechanical properties, particularly in thick plates and dissimilar materials.
Implementation Method 1
temperature measurement elements (for example, thermocouples in this embodiment) are provided in the lower end channel and the outer edge channel
Implementation Method 2
members to be welded are stirred (to induce plastic flow) after the deformation resistance of members to be welded is reduced by frictional heat
Data Source
AI summary
An objective of the present invention is to provide a friction stir welding device with which the temperature in the proximity of a weld part on a member to be welded can be intermittently measured by enabling the temperature of a plurality of sites in a rotary tool (4) used for friction stir welding to be ascertained in real-time when welding. This rotary tool (4) for a friction stir welding device comprises: a hollow channel (26a) that extends from the upper end of a shoulder part (4c) to the proximity of the lower end of a probe (4d), and that is on substantially the same axis as the axis of rotation of the shoulder part (4c); and a hollow, outer periphery channel (26b) that is apart from the axis of rotation of the shoulder part (4c) in the radial direction and in proximity of the outer periphery of the shoulder part (4c), and that extends from the upper end of the shoulder part to the proximity of the lower end thereof. A temperature measurement element (5a) is respectively disposed in the proximity of the lower end of the hollow channel and of the outer periphery channel.